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Models and descriptions in this manual are listed below. Models and descriptions in this manual Description in this manual Model Product Name Specification Installation Operation Maintenance CMPL ZR202G Integrated type Oxygen ○ ○ ○ ○ ○ Analyzer ZO21R Probe protector ○...
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For the safe use of this equipment WARNING Be sure not to accidentally drop it. Handle safely to avoid injury. 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 sample gas is dangerous to people.
The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor responsibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA can not predict in advance. IM 11M12A01-04E...
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• No part of the user’s manuals may be transferred or reproduced without prior written consent from YOKOGAWA. • YOKOGAWA reserves the right to make improvements in the user’s manuals and product at any time, without notice or obligation. • If you have any questions, or you find mistakes or omissions in the user’s manuals, please contact our sales representative or your local distributor.
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Special descriptions in this manual This manual indicates operation keys, displays and drawings on the product as follows: Operation keys, displays on the panel Enclosed in [ ]. (Ex. “MODE” key) (Ex. message display → “BASE”) (Ex. data display → “102”...
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Batteries are included in this product. Batteries incorporated into this product cannot be removed by yourself. Dispose them together with this product. When you dispose this product in the EU, contact your local Yokogawa Europe B.V.office. Do not dispose them as domestic household waste.
Toc-1 Model ZR202G Integrated type Oxygen/Humidity Analyzer IM 11M12A01-04E 11th Edition CONTENTS Introduction ....................i Safety Precautions ..................iv CE marking products .................vii Overview ....................1-1 < EXAxt ZR > System Configuration ............... 1-1 1.1.1 System 1 .................... 1-1 1.1.2 System 2 .................... 1-2 1.1.3 System 3 ....................
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Toc-2 3.1.1 Probe Insertion Hole ................3-1 3.1.2 Installation of the Probe ..............3-2 3.1.3 Installation of the Dust Filter (K9471UA), Dust Guard Protector (K9471UC) Probe Protector (ZO21R) ..........3-2 3.1.4 Installation of ZH21B Dust Protector ..........3-4 Installation of ZA8F Flow Setting Unit ............3-5 Installation of ZR20H Automatic Calibration Unit .........
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Toc-3 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit ......6-2 Startup ....................... 7-1 Checking Piping and Wiring Connections ............. 7-1 Valve Setup ......................7-1 Supplying Power to Converter ................ 7-2 Operation of Infrared Switch ................7-2 7.4.1 Display and Switches ................. 7-2 7.4.2 Display Configuration .................
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Toc-4 8.2.2 Preference Order of Output Hold Value ..........8-7 8.2.3 Output Hold Setting ................8-7 8.2.4 Default Values ..................8-7 Setting Alarms ....................8-8 8.3.1 Alarm Values ..................8-8 8.3.2 Alarm Output Actions ................. 8-8 8.3.3 Alarm Setting..................8-9 8.3.4 Default Values ..................
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Toc-5 10.1.1 Oxygen Concentration ..............10-2 10.1.2 Humidity ................... 10-2 10.1.3 Mixing Ratio ..................10-2 10.1.4 Relative Humidity ................10-2 10.1.5 Dew Point ..................10-2 10.1.6 Air Ratio.................... 10-3 10.1.7 Cell Temperature ................10-3 10.1.8 Process Gas Temperature ............... 10-3 10.1.9 C.
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Toc-6 11.1.2 Replacing the Sensor Assembly ............11-2 11.1.3 Replacement of the Heater Assembly ..........11-4 11.1.4 Replacement of Dust Filter .............. 11-6 11.1.5 Replacement of O-ring ..............11-6 11.1.6 Stopping and Re-starting Operation ..........11-7 11.2 Inspection and Maintenance of the Converter ..........11-7 11.3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit ..
<1. Overview> Overview The EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer is used to monitor and control the oxygen concentration in combustion gases, in boilers and industrial furnaces, for wide application in industries which consume considerable energy-such as steel, electric power, oil and petrochemical, ceramics, pulp and paper, food, or textiles, as well as incinerators and medium/small boilers.
<1. Overview> ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer Stop valve 100 to 240 V AC Contact input Analog output, contact output Digital output (HART) Calibration gas 100/110/115 200/220/240 V AC ZO21S Standard gas unit F1.1E.ai Figure1.1 Example of System 1 NOTE •...
<1. Overview> 1.1.3 System 3 This example, System 3, represents typical applications in large boilers and heating furnaces, where is a need to monitor and control oxygen concentration. The reference gas and calibration- time span gas are (clean, dry) instrument air. Zero gas is supplied from a gas cylinder. System 3 uses the ZR20H automatic calibration unit, with auto-switching of the calibration gas.
<1. Overview> < EXAxt ZR > System Components 1.2.1 System Components Separate type Oxygen Humidity System Components System config. Analyzer Analyzer Ex.1 Ex.2 Ex.3 Model ZR202G Integrated type Zirconia Oxygen Analyzers Model ZO21R Probe Protector for Zirconia Oxygen Analyzers K9471UA Dust Filter for Oxygen Analyzer K9471UC Dust Guard Protector ZH21B Dust protector (only for Humidity Analyzer) Model ZO21S Standard Gas Unit...
