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Summary of Contents for YOKOGAWA ZO21DW
- Page 1 User’s Manual In-Situ Type Zirconia Oxygen Analyzer Model ZO21DW Detector IM 11M03A02-00E IM 11M03A02-00E 3rd Edition...
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Page 2: Introduction
The Model ZO21DW zirconia oxygen detector is constructed in such a way that the reference gas outlet is open to the inside of the furnace. Hence, the measured gas and reference gas pressures can be kept at about the same level, making high accuracy measurements possible. -
Page 3: For The Safe Use Of This Equipment
• Every effort has been made to ensure accuracy in the preparation of this manual. However, should any errors or omissions come to the attention of the user, please contact the nearest Yokogawa Electric representative or sales office. • This manual does not cover the special specifications. This manual may not be changed on any change of specification, construction and parts when the change does not affect the functions or performance of the product. - Page 4 <INTRODUCTION> l Safety and Modification Precautions • Follow the safety precautions in this manual when using the product to ensure protection and safety of personnel, product and system containing the product. The following safety symbols are used on the product as well as in this manual.
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Page 5: After-Sales Warranty
If we replace the product with a new one, we won’t provide you with a repair report. l Yokogawa warrants the product for the period stated in the pre-purchase quotation Yokogawa shall conduct defined warranty service based on its standard. When the customer site is located outside of the service area, a fee for dispatching the maintenance engineer will be charged to the customer. -
Page 6: Table Of Contents
<CONTENTS> Model ZO21DW Detector In-Situ Type Zirconia Oxygen Analyzer IM 11M03A02-00E 3rd Edition CONTENTS INTRODUCTION .......................i For the safe use of this equipment .............ii After-sales Warranty ...................iv SPECIFICATIONS ..................1-1 1.1 Standard Specifications ................... 1-1 Model and Codes ....................1-2 External Dimensions .................. - Page 7 <CONTENTS> NAME AND FUNCTION OF COMPONENTS ........... 5-1 OPERATION ....................6-1 Start-Up ......................6-1 6.1.1 Inspection of Piping and Wiring Conditions ........6-1 6.1.2 Checking of Set Valves ..............6-1 6.1.3 Supplying Heater Power ..............6-1 6.1.4 Calibration ..................6-1 Stationary Operation ..................6-2 6.2.1 Checking Operating Conditions ............
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Page 8: Specifications
<1. SPECIFICATIONS> SPECIFICATIONS In this chapter, the specifications of the ZO21DW detector is described. 1.1 Standard Specifications The probe, as a whole, is not explosion-protected (Calibration gas inlet, reference gas outlet) and only its terminal box section is explosion-protected. Sample Gas Temperature: 0 to 600°C... -
Page 9: Model And Codes
<1. SPECIFICATIONS> Model and Codes Model Suffix code Option code Description ZO21DW · · · · · · · · · · Probe with flameproof terminal box -040 Insertion length · · · · · · · · · · 0.4 m -100 ·... -
Page 10: External Dimensions
8 - ø19 18 Approx. 13 ( or equivalent ) ZO21DW-L-200-J*A 2000 Approx. 17 ZO21DW-L-300-J*A 3000 Approx. 20 ZO21DW-L-040-A*A 400 Approx. 6.5 ZO21DW-L-100-A*A 1000 Approx. 10 ANSI CLASS 150-4- ZO21DW-L-150-A*A 1500 228.6 190.5 8 - ø19 24 Approx. 13 ( or equivalent ) ZO21DW-L-200-A*A 2000 Approx. - Page 11 Blank Page...
