SICK ZIRKOR200 Ex-G User manual

MMM
I
MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
ZIRKOR200 Ex-G
Oxygen Analyzer
Title page

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Described product
Product name: ZIRKOR200 Ex-G
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law.
Any modification, shortening or translation of this document is prohibited without the
express written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.

CONTENTS
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1 About this document................................................................................. 8
1.1 Function of this document.............................................................................. 8
1.2 Scope of application ....................................................................................... 8
1.3 User qualification ............................................................................................8
1.4 Further information .........................................................................................8
1.5 Symbols and document conventions .............................................................9
1.5.1 Warning symbols.............................................................................9
1.5.2 Warning levels and signal words.................................................... 9
1.5.3 Information symbols .....................................................................10
1.6 Data integrity.................................................................................................10
2 For your safety..........................................................................................11
2.1 Basic safety information ...............................................................................11
2.2 Warning information on device ....................................................................12
2.3 Intended use .................................................................................................13
2.3.1 Purpose of the device...................................................................13
2.3.2 Operation in potentially explosive atmospheres .........................13
2.3.3 Restrictions of use........................................................................15
2.4 Responsibility of user....................................................................................16
2.4.1 Designated users..........................................................................16
2.4.2 Correct project planning ...............................................................16
2.4.3 Correct use....................................................................................16
2.4.4 Special local conditions................................................................16
2.4.5 Read the Operating Instructions ..................................................16
3 Product description .................................................................................17
3.1 Product identification ...................................................................................17
3.2 Type plates ....................................................................................................17
3.3 Device versions .............................................................................................20
3.4 Device variants..............................................................................................23
3.5 Options ..........................................................................................................23
3.6 Expansion modules.......................................................................................23
4 Layout and function.................................................................................24
4.1 System overview............................................................................................24
4.2 Measuring principle ......................................................................................26
4.3 Scope of application .....................................................................................26
4.4 Potential hazards .........................................................................................26
4.5 Process interruption......................................................................................26
4.6 Pneumatic unit ..............................................................................................27
4.7 Explosion protection description - ignition protection types .......................27
4.7.1 Ignition protection type “flameproof enclosure” Ex “d” ..............27
4.7.2 Ignition source monitoring of the analyzer unit by means of
temperature monitoring ...............................................................30
4.7.3 Ignition protection types on solenoid valves ...............................30
Contents
Contents

CONTENTS
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5 Installation................................................................................................31
5.1 Determination of the requirements for explosion protection ..................... 31
5.2 Information on installation in potentially explosive atmospheres.............. 31
5.3 Tools required ............................................................................................... 33
5.4 Material required .......................................................................................... 33
5.5 Preparing the measuring point ................................................................... 33
5.6 Transport....................................................................................................... 33
5.7 Storage information...................................................................................... 34
5.8 Scope of delivery .......................................................................................... 34
5.9 Installation .................................................................................................... 34
5.9.1 Fitting the counter flange on the duct ....................................... 35
5.9.2 Installing the control unit ............................................................. 35
5.9.3 Fitting the analyzer unit ............................................................... 36
5.9.4 Fitting the analyzer unit with cooling protection pipe................. 38
5.9.5 Installing the analyzer unit........................................................... 38
5.9.6 Aligning the V-shield..................................................................... 39
5.9.7 Laying the connection cable ........................................................ 40
5.9.8 Installing connection cables ........................................................ 41
5.9.9 Fitting the pneumatic unit............................................................ 42
5.10 Electrical installation .................................................................................... 43
5.10.1 Accessing the connection terminals ........................................... 44
5.10.2 Instructions for the function of the spring-loaded terminal ....... 44
5.10.3 Potential equalization, (PE, ground) ............................................ 44
5.10.4 Connecting the control unit ........................................................ 45
5.10.5 Electrical connection plan (Ex-control unit and Ex-analyzer
unit)............................................................................................... 46
5.10.6 Power connection......................................................................... 48
5.10.7 Connecting the connection cable to the control unit ................. 49
5.10.8 Connecting the valve cable of the analyzer unit to the control
unit .............................................................................................. 49
5.10.9 Connecting the pneumatic unit line to the control unit ............. 49
5.10.10 Outputs/functions and relay assignment.................................... 49
5.10.11 Digital inputs ................................................................................ 50
5.10.12 Installing connection cables ........................................................ 50
5.10.13 Connecting the connection cable ................................................ 50
5.10.14 Connecting the analyzer electronics to the connection cable ... 52
5.10.15 Connecting the valve cable of the analyzer unit to the solenoid
valve.............................................................................................. 53
5.10.16 Connecting the pneumatic unit to the solenoid valve ............... 53
5.10.17 Closing the enclosure................................................................... 53
5.11 Pneumatic connections and settings .......................................................... 54
5.11.1 Pneumatic hose requirements ................................................... 54
5.11.2 Preparing the pneumatic hose .................................................... 54
5.11.3 Pneumatic connections on the analyzer unit.............................. 54

