YOKOGAWA vigilantplant EXAxt ZR202G User Manual
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YOKOGAWA vigilantplant EXAxt ZR202G User Manual

YOKOGAWA vigilantplant EXAxt ZR202G User Manual

Integrated type zirconia high temperature humidity analyzer
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User's
Manual
Model ZR202G
Integrated type Zirconia High
Temperature Humidity Analyzer
IM 11M12A01-05E
IM 11M12A01-05E
6th Edition

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Summary of Contents for YOKOGAWA vigilantplant EXAxt ZR202G

  • Page 1 User's Manual Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer IM 11M12A01-05E IM 11M12A01-05E 6th Edition...

  • Page 2: Introduction

    Check valve (Part No. K9292DN, K9292DS) Dust filter for the detector (Part No. K9471UA) ZO21S Standard gas unit T.Int.1E CMPL: Customer Maintenance Parts List IM 11M12A01-05E 6th Edition: Sep. 2006 (YK) All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation IM 1M12A01-05E...
  • Page 3 This manual consists of twelve chapters. Please refer to the reference chapters for installation, operation and maintenance. References Chapter Outline Installation Operation Maintenance 1. Overview Equipment models and system configuration examples 2. Specifications Standard specification, model code (or part number), dimension drawing for each equipment 3.

  • Page 4: For The Safe Use Of This Equipment

    For the safe use of this equipment CAUTION The cell (sensor) at the tip of the probe is made of ceramic (zirconia element). Do not drop the equipment or subject it to pressure stress. • Do NOT allow the sensor (probe tip) to make contact with anything when installing the analyzer.

  • Page 5: About This Manual

    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 6 (3) The following safety symbols are used in this manual. DANGER This symbol indicates that the operator must follow the instructions laid out in this manual in order to avoid the risk of personnel injury, electric shock or fatalities . The manual describes what special care the operator must exercise to avoid such risks.
  • Page 7 Special descriptions in this manual This manual indicates operation keys, displays and drawings on the product as follows: • Operation keys, displays on the panel Enclosed in [ ]. (Ex. "MODE" key) (Ex. message display "BASE-L") (Ex. data display "102" lit, "102" flashing) •...

  • Page 8: Notice

    Do not modify the product. During the warranty period, for repair under warranty carry or send the product to the local sales representative or service office. Yokogawa will replace or repair any damaged parts and return the product to you.
  • Page 9 Yokogawa does not warrant conformance with the specific application at the user site. Yokogawa will not bear direct/indirect responsibility for damage due to a specific application. Yokogawa Electric will not bear responsibility when the user configures the product into systems or resells the product.

  • Page 10: Table Of Contents

    Contents Introduction ........................... i r For the safe use of this equipment ................iii r NOTICE ......................... vii r After-Sales Warranty ....................vii 1. Overview ........................1-1 < EXAxt ZR > System Configuration ............1-2 1.1.1 System 1 ....................1-2 1.1.2 System 2 ....................
  • Page 11 3.2.2 Mounting of ZA8F Flow Setting Unit ........... 3-4 Installation of ZR20H Automatic Calibration Unit ........3-6 3.3.1 Location ....................3-6 3.3.2 Mounting of ZR20H Automatic Calibration Unit ........3-6 Installation of the Calibration-gas Unit Case (E7044KF) ......3-8 3.4.1 Location ....................
  • Page 12 Operation of Infrared Switch ................7-3 7.4.1 Display and Switches ................7-3 7.4.2 Display Configuration ................7-5 7.4.3 Entering Parameter Code Selection Display .......... 7-6 7.4.4 Selecting Parameter Codes ..............7-7 7.4.5 Changing Set Values ................7-8 Confirmation of Equipment Type Setting ............ 7-10 Setting Display Item ..................
  • Page 13 9. Calibration ........................9-1 Calibration Briefs .................... 9-1 9.1.1 Measurement Principle of Zirconia Humidity Analyzer ......9-1 9.1.2 Calibration Gas ..................9-3 9.1.3 Compensation ..................9-4 9.1.4 Characteristic Data from a Sensor Measured During Calibration ..9-5 Calibration Procedures ..................9-6 9.2.1 Calibration Setting ..................
  • Page 14 11. Inspection and Maintenance ................... 11-1 11.1 Inspection and Maintenance of the Detector ..........11-2 11.1.1 Cleaning the Calibration Gas Tube ............11-2 11.1.2 Replacing the Sensor Assembly ............11-3 11.1.3 Replacement of the Heater Unit ............11-5 11.1.4 Replacement of O-ring ................. 11-7 11.1.5 Stopping and Re-starting Operation .............

  • Page 15: Overview

    1. Overview Overview The EXAxt ZR Integrated-type Zirconia High-temperature Humidity Analyzer integrates the detector and the converter in one unit. This analyzer can measure humidity of hot air continuously, so can be used to measure humidity of air in driers which are heated by steam or electricity.

  • Page 16: Exaxt Zr > System Configuration

    1.1 < EXAxt ZR > System Configuration The system configuration determines whether calibration is initiated automatically or manually. The three basic system configurations are given below: 1.1.1 System 1 This is the simplest system which consists of an integrated-type (all-in-one) detector and analyzer.

  • Page 17: System 3

    1. Overview 1.1.3 System 3 This system is also used where accurate monitoring and controlling of the humidity is required. Instrument air (clean and dry air of oxygen concentration 21%) is used as the reference gas and span gas for calibration. A calibration zero gas is supplied from a cylinder.

  • Page 18: Exaxtzr > System Components

    1.2 < EXAxtZR > System Components 1.2.1 System Components Integrated type System config. System Components Ex.1 Ex.2 Ex.3 Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzers Model ZH21B Dust Protector Model ZO21S Standard Gas Unit Model ZA8F Flow setting unit for manual calibration Model ZR20H Automatic Calibration Unit for integrated type Analyzer L9852CB, G7016XH Stop Valve for Calibration-gas line K9292DN, K9292DS Check Valve for Calibration-gas line...

  • Page 19: Specifications

    2. Specifications Specifications This chapter focuses on the specifications for the High-temperature Humidity Analyzer (integrated model) and associated equipment, including: ZR202G Integrated type Zirconia High-temperature Humidity Analyzer (See Section 2.1.2) ZH21B Dust protector (See Section 2.1.3) ZA8F Flow setting unit (See Section 2.2.1) ZR20H Automatic calibration unit...

  • Page 20: Zr202G Integrated-Type Zirconia High-Temperature Humidity Analyzer

    Linearity : (Excluding standard gas tolerance) (See Note 1) (Use oxygen of known concentration (in the measuring range) as the zero and span calibration gas.) 2 vol% H O; (Sample gas pressure: within 0.49 kPa) 3 vol% H O; (Sample gas pressure: 2 kPa or less) Drift: (Excluding the first two weeks in use) (See Note 1) Both zero and span 3 vol% H...
  • Page 21 2. Specifications EMC : EN 61326 Class A EN 55011 Class A Group 1 EN 61000-3-2 AS/NZS CISPR 11 Reference Air System : Natural Convection, Instrument Air Instrument Air System (excluding Natural Convection): Pressure; 200 kPa + the pressure inside the dryer (It is recommended to use air which is dehumidified to dew point -20 C or less, and with dust or oil mist removed.) Consumption;...
  • Page 22 Initial settings should be set to match the plant conditions when installing the converter. Current output data settings, alarm data settings, contact data settings, other settings. Display and setting content: Display Related Items : Oxygen concentration (vol% O ), Moisture quantity (vol% O), mixture ratio (kg/kg), relative humidity (%RH), dew point ( C), cell tempera- ture ( C), thermocouple reference junction temperature ( C), maximum/minimum/ average oxygen concentration (vol% O...
  • Page 23 2. Specifications (1) Abnormal, (2) High-high alarm, (3) High-alarm, (4) Low-low alarm, (5) Low- alarm, (6) Maintenance, (7) Calibration, (8) Range switching answer-back, (9) Warm-up, (10) Calibration-gas pressure decrease (answerback of contact input), (11) Flameout gas detection (answerback of contact input). Contact Input : Two points, voltage-free contacts The following functions are programmable for contact inputs: (1) Calibration-gas pressure decrease alarm, (2) Range switching (switched range is...
  • Page 24 • Model and Codes Option Model Suffix code Description code Integrated type Zirconia High Temperature Homidity Analyzer ZR202G Length -040 0.4 m -070 0.7 m -100 1.0 m -150 1.5 m -200 2.0 m -250 2.5 m (*1) -300 3.0 m (*1) Wetted material SUS316...
  • Page 25 2. Specifications • External Dimensions Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzers Unit: mm 338 to 351 Display side L= 0.4, 0.7, Rc1/4 or 1/4NPT 1.0, 1.5, 2.0, Reference air inlet 2.5, 3.0 (m) Rc1/4 or 1/4NPT Calibration gas inlet 153 to 164 4-G1/2,2-1/2NPT etc.
  • Page 26 Model ZR202G...-P(with pressure compensation) Integrated type Zirconia High Temperature Humidity Analyzer Unit : mm 342 4 Display side L= 0.4, 0.7, Rc1/4 or 1/4NPT 1.0, 1.5, 2.0, Reference air inlet 2.5, 3.0 (m) Reference air outlet PIPING 4-G1/2,2-1/2NPT etc. Terminal side PIPING:A Cable connection port 156 3...
  • Page 27 2. Specifications • Hood (Option code /H) Hood Material : Aluminum Hood Weight : Approx. 800g ZR202G-F.eps IM 11M12A01-05E...

  • Page 28: Zh21B Dust Protector

    2.1.3 ZH21B Dust Protector This protector is designed to protect the probe output from dust agitation (i.e., to prevent combustible materials from entering the probe cell where humidity measurements are made) in a dusty environment. Insertion length : 0.428m Flange : JIS 5K 80 FF equivalent or ANSI Class 150 4 FF SUS304. (However, flange thickness is different.) Material : SUS 316 (JIS), SUS 304 (JIS) (flange) Weight: Approx.

  • Page 29: Za8F Flow Setting Unit And Zr20H Automatic Calibration Unit

    Weight: Approx. 2.3 kg Calibration gas (zero gas, span gas) flow: 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 Suffix code Option code...
  • Page 30 External Dimensions Unit: mm 6 hole REFERENCE CHECK REFERENCE ZERO SRAN Span gas inlet Reference air outlet Zero gas outlet Zero gas inlet 4-Rc1/4 or 4-NPT(F) Instrument air inlet CHECK Flow Flow meter meter ZERO SPAN AIR IN GAS IN GAS IN Instrument air Approx 1.5 l/min.

  • Page 31: Zr20H Automatic Calibration Unit

    Pressure compensated Horizontal mounting Mounting Vertical mounting Always -A *1 Ask Yokogawa service station for additional mounting of ZR20H to the preinstalled ZR202G. *2 Select the appropriate reference air of ZR20H according to the one of ZR202G. T22E.EPS IM 11M12A01-05E 2-13...
  • Page 32 • External Dimensions (1) For Horizontal Mounting (-A) Unit: mm AUTO CAL. UNIT MODEL ZR20H SUFFIX STYLE SPAN IN REF IN ZERO IN SUPPLY 690kPa MAX. -20 TO 558C AMB.TEMP ZR202G USED WITH 66.5 166.5 Zero gas inlet Rc1/4 or 1/4NPT(Female) Span gas inlet Reference gas inlet Rc1/4 or 1/4NPT(Female)

  • Page 33: Zo21S Standard Gas Unit

    2. Specifications 2.3 ZO21S Standard Gas Unit This is a handy unit to supply zero gas and span gas to the detector in a system configu- ration based on System 1. It is used in combination with the detector only during calibration.

  • Page 34: Other Equipment

    2.4 Other Equipment 2.4.1 Stop Valve (part number: L9852CB or G7016XH) This valve is mounted on the calibration gas line in the system to allow for one-touch calibration. This applies to the system configuration shown for System 1 in section1. Standard Specifications Connection : Rc 1/4 or 1/4 FNPT Material : SUS 316 (JIS)

  • Page 35: Air Set

    2. Specifications K9292DN : Rc 1/4(A part),R 1/4(B) unit : mm K9292DS : 1/4FNPT(A part),1/4NPT(Male)(B part) Approx.19 Approx.54 F2.11E.EPS 2.4.3 Air Set This set is used to lower the pressure when instrument air is used as the reference and span gases. •...
  • Page 36 • Part. no. G7004XF or K9473XG Standard Specification Primary Pressure: Max. 1 MPa G Secondary Pressure: 0.02 to 0.5 MPa G Connection: Rc1/4 or 1/4 FNPT with joint adapter Weight : Approx. 1 kg Description Part No. Joint: Rc 1/4, Material: Zinc Alloy G7004XF Joint: 1/4 NPT (F) , Material: Body;...

  • Page 37: Zero-Gas Cylinder (Part Number: G7001Zc)

    2. Specifications 2.4.4 Zero-gas Cylinder (part number: G7001ZC) The gas from this cylinder is used as the calibration zero gas and detector purge gas. Standard Specifications Capacity : 3.4 l Filled pressure : 9.8 to 12 MPa G Composition : 0.95 to 1.0 vol% O in N (Note) Export of such high pressure filled gas cylinders to most countries is prohibited or restricted.

  • Page 38: Case Assembly For Calibration-Gas Cylinder (Part Number: E7044Kf)

    2.4.6 Case Assembly for Calibration-gas Cylinder (part number: E7044KF) This case is used to store the zero gas cylinders. Standard Specifications Case Paint : Baked epoxy resin, Jade green (Munsell 7.5 BG 4/1.5) Installation : 2B pipe mounting Material : SPCC (Cold rolled steel sheet) Weight : Approx.

  • Page 39: Model Zr202A Heater Assembly

    2. Specifications 2.4.7 Model ZR202A Heater Assembly Model Suffix code Option code Description ZR202A Heater Assembly for ZR202G 0.4 m -040 Length 0.7 m -070 ( 1) -100 -150 1.5 m -200 2.5 m -250 -300 Jig for change with Jig None Always -A T2.2E.EPS...

  • Page 41: Installation

    3. Installation 3. Installation This chapter describes how to install the following equipment and how to test the insulation resistance. 3.1 High-temperature Humidity Analyzer 3.2 ZA8F Flow Setting Unit 3.3 ZR20H Automatic Calibration Unit 3.4 Case Assembly for Calibration-gas Cylinder (E7044KF) 3.5 Insulation Resistance Test 3.1 Installation of High-temperature Humidity Analyzer 3.1.1 Location...

  • Page 42: Probe Insertion

    3.1.2 Probe Insertion CAUTION • The outside dimension of detector may vary depending on its options. Use a pipe that is large enough for the detector. Refer to Figure 3.1 for the dimensions. • If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards.

  • Page 43: Installation Of The Detector

    3. Installation 3.1.3 Installation of the Detector CAUTION • The cell (sensor) at the tip of the detector is made of ceramic (zirconia). Do not drop the detector, as impact will damage it. • If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should face downwards.

