Yokogawa Integral Oxygen Analyzer ZR202 User Manual

User’sManualRModel ZR202GIntegrated typeZirconia Oxygen AnalyzerIM 11M12A01-04EIM 11M12A01-04E7th Edition

Toc-1IM 11M12A01-04E<CONTENTS>Model ZR202G Integrated type Zirconia Oxygen AnalyzerCONTENTSIM 11M12A01-04E 7th EditionIntroduction ...

<8. Detailed Data Setting>8-17IM 11M12A01-04ETable 8.16 Fuel Data For liquid fuelABCC H ONSwCO2 H2OSO2N20.78~ 0.830.81~ 0.840.85

<8. Detailed Data Setting>8-18IM 11M12A01-04E 8.7.3.2 ProcedureUse the parameter code table below to set fuel values.Table 8.17 Setting Fuel V

<9. Calibration>9-1IM 11M12A01-04E9. Calibration9.1 Calibration Briefs9.1.1 Principle of MeasurementThis section sets forth the principle

<9. Calibration>9-2IIM 11M12A01-04E 0.10.515 10 21.050 100120100806040200-20-400.51 vol%O2,81.92mV(Zero origin of calibration)21.0 vol%O2, 0mV(S

<9. Calibration>9-3IM 11M12A01-04E21.0 p1 p2 0.5181.92eze2e1es0CABZero correction ratio = (B/A) x 100 (%) Correctable range: 100 ±

<9. Calibration>9-4IIM 11M12A01-04E 9.1.4 Characteristic Data from a Sensor Measured During CalibrationDuring calibration, calibration data and

<9. Calibration>9-5IM 11M12A01-04E9.2 Calibration ProceduresCAUTIONCalibration should be made under normal operating conditions (if the pro

<9. Calibration>9-6IIM 11M12A01-04E 9.2.1.4 Span gas ConcentrationSet the oxygen concentration for span calibration. If instrument air is used

<9. Calibration>9-7IM 11M12A01-04E9.2.1.6 SettingWhen setting calibration timing requirements, bear the following precautions in mind:CAUTI

<9. Calibration>9-8IIM 11M12A01-04E 9.2.2 Calibration9.2.2.1 Manual CalibrationFor manual calibration, consult Section 7.10, “Calibration,” ea

Toc-2IM 11M12A01-04E <CONTENTS>3. Installation ...

<10. Other Functions>10-1IM 11M12A01-04E10. Other Functions10.1 Detailed DisplaySelect the desired parameter code to display the detailed

<10. Other Functions>10-2IM 11M12A01-04E Table 10.1 Parameter Codes for Detailed Operation DataCode Item Engineering unit Code Item Engineerin

<10. Other Functions>10-3IM 11M12A01-04E10.1.1 Air Ratio“Air ratio” is dened as the ratio of (the amount of air theoretically required to

<10. Other Functions>10-4IM 11M12A01-04E 10.1.5 Cell VoltageThe cell (sensor) voltage will be an index to determine the amount of degradation o

<10. Other Functions>10-5IM 11M12A01-04E10.1.9 Response TimeThe cell’s response time is obtained in the procedure shown in Figure 10.1. If

<10. Other Functions>10-6IM 11M12A01-04E 10.1.12 Heater On-Time RatioThe probe sensor is heated to and maintained at 750°C. When the sample gas

<10. Other Functions>10-7IM 11M12A01-04E10.1.18 History of Calibration TimeThe calibration-conducted dates and times for the past ten calib

<10. Other Functions>10-8IM 11M12A01-04E 10.3 Initialization ProcedureFollow the table below to initialize parameters. The password for initia

<10. Other Functions>10-9IM 11M12A01-04E10.4 ResetResetting enables the equipment to restart. If the equipment is reset, the power is turne

<10. Other Functions>10-10IM 11M12A01-04E Table 10.6 ResettingSwitch operation Display Brief Description> ∧ENTErr-01/------If an error occu

Toc-3IM 11M12A01-04E<CONTENTS>5.3 Wiring Power and Ground Terminals ...5-45.3.1 Wiri

<10. Other Functions>10-11IM 11M12A01-04ECAUTION• Parameters of blank item are not used for Oxygen Analyzer.Table 10.7 Parameter Codes Di

