SICK ZIRKOR200 Ex-G User manual

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

28024250/18HT/V2-0/2020-12 | SICKOPERATING INSTRUCTIONS | ZIRKOR200Ex-G
Subject to change without notice
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
48024250/18HT/V2-0/2020-12 | SICKOPERATING INSTRUCTIONS | ZIRKOR200Ex-G
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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

CONTENTS
68024250/18HT/V2-0/2020-12 | SICKOPERATING INSTRUCTIONS | ZIRKOR200Ex-G
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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

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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

88024250/18HT/V2-0/2020-12| SICKOPERATING INSTRUCTIONS |ZIRKOR200Ex-G
Subject to change without notice
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