YOKOGAWA IR400 series User manual

User’s
Manual Model IR400
Infrared Gas Analyzer
IM 11G02N01-01E
IM 11G02N01-01E
7th Edition

i
IM 11G02N01-01E
<Preface>
uPREFACE
We are grateful for your purchase of Yokogawa’s Infrared Gas Analyzer, Model: IR400. Read this
instruction manual carefully.
The related documents are as follows.
 GeneralSpecications:GS11G02N01-01E
User’s Manual: IM 11G02N01-01E (this manual)
IM 11G02P01-01E Communication Functions (MODBUS)
IM 11G00E01-01EN ZX8D Zirconia Oxygen Analyzer
IM 11G00E02-01EN K9350LE NO²/NO Converter
IM 11G00E02-02EN K9350LF NO²/NO Converter
The “E” or “EN” in the document number is the language code, meaning English
AnexclusiveUser’sManualmightbeattachedtotheproductswhosesu󰀩xcodesoroption
codescontainthecode“Z”(madetocustomers’specications).Pleasereaditalongwiththis
manual.
WARNING
This unit is not explosion-proof type. Do not use it in a place with explosive gases to prevent
explosion,reorotherseriousaccidents.
CAUTION
• For installation, observe the rule on it given in the instruction manual and select a place where
the weight of gas analyzer can be endured. Installation at an unsuited place may cause turnover
or fall and there is a risk of injury.
• During installation work, care should be taken to keep the unit free from cable chips or otherfor-
eignobjects.Otherwise,itmaycausere,troubleormalfunctionoftheunit.
WARNING
In piping, the following precautions should be observed. Wrong piping may cause gas leakage.
If the leaking gas contains a toxic component, there is a risk of serious accident being induced.
Also,ifcombustiblegasiscontained,thereisadangerofexplosion,reorthelikeoccurring.
• Connect pipes correctly referring to the instruction manual.
• Exhaust should be led outdoors so that it will not remain in the locker and installation room.Ex-
haust from the analyzer should be relieved in the atmospheric air in order that an unnecessary
pressure will not be applied to the analyzer. Otherwise, any pipe in the analyzer may be discon-
nected to cause gas leakage.
• For piping, use a pipe and a pressure reducing valve to which oil and grease are not adhering. If
suchamaterialisadhering,areorthelikeaccidentmaybecaused.
Media No.IM 11G02N01-01E 7th Edition :May 2018 (YK)
All Rights Reserved Copyright © 2002, Yokogawa Electric Corporation

ii
IM 11G02N01-01E
<Preface>
CAUTION
• Wiring work must be performed with the main power set to OFF to prevent electric shocks.
•Enforceconstructionofclass-Dgroundingwirebyallmeans.Ifthespeciedgroundingcon-
struction is neglected, a shock hazard or fault may be caused.
• Wires should be the proper one meeting the ratings of this instrument. If using a wire which can-
notenduretheratings,aremayoccur.
• Be sure to use a power supply of correct rating. Connection of power supply of incorrect rating
maycausere.
WARNING
•Donotsmokenoruseaamenearthegasanalyzer.Otherwise,aremaybecaused.
•Donotallowwatertogointothegasanalyzer.Otherwise,hazