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Model OX102 Current limit type Oxygen Analyzer

1. 212 J 96 K 10 180 22 YOKOGAWA TENE ING D LI ppm O D NM L ALM FAIL PASS Dj 38 7 4 20mA 9 SNSR sos sss Cs Jen B Weight Approx 1 2 kg Panel Dimensions E 1 89 100 Allow a minimum of 115 mm if easy N removal for servicing is required 89 55 100 Panel Cutout Minimum Clearance Required for side by side installation of multiple analyzers NC 141004 240110 VAC II C9 C9 C9 C9 9 C9 e9r 9 ORBIS 7 SNSR RENNES G Terminal Configuration F1301E EPS Figure 1 1 Converter Unit mm IM 11M10A01 03E 1 5 1190 i 81 150 gaxo5 T 3 41 Il Hc j ha 50 pa Temp 250 C Max Temp 150 C Max Temp 70 C Max
2. CAL3 is for 0 1000 ppm rH range calibration ppm e Assuming the O2 concentration of calibration gas is 995 ppm enter this value using A Jand Lv keys ICM O I LIL ppm e Entering calibration value Calibration completed 99G O Y ppm e CALA to the following page IM 11M10A01 03E 6 Operation Measurement Mode ES Stop supplying calibration gas No 3 A Supplying calibration gas No 5 O2 concentration allowance 900 1100 ppm Calibration value e Ta Tv De 2 8 Calculating Chanai eaeuatno TerareneT Calibration KA gt 4 Entered to skip calibration 2 Entered to enter calibration value 3 Entered to return to measurement mode E634 EPS 6 19 10000 ppm Oz Calibration CAL4 is for 0 10000 ppm range calibration Assuming the O2 concentration of calibration gas is 9310 ppm enter this value using and keys 6 20 Measurement Mode Continued from CAL 3 A Indication GAT Stop supplying calibration gas No 5 r g ul ppm e CAL 4 Supplying calibration gas No 6 O2 concentration Lx allowance 8500 9500 ppm CAL ppm CAL gt Calibration value Entering calibration value 4 ed B7 NO li Calibration accepted Calibration completed m pp v CAL5 to the following page gt 1 Entered to skip calibration 2 Entered to ent
3. O T ESE o To the factory default values F6321E EPS Figure 6 9 Flow Chart of Sensor Parameter Resetting IM 11M10A01 03E IM 11M10A01 03E 7 Key lock This is to lock each key operation Indication Flow Chart F6322E EPS C While the PASS lamp is on the key lock mode is enabled so that key operations are not permitted Figure 6 10 Flow Chart of Key Lock 6 Operation 6 15 6 4 Calibration 6 16 1 Calibration This mode is to calibrate the OX102 oxygen analyzer using the calibration gases including atmospheric air Enter the known concentration value of a calibration gas and then analyzer apply the calibration gas to the sensor and calibrate the sensor The calibration requires calibration gases with known concentrations 1000 ppm O or 10000 ppm O calibration gases and the calibration kit Before shipment a complete calibration of the OX102 oxygen analyzer from 0 100 ppm to 0 25 was performed with standard calibration gases at the factory When using the equipment right after the delivery first check the reading of the converter with the sensor in atmospheric air If the reading is within a deviation of 0 25 O from 20 9 the equipment does not need calibration and is ready for use If the reading is out by a deviation of 0 2596 O or greater the equipment needs one point calibration for each range Calibration is basically performed at one point for each meas
4. IML Measured 1 gt FII 2 I Output Changing 2 accepted value 1 When AUTO is selected the measurement mode remains unchanged 2 Use A and V keys to configure Out 1 to 4 Out 1 Full scale 2596 O2 Out 2 Full scale 10000 ppm O2 Out 3 Full scale 1000 ppm O2 Out 4 Full scale 100 ppm O2 F6308E EPS Figure 6 6 Flow Chart of 4 20 mA Output Signal Setting IM 11M10A01 03E 6 11 6 12 4 Configuring the 1 5 V output signal This mode is to configure the 1 5 V output signal to correspond to a fixed range Configure the signals following the procedure shown in the flow chart below This output signal is always set to correspond to a fixed range Therefore even if automatic range switching is selected this output signal should be configured for each range Indication cub Figure 6 7 Flow Chart of 1 5 V Output Signal Setting Operational Flow Chart Measured ppm O Value V 4 20mA O Out 1 4 Use A and V keys to configure Out 1 to 4 Out 1 Full scale 25 O2 Out 2 Full scale 10000 ppm O2 Out 3 Full scale 1000 ppm O2 Out 4 Full scale 100 ppm O2 IM 11M10A01 03E Indication An CLO o m o gt oo H ALM IM 11M10A01 03E 6 Operation 5 Configuring high low alarm contact output settings This mode is to configure the oxygen concentration high low alarm contact output settingsalarm C
5. 8 1 Appendix Appendix 1 Sampling Unit K9424GA Sampling Unit for OX100 102 This sampling unit is designed for the OX100 Series Oxygen Analyzers when they are used where a sample gas contains a small amount of organic solvents isopropyl alco hol such as in reflow furnaces The sampling unit comprises two membrane filters to eliminate dust and mist a suction pump to draw a sample gas an activated carbon filter to eliminate organic solvents and a flowmeter to monitor sample gas flow rates A Notes If repair is required the is equipment will need to be returned to the factory For repair or maintenance contact your Yokogawa representative 1 Specifications Pressure at sampling point Atmospheric pressure Pressure at sample outlet Atmospheric pressure Gas temperature 50 C max Organic solvent content ppm to a few percentage level of isopropyl alcohol IPA equivalent Dust content 5 mg Nm max Life expectancy of activated carbon The expected life of the activated carbon filter is approx 50 hours when a sample gas contains 500 ppm of isopropyl alcohol and flows at 500 ml min Power supply 100 to 240 V AC 50 60 Hz Piping connection Re1 4 Operating environment temperature range 0 to 40 C Life of disk filter When specified flow is no longer possible Replace as early as possible Pump life Approximately one year when used eight hours a day Included Accessories 1 Power cord
6. Item Part No Ms code Qty Description 1 OX102 1N 2 K9424LA 3 K9424LB K9424LC K9424LD a oo Converter Sensor Sensor Cable Cable 4m Cable 9m Cable 29m All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M10A01 03E YOKOGAWA e Subject to change without notice 1st Edition Apr 2000 YK Yokogawa Electric Corporation 5th Edition Nov 2007 YK K9424GA SAMPLING UNIT E Jj UJ uJ Item Part No Qty Description 1 L9866CX 1 Flow Meter 2 K9424GN 1 Pump Assy 3 K9424HE 1 Power Unit 4 K9424GZ 1 Filter Assy 1 5 K9424GY 1 Filter Element active carbon filter 5 packs 6 E7050AC 1 Valve 7 A1109EF 1 Fuse 8 K9424GQ 1 Disk Filter 1 Comprises a stainless steel case including an activated carbon filter and a disk filter and a spere activated carbon element CMPL 11M10A01 03E All Rights Reserved Copyright 2000 Yokogawa Electric Corporation 5th Edition Nov 2007 K9424JC NEEDLE VALVE ASSY Item Part No Qty Description 1 K9424JD 1 Needle Valve Assy 2 K9424HQ 1 Regulator 5th Edition Nov 2007 All Rights Reserved Copyright 2000 Yokogawa Electric Corporation CMPL 11M10A01 0
7. Max temp 70 C when plastic nipple F1302 EPS option code J or P N L9811LA is used Figure 1 2 Sensor bim gt D sub 15 pin M Ll Model and Code L m OX102 11 4 OX102 12 9 OX102 13 29 F1303 EPS Figure 1 3 Extension cable Sample Inlet Rc1 4 Disk filter K9424GQ Sample Outlet Rc1 4 V Power Connector Gian rnm c gt r N ya i ol i e as i N Te w V ke 220 gt Needle Valve MM ba T Z a Activated e Carbon Filter TA JE WU CJ Y d Flowmeter Switch Sensor Connector D mm d F1304 EPS Figure 1 4 Sampling Unit K9424GA Optional 1 6 IM 11M10A01 03E OX102 Sensor IM 11M10A01 03E 1 Overview Unit mm Needle Valve Assembly Part Number K9424JA Description S 2 K9424JC HT DON Needle Valve Assembly with Pressure Reducing Valve Gas Vent Tubing and Fixed Throttle Sete o Rc1 8 Nominal diameter of piping ne Approx 300 connection for K9424JD Standard Calibration 3 HK Standard Gas Cylinder Qas AN amp 2 go 0 eee AA ee a HE i 5 oe Va Mos ui rtr IN l F A Na M MP E 255 Approx 340 K9424JD F1305 EPS Calibration kit 1000 ppm 6 cylinders 1L needle valve assembly with flow adjustment K9424JB Calibration kit 1000 ppm 6
8. Standard Calibration 3 Standard Gas Cylinder Gas 6 botiles box 8 _ S quo THOSE IM AB BABA 7 715 fi n e li e 1 li NEN NNUS NS NI N GU nen S iis o 255 Approx 340 K9424JD F1305 EPS Needle Valve Assembly Part Number K9424JA Description Calibration kit 1000 ppm 6 cylinders 1L needle valve assembly with flow adjustment K9424JB Calibration kit 1000 ppm 6 cylinders 1L needle valve assembly without flow adjustment K9424JR Calibration kit 10000 ppm 6 cylinders 1L needle valve assembly with flow adjustment K9424JS Calibration kit 10000 ppm 6 cylinders 1L needle valve assembly without flow adjustment For a system without flow adjustment adjust the flow rate to 500 ml min using the needle valve K9424JD TI301E EPS Figure 5 4 Calibration Kit A CAUTION Shelf life of gas cylinder The shelf life of a calibration gas shall be one year from the manufacturing date speci fied on the label of the cylinder Yokogawa shall not guarantee accuracy of the equip ment if it is calibrated with an expired calibration gas 5 4 IM 11M10A01 03E 6 Operation 6 Operation 6 1 Startup IM 11M10A01 03E This chapter explains how to operate the OX102 oxygen analyzer The startup procedure is outlined in the following chart Checking wiring and piping Checking gas flow rate when using sampling unit Applying power to co
