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YOKOGAWA ZR22G User Manual

Zirconia oxygen/humidity analyzer
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User's
Manual
ZR22G and ZR802G
Zirconia Oxygen/Humidity
Analyzer
IM 11M12G01-02EN
IM 11M12G01-02EN
1st Edition

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Summary of Contents for YOKOGAWA ZR22G

  • Page 1 User’s Manual ZR22G and ZR802G Zirconia Oxygen/Humidity Analyzer IM 11M12G01-02EN IM 11M12G01-02EN 1st Edition...
  • Page 2 Zirconia Oxygen/Humidity Analyzer is an oxygen analyzer in general use, composed of ZR802G converter and ZR22G detector. However, when you place an order for ZR802G as a Humidity Analyzer, or you specify the Humidity Analyzer due to a change of specification requirements, ZR802G is provided as Humidity Analyzer.
  • Page 3 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 ZR22G General use detector ○ ○ ○ ○ ○ ZR22G High temperature detector (0.15m)
  • Page 4 Table of Contents Relates to Chapter Outline Installation Operation Maintenance Equipment models and system 1. Overview configuration examples Standard specification, model code (or part 2. Specifications number), dimension drawing for each equipment 3. Installation Installation method for each equipment Examples of piping in three standard system 4.
  • Page 5 NOTICE Specification check When the instrument arrives, unpack the package with care and check that the instrument has not been damaged during transportation. In addition, please check that the specification matches the order, and required accessories are not missing. Specifications can be checked by the model codes on the nameplate.
  • Page 6 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 11M12G01-02EN...
  • Page 7 • 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.
  • Page 8 CE marking products Authorized Representative in EEA The Authorized Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2, 3825 HD Amersfoort, The Netherlands). Identification Tag This manual and the identification tag attached on packing box are essential parts of the product.
  • Page 9 Blank Page...

  • Page 10: Table Of Contents

    ZH21B Dust Protector ..............2-10 Separate type Detector for High Temperature and Related Equipment ... 2-11 2.3.1 ZR22G (0.15m) Separate type Detector for High Temperature ..2-11 2.3.2 ZO21P High Temperature Probe Adapter ........2-12 ZR802G Zirconia Oxygen/Humidity Converter ..........2-14 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit ....
  • Page 11 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 High Temperature Detector (ZR22G-015) ......3-5 3.2.1 Usage of the High Temperature Probe Adapter (ZO21P-H) ....3-5 3.2.2 Probe Insertion Hole ................
  • Page 12 Pressure or Temperature Input Wiring ..........5-12 5.2.11 Communication wiring ..............5-13 Components ..................... 6-1 ZR22G Detector ....................6-1 6.1.1 General-purpose Detector (except for ZR22G-015)......6-1 6.1.2 High Temperature Detector (ZR22G-015) ......... 6-2 ZR802G Converter .................... 6-3 Touchpanel Switch Operations ............... 6-4 6.3.1 Home screen and icons ..............
  • Page 13 Toc-4 Output Hold Setting ..................8-5 8.2.1 Definition of Equipment Status ............8-5 8.2.2 Preference Order of Output Hold Value ..........8-6 8.2.3 mA output settings ................8-6 8.2.4 Default Values ..................8-7 Output limit setting ................... 8-7 8.3.1 Action of Output limit setting .............. 8-7 8.3.2 Setting of Output limit .................
  • Page 14 Toc-5 Calibration ....................... 9-10 9.3.1 Manual Calibration ................9-10 9.3.2 Semi-automatic Calibration ............. 9-10 9.3.3 Automatic Calibration ............... 9-10 Other Functions ..................10-1 10.1 Detailed-data Display ..................10-1 10.1.1 Span correction ratio, Zero correction ratio ........10-1 10.1.2 Cell response time ................10-1 10.1.3 Cell robustness ................
  • Page 15 Toc-6 10.6 Simple cell resistance measurement ............10-14 10.6.1 MODE ....................10-14 10.6.2 Setup of Hold time, interval, start date, and start time ....10-15 10.6.3 Default ....................10-15 10.6.4 Procedure for Simple Cell Resistance Measurement ....10-16 10.7 Communication Function ................10-17 10.8 Save load ......................10-18 10.8.1 Log file output .................10-18 10.8.2...
  • Page 16 Toc-7 12.3 Measures to be taken when measured values indicate abnormalities ... 12-11 12.3.1 The measured value is higher than the actual value (lower in the case of a hygrometer)..........12-11 12.3.2 The measured value is lower than the actual value (higher in the case of a hygrometer).
  • Page 17 Blank Page...

  • Page 18: Overview

    CO2, SOx and NOx. The ZR22G Separate type Detector uses a high-reliability Zirconia sensor, and its heater assembly can be replaced on site. The detector is mounted, for example, on the wall of a flue and can measure the gases directly.

  • Page 19: System 2

    <1. Overview> ZR802G Converter ZR22G Separate type Zirconia Oxygen/Humidity Analyzer, Detector Signal Stop valve (6-core shield cable) 100 to 240 V AC Heater(2-core) Contact input Analog output, contact output (Digital output HART) Calibration gas ZO21S Standard gas unit F1-1E.ai Figure1.1...

  • Page 20: System 3

    A “combustible gas detected” contact input turns off power to the heater. There’s also contact output from the converter that can be used to operate a purge gas valve to supply air to the detector. ZR22G Separate type ZR802G Converter Zirconia Oxygen/Humidity Analyzer, Detector...

  • Page 21: System Components

    G7013XF, G7014XF Pressure Reducing Valve for Gas Cylinder E7044KF Case Assembly for Calibration gas Cylinder Model ZR22A Heater Assembly (Spare Parts for Model ZR22G) A: Items required for the above system example B: To be selected depending on each application. For details, refer to corresponding chapter.

  • Page 22: Specifications

    Response Time: Response of 90% within 5 seconds. (Measured after gas is introduced from calibration gas inlet and analog output starts changing.) Safety, EMC, and RoHS conformity standards of ZR22G, ZR802G Installation altitude: 2000 m or less Installation category: (IEC61010); II Pollution degree: (IEC61010);...
  • Page 23 · This instrument is a Class A product, and it is designed for use in the industrial environment. Please use this instrument in the industrial environment only. · Influence of immunity environment (Criteria A) : Output shift is specified within ±20% of F.S. RoHS: ZR22G; EN 50581 ZR802G; EN IEC 63000 Others: REACH Regulation EC 1907/2006...
  • Page 24 Response Time: Response of 90% within 5 seconds. (Measured after gas is introduced from calibration gas inlet and analog output starts changing.) Safety, EMC, and RoHS conformity standards of ZR22G, ZR802G Installation altitude: 2000 m or less Installation category: (IEC61010); II Pollution degree: (IEC61010);...

  • Page 25: General Use Separate Type Detector And Related Equipment

    <2. Specifications> General use Separate type Detector and Related Equipment General use separate type detector ZR22G can be used in combination with the probe protector ZO21R (see Section "2.2.2 ZO21R Probe Protector"). In case of Humidity Analyzer, the “Detector with dust protector” consists of ZR22G general-use separate-type detector and ZH21B dust protector (refer to Section "2.2.3 ZH21B Dust Protector").
  • Page 26 <2. Specifications> ■ Weight: STANDARD SPECIFICATIONS (High Insertion length of 0.4 m: approx. 6 kg (JIS 5K 65) Temperature Humidity Analyzer) / approx. 11 kg (ANSI 150 4) Sample Gas Temperature: 0 to 700°C (Probe Insertion length of 1.0 m: approx. 8 kg (JIS 5K 65) only) / approx.
  • Page 27 Option code Description ZR22G - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 28 <2. Specifications> EXTERNAL DIMENSIONS 1. Model ZR22G Separate type Zirconia Oxygen/Humidity Analyzer, Detectors 283 to 292 Unit : mm L=0.15, 0.4, 0.7, 1.0, Rc1/4 or 1/4NPT 1.5, 2.0, 2.5, 3.0 Reference gas inlet 3.6, 4.2, 4.8, 5.4 (m) 155 to 163 2-G1/2,2-1/2NPT etc.
  • Page 29 <2. Specifications> 2. Model ZR22G...-P (with pressure compensation) Separate type Zirconia Oxygen Analyzer, Detectors L=0.15, 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 Rc1/4 or 1/4NPT 3.6, 4.2, 4.8, 5.4 (m) Reference gas inlet 2-G1/2, 2-1/2NPT etc. Cable connection port Reference gas outlet...

  • Page 30: Zo21R Probe Protector

    <2. Specifications> 2.2.2 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. When probe insertion length is 2.5 m or more and □...

  • Page 31: Zh21B Dust Protector

    - - - - - - ANSI Class 150 4B FF (*2) Style code - - - - - - Style B Note: The flange thickness varies. Specify the probe ZR22G-040-□-K Specify the probe ZR22G-040-□-C Unit: mm 428 (Insertion length) JIS flange Install facing upwards ANSI flange ZH21B.ai...

  • Page 32: Separate Type Detector For High Temperature And Related Equipment

    2-11 <2. Specifications> Separate type Detector for High Temperature and Related Equipment 2.3.1 ZR22G (0.15m) Separate type Detector for High Temperature Standard Specifications Construction: Water-resistant, non-explosionproof Probe length: 0.15 m Terminal box: Aluminum alloy Probe material: Probe material in contact with gas: SUS 316 (JIS) (Probe), SUS304 (JIS)

  • Page 33: Zo21P High Temperature Probe Adapter

    /EJ2 Ejector Assy with E7046EN Tag plate /SCT Stainless steel tag plate Note: For this high-temperature use probe adapter, be sure to specify the ZR22G probe of its insertion length 0.15 meters. IM 11M12G01-02EN 1sh Edition : Mar. 25, 2021-00...
  • Page 34 Sample gas outlet Flange (Thickness 5) JIS 5K 32 FF equivalent Rc1/2(Note2) Gasket (Thickness 1.5) Ø60.5 ØA Flange <1> Detector(ZR22G) Flange provided Approx. 48 by customer Ø52 over Reference gas inlet Rc1/4 or 1/4NPT High temperature Probe SiC pipe Ø30...

