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ZR402 Instruction Manual

1. ZR22G 0 G P i Flange Equivalent to DIN PN10 DN100 Unit mm Rc1 4 or 1 4NPT Reference air inlet ___156 4 87 2 2 G1 2 2 1 2NPT etc i Cable connection port c M eA FE Oh z E p S Reference gas outlet Flange 2 Rc1 4 or 1 4NPT Calibration gas inlet Stop Valve Flange PIPING A Weight Specification PIPING kg DIN PN10 DN100 SUS304 ZR22G 300 L Approx 19 F3 8 6E EPS 2ZR22G O K P Flange Eguivalent to JIS 5K 65 FF Unit mm Rc1 4 or 1 4NPT Reference air inlet c L N56 y 287 2 G1 2 2 1 2NPT etc Cable connection port Lor 2 QE el Fa Reference gas outlet PIPING Flange H B Rci 4 or 1 ANPT Flange 1 Calibration gas inlet Stop Valve PIPING A Weight Specification PIPING kg JIS 5K 65 FF SUS304 ZR22G 300 0 F3 8 7E EPS IM 11M12A01 03E 3 Installation ZR22G 0 L P Flange JIS 10K 65 FF Unit
2. 8 7 8 2 3 Output Hold Settings 8 8 S24 Default Values ce csiie russe R IL Mais Mt 8 8 IM 1M12A01 03E 8 3 Alarm S tting is ss reeset ses aroraa aTeo EESE Eee Ii reS r EER bE ES ESE ESS EEEO SES SRS 8 9 8 35 Alarm Valles sara cesta corer ness abe settee EEEE EEEE TE 8 9 8 3 2 Alarm Output Actions sus must series messes tt 8 9 8 3 3 Alarm Setting Procedure 8 10 8 34 1 Default V ales toes celeses intense Rd Tes Rens 8 11 8 4 Output Contact Setup oo eee sessions 8 12 8 4 19 Output Contact ss estechi see i nr nt nl nl ei 8 12 8 42 Setting Proc dure coc vieiiieti cea har int 8 12 8 43 Default Valu s ssss ue ie ee donnee Ads 8 15 8 5 Input Contact Settings ss 8 16 8 5 1 Input Contact Functions ss 8 16 85 2 Setting Proc dure musette E items 8 17 8 3 3 Default Values oarn tes TR ner EEOSE 8 17 8 6 Other Settings hist ann tint este 8 18 8 6 1 Setting the Date and Time 0 eee cesses ceeceeeceeeeeeecaeeeaecneeaeenaes 8 18 8 6 2 Setting Periods over which Average Values Are Calculated and Periods over which Maximum and Minimum Values Are Monitored 8 19 8 6 3 Setting Measurement Gas Temperature and Pressure ee 8 20 8 6 4 Setting Purging seen 8 22 6 5 Setting Passwords israe ieena RER AE ete tech EE 8 23 9 Cali PathOnrsisiscessiciectestecssctasaccaccececacaedbelacdessessscessesdacessasacaeabelavcsddetasesdaetancssvatscc
3. Span origin 21 0 pi p2 0 51 Span gas concentration Zero gas concentration Oxygen concentration vol 02 Zero point correction factor B A x 100 Correctable range 100 30 Span correction factor C A x 100 Correctable range 0 18 F9 2E EPS Figure 9 2 Calculation of a Two point Calibration Curve and Correction Factors using Zero and Span Gases IM 11M12A01 03E 9 Calibration Figure 9 3 shows a one point calibration using only a span gas In this case only the cell electromotive force for a span gas with oxygen concentration pl 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 81 92 ez 7 Zero origin Cell electromotive force mV Previous zero gas data el a Corrected calibration curve theoretical calibration curve es cf 0 Span origin 21 0 P Span gas concentration Oxygen concentration vol O2 Zero point correction factor B A x 100 Correctable range 100 30 Span correction factor C A x 100 Correctable range 0 18 F9 3E EPS Figure 9 3 Calculation of a One point Calibration Curve and Correction Factors using a Span Gas 9 1 4 Characteristic Data from a Sensor Measured During Calibration IM 11M12A01 03E During calibration calibration data
4. Specification JPI Class 150 3 RF SUS304 PIPING F3 8 12E EPS Unit mm Rc1 4 or 1 4NPT Reference air inlet L 156 _ 67 2 G1 2 2 1 2NPT etc Sie Cable connection port ial Lot al INI vt IEEE AWU Reference gas outlet PIPING Flange B Rc1 4 or 1 4NPT Flange Calibration gas inlet Stop Valve PIPING A Model Code Specification Weight PIPING kg ZR22G 040 ZR22G 300 IM 11M12A01 03E Westinghouse Approx 6 Approx 15 F3 8 13E EPS 3 19 4 Piping 4 Piping This chapter describes piping procedures based on three typical system configurations for EXAxt ZR Separate type Zirconia High temperature Humidity Analyzer Ensure that each check valve stop valve and joint used for piping do not allow leakage Especially if there is any leakage of from the calibration gas pipes and joints it may cause clogging of the piping or incorrect calibration Be sure to conduct leakage test after pipes piping Basically apply instrument air dehumidified by cooling to the dew point 20 C or lower and removing any dust oil mist and the like for the reference gas piping When the instrument uses natural convection for reference gas ambient air near the detector is used for r
5. Contact input 2 F5 14E EPS Figure 5 14 Contact Input Wiring 5 8 1 Cable Specifications Use a 2 core or 3 core cable for this wiring Depending on the number of input s determine which cable to use 5 8 2 Wiring Procedure 1 M4 screws are used for the terminals of the converter Each cable should be termi nated in the corresponding crimp on terminals 2 The ON OFF level of this contact input is identified by the resistance Connect a contact input that satisfies the specifications in Table 5 2 Table 5 2 Identification of Contact Input ON OFF Closed Open Resistance 2000 or less 100 kQ or more T5 2E EPS IM 11M12A01 03E 5 15 5 9 Temperature Input Wiring When inputting the measurement gas temperature from external of the equipment connect a two wire temperature transmitter The relative humidity and dew point are acquired based on the temperature signal from the connected transmitter in the case where the setting is Temperature input selected and external input As for the wiring of the temperature transmitter and thermocouples refer to appropriate temperature transmitter instruction manual Converter Temperature transmitter A O O FG Shielded cables F5 15E EPS 5 9 1 Applicable Temperature Transmitter Apply a temperature transmitter that is suit for the following interfaces Output signal 4 to 20 mA DC two wire system Maximum supply voltage from
6. 102 lit 102 flashing e Drawing for flashing p ic lit Indicated by gray characters Flashing l j a j l M Z IM 11M12A01 03E NOTICE e Specification check When the instrument arrives unpack the package with care and check that the instrument has not been damaged during transportation In addition please check that the specification matches the order and required accessories are not missing Specifi cations can be checked by the model codes on the nameplate Refer to Chapter 2 Specifications for the list of model codes e Details on operation parameters When the EXAxt ZR Separate type High Temperature Humidity Analyzer arrives at the user site it will operate based set before shipping parameters initial data on the departure from the factory Ensure that the initial data is suitable for the operation conditions before conducting analysis Where necessary set the instrument parameters for appropriate operation For details of setting data refer to chapters 7 to 10 When user changes the operation parameter it is recommended to note down the changed setting data After Sales Warranty vi Do not modify the product During the warranty period for repair under warranty carry or send the product to the local sales representative or service office Yokogawa will replace or repair any damaged parts and return the product to you Before returning a product for re
7. IM 11M12A01 03E 7 9 7 8 Setting Display Item This section briefly describes the display item settings shown in Figure 7 11 Basic Panel Display If the humidity analyzer HS option was specified at the time of pur chase the primary value has set Humidity If a mixing ratio is to be measured change the current primary value following the steps below Additionally if the humidity has been selected in the Detector Type Setting in Section 7 6 earlier in this manual the primary value is set to the humidity and the secondary and tertiary values are current outputs and 2 respectively when data initialization is performed Tag name Primary value 0 0 Oo H20 Secondary value 4 00mA Output1 Tertiary value 4 00mA Output2 F7 11E EPS Figure 7 11 Basic Panel Display 1 Press the Setup key in the basic panel display to display the Execution Setup display Then select Maintenance in the Execution Setup display 2 Select the Display setup from the Maintenance panel display Figure 7 12 The Display setup display Figure 7 13 then appears 3 In the above Display setup display select the Display item The Display item display Figure 7 14 then appears From this display select the Primary value and press the Enter key to display the Display item selection display Figure 7 15 4 Select the Secondary and Tertiary values
8. 1 8 turn tighten bolts 1 8 turn approximately 45 each Contact F11 3E EPS Figure 11 3 Exploded View of Sensor Assembly A CAUTION Optional Inconel bolts have a high coefficient of expansion If excess torque is applied while the bolts are being tightened abnormal strain or bolt breakage may result So tighten the bolts following the instructions given above 11 1 3 Replacement of the Heater Unit This section describes the replacement procedure for the heater unit The sensor or ceramic heater furnace core internal 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 A CAUTION If the heater strut assembly can not be removed because a screw hes fused to its thread one of our service representatives can fix it IM 11M12A01 03E 11 5 Figure 11 4 Exploded View of Detector Note The parts marked by is not equipped with the types except the pressure compen sation type 11 6 IM 11M12A01 03E IM 11M12A01 03E 11 Inspection and Maintenance Replacement of heater strut assembly ZR22G Style S2 and after Refer to Figure 11 4 as an aid in the following discussion Remo
9. 2nd 3rd Nov 2000 Mar 2001 Sept 2001 Newly published Revision Record apart from a general rewrite of English Section 2 2 Some changes to ZR22G Separate type in MS code table and notes added 2 3 Corrected drawing of ZR402G and part of its MS code table Sun shied hood added 2 4 1 Changed reference air pressure ZA8F Flow setting unit changed to styleB 2 4 2 Added detail to ZR40H AutoCalibration Unit 3 2 2 Corrected Figure 3 6 Panel Cutout dimensions 3 4 Added 3 4 ZR40H Automatic Calibration Unit 3 7 Added drawing of Pressure Compensated Detector 4 3 Added explanation for piping to System 3 example 4 4 Added pressure compensation piping 5 7 Added 5 7 ZR40H AutoCalibration Unit wiring 6 1 Added Filter to 6 1 ZR22G Detector 6 3 Added Names and Functions to 6 3 ZR40H AutoCalibration Unit 7 2 Changed reference air pressure 7 11 2 1 Changed reference air pressure 8 4 1 Corrected Table 8 5 10 6 1 Changed reference air pressure 11 1 Added Filter to 11 1 Inspection and Maintenance of the ZR22G Detector Added Filter to CMPL11M12A01 03E added ZR40H AutoCalibration Unit to CMPL11M12A01 11E and added Sun shield hood to ZR402G of CMPL 11M12C01 01E Revised Section 1 2 1 Model ZR22A Heater Assembly added to System Components Table 2 2 1 Some part change to ZR22G Detectors External Dimensions F French Display code added to ZR402G MS code 2 4 1 ZA8F Flow setting unit error correced 2 6 7 Model ZR22A Heater Assembly added 5 12 Figure 5 3 cor
10. 5 13 5 7 1 Cable Specifications siirsin ee a a peaa ines 5 14 DED Wining Procedure 4 iui Sees eoe E EE E E N ES dite 5 14 IM 11M12A01 03E 5 8 Wiring for Contact Input 5 15 9 8 1 Cable Specifications 4 ss asvses sete eon te estes ie letecis ses apes aida its 5 15 5 8 2 Witing Procedure ss sites aaeasseiun ashi bias estes 5 15 5 9 Temperature Input Wiring ss 5 16 5 9 1 Applicable Temperature Transmitter 5 16 5 9 2 Cable Specifications ses 5 16 59 3 Waring Procedure teste nl ai APN En 5 16 0 COMA OTIC INES is RSR ATTA nr ns ane eee OPE 6 1 JAR22G Detector sn enichiakinciigivg ahd is iid Ma knwdeig hain hag tt 6 1 6 1 1 General purpose Detector ss 6 1 6 2 ZR402G Converter nine nn ehh aaa 6 2 6 3 ZA8F Flow Setting Unit ZR40H Automatic Calibration Unit 0 000 6 3 Te Startu Prii niniin ainiai iiaii ie aiteas eases seasea aL 7 1 Checking Piping and Wiring Connections sssseesseseseeesessesreresteersrrererreeeses 7 1 T2 Checking Valve Sepre nine ERNEK eE EEEE REEE 7 1 7 3 Supplying Power to the Converter 7 2 74 Touchpanel Switch Operations ss 7 3 TAD Basie Panel and S with iccjss es manne sin 7 3 74 2 Display Configuration for High temperature Humidity Analyzer 7 4 LAB Display Unc ons sis nana minette M ae nu 7 5 74 4 Entering Numeric and Text Data occ cee ceeeecnseeseceeeeteeneeeerees 7 5 7 5 Confirmation of Converter Type Setting 0 cc
11. F2 6 2E EPS 2 19 2 20 A A CHECK 1 REF OUT OUT O O a Eee a flow flow meter meter ee on a XE Xe b ZERO GAS IN Instrument air Approx 1 5 l min 2 Needle valve is supplied as accessory with flow meter F2 6 3E EPS IM 11M12A01 03E 2 Specifications 2 5 ZO21S Standard Gas Unit This is a handy unit to supply zero gas and span gas to the detector in a system configu ration based on System 1 It is used in combination with the detector only during calibration Standard Specifications Function Portable unit for calibration gas supply consisting of span gas air pump zero gas cylinder with sealed inlet flow rate checker and flow rate needle valve Sealed Zero Gas Cylinders 6 provided E7050BA Capacity 11 Filled pressure Approx 686 kPa G at 35 Composition 0 95 to 1 0 vol O N based 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 sheet Point Epoxy resin baked Paint Color Mainframe Munsell 2 0 GY3 1 0 5 equivalent Cover Munsell 2 8 GY6 4 0 9 equivalent Piping 664mm flexible tube connection Span Gas Internal pump draws in air from atmosphere and feeds to detector Weight Approx 3 kg Non CE Mark Model and Codes Suffix code Option code Description LOIS rss Standard gas unit D 200 V
12. Trend graph Auto return time 0 min QE CF Language ET Deutsch Francias Figure 10 19 Manual Calibration Display m 2 g F10 7E EPS 2 Adjust the flowrate and select Valve opened from the Manual calibration display Check the Trend graph display to see that the measured value is stabilized Then press the Enter key The Manual calibration display shown in Figure 10 18 appears Manual calibration Zero calibration NA Close the zero gas valve Cp Span calibration End F10 18E EPS Figure 10 20 Zero point Calibration Complete in Manual Calibration 3 Close the zero gas flow setting valve to stop the zero gas flow If the valve has a lock nut be sure to tighten the lock nut to prevent the any leakage of the zero gas into the sensor because the valve may become loose during measurement 10 6 4 Operation After Calibration No special operation of the instrument is needed after calibration However it is recommended that the pressure regulator for the zero gas cylinders be closed because calibration is not required so often 10 24 IM 11M12A01 03E 11 Inspection and Maintenance 11 Inspection and Maintenance This chapter describes the inspection and maintenance procedures for the EXAXTZR Zirconia High temperature Humidity Analyzer to maintain its measuring performance and normal operating conditions A CAUTION When checking the detector carefully observe the foll
13. A Handle safely to avoid injury DANGER Connect the power supply cord only after confirming that the supply voltage matches the rating of this equipment In addition confirm that the power is switched off when connecting power supply Some process gas is dangerous to people When removing this equipment from the process line for maintenance or other reasons protect yourself from potential poisoningby using a protective mask or ventilating the area well 1 About This Manual e This manual should be passed on to the end user e The contents of this manual are subject to change without prior notice e The contents of this manual shall not be reproduced or copied in part or in whole without permission e This manual explains the functions contained in this product but does not warrant that those will suit the particular purpose of the user e Every effort has been made to ensure accuracy in the preparation of this manual However should any errors or omissions come to the attention of the user please contact the nearest Yokogawa Electric representative or sales office e This manual does not cover the special specifications This manual may not be changed on any change of specification construction and parts when the change does not affect the functions or performance of the product e If the product is used in a manner not specified in this manual safety of this product may be impaired IM 11M12A01 03E iii 2 Safety and Mo
14. Cal gas press low OFF e Process up set OFF Enter F8 11E EPS Figure 8 11 Contacti Others Display IM 11M12A01 03E 8 13 Table 8 6 Output Contact Settings Item to be selected Brief description Alarm and Error settings Other settings High high limit alarm If high high alarm ON is selected contact output occurs when the high high limit alarm is issued To do this it is required in alarm setup that the high high alarm be set on beforehand see Section 8 3 High limit alarm If high alarm ON is selected contact output occurs when the high limit alarm is issued To do this it is required in alarm setup that the high limit alarm be set on beforehand see Section 8 3 Low limit alarm If low alarm ON is selected contact output occurs when the low limit alarm is provided To do this it is required in alarm setup that the low limit alarm be set on beforehand see Section 8 3 Low low limit alarm If low low alarm ON is selected contact is on when the low low limit alarm is issued To do this it is required in alarm setup that the low low Calibration coefficient alarm If calibration coefficient alarm is ON enabled then when a zero calibration coefficient alarm alarm 6 or span calibration coefficient alarm alarm 7 occurs then calibration coefficient alarm contact output occurs see Sec 12 2 1 Alarms Startup power
15. Output1 21 0 H20 Output2 This deta provides for interective operation Example of trend display displays data changes During automatic calibration you can check has stabilized of display data while viewing oxygen trend data thus providing highly reliable calibration Example of setting data display displays data changes Commissioning A Cp Basic setup mA output setup Alarms setup Contact setup Others One touch interactive display operation SET User friendly design providing easy operation without need to use the instruction manual F6 3E EPS IM 11M12A01 03E 6 Components 6 3 ZASF Flow Setting Unit ZR40H Automatic Calibra tion Unit Reference gas flow setting valve Span gas flow setting valve Zero gas flow setting valve A 2 9 0 Flowmeter for reference gas Flowmeter for Calibration gas F6 4E EPS Figure 6 4 ZA8F Flow Setting Unit Flowmeter for Calibration gas Flowmeter for Reference gas Terminal Box our Made in Japan REF OUT CAL OUT SPAN IN ZERO IN Reference gas flow setting valve CS 7 Calibration gas flow setting valve er F6 5E EPS Figure 6 5 ZR40H Automatic Calibration Unit IM 11M12A01 03E 6 3 7 Startup 7 Startup The following describes the minimum operating requirements from supplying pow
16. e If the blow back is executed with an input contact it must be preset in the Input contacts setting for more details see Section 8 5 earlier in this manual In Section 8 4 Output Contact Setup earlier in this manual set the contact used as the blow back switch beforehand Do not set any other function for the contact used as the blow back switch Other wise blow back may be activated when the contact is closed by any other function No blow back is executed during calibration or maintenance service If automatic blow back reaches the preset start time during calibration or maintenance service blow back will be executed after completing the calibration or maintenance service and after the equipment returns to the measurement mode If automatic blow back reaches the preset start time during semi automatic blow back the current automatic blow back will not be executed If you set the blow back interval at 000 days 00 hours only the first blow back is then executed No subsequent blow backs will be executed If a past date is set for the Start time no blow back will be executed IM 11M12A01 03E 10 11 10 2 1 5 Default Setting When the analyzer is delivered or if data are initialized the blowback settings are by default as shown in Table 10 4 Table 10 4 Blowback Default Setting Item Default setting Mode No function invalid Hold time 10 minutes 00 seconds Blow back time 10 m
17. o oN O O O O Insertion hole minimum 80 O j ANSI flange JIS flange F2 3E EPS Size of each part of flange Flange A B Cc t D JIS 5K 80 FF four holes of SUS304 180 145 diameter 19 12 40 ANSI Class eight holes of 150 4B FFSUS304 228 6 190 5 diameter 19 12 50 2 3E 1 EPS IM 11M12A01 03E 2 Specifications 2 3 ZR402G Separate type Converter 2 3 1 Standard Specifications IM 11M12A01 03E Operated using an LCD touchscreen on the converter Display LCD display of size 320 by 240 dot with touchscreen Output Signal 4 to 20 mA DC two points maximum load resistance 550 Q Contact Output Signal four points one is fail safe normally open Contact Input two points Analog Input one point thermal input 4 20 mA Auto calibration Output Two points for dedicated auto calibration unit Ambient Temperature 20 to 55 C Storage Temperature 30 to 70 C Humidity Ambient 0 to 95 RH Non condensing Installation Altitude 2000 m or less Category based on IEC 1010 II Note Pollution degree based on IEC 1010 2 Note Note Installation category called over voltage category specifies impulse withstand ing voltage Category II is for electrical equipment Pollution degree indicates the degree of existence of solid liquid gas or other inclusions which may reduce breakdown voltage Degree 2 is the normal indoor environment Power Supply Voltage Ratings 100 to 240 V AC Acceptable range 85 to 264
18. 19 18 B JIS 10K 100 FF SUS304 210 175 8 19 18 B JPI Class 150 4 RF SUS304 229 190 5 8 19 24 B JPI Class 150 3 RF SUS304 190 152 4 4 19 24 B Westinghouse 155 127 4 11 5 14 A IM 11M12A01 03E Flange Flange F07_02 EPS 2 7 2 2 2 2 8 ZH21B Dust Protector This protector is designed to protect the probe output from dust agitation 1 e to prevent combustible materials from entering the probe cell where humidity measurements are made in a dusty environment Standard Specification Insertion length Flange Material Weight Mounting 0 428m JIS 5K 80 FF SUS304 or ANSI Class 150 4 FF SUS304 However flange thickness is different SUS 316 JIS SUS 304 JIS flange Approximately 6kg JIS approximately 8 5kg ANSI Mounted on the probe or process flange with bolts and associated nuts and washers Description Dust Protector 0 to 600 C 0 428 m JIS 5K 80 FF SUS304 1 ANSI Class 150 4B FF SUS304 2 Style code Style B The flange thickness varies T22E EPS Specify the probe ZR22G 04011 K in code of 1 ZR22G 040 L C in code of 2 Dust protector Unit mm 428 Ress SKK KOR KO SRR RSS SOS KI KRONE FESSES oO SOKO OY PORK KR RKO OVS 5 osese sss RRR R e RS 9 E Install facing upwards
19. Alarm value of temperature and enter an alarm temperature from the numeric data entry display A CAUTION The critical temperature of the saturated water vapor pressure is 374 C If a gas temperature exceeding 370 C is entered no correct calculation will be obtained If an invalid value is set no correct calculation will be obtained Be sure to check allowable temperature ranges of the temperature transmitter you use and then enter the value correctly Exhaust gas setup Exhaust gas setup Cc Temperature input mode Cp Temperature input mode mA input mA input Temperature at 4mA Input temperature value 0 C o Temperature at 20mA 300 C v 4 1000 C Pressure 101 33kPa temperature 1000 C Pressure 101 33kPa Enter FB 18 EPS FB 19 EPS JASE Alarm value of Figure 8 18 Exhaust Gas Setup Figure 8 19 Exhaust Gas Setup Display Display Preset Entry Entering mA input IM 11M12A01 03E 8 21 8 6 3 2Setting Measurement Gas Pressure To set the measurement gas pressure follow these steps 1 Call up the Exhaust gas setup display and choose Pressure 2 Enter the measurement gas pressure absolute pressure from the numeric data entry display 8 6 3 3Default Values When the analyzer is delivered or if data are initialized measurement gas temperature and pressure set ranges and their default settings are as shown in Table 8 9 Table 8 9 Measureme
20. Calibration gas inlet Stop Valve PIPING A Specification PIPING JIS 10K 100 FF SUS304 ZR22G 300 F3 8 10 EPS ZR22G O R P Flange JPI Class 150 4 RF Unit mm Rc1 4 or 1 4NPT Reference air inlet L e IDG BE 2 G1 2 2 1 2NPT ete mie C Cable connection port H 41 el j vr Z E ID Reference gas outlet PIPING Flange B Rc1 4 or 1 4NPT Flange Calibration gas inlet Stop Valve PIPING A Weight Specification PIPING kg JPI Class 150 4 RF SUS304 ZR22G 300 F3 8 11 EPS IM 11M12A01 03E 2ZR22G Flange JPI O S P Class 150 3 RF 3 Installation Unit mm Rc1 4 or 1 4NPT Reference air inlet 87 2 G1 2 2 1 2NPT etc Cable connection port L 156 R the g 2 g 1 in CAF Reference gas outlet Flange Rc1 4 or 1 4NPT PIPING A Flange Calibration gas inlet Stop Valve ZR22G 300 ZR22G O W P Flange Westinghouse
21. F12 7E EPS Figure 12 7 Alarm 7 Span point Calibration Coefficient Alarm In automatic or semiautomatic calibration this alarm is generated when the span correction factor is out of the range of 0 18 refer to Section 9 1 3 Compensa tion The following are suspected as the cause 1 The oxygen concentration of the span gas does not agree with the value of the span gas set Calibration setup 2 The flow of the span gas is out of the specified flow value 600 60 mL min 3 The sensor assembly is damaged and the cell voltage is abnormal IM 11M12A01 03E 12 Troubleshooting lt Locating cause of failure and countermeasures gt 1 Confirm the following and carry out calibration again If the items are not within their proper states correct them a Ifthe display Span gas conc is selected in Calibration setup the set point should agree with the concentration of span gas actually used b The calibration gas tubing should be constructed so that the span gas does not leak 2 If no alarm is generated as a result of carrying out re calibration it is suspected that improper calibration conditions were the cause of the alarm in the preceding calibra tion In this case no specific restoration is necessary 3 If an alarm is generated again as a result of carrying out re calibration deterioration of or damage to the cell sensor is suspected as the cause of the alarm Replace ment of the cell w
22. Max 1 MPa G Secondary Pressure 0 02 to 0 5 MPa G Connection Rc1 4 or 1 4 FNPT with joint adapter 2 Specifications Part No Description G7004XF Joint Re 1 4 Material Zinc Alloy K9473XG Joint 1 4 NPT F Material Body Zinc Alloy Adapter SUS316 T2 13E EPS External Dimensions Unit mm Panel cut dimensions View A Horizontal Vertical mounting mounting 22 615 J 0 5 40 2 2 2 0 2 56 5 j ry LQ Ww x Panel Horizontal mounting Secondary ressure pauge Panel Vertical 2 r ee mounting N 1 i Secondary H 7 lt A Le G7004XF Re 1 4 po sy K9473XG 1 4NPT connector Approx 122 IM 11M12A01 03E 2 25 2 6 4 Zero gas Cylinder Part Number G7001ZC The gas from this cylinder is used as the calibration zero gas and detector purge gas Standard Specifications Capacity 3 4 1 Filled pressure 9 8 to 12 MPa G Composition 0 95 to 1 0 vol O in N Note Export of such high pressure filled gas cylinders to most countries is prohibited or restricted 325 140 485 Unit mm Weight Approx 6 kg F2213 EPS 2 6 5 Pressure Regulator for Gas Cylinder Part Number G7013XF or G7014XF 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
23. Ra eI Set period over which maximum and minimum is stored 24h F8 15E EPS Figure 8 17 Setting Average Value Calculation Periods and Maximum and Minimum Value Monitoring Periods 8 6 3 8 20 Setting Measurement Gas Temperature and Pressure The analyzer calculates the moisture content contained in exhaust gases and saturated water vapors from the entered gas temperature and pressure to obtain the relative humidity and dew point The relative humidity may be obtained using the following theoretical equation JIS Z 8806 To obtain the relative humidity The relative humidity U that is obtained from JIS Z 8806 is U ees x 100 where e water vapor pressure of moist air es Saturated water vapor Since the gas pressure ratio is equal to the volume ratio the above equation may be expressed mathematically by U PxH es x 100 where P Gas pressure H moisture content volume ratio The saturated water vapor pressure es is determined by a gas temperature so the relative humidity can be obtained by entering the above parameters To obtain the dew point The dew point is the temperature at which a water vapor pressure in the moist air is equal to the saturated water vapor pressure The water vapor pressure in the moist air can be obtained from the gas pressure a d volume ratio pressure ratio as given belo where e water vapor pressure in moist a P gas pressu H Humidity moisture conte
24. mm Rc1 4 or 1 4NPT Reference air inlet c L 6 2 G1 2 2 1 2NPT etc ae Cable connection port 3 Flo 9 4 FA HAI Reference gas outlet PIPING Flange 4 B Rc1 4 or 1 4NPT Flange Calibration gas inlet Stop Valve PIPING A Weight PIPING kg JIS 10K 65 FF SUS304 ZR22G 300 Approx 16 F3 8 8E EPS ZR22G 0 M P Flange JIS 10K 80 FF Unit mm Rc1 4 or 1 4NPT Reference air inlet 156 s 2 G1 2 2 1 2NPT etc Re Cable connection port 6 a dil a 4 1 CT vt 3 i jH X Reference gas outlet L Flange H Rc1 4 or 1 4NPT Flange Calibration gas inlet Stop Valve PIPING A Weight PIPING kg JIS 10K 80 FF SUS304 ZR22G 300 F3 8 9E EPS IM 11M12A01 03E 3 17 2ZR22G O P P Flange JIS 10K 100 FF Unit mm Rc1 4 or 1 4NPT Reference air inlet L 156 87 2 G1 2 2 1 2NPT etc E Les Cable connection port A a Rd al s al n d OO D Reference gas outlet PIPING Flange B Rc1 4 or 1 4NPT Flange
25. the cold junction tempera ture sensor seems to be faulty Replace the cold junction temperature sensor 2 If the voltage between the terminals is within the above range the cold junction temperature sensor seems to be normal Check whether or not the cable is broken or shorted out and whether the cable is securely connected to the terminals Also check that the resistance of the wiring between the converter and detector is 10Q or less 3 If there is no failure in the wiring the electrical circuits inside the converter may possibly fail Contact the service personnel at Yokogawa Electric Corporation A CAUTION The operating temperature range of the Model ZO21D Detector is 10 C to 80 C except for the high temperature detector ZO21D H Since a cold junction tempera ture alarm for this analyzer is not generated until the temperature exceeds 155 C if the Model ZO21D Detector is used be careful in controlling the ambient temperature of the terminal block 12 2 2 7 Alarm 11 Thermocouple Voltage Alarm This alarm is generated when the emf voltage of the thermocouple falls below 5 mV about 170 C or exceeds 42 1 mV about 1020 C Whenever Alarm 11 is generated Error 2 heater temperature failure occurs 1 Breakage of the heater thermocouple signal wire between the converter and the detector occurred or the cable is not securely connected to the connecting terminals 2 The positive and negative poles of
26. 01 kg kg for the mixture ratio 4 to 20 mA DC linear or log can be selected Input output isolation provided Output damping 0 255 sec Can select hold or non hold and set preset value for hold Contact Output Four points contact capacity 30V DC 3A 250V AC 3A resistive load Three of the output points can be selected to either normally energized or normally de energized status Delayed functions 0 to 255 seconds and hysteresis function 0 to 9 9 vol O can be added to high low alarms The following functions are programmable for contact outputs 1 Abnormal 2 High high alarm 3 High alarm 4 Low low alarm 5 Low alarm 6 Maintenance 7 Calibration 8 Range switching answer back 9 Warm up 10 Calibration gas pressure decrease answerback of contact input 11 Temperature high alarm 12 Blowback start 13 Flameout gas detection answerback of contact input 14 Calibration coefficient alarm 15 Startup power stabilization timeout alarm Contact output 4 is set to normally operated and fixed error status Converter Input Thermal input one point 4 to 20 mA DC Contact Input Two points voltage free contact inputs The following functions are programmable for contact inputs 1 Calibration gas pressure decrease alarm 2 Range switching switched range is fixed 3 External calibration start 4 Process alarm if this signal is received the heater power turns off 5 Blowback start
27. 100 0 ZR22G 150 0 ZR22G 200 0 ZR22G 250 0 ZR22G 300 0 ANSI Class 150 4 RF SUS304 Approx 11 228 6 190 5 F3 8 3E EPS IM 11M12A01 03E 3 Installation ZR22G O E P Flange DIN PN10 DN50 Rc1 4 or 1 4NPT Reference air inlet C L 156 87 2 G1 2 2 1 2NPT etc Cable connection port Rc1 4 or 1 4NPT Calibration gas inlet Stop Valve J oO g m 48 1 Reference gas outlet Flange DIN PN10 DN50 SUS304 ZR22G 300 F3 8 4E EPS ZR22G 0 F P Flange DIN PN10 DN80 Unit mm Rc1 4 or 1 4NPT Reference air inlet L er 2 G1 2 2 1 2NPT etc RE Cable connection port ae ce E H 2 vt 1 Ion A CAF Reference gas outlet PIPING Flange B Rc1 4 or 1 4NPT Flange Calibration gas inlet Stop Valve PIPING A Weight PIPING kg DIN PN10 DN80 SUS304 ZR22G 300 C F3 8 5E EPS IM 11M12A01 03E 3 15
28. 25 O2 Lower limit oxygen concentration 0 02 Upper limit humidity 25 H20 Lower limit humidity 0 H20 Upper limit mixing ratio Lower limit mixing ratio T10 3E EPS A CAUTION If a rapid change in the measured value occurs during sampling no sampled data are plotted on the graph Use the graph indication tentatively Check the output current for accurate data 10 1 3 Auto matic Display Revert Time IM 11M12A01 03E While the Execution Setup display or any other display that is positioned lower than the Execution Setup display see Figure 7 3 1 earlier in this manual is displayed if there is no key entry from the touchpanel for a certain time the current display will automati cally return to the basic panel display This action is referred to as auto return The auto return time setting starts from no key entry to the return to automatic return The auto return time can be set from 0 to 255 minutes If 0 is set there will be no automatic return By default the auto return time is set to 0 zero To set the auto return time follow these steps 1 Select the Setup key from the basic panel display to display the Execution Setup display Then select Maintenance from the Execution Setup display 2 Select the Display setup from the Maintenance display 3 Select Auto return time The numeric data entry display then appears 4 Enter your desired automatic retu