<10. Other Functions>10-12IM 11M12A01-04E Calibration-related Items in Group BCode Item Tuning Engineering unit Default settingB01 Zero gas

<10. Other Functions>10-13IM 11M12A01-04EOutput-related Items in Group CCode Item Tuning Engineering unit Default settingC01 Analog outp

<10. Other Functions>10-14IM 11M12A01-04E Contact-related Items in Group ECode Item Tuning Engineering unit Default settingE01 Selection of

<10. Other Functions>10-15IM 11M12A01-04EEquipment Setup and Others in Group FCode Item Tuning Engineering unit Default settingF01 Equ

<10. Other Functions>10-16IM 11M12A01-04E 10.5 Handling of the ZO21S Standard Gas UnitThe following describe how to ow zero and span gases usi

<10. Other Functions>10-17IM 11M12A01-04EThe operating details and handling precautions are also printed on the product. Please read them be

<10. Other Functions>10-18IM 11M12A01-04E (2) Next, adjust the ow rate to 600 ± 60 ml/min using the span gas valve “AIR” (the ow check ball st

<10. Other Functions>10-19IM 11M12A01-04E10.6 Methods of Operating Valves in the ZA8F Flow Setting UnitThe ZA8F Flow Setting Unit is used a

<10. Other Functions>10-20IM 11M12A01-04E Table 10.9Sample gas pressure, (kPa) 50 100 150 200 250Flow rate, (ml/min) 500 430 380 350 3

Toc-4IM 11M12A01-04E <CONTENTS>8. Detailed Data Setting ... 8-18.1

<11. Inspection and Maintenance>11-1IM 11M12A01-04E11. Inspection and MaintenanceThis chapter describes the inspection and maintenance proc

<11.Inspection and Maintenance>11-2IM 11M12A01-04E F11.1E.aiCalibration gas tubeExploded view of componentsRod(with outside diameter of 2 to 2.5

<11. Inspection and Maintenance>11-3IM 11M12A01-04E(4) Use tweezers to pull the contact out of the groove.(5) Clean the sensor assembly, esp

<11.Inspection and Maintenance>11-4IM 11M12A01-04E F11.3E.aiDust filter (optional)Bolts (four)Washers (four)Sensor (cell)U-shaped pipeMetal O-ri

<11. Inspection and Maintenance>11-5IM 11M12A01-04EAAView A-A2512345678910111213141516141317181920212223242424F11.4E.aiFigure 11.4 Explode

<11.Inspection and Maintenance>11-6IM 11M12A01-04E Replacement of heater assemblyRefer to Figure 11.4 as an aid in the following discussion.Remo

<11. Inspection and Maintenance>11-7IM 11M12A01-04ECAUTIONWhen operating an instrument such as boiler or industrial furnace is stopped with

<11.Inspection and Maintenance>11-8IM 11M12A01-04E 11.2 Inspection and Maintenance of the ConverterThe converter does not require routine inspe

<11. Inspection and Maintenance>11-9IM 11M12A01-04E(7) To restore the electronics, reverse the above removal procedures. When restoring the

<11.Inspection and Maintenance>11-10IM 11M12A01-04E 11.3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit (1) Remove pipe holding

Toc-5IM 11M12A01-04E<CONTENTS>10. Other Functions ... 10-110

<12. Troubleshooting>12-1IM 11M12A01-04E12. TroubleshootingThis chapter describes errors and alarms detected by the self-diagnostic functio

<12. Troubleshooting>12-2IM 11M12A01-04E 12.1.2 Measures to Take When an Error Occurs12.1.2.1 Error-1: Cell Voltage FailureError-1 occurs when

<12. Troubleshooting>12-3IM 11M12A01-04E(3) Next, check the resistance of the thermocouple from the probe. Use a multimeter to measure the t

<12. Troubleshooting>12-4IM 11M12A01-04E 12.2 Displays and Measures to Take When Alarms are Generated12.2.1 What is an Alarm?When an alarm is

<12. Troubleshooting>12-5IM 11M12A01-04E<Search for cause of failure and Take measures>(1) Conrm the following and carry out calibrat