  • Page 35: Zr802G Zirconia Oxygen/Humidity Converter

    2-14 <2. Specifications> ZR802G Zirconia Oxygen/Humidity Converter Standard Specification (Oxygen Analyzer) Display: LCD color display of size 320 by 240 dot with touchscreen Analog Output: Number of points; Two points (input-output isolation) Out put signal; • 4 to 20 mA DC linear or log can be selected (maximum loadresistance 550 Ω) •...
  • Page 36 2-15 <2. Specifications> Acceptable range; 85 to 264 V AC Power Supply Frequency: Ratings; 50/60 Hz Acceptable range; 47 to 63 Hz Power Consumption: Max. 800 VA, approx. 330 VA for ordinary use. Power supply 100V AC: Max. 160 VA (160 W), approx. 120 VA (approx. 100 W) for ordinary Power supply 230 V AC: Max 550 VA (370 W), approx.
  • Page 37 2-16 <2. Specifications> Function; Alarm keeps turning on until potential causes of a problem are eliminated. Type; Oxygen concentration alarm, Zero-point calibration coefficient alarm, Span-point calibration coefficient alarm, EMF stabilization time-up alarm, Cold junction temperature alarm, Thermocouple voltage alarm, Input current alarm, Battery low alarm, Input-pressure alarm, Cell resistance alarm NAMUR NE 107 Alarm Display Function: Displays 4 warnings of NAMUR NE 107 standard;...
  • Page 38 2-17 <2. Specifications> Number of points; Two points (input-output isolation) Out put signal; • 4 to 20 mA DC linear or log can be selected (maximum loadresistance 550 Ω) • HART7 Communication (maximum loadresistance 550 Ω) • Burn out signal according to NAMUR NE43. Out put range;...
  • Page 39 2-18 <2. Specifications> Maximum Distance between Detector and Converter: Conductor two-way resistance must be 10 Ω or less (when a 1.25 mm cable or equivalent is used, 300 m or less.) Construction: NEMA/CSA TYPE 4X (with conduit holes completely sealed with a cable gland) Wiring Connection: eight holes Type: G1/2, M20 ×...
  • Page 40 2-19 <2. Specifications> Displays 4 warnings of NAMUR NE 107 standard; F: Failure (Fault equivalent, Power supply to the heater shuts down.) C: Function Check S: Out of Specification M: Maintenance Required Data Logging Function: Stores following data to SD card or visualizes on the instrument display. SD cards which are recommended or equivalent must be supplied by customers, •...
  • Page 41 2-20 <2. Specifications> Model and Codes Model Suffix code Option code Description ZR802G - - - - - - - - - - - - - - - - - - - - - - Zirconia Oxygen/Humidity Analyzer, Converter Converter thread - - - - - - - - - - G1/2 - - - - - - - - - -...
  • Page 42 2-21 <2. Specifications> ● STANDARD ACCESSORIES Item Q'ty Parts No. Description Fuse A1113EF Mounting bracket (standard) F9800AP Bolt for mounting bracket M6x10 mm Washer for mounting bracket for M6 Bolt for pipe mounting M6x70 mm Screws for pipe mounting M6x100 mm Tag label (standard) (Note) (Note) Tag label is included when suffix code except for /SCT is specified.
  • Page 43 2-22 <2. Specifications> External Dimensions Unit: mm 2B mounting pipe 1 to 6 (Panel Thickness) 4 - Ø6 for Wall mounting 46.9 10.5 120.9 Stainless steel tag plate (option) 34.7 80.5 8 - G1/2, *8 - 1/2 NPT etc (Wiring connection) (Female) *: 1/2 NPT with plug 4-R8 to R10 or 4-C5 to C8 4 - Ø6...
  • Page 44 2-23 <2. Specifications> ● With Replacement Bracket (option code /BR, ZR402G replacement Wall mounting Bracket) Unit : mm 4 - Ø6 4 - Ø6 for Wall mounting Wall mounting ● With sun shield hood (option code /H) Unit : mm IM 11M12G01-02EN 1sh Edition : Mar.

  • Page 45: Za8F Flow Setting Unit And Zr40H Automatic Calibration Unit

    Weight: 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. Model and Codes Model Suffix code...
  • Page 46 2-25 <2. Specifications> External Dimensions Unit : mm 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 Model Piping connection port A ZA8F-J*C 5 - Rc1/4 ZA8F-A*C...
  • Page 47 2-26 <2. Specifications> 2.5.2 ZR40H Automatic Calibration Unit This automatic calibration unit is applied to supply specified flow of reference gas and calibration gas during automatic calibration to the detector in a system configuration (System 3). It can also be used for safety purge when unburned gas is detected. Specifications Used when auto calibration is required for the separate type and instrument air is provided.
  • Page 48 2-27 <2. Specifications> External Dimensions Unit: mm 2B pipe mounting example Wiring inlet ; 2-G1/2,Pg13.5,M20X1.5 or 1/2NPT(Female) (wiring inlet is at same position on rear) *1 with four ISO M6 screws can wall-mount 116.5 71.5 41.2 41.2 4 - Ø6.5 Connection port Flowmeter Needle valve Terminal box...

  • Page 49: Zo21S Standard Gas Unit

    2-28 <2. Specifications> Piping Diagram CHECK ZR40H Automatic ZR402G Converter Calibration Unit AC-Z Zero Flowmeter Flowmeter AC-S Solenoid valve EV1,2 AC-C Span F35_00.ai AIR IN ZERO GAS IN Instrument air Approx. 1.5 l/min Needle valve is supplied as on accessory with flowmeter F2-6_3E.ai ZO21S Standard Gas Unit This is a handy unit to supply zero gas and span gas to the detector in a system configuration...

  • Page 50: Other Equipments

    2-29 <2. Specifications> External Dimensions Unit: mm Flow checker Span gas valve Zero gas valve Gas outlet Zero gas cylinder (6 cylinder): E7050BA F2-7E.ai Other Equipments 2.7.1 Dust Filter for the Detector (K9471UA) This filter is used to protect the detector sensor from a corrosive dust components or high velocity dust in recovery boilers and cement kilns.

  • Page 51: Dust Guard Protector (K9471Uc)

    2-30 <2. Specifications> 2.7.2 Dust Guard Protector (K9471UC) Recommended to be used when sample gas is likely to flow directly into the cell due to its flow direction in the stack or the like, flammable dust may go into the cell, or water drops are likely to fall and remain in the cell during downtime or the like due to the installation position.
  • Page 52 2-31 <2. Specifications> To set this, proceed as follows: (1) In Graph 4, draw a horizontal line from the 5 l/min point. on the vertical axis (Suction flow: Qg) toward the gas pressure line to be used, to find the point of intersection. Draw a line vertically down from the point of intersection to the axis to find the drive pressure, P (at the ejector entrance).
  • Page 53 2-32 <2. Specifications> Pressure gauge assembly Pressure gauge Ejector Needle valve <2> Nozzle (Note1) Ø43 Detector R1/2 <3> Instrument air inlet <1> Blow Rc1/4 (Note1) The connecter of ejector assembly is a <1> Rc1/4 or 1/4 FNPT dedicated connecter with nozzle function. <2>...

  • Page 54: Stop Valve (L9852Cb, G7016Xh)

    2-33 <2. Specifications> 2.7.4 Stop Valve (L9852CB, G7016XH) This valve mounted on the calibration gas line in the system to allow for manual calibration. This is applies to the system configuration shown for system 1 in section 1. Standard Specifications Connection: Rc 1/4 or 1/4 NPT(F) Material: SUS 316 (JIS)

  • Page 55: Air Set

    2-34 <2. Specifications> Unit: mm K9292DN : Rc 1/4(A),R 1/4(B) K9292DS : 1/4FNPT(A),1/4NPT(Male)(B) Approx. 19 Approx. 54 F2-11E.ai 2.7.6 Air Set This set is used to lower the pressure when instrument air is used as the reference and span gases. Standard Specifications G7003XF, K9473XK Primary Pressure: Max.

  • Page 56: Zero Gas Cylinder (G7001Zc)

    2-35 <2. Specifications> External Dimensions Unit : mm View A Panel cut dimensions Horizontal Vertical mounting mounting ø15 +0.5 2-ø2.2 2-ø6.5 2-ø6 screw depth 8 Panel (Horizontal mounting) Secondary pressure gauge Panel (Vertical mounting) Ø74 Secondary Primary G7003XF, G7004XF: Rc 1/4 K9473XK, K9473XG: 1/4NPT connector Approx.

  • Page 57: Cylinder Pressure Reducing Valve (G7013Xf, G7014Xf)

    2-36 <2. Specifications> 2.7.8 Cylinder Pressure Reducing Valve (G7013XF, G7014XF) This pressure reducing 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;...
  • Page 58 2-37 <2. Specifications> Pressure reducing valve ( G7013XF / G7014XF ) Zero gas cylinder (G7001ZC) (158.3) 2B mounting pipe ( Ø60.5 ) The oblique line is an opening portion. (Note)The zero gas cylinder and the reducing valve are not included in the E7044KF (case assembly) F2-15E.ai IM 11M12G01-02EN 1sh Edition : Mar.

  • Page 59: Zr22A Heater Assembly

    - - - - - - - - - - - Pressure compensated (for ZR22G S1) *1 Suffix code of length should be selected as same as ZR22G installed. *2 Jig part no. is K9470BX to order as a parts after purchase.