Oxygen concentration in combustion exhaust gas and mixed gas (excluding inflammable gases). May not be applicable corrosive gas such as ammonia, chlorine is present-check with YOKOGAWA.) (In case of Humidity Analyzer, Water vapor (in vol%) in mixed gases (air and water vapor))
<2. Specifications> Linearity: (Excluding standard gas tolerance) (Excluding the case where the reference gas is by natural convection) (Use oxygen of known concentration (within the measuring range) as the zero and span calibration gases.) ±1% Maximum value of set range; less than 0 to 25 vol%O range (Sample gas pressure: within ±4.9 kPa) ±3% Maximum value of set range;...
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Note: When the detector is used in conjunction with a check valve and the ZA8F Flow Setting Unit, the maximum pressure of sample gas is 150 kPa. When with a check valve and the ZR20H Automatic Calibration Unit, it is 200 kPa. If the pressure of your sample gas exceeds these limits, consult with Yokogawa. Probe Length: 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 m...
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<2. Specifications> Functions (inclused Humidity Analyzer) Display Function: Displays values of the measured oxygen concentration, moisture quantity, mixture ratio, etc. Alarm, Error Display: Displays alarms such as “AL-06” or errors such as “Err-01” when any such status occurs. Calibration Functions: Automatic calibration; Requires the Automatic Calibration Unit. It calibrates automatically at specified intervals.
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<2. Specifications> Converter Output: One mA analog output point (4 to 20 mA DC (maximum load resistance of 550Ω)) with mA digital output point (HART) (minimum load resistance of 250Ω). Oxygen analyzer; Range; Any setting between 0 to 5 through 0 to 100 vol% O 1 vol% O , and partial range is available (Maximum range value/ minimum range value 1.3 or more)
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<2. Specifications> EXTERNAL DIMENSIONS Model ZR202G Integrated type Zirconia Oxygen/Humidity Analyzers Unit: mm 338 to 351 Ø123 Display side L= 0.4, 0.7, Rc1/4 or 1/4NPT 1.0, 1.5, 2.0, Reference gas inlet 2.5, 3.0 (m) 153 to 164 4-G1/2,2-1/2NPT etc. Terminal side Cable connection port 252 to 265 Rc1/4 or 1/4NPT...
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<2. Specifications> Model ZR202G...-P Integrated type Zirconia Oxygen/Humidity Analyzer with pressure compensation Unit: mm 342 ± 4 Ø123 Display side L= 0.4, 0.7, Rc1/4 or 1/4NPT 1.0, 1.5, 2.0, Reference gas inlet 2.5, 3.0 (m) Reference gas outlet PIPING 4-G1/2,2-1/2NPT etc. Terminal side PIPING:A Cable connection port...
<2. Specifications> Hood (Option code /H) Unit: mm ± 4 ± 3 F13.ai Material of HOOD : Aluminum Food Weight : Approx. 800g 2.1.3 ZO21R Probe Protector Used when sample gas flow velocity is approx. 10 m/sec or more and dust particles wears the detector in cases such as pulverized coal boiler of fluidized bed furnace (or burner) to protect the detector from wearing by dust particles.
Approx. 2.3 kg Calibration gas (zero gas, span gas) Consumption: Approx. 0.7 l/min (at calibration time only) NOTE Use instrument air for span calibration gas, if no instrument air is available, contact YOKOGAWA. IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00...
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2-13 <2. Specifications> External Dimensions Unit : mm (inch) ø6 Hole REFERENCE CHECK REFERENCE SPAN ZERO 2B mounting pipe 235.8 222.8 Calibration gas outlet Span gas inlet Reference gas outlet Zero gas inlet Piping connection port A CHECK SPAN ZERO Model Piping connection port A ZA8F-J*C 5 - Rc1/4...
Vertical mounting — - - - - - - - - Always -A Ask Yokogawa service station for additional mounting of ZR20H to the preinstalled ZR202G. Select the appropriate reference gas of ZR20H according to the one of ZR202G. IM 11M12A01-04E...
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2-15 <2. Specifications> External Dimensions (1) Horizontal Mounting (-A) Unit: mm Ø80 AUTO CAL. UNIT MODEL ZR20H SUFFIX STYLE SPAN IN REF IN ZERO IN SUPPLY 690kPa MAX. -20 TO 558C AMB.TEMP ZR202G USED WITH 66.5 166.5 Zero gas inlet Rc1/4 or 1/4NPT(Female) Span gas inlet Reference gas inlet Rc1/4 or 1/4NPT(Female)
2-16 <2. Specifications> ZO21S Standard Gas Unit This is a handy unit to supply zero gas and span gas to the detector in a system configuration based on System 1. It is used in combination with the detector only during calibration. The ZO21S does not conform to CE marking.
2-17 <2. Specifications> Other Equipment 2.4.1 Dust Filter for Oxygen Analyzer (part no. K9471UA) This filter is used to protect the detector sensor from corrosive dust components or from a high concentration of dust when the oxygen concentration in utility boilers or concrete kilns are to be measured.
2-18 <2. Specifications> Unit: mm Increasing of insertion length 4-Ø6 F11-1.ai 2.4.3 Stop Valve (part no. L9852CB or G7016XH) This valve is mounted on the calibration gas line in the system to allow for manual calibration. This is applied to a system configuration (System 1). Standard Specifications Connection: Rc1/4 or 1/4NPT (Female)
2-19 <2. Specifications> Part No. Description K9292DN Joint: Rc 1/4, Material: SUS304 (JIS) K9292DS Joint: 1/4 NPT (F), Material: SUS304 (JIS) Unit: mm K9292DN : Rc 1/4(A),R 1/4(B) K9292DS : 1/4FNPT(A),1/4NPT(Male)(B) Approx. 19 Approx. 54 F30.EPS 2.4.5 Air Set This set is used to lower the pressure when instrument air is used as the reference and span gases.