<12. Troubleshooting>12-6IM 11M12A01-04E 12.2.2.3 Alarm 7: Span Calibration Coefcient AlarmIn calibration, this alarm is generated when the sp

<12. Troubleshooting>12-7IM 11M12A01-04EIn addition, if an error occurs in calibration even after the cell assembly is replaced, the inuenc

<12. Troubleshooting>12-8IM 11M12A01-04E CAUTION• Measure the thermocouple resistance value after the difference between the probe tip tempera

<12. Troubleshooting>12-9IM 11M12A01-04E12.3 Measures When Measured Value Shows an ErrorThe causes that the measured value shows an abnorma

<12. Troubleshooting>12-10IM 11M12A01-04E 12.3.2 Measured Value Lower Than True Value<Causes and Measures>(1) The measuring gas pressure

Toc-6IM 11M12A01-04E <CONTENTS>11.2 Inspection and Maintenance of the Converter ... 11-811.2.1 Replac

CustomerMaintenanceParts ListAll Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation.Subject to change without notice. Model ZR202GZircon

CMPL 11M12A01-04E 7th Edition : Apr. 2011 (YK)Hood for ZR202GZR202G_F.ai1Item Part No. Qty Description1 K9471UA 1 Hood

CustomerMaintenanceParts ListAll Rights Reserved, Copyright © 2001, Yokogawa Electric Corporation.Subject to change without notice. Model ZR20HIntegra

CustomerMaintenanceParts ListAll Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation.Subject to change without notice. Model ZO21SZirconi

iIM 11M12A01-04ERevision Information Title: Model ZR202G Integrated type Zirconia Oxygen Analyzer Manual No.: IM 11M12A01-04EEdition Date Rema

iiIM 11M12A01-04E  If you want have more information about Yokogawa products, you can visit Yokogawa’s home page at the following website. Home p

<1.Overview>1-1IM 11M12A01-04E1. OverviewThe EXAxt ZR Integrated type Zirconia Oxygen Analyzer is used to monitor and control the oxygen co

<1. Overview>1-2IM 11M12A01-04E CAUTION• As this system uses ambient air for the reference gas, measuring accuracy will be affected by the inst

<1.Overview>1-3IM 11M12A01-04E1.1.3 System 3This example, System 3, represents typical applications in large boilers and heating furnaces,

<1. Overview>1-4IM 11M12A01-04E 1.2 < EXAxt ZR > System Components1.2.1 System ComponentsSystem ComponentsZR202G Integrated type Zirconi

iIM 11M12A01-04E<Introduction>IntroductionThe EXAxt ZR Integrated type Zirconia Oxygen Analyzer has been developed for combustion control in var

<2. Specications>2-1IM 11M12A01-04E2. SpecicationsThis chapter describes the specications for the following:ZR202G General-use Integrat

<2. Specications>2-2IM 11M12A01-04E Drift: (Excluding the rst two weeks in use) (Excluding the case where the reference gas is by natural c

<2. Specications>2-3IM 11M12A01-04ESafety and EMC conforming standardsSafety: EN61010-1, CSA C22.2 No.61010-1, UL61010-1EMC: EN 61326

<2. Specications>2-4IM 11M12A01-04E FunctionsDisplay Function: Displays values of the measured oxygen concentration, etc. Alarm, Error Displa

<2. Specications>2-5IM 11M12A01-04EConverter Output: One mA analog output point (4 to 20 mA DC (maximum load resistance of 550Ω)) with mA

<2. Specications>2-6IM 11M12A01-04E Model and CodesModel Sufx code Option code Description ZR202G - - - - - - - - - - - - - - - - - - - - - -

<2. Specications>2-7IM 11M12A01-04E• External DimensionsModel ZR202G Integrated type Zirconia Oxygen Analyzers Unit: mmF11_01.ai25t153

<2. Specications>2-8IM 11M12A01-04E Model ZR202G...-P Integrated type Zirconia Oxygen Analyzer with pressure compensation

<2. Specications>2-9IM 11M12A01-04E2.1.3 ZO21R Probe ProtectorThis probe protector is required for the general-use detector when it is use

<2. Specications>2-10IM 11M12A01-04E 2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit2.2.1 ZA8F Flow Setting UnitThis ow sett

iiIM 11M12A01-04E <Introduction>This manual consists of twelve chapters. Please refer to the reference chapters for installation, opera-tion and

