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YOKOGAWA ZR22S, User Manual

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YOKOGAWA ZR22S User Manual Download Page 169

 

 

<11.  Inspection and Maintenance>

11-5

11.1.3   Replacement of the Heater Unit (Assembly)

This Subsection describes the replacement procedure for the heater unit.
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 unit reaches high temperatures 

and is subjected to high voltages. So, maintenance services should be performed after the power 

is off and the heater unit temperature has returned to normal room temperature.
For details, refer to IM11M12A01-21E “ Heater Assembly ”.

NOTE

If the heater strut assembly cannot be removed because a screw has fused to its thread, one of 

our service representatives can fix it.

IM 11M13A01-02E

Summary of Contents for ZR22S

Page 1: ...User s Manual Model ZR22S ZR402G Separate type Explosion proof Zirconia Oxygen Analyzer IM 11M13A01 02E IM 11M13A01 02E 7th Edition...

Page 2: ...various industrial processes This analyzer basically consists of a detector and a converter You can select between several versions based upon your application Optional accessories are also available...

Page 3: ...ndard system configurations A C 5 Wiring Wiring procedures such as Power supply wiring output signal wiring or others A C 6 Components and Their Functions Major parts and function are described in thi...

Page 4: ...iii IM 11M13A01 02E n ATEX Documentation This procedure is only applicable to the countries in European Union GB DK I E NL SF P F D S LT LV PL EST SLO H BG RO M CZ SK GR...

Page 5: ...F and G T2 ZR22S D IECEx Ex db IIB H2 T2 Gb Ex tb IIIC T300 C Db n For the safe use of this equipment WARNING EXAxtZR is very heavy Handle it with care Do not drop it Handle safely to avoid injury Con...

Page 6: ...in this product but does not warrant that those will suit the particular purpose of the user Every effort has been made to ensure accuracy in the preparation of this manual However should any errors...

Page 7: ...ual in order to prevent the instrument hardware or software from being damaged or a system failure from occurring NOTE This symbol draws attention to information essential for understanding the operat...

Page 8: ...rameters initial data set before shipping from the factory Ensure that the initial data is suitable for the operation conditions before conducting analysis Where necessary set the instrument parameter...

Page 9: ...used by a person with specialized knowledge l How to dispose the batteries This is an explanation about the EU Battery Directive This directive is only valid in the EU Batteries are included in this...

Page 10: ...stated in instruction manual Failure caused by usage of software hardware or auxiliary equipment which Yokogawa did not supply Failure due to improper or insufficient maintenance by user Failure due t...

Page 11: ...Blank Page...

Page 12: ...otector 2 8 2 3 Separate type Explosion proof Detector for High Temperature and Related Equipment 2 9 2 3 1 ZR22S 0 15 m Separate type Explosion proof Detector for High Temperature 2 9 2 3 2 ZO21P Hig...

Page 13: ...4 1 Installation Location 3 14 3 4 2 Mounting of ZA8F Flow Setting Unit 3 14 3 5 Installation of ZR40H Automatic Calibration Unit 3 15 3 5 1 Installation Location 3 15 3 5 2 Mounting of ZR40H Automati...

Page 14: ...Cable Specifications 5 10 5 6 2 Wiring Procedure 5 11 5 7 Wiring for ZR40H Automatic Calibration Unit 5 11 5 7 1 Cable Specifications 5 11 5 7 2 Wiring Procedure 5 12 5 8 Contact Input Wiring 5 12 5 8...

Page 15: ...mA and Maximum Current 20 mA 8 1 8 1 2 Input Ranges 8 1 8 1 3 Setting Output Smoothing Coefficient 8 2 8 1 4 Selection of Output Mode 8 2 8 1 5 Default Values 8 2 8 2 Output Hold Setting 8 3 8 2 1 Def...

Page 16: ...ocouple Voltage 10 2 10 1 3 Cold Junction Resistance C J Voltage 10 2 10 1 4 Cell s Internal Resistance 10 2 10 1 5 Software Revision 10 2 10 1 6 Span gas and Zero gas Correction Ratios 10 2 10 1 7 Ce...

Page 17: ...Inspection and Maintenance 11 1 11 1 Inspection and Maintenance of the Detector 11 2 11 1 1 Cleaning the Calibration Gas Tube 11 2 11 1 2 Replacing the Sensor Assembly 11 2 11 1 3 Replacement of the...

Page 18: ...12 Customer Maintenance Parts List CMPL 11M13A01 02E Customer Maintenance Parts List CMPL 11M12C01 01E Customer Maintenance Parts List CMPL 11M12A01 11E Customer Maintenance Parts List CMPL 11M03B01...

Page 19: ...Blank Page...

Page 20: ...asurement and calculation as well as maintenance functions including self test Analyzer calibration can also be fully automated and ZR40H an automatic calibration unit is available Choose the detector...

Page 21: ...purge gas valve to supply air to the sensor Instrument air Pressure regulating valve Air Set Needle valve Flowmeter Reference gas Calibration gas Check valve Zero gas cylinder ZR40H Automatic Calibrat...

Page 22: ...arts for ZR22S Items required for the above system example To be selected depending on each application For details refer to corresponding chapter Select either 1 2 2 Detectors and Accessories Sample...

Page 23: ...Blank Page...

Page 24: ...inal box temperature does not exceed 150 C Oxygen concentration of sample reference calibration gas shall not exceed that found in normal air typically 21 vol 2 1 General Specifications Standard Speci...

Page 25: ...ty standards of ZR22S and ZR402G Installation altitude based on IEC 61010 2000 m or less Category based on IEC 61010 II Note Pollution degree based on IEC 61010 2 Note Not Installation category called...

Page 26: ...p II Category 2GD Temperature class for Ex db T2 The maximum surface temperature for Ex tb T300 C Degree of protection of enclosure IP66 NAME PLATE MODEL Specified model code SUFFIX Specified suffix c...

Page 27: ...Temperature Class T2 IECEx Flameproof ZR22S D Applicable Standard IEC 60079 0 2011 IEC 60079 1 2014 IEC 60079 31 2013 Certificate Number IECEx KEM 06 0006X Type of protection Ex db IIB H2 T2 Gb Ex tb...

Page 28: ...r ASTM grade 304 flange Hastelloy B Inconel 600 601 Construction Heater and thermocouple replaceable construction Equivalent to NEMA 4X IP66 Achieved when pipes are installed at calibration gas and re...

Page 29: ...ted tag plate 6 1 Used with the ZO21P High Temperature Probe Adapter Select flange Q 2 The thickness of the flange depends on its dimensions 3 The thickness of the flange depends on its dimensions 3 T...

Page 30: ...150 4 RF DIN PN10 DN50 A DIN PN10 DN80 A DIN PN10 DN100 A JIS 5K 65 FF JIS 10K 65 FF JIS 10K 80 FF JIS 10K 100 FF JIS 5K 32 FF JPI Class 150 4 RF JPI Class 150 3 RF Westinghouse 152 4 190 5 228 6 165...

Page 31: ...13 kg JIS ANSI 2 05 m Approx 12 16 kg JIS ANSI Installation Bolts nuts and washers are provided for detector probe protector and process side flange Model and Codes Model Suffix code Option code Descr...

Page 32: ...temperature probe is fitted with an adapter Reference gas and calibration gas piping connection Rc1 4 or 1 4 NPT female Ambient temperature 20 to 60 C 20 to 150 C on the case surface Sample gas tempe...

Page 33: ...Installation Flange mounting FF type or RF type Probe Mounting Angle Vertically downward within 5 Where the probe material is 310S SS horizontal mounting is available Construction Non explosion proof...

Page 34: ...lange 1 Reference gas inlet Rc1 4 or 1 4 NPT Calibration gas inlet Rc1 4 or 1 4 NPT High temperature Probe SiC pipe Insertion length Note1 Sample gas outlet Flange provided by customer Flange Thicknes...

Page 35: ...Ambient Humidity 0 to 95 RH Non condensing Power Supply Voltage Ratings 100 to 240 V AC Acceptable range 85 to 264 V AC Power Supply Frequency Ratings 50 60 Hz Acceptable range 45 to 66 Hz Power Consu...

Page 36: ...Automatic Calibration Unit Input calibration direction on the touchscreen or contact then it calibrates automatically afterwards Manual Calibration Calibration with opening closing the valve of calib...

Page 37: ...normal high high alarm high alarm low alarm low low alarm maintenance calibrating range switching warming up calibration gas pressure decrease temperature high alarm blow back flameout gas detection c...

Page 38: ...oxygen and 80 to 100 vol O2 scale of oxygen for standard zero gas and standard span gas respectively Calibration interval date time setting maximum 255 days Model and Codes Model Suffix code Option co...

Page 39: ...R10 or 4 C5 to C8 4 6 holes for wall mounting 2B mounting pipe Wall 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 2414 36 23 20 2 1 2NPT...

Page 40: ...to 1 0 L min Reference gas 0 1 to 1 0 L min 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 samp...

Page 41: ...nt 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 inlet JIS 50A 60 5mm m...

Page 42: ...unting no vibration Materials Body Aluminum alloy Piping 316 SS JIS 304 SS JIS Flowmeter MA Metha acrylate resin Bracket 304 SS JIS Finish Polyurethane corrosion resistance coating mint green Munsell...

Page 43: ...ference gas Wiring inlet 2 G1 2 Pg13 5 M20X1 5 or 1 2NPT Female Calibration gas outlet Rc1 4 or 1 4 NPT Female Zero gas inlet Rc1 4 or 1 4 NPT Female Reference gas inlet Rc1 4 or 1 4 NPT Female Rc1 4...

Page 44: ...illed pressure Approx 686 kPaG at 35 C Composition 0 95 to 1 0 vol O2 N2 balance Power Supply 100 110 115 200 220 240 V AC 10 50 60 Hz Power Consumption Max 5 VA Case material SPCC cold rolled steel s...

Page 45: ...Consumption Approx 30 to 40 L min Suction gas flow rate 3 to 7 L min Connection to Blow Rc1 4 304 SS JIS Tube Connection 6 4 mm or 1 4 inch copper tube stainless tube Note Pipe and connections are not...

Page 46: ...oward the gas pressure line to be used to find the point of intersection Draw a line vertically down from the point of intersection to the axis to find the drive pressure P at the ejector entrance 2 I...

Page 47: ...470ZN 2 1 4NPT L9852CB 2 Rc1 4 G7016XH 2 1 4NPT Analyzer Approx 100 Unit mm 2 7 3 Check Valve K9292DN K9292DS This valve is mounted on the calibration gas line directly connected to the detector This...

Page 48: ...ent air is used as the reference and span gases Standard Specifications G7003XF K9473XK Primary Pressure Max 1 MPaG Secondary Pressure 0 02 to 0 2 MPaG Connection Rc1 4 or 1 4 FNPT with joint adapter...

Page 49: ...dapter F02 16E ai A 22 15 2 2 2 0 5 0 2 6 5 40 2 6 screw depth 8 40 Horizontal mounting Vertical mounting Panel cut dimensions View A Unit mm 2 7 5 Cylinder Pressure Reducing Valve G7013XF G7014XF Thi...

Page 50: ...prox 174 Unit mm 2 7 6 ZR22A Heater Assembly Model and Codes Style 2 Model Suffix code Option code Description ZR22A Heater Assembly for ZR22S Length 1 015 040 070 100 150 200 0 15 m 0 4 m 0 7 m 1 m 1...

Page 51: ...ensions K9470BX L Weight kg ZR22A 015 ZR22A 040 ZR22A 070 ZR22A 100 ZR22A 150 ZR22A 200 302 552 852 1152 1652 2152 Approx 0 5 Approx 0 8 Approx 1 2 Approx 1 6 Approx 2 2 Approx 2 8 Jig for change L 12...

Page 52: ...2 Specifications 2 29 IM 11M13A01 02E...

Page 53: ...ation of sample reference calibration gas shall not exceed that found in normal air typically 21 vol CAUTION When connecting an AV550G the AV550G should be installed in a non hazardous area When using...

Page 54: ...ndicates that the equipment is subjected to special conditions for safe use Refer to Note 6 Type of protection Ex db IIB H2 T2 Gb Ex tb IIIC T300 C Db Equipment Group II Category 2GD Temperature class...

Page 55: ...the risk from electrostatic discharges and propagating brush discharges caused by rapid flow of dust is avoided Note 7 Special fastener Hexagon socket head cap screws below are special fastener accor...

Page 56: ...proval 3 1 4 CSA Explosion proof Type ZR22S C Detector for use in hazardous locations Note 1 Applicable Standard C22 2 No 0 M1991 C22 2 No 0 4 04 C22 2 No 0 5 1982 C22 2 No 25 1966 C22 2 No 30 M1986 C...

Page 57: ...13 Certificate Number IECEx KEM 06 0006X The symbol X placed after certificate number indicates that the equipment is subjected to special conditions for safe use Refer to Note 6 Type of protection Ex...

Page 58: ...s protection of at least IP66 Note 6 Special conditions for safe use Electrostatic charge may cause an explosion hazard Avoid any actions that cause the generation of electrostatic charge such as rubb...

Page 59: ...e probe tip should point downstream 100 mm 100 mm F03 4E ai vertical Bounds of the probe insertion hole location Flange matches the detector size horizontal Type Outside diameter of detector Standard...

Page 60: ...d Direction of the sample gas flow Mount the protector so that the notch is on the downstream side of the gas flow Unit mm F03 5E ai Probe top 1050 1550 2050 Gasket t1 5 Figure 3 7 Mounting of detecto...

Page 61: ...ds 300 C 1 When the furnace pressure is negative lower the pressure setting to reduce induction flow of the sample gas Refer to Subsection 2 7 1 Ejector Assembly for High Temperature for the setting o...

Page 62: ...A high temperature detector consists of a ZR22S 015 Detector and ZO21P High Temperature Probe Adapter When forming the probe insertion hole the following should be taken into consideration 1 If the p...

Page 63: ...by 60 8 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...

Page 64: ...propriate sunshade 7 Non hazardous location 3 3 2 Mounting of the Converter 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 angl...

Page 65: ...acket and bolts are not used Panel Mounting 1 Cut out the panel according to Figure 3 13 274 2 0 183 2 0 F03 11E ai Unit mm Clamp screw Washer Bolt Fitting F03 12E ai Figure 3 13 Panel cutout sizes Fi...

Page 66: ...positioned vertically so that the flowmeter works correctly Pipe Mounting 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the flow setting unit The unit weigh...

Page 67: ...o vibration 6 Little exposure to rays of the sun or rain 7 Non hazardous location 3 5 2 Mounting of ZR40H Automatic Calibration Unit The automatic calibration unit can be mounted either on a pipe nomi...

Page 68: ...9 223 140 F03 17E ai 4 6 5 hole or M6 screw Unit mm Figure 3 19 Mounting holes 2 Mount the automatic calibration unit Remove the U bolt from the automatic calibration unit and attach the unit on the w...

Page 69: ...1 min During discharge do not touch the terminal 6 Testing between the heater terminal and ground contact output terminal and ground analog output input terminal and ground can be conducted in the sam...

Page 70: ...Blank Page...

Page 71: ...logging of the pipes or incorrect calibration Be sure to conduct leakage test after piping Basically apply instrument air dehumidified by cooling to the dew point 20 C or lower and removing any dust o...

Page 72: ...negative connect an auxiliary ejector to the sample gas exhaust hole of the high temperature probe adapter see Subsection 4 1 5 Figure 4 3 When a high temperature detector is used and the pressure of...

Page 73: ...reducing valve Recommended by YOKOGAWA G7013XF or G7014XF Joint for tube connection R1 4 or 1 4 NPT General parts Reference gas inlet Air set Recommended by YOKOGAWA G7003XF K9473XK or G7004XF K9473X...

Page 74: ...ce gas outlet 6 mm O D by 4 mm I D Stainless steel pipe Figure 4 2 Piping for the Calibration Gas Inlet 4 1 3 Piping for the Reference Gas Inlet Reference gas piping is required between the air source...

Page 75: ...le also found on the local market to the sample gas outlet Rc1 2 of the probe adapter so that the sample gas exhaust volume is restricted In cases where condensation is likely to occur in the probe ad...

Page 76: ...ure reducing valve Air Set Needle valve Flowmeter Reference gas Calibration gas Check valve Zero gas cylinder ZR40H Automatic Calibration Unit Zirconia Oxygen Analyzer Detector ZR402G Converter Calibr...

Page 77: ...R1 4 or 1 4 NPT General parts High temperature detector 0 15 m Calibration gas inlet Check valve Recommended by YOKOGAWA L9852CB or G7016XH Provided by YOKOGAWA K9292DN or K9292DS Nipple R1 4 or 1 4 N...

Page 78: ...tput and adjust air set so that span gas flow is within the permitted range CHECK OUT ZERO GAS IN To zero gas pressure reducing valve AIR IN Instrument air Approx 1 5 L min flowmeter flowmeter REF OUT...

Page 79: ...operation when the blow back start command is entered to the converter Solenoid valve Pipe junction Blow pipe F04 8E ai Pressure reduction valve Figure 4 8 Blow back Piping CAUTION When mounting solen...

Page 80: ...ow pipe as illustrated in Figure 4 9 and mount it on the high temperature probe adapter Approximately 200 Rc1 4 Blind flange of the high temperature probe adapter Welded Unit mm 8 O D by 6 I D Stainle...

Page 81: ...ing procedure Wiring should be performed according to the following procedure 1 Be sure to connect the shield line to FG terminal of the converter 2 The outer sheath of the signal line should be strip...

Page 82: ...communication For the detail refer to Subsection 1 1 2 of the IM 11M12A01 51E Communication Line Requirements 5 1 1 Terminals for the External Wiring in the Converter Open the front door and remove t...

Page 83: ...25 DO 2 26 DO 2 27 DO 3 28 DO 3 29 DO 4 30 DO 4 31 HTR 32 HTR 33 L 34 N 35 G 36 FG HTR HTR 100 240V AC 50 60 Hz F05 2E ai ZR402G Separate type Zirconia Oxygen Analyzer Converter ZR22S Separate type E...

Page 84: ...For each cable connection opening of the converter mount a conduit that matches the thread size or a cable gland EXA ZR402G Ground terminal M4 Adaptor for 1 2 NPT thread F05 3E ai 8 G1 2 8 1 2NPT or...

Page 85: ...Terminal box 1 Surface temperature of the detector terminal box 75 C or less F05 4E ai Non hazardous area Hazardous area Hazardous area Figure 5 4 Wiring for detector output CAUTION If shielded cable...

Page 86: ...sizes of the terminal screw threads are M3 5 except for the M4 on grounding terminal Each wire in the cable should be terminated in the corresponding size of crimp terminal 1 respectively 1 If the sur...

Page 87: ...ll a terminal box and connect to the detector using six piece 600 V silicon rubber insulated glass braided wires 5 3 2 Connection to Detector When connecting the cable to the detector proceed as follo...

Page 88: ...he converter Each cable should be terminated in the corresponding size crimp on terminals 2 When a rubber insulated glass braided wire is used for wiring to the detector use a terminal box For wiring...

Page 89: ...n terminals Ensure that the cable shield is connected to the FG terminal of the converter 2 Be sure to connect and polarities correctly 5 5 Power and Grounding Wiring This wiring supplies power to the...

Page 90: ...terminal and the protective ground terminal of the converter 5 No intermediate parts are used for the internal ground terminal of the detector Use crimping terminal for connection to the internal grou...

Page 91: ...solenoid valve for the zero gas and the span gas in the ZR40H Automatic Calibration Unit in a system where the calibration gas flow rate is automatically controlled e g System configuration 2 When ins...

Page 92: ...ese contact signals proceed wiring as follows Converter Terminal box DI 1 DI C DI 2 Contact input 1 Contact input 2 F05 13E ai ZR402G Figure 5 13 Contact Input Wiring 5 8 1 Cable Specifications Use 2...

Page 93: ...purpose Explosion proof Detector except for ZR22S 015 Probe This part is inserted in the furnace Select length from 0 15 0 4 0 7 1 0 1 5 or 2 0 m Flange Used to mount the detector Select from JIS ANSI...

Page 94: ...sure control valve e g a needle valve Separate type High Temperature Detector ZR22S 015 When the temperature of the sample gas is between 700 C and 1400 C mount this detector with a ZO21P probe adapte...

Page 95: ...Error 3 Defective A D converter Error 4 Faulty EEPROM Alarm 1 Abnormal oxygen concentration Alarm 2 Abnormal moisture Alarm 3 Abnormal mixing ratio Alarm 6 Abnormal zero calibration ratio Alarm 7 Abno...

Page 96: ...10 3 2 Entering Tag Name Primary to tertiary value Displays the selected item Refer to Section 7 9 Setting Display Item Switch display area Displays switches and functions selected according to the p...

Page 97: ...he Execution Setup display Returns to the Execution Setup display Maintenance panel display Commissioning display Basic setup mA output setup mA output1 mA output2 Set presets Alarms setup Hysteresis...

Page 98: ...ons later in this manual 6 3 4 Entering Numeric and Text Data This section sets out how to enter numeric and text data If only numeric values are entered a numeric data entry display as in Figure 6 6...

Page 99: ...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 the entry Siki06E ai F0...

Page 100: ...ve Zero gas flow setting valve Flowmeter for reference gas Flowmeter for calibration gas F06 8E ai Figure 6 8 ZA8F Flow Setting Unit CAL OUT REF OUT Made in Japan ZERO IN SPAN IN F06 9E ai Flowmeter f...

Page 101: ...o change the detector parameters Before connecting power refer to Section 7 6 Confirmation of Detector Type Setting The ZO21D is not a explosion proof detector Check valve type setting Check piping wi...

Page 102: ...e needle valve in the flow setting unit 7 4 Supplying Power to the Converter CAUTION To avoid temperature changes around the sensor it is recommended that rather than turning it on and off power be co...

Page 103: ...ption 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 changed press the Enter key The display shown in...

Page 104: ...Current Output Setting later in this manual 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 in th...

Page 105: ...d press the Enter key to display the Display item selection display Figure 7 14 4 Select the Secondary and Tertiary values in the same manner as in the steps above 5 Consult Table 7 1 Display Items en...

Page 106: ...or estimating the combustion efficiency etc check that no air is leaking in beforehand and that the measured value has not been affected by any interference gas CH4 CO H2 etc About moisture quantity T...

Page 107: ...el display to display the Output contacts display see Figure 7 17 3 In this display select the desired output contact for checking The display which enables the closing and opening of contacts then ap...

Page 108: ...18E ai Figure 7 18 Calibration contacts Check Panel Display NOTE Open and Closed displayed on the Calibration contacts display indicate actions of drive contacts and are opposite to the valve open an...

Page 109: ...low automatic supply of the calibration gases The following sections set forth the manual calibration procedures For details on semi automatic and automatic calibrations consult Chapter 9 Calibration...

Page 110: ...check valve is used maximum pressure rating is 300 kPa This applies even if you are using the ZR40H Automatic Calibration Unit Calibration Procedures This manual assumes that the instrument air is th...

Page 111: ...e graph At this point calibration has not yet been executed yet so even if the measured value is above or below 21 no problem occurs 5 After the measured value has stabilized press the Enter key to di...

Page 112: ...o even if the measured value is above or below the zero gas concentration value no problem occurs 9 After the measured value has stabilized press the Enter key to display the Zero calibration complete...

Page 113: ...enter the oxygen concentration for the maximum current 20 mA in the same manner as in step 4 above 6 Set the mA output2 in the same way as the setting procedure for mA output1 given above 8 1 2 Input...

Page 114: ...nt ON OFF switching You can set a smoothing time constant of between 0 and 255 seconds to reduce the effect Select the appropriate output damping constant from the numeric data entry display To set 30...

Page 115: ...menu displays of the Execution Setup display 3 Under Calibration see Chapter 9 Calibration later in this manual For manual Calibration Under calibration is the time that starts when you move to the M...

Page 116: ...resets then the mA outputs presets display as shown in Figure 8 1 Warm up 4mA Preset value 4 0 mA Maintenance Hold Preset value 4 0 mA Cal blowback Hold Preset value 4 0 mA Error Preset Preset value 3...

Page 117: ...Table 8 3 Output Hold Default Values Status Output hold setting Preset value During warm up 4 mA 4 mA Under maintenance Holds output at value just before maintenance started 4 mA Under calibration or...

Page 118: ...hows When a 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 t...

Page 119: ...y The Alarms setup display shown in Figure 8 4 then appears To set the hysteresis proceed to the following steps 4 Select Hysteresis in the Alarms setup display The numeric data entry display then app...

Page 120: ...ol O2 100 vol O2 Low limit alarm OFF Low limit alarm setpoint 0 to 100 vol O2 0 vol O2 Low low limit alarm OFF Low low limit alarm setpoint 0 to 100 vol O2 0 vol O2 8 4 Contact Output Setting 8 4 1 Co...

Page 121: ...alibration 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 Move the pointer to During power o...

Page 122: ...If Warm up ON is selected contact output occurs during warm up For the definition of Warm up see Subsection 8 2 1 Output range change If Range change ON is selected contact output occurs answer back s...

Page 123: ...ngs High high limit alarm High limit alarm ON Low limit alarm ON Low low limit alarm Calibration coefficient correction ratio alarm Startup power stabilization timeout alarm Error ON Other settings Wa...

Page 124: ...1 second time interval 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 an...

Page 125: ...ct 1 select operate if Closed You can select Open or Closed 7 Change Closed to Open Input1 No function Input1 contact is active at Closed Input2 No function Input2 contact is active at Closed Enter In...

Page 126: ...0 7 0 0 Set time 1 4 3 9 1 3 J ul 2 0 0 0 1 4 3 9 5 5 Clock F08 13E ai Figure 8 12 Other Settings Figure 8 13 Clock Display 8 6 2 Setting Periods over which Average Values Are Calculated and Periods...

Page 127: ...or m3 m3 Gw Water vapor contained in exhaust gas per unit quantity of fuel by hydrogen and moisture content in fuel m3 kg or m3 m3 1 in Table 8 9 Gw1 Water vapor contained in exhaust gas per unit qua...

Page 128: ...n 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...

Page 129: ...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...

Page 130: ...8 43 11 27 0 77 No 4 0 94 0 97 83 0 10 5 0 5 0 4 3 5 2 0 0 1 43032 40604 10 3 1 55 1 18 0 02 8 18 10 93 0 72 2 1 3 For gas fuel Fuel properties Type Specific weight kg m3 Chemical component weight pe...

Page 131: ...eric data to the Value of the X coefficient and then to the Absolute humidity of the atmosphere 7 Choose finished to return to the display shown in Figure 8 17 See Manual for details Contents of moist...

Page 132: ...during Purging Procedure Set the purging time as follows 1 Press the Setup key in the Basic panel display to display the Execution Setup display 2 Select the Commissioning in the Execution Setup disp...

Page 133: ...ation Blow back and Maintenance 4 Select Calibration Blow back and Maintenance 5 A text entry display appears Enter password as up to 8 alphanumeric characters 6 You can enter a password for Commissio...

Page 134: ...Blank Page...

Page 135: ...ectrode 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...

Page 136: ...nducted so that a calibration curve is obtained which corrects the deviation from the theoretical cell electromotive force 9 1 2 Calibration Gas A gas with a known oxygen concentration is used for cal...

Page 137: ...correction ratio C A x 100 Correctable range 0 18 Cell electromotive force mV Calibration curve before correction Corrected calibration curve theoretical calibration curve Zero origin Span gas concent...

Page 138: ...ro 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 ca...