2-21 <2. Specifications> 2.4.7 Pressure Regulator (G7013XF or G7014XF) for Gas Cylinder This regulator valve is used with the zero gas cylinders. Standard Specifications Primary Pressure: Max. 14.8 MPa G Secondary Pressure: 0 to 0.4 MPa G Connection: Inlet; W22 14 threads, right hand screw Outlet;...
2-22 <2. Specifications> Pressure regulator G7013XF/ G7014XF Zero gas cylinder (G7001ZC) 2B mounting pipe (158.3) ( Ø60.5 ) F23.ai The oblique line is an opening portion. (Note)The zero gas cylinder and the regulator valve are not included in the E7044KF (case assembly) 2.4.9 ZR202A Heater Assembly Model and Codes...
<3. Installation> Installation This chapter describes installation of the following equipment: Section 3.1 Model ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer Section 3.2 Model ZA8F Flow Setting Unit Section 3.3 Model ZR20H Automatic Calibration Unit Section 3.4 Case Assembly (E7044KF) for Calibration gas Cylinder Installation of ZR202G Zirconia Oxygen/ Humidity Analyzer The following should be taken into consideration when installing the probe:...
<3. Installation> (1) Do not mount the probe with the tip higher than the probe base. (2) If the probe length is 2.5 m or more, the detector should be mounted vertically (no more than a 5° tilt). (3) The detector probe should be mounted at right angles to the sample gas flow or the probe tip should point downstream.
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<3. Installation> When you specify option code /F1, the detector is shipped with the dust filter mounted. Follow this procedure when replacing the filter in the detector. It is recommended that you read Chapter 11 prior to filter mounting, for it is necessary to be familiar with the detector’s construction, especially the sensor assembly.
<3. Installation> (2) Make sure that the sensor assembly mounting screws (four bolts) at the probe tip are not loose. (3) Mount the detector so that the calibration/reference gas inlet faces downward. Unit: mm Gasket (t1.5) Direction of the sample gas flow 2050 Ø60.5 Detector top...
<3. Installation> (3) Mount the detector so that the calibration gas inlet and the reference gas inlet face downward. Unit : mm Unit : mm Reference gas inlet Calibration gas inlet F3-2E.ai F3-2E.ai Figure 3.6 Installation of the dust filter Installation of ZA8F Flow Setting Unit The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work.
<3. Installation> <Wall Mounting> (1) Make a hole in the wall as illustrated in Figure 3.8. Unit: mm 4 - Ø6 hole, or M5 screw F3.13E.ai Figure 3.8 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.
<3. Installation> Unit: mm Horizontal mounting on the ZR202G (-A) Display side Terminal box side Zero gas inlet Rc1/4 or 1/4NPT(Female) 66.5 166.5 Reference gas inlet Span gas inlet Rc1/4 or 1/4NPT(Female) Rc1/4 or 1/4NPT(Female) Vertical mounting on the ZR202G (-B) 166.5 Span gas inlet...
<3. Installation> Mounting Mount case assembly on a pipe (nominal JIS 50 A) as follows: (1) Prepare a vertical pipe of sufficient strength (nominal JIS 50A: O.D. 60.5 mm) for mounting the case assembly. (The sum of the case assembly and the calibration gas cylinder weighs approximately 4.2 kg.) (2) Mount the case assembly on the pipe by tightening the nuts with the U-bolt so that the metal fitting is firmly attached to the pipe.
<4. Piping> Piping This chapter describes piping procedures in the three typical system configurations for EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer. • Ensure that each check valve, stop valve and joints used for piping are not leaking. Especially, when there is any leakage at piping and joints for the calibration gas, it may cause clogging of the piping or incorrect calibration.
Mount the stop valve (of a quality specified by YOKOGAWA) through a nipple (found on the local market) as illustrated in Figure 4.2, and mount a joint (also found on the local market) at the stop valve tip. (The stop valve may be mounted on the equipment when the oxygen analyzer is shipped.)
Mount the pressure regulator (recommended by YOKOGAWA) on the cylinder. Mount the stop valve or the check valve (recommended by YOKOGAWA) through the nipple (found on the local market) at the calibration gas inlet of the equipment as illustrated in Figure 4.4.
<4. Piping> Piping for the reference gas 6mm (O.D.) by 4mm (I.D.) stainless steel pipe Piping for the calibration gas 6mm (O.D.) by 4mm (I.D.) stainless steel pipe Stop valve or check valve F4.8E.ai Figure 4.4 Piping for the Calibration Gas Inlet 4.2.3 Piping for the Reference Gas Reference gas piping is required between the air source (instrument air) and the flow setting unit,...
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<4. Piping> Installation of ZR20H Automatic Calibration Unit Unit: mm Horizontal mounting on the ZR202G (-A) Display side Terminal box side Zero gas inlet Rc1/4 or 1/4NPT(Female) 66.5 166.5 Reference gas inlet Span gas inlet Rc1/4 or 1/4NPT(Female) Rc1/4 or 1/4NPT(Female) Vertical mounting on the ZR202G (-B) 166.5...
<4. Piping> Piping for the Oxygen Analyzer with Pressure Compensation ZR202G-----P Oxygen Analyzer with pressure compensation may be used in System 2 and System 3. Use this style analyzer whenever the furnace pressure exceeds 5 kPa (see Note). Even if the furnace pressure is high, the detector can measure by adjusting pressure of the probe with the furnace pressure using instrument air.
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<4. Piping> CAUTION • Use suitable cable glands to completely seal the detector. As far as possible do not stop the instrument air flow, to prevent the sample gas from entering the detector and damaging the zirconia cell. • Connect the stop valve, which is at the calibration gas inlet, directly to the equipment. If piping connections are made between the detector and the needle valve, condensation will result inside the piping and cause the sensor to be damaged when the calibration gas is introduced.
General parts Reference gas inlet Air set (G7003XF/ K9473XK or G7004XF / K9473XG) recommended by YOKOGAWA Joint for tube connection Rc1/4 or 1/4 NPT General parts Note: Use parts with marking * as required. General parts can be found on the local market.
<5. Wiring> Wiring This chapter describes wiring procedures necessary for the EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer. General WARNING NEVER supply current to the converter or any other device constituting a power circuit in combination with the converter, until all wiring is completed. CAUTION This product complies with CE marking.
<5. Wiring> WARNING Cables that withstand temperatures of at least 80 °C should be used for wiring. CAUTION • Select suitable cable O.D. to match the cable gland size. • Protective grounding should be connected in ways equivalent to JIS D style (Class 3) grounding (the grounding resistance is 100 Ω...
<5. Wiring> Model ZR202G Integrated type Zirconia Oxygen Analyzer Contact output 1 Contact output 2 Contact input 1 Contact input 2 DI-1 DI-2 DI-C DO-1 DO-1 DO-2 DO-2 100 to 240 V AC, Analog output 50 or 60 Hz 4-20 mA DC Digital output F28.EPS The protective grounding for the analyzer shall be connected either the protective ground terminal...
<5. Wiring> 5.2.1 Cable Specifications Use a 2-core shielded cable for wiring. 5.2.2 Wiring Procedure (1) M4 screws are used for the terminals. Use crimp-on terminals appropriate for M4 terminal screws for cable connections. Ensure that the cable shield is connected to the FG terminal of the equipment.
<5. Wiring> 5.3.2 Wiring for Ground Terminals The ground wiring of the analyzer should be connected to either the ground terminal of the equipment case or the terminal inside of the equipment. Proceed as follows: (1) Keep the ground resistance of 100Ω or less (JIS Class D grounding). (2) When connecting the ground wiring to the ground terminal of the equipment case, be sure that the lock washer is in contact with the case surface (see Figure 5.5.).
<5. Wiring> 5.5.1 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. 5.5.2 Wiring Procedure (1) M4 screws are used for the terminal of the converter. Each cable should be equipped with the corresponding crimp contact.
<6. Components> Components This chapter describes the names and functions of components for the major equipment of the EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer. ZR202G Zirconia Oxygen/Humisity Analyzer 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...
<6. Components> ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit Reference gas flow setting valve Span gas flow setting valve Zero gas flow setting valve Flowmeter for reference gas Flowmeter for calibration gas F6-4E.ai Figure 6.2 ZA8F Flow Setting Unit Horizontal mounting Vertical mounting Flowmeter for...
<7. Startup> Startup The following describes the minimum operating requirements — from supplying power to the converter to analog output confirmation to manual calibration. In the figure listed in this manual, the example of the oxygen analyzer is shown mainly. In the case of the humidity analyzer, unit indication may be different.
<7. Startup> (2) If instrument air is used as the reference gas, adjust the Air set secondary pressure so that the air pressure of sample gas pressure plus approx. 50 kPa (plus approx. 150 kPa for with check valve) (300 kPa maximum for the ZA8F, 690 kPa maximum for the ZR20H) is obtained.
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<7. Startup> 4: Decimal point 1: Data display area µ M m N k g a l b b l scftm3 /d /s /h /m > 3: Engineering-unit display area 2: Infrared switch F7.3E.ai Figure 7.4 Infrared switch and the display 1.
<7. Startup> 7.4.2 Display Configuration The parameter codes provided for the equipment are used to control the equipment display panels (see below). By selecting appropriate parameter codes, you can conduct calibration and set operation parameters. Figure 7.5 shows the configuration of display items. The parameter codes are listed in groups of seven;...
<7. Startup> 7.4.3 Entering Parameter Code Selection Display This section briefly describes the password entry procedure for entering the parameter code selection display. The password is 1102 - it cannot be changed to a different password. Switch operation Display Description 21.0% >...
<7. Startup> 7.4.4 Selecting Parameter Codes Switch operation Display Description > ∧ Password has been entered and the parameter code selection display has appeared. Character A is flashing, indicating that character A can be changed. > ∧ If you touch the [>] key once, the position of the digit that is flashing will move to the right.
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<7. Startup> (2) Entering numeric values such as oxygen concentration values and factors Switch operation Display Description > ∧ 00.0 The set value is displayed after the parameter code selection. An example of entering "9.8" is given below. (The currently set value is 0.0) >...
<7. Startup> Confirmation of Equipment Type Setting This equipment can be used for both the Oxygen Analyzer and the Humidity Analyzer. If you choose optional specification /HS at the time of purchase, the equipment is set for the Humidity Analyzer. Before setting the operating data, be sure to check that the desired model has been set.
<7. Startup> Selection of Measurement Gas Combustion gases contain moisture created by burning hydrogen in the fuel. If this moisture is removed, the oxygen concentration might be higher than before. You can select whether the oxygen concentration in a wet gas is to be measured directly, or compensated for its dry-gas value before use.