  • Page 44: Installation Of Za8F Flow Setting Unit

    3.2 Installation of ZA8F Flow Setting Unit 3.2.1 Location The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the analyzer for operating keys on the panel. (3) No corrosive gas. (4) An ambient temperature of not more than 55 C and little changes of temperature.
  • Page 45 3. Installation <Wall Mounting> (1) Make a hole in the wall as illustrated in Figure 3.4. unit : mm 6 hole, or M5 screw F3.13E.EPS Figure 3.4 Mounting holes (2) Mount the flow setting unit. Remove the pipe mounting parts from the mount fittings of the flow setting unit and attach the unit securely on the wall with four screws.

  • Page 46: Installation Of Zr20H Automatic Calibration Unit

    3.3 Installation of ZR20H Automatic Calibration Unit 3.3.1 Location The following should be taken into consideration: (1) Easy access to the unit for checking and maintenance work. (2) Near to the detector and the converter (3) No corrosive gas. (4) An ambient temperature of not more than 55 C and little change of temperature. (5) No vibration.
  • Page 47 3. Installation Basic spec. code -A : Horizontal mounting Display Terminal box unit ; mm Zero gas inlet Rc 1/4 or 1/4NPT(Female) 66.5 166.5 Reference gas inlet Span gas inlet Rc 1/4 or 1/4NPT(Female) Rc 1/4 or 1/4NPT(Female) Basic spec. code -B : Vertical mounting 166.5 Span gas inlet Rc 1/4 or 1/4NPT(Female)

  • Page 48: Installation Of The Calibration-Gas Unit Case (E7044Kf)

    3.4 Installation of the Calibration-gas Unit Case (E7044KF) The calibration gas unit case is used to store the G7001ZC zero gas cylinders. 3.4.1 Location The following should be taken into consideration: (1) Easy access for cylinder replacement (2) Easy access for checking (3) Near to the detector and converter as well as the flow setting unit.

  • Page 49: Insulation Resistance Test

    3. Installation 3.5 Insulation Resistance Test Even if the testing voltage is not so great it causes dielectric breakdown, testing may cause deterioration in insulation and a possible safety hazard. Therefore, conduct this test only when it is necessary. The applied voltage for this test shall be 500 V DC or less. The voltage shall be applied for as short a time as practicable to conform that insulation resistance is 20 M or more.

  • Page 50: Installation Of The High Temperature Humidity Analyzer (With Pressure Compensation)

    3.6 Installation of the High Temperature Humidity Ana- lyzer (with pressure compensation) Installation for each flange type Unit: mm 1. ANSI Class 150 2 RF ZR202G- - -A-P Flange : ANSI Class 150 2 RF SUS304 34264 Rc1/4or1/4NPT Reference air inlet Reference gas outlet PIPING Flange...
  • Page 51 3. Installation 2. ANSI Class 150 3 RF ZR202G- - -B-P Flange : Equivalent to ANSI Class 150 3 RF SUS304 Rc1/4 or 1/4NPT Reference air inlet 342 4 2-G1/2, 2-1/2NPT etc. Cable connection port Reference gas outlet PIPING Flange Flange PIPING:A 156 3...
  • Page 52 4. DIN PN10 DN50 ZR202G- - -E-P Flange : DIN PN10 DN50 SUS304 Rc1/4 or 1/4NPT Reference air inlet 342 4 2-G1/2, 2-1/2NPT etc. Cable connection port Reference gas outlet PIPING Flange Flange PIPING:A 156 3 Stop Valve 256 4 Flange Weight Model, Code...
  • Page 53 3. Installation 6. DIN PN10 DN100 ZR202G- - -G-P Flange : DIN PN10 DN100 SUS304 Rc1/4 or 1/4NPT Reference air inlet 342 4 2-G1/2, 2-1/2NPT etc. Cable connection port Reference gas outlet PIPING Flange Flange PIPING:A 156 3 Stop Valve 256 4 Flange Weight...
  • Page 54 8. JIS 10K 65 FF ZR202G- - -L-P Flange : JIS 10K 65 FF SUS304 342–4 Rc1/4 or 1/4NPT Reference air inlet Reference gas outlet PIPING Flange 2-G1/2, 2-1/2NPT etc. PIPING:A Cable connection port 156–3 Stop Valve 256–4 Rc1/4 or 1/4NPT Calibration gas inlet Flange Weight...
  • Page 55 3. Installation 10. JIS 10K 100 FF ZR202G- - -P-P Flange : JIS 10K 100 FF SUS304 Rc1/4 or 1/4NPT Reference air inlet 342 4 2-G1/2, 2-1/2NPT etc. Cable connection port Reference gas outlet PIPING Flange Flange PIPING:A 156 3 Stop Valve 256 4 Flange...
  • Page 56 12. JPI Class 150 3 RF ZR202G- - -S-P Flange : JPI Class 150 3 RF Rc1/4 or 1/4NPT Reference air inlet 342 4 Reference gas outlet PIPING Flange Flange 2-G1/2, 2-1/2NPT etc. PIPING:A Cable connection port 156 3 Stop Valve 256 4 Rc1/4 or 1/4NPT...

  • Page 57: Piping

    4. Piping 4. Piping This chapter describes piping procedures in the three typical system configurations for EXAxt ZR Integrated-type Zirconia High Temperature Humidity Analyzer. • Ensure that each check valve, stop valve and joints used for piping are not leaking. Especially, if there is any leakage of the calibretion gas from piping and joints, it may cause clogging of the piping or incorrect calibration.

  • Page 58: Piping Parts For System Configuration 1

    Mount the stop valve (of a quality specified by YOKOGAWA) through a nipple (found on the open market) as illustrated in Figure 4.2, and mount a commercially available joint at the stop valve tip.

  • Page 59: Piping For System Configuration 2

    Description General-use Calibration gas inlet Stop valve or check valve Stop valve (L9852CB or G7016XH Analyzer provided by YOKOGAWA), check valve (K9292DN or K9292DS) recommended by YOKOGAWA Nipple * Rc1/4 or 1/4 NPT Commercially available Zero gas cylinder User´s scope...

  • Page 60: Piping For The Calibration Gas

    40 C. Mount a pressure regulator (recommended by YOKOGAWA) on the cylinder. Mount a stop valve or the check valve (recommended by YOKOGAWA) on the nipple (commercially available) at the calibration gas inlet of the equipment as illustrated in Figure 4.8.

  • Page 61: Piping For System Configuration 3

    4. Piping 4.3 Piping for System Configuration 3 Piping in System 3 is illustrated in Figure 4.9. In System 3, calibration is automated; however, the piping is basically the same as that of System 2. Refer to Section 4.2. Adjust secondary pressure of both the air set and the zero gas regulator so that these two pressures are approximately the same.
  • Page 62 Installation of ZR20H AutoCalibretion Unit Unit: mm Horizontal mounting on the ZR202G (-A) display side terminal box side Zero gas inlet Rc1/4 or 1/4NPT(Female) 66.5 166.5 Reference air inlet Span gas inlet Rc1/4 or 1/4NPT(Female) Rc1/4 or 1/4NPT(Female) Vertical mounting on the ZR202G (-B) 166.5 Span gas inlet...
  • Page 63 4. Piping Piping Diagram of ZR20H ZR202G body Calibration gas Span-gas solenoid valve Span-gas flowmeter Reference gas Check valve Reference-gas flowmeter SPAN IN Zero-gas solenoid valve To Air set REF. IN To Zero-gas cylinder ZERO IN Needle valve Autocalibration unit Span-gas flowmeter F4.11E.EPS IM 11M12A01-05E...

  • Page 64: Wiring

    5. Wiring 5. Wiring In this Chapter, the wiring necessary for connection to the EXAxtZR Integrated type Zirconia High-temperature Humidity Analyzer is described. 5.1 General CAUTION • Never supply current to the equipment or any other device constituting a power circuit in combination with the equipment, until all wiring is completed.

  • Page 65: Terminals For The External Wiring

    5.1.1 Terminals for the External Wiring Remove the terminal cover on the opposite side of the display to gain access to the external wiring terminals. G FG F5.1E.EPS Figure 5.1 Terminals for External Wiring 5.1.2 Wiring Make the following wiring for the equipment. It requires a maximum of four wiring connections as shown below.

  • Page 66: Mounting Of Cable Gland

    5. Wiring 5.1.3 Mounting of Cable Gland For each wiring inlet connection of the equipment, mount the conduit appropriate for the screw size or a cable gland. Rc1/4 or 1/4NPT (Reference air inlet) Cable gland Rc1/4 or 1/4NPT (Calibration gas inlet) 4-G1/2, 1/2 NPT or the like (Wiring connection) F5.3E.EPS...

  • Page 67: Wiring For Analog Output

    5.2 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 of 550 or less. Analyzer Receiver AO(+) Shielded cables F5.4E.EPS Figure 5.4 Wiring for Analog Output 5.2.1 Cable Specifications...

  • Page 68: Wiring Power And Ground Terminals

    5. Wiring 5.3 Wiring Power and Ground Terminals Wiring for supplying power to the analyzer and grounding the equipment. Ground Grounding to the ground terminal on the equipment case Equipment case Crimp contact of Jumper plate the grounding line Lock washer Grounding terminal 100~240 V AC...

  • Page 69: Wiring For Contact Output

    5.4 Wiring for Contact Output The equipment can output a maximum of two contact signals. These contact outputs can be used for different applications such as a low-limit alarm or high-limit alarm. Do the contact output wiring according to the following requirements. Analyzer Terminal box Annunciator or the like...

  • Page 70: Wiring For Contact Input

    5. Wiring 5.5 Wiring for Contact Input The converter can execute specified function when receiving contact signals. To use these contact signals, proceed wiring as follows: Converter Terminal box DI-1 Contact input 1 DI-2 DI-C Contact input 2 F5.7E.EPS Figure 5.14 Contact Input Wiring 5.5.1 Cable Specifications Use a 2-wire or 3-wire cable for this wiring.

  • Page 72: Components

    6. Components 6. Components This chapter describes the names and functions of components for the major equipment of the EXAxt ZR Integrated type Zirconia High-temperature Humidity Analyzer. 6.1 ZR202G High-temperature Humidity Analyzer 6.1.1 Integrated-type High-temperature Humidity Analyzer Terminal box, Non explosion-proof JIS C0920 / equivalent to IP44D.

  • Page 73: Za8F Flow Setting Unit And Zr20H Automatic Calibration Unit

    6.2 ZA8F Flow Setting Unit and ZR20H Automatic Cali- bration Unit Reference gas flow setting valve Span gas flow setting valve Zero gas flow setting valve Flowmeter for reference gas Flowmeter for calibration gas F6.2E.EPS Figure 6.2 ZA8F Flow Setting Unit Flowmeter for Flowmeter for Flowmeter for...

  • Page 74: Startup

    7. Startup 7. Startup The following describes the minimum operating requirements — from supplying power to the converter to analog output confirmation to manual calibration. Check piping and Set output ranges wiring connections Set up valves Check current loop Supply power Check contact action Confirm converter Calibrate analyzer...

  • Page 75: Checking Piping And Wiring Connections

    7.1 Checking Piping and Wiring Connections Refer to Chapters 4 and 5, earlier in this manual, for piping and wiring confirmations. 7.2 Valve Setup Set up valves and associated components used in the analyzer system as follows proce- dures: (1) If a stop valve is used in the detector’s calibration-gas inlet, fully close this valve. (2) If instrument air is used as the reference gas, adjust the air-set secondary pressure so that an air pressure of measured gas pressure plus approx.

  • Page 76: Operation Of Infrared Switch

    7. Startup 7.4 Operation of Infrared Switch 7.4.1 Display and Switches This equipment uses an infrared switch that enables operation with the cover closed. Figure 7.3 shows the infrared switch and the display. Table 7.1 shows the three switch (keys) and functions. Figure 7.3 shows the infrared switch and the display. 4: Decimal point 1: Data display...
  • Page 77 CAUTION 1. Be sure to put the equipment case cover back on. If this is not done, the infrared switch will not reflect the infrared light-waves, and a “dSPErr” error will be issued. 2. Before placing the equipment in operation, be sure to wipe off any moisture or dust on the glass surface if it is wet or dirty.

  • Page 78: Display Configuration

    7. Startup 7.4.2 Display Configuration The parameter codes provided for the equipment are used to control the equipment display panels (see below). By selecting appropriate parameter codes, you can conduct calibration and set operation parameters. Figure 7.4 shows the configuration of display items.

  • Page 79: Entering Parameter Code Selection Display

    7.4.3 Entering Parameter Code Selection Display This section briefly describes the password entry procedure for entering the parameter code selection display. The password is 1102 - it cannot be changed to a different password. Switch operation Display Description 21.0% Warm-up is complete, and the basic panel is now displayed. Continuously touch the [ENT] key for at least three seconds PASSno to display "PASSno."...

  • Page 80: Selecting Parameter Codes

    7. Startup 7.4.4 Selecting Parameter Codes Table Parameter Code Selection Switch operation Display Description Password has been entered and the parameter code selection display has appeared. Character A is flashing, indicating that character A can be changed. If you touch the [>] key once, the position of the digit that is flashing will move to the right. This allows you to change 0.

  • Page 81: Changing Set Values

    7.4.5 Changing Set Values (1) Selecting numeric values from among preset values Switch operation Display Description The set value is displayed after the parameter code selection. An example of how to select either 0, 1, or 2 as the set value is given below. (The currently set value is 0.) Touch the [ ] key once to change the current value from 0 to 1.
  • Page 82 7. Startup (3) If invalid numeric values are entered: 98.0 If an invalid numeric value (beyond the input range specified) is entered, "ERR" will appear for two seconds after touching the [ENT] key. 00.0 "ERR" appears for two seconds, and the display returns to the first set value. Re-enter the numeric value.

  • Page 83: Confirmation Of Equipment Type Setting

    7.5 Confirmation of Equipment Type Setting This equipment can be used for both the Oxygen Analyzer and the Humidity Analyzer. If you choose optional specification /HS at the time of purchase, the equipment is set for the Humidity Analyzer. Before setting the operating data, be sure to check that the desired model has been set. Note that if the equipment type setting is changed after operating data are set, the operating data that have been set are then initialized and the default settings remain.

  • Page 84: Setting Display Item

    7. Startup 7.6 Setting Display Item Display items are those items that are displayed on the basic panel display. Parameter code A00 or F08 is used to set the display items as shown in the table below. If the humidity analyzer /HS option was specified at the time of purchase, the equipment is a humidity analyzer.

  • Page 85: Current Output Setting

    7.7 Current Output Setting 7.7.1 Analog Output Setting Select any one of the analog output settings — oxygen, humidity, and mixing ratio. If the /HS option was specified at the time of purchase, the equipment is a humidity analyzer. For other than this setting, the analyzer is an oxygen analyzer. If mixed measurement is required, change the existing output setting as follows.

  • Page 86: Output Range Setting

    7. Startup 7.7.2 Output Range Setting This section describes how to set the analog output range. (1) To provide an oxygen concentration, use parameter code C11 to set the minimum oxygen concentration at 4 mA, and use parameter code C12 to set the maximum oxygen concentration at 20 mA.

  • Page 87: Minimum Current (4 Ma) And Maximum Current (20 Ma) Settings

    7.7.3 Minimum Current (4 mA) and Maximum Current (20 mA) Settings This section describes how to set the humidity readings corresponding to 4 mA and 20 mA to 30% H O and 80% H O respectively. Switch operation Display Description Display after the password has been entered.

  • Page 88: Checking Current Loop

    7. Startup 7.8 Checking Current Loop The set current can be output as an analog output. This enables the checking of wiring between the converter and the receiving instrument. Current loop checking is performed using parameter code G01. Table 7.7 Checking Current Loop Switch operation Display Description...

  • Page 89: Checking Contact I/O

    7.9 Checking Contact I/O Conduct a contact input and output check as well as an operation check of the solenoid valves for the optional automatic calibration unit. Table 7.8 Parameter Codes for Checking Contact I/O Set value and Check item Parameter code contact action Contact output 1...

  • Page 90: Contact Output Check

    7. Startup 7.9.1 Contact Output Check Follow Table 7.9 to check the contact output. The table uses an example with contact output 1. Table 7.9 Checking Contact Output Switch operation Display Description > Display after the password has been entered. >...

  • Page 91: Checking Calibration Contact Output

    7.9.2 Checking Calibration Contact Output The calibration contacts are used for the solenoid valve drive signals for the Automatic Calibration Unit. This output signal enables you to check the equipment operation. Check the flowmeter gas flow for that operation. Follow the steps in Table 7.10. The table uses an example with a zero-gas solenoid valve.

  • Page 92: Checking Input Contacts

    7. Startup 7.9.3 Checking Input Contacts Follow Table 7.11 to check the input contacts. The table uses an example with input contact 1. Table 7.11 Checking Input Contacts Switch operation Display Description Display after the password has been entered. > >...

  • Page 93: Calibration

    7.10 Calibration The converter is calibrated in such a way that the actual zero and span gases are mea- sured and those measured values are used to agree with the oxygen concentrations in the respective gases. There are three types of calibration procedures available: (1) Manual calibration conducting zero and span calibrations, or either of these calibra- tions in turn.
  • Page 94 7. Startup Table 7.13 Calibration Setup Procedure Switch operation Display Description > Display after the password has been entered. > Set the zero-gas concentration. Switch the parameter code to B01. Here, set 0.98%. > 001.00 Touch the [ENT] key to display the currently set value. >...

  • Page 95: Manual Calibration

    7.10.2 Manual Calibration The following describes how to perform a calibration. 7.10.2.1 Preliminary Before performing a manual calibration, be sure that the ZA8F Flow Setting Unit zero- gas flow valve is fully closed. Open the zero-gas cylinder pressure regulator so that the secondary pressure equals measured gas plus approx.

  • Page 96: Performing Calibration

    7. Startup 7.10.2.2 Performing Calibration This manual assumes that the instrument air is the same as the reference gas used for the span gas. Follow the steps below to conduct manual calibration. When using the ZO21S Standard Gas Unit (for use of the atmospheric air as a span gas), use a hand-held oxygen analyzer to measure the actual oxygen concentration, and then enter it.
  • Page 97 Table 7.14 Performing Calibration (Continued) Switch operation Display Description > OPEn If you touch the [ENT] key, "OPEN" and the currently measured value are displayed alternately. Open the Flow Setting Unit zero-gas flow valve /0.89 and adjust the zero-gas flow to 600 60 ml/min.

  • Page 98: Detailed Data Setting

    8. Detailed Data Setting 8. Detailed Data Setting 8.1 Current Output Setting This section describes setting of the analog output range. Table 8.1 shows the parameter codes for each setting item and set values. Table 8.1 Display Items Set item Parameter code Set value Current output...

  • Page 99: Minimum And Maximum Settings Corresponding To 4 Ma And 20 Ma

    8.1.1 Minimum and Maximum Settings Corresponding to 4 mA and 20 mA Set the output items for oxygen concentration reading, humidity reading and mixing ratio corresponding to 4 mA and 20 mA. When the oxygen concentration was selected with parameter code C01, use parameter codes C11 and C12 for the minimum and maximum settings;...
  • Page 100 8. Detailed Data Setting Humidity setting range The minimum humidity is set to 0% H O or ranges from 26 to 100% H O. The maxi- mum humidity ranges from 25% to 100% H O, and must be greater than 0.8 times plus 23 the humidity set for the minimum.
  • Page 101 “Mix ratio” setting range The minimum mix ratio is set to 0 kg/kg or ranges from 0.201 to 0.625 kg/kg. The maximum mix ratio setting ranges from 0.2 to 1.0 kg/kg, and must be greater than 1.3 times plus 0.187 the mix ratio set for the minimum. Setting example 1 If the setting (for a 4 mA current) is 0 kg/kg, you must set the maximum (20 mA) point at more than 0.2 kg/kg.

  • Page 102: Entering Output Damping Constants

    8. Detailed Data Setting 8.1.2 Entering Output Damping Constants If a measured value which is adversely affected by rapid changes in the process is used as the basis for control, frequent on-off actions of the output may result. To avoid this, the analyzer allows the setting of output damping constants ranging from 0 to 255 seconds.

  • Page 103: Output Hold Setting

    8.2 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. Table 8.3 shows the analog outputs that can be retained and the individual states. Table 8.3 Current Output Parameter Codes Equipment status During warm-up...
  • Page 104 8. Detailed Data Setting Switch operations Display > > > > SPAn > 21.00 > OPEn/20.84 > 20.84 > ZEro > 0.98 Output hold time during calibration > OPEn/0.89 > 0.89 > CALEnd > > Measured-value display F8.1E.EPS Figure 8.1 Definition of during calibration During semi-automatic calibration, “under calibration”...

  • Page 105: Preference Order Of Output Hold Values

    8.2.2 Preference Order of Output Hold Values The output hold value takes the following preference order: During error occurrence During calibration Preference order (high) During maintenance During warm-up 8.2.2E.siki For example, if the output current is set to 4 mA for “under maintenance”, and no output-hold output for during calibration is preset, the output is held at 4 mA during the “...

  • Page 106: Alarm Setting

    8. Detailed Data Setting 8.3 Alarm Setting The analyzer provides four alarms — high-high, high, low, and low-low alarms - settable with measured values. The following sections describe the alarm operations and setting procedures for the oxygen concentration, humidity, and mixing ratio. 8.3.1 Alarm Values (1) High-high and high alarm values...
  • Page 107 In the example in Figure 8.2, the high-limit alarm point is set to 7.5% H O, the delayed time is set to five seconds, and hysteresis is set to 2% H Alarm output actions in this figure are expressed as follows: (1) Although the measured value “A”...

  • Page 108: Alarm Setting Procedure

    8. Detailed Data Setting 8.3.3 Alarm Setting Procedure Set the alarm setpoints following Table 8.6 listing parameter codes. Table 8.6 Alarm Parameter Codes Set item Parameter code Set value Oxygen concentration high-high alarm setpoint 0-100% O Oxygen concentration high-alarm setpoint 0-100% O Oxygen concentration low-alarm setpoint 0-100% O...

  • Page 109: Default Values

    8.3.4 Default Values When the analyzer is delivered, or if data are initialized, the alarm set values are by default as shown in Table 8.7. Table 8.7 Alarm Setting Default Values Set item Set value Oxygen concentration high-high alarm setpoint 100% O Oxygen concentration high-alarm setpoint 100% O...

  • Page 110: Output Contact Setup

    8. Detailed Data Setting 8.4 Output Contact Setup 8.4.1 Output Contact Mechanical relays provide contact outputs. Be sure to observe relay contact ratings. (For details, see Section 2.1, General Specifications.) The operation modes of each contact output are as follows. Output contact 1 enables the selection of an open or closed contact when the contact is "operated".

