SICK ZIRKOR302 P User manual

OPERATING INSTRUCTIONS
ZIRKOR302 P
Oxygen Analyzer
Standalone Version
with Measuring Gas Pump

Table of contents Docu No. DLT6230-07_eng_0017
2
1General 4
1.1 Purpose of this Document 4
1.2 Operating Personnel 4
1.3 Other Documents 4
1.4 Obligations and Liability 5
1.5 Safety Symbols 6
1.6 Intended Use 6
1.7 Incorrect Usage 7
1.8 Informal Safety Measures 7
1.9 Danger from Electrical Power 8
1.10 Hazardous Areas 8
1.11 Removal from Service 8
1.12 Alterations to the Construction of Devices 8
2General Description 9
2.1 Theoretical Fundamentals and Measuring Principle 9
2.2 Functional Description 12
2.3 General View 19
2.4 Probe Section View 21
2.5 Gas Extraction Device 23
2.6 Protective Pipe with Aluminum Core 25
2.7 Conformity 25
3Installation 26
3.1 Prerequisites 26
3.2 Installing the Counterflange 27
3.3 Installing the Gas Extraction Device (GED) and Protective Pipe 28
3.4 Installing the LAMBDA TRANSMITTER P Oxygen Analyzer 29
3.5 System Settings in Accordance with System Composition (Reduced to Case Studies) 30
3.6 Installing the Gas Extraction Device and Pre-Filter Heater (Optional) 31
3.7 Installing the High-Dust Protective Pipe 39
4Operation and Display Controls 41
4.1 Multi-Function Key 41
4.2 LED-Display 42
4.3 Monitor Output / DIP Switch on Processor card 43
4.4 Remote Display Software 43
4.5 Display/Control Unit 44
4.6 Parameter Groups 50
5Operation 51
5.1 Activating Measurement Mode 51
5.2 Operating and Status Messages 52
5.3 Practical Notes 54
5.4 Removal from Service 56
6Alarms and Faults 57
6.1 Fault history 57
6.2 Display via Processor Board 57
6.3 Display via Display/Control Unit 59

Table of contents Docu No. DLT6230-07_eng_0017
3
6.4 Causes of Faults 60
6.5 Causes of Warnings 61
6.6 Internal Electronics Fault 62
7Service and Maintenance 63
7.1 Recommendations for practical application 63
7.2 Checking and Calibration the Probe 64
7.3 Check with Test Gas 65
7.4 Software Update to 5V006 with Flash-Update-Software V1.2 67
7.5 Removing the Gas Extraction Device and Checking Penetrability 70
7.6 Removing the Probe Body 72
7.7 Checking the Measuring Cell Heaters 73
7.8 Replacing the Measuring Cell and Measuring Cell Heater 73
7.9 Cleaning and Replacing the Extraction Device (Incl. Heater) 74
7.10 Checking the PT 100 Temperature Sensor 75
7.11 Replacing the Quartz Glass Measuring Chamber 76
7.12 Replacement of the pressure sensors 80
7.13 Replacement of the analog output card 81
7.14 Replacement of the base electronic 81
8Disposal 82
9Optional Accessories 83
9.1 LSB-Module with 4 Analog Outputs Voltage, alternatively Current 83
9.2 LSB-Module with 4 Analog Inputs 86
9.3 LSB-Moduel with 4 Digital Outputs 88
9.4 LSB-Module with 4 Digital Inputs 93
9.5 Internal Connection of the LSB-Module (max. 2 Pieces) 98
9.6 External LSB-Module Connections 99
9.7 Activating of LSB-Modules 100
9.8 Gas Extraction Kit with Heater for Gas Extraction Device 102
9.9 Gas Extraction Kit with Gas Extraction Device and Filter Heater 102
9.10 Protective Pipe for High-Dust Applications 103
9.11 Ceramic Gas Extraction Device 104
9.12 Counterflange 104
9.13 Optional Second RS422 Interface, Type K6029318 105
10 Spare Parts and Consumables 108
10.1 Consumables 108
10.2 Spare Parts 109
11 Appendix 111
11.1 Technical Specifications 111
11.2 Connection Diagram 113
11.3 Dimensions 114
11.4 Base Electronic 115
11.5 Plug-In Jumpers 117
11.6 Analog Output Card 118
11.7 Probe Record Pass (Front) 120