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5.11.4 Pneumatic connection, pneumatic unit semi-automatic or fully
automatic .....................................................................................55
5.11.5 Test air volumes and reference air volume .................................55
5.11.6 Setting the flow volume................................................................55
6 Commissioning ........................................................................................56
6.1 Safety information on commissioning.........................................................56
6.2 Checklist before initial commissioning of the system .................................56
6.3 Operation.......................................................................................................57
6.4 Initial commissioning ....................................................................................58
6.5 Display - heating process..............................................................................58
6.6 Display - Measuring mode ............................................................................58
6.7 Operating elements and display...................................................................59
6.8 Status LEDs ...................................................................................................59
6.9 Softkey symbols ............................................................................................59
6.10 System code .................................................................................................59
7 Menu overview and explanations..........................................................60
7.1 SYS-MENU ....................................................................................................60
7.2 Menu explanations........................................................................................63
7.2.1 O2measuring ranges (scaling).....................................................63
7.2.2 Measured value average over [s].................................................63
7.2.3 mA output for system error ..........................................................63
7.2.4 O2limit value alarms ....................................................................64
7.2.5 O2sensor adjustment values.......................................................64
7.2.6 Time per test gas feed..................................................................64
7.2.7 Stopping time until process (O2) .................................................65
7.2.8 Auto. Adjustment (ACAL) ..............................................................65
7.2.9 Settings for auto. adjustment ......................................................65
7.2.10 REMOTE ........................................................................................66
7.2.11 Units of measure ..........................................................................66
7.2.12 Language.......................................................................................66
7.2.13 Change system code ....................................................................67
7.2.14 Loading the factory settings.........................................................67
7.2.15 Service (factory service settings) .................................................67
7.2.16 Adjustment menu ........................................................................67
7.2.17 Display - Adjustment.....................................................................67
7.2.18 1-point adjustment (manual) .......................................................68
7.2.19 2-point adjustment (manual) .......................................................69
7.3 System check ...............................................................................................70
8 Maintenance.............................................................................................71
8.1 Technical knowledge necessary for maintenance work..............................71
8.2 Safety instructions for maintenance work .................................................71
8.3 Information on use in Ex-areas .................................................................72
8.4 Maintenance plan .........................................................................................72