  • Page 111: Setting Output Contact

    8.4.2 Setting Output Contact Set the output contacts following Table 8.9. Table 8.9 Parameter Codes for Output Contact Setting Set item Parameter Set value code Output contact 1 Operation Operated in closed status. (Normally deenergized) Operated when open. (Normally energized) (Note 1) Error Not operated if an error occurs.

  • Page 112: Default Values

    8. Detailed Data Setting 8.4.3 Default Values When the analyzer is delivered, or if data are initialized, output contacts are by default as shown in Table 8.10. Table 8.10 Output Contact Default Settings Item Output contact 1 Output contact 2 High-high-limit alarm High-limit alarm Low-limit alarm...

  • Page 113: Input Contact Settings

    8.5 Input Contact Settings The equipment input contacts execute set functions by accepting a remote contact signal. Table 8.11 shows the functions executed by a remote contact signal. Table 8.11 Input Contact Functions Set item Function Calibration-gas pressure While the contact signal is on, neither semi-automatic nor decreased automatic calibration is possible.
  • Page 114 8. Detailed Data Setting 8.5.2 Default Values When the analyzer is delivered, or if data are initialized, both input setting are invalid, and operated when closed. IM 11M12A01-05E 8-17...
  • Page 115 8.6 Input Contact Settings 8.6.1 Setting Input Contact The following describe how to set the date-and-time. Automatic calibration works following this setting. Use parameter code “F10” to set the date-and-time. Table 8.13 Data-and-time Settings Switch operations Display Brief description Select the parameter code "F10." >...

  • Page 116: Default Values

    8. Detailed Data Setting 8.6.2 Setting Periods over which Maximum and Minimum Values Are Monitored and Average Values are Calculated. The equipment enables the display of oxygen concentration average values and maxi- mum and minimum values under measurement (see Section 10.1, later in this manual). The following section describes how to set the periods over which oxygen concentration average values are calculated and maximum and minimum values are monitored.

  • Page 117: Setting Purging

    8.6.4 Setting Purging Purging is to remove condensed water in the calibration gas pipe by supplying a span calibration gas for a given length of time before warm-up of the detector. This prevents cell breakage during calibration due to condensed water in the pipe. Open the solenoid valve for the automatic calibration span gas during purging and after the purge time has elapsed, close the valve to start warm-up.

  • Page 118: Calibration

    9. Calibration 9. Calibration The following describes the calibration procedures for the ZR202G Zirconia High- temperature Humidity Analyzer (integrated model). 9.1 Calibration Briefs 9.1.1 Measurement Principle of Zirconia Humidity Analyzer A solid electrolyte such as zirconia allows the conduction of oxygen ions at high temperatures.
  • Page 119 Water vapor 100% 100% Zirconia element Comparison Sample gas water vapor 100% concentration indicator Electrode Sample-gas composition F9.1.EPS Figure 9.1 Schematic Diagram of Measurement Principle (B) For the “mixing ratio” measurement Assuming that the mixing ratio is r kg/kg, then “r” can be calculated from the value of O vol% as follows: r = 0.622 x/(100 –...

  • Page 120: Calibration Gas

    9. Calibration Oxygen concentration vs, Humidity, Mixing ratio Humidity, vol % H2O Mixing ratio, kg/kg 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Oxygen concentration, vol % O FBE.EPS 9.1.2 Calibration Gas A gas with a known oxygen concentration is used for calibration. Normal calibration is performed using two different gases: a zero gas of low oxygen concentration and a span gas of high oxygen concentration.

  • Page 121: Compensation

    9.1.3 Compensation The deviation of a measured value from the theoretical cell electromotive force is checked by the method in Figure 9.2 or 9.3. Figure 9.2 shows a two-point calibration using two gases: zero and span. Cell electromo- tive forces for a span gas with an oxygen concentration p1 and a zero gas with an oxygen concentration p2 are measured while determining the calibration curve passing between these two points.

  • Page 122: Characteristic Data From A Sensor Measured During Calibration

    9. Calibration 9.1.4 Characteristic Data from a Sensor Measured During Calibration During calibration, calibration data and sensor status data (listed below) are acquired. However, if the calibration is not properly conducted (an error occurs in automatic or semi-automatic calibration), these data are not collected in the current calibration. These data can be observed using parameter codes A20 to A22, and A50 to A79.

  • Page 123: Calibration Procedures

    9.2 Calibration Procedures CAUTION Calibration should be made under normal operating conditions (if the probe is connected to a dryer, the analyzer will undergo calibration under the operating conditions of the dryer). To make a precise calibration, conduct both zero-point and span calibrations. 9.2.1 Calibration Setting The following sets forth the required calibration settings:...
  • Page 124 9. Calibration CAUTION (1) When instrument air is used for the span calibration, remove the moisture from the instrument air at a dew-point temperature of -20 C and also remove any oily mist and dust from that air. (2) If dehumidifying is not enough, or if foul air is used, the measurement accuracy will be adversely affected.
  • Page 125 9.2.1.6Setting When setting calibration timing requirements, bear the following precautions in mind: CAUTION (1) If the calibration interval is shorter than the sum of stabilization time plus calibration time, the second calibration start time will conflict with the first calibration. In such a case, the second calibration will not be conducted.

  • Page 126: Calibration

    9. Calibration 9.2.2 Calibration 9.2.2.1Manual Calibration For manual calibration, consult Section 7.10, “Calibration”, earlier in this manual. 9.2.2.2Semi-automatic Calibration (1) Calibration startup using infrared switches Table 9.3 Semi-automatic Calibration Procedure Switch operation Display Brief description > Change the parameter code to B11. (Previous operations omitted) SA-CAL >...

  • Page 128: Other Functions

    10. Other Functions 10. Other Functions 10.1 Detailed Display Select the desired parameter code to display the detailed operation data (see Table 10.1, “Parameter Codes for Detailed Operation Data.” IM 11M12A01-05E 10-1...
  • Page 129 Table 10.1 Parameter Codes for Detailed Operation Data Parameter Item Engineering unit Code Item Engineering unit code Selection of display items 0: Oxygen concentration Span-gas ratio 0 1: Oxygen analyzer (0.0) Span-gas ratio 1 2: Oxygen analyzer (0.0) Span-gas ratio 2 3: Analog output selected Span-gas ratio 3 Oxygen concentration...

  • Page 130: Oxygen Concentration

    10. Other Functions 10.1.1 Oxygen Concentration The oxygen concentration in the process gas is displayed (consult Section 9.1.1, earlier in this manual). 10.1.2 Humidity The moisture content contained in air is displayed where the process gas contains water vapors and air (refer to Section 9.1.1, earlier in this manual). 10.1.3 Mixing Ratio Where the process gas contains water vapors and air, their mixing ratio is displayed (refer to Section 9.1.1, earlier in this manual).

  • Page 131: Cell Temperature

    10.1.6 Cell Temperature The cell temperature can be obtained from the thermoelectromotive force and cold junction temperature; normally 750 C is displayed. 10.1.7 Process Gas Temperature A process gas temperature set with parameter code F13 is displayed. 10.1.8 Cold Junction Temperature This is the internal (where the electronics is installed) temperature of equipment, which compensates for the cold junction temperature for a thermocouple measuring the cell temperature.

  • Page 132: Current Output

    10. Other Functions 10.1.12 Current Output The analog output current is displayed. 10.1.13 Response Time The cell’s response time is obtained in the procedure shown in Figure 10.1. If only either a zero-point or span calibration has been carried out, the response time will not be measured just as it will not be measured in manual calibration.