9. Turn on the power of the OX100 Series oxygen analyzers 3 2 Stopping operation Take the following steps to stop operating the unit 1 Remove power from the OX100 Series oxygen analyzers 2 Turn off the power switch of the sampling unit 3 Close both stop valves for sampling gas intake and for gas vent completely by turning the valves clockwise completely IM 11M10A01 03E A 3 4 Maintenance When this sampling unit is used with OX100 serise Oxygen Analyzer if the sampling unit is not properly maintained the life of the Oxygen Analyzer sensor will be adversely affected drift will occur or the instrument will not calibrate Frequent filter maintenance is particularly important If zero or span need frequent adjustment check the filter first 4 1 Replacing the activated carbon pack 1 Remove the tubing from the case s lid 2 Turn the lid counterclockwise to open it 3 Remove an old filter pack 4 Open a new filter pack and follow the steps below referring to the figures to put it into the case Shape the pack into cylinders Figure 1 Put it into the case by pushing it while pulling the tug 1 to puff out the pack and folding the both top corners 2 and 3 of the pack outside Figure 2 Push the pack into the case until the top of the pack sinks under the brim Thrust the pipe protruding from the back of the lid onto the top center not on the tug and tighten the lid securely Figure 3 5 Connect th
10. 1 A1007WD AC 100 V standard A1009WD AC 200 V by special order 2 Fuse 2 A1109EF rating 1A 3 Instruction Manual 1 K9424JY IM 11M10A01 03E A 1 2 Installation The sampling unit is a desktop type and should be installed on a stand near the sampling point Note the following when installing the unit N NOTE The unit should be installed in places where Ambient temperature is in the range of 0 to 40 C and temperature fluctuations are minimal Mechanical vibration is negligible Adequate space for inspection and maintenance such as replacing filter element is secured The unit should be securely mounted on a stand to prevent dropping No exposure to rain or water is allowed Procedure 1 Feed sampling tubing from the sampling point through a stop valve to the sample gas inlet GAS IN with care not to produce gas leakage The piping connection of the sample gas inlet is Rc1 4 Use an appropriate joint for this connection 2 Feed gas vent tubing from the sampling outlet GAS OUT with care not to produce gas leakage The piping connection of the sampling gas outlet is Rc1 4 Use an appropriate joint for his connection 3 Insert a power cable to the power connector of the sampling unit SE ESTUFAS 500ml min GAS IN 0 Cy y jE gt Fi PUI c9 FM1 SENSOR sq Vi GAS OUT a s n n
11. Configuration 1 IM 11M10A01 03E 2 1 2 20 System Configuration 2 This configuration incorporating an optional sampling unit to remove organic solvents should be used when a sample gas contains such solvents at a level of a few ppm to a few percent Sensor Sampling Unit K9424GA Converter Power Supply Fail Contact Output 4 20 mA DC Output 1 5 V DC Alarm Contact F202 EPS Figure 2 2 System Configuration 2 2 2 IM 11M10A01 03E 3 Installation 3 Installation This chapter explains installation procedures for components of the OX102 oxygen analyzer 3 1 Installing the Sensor 1 Installation Site The OX102 should be installed in a place where there is adequate space for inspection and maintenance For calibration the sensor should be removed from the process and installed in the calibration kit 2 Mounting The sensor should be mounted and fixed horizontally and securely using an optional nipple so that it cannot vibrate Note the following when mounting the nipple A Notes When the measuring range used is 0 1000 10000 ppm O or 0 25 O or when the sensor is mounted in a location with severe vibration a plastic nipple L981 ILA should be used Its connection is G3 8 screw or 17 mm O D hole The maximum thickness of the mounting plate is 4 mm for a 17 mm O D hole When the measuring range used is 0 100 ppm O a metal nipple K9424DB should be used Its connection is Rc1 4 The ni
12. Value gt i Value ji li Changing ji accepted value O Gain 2 B Value ppm Value Changing accepted value on l LI v v To be continued to GIN 3 F6302 EPS IM 11M10A01 03E _ lt m Nag an al socal _ IM 11M10A01 03E O ppme O ppme O ppme 6 Operation Continued To measurement mode v ppm CAL Gain 3 A Value Value accepted Gain 3 B Value Changing value Value Changing accepted value To be continued to GIN 4 F6303E EPS 6 7 6 8 IA L1 m LI taman O ppme O ppme O ppme Continued To measurement mode af Gain 4 B Value lt A p Ez accepted value ENT A V ppm GAL gt gt accepted value v To be continued to GIN 5 F6304E EPS IM 11M10A01 03E 6 Operation Continued To measurement mode ppme ENT ppm CAL gt Gain 5 A Value p gt Value Changing accepted value i7 O T
13. a suction pump which requires power supply of 100 240 V AC A Notes The pumps and activated charcoal filter used in this equipment have limited life and periodic maintenance or replacement will be required Install this equipment in an accessible location to facilitate maintenance Maintenance conditions vary depending on the gas conditions Replacement intervals for the filter and activated charcoal should be determined in accordance with the operating conditions e Used eight hours a day pump life will be approximately one year e Filter life is about 50 hours if measured gas contains isopropyl alcohol of concentra tion 500 ppm and flow is 500 ml min IM 11M10A01 03E 4 Wiring 4 Wiring This chapter explains the procedures for wiring the converter 4 1 Precautions A Notes Do not apply power to the converter or any other devices such as alarm devices relating to the power circuit of the converter until all wiring has been completed 4 2 Wiring Types The converter requires the following wiring 1 Sensor special cable 2 Output signal two analog output 4 20 mA DC two core shielded cable 1 5 V DC fixed range only two core shielded cable 3 Range identification signal automatic range switching only two core shielded cable 4 High Low alarm contact signal 600 V rated heavy vinyl insulated wire or wire of equivalent or greater capacity 5 Fail contact signal 600 V rated
14. estrictions on Use ssssss00eoeeeec VI How to Use This Manual 0 0s0sssss0eee VIL 1 OVELVIEW ecco eo a a d ve TANANG dd eund e W oca e de eroe e a dea k ek KNA 1 1 Standard Specifications waa i5i AA AKE 1 1 1 2 Model and Suffix Codes 20s 1 4 13 External Dimensions 2 System Configuration Ka KANA eeu ea vo d e e lis eu Z1 2 1 System Configuration 1 itane nieder ette ier 2 1 2 2 System Configuration 2 siasio eer ee nennen SEVEN Evan TE E YEK 2 2 3 Installation pe ES D 3 1 Installing the Sensor eie tero eene ee ke y e 3 2 Installing the Converter 3 3 Installing the Optional Sampling Unit K9424GA 4 Wiri 4 1 4L JPrecautiOBScus cone dees AA 4 42 Waring Types Baa FERRE RO EEUU EO ERE RE PI 4 1 4 3 Terminals for External Connections bee 44 Wiring Procedures Awe 4 3 5 Component Functions maa kaa GAGA Ga 5 1 S GSES OF Aa 52 Converter iiiss cec tates ea ned Wen ena ee ee Aa oe E 5 3 Sampling Unit Optional 5 4 Calibration Kit Optional 6 CDCR ALTONA GAAN KAG leke 5 caesa repe ev d an e S sae ste vet e evita ese OFL 6 Startup 4o05 dinan tte Se Aen bs eie 6 1 6 2 Operational Flow Chart eene enne 6 3 6 3 Configuring Data Hs AA ues
15. heavy vinyl insulated wire or wire of equivalent or greater capacity 6 Power supply 600 V rated heavy vinyl insulated wire or wire of equivalent or greater capacity IM 11M10A01 03E 4 1 4 3 Terminals for External Connections 4 2 External connections should be made from the terminals on the rear side of the con verter Be careful not to make any mistakes e 14 CA 4 20 ls x 2mA 1 5V C9 i x sep CO rr RNG F3 NG z COU N C9 y Ol L C9 NC 17 1 GEO o F401 EPS Figure 4 1 Terminal Configuration FUN CAUTION e When wiring ensure that the mains power supply is disconnected to minimize the risk of electric shock Use 600 V rated heavy vinyl insulated wire JIS C3307 or wires or cables of equivalent or greater capacity for connections Connect to a ground with a ground resistance of 1000 or less Use 4 mm screw crimp on terminals with insulating sleeves for power supply and ground terminals The converter is not equipped with a power switch Use an external two pole power switch e All wiring should be attached to the installation panel so that the connection terminals and cables are
16. locknut down See Figure 2 Figure 1 Needle Lock nut Packin Container Figure 2 ra BA AP201E 1 eps A 5 2 Supplying the calibration gas Take the following steps to supply the calibration gas 1 Mount an OX100 Series sensor to the needle valve assembly by inserting 70 to 80 mm of the sensor and screwing down the locknut firmly with fingers The locknut should be finger tight only and do not use a wrench for tightening 2 Turn the pressure regulating handle of the needle valve assembly s regulator counter clockwise completely 3 Turn the handle of the needle valve clockwise until it can no longer turn so that the needle tip pokes into the gas cylinder See Figure 3 4 Turn the handle of the needle valve counterclockwise to the position shown in Figure 1 5 Turn the pressure regulating handle of the regulator gradually in a clockwise direc tion to set the pressure at approximately 0 05 MPa This allows the calibration gas to be supplied to the sensor for calibration Figure 3 AP201E 2 eps 3 Stopping supplying the calibration gas Take the following steps to stop supplying the calibration gas 1 Turn the handle of the needle valve clockwise until it meets resistance 2 Turn the pressure regulating handle of the regulator counterclockwise completely A 6 IM 11M10A01 03E EZS E E CU remrr Customer Model OX102 Maintenance Parts List Current Limit Type Oxygen Analyzer
17. the 1 5 V output setting mode used together with V key to enter the automatic manual switching mode Used for percentage indication for reading Used for ppm indication for reading used together with CAL key to enter the measurement mode from any other modes Used for entering the calibration mode Used for increasing the value during data setting Used for decreasing the value during data setting Used for confirming the data entry F5201 EPS Figure 5 2 Converter IM 11M10A01 03E 5 Component Functions 5 3 Sampling Unit Optional The sampling unit comprises membrane filters suction pump flowmeter and activated carbon filter to absorb organic solvents When a sample gas contains organic solvents use this sampling unit to filter out such solvents The expected life of the activated carbon filter is approximately 50 hours when a sample gas contains 500 ppm of isopro pyl alcohol and flows at 500 ml min Used eight hours a day suction pump life will be approximately one year Sample Inlet Rc1 4 Disk filter KO424GQ Sample Outlet Rc1 4 Power Connector Gas temperature Dust content Power supply Sampling Conditions Pressure at sampling point Sample gas flow rate Pressure at sample outlet Organic solvent content 1013 40 hPa abs 500 100 ml min 1013 40 hPa abs 50 C max ppm to a few percentage 5 mg Nm max 100 to 240 V
18. the sensor Replace the activated carbon filter Slow response Ambient pressure around sensor is negative Sensor has been clogged Use within the specified pressure range Clean the sensor head Large error in measurement Operating temperature is out of specified range Operating pressure is out of specified range Sample gas contains oxidation reduction gas or corrosive gas Sensor head touches wall Expired activated carbon has been used Use within the specified temperature range Use within the specified pressure range Specified accuracy cannot be expected in measurement Reinstall the sensor following procedure as in Section 3 1 Replace the activated carbon filter Occasional large fluctuations in readings Sensor failure Operating pressure is out of specified range Replace the sensor Use within the specified pressure range Calibration fails Improper calibration gas concentration Sensor failure Operating pressure is out of specified range Useful life of activated charcoal filter is over Use proper calibration gas Replace the sensor Recalibrate within the specified pressure range 4 Replace activated charcoal filter No alarm contact signal is activated IM 11M10A01 03E 1 Alarm contact signal is not set Alarm contact relay failure 1 Set the alarm contact signal properly 2 Contact Yokogawa T801E EPS
19. 3E Revision Record Manual Title Model OX102 Current Limit type Oxygen Analyzer Manual Number IM 11M10A01 03E Edition 1st 2nd 3rd Date Dec 2000 Nov 2002 Dec 2007 Remark s Newly published Shown Belew Added caution about requirement for return of equipment to factory for repaia 1 1 Added conditions requiring sampling unit to specification 3 3 Added sampling unit installation environment conditions 5 3 Added caution regarding life of sampling unit suction pump 7 Added caution about requirement for return of equipment to factory for repair 7 3 Added sampling unit maintenance cautions 8 Added activated charcoal filter to items to check when troubleshooting Appendix 1 Added cautions regarding activated chacoal filter life operating environment temperature renge membrane filter life and pump life and requirement for return of equipment to factory for repair Appendix 4 Added cautions regarding maintenance Revised and Corrected all over IM 12E04A03 02E User s Model 0X102 Supplement Manual Current limit type Oxygen Analyzer aQ YyY Thank you for selecting our Model OX 102 Current limit type Oxygen Analyzer In User s Manual IM 11M10A01 03E 3rd Edition supplied with the product some corrections additions have been made Please replace the corresponding pages in your copy with the attached revised pages Revisions p iv After Sales Warranty Deleted a part of descript
20. 50 60 Hz Piping connection Re1 4 St Needle Valve D T Activated i A a p arbon Filter n ji Carbon Filter O e AN T a OX102 Sensor N W u Ww UU Flowmeter Switch Sensor Connector for 8 mm O D F5301 EPS Switching Power Supply Switch _ MEME X ee cae eae aa O 4 Power Supply Disk Filter Felt Filter Flowmeter po K9346WH 500 ml min Sample Gas L C i HE u Inlet Pump rad i X Sensor A a Carbon Filter Sample Gas Insertion Port Outlet me j z o Rc 1 4 Provided by customer Stop valves must be installed at the sample gas inlet and outlet Figure 5 3 Sampling Unit IM 11M10A01 03E F5302 eps 5 4 Calibration Kit Optional The calibration kit for the OX102 oxygen analyzer comprises a standard gas cylinder and pressure regulating valve to supply standard gas for calibration when necessary Unit mm OX102 Sensor a 2 f K9424JC ZE nen HI Needle Valve Assembly with Pressure Reducing Valve Gas Vent Tubing _ and Fixed Throttle gt UA sil Rc1 8 Nominal diameter of piping o connection for K9424JD
21. IL Gain 5 B Value ppme Val Changi HEZWJI v v To be continued to GIN 6 F6305E EPS IM 11M10A01 03E 6 9 6 10 Continued To measurement mode A b nb ppm e 96 ENT ppm CAL All GAIN Value ppm CAL ON gt v y v gt Gain 6 Gln 6 is not user configurable 2 Automatic Manual Switching F6306E EPS In this mode either automatic or manual range switching can be selected Set either mode following the procedure shown in the flow chart below When the autoswitching is selected the mode of Configuring the 4 20 mA output signal described in Section 3 is automatically determined Indication Operational Flow Chart r Measured pamo A 4 20mA x AUTO or SELC gt Mode Changing accepted Mode gt x Use A and V keys to change the mode of AUTO or SELC AUTO Automatic range mode SELC Fixed range mode F6307E EPS Figure 6 5 Flow Chart of Automatic Manual Switching Setting IM 11M10A01 03E 6 Operation 3 Configuring the 4 20 mA output signal This mode is to configure the 4 20 mA output signal for the fixed range Configure the signals following the procedure shown in the flow chart below This mode is automatically determined if the automatic manual range switching mode is set to autorange mode Indication Operational Flow Chart
22. O2 range calibration When using dry air as calibration gas enter 20 9 using A ana v keys Entering calibration value Calibration completed n v 2037 O 6 Operation Operational Flow Chart Measured Value Supplying calibration gas No 1 O2 concentration in the range 15 25 gt gt i Changin ER Value IE gt CAL2 to the following page 4 Entered to skip calibration F6312 EPS 2 Entered to enter calibration value 3 Entered to return to measurement mode Figure 6 11 Calibration Flow IM 11M10A01 03E 6 17 6 18 100 ppm O Calibration CAL2 is for 0 100 ppm range calibration Assuming the O2 concentration of calibration gas is 110 ppm enter this value using and keys Continued from CAL 1 GE Stop supplying calibration gas No 1 Indication O wie O fu ppm e elan value Measurement Mode Supplying calibration gas No 3 O2 conceniration in the range 80 120 ppm r tti Entering calibrated value Calculating Changing ES NO Calibration Calibration accepted completed ppm e 110 CAL3 to the following page 1 Entered to skip calibration 2 Entered to enter calibration value 3 Entered to re turn to measurement mode F6313E EPS IM 11M10A01 03E Continued from CAL 2 1000 ppm O2 Calibration Indication
23. User s Manual Model 0X102 Current limit type Oxygen Analyzer IM 11M10A01 03E vigilantplant YOKOGAWA IM 11M10A01 03E Yokogawa Electric Corporation 3rd Edition Safety Precautions Safety Precautions This Analyzer is a component type stand alone instrument designed for instrument panel or rack mounting e To ensure safe operation of this instrument strictly observe the following safety instructions during operation maintenance and servicing Yokogawa will not be responsible or liable for damage caused by not following these instructions when using the instrument e Symbols The following graphical symbols are used in this manual A WARNING Emphasizes instructions that must be observed or electric shock and injury to or death of personnel could result YUN CAUTION Emphasizes instructions that must be observed or damage to hardware software or system crashes could result 2 NOTE Emphasizes points that require special attention in understanding the operation and functions A Notes Notes on Instruction Manuals Please pass on the Instruction Manuals to the end user Please read the manual thoroughly before using the instrument This manual describes the functions of the product in detail they do not imply any warranty that the instrument will meet the special needs of the user e No part of the manual may be reproduced without prior written consent from Yokogawa Yokogawa reserves t