General - Purpose of this Document
4
1 General
1.1 Purpose of this Document
These operating instructions provide operators with information about:
Operation
Safety instructions
Maintenance
Troubleshooting
Although other documents (e.g. Product Information) may provide additional
information, they must not be regarded as a substitute for these operating instructions.
1.2 Operating Personnel
For certain activities (electrical installation, for example), specialist knowledge is
required. Such activities must only be carried out by suitably qualified personnel.
Those responsible for personal safety must make sure that:
All work on the device components is carried out by qualified personnel only.
They always have access to the operating instructions supplied with the device as well
as the associated order documentation when carrying out work and observe this
documentation to avoid hazards and damage.
Faults must be analyzed by qualified personnel. Measures must be taken to prevent
consequential damage, personal injury, and damage to the system.
Qualified personnel
These persons must be qualified by virtue of their expertise (training, education,
experience) or understanding of the relevant standards, specifications, accident
prevention regulations, and properties of the system. It is crucial that these persons be
able to identify and avoid potential hazards in good time.
Technical experts are those persons defined in DIN VDE 0105, IEC 364, or directly
equivalent standards, such as DIN 0832.
Two user groups have been defined for handling the LAMBDA TRANSMITTER P
oxygen analyzer:
Service technicians and trained customer personnel:
Qualified technicians/engineers who have an in-depth knowledge of the device.
Operators, in-house installation engineers:
Technicians for instrumentation and control technology, electrical engineering and
electronics, who have a basic knowledge of the device.
1.3 Other Documents
For accessories and special applications, consult the documentation supplied.
Basic Safety Instructions
These operating instructions contain the most important information regarding the safe
operation of the LAMBDA TRANSMITTER P oxygen analyzer. Always read them
before starting work. Warnings must be observed at all times.
User groups

General - Obligations and Liability
5
1.4 Obligations and Liability
Observe notes in these operating instructions
Before you can operate the device safely and properly, you must be familiar with the
basic safety precautions and regulations. These operating instructions (in particular
the safety precautions) must be observed by everyone who uses the LAMBDA
TRANSMITTER P oxygen analyzer and connected components. In addition, the
general and local accident prevention rules and regulations must be observed.
Hazards when using the LAMBDA TRANSMITTER P
The LAMBDA TRANSMITTER P oxygen analyzer is constructed in accordance with
the current state of the art and recognized safety regulations. Measures must
nonetheless be taken to prevent injury to the operator or a third person and to prevent
the LAMBDA TRANSMITTER P or other objects from being damaged. The LAMBDA
TRANSMITTER P must only be used:
For its intended purpose
When it is in good working order.
Faults that could compromise safety must be rectified immediately.
Warranty and liability
Our "General Terms of Sale and Delivery" always apply. These are available to the
operator as soon as a contract has been concluded. Warranty and liability claims for
personal injury or material damage shall be excluded if they are attributable to one or
more of the following causes:
The LAMBDA TRANSMITTER P oxygen analyzer and connected components have
not been used for their intended purpose.
The LAMBDA TRANSMITTER P and connected components have been installed,
commissioned, operated, or serviced incorrectly.
The LAMBDA TRANSMITTER P oxygen analyzer and connected components have
been operated with safety and protective equipment that is either defective, incorrectly
installed, or not in working order.
The information in the operating instructions regarding the operation, maintenance,
and installation of the LAMBDA TRANSMITTER P and connected components has
not been observed.
Unauthorized alterations to the construction of the LAMBDA TRANSMITTER P and
connected components have been made.
Components subject to servicing have not been checked properly.
Repairs have been carried out incorrectly.
Rough handling or the ingress of foreign bodies has resulted in catastrophic damage.