  • Page 60: Installation Of General-Purpose Detector

    (3) A clean environment without any corrosive gases. NOTE A natural convection type detector (model ZR22G----C), which uses ambient air as reference gas, requires that the ambient oxygen concentration be constant. (4) No vibration. (5) The sample gas satisfies the specifications described in Chapter “2.

  • Page 61: Installation Of The Detector

    <3. Installation> (3) The detector probe should be mounted at right angles to the sample gas flow or the probe tip should point downstream. Bounds of the probe (vertical) Type Outside diameter of detector insertion hole location Standard 50.8 mm in diameter (Note) Flange matches With dust filter 51 mm in diameter (Note)
  • Page 62 < Procedures for installing the dust guard protector (K9471UC)> The ZR22G detector is shipped with the dust guard protector when the option code / F2 is specified in case of ordering the detector. The protector should be used when preventing dusts and water drops from lowering the detector performance is desired.

  • Page 63: Installation Of Zh21B Dust Protector

    (3) Where the detector is mounted horizontally, the reference gas and calibration gas inlet should face downward. CAUTION When the probe protector is used in the ZR22G with pressure compensation (-P), instrument air leaking from the probe protector may affect the measured value. Gasket (t1.5)

  • Page 64: Installation Of High Temperature Detector (Zr22G-015)

    Installation of the dust filter Installation of High Temperature Detector (ZR22G-015) This detector is used with the High Temperature Probe Adapter (Model ZO21P-H) when the temperature of sample gas exceeds 700°C, or when it is required due to maintenance spaces.

  • Page 65: Probe Insertion Hole

    3.2.2 Probe Insertion Hole A high temperature detector consists of a ZR22G-015 Detector and ZO21P High Temperature Probe Adapter. When forming the probe insertion hole, the following should be taken into consideration: (1) If the probe is made of silicon carbide (SiC), the probe hole should be formed so that the probe is mounted vertically (within ±...

  • Page 66: Mounting Of The High Temperature Detector

    <3. Installation> 3.2.3 Mounting of the High Temperature Detector CAUTION • Ceramic (zirconia) is used in the sensor (cell) portion on the detector probe tip. Care should be taken not to drop the detector during installation. • The same applies to a probe made of silicon carbide (SiC). •...

  • Page 67: Installation Of The Zr802G Converter

    <3. Installation> Installation of the ZR802G Converter The following should be taken into consideration when installing the converter: (1) Readability of the indicated values of oxygen concentration or messages on the converter display. Easy and safe access to the converter for operating keys on the panel. (2) Easy and safe access to the converter for checking and maintenance work.
  • Page 68 <3. Installation> <Wall Mounting> (1) Drill mounting holes through the wall as shown in Figure 3.10. 4 - ø6 hole Wall mount hole 4 - ø6 hole Wall mount hole （/BR） Figure 3.10 Mounting holes Figure 3.11 Wall Mounting (2) Mount the converter. Secure the converter on the wall using four screws. <Panel Mounting>...

  • Page 69: Installation Of Za8F Flow Setting Unit

    3-10 <3. Installation> Installation of ZA8F Flow Setting Unit The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the detector or the converter (3) No corrosive gas. (4) An ambient temperature of not more than 55°C and little changes of temperature. (5) No vibration.

  • Page 70: Installation Of Zr40H Automatic Calibration Unit

    3-11 <3. Installation> Installation of ZR40H Automatic Calibration Unit The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the detector or the converter (3) No corrosive gas. (4) An ambient temperature of not more than 55°C and little change of temperature. (5) No vibration.

  • Page 71: Installation Of The Case Assembly (E7044Kf)

    3-12 <3. Installation> 4-Φ6.5 F3-16_1E.ai Figure 3.19 Wall Mounting Installation of the Case Assembly (E7044KF) The case assembly is used to store the G7001ZC zero gas cylinders. The following should be taken into consideration: (1) Easy access for cylinder replacement (2) Easy access for checking (3) Near to the detector or converter as well as the flow setting unit.

  • Page 72: Insulation Resistance Test

    3-13 <3. Installation> A pipe to be mounted (nominal JIS 50A : O.D. 60.5 mm) F3-16E.ai Figure 3.20 Pipe Mounting Insulation Resistance Test Even if the testing voltage is not so great that it causes dielectric breakdown, testing may cause deterioration in insulation and a possible safety hazard.
  • Page 73 3-14 <3. Installation> ZR802G Zirconia Oxygen / Model ZR22G Separate type Zirconia Oxygen / Insulation High Temperature Humidity Analyzer, Converter High Temperature Humidity Analyzer, Detector resistance tester CELL CELL CELL CELL DI-1 DI-2 DI-C ZERO SPAN Contact input 2 Solenoid valve for zero gas...

  • Page 74: Piping

    Stable analyzing can be conducted when using instrument air. Piping for System 1 The piping in System 1 is illustrated in Figure 4.1. ZR802G Zirconia Oxygen/Humidity Analyzer, ZR22G Separate type Explosion-proof Converter Zirconia Oxygen/Humidity Analyzer, Detector Signal (6-core shield cable)

  • Page 75: Parts Required For Piping In System 1

    Table 4.1 Detector Piping location Parts Name Note General use Calibration gas inlet Stop valve Recommended by YOKOGAWA detector (L9852CB or G7016XH) Nipple * Rc 1/4 or 1/4 NPT General parts Joint for tube connection Rc 1/4 (1/4 NPT) General parts for a Ø6 x Ø4 mm soft tube...

  • Page 76: Connection To The Calibration Gas Inlet

    First, mount a stop valve (of a quality specified by YOKOGAWA) on 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 detector prior to shipping the detector.)
  • Page 77 <4. Piping> In such a case, connect a needle valve (found on the local market) through a nipple (also found on the local market) to the probe adapter sample gas exhaust (Rc 1/2) so that the sample gas exhaust volume is restricted. Reducing nipple (R1/2-R1/4 or R1/2-1/4NTP) Needle valve...

  • Page 78: Piping For System 2

    <4. Piping> Piping for System 2 Piping in System 2 is illustrated in Figure 4.7. ZR22G Separate type ZR802G Converter Zirconia Oxygen/Humidity Analyzer, Detector Signal (6-core shield cable) Stop valve 100 to or Check valve 240 V AC Heater (2-core)

  • Page 79: Piping Parts For System 2

    This piping is to be installed between the zero gas cylinder and the ZA8F flow setting unit, and between the ZA8F flow setting unit and the ZR22G detector. The cylinder should be placed in a case assemble E7044KF or the like to avoid any direct sunlight or radiant heat so that the gas cylinder temperature does not exceed 40°C.

  • Page 80: Piping For The Reference Gas

    <4. Piping> Mount a check valve or stop valve (specified by YOKOGAWA) on the nipple (found on the local market) at the calibration gas inlet of the detector as illustrated in Figure 4.8. (The check valve or the stop valve may have been mounted on the detector when shipped.) Connect the flow setting unit and the detector to a stainless steel pipe 6 mm (O.D.) x 4 mm or...
  • Page 81 Normally, approximately 1 vol%O balanced) is used. Figure 4.9 Piping inside in System 3 ZR802G Converter ZR22G Separate type Zirconia Oxygen/Humidity Analyzer, Detector Signal (6-core shield cable) Check valve 100 to 240 V AC...
  • Page 82 • Blow pipe (to be prepared as illustrated in Figure 4.12.) • Two-way solenoid valve: “ Open “ when electric current is on. (Found on the local market) . • Air set (recommended by YOKOGAWA, G7003XF / K9473XK or G7004XF / K9473XG) <Blow pipe manufacturing>...

  • Page 83: Piping For The Detector With Pressure Compensation

    Piping for the Detector with Pressure Compensation The ZR22G----P Detector with Pressure Compensation may be used in System 2 and System 3. However, it cannot use piping for high temperature probe adapter or blow back piping. Use this detector 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 detector to the furnace pressure using instrument air.

  • Page 84: Piping Parts For A System Using Detector With Pressure Compensation

    (K9292DN or K9292DS) Nipple * Rc 1/4 or 1/4 NPT General parts Zero gas cylinder User´s scope Pressure reducing valve Recommended by YOKOGAWA (G7013XF or G7014XF) Joint for tube connection Rc 1/4 or 1/4 NPT General parts Reference gas inlet Air set...

  • Page 85: Piping For The Reference Gas

    4-12 <4. Piping> 4.4.3 Piping for the Reference Gas Reference gas piping is basically identical to that of for System 2. See Section “4.2.3 Piping for the Reference Gas”. IM 11M12G01-02EN 1sh Edition : Mar. 25, 2021-00...

  • Page 86: Wiring

    <5. Wiring> Wiring In this Chapter, the wiring necessary for connection to the Zirconia Oxygen/Humidity Analyzer is described. 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.
  • Page 87 <5. Wiring> Table 5.1 Cable specifications Terminal name of converter Name Need for shields Number of cores CELL+, CELL- HTR TC+, HTR TC- Detector signal О CJ+, CJ- HEATER Detector heater L, N Power supply 2 or 3 * AO-1+, AO-1-, AO-2+, AO-2- Analog output О...

  • Page 88: Terminals For The External Wiring In The Converter

    <5. Wiring> 5.1.1 Terminals for the External Wiring in the Converter Open the front door and remove the terminal covering plate to gain access to the converter external wiring terminals (see Figure 5.1). CAUTION After wiring necessary cable to the converter terminals, be sure to fix the terminal covering plate with two screws again.