Page 139: ...following preset calibration interval Calibrations are limited by the following mode selection When Manual calibration is selected Manual calibration only can be conducted This mode does not allow sem...

Page 140: ...e zero gas set ranges from 0 3 to 100 vol O2 Enter 00098 for an oxygen concentration of 0 98 vol O2 Span gas Concentration Set the oxygen concentration for span calibration If instrument air is used a...

Page 141: ...ization time Analog output remains held when output remains held Calibration start contact or switch input Span calibration span gas valve open Zero calibration zero gas valve open Analog output statu...

Page 142: ...or blow back operations calibration will start after completing the maintenance service or blow back operations see Subsection 8 2 1 earlier in this manual 4 If 000 days 00 hours are set for the cali...

Page 143: ...these steps 1 Press the Setup key in the Basic panel display to display the Execution Setup display Then select the Calibration in the Execution Setup display The Calibration display shown in Figure...

Page 144: ...tion will stop and the hold output stabilization time will be set up 2 Press the Reject key once again to return to the Basic panel display and the analyzer will be in normal measurement Automatic Cal...

Page 145: ...be an index to determine the amount of degradation of the sensor The cell voltage corresponds to the oxygen concentration currently being measured If the indicated voltage approximates the ideal valu...

Page 146: ...nce increase The degradation of the cell cannot be evaluated just by changes in cell s internal resistance however Those changes in the cell s internal resistance are just a guide to the extent the ce...

Page 147: ...characteristic 10 1 8 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 periods during which the cell may sti...

Page 148: ...changed the current minimum oxygen concentration will be displayed for more details see Subsection 8 6 2 earlier in this manual 10 1 13 Average Oxygen Concentration The average oxygen concentration d...

Page 149: ...Items Selected item Description Oxygen concentration Oxygen concentration graph under measurement Output 1 If this equipment is for the oxygen analyzer the trend graph will be an oxygen concentration...

Page 150: ...ears Enter the upper limit value Also enter the lower limit value in the same way The allowable settings for both upper limit and lower limit values range from 0 to 100 O2 10 2 4 Default Setting When...

Page 151: ...cution Setup display Then select the Maintenance in the Execution Setup display 2 Select the Display setup in the Maintenance display 3 Select the Display item in the Display setup display The display...

Page 152: ...llows you to select between No function Semi_Auto and Auto see Figure 10 8 Enter No function Semi_Auto Auto Mode Blow back setup F10 8E ai Figure 10 8 Blow back setup Display 10 4 2 Operation of Blow...

Page 153: ...Blow back setup F10 10E ai Figure 10 10 Blow back Setup Display In the Blow back setup display shown in Figure 10 10 if you choose Mode No function or Semi_Auto the Interval Start date and Start time...

Page 154: ...at can be initialized and their defaults are listed in Table 10 5 To initialize the set data follow these steps 1 On the Basic panel display touch the Setup key to display the Execution Setup display...

Page 155: ...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 date 01 01 00 Auto Start time 0 00 Auto Blow...

Page 156: ...Blow back OFF High limit temp alarm OFF Calibration gas press drop OFF Gas leak detection OFF Contact output action Open Output contact 2 Alarm OFF Other settings Warm up OFF Output range switching O...

Page 157: ...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 d...

Page 158: ...the power to operate the pump to supply the span gas Carrying case Flow checker Span gas valve Checks the zero and span gas flow Controls the span gas air flow Zero gas valve regulator Tube connection...

Page 159: ...m of the cylinder with the clamp 5 Take note of the oxygen concentration of the sealed gas indicated on the gas cylinder and replace the carrying case Enter the oxygen concentration of the sealed gas...

Page 160: ...span gas to 600ml min Valve opened Cancel calibration Manual calibration F10 15E ai Enter Span calibration Close the span gas valve Zero calibration End Manual calibration F10 16E ai Figure 10 15 Man...

Page 161: ...cylinder Each gas cylinder is operable for nine minutes or more provided the gas is discharged at the specified rate Therefore if your calibration time is estimated at four minutes you can operate th...

Page 162: ...open the span gas flow setting valve of the flow setting unit and adjust the flow rate to 600 60 ml min Turn the valve slowly counterclockwise after loosening the lock nut if the valve has a lock nut...

Page 163: ...tion Close the zero gas valve Span calibration End Manual calibration F10 20E ai Figure 10 20 Zero point Calibration Complete in Manual Calibration 3 Close the zero gas flow setting valve to stop the...

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Page 165: ...o NOT touch the probe if it has been in operation immediately just before being checked The sensor at the tip of the probe heats up to 750 C during operation If you touch it you will get burned CAUTIO...

Page 166: ...0 ml min and insert the rod into the tube 3 mm inside diameter However be careful not to insert the rod deeper than 40 cm for a general purpose detector or 15 cm for a high temperature detector 4 Clea...