24. a Class D 1000 or less ground before turning on the power to minimize the possibility of shock Need for Grounding Do not cut the internal or external protective ground wire or remove the ground wire from the terminal This creates a shock hazard Do not Operate without Protective Grounding and Fuse Do not operate the instrument without protective grounding and correct fuse Fuse For safety this product is fused internally It is recommended that you ask the local service representative to change the fuse do not either change it yourself or open the case to check the fuse Turn off the power switch and disconnect the instrument from the power before changing the fuse Do not use a fuse of different type or size or short circuit the fuse holder IM 1M11A01 03E IM 1M11A01 03E Safety Precautions Environmental Restrictions Danger Do not use this instrument in a flammable explosive or steamy environment Do not try to measure gases with traces of redox gas corrosive gas or organic silicon e gas Keep Hands Out While voltage is applied keep hands out Internal parts should be replaced by our service representative or by an authorized person External Connections Before wiring to minimize the possibility of shock disconnect power from the instru ment Also check ground connection to this instrument to the system being measured and to any associated external control equipment After Sales Warranty Yokogaw
25. a warrants the product for the period specified in the pre purchase quotation Yokogawa shall perform warranty service according to its own standards For on site service outside of the normal service area you may be billed for travel expenses of technical personnel even during the warranty period In the event of any failure caused by the following service including shipment to the factory for repair where necessary may be billed for even during the warranty period the use of software hardware or spare parts not supplied by Yokogawa improper or insufficient maintenance by the user e unauthorized modification abuse misuse or mishandling improper installation or transportation of the equipment the use of unspecified power supply voltage frequency or abnormal power supply use under conditions not meeting the required standards or improper maintenance of the installation site force majeure events including but not limited to fires earthquakes windstorms lightning riots civil disorder war or other hostilities radiation contamination or acts of God Yokogawa makes no warranty with respect to the fitness of this equipment for a particular user purpose In no event shall Yokogawa be liable for direct incidental or consequential damages In the event that the equipment is incorporated into other equipment or resold Yokogawa assumes no liability to the end user for direct incidental or consequential
26. ake and for gas vent completely by turning the valves clockwise completely A 3
27. ameter Table attached to the sensor control block into the converter This ensures sensor compatibility Sensor Parameter Table F501 EPS Figure 5 1 Sensor Sensor Parameter Table Example Sensor Parameter Table j Sens YA 0007 When replacing the sensor enter values in the ensor No YA Sensor Parameter Table into the converter Gain 1 1 015 See Section 6 3 1 Setting Sensor Parameter Gain 2 A 1 043 for procedure B 65 Gain 3 A 1 002 B 25 Gain 4 A 0 990 B 19 Gain 5 A 1 429 B 17 T5101 EPS IM 11M10A01 03E 5 1 5 2 Converter The converter provides oxygen concentration readings based on the signals from the sensor and outputs a 4 20 mA 1 5 V DC signal outside Also the converter has various functions including the high low alarm contact output easy one touch calibration and self diagnosis function Data Display 7 YOKOGAWA 4 Unit Indication 95 e Lamps ppm O Status Indication Lamps ch es H ALM L ALM FAIL PASS ALM zona Yo ppm H 5 KA a i Operating Keys Cat A v ENT C z Operating Keys ALM 4 20mA 96 ppm CAL 4 V ENT Used to enter the high low alarm setting mode Used to configure 4 20 mA output used together with A key to enter
28. cylinders 1L needle valve assembly with flow adjustment K9424JS Calibration kit 10000 ppm 6 cylinders 1L needle valve assembly without flow adjustment T1202E EPS 3 Optional Accessories Part Number Description K9424GY Activated carbon element 5 pieces pack for sampling unit K9424JP 1000 ppm O2 calibration gas IL x 6 cylinders box K9424JQ 10000 ppm O2 calibration gas 1L x 6 cylinders box K9424JC Needle valve assembly with flow adjustment K9424JD Needle valve assembly without flow adjustment K9424LA Sensor assembly specially designed for OX102 K9424LB Extension cable 4 m specially designed for OX102 K9424LC Extension cable 9 m specially designed for OX102 K9424LD Extension cable 29 m specially designed for OX102 K9424DB Metal nipple ferrule metal Rc1 4 100 to 150 C K9424DF Metal nipple ferrule teflon Rc1 4 For 100 C or less L9811LA Plastic nipple 17 mm O D or G3 8 hole for measuring range 0 1000 ppm or greater K9424GQ Disk filter for Sampling Unit K9346WH Felt filter for Sampling Unit The insertion length cannot be changed once a metal ferrule is tightened with a nipple It is because the ferrule engages with the sheath of the sensor once tightened a T1203E EPS 1 4 IM 11M10A01 03E 1 Overview 1 3 External Dimensions Instrument Body Unit mm
29. cylinders 1L needle valve assembly without flow adjustment K9424JR Calibration kit 10000 ppm 6 cylinders 1L needle valve assembly with flow adjustment K9424JS Figure 1 5 Calibration Kit Optional Calibration kit 10000 ppm 6 cylinders 1L needle valve assembly without flow adjustment T1301E EPS 1 7 2 System Configuration 2 System Configuration A basic system of the OX102 oxygen analyzer comprises a sensor extension cable and converter The length of the extension cable is selectable any of 4 m 9 m and 29 m to accommodate your application An optional sampling unit K9424GA is available to filter out organic solvents if a sample gas contains such solvents at a level between a few ppm and a few percent such as in reflow applications One point calibration should be performed corresponding to the measuring range normally used This can be conve niently achieved using the optional calibration kit Refer to Section 1 3 figure 1 5 When all ranges are used they all need to be calibrated Refer to Section 1 1 14 Calibration 2 1 System Configuration 1 This basic system configuration comprises sensor extension cable and converter Approx 1 m 150 C Max Heater Control Block Converter Extension Cable Approx 50mm 250 C Max Power Supply Fail Contact Output 4 20 mA DC Output 1 5 V DC Alarm Contact F201 EPS Figure 2 1 System
30. damages iv IM 1M11A01 03E Safety Precautions Notes on Use e Do not drop or jolt the equipment or its accuracy may be adversely affected Do not attempt to disassemble the equipment or it may malfunction e As far as possible install the equipment horizontally The sensor should be installed securely so that it does not vibrate Avoid installing the equipment in places where the temperature exceeds 70 C Avoid installing the equipment where it would be exposed to direct sunlight radiant heat or the weather and where vibration exists e Avoid installing the equipment in atmospheres containing corrosive gases gas atmospheres out of measuring scope or atmospheres where the sensor is exposed to silane silicone gas e Keep the equipment away from noise generating devices to minimize the possibility of malfunction although it is designed to cope with noise e The sensor has a limited life which varies depending on operating conditions It is strongly recommended that you replace the sensor once a year from a preventive maintenance standpoint Keep this instruction manual handy for your quick reference during operation and maintenance IM 1M11A01 03E V vi Restrictions on Use Do not use the equipment in atmospheres containing combustible corrosive or flue gases or organic compounds If it is used in silicon gas atmospheres in flow furnaces or nitrogen reflow furnaces the equipment must be used in the f
31. e F6301E EPS To be continued to GIN 2 Note After one point calibration if V ppm and ENT key are pressed GIN6 value is reset to 1 00 In this case the calibration is required again To check the sensor parameter press A W J Press ENT to confirm the parameter Figure 6 4 Flow Chart of Sensor Parameter Setting IM 11M10A01 03E 6 5 Continued Measurement mode A J r O LAML ppm Low alarm HEN L ALM ALM ENT ppm CAL Low alarm setting Changing value v Value accepted If the entered high alarm setting is less than the low alarm setting the display will show E for about 3 seconds and the entered setting will flash to prompt reentry An appropriate value should be reentered F6311E EPS 6 Resetting the sensor parameters to the default values This is to reset the sensor parameters A and B values for each gain see Section 5 to the factory default values Note In the case of the sensor is replaced and the parameters are changed refer to 6 3 1 Configuring the sensor parameters the parameter are reset to those changed value Indication Operational Flow Chart Measured CL ppm O Value O T PE SE nO To the factory default values F6321E EPS Figure 6 9 Flow Chart of Sensor Parameter Resetting IM 11M10A01 03E Appendix 3 Operating Procedures 3 1 Starting operati