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8.5 Tools required ............................................................................................... 73
8.6 Maintenance work ........................................................................................ 73
8.6.1 Replace fuses............................................................................... 73
8.6.2 Replacing the filter head ............................................................. 74
8.6.3 Replacing an analyzer unit .......................................................... 74
8.6.4 Replacing the O2measuring cell ............................................... 75
8.6.5 Replacing the inner part of the analyzer unit.............................. 76
8.6.6 Visual check of the flameproof enclosure................................... 76
8.6.7 Stability criteria during adjustment ............................................. 77
9 Status messages .....................................................................................78
9.1 Error messages............................................................................................. 78
9.2 Alarm messages .......................................................................................... 80
9.3 Maintenance messages .............................................................................. 80
10 Heating shutdown in case of malfunction ...........................................81
10.1 General information ..................................................................................... 81
10.2 Functional description.................................................................................. 82
10.3 Maintenance ................................................................................................. 82
11 Troubleshooting .......................................................................................83
11.1 Strongly fluctuating O2 measured value .................................................... 83
11.2 O2 display remains at end of measuring range or is higher than
expected ....................................................................................................... 83
11.3 Indications on the display are OK, mA output signal is not correct .......... 83
11.4 O2 display on 0%, although the operating mode indicates a higher O2
value ............................................................................................................. 84
12 Decommissioning....................................................................................85
12.1 Safety information on decommissioning ..................................................... 85
12.2 Shutdown procedure .................................................................................... 86
12.3 Removing the device .................................................................................... 86
12.4 Environmentally compatible disposal.......................................................... 86
13 Technical data..........................................................................................87
13.1 Dimension drawings ..................................................................................... 87
13.1.1 Dimension sheets of the control unit .......................................... 87
13.1.2 Dimension sheets of the analyzer unit........................................ 88
13.1.3 Counter flange dimensions.......................................................... 90
13.1.4 Dimension of protective pipe flanges.......................................... 90
13.1.5 Analyzer unit components ........................................................... 91
13.1.6 Dimension sheets of the pneumatic unit .................................... 93
13.1.7 Display board................................................................................ 95

CONTENTS
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13.2 Technical data...............................................................................................96
13.2.1 Installation location ......................................................................96
13.2.2 Technical data of the control unit ..............................................96
13.2.3 Technical data of the analyzer unit ............................................97
13.2.4 Data of the external pneumatics ................................................97
13.2.5 Technical specification for the gas supply...................................98
13.3 Tightening torques for Ex-relevant screw fittings ........................................99

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1ABOUT THIS DOCUMENT
1 About this document
1.1 Function of this document
These Operating Instructions describe:
●Device components
●Installation
●Operation
●Maintenance work required for reliable operation
●Decommissioning
1.2 Scope of application
These Operating Instructions are only applicable for the measuring device described in the
product identification.
They are not applicable for other SICK measuring devices.
The standards referred to in these Operating Instructions are to be observed in the
respective valid version.
1.3 User qualification
These Operating Instructions are intended for persons installing, operating and maintaining
the device.
Table 1: Qualification requirements
1.4 Further information
Observe the supplied documents.
●Final inspection record ZIRKOR200 Ex-G
●USB stick with technical information and certificates
●Manual for solenoid valve/test gas
●Data sheets for 1/2" NPT and 3/4" NPT screw fitting
●Processing instructions for sealing compound, screw fittings
Work User groups Qualification
Installation Operator / system integrator ●E.g. plant operator, untrained in measurement
technology
●Qualification for explosion protection
Electrical installation Qualified personnel ●Authorized electrician (authorized skilled
electrician or person with similar training)
●Qualification for explosion protection
Initial commissioning Authorized operator Ü ●General knowledge of measurement
technology, device expertise (customer training
at SICK if necessary)
●Qualification for explosion protection
Recommissioning
Decommissioning ●Operator / system integrator
●Authorized operator Ü
●E.g. plant operator, untrained in measurement
technology
●Authorized electrician (authorized skilled
electrician or person with similar training)
●Qualification for explosion protection
Operation
Maintenance
Troubleshooting

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ABOUT THIS DOCUMENT 1
1.5 Symbols and document conventions
1.5.1 Warning symbols
Table 2: Warning symbols
1.5.2 Warning levels and signal words
DANGER:
Risk or hazardous situation which will result in severe personal injury or death.
WARNING:
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION:
Hazard or unsafe practice which could result in less severe or minor injuries.
NOTICE:
Hazard which could result in property damage.
Note:
Hints
Symbol Significance
Hazard (general)
Hazard by electrical voltage
Hazard in potentially explosive atmospheres
Hazard by explosive substances/mixtures
Hazard by oxidizing substances
Hazard by toxic substances
Hazard by unhealthy substances
Hazard by high temperature or hot surfaces
Hazard for environment/nature/organisms