  • Page 89: Mounting Of Cable Gland

    <5. Wiring> ZR22G Zirconia Oxygen/Humidity Analyzer, ZR802G Detector Zirconia Oxygen/Humidity Analyzer Ethernet RS485 RS-485 Ether Termination Termination Analog output 1 4–20 mA DC Analog Digital output output 2 (HART) 4–20 mA DC CELL CELL CELL CELL DI-1 DI-2 DI-C ZERO...

  • Page 90: Wiring

    <5. Wiring> Wiring 5.2.1 Connection to Converter To connect the wiring to the converter, proceed as follows: (1) M4 screws are used for the terminals of the converter. Each cable should be terminated in the corresponding size crimp-on terminals. (2) When a rubber insulated glass braided wire is used for wiring to the detector, use a terminal box.

  • Page 91: Power And Grounding Wiring

    Detector cover F5-8E.ai Figure 5.5 5.2.3 Power and Grounding Wiring This wiring supplies power to the converter and grounds the converter/detector. ZR802G ZR22G Converter Detector Grounding to the ground terminal on the converter case Converter case Ground Crimp-on terminal of...

  • Page 92: Wiring For Power To Detector Heater

    Wiring for Power to Detector Heater This wiring provides electric power from the converter to the heater for heating the sensor in the detector. (1) Ambient temperature of the detector: 75°C or less ZR802G ZR22G Converter Detector HTR 7 HTR 8 (2) Ambient temperature of the detector: exceeding 75°C...
  • Page 93 <5. Wiring> (1) Ambient temperature of the detector: 75°C or less ZR802G ZR22G Converter Detector CELL(+) CELL(+) CELL(-) CELL(-) TC(+) TC(+) TC(-) TC(-) CJ(+) CJ(+) CJ(-) CJ(-) Shielded cables (2) Ambient temperature of the detector: exceeding 75°C ZR802G ZR22G Terminal box...

  • Page 94: Wiring For Analog Output

    <5. Wiring> Figure 5.9 Connection of CJ compensation elements 5.2.6 Wiring for Analog Output This wiring is for transmitting 4 to 20 mA DC output signals to a device, e.g. recorder. Maintain the load resistance including the wiring resistance at 550 Ω or less. ZR802G Converter Receiver 1...

  • Page 95: Contact Output Wiring

    5-10 <5. Wiring> 5.2.7 Contact Output Wiring Contact outputs 1 to 3 can be freely assigned to “low limit alarm”, “high limit alarm”, etc. user selectable, but the assignment of contact output 4 is fixed (“fault output”). And the action (contact closed on error output) also cannot be changed.

  • Page 96: Wiring For Zr40H Automatic Calibration Unit

    5-11 <5. Wiring> (2) The ON/OFF level of this contact input is identified by the resistance or voltage. Connect a contact input that satisfies the specifications in Table 5.2. Table 5.2 Identification of Contact Input ON/OFF Closed Open Resistance 200 Ω or less 100 kΩ...

  • Page 97: Pressure Or Temperature Input Wiring

    5-12 <5. Wiring> ZR40H Automatic ZR802G Converter Calibration Unit AC-ZERO Zero AC-SPAN AC-COM Span Figure 5.14 Wiring for Automatic Calibration Unit 5.2.10 Pressure or Temperature Input Wiring (Only for Humidity Analyzer) When inputting the measurement gas pressure or temperature from external of the equipment, connect a two-wire pressure or temperature transmitter (hereinafter referred to as transmitter).

  • Page 98: Communication Wiring

    5-13 <5. Wiring> 5.2.11 Communication wiring ZR802G wired digital communication can be Ethernet(Modbus TCP) or RS-485 (Modbus RTU) depending on your requirements. Be sure to use shielded cables to prevent malfunction due to external noise ad to avoid the effects of radiated noise from ZR802G on other equipment. RS-485 cable Use RS-485 cable when the digital communication code-M (Modbus RTU) is selected.
  • Page 99 5-14 <5. Wiring> Ethernet cable Use Ethernet cable when the digital communication code -E (Modbus TCP) is selected. RJ45 connectors are provided in the positions shown in Fig. 5.18. Insert a Category 5 or higher STP cable (shielded cable) into RJ45 connector. Both straight and cross connection is available for cable connection.

  • Page 100: Components

    In the case of the humidity analyzer, unit indication may be different. Please read it appropriately. ZR22G Detector 6.1.1 General-purpose Detector (except for ZR22G-015) Terminal box, Non explosion-proof JIS C0920 equivalent to IP44D. Equivalent to NEMA 4X/IP66 (Achieved when the cable entry is completely sealed with a cable gland in the recirculation pressure compensated version.)

  • Page 101: High Temperature Detector (Zr22G-015)

    <6. Components> 6.1.2 High Temperature Detector (ZR22G-015) Sample gas outlet When a sample gas pressure is negative, connect the ejector assembly. When the sample gas is high temperature and high pressure, and does Separate type not fall below 700°C, connect a pressure High Temperature Detector (ZR22G-015) control valve (e.g.

  • Page 102: Zr802G Converter

    <6. Components> ZR802G Converter Operation panel ● LCD touch screen ● It is an easy-to-understand Japanese Display. ● You can operate while interacting with screen ● Various Display modes are available ● LCD with backlight for visible darkness ● Alarm code is displayed in addition to the alarm number.

  • Page 103: Touchpanel Switch Operations

    <6. Components> Touchpanel Switch Operations 6.3.1 Home screen and icons ZR802G adopts touch screen type which is operated by pressing the display. Fig. 6.3 shows the home screen. Icons displayed on the screen depend on setup and device status. Tag name Converter menu 1st display item Alarm icon...
  • Page 104 <6. Components> Status Display icon area: Icons are displayed depending on the device status. Some can be interrupted by pressing the corresponding icon. Status Left Display Right Priority Interruption Display Purging in progress High × (before warm-up × Warm-up О Calibration in progress О...

  • Page 105: Screen Flow

    <6. Components> 6.3.2 Screen flow Figure 6.8 shows the screen flow chart. You can move to each setting, execution or confirmation screen from “Converter menu”, “Sensor menu” on Home screen. [Home] returns to Home screen from any screen. Short cut Calibration Home screen Favorite...

  • Page 106: Entering Numeric And Text Data

    <6. Components> 6.3.4 Entering Numeric and Text Data When you enter a password, for instance, which uses text, numeric data or symbols, first an alphabetic entry screen appears. Pressing the [123] key changes the numeric value entry screen and allows you to enter a numeric value.

  • Page 107: Za8F Flow Setting Unit, Zr40H Automatic Calibration Unit

    <6. Components> ZA8F Flow Setting Unit, ZR40H 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 6.10 ZA8F Flow Setting Unit Flowmeter for Calibration gas Flowmeter for...

  • Page 108: Startup

    <7. Startup> Startup The following describes the minimum operating requirements — from supplying power to the converter to analog output confirmation to manual calibration. System tuning by the HART communicator, refer to IM11M12A01-51E “ HART Communication Protocol ”. 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.

  • Page 109: Checking Piping And Wiring Connections

    <7. Startup> Checking Piping and Wiring Connections Check that the piping and wiring connections have been properly completed in accordance with Chapter “4. Piping” and Chapter “5. Wiring” Checking Valve Setup Set up valves and associated components used in the analyzer system as follows: (1) If a stop valve is used in the detector’s calibration gas inlet, fully close this valve.

  • Page 110: Confirmation Of Converter Type Setting

    <7. Startup> Confirmation of Converter Type Setting This converter can be used for both the Oxygen Analyzer and the Humidity Analyzer. Before setting the operating data, be sure to check that the desired converter model has been set. CAUTION If the converter type setting is changed, the operating data that have been set are initialized and the default settings remain.

  • Page 111: Confirmation Of Detector Type Setting

    <7. Startup> Confirmation of Detector Type Setting (1) Press the [Sensor menu] key. (2) Select [Setting] > [Setting]. (3) Confirm ZR22 (PT1000:Ohm) is selected as sensor. Factory default is ZR22. (4) To change detector, press [Selection of detector] Figure 7.4 Selection of detector CAUTION If sensor/detector settings are to be changed, first disconnect the wiring connections between the...

  • Page 112: Output Range Setting

    <7. Startup> Figure 7.5 Choise of moisture base Output Range Setting This section sets forth analog output range settings. For details, consult Section “8.1 Current Output Setting”, later in this manual. Minimum Current (4 mA) and Maximum Current (20 mA) Settings To set the minimum and maximum current settings, follow these steps: (1) Select the “Setting”...

  • Page 113: Setting Display Item

    <7. Startup> Setting Display Item 7.9.1 Oxygen Analyzer - Setting Display Item This section briefly describes the Home screen item shown in Figure 7.7 1st item 2nd item 3rd item Figure 7.7 Home screen [Converter menu] > [Maintenance] (2) Select the “Display settings”. (3) Select “Display item”.
  • Page 114 <7. Startup> Table 7.1 Display Items 1st display 2nd, 3rd Item Display item display item Oxygen ○ ○ Oxygen concentration during measurement concentration ○ Air ratio Current computed air ratio ○ Moisture content Moisture content (%H O) in the exhaust gas ○...

  • Page 115: Humidity Analyzer - Setting Display Item

    <7. Startup> About moisture content: The moisture content in the exhaust gas is calculated based on the parameters of the fuel setting (refer to Section “8.7.3 Setting Fuels”). The moisture content may be expressed mathematically Moisture content = {(water vapor content per fuel unit quantity) + (water content in air)}/ total amount of exhaust gas = { Gw + ( 1.61 ...