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7-10 <7. Startup> Table 7.5 Minimum and Maximum Value Setting Procedure Switch operation Display Description > ∧ Display after the password has been entered. > ∧ Set the oxygen concentration at 4 mA. Change the parameter code to C11. Touch the [∧] key to switch to Group C. >...
7-11 <7. Startup> 7.7.2 Output Range Setting Select any one of the analog output settings — oxygen, humidity, and mixing ratio. If the /HS option was specified at the time of purchase, the equipment is a humidity analyzer. For other than this setting, the analyzer is an oxygen analyzer.
7-12 <7. Startup> Switch operation Display Description > ∧ Touch the [>] key to move the position of the digit that is flashing to the right. > ∧ Touch the [∧] key to change the number 2 in C25 to “8.” >...
7-13 <7. Startup> 7.8.2 Humidity Analyzer - Setting Display Item Display items are those items that are displayed on the basic panel display. Parameter code A00 or F08 is used to set the display items as shown in the table below. If the humidity analyzer /HS option was specified at the time of purchase, the equipment is a humidity analyzer.
7-14 <7. Startup> 7.10 Checking Contact I/O Conduct a contact input and output check as well as an operation check of the solenoid valves for the optional automatic calibration unit. Table 7.10 Parameter Codes for Checking Contact I/O Check item Parameter code Set value and contact action Contact output 1 Open...
7-15 <7. Startup> CAUTION If you conduct an open-close check for the contact output 2, Error 1 (cell voltage failure) or Error 2 (heater temperature abnormal) will occur. This is because the built-in heater power of the detector, which is connected to contact output 2, 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,”...
7-16 <7. Startup> 7.10.3 Checking Input Contacts Follow Table 7.13 to check the input contacts. The table uses an example with input contact 1. Table 7.13 Checking Input Contacts Switch operation Display Description > ∧ Display after the password has been entered. >...
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7-17 <7. Startup> (3) Oxygen concentration in span gas Enter the span gas oxygen concentration for calibration. If instrument air is used, enter 21 vol % O . 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.
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7-18 <7. Startup> Table 7.15 Calibration Setup Procedure Switch operation Display Description > ∧ Display after the password has been entered. > ∧ Set the zero gas concentration. Switch the parameter code to B01. Here, set 0.98%. > ∧ 001.00 Touch the [ENT] key to display the currently set value.
7-19 <7. Startup> 7.11.2 Manual Calibration The following describes how to conduct a calibration. Preliminary Before conducting 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 will be a sample gas plus approx.
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7-20 <7. Startup> Switch operation Display Description > ∧ 0.98 Touch the [ENT] key to display the calibration gas value. This value must be the zero gas concentration set in Section 7.10.1, "Calibration Setup," earlier in this manual. To cancel the above, touch the [>] key and [ENT] key together, then the display returns to "ZEro Y."...
<8. Detailed Data Setting> Detailed Data Setting Current Output Setting 8.1.1 Oxygen Analyzer_Current Output Setting This section describes setting of the analog output range. Table 8.1 shows parameter codes for the set items. Table 8.1 Current Output Parameter Codes Set item Parameter code Set value Analog output...
<8. Detailed Data Setting> NOTE When you select logarithmic mode in Section 8.1.3, “Output Mode,” later in this manual, the oxygen concentration, humidity reading, and mixing ratio remain constant at 0.1% O , 0.1% H and 0.01 kg/kg respectively. 8.1.3 Setting Minimum Oxygen Concentration (at 4 mA) and Maximum Oxygen Concentration (at 20 mA) Set the oxygen concentration values at 4 mA and 20 mA.
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<8. Detailed Data Setting> If you do not observe this restriction, the measurement will be invalid, and any previous valid value will be used. The gray area in figure represents the valid setting range. Setting example 1 If the range minimum (corresponding to 4 mA output) is set to 10 vol%O then range maximum (corresponding to 20 mA output) must be at least 13 vol%O Setting example 2...
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<8. Detailed Data Setting> Ranges over which oxygen concentrations can be set Outside ranges Minimum humidity (for a 4-mA current), % H F8-2E.ai Figure B Max. and Min. Humidity Set Ranges “Mixing ratio” setting range The minimum mixing ratio is set to 0 kg/kg or ranges from 0.201 to 0.625 kg/kg. The maximum “mixing ratio”...
<8. Detailed Data Setting> 8.1.6 Entering Output Damping Constants If a measured value adversely affected by a rapid change in the sample gas oxygen concentration is used for the control means, frequent on-off actions of the output will result. To avoid this, the converter allows the setting of output damping constants ranging from 0 to 255 seconds.
<8. Detailed Data Setting> 8.2.1 Definition of Equipment Status (1) During warm-up “During warm-up” is the time required after applying power until the sensor temperature stabilizes at 750°C, and the equipment is in the measurement mode. This status is that the sensor temperature is displayed on the basic panel.
<8. Detailed Data Setting> In a semi-automatic calibration, “during calibration” is the time, starting when a calibration instruction is executed with an infrared switch or a contact input, to make a series of calibrations, until the preset output stabilization time elapses. In an automatic calibration, “during calibration”...
<8. Detailed Data Setting> Setting Alarms The analyzer enables the setting of four alarms high-high, high, low, and low-low alarms depending upon the oxygen concentration. The following section sets forth the alarm operations and setting procedures. 8.3.1 Alarm Values (1) High-high and high alarm values High-high alarms and high alarms are issued when they are set to be detected with parameter codes “D41”...
