YOKOGAWA EXAxtZR User manual

Instruction
Manual
IM 11M12A01-02E
Model ZR22G, ZR402G
Separate type
Zirconia Oxygen Analyzer
IM 11M12A01-02E
3rd Edition

i
IM 11M12A01-02E
IM 11M12A01-02E
3rd Edition: Sept. 2001 (YK)
All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation
Introduction
The EXAxtZR Separate type Zirconia Oxygen Analyzer has been developed for com-
bustion control in various industrial processes. This analyzer basically consists of a
detector and a converter. You can select between several versions, based upon your
application.
Optional accessories are also available to improve measurement accuracy and automate
calibration. An optimal control system can be realized by adding appropricate options.
This instruction manual refers to almost all of the equipment related to the EXAxtZR.
You may skip any section(s) on the equipment which is not included in your system.
Regarding the HART communication protocol, refer to IM 11M12A01-51E.
IM 11M12A01-51E has been published as 0 Model EXAxt ZR Series HART Protocol0 .
The all-in-one version (with sensor and analyzer integrated in one body) is described in
IM 11M12A01-04E
<Before using the equipment, please read any descriptions in this manual related to the
equipment and system that you have, on appropriate use and operation of the
EXAxtZR.>
Models and descriptions in this manual are as follows:
Models and descriptions in this manual
Description in this manual
Model Product Name Specification Installation Operation Maintenance CMPL
ZR22G General-use detector ss s ss
ZR22G High-temperature detector (0.15m) ssss
ZR402G Converter sssss
ZO21R-L Probe protector ss
ZO21P-H High-temperature probe adapter sss
ZA8F Flow setting unit (for manual calibration use) sss
ZR40H Automatic Calibration unit ssss
- Auxiliary ejector for high-temperature use
(Part No. E7046EC, EN) sss
- Calibration gas unit case (Part No. E7044KF) ss
- Check valve (Part No. K9292DN, K9292DS) ss
- Dust filter for the detector (Part No. K9471UA) ss
ZO21S Standard gas unit ssss
T.Int.1E
CMPL : Customer Maintenance Parts List

IM 1M12A01-02E
ii
This manual consists of twelve chapters. Please refer to the reference chapters for
installation, operation and maintenance.
Table of Contents
T.Int.2E
s
s
s
s
n
s
s
s
n
n
n
n
n
n
n
s
s
s
s
s
s
s
Relates to
Chapter Outline Installation Operation Maintenance
1. Overview Equipment models and system configuration examples
2. Specifications Standard specification, model code (or part number),
dimension drawing for each equipment
3. Installation Installation method for each equipment
4. Piping Examples of piping in three standard system
configurations
5. Wiring Wiring procedures such as “Power supply wiring”, “output
signal wiring” or others
6. Components Major parts and function are described in this manual
7. Startup Basic procedure to start operation of EXAxtZR. Chapter 7
enables you to operate the equipment immediately.
8. Detailed Data Setting Details of key operations and displays
9. Calibration Describes the calibration procedure required in the course
of operation.
10. Other Functions Other functions described
11. Inspection and How to conduct maintenance of EXAxtZR and procedures
Maintenance for replacement of deteriorated parts
12. Troubleshooting This chapter describes measures to be taken when an
abnormal condition occurs.
CMPL (parts list) User replaceable parts list
s
s
n
: Read and completely understand before operating the equipment.
: Read before operating the equipment, and refer to it whenever necessary.
: Recommended to read it at least once.
s
n
n
n
s
s
s

iii
IM 11M12A01-02E
rFor the safe use of this equipment
CAUTION
The cell (sensor) at the tip of the detector is made of ceramic (zirconia element). Do not
drop the detector or subject it to pressure stress.
• Do NOT allow the sensor (probe tip) to make contact with anything when installing
the detector.
• Avoid any water dropping directly on the probe (sensor) of the detector when install-
ing it.
• Check the calibration gas piping before introducing the calibration gas to ensure that
there is no leakage of the gas. If there is any leakage of the gas, the moisture drawn
from the measured gas may damage the sensor.
• The detector (especially at the tip) becomes very hot. Be sure to handle it with gloves.
DANGER
EXAxtZR is very heavy. Handle it with care. Do not drop it. Handle safely to avoid
injury.
Connect the power supply cord only after confirming that the supply voltage matches
the rating of this equipment. In addition, confirm that the power is switched off when
connecting power supply.
Some process gas is dangerous to people. When removing this equipment from the
process line for maintenance or other reasons, protect yourself from potential poisoning
by using a protective mask or ventilating the area well.
(1) About This Manual
• This manual should be passed on to the end user.
• The contents of this manual are subject to change without prior notice.
• The contents of this manual shall not be reproduced or copied, in part or in whole,
without permission.
• This manual explains the functions contained in this product, but does not warrant that
those will suit the particular purpose of the user.
• Every effort has been made to ensure accuracy in the preparation of this manual.
However, should any errors or omissions come to the attention of the user, please
contact the nearest Yokogawa Electric representative or sales office.
• This manual does not cover the special specifications. This manual may not be
changed on any change of specification, construction and parts when the change does
not affect the functions or performance of the product.
• If the product is used in a manner not specified in this manual, the safety of this
product may be impaired.