32. e tubing to the lid Figure 1 Figure 2 Figure 3 AP103E eps 4 2 Maintenance of the disk filter attached to the gas inlet 1 Disconnect the fitting from the sampling gas inlet 2 Remove the filter with tweezers 3 Clean the captured foreign substances out of the filter by air purges 4 Replace the restored filter with its smooth surface facing to the gas inlet When the filter becomes clogged shortly after the restoration the filter needs to be replaced A 4 IM 11M10A01 03E Appendix Appendix 2 Calibration Gas Kits K9424JA K9424JB KI424JR K9424JS Calibration Gas Kits for OX100 102 The calibration gas kits are designed for calibration of the OX100 Series Oxygen Analyzers The Kit comprises a calibration gas filled pressure of 0 7 MPa 6 one litter cylinders and a needle valve assembly The calibration gas is available in two types 900 to 1100 ppm O and 8500 to 9500 ppm O N based Prepare either one according to your application 1 Connecting the needle valve assembly to the gas cylinder IM 11M10A01 03E Take the following steps to connect the gas cylinder to the needle valve assembly 1 Turn the handle of the needle valve counterclockwise to pull the needle tip inside the gasket to the position shown in Figure 1 2 Loosen the locknut of the needle valve Screw the valve into the mouth of the gas cylinder in a clockwise direction with fingers until it meets resistance and then screw the
33. eene tem DD VEKE RE EE viii IM 11M10A01 03E 7 Inspection and Maintenance 4 eere esee eene e eene seen esee esseeessseeessseess 7 1 Td Sensorszans ssh peo eked Ha celeste asd a Nes ala eto DAA 7 1 742 GOnDVETeE coerente Ua re E Re n er Gotha cb tes vane dk AAA 7 1 7 3 Sampling Unit Optional ss 7 1 8 Troubleshooting AA AA We Re TOI eda pr DET Appendix L Sampling UN mama eti n einander toe inasar AS K9424GA Sampling Unit for OX100 102 essere A 1 Specifications DD ete iere deme et e rores A 1 2 Installation eee hi e me re ewe KE Ha EY A 2 3 Operating Procedures ise de HE ree A 3 3 1 Starting operation 2 sie ect teta aree d ens GANAN A 3 3 2 StoppIDg Operation ia NAT KE RAT man kabi v KER A 3 4 Maintenance wi p OH DO RERO EWAR BE je U S ku e V R AGE K N A 4 4 1 Replacing the activated carbon pack u seen A 4 4 2 Maintenance of the disk filter attached to the gas inlet A 4 Appendix 2 Calibration Gas Kits c eere ecce eere eee eene ee eese esee eese eo seesseessess A3 K9424JA K9424JB K9424JR K9424JS Calibration Gas Kits for OX100 102 A 5 1 Connecting the needle valve assembly to the gas cylinder A 5 2 Supplying the calibration gas seen A 6 3 Stopping supplying the calibration gas sse A 6 Customer Maintenance Pa
34. elow the low alarm setting c FAIL turns on when self diagnostics detect sensor disconnected d PASS turns on when key lock is enabled turns off when disabled 14 Calibration a Atmospheric air one point calibration Calibration point setting range 15 to 25 O b One point calibration at 100 ppm Calibration point setting range 80 to 120 ppm O c One point calibration at 1000 ppm Calibration point setting range 900 to 1100 ppm O d One point calibration at 10000 ppm Calibration point setting range 8500 to 9500 ppm O e Complete calibration Calibration with air 20 100 500 1000 10000 ppm in that order Calibration Setting Range Calibration Order Calibration Point Calibration Point Setting Range Atmospheric air 15 2596 O2 20 ppm 15 25 ppm O2 100 ppm 80 120 ppm O2 500 ppm 400 600 ppm O2 1000 ppm 900 1100 ppm O2 10000 ppm 8500 9500 ppm O2 A calibration kit for calibrating all ranges is not available Prepare calibration gas of specified concentration on site or contact us for factory calibration T104E EPS IM 11M10A01 03E IM 11M10A01 03E 1 Overview 15 Fine tune mode The measuring value can be adjusted to true analyzer value 16 Operating temperature Converter 0 to 50 C Sensor 0 to 150 C 0 to 250 C within 50mm of sensor tip 17 Extension cable 4 m 9 m 29 m operating temperature 0 to 70 C 18 Gas flow rate 1 m sec max 19 Operating
35. er calibration value F6315 EPS 3 Entered to return to measurement mode IM 11M10A01 03E 6 Operation The procedure for complete calibration requiring six types of calibration gas is illustrated in the following flow chart Continued from CAL 4 Measurement Mode A Air Calibration Indication O Calibration using air CALS ppm When using dry air as r Supplying calibration gas No 1 O2 calibration gas enter 20 9 concentration allowance 15 2596 using 4 and Lv Jkeys CAL ppm CAL Entering calibration value gt ppm o e ppm O gt TE YES Calibration ERROR v completed E LI ppm O Display shows automatically in about 3 seconds and wait for a 20 ppm calibration 20 ppm calibration value F6316 EPS IM 11M10A01 03E 6 21 6 22 20 ppm O2 Calibration v 100 ppm O2 Calibration Indication 7 ppm e Entering calibration value O J ppm e I O Ba ne Entering calibration value ppm ies LA ge j Calibration completed O Continued Measurement mode E Stop supplying calibration gas No 1 and supply No 2 O2 concentration ENT allowance 15 25 ppm gt value value gt esses T ERT NO 100 L Waiting for 100 ppm calibration REX Stop supplying ca
36. g to Sections 6 2 and 6 3 Briefly after the converter is energized it shows values at random on the display for about 5 seconds and then switches to measurement mode to indicate approximate values of the oxygen concentration at sampling point At this stage the readings are invalid since the sensor temperature has not reached the required operating temperature 6 1 4 Operating procedure for the calibration gas kit Needle tip Valve Locknut Container Figure 1 Figure 2 1 2 Pull the needle tip up inside the gasket to the position shown in Figure 1 Screw the valve onto the mouth of a container with the fingers until it meets resistance and then screw the locknut down Figure 2 Turn the needle valve clockwise until it can no longer turn Figure 3 Make a piping connection to the piping port of the valve Figure 4 Turn the needle valve gradually ina counterclockwise direction to start the gas flowing Adjust the needle valve for the required flow rate To shut off the gas flow turn the needle valve clockwise For storage the needle valve should be firmly tightened as in Step 3 Figure 3 Figure 4 calibration gas kit Valve Locknut Container Figure 4 F602E EPS IM 11M10A01 03E 6 Operation 6 2 Operational Flow Chart The following definitions apply in general to the notation used in the text to express and explain t
37. he operation keys and the display descriptions Refer to Figure 5 2 for the functions of the operation keys and the indications on the converter front panel Notation descriptions for the operational flow chart IM 11M10A01 03E 1 Display Indicates high alarm Concentration indication ON status occurs 2 lamp ON 3 ppm lamp OFF 4 High alarm lamp ON Normally displays 1 Concentration indication ON oxygen concentration 2 96 lamp OFF reading 3 ppm lamp ON Indicates flashing display prompting you to configure 2 2 5 Indicates continuous non flashing display 95 A black circle indicates that the lamp is on ppm O A white circle indicates that the lamp is off EM A black square indicates that the high alarm lamp is on H ALM F6201E EPS 2 Key operations ppm CAL Indicates that keys specified should be pressed simultaneously in left to right order In this case press the ppm key while simultaneously pressing the CAL key 6 3 6 4 Operational Flow Chart A For readings in percentage the lamp is ON and the ppm lamp is OFF For the high alarm conditions the H ALM lamp is ON and two concentration unit lamps are OFF O ppmO Press ALM Measurement mode Press ppm CAL to return to measurement mode Measured Value Press ALM for setting alarm setting HI AL is displayed to prompt setting entry High Alarm Press ENT to enter setting ent
38. he right to improve the instrument and manuals at any time without notice or obligation If you have any questions about the manuals or feel that there are mistakes or omissions please contact our sales representative or your local distributor agent IM 11M10A01 03E 3rd Edition Nov 2007 YK All Rights Reserved Copyright 2000 Yokogawa Electric Corporation i Maintenance Safety and Product Modification In order to protect the system controlled by the instrument and the instrument itself and to ensure safe operation observe the safety precautions described in this manual If any protective or safety circuitry is required for the system used with this instru ment or for the instrument itself prepare and install it Do not change the internal parts or circuitry of the instrument in any way Disclaimers Limitation of Liability Yokogawa grants no warranties other than the express warranty set forth under the warranty provisions Yokogawa shall not be liable to you or any third party for any damage including consequential or incidental damages arising out of or in connection with the use of this equipment defects beyond our knowledge or any other contingency beyond our control A WARNING High temperature take care When the sensor is powered on the sensor tip gets very hot Be careful not to touch it Power Be sure to check the power supply voltage before turning on the power Grounding Be sure to connect