<8. Detailed Data Setting> (3) Although oxygen concentration measurement “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) Oxygen concentration measurement “D” has fallen below the hysteresis set value and the preset delayed time during measurement has elapsed, so the alarm is canceled.
8-10 <8. Detailed Data Setting> CAUTION Even with alarms set, if “Not detected” has been set in the above alarm detection, no alarm is issued. Be sure to set “Detected” in the above alarm detection if you use alarm features. 8.3.4 Default Values When the analyzer is delivered, or if data are initialized, the default alarm set values are as...
8-11 <8. Detailed Data Setting> Table 8.9 Setting Output Contacts Operating state When no power is applied to this equipment Output contact 1 Open (de-energized) or closed Open (energized) selectable. Output contact 2 Closed (de-energized) only. Closed 8.4.2 Setting Output Contact Set the output contacts following Table 8.10.
8-12 <8. Detailed Data Setting> 8.4.3 Default Values When the analyzer is delivered, or if data are initialized, output contacts are by default as shown in Table 8.11. Table 8.11 Output Contact Default Settings Item Output contact 1 Output contact 2 High-high alarm High alarm Low alarm...
8-13 <8. Detailed Data Setting> CAUTION • Measurement range switching function by an external contact input is available for analog output 1 only and the range is fixed to 0-25%O • To conduct a semi-automatic calibration, be sure to set the Calibration setup mode to “Semi- automatic”...
8-14 <8. Detailed Data Setting> Table 8.14 Data-and-time Settings Switch operation Display Description > ∧ Select the parameter code F10. > ∧ 00.01.01 If you touch the [ENT] key, the current date will be displayed. The display on the left indicates the date - January 1, 2000. To set June 21, 2000, follow the steps below: >...
8-15 <8. Detailed Data Setting> Table 8.15 Parameter Codes for Average, Maximum and Minimum Values Set item Parameter code Set range Units Periods over which average values 1 to 255 Hours are calculated Periods over which maximum 1 to 255 Hours and minimum values are monitored Default Value...
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8-16 <8. Detailed Data Setting> For liquid fuel Amount of water vapor in exhaust gas (Gw) = (1/100) {1.24 (9h + w)} (m /kg) Theoretical amount of air (Ao) = 12.38 x (Hl/10000) – 1.36 (m /kg) Low calorific power = Hl X value = (3.37 / 10000) x Hx –...
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8-18 <8. Detailed Data Setting> Table 8.16 Fuel Data • For liquid fuel Fuel Chemical component Amount of combustion Calorific power Theoretical Specific properties amount of (weight percentage) gas Nm kJ/kg weight value air for kg/l combustion Type Higher Lower Total O SO content...
8-19 <8. Detailed Data Setting> Procedure Use the parameter code table below to set fuel values. Table 8.17 Setting Fuel Values Set item Parameter code Set value Engineering units Amount of water vapor in exhaust gas 0 to 5 /kg (m Theoretical amount of air 1 to 20 /kg (m...
8-20 <8. Detailed Data Setting> Default Values When the analyzer is delivered or data are initialized, the parameters are by default as shown in Table 8.20. Table 8.20 Parameter Codes for Exhaust Gas Temperature and Pressure Settings Item Default setting Exhaust gas temperature 300°C Exhaust gas pressure...
<9. Calibration> Calibration Calibration Briefs 9.1.1 Principle of Measurement with a zirconia oxygen analyzer This section sets forth the principles of measurement with a zirconia oxygen analyzer before detailing calibration. A solid electrolyte such as zirconia allows the conductivity 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 oxygen partial pressures on each side, the element shows the action of the concentration cell.
<9. Calibration> 0.51 vol%O ,81.92mV(Zero origin of calibration) Cell voltage (mV) 21.0 vol%O , 0mV (Span origin of calibration) 21.0 Oxygen concentration (vol % O F9.1E.ai Figure 9.1 Oxygen Concentration in a Measurement Gas vs. Cell Voltage (21 vol%O Equivalent) The measurement principles of a zirconia oxygen analyzer have been described above.
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<9. Calibration> From the above equations (1) and (2), we obtain: E = -K log y/a = -Klog [(100 – x) 30.21] /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. Calibration> Humidity, vol % H Mixing ratio, kg/kg 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Oxygen concentration, vol % O Oxygen concentration vs. Humidity, Mixing ratio F9-3E.ai Figure 9.4 9.1.3 Calibration Gas A gas with a known oxygen concentration is used for calibration.
<9. Calibration> (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.
<9. Calibration> 9.2.3 Zero gas Concentration Set the oxygen concentration for zero calibration. Enter the oxygen concentration for the zero gas in the cylinder used. 9.2.4 Span gas Concentration Set the oxygen concentration for span calibration. If instrument air is used as the span gas, enter 21 %O 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.
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<9. Calibration> • When the calibration mode is in automatic: In addition to the above hold (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 255 days, 23 hours.
9-10 <9. Calibration> 9.3.3 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. NOTE Before conducting a semi-automatic or automatic calibration, run the automatic calibration unit beforehand to obtain a calibration flow of 600 ±...
10-1 <10. Other Functions> Other Functions 10.1 Detailed Display Select the desired parameter code to display the detailed operation data (see Table 10.1, “Parameter Codes for Detailed Operation Data”. NOTE Refer to Section 7.8, “Setting Display Item”, for parameter code “A00”. Table 10.1 Parameter Codes for Detailed Operation Data Engineering...