  • Page 133: Robustness Of A Cell

    10.1.15 Robustness of a Cell The robustness of a cell is an index for predicting the remaining life of a sensor and is expressed as one of four time periods during which the cell may still be used: (1) more than a year (2) more than six months (3) more than three months (4) less than one month...

  • Page 134: Average Oxygen Concentration, And Mixing Ratio

    10. Other Functions 10.1.20 Average Oxygen Concentration, and Mixing Ratio The average oxygen concentration during the periods over which average values are calculated is displayed. If the setup period elapses, the average oxygen concentration that has been displayed so far will be cleared and a new average oxygen concentration will be displayed.

  • Page 135: Operational Data Initialization

    10.2 Operational Data Initialization Individual set data initialization enables you to return to the default values set at the time of delivery. There are two types of initializations: an all set-data initialization and a parameter-code-based initialization. Table 10.7 lists the initialization items by a param- eter code, and default values.

  • Page 136: Initialization Procedure

    10. Other Functions 10.3 Initialization Procedure Follow the table below to initialize parameters. The password for initialization is 1255. Table 10.5 Initialization Procedure Switch operation Display Description > Enter the parameter code for the item to be initialized. The following show an example of entering "F30." (Previous needed operations are omitted.) >...

  • Page 137: Reset

    10.4 Reset Resetting enables the equipment to restart. If the equipment is reset, the power is turned off and then back on. In practical use, the power remains on, and the equipment is restarted under program control. Resetting will be possible in the following conditions: (1) Error 1 if the cell voltage is defective (2) Error 2...
  • Page 138 10. Other Functions Table 10.6 Resetting Switch operation Display Brief description Err-01 If an error occurs, the error number and "------" are displayed /------ alternately, as given on the left. PASSno Hold down the [ENT] key for at least three seconds. 0000 Touch the [ENT] key again to switch to the password entry display.
  • Page 139 Note • Parameters of blank item are not used for High Temperature Humidity Analyzer. Table 10.7 Parameter Codes Display-related Items in Group A Parameter Item Engineering unit Code Item Engineering unit code Selection of display items 0: Oxygen concentration Span-gas ratio 0 1: Oxygen analyzer (0.0) Span-gas ratio 1 2: Oxygen analyzer (0.0)
  • Page 140 10. Other Functions Calibration-related Items in Group B Code Item Tuning Engineering unit Default setting Zero-gas concentration 0.3 to 100 1% O Span-gas concentration 4.5 to 100 21% O Calibration mode 0: Manual calibration Manual calibration 1: Semi-automatic and manual calibration 2: Automatic, semi-automatic, and manual calibration...
  • Page 141 Output-related Items in Group C Code Item Tuning Engineering Default setting unit Analog output 0: Oxygen concentration Humidity 1: Humidity 2: Mixed ratio Output mode 0: Linear Linear 1: Logarithm Output during warm-up 0: Held at 4 mA 1: Held at 20 mA 2: Set value remains held.
  • Page 142 10. Other Functions Alarm-related Items in Group D Code Item Tuning Engineering unit Default setting Oxygen concentration, high-high 0 to 100 100% O alarm setpoint Oxygen concentration, high-limit 0 to 100 100% O alarm setpoint Oxygen concentration, low-limit 0 to 100 0% O alarm setpoint Oxygen concentration, low-low...
  • Page 143 Contact-related Items in Group E Code Item Tuning Engineering Default setting unit Selection of input contact 1 0: Invalid Invalid 1: Calibration gas pressure drop 2: Measurement range change 3: Calibration start 4: Detection of non-combusted gas Selection of input contact 2 0: Invalid Invalid 1: Calibration gas pressure drop...
  • Page 144 10. Other Functions Equipment Setup and Others in Group F Code Item Tuning Engineering Default setting unit Equipment setup 0: Oxygen analyzer Not initialized 1: Humidity analyzer Selection of temperature units 0: degree C degree C 1: degree F Selection of pressure units 0: kPa 1: psi Selection of display items...
  • Page 145 Inspection-related Items in Group G Code Item Tuning Engineering Default unit setting mA-output loop 4 to 20 4 mA Output contact 1 0: Open Open 1: Closed Output contact 2 0: Open Open 1: Closed Automatic calibration 0: Off solenoid valve (zero) 1: On Automatic calibration 0: Off...

  • Page 146: Handling Of The Zo21S Standard Gas Unit

    10. Other Functions 10.5 Handling of the ZO21S Standard Gas Unit The following describe how to flow zero and span gases using the ZO21S Standard Gas Unit. Operate the ZO21S Standard Gas Unit, for calibrating a system classified as System 1, according to the procedures that follow. 10.5.1 Standard Gas Unit Component Identification Carrying case Flow checker...

  • Page 147: Installing Gas Cylinders

    10.5.2 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%O (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 148 10. Other Functions <Flow of span gas (air)> The standard gas unit is used only when manual calibration is employed. Therefore, the timing for flowing span gas (air) is included in the manual calibration flowchart described in Section 7.10.2, earlier in this manual. For operation of the converter, see Section 7.10.2.
  • Page 149 <Treatment after completion of calibration> (1) Fully close the needle valve mounted on the calibration gas inlet of the detector. (2) Remove the tube connecting the detector to the standard gas unit. WARNING Store the standard gas unit with the gas cylinder mounted where the ambient tempera- ture does not exceed 40 C.

  • Page 150: Methods Of Operating Valves In The Za8F Flow Setting Unit

    10. Other Functions 10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit The ZA8F Flow Setting Unit is used as the calibration equipment for a system conform- ing to System 2. Calibration in such a system is to be manually operated. So, you have to operate the valve of the Flow Setting each time calibration is made (starting and stopping the calibration gas flow and adjusting the flow rate).

  • Page 151: Operating The Zero Gas Flow Setting Valve

    (3) Close the span gas flow setting valve to stop the span gas (air) flow. If the valve shaft has a lock nut, be sure to tighten the lock nut to prevent any leakage of span gas into the sensor during measurement. 10.6.3 Operating the Zero Gas Flow Setting Valve Operate the zero gas flow setting valve during zero-point calibration in the following procedures:...

  • Page 152: Inspection And Maintenance

    11. Inspection and Maintenance 11. Inspection and Maintenance This chapter describes the inspection and maintenance procedures for the EXAxtZR Zirconia High-temperature Humidity Analyzer (integrated model) 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 153: Inspection And Maintenance Of The Detector

    11.1 Inspection and Maintenance of the Detector 11.1.1 Cleaning the Calibration Gas Tube The calibration gas, supplied through the calibration gas inlet of the terminal box into the detector, flows through the tube and comes out at the tip of the probe. The tube might become clogged with dust from the measurement gas.

  • Page 154: Replacing The Sensor Assembly

    11. Inspection and Maintenance 11.1.2 Replacing the Sensor Assembly The performance of the sensor (cell) deteriorates as its surface becomes soiled during operation. Therefore, you have to replace the sensor when its life expectancy expires, for example, when it can no longer satisfy a zero-gas ratio of 100 30 % or a span-gas ratio of 0 18 %.
  • Page 155 3. Part assembly procedure (1) First, install the contact. Being careful not to cause irregularities in the pitch of the coil spirals (i.e., not to bend the coil out of shape), place it in the ringed groove properly so that it forms a solid contact. Groove in which the contact (E7042BS) is placed F11.2E.EPS...