39. ich Yokogawa did not supply e Failure due to improper or insufficient maintenance by user e Failure due to misoperation misuse or modification which Yokogawa does not authorize e Failure due to power supply voltage frequency being outside specifications or abnormal Failure caused by any usage out of scope of recommended usage Any damage from fire earthquake a storm and flood lightning disturbance riot warfare radiation and other natural changes Yokogawa does not warrant conformance with the specific application at the user site Yokogawa will not bear direct indirect responsibility for damage due to a specific application Yokogawa 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 this product please contact the nearest sales office described in this instruction manual iv IM 1M11A01 03E Safety Precautions Notes on Use e Do not drop or jolt the equipment or its accuracy may be adversely affected Do not attempt to disassemble the equipment or it may malfunction e As far as possible install the equipment horizontally The sensor should be installed securely so that it does not vibrate Avoid installing the equipment in places where the temperature exceeds 70 C Avoid installing the equipment where it would be exposed to di
40. ion p V Notes on Use Added the Notes on Use in Korea p 6 5 Section 6 3 Configuring Data Figure 6 4 Added the description of note ep 6 14 Section 6 3 Configuring Data Added the note of 6 ep A 3 Section 3 1 Starting Operation Changed the description of I All Rights Reserved Copyright 2000 1st Edition May 2012 YK IM 1 1 M1 OA01 03E YOKOGAWA Subject to change without notice 3rd Edition Yokogawa Electric Corporation After Sales Warranty 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 repair under warranty provide us with the model name and serial number and a description of the problem Any diagrams or data ex plaining 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 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 wh
41. leted a YES nnn v ppm Note To return to measurement mode press ppm CAL F6319E EPS 2 Moving zero point This is to translate the output function to change value b of the characteristic function y ax b The range for moving the zero point is from 999 to 999 ppm Indication Operational Flow Chart Measured O LI ppm e O i Increment decrement Ippmo v Calculating Changing Configuring value Note To return to measurement mode press ppm CAL F6320E EPS Figure 6 13 Flow Chart of Moving Zero Point 6 24 IM 11M10A01 03E 7 Inspection and Maintenance 7 Inspection and Maintenance 7 1 Sensor This chapter explains inspections to ensure best performance and operations of the OX102 oxygen analyzer If repair is required this equipment will need to be returned to the factory Contact your Yokogawa representative A NOTE e Do not touch the sensor head accidentally while the sensor is hot right after removing it from the process The sensor can be as hot as 700 C This can cause severe burns e The sensor contains components made from ceramics zirconia Physical damage by dropping or jolting can result in sensor failure 1 The sensor is of limited life and its service life varies depending on operating conditions When the sensor cannot be calibrated it should be replaced 2 After replacement the sensor parameters s
42. libration gas No 2 and supply No 3 O2 concentration allowance 80 120 ppm Calibration value value ENT Calculating Changing YES y ERROR L Waiting for 500 ppm calibration Note To return to measurement mode press ppm CAL F6317E EPS IM 11M10A01 03E IM 11M10A01 03E 500 ppm calibration M 1000 ppm calibration Indication nn uu ppm Entering calibration value O Cor TI Li ppm e O WA Some Calibration completed Yo L n Ju ppm ppm e TENA o uidi ppm e O INEC PU a i ppm completed supply No 4 A ppm CAL YES y 1060 lt lt Waiting for 1000 ppm calibration supply No 5 gt Changing value YES 6 Operation Stop supplying calibration gas No 3 and lt Waiting for 10000 ppm calibration QE 02 concentration allowance 400 600 ppm Measurement mode Stop supplying calibration gas No 4 and O2 concentration allowance 900 1100 ppm Note To return to measurement mode press ppm CAL F6318E EPS 6 23 10000 ppm O2 Calibration Indication unnm O Stop supplying calibration gas No 5 ppm o and supply No 6 GE O concentration allowance 8500 9500 ppm Measurement mode Entering calibration value gt lt Measured Sp HUU ppm e gt sesso Calibration v comp
43. m zA u u Note Piping connection Rc1 4 Provided by customer DN Figure 1 Piping Diagram Needle Valve V1 Activated Filters F2 F3 Flowmeter FM1 Sensor Connector 8 O D Switch AP102 Eeps Figure 2 Sampling Unit A 2 IM 11M10A01 03E Appendix 3 Operating Procedures 3 1 Starting operation Before starting the operation of the sampling unit make sure to power down the OX100 Series oxygen analyzers Take the following steps to start operating the unit 1 Mount an OX100 Series sensor to the sensor connector of the sampling unit by inserting 70 to 80 mm of the sensor and tightening the locknut firmly with fingers The locknut should be finger tight only and do not use a wrench for tightening 2 Completely open both stop valves sampling gas intake and gas vent 3 Turn off the power switch of the unit and apply the voltage conforming to the specification 4 Open the flow regulating valve of the flowmeter and the needle valve on the front completely by turning the valves counterclockwise completely 5 Turn on the power switch of the unit The suction pump starts working 6 If the flowmeter reads below 0 5 l min close the needle valve on the front gradually by turning it clockwise until the flowmeter reads 0 5 l min If the flowmeter reads over 0 5 l min close the flow regulating vale of the flowmeter gradually by turning it clockwise until the flowmeter reads 0 5 l min 7
44. m 0 1000 ppm 0 10000 ppm 0 25 automatic fixed switching mode 6 External output a 4 20 mA DC automatic manual switching mode b 1 5 V DC fixed 0 100 ppm 0 1000 ppm 0 10000 ppm 0 2590 c 4 20 mA DC identification signal for automatic switching See below Output Range 0 100 ppm 0 1000 ppm 0 10000 ppm Range Identification Signal 4V DC 3 V DC 2 V DC T101E EPS 7 Repeatability Measuring Range Repeatability 20 100 ppm 15 ppm O2 100 1000 ppm 25 ppm 02 1000 5000 ppm 0 3 of reading 5000 10000 ppm 7 5 of reading 1 25 0 25 02 T102E EPS 1 1 8 Alarm contact output 2 contact outputs contact rating 110 V AC 24 V DC 1 A a Alarm output if oxygen concentration abnormal Hi Lo b Alarm output if sensor disconnected FAIL 9 Alarm setting for abnormal oxygen concentration a Setting range 1 ppm to 24 9 O b Setting conditions High alarm Hi 2 Low alarm Lo 10 Indication LED Digital indication ranges 0 9995 ppm to 1 0 25 0 autoswitching 11 Display and resolution 3 steps Display Resolution 20 N 100 ppm 100 N 10000 ppm LOSN 32590 T103E EPS 12 Unit indication lamp a ppm LED turns on for O measurement range 0 9995 ppm b LED turns on for O measurement range 1 25 0 13 Operation lamp a Hi ALM turns on when the O concentration exceeds the high alarm setting b Lo ALM turns on when the O concentration goes b
45. m thickness using the supplied brackets Procedure Insert the unit through the mounting hole from the front e Mount the converter on the panel using brackets The brackets should be fixed to the designated position on the right and left sides of the housing by tightening the screws See Figure 3 2 The converter should be upright and horizontal e Ensure that the converter bracket screws are tightly secured so there is no movement Removal of Protective Film Upon completing installation remove the transparent film from the operation panel of This film is for protecting the panel from damage during shipment Mounting Brackets 2 sets E Figure 3 2 Converter Mounting YUN CAUTION Over tightening the screws may distort the case or damage the brackets IM 11M10A01 03E 3 3 3 3 Installing the Optional Sampling Unit K9424GA 3 4 The sampling unit is a desktop type and should be installed on a stand near the sampling point Note the following when installing the unit A Notes The unit should be installed in places where Ambient temperature is in the range of 0 to 40 C and temperature fluctuations are minimal e Mechanical vibration is negligible Adequate space for inspection and maintenance such as replacing filter element is secured e The unit should be securely mounted on a stand to prevent it falling e No exposure to rain or water is allowed The sampling unit incorporates