<2. Specications>2-11IM 11M12A01-04E• External DimensionsCHECKOUTREFOUTREFERENCESPANZEROREFERENCE CHECKAIRINZEROINSPANINCHECKOUTPIPNG INSID

<2. Specications>2-12IM 11M12A01-04E 2.2.2 ZR20H Automatic Calibration UnitThis automatic calibration unit is applied to supply specied ow o

<2. Specications>2-13IM 11M12A01-04E External Dimensions(1) Horizontal Mounting (-A)Rc1/4 or 1/4NPT(Female)Rc1/4 or 1/4NPT(Female)Rc1/4 or

<2. Specications>2-14IM 11M12A01-04E 2.3 ZO21S Standard Gas UnitThis is a handy unit to supply zero gas and span gas to the detector in a syst

<2. Specications>2-15IM 11M12A01-04E2.4 Other Equipment2.4.1 Dust Filter for Oxygen Analyzer (part no. K9471UA)This lter is used to prot

<2. Specications>2-16IM 11M12A01-04E 2.4.3 Stop Valve (part no. L9852CB or G7016XH)This valve is mounted on the calibration gas line in the sy

<2. Specications>2-17IM 11M12A01-04E2.4.5 Air SetThis set is used to lower the pressure when instrument air is used as the reference and s

<2. Specications>2-18IM 11M12A01-04E 2.4.6 Zero Gas Cylinder (part no. G7001ZC)The gas from this cylinder is used as the calibration zero gas

<2. Specications>2-19IM 11M12A01-04E2.4.8 Case Assembly (E7044KF) for Calibration gas CylinderThis case is used to store the zero gas cyli

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iiiIM 11M12A01-04E<Introduction> For the safe use of this equipmentWARNINGEXAxt ZR is very heavy. Be sure not to accidentally drop it. Handle s

<3. Installation>3-1IM 11M12A01-04E3. InstallationThis chapter describes installation of the following equipment:3.1 Model ZR202G Integra

<3. Installation>3-2IM 11M12A01-04E 3.1.2 Probe Insertion HoleCAUTION• The outside dimension of detector may vary depending on its options. U

<3. Installation>3-3IM 11M12A01-04EThe following should be taken into consideration when mounting the general-use detector:<General-use d

<3. Installation>3-4IM 11M12A01-04E < Procedures for installing the dust guard protector (K9471UC)>The ZR202G is shipped with the dust gua

<3. Installation>3-5IM 11M12A01-04E<Detector with a probe protector (Model ZO21R-L-- *B for dust wear protect>The detector is used

<3. Installation>3-6IM 11M12A01-04E 3.2.2 Mounting of ZA8F Flow Setting UnitThe ow setting unit can be mounted either on a pipe (nominal JIS 5

<3. Installation>3-7IM 11M12A01-04E(2) Mount the ow setting unit. Remove the pipe mounting parts from the mount ttings of the ow setting

<3. Installation>3-8IM 11M12A01-04E Zero gas inlet Rc1/4 or 1/4NPT(Female)Reference gas inletRc1/4 or 1/4NPT(Female)Terminal box sideSpan gas in

<3. Installation>3-9IM 11M12A01-04E3.4 Installation of the Case Assembly (E7044KF) for Calibration Gas CylinderThe case assembly is used to

<3. Installation>3-10IM 11M12A01-04E 3.5 Insulation Resistance TestEven if the testing voltage is not so great that it causes dielectric breakd

ivIM 11M12A01-04E <Introduction>(2) Safety and Modication PrecautionsFollow the safety precautions in this manual when using the product to e

<4. Piping>4-1IM 11M12A01-04E4. PipingThis chapter describes piping procedures in the three typical system congurations for EXAxt ZR Inte

<4. Piping>4-2IM 11M12A01-04E 4.1.1 Piping Parts for System 1Check that the parts listed in Table 4.1 are provided.Table 4.1 Piping PartsEqu

<4. Piping>4-3IM 11M12A01-04E4.2 Piping for System 2Piping in System 2 is illustrated in Figure 4.7.~ZR202G Integrated type Zirconia Oxyge