  • Page 116: Checking Current Loop

    <7. Startup> 7.10 Checking Current Loop The set current can be output as an analog output. (1) “Converter menu” > “Maintenance” (2) Select “Loop check setting”. (3) Set AO1 test output, AO2 test output on “Loop check setting”. (4) Select “Test validity AO1/AO2”. Check an item to enable. Press the save icon to store the data.
  • Page 117 7-10 <7. Startup> (6) Press the save icon on “Contact output” to output the setup data. (7) When you exit the maintenance screen, test validity of DO1 to DO4 becomes OFF. Figure 7.11 Contact output check CAUTION If you conduct an open-close check for contact output 4, Alarm 016 or Alarm 017 will occur. This is because the built-in heater power of the detector, which is connected to contact output 4, is turned off during the above check.

  • Page 118: Checking Calibration Contact Output

    7-11 <7. Startup> 7.11.2 Checking Calibration Contact Output The calibration contacts are used for solenoid valve drive signals for the ZR40H Automatic Calibration Unit. When using the ZR40H Automatic Calibration Unit, use the calibration contact output to check that the wiring connections have been properly completed and check equipment operation.

  • Page 119: Calibration

    7-12 <7. Startup> 7.12 Calibration To calibrate this instrument, the procedure is to measure zero gas and span gas and set the instrument to read the known concentrations. The procedure for both zero and span calibration, or for either zero or span calibration, can be performed manually from the touch display, or can be performed semi-automatically using contact signal inputs to start calibration, (allowing preset calibration and stabilization times), or it can be performed automatically at preset intervals.

  • Page 120: Manual Calibration

    7-13 <7. Startup> CAUTION • If instrument air is used for the span gas, dehumidify to a dew point of -20°C or less to remove oil mist and dust before use. • Insufficient dehumidification or use of dirty air may affect measurement accuracy. 7.12.2 Manual Calibration Preparing for calibration Implementation...
  • Page 121 7-14 <7. Startup> (3) After the message of Figure 7.17 appears, feed the span gas to follow the message. Open the span gas flow setting valve and adjust the flow rate to The Manual calibration display shown in Figure 7.29 then appears. Check that the oxygen concentration for the span gas in this display coincides with the oxygen concentration in the calibration gas actually used.
  • Page 122 7-15 <7. Startup> Select “Zero calibration”. The screen of Figure 7.20 appears. Check that the oxygen concentration value on screen matches the oxygen concentration value of calibration gas that is actually used. Then select “Next”. Figure 7.20 Zero gas concentration check (7) Follow the instructions in the display as in Figure 7.21 to turn on the zero gas flow.
  • Page 123 7-16 <7. Startup> (9) After the measured value has stabilized, press the [Enter] key to display the “Zero calibration complete” display shown in Figure 7.36. At this point, the measured value is corrected to equal the zero gas concentration setting. Close the zero gas flow valve. The valve lock nut should be tightened completely so that the zero gas does not leak.

  • Page 124: Detailed Data Setting

    <8. Detailed Data Setting> Detailed Data Setting Current Output Setting This section describes setting of the analog output range. 8.1.1 Setting Minimum Current (4 mA) and Maximum Current (20 mA) (1) “Converter menu” > “Setting” (2) Select the “mA output settings”. (3) Select “mA output1”.
  • Page 125 <8. Detailed Data Setting> Ranges over which oxygen concentrations can be set Outside ranges Minimum oxygen concentration, vol%O (for a minimum current of 4 mA) F8.0E.ai Minimum-Maximum setting range of oxygen concentration Figure 8.1 Humidity (amount-of-moisture-content) and relative humidity setting range The minimum humidity is set to 0% H O or ranges from 26 to 100% H O.
  • Page 126 <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 8.2 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”...

  • Page 127: Setting Output Smoothing Factor

    <8. Detailed Data Setting> 8.1.3 Setting Output Smoothing Factor If the measured value changes suddenly, using this measured value as a control may cause harm such as frequent on-off operation. In such a case, you can set a smoothing time constant of between 0 and 255 seconds to reduce the effect.

  • Page 128: Output Hold Setting

    <8. Detailed Data Setting> Output Hold Setting The “output hold” functions hold an analog output signal at a preset value during the equipment’s warm-up time or calibration or if an error arises. Outputs 1 and 2 can not be set individually. Table 8.5 shows the analog outputs that can be retained and the individual states.

  • Page 129: Preference Order Of Output Hold Value

    <8. Detailed Data Setting> (4) During Blow back (see Section “10.5 Blow Back”) During semi-automatic blow back: “During semi-automatic blow back” is the time required after pressing the [Blow back start] key, by using the touchpanel or entering a blow back start instruction by using a contact input, until the blow back time and Hold time (output stabilization) elapse.

  • Page 130: Default Values

    <8. Detailed Data Setting> 8.2.4 Default Values When the analyzer is delivered, or if data are initialized, output hold setting is the default as shown in Table 8.7. Table 8.7 Output Hold Default Values Status Output hold setting Preset value Warm-up mode 4 mA 3.4 mA...

  • Page 131: Alarm Setting

    <8. Detailed Data Setting> Alarm Setting The analyzer enables the setting of four alarms — high-high, high, low, and low-low alarms — depending upon the measurement conditions. In addition, You can set calibration coefficient alarm, temperature / pressure input alarm, simple cell resistance alarm, etc. The following section sets out the alarm operations and setting procedures.

  • Page 132: Alarm Output Actions

    <8. Detailed Data Setting> 8.4.3 Alarm Output Actions If the measured values of the oxygen concentration fluctuate between normal (steady state) values and the alarm setting, alarm outputs may be frequently issued and canceled. To avoid this, set the alarm delay and hysteresis for alarm canceling under the alarm output conditions, as Figure 8.7 shows.

  • Page 133: Alarm Setting Procedure

    8-10 <8. Detailed Data Setting> 8.4.4 Alarm Setting Procedure (1) “Converter menu” > “Setting” (2) Select “Alarm setting”. Figure 8.8 Alarm setting • To set the hysteresis (3) Select “Hysteresis” in the Alarm setting display. The numeric-data entry display then appears.

  • Page 134: Default Values

    8-11 <8. Detailed Data Setting> 8.4.5 Default Values When the analyzer is delivered, or if data are initialized, the default alarm set values are as shown in Table 8.9. Table 8.9 Alarm Setting Default Values Set item Oxygen Humidity (amount of Mixing ratio Relative humidity concentration...

  • Page 135: Output Contact Setup

    8-12 <8. Detailed Data Setting> Output Contact Setup 8.5.1 Output Contact Mechanical relays provide contact outputs. Be sure to observe relay contact ratings. (For details, see Section “2.1 General Specifications”) The operation modes of each contact output are as follows. For output contacts 1 to 3 you can select open or closed contact when the contact is “operated.”...

  • Page 136: Setting Contact Outputs

    8-13 <8. Detailed Data Setting> 8.5.2 Setting Contact Outputs To set the contact outputs, follow these steps. (1) “Converter menu” > “Setting” (2) Select “Contact setting”. (3) Select item to setup. See Table 8.12. An example setting is displayed below. In this example, Contact output1 is expected to setup to output “Open”...
  • Page 137 8-14 <8. Detailed Data Setting> Table 8.12 Output Contact Settings Item to be selected Description (HH) high-high alarm If “High-High alarm ON” is selected, contact output occurs when the high-high limit is issued. To do this, it is required, in Alarms setup, that the high-high alarm be set to be enabled beforehand (see Section “8.4 Alarm Setting”).

  • Page 138: Default Values

    8-15 <8. Detailed Data Setting> 8.5.3 Default Values When the analyzer is delivered, or if data are initialized, alarm and other setting defaults are as shown in Table 8.13. Table 8.13 Output Contact Default Settings Item to be selected Contact Contact Contact Contact...

  • Page 139: Input Contact Settings

    8-16 <8. Detailed Data Setting> Input Contact Settings 8.6.1 Input Contact Functions The converter input contacts execute set functions by accepting a remote dry-contact (“voltage- free contact”) signal. Table 8.14 shows the functions executed by a remote contact signal. Table 8.14 Input Contact Functions Item Function...

  • Page 140: Default Values

    8-17 <8. Detailed Data Setting> CAUTION • Measurement range switching function by an external contact input is available for analog output1 only. The range during switching is 0–25%O or 0–100%O . See below. For Humidity, mixing ratio, relative humidity, the range is 0–100%H 0, 0–1kg/kg, 0–100 R.H.(static), respectively.

  • Page 141: Other Settings

    8-18 <8. Detailed Data Setting> Other Settings 8.7.1 Setting the Date-and-Time The following describe how to set the date-and-time. Automatic calibration or blow back works following this setting. Proceed as follows: (1) “Converter menu” > “Others” (2) Select “Date/Time setting”. (3) Input date and time.

  • Page 142: Setting The Monitoring Time For Mean/Max. Min

    8-19 <8. Detailed Data Setting> 8.7.2 Setting the monitoring time for mean/max. min The instrument can display the mean, minimum, maximum values of the oxygen concentration being measured. See 10.1. This section explains how to setup the calculation time of the average value and the monitoring time of the maximum/minimum value.

  • Page 143: Setting Fuels

    8-20 <8. Detailed Data Setting> 8.7.3 Setting Fuels Input Parameters The analyzer calculates the moisture content contained in exhaust gases. The following sets forth the fuel parameters necessary for calculation and their entries. The moisture content may be mathematically expressed by: (water vapor caused by combustion and water vapor contained in the exhaust gas) + (water vapor contained in air for combustion) ..
  • Page 144 8-21 <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 –...
  • Page 145 8-22 <8. Detailed Data Setting> 0.046 0.044 0.042 0.040 0.038 0.036 0.034 0.032 0.030 0.028 Wet-bulb 0.026 Absolute temperature, °C humidity, kg/kg 0.024 0.022 0.020 0.018 0.016 0.014 0.012 0.010 0.008 0.006 0.004 0.002 0.000 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 Dry-bulb temperature, °C...
  • Page 146 8-23 <8. Detailed Data Setting> Table 8.15 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...