29. 3 calibration is automated however the piping is basically the same as that of System 2 Refer to Section 4 2 Adjust secondary pressure of both the air set and the zero gas reducing valve so that these two pressures are approximately the same The flow rate of zero and span gases normally instrument air are set by a single needle valve After installation and wiring check the calibration contact output see Sec 7 10 2 and adjust zero gas reducing valve and calibration gas needle valve so that zero gas flow is within the permitted range Next check span gas calibration contact output and adjust air set so that span gas flow is within the permitted range XH EV1 XH EV2 ZERO GAS IN A gt A Instrument air Approx PA 1 5 l min gt F2 6 3E EPS 2 Needle valve comes with flowmeter It is recommended to use ZH21B dust protector to protect the probe output from dust agitation i e to prevent combustible materials from entering the probe cell where humidity measurements are made under dusty or combustible environment Separate type Zirconia High Temperature Humidity Analyzer Model ZR22G Detecor Model ZR402G Converter Conduit Signal 1 100 to 240 V AC IW M a EE Contact input Ge ep ee ee gt Analog output contact output I Heater 2 core shield cable Need 1 Digital output HART Flowmeter Nesce g put A Instrum
30. 3 Automatic Calibration No execution operations are required for automatic calibration Automatic calibration starts in accordance with a preset start day and time Calibration is then executed at preset intervals A CAUTION Before conducting a semi automatic or automatic calibration run the automatic calibra tion unit beforehand to obtain a calibration flow of 600 60 ml min IM 11M12A01 03E 9 11 10 Other Functions 10 Other Functions 10 1 Display 10 1 1 Detailed Display Press the Detailed data key on the basic panel display to display the detailed operation data as shown in Figure 10 1 Pressing the V or A key you can advance the page or go back to your desired page e Detailed data display There are ten panel displays for viewing detailed data The following briefly describe the operational data displayed on the detailed data display Tag A Span gas ratio 0 0 Zero gas ratio 100 0 Response time Os Cell robustness life gt 1year Cell temperature 750 C C J temperature 47 C F10 1E EPS Figure 10 1 Detailed data Display 10 1 1 1 Span gas and Zero gas Correction Ratios These are used to check for degradation of the sensor cell If the correction ratio is beyond the limits as shown in Figure 10 2 the sensor should no longer be used These ratios can be found by calculating the data as shown below Zero origin ez Cell Calibration curve j before correction
31. Average Oxygen Concentration Humidity and Mixing Ratio The average oxygen concentration humidity and mixing ratio during the periods over which average values are calculated are displayed If the setup period elapses the average values that have been displayed so far will be cleared and new average values will be displayed If the setup period of time is changed the current average values will be displayed for more details see Section 8 6 2 earlier in this manual 10 1 1 14 Heater On Time Ratio The probe sensor is heated to and maintained at 750 C When the measured gas tem perature is high the amount of heater ON time decreases 10 1 1 15 Time The current date and time are displayed These are backed up with built in batteries so no adjustment is required after the power is switched off 10 1 1 16 History of Calibration Time The calibration conducted dates and times and span gas and zero gas ratios for the past ten calibrations are stored in memory 10 1 1 17 Power Supply Voltage For the temperature control for the heater of the detector to work best you should set the power supply voltage and frequency appropriately as the control parameters are based on this Set the AC supply voltage to Low if supply is 140 V AC or less and to High if it is 180 V or more 10 1 1 18 Power Frequency Set the AC supply frequency setting appropriately Low for 50Hz and High for 60Hz 10 4 IM 11M12A01 03E 10 1 2 Trend Graph Pr
32. Inconel bolt 3 Check valve 4 Stop valve 4 Stainless steel tag plate _ 5 Specify the flange suffix code either C or K Printed tag plate 5 T2 1E EPS 3 Inconel probe bolts and U shape pipe for calibration are used Use this option for high temperature use ranging from 600 to 700 C 4 Specify either CV or SV option code 5 Specify either SCT or PT option code 6 Not waterproof protect from rain Operating maximum temperature is 80 C Available only in the U S 7 Available only in the U S DERAKANE is a registered trademark of the Dow Chemical Company 8 Piping for reference air must be installed to supply reference air constantly at a specified flow rate IM 11M12A01 03E 2 5 EXTERNAL DIMENSIONS Model ZR22G Detectors Separate type Zirconia High Temperature Humidity Analyzer 2 L ie 283 to 292 gt t it 2 il 3 ots Q Q LIT T L 0 15 0 4 0 7 1 0 1 5 2 0 2 5 3 0 m Het or NET Reference air inlet 155 to 163 69 C lt 2 G1 2 2 1 2NPT etc Cable connection port Flange Calibration gas inlet Flange Flange A B C t C ANSI Class 150 2 RF SUS304 152 4 120 6 4 19 19 ANSI Class 150 3 RF SUS304 190 5 152 4 4 19 24 ANSI Class 150 4 RF SUS304 228 6 190 5 8 19 24 SA DIN PN10 DN50 SUS30
33. Material Brass body Approx 112 Approx 59 Outlet Rc1 4 or 1 4FNPT Approx 163 Secondar Primary safety valve Primary pressure gauge pressure gauge Unit mm Approx 174 W22 Right handed screw Secondary safety valve Approx 82 2 26 Part No Outlet G7013XF Rci 4 G7014XF 1 4 NPT female screw IM 11M12A01 03E 2 Specifications 2 6 6 Case Assembly for Calibration gas Cylinder Part Number E7044KF IM 11M12A01 03E This case is used to store the zero gas cylinders Standard Specifications Case Paint Baked epoxy resin Jade green Munsell 7 5 BG 4 1 5 Installation 2B pipe mounting Material SPCC Cold rolled steel sheet Weight Approx 3 6kg 10 kg with gas cylinder Note Export of such high pressure filled gas cylinders to most countries is prohibited or restricted Unit mm 324 Pressure regulator ee 3XF G7014XF Zero gas cylinder G7001ZC Note E7044KF case assembly has no zero gas cylinder and pressure regulator 2B pipe 60 5 F2 15E EPS 2 27 2 6 7 Model ZR22A Heater Assembly Table 2 1 ZR22A Style S2 Suffix code Option code Description ZR22A Heater Assembly for ZR22G 0 15m 0 4m 0 7m 1m 1 5m 2m 2 5m 3m Jig for change with Jig 2 None Reference air 3 Reference a
34. 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 For best accuracy as the span gas use oxygen whose concentration is near the top of the measurement range in a nitrogen mixture IM 11M12A01 03E 9 3 9 1 3 9 4 Compensation The deviation of a measured value from the theoretical cell electromotive force is checked by the method in Figure 9 1 or 9 2 Figure 9 1 shows a two point calibration using two gases zero and span Cell electromo tive forces for a span gas with an oxygen concentration pl and a zero gas with an oxygen concentration p2 are measured while determining the calibration curve passing between these two points The oxygen concentration of the measurement gas is deter mined from this calibration curve In addition the calibration curve corrected by calibration is compared with the theoretical calibration curve for determining the zero point correction ratio represented by B AX100 on the basis of A B and C shown in Figure 9 2 and a span correction ratio of C A X 100 If the zero point correction ratio exceeds the range of 100430 or the span correction ratio becomes larger than 0 18 calibration of the sensor becomes impossible 31 92 7 Zero origin ez e2 Calibration curve Cell before correction electromotive force mV el f Corrected calibration curve theoretical calibration curve
35. Select the Setup key from the basic panel display to display the Execution Setup display Then select Maintenance from the Execution Setup display 2 Select Calibration setup from the Maintenance display Then select Mode from the Calibration setup display see Figure 9 4 Now you can select manual semi automatic or automatic calibration IM 11M12A01 03E 9 Calibration 9 2 1 2 Calibration Procedure Select both span and zero calibrations or span calibration only or zero calibration only Usually select span and zero calibrations Select Points from the Calibration setup display and then you can select Both Span or Zero see Figure 9 5 below Calibration setup A Calibration setup Al CP Mode Cp Mode Manual Points ela Points EA Zero gas cone 1 00 al Zero gg SPA 1 00 a Span gas conc 21 00 gt Span gas conc 21 00 v Timing Timing Enter FIA ERS F9 5E EPS Figure 9 4 Calibration Setup Figure 9 5 Calibration Setup 9 2 1 3 Zero gas Concentration Set the oxygen concentration for zero point calibration Enter the oxygen concentration for the zero gas in the cylinder used in the following procedures Select Zero gas conc from the Calibration setup display The numeric data entry display then appears Enter the desired oxygen concentration for the zero point calibration The zero gas set ranges from 0 3 to 100 0
36. Set Part No G7004XF or K9473XG Standard Specification Changed descriptions partly 2 6 5 Cylinder Regulator Valve Part No G7013XF or G7014XF Standard Specification Change description partly and drawing 4 4 Piping for the Detector with Pressure Compensation Deleted Section 8 2 3 Output Hold Setting Changed value in Figures 8 2 and 8 3 8 2 4 Default Values Changed value and description in Table 8 3 8 6 1 Setting the Date and Time Added Item in Figure 8 15 8 6 4 Setting Purging Added Item 8 6 5 Setting Passwords Changed section number 10 3 Operational Data Initialization Changed value in Table 10 5 IM 11M12A01 03E
37. V AC Power Supply Frequency Ratings 50 60 Hz Acceptable range 45 to 66 Hz Power Consumption Max 300 W approx 100 W for ordinary use Safety and EMC conforming standards Safety EN61010 1 CSA C22 2 No 61010 1 UL61010 1 EMC EN 61326 Class A EN 55011 Class A Group 1 EN 61000 3 2 AS NZS CISPR 11 Maximum Distance between Probe and Converter Conductor two way resistance must be 10 Q or less when a 1 25 mm cable or equivalent is used 300 m or less Construction Outdoor installation equivalent to NEMA 4 with conduit holes completely sealed with a plastic cable gland optional Wiring Connection G1 2 Pg13 5 M20 by 1 5 mm 1 2 NPT eight holes Installation Panel wall or 2B pipe mounting Case Aluminum alloy Paint Color Door Sliver gray Munsell 3 2PB7 4 1 2 Case Sliver gray Munsell 3 2PB7 4 1 2 Finish Polyurethane corrosion resistant coating Weight Approx 6 kg 2 9 2 3 2 Function Display Functions Value Display Displays values of the measured Oxygen concentration moisture quantity mixture ratio etc Graph Display Displays trends of measured oxygen concentration moisture quantity mixture ratio etc Data Display Displays various useful data for maintenance such as cell temperature reference junction temperature maximum minimum moisture quantity and the like Status Messages Indicates an alarm or error occurrence with flashing of the corre sponding icon Indicates status such as warming up c
38. YK Yokogawa Electric Corporation Customer Model ZR40H Maintenance Separate type Zirconia Oxygen Analyzer Parts List High Temperature Humidity Analyzer Automatic Calibration Unit Item Part No Qty Description 6 K9473XC 1 Flowmeter YOKOG AWA All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M12A01 11E 1st Edition Dec 2000 YK Yokogawa Electric Corporation 2nd Edition Feb 2001 YK Customer Model ZO21S Maintenance Zirconia Oxygen Analyzer High Temperature Parts List Humidity Analyzer Standard Gas Unit 1 2 Ay Item Part No Qty Description 1 E 1 Pump see Table 1 2 E7050BA 1 Zero Gas Cylinder x6 pcs 3 E7050BJ 1 Needle Valve Table 1 Power Pump AC 100V 110 E7050AU 115 AC 200V 220 E7050AV 240 YOKOG AWA Copyright 2000 YK 3rd Edition Dec 2000 YK CMPL 11M3D1 01E Yokogawa Electric Corporation Revision Record Manual Title Model ZR22G ZR402G Separate type Zirconia High Temperature Humidity Analyzer Manual Number IM 11M12A01 03E Edition Date Remark s Ist
39. ZA8F flow setting unit and the ZR22G detector The cylinder should be placed in a calibration gas unit case or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature does not exceed 40 C Mount a regulator valve specified by YOKOGAWA on the cylinder Mount a check valve or the stop valve specified by YOKOGAWA or the nipple found on the open market at the calibration gas inlet of the detector as illustrated in Figure 4 8 The check valve or the stop valve may have been mounted on the detector when shipped Connect the flow setting unit and the detector to a stainless steel pipe 6 mm O D X4 mm or larger I D or nominal size 1 4 inch Stop valve or Check valve Piping for the Calibration gas 6 mm O D Piping for the Reference gas 6 mm O D by 4 mm I D Stainless steel pipe F4 8E EPS Figure 4 8 Piping for the Calibration Gas Inlet Piping for the Reference Gas Reference gas piping is required between the air source instrument air and the flow setting unit and between the flow setting unit and the detector Insert the air set next to the flow setting unit in the piping between the air source and the flow setting unit Use a 6 mm O D X 4 mm or larger I D or nominal size 1 4 inch stainless steel pipe between the flow setting unit and the detector IM 11M12A01 03E 4 Piping 4 3 Piping for System 3 Piping in System 3 is illustrated in Figure 4 9 In System
40. and sensor status data listed below are acquired However if the calibration is not properly conducted an error occurs in automatic or semi automatic calibration these data are not collected in the current calibration These data can be observed by selecting the detailed data display key from the basic panel display For an explanation and the operating procedures of individual data consult Section 10 1 1 Detailed Display 1 Record of span correction factor Recorded the past ten span correction factors 2 Record of zero correction factors Recorded the past ten zero correction factors 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 these values include the cell s internal resistance and other wiring connection resistance So the cell s degrading cannot be estimated from these values only When only a span calibration has been made these values will not be measured and previously measured values will remain 5 Robustness of a cell The robustness of a cell is an index for predicting the remaining life of a sensor and is expressed in a number on four levels 9 5 9 2 Calibration Procedures A CAUTION Calibration shoul
41. back setup from the Maintenance display and select Mode The mode selection display as shown in Figure 10 8 then appears Blow back setup CP Mode Semi_ Auto Auto alo m 2 g F10 9E EPS Figure 10 8 Blow back Setup Display IM 11M12A01 03E 10 9 10 2 1 2 10 2 1 3 10 10 Operation of Blow back Figure 10 9 shows a timing chart for the operation of blow back To execute blow back with a contact input use a contact input with an ON time period of one to 11 seconds Once blow back starts a contact output opens and closes at ten second intervals during the preset blow back time After the blow back time elapses the analog output remains held at the preset status until the hold time elapses refer to Section 8 2 earlier in this manual As the hold output stabilization time set the time until the measured gas is returned to the sensor and output returns to the normal operating conditions after completing blow back operations lt ON time period of 1 to 11 seconds for the contact input Blow back start with contact input or touchpanel operation Blow back time ON for 10 seconds OFF seconds for 10 seconds Contact output blow back switch Hold time Analog output remains held Analog output with HOLD feature specified F10 9E EPS Figure 10 9 Operation of Blockback Setting Output Hold Time and Blow back Time If the blow back mode is
42. check Panel Display 7 12 IM 11M12A01 03E 7 Startup 7 10 Checking Contact I O Conduct the contact input and output checking as well as operational checking of the solenoid valves for automatic calibration 7 10 1 Checking Contact Output To check the contact output follow these steps 1 Press the Setup key in the basic panel display to display the Execution Setup display Select Maintenance in that display 2 Select Contact check then Contact output in the Maintenance panel display to display the Output contacts display see Figure 7 15 2 3 Select the desired output contact for checking The display which enables the closing and opening of contacts then appears Use the display to conduct continuity check ing Output contacts CP Output contact 1 Open Output contact 2 Open Output contact 3 Open Output contact 4 Open dels Enter F7 15 2E EPS Figure 7 15 2 Output Contact Check Panel Display WARNING If you conduct an open close check for contact output 4 Error 1 or Error 2 will occur This is because the built in heater power of the detector which is connected to contact output 4 is turned off during the above check So if the above error occurs reset the equipment or turn the power off and then back on to restart refer to Section 10 4 Reset later in this manual IM 11M12A01 03E 7 13 7 10 2 Checking Calibration Contact Output The calibration c
43. detector After screwing the cover in the detector body secure it with the lock screw Detector cover F5 8E EPS Figure 5 8 5 3 3 Connection to Converter To connect the wiring to the converter proceed as follows 1 M4 screws are used for the terminal of the converter Each cable should be termi nated 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 between the terminal box and the converter use basically a cable e g PVC sheathed PVC insulated cable rather than wire AN Note The above is to prevent moisture or corrosive gas from entering the converter Where the ambient environment of the detector and the converter is well maintained it is permissible allowed to connect the wiring from the detector directly to the converter with protection by conduits WARNING This wiring is to carry power for the heater Be careful to wire the correct terminals and be careful not to ground or short circuit terminals when wiring as otherwise the instrument may be damaged IM 11M12A01 03E 5 9 5 4 Wiring for Analog Output This wiring is for transmitting 4 to 20 mA DC output signals to a device e g recorder Maintain the load resistance including the wiring resistance at 5500 or less Converter Receiver 1 F5 9E EPS Figure 5 9 Wiring for analog output 5 4 1 Cable Specifications For this wirin
44. display 3 Select mA outputl in the mA outputs display 4 Select the Max humidity conc in the mA output range display and press the Enter key The numeric data entry display then appears Enter the humidity value for the maximum current 20 mA for example enter 100 for 100 H O A CAUTION For the humidity measurement 0 H O is a default setting for the minimum humidity and 25 H O is the default for the maximum humidity If you first attempt to set 50 H O for the minimum humidity you cannot set it because that value is outside the set range In such a case set the maximum humidity first 5 Select the Min humidity conc and enter a minimum humidity value e g 050 for 50 H O 6 Follow the above steps to set the mA output2 if necessary 8 1 3 Entering Output Damping Constants If a measured value which is adversely affected by rapid changes in the measurement object is used as the basis for control frequent on off actions of the output may result To avoid this the analyzer allows the setting of output damping constants ranging from 0 to 255 seconds Select the appropriate output damping constant from the numeric data entry display To set 30 seconds enter 030 8 1 4 Selection of Output Mode You can select linear or logarithmic output mode Press the Enter key in the output mode display A linear logarithmic selection display then appears Select your desired mode A CAUTION When you select log
45. eq Enter Output mode Linear Enter _ Figure 7 9 mA outputs Setting Figure 7 10 mA outputl Range Display Display 7 8 IM 11M12A01 03E 7 Startup mA outputi range CF Parameter Cr Parameter Mixing Set range Humidity Set range Min humid Mixing _ Min mixing ratio 4 x x mA outputi range 0 H20 0 000 kg kg Max humidity conc Max mixing ratio 25 H20 0 200 kg kg Output damping Os Output damping Os Output mode Linear Enter Output mode Linear Enter Figure 7 10 1 mA output1 Range Figure 7 10 2 Mixing Ratio Display Selection 7 7 2 Minimum Current 4 mA and Maximum Current 20 mA Settings To set the analog output range follow these steps 1 Select the Setup from the Execution Setup display 2 From the Commissioning Setup display select the mA output setup Select mA output1 from the mA outputs display The mA output range that displays Parameter Humidity as shown in Figure 7 10 then appears 3 To set the minimum humidity at 4 mA choose the Min humidity conc To set the maximum humidity at 20 mA choose the Max humidity conc 4 To set 50 H O type in 050 and press the Enter key 5 Set mA output2 in the same manner as in the appropriate steps above A CAUTION Note Analog output range settings should be limited For more details consult Section 8 1 Current Output setting later in this manual
46. gland EXAZRAO2G EX 8 G1 2 8 1 2NPT or the like Wiring connection YOIDA w Ground terminal M4 Adaptor for 1 2 NPT thread F5 4E EPS Figure 5 4 Cable gland mounting 5 4 IM 11M12A01 03E 5 Wiring 5 2 Wiring for Detector Output This wiring enables the converter to receive cell output from the detector output from a thermocouple and a reference junction compensation signal Install wires that allow for 10 Q of loop resistance or less Keep detector signal wiring away from power wiring Separate the signal and the power wiring 1 Ambient temperature of the detector 80 C or less Detector Converter CELL 0 CELL CELL CELL TC TC TC TC CJ CJ aaa a CE ae FG AR Shielded ae 2 Ambient temperature of the detector exceeding 80 C Detector Terminal box Converter a FG Heat resistant wiring Shielded cables F5 5E EPS Figure 5 5 Wiring for detector output A CAUTION If shielded cables cannot be used between the detector and the terminal box for ex ample when heat resistant wiring is used locate the detector and the terminal box as close together as possible 5 2 1 Cable Specifications Basically PVC sheathed PVC insulated cabl
47. i Digital output HART Reference gas v ny i Air Set i Calibration gas a k et A Instrument air ce gas pressure regulator T Calibration gas Model ZR40H Auto Calibration unit unit case 3 Zero gas cylinder F1 3E EPS Figure1 3 1 Shield cable Use shielded signal cables and connect the shield to the FG terminal of the converter 2 Select the desired probe from the Probe Configuration table on page 1 5 3 100 N gas cannot be used as the zero gas Use approximately 1 of O gas N2 based IM 11M12A01 03E 1 2 lt EXAxtZR gt System Components 1 Overview 1 2 1 System Components Model or Part No Product Name System 2 ZR22G Detector Separate type High temperature e Humidity Analyzer Detector ZR402G Converter Separate type High temperature e Humidity Analyzer Converter ZH21B Dust protector ZO21S Standard gas unit ZA8F Flow setting unit for manual calibration ZR40H Automatic calibration unit for separate type L9852CB G7016XH Stop valve K9292DN K9292DS Check valve K9473XH K9473XJ Air set G7004XF K9473XG G7001ZC Zerg gas cylinder G7013XF G7014XF Pressure regulator for gas cylinder E7044KF Case assembly for calibration gas cylinder ZR22A Heater Assembly Spare parts for Model ZR22G The essential products for the system D O Selected depending on your applications Select either 1 2 2 Detectors and Accessories General use
48. in the same manner as in the steps above 5 Consult Table 7 2 Display Items enabling the selection of display items in individual display areas Maintenance ES Display setup A CF Display setup CP Display item Calibration setup lt Trend graph Blow back setup Auto return time Omin mA output loop check Language English WwW Contact check 4 e Enter F712 EPS F7 13 EPS Figure 7 12 Maintenance Panel Display Figure 7 13 Display Setup 7 10 IM 11M12A01 03E 7 Startup Display item Cp Primary value Humidity Secondary value mA output1 Tertiary value mA output2 Tag name Display item CP Primary value pe Mixing Item of output damping Item of output2 damping mA output2 Tag name Enter Enter Figure 7 14 Display Item Display Table 7 2 Display Items Item Primary value Secondary and tertiary values F7A4EPS Figure 7 15 Display Item Selection Display Oxygen concentration O Oxygen concentration during measurement Humidity O Humidity H20 in the exhaust gas Mixing ratio O Mixing ratio during measurement Relative humidity Relative humidity calculated from the measured value Dew point Dew point calculated from the measured value Output 1 item Oxygen concentration with the equipment set for oxygen analyzer
49. is not repeated If you want to perform a second calibration turn the contact signal off and then back on Process If the contact signal is on heater power will be switched off upset A one to 11 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 and then back on or reset the analyzer Blow back start If the contact signal is on blow back starts A one to 11 second time interval single output signal is available as a contact signal Even if a continuous contact signal is applied calibration is not repeated If you want to make a second calibration turn the contact signal off and then back on Refer to Section 10 2 Blow back Tag 0 0 H20 4 00mA Output1 4 00mA Output2 F8 12E EPS Figure 8 12 Changing Measuring Range with Input Contact 8 16 IM 11M12A01 03E 8 Detailed Data Setting AN Note Measurement range switching function by an external contact input is available for analog output only When making a semi automatic calibration be sure to set semi automatic or auto matic mode using the Calibration setup display When carrying out blowback be sure to set blowback in the output contact setup When the unburnt gas detection signal is sent to the contact input the converter will cut the power supp
50. just before starting calibration or blow back 4mA On Error occurrence 8 8 Holds output at a preset value 3 4mA T8 3E EPS IM 11M12A01 03E 8 Detailed Data Setting 8 3 Alarm Setting The analyzer enables the setting of four alarms high high high low and low low alarms depending upon the measurement conditions The following section sets forth the alarm operations and setting procedures 8 3 1 Alarm Values 1 High high and high alarm values If high high and high alarm values are set to ON then alarms occur if measured values exceed the alarm set values 2 Low and low low alarm values If low low and low alarm values are set then alarms occur if measured values fall below the alarm set values 8 3 2 Alarm Output Actions If the measured values fluctuate between normal steady state values and alarm setting there may be a lot of alarm output issuing and canceling To avoid this set the alarm delay and hysteresis for alarm canceling under the alarm output conditions as Figure 8 4 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 result On the other hand there will be a similar delay each time the measured value returns to the steady state f
51. maintenance service or blowback operations calibration will start after completing the maintenance service or blowback opera tions see Section 8 2 1 earlier in this manual 4 If 000 days 00 hours are set for the calibration intervals only the first calibration will be conducted a second or later calibration will not be conducted 5 If a past date is set to the calibration start day no calibration will be conducted Default Values When the analyzer is delivered or if data are initialized the calibration settings are by default as shown in Table 9 1 Table 9 1 Default Settings for Calibration Default Setting Manual Calibration Calibration mode Manual Calibration procedure Span zero Zero gas oxygen concentration 1 00 Span gas oxygen concentration 21 00 Semi automatic Calibration Output hold stabilization time 10 minutes 00 seconds Calibration time 10 minutes 00 seconds Automatic Calibration IM 11M12A01 03E Calibration interval 30 days 00 hours Start day 01 01 00 Start time 00 00 T9 1E EPS 9 2 3 Calibration 9 2 3 1 Manual Calibration For manual calibration consult Section 7 11 Calibration earlier in this manual 9 2 3 2Semi automatic Calibration To start calibration follow these steps 1 Press the Setup key in the basic panel display to display the Execution Setup display Then select Calibration fr
52. measured value shows a value a little higher than normal Check valves needle valves check valves solenoid valves for automatic calibration etc in the calibration gas tubing system for leakage For manual valves check them after confirming that they are in fully closed states In addition check the tubing joints for leakage 4 The reference gas is mixing into the measuring gas or vice versa Since the difference between oxygen partial pressures on the sensor anode and cathode sides becomes smaller the measured value shows a smaller value An error which does not appear as the Error 1 may occur in the sensor Measured gas and or the reference gas may be leaking Visually inspect the sensor If any crack is found replace the sensor assembly with a new one Referring to Section 11 1 2 check if there is a problem with the sensor mounting If things are abnormal but there is no error indication then maybe the sensor assembly isn t properly secured the O ring seal is dirty the measurement gas and ratio gas are leaking into each other if measurement gas pressure is high then it may leak into ratio gas and vice versa as oxygen partial pressure difference between ratio gas and 12 13 measurement gas is small the oxygen concentration in measured gas will read high and the humidity value will read low Replace the sensor assembly as shown in 11 1 2 and be sure to replace the metal O ring with a new one If the sensor is cracked the sym
53. output setup and then the mA output preset display as shown in Figure 8 2 mA outputs presets Cp Warmup 4mA Preset value 4 0mA Maintenance Hold Preset value 4 0mA Cal blowback Hold Preset value 4 0mA Error Preset Preset value 3 4mA L A A A a a AE g mA outputs presets CP Warm up 4mA Preset value 4 0 mA Maintenance Preset value Hold Cal blowback LPreset Preset value 4 0 mA Error Preset Preset value 3 4mA EE RRRAAZ F8 2E EPS Figure 8 2 mA output Preset Display Figure 8 3 2 From the this display Fig 8 2 select the desired display Figure 8 3 shows an example of selecting Maintenance Select the desired output status 3 If a preset value is selected set the corresponding output current If you select a preset value just below Maintenance on the screen the numeric data entry display will appear Enter the current value you want To set 10 mA type in 100 and press the Enter key to complete the setting The setting range is from 2 4 to 21 6 mA 8 2 4 Default Values When the analyzer is delivered or if data are initialized output hold is the default as shown in Table 8 3 Table 8 3 Output Hold Default Values Status Output hold min and max values Preset value During warm up 4 mA 4 mA Under maintenance Holds output at value just before maintenance started 4 mA Under calibration or blow back Holds output at value
54. sent to the detector through a tube which is connected during calibration A CAUTION e A needle stop valve should be connected to the calibration gas inlet of the detector The valve should be fully closed unless calibration is in progress e As this system uses ambient air for the reference gas measuring accuracy will be affected by the installation location Separate type Zirconia High Temperature Humidity Analyzer Model ZR402G Converter Model ZR22G Detector 11 Signal Stop valve X 1 6 core shield cable 7 100 to 240 V AC E rer i See Contact input frere Analog outout contact output Digital output HART Model ZO21S Standard gas unit Heater 2 core Calibration gas F1 1E EPS Figure 1 1 IM 11M12A01 03E 1 1 2 System 2 1 Overview This system is for accurate monitoring and controlling humidity when the installation environment is polluted with gases other than the air Instrument air clean and dry air of oxygen concentration 21 is used for the reference gas and the span gas for calibra tion Zero gas is fed in from a cylinder during calibration The gas flow is controlled by the ZA8F flow setting unit for manual valve operation Separate type Zirconia High Temperature Humidity Analyzer Model ZR22G Detector Signal Check valve Q Model ZR402G Converter 1 6 core shi
55. setting content Measuring related items Oxygen concentration vol O moisture quantity vol H O IM 11M12A01 03E 2 Specifications mixture ratio kg kg relative humidity RH and dew point Display Related Items Oxygen concentration vol O Moisture quantity vol H O mixture ratio kg kg relative humidity RH dew point C cell tempera ture C thermocouple reference junction temperature C maximum minimum average oxygen concentration vol O maxi mum minimum average moisture quantity vol H O maximum minimum average mixture ratio kg kg cell e m f mV output 1 2 current mA cell response time seconds cell internal resistance Q cell condition in four grades heater on time ratio calibration history ten times time year month day hour minute Calibration Setting Items Span gas concentration vol O zero gas concentration vol O calibration mode auto semi auto manual calibration type and method zero span calibration zero calibration only span calibration only stabilization time min sec calibration time min sec calibration period day hour starting time year month day hour minute Output Related Items Analog output output mode selection value conditions when warming up maintenance calibrating or blowback abnormal oxygen concentra tion at 4mA 20mA vol O moisture quantity at 4mA 20mA vol HO mixture ratio at 4mA 20mA kg kg
56. sheathed control cables 2 cores are used for this wiring When the ambient temperature of the detector exceeds 80 C install a terminal box and connect to the detector using six 600V silicon rubber insulated glass braided wires 5 3 2 Connection to Detector When connecting the cable to the detector proceed as follows 1 Mount cable glands or conduits of the specified thread size to the wiring connections of the detector The detector may need to be removed in future for maintenance so be sure to allow sufficient cable length 2 If the ambient temperature at the location of wire installation is 80 to 150 C be sure to use a flexible metallic conduit for the wire If a non shielded 600V silicon rubber insulated glass braided wire is used keep the wire away from noise sources to avoid noise interference 3 The size of the terminal screw threads is M3 5 Each cable should be terminated in the corresponding size crimp on terminals 1 respectively 1 If the ambient temperature at the detector installation site exceeds 60 C use a bare crimp on terminal 5 8 IM 11M12A01 03E 5 Wiring A CAUTION Before opening the detector cover loosen the lock screw If the screw is not loosened first the screw will damage the cover and the terminal box will require replacement When opening and closing the cover remove any sand particles or dust to avoid gouging the thread e Notice when closing the cover of the