10-2 <10. Other Functions> Min. oxygen concentration Calibration history 7 YY.MM.DD/ HH.MM Occurrence of minimum oxygen YY.MM.DD/ Calibration history 8 YY.MM.DD/ concentration HH.MM HH.MM Average oxygen concentration Calibration history 9 YY.MM.DD/ HH.MM Maximum humidity Time YY.MM.DD/ HH.MM Occurrence of maximum humidity YY.MM.DD/ Software revision HH.MM...
10-3 <10. Other Functions> The water vapor pressure in the moist air can be obtained from the gas pressure and volume ratio (= pressure ratio), as given below. e = P x H where, e = Water vapor pressure in moist air P = Gas pressure H = Humidity (volume ratio) Use the above equation to find the water vapor in the moist air, and use the theoretical equation...
10-4 <10. Other Functions> 10.1.11 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 oxygen concentration), the sensor will be assumed to be normal.
10-5 <10. Other Functions> Five minutes maximum Response time 100% 10% of analog output span 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.
10-6 <10. Other Functions> 10.1.19 Oxygen Concentration (with time constant), Humidity (with time constant), and Mixing Ratio (with time constant) When the output damping is specified in the mA-output range setting, the corresponding time constant is also displayed. 10.1.20 Maximum Oxygen Concentration, Humidity, and Mixing Ratio The maximum oxygen concentration and the time of its occurrence during the period specified in the Averaging display are displayed.
10-7 <10. Other Functions> 10.1.24 History of Calibration Time The calibration-conducted dates and times for the past ten calibrations are stored in memory. 10.1.25 Time The current date and time are displayed. These are backed up by built-in batteries, so no adjustment is required after the power is switched off.
10-8 <10. Other Functions> 10.3 Initialization Procedure Follow the table below to initialize parameters. The password for initialization is 1255. Table 10.5 Initialization Procedure Switch operation Display Description > ∧ Enter the parameter code for the item to be initialized. The following show an example of entering "F30."...
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10-9 <10. Other Functions> (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.
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10-10 <10. Other Functions> Table 10.7 Parameter Codes for Oxygen Analyzer Display-related Items in Group A Engineering Engineering Code Item Code Item unit unit Selection 0 Oxygen concentration Span correction ratio 0 of display 1 Oxygen analyzer (0.0) Span correction ratio 1 items 2 Oxygen analyzer (0.0) Span correction ratio 2...
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10-11 <10. Other Functions> Calibration-related Items in Group B Code Item Tuning Engineering unit Default setting Zero gas concentration 0.3 to 100 1% O Span gas concentration 4.5 to 100 21% O Calibration mode 0 Manual calibration Manual calibration 1 Semi-automatic and manual calibration 2 Automatic, semi-automatic, and manual calibration...
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10-12 <10. Other Functions> Output-related Items in Group C Code Item Tuning Engineering unit Default setting C01 Analog output 0 Oxygen concentration Oxygen concentration 1 Amount of moisture content 2 Mixed ratio C03 Output mode 0 Linear Linear 1 Logarithm C04 Output during warm-up 0 Held at 4 mA 1 Held at 20 mA...
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10-13 <10. Other Functions> Contact-related Items in Group E Code Item Tuning Engineering unit Default setting Selection of input contact 1 0 Invalid Invalid 1 Calibration gas pressure decrease 2 Measurement range change 3 Calibration start 4 Detection of non-combusted gas Selection of input contact 2 0 Invalid Invalid 1 Calibration gas pressure decrease...
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10-14 <10. Other Functions> Equipment Setup and Others in Group F Code Item Tuning Engineering unit Default setting Equipment setup 0 Oxygen analyzer Oxygen analyzer 1 Humidity analyzer Selection of measurement 0 Wet 1 Dry Selection of temperature 0 degree C degree C units 1 degree F...
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10-15 <10. Other Functions> Table 10.8 Parameter Codes for Humidity Analyzer Display-related Items in Group A Engineering Engineering Code Item Code Item unit unit Selection 0 Oxygen concentration Span correction ratio 0 of display 1 Oxygen analyzer (0.0) Span correction ratio 1 items 2 Oxygen analyzer (0.0) Span correction ratio 2...
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10-16 <10. Other Functions> Maximum mixing ratio kg/kg Occurrence of max. mixing ratio YY.MM.DD/ HH.MM Minimum mixing ratio kg/kg Occurrence of min. mixing ratio YY.MM.DD/ HH.MM Average mixing ratio kg/kg Note1: “/” indicates that both are displayed alternately. Note2: Parameter codes with no items in the above table are not used in the oxygen analyzer. Calibration-related Items in Group B Code Item...
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10-17 <10. Other Functions> Output-related Items in Group C Code Item Tuning Engineering unit Default setting C01 Analog output 0 Oxygen concentration Humidity 1 Amount of moisture content 2 Mixed ratio C03 Output mode 0 Linear Linear 1 Logarithm C04 Output during warm-up 0 Held at 4 mA 1 Held at 20 mA 2 Set value remains held.
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10-18 <10. Other Functions> Alarm-related Items in Group D Code Item Tuning Engineering unit Default setting D01 Oxygen concentration, 0 to 100 100% O high-high alarm setpoint D02 Oxygen concentration, 0 to 100 100% O high alarm setpoint D03 Oxygen concentration, 0 to 100 0% O low alarm setpoint...