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1ABOUT THIS DOCUMENT
1.5.3 Information symbols
1.6 Data integrity
SICK AG uses standardized data interfaces, such as standard IP technology, in its products.
The focus here is on product availability and features.
SICK AG always assumes that the customer is responsible for the integrity and
confidentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures
suitable for the respective situation, e.g., network separation, firewalls, virus protection and
patch management.
Symbol Significance
Information on the nature of the product in relation to Directive 2014/34/EU for devices
and protective systems intended for use in potentially explosive atmospheres
Important technical information for this product
Important information for electrical or electronic functions

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FOR YOUR SAFETY 2
2Foryoursafety
2.1 Basic safety information
Work on the device
DANGER: Danger of explosion
Danger of explosion when working on the device.
▸Ensure no explosive atmosphere is present when working on the device.
▸Make sure the stack is switched off.
DANGER: Danger of explosion through explosive mixture in the components
Close filter, control unit and analyzer electronics covers completely after working on the
device, otherwise ignitable sparks can escape and lead to explosions.
▸Close filter, analyzer electronics and control unit covers completely after working on
the device..
▸
DANGER: Danger of explosion through sparking
Damaged threads relevant for ignition protection can lead to explosion by sparking.
▸Damaged threads relevant for ignition protection must be replaced. Repair is not
permitted.
DANGER:
Risk for system safety through work on the device not described in these
Operating Instructions
Work on the device not described in these Operating Instructions or associated
documents can lead to unsafe operation of the measuring system and therefore
endanger plant safety.
▸Only carry out the work on the device described in these Operating Instructions and
associated documents.
DANGER:
Danger of explosion through incorrect performance of work described in these
Operating Instructions
Incorrect performance of work in potentially explosive atmospheres can cause serious
injuries to people and damage during operation.
▸Maintenance and commissioning tasks as well as checks should only be carried out
by experienced/trained personnel with knowledge of the rules and regulations for
potentially explosive atmospheres, especially:
– Ignition protection types
– Installation rules
– Zone classification
DANGER:
Danger of explosion when opening the analyzer electronics cover (see “Installing and
insulating the analyzer unit”, page 37)
Opening the analyzer electronics cover during operation can lead to explosions.
▸Only open the analyzer electronics cover in an Ex-free area.
▸Only open the analyzer electronics cover when the stack is switched off.

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2FOR YOUR SAFETY
Escaping gases
Potential equalization
2.2 Warning information on device
Control unit Z200EXG-y1********************* (y= 1, 2)
Fig. 1: Warning information on control unit
●Warning - Only open in an Ex-free environment.
●Warning - Do not open under voltage.
DANGER:
Risk of burns and poisoning from escaping hot and toxic gas in systems with
overpressure conditions
In systems with overpressure, hot and toxic gas can escape from the process
connection. This can lead to burns or damage to health.
▸Always keep the process connection tightly closed.
▸Pay attention to hot surfaces.
▸Wear appropriate protective equipment.
CAUTION:
Danger of explosion through incorrect or missing grounding
Incorrectly connected potential equalization can lead to potential differences which can
create sparks due to transient phenomena (discharges) and lead to explosions in Ex-
atmospheres.
▸Connect a potential equalization on all planned points on the device components.
▸Ensure the potential equalization is connected during all work on the device
described in these Operating Instructions.
▸Ensure there is a ground connection via the voltage supply.
▸Perform regular checks of the grounding connections for intactness.
Warning