General - Safety Symbols
6
1.5 Safety Symbols
The following designations and symbols for hazards, warnings, and information are
used in these operating instructions:
DANGER
Indicates potential danger for personnel, particularly due to electrical equipment.
WARNING
Indicates potential danger for personnel due to incorrect handling of system
components.
IMPORTANT!
Indicates a risk of damage to system components and potential functional
impairments.
NOTE
Highlights information on the features of the system or system components and
provides additional tips.
The operator must observe the legal accident prevention guidelines at all times and
take all the appropriate measures to prevent personal injury and material damage.
1.6 Intended Use
The LAMBDA TRANSMITTER P continuous measuring system measures the O2
concentration in gases in the hyperstoichiometric range.
All planning, mounting, installation, commissioning, maintenance, and repair work
must be carried out by adequately trained personnel only and checked by experts.
You must make sure that:
The system is used in accordance with the technical data and specifications regarding
usage, assembly, connection, ambient, and operating conditions (see the order
documentation, user information, rating plates, and so on) and the documentation
supplied.
Users act in accordance with the local, system-specific conditions and with due
consideration paid to operational hazards and specifications.
All of the measures required to maintain the device, for example, transportation and
storage, as well as maintenance and inspection requirements, are provided.
Intended use also includes:
Observing all the information in the operating instructions.
Carrying out all inspection and maintenance work.
Prerequisite
Proper usage
Observing the operating
instructions

General - Incorrect Usage
7
1.7 Incorrect Usage
It is forbidden to use the device in any other way than described above. Incorrect
usage can be hazardous.
If the measuring system is to be used in any other application in which its proper
functioning cannot be ensured, consult the manufacturer beforehand.
1.8 Informal Safety Measures
The LAMBDA TRANSMITTER P oxygen analyzer must only be operated when all the
safety equipment is in good working order.
The operator must take all the appropriate measures to prevent personal injury and
material damage.
You must make sure that:
• The system is used in accordance with the technical data and specifications
regarding usage, ambient, and operating conditions (see the order documentation,
user information, rating plates, and so on) and the documentation supplied.
• Users act in accordance with the local, system-specific conditions and with due
consideration paid to operational hazards and specifications.
• All of the measures required to maintain the device (e.g. for transportation and
storage, as well as maintenance and inspection requirements) are provided.
If the system is used or handled incorrectly, this can pose a risk to health or cause
material damage. To prevent damage, observe the safety precautions at all times.
If the LAMBDA TRANSMITTER P is used as a sensor in conjunction with a control
system, the operator must ensure that a failure or malfunction cannot lead to operating
conditions that cause damage or lead to other hazardous operating conditions.
To prevent malfunctions, which can cause personal injury or damage to the system
either directly or indirectly, the operator must ensure that:
• The maintenance personnel can be alerted immediately and at any time.
• The maintenance personnel is qualified to respond to malfunctions on the
LAMBDA TRANSMITTER P and associated system malfunctions correctly.
• The defective equipment can be switched off immediately if necessary.
• Switching off equipment does not indirectly cause further malfunctions.
The LAMBDA TRANSMITTER P oxygen analyzer is a high-quality electronic
measuring system. It must be handled with care when it is removed from service,
transported, and stored.

General - Danger from Electrical Power
8
1.9 Danger from Electrical Power
DANGER
The LAMBDA TRANSMITTER P system components are designed for use in
industrial power installations. When working on power connections or on live
components, make sure that the power supply is switched off. Before reconnecting
the power supply, install any shock protection devices that may have been removed.
The relevant safety regulations must be observed at all times.
1.10 Hazardous Areas
The LAMBDA TRANSMITTER P is installed directly in the gas-carrying duct above the
counterflange. When the LAMBDA TRANSMITTER P is removed, corrosive and/or hot
gases can – depending on the device and, in particular, if the duct is pressurized –
escape from the duct. This gas can cause serious injury if appropriate protection
measures are not taken.
WARNING
If the duct is pressurized and corrosive gases and/or temperatures in excess of
200°C (390°F) are present in the gas duct, gas can escape from the duct when the
LAMBDA TRANSMITTER P is removed. For this reason, you must observe the
following:
Switch the system off before you open it. If this is not possible, wear protective
clothing and a mask.
Attach warning signs in the vicinity of the mounting location.
Close the opening immediately. Cover flange plates (dummy flanges) are available as
accessories.
WARNING
The flange and the tube of the LAMBDA TRANSMITTER P is very hot.
Cooling down before removing or wear protective gloves.
1.11 Removal from Service
IMPORTANT!
The LAMBDA TRANSMITTER P must not be switched off once it has been installed
nor when the plant is shut down. Residual gases can cause corrosion and damage
system components.
If the device is stored outdoors, it must be protected from the elements. It must
always be stored in a dry place and, if possible, in its original packaging.
When decommissioning the device, protect the cable ends and connectors against
corrosion. Corroded connectors can cause the device to malfunction.
Whenever possible, transport the device in its original packaging.
1.12 Alterations to the Construction of Devices
No alterations must be made to the construction of or equipment fitted to the LAMBDA
TRANSMITTER P oxygen analyzer without the prior approval of the manufacturer.