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Page 12: Installation
<2. INSTALLATION> INSTALLATION Installation Site The following should be taken into consideration when installing the detector : (1) Easy access to the detector for checking and maintenance work. (2) A location in which the ambient temperature is not too high (below 70°C) and the terminal box is not subject to radiant heat. -
Page 13: Detector Installation
<2. INSTALLATION> Bounds of the probe (vertical) insertion hole location Flange matches the detector specifiions 100 mm (horizontal) Greater than 100 mm ∅52 mm Eight-hole flange F2.1E.ai Note : Make sure the reference gas outlet of the detector is not blocked by the gasket on the flange surface. Figure 2.1 Example of probe insertion hole Detector Installation... -
Page 14: Piping
PIPING This chapter describes the line - installation procedures for two typical system configurations of the zirconia oxygen analyzer using the ZO21DW detector. CAUTION • Ensure that each check valve, stop valve and joint used for piping do not allow leakage. -
Page 15: Parts Required For Piping In System 1
First, mount a stop valve (of a quality specified by YOKOGAWA) on a nipple (found on the open market) as illustrated in Figure 3.2, and mount a joint (also found on the open market) at the stop valve tip. (The stop valve may be mounted on the detector prior to shipping the detector.) -
Page 16: Piping For The Reference Gas Inlet
<3. PIPING> 3.1.3 Piping for the Reference Gas Inlet Reference gas piping is required between the air source (fresh air) and the flow setting unit and between the flow setting unit and the detector. Insert the air set next to the flow setting unit in the piping between the air source and the flow setting unit. -
Page 17: Piping For System 2
<3. PIPING> 3.2 Piping for System 2 Piping in System 2 is illustrated in Figure 3.3. ZO21DW Zirconia Oxygen Model ZR402G Converter Analyzer, Detector EXA ZR402G Signal (6-core shield cable) Stop valve 100 to 240 V AC or Check Heater (2-core) valve Contact input... -
Page 18: Piping For The Calibration Gas
Mount a regulator valve (specified by YOKOGAWA) on the cylinder. Mount a check valve or stop valve (specified by YOKOGAWA) on the nipple (found on the open market) at the calibration gas inlet of the detector as illustrated in Figure 3.4. -
Page 19: Piping For The Reference Gas
Piping for System 3 Piping in System 3 is illustrated in Figure 3.5. In System 3, calibration is automated but the piping is basically the same as that of System 2. See section 3.2. ZO21DW Zirconia Oxygen Model ZR402G Converter Analyzer, Detector EXA ZR402G... -
Page 20: Wiring
<4. WIRING> WIRING In this Chapter, the wiring necessary for connection to the Model ZO21DW detector is described. General CAUTION NEVER supply current to the converter or any other device constituting a power circuit in combination with the converter, until all wiring is completed. -
Page 21: Wiring Procedure
Install metal blind plug(s) in unused cable connection gland(s) of the converter. Metal conduit should be grounded. Model ZR402G Separate type Zirconia Oxygen Analyzer/ Zirconia Oxygen Analyzer, Converter Model ZO21DW Detector Analog Analog output 1 output 2 4-20 mA DC... -
Page 22: Wiring For Detector Output
<4. WIRING> Wiring for Detector Output This wiring enables the converter to receive cell output from the detector, output from a thermocouple and a reference junction compensation signal. Install wires that allow for 10 Ω of loop resistance or less. Keep detector wiring away from power wiring. Basically, PVC sheathed PVC insulated cable (six cores) is used for this wiring. -
Page 23: Wiring For Power To Detector Heater
<4. WIRING> 4.3 Wiring for Power to Detector Heater This wiring provides electric power from the converter to the heater for heating the sensor in the detector. Basically, PVC insulated PVC sheathed control cables (2 cores) are used for this wiring. ZR402G Detector Converter HTR 7 HEATER HTR 8 F4.3E.ai... -
Page 24: Power And Grounding Wiring
<4. WIRING> 4.4 Power and Grounding Wiring This wiring supplies power to the converter and grounds the converter/detector. ZR402G ZO21DW Converter Detector L N G Grounding to the ground terminal on the converter case Converter case Ground Jumper plate Crimp-on terminal of the ground wire... - Page 25 Blank Page...