  • Page 147: Setting Measurement Gas Pressure (Oxygen Analyzer)

    8-24 <8. Detailed Data Setting> Procedure (1) “Sensor menu” > “Setting”. (2) Select “Fuel setup”. (3) Enter numerical value on “Exhaust water vapor content”, “Theoretical air volume” “X value”, “Absolute humidity of outside air”. Figure 8.16 Fuel Setup Default Values When the analyzer is delivered, or if data are initialized, default, parameter settings are as shown in Table 8.16.
  • Page 148 8-25 <8. Detailed Data Setting> (4) When you select “Pressure input selection”, a dialog box appears to select “Preset value”, “External input”. Select according to your system. When Preset value is selected (5) When “Preset value” is selected on “Pressure input selection”, enter a sample gas pressure on “Input pressure set value”.

  • Page 149: Setting Measurement Gas Temperature And Pressure

    8-26 <8. Detailed Data Setting> 8.7.5 Setting Measurement Gas Temperature and Pressure The analyzer calculates the moisture content contained in exhaust gases and saturated water vapors from the entered gas temperature and pressure to obtain the relative humidity and dew point.
  • Page 150 8-27 <8. Detailed Data Setting> How to setup the measured gas pressure (8) Enter the pressure (absolute pressure) of the measured gas in “Exhaust gas pressure.” Figure 8.18 Setting Measurement Gas Temperature and Pressure (Humidity Analyzer) NOTE • The critical temperature of the saturated water vapor pressure is 374°C. If a gas temperature exceeding 370°C is entered, no correct calculation will be obtained.

  • Page 151: Setting Purging

    8-28 <8. Detailed Data Setting> 8.7.6 Setting Purging Purging is to remove condensed water in the calibration gas pipe by supplying a span calibration gas for a given length of time before warm-up of the detector. This prevents cell breakage during calibration due to condensed water in the pipe.
  • Page 152 8-29 <8. Detailed Data Setting> Figure 8.20 Passwords Display <Default setting> The passwords are not set as shipped from factory. If you reset data, the password settings are deleted. CAUTION If you setup a password, write down the password so you won’t forget it. You are asked for the password when entering a protected operation, such as “Setting”...
  • Page 153 Blank Page...

  • Page 154: Calibration

    <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.

  • Page 155: Measurement Principle Of Zirconia Humidity Analyzer

    <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.EPS Figure 9.1 Oxygen concentration in a Sample Gas vs Cell Voltage (21 vol%O Equivalent) The measurement principles of a zirconia oxygen analyzer have been described above.
  • Page 156 <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.

  • Page 157: Calibration Gas

    <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.

  • Page 158: Characteristic Data From A Sensor Measured During Calibration

    <9. Calibration> 81.92 Zero origin Calibration curve before correction Cell electromotive force, mV Corrected calibration curve (theoretical calibration curve) Span origin 21.0 0.51 Zero gas concentration Span gas concentration Oxygen concentration (vol%O Zero-point correction ratio = (B/A) x 100 (%) Correctable range: 100 ± 30% Span correction ratio = (C/A) x 100 (%) Correctable range: 0 ±...

  • Page 159: Calibration Procedures

    <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.

  • Page 160: Calibration Procedure

    <9. Calibration> Figure 9.7 Calibration mode 9.2.2 Calibration procedure Select one among Calibration of both span and zero, Calibration of only span, Calibration of only zero. Normally select “span-zero.” 9.2.3 Zero gas Concentration Set the oxygen concentration for zero-point calibration. Enter the oxygen concentration for the zero gas in the cylinder used in the following procedures: Select “Zero gas concentration”...
  • Page 161 <9. Calibration> When the mode is turned setup to “Semi-automatic”: In addition to the “Hold time” “stabilization time” described above, “calibration time” is turned setup. Calibration time is the time from when calibration begins to flow until calibration is executed. Setup times work commonly for both zero calibration and span calibration. The settling time and calibration time can be setup from 00 minutes 00 seconds to 60 minutes 59 seconds.

  • Page 162: Default Values

    <9. Calibration> NOTE When setting calibration timing requirements, bear the following precautions in mind: (1) If the calibration interval is shorter than the sum of Hold (output stabilization) time plus calibration time, the second calibration start time will conflict with the first calibration. In such a case, the second calibration will not be conducted.

  • Page 163: Calibration

    9-10 <9. Calibration> Calibration 9.3.1 Manual Calibration For manual calibration, consult Section “7.12 Calibration”, earlier in this manual. 9.3.2 Semi-automatic Calibration By the touch panel (1) Press[set up] on Home screen to enter a calibration screen. Select “Span” of “Semi-auto calibration”.

  • Page 164: Other Functions

    10-1 <10. Other Functions> Other Functions 10.1 Detailed-data Display “Sensor menu” > “Detail” This section describes each data of sensors. Figure 10.1 Detailed-data Display 10.1.1 Span correction ratio, Zero correction ratio These are used to check for degradation of the sensor (cell). If the correction ratio is beyond the limits as shown in Figure 10.2, the sensor should no longer be used.

  • Page 165: Cell Robustness

    10-2 <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.

  • Page 166: Measurement Gas Press. (Oximeter), Measurement Gas Temperature (Hygrometer)

    10-3 <10. Other Functions> 10.1.6 Measurement gas press. (oximeter), Measurement gas temperature (hygrometer) Displays the preset value or the value entered by the transmitter. Turn Display the measured gas pressure for the oximeter and the measured gas temperature for the hygrometer. 10.1.7 Cell voltage The cell (sensor) voltage will be an index to determine the amount of degradation of the...

  • Page 167: Cell Heater Duty

    10-4 <10. Other Functions> 10.1.12 Cell heater duty The probe sensor is heated to and maintained at 750°C. When the sample gas temperature is high, the amount of heater ON-time decreases. 10.1.13 Pwr. supply voltage mode For the best control of the detector’s heater, the control parameters are automatically configured by power supply voltage and frequency.

  • Page 168: Analog Output

    10-5 <10. Other Functions> 10.2.1 Analog output Displays Analog output1, Analog output2 on graphs with the unit (mA). Figure 10.5 Analog output 10.2.2 Contact output Displays the status of contact output from DO1 to DO4. When the contact is active, ON, not active, OFF is lit on.

  • Page 169: Measurement Info

    10-6 <10. Other Functions> 10.2.4 Measurement info Displays average, maximum, minimum value of measurement. Maximum and minimum value show the date when the measurement is conducted. Setup the monitoring hour value of average/ max. min according to the setting described in 8.6.2. Figure 10.8 measurement info 10.2.5...

  • Page 170: Trend Graph

    10-7 <10. Other Functions> Figure 10.10 Log information Changing HMI setting of Logbook configuration You can change what to display on the Log information. (1) “Converter menu” > “Maintenance” > “Display setting” > “other settings” (2) Select “Logbook settings”. Check items to change. You can see Cell resistance of zero calibration in “Calibration history”, power ON/Firm update/Operator ID in “Other”.
  • Page 171 10-8 <10. Other Functions> Table 10.3 Trend graph setting selectable item Description Oxygen concentration The graph shows the oxygen concentration during measurement. Humidity The graph shows the moisture content during measurement. Mixing ratio The graph shows the mixing ratio during measurement. Relative Humidity The graph shows the relative humidity during measurement.

  • Page 172: Simple Cell Resistance Trend

    10-9 <10. Other Functions> 10.3.2 Simple cell resistance trend Displays the result of the simple cell resistance measurement (see “10.6 Simple cell resistance measurement”). On the measurement date the result is displayed in dots. (An example shown below shows a measurement taken once a day). Trend displays only one data per day and the value measured at the earliest time of the day.

  • Page 173: Ne107 Mode

    10-10 <10. Other Functions> Figure 10.15 Other settings Display 10.4.2 NE107 mode You can change the alarm display according to the NAMUR NE 107. (1) "Converter" > "Maintenance" > "Display setting" > "Others setting" (2) Select NE107 Mode. Select ON/Off. Table 10.4 NE107 - Off Icon...

  • Page 174: Language Selection

    When the language is changed, the trend data of the trend screen is cleared. 10.4.6 Unit You cannot change the unit displayed on the screen. If you need to change the temperature to °F, the pressure to psi, please contact Yokogawa. IM 11M12G01-02EN 1sh Edition : Mar. 25, 2021-00...

  • Page 175: Blow Back

    10-12 <10. Other Functions> 10.5 Blow Back This section explains the parameter settings for performing blow back. 10.5.1 Mode There are three modes of blow back operation: no function, semi-automatic, and automatic. Blow back is not performed when the mode is set to “No function”. In “Semi_Auto” mode, blow back can be started by key operation on the display or by a contact input signal, and then sequentially performed at a preset blow back time and hold time.

  • Page 176: Setting Output Hold Time And Blow Back Time

    10-13 <10. Other Functions> 10.5.3 Setting Output Hold Time and Blow back Time If the blow back mode is in “No function”, the output “Hold time” and “Blow back time” are not displayed. If you select “Hold time”, the numeric-data entry display appears. Enter the desired “Hold time”...

  • Page 177: Default Setting

    10-14 <10. Other Functions> 10.5.5 Default Setting When the analyzer is delivered, or if data are initialized, the blow back settings are by default, as shown in Table 10.6. Table 10.6 Blow back Default Setting Item Default setting Mode None Hold time [mm:ss] 10:00 Blowback time [min]...

  • Page 178: Setup Of Hold Time, Interval, Start Date, And Start Time

    10-15 <10. Other Functions> 10.6.2 Setup of Hold time, interval, start date, and start time The stabilization time is turned setup because the measured value changes temporarily immediately after the simple cell resistance measurement. When “Hold time” is selected, the numeric entry screen is turned Display, so enter the hold time.