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FOR YOUR SAFETY 2
Analyzer unit Z200EXG-y2********************* (y= 1, 2)
●Warning - Do not open under voltage and when the incinerator is in operation.
●Warning – Observe the wait time for cooling down of all analyzer unit components to
200 °C (T3) (min. 1 hour)
●Warning - Follow the instructions in the Manual.
●Warning – Hot surfaces
Pneumatic unit Z200EXG-…
●Warning – In Ex-areas, only clean the surface with a damp cloth
Optional electric pneumatic valve
●Warning – Risk of electrostatic charge - see Instructions
2.3 Intended use
2.3.1 Purpose of the device
The device is a stationary oxygen measuring device and serves continuous measurement
of oxygen as emission and process monitoring in the industrial sector. The device
measures continuously directly in the gas duct (in-situ).
2.3.2 Operation in potentially explosive atmospheres
ZIRKOR200 Ex-G is suitable for use in explosive gas atmospheres of gas groups IIA, IIB and
IIC according to ATEX (EN60079-10) and according to IECEx (IEC60079-10) and
corresponds to categories 2G and EPL Gb for use in Zone 1.
The control unit is classified in temperature class T6, the analyzer unit in temperature class
T3.
Warning

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2FOR YOUR SAFETY
Marking of device components
Control unit Z200EXG-y1********************* (y= 1, 2)
●ATEX
II 2G Ex db IIC T6 Gb
●IECEx
Ex db IIC T6 Gb
●Special conditions:
Equipment used to the cable inlets and plugs for unused threads for cable inlets must be
certified according to IEC 60079-0 and IEC 60079-1.
It is not permitted to repair flameproof joints in the enclosure.
Analyzer unit Z200EXG-y2********************* (y= 1, 2)
●ATEX
II 2G Ex db IIC T3 Gb
●IECEx
Ex db IIC T3 Gb
●Special conditions for safe use:
– The specification of temperature class T3 applies to an ambient temperature range of
-20 °C to +55 °C.
– The heater voltage of the measuring probe must be switched off by a monitoring
device independent of the control and certified for this use when a limit temperature
of 890 °C for an ambient temperature of up to 40 °C and a limit temperature of
845 °C for an ambient temperature of up to 55 °C is reached.
– The warning to open the enclosure and the manufacturer's instructions must be
strictly followed.
– Only use the oxygen analyzer unit with associated protective pipe with flue gas feed in
flue gases, when the composition is not critical concerning the corrosion effect on the
materials used. If this cannot be ensured, regular recurring checks must be carried
out at sufficiently short intervals.
– The flue gas temperature must not exceed 500 °C on the measuring probe. Higher
process temperatures are possible when a suitable flue gas line with flue gas cooling
ensures that the flue gas does not exceed the limit value of 500 °C under all process
conditions when it reaches the analyzer unit.
Pneumatic unit Z200EXG
●Special conditions for safe use:
– In Ex-areas, only clean the surface with a damp cloth.
Optional electric pneumatic valve Z200EXG
●ATEX
II 2G Ex eb mb IIC T4 Gb
●IECEx
Ex eb mb IIC T4 Gb
Do not remove, add or modify any components to or on the device unless described and
specified in the official manufacturer information. Otherwise the approval for the device for
use in potentially explosive atmospheres becomes void.
Adhere to the prescribed maintenance intervals, see “Maintenance plan”, page 72.

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FOR YOUR SAFETY 2
2.3.3 Restrictions of use
●The ZIRKOR200 Ex-G is certified for a process-side operating range of 800 mbar abs. to
1100 mbar abs. The use in different pressures is not conform to the EX-certification and
therefore not allowed.
●Operate the ZIRKOR200 Ex-G within the described specifications (see “Technical data”,
page 96). If the ZIRKOR200 Ex-G is operated outside the specifications, it does not con-
form to the Ex-certification and is therefore not allowed.