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Page 26: Name And Function Of Components
<5. NAME AND FUNCTION OF COMPONENTS> NAME AND FUNCTION OF COMPONENTS In this Chapter, the name and function of components are described for the ZO21DW detector. Flange Stop valve Vent pipe for reference air Probe Insert this part into the furnace. - Page 27 Blank Page...
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Page 28: Operation
<6. OPERATION> OPERATION This chapter describes the operations for running the system related only to the ZO21DW Detector. For the entire zirconia oxygen analyzer operation, see the instruction manual for the converter. Start-Up 6.1.1 Inspection of Piping and Wiring Conditions In referring to Chapters 3 and 4, inspect the piping and wiring to see that they are correctly installed. -
Page 29: Stationary Operation
<6. OPERATION> Stationary Operation 6.2.1 Checking Operating Conditions In order to maintain normal operating conditions, determine which items are to be inspected periodically, and check them regularly for errors. Items recommended for periodic inspections are as follows for your reference. For maintaining or recovering performance, see Chapter 7. -
Page 30: Inspection And Maintenance
<7. INSPECTION AND MAINTENANCE> INSPECTION AND MAINTENANCE This chapter describes the inspection and maintenance procedures for the ZO21DW Zirconia Oxygen Analyzer to maintain its measuring performance and normal operating conditions. CAUTION When checking the detector, carefully observe the following: (1) Do NOT touch the probe if it has been in operation immediately just before being checked. -
Page 31: Inspection And Maintenance Of The Detector
<7. INSPECTION AND MAINTENANCE> Inspection and Maintenance of the Detector 7.1.1 Cleaning the Calibration Gas Tube The calibration gas, supplied through the calibration gas inlet of the terminal box into the detector, flows through the tube and comes out at the tip of the probe. The tube might become clogged with dust from the measurement gas. -
Page 32: Replacing The Sensor Assembly
<7. INSPECTION AND MAINTENANCE> 7.1.2 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-gas ratio of 100±30 % or a span-gas ratio of 0±18 %. In addition, the sensor assembly is to be replaced if it becomes damaged and can no longer operate during measurement. - Page 33 <7. INSPECTION AND MAINTENANCE> Part assembly procedure (1) First, install the contact. Being careful not to cause irregularities in the pitch of the coil spirals (i.e., not to bend the coil out of shape), place it in the ringed groove properly so that it forms a solid contact.
- Page 34 <7. INSPECTION AND MAINTENANCE> Metal O-ring Sensor U-shaped pipe support Bolts (four) Probe Contact Filter U-shaped pipe Washers (four) 1/8 turn – tighten bolts 1/8 turn (approximately 45°) each F7.3E.ai Figure 7.3 Exploded View of Sensor Assembly CAUTION Optional Inconel bolts have a high coefficient of expansion. If excess torque is applied while the bolts are being tightened, abnormal strain or bolt breakage may result.
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Page 35: Stopping And Re-Starting Operation
<7. INSPECTION AND MAINTENANCE> 7.1.3 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. -
Page 36: Customer Maintenance Parts List
Nipple (for ZO21DW-L ...-J, -E/SV) G7248XA Nipple (for ZO21DW-L ...-A/SV) G7007XH Needle Valve CMPL 11M06B02-01E All Rights Reserved, Copyright © 1989, Yokogawa Electric Corporation. Subject to change without notice. 1st Edition : Apr. 1989 (YK) 7th Edition : Apr. 2013 (YK) -
Page 38: Revision Information
Revision Information Title : In-Situ Type Zirconia Oxygen Analyzer Model ZO21DW Detector Manual No. : IM 11M03A02-00E Aug. 2018/3rd Edition Modified specification of flange material (p,1-1, 1-2) Revised tables. (p.3-2, 3-5) Revised “CMPL 11M06B02-01E”: to 7th edition Aug. 2009/2nd Edition All over revised Apr. 1989/1st Edition... - Page 39 Blank Page...
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