57. the detector terminal box exceeds 155 C or falls below 25 C Alarm 11 Thermocouple voltage alarm Occurs when thermocouple voltage exceeds 42 1 mV about 1020 C or falls below 5 mV about 170 C Alarm 12 Input current alarm When mA input is selected in the Exhaust gas setup display this alarm occurs if the input current from the temperature transmitter is outside from 3 2 to 21 6 mA Alarm 13 Battery low alarm Internal battery needs replacement T12 2E EPS 12 5 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 the measure taken for this error has priority If the converter power is turned off after an alarm is generated and restarted before the cause of the alarm has been eliminated the alarm will be generated again However Alarms 6 7 and 8 alarms related to calibration are not generated unless calibration is executed 42 6 IM 11M12A01 03E 12 Troubleshooting 12 2 2 Measures Taken When Alarms are Generated 12 2 2 1 Alarm 1 Alarm 2 and Alarm 3 Oxygen Concentration Alarm Humidity Alarm and Mixing Ratio Alarm These alarms occur when a measured value exceeds an alarm set value or falls below it For details on these alarms see Section 8 3 Alarm Sett
58. the operating temperature range The operating temperature range varies with the type of detector If the detector terminal block is out of its operating temperature range take the measure to lower the temperature such as situating it so that it is not subjected to radiant heat IM 11M12A01 03E 12 Troubleshooting The case where the Model ZR22 Detector is used 1 Stop the power to the converter 2 Remove the wiring from terminals 5 and 6 of the detector and measure the resistance between these terminals If the resistance value is out of the range of 1 to 1 6 KO the cold junction temperature sensor is considered to be faulty Replace that tem perature sensor with a new one 3 If the resistance value is within the above range the cold junction temperature sensor seems to be normal Check whether or not the cable is broken or shorted out and whether the cable is securely connected to the terminals Also check that the resistance of the wiring between the converter and detector is 10Q or less 4 If there is no failure in the wiring the electrical circuits inside the converter may possibly fail Contact the service personnel at Yokogawa Electric Corporation The case where the Model ZO21D Detector is used 1 Without stopping the power to the converter remove the wiring from terminals 5 and 6 of the detector and measure the voltage between these terminals If the voltage between the terminals is out of the range of 0 4 to 0 7 V
59. time constant Alarm Related Items Oxygen concentration high alarm high high alarm limit values vol O Oxygen concentration low alarm low low alarm limit values vol O moisture quantity high alarm high high alarm limit values vol H O moisture quantity low alarm low low alarm limit values vol H O mixture ratio high alarm high high alarm limit value kg kg mixture ratio low alarm low low alarm limit values kg kg oxygen concentration alarm hysteresis vol O moisture quantity alarm hysteresis vol H O mixture ratio alarm hysteresis kg kg oxygen concentration moisture quantity mixture ratio alarm detection alarm delay seconds Contact Related Items Selection of contact input 1 and 2 selection of contact output 1 to 3 abnormal high high alarm high alarm low alarm low low alarm maintenance calibrating range switching warming up calibration gas pres sure decrease temperature high alarm blow back unburnt gas detected Converter Output Two points mA analog output 4 to 20 mA DC maximum load resistance of 550Q and one of two mA digital output points HART mini mum load resistance of 2500 Range any setting between 0 to 5 through 0 to 100 vol O 0 to 25 through 0 to 100 vol H O 0 to 0 200 through 0 to 1 000 kg kg or partial range is available For the log output the minimum range values are fixed at 0 1 vol O for the oxygen concentration 0 1 vol H O for the moisture quantity and 0
60. will the cell s internal resistance increase The degradation 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 IM 11M12A01 03E 10 3 10 1 1 10 Software Revision The revision number of the software installed is displayed 10 1 1 11 Maximum Oxygen Concentration Humidity and Mixing Ratio The maximum oxygen concentration humidity and mixing ratio and the time of their occurrence during the period specified in the Averaging display are displayed If the setup period elapses the maximum values that have been displayed so far will be cleared and new maximum values will be displayed If the setup period of time is changed the current maximum values will be displayed for more details see Section 8 6 2 earlier in this manual 10 1 1 12 Minimum Oxygen Concentration Humidity and Mixing Ratio The minimum oxygen concentration humidity and mixing ratio and the time of their occurrence during the period specified in the Averaging display are displayed If the setup period elapses the minimum set values that have been displayed so far will be cleared and new minimum values will be displayed If the setup period of time is changed the current minimum values will be displayed for more details see Section 8 6 2 earlier in this manual 10 1 1 13
61. 0 O2 setpoint 0 to 100 H20 0 0 H20 Oto lkg kg Okg kg T8 4E EPS 8 4 Output Contact Setup 8 4 1 Output Contact Mechanical relays provide contact outputs Be sure to observe relay contact ratings For details see section 2 1 General specifications The operation modes of each contact output are as follows For output contacts 1 to 3 you can select open or closed contact when the contact is operated Default is closed For output contact 4 contact is closed When power fails contact outputs 1 to 3 are open and 4 is closed Table 8 5 Operating state When no power is applied to this equipment Output contac Open deenergized or closed Open energized selectable Output contac Open deenergized or closed Open energized selectable 2 Output contact 3 Open deenergized or closed Open 4 energized selectable Closed deenergized only Closed T8 5E EP 8 4 2 Setting Procedure To set the output contact follow these steps 1 Press the Setup key in the basic panel display to display the Execution Setup display 2 Select Setup in the Execution Setup display The Commissioning Setup display then appears 3 Select the Contact setup in the Commissioning Setup display The Contact setup display shown in Figure 8 9 then appears 4 Select the desired output contact This section shows an example where contact output 1 is selected see Fi
62. 0H Automatic Calibration Unit The Automatic Calibration Unit can be mounted either on a pipe nominal JIS 50A or on a wall It should be positioned vertically so that the flowmeter works correctly lt Pipe Mounting gt 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting of Automatic Calibration Unit The unit weights approximately 3 5 kg 2 Mount the Automatic Calibration Unit on the pipe by tightening the nuts with the U bolt so that the metal fitting is firmly attached to the pipe F3 11E EPS Figure 3 11 Pipe Mounting IM 11M12A01 03E 3 9 3 10 lt Wall Mounting gt 1 Make a hole in the wall as illustrated in Figure 3 12 WE L g 4 Der 5 hole or M6 screw F3 12E EPS Unit mm Figure 3 12 Mounting holes 2 Mount the Automatic Calibration Unit Remove the pipe mounting parts from the mount fittings of the flow setting unit and attach the unit on the wall with four screws When setting it with M5 bolts use washers 466 5 Le rT F3 13E EPS Figure 3 13 Wall Mounting IM 11M12A01 03E 3 Installation 3 5 Installation of E7044KF Case Assembly for the Calibration gas Cylinder 3 5 1 Location 3 5 2 Mounting IM 11M12A01 03E The calibration gas unit case is used to store the G7001ZC zero gas cylinders The following should be taken into consideration 1 Easy access for cylinder replacement 2 Easy access for
63. 2 Enter 00098 for an oxygen concentration of 0 98 vol 02 9 2 1 4Span gas Concentration Set the oxygen concentration for span calibration If instrument air is used as the span gas enter 21 02 Select Span gas conc from the Calibration setup display Enter the desired span gas oxygen concentration from the numeric data entry display The span gas set ranges from 4 5 to 100 02 Enter 02100 for an oxygen concentration of 21 vol 02 Instrument air is here defined as dry air with a dew point temperature of no higher than 20 C If the dew point temperature is higher than 20 C use a hand held oxygen analyzer to measure the actual oxygen concentration When using the ZO21S Standard Gas Unit for use of the atmospheric air as a span gas use a hand held oxygen analyzer to measure the actual oxygen concentration and then enter it A CAUTION e When instrument air is used for the span calibration remove the moisture from the instrument air at a dew point temperature of 20 C and also remove any oily mist and dust from that air e If dehumidifying is not enough or if foul air is used the measurement accuracy willbe adversely affected IM 11M12A01 03E 9 7 9 2 1 5Setting Calibration Time 9 8 e When the calibration mode is in manual First set the output stabilization time This indicates the time required from the end of calibration to entering a measurement again This time after calibration the measure me
64. 2 If the probe length is 2 5 meters or more the detector should be mounted vertically nomore than a 5 tilt 3 The detector probe should be mounted at right angles to the measurement gas flow or the probe tip should point downstream Figure 3 1 illustrates an example of the probe insertion hole Bounds of the probe vertical insertion hole location Flange matches 100mm to the detector size 1 Type Outside diameter of detector Standard 50 8 mm in diameter Note With dust protector 80 mm in diameter or longer Note horizontal 100mm Four hole flange Eight hole flange JIS flange the detector with dust protector Note When using the detector with ZH21B dust protector the diameter of the hole should be 80mm or larger F3 1E EPS When using the detector with pressure compensation ensure that the flange gasket does not block the reference air outlet on the detector flange If the flange gasket blocks the outlet the detector cannot conduct pressure compensation Where necessary make a notch in the flange gasket Confirm the outside dimensions of the detector in Section 3 7 before installation Figure 3 1 Example of forming probe insertion hole 3 2 IM 11M12A01 03E 3 Installation 3 1 3 Installation of the Detector A CAUTION e The cell sensor at the tip of the detector is made of ceramic zirconia Do not drop the detector as impact will damage it e A gask
65. 2 2 8 Alarm 12 Input Current Alarm When mA input is selected in the Exhaust gas setup display this alarm occurs if the current input from the temperature transmitter goes outside he range from 3 2 to 21 6 mA If this alarm occurs simultaneously with Alarm 9 Exhaust Gas Temperature Alarm first solve the problem for Alarm 9 If Alarm 12 occurs independently the cable connection between this equipment and the temperature transmitter may be improper disconnected lt Locating cause of failure and countermeasures gt 1 Check that cable connections including connecting lugs are proper 2 If the cable connections are correct display the exhaust gas temperature and check that it matches the temperature transmitter s temperature signals If mismatched check whether the transmitter output range meets the Exhaust gas setup of this equipment 3 If the range setting is correct the analyzer electronics may be defective In such a case contact your local Yokogawa service or sales representative 12 2 2 9 Alarm 13 Battery low Alarm An internal battery is used as backup for the clock After this alarm occurs removing power from the instrument may cause the clock to stop but should not affect stored parameters The internal clock is used for blowback 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 lt Corre
66. 2 and 3 in turn ABC 123 Press the Enter key to complete the entry siirde Enter your password FT To lc ln GAME The K LIN O sv ME F7 5E EPS Figure 7 5 Text Entry Display IM 11M12A01 03E 7 Startup 7 5 Confirmation of Converter Type Setting This converter can be used for both the Oxygen Analyzer and the Humidity Analyzer Before setting the operating data be sure to check that the desired converter model has been set Note that if the converter type setting is changed the operating data that have been set are then initialized and the default settings remain To set the desired operating data follow these steps 1 Press the setup key 2 Use the Wkey to select Setup and press the Enter key 3 In the password display enter the Enter key If the password is to be set again enter the new password for details see Section 8 6 5 Passwords later in this manual 4 The Setup display shown in Figure 7 6 appears Select Basic setup and press the Enter key 5 The Basic setup display shown in Figure 7 7 then appears Confirm the currently set converter type If the Humidity Analyzer option HS was selected at the time of purchase the converter was set for high temperature humidity use before shipment 6 If the converter type is to be changed press the Enter key The display shown in Figure 7 8 then appears 7 Use the Wkey to select the type of equipment Then press the Ente
67. 255 days 23 hours Set the first calibration day and the start calibration time to the start date and start time respectively For example to start the first calibration at 1 30 p m on March 25 2001 enter 25 03 01 to the start date and 13 hours 30 minutes to the start time following the steps below IM 11M12A01 03E 9 Calibration 1 Select the Calibration timing display A panel display as shown in Figure 9 7 appears 2 Select each item for the calibration to display the numeric data entry display Enter the desired numeric values for the calibration Calibration timing Cp Hold time 10 min 00s Csltime 10 minOOs Interval 30d 00h Startdate 01 01 00 Starttime 00 00 F9 7E EPS Figure 9 7 Calibration Timing Display When setting calibration timing requirements bear the following precautions in mind 1 If the calibration interval is shorter than the sum of stabilization time plus calibration time the second calibration start time will conflict with the first calibration In such a case the second calibration will not be conducted When both zero and span calibrations are to be performed the calibration time is double that required for a single zero or span calibration 2 For the same reason if the calibration start time conflicts with manual calibration or semi automatic calibration the current calibration will not be conducted 3 If the calibration time conflicts with
68. 3E IM 11M12A01 03E 3 Installation 1 Drill mounting holes through the wall as shown in Figure 3 4 Unit mm Z YU Four holes 6 mm in diameter or M5 screw UW 126 5 7 F3 8E EPS Figure 3 4 Mounting holes 2 Mount the converter Secure the converter on the wall using four screws Note For wall mounting the bracket and bolts are not used F3 5E EPS Figure 3 5 Wall Mounting 3 5 3 6 lt Panel Mounting gt 1 Cut out the panel according to Figure 3 6 Unit mm 2 274 5 2 183 6 Figure 3 6 Panel cutout sizes F3 6E EPS 2 Remove the fitting from the converter by loosening the four screws 3 Insert the converter case into the cutout hole of the panel 4 Attach the mounting fitting which is once removed in step 2 again to the converter 5 Firmly fix the converter to the panel Fully tighten the two clamp screws to hold the panel with the fitting Washer LS S Figure 3 7 Panel mounting Clamp screw Fitting F3 7E EPS IM 11M12A01 03E 3 Installation 3 3 Installation of ZA8F Flow Setting Unit 3 3 1 Location The following should be taken into consideration 1 Easy access to the unit for checking and maintenance work 2 Near to the detector and the converter for operating keys on the panel 3 No corrosive gas 4 An ambient temperature of not more than 55 C and little changes of temperature 5 No vibration 6 Little exposure to rays of the sun or r
69. 4 165 125 4 18 18 DIN PN10 DN80 SUS304 200 160 8 18 20 DIN PN10 DN100 SUS304 220 180 8 18 20 JIS 5K 65 FF SUS304 155 130 4 15 14 P JIS 10K 65 FF SUS304 175 140 4 19 18 JIS 10K 80 FF SUS304 185 150 8 19 18 Flange JIS 10K 100 FF SUS304 210 175 8 519 18 9 JIS 5K 32 FF SUS304 115 90 4 15 5 JPI Class 150 4 RF SUS304 229 190 5 8 19 24 JPI Class 150 3 RF SUS304 190 152 4 4 19 24 FO7_01 EPS Westinghouse 155 127 4 11 5 14 2 6 IM 11M12A01 03E 2 Specifications Model ZR22G P Detectors with pressure compensation Separate type Zirconia High Temperature Humidity Analyzer Detectors 303 50 8 L 0 15 0 4 0 7 1 0 1 5 2 0 2 5 3 0 m i J 124 LO 00 oh Rc1 4 or 1 4NPT Reference air inlet 2 G1 2 2 1 2NPT etc Cable connection port Reference gas outlet PIPING Flange B Rc1 4 or 1 4NPT Calibration gas inlet Stop Valve PIPING A Flange A B C t PIPING ANSI Class 150 2 RF SUS304 ANSI Class 150 3 RF SUS304 ANSI Class 150 4 RF SUS304 DIN PN10 DN50 SUS304 DIN PN10 DN80 SUS304 DIN PN10 DN100 SUS304 w w gt JIS 5K 65 FF SUS304 155 130 4 15 14 A JIS 10K 65 FF SUS304 175 140 4 19 18 A JIS 10K 80 FF SUS304 185 150 8
70. 40H Automatic Calibration Unit This wiring is for operating the 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 3 When installing this wiring proceed as follows Wiring inlet Span gas solenoid valve 2 G1 2 Pg13 5 M20 or 1 2NPT Zero gas solenoid valve COMMON SPAN ZERO to ZR402G terminal AC COM to ZR402G terminal AC SPAN to ZR402G terminal AC ZERO Terminal screw M4 Wire or equivalent F5 12E EPS Figure 5 12 Automatic Calibration Unit IM 11M12A01 03E 5 13 5 7 1 Cable Specifications Use a three core cable for this wiring 5 7 2 Wiring Procedure M4 screws are used for the terminals of the converter Each cable should be terminated in the corresponding crimp on terminals M4 screws are used for the terminals of the solenoid valve as well Converter AC Z AC C ZR40H Automatic Calibration unit AC S o Zero o Span EJ F5 13 EPS Figure 5 13 Wiring for Automatic Calibration Unit 5 14 IM 11M12A01 03E 5 Wiring 5 8 Wiring for Contact Input The converter can execute specified function when receiving contact signals To use these contact signals wire as follows Converter Terminal box ae 0 Contact input 1
71. 6 10 Table 10 6 Measurement gas pressure kPa 50 100 150 200 250 Flowrate ml min 500 430 380 250 320 T10 6E EPS 2 Adjust the flow rate and select Valve opened from the Manual calibration display Check the Trend graph display to see that the measured value is stabilized Then press the Enter key The Manual calibration display shown in Figure 10 16 appears 3 Close the span gas flow setting valve to stop the span gas air flow If the valve has a lock nut be sure to tighten the lock nut to prevent any leakage of span gas into the sensor during measurement IM 11M12A01 03E 10 23 10 6 3 Operating the Zero Gas Flow Setting Valve Operate the zero gas flow setting valve during zero point calibration in the following procedures 1 When the display shown in Figure 10 19 appears during calibration open the zero gas flow setting valve of the flow setting unit and adjust the flowrate to 600 60 ml min To rotate the valve shaft if the valve has a lock nut loosen the lock nut and slowly turn it counterclockwise To check the flowrate monitor the calibration gas flow meter If the measurement gas pressure is extremely high adjust the measurement gas pressure to obtain pressures listed in Table 10 6 10 Table 10 6 Measurement gas pressure kPa 50 100 50 200 250 Flowrate ml min 500 430 380 250 320 T10 6E EPS Display setup Display item
72. 7ZA and tighten the screw 8 with a special tool part no K9470BX or equivalent with a tightening torque of 12N m 10 Next to install the O rings 22 on the calibration gas and reference gas pipes disas semble the connector 13 in the following procedure First remove the screw 25 and then remove the plate 17 and two caps 20 If the O ring 22 remains in the hole pull them out from the back Pass the heater and thermo couple leadwire through the connector 13 Also pass the calibration gas and reference gas pipes through the opening of the connector 13 If the O ring 22 fails replace it with a new one Push the two caps 20 into the associated opening of the connector 13 Insert the plate 17 aligning it with the groove of the cap 20 and tighten it with the screw 25 If you attempt to insert the calibration gas and reference gas pipes into the connector 13 without disassembling the connector 13 the O ring may be damaged Tighten the Tighten Screw 19 in Heater Strut Assembly 23 until connector 13 can t move Reassemble in reverse order to the above disassembly procedure The two wires with ceramic insulators from the heater strut assembly are heater wires and the single core shielded wire is the cell signal terminal for the two core shielded cable the semi translucent rubber sheathed wire is the thermocouple terminal and the other wire is the terminal If the wires are marked matc
73. 8 6 2 1 Procedure 8 6 2 2 Default Values IM 11M12A01 03E The equipment enables the display of oxygen concentration average values and maxi mum and minimum values under measurement see Section 10 1 1 later in this manual The following section describes how to set the periods over which oxygen concentration average values are calculated and maximum and minimum values are monitored 1 Press the Setup key in the Basic panel display to display the Execution Setup display 2 Select Setup in the Execution Setup display to display the Commissioning Setup display 3 Select Others in that display and then select Averaging in the Others display The averaging display shown in Figure 8 15 then appears 4 Choose Set period over which average is calculated and enter the desired numeric value from the numeric data entry display To enter three hours type in 003 The period over which average values can be calculated ranges from 1 to 255 hours 5 Choose Set period over which maximum and minimum is stored and enter the desired numeric value from the numeric data entry display To enter 48 hours type in 048 The allowable input ranges from 1 to 255 hours When the analyzer is delivered or if data are initialized the average value calculation periods and maximum and minimum value monitoring periods are by default one hour and 24 hours respectively Averaging CP Set period over which average is calculated th
74. AC 50 60 Hz IM 11M12A01 03E 220 V AC 50 60 Hz Power 4 240 V AC 50 60 Hz supply 5 t 100 V AC 50 60 Hz v 110 V AC 50 60 Hz 8 115 V AC 50 60 Hz Panel EL TE Japanese version English version Style code Style A T2 6E EPS 2 21 External Dimensions Unit mm Flow checker Span gas valve Zero gas valve Gas outlet Zero gas cyilnder 6 cyilnder E7050BA F2 7E EPS 2 6 Other Equipment 2 6 1 Stop Valve Part Number L9852CB or G7016XH This valve is mounted on the calibration gas line in the system to allow for one touch calibration This applies to the system configuration shown for system 1 in section 1 Standard Specifications Connection Re 1 4 or 1 4 FNPT Material SUS 316 JIS Weight Approx 80 g Part No Description L9852CB Joint RC 1 4 Material SUS 316 JIS G7016XH Joint 1 4 NPT Material SUS 316 JIS T2 9E EPS Unit mm 943 B Q e Z Rc1 4 or 1 4NPT lt F15 EPS 2 22 IM 11M12A01 03E 2 Specifications 2 6 2 Check Valve Part Number K9292DN or K9292DS IM 11M12A01 03E This valve is mounted on the calibration gas line directly connected to the detector This is applied to a system based on the System 2 and 3 system configuration This valve prevents the process gas from entering the calibration gas line Although it functions
75. Approx 1 5 l min Weight Approx 3 5 kg Ambient Temperature 20 to 55 C no condensation or freezing Ambient Humidity 0 to 95 RH Storage Temperature 30 to 65 C Model and Codes Suffix code Option code Description Gas piping connection Selene Automatic calibration unit for ZR402G areas Re 1 4 Deere 1 4 NPT Wiring connection P f Pipe connection G1 2 Teese Pg 13 5 So 20 mm M20 x 1 5 He 1 2 NPT Always A 4zO T2 5 1E EPS IM 11M12A01 03E External Dimensions 2B pipe mounting example 2 Specifications Unit mm wiring inlet 2 G1 2 Pg13 5 M20x 1 5 or 1 2NPT Female 1 with four M6 screws can wall mount Flowmeter reference air Setting Valve fo IM 11M12A01 03E calibration gas calibration gas outlet Setting Valve for 4d 4 b 6 5 r Rc1 4 or 1 4 NPT Female reference air outlet Rc1 4 or 1 4 NPT Female 90 wiring inlet is at same position on rear 71 5 Zero gas air inlet Rc1 4 or 1 4 NPT Female 116 5 40 47 5 E5 reference gas inlet Rc1 4 or 1 4 NPT Female
76. Contact capacity Off state leakage current 3 mA or less Self diagnosis cell abnormal cell temperature abnormal low high calibration abnormal A D converter defective digital circuit defective Calibration Method zero span calibration Calibration mode automatic semi automatic and manual All are operated interactively with an LCD touchpanel Either zero or span can be skipped Zero calibration gas concentration setting range 0 3 to 100 vol O minimum in 0 01 vol Span calibration gas concentration setting range 4 5 to 100 vol O minimum in 0 01 vol Use nitrogen based mixed gas containing about 10 of oxygen for standard zero gas and 80 to 100 of oxygen for standard span gas Calibration period date time setting maximum 255 days 2 12 IM 11M12A01 03E IM 11M12A01 03E Model and Suffix Codes ZR402G Converter thread Suffix code Option code Description Separate type Zirconia High Temperature Humidity Analyzer Converter G1 2 Pg13 5 M20x1 5 mm 1 2NPT Display Japanese English German French Instruction manual Japanese English Always A Options Set for Humidity Analyzer 3 Hood 2 Tag plates Stainless steel tag plate 1 Printed tag plate 1 1 Specify either SCT or PT option code TRABERG 2 Sun shield hood is still effective even if scratched 3 Be sure to use the equipment with the optio
77. DI 2 DI C Al AI AC AC AC FG FG Contact input 2 SO Solenoid valve for spah gas Contact input 1 for automatid calibration T 1 1 i 1 i I i 1 i I I i i T i I I I T I I f i I i i Q Temperature transmitter input 4to Co E ple Solenoid valve for zero gas i for automatic calibration I 1 1 I I i i I i I i 1 i i i i i T I Flow setting unit 23 24 25 26 27 28 29 30 31 32 33 34 35 36 O DO 1 DO 1 DO 2 DO 2 DO 3 DO 3 DO 4 DO 4 HTR HTR L N G FG HTR HTR I I I I I I I Ig 1 I 1 I 1 l I a L iy 100 240V AC i 50 60 Hz ous Contact Contact Contact Contact 1 _ output 1 __ output 2 __output3 __ output 4 le T E eee eee F5 3E EPS 1 The protective grounding for the converter should be connected either the protective ground terminal in the equipment or the ground terminal on the case Standard regarding grounding Ground to earth Class 3 grounding ground resistance 100 or less Figure 5 3 Wiring connection to the converter 5 13 Mounting of Cable Gland For each cable connection opening of the converter mount a conduit that matches the thread size or a cable
78. Detector sample gas temperature 0 to 700 C Standard detector Model ZR22G Mounting angle Vertical to horizontal Vertical The probe insertion length 0 4 to 2m The probe insertion length 2 5 to 3m st protector IM 11M12A01 03E Model ZR22G 040 and ZH21B Mounting angle Vertical to horizontal The probe insertion length 0 4m F1 4E EPS 1 5 2 Specifications 2 Specifications This chapter describes the specifications for the following ZR22G General use separate type detector See Section 2 2 1 ZH21B Dust protector See Section 2 2 2 ZR402G Separate type converter See Section 2 3 ZA8F Flow setting unit See Section 2 4 1 ZR40H Automatic calibration unit See Section 2 4 2 ZO21S Standard gas unit See Section 2 5 2 1 General Specifications 2 1 1 Standard Specifications High Temperature Humidity Analyzer Oxygen concentration in mixed gas which consists of water vapor and air is proportional to the volume rate of air so the volume rate of water vapor can be calculated by the oxygen concentration Measured Object Water vapor in vol in mixed gases air and water vapor Measured System Zirconia system Measured Range 0 01 to 100 vol O 0 to 100 vol H O or 0 to 1 000 kg kg Output Signal 4 to 20 mA DC maximum load resistance 550Q Oxygen concentration Any setting in the range of 0 to 5 through 0 to 100 vol O in 1 vol O or partial ran
79. K9473AN 1 5 E7042DW 4 6 G7109YC 4 K9470BK 4 7 1 ZRO1A01 01 ZRO1A01 02 ZRO1A01 05 ZRO1A01 10 8 E7042BS 1 9 K9470BJ 1 10 E7042AY 1 Ti Steet K9470ZF 1 K9470ZG 1 e K9470ZK 1 K9470ZL 1 13 ZR22A 1 F02E EPS Description 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 1 piece 2 pieces 5 pieces 10 pieces Contact Metal O ring Filter Assembly Bolt and Washeres G7109YC 3 4 E7042DW 3 4 K9470BK 3 4 E7042DW 3 4 for Option code C Calibration Tube Assembly Calibration Tube Assembly Calibration Tube Assembly for Option code C Heater Assembly YOKOGAWA All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M12A01 03E Subject to change without notice Yokogawa Electric Corporation 1 st Edition Aug 2000 YK 6 th Edition Oct 2006 YK Customer Model ZR402G Maintenance Zirconia Oxygen Analyzer High Temperature Parts List Humidity Analyzer Converter Hood for ZR402G la N 5 Fr E Item Parts No Qty Description 1 A1113EF 1 Fuse 3 15A 2 K9471UF 1 Hood YOKOGAWA All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M12C01 01E 2nd Edition Feb 2001
80. M 11M12A01 03E 8 17 8 6 Other Settings 8 6 1 8 18 Setting the Date and Time The following describe how to set the date and time Automatic calibration or blowback works following this setting Proceed as follows 1 Press the Setup key in the Basic panel display to display the Execution Setup display 2 Select Setup in the Execution Setup display to display the Commissioning Setup display 3 Select Others in the Commissioning Setup display The Others display then appears as shown in Figure 8 15 4 Select Clock The Clock display then appears as shown in Figure 8 16 5 Select Set date to display the numeric data entry display To set the date June 21 2000 enter 000621 and press the Enter key The display then returns to the one shown in Figure 8 16 5 Select Set time Enter the time on a 24 hour basis To enter 2 30 p m type in 1430 in the numeric data entry display Press the Enter key and the time starts at 00 second Others Fay Clock Al CF Clock Setdate 21 06 00 k Averaging Settime 14 39 Kij Fuel setup i l 21Jun 2000 l Purging 14 30 00 Unit setup Passwords Defaults sis RENE Figure 8 15 Other Settings Figure 8 16 Clock Display IM 11M12A01 03E 8 Detailed Data Setting 8 6 2 Setting Periods over which Average Values Are Calculated and Periods over which Maximum and Minimum Values Are Monitored
81. Name Specification Installation Operation Maintenance CMPL ZR22G General use detector O O O O ZR402G Converter O O O O O ZH21B Dust protector O O ZA8F Flow setting unit for manual calibration use O O O ZR40H Automatic Calibration unit O O O O Calibration gas unit case Part No E7044KF O O Check valve Part No K9292DN K9292DS O O ZO21S Standard gas unit O Q O O TintiE CMPL Customer Maintenance Parts List IM 11M12A01 03E 7th Edition Sep 2006 YK All Rights Reserved Copyright 2000 Yokogawa Electric Corporation IM 11M12A01 03E This manual consists of twelve chapters Please refer to the reference chapters for installation operation and maintenance Table of Contents References Chapter Outline Installation Operation Maintenance 1 Overview Equipment models and system configuration examples A 2 Specifications Standard specification model code or part number dimension drawing for each equipment 9 2 9 3 Installation Installation method for each equipment A 4 Piping Examples of piping in three standard system A configurations 5 Wiring Wiring procedures such as Power supply wiring output signal wiring or others 6 Components These are described in this manual O 7 Startup Basic procedure to start operation of EXAxt ZR Chapter 7 enables you to operate the equipment immediately 8 Detailed Data Setting Details of k
82. O or greater 75 1 3 O Numbers after the decimal point are rounded up Ranges over which oxygen concentrations can be set Outside ranges Maximum oxygen concentration O2 for a maximum current of 20 mA 5 15 25 35 45 55 65 75 Minimum oxygen concentration O2 for a minimum current of 4 mA FAE EPS Figure A Max and Min Oxygen Concentration Set Ranges IM 11M12A01 03E 8 1 8 2 Humidity amount of moisture content setting range The minimum humidity is set to 0 H O or ranges from 26 to 100 H O The maxi mum humidity ranges from 25 to 100 H O and must be greater than 0 8 times plus 23 the humidity set for the minimum Setting example 1 If the setting for a 4 mA current is 0 H O you must set the maximum 20 mA point at more than 25 H O Setting example 2 If the setting for a 4 mA current is 26 H O you must set the maximum 20 mA point at more than 44 HO 26X 0 8 23 HO Numbers after the decimal point are rounded up 100 90 0 Range over which humidity can be set o Outside ranges o Maximum humidity amount of moisture content 3 for a 20 mA current H20 40 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Minimum humidity amount of moisture content for a 4 mA current H20 FBE EPS Figure B Max and Min Humidity Set Ranges IM 11M12A01 03E IM 11M12A01 03E 8 Detailed Data Setting Mixing ratio setting range The minimum mixing ratio is s
83. S8F Flow Setting Unit and ZR40H Automatic Cali 2 4 1 2 16 bration Unit ZASF Flow Setting Unit This flow setting unit is applied to the reference gas and the calibration gas in a system configuration System 2 This unit consists of a flow meter and flow control valves to control the flow of calibra tion gas and reference air e Standard Specifications Flowmeter Calibration gas 0 1 to 1 0 l min Reference air 0 1 to 1 0 l min Construction Dust proof and rainproof construction Case Material SPCC Cold rolled steel sheet Painting Baked epoxy resin Dark green Munsell 2 0 GY 3 1 0 5 or equivalent Pipe Connections Rc1 4 or 1 4FNPT Reference Air pressure Clean air supply of measured gas pressure plus approx 50 kPa G or measured gas pressure plus approx 150kPa G when a check valve is used pressure at inlet of the auto calibration unit Maximum 300 kPaG Air Consumption Approx 1 5 l min Weight Approx 2kg Calibration gas zero gas span gas flow 0 7 l min at calibration time only Model and Codes Suffix code Option code Description TANS RE Flow setting unit PEE E RT Rc 1 4 sa s rsmrr ttet With 1 4 NPT adapter Style code B_ Style A Joint T2 5E EPS IM 11M12A01 03E Reference air outlet Zero gas outlet Span gas inlet IM 11M12A01 03E 2 Specifications External Dimensions REFERENCE CHECK 70 1 REFERENCE SRAN Zer