  • Page 179: Procedure For Simple Cell Resistance Measurement

    10-16 <10. Other Functions> 10.6.4 Procedure for Simple Cell Resistance Measurement Semi-automatic simple cell resistance measurement (1) Select “Cell resist” from the “sensor Menu” screen. (2) The message screen is displayed prior to starting the measurement. When “Start” is selected, measurement starts. (3) The message “Simple cell resistance measurement in progress...”...

  • Page 180: Communication Function

    10-17 <10. Other Functions> 10.7 Communication Function MODBUS Communication setup ZR802G has a MODBUS function. RS485 communication and Ethernet (MODBUS TCP/IP) are available by specification of the model of ZR802G. Here, setup it according to your hardware configuration. For MODBUS communication, refer to TI 11M12G01-62EN.

  • Page 181: Save Load

    10-18 <10. Other Functions> (1) “Converter menu” > “Maintenance” > “Communication settings.” (2) Select “TCP settings” to setup. Figure 10.24 TCP settings Note Setup of Ethernet is reflected after ZR802G is restarted. 10.8 Save load Converter has functions for outputting log files, setup load, and updating software using SD-Card. Precautions When Using SD Card •...
  • Page 182 10-19 <10. Other Functions> Selecting Measurement log storage cycle (1) “Converter menu” > “Setting” > “Other setting” (2) Select “Measurement log storage cycle” to setup. Default is 2 seconds (16 days). Figure 10.25 Measurement log storage cycle • Setup File You can save a variety of set value.

  • Page 183: Load Configuration

    10-20 <10. Other Functions> Figure 10.26 Outputting log files 10.8.2 Load configuration (1) "Converter menu" > "Other" > " Save/Load" (2) Select "Load configuration" (3) Save the file output by "Save configuration" into a SD card. Press "Execute" to load the data. Figure 10.27 Load configuration IM 11M12G01-02EN...

  • Page 184: Update Software

    (1) “Converter menu” > “Other” > “Save/Load” (2) Select “Update software” (3) Save a designated file into a SD card to update the software. Normally you don't need to update the software. If you need the update file, contact Yokogawa. Figure 10.28 Update software 10.9...
  • Page 185 10-22 <10. Other Functions> Table 10.9 Initialization Items and Default Values (Oxygen Analyzer) Item Initialization Parameter Default setting Model Setting Not initialized Language Not initialized Display settings Display item 1st display item selection Oxygen concentration 2nd display item selection Output item 1 3rd display item selection Favorite Tag name...
  • Page 186 10-23 <10. Other Functions> Item Initialization Parameter Default setting Simple cell resist. Measurement mode Semi-automatic setting Simple cell Hold time [mm:ss] 01:00 resistance time Interval [day] setting Interval [hour] First start date [YY/MM/DD] 00/01/01 First start time [hh:mm] 00:00 mA output settings mA output 1 Setting items Selection of AO1...
  • Page 187 10-24 <10. Other Functions> Item Initialization Parameter Default setting Alarm setting Hysteresis O2 concentration hysteresis 0.1%O2 Alarm operation Alarm operation delay delay Oxygen Oxygen (HH) high-high alarm concentration alarm concentration alarm (HH) high-high alarm 100.0%O2 value (H) high alarm (H) high alarm value 100.0%O2 (L) low alarm (L) low alarm value...
  • Page 188 10-25 <10. Other Functions> Item Initialization Parameter Default setting Contact setting Contact output 1 Contact state during operation Open (continued on next Selection of contact Fault page) output (HH) high-high alarm event (H) high alarm event (L) low alarm event (LL) low-low alarm event Maintenance Calibration...
  • Page 189 10-26 <10. Other Functions> Item Initialization Parameter Default setting Contact setting Contact output 3 Contact state during Closed (continuation of the operation previous page) Selection of contact Fault output (HH) high-high alarm event (H) high alarm event (L) low alarm event (LL) low-low alarm event Maintenance Calibration...
  • Page 190 10-27 <10. Other Functions> Item Initialization Parameter Default setting Sensor setting Device settings Choice of moisture base Selection of detector ZR22(PT1000:Ohm) Input temp./press. Oxygen model Pressure input selection Preset value setting setting Input pressure set value 0.00kPaG 4mA input pressure -5.00kPaG value 20mA input pressure...
  • Page 191 10-28 <10. Other Functions> Table 10.10 Initialization Items and Default Values (Humidity Analyzer) Item Initialization Parameter Default setting Model Setting Not initialized Language Not initialized Display settings Display item 1st display item selection Humidity 2nd display item selection Output item 1 3rd display item selection Favorite Tag name...
  • Page 192 10-29 <10. Other Functions> Item Initialization Parameter Default setting Simple cell resist. Measurement mode Semi-automatic setting Simple cell Hold time [mm:ss] 01:00 resistance time Interval [day] setting Interval [hour] First start date [YY/MM/DD] 00/01/01 First start time [hh:mm] 00:00 mA output settings mA output 1 Setting items Selection of AO1...
  • Page 193 10-30 <10. Other Functions> Item Initialization Parameter Default setting Alarm setting Hysteresis O2 concentration hysteresis 0.1%O (continued on next Humidity hysteresis 0.1%H page) Mixing ratio hysteresis 0.001kg/kg Relative humidity hysteresis 0.1%R.H. Alarm operation delay Alarm operation delay Oxygen Oxygen (HH) high-high alarm concentration alarm concentration alarm (HH) high-high alarm value...
  • Page 194 10-31 <10. Other Functions> Item Initialization Parameter Default setting Alarm setting Mixing ratio alarm Mixing ratio alarm (HH) high-high alarm (continuation of the (HH) high-high alarm value 1.000 kg/kg previous page) (H) high alarm (H) high alarm value 1.000 kg/kg (L) low alarm (L) low alarm value 0.000 kg/kg...
  • Page 195 10-32 <10. Other Functions> Item Initialization Parameter Default setting Contact setting Contact output 1 Contact state during operation Open (to be continue) Selection of contact Fault output (HH) high-high alarm event (H) high alarm event (L) low alarm event (LL) low-low alarm event Maintenance Calibration Switching output range...
  • Page 196 10-33 <10. Other Functions> Item Initialization Parameter Default setting Contact setting Contact output 3 Contact state during Closed (continuation of the operation previous page) Selection of contact Fault output (HH) high-high alarm event (H) high alarm event (L) low alarm event (LL) low-low alarm event Maintenance Calibration...
  • Page 197 10-34 <10. Other Functions> Item Initialization Parameter Default setting Sensor setting Device settings Choice of moisture base Selection of detector ZR22 (PT1000: Ohm) Input temp./press. Humidity model Temperature input Preset value setting setting selection Input temperature setting 300°C 4mA input temperature 0°C value 20mA input temperature...

  • Page 198: 10.10 Reboot

    10-35 <10. Other Functions> 10.10 Reboot Reboot enables the equipment to restart. If the equipment is rebooted, the power is turned off and then back on. In practical use, the power remains on, and the equipment is restarted under program control. When Fault happens, for safety, the power supply to the sensor heater is turned off.

  • Page 199: 10.11 Handling Of The Zo21S Standard Gas Unit

    10-36 <10. Other Functions> 10.11 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.

  • Page 200: Installing Gas Cylinders

    10-37 <10. Other Functions> 10.11.2 Installing Gas Cylinders Each ZO21S Standard Gas Unit comes with six zero gas cylinders including a spare. Each gas cylinder contains 7-liters of gas with a 0.95 to 1.0 vol%O2 (concentration varies with each cylinder) and nitrogen, at a pressure of 700 kPaG (at 35°C). The operating details and handling precautions are also printed on the product.
  • Page 201 10-38 <10. Other Functions> Figure 10.32 Flow of span gas (air) (2) Next, adjust the flow rate to 600 ± 60 ml/min using the span gas valve “AIR” (the flow check ball stops floating on the green line when the valve is slowly opened). To rotate the valve shaft, loosen the lock nut and turn it using a flat-blade screwdriver.

  • Page 202: Methods Of Operating Valves In The Za8F Flow Setting Unit

    10-39 <10. Other Functions> NOTE Be sure not to terminate a calibration in progress because of a shortage of gas in the cylinder. Each gas cylinder is operable for nine minutes or more provided the gas is discharged at the specified rate.

  • Page 203: Operating The Zero Gas Flow Setting Valve

    10-40 <10. Other Functions> (2) Adjust the flow rate and select “Valve opened” from the Manual calibration display. Check the Trend graph display to see that the measured value is stabilized. Then press the [Enter] key. The Manual calibration display shown in Figure 10.16 appears. Close the span gas flow setting valve to stop the span gas (air) flow.

  • Page 204: Inspection And Maintenance

    11-1 <11. Inspection and Maintenance> Inspection and Maintenance This chapter describes the inspection and maintenance procedures for the Zirconia Oxygen 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.

  • Page 205: Replacing The Sensor Assembly

    11-2 <11. Inspection and Maintenance> (4) Clean the U-shaped pipe. The pipe can be rinsed with water. However, it should be dried out thoroughly before reassembly. (5) Restore all components you removed for cleaning. Follow Section 11.1.3 to restore all components in their original positions.
  • Page 206 11-3 <11. Inspection and Maintenance> Metal O-ring Sensor U-shaped pipe support Dust filter Bolts (four) (optional) Probe Contact Filter U-shaped pipe Washers (four) 1/8 turn – tighten bolts 1/8 turn (approximately 45°) each Figure 11.2 Exploded View of Sensor Assembly CAUTION Inconel bolts have large elongation, so if excessive torque is applied when tightening the bolts, abnormal elongation or breakage will occur.