  • Page 156: Replacement Of The Heater Unit

    11. Inspection and Maintenance Metal O-ring Sensor U-shaped pipe support Bolts (four) Probe Contact Screw Filter U-shaped pipe Washers (four) 1/8 turn — tighten bolts 1/8 turn (approximately 45 ) each F11.3E.EPS Figure 11.3 Exploded View of Sensor Assembly CAUTION Optional Inconel bolts have a high coefficient of expansion.
  • Page 157 View A-A F11.4E.EPS Figure 11.4 Exploded View of Detector IM 11M12A01-05E 11-6...

  • Page 158: Replacement Of O-Ring

    11. Inspection and Maintenance Replacement of heater strut assembly 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. Remove the two screws (15) that tighten the cover (12) and slide it to the flange side. Remove the four bolts (10) to remove the converter (16).

  • Page 159: Stopping And Re-Starting Operation

    11.1.5 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 160: Inspection And Maintenance Of The Converter

    11. Inspection and Maintenance 11.2 Inspection and Maintenance of the Converter The converter does not require routine inspection and maintenance. If the converter does not work properly, in most cases it probably comes from problems or other causes. 11.2.1 Replacing Fuses This equipment incorporates a fuse.
  • Page 161 (7) To restore the electronics, reverse the above removal procedures. When restoring the electronics, do not get leadwire jammed in any part of the unit. (8) Place the electronics and the printed-circuit board on which the fuse is installed properly; these are directly connected with connectors. (9) Tighten the four screws in their positions.

  • Page 162: Replacement Of Flowmeter For Zr20H Autocalibration Unit

    11. Inspection and Maintenance 11.3 Replacement of Flowmeter for ZR20H Autocalibration Unit (1) Remove pipe holding piping connection. (2) Remove bolts holding flowmeter, and replace it. A white back plate (to make the float easy to see) is attached. The end of the pin holding down the back plate must be on the bracket side.

  • Page 164: Troubleshooting

    12. Troubleshooting 12. Troubleshooting This chapter describes errors and alarms detected by the self-diagnostic function of the converter. This chapter also describes the check and restoration methods to use when problems other than the above occur. 12.1 Displays and Measures to Take When Errors Occur 12.1.1 What is an Error? An error is detected if any abnormality is generated in the detector or the converter, e.g., in the cell (sensor) or heater in the detector, or the internal circuits in the converter.

  • Page 165: Measures To Take When An Error Occurs

    5) Remove the probe to gain access to the two connectors (four connectors for the optional automatic calibration unit), as indicated in Figure 12.2. Check these connectors are properly connected. 6) If Error-1 still occurs, the electronics may be defective. Contact your local Yokogawa service or sales representative. 12.1.2.2...
  • Page 166 Multimeter F12.3E.EPS Figure 12.3 (4) If the inspection indicates that the thermocouple is normal, the electronics may be defective. Consult your local Yokogawa service or sales representative. 12.1.2.3 Error-3: A/D Converter Failure/Error-4: Writing-to-memory Failure • A/D Converter Failure It is suspected that a failure has occurred in the A/D converter mounted in the converter electronics.

  • Page 167: Displays And Measures To Take When Alarms Are Generated

    12.2 Displays and Measures to Take When Alarms are Gen- erated 12.2.1 What is an Alarm? When an alarm occurs, the alarm indication blinks in the display to notify of the alarm (Figure 12.4). Pressing the alarm indication displays a description of the alarm. Alarms include those shown in Table 12.2.
  • Page 168 12. Troubleshooting <Locating cause of failure, and countermeasures> (1) Confirm the following and carry out calibration again: If the items are not within their proper ranges, correct them. a. If the indication for “Zero gas conc.” is selected in “Calibration setup,” the set value should agree with the concentration of zero gas actually used.
  • Page 169 12.2.2.3 Alarm 7: Span Calibration Coefficient Alarm In calibration, this alarm is generated when the span gas ratio is out of the range of 0 18% (refer to Section 9.1.3, “Compensation”). The following are suspected as the cause: (1) The oxygen concentration of the span gas does not agree with the value of the span gas set “Calibration setup.”...
  • Page 170 If this alarm occurs even when the ambient temperature is under 55 C, the electronics may be defective. Contact your local Yokogawa service or sales representative. 12.2.2.6...
  • Page 171 Figure 12.6 (4) If the inspection indicates that the thermocouple is normal, the electronics may be defective. Consult your local Yokogawa service or sales representative. 12.2.2.7 Alarm 13: Battery Low Alarm An internal battery is used as backup for the clock. After this alarm occurs, removing power from the instrument may cause the clock to stop but should not affect stored parameters.

  • Page 172: Countermeasures When The Measured Value Shows Error

    12. Troubleshooting 12.3 Countermeasures When the Measured Value Shows Error The causes that the measured value shows an abnormal value is not always due to instrument failures. There are rather many cases where the causes are those that measur- ing gas itself is in abnormal state or external causes exist, which disturb the instrument operation.

  • Page 173: Measured Value Lower Than True Value

    (4) The reference gas is mixing into the measuring gas and vice versa. When such mixing occurs, since the deference between oxygen partial pressures on the sensor anode and cathode sides becomes smaller, the measured value shows a lower value. See Section 11.1.2 to check that the sensor has been properly installed. An error which does not indicate Error-1 may occur in the sensor.

  • Page 174: Measurements Sometimes Show Abnormal Values

    12. Troubleshooting 12.3.3 Measurements Sometimes Show Abnormal Values <Causes and Countermeasures> (1) Noise may be mixing in with the converter from the detector output wiring. Check whether the converter and detector are securely grounded. Check whether or not the signal wiring is laid along other power cords. (2) The converter may be affected by noise from the power supply.
  • Page 175 IM 11M12A01-05E 12-12...
  • Page 176 Calibration Tube Assembly for Option code "/C" K9470ZL Heater Assembly ZR202A- - -A CMPL 11M12A01-05E All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation. Subject to change without notice. 1 st Edition : Aug.2000(YK) Yokogawa Electric Corporation 5t h Edition : Jul.2005(YK)
  • Page 177 Hood for ZR202G ZR202G_F.eps Item Parts No. Qty. Description K9472UF Hood CMPL 11M12A01-05E 5 th Edition : Jul.2005(YK) All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation.

  • Page 178: Customer Maintenance Parts List

    Automatic Calibration Unit SPAN IN REF IN ZERO IN Item Part No. Description K9473XC Flowmeter CMPL 11M12A01-12E All Rights Reserved, Copyright © 2001, Yokogawa Electric Corporation. 1st Edition : Feb. 2001 (YK) Yokogawa Electric Corporation 2nd Edition : Aug. 2001 (YK)

  • Page 179: Customer Maintenance Parts List

    Item Part No. Description Pump (see Table 1) E7050BA Zero Gas Cylinder (x6 pcs) E7050BJ Needle Valve Table 1 Power Pump AC 100V E7050AU AC 200V E7050AV © Copyright 2000(YK). 3rd Edition: Dec. 2000 (YK) CMPL 11M3D1-01E Yokogawa Electric Corporation...

  • Page 180: Revision Record

    Revision Record Manual Title : Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer Manual Number : IM 11M12A01-05E Edition Date Remark (s) Nov. 2000 Newly published Mar. 2001 Revised Section 2.1.2 Some parts of MS Code changed, Sun shield hood external dimensions added; 2.2 ZA8F Flow setting unit style changed, adjusting pressure value changed when a check valve is used, ZR20H Autocalibration unit added;...
  • Page 181 Edition Date Remark (s) Sep. 2006 Revised Section 2.4.3 "Air Set," Part No. K9473XH or K9473XJ, Standard Specification: Changed descriptions partly; "Air Set,"Part No. G7004XF or K9473XG, Standard Specification: Changed descriptions partly; 2.4.5 "Cylinder Regulator Valve (Part No. G7013XF or G7014XF)", Standard Specifications;...

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