84. See 1 below Output 2 item Oxygen concentration with the equipment set for oxygen analyzer See 1 below Current output 1 Current output 2 A Tip Current value output from analog output 1 Current value output from analog output 2 1 If an analog output damping constant is set display data then includes these settings T7 2E EPS For the relative humidity and dew point calculations appropriate operation parameters should be entered For details on the parameters consult Section 8 6 3 Setting Measurement Gas Temperature and Pressure later in this manual IM 11M12A01 03E 7 9 Checking Current Loop The set current can be output as an analog output 1 Press the Setup key on the basic panel display to display the Execution Setup display Then select Maintenance in the Execution Setup display 2 Select mA output loop check in the Maintenance panel display to display the mA output loop check display enabling you to check mA output1 and mA output2 Select the desired output terminal for current loop checking see Figure 7 15 1 3 At the time of entering the numeric data entry display the output current will change to 4 mA default value If the desired current is entered the corresponding output will be provided mA output loop check F mA output 1 mA output 2 RES m 2 2 F7 15 1E EPS Figure 7 15 1 mA output loop
85. TC CJ CJ oO G 0 ML OLM O l Oj 12 13 14 15 16 17 18 19 20 21 22 1i 1 FG DI 1 DI 2 DI C Al Al AC AC AC FG FG i i _ ZERO SPAN COM La 1 Tad Le i i ii 1 oo 4Contact T f OT input 2 i i D Solenoid valve i oO Span gas for automatic 4 i Contact i calibration it 1 input 1 i i i it 1 Temperature transmitter input i Solenoid valve for n 1 automatic calibration ii 1 gala ee gas if i i l i Automatic Calibration Unit _ il RAS RER AE DR NEO RES EDR iy i 4 i ii i H i di i fal ol fN Remove O j jumper plate ernal circuits Remove wiring to connect ex and connect crossover wiring 1 Insulation resistance tester O crossover wiring F3 17E EPS Insulation resistance tester 3 12 IM 11M12A01 03E 3 Installation 3 7 External Dimensions of Detectors with Pressure Com pensation ZR22G P Flange ANSI Class 150 2 RF SUS304 Unit mm Rc1 4 or 1 4NPT Reference air inlet L 156 ET x 2 G1 2 2 1 2NPT etc ie Cable connection port mil mn ap 1 ol Re1 4 or 1 4NPT Flange Calibration gas inlet Stop Valve Reference gas outlet Flange PIPING A Weig
86. TION e If instrument air is used for the span gas dehumidify the air down to a dew point of 20 C and remove any oil mist or dust e If dehumidification is insufficient or polluted air is used a measurement accuracy may be adversely affected 7 11 2 Manual Calibration 7 11 2 1 Preliminary Before performing a manual calibration be sure that the ZA8F Flow Setting Unit zero gas flow valve is fully closed Open the zero gas cylinder pressure regulator so that the secondary pressure equals measured gas pressure plus approx 50 kPa or measured gas pressure plus approx 150 kPa when a check valve is used maximum pressure rating is 300kPa This applies even if you are using the ZR40H Auto Calibration Unit 7 11 2 2 Calibration Procedures This manual assumes that the instrument air is the same as the reference gas used for the span gas Follow the steps below to conduct manual calibration 1 Press the Setup key in the basic panel display to display the Execution Setup display Then select Calibration in the Execution Setup display In doing so the Calibration display as in Figure 7 17 appears Calibration Manual calibration Check the span gas lt concentration value 7 CP Manual calibration CP Next Cancel calibration Change value 21 00 F7 17E EPS F7 18E EPS Figure 7 17 Calibration Display Figure 7 18 Manual Calibration 7 16 IM 11M12A01 03E 7 Startup 2 Pr
87. User s EKA Manual Model ZR22G ZR402G Separate type Zirconia High Temperature Humidity Analyzer IM 11M12A01 03E vigilant YOKOGAWA IM 11M12A01 03E 7th Edition Yokogawa Electric Corporation Introduction The EXAxt ZR Separate type Zirconia High temperature Humidity Analyzer has been developed for humidity control in 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 to improve measurements and automate calibra tion An optimal control system can be realized by adding appropriate options This instruction manual refers to almost all of the equipment related to the EXAxt ZR You may skip any section s on the equipment which is are not included in your system Regarding the HART communication protocol refer to the IM 11M12A01 51E IM 11M12A01 51E has been published as Model EXAxt ZR Series HART Protocol The all in one version with sensor and analyzer integrated in one body is described in IM 11M12A01 05E lt Before using the equipment please read any related descriptions in this manual for the equipment and the system you have on appropriate use and operation of the EXAxt ZR gt Models and descriptions in this manual are as follows Models and descriptions in this manual Description in this manual Model Product
88. age 0 kg kg T10 5E 2 EPS 10 15 10 16 Data to be initialized Default setting Contacts Output contact 1 Alarm None Other settings Warm up On Output range now being switched None Now calibrating None Now maintenance servicing On Blowback None High limit temp alarm None Calibration gas press drop None Gas leak detection None Contact output action Open Output contact 2 Alarm None Other settings Warm up None Output range switching None Now calibrating On Now maintenance servicing None Blowback None High limit temp alarm None Calibration gas press drop None Unburnt gas detection None Contact output action Closed Output contact 3 High high alarm None High limit alarm On Low limit alarm On Low low alarm None Calibration Coefficient Alarm None Startup power stabilization timeout None Error None Other settings None Contact output Closed Input contact 1 Function None Input contact 2 Action Closed Other data Averaging Set periods over which average is calculated One hour Set periods over which max and min is stored 24 hours Measurement gas temperature Temperature input mode Preset Measurement gas tem
89. ain 3 3 2 Mounting of ZA8F Flow Setting Unit The flow setting unit can be mounted either on a pipe nominal JIS 50A or on a wall It should be positioned vertically so that the flowmeter works correctly lt Pipe Mounting gt 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the flow setting unit The unit weighs approximately 2 to 3 5 kg 2 Mount the flow setting unit on the pipe by tightening the nuts with the U bolt so that the metal fitting is firmly attached to the pipe F3 8E EPS Figure 3 8 Pipe Mounting IM 11M12A01 03E 3 7 3 8 lt Wall Mounting gt 1 Make a hole in the wall as illustrated in Figure 3 9 WE 14 Unit mm 4 Durs hole or M5 screw F3 9E EPS Figure 3 9 Mounting holes 2 Mount the flow setting unit Remove the pipe mounting parts from the mount fittings of the flow setting unit and attach the unit securely on the wall with four screws F3 10E EPS Figure 3 10 Wall mounting IM 11M12A01 03E 3 Installation 3 4 Installation of ZR40H Automatic Calibration Unit 3 4 1 Location The following should be taken into consideration 1 Easy access to the unit for checking and maintenance work 2 Near to the detector 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 4 2 Mounting of ZR4
90. alibrating or the like by symbols Alarm Error Display Displays alarms such as Abnormal moisture quantity or errors such as Abnormal cell e m f when any such status occurs Calibration Functions Auto Calibration Requires the Auto calibration Unit It calibrates automatically at specified intervals Semi auto Calibration Requires the Auto calibration Unit Input calibration direction on the touchpanel or contact then it calibrates automatically afterwards Manual Calibration Calibration with opening closing the valve of calibration gas in operation interactively with an LCD panel Blowback Function Output through the contact at a set period and time Auto semi auto selectable Maintenance Functions Can update data settings during daily operation and checking Display data settings calibration data settings blowback data settings current output loop check input output contact check Setup Functions Initial settings suit for the plant conditions when installing the con verter Equipment settings current output data settings alarm data settings contact data settings other settings Self diagnosis This function diagnoses conditions of the converter or the probe and indicates when any abnormal condition occurs Password Functions Enter your password to operate the analyzer excepting data display Individual passwords can be set for maintenance and setup 2 10 IM 11M12A01 03E Display and
91. alibration gas low pressure signal when a calibration gas low pressure signal is applied to the contact input To do this it is required in input contact setup that Cal gas press Low be selected beforehand For more on this see Section 8 5 Process upset If Process upset is selected contact output occurs answer back signal to a process upset signal when the process upset signal is applied to the contact input To do this it is required in input contact setup that process upset be selected beforehand see Section 8 5 Note To provide an alarm with an output contact be sure to make an alarm setting When using contact output as an answer back signal for an input contact be sure to make an input contact T8 6E EPS IM 11M12A01 03E 8 4 3 IM 11M12A01 03E Default Values 8 Detailed Data Setting When the analyzer is delivered or if data are initialized alarm and other setting are defaults as shown in Table 8 7 Table 8 7 Output Contact Default Settings Item Output contact 1 Output contact 2 Output Output contact 3 contact 4 High high limit alarm High limit alarm Low limit alarm Low low limit alarm Calibration coefficient alarm Startup power stabilization timeout alarm Error Warm up Output range change Calibration Maintenance Blow back High limit temperature alarm Cal
92. analyzer to measure the actual oxygen concentration and then enter it lt Flow of span gas air gt The standard gas unit is used only when manual calibration is employed Therefore the timing for flowing span gas air is included in the manual calibration flowchart de scribed in Section 10 5 2 For operation of the converter see Section 7 12 earlier in this manual 1 When the message Did you open span valve Y is displayed on the converter display during calibration plug the power cord into the power supply socket to start the pump of the standard gas unit Manual calibration Open span gas valve Set flow span gas to El 600ml min CP Valve opened Ly Cancel calibration F10 15E EPS Figure 10 15 Manual Calibration Display 2 Next adjust the flow rate to 600 60 ml min using the span gas valve AIR the flow check ball stops floating on the green line when the valve is slowly opened To rotate the valve shaft loosen the lock nut and turn it using a flat blade screwdriver Turning the valve shaft counterclockwise increases the flow rate 3 After adjusting the flow rate tighten the valve lock nut 4 Select Valve opened to start calibration from the Manual calibration display shown in Figure 10 15 Check the Trend graph display to see that the measured value is stabilized Then press the Enter key The Manual calibration display shown in Figure 10 16 appears Disconnect the power
93. arithmic mode the minimum output remains constant at 0 1 O and the humidity remains set to 0 1 H O and mixing ratio is set to 0 01 kg kg 8 4 IM 11M12A01 03E 8 15 Default Values When the analyzer is delivered or reset to defaults the output current default settings are IM 11M12A01 03E as shown in Table 8 1 8 Detailed Data Setting Table 8 1 Output Current Default Values Item Default setting Min oxygen concentration 0 O2 Max oxygen concentration 25 Or Minimum humidity conc 0 H20 Maximum humidity conc 25 H20 Minimum mixing ratio 0 000 kg kg Maximum mixing ratio Output damping constant 0 2 00 kg kg 0 seconds Output mode Linear T8 1E EPS 8 5 8 2 Output Hold Setting 8 2 1 8 6 The output hold functions hold an analog output signal at a preset value during the equipment s warm up time or calibration or if an error arises Outputs 1 and 2 can be set individually Table 8 2 shows the analog outputs that can be retained and the individual states Table 8 2 Equipment status During warm up Under Under calibration On Error maintenance During blow back occurrence Output hold values available 4mA 20 mA Without hold feature Retains output from just before occurrence Set value 2 4 to 21 6 mA O The output hold functions are available T8 2E EPS Definition of Equipme
94. as Calibration gas pressure regulator Zero gas Calibration gas cylinder unit case F4 7E EPS Figure 4 7 Piping for System 2 Piping in System 2 is as follows e Place a stop valve or check valve through the nipple at the calibration gas inlet of the detector e It is recommended to use ZH21B dust protector to protect the probe output from dust agitation 1 e to prevent combustible materials from entering the probe cell where humidity measurements are made under dusty or combustible environment 4 2 1 Piping Parts for System 2 Check that the parts listed in Table 4 2 are ready Table 4 2 Detector Piping location Parts Note General use Calibration gas inlet Stop valve or check valve Recommended by YOKOGAWA detector L9852CB or G7016XH Provided by YOKOGAWA K9292DN or K9292DS Nipple Rc1 4 or 1 4 NPT generic parts Zero gas cylinder User s scope Gas pressure regulator Recommended by YOKOGAWA G7013XF or G7014XF Joint for tube connection Rc1 4 or 1 4 NPT generic parts Reference gas inlet Air set Recommended by YOKOGAWA K9473XH K9473XJ or G7004XF K9473XG Joint for tube connection Rc1 4 or 1 4 NPT generic parts Note Parts with marking are used when required T4 2E EPS IM 11M12A01 03E 4 3 4 2 2 4 2 3 4 4 Piping for the Calibration Gas This piping is to be installed between the zero gas cylinder and the ZA8F flow setting unit and between the
95. as a stop valve operation is easier than a stop valve as it does not require opening closing at each calibration Screw a check valve into the calibration gas inlet of the detector instead of the stop valve Standard Specifications Connection Rc1 4 or 1 4FNPT Material SUS304 JIS Pressure 70 kPa G or more and 350 kPa G or less Weight Approx 40 g Part No Description K9292DN Joint RC 1 4 Material SUS304 JIS K9292DS Joint 1 4 NPT Material SUS304 JIS T2 10E EPS K9292DN Re 1 4 Apart R 1 4 B part K9292DS 1 4FNPT A part 1 4NPT Male B part Unit mm A B Approx 19 Approx 54 F2 11E EPS 2 23 2 6 3 Air Set Part Number K9473XH or K9473XJ This set is used to lower the pressure when instrument air is used as the reference and span gases Standard Specifications Primary Pressure Max 2 MPa G Secondary Pressure 0 to 0 25 MPa G Connection Rc1 4 or 1 4FNPT includes joint adapter Weight Approx l kg Part No Description K9473XH Joint Re 1 4 Material Aluminum K9473XJ Joint 1 4 NPT F Material Body Aluminum Adapter Zinc alloy T2 11E EPS Unit mm Dimensions in parentheses are approximate Bracket Mounting Dimensions K9473XH Piping connection IN Primary side OUT Secondary side Rc1 4 K9473XJ Piping connection IN Primary side OUT Secondary side 1 4NPT 2 24 IM 11M12A01 03E Part Number G7004XF or K9473XG Primary Pressure
96. awa will not bear direct indirect responsibility for damage due to a specific application Yokogawa Electric will not bear responsibility when the user configures the product into systems or resells the product Maintenance service and supplying repair parts will be covered for five years after the production ends For repair for this product please contact the nearest sales office described in this instruction manual vii Contents Tntrod ctioi Sniper dite eoa soes itero oerein soosis ne sod For the safe use of this equipment e sesseseesossesccsoesescossesccsossescesoeseeoossesoesossesoesoeseesesses After Sales Warranty scsedeicssacssivcactcesiensediictccceasecsusicancentiansenscacdesdeceaieasveacandspscrvacsoeigaiee VI 1 Overview E EEEE AE EEE E EEEE EE EAE EA L 1 1 1 lt EXAxt ZR gt System Configuration 1 2 tll SySt mr ls ea ae Ri a aa a A ee eae 1 2 11527 SYSTEM sr nn nn ne nr a frere 1 3 11 37 Systems ss ts ts Ain A ssaases ete diese 1 4 1 2 lt EXAXxtZR gt System Components ss 1 5 EZI System Components 002 05 sessstsssesseastesvsascashspesssees anae EE E EES 1 5 1 2 2 Detectors and Accessories ss 1 5 Za SPECICATION ccs remises 2 2 1 General Specifications ssh sesso cba eisene sitter Auot 2 1 2 1 1 Standard Specifications ss 2 1 2 2 General use Separate type Detector and Related Equipment 0 2 3 2 2 1 ZR22G General use Separate type Detector ee cece eeeeeeee
97. bare crimp on terminal 4 Except when a 600V silicon rubber insulated glass braided wire is used connect the cable shield to the FG terminal of the converter 5 6 IM 11M12A01 03E 5 Wiring 5 2 3 Connection to the Converter To connect the wiring to the converter proceed as follows 1 M4 screws are used for the terminals of the converter Each wire in the cable should be terminated in the corresponding sige crimp on terminal 2 When a rubber insulated glass braided wire is used for wiring to the detector use a terminal box For wiring between the terminal box and the converter use basically a cable e g PVC sheathed PVC insulated cable rather than individual wires AN Note The above is to prevent moisture or corrosive gas from entering the converter and to ground the detector without fail IM 11M12A01 03E 5 7 5 3 Wiring for Power to Detector Heater This wiring provides electric power from the converter to the heater for heating the sensor in the detector 1 Ambient temperature of the detector 80 C or less Detector Converter HTR 7 OF HTR 8 OO HEATER et re 2 Ambient temperature of the detector exceeding 80 C Detector Terminal box Converter Hie 7 O OJ HEATER HTR 8 J Heat resistant wiring Figure 5 7 Wiring for power to the detector heater F5 7E EPS 5 3 1 Cable Specifications Basically PVC insulated PVC
98. c eceseseeseeeecneeneeseeseceeeeeeeeees 7 7 7 6 Confirmation of Detector Type Setting 0 eeeeecseeeeeceeseeeneesaeenees 7 8 7 7 Current Output Setting sise 7 8 7 7 1 Analog Output Setting c cc ccssc ccstespcssssssacoessachsscbedesegessensdscsacansesoessees 7 8 7 1 2 Minimum Current 4 mA and Maximum Current 20 mA Settings 7 9 78 Setting Display Item serisi e ea iaee E a aee aS 7 10 T9 Checking Current Loop i ei ree oeseri Er eE trend EEKE EEKE EEEE E 7 12 7 10 Checking Contact W O 5 sent nt entrer titine tetes 7 13 7 10 1 Checking Contact Output ss 7 13 7 10 2 Checking Calibration Contact Output ss 7 14 7 10 3 Checking Input Contacts ss 7 14 PAD EAS a ke LeO a ANNEN REEERE OEE nn ln nn fe seers med sureee 7 15 TALT Calibration Setup ss 7 15 T2 Mantal Calibration css ss seen de Mint nr eh 7 16 Detailed Data Settings ssisssenisennsenenenneenenneneneeteeneentnesseneesesss D 8 1 Current Output Settinpsssstnsnsn shine se sd ERE EEEE titine aE 8 1 8 1 1 About Input Ranges ss 8 1 8 1 2 Setting Minimum Current 4 mA and Maximum Current 20 mA 8 4 8 1 3 Entering Output Damping Constants 8 4 8 1 4 Selection of Output Mode oo eee cee ceeceseeeeceeeeeceeeeseeeeeeeeseneeees 8 4 8 1 5 Default Values uns hein EEES E 8 5 82 Output Hold Settings fetes nn Et wine ere nents de Et A 8 6 8 2 1 Definition of Equipment Status 8 6 8 2 2 Preference Order of Output Hold Value
99. checking 3 Near to the detector and converter as well as the flow setting unit 4 The temperature of the case should not exceed 40 C due to rays of the sun or radiated heat 5 No vibration Mount the calibration gas unit case on a pipe nominal JIS 50A as follows 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the flow setting unit The sum of the calibration gas unit case and the calibration gas cylinder weighs approximately 4 2 kg 2 Mount the unit case on the pipe by tightening the nuts with the U bolt so that the metal fitting is firmly attached to the pipe A pipe to be mounted i nominal JIS 50A O D 60 5 mm F3 14E EPS Figure 3 14 Pipe Mounting 3 11 3 6 Insulation Resistance Test Even if the testing voltage is not so great that it causes dielectric breakdown testing may cause deterioration in insulation and a possible safety hazard Therefore conduct this test only when it is necessary The applied voltage for this test shall be 500 V DC or less The voltage shall be applied for as short a time as practicable to confirm that insulation resistance is 20 MQ or more Remove wiring from the converter and the detector 1 Remove the jumper plate located between terminal G and the protective grounding terminal 2 Connect crossover wiring between L and N 3 Connect an insulation resistance tester with its power OFF Connect terminal to
100. ck see Section 10 2 Blow back later in this manual Under semi automatic blow back During blow back is the time required after pressing the blow back start key by using the touchpanel or entering a blow back start instruction by using a contact input until the blow back time and output stabilization time elapse Under automatic blow back During blow back is the time required after reaching the blow back start time until the blow back time and output stabilization time elapse 5 On Error occurrence This is the time of which any of Errors 1 to 4 occurs 8 2 2 Preference Order of Output Hold Value IM 11M12A01 03E The output hold value takes the following preference order On error occurrence Under calibration or during blow back Preference order high During warm up Under maintenance 8 2 2 siki For example if the output current is set to 4 mA during maintenance and no output hold output for during calibration is preset the output is held at 4 mA during the maintenance display However the output hold is released at the time of starting the calibration and the output will be again held at 4 mA after completing the calibration and when the output stabilization time elapses 8 7 8 2 3 Output Hold Setting To set the output hold follow these steps 1 Press the Setup key in the basic panel display to display the Execution Setup display Then select Setup in the Execution Setup display Next select the mA
101. cord to stop the pump 10 20 IM 11M12A01 03E 10 Other Functions Manual calibration Span calibration NA Close the span gas valve End CP Zero calibration Enter F10 16E EPS Figure 10 16 Manual Calibration Display lt Flow of zero gas gt Cause a zero gas to flow according to the Manual calibration display shown in Figure 10 17 Manual calibration Open zero gas valve Set flow span gas to Kij 600ml min CP Valve opened Cancel calibration F10 17E EPS Figure 10 17 Manual Calibration Display IM 11M12A01 03E 10 21 1 Use the needle of the zero gas valve CHECK GAS to puncture a hole in the gas cylinder installed as described in Section 10 5 2 Fully clockwise turn the valve regulator by hand 2 Next adjust the flow rate to 600 60 ml min the flow check ball stops floating on the green line when the valve is slowly opened Turn the regulator of the zero gas valves back slowly counterclockwise At that time the flow rate also decreases as the inner pressure of the gas cylinder decreases Therefore monitor the flow check and when the ball s position changes greatly readjust the valve 3 Select Valve opened to start calibration from the Manual calibration display Check the Trend graph display to see that the measured value is stabilized Then press the Enter key The Manual calibration display shown in Figure 10 18 appears Then stop the zero gas
102. ctive action gt When the battery low alarm occurs remember that the battery cannot be replaced by the user Contact your Yokogawa service representative AN Note Battery life varies with environmental conditions If power is applied to the instrument continuously then the battery should not run down and life is typically about ten years However the battery will be used during the time interval between shipment from the factory and installation If power is not applied to the instrument at normal room temperatures of 20 to 25 C then battery life is typically 5 years and outside this range but within the range 30 to 70 C then battery life is typically 1 year 12 12 IM 11M12A01 03E 12 Troubleshooting 12 3 Countermeasures When Measured Value Shows Error The causes that the measured value shows an abnormal value is not always due to instrument failures There are rather many cases where the causes are those that measur ing gas itself is in abnormal state or external causes exist which disturb the instrument operation In this section causes of and measures against the cases where measured values show the following phenomena will be described 1 The measured value is higher than the true value 2 The measured value is lower than the true value 3 The measured value sometimes shows abnormal values 12 3 1 Measured Value Higher Than True Value IM 11M12A01 03E lt Causes and countermeasures gt 1 The
103. ctrode a O vol to 21 0 vol O on the zirconia element reference electrode The humidity analyzer uses a sample gas composed of water vapor and air A For the vol H O measurement x Assuming that H O vol in a mixed gas is measured y 100 x X 0 21 wo eee eee Equation 2 From the above equations 1 and 2 we obtain E K log y a Klog 100 x lt 0 21 21 K log 1 0 01 x Equation 3 where K Constant Using the above equation 3 we can calculate the water vapor in vol from the electromotive force 9 1 Water vapor Air Zirconia element 100 100 VfL LLALLA LL 2 C om p a ri son Sample gas AR water vapor i i 79 100 EZZZZZZZZXJ ZIT concentration indicator Electrode LATE Ey Sample gas composition F9 1 EPS Figure 9 1 Schematic Diagram of Measurement Principle B For the mixing ratio measurement Assuming that the mixing ratio is rkg kg then r can be calculated from the value of HO vol as follows r 0 622 X x 100 x Equation 4 From the above equations 1 2 and 4 we obtain E K log y a K log 0 622 X 21 0 622 r 21 K log 0 622 0 622 r Equation 5 where K Constant With Equation 5 we can obtain the mixing ratio rkg kg from the electromotive force Oxygen concentration vs cell output 120 LACET oe al Emma HAA Se DRE A
104. d 2 When the ambient temperature of the wiring installation is 80 to 150 C for the wiring of the detector use wiring material with sufficient heat resistance 3 When connecting the ground wiring to the ground terminal of the converter case be sure that the lock washer is in contact with the case surface see Figure 5 10 4 Ensure that the jumper plate is connected between the G terminal and the protective ground terminal of the converter IM 11M12A01 03E 5 11 5 6 Wiring for Contact Output Contact outputs to 3 can be freely assigned to low limit alarm high limit alarm etc user selectable but the assignment of contact output 4 is fixed error output And the action contact closed on error output also cannot be changed When using these contact outputs install the wiring as follows Converter Terminal box Annunciator or the like 1 Output O 2 Output O O 3 Output O 4 Output O F5 11E EPS Figure 5 11 Contact output wiring 5 6 1 Cable Specifications Number of wires in cable varies depending on the number of contact used 5 62 Wiring Procedure 1 M4 screws are used for the terminals of the converter Each wire in the cable should be terminated in the corresponding crimp on terminal 2 The capacities of the contact output relay are 30 V DC 3 A 250V AC 3 A Connect a load e g pilot lamp and annunciator within these limits 5 12 IM 11M12A01 03E 5 Wiring 5 7 Wiring for ZR
105. d be made under normal operating conditions if the probe is connected to a furnace the analyzer will undergo calibration under the operating conditions of the furnace To make a precise calibration conduct both zero point and span calibrations 9 2 1 Calibration Setting 9 2 1 1 Mode 9 6 The following sets forth the required calibration settings There are three calibration modes available 1 Manual calibration which allows zero and span calibrations or either one manually in turn 2 Semi automatic calibration which lets calibration start with the touchpanel or a contact input and undergoes a series of calibration operations following preset calibration periods and stabilization time and 3 Automatic calibration which is carried out automatically following preset calibration periods Calibrations are limited by the following mode selection e 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 e When semi automatic calibration is selected This mode enables manual and semi automatic calibrations to be conducted The mode however does not allow automatic calibration even when its start up time has reached e When automatic calibration is selected This calibration can be conducted in any mode To execute this calibration follow these steps 1
106. dification Precautions e Follow the safety precautions in this manual when using the product to ensure protec tion and safety of personnel product and system containing the product 3 The following safety symbols are used on the product as well as in this manual A DANGER This symbol indicates that the operator must follow the instructions laid out in this manual in order to avoid the risk of personnel injuries or fatalities such as electric shock The manual describes what special care the operator must exercise to prevent such risks A WARNING This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument hardware or software from being damaged or a system failure from occurring A CAUTION This symbol draws attention to information essential for understanding the operation and functions A Tip This symbol gives information that complements the present topic CX SEE ALSO This symbol identifies a source to which to refer D Protective Ground Terminal A Function Ground Terminal Do not use this terminal as the protective ground terminal o Alternating current IM 1M12A01 03E e Special descriptions in this manual This manual indicates operation keys displays and drawings on the product as follows e Operation keys Enclosed in displays on the panel Ex MODE key Ex message display BASE Ex data display
107. display shown in Figure 10 13 appears 3 Choose Start reset and then press the Enter key to reset the equipment and the equipment will then be in its warm up state Reset CP Start reset oe 1A Cancel reset LC Figure 10 13 Reset Display IM 11M12A01 03E 10 17 10 5 Handling of the ZO21S Standard Gas Unit The following describe how to flow zero and span gases using the ZO21S Standard Gas Unit Operate the ZO21S Standard Gas Unit for calibrating a system classified as System 1 according to the procedures that follow 10 5 1 Standard Gas Unit Component Identification Carrying case Flow checker Checks the zero and span gas flow Span gas valve Controls the span gas air flow Zero gas valve regulator Cover screws six pcs Tube connection Pump Gas cylinder Supplies span gas air Contains the zero gas A gas of 7 NI is charged to 700 kPa Zero gas valve Attaches to the gas cylinder for use Clamp Clamps the gas cylinder Power cord Applies the power to operate the pump to supply the span gas MOIE RPS Figure 10 14 Standard Gas Unit Component Identification 10 18 IM 11M12A01 03E 10 Other Functions 10 5 2 Installing Gas Cylinders IM 11M12A01 03E Each ZO21S Standard Gas Unit comes with six zero gas cylinders including a spare Each gas cylinder contains 7 liters of gas with a 0 95 to 1 0 vol O2 concentration varies with eac
108. duation on the time axis So if you set a ten second sampling period one graduation corresponds to 600 seconds Figure 10 5 The allowable sampling periods range from 1 to 30 seconds If you set a one second sampling period the axis of the abscissas then corresponds to five minutes If you set it to 30 seconds the axis of the abscissas then corresponds to 150 minutes 25 0 O0o 10min div Upper limit set Time per graduation calculated by the set sampling period Lower limit set 12 3 0 60 data items Currently measured value Sampling period F10 5E EPS Figure 10 5 Plotting Graph for Sampling Period 10 1 2 3 Setting Upper and Lower Limit Values on Graph Set upper and lower limit values on the graph in the following procedure Press Upper limit in the Trend graph display The numeric data entry key appears 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 1 0 to 100 O for oxygen concentration 2 0 to 100 H O for humidity and 3 0 to 1 kg kg for mixing ratio IM 11M12A01 03E 10 1 2 4 10 Other Functions Default Setting When the analyzer is delivered or if data are initialized the set data are by default as shown in Table 10 3 Table 10 3 Default Values for Graph Setting Item Default Value Parameter Humidity Sampling period 30 seconds Upper limit oxygen concentration
109. e Leet this part is inserted in the process stangar models Select length from 0 4 0 7 1 0 1 5 2 0 2 5 or 3 0 m Dust filter mounting screw Calibration gas ipe openin Contact PES Sp ih Metal O ring Pipe support U shaped pipe Washer or plain washer F6 1E EPS Figure 6 1 General use Detector IM 11M12A01 03E 6 1 6 2 ZR402G Converter Complete Operation Display Interactive operations along with operation display A variety of display modes enabling you to select the operation mode freely Back lit LCD display allows viewing even in areas of low lighting Error codes and details of errors are displayed no need to refer to the appropriate instruction manual Password for security EDA ZR402G Self testing suggests countermeasures for problems If a problem occurs the liquid crystal display will provides an error code and description of the problem This enables prompt and appropriate corrective action to be taken Error code Reason for error E 1 Cell failure E 2 Abnormal heater temperature E 3 Defective A D converter E 4 Faulty EEPROM ALARM1 Abnormal oxygen concentration ALARM2 Abnormal moisture ALARM3 Abnormal mixing ratio ALARM6 Abnormal zero calibration factor ALARM7 Abnormal span calibration factor ALARM8 Stabilization time over Figure 6 3 Converter 6 2 C Typical Converter Displays _ Example of basic display 0 0 H20 21 0 H20