<4. Piping>4-4IM 11M12A01-04E F4.8E.aiStop valve or check valvePiping for the reference gas6mm (O.D.) by 4mm (I.D.) stainless steel pipe Piping

<4. Piping>4-5IM 11M12A01-04E• Installation of ZR20H Automatic Calibration UnitZero gas inlet Rc1/4 or 1/4NPT(Female)Reference gas inletRc1/

<4. Piping>4-6IM 11M12A01-04E 4.4 Piping for the Oxygen Analyzer with Pressure CompensationZR202G-----P Oxygen Analyzer with pressure comp

<4. Piping>4-7IM 11M12A01-04E4. Set the instrument air pressure higher than furnace internal pressure.5. Completely open the stop valve in

<4. Piping>4-8IM 11M12A01-04E 4.4.1 Piping Parts for Oxygen Analyzer with Pressure CompensationCheck that the parts listed in Table 4.3 are pr

<5. Wiring>5-1IM 11M12A01-04E5. WiringThis chapter describes wiring procedures necessary for the EXAxt ZR Integrated type Zirconia Oxygen A

<5. Wiring>5-2IM 11M12A01-04E 5.1.1 Terminals for the External WiringRemove the terminal cover on the opposite side of the display to gain acce

vIM 11M12A01-04E<Introduction>Special descriptions in this manualThis manual indicates operation keys, displays and drawings on the product as

<5. Wiring>5-3IM 11M12A01-04E5.1.3 Mounting of Cable GlandFor each wiring inlet connection of the equipment, mount the conduit appropriate

<5. Wiring>5-4IM 11M12A01-04E 5.3 Wiring Power and Ground TerminalsWiring for supplying power to the analyzer and grounding the equipment.1 2 C

<5. Wiring>5-5IM 11M12A01-04E5.4 Wiring for Contact OutputThe equipment can output a maximum of two contact signals. These contact outputs

<5. Wiring>5-6IM 11M12A01-04E 5.5.2 Wiring Procedure(1) M4 screws are used for the terminal of the converter. Each cable should be equipped wit

<6. Components>6-1IM 11M12A01-04E6. ComponentsThis chapter describes the names and functions of components for the major equipment of the

<6. Components>6-2IM 11M12A01-04E 6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration UnitReference gas flow setting valveSpan gas flow set

<7. Startup>7-1IM 11M12A01-04E7. StartupThe following describes the minimum operating requirements — from supplying power to the converter

<7. Startup>7-2IM 11M12A01-04E 7.1 Checking Piping and Wiring ConnectionsRefer to Chapters 4 and 5, earlier in this manual, for piping and wiri

<7. Startup>7-3IM 11M12A01-04E7.4 Operation of Infrared Switch7.4.1 Display and SwitchesThis equipment uses an infrared switch that enable

<7. Startup>7-4IM 11M12A01-04E CAUTION1. Be sure to put the equipment case cover back on. If this is not done, the infrared switch will not re

viIM 11M12A01-04E <Introduction> NOTICE• Specication checkWhen the instrument arrives, unpack the package with care and check that the instrum

<7. Startup>7-5IM 11M12A01-04ETable 7.2 Display FunctionsDisplay Function and item to be setBasic panel Displays the oxygen concentration

<7. Startup>7-6IM 11M12A01-04E 7.4.4 Selecting Parameter CodesSwitch operation Display Description> ∧ENTA01Password has been entered and the

<7. Startup>7-7IM 11M12A01-04E(2) Entering numeric values such as oxygen concentration values and factorsSwitch operation Display Descriptio

<7. Startup>7-8IM 11M12A01-04E 7.5 Conrmation of Equipment Type SettingThis equipment can be used for both the Oxygen Analyzer and the Humidit

<7. Startup>7-9IM 11M12A01-04E7.6 Selection of Measurement GasCombustion gases contain moisture created by burning hydrogen in the fuel. If

<7. Startup>7-10IM 11M12A01-04E Table 7.5 Minimum and Maximum Value Setting ProcedureSwitch operation Display Description> ∧ENTA01Display af

<7. Startup>7-11IM 11M12A01-04E7.8 Checking Current LoopThe set current can be output as an analog output. This enables the checking of wir