Page 167: ...en 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 senso...

Page 168: ...ing careful not to cause irregularities in the pitch of the coil spirals i e not to bend the coil out of shape place it in the ringed groove properly so that it forms a solid contact Groove in which t...

Page 169: ...o strong vibrations or shock Additionally the heater unit reaches high temperatures and is subjected to high voltages So maintenance services should be performed after the power is off and the heater...

Page 170: ...ce 11 6 TC CELL CJ 1 2 3 4 5 6 8 7 H T R 10 11 13 14 12 22 7 8 9 22 1 2 3 4 5 6 21 22 26 28 27 31 32 24 25 29 30 23 17 15 18 19 20 13 12 16 CELL TC TC F11 4E ai A A View A A Figure 11 4 Exploded View...

Page 171: ...ER SEEZ G7067ZA and tighten the screw for the heater assembly fixation 8 with a special wrench part no K9470BX or equivalent with a tightening torque of 12N m 10 percent Next to install the O rings 20...

Page 172: ...tector 22 with an ceramic adhesive To remove the flame arrestor assembly 1 crack the hardened adhesive on the joint by tapping it with a flat blade screwdriver and a hammer or appropriate tools After...

Page 173: ...o remove dust blow air on them or rinse them with water 11 1 7 Stopping and Re starting Operation Stopping Operation When operation is stopped take care of the followings so that the sensor of the det...

Page 174: ...a fuse as indicated in Figure 11 6 If the fuse blows out replace it in the following procedure NOTE If a replaced fuse blows out immediately there may be a problem in the circuit Go over the circuit c...

Page 175: ...the holder together with the cap and push and turn the cap clockwise 90 with the screwdriver to complete installation of the fuse Cap Flat blade screwdriver Fuse Socket F11 7E ai Figure 11 7 Removing...

Page 176: ...see is attached The end of the pin holding down the back plate must be on the bracket side 4 Replace piping and fix M6 bolts between brackets 1 1 When disassembling and reassembling mark original posi...

Page 177: ...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 The content...

Page 178: ...r indicated on the display End Carry out calibration Replace the damaged portions Examine the wiring connection to converter terminals CELL and CELL Also check the wiring connection in the repeater te...

Page 179: ...se wrong polarity Overcurrent protection is triggered if there are problems in the heater wiring When the protective circuit is triggered the internal fuse blows and the heater is disconnected resulti...

Page 180: ...ing to the memory EEPROM mounted in the electrical circuits inside the converter Locating cause of failure and countermeasures Turn off the power to the converter once and then restart the converter I...

Page 181: ...utside the range of 0 18 refer to Subsection 9 1 3 Compensation Alarm 8 EMF stabilization time up alarm In automatic or semi automatic calibration cell voltage does not stabilize after the calibration...

Page 182: ...tion value has agreed with the concentration of the zero gas actually used b The piping for calibration gases has been constructed so that the zero gas does not leak 2 If the alarm is not generated du...

Page 183: ...teriorated suddenly the check valve that prevents moisture in the furnace from entering into the calibration pipes may have malfunctioned If the furnace gas flows into calibration lines the gas is coo...

Page 184: ...eplacement carry out the procedure described in step 3 and later of Location cause of alarm and countermeasures in Subsection 12 2 2 Alarm 6 Zero Calibration Coefficient Correction Ratio Alarm Alarm 8...

Page 185: ...uits inside the converter occurred Locating cause of alarm and countermeasures Before proceeding to the following troubleshooting procedure examine whether or not the temperature of the detector termi...

Page 186: ...C or less If the thermocouple voltage is large accurate measurement cannot be achieved 3 If the thermocouple is normal check whether or not the wiring cable is broken or shorted out and also whether t...

Page 187: ...ges 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 t...

Page 188: ...ponents exist in the sample gas they burn in the sensor and thus oxygen concentration decreases Check that there are no combustible components 5 Temperature of the detector cell reaches 750 C or more...

Page 189: ...9477EA G7109YC K9470BK E7042DW K9470ZF K9470ZG E7042BR K9470BM K9473AN ZR01A01 01 ZR01A01 02 ZR01A01 05 ZR01A01 10 E7042BS K9470BJ E7042AY K9470ZK K9470ZL 1 4 4 1 1 1 1 1 1 1 1 1 Flame Arrestor Bolt M...

Page 190: ......

Page 191: ...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 192: ......

Page 193: ...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 194: ......

Page 195: ...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...

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Page 197: ...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...

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Page 199: ...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 200: ......

Page 201: ...mensions 2 7 3 Check Valve Changed of the weight Nov 2014 3rd Edition Revised and Corrected over all Jul 2006 2nd Edition Introduction Warning about Explosion proof Deleted description Introduction Ex...

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