General Description - Theoretical Fundamentals and Measuring Principle
9
2 General Description
2.1 Theoretical Fundamentals and Measuring Principle
The O2measuring cell essentially comprises a zirconium dioxide solid electrolyte tube,
which is sealed at one end. The internal and external surface is coated with layers of
precious metal as electrodes. The crystal lattice of the zirconium dioxide solid
electrolyte, which is doped with yttrium oxide or other rare earth oxides, contains
oxygen vacancies to enable oxygen ion conductivity that increases exponentially with
the temperature. The solid-electrolyte cell, which can be heated by means of an
internal electric heater, is surrounded by a quartz or ceramic cladding tube. A defined
sample gas flow (500 ml/h) passes through the cladding tube by means of a flow-
control capillary and an extraction device/measuring gas pump.
Fig. 2-1:
Measuring principle
Differential pressure N
ZrO2electrolyte pipe
Pt electrodes
Flow-control
capillary
Calibration gas
Differential pressure V
Probe section
Absolut pressure
Calibration
GED
(gas extraction
device)
Measured gas
System Bus
(LSB)
Analog
output
0/4...20mA
0...10V
Connection terminals
Absolut
pressure
sensor
Differential
pressure
sensor Processor
card
Electronics power pack
Electronic section
Measuring gas pump
(frequently controled)
Automatic calibration
device (frequently
controled)
Fuel gas return
elec. sensor
heater
Changes in the sample gas flow (e.g. as a result of pressure variations upstream or
downstream of the capillary) are recorded by means of a differential pressure
measurement and corrected by the microprocessor.
To determine the oxygen concentration in the sample gas, a direct-current voltage of
between 0.4 and 1.0 V is applied to the electrodes in the cell (at an operating
temperature of > 800°C (1470°F)); the oxygen ions flowing through the solid
electrolytes are measured using a milliammeter. All the oxygen in the sample gas
ionizes under the influence of the direct-current voltage at the negative outer
electrode.

General Description - Theoretical Fundamentals and Measuring Principle
10
The negative oxygen ion flow is transported to the positive internal electrode and is
discharged to form molecular oxygen. A linear correlation exists between the ionic
current, which is measured as the probe current signal, and both the oxygen
concentration and sample gas quantity that passes through the cell in each time unit.
Calibrating this in line with a gas with a known oxygen concentration (preferably air
with 20.96 vol.% O2) enables the sample gas flow rate to be determined. Variations in
the sample gas flow rate are compensated by means of the differential pressure
compensation.
Fig. 2-2:
Structure and function of
the oxygen probe
0 8 16 24 32
400
600
200
850 °C
800 °C
O2[vol %]
I [mA]
I Current as function of oxygen
H Electric sensor heater
M Test gas
A Adjustment value (Iair ≈21 vol. % O2)
d Test/sample gas quantity
This characteristic shows that it is not necessary to know the proportionality factor or
the measuring gas quantity in order to measure the oxygen. It is sufficient to assign
the oxygen concentration (O2= 21%) to the probe current measured with air I (air) and
then draw a straight line to the zero-point (I = 0; (O2) = 0) through the adjustment point
derived in this way. In practice, this means that the probe can be easily aligned and
adjusted by assigning ~ 21 Vol. % O2to the measured air value (20.96).
If the cell is structured appropriately and a suitable voltage is applied, the linear
characteristic of the probe depends solely on the sample gas quantity, which governs
the gradient of the straight lines (see diagram).
ZrO2electrolyte tube
Pt electrodes
I
air
Test gas
d=0.42 l/h
d=0.5 l/h
1,560 °F
1,470 °F
(0.11 gal/hr)
(0.13 gal/hr)