IM 1M12A01-02E
iv
(2) Safety and Modification Precautions
• Follow the safety precautions in this manual when using the product to ensure protec-
tion and safety of personnel, product and system containing the product.
(3) The following safety symbols are used on the product as well as in this manual.
DANGER
This symbol indicates that the operator must follow the instructions laid out in this
manual in order to avoid the risk of personnel injury electric shock, or fatalities. The
manual describes what special care the operator must exercise to avoid such risks.
WARNING
This symbol indicates that the operator must refer to the instructions in this manual in
order to prevent the instrument (hardware) or software from being damaged, or a system
failure from occurring.
CAUTION
This symbol draws attention to information essential for understanding the operation and
functions.
Tip
This symbol gives information that complements the present topic.
SEE ALSO
This symbol identifies a source to which to refer.
Protective Ground Terminal
Function Ground Terminal (Do not use this terminal as the protective ground
terminal.)
Alternating current

v
IM 11M12A01-02E
• Special descriptions in this manual
This manual indicates operation keys, displays and drawings on the product as follows:
• Operation keys, Enclosed in [ ], displays on the panel 0 0.
(Ex. [MODE] key)
(Ex. message display 0 BASE 0)
(Ex. data display 0 1020 lit, 0 1020flashing)
• Drawing for flashing
Indicated in light print. (Flashing) (lit)

IM 1M12A01-02E
vi
rNOTICE
• Specification check
When the instrument arrives, unpack the package with care and check that the
instrument has not been damaged during transportation. In addition, please check that
the specification matches the order, and required accessories are not missing. Specifi-
cations can be checked by the model codes on the nameplate. Refer to Chapter 2
Specifications for the list of model codes.
• Details on operation parameters
When the EXAxt ZR Separate type Oxygen Analyzer arrives at the user site, it will
operate based on the operation parameters (initial data) set befor shipping from the
factory.
Ensure that the initial data is suitable for the operation conditions before conducting
analysis. Where necessary, set the instrument parameters for appropriate operation.
For details of setting data, refer to chapters 7 to 10.
When user changes the operation parameter, it is recommended to note down the
changed setting data.
rAfter - Sales Warranty
dYokogawa warrants the product for the period stated in the quotation which was
delivered upon purchase. Yokogawa shall conduct defined warranty service based on
its standard. When the customer site is located out of the specified scope, a fee for
dispatching the maintenance engineer will be charged to the customer.
dIn the following cases, customer will be charged repair fee regardless of warranty
period.
• Failure of components which are out of scope of warranty stated in instruction
manual.
• Failure caused by usage of software, hardware or auxiliary equipment, which
Yokogawa Electric Corporation did not supply.
• Failure due to improper or insufficient maintenance by user.
• Failure due to modification, misuse or operation of specification which Yokogawa
does not authorize.
• Failure due to power supply (voltage, frequency) being outside specifications or
abnormal.
• Failure caused by any usage out of scope of recommended usage
• Any damage from fire, earthquake, a storm and flood, lightning, disturbance, riot,
warfare, radiation and other natural changes.
dYokogawa does not warrant conformance with the specific application at the user
site. Yokogawa will not bear direct/indirect responsibility for damage due to a specific
application.
dYokogawa Electric Corporation will not bear responsibility when the user configures
the product into systems or resells the product.
dMaintenance service and supplying repair parts will be covered for five years after
the production ends. For repair this product, please contact the nearest sales office
described in this instruction manual.

vii
IM 11M12A01-02E
Introduction........................................................................................................................... i
rFor the safe use of this equipment .......................................................................... iii
rNOTICE....................................................................................................................vi
rAfter - Sales Warranty..............................................................................................vi
1. Overview .......................................................................................................................1-1
1.1 < EXAxtZR > System Configuration ............................................................. 1-1
1.1.1 System 1 .................................................................................................. 1-1
1.1.2 System 2 .................................................................................................. 1-2
1.1.3 System 3 .................................................................................................. 1-3
1.2 < EXAxtZR > System Components ............................................................... 1-4
1.2.1 System Components ................................................................................ 1-4
1.2.2 Detectors and Accessories....................................................................... 1-4
2. Specifications ................................................................................................................2-1
2.1 General Specifications .................................................................................... 2-1
2.1.1 Standard Specifications ........................................................................... 2-1
2.2 General-use Separate-type Detector and Related Equipment ........................ 2-3
2.2.1 ZR22G General-use Separate-type Detector........................................... 2-3
2.2.2 ZO21R-L Probe Protector ....................................................................... 2-8
2.3 High-Temperature Separate-type Detector and Related Equipment .............. 2-9
2.3.1 ZR22G (0.15m) High-Temperature Separate-type Detector .................. 2-9
2.3.2 ZO21P-H Adapter for High-Temperature Probe .................................. 2-10
2.4 ZR402G Separate-type Converter................................................................. 2-12
2.4.1 Standard Specification........................................................................... 2-12
2.4.2 Functions................................................................................................ 2-13
2.5 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit ............. 2-17
2.5.1 ZA8F Flow Setting Unit........................................................................ 2-17
2.5.2 ZR40H Automatic Calibration Unit...................................................... 2-19
2.6 ZO21S Standard Gas Unit ............................................................................ 2-22
2.7 Other Equipment ........................................................................................... 2-24
2.7.1 Dust Filter for the Detector (Part No.: K9471UA)............................... 2-24
2.7.2 Auxiliary Ejector for High Temperature
(Part No. E7046EC or E7046EN)........................................................ 2-25
2.7.3 Stop Valve (Part No. L9852CB or G7016XH) .................................... 2-27
2.7.4 Check Valve (Part No. K9292DN or K9292DS) ................................. 2-28
2.7.5 Air Set (Part No. G7011XF or E7040EL) ............................................ 2-29
2.7.6 Zero Gas Cylinder (Part No. G7001ZC)............................................... 2-29
2.7.7 Cylinder Regulator Valve (Part No. G7013XF or G7014XF) ............. 2-30
2.7.8 Calibration Gas Unit Case (Part No. E7044KF) .................................. 2-30
2.7.9 Model ZR22A Heater Assembly........................................................... 2-31
Contents

IM 1M12A01-02E
viii
3. Installation .................................................................................................................... 3-1
3.1 Installation of the Detector ............................................................................. 3-1
3.1.1 Location ................................................................................................... 3-1
3.1.2 Probe Insertion Hole................................................................................ 3-1
3.1.3 Installation of the Detector...................................................................... 3-2
3.1.4 Installation of the Dust Filter( Part No K9471UA)................................ 3-3
3.2 Installation of the Detector (Model ZR22G-015)........................................... 3-5
3.2.1 Installation Location ................................................................................ 3-5
3.2.2 Usage of the High-temperature Probe Adapter (Model ZO21P-H) ....... 3-5
3.2.3 Probe Insertion Hole................................................................................ 3-7
3.2.4 Mounting of the High-Temperature Detector ......................................... 3-7
3.3 Installation of the Converter ........................................................................... 3-9
3.3.1 Location ................................................................................................... 3-9
3.3.2 Mounting of the Converter...................................................................... 3-9
3.4 Installation of ZA8F Flow Setting Unit ....................................................... 3-12
3.4.1 Location ................................................................................................. 3-12
3.4.2 Mounting of ZA8F Flow Setting Unit .................................................. 3-12
3.5 Installation of ZR40H Automatic Calibration Unit...................................... 3-14
3.5.1 Location ................................................................................................. 3-14
3.5.2 Mounting of ZR40H Automatic Calibration Unit ................................ 3-14
3.6 Installation of the Calibration Gas Unit Case (E7044KF) ........................... 3-16
3.6.1 Location ................................................................................................. 3-16
3.6.2 Mounting................................................................................................ 3-16
3.7 Insulation Resistance Test............................................................................. 3-17
3.8 External Dimensions of Detectors with Pressure Compensation................. 3-18
4. Piping............................................................................................................................. 4-1
4.1 Piping for System 1 ........................................................................................ 4-1
4.1.1 Parts Required for Piping in System 1 ................................................... 4-2
4.1.2 Connection to the Calibration Gas Inlet ................................................. 4-3
4.1.3 Connection to the Reference Gas Inlet ................................................... 4-3
4.1.4 Piping to the High-temperature Probe Adapter ...................................... 4-4
4.2 Piping for System 2 ........................................................................................ 4-6
4.2.1 Piping Parts for System 2........................................................................ 4-7
4.2.2 Piping for the Calibration Gas ................................................................ 4-8
4.2.3 Piping for the Reference Gas .................................................................. 4-8
4.2.4 Piping to the High-temperature Probe Adapter ...................................... 4-8
4.3 Piping for System 3 ........................................................................................ 4-9
4.3.1 Blow Back Piping.................................................................................. 4-10
4.4 Piping for the Detector with Pressure Compensation .................................. 4-12
4.4.1 Piping Parts for a System using Detector with Pressure Compensation4-14
4.4.2 Piping for the Calibration Gas .............................................................. 4-14
4.4.3 Piping for the Reference Gas ................................................................ 4-14
5. Wiring ........................................................................................................................... 5-1
5.1 General ............................................................................................................ 5-1
5.1.1 Terminals for the External Wiring in the Converter .............................. 5-2
5.1.2 Wiring ...................................................................................................... 5-3
5.1.3 Mounting of Cable Gland........................................................................ 5-4
5.2 Wiring for Detector Output............................................................................. 5-5
5.2.1 Cable Specifications ................................................................................ 5-5
5.2.2 Connection to the Detector...................................................................... 5-6
5.2.3 Connection to the Converter ................................................................... 5-7

ix
IM 11M12A01-02E
5.3 Wiring for Power to Detector Heater ............................................................. 5-8
5.3.1 Cable Specifications ................................................................................ 5-8
5.3.2 Connection to Detector............................................................................ 5-8
5.3.3 Connection to Converter ......................................................................... 5-9
5.4 Wiring for Analog Output............................................................................. 5-10
5.4.1 Cable Specifications .............................................................................. 5-10
5.4.2 Wiring Procedure................................................................................... 5-10
5.5 Power and Grounding Wiring....................................................................... 5-11
5.5.1 Power Wiring......................................................................................... 5-11
5.5.2 Grounding Wiring ................................................................................. 5-11
5.6 Contact Output Wiring.................................................................................. 5-12
5.6.1 Cable Specifications .............................................................................. 5-12
5.6.2 Wiring Procedure................................................................................... 5-12
5.7 Wiring for ZR40H Automatic Calibration Unit ........................................... 5-13
5.7.1 Cable Specifications .............................................................................. 5-13
5.7.2 Wiring Procedure................................................................................... 5-14
5.8 Contact Input Wiring .................................................................................... 5-15
5.8.1 Cable Specifications .............................................................................. 5-15
5.8.2 Wiring Procedure................................................................................... 5-15
6. Components ..................................................................................................................6-1
6.1 ZR22G Detector .............................................................................................. 6-1
6.1.1 General-purpose Detector (except for Model ZR22G-015) ................... 6-1
6.1.2 High-Temperature Detector (Model ZR22G-015).................................. 6-2
6.2 ZR402G Converter.......................................................................................... 6-3
6.3 ZA8F Flow Setting Unit, ZR40H Automatic Calibration Unit ..................... 6-4
7. Startup...........................................................................................................................7-1
7.1 Checking Piping and Wiring Connections ..................................................... 7-1
7.2 Checking Valve Setup..................................................................................... 7-1
7.3 Supplying Power to the Converter.................................................................. 7-2
7.4 Touchpanel Switch Operations ....................................................................... 7-3
7.4.1 Basic Panel and Switch ........................................................................... 7-3
7.4.2 Display Configuration (for Oxygen Analyzer) ....................................... 7-4
7.4.3 Display Functions .................................................................................... 7-5
7.4.4 Entering Numeric and Text Data ............................................................ 7-5
7.5 Confirmation of Converter Type Setting........................................................ 7-7
7.6 Confirmation of Detector Type Setting .......................................................... 7-8
7.7 Selection of Measurement Gas ....................................................................... 7-8
7.8 Output Range Setting ...................................................................................... 7-8
7.8.1 Minimum Current (4 mA) and Maximum Current (20 mA) Settings ... 7-8
7.9 Setting Display Item ....................................................................................... 7-9
7.10 Checking Current Loop................................................................................. 7-11
7.11 Checking Contact I/O ................................................................................... 7-12
7.11.1 Checking Contact Output ...................................................................... 7-12
7.11.2 Checking Calibration Contact Output ................................................... 7-13
7.11.3 Checking Input Contacts ....................................................................... 7-13
7.12 Calibration ..................................................................................................... 7-14
7.12.1 Calibration Setup ................................................................................... 7-14
7.12.2 Manual Calibration ................................................................................ 7-15