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2FOR YOUR SAFETY
2.4 Responsibility of user
2.4.1 Designated users
see “User qualification”, page 8
The ZIRKOR200 Ex-G should only be installed and operated by skilled technicians who,
based on their technical training and knowledge as well as knowledge of the relevant
regulations, can assess the tasks given and recognize the hazards involved.
2.4.2 Correct project planning
This Manual presumes that the device has been delivered as specified during project
planning (i.e., based on the SICK application questionnaire) and the relevant delivery state
of the device (delivered System Documentation).
▸If you are not sure whether the device complies with the planned configuration or the
delivered system documentation:
Contact SICK Customer Service.
2.4.3 Correct use
▸Only use the ZIRKOR200 Ex-G as described in these Operating Instructions (see
“Intended use”, page 13). The manufacturer bears no responsibility for any other use.
▸Carry out the prescribed maintenance work (see “Maintenance plan”, page 72).
!▸ Do not carry out any work on the ZIRKOR200 Ex-G not described in these Operating
Instructions.
Do not remove, add or modify any components to or on the ZIRKOR200 Ex-G unless
described and specified in the official manufacturer information.
Otherwise:
– Any warranty by the manufacturer becomes void.
– The ZIRKOR200 Ex-G can become dangerous.
– The approval for use in potentially explosive atmospheres is no longer valid.
2.4.4 Special local conditions
▸Follow all local laws, regulations and company-internal operating directives applicable at
the installation location.
2.4.5 Read the Operating Instructions
▸Only put the ZIRKOR200 Ex-G into operation after reading and understanding the
Operating Instructions.
▸Observe all safety information.
▸If anything is not clear: Contact SICK Customer Service.
These Operating Instructions must be:
▸Available for reference.
▸Passed on to new owners.

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PRODUCT DESCRIPTION 3
3 Product description
3.1 Product identification
*The system code of the complete system serves as additional information but has no reference for the approval.
3.2 Type plates
The type plate is located on the unit components as shown in the Figures below.
Product name ZIRKOR200 Ex-G GasEx Oxygen analyzer with analyzer unit and
control unit
Manufacturer SICK AG
Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
Type designation Z200EXG-y0********************* (y= 1, 2) for control unit
and analyzer unit*
Z200EXG-y1********************* (y= 1, 2) for control unit
Z200EXG-y2********************* (y= 1, 2) for analyzer unit

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3PRODUCT DESCRIPTION
Fig. 2: Type plates (1)
Control unit Z200EXG-y1********************* (y= 1, 2)
Analyzer unit Z200EXG-y2********************* (y= 1, 2)

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PRODUCT DESCRIPTION 3
Type plate of the automatic pneumatic unit
Type plate of the semi-automatic pneumatic unit
See type plate of automatic pneumatic unit

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3PRODUCT DESCRIPTION
3.3 Device versions
Fig. 3: Type code for Ex-device versions
Z200EXG - 1 0 0 Z Z 0 0 0 1 1 0 0 0 0 0 0 A 1 1
Designation of device type
Plausi=
Z200EXG GasEx Oxygen-Analyzer with
probe and electronics
Ex-Approval (EX)
1 ATEX/IECEx Zone 1 [2G]
2 ATEX/IECEx Zone 2 [3G]
Configuration (KF)
0 Probe and electronics
1 Electronics only
2 Probe only
Probe length (required) (LZ)
0 Electronics only
A Probe immersion depth 464 mm
(incl. sinter metal filter)
B Probe immersion 924 mm (incl.
sinter metal filter)
Protection tube & Cooling
tube (required / optional)
(SR)
Z without protection tube /
Electronics only
Y Protection tube for 464 mm <=
500 °C
X Protection tube for 924 mm <=
500 °C
W Cooling tube (SiSiC) 500 mm
with probe 464 mm immersion
depth <= 1400 °C
V Cooling tube (SiSiC) 1000 mm
with probe 464 mm immersion
depth <= 1400 °C
Flange (required) (FL)
Z without flange / electronics only
A ANSI 4" 150 lbs FF
B ANSI 2" 150 lbs RF (only with
cooling tube)
C ANSI 3" 150 lbs RF
D ANSI 3" 300 lbs RF
E ANSI 4" 150 lbs RF
F ANSI 4" 300 lbs RF
G DN50 PN16 (only with cooling
tube)
H DN65 PN6 (only with cooling
tube)
I DN65 PN16 (only with cooling
tube)
K DN80 PN6
L DN80 PN16
M DN100 PN16
Test gas shut-off (optional)
(TG)
0 No option / electronics only
A Ex Manual test gas valve for
probe
B Ex Solenoid valve for probe