110. e six core is used for this wiring When the ambient temperature of the detector exceeds 80 C install a terminal box and connect with the detector using six piece 600 V silicon rubber insulated glass braided wire IM 11M12A01 03E 5 5 5 2 2 Connection to the Detector To connect cables to the detector proceed as follows 1 Mount conduits of the specified thread size or cable glands to the wiring connections of the detector The detector may need to be removed in future for maintenance so be sure to allow a sufficient cable length 2 If the ambient temperature at the location of wire installation is 80 to 150 C be sure to use a flexible metallic wire conduit If a non shielded 600V silicon rubber insulated glass braided wire is used keep the wire away from noise sources to avoid noise interference 3 Figure 5 6 shows the layout of the detector terminals TC with Si TUBE CELL CELL TC TC CJ CJ To the To the converter To the converter or the ground or the i terminal box terminal box F5 6E EPS Figure 5 6 Detector terminals The 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 on terminal 1 If the ambient temperature at the detector installation site exceeds 60 C use a
111. e display configuration A password positioned below the displays enables Execution Setup to be protected If a password has not been set press the Enter key to proceed to the next panel display The Home key enables you to return to Execution Setup from any panel display Detailed data display Calibration execution Returns to the Execution Setup display Blow back execution Returns to the Execution Setup display Basic panel display Execution Setup display Password Entry display Reset panel display Returns to the Execution Setup display Figure 7 3 1 Display Configuration Trend Graph display Maintenance panel display Display setup Display item Trend graph Auto return time Language Calibration setup Mode Points Zero and Span gas conc Timing Blow back setup mA output loop check Contact check Returns to the Execution Setup display Commissioning Setup display mA output setup mA output1 mA output2 Set presets Alarms setup Hysteresis Contact delay Setpoints Contact setup Input contacts Output contacts Others Clock Averaging Input temp Passwords Defaults Returns to the Execution Setup display F7 3 1E EPS IM 11M12A01 03E 7 Startup 74 3 Display Functions Individual panel displays in the display configuration provide the following functions 1 Basic panel display Displays the values measured in three selected items see Section 7 9 Sett
112. e gas is 150 kPa When with a check valve and a ZR40H Auto Calibration Unit it is 200 kPa If the pressure of your sample gas exceeds these limits consult with Yokogawa Material in Contact with Gas SUS 316 JIS Zirconia SUS 304 JIS flange Hastelloy B Inconel 600 601 Construction Heater and thermocouple replaceable construction Non explosion proof JIS C0920 equivalent to IP44D Equivalent to NEMA 4X IP66 Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version Terminal Box Case Material Aluminium alloy Terminal Box Paint Color Case Mint green Munsell 5 6BG3 3 2 9 Cover Mint green Munsell 5 6BG3 3 2 9 Finish Polyurethane corrosion resistant coating Gas Connection Re 1 4 or 1 4 FNPT Wiring Connection G1 2 Pg13 5 M20 by 1 5mm 1 2 NPT Installation Flange mounting 2 3 2 4 Probe Mounting Angle Horizontal to vertically downward When the probe insertion length is 2 m or less installing at angles from horizontal to vertically downward is available When the probe insertion length exceeds 2 5 m mount vertically down ward within 5 and use a probe protector Weight Insertion length of 0 4 m approx 6 kg JIS 5K 65 approx 11 kg ANSI 150 4 Insertion length of 1 0 m approx 8 kg JIS 5K 65 approx 13 kg ANSI 150 4 Insertion length of 1 5 m approx 10 kg JIS 5K 65 approx 15 kg ANSI 150 4 Insertion length o
113. e periods are tentative and only used for preventive maintenance not for warranty of the performance This cell s robustness can be found by a total evaluation of data involving the response time the cell s internal resistance and calibration factor However if a zero or span calibration was not made the response time cannot be measured In such a case the cell s robustness is found except for the response time 10 1 1 4 Cell Temperature This indicates the cell sensor temperature usually indicating 750 C obtainable from the thermoelectromotive force and cold junction temperature described below 10 1 1 5 Cold Junction Temperature This indicates the detector terminal box temperature which compensates for the cold junction temperature for a thermocouple measuring the cell temperature When the ZR22 Detector is used the maximum Cold Junction temperature will be 150 C If the terminal box temperature exceeds this take measures for example so that the terminal box is not exposed to radiation to reduce that temperature The maximum Cold Junction temperature varies depending on the type of detector 10 2 IM 11M12A01 03E 10 Other Functions 10 1 1 6 Cell Voltage The cell sensor voltage will 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 value corresponding to the measured
114. ean environment without any corrosive gases FAN CAUTION e A natural convection type detector model ZR22G L C which uses ambient air as reference gas requires that the ambient oxygen concentration be constant 4 No vibration 5 The measurement gas satisfies the specifications described in Chapter 2 6 No measurement gas pressure fluctuations IM 11M12A01 03E 3 1 3 1 2 Probe Insertion Hole Includes those analyzers equipped with a dust protector When preparing the probe insertion hole the following should be taken into consider ation FAN CAUTION e The outside dimension of detector may vary depending on its options Use a pipe that is large enough for the detector Refer to Figure 3 1 for the dimensions e If the detector is mounted horizontally the calibration gas inlet and reference gas inlet should face downwards When using the detector with pressure compensation ensure that the flange gasket does not block the reference air outlet on the detector flange If the flange gasket blocks the outlet the detector cannot conduct pressure compensation Where neces sary make a notch in the flange gasket Confirm the external dimensions of the detector in Section 3 7 before installation e The sensor zirconia cell at the probe tip may deteriorate due to condensation as it is always at high temperature 1 Do not mount the probe with the tip higher than the probe base
115. easeiacesse QOL 91 Calibration Briefs seirinin a nial le ist nest 9 1 9 1 1 Measurement Principle of Zirconia Humidity Analyzer ee 9 1 91 2 Calibration Gas isseire aae aE Es EEE eye 0m a 9 3 9 1 3 COMPENSAHON srir eE E E E E EEEE E T EE EEE SS 9 4 9 1 4 Characteristic Data from a Sensor Measured During Calibration 9 5 9 2 Calibration Procedures ss 9 6 9 2 T Calibration Setting siiperi sne anas peesi aisr 9 6 9 2 2 Default Values cri eneee E AEE EE Svs chen EE E 9 9 9 253 CANDPATION 5er Mr segs odes aE a E ES AA NEESON 9 10 10 Other Functions ooooooooosooooooososooososesesoseseoesesesesesesesesosesesesesosesesesesesesesssesessseseses 021 IM 11M12A01 03E TOT D Display nena D Re a a O re A AN 10 1 10 1 1 Detailed Display c ssceecesscsvccseg e ee npe nine ten pE EERE En 10 1 10 1 2 Trend Graphire e se tiene bead ab aise E 10 5 10 1 3 Auto matic Display Revert Time 10 7 10 1 4 Entering Fag Names is munies enne eea Esis 10 8 10 1 5 Language Selection ss 10 8 10 2 Blowbackses nn nie ne Me imminent E SESE Si 10 9 10 2 1 Blowback Setup 4 msn nianannre antennes Ass 10 9 10 3 Operational Data Initialization ss 10 13 LOA RES in ne ER leh she see ats ads aks shies E hanes DOS 10 17 10 5 Handling of the ZO21S Standard Gas Unit 10 18 10 5 1 Standard Gas Unit Component Identification eee eeteeeeeeeeeee 10 18 105 2 Installing Gas Cylinders issue msn
116. ececesseaeceececesaseeseeceenees 3 3 3 1 4 Installation of ZH21B Dust Protector ccc ccccessseceeeeeseseceeeeeseees 3 3 viii IM 1M12A01 03E 3 2 Installation of the Converter sis 3 4 3 221 2 Locations re sean menti nude ities dut dons dre SM nent 3 4 3 2 2 Mounting of the Converter 3 4 3 3 Installation of ZA8F Flow Setting Unit oc ceseeeeceseeeeeeeeeeeeeeeees 3 7 3 32 LOCAHOM ne ste E san Aine Ades EE OE 3 7 3 3 2 Mounting of ZA8F Flow Setting Unit 0 ee ceeeeeeeeeeeeeeneeaee 3 7 3 4 Installation of ZR4OH Automatic Calibration Unit 3 9 ZAE Locations enen a BEd ie Siena ee eee 3 9 3 4 2 Mounting of ZR40H Automatic Calibration Unit oes 3 9 3 5 Installation of E7044KF Case Assembly for the Calibration gas Cylinder ss 3 11 3 5 1 Location uisctign ohne E E ees E 3 11 3 952 Monno eein oes conn msn a Nes cs Suse Peles Dns RER 3 11 3 6 Insulation Resistance Test 3 12 3 7 External Dimensions of Detectors with Pressure Compensation 3 13 ize A PUIG EET E AE ETE A a a l AA Piping for Systemi I secisccscsecieeslessstadsaasssssheseesssseesstussevetaioassnasseticashastaatevenenses 4 1 4 1 1 Parts Required for Piping in System 1 esssessseeseeeeesseresssrsrrsresrsreeeeees 4 2 4 1 2 Connection to the Calibration Gas Inlet essseeseeeeeesseeeessesersreerereereses 4 2 4 1 3 Connection to the Reference Gas Inlet 0 0 eee eee ceeseececneeeneeneenees 4 2 AD Pipe Tor SYStemy 2 Sn rte menant Mantes 4 3 4 2 1 Pipi
117. ee seconds enter 003 The delay time setting can be in the ranges from 0 to 255 seconds To set the alarm point proceed the following steps 8 Select Setpoints in the Alarms setup display to display the Humidity alarms as shown in Figure 8 8 9 When you select High alarm in the display the off or on selection display then appears If you select on the High alarm will then be enabled enable disable 10 To set the High alarm values select the Set value just below the High alarm The numeric data entry display then appears Enter the alarm set value in H O If you want to set the alarm value to 10 H O enter 0100 11 Set the other alarm settings in the same manner as in the steps above 8 10 IM 11M12A01 03E 8 3 4 IM 11M12A01 03E A CAUTION 8 Detailed Data Setting No alarm is issued when alarm is set to off disabled To use the alarm functions be sure to set the alarm on Alarms setup Cp Parameter Oxygen Hysteresis 0 1 02 Contact delay 3s Setpoints alo m 2 s Alarms setup F Parameter Hysteresis Humidity Lo Mixing Contact delay S Setpoints dale Enter F8 5E EPS Figure 8 5 Alarms Setup Display Alarms setup Cr Parameter Humidity Hysteresis 0 1 H20 Contact delay 3s Setpoints Je m 2 2 FES EPS Figure 8 6 Alarms Setup Dis
118. eeeeeee 2 3 222 ZH VB Dust Protector rro nine me ei ds 2 8 2 3 ZR402G Separate type Converter 2 9 2 3 1 Standard Specifications ss 2 9 2 3 2 FUNC steam hl Alin Widsets Sid con ea aot 2 10 24 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit 2 16 24 1 ZASF Flow Setting Unit eme mie i i ist 2 16 24 2 ZR40H Automatic Calibration Unit ss 2 18 2 5 ZO21S Standard Gas Units sisike sitsers sosterse hentai ess 2 21 2 6 Other Equipment sessions titine bees Mou ees nee EEE 2 22 2 6 1 Stop Valve Part Number L9852CB or G7016XH eee eeseeeneeeee 2 22 2 6 2 Check Valve Part Number K9292DN or K9292DS c ce eeeseeeee 2 23 233 AIT Set hr mener ter ME A fon 2 24 2 6 4 Zero gas Cylinder Part Number G7001ZC 0 eee eseeeecteeeeee 2 26 2 6 5 Pressure Regulator for Gas Cylinder Part Number G7013XF or G7014XF oo eecccecesseceseeeeeseeeeeeeees 2 26 2 6 6 Case Assembly for Calibration gas Cylinder Part Number E7044 KF ss 2 27 2 6 7 Model ZR22A Heater Assembly 2 28 3 Installation ccscessatedceesassucsdsecedseesecoscesdeCessdesasssoossecedcdesecoscessetedceseen Oo L 3 1 Installation of the Detector ccccccccccccecsssscececesenssecececesssasececeessaececceeeessaeees 3 1 3 1 1 LOCATION Este Peds So cos Cones beta ee Selec Sees SER ees En tec ieee odes PRE 3 1 3 1 2 Probe Insertion Hole cc e E a a n 3 2 3 1 3 Installation of the Detector 0 c cc ccecsecccccesessece
119. eel S ae a Pr ese an Das A E E SRE Sl MES DE EE ES RE DRE DS DS RE EN EE 100 pi Et a EE pS H m S BASE EG Co or SS ee ee RE RUE g PPS RE E aN 8 ET EEE co EX DE ee MARINE ES CO mu ee aS DE HER SR SS HN I S A E D S A D E sa a8 RE DE DO AU ONE a8 a RI RE PS D DE D RO EEN ares a EE e CT ae 60 m HHHH T on Carer PaO es ee EEE 3 as eee EEE Co 25 PR OE A SE CEE EEE obs DONE es BU Snr op 36 a a NE EEE ee M ee AAN DARN T S A E R O E I P R Se aaa Serr RE EEE al D A EE ER A mun OE RS rer D JAN ARR AS E 20 D PE OC a em EE A lt a E NA H RS DS E freee te so ECC 0 CCR EEE 0 1 1 10 100 Oxygen concentration PX 02 FAE EPS IM 11M12A01 03E 9 Calibration Oxygen concentration vs Humidity Mixing ratio 100 Humidity vol H20 Mixing ratio kg kg Humidity vol H20 Mixing ratio kg kg 0 OO 0 1 2 3 4 5 6 7 8 9 10 11 1213 1415 16 17 18 19 20 21 22 Oxygen concentration vol O2 FBE EPS 9 1 2 Calibration Gas A gas with a known oxygen concentration is used for calibration Normal calibration is performed using two different gases a zero gas of low oxygen concentration and a span gas of high oxygen concentration In some cases only one of the gases needs to be 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
120. eference gas therefore the accuracy of analysis will be affected by ambient temperature changes or the like If more accurate analysis is necessary use instrument air dehumidified by cooling to the dew point 20 C or lower and removing 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 IM 11M12A01 03E The piping in System 1 is illustrated in Figure 4 1 Separate type Zirconia High Temperature Humidity Analyzer Model ZR402G Converter Model ZR22G Detector at T Signal Stop valve X 41 _ 6 core shield cable 1 Heater 2 core 100 to 240 V AC Contact input Analog output contact output Digital output HART Model ZO21S Standard gas unit Calibration gas 100 110 115 200 220 240 V AC F4 1E EPS Figure 4 1 Piping in System 1 Piping in System 1 is as follows Place a stop valve through the nipple at the calibration gas inlet of the detector Then mount a joint for a 6 mm O D X4 mm LD soft tube at the stop valve connection hole of the inlet side see Section 4 1 2 The tube is to be connected to this joint only during calibration A CAUTION e The stop valve should be connected directly to the detector If any piping is present between the detector and the stop valve water may condense in the pipe which may cause damage to the sensor by rapid cool
121. eld cable or Stop valve Wee en a Heater 2 core Model ZABF flow setting unit 100 to 240 VAC Pre Contact input Analog outout contact output Digital output HART A Instrument air Span gas Same as Zero gas calibration unit Needle Le Flowmeter valve y ny Air Set v pk Calibration gas pk Figure1 2 IM 11M12A01 03E e gas pressure regulator Calibration gas unit case Zero gas cylinder F1 2E EPS 1 3 1 1 3 System 3 This system is for accurate monitoring and controlling of humidity Instrument air clean and dry air is used for the reference gas and the span gas for calibration Zero gas is fed in from a cylinder during calibration The calibration gas flow is controlled automatically by the ZR40H automatic calibration unit This system is similar to system 2 except that the calibration gas flow is automated using the ZR40H automatic calibration unit Separate type Zirconia High Temperature Humidity Analyzer Model ZR22G Detector Model ZR402G Converter lt J Signal 6 core shield cable TF I Check valve 100 to 240 VAC Contact input Analog output contact output Heater 2 core shield cable 1 ji FlowmeterVeedle
122. elect Maintenance in the Execution Setup display to display the Maintenance panel display Then select Calibration setup to display the Calibration setup display as Figure 7 16 shows Select Mode in this panel and then select Manual for the intended calibration herein Calibration setup CP Mode Manual Points Both Zero gas conc 1 00 L l Span gas conc 21 00 Timing Figure 7 16 Calibration Setup 7 11 1 2 Calibration Setting Procedures Select Points calibration procedure in the Calibration setup display to display the Span Zero Span Zero selection display In this display select Span Zero IM 11M12A01 03E 7 15 7 11 1 3 Calibration Gas Concentration Setting 1 Zero gas concentration If zero gas concentration is selected the Numeric data Entry display then appears Use this display to enter an oxygen concentration value for the zero gas calibration if the oxygen concentration is 0 98 vol O enter 00098 2 Span gas concentration With Span gas conc selected in the Calibration setup display display the Numeric data Entry display and enter an oxygen concentration value for the span gas calibra tion If instrument air is used enter 02100 for a 21 vol O value When using the ZO21S Standard Gas Unit for use of the atmospheric air as a span gas use a hand held oxygen analyzer to measure the actual oxygen concentration and then enter it A CAU
123. emove piping and wiring and remove the ZR40H from the 2B pipe or wall mounting 2 Remove four M6 bolts between brackets 3 Remove piping extension 4 Remove bolts holding flowmeter and replace it A white back plate to make the float easy to see is attached The end of the pin holding down the back plate must be on the bracket side 5 Replace piping and fix M6 bolts between brackets 1 1 When disassembling and reassembling mark original positions and tighten an extra 5 10 when reassembling After tightening do a liquid leakage test Flowmeter with back plate Bolt fixes bracket Connecter mt F11 7E eps Figure 11 8 Flowmeter replacement IM 11M12A01 03E 11 11 b i i E A BN J SRY f f c D L T _ lt F LJ Two screws fix flowmeter Connect piping pairs A A B B C C D D Fr LA a SB Nel l3 oje O Z a a d L S oe F11 8E eps Figure 11 9 Fixing Flowmeter 11 12 IM 11M12A01 03E 12 Troubleshooting 12 Troubleshooting This chapter describes errors and a
124. ence Error 1 Cell voltage failure The cell sensor voltage signal input to the converter falls below 50 mV Error 2 Heater temperature The heater temperature does not rise during failure warm up or it falls below 730 C or exceeds 780 C after warm up is completed Or this occurs if the TC TC thermocouple terminals are wired to converter with reverse wrong polarity Error 3 A D converter failure The A D converter fails in the internal electrical circuit in the converter Error 4 Memory failure Data properly are not written into memory in the internal electrical circuit in the converter T121E EPS IM 11M12A01 03E 12 1 12 1 2 Measures to Take When an Error Occurs 12 1 2 1 Error 1 Cell Voltage Failure Error 1 occurs when the cell sensor voltage input to the converter falls below 50 mV corresponding to about 200 O2 The following are considered to be the causes for the cell voltage falling below 50 mV 1 Poor contact in terminal connections between the converter and detector 2 Breakage in wiring cable between the converter and the detector 3 Damage or deterioration of the sensor assembly 4 Continuity failure between the sensor assembly electrode and the contact 5 Wiring failure inside the detector 6 Abnormality in electrical circuits in the converter lt Locating the failure and countermeasures gt Turn off power to the converter eee n me ee ee ee Seen Examine the
125. ent air m Re In gas pressure regulator T ee a Calibration gas Model ZR40H Auto Calibration unit unit case Reference gas Calibration gas Fi sky Zero gas cylinder F4 9E EPS Figure 4 9 Piping for System 3 IM 11M12A01 03E 4 5 5 Wiring 5 Wiring In this Chapter the wiring necessary for connection to the EXAxtZR Separate type Zirconia High temperature Humidity Analyzer is described 5 1 General A CAUTION e NEVER supply current to the converter or any other device constituting a power circuit in combination with the converter until all wiring is completed e This product complies with CE marking Where compliance with CE marking is necessary the following piping procedure is necessary 1 Install an external switch or circuit breaker to the power supply of the converter 2 Use an external switch or circuit breaker rated 5A and conforming with IEC 947 1 or IEC947 3 3 It is recommended that the external switch or circuit breaker be mounted in the same room as the converter 4 The external switch or circuit breaker should be installed within the reach of the operator and marked as the power supply switch of this equipment IM 11M12A01 03E 5 1 Wiring procedure Wiring should be preformed 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 stripped to a length of 50 mm or l
126. er to the converter to analog output confirmation to manual calibration System tuning by the HART communicator refer to IM11M12A01 51E HART Communication Protocol 7 1 Checking Piping and Wiring Connections Check that the piping and wiring connections have been properly completed in accor dance with Chapter 4 Piping and Chapter 5 Wiring 7 2 Checking Valve Setup Set up valves and associated components used in the analyzer system as follows procedures 1 If a stop valve is used in the detector s calibration gas inlet fully close this valve 2 If instrument air is used as the reference gas adjust the air set secondary pressure so that an air pressure equals measured gas pressure plus approx 50 kPa or measured gas pressure plus approx 150 kPa when a check valve is used maximum pressure rating is 300 kPa is obtained Turn the reference gas flow setting valve in the flow setting unit to obtain a flow of 800 to 1000 ml min Turning the valve shaft counter clockwise increases the rate of flow Before turning the valve shaft if the valve has a lock nut first loosen the lock nut After completing the valve setup be sure to tighten the lock nut AN Note The calibration gas flow setting is described later Fully close the needle valve in the flow setting unit IM 11M12A01 03E 7 1 7 3 Supplying Power to the Converter 7 2 A CAUTION To avoid temperature changes around the sensor it is
127. ermo voltage 42 1 mV Span gas ratio 2 9 C J resistance 1181 40 Zero gas ratio 70 3 Cell resistance 4Q e T eens 1 no Soft rev 0 24 Zero gas ratio 89 7 w zi VV Fri nee Pa Fos Es FI2SE EPS Figure 12 5 Detailed Data Display Figure 12 6 Calibration History 5 If deterioration of the sensor assembly has occurred abruptly it may show that the check valve which prevents moisture in the furnace from getting into the calibration gas tubing has failed If the gas in the furnace gets into the calibration gas tubing it condenses and remains in the gas tubing as condensate The sensor assembly is considered to be broken for the reason that the condensate is blown into the sensor assembly by the calibration gas during calibration and so the cell cools quickly 6 If the sensor assembly has been gradually deteriorating check the sensor assembly status in the following procedure a Display Cell resistance by pressing the W key A new cell will show a cell resistance value of 2000 or less On the other hand a cell sensor that is approaching the end of its service life will show a resistance value of 3 to 10 KO b Display Cell robustness by pressing the W key A good cell sensor will show Life gt 1 year Figure 12 7 Tag a Span gas ratio 2 9 Zero gas ratio 70 3 Response time Os Cell robustness life lt 1 month Cell temperature 1067 C C J temperature 47 C
128. ess The outer sheath of the power cable should be stripped to a length of 20 mm or less 3 Signals may be affected by noise emission when the signal lines power cable and heater cable are located in the same conduit When using conduit signal lines should be installed in a separate conduit from power and heater cables 4 Install metal blind plug s in unused cable connection gland s of the converter Metal conduit should be grounded 6 The following cables are used for wiring sn Table 5 1 Cable specifications Terminal name of converter Need for shields Cable type Number of wires CELL CELL HTR TC HTR TC Converter signal O CJ CJ HEATER Converter heater L N Power supply AO 1 AO 1 AO 2 AO 2 Analog output DO 1 DO 2 DO 3 DO 4 Contact output AC Z AC S AC C Automatic Calibration unit DI 1 DI 2 DI C Contact input Note When the case is used for protective grounding use a 2 wire cable T5 1E EPS A CAUTION e Select suitable cable O D to match the cable gland size e Protective grounding should be connected Class 3 grounding the grounding resistance is 100Q or less e Special cable length should be taken consideration For detail of the HART communication refer to IM11M12A01 51E HART Protocol Section 1 1 2 Communication Line Requirement 5 2 IM 11M12A01 03E 5 Wiring Terminals for the External Wiring in the Converter Open the front door and
129. ess the Enter key to select span gas calibration The Manual calibration display shown in Figure 7 18 then appears Check that the oxygen concentration for the span gas in this display coincides with the oxygen concentration in the calibration gas actually used If the check results are assumed to be OK select Next in the Manual calibration display 3 Follow the display message in Figure 7 19 to turn on span gas flow Open the span gas flow valve of the Flow Setting Unit by loosening the valve lock nut and slowly turning the valve shaft counterclockwise to set the span gas flow at 600 60 ml min Use the calibration gas flowmeter to check the flow Manual calibration Manual calibration Open span gas valve 0 5min div Set flow span gas to e 600ml min J H l CP Valve opened Cancel calibration Enter J 21 0 02 ENST __ Figure 7 19 Span gas Flow Display Figure 7 20 Manual Calibration Trend for Manual Calibration Graph 4 If Valve opened is selected as in Figure 7 19 an oxygen concentration trend graph with the oxygen concentration being measured appears see Figure 7 20 The CAL TIME in the bottom area of the panel flashes Observe the trend graph and wait until the measured value stabilizes in the vicinity of 21 percent on the graph At this point calibration has not yet been is executed so even though the measured value is above or below 21 percent no problem occ
130. ess the Graph display key in the basic panel display to switch to the graph display This will help grasp the measured value trend Touching anywhere on the graph display will return to the basic panel display To set the trend graph display follow the steps in Section 10 1 2 1 10 1 2 1 Setting Display Items 1 Press the Setup key in the Basic panel display to display the Execution Setup display Select Maintenance from the Execution Setup display 2 Select Display setup from the Maintenance display 3 Select Trend graph from the Display setup display The Trend graph display shown in Figure 10 4 appears Select Parameter Oxygen from the Trend graph display Then select the desired display item shown in Table 10 2 IM 11M12A01 03E 10 Other Functions Table 10 2 Trend Graph Display Items Selected item Description Oxygen concentration Humidity Mixing ratio Output 1 Oxygen concentration graph under measurement Humidity graph under measurement Mixing ratio graph under measurement Output 1 selected item graph Output 2 Output 2 selected item graph T10 2E EPS Trend graph Cp Parameter Oxygen Sample interval Scale Oxygen Upper limit 25 0 Lower limit 0 0 30s O2 O2 Figure 10 4 Trend Graph 10 5 10 1 2 2 Sampling Period To plot a graph set the sampling period for the measurement data This graph allows the plotting of 60 data items on one gra
131. et should be used between the flanges to prevent gas leakage The gasket material should be heatproof and corrosion proof suited to the characteristics of the measured gas The following should be taken into consideration when mounting the general use detector lt General use detector gt 1 Make sure that the cell mounting screws four at the probe tip are not loose 2 Where the detector is mounted horizontally the calibration gas inlet and the refer ence gas inlet should face downward 3 1 4 Installation of ZH21B Dust Protector 1 Put the gasket that is provided by the user between the flanges and mount the dust protector in the probe insertion hole 2 Make sure that the cell assembly mounting screws four at the probe tip are not loose 3 Mount the detector so that the calibration gas inlet and the reference gas inlet face downward Unit mm SSSR RTE etes Ses RSS Calibration gas inlet Reference gas inlet F3 2E EPS Figure 3 2 Installation of the dust filter IM 11M12A01 03E 3 3 3 2 Installation of the Converter 3 2 1 3 2 2 3 4 Location The following should be taken into consideration when installing the converter 1 Readability of the indicated values of moisture concentration or messages on the converter display Easy and safe access to the converter for operating keys on the panel 2 Easy and safe access to the converter for checking and maintenance w
132. et to 0 kg kg or ranges from 0 201 to 0 625 kg kg The maximum mixing ratio setting ranges from 0 2 to 1 0 kg kg and must be greater than 1 3 times plus 0 187 the mixing ratio set for the minimum Setting example 1 If the setting for a 4 mA current is 0 kg kg you must set the maximum 20 mA point at more than 0 2 kg kg Setting example 2 If the setting for a 4 mA current is 0 201 kg kg you must set the maximum 20 mA point at more than 0 449 kg kg 0 201 X 1 3 0 187 kg kg Numbers after the decimal point are rounded up 1 0 95 0 9 0 85 0 8 Range over which mixing ratio can be set 0 75 0 7 0 65 Outside ranges 0 6 0 55 Maximum mixing ratio kg kg at 20 mA 0 5 0 45 0 4 0 201 0 25 0 3 0 35 0 4 0 45 0 5 0 55 0 6 0 65 Minimum mixing ratio kg kg at 4 mA FCE EPS Figure C Max and Min Mixing Ratio Set Ranges 8 3 8 1 2 Setting Minimum Current 4 mA and Maximum Current 20 mA To set the minimum humidity to 50 H O and the maximum humidity to 100 H O follow these steps 1 Select Setup in the Execution Setup display 2 Select the mA output setup in the Commissioning Setup
133. et value 4mA Maintenance Previous value held Set value 4mA Calibration blowback Previous value held Set value 4mA Error Preset value held Set value 3 4mA T10 5E 1 EPS IM 11M12A01 03E Data to be initialized 10 Other Functions Default setting IM 11M12A01 03E Alarm data Alarm setting Parameter Oxygen concentration Hysteresis 0 1 O2 Delayed action of alarm contact 3 seconds Alarm set value High high alarm None Alarm value 100 O2 High limit alarm None Alarm value 100 O2 Low limit alarm None Alarm value 0 O2 Low low alarm None Alarm value 0 O2 Humidity alarm setting Hysteresis 0 1 H20 Contact delay 3 seconds Humidity alarm set value High high alarm Off Alarm set value 100 H20 High alarm Off Alarm set value 100 H20 Low alarm Off Alarm set value 0 H20 Low low alarm Off Alarm set value 0 H20 Mixing ratio alarm setting Hysteresis 0 01 kg kg Contact delay 3 seconds Mixing ratio alarm set value High high alarm Off Alarm set value 1 kg kg High alarm Off Alarm set value 1 kg kg Low low alarm off Alarm set value 0 kg kg Low low alarm off Alarm set value to be continued next p
134. eter to check the flow Manual calibration Open zero gas valve Set flow zero gas to 600ml min Cr Valve opened Cancel calibration Gime Enter F7 23E EPS Figure 7 23 Zero gas Flow Display for Manual calibration 8 If Valve opened is selected as in Figure 7 23 an oxygen concentration trend graph with the oxygen concentration being measured appears see Figure 7 25 The CAL TIME in the bottom area of the panel flashes Observe the trend graph and wait until the measured value stabilizes in the vicinity of the zero gas concentration on the graph At this point no calibration has been executed yet so even if the measured value is above or below the zero gas concentration value no problem occurs Manual calibration 0 5min div 21 00 ar a Enter F7 25E EPS 21 0 02 Remi Figure 7 25 Manual Calibration Trend Graph IM 11M12A01 03E IM 11M12A01 03E 7 Startup 9 After the measured value has stabilized press the Enter key to display the zero calibration complete display shown in Figure 7 26 At this point the measured value is corrected to equal the zero gas concentration setting Close the zero gas flow valve The valve lock nut should be tightened completely so that the zero gas does not leak Manual calibration Zero calibration MA Close the zero gas valve Cp Span calibration End Enter F7 26E EPS Figure 7 26 Zer
135. ey operations and displays Q A 9 Calibration Describes the calibration procedure required in the course o A of operation 10 Other Functions Other functions described O A 11 Inspection and How to conduct maintenance of EXAxt ZR and procedures 6 Maintenance for replacement of deteriorated parts 12 Troubleshooting This chapter describes measures to be taken when an A abnormal condition occurs CMPL parts list User replaceable parts list O Read and completely understand before operating the equipment O Read before operating the equipment and refer to whenever necessary A Recommended to read it at least once T int 2E IM 1M12A01 03E For the safe use of this equipment A CAUTION The cell sensor at the tip of the detector is made of ceramic zirconia element Do not drop the detector or subject it to pressure stress e Do NOT allow the sensor probe tip to make contact with anything when installing the detector e Avoid any water dropping directly on the probe sensor of the detector when install ing it e Check 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 measuring gas can damage the sensor e The detector especially at the tip becomes very hot Be sure to handle it with gloves EXAxt ZR is very heavy Handle it with care Be sure not to accidentally drop it
136. f 2 0 m approx 12 kg JIS 5K 65 approx 17 kg ANSI 150 4 Insertion length of 3 0m approx 15 kg JIS 5K 65 approx 20 kg ANSI 150 4 IM 11M12A01 03E 2 Specifications Model and Codes Style S2 Suffix code Option Description ZR22G Separate type Detector of Zirconia High Temperature Humidity Analyzer Length 040 0 4m RER SHEE AHS 0 7 m PSS run 1 0m B SS 1 5m FESSES 2 0m oie ne 2 5m 1 SESH e Seas 3 0m 1 Wetted material S 900 errr rrr rnin e SUS316 Stainless steel with Inconel calibration gas tube Flange 2 Reference air ANSI Class 150 2 RF SUS304 ANSI Class 150 3 RF SUS304 ANSI Class 150 4 RF SUS304 DIN PN10 DN50 SUS304 DIN PN10 DN80 SUS304 DIN PN10 DN100 SUS304 JIS 5K 65 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 Natural convection External connection Instrument air 8 Pressure Compensation 8 Gas Thread Rc 1 4 1 4 NPT F Connection box thred G1 2 Pg13 5 M20 x1 5 mm 1 2NPT Quick connect 6 Instruction manual Japanese English Options When installing horizontally the probe whose insertion length is 2 5 meters or more use the Probe Protector Be sure to specify ZO21R L 2 The thickness of the flange depends on its dimensions Always A DERAKANE coating 7
137. f the cell with a new one is necessary However before replacement carry out the following Check the cell voltages when passing the zero gas and span gas a Display the detailed data display by pressing the detail display key in the basic panel display b When the Y key is pressed once the cell voltage should be indicated on the top line Figure 12 5 c Check whether or not the value of the displayed cell voltage is very different from the theoretical value at each oxygen concentration Confirm the theoreti cal values of the cell voltage in Table 12 3 Although it cannot be generally specified as to what extent the difference from the theoretical value is allowed consider it to be approximately 10 mV Table 12 3 Oxygen Concentration and Cell Voltage Oxygen concentration Cell voltage O mV 1 67 1 21 0 T12 8E EPS 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 a Call up the detailed data display IM 11M12A01 03E 12 7 12 2 2 3 12 8 b Display Calibration time history by pressing the V key Figure 12 6 Since the ten previous span correction factor and zero correction factor values can be checked in this display changes in deterioration of the sensor can be seen Tag Tag El A E ll Calibration data amp LL Cell voltage 0 6mV 1 2000 07 07 14 57 Th