46. n in Figure 4 3 Converter Terminal Board Annunciator etc Note Alarm contact is a relay contact F403 EPS Figure 4 3 Alarm Contact Output 4 3 5 Fail Contact Signal This contact output is a relay contact and closes when a failure condition exists such as disconnection of the sensor heater and failure or disconnection of cable between the sensor and the converter Use 600 V rated vinyl insulated wires JIS C3307 or wires or cables of equivalent or greater capacity for connections as shown in Figure 4 4 Converter Terminal Board Annunciator etc Note Fail contact is a relay contact F404 EPS Figure 4 4 Fail Contact Output 6 Power Supply Wiring Use 600 V rated vinyl insulated wires JIS C3307 or wires or cables of equivalent or greater capacity for power supply wiring as shown in Figure 4 5 Converter Terminal Board 100V 240V 50 60Hz Ground Resistance 1000 max Class D Ground F405 EPS Figure 4 5 Power Supply IM 11M10A01 03E 5 Component Functions 5 Component Functions This chapter describes functions of main equipment of the OX102 oxygen analyzer 5 1 Sensor The sensor uses a zirconia current limiting system enabling direct insertion of the sensor at elevated temperatures up to 150 C 0 to 250 C within 50 mm of sensor tip The sensor should be used at a measuring point pressure of 1013 40 hPa abs When replacing the sensor enter the data in the Sensor Par
47. nverter Warming up Configuring parameter Calibration Note For operating procedure of the calibration kit see Section 6 1 4 1 See Section 6 1 1 2 See Section 6 1 2 3 See Section 6 1 3 4 See Section 6 3 5 See Section 6 3 6 F601E EPS Figure 6 1 Startup 1 Checking wiring and piping when using the sampling unit Ensure that wiring is made correctly in accordance with the procedures described in Chapter 4 Piping is only required when using a sampling unit Ensure that piping is installed properly so that it is free from gas leakage 2 Checking gas flow rate when using the sampling unit Turn on the power switch of the sampling unit Adjusting the gas flow rate should be performed with the sensor connected to the sampling unit While opening the flow regulating valve of the flowmeter completely adjust the front needle valve until the flowmeter reads approximately 500 100 ml min See Figure 5 3 3 Applying power to the converter Ensure that the power supply voltage conforms to the specification of the converter before applying power to the converter see Section 1 1 19 Turn on power to the converter Measurement is not available for the initial 10 minutes since it takes that time for the sensor to reach the required operating temperature The initial converter parameters are the default settings If necessary change the parameters to meet your application requirements referrin
48. ollowing system The sampling unit K9424GA must be used e The sampling unit requires appropriate maintenance which is determined by gas conditions Filters and activated carbon packs should be replaced at intervals which depend on the operating conditions For best measurement use new activated carbon packs Using expired packs may result in invalid measurement results or even sensor deterioration If you have any questions please contact your Yokogawa representative IM 1M11A01 03E Safety Precautions How to Use This Manual The structure of this manual is as shown in the table below This table shows which sections you are recommended to read when performing the corresponding tasks Unpacking Initial Daily Changing Maintenance Section to refer to installation setting operation settings troubleshooting Safety precautions Sect 1 Overview Sect 2 System Configuration Sect 3 Installation Sect 4 Wiring Sect 5 Component Functions Sect 6 Operation Sect 7 Inspection and Maintenance Sect 8 Troubleshooting App 1 Sampling Unit App 2 Calibration Gas Kits CMPL Parts List T1 EPS IM 1M11A01 03E vii Contents A Safety Precauti S NGA cC ES After Sales W i ter Sales Warranty s s s ssseeeeeeecece IV Notes 1 DE A ANAN AA AA AANTAY Restricti U i
49. on Before starting the operation of the sampling unit make sure to power down the OX100 Series oxygen analyzers Take the following steps to start operating the unit 1 Mount an OX 100 Series sensor to the sensor connector of the sampling unit until it stops against the end Then pall out the sensor to 1 2 mm front and tightening the locknut firmly with fingers The locknut should be finger tight only and do not use a wrench for tightening 2 Completely open both stop valves sampling gas intake and gas vent 3 Turn off the power switch of the unit and apply the voltage conforming to the specification 4 Open the flow regulating valve of the flowmeter and the needle valve on the front completely by turning the valves counterclockwise completely 5 Turn on the power switch of the unit The suction pump starts working 6 If the flowmeter reads below 0 5 l min close the needle valve on the front gradually by turning it clockwise until the flowmeter reads 0 5 l min If the flowmeter reads over 0 5 l min close the flow regulating vale of the flowmeter gradually by turning it clockwise until the flowmeter reads 0 5 l min 7 Turn on the power of the OX100 Series oxygen analyzers 3 2 Stopping operation IM 11M10A01 03E Take the following steps to stop operating the unit 1 Remove power from the OX100 Series oxygen analyzers 2 Turn off the power switch of the sampling unit 3 Close both stop valves for sampling gas int
50. onfigure settings following the procedure shown in the flow chart below The high alarm setting should be equal or greater than the low alarm setting Operational Flow Chart 9 4 Measured ppm O Value ALM O v ppm O M ENT ppm CAL High Alarm Setting UY y yy 3 PALM ENT v bm ppm GAL Changing value Value accepted v To low alarm setting following page If the entered high alarm setting is less than the low alarm setting the display will show for about 3 seconds and the entered setting will flash to prompt reentry An appropriate value should be reentered F6310E EPS Figure 6 8 Flow Chart of High Low Alarm Setting 6 13 6 14 Continued Measurement mode A Li O L n HL ppm O Low alarm pn L ALM ALM ENT ppm CAL Low alarm setting Changing value v Value accepted If the entered high alarm setting is less than the low alarm setting the display will show E for about 3 seconds and the entered setting will flash to prompt reentry An appropriate value should be reentered F6311E EPS 6 Resetting the sensor parameters to the default values This is to reset the sensor parameters A and B values for each gain see Section 5 to the factory default values Indication Operational Flow Chart Measured Cu ppm O Value
51. pecified in the Sensor Parameter Table Figure 5 1 of a new sensor must be entered following the procedure described in Section 6 3 1 Configuring the sensor parameters 3 If the slots of the sensor head get clogged it may cause false measurement When clogging becomes severe enough to block the gas flow clean the slots with a brush and subsequently by applying pressurized air 300 kPa max to the sensor while keeping the sensor head facing downward to prevent dust from getting into the inside of the sensor 7 2 Converter The fuse is mounted on a printed board inside the converter If no display appears after applying power the fuse needs to be replaced Contact our service station for fuse replacement 7 3 Sampling Unit Optional IM 11M10A01 03E The sampling unit is used to eliminate organic solvents using a built in activated carbon filter when the sample gas contains a small amount of organic solvents When this sampling unit is used with OX100 series Oxygen Analyzer if the sampling unit is not properly maintained the life of the Oxygen Analyzer sensor will be adversely affected drift will occur or the instrument will not calibrate Frequent filter maintenance is particularly important If zero or span need frequent adjustment check the filter first 1 When the sample gas contains 500 ppm of isopropyl alcohol and flows at 500 ml min the expected life of the activated carbon filter element is approximately 50 ho
52. pple should be securely tightened so that no leakage occurs When mounting the sensor with a plastic nipple use a finger tight connection when mounting the sensor with a metal nipple finger tighten the connection then use a wrench to tighten it a further 1 2 turn Within 50 mm of the sensor tip it can get very hot Do not mount the nipple in this hot area IM 11M10A01 03E 3 1 3 2 A WARNING Sensor cable should be within 30 cm of sensor housing and angle of bend see figure below should not be greater than 60 When mounting sensor through a 17 mm hole mounting plate should be no greater than 4 mm thick For metal nipple Rc1 4 For plastic nipple 17 mm O D hole or G3 8 F301 EPS Figure 3 1 Sensor Mounting IM 11M10A01 03E 3 Installation 3 2 Installing the Converter 1 Installation Site The converter should be installed in places where e Easy access to display and key operations can be achieved e Inspection and maintenance can be easily performed Ambient temperature does not exceed 50 C and temperature fluctuations are minimal Avoid exposure to direct sunlight or radiant heat Humidity is moderate 40 to 75 RH recommended and no corrosive gases or metal dust are present e Mechanical vibration should be negligible e No electromagnetic field should be present No exposure to rain or water is allowed 2 Mounting The converter is panel mounted copperplate of 1 to 10 m