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10-19 <10. Other Functions> D54 Mix ratio, low-low alarm 0 Not detected Not detected detection 1 Detection Contact-related Items in Group E Code Item Tuning Engineering unit Default setting Selection of input contact 1 0 Invalid Invalid 1 Calibration gas pressure decrease 2 Measurement range change 3 Calibration start 4 Detection of non-combusted gas...
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10-20 <10. Other Functions> Equipment Setup and Others in Group F Code Item Tuning Engineering unit Default setting Equipment setup 0 Oxygen analyzer Not initialized 1 Humidity analyzer Selection of temperature 0 degree C degree C units 1 degree F Selection of pressure units 0 kPa 1 psi...
10-21 <10. Other Functions> 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.
10-22 <10. Other Functions> 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.
10-23 <10. Other Functions> (4) After the measured oxygen concentration is stabilized, touch the [ENT] key, then all the digits flash. Touch the [ENT] key again to display “ZEro Y”. Disconnect the power cord to stop the pump. <Flow of zero gas> Touch the [ENT] key to display a zero gas value set with the parameter code B01.
10-24 <10. Other Functions> 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 is sample gas pressure plus approx.
11-1 <11. Inspection and Maintenance> Inspection and Maintenance This chapter describes the inspection and maintenance procedures for the EXAxt ZR Zirconia Oxygen/Humidity Analyzer to maintain its measuring performance and normal operating conditions. WARNING 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.
11-2 <11. Inspection and Maintenance> Exploded view of components Calibration gas tube (with outside diameter of 2 to 2.5 mm) F11.1E.ai Figure 11.1 Cleaning the Calibration Gas Tube 11.1.2 Replacing the Sensor Assembly 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 zero correction ratio of 100 ±...
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11-3 <11. Inspection and Maintenance> (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.
11-6 <11. Inspection and Maintenance> Replacement of heater assembly Refer to Figure 11.4 as an aid in the following discussion. Remove U-shaped pipe support , U-shaped pipe , Filter and the sensor (cell) , following Section 11.1.2, earlier in this manual. Remove the two screws that tighten the cover and slide it to the flange side.
11-7 <11. Inspection and Maintenance> 11.1.6 Stopping and Re-starting Operation <Stopping Operation> When operation is stopped, take care of the followings so that the sensor of the detector cannot become unused. 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.
11-8 <11. Inspection and Maintenance> SCREW Cover of Display F11.6E.ai F11.5E.ai Figure 11.5 Cover of Display Figure 11.6 Location of Screw (4) Disconnect the three connectors from the printed-circuit board, as shown in Figure 11.7, by holding the connector housing. Do not pull the leadwire out to remove the connectors, otherwise, disconnection may result.
11-9 <11. Inspection and Maintenance> 11.3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit (1) Remove pipe holding piping fitting (2) 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.
12-1 <12. Troubleshooting> Troubleshooting This chapter describes errors and alarms 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?
5) Remove the probe to gain access to the two connectors (four connectors for the optional automatic calibration unit), as indicated in Figure 12.2. Check these connectors are properly connected. 6) If Error-1 still occurs, the electronics may be defective. Contact your local Yokogawa service or sales representative. 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.
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F12.3E.ai Figure 12.3 (4) If the inspection indicates that the thermocouple is normal, the electronics may be defective. Consult your local Yokogawa service or sales representative. Error-3: A/D Converter Failure/Error-4: Writing-to-memory Failure • A/D Converter Failure It is suspected that a failure has occurred in the A/D converter mounted in the converter electronics.
12-4 <12. Troubleshooting> 12.2 Displays and Measures to Take When Alarms are Generated 12.2.1 What is an Alarm? 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.
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12-5 <12. Troubleshooting> Alarm 6: Zero Calibration Coefficient Alarm In calibration, this alarm is generated when the zero correction ratio is out of the range of 100 ± 30% (refer to Section 9.1.4, “Compensation”). 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 (refer to Section 9.2,“Calibration Procedures.)”...
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12-6 <12. Troubleshooting> Alarm 7: Span Calibration Coefficient Alarm In calibration, this alarm is generated when the span gas correction ratio is out of the range of 0 ± 18% (refer to Section 9.1.4, “Compensation”). 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.”...
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If this alarm occurs even when the ambient temperature is under 55°C, the electronics may be defective. Contact your local Yokogawa service or sales representative. Alarm 11: Thermocouple Voltage Alarm This alarm is generated when the emf (voltage) of thermocouple falls below -5 mV (about -170°C) or exceeds 42.1 mV (about 1020°C).
<Corrective action> When the battery low alarm occurs, remember that the battery cannot be replaced by the user. Contact your Yokogawa service representative. 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.
12-9 <12. Troubleshooting> (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.
12-10 <12. Troubleshooting> 12.3.3 Measurements Sometimes Show Abnormal Values <Cause and Measure> (1) Noise may be mixing in with the converter from the detector output wiring. Check whether the equipment is 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.
Revision Information Manual Title : Model ZR202G Integrated type Oxygen/Humidity Analyzer Manual No. : IM 11M12A01-04E Jul. 2017/11th Edition Changed flange materials of ZR202G, ZO21R and ZH21B. (pages 2-3, 2-6 to 2-11) May 2017/10th Edition Addition RoHS etc. (pages i, v, vii, 2-2) Feb.
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12.2.1 Corrected explanation of Alarm 10 Added Filter to CMPL 11M12A01-04E, and added ZR20H Automatic Calibration Unit to CMPL 11M12A01-12E Oct. 2000/1st Edition Newly published Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, JAPAN Homepage: http://www.yokogawa.com/ IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00...
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