  • Page 207: Replacement Of The Heater Unit

    11-4 <11. Inspection and Maintenance> Groove in which the contact (E7042BS) is placed F11.2E.ai Figure 11.3 Installing the Contact (2) Next, make sure that the O-ring groove on the flange surface of the sensor is clean. Install the metal O-ring in that O-ring groove, and then insert the sensor in the probe while turning it clockwise.
  • Page 208 11-5 <11. Inspection and Maintenance>    TC + TC - View A-A CELL + CELL H T R     Figure 11.4 Oxygen Analyzer Exploded View of Detector (When pressure compensation specified) Note: The parts marked by is not equipped with the types except the pressure compensation type.
  • Page 209 High Temperature Humidity Analyzer Exploded View of Detector (When pressure compensation specified) Replacement of heater strut assembly (ZR22G : Style S2 and after) Refer to Figure 11.4 as an aid in the following discussion. Remove the cell assembly (6), following Section 11.1.2, earlier in this manual. Open the terminal box (16) and remove the three terminal connections –...

  • Page 210: Replacement Of Dust Filter

    11-7 <11. Inspection and Maintenance> Remove the two screws (15) that fasten the cover (12) and slide it to the flange side. Remove the four bolts (10) and terminal box (16) with care so that the already disconnected wire will not get caught in the terminal box. In case of the pressure compensation type detector, remove the screw (36) and the plate (37) on the adapter (35).

  • Page 211: Cleaning The High Temperature Probe Adapter

    11-8 <11. Inspection and Maintenance> 11.1.7 Cleaning the High Temperature Probe Adapter CAUTION Do not subject the probe of the High Temperature Probe Adapter (ZO21P-H-A) to shock. This probe uses silicon carbide (SiC) which may become damaged if it is subjected to a strong shock or thermal shock.

  • Page 212: Replacing Fuses

    11-9 <11. Inspection and Maintenance> 11.2.1 Replacing Fuses The converter incorporates a fuse, as indicated in Figure 11.5. If the fuse blows out, replace it in the following procedure. CAUTION • If a replaced fuse blows out immediately, there may be a problem in the circuit. Go over the circuit completely to find out why the fuse has blown.

  • Page 213: Cleaning

    11-10 <11. Inspection and Maintenance> 11.2.2 Cleaning Use a soft dry cloth to clean any part of the converter during inspection and maintenance. 11.2.3 Adjust LCD panel Adjust he position of touch button or brightness of LCD panel. “Sensor menu” > “Other menu” > “Adjust panel” Figure 11.8 Adjust panel Touch panel...

  • Page 214: Replacing Flowmeter In Zr40H Automatic Calibration Unit

    11-11 <11. Inspection and Maintenance> Figure 11.9 Touch panel position adjustment Brightness Adjust “Brightness” of back light. Select the level from below. The default is 50%. The larger % the brightness indicates, the brighter the light glows. Brightness: 0%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100% 11.3 Replacing Flowmeter in ZR40H Automatic Calibration Unit...
  • Page 215 11-12 <11. Inspection and Maintenance> Flowmeter with back plate Bolt fixes bracket COM ON S N Z RO Connecter F11.8E.ai Figure 11.10 Flowmeter replacement Two screws fix flowmeter Connect piping pairs A-A', B-B', C-C', D-D' F11.9E.ai Figure 11.11 Fixing Flowmeter IM 11M12G01-02EN 1sh Edition : Mar.

  • Page 216: Troubleshooting

    12-1 <12. Troubleshooting> Troubleshooting This chapter describes Fault (errors) and alarms detected by the self-diagnostic function of the converter. It also explains inspections and remedies when other problems occur. 12.1 Displays and Remedies When Fault Occur 12.1.1 Fault A Fault occurs when an abnormality is detected in the detector or the converter, e.g., in the cell (sensor), detector heater, or internal circuits of the the converter.

  • Page 217: Remedies When Fault Occurs

    12-2 <12. Troubleshooting> Table 12.1 Types of Fault , Reasons for Occurrence Alarm Type Occurrence Conditions Number Hardware failure Occurs when internal storage hardware fails. Internal com. failure This error occurs when there is an error in internal storage communication. MAC address read failure This error occurs when there is an error in MAC address being read.
  • Page 218 A failure in the detector or the converter is suspected. End. Carry out calibration. Contact Yokogawa. (2) Alarm 017: Heater Temperature Failure This alarm occurs if the temperature of the detector heater does not rise during warm-up, or it drops below 730°C or exceeds 780°C after the warm-up ends.
  • Page 219 (a) Heater terminals shorted. (b) Heater terminal(s) shorted to ground. (c) Heater terminals shorted to power supply. If the internal fuse blows, this cannot be replaced by the user. Contact your Yokogawa service representative. NOTE Measure the thermocouple resistance value after the temperature difference between the detector tip and the ambient atmosphere has decreased to 50°C or less.

  • Page 220: Displays And Remedies When Alarms Are Generated

    12-5 <12. Troubleshooting> 12.2 Displays and Remedies When Alarms are Generated 12.2.1 Alarm Types When an alarm is generated, the alarm indication blinks in the display to notify of the alarm. Pressing the alarm indication displays a description of the alarm. Alarms include those shown in Table 12.2.

  • Page 221: Remedies When Alarms Are Generated

    12-6 <12. Troubleshooting> Battery low alarm The internal battery is low. Turning OFF Power Supply when the battery is exhausted will reset the clock. Fast warm-up function alarm The function to shorten the warm-up time when an instantaneous power failure occurs does not work. If an alarm is generated, actions such as turning off the heater power are not carried out.
  • Page 222 12-7 <12. Troubleshooting> (5) Alarms 201 and 202: Zero correction ratio high and low alarm Occurs when the zero-point compensation ratio exceeds 100 ± 30% in the auto calibration or semi-auto calibration (see section: “9.1.4 Compensation”). Possible causes of this are as follows.
  • Page 223 12-8 <12. Troubleshooting> (6) Alarms 203 and 204: Span correction ratio high and low alarm This error occurs when the span point correction rate exceeds the range of 0 ± 18% in automatic calibration or semi-automatic calibration (see Section: “9.1.4 Compensation”).
  • Page 224 12-9 <12. Troubleshooting> (3) If the resistance value is within the range, the cold junction temperature sensor is considered normal. Check that the wiring cable is not broken or short-circuited and that it is securely connected to the terminal. Also check that the wiring resistance between the transmitter and sensor is 10 Ω...
  • Page 225 12-10 <12. Troubleshooting> (10) Alarm 211 to 214: Input temperature high and low alarm If “External input” is selected in “Set measured gas pressure” or “Set measured gas temperature”, this alarm occurs when the input current exceeds the set alarm value. Possible causes are as follows •...

  • Page 226: Measures To Be Taken When Measured Values Indicate Abnormalities

    12-11 <12. Troubleshooting> 12.3 Measures to be taken when measured values indicate abnormalities The cause that the measured value indicates an abnormal value is not necessarily a failure of the equipment. Rather, there are many cases in which the measured gas itself is in an abnormal state or due to external factors that disturb the operation of the equipment.

  • Page 227: The Measured Value Is Lower Than The Actual Value (Higher In The Case Of A Hygrometer)

    12-12 <12. Troubleshooting> 12.3.2 The measured value is lower than the actual value (higher in the case of a hygrometer). <Cause and remedy> (1) The pressure of the measured gas decreases. If the change in the measured value due to pressure fluctuation cannot be ignored, take measures according to (1) in section 12.3.1.

  • Page 228: Customer Maintenance Parts List

    Cal. Gas Tube Assembly K9470ZL Cal. Gas Tube Assembly for Option code "/C" CMPL 11M12A01-02E All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. Subject to change without notice. 1st Edition : Aug. 2000 (YK) 10th Edition : Oct. 2019 (YK)
  • Page 230 Parts List Hood for ZR802G Item Part No. Description A1113EF Fuse (3.15A) K8000PA Hood Assy (include Bolt and washer) CMPL 11M12G01-01EN All Rights Reserved, Copyright © 2021, Yokogawa Electric Corporation. Subject to change without notice. 1st Edition : Mar. 2021 (YK)

  • Page 232: Customer Maintenance Parts List

    E7046AQ Probe (SUS, L=1.5m G7073XL Gasket Y9630RU Bolt Y9121BU Y9120WU Washer Y9801BU CMPL 11M03B01-10E All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. Subject to change without notice. 1st Edition : Dec. 2000 (YK) 8th Edition : Sep. 2012 (YK)
  • Page 234 Nozzle Assembly, Tube Connection 1/4 inch tube G7031XA Tee, Connection Rc1/4 E7046EJ Reducing nipple, Connection R1/4 CMPL 11M03B01-05E All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. Subject to change without notice. 1st Edition : Dec. 2000 (YK) 8th Edition : Mar. 2013 (YK)
  • Page 236 Made in Japan REF.OUT CAL.OUT SPAN IN ZERO IN Item Part No. Description K9473XC Flowmeter CMPL 11M12A01-11E All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. Subject to change without notice. 1st Edition : Dec. 2000 (YK) 4th Edition : Mar. 2013(YK)
  • Page 238 Table 1 Power Pump AC 100 V E7050AU AC 200 V E7050AV CMPL 11M3D1-01E All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. Subject to change without notice. 1st Edition : Jan. 2000 (YK) 4th Edition : Mar. 2011 (YK)

  • Page 240: Revision Information

    Revision Information Manual Title : ZR802G Zirconia Oxygen/Humidity Analyzer, Converter Manual No. : IM 11M12G01-02EN Mar. 2021/1st Edition Newly published Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, JAPAN Homepage: http://www.yokogawa.com/ IM 11M12G01-02EN 1sh Edition : Mar. 25, 2021-00...
  • Page 241 Blank Page...

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