53. pressure 1013 40 hPa abs 20 Power supply 100 to 240 V AC 50 60 Hz approx 15 W 21 Storage temperature 0 to 70 C for both sensor and converter 22 Self diagnostic function Detects sensor disconnection 23 Sensor replacement Compatibility can be achieved by entering a sensor specific constant 1 3 12 Model and Suffix Codes 1 OX102 Current limiting Type Oxygen Analyzer Suffix Code Option Code Description OX102 Current limit type oxygen analyzer Measuring 5 T Range 0 100 1000 10000 ppm 0 259602 5 m 1 m sensor assembly 4 m cable 10 m 1 m sensor assembly 9 m cable Sensor 30 m 1 m sensor assembly 29 m cable Not required Manual Japanese English Plastic nipple 17 mm O D or G3 8 hole for measuring Optional Nipple 1 range 0 1000 ppm or greater Metal nipple ferrule teflon Rc1 4 for measuring range 0 100 ppm 1 Either plastic or metal nipple should be specified according to the measuring range of the application if required When the OX102 is used with a sampling unit nipple is not required T1201E EPS 2 Sample unit calibration kit optional Part Number Description K9424GA Sampling unit K9424JA Calibration kit 1000 ppm 6 cylinders IL needle valve assembly with flow adjustment K9424JB Calibration kit 1000 ppm 6 cylinders 1L needle valve assembly without flow adjustment K9424JR Calibration kit 10000 ppm 6
54. protected if the cable is pulled or jerked Fix the extension cable from the sensor and the AC power cable at separate points IM 11M10A01 03E 4 Wiring 4 4 Wiring Procedures IM 11M10A01 03E Follow the instructions below for wiring the converter 1 Sensor wiring Sensor is connected using a special extension cable with 15P connector Plug in the connector and tighten the screws to secure it 2 Signal output There are two types for signal output 4 20 mA DC and 1 5 V DC The 1 5 V DC output signal is only available for a fixed range Use two core shielded wires for signal output wiring Perform the wiring as shown in Figure 4 2 External Devices Recorder etc G Converter Terminal Board 4 20 mA DC 14 2 Note 1 1 5 V DC Note 2 Note 1 Connect the shield to ground on the receiver side Note 2 Only available for a fixed range F402 EPS Figure 4 2 Output Signal 3 Range Identification Signal The range identification signals are output when automatic range switching mode is selected See Section 1 1 6 For these range identification signals terminal 3 is positive and terminal 4 negative see Figure 4 1 Use two core shielded wires for the wiring 4 High Low Alarm Contact Output This contact output is a relay contact and closes when an alarm condition exists Use 600 V rated insulated wires JIS C3307 or wires or cables of equivalent or greater capacity for connections as show
55. rect sunlight radiant heat or the weather and where vibration exists e Avoid installing the equipment in atmospheres containing corrosive gases gas atmospheres out of measuring scope or atmospheres where the sensor is exposed to silane silicone gas e Keep the equipment away from noise generating devices to minimize the possibility of malfunction although it is designed to cope with noise e The sensor has a limited life which varies depending on operating conditions It is strongly recommended that you replace the sensor once a year from a preventive maintenance standpoint Keep this instruction manual handy for your quick reference during operation and maintenance E Notes on Use in Korea The AC electric cable included with this product is not compliant with the safety standards in korea Please do not use it to connect household appliances in Korea It is prohibited to use an adapter connector to change the plug shape for the AC electric cable of this product IM 1M11A01 03E V 6 Operation 6 3 Configuring Data 1 Configuring the sensor parameters Upon replacing sensors parameters must be configured following the chart below Parameters to be configured are specified in the Sensor Parameter Table Figure 5 1 attached on a new sensor Indication Operational Flow Chart Measured ppm O AtV t ppm ET 1 O row ppm O O Hit L ITI pomo Yo e ain 1 Value Value Changing accepted valu
56. rts List CMPL 11M10A01 03E Revision Record IM 11M10A01 03E 1 Overview 1 Overview The OX102 Current limit Oxygen Analyzer is an advanced oxygen analyzer which is capable of measuring a wide range of oxygen concentrations from ppm level to percent age level The OX102 is best suited to ppm level oxygen measurement for example monitoring the furnace gas of nitrogen reflow furnaces and the atmosphere of semicon ductor plants This analyzer uses a compact zirconia current limiting sensor The sensor is designed for direct insertion type installation Where the furnace gas of a nitrogen reflow furnace contains organic solvent at a few ppm to percentage level the sensor should be used with the K9424GA sampling system to avoid contact with the solvent Note that the OX102 cannot measure oxygen concentration if combustible or corrosive gases are present in the atmosphere to be measured This equipment needs to be returned to the factory for repair Contact your Yokogawa representative 1 1 Standard Specifications IM 11M10A01 03E 1 Measurement principle Zirconia current limiting method 2 Sampling system Natural diffusion system If the sampled gas may include organic solvents use a sampling unit 3 Measured gas O in N or mixed gases cannot be used with silicone vapor combustible gases and organic solvents 4 Measuring range 0 to 25 5 Output range 0 100 pp
57. ry or press ALM to skip Press ppm CAL to return to measurement mode Press ENT to enter setting entry The setting displayed will flash and H ALM lamp turns on to prompt setting reentry High Alarm Setting Enter a new setting using A V ppm keys and press ENT to accept it rv v iv vv Y ALM ENT A Y ppm ppm CAL to skip reentry To low alarm alarm sett Figure 6 3 Changing value High Alarm No gt Low Alarm Reset reguired if entered value is rejected Yes Value accepted Return to measurement mode h Move to next setting mode ing entry F6202E EPS Operational Flow Chart IM 11M10A01 03E 6 Operation 6 3 Configuring Data 1 Configuring the sensor parameters Upon replacing sensors parameters must be configured following the chart below Parameters to be configured are specified in the Sensor Parameter Table Figure 5 1 attached on a new sensor Indication Operational Flow Chart Measured inc 8 LL ppm O A Y ppm O FL in an E ppm O 9 ppm O Gain 1 Value ppm O Value Changing accepted value F6301E EPS To be continued to GIN 2 Note To check the sensor parameter press A W 5 tr will appear on the display Press ENT to confirm the parameter Figure 6 4 Flow Chart of Sensor Parameter Setting IM 11M10A01 03E 6 5 Continued To measurement mode A Gain 2 A
58. uring range Perform calibration following the procedure shown in the flow chart in the following pages Flow charts illustrate how to perform calibration for each range To perform calibra tion only for required ranges skip unwanted ranges by pressing the CAL key repeatedly until the desired range appears For complete calibration contact us for factory calibration Quick adjustment is available that enables the analyzer to harmonize output values with actual ones For details see Section 6 4 2 Moving zero point This function is useful when temporary adjustment is required or when calibration gas is not available at hand The sensor deteriorates progressively in service Its life varies depending on operating conditions If the sensor cannot be calibrated or the response becomes quite slow the sensor should be replaced No Calibration Point Calibration Setting Range 1 Air Atmospheric air or 15 25 O2 2 20 ppm 15 25 ppm O2 gas cylinder 3 100 ppm 80 120 ppm O2 gas cylinder 4 500 ppm 400 600 ppm O2 gas cylinder 5 1000 ppm 900 1100 ppm O2 gas cylinder 1 6 10000 ppm 8500 9500 ppm O2 gas cylinder 2 1 Or 1000 ppm O calibration gas 1L P N K9424JP T6401E EPS 2 Or 10000 ppm C2 calibration gas 1L P N K9424JQ For complete calibration contact YOKOGAWA for factory calibration IM 11M10A01 03E Air Calibration Indication 283 como CAL1 is for 0 25
59. urs After 50 hours service the activated carbon filter element must be replaced Using expired carbon filter may result in false measurement or even sensor deterio ration 7 1 7 2 2 Replacement interval for the disk filter P N K9424GQ varies depending on dust content in the sample gas Check the cleanness of element to determine the filter replacement cycle The felt filter P N K9346WH is for preventing the activated carbon from leaking so it requires no replacement unless abnormal conditions occur 3 Increasing contamination of the filter may deteriorate the flow rate of sucked sample gas The flow rate should be checked regularly by the flowmeter of the sampling unit If the flow rate is outside of the specified range 500 100 ml min readjust the flow rate IM 11M10A01 03E 8 Troubleshooting 8 Troubleshooting The table below summarizes troubles that may develop in the OX102 problem source and corrective action Abnormal symptom No indications No power applied Fuse has blown Apply power Replace the fuse FAIL lamp lit Sensor connector failure Sensor heater is disconnected Connect the sensor connector securely Replace the sensor Low value displayed High value displayed Operating pressure is out of specified range Improper calibration Sensor failure Expired activated carbon has been used Use within the specified pressure range Recalibration Replace

Model OX102 Current limit type Oxygen Analyzer

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