138. ff the power to the converter for safe replacement 2 Remove the fuse from its holder With the appropriate flat blade screwdriver that just fits the holder cap slot Figure 11 6 turn the fuse holder cap 90 counterclockwise By doing so you can remove the fuse together with the cap Cap Flat blade screwdriver ion Socket Fuse F11 6E EPS Figure 11 6 Removing the Fuse 3 Check the rating of the fuse and that it satisfies the following Maximum rated voltage 250 V Maximum rated current 3 15 A Type Time lag fuse Standards UL CSA or VDE approved Part number A1113EF Place a new properly rated fuse in the holder together with the cap and push and turn the cap clockwise 90 Cwith the screwdriver to complete installation of the fuse Use a soft dry cloth to clean any part of the converter during inspection and maintenance 11 2 3 Adjust LCD screen contrast 11 10 An LCD is built in the ZR402G converter The contrast of this LCD is affected by its ambient temperature For this reason the LCD is shipped after adjusting the contrast so as to become the most suitable in a room temperature 20 30 C However when display on the LCD is hard to see adjust the LCD contrast by change the resistance of the variable resistor its position is shown in Fig 11 7 Variable register Figure 11 7 IM 11M12A01 03E 11 Inspection and Maintenance 11 3 Replacing Flowmeter in ZR40H Autocalibration Unit 1 R
139. flow immediately Turn the zero gas valve regulator fully clock wise If this valve regulator is not properly adjusted the needle valve will not close completely and a cylinder gas may leak Manual calibration Zero calibration NA Close the zero gas valve Cp Span calibration iM a BA F10 18E EPS Figure 10 18 Zero gas Calibration Complete in Manual Calibration Display A CAUTION Be sure not to terminate a calibration in progress because of a shortage of gas in the cylinder Each gas cylinder is operable for nine minutes or more provided the gas is discharged at the specified rate Therefore if your calibration time is estimated at four minutes you can operate the zero point calibration twice lt Treatment after completion of calibration gt 1 Fully close the needle valve mounted on the calibration gas inlet of the detector 2 Remove the tube connecting the detector to the standard gas unit A WARNING e Store the standard gas unit with the gas cylinder mounted where the ambient tempera ture does not exceed 40 C Otherwise the gas cylinder may explode Store the spare gas cylinders under the same condition 10 22 IM 11M12A01 03E 10 Other Functions 10 6 Methods of Operating Valves in the ZASF Flow Setting Unit The ZA8F Flow Setting Unit is used as a calibration device for a system conforming to System 2 Calibration in such a system is to be manually operated So you have to opera
140. g use a 2 core or a 4 core shielded cable 542 Wiring Procedure 1 M4 screws are used for the terminals of the converter Each wire of the cable should be terminated in corresponding crimp on terminals Ensure that the cable shield is connected to the FG terminal of the converter 2 Be sure to connect and polarities correctly 5 10 IM 11M12A01 03E 5 Wiring 5 5 Power and Grounding Wiring This wiring supplies power to the converter and grounds the converter detector Converter Detector Grounding to the ground terminal on the converter case Converter case Earth Crimp on terminal Lock washer the ground wire 100 240VAC 4 FG terminal 50 60Hz F5 10E EPS Figure 5 10 Power and Grounding wiring 5 5 1 Power Wiring Connect the power wiring to the L and N terminals of the converter Proceed as follows 1 Use a 2 core or a 3 core shielded cable 2 The size of converter terminal screw threads is M4 Each cable should be terminated corresponding crimp on terminals 5 5 2 Grounding Wiring The ground wiring of the detector should be connected to the ground terminal of the detector case The ground wiring of the converter should be connected to either the ground terminal of the converter case or the protective ground terminal in the equip ment The ground terminals of the detector and the converter are of size M4 Proceed as follows 1 Keep ground resistance to 1000 or less JIS Class 3 groun
141. ge Moisture quantity 0 to 25 through 0 to 100 vol H O in 1 vol H O or partial range Mixture ratio 0 to 0 2 through 0 to 1 000 kg kg in 0 001 kg kg or partial range Digital Communication HART 250 to 5500 depending on quantity of field devices connected to the loop multi drop mode Note HART is a registered trademark of the HART Communication Foundation Display Range Oxygen concentration 0 to100 vol O Moisture quantity 0 to 100 vol H O Mixture ratio 0 to 1 kg kg Relative humidity 0 to 100 RH Dew point 40 to 370 C Note Those values are calculated by temperature and absolute pressure Then accurate temperature and pressure value must be input to the converter Warm up Time Approx 20 min Note These characteristics are calculated by oxygen concentration measured in air which include water vapor IM 11M12A01 03E 2 1 2 2 Repeatability Notel 1 vol H O sample gas pressure 2 kPa or less Linearity Excluding standard gas tolerance Note 1 Use oxygen of known concentration in the measuring range as the zero and span calibration gas 2 vol H O Sample gas pressure within 0 49 kPa 3 vol H O Sample gas pressure 2 kPa or less Drift Excluding the first two weeks in use Notel both zero and span 3 vol H O month Response Time Response of 90 within 5 seconds Measured after gas is introduced from calibration gas inlet and analog output starts changi
142. gure 8 10 5 Each set item and the selected items are briefly described in Table 8 6 The following describes an example of setting where output contact 1 is closed during calibration 6 Select Others in the Output contact 1 display The Contact1 display shown in Figure 8 11 then appears Select Calibration in the Contact display 7 The on or off selection display then appears Select on herein 8 Press the Return key to go back to the previous display 9 Move the pointer to During power off the contact is open and in condition it is Open and press the Enter key The off or on selection display then appears If you select off this mean open in normal conditions and closed when the contact output is on A WARNING e The contact output 4 is fixed as close in power on which cannot be changed by setting 8 12 IM 11M12A01 03E 8 Detailed Data Setting Contact setup CP Output contact 1 Output contact 1 CP Alarms Others During power off the contact is open and in condition it is Open Output contact 2 Output contact 3 Input contacts JASE alo m 2 s m nter g ful m 5 B F8 10E EPS Figure 8 9 Contact Setup Display Figure 8 10 Output Contact 1 Display Contacti Others Al F Warm up ON Range change OFF Calibration orr 4 Maintenance ON Blow back OFF v Temp input high OFF
143. h cylinder and nitrogen at a pressure of 700 kPaG at 35 C The operating details and handling precautions are also printed on the product Please read them beforehand To install the gas cylinder follow these steps 1 Attach the zero gas valves onto the gas cylinder First turn the valve regulator of the zero gas valves counterclockwise to completely retract the needle at the top from the gasket surface Maintaining the valve in this position screw the valve mounting into the mouthpiece of the gas cylinder If screw connection is proper you can turn the screw manually Do not use any tool When the gasket comes in contact with the mouthpiece of the gas cylinder and you can no longer turn it manually tighten the lock nut with a wrench 2 Remove the carrying case from the standard gas unit The case is attached to the unit with six screws So loosen the screws and lift them off 3 Slide the gas cylinder through the hole in the back of the unit and connect the tube the piping in the unit to the valve connections Insert each tube at least 10 mm to prevent leakage and secure it using a tube clamp 4 Attach the gas cylinder to the case Extend the valve regulator of the zero gas valves through the hole in the front panel of the unit and secure the bottom 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 concen
144. h the markings with those on the terminal board When installing the cell assembly 6 replace the metal O ring 7 with a new one 11 1 4 Replacement of O ring The detector uses three different types of O rings 14 21 and 22 One O ring alone 14 or two O rings 21 and 22 are used For a pressure compensating model two O rings are used for individual uses Two O rings 21 and 22 are used for reference gas sealing and require periodic replacement 11 1 5 Stopping and Re starting Operation lt Stopping Operation gt When operation is stopped take care of the followings so that the sensor of the detector cannot become unused ieee ower K9470BJ Metal ring 14 K9470ZS Metal ring with grease 21 Two pairs of O rings K9470ZP 22 0 with grease T11 1 5E ES A CAUTION When operating an instrument such as boiler or industrial furnace is stopped with the zirconia oxygen analyzer operation moisture can condensate on the sensor portion and dusts may stick to it If operation is restarted in this condition the sensor which is heated up to 750 C firmly fix the dusts on itself Consequently the dusts can make the sensor performance very lower If a large amount of water is condensed the sensor can be broken and never re useful To prevent the above nonconformity take the following action when stopping operation 1 If possible keep on supplying the power to converter and flowing reference air to
145. he wiring connections have been properly completed Input contacts Input contact 1 Open Input contact 2 Open QE t Enter F7 15 4E EPS Figure 7 15 4 Input Contact Check Display 7 14 IM 11M12A01 03E 7 Startup 7 11 Calibration The analyzer is calibrated in such a way that the actual zero and span gases are mea sured and those measured values are used to agree with the oxygen concentrations in the respective gases There are three types of calibration procedures available 1 Manual calibration conducting zero and span calibrations or either of these calibra tions in turn 2 Semi automatic calibration which uses the touchpanel or a contact input signal and conducts calibration operations based on a preset calibration time and stable time 3 Automatic calibration conducted at preset intervals Manual calibration needs the ZA8F Flow Setting Unit to allow manual supply of the calibration gases Semi automatic and automatic calibrations need the ZR40H Automatic Calibration Unit to allow 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 later in this manual 7 11 1 Calibration Setup 7 11 1 1 Mode Setting For the mode setting do the following Press the Setup key in the basic panel display to display the Execution Setup display S
146. ht PIPING kg ANSI Class 150 2 RF SUS304 ZR22G 300 L F3 8 1E EPS IM 11M12A01 03E 3 13 3 14 ZR22G B P Flange ANSI Class 150 3 RF 156 Unit mm Rc1 4 or 1 4NPT Reference air inlet 87 C 2 G1 2 2 1 2NPT etc Cable connection port a 1 oll Reference gas outlet Flange PIPING A Rc1 4 or 1 4NPT Calibration gas inlet Stop Valve Weight Model Code Specification PIPING kg ZR22G 040 U ZR22G 070 U ZR22G 100 U ZR22G 150 U ZR22G 200 U ZR22G 250 U ZR22G 300 U ANSI Class 150 3 RF SUS304 190 5 152 4 F3 8 2E EPS ZR22G 0 C P Flange ANSI Class 150 4 RF Unit mm Rc1 4 or 1 4NPT Reference air inlet L iF 156 Se 2 G1 2 2 1 2NPT etc TT Cable connection port c i A o 4 H OL 1 T T ye Reference gas outlet Flange D PIPING A Rc1 4 or 1 4NPT Calibration gas inlet Stop Valve Flange Weight Model Code Specification PIPING kg ZR22G 040 0 ZR22G 070 0 ZR22G
147. ibration gas press low default default default Process upset O Present Operating contact status Closed fixed T8 7E EPS Note Blank boxes in the above table indicate that the default is disabled 8 15 8 5 Input Contact Settings 8 5 1 Input Contact Functions The converter input contacts execute set functions by accepting a remote contact signal Table 8 8 shows the functions executed by a remote contact signal Table 8 8 Input Contact Functions Item Function Calibration gas press low While the contact signal is on neither semi automatic nor automatic calibration is possible Measuring range change While contact input is On range of Analog Output 1 is switched as follows When analog output range is set to Humidity then output range is switched to 0 to 100 H20 When analog output 1 range is set to Mixing ratio then output range is switched to 0 to 1 kg kg When analog output range is set to Oxygen then range is switched to 0 to 25 O2 While range is switched by the contact input Range is displayed on the screen See Figure 8 12 Calibration start If the contact signal is applied semi automatic calibration starts only if the semi automatic or automatic mode has been setup Calibration is started with an applied one to 11 second time interval single output contact signal Even if a continuous contact signal is applied a calibration
148. in No function the output Hold time and Blow back time are not displayed If you select Hold time the numeric data entry display appears Enter the desired Hold time output stabilization time from 00 minutes 00 seconds to 60 minutes 59 seconds When you select Blow back time the numeric data entry display appears Enter the desired Blow back time from 00 minutes 00 seconds to 60 minutes 59 seconds IM 11M12A01 03E 10 Other Functions 10 2 1 4 Setting Interval Start Date and Start Time The interval is the time to execute blowback Display the numeric data entry panel display to set the desired interval from 000 days 00 hours to 255 days 59 hours For the Start day and Start time set the date when the blowback is first executed and the time when to start the blow back respectively If you want to execute the first blow back for example at 4 00 p m on March 25 2001 enter 25 03 01 for the Start date and 16 00 for the Start time Blow back setup CPMode Auto A Holdtime 10min00s Blow back time 10min00s Interval 30d 00h WV Start date 01 01 00 Start tine 00 00 F10 10E EPS 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 blow back the Interval Start Date and Start Time for these are not displayed A CAUTION
149. in an operation writing to the memory EEPROM mounted in the electrical circuits inside the converter lt Locating the failure and countermeasures gt Turn off the power to the converter once and then restart the converter If the converter operates normally after restarting an error might have occurred due to a temporary drop in the voltage falling below 85 V the least amount of voltage required to operate the converter or a malfunction of the electrical circuits affected by noise Check whether or not there is a failure in the power supply system or whether the converter and detector are securely grounded If the error occurs again after restarting a failure in the electrical circuits is suspected Consult the service personnel at Yokogawa Electric Corporation IM 11M12A01 03E 12 Troubleshooting 12 2 Displays and Measures to Take When Alarms are Gen erated 12 2 1 What is an Alarm IM 11M12A01 03E When an alarm is generated the alarm indication blinks in the display to notify of the alarm Figure 12 3 Pressing the alarm indication displays a description of the alarm Alarms include those shown in Table 12 2 Tag 0 0 H20 4 00mA Ouiput1 4 00mA Output2 Pa Tag Ei Alarm 6 Zero conc ratio Figure 12 3 F123E EPS F12 4E EPS Figure 12 4 Table 12 2 Types of Alarms and Reasons for Occurrence Alarm Type of alarm Reason for occurrence Alarm 1 Oxygen conce
150. ing 12 2 2 2 Alarm 6 Zero point Calibration Coefficient Alarm In automatic or semiautomatic calibration this alarm is generated when the zero correction factor is out of the range of 100 30 refer to Section 9 1 3 Compensa tion The following can be considered the causes for this 1 The zero gas oxygen concentration does not agree with the value of the zero gas concentration set Calibration Setup Otherwise the span gas is used as the zero gas 2 The zero gas flow is out of the specified flow 600 60 mL min 3 The sensor assembly is damaged and so cell voltage is not normal lt Locating cause of failure and countermeasures gt 1 Confirm the following and carry out calibration again If the items are not within their proper states correct them a If the indication for Zero gas conc is selected in Calibration setup the set point should agree with the concentration of zero gas actually used b The calibration gas tubing should be constructed so that the zero gas does not leak 2 If no alarm is generated as a result of carrying out re calibration it is suspected that improper calibration conditions were the cause of the alarm in the preceding calibra tion In this case no specific restoration is necessary 3 If an alarm is generated again as a result of carrying out re calibration deterioration of or damage to the sensor assembly is suspected as the cause of the alarm Replace ment o
151. ing Display Items 2 Execution Setup display Selects the calibration maintenance and setup items 3 Detailed data display This allows you to view such detailed data as the cell electro motive force and cell temperature see Section 10 1 1 Detailed data Display later in this manual 4 Trend Graph display Displays a trend graph see Section 10 1 2 Trend Graphs later in this manual 5 Calibration execution Makes zero and span calibrations see Chapter 9 Calibra tion and the associated sections later in this manual 6 Blow back execution Executes a blow back see Section 10 2 Blow Back later in this manual 7 Reset panel display If an error arises you can restart the equipment from this display for more details see Section 10 4 Reset later in this manual 8 Maintenance panel display Sets the data for equipment maintenance or makes a loop check 9 Commissioning Setup display Sets up the operation data For details see Chapter 8 Detailed data Settings and the associated sections later in this manual 7 4 4 Entering Numeric and Text Data IM 11M12A01 03E 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 7 4 then appears Press the numeral keys to enter numeric values If those values include a decimal point as in Figure 7 4 the decimal point need not be entered becau
152. ing when the calibration gas is introduced The stop valve should be closed except while the calibration gas is being introduced Piping is required if the air around the detector is not clean e The reference gas should have an oxygen concentration identical to that of fresh air 21 e It is recommended to use ZH21B dust protector to protect the probe output from dust agitation i e to prevent combustible materials from entering the probe cell where humidity measurements are made under dusty or combustible such as paper dust environment 4 1 1 Parts Required for Piping in System 1 Check that the parts listed in Table 4 1 are ready Table 4 1 Detector Piping location Parts Note General use Calibration gas inlet Stop valve Recommended by YOKOGAWA detector L9852CB or G7016XH nipple Rc1 4 or 1 4 NPT generic parts joint for tube connection Rc1 4 1 4NPT for b6Xh4mm generic parts soft tube Reference gas inlet sealed up when piping is required refer to section 4 1 3 Note Parts with marking are used when required T4 1E EPS 4 1 2 Connection to the Calibration Gas Inlet When carrying out calibration connect the piping 6 0 D x4 D mm tube from the standard gas unit to the calibration gas inlet of the detector First mount a stop valve of a quality specified by YOKOGAWA or a nipple found on the open market as illus trated in Figure 4 2 and mount a joint also found on the
153. inutes 00 seconds Interval 30 days 00 hours Start date 01 01 00 Start time 00 00 T10 4E EPS 10 12 IM 11M12A01 03E 10 Other Functions 10 3 Operational Data Initialization IM 11M12A01 03E Individual set data initialization enables you to return to the default values set at the time of delivery There are two types of initialization an all set data initialization and a function by function initialization Table 10 5 lists the initialization items and default values To initialize the set data follow these steps 1 Press the Setup key in the Basic panel display to display the Execution Setup display Then choose Setup 2 Select Others from the Commissioning Setup display 3 Choose Defaults The Defaults display shown in Figure 10 11 appears 4 Select your desired item to initialize in order to display the Defaults Display shown in Figure 10 12 5 Choose Defaults start Initialization then starts Defaults CP Display a Defaults Display Calibration Blow back mA outputs Alarms v Contacts Others All data Enter CP Defaults start Cancel Se A a a a JE g F10 11EEPS Figure 10 11 Defaults Display Figure 10 12 Initialization Start Display A WARNING e Do NOT turn off the power during initialization Otherwise initialization will not be performed properly 10 13 10 14 Table 10 5 Initialization Items and Default Val
154. ion manual for solving problems Alarm 10 Cold Junction Temperature Alarm This alarm is generated when the temperature of the cold junction located at the terminal block of the detector falls below 25 C or exceeds 155 C Check the following Display C J Temperature in the detailed data display If C J Temperature is indicated as 200 C or 50 C the following can be considered 1 Breakage of the cold junction signal wires between the converter and the detector or the cable is not securely connected to the connecting terminals 2 The positive and negative poles of the cold junction signal wiring are shorted out in the wiring extension or at the connection terminals 3 A failure of the cold junction temperature sensor located at the detector terminal block occurred 4 A failure of the electrical circuits inside the converter occurred If C J Temperature exceeds 150 C or falls below 20 C the following can be considered 1 The temperature of the detector terminal block is out of the operating temperature range 20 C to 150 C 2 A failure of the cold junction temperature sensor located at the detector terminal block occurred 3 A failure of the electrical circuits inside the converter occurred lt Locating cause of failure and countermeasures gt Before proceeding to the following troubleshooting procedure examine whether or not the temperature of the detector terminal block is out of
155. ir Natural convention External connection Instrument air Pressure compensated for ZR22G S2 Pressure compensated for ZR22G S1 1 Suffix code of length should be selected as same as ZR22G installed 2 Jig part no is K9470BX to order as a parts after purchase 3 Select appropriately among A B C according to the reference air supply method and style Note The heater is made of ceramic do not drop or subject it to pressure stress T23 EPS External Dimensions 4 Jig for change Oji Unit mm K9470BX ST 30 45 L 12 L length Model amp Code Weight kg ZR22A 040 Approx 0 8 ZR22A 070 Approx 1 2 ZR22A 100 Approx 1 6 ZR22A 150 Approx 2 2 ZR22A 200 Approx 2 8 ZR22A 250 Approx 3 4 F2 16E EPS ZR22A 300 Approx 4 0 2 28 IM 11M12A01 03E 3 Installation 3 Installation This chapter describes installation of the following equipment 3 1 3 2 3 3 3 4 3 5 Detector Converter ZASF Flow Setting Unit ZR40H Automatic Calibration Unit E7044KF Case Assembly for Calibration gas Cylinder 3 1 Installation of the Detector 3 1 1 Location The following should be taken into consideration when installing the detector 1 Easy and safe access to the detector for checking and maintenance work 2 Ambient temperature of not more than 150 C and the terminal box should not affected by radiant heat 3 A cl
156. ith a new one is necessary However before replacement carry out the procedure described in step 3 and later of lt Search for cause of failure and taking measure gt in Section 12 2 2 2 Alarm 6 Zero point Calibration Coefficient Alarm 12 2 2 4 Alarm 8 EMF Stabilization Time Over This alarm is generated if the sensor cell voltage has not stabilized even after the calibration time is up for the reason that the calibration gas zero gas or span gas has not filled the sensor assembly of the detector lt Cause of alarm gt 1 The flow of the calibration gas is less than normal a specified flow of 600 60 mL min 2 The length or thickness of the calibration gas tubing has been changed lengthened or thickened 3 The measuring gas flows toward the tip of the probe 4 The sensor cell response has deteriorated lt Locating cause of failure and countermeasures gt 1 Carry out calibration by passing the calibration gas at the specified flow 600 60 mL min after checking that there is no leakage in the tubing 2 If calibration is carried out normally perform a steady operation without changing the conditions If the error occurs again check whether or not the reason is appli cable to the following and then replace the sensor assembly e A lot of dust and the like may be sticking to the tip of the detector probe If dust is found clean the probe see Section 11 1 1 In addition if an error occurs in calib
157. larms detected by the self diagnostic function of the converter This chapter also describes the check and restoration methods to use when problems other than the above occur 12 1 Displays and Measures to Take When Errors Occur 12 1 1 What is an Error An error is detected if any abnormality is generated in the detector or the converter e g in the cell sensor or heater in the detector or the internal circuits in the converter If an error occurs the converter performs the following 1 Stops the supply of power to the heater in the detector to insure system safety 2 Causes an error indication in the display to start blinking to notify of an error generation Figure 12 1 3 Sends an output contact if the error is set up for Output contact setup for that contact refer to Section 8 4 Output Contact Setup 4 Changes the analog output status to the one set in Output hold setting refer to Section 8 2 Output Hold Setting When the display shown in Figure 12 1 appears pressing the error indication brings up a description of the error Figure 12 2 The content of errors that are displayed include those shown in Table 12 1 Tag Tag al Error 2 Heater temp Alarm 1 1 T C voltage 4 00mA Output1 4 00mA Output2 F12 1E EPS F12 2E EPS Figure 12 1 Figure 12 2 Table 12 1 Types of Errors and Reasons for Occurrence Error Type of error Reason for Occurr
158. lue C has fallen lower than the hysteresis set value that measurement exceeds the hysteresis set value before the preset delayed time has elapsed So the alarm is not canceled 4 The measured value D has fallen below the hysteresis set value and the preset delayed time during measurement has elapsed so the alarm is canceled 8 3 3 Alarm Setting Procedure To set the alarm setpoints follow these steps 1 Press the Setup key in the basic panel display to display the Execution Setup display 2 Select Setup in the Execution Setup display The Commissioning Setup display then appears 3 Select the Alarm setup in the Commissioning Setup display The Alarms setup display shown in Figure 8 5 then appears 4 Select Parameter in the Alarms setup display to display Oxygen Humidity and Mixing as Figure 8 6 shows 5 Select the Humidity and press the Enter key to confirm the humidity measure ment as Figure 8 7 shows To set the hysteresis proceed to the following steps 6 Select Hysteresis in the Alarms setup display The numeric data entry display then appears Enter the desired hysteresis value in H O To set 2 5 HO enter 25 The hysteresis can be in the setting range 0 to 9 9 H O To set the delay time proceed to the following steps 7 Select the Contact delay in the Alarms setup display The numeric data entry display then appears Enter the desired delay time in seconds To set thr
159. ly to the heater of the detector As a result the heater temperature becomes low and Error or Error2 happens 8 5 2 Setting Procedure The following are set so that semi automatic calibration starts when input contact open is applied to Input1 Proceed as follows 1 Press the Setup key in the Basic panel display to display the Execution Setup display 2 Select Setup Setup in the Execution Setup display to display the Commission ing Setup display 3 Select Contact setup in the Commissioning Setup display 4 Select Input contacts in the Contact setup display The Input contacts display then appears as shown in Figure 8 13 5 Select Input in that display The Input contacts display then appears as shown in Figure 8 14 6 Select Calibration start 7 Select Input closed An Open or Closed selection display then appears 8 Choose Open Input contacts ES Input contacts ES CP Inputi No function amp Input NAME i Cal gas press low inputi contact is active at inputi Range change Closed Calibration start Input2 No function Input2 Process up set Input contact is active at nd Input2 Blow back start bd Closed Closed Figure 8 13 Input Contacts Display Figure 8 14 Input Contacts Display 8 5 3 Default Values When the analyzer is delivered or if data are initialized contact input is disabled I
160. me display area Switch display area Primary value H20 Secondary value 4 00mA Output1 display area Alarm and error Tertiary value 4 00mA Output2 IM 11M12A01 03E F7 3E EPS Figure 7 3 Basic Panel Display Tag name display area Displays the set tag name Refer to Section 10 1 4 Entering Tag Name Primary to tertiary display items Displays the selected item Refer to Section 7 8 Setting Display Item Switch display area Displays switches and functions selected according to the panel display Alarm and error display area Displays an error if an alarm or error occurs If you touch this area the details of the error or alarm are then displayed Table 7 1 Switches and Their Functions Enter key Home key Enters the input value and sets up the Returns to the Execution Setup display Enter selected item Reject key Setup key Moves back to the previous display Used to enter the Execution Setup display Cursor key Detailed data key Moves the cursor down Displays the analog input value Cursor Graph display key Points the cursor at the currently Displays a trend graph selected item Alarm Error Displayed if an alarm arises Displayed if an error occurs T7 1E EPS 7 3 7 4 2 Display Configuration for High temperature Humidity Analyzer Figure 7 3 1 shows th
161. measuring gas pressure becomes higher The measured oxygen concentration value X vol O is expressed as shown below when the measuring gas pressure is higher than that in calibration by Ap kPa X Y 1 Ap 101 30 where Y Measured oxygen concentration value at the same pressure as in calibration vol O Where an increment of the measured value by pressure change cannot be neglected measures must be taken Investigate the following points to perform improvement available in each process Is improvement in facility s aspect available so that pressure change does not occur Is performing calibration available under the average measuring gas pressure internal pressure of a dryer 2 Moisture content in a reference gas changes increases greatly If air at the detector installation site is used for the reference gas large change of moisture in the air may cause an error in measured oxygen concentration value vol O 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 exhaust gas after combustion is also considered as a cause of error However normally this error is negligible 3 Calibration gas span gas is mixing into the detector due to leakage If the span gas is mixing into the detector due to leakage as a result of failure of the valve provided in the calibration gas tubing system the
162. n code HS 2 Specifications 2 13 External Dimensions Unit mm _ 1 to 6 Panel Thickness 2 inch mounting pipe 4 46 holes for Wall mounting Q O LE i i Lo H b 2 U NE ns 8 2 Il SJ A 8 10 _ 57 3 36 228 136 3 54 7 111 40 40 40 l 7 8 G1 2 8 1 2NPT etc Wiring connection eo O 66 oO 2000 L AT 38 12414 38 for wall mounting ra 4 46 holes p 9 N 1 o N A i 4 R8 to R10 or et _4 C5 to C8 Z J 190 183 5 Wall mounting Panel Cut out F2 5E EPS Accessories Item Part No Qty Description Fuse A1113EF 1 3 15A Bracket for mounting F9554AL 1 for pipe mounting panel mounting or wall mounting Screw for Bracket F9123GF 1 2 14 IM 11M12A01 03E IM 11M12A01 03E 2 Specifications Hood Option H Unit mm 243 4 Le 205 5 4 5 2 123 3 i 155 5 3 7 j an Exam ZR402G w 4 ner kat a a 251 5 p TNT ST Hood material Aluminum 2 15 2 4 ZA
163. ng Notel These tolerances do not apply to the pressure compensated version or where natural convection is used for the reference air IM 11M12A01 03E 2 Specifications 2 2 General use Separate type Detector and Related Equipment The Detector with dust protector consists of ZR22G general use separate type detector and ZH21B dust protector refer to Section 2 2 2 2 2 1 ZR22G General use Separate type Detector IM 11M12A01 03E Sample Gas Temperature 0 to 700 C Probe only It is necessary to mount the cell using Inconel cell bolts when the temperature is 600 C or greater Sample Gas Pressure 5 to 20 kPa When the pressure in the process exceeds 3kPa it is recommended that you compensate the pressure When the pressure in the process exceeds 5kPa you must perform pressure compensation No pressure fluctuation in the process should be allowed Probe Length 0 4 0 7 1 0 1 5 2 0 2 5 3 0 m Probe Material SUS 316 JIS Ambient Temperature 20 to 150 C Reference Air System Natural Convection Instrument Air Instrument Air System excluding Natural Convection Pressure 200 kPa the pressure inside the dryer It is recommended to use air which has been dehumidified by cooling to dew point 20 C or less and with dust or oil mist removed Consumption Approx 1NI min Note When the detector is used in conjunction with a check valve and a ZA8F Flow Setting Unit the maximum pressure of sampl