<7. Startup>7-12IM 11M12A01-04E 7.9.1 Contact Output CheckFollow Table 7.8 to check the contact output. The table uses an example with contact

<7. Startup>7-13IM 11M12A01-04E7.9.2 Checking Calibration Contact OutputThe calibration contacts are used for the solenoid valve drive sign

<7. Startup>7-14IM 11M12A01-04E 7.9.3 Checking Input ContactsFollow Table 7.10 to check the input contacts. The table uses an example with inpu

viiIM 11M12A01-04E<Introduction> After-Sales Warranty Do not modify the product. During the warranty period, for repair under warranty ca

<7. Startup>7-15IM 11M12A01-04E7.10 CalibrationThe converter is calibrated in such a way that the actual zero and span gases are measured a

<7. Startup>7-16IM 11M12A01-04E Table 7.12 Calibration Setup ProcedureSwitch operation Display Description> ∧ENTA01Display after the passwor

<7. Startup>7-17IM 11M12A01-04E7.10.2 Manual CalibrationThe following describes how to conduct a calibration. 7.10.2.1 PreliminaryBefore co

<7. Startup>7-18IM 11M12A01-04E Table 7.13 Conducting Calibration (Continued)Switch operation Display Description> ∧ENTZEro YIf you touch th

<8. Detailed Data Setting>8-1IM 11M12A01-04E8. Detailed Data Setting8.1 Setting Display ItemDisplay items are dened as items displayed on

<8. Detailed Data Setting>8-2IM 11M12A01-04E 8.2.1 Setting Minimum Oxygen Concentration ( at 4 mA) and Maximum Oxygen Concentration ( at 20 mA)

<8. Detailed Data Setting>8-3IM 11M12A01-04E8.3 Output Hold SettingThe “output hold” functions retain an analog output signal at a preset v

<8. Detailed Data Setting>8-4IM 11M12A01-04E Switch operation Display> ∧ENTb10> ∧ENTCAL> ∧ENTCAL> ∧ENTSPAn Y> ∧ENT21.00 %> ∧EN

<8. Detailed Data Setting>8-5IM 11M12A01-04E8.3.2 Preference Order of Output Hold ValueThe output hold value takes the following preference

<8. Detailed Data Setting>8-6IM 11M12A01-04E 8.4 Setting Oxygen Concentration AlarmsThe analyzer enables the setting of four alarms high-high,

viiiIM 11M12A01-04E <Introduction>

<8. Detailed Data Setting>8-7IM 11M12A01-04EIn the example in Figure 8.2, the high alarm point is set to 7.5% O2, the delayed time is set to

<8. Detailed Data Setting>8-8IM 11M12A01-04E 8.4.4 Default ValuesWhen the analyzer is delivered, or if data are initialized, the default alarm

<8. Detailed Data Setting>8-9IM 11M12A01-04E8.5.2 Setting Output Contact Set the output contacts following Table 8.10.Table 8.10 Parameter

<8. Detailed Data Setting>8-10IM 11M12A01-04E 8.5.3 Default ValuesWhen the analyzer is delivered, or if data are initialized, output contacts a

<8. Detailed Data Setting>8-11IM 11M12A01-04E8.6 Input Contact SettingsThe converter input contacts execute set functions by accepting a re

<8. Detailed Data Setting>8-12IM 11M12A01-04E 8.7 Other Settings8.7.1 Setting the Date-and-TimeThe following describe how to set the date-and-

<8. Detailed Data Setting>8-13IM 11M12A01-04E8.7.2 Setting Periods over which Average Values are Calculated and Periods over which Maximum

<8. Detailed Data Setting>8-14IM 11M12A01-04E 8.7.3 Setting Fuels8.7.3.1 Input ParametersThe analyzer calculates the moisture content containe

<8. Detailed Data Setting>8-15IM 11M12A01-04E For liquid fuelAmount of water vapor in exhaust gas (Gw) = (1/100) {1.24 (9h + w)} (m /k

<8. Detailed Data Setting>8-16IM 11M12A01-04E 400.0460.0440.0420.0400.0380.0360.0340.0320.0300.0280.0260.0240.0220.0200.0180.0160.0140.0120.0100