164. ng Parts for System 2 4 3 4 2 2 Piping for the Calibration Gas ss 4 4 4 2 3 Piping for the Reference Gas ss 4 4 4 37 Piping Tor System sr prime re nt nd Ne eat te 4 5 5 Wiri 5 1 TAT e i iT ste en EEE De Dl General ieee i E E e EEE a EE ESEESE 5 1 5 1 1 Terminals for the External Wiring in the Converter 0 eee 5 3 512 Wings sont im tn bte End tentes 5 3 5 1 3 Mounting of Cable Gland ss 5 4 5 2 Wiring for Detector Output ss 5 5 5 2 1 Cable Specifications Grae ib panei tenis e E eA S 5 5 5 2 2 Connection to the Detector ss 5 6 5 2 3 Connection to the Converter ss 5 7 5 3 Wiring for Power to Detector Heater occ ee esceesceecneeeeeeecseceeeseeaecaeeeeeaeens 5 8 5 3 1 Cable Specitications s iscesssisciuseesssccciveposssscusteesstaekeiepubassestspuscbssedetagesessesss 5 8 5 3 2 Connection to Detector ss 5 8 5 3 3 Connection to Converter ss 5 9 5 4 Wiring for Analog Output 5 10 SAT Cable Specifications ssena er a apie pease eE 5 10 54 2 Winng Procedures meco E ds Shige EE EE EE E T 5 10 5 5 Power and Grounding Wiring ss 5 11 5 5 1 Power WINS cenaren e pa antenne Rie ee 5 11 5 952 Grounding WINS cess coerce ects iea got E EE NES 5 11 5 6 Wiring for Contact Output ss 5 12 5 6 Eabl Sp cifi ations Assis dns nent nr 5 12 5 6 2 Wiring Procedure uns nn e iets rein eae 5 12 5 7 Wiring for ZR40H Automatic Calibration Unit
165. nt volume rati IM 11M12A01 03E 8 Detailed Data Setting Use the above equation to find the water vapor in the moist air and use the theoretical equation JIS Z 8806 to obtain the temperature at which that water vapor is equal to the saturated water vapor pressure 8 6 3 1Setting Measurement Gas Temperature There are two ways of entering measurement gas temperatures one is to measure actual gas temperature using a two wire temperature transmitter and the other is to enter the preset value manually Set the measurement gas temperature as follows 1 Press the Setup key in the basic panel display to display the Execution Setup display 2 Select Setup in the Execution Setup display The Commissioning Setup display then appears 3 Select Others in that display and then the Exhaust gas setup shown in Figure 8 18 4 Point to the Temperature input mode and press the Enter key Then the display for selecting either Preset or mA input appears Choose the desired one for your system requirements 5 If you choose the Preset a display for entering numeric data then appears Enter the measurement gas temperature see CAUTION 6 If you choose mA input the Exhaust gas setup display shown in Figure 8 19 appears Enter temperatures at 4 and 20 mA outputs of the temperature transmitter from the numeric data entry display See CAUTION 7 If you use measurement gas temperature alarms choose the
166. nt Gas Temperature and Pressure Set Ranges and Default Settings Set Item Set range Default setting Temperature input selection Preset value Measurement gas temperature 0 to 3000 C 300 C Temperature at 4 mA 0 to 3000 C 0 C Temperature at 20 mA 0 to 3000 C 1000 C Absolute humidity of the atmosphere 0 to 689 47 kPa abs 101 33 kPa abs T8 9E EPS 8 6 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 The solenoid valve for the automatic calibration span gas is opened during purging and after the purge time has elapsed the valve is closed to start warm up Purging is enabled when the cell temperature is 100 C or below upon power up and the purge time is set in the range of 1 to 60 minutes 30 4mA Output1 4mA Output2 e F20 EPS Tag Figure 8 20 Display during Purging 8 6 4 1 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 Setup in the Execution Setup display The Commissioning Setup display then appears 3 Select Others in that display and the Others display then appears as shown in Figure 8 21 4 Select Purging The Purging time setting display appears a
167. nt Status 1 During Warm up Warming up is the time required after applying power until the sensor tempera ture stabilizes at 750 C and the equipment is in the measurement mode 2 Under maintenance During maintenance is the time starting from pressing the Setup key in the basic panel display the Execution Setup display to go back to the basic panel display The display panels under the Execution Setup display which are in Figure 7 3 1 are included 3 Under calibration see Chapter 9 Calibration During calibration is the time during manual calibration starting from entering the Manual calibration display shown in Figure 8 1 and making a series of calibrations until the Calibration End key is pressed or until the preset output stabilization time elapses Manual calibration Open span gas valve fl nl Set flow span gas to 600ml min F Valve opened Cancel calibration E F8 1E EPS Figure 8 1 IM 11M12A01 03E 8 Detailed Data Setting For semi automatic calibration under calibration is the time required from entering calibration instructions to perform a calibration either by using the touchpanel or by a contact input until the output stabilization time elapses For automatic calibration under calibration is the time required after performing an appropriate calibration until the output stabilization time elapses 4 During Blow ba
168. nt gas enters the sensor to set the time until the output returns to normal The output remains held after completing the calibration operation until the output stabilization time elapses The calibration time set ranges from 00 minutes 00 seconds to 60 minutes 59 seconds For more details consult Section 8 2 Setting Output Hold Setting When the calibration mode is in semi automatic set the 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 ranges from 00 minutes 00 seconds to 60 minutes 59 seconds Figure 9 6 shows the relationship between the calibration time and output stabilization time Calibration start contact or switch input I Span calibration a span gas valve open Calibration time Zero point calibration libration t zero gas valve open alibration time I L Analog output status _ Stabilization time 1 Analog output remains held when output remains held F9 6E EPS Figure 9 6 Calibration and Output stabilization Time Settings e When the calibration mode is in automatic In addition to the above output stabilization time and calibration time set the interval start date and start time Interval means the calibration intervals ranging from 000 days 00 hours to
169. ntration alarm Occurs when the oxygen concentration to be measured exceeds or falls below the set alarm points refer to Section 8 3 Alarm Setting Alarm 2 Humidity alarm Occurs when the humidity to be measured exceeds or falls below the set alarm points refer to Section 8 3 Alarm Setting Alarm 3 Mixing ratio alarm Occurs when the mixing ratio to be measured exceeds or falls below the set alarm points refer to Section 8 3 Alarm Setting Alarm 6 Zero point calibration coefficient alarm Occurs when the zero correction factor is out of the range of 100 30 in automatic and semiautomatic calibration refer to Section 9 1 3 Compensation Alarm 7 Span point calibration coefficient alarm Occurs when the span correction factor is out of the range of 0 18 in automatic and semiautomatic calibration refer to Section 9 1 3 Compensation Alarm 8 EMF stabilization time up Occurs when the cell sensor voltage is not stabilized even after the calibration time is up in automatic and semiautomatic calibration Alarm 9 Exhaust gas temperature alarm When mA input is selected in the Exhaust gas setup display this alarm occurs if the exhaust gas temperature exceeds the set alarm values refer to Section 8 6 3 Setting Measurement Gas Temperature and Pressure Alarm 10 Cold junction emperature alarm Occurs when temperature of the cold junction placed in
170. o Calibration Complete Display 10 Select End in the display as shown in Figure 7 26 An oxygen concentration trend graph with the oxygen concentration being measured appears and HOLD TIME then flashes This time is referred to as the output stabilize time If the HOLD TIME has been set with the output hold setting the analog output remains held refer to Section 8 2 Output Hold Setting later in this manual Manual calibration is completed when the preset output stabilize time elapses This output stabilized time is set to 10 minutes at the factory before shipment If you press the Enter or Return key within the output stabilize time manual calibration is then completed 7 19 8 Detailed Data Setting 8 Detailed Data Setting 8 1 Current Output Setting This section describes setting of the analog output range 8 1 1 About Input Ranges The minimum concentration of oxygen for the minimum current 4 mA is 0 O or 6 to 76 O The maximum concentration of oxygen for the maximum current 20 mA ranges from 5 to 100 O and must be at least 1 3 times the concentration of oxygen set for the minimum Setting example 1 If the setting for a 4 mA current is 10 O you must set the oxygen concentration for the maximum 20 mA point at more than 13 O Setting example 2 If the setting for a 4 mA current is 75 O you must set the oxygen concentration for the maximum 20 mA point at more than 98
171. o gas inlet 4 Rc1 4 Piping connection port Instrument air inlet X A A CHECK REF OUT OUT O a O se Flow Flow meter meter ZERO SPAN 4 GASIN GASIN Instrument air Approx 1 5 l min Air pressure without check valve measured gas pressure approx 50 kPaG with check valve measured gas pressure approx 150 kPaG F2 6E EPS Unit mm 2 17 2 4 2 2 18 ZR40H Automatic Calibration Unit This automatic calibration unit is applied to supply specified flow of reference gas and calibration gas during automatic calibration to the detector in a system configuration System 3 e Specifications Used when auto calibration is required for the separate type and instrument air is provided The solenoid valves are provided as standard Construction Dust proof and rainproof construction NEMA4X IP67 solenoid valve only excluding flowmeter Mounting 2 inch pipe or wall mounting no vibration Materials Body Aluminum alloy Piping SUS316 JIS SUS304 JIS Flowmeter MA acrylic resin Bracket sus304 JIS Finish Polyurethane corrosion resistance coating mint green Munse11 5 6BG3 3 2 9 Piping Connection Refer to Model and Suffix Codes Power Supply 24V DC from ZR402G Power consumption Approx 1 3W Reference Air Pressure Sample gas pressure plus Approx 150 kPa 690 kPa max Pressure at inlet of auto calibration unit Air Consumption
172. oe Previous orce m zero gas data f 1 el TN 7 Corrected calibration curve theoretical calibration curve es of 0 Span origin 21 0 pi 0 51 Span gas concentration Oxygen concentration vol O2 Zero gas ratio B A x 100 Correctable range 100 30 Span gas ratio C A x 100 Correctable range 0 18 F10 2E EPS Figure 10 2 IM 11M12A01 03E 10 1 10 1 1 2 Response Time The cell s response time is obtained in the procedure shown in Figure 10 3 If only either a zero point or span calibration has been carried out the response time will not be measured just as it will not be measured in manual calibration Five minutes maximum Response time mA 10 of analog output span Le Time Start calibration Calibration complete The response time is obtained after the corrected calibration curve has been found The response time is calculated starting at the point corresponding to 10 of the analog output up to the point at 90 of the analog output span That is this response time is a 10 to 90 response F10 3E EPS Figure 10 3 Functional Drawing of Response Time 10 1 1 3 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 still be used 1 more than a year 2 more than six months 3 more than three months 4 less than one month The above four tim
173. om the Execution Setup display The Calibration display shown in Figure 9 8 appears 2 Select Semi auto calibration to display the Semi automatic calibration display shown in Figure 9 9 3 Select Start calibration The display shown in Figure 9 10 appears and then start calibration Calibration Semi auto calibration A Cp Manual calibration Check settings Semi auto calibration Zerogasconc 1 00 Span gas conc 21 00 Ly Caltime 10min00s Go to setup to change value dx Start calibration Cancel calibration a QE t m 2 7 F9 8E EPS F9 9E EPS Figure 9 8 Calibration Display Figure 9 9 Semi automatic Calibration Display Semi auto calibration 0 5min div 21 00 1 00 21 0 O2 Roi F9 10E EPS Figure 9 10 Semi automatic Calibration Display To start calibration using an input contact follow these steps 1 Make sure that Calibration start has been selected in the Input contacts display see Section 8 5 earlier in this manual 2 Apply an input contact to start calibration To stop calibration midway follow these steps 1 Press the Return key If this key is pressed midway during calibration the calibration will stop and the output stabilization time will be set up 2 Press the Return key once again to return to the basic panel display and the analyzer will be in normal measurement 9 10 IM 11M12A01 03E 9 Calibration 9 2 3
174. om the detector output wiring Check whether the converter and detector are securely grounded Check whether or not the signal wiring is laid along other power cords 2 The converter may be affected by noise from the power supply Check whether or not the converter power is supplied from the same outlet switch or breaker as other power machines and equipment 3 Poor wiring contact If there is poor contact in the wiring the sensor voltage or thermocouple emf voltage may vary due to vibration or other factors Check whether or not there are loose wiring connections or loose crimping caulking at the crimp on terminal lugs 4 There may be a crack in the sensor or leakage at the sensor mounting portion If the indication of concentration varies in synchronization with the pressure change in the furnace check whether or not there is a crack in the sensor or whether the sensor flange is sticking tightly to the probe attaching face with the metal O ring squeezed 5 There may be leakage in the calibration gas tubing In the case of a negative furnace inner pressure if the indication of concentration varies with the pressure change in the furnace check whether or not there is leakage in the calibration gas tubing 12 14 IM 11M12A01 03E Customer Maintenance Parts List Model ZR22G Zirconia High Temperature Humidity Analyzer Detector Separate type Parts No Item MS code Qty D2 sesasi 1 3 E7042BR 1 4 K9470BM 1
175. ontacts are used for solenoid valve drive signals for the ZR40H Automatic Calibration Unit When using the ZR40H Automatic Calibration Unit use the calibration contact output to check that the wiring connections have been properly completed and check equipment operation 1 Referring to Section 7 10 1 display the contact check display 2 Select the Calibration contacts to display the panel display as Figure 7 15 3 shows 3 Perform the same action as in the previous section to cause the zero gas and span gas contacts to act this will help check the automatic calibration unit and wiring connec tions Calibration contacts Crp Zero gas contact Open Span gas contact Open QE Enter Ft F7 15 3E EPS Figure 7 15 3 Calibration Contact Check Display A Tip Open and Closed displayed on the Calibration contact display indicate actions of drive contacts and are opposite to the valve open and close actions If Open is displayed on the Calibration contact display no calibration gas flows If Closed is displayed on that display calibration gas flows 7 10 3 Checking Input Contacts 1 Follow the previous section to display the contact check display 2 Display the Input contacts as Figure 7 15 4 shows The Open or Closed on this display shows the current contact input terminal status and the display changes according to the contact status This enables you to check that t
176. open market at the stop valve tip The stop valve may be mounted on the detector prior to shipping the detector is shipped Note Mount the stop valve close to the detector joint F4 2E EPS Figure 4 2 Connection to the calibration gas inlet 4 1 3 Connection to the Reference Gas Inlet e Normally no piping is required for the reference gas inlet when the equipment uses natural convection for reference gas models ZR22G I4 414C Leave the plug as it is If the air around the detector is polluted and the necessary oxygen concentration 21 vol O cannot be obtained prepare piping the same as which described in Section 4 2 System 2 e When the equipment uses instrument air for the reference gas piping is required as described in Section 4 2 System 2 models ZR22G L4 UE 4 2 IM 11M12A01 03E 4 Piping 4 2 Piping for System 2 Piping in System 2 is illustrated in Figure 4 7 Separate type Zirconia High Temperature Humidity Analyzer Model ZR402G Converter Model ZR22G Detector Ti Signal Stop valve mi 6 core shield cable 7 or Check valve LL LLL LL it 100 to 240 V AC Heater 2 core E Mnaserensser Contact input PRRTASS ATTA gt Analog output contact output Digital output HART Model ZAS8F flow setting unit Flowmeter Needle Reference valve gas Air Set Instrument air Span gas Same as Zero gas Calibration unit Calibration g
177. ork 3 An ambient temperature of not more than 55 C and little change in temperature recommended within 15 C in a day 4 The normal ambient humidity recommended between 40 to 75 RH and without any corrosive gases 5 No vibration 6 Near to the detector 7 Not in direct rays of the sun If the sun shines on the converter prepare the hood H or other appropriate sunshade 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 angle to the vertical however it is recom mended to mount it vertically plane Mount the converter as follows lt Pipe Mounting gt 1 Prepare a vertical pipe of sufficient strength nominal JIS 50A O D 60 5 mm for mounting the converter Converter weighs approximately 6 kg 2 Mount the converter on the pipe Fix it firmly on the pipe in the procedure described in Figure 3 3 Mounting procedure 1 Put four bolts in the holes on the fitting 2 Clamp the pipe with the fitting and a bracket with the four bolts passing through the bracket holes 3 Secure the fitting and the bracket tightly to the pipe with four washers and nuts A pipe to be mounted nominal JIS 50A LE Bracket A ORONS Fiting 7 FO nn A Nut Washer CT Screw i Bolt Note These fittings are attached to the equipment when it is delivered Washer F3 7E EPS Figure 3 3 Pipe Mounting IM 11M12A01 0
178. owing 1 Do NOT touch the probe if it has been in operation immediately just before being checked The sensor at the tip of the probe heats up to 750 C during operation If you touch it you will get burned 2 Do not subject the probe to shock or cool it rapidly The sensor is made of ceramic zirconia If the detector is dropped or bumped into something the sensor may be damaged and no longer work 3 Do not reuse a metal O ring to seal the cell assembly If you replace the cell or remove it from the probe for checking be sure to replace the metal O ring Other wise the furnace gas may leak and then the leaking corrosive gas will cause the built in heater or thermocouple to go open circuit or the detector may corrode 4 Handle the probe with care so that the dust filter mounted screws on the tip of the probe do not hurt your finger s 5 Before opening or closing the terminal box first remove dust sand or the like from the terminal box cover IM 11M12A01 03E 11 1 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 measurement gas If you become aware of clogging such as when a higher pressure is required to achieve a specified flow rate clean the calibration ga
179. oxygen concentration the sensor will be assumed to be normal The ideal value of the cell voltage E when the oxygen concentration measurement temperature is controlled at 750 C may be expressed mathematically by E 50 74 log Px Pa mV where Px Oxygen concentration in the measured gas Pa Oxygen concentration in the reference gas 21 O2 Table 10 1 shows oxygen concentration versus cell voltage Table 10 1 Oxygen Concentration Vs Cell Voltage cell temperature 750 C mv 16 35 0 7 86 14 2 19 2 23 1 26 5 29 5 32 1 Oo 100 T10 1E EPS mv 34 4 10 1 1 7 Thermocouple Voltage The cell temperature is measured with a Type K chromel alumel thermocouple The thermocouple cold junction is located in the detector terminal box The cell temperature and the thermocouple voltage including the voltage corresponding to the cold junction temperature are displayed 10 1 1 8 Cold Junction Resistance C J Voltage The ZR22 Detector measures the cold junction temperature using an RTD Pt 1000 The earlier model of Z021D uses transistors to measure the cold junction temperature If Detector is ZR22 is selected in the Basic setup display the RTD resistance values will be displayed If Z021D is selected the transistor voltage will be displayed 10 1 1 9 Cell s Internal Resistance A new cell sensor indicates its internal resistance of 200Q maximum As the cell degrades so
180. pair under warranty provide us with the model name and serial number and a description of the problem Any diagrams or data explaining the problem would also be appreciated If we replace the product with a new one we won t provide you with a repair report Yokogawa warrants the product for the period stated in the pre purchase quotation Yokogawa shall conduct defined warranty service based on its standard When the customer site is located outside of the service area a fee for dispatching the mainte nance engineer will be charged to the customer In the following cases customer will be charged repair fee regardless of warranty period e Failure of components which are out of scope of warranty stated in instruction manual e Failure caused by usage of software hardware or auxiliary equipment which Yokogawa Electric did not supply e Failure due to improper or insufficient maintenance by user e Failure due to modification misuse or outside of specifications operation which Yokogawa does not authorize e Failure due to power supply voltage frequency being outside specifications or abnormal e Failure caused by any usage out of scope of recommended usage e Any damage from fire earthquake storms and floods lightning disturbances riots warfare radiation and other natural changes IM 1M12A01 03E IM 11M12A01 03E Yokogawa does not warrant conformance with the specific application at the user site Yokog
181. perature 300 C Temperature at 4 mA 0 C Temperature at 20 mA 1000 C Measurement gas pressure 101 33 kPa abs Password Deleted T10 5E 3 EPS IM 11M12A01 03E 10 Other Functions 10 4 Reset Resetting enables the equipment to restart If the equipment is reset the power is turned off and then back on In practical use the power remains on and the equipment is restarted under program control Resetting will be possible in the following conditions 1 Error 1 if the cell voltage is defective 2 Error 2 if a temperature alarm occurs 3 Error 3 if the A D converter is defective 4 Error 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 A CAUTION Make sure that before resetting or restarting the power that there is no problem with the detector or converter If a problem arises again after the resetting turn the power off and troubleshoot the problem by consulting the Troubleshooting chapter later in this manual To reset the equipment follow these steps 1 Press the Setup key in the Basic panel display to display the Execution Setup display 2 Choose Reset The Reset
182. play Humidity alarms Al CP High High alarm OFF Set value 100 0 H20 High alarm OFF Set value 100 0 H20 Low alarm OFF v Setvalue 0 0 H20 LowLowalarm OFF ei Setvalue 0 0 H20 Enter F8 7 EPS Figure 8 7 Alarms Setup Display Default Values F8 8 EPS Figure 8 8 Humidity Alarms Display When the analyzer is delivered or if data are initialized the default alarm set values are as shown in Table 8 4 Table 8 4 Alarm Setting Default Values Set item Oxygen concentration Humidity amount of moisture content Mixing ratio Set value Default setting Set value Default setting Default setting Set value Hysteresis 0 1 to 9 9 O2 0 1 O2 0 to 9 9 H20 0 1 H20 0 to 0 1 kg kg 0 001 kg kg 0 to 255 seconds Delay time 3 seconds 0 to 255 3 seconds seconds 0 to 255 3 seconds seconds High high limit alarm Off Off off High high limit 0 to 100 O2 alarm setpoint 100 O2 0 to 100 100 H20 H20 0 Otolkg kg 1kg ke High limit alarm Off Off Off High and low 0 to 100 O2 limit alarm setpoints 100 O2 0 to 100 100 0 H20 H20 0 to 1 kg kg 1 kg kg Low limit alarm Off Off Off Low limit alarm 0 to 100 O2 setpoint 0 to 100 0 0 H20 H20 Otol kg kg Okg kg Low low limit alarm Off Off Low low limit alarm 0 to 10
183. ptoms will be the same low humidity measured value Perform a visual inspection and if a crack is found replace the sensor assembly as described in 11 1 2 Note Data such as cell robustness displayed in the detailed data display should also be used for deciding sensor quality as references 12 3 2 Measured Value Lower Than True Value lt Causes and countermeasures gt 1 The measuring gas pressure becomes lower Where an increment of the measured value due to a pressure change cannot be neglected take measures per Section 11 1 1 1 2 Moisture content in a reference gas changes decreases greatly A change in moisture content contained in the instrument air which is used for the reference gas may cause an error in the measured humidity value vol H O or kg kg When this error is not ignored use a drier or dehumidifier to make the instrument air constant to be almost dried as a reference gas 3 Calibration gas zero gas is leaking in the detector If the calibration gas is leaking in the detector due to a faulty valve provided in the calibration gas tubing system the measured value shows a value a little lower than normal Check valves in the calibration gas tubing system for leakage When manual valves are used check them after confirming that they are in fully closed states 12 3 3 Measurements Sometimes Show Abnormal Values lt Cause and countermeasures gt 1 Noise may be mixing in with the converter fr
184. r key to com plete the converter selection 8 If the type of converter is changed after setting the operating data those data are then initialized and the default settings remain Reset the operating data to meet the new type of equipment Commissioning Cp Basic setup mA output setup Basic setup CP This instrument is for Humidity Please note changing this AIME Sup Basic setting will return ALL gt pan Contact setup other setting to Default JADE Others Detector is ZR22 Enter Enter Figure 7 6 Commissioning Setup Figure 7 7 Basic Setup Display Display Basic setup CP This instrument is for Oxygen Please na g this Basic setting will return ALL other setting to Default Detector is ZR22 a Ld Figure 7 8 Basic Setup IM 11M12A01 03E 7 7 7 6 Confirmation of Detector Type Setting Check that the detector in Figure 7 7 is the one for this equipment DANGER e If this converter is to be used in conjunction with the ZO21D the power requirements are limited to 150 V AC or less 50 Hz or 60 Hz it cannot be used with a 150V or greater or in the EEC If detector settings are to be changed first disconnect the wiring connections between the detector and the converter Then change detector settings appropriately 7 7 Current Output Setting This section sets forth analog output settings For details consul
185. ration even after the sensor assembly is re placed the influence of measured gas flow may be suspected Do not let the mea sured gas flow toward the tip of the detector probe for example by changing the mounting position of the detector IM 11M12A01 03E 12 9 12 2 2 5 12 2 2 6 12 10 Alarm 9 Exhaust Gas Temperature Alarm When mA input is selected in the Exhaust gas setup display this alarm occurs if the exhaust gas temperature exceeds the set alarm values The following are probable causes 1 The temperature transmitter output range does not meet the analyzer Exhaust gas setup if this alarm occurs when the equipment starts up 2 Thermocouple s connected to the temperature transmitter may be defective discon nected 3 Temperature transmitter may be defective 4 Exhaust gas temperature may exceed the set alarm value lt Locating cause of failure and countermeasures gt 1 Check that the temperature transmitter output temperatures at 4 and 20 mA meet the temperatures at 4 mA and 20 mA set with this equipment 2 Check that an actual exhaust gas is normal Press the detailed data display key to display and check that the exhaust gas temperature in the displayed detailed data is normal If this value is outside the temperature transmitter s normal output the thermocouple s connected to the temperature transmit ter may be damaged disconnected See the applicable temperature transmitter instruc t
186. recommended that rather than tuning it on and off power be continuously supplied to the High temperature Humidity Analyzer if it is used in an application where it is used periodically It is also recommended to flow a span gas instrument air beforehand Supply power to the converter A display as in Figure 7 1 which indicates the detector s sensor temperature then appears As the heat in the sensor increases the temperature gradually rises to 750 C This takes about 20 minutes after the power is turned on depending somewhat on the ambient temperature and the measured gas temperature After the sensor temperature has stabilized at 750 C the converter is in measurement mode The display panel then displays the oxygen concentration as in Figure 7 2 This is called the basic panel display 3195 0 0 C H20 4 00mA Output1 4 00mA Output1 4 00mA Output2 4 00mA Output2 Figure 7 1 Display of Sensor Figure 7 2 Measurement Mode Display P Ae F7 02E EPS Temperature During Warmup IM 11M12A01 03E 7 Startup 7 4 Touchpanel Switch Operations 7 4 1 Basic Panel and Switch The converter uses a touchpanel switch which can be operated by just touching the panel display Figure 7 3 shows the basic panel display The switches that appear in the switch display area vary depending on the panel display allowing all switch operations Table 7 1 shows the switch functions Tag na
187. rected 10 1 5 French display added to Language Selection 11 1 3 IM11M12A01 21E added to reference document ZR22A Heater Assembly added to CMPL 11M12A01 03E Edition Date Remark s 4th July 2003 Style of model ZR22G and ZR22A changed to S2 Notation of flange specification unified G7004XF K9473XG Airset added CMPL 11M12A01 03E Cell assembly parts no change revised to 4th edition 5th Dec 2003 Changes of related by ROM and Main Board Assembly changed 6th Apr 2005 Revised Section Introduction Added description in DANGER Added description regarding modification 1 2 1 System Components Changed part numbers of air set in table 2 2 1 Changed terminal box paint colors 2 3 1 Changed safety and EMC conforming standards and paint colors 2 4 2 Changed Finish color 2 5 Added description Non CE Mark 2 6 3 Air Set Changed part numbers and drawing of air set 4 2 1 Piping Parts for System 2 Change part numbers of air set in Table 4 2 5 3 3 Added WARNING 11 2 1 Added instruction in CAUTION 12 1 1 Added description in Error 2 of Table 12 1 Type of Errors and Reasons for Occurrence 12 1 2 1 Changed reference information 12 1 2 2 Added descriptions 12 2 1 Added Alarm 13 in Table 12 2 Types of Alarms and Reasons for Occurrence 12 2 2 9 Added Section 12 2 2 9 Alarm 13 Battery Low Alarm 7th Sep 2006 Revised Section 2 6 3 Air Set Part No K9473XH or K9473XJ Standard Specification Changed descriptions partly Air
188. remove the terminal cover to gain access to the converter external wiring terminals see Figure 5 2 A CAUTION 5 1 1 Front door 5 1 2 Wiring IM 11M12A01 03E After wiring necessary cable to the converter terminals be sure to fix the terminal covering plate with two screws again SSS HEATER POWER Terminals are visible when the terminal cover is removed Cable inlet F5 2E EPS Figure 5 2 Terminals for external wiring in the converter Connect the following wiring to the converter It requires a maximum of eight wiring connections as shown below 1 Detector output connects the converter with the detector 2 Detector heater power connects the converter with the detector 3 Analog output signal 4 Power and ground 5 Contact output 6 Operation of the solenoid valve of automatic calibration unit 7 Contact input 8 Temperature input Model ZR402G Separate type Zirconia High Temperature Humidity Analyzer Model ZR22G Separate type Zirconia Converter High Temperature Humidity Analyzer Detector 4 20 MA DC output 2 Digital output 4 20 mA DC o i output Analog lt D 1 273 74 75 6 7 78 7 9 10 11 FG AO1 AO1 AO2 AO2 CJ CJ TC TC CELL CELL CELL CELL TC TC CJ CJ O1 LOL QT LOL D 0 G HTC 12 13 14 15 16 17 18 19 20 21 22 FG DI 1
189. ring from terminals 3 and 4 of the detector and measure the resistance value between these terminals The thermocouple will be considered normal if the resistance value is 50 or less If the value is higher than 50 it may indicate thermocouple wire breakage or a state in which the thermocouple wire is about to break In this case replace the heater unit refer to Section 11 1 3 Replacement of the Heater Unit Also check that the wiring resistance between the converter and detector is 100 or less IM 11M12A01 03E 12 3 12 1 2 3 12 4 5 Even if items 2 to 4 are normal the heater overcurrent protection fuse may have blown Check for wiring problems such as the following 1 Heater terminals shorted 2 Heater terminal s shorted to ground 3 Heater terminals shorted to power supply If the internal fuse blows this cannot be replaced by the user Contact your Yokogawa service representative A CAUTION e Measure the thermocouple resistance value after the difference between the detector tip temperature and the ambient temperature decreases to 508C or less If the thermocouple voltage is large accurate measurement cannot be achieved Error 3 A D Converter Failure Error 4 Writing to memory Failure e A D Converter Failure It is suspected that a failure has occurred in the A D converter mounted in the electrical circuits inside the converter e Writing to memory Failure It is suspected that a failure has occurred
190. rn time If you want to set one hour enter 060 10 7 10 1 4 Entering Tag Name You can attach a desired tag name to the equipment To attach it follow these steps 1 Select the Setup key from the basic panel display to display the Execution Setup display Then select Maintenance from the Execution Setup display 2 Select the Display setup from the Maintenance display 3 Select the Display item from the Display setup display The display shown in Figure 10 6 then appears 4 Select the Tag name from the Display item The text data entry display then appears 5 Enter up to 12 alphanumeric characters including codes for the desired tag name Display item Primary value Humidity Secondary value mA ouput1 e Tertiary value mA output2 CP Tag name F10 6E EPS Figure 10 6 Display Item Display 10 1 5 Language Selection You can select either English German or French as the language for the display If you selected an English display basic code E for the display at the time of purchase English has already been selected for the language To select the language you want follow these steps 1 Select the Setup key from the basic panel display to display the Execution Setup display Then select Maintenance from the Execution Setup display 2 Select the Display setup from the Maintenance display 3 Select Language from the Display setup display The language
191. rom the alarm setpoint range canceling the alarm status If hysteresis is set alarms will be canceled when the measured value is less than or greater than the preset hysteresis values If both the delay time and hysteresis are set an alarm will be issued if the measured value is in the alarm setpoint range and the delayd time has elapsed When the alarm is reset canceled it is required that the measured value be beyond the preset hysteresis value and that the preset delay time has elapsed Refer to Figure 8 4 for any further alarm output actions The delay time and hysteresis settings are common to all alarm points Alarm range High limit alarm setpoint Hysteresis 2 0 Humidity Delay time Delay time Delay time 5 seconds 5 seconds 5 seconds Alarm output ON OFF F8 4E EPS Figure 8 4 Alarm Output Action IM 11M12A01 03E 8 9 In the example in Figure 8 4 the high limit alarm point is set to 7 5 the delayed time is set to five seconds and hysteresis is set to 2 Alarm output actions in this figure are expressed as follows 1 Although the measured value A has exceeded the high limit alarm setpoint A falls lower than the high limit alarm setpoint before the preset delayed time of five seconds elapses So no alarm is issued 2 The measured value B exceeds the high limit alarm setpoint and the delayed time has elapsed during that measurement So an alarm results 3 Although the measured va
192. rsed Check the connection from the detector Causes considered for cases where Error 2 occurs independently are shown below 1 Faulty heater in the detector heater wire breakage 2 Faulty thermocouple in the detector 3 Faulty cold junction sensor located at the detector terminal block 4 Failure in electrical circuits inside the converter 5 Heater temperature control overcurrent limiting triggered 6 TC TC thermocouple terminals wired to detector with reverse 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 resulting in Error 2 temperature failure lt Locating cause of failure and countermeasures gt 1 Turn off power to the converter 2 Remove the cable from terminals 7 and 8 of the detector and measure the resistance value between these terminals The heater unit will be normal if the resistance is lower than about 900 If the resistance value is higher failure of the heater unit is suspected In this case replace the heater unit refer to Section 11 1 3 Replacement of the Heater Unit In addition check that the wiring resistance between the converter and detector is 100 or less 3 Ensure that TC terminal terminal 3 in detector is connected to converter TC terminal and TC terminal terminal 4 is connected to converter TC terminal 4 Remove the wi
193. s placed F11 2E EPS Figure 11 2 Installing the Contact 2 Next make sure that the O ring groove on the flange surface of the sensor is clean Install the metal O ring in that O ring groove and then insert the sensor in the probe while turning it clockwise After inserting it until the metal O ring comes in contact with the probe s O ring contact surface properly align the U shaped pipe insertion holes with the bolt openings 3 Attach the U shaped pipe to its support with filter then fully insert the U shaped pipe and its support with filter 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 four bolts uniformly by hand and then use a torque wrench to tighten all areas of the metal O ring uniformly that is to make sure the sensor flange is perfectly horizontal to the O ring s working face in the probe This is done by tightening first one bolt and then its opposing bolt each 1 8 turn and then one of the other bolts followed by its opposing bolt each also 1 8 turn This continues in rotating fashion until they are all fully tightened with the torque wrench preset to approximately 5 9 N m If they are not uniformly tightened the sensor or heater may be damaged IM 11M12A01 03E 11 Inspection and Maintenance Metal O ring U shaped pipe support Bolts four Q a go ee gear Filter bo U shaped pipe Washers four
194. s shown in Figure 8 22 5 Point to the Purging time and press the Enter key Then the display for selecting purging time appears 6 Enter the desired numeric value from the numeric data entry display The allowable input ranges from 0 to 60 minutes 8 22 IM 11M12A01 03E 8 Detailed Data Setting Others A Purging A Clock CP Purging time 0 min Averaging al pu Fuel setup H H Cp Purging Unit setup Passwords 4 Defaults Enter YE Figure 8 21 Other Settings Figure 8 22 Purging Display 8 6 5 Setting Passwords The analyzer enables password settings to prevent unauthorized switching from the Execution Setup menu to lower level menu displays Set passwords for calibration blowback and maintenance use and for setup use individually Proceed as follows 1 Press the Setup key in the basic panel display to display the Execution Setup display 2 Choose Setup to display the Commissioning Setup display 3 Choose Others and then Passwords to display the Passwords display shown in Figure 8 20 4 Choose Calibration Blow back and Maintenance to set passwords for calibration blow back and maintenance respectively 5 The text entry display then appears Enter up to eight alphanumeric characters as the password 6 In the same manner follow steps 1 through 5 above to set a password for setup 7 Record passwords to manage them appropriately Pass
195. s tube To clean the tube follow these steps 1 Remove the detector from the installation assembly 2 Following Section 11 1 2 later in this manual remove the four bolts and associated spring washers that tighten the sensor assembly and the pipe support as well as the U shaped pipe 3 Use a rod 2 to 2 5 mm in diameter to clean the calibration gas tube inside the probe In doing this keep air flowing from the calibration gas inlet at about 600 ml min and insert the rod into the tube 3 mm inside diameter However be careful not to insert the rod deeper than 40 cm for a general purpose detector or 15 cm for a high temperature detector 4 Clean the U shaped pipe The pipe can be rinsed with water However it should be dried out thoroughly before reassembly 5 Restore all components you removed for cleaning Follow Section 11 1 2 to restore all components in their original positions Be sure to replace the O ring s with new ones Exploded view of components Calibration gas tube Rod with outside diameter of 2 to 2 5 mm F11 1E EPS Figure 11 1 Cleaning the Calibration Gas Tube 41 2 IM 11M12A01 03E 11 Inspection and Maintenance 11 1 2 Replacing the Sensor Assembly IM 11M12A01 03E The performance of the sensor cell deteriorates as its surface becomes soiled during operation Therefore you have to replace the sensor when its life expectancy expires for example when it can no longer satisfy a
196. se the decimal point position is already fixed so just enter 00098 New value 000 98 O2 F7 4E EPS Figure 7 4 Numeric data Entry Display To enter a password in combination with text data numeric values and codes the alphabetic character entry panel display first appears If you press any numeral key 0 to 9 the current display then changes to the numeric value entry panel display enabling you to enter numeric values If you press the other key the current display then changes to the code entry display enabling you to enter codes These displays alternate between the three Figure 7 5 shows the relationship between these three displays Three alphabetic characters and three codes are assigned for each individual switch If the alphabetic character key is pressed and held three characters appear in turn Move the cursor to the desired character and release the key to enter it If an incorrect character is entered move the cursor to re enter the characters The following shows an example of entering abc 123 7 5 Operation Display Press the ABC key once Press and hold the ABC key AA B C Release the ABC key when the character B AB appears in the cursor position Enter the character C in the same manner ABC as above Press the other key Press and hold the amp key and enter ABC Then press the 0 9 key Enter the numeric characters 1
197. selection display as shown in Figure 10 7 then appears Display setup Display item Al Trend graph Auto return time 0 min CP Language ET Deutsch v Fran ias Figure 10 7 Display Setup Display 10 8 IM 11M12A01 03E 10 Other Functions 10 2 Blow back 10 2 1 Blow back Setup The following sections describe the blow back setup procedures required for carrying out blow back 10 2 1 1 Mode There are three blow back modes available 1 No function blow back disabled 2 Semi automatic in this mode touchpanel operations or contact input signals will start and perform blow back operations according to a preset time and output stabilization time 3 Automatic performs blow back operations automatically according to a preset interval These three modes each have the specific limitations described below e If No Function is selected No blow back operations are executed e If Semi auto is selected semi automatic blow back can be executed but no calibration is made even when the automatic calibration startup time is reached e If Auto is selected automatic blow back can be executed in either the Auto or Semi auto mode To select the desired mode follow these steps 1 Select the Setup key from the basic panel display to display the Execution Setup display Then select Maintenance from the Execution Setup display 2 Select the Blow
198. ssembly Normally replace the sensor metal O ring and contact together at the same time If required also replace the U shaped pipe bolts filter and associated spring washers 2 Removal procedures 1 Remove the four bolts and associated washers from the tip of the detector probe 2 Remove the U shaped pipe support together with the U shaped pipe Remove filter also 3 Pull the sensor assembly toward you while turning it clockwise Also remove the metal O ring between the assembly and the probe When replacing the assembly be careful not to allow any flaws on the tip of the probe with which the metal O ring comes in contact the surface with which the sensor flange also comes in contact Otherwise the measurement gas will not be sealed 4 Use tweezers to pull the contact out of the groove 5 Clean the sensor assembly especially the metal O ring contact surface to remove any contaminants adhering to that part If you can use any of the parts from among those removed also clean them up to remove any contaminants adhering to them Once the metal O ring has been tightened it can no longer be used So be sure to replace it 11 3 3 Part assembly procedure 1 First install the contact Being careful not to cause irregularities in the pitch of the coil spirals i e not to bend the coil out of shape place it in the ringed groove properly so that it forms a solid contact Groove in which the contact E7042BS i
199. stabilization timeout alarm If set ON then contact output occurs when startup power stabilization timeout alarm alarm 8 occurs see Sec 12 2 1 Alarms alarm be set on beforehand see Section 8 3 Error Warm up If Error ON is selected contact output occurs when an error results See Chapter 12 Troubleshooting If Warm up ON is selected contact output occurs during warm up For the definition of warm up see Section 8 2 1 Output range change If Range Change ON is selected contact output occurs answer back signal to a range change signal while a range change signal is applied to a contact input To do this it is required in input contact setup that the range change be selected beforehand For more on this see Section 8 5 Calibration If Calibration ON is selected contact output occurs during calibration For the definition of During calibration consult Section 8 2 1 Maintenance If Maintenance ON is selected contact output occurs during maintenance For the definition of During maintenance consult Section 8 2 1 Blow back If Blow back ON is selected contact output occurs during blow back For the definition of During blow back consult Section 8 2 1 High limit temperature alarm Not supported by the oxygen analyzer Calibration gas press low If Cal gas press low ON is selected contact output occurs answer back signal to a c
200. status Replace the sensor Is an error indicated assembly and temporarily The analyzer operates normally on the display place the analyzer in the operating status No See Section 11 1 2 for the replacement procedure A failure in the detector or P the converter is suspected End EL Contact Yokogawa Electric Corporation F12 1 2E EPS 12 2 IM 11M12A01 03E 12 Troubleshooting 12 1 2 2 Error 2 Heater Temperature Failure This error occurs if the detector heater temperature does not rise during warm up or if the temperature falls below 730 C or exceeds 780 C after warm up is completed In addition when error 2 occurs alarm 10 cold junction temperature alarm or alarm 11 thermocouple voltage alarm may be generated at the same time Be sure to press the error indication to get a description of the error and confirm whether or not these alarms are being generated simultaneously If Alarm 10 is generated a failure in the cold junction system is suspected In this case follow the procedure according to troubleshooting for alarm 10 in Section 12 2 2 5 If Alarm 11 is generated a failure in the thermocouple system located in the detector heater is suspected In this case follow the procedure according to troubleshooting for Alarm 11 in Section 12 2 2 6 If this failure occurs immediately after the power is supplied the polarity at thermocouple input connection TC TC on the converter may be reve
201. t Section 8 1 Current Output Settings later in this manual 7 7 1 Analog Output Setting Select any one of the analog output settings Oxygen Humidity and Mixing from the mA output range display If the HS option is specified at the time of purchase the equipment is a humidity analyzer For other than this setting the analyzer is an oxygen analyzer If a mixed measurement is required change the current output setting as given below If the humidity analyzer is specified in the above detector type setting the analog output is set to humidity when the data initialization is attempted 1 Select the Setup from the Execution Setup display 2 From the Commissioning Setup display select mA output setup the display shown in Figure 7 9 then appears 3 Select mA output from the mA outputs display The mA outputl range display shown in Figure 7 10 then appears 4 Select the Parameter then the Oxygen Humidity and Mixing appear in the mA output range display Figure 7 10 1 Select Mixing and press the Enter key 5 The Mixing in Figure 7 10 2 appears 6 Perform the same setting in mA outpout2 if necessary mA outputs mA outputi range Both outputs are 4 20mA Cr Parameter Humidity Set range CF mA output1 al Min humidity conc 4 z M mA output2 0 H20 Set presets Max humidity conc 25 H20 qa Output damping Os
202. te the valve of the Flow Setting each time calibration is made starting and stop ping the calibration gas flow and adjusting the flow rate This applies even if you are using the ZR40H Autocalibration Unit For operation of the converter see Section 7 11 earlier in this manual 10 6 1 Preparation Before Calibration To operate the ZA8F Flow Setting Unit prepare for calibration as follows 1 Check for a complete closing of the zero gas flow setting valve in the unit and open the regulator valve for the zero gas cylinder until the secondary pressure equals measured gas pressure plus approx 50 kPa or measured gas pressure approx 150 kPa when used with check valve 300 kPa maximum 2 Check that the oxygen concentration of the zero gas and span gas instrument air 21 vol O2 in the cylinder is set in the converter 10 6 2 Operating the Span Gas Flow Setting Valve The following description is given assuming that instrument air the same as the refer ence gas is used as the span gas 1 When the display shown in Figure 10 15 appears during calibration 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 To check the flow rate use the calibration flow meter If the measurement gas pressure is extremely high adjust the measurement gas pressure to obtain pressures listed in Table 10
203. the analyzer 24 V DC Input resistance of the analyzer Maximum 250 Q The load resistance of the transmitter is the total of wiring resistance and input resistance Temperature Transmitter Burnout When outputting a burnout signal of the temperature transmitter with a contact output of the analyzer use high limit temperature alarm Refer to Section 8 4 Contact Output Setting In this case set the burnout signal of the temperature transmitter to exceed the high limit 20 mA or more 5 9 2 Cable Specifications Use a two core shielded cable for wiring 5 9 3 Wiring Procedure 1 M4 screws are used for the converter terminals Cables should be equipped with appropriate crimp contacts Ensure that the cable shield be connected to the FG terminal of the converter 2 Be sure to connect and polarities correctly 5 16 IM 11M12A01 03E 6 Components 6 Components In this chapter the names and functions of components are described for the major equipment of the EXAxt ZR Separate type Zirconia High temperature Humidity Ana lyzer 6 1 ZR22G Detector 6 1 1 General purpose Detector Terminal box Non explosion proof JIS C0920 equivalent to IP44D Equivalent to NEMA 4X IP66 Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version Flange used to mount the detector Select from JIS or ANSI yg Probe z Is At
204. the crossover 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 KQ resistance between the cross over wiring and ground to discharge 6 Testing between the heater terminal and ground contact output terminal and ground analog output input terminal and ground can be conducted in the same manner 7 Although contact input terminals are isolated insulation resistance test cannot be conducted because the breakdown voltage of the surge preventing arrester between the terminal and ground is low 8 After conducting all the tests replace the jumper plate as it was Separate type Zirconia High Temperature Humidity Separate type Zirconia High Temperature resistance tester Analyzer ZR402G Converter Humidity Analyzer ZR22G Detector Insulation 24 27 28 29 30 31 32 33 34 35 36 23 25 26 DO 1 DO 1 DO 2 DO 2 DO 3 DO 3 DO 4 DO 4 HTR HTR L N G HTR HTR i 1 i 1 i f i it 1 i lt D n ni i 1 2 4 6 7 8 9 10 11 i i FG AO AO1 AO2 AO2 CJ CJ TC TC CELL CELL 11 CELL ICELL TC
205. the heater thermocouple signal wiring are shorted out in the wiring extension or at the connection terminals 3 A failure of the thermocouple at the detector heater assembly occurred 4 A failure of the electrical circuits inside the converter occurred lt Locating cause of failure and countermeasures gt 1 Stop the power to the converter 2 Remove the wiring from terminals 3 and 4 of the detector and measure the resistance between these terminals If the resistance value is 50 or less the thermocouple seems to be normal If it is higher than 5Q it may indicate the possibility that the thermocouple has broken or is about to break In this case replace the heater unit refer to Section 11 1 3 Replacement of the Heater Unit IM 11M12A01 03E 12 11 A CAUTION e Measure the thermocouple resistance value after the difference between the detector tip temperature and ambient temperature falls to 50 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 the wiring cable is securely connected to the terminals Also check that the wiring resistance between the converter and the detector is 10Q or less 4 If there is no failure in the wiring the electrical circuits inside the converter may possibly fail Contact the service personnel at Yokogawa Electric Corporation 12
206. the sensor If impossible to do the above remove the detector 2 If unavoidably impossible to supply the power and removing the detector keep on following air at 600ml min into the calibration gas pipe lt Restarting Operation gt When restarting operation be sure to flow air for 5 10 minutes at 600ml min into the calibration gas pipe before supplying the power to converter 11 8 IM 11M12A01 03E 11 Inspection and Maintenance 11 2 Inspection and Maintenance of the Converter The converter does not require routine inspection and maintenance If the converter does not work properly in most cases it probably comes from problems or other causes A dirty touchpanel should be wiped off with a soft dry cloth 11 2 1 Replacing Fuses The converter incorporates a fuse as indicated in Figure 11 5 If the fuse blows out replace it in the following procedure A CAUTION e If a replaced fuse blows out immediately there may be a problem in the circuit Go over the circuit completely to find out why the fuse has blown e This fuse is for protecting the main power supply circuit and does not provide overcurrent protection for the heater temperature control circuit For overcurrent protection circuitry refer to Section 12 1 2 2 Heater Temperature Failure Fuse F11 5E EPS Figure 11 5 Location of Fuse in the Converter IM 11M12A01 03E 11 9 11 2 2 Cleaning To replace the fuse follow these steps 1 Turn o
207. titres 10 19 10 5 3 Calibration Gas FlOW ii 10 20 10 6 Methods of Operating Valves in the ZA8F Flow Setting Unit 10 23 10 6 1 Preparation Before Calibration ce eceesessecseeeeseeseeeseeceseeereeeeeens 10 23 10 6 2 Operating the Span Gas Flow Setting Valve n 10 23 10 6 3 Operating the Zero Gas Flow Setting Valve oo eee eeeeeeeeee 10 24 10 6 4 Operation After Calibration ss 10 24 xi xii 11 Inspection and Maintenance esssesssocesocesoocesocsssecesocesocesoocesoccssocesocesooessoesssesssesese L 1 1 11 1 Inspection and Maintenance of the Detector s esseesseeeeereereseeersesresrsereeeee 11 2 11 1 1 Cleaning the Calibration Gas Tube seseeeesseeessseesrsssereesrerrereeresesreses 11 2 11 1 2 Replacing the Sensor Assembly 0 eee ceeeeeceeeeceeceeeeeeeseecnecseecneenaes 11 3 11 1 3 Replacement of the Heater Unit occ ceeeeeecseessecneesaeeneenaes 11 5 11 1 4 Replacement Of OTING i cisccscscsssscesstescssesesebocnonsonsesshp sbensesbeassnasesosacs 11 8 11 1 5 Stopping and Re starting Operation 11 8 11 2 Inspection and Maintenance of the Converter 11 9 112 1 Replacing Fuses sn Rennes ies Dens EEEE 11 9 11 2 2 Cle am Gs cesses suis das eenean eantas hassaagcoadeabssaceudeshesssadiastes EESE 11 10 11 2 3 Adjust LCD screen Contrast 0 0 eeeceseeeseeseecseceecaeceseeseesseeseeneees 11 10 11 3 Replacing Flowmeter in ZR40H Autocalibration Unit ee 11 11 T2 Troubleshootiht oes Ses nn ts
208. tration of the sealed gas following instructions on the converter display Also check that no piping is disconnected Thus the work of installing a gas cylinder is completed However gases in the cylinders cannot immediately 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 19 10 5 3 Calibration Gas Flow lt Preparation before calibration gt 1 To operate the standard gas unit place it on a nearly horizontal surface in order to allow the flow check to indicate the precise flow rate In addition a power supply for driving the span gas air supply pump is required near the unit the length of the power cord attached to the unit is 2 m Select a suitable location for the unit near the installation site of the converter 2 Connect the tube connector port of the standard gas unit to the calibration gas inlet of the detector using a polyethylene resin tube with an outside diameter of 6 mm Be careful to prevent gas leakage 3 Fully open the needle valve mounted on the calibration gas inlet of the detector 4 Enter the oxygen concentration of the sealed gas noted from the cylinder into the converter Also check that the oxygen concentration of the span gas is correctly set 21 vol O2 for clean air When using the ZO21S Standard Gas Unit for use of the atmospheric air as a span gas use a hand held oxygen
209. tt ie insectes LEE 12 1 Displays and Measures to Take When Errors Occur ou eee eeeeeeeereeeee 12 1 121 1 What isan EITOT Let nn dent les sn E E unies 12 1 12 1 2 Measures to Take When an Error Occurs c cccccceesssececeeessneeeeeeenees 12 2 12 2 Displays and Measures to Take When Alarms are Generated 12 5 12 2 1 What 1s an Alarm 52 6 ciceisssccsvesisiesesice a mnt a AEE E ARES 12 5 12 2 2 Measures Taken When Alarms are Generated 0 cccccccsssseeeees 12 7 12 3 Countermeasures When Measured Value Shows Error cccceeeseeeee 12 13 12 3 1 Measured Value Higher Than True Value 12 13 12 3 2 Measured Value Lower Than True Value cccccsssccccecesssteeeeees 12 14 12 3 3 Measurements Sometimes Show Abnormal Values cc ccceeee 12 14 Customer Maintenance Parts List ses CMPL 11M12A01 03E Customer Maintenance Parts List ses CMPL 11M12C01 01E Customer Maintenance Parts List ses CMPL 11M12A01 11E Customer Maintenance Parts List ses CMPL 11M3D1 01E R vision Record icaicissiscesccdicccsisscscescadecscesussececnes beaccsonedccecececaaencoas Cates bescansocccasCecsessecoucececasee 1 IM 1M12A01 03E 1 Overview 1 Overview IM 11M12A01 03E The EXAxt ZR Separate type Zirconia High temperature Humidity Analyzer is used to measure the humidity of hot gases continuously in driers which use hot gas or electricity as the heat source It can also be used in a variety of manufact
210. ues Item Data to be initialized Default setting Equipment selection Type of equipment Not initialized Detector ZR22 Measurement gas Wet gas Displayed data Display item Ist display item Humidity 2nd display item Current output 1 3rd display item Current output 2 Tag name Deleted Trend graph Parameter Sampling interval Humidity 30 seconds Upper limit graph 25 O2 Lower limit graph 0 O gt Automatic return time 0 min Language Not initialized Calibration data Calibration setting Mode Manual Calibration procedure Span zero Zero gas concentration 1 00 O Span gas concentration 21 00 O2 Output hold time 10 min 00 sec Calibration time 10 min 00 sec Interval 30 days 00 hr Start date 10 01 00 Start time 00 00 Blow back Blow back setting Mode No function invalid Output hold time 10 min 00 sec Blow back time 10 min 00 sec Interval 30 days 00 hr Start date 01 01 00 Start time 00 00 Current output data mA output 1 mA output 2 Parameter Humidity Min oxygen concentration 0 O Max oxygen concentration 25 Oz Output damping 0 Output mode Linear Output hold setting to be continued next page Warm up 4mA S
211. uring applications in humidifiers as well as in driers for humidity measurement and control It can help improve productivity in these application fields The ZR402G Separate type converter is equipped with an LCD touchpanel which has various setting displays a calibration display humidity trend display with easier operation and improvement of display functions The converter is equipped with various standard functions such as measurement and calculation as well as maintenance func tions including a self test Analyzer calibration can also be fully automated and ZR40H the automatic calibration unit is provided Choose the detector which best suits your needs so that an optimal humidity control system can be obtained Some examples of typical system configuration are illustrated following pages 1 1 1 1 lt EXAxt ZR gt System Configuration 1 1 1 1 2 System 1 The system configuration should be determined by the conditions e g whether the calibration gas flow should be automated The system configuration can be classified into three basic patterns as follows This is the simplest system consisting of a detector and a converter This system can be implemented for monitoring humidity in a production process such as food production No piping is required for the reference gas air which is fed in at the installation site The handy ZO21S standard gas unit is used for calibration Zero gas from this unit and span gas air is
212. urs 5 After the measured value has stabilized press the Enter key to display the span calibration complete display shown in Figure 7 21 At this point the measured value is corrected to equal the span gas concentration Close the span gas flow valve The valve lock nut should be tightened completely so that the span gas does not leak Manual calibration Manual calibration Al ke a ee Span calibration NA Check the zero gas Close the span gas valve concentration value gt F Next F Zero calibration Cancel calibration End Change value 1 00 T F7 21E EPS F7 22E EPS Figure 7 21 Span Calibration Figure 7 22 Zero gas Concentration Complete Zero Calibration Start Check Display Display in Manual Calibration in Manual Calibration 6 Select Zero calibration as in Figure 7 21 to display the zero gas concentration check display in Manual calibration Check that the zero gas oxygen concentration value and the calibration gas oxygen concentration value agree Then select Next as in Figure 7 22 IM 11M12A01 03E 7 17 7 18 7 Follow the instructions in the display as in Figure 7 23 to turn on the zero gas flow To do this open the zero gas flow valve for the Flow Setting Unit and adjust that valve to obtain a flow of 600 60 ml min The valve should be adjusted by loosening its lock nut and slowly turning the valve shaft counterclockwise Use the calibration gas flowm
213. ve the cell assembly 6 following Section 11 1 2 earlier in this manual Open the terminal box 16 and remove the three terminal connections CELL TC and TC Before disconnect the HTR terminals remove the terminal block screw 28 Keeping the other terminal remaining to be connected Disconnect the two HTR connections These terminals have no polarity Remove the two screws 15 that fasten the cover 12 and slide it to the flange side Remove the four bolts 10 and terminal box 16 with care so that the already discon nected wire will not get caught in the terminal box In case of the pressure compensation type detector remove the screw 35 and the plate 37 on the adapter 35 Remove the adapter 35 drawing out the wires of the heater strut easy 23 from it Loosen Screw 19 until Heater Strut Assembly 23 plate can be removed There s no need to remove O ring 18 which prevents Screw 19 from coming out Pull out connector 13 Loosen and remove the screw 8 with a special wrench part no K9470BX or equiva lent and then remove the heater strut assembly 23 from the detector 24 To reassemble the heater strut assembly reverse the above procedure Insert the heater strut assembly 23 into the detector 24 while inserting the calibration pipe in the detector 24 into the heater section in the heater strut assembly 23 as well as in the bracket hole Coat the screw 8 with grease NEVER SEEZ G706
214. wiring connection to converter terminals CELL and CELL Also check the wiring connection in the repeater terminal box if it is used Is there any breakage or poor contact in the wiring to the converter terminals Replace the damaged portions ara aa a Examine the wiring connection status to detector terminals 1 and 2 Also check that terminals and cable conductors are not corroded Replace the damaged portions R esse sense Remove the sensor assembly from the detector and check for the presence of corrosion that may cause a poor contact between the electrode and the contact also check for dirt A sensor assembly in which no abnormality is found may be used again However be sure to use a new metal O ring and contact even in such a case Replace the sensor assembly Is the sensor extremely dirty corroded or broken See Section 11 1 2 for the replacement procedure clei ela a Remove the wiring conductors from detector a terminals 1 and 2 and short out the removed conductors Measure the resistance of these wiring conductors on the converter side The resistance value is normal if it indicates 10 Q or less Is there any disconnection or poor continuity in the wiring between the detector and converter Replace the wiring cable 27 Turn on the power to the converter and temporarily place the analyzer in the operating
215. words dx Calibration Blow back and Maintenance J Commissioning Figure 8 23 Passwords Display If you forget a password select Setup in the Execution Setup display and enter MOON By doing so you can enter the Setup display only Then display the Passwords and verify the set passwords IM 11M12A01 03E 8 23 8 24 IM 11M12A01 03E 9 Calibration 9 Calibration The following describes the calibration procedures for the EXAXTZR Zirconia High temperature Humidity Analyzer 9 1 Calibration Briefs 9 1 1 Measurement Principle of Zirconia Humidity Analyzer IM 11M12A01 03E A solid electrolyte such as zirconia allows the conduction of oxygen ions at high temperatures Therefore when a zirconia plated element with platinum electrodes on both sides is heated up in contact with gases having different partial oxygen pressures on each side oxygen ions flow from a high partial oxygen pressure to a low partial oxygen pressure causing a voltage When a sample gas introduced into the zirconia plated element with the measurement electrode and air 21 0 vol O is flowed through the reference electrode an electromotive force mV is produced between the two elec trodes governed by Nernst s equation as follows E RT nF log e y a ue cece cece eeeeeceeeeeees Equation 1 where R Gas constant T Absolute temperature n 4 F Faraday s constant y O vol on the zirconia element measurement ele
216. zero gas ratio of 100 30 or a span gas ratio of 0 18 In addition the sensor assembly is to be replaced if it becomes damaged and can no longer operate during measurement If the sensor becomes no longer operable for example due to breakage investigate the cause and remedy the problem as much as possible to prevent recurrence A CAUTION e If the sensor assembly is to be replaced allow enough time for the detector to cool down from its high temperature Otherwise you may get burned If the cell assembly is to be replaced be sure to replace the metal O ring and the contact together Additionally even in a case where the cell is not replaced if the contact becomes deformed and cannot make complete contact with the cell replace the contact e If there 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 sensor assemblies manufactured in or after Sept 2000 the serial number on the side of the sensor assembly should be 0J000 or later for example 0K123 1AA01 etc 1 Identifying parts to be replaced In order not to lose or damage disassembled parts identify the parts to be replaced from among all the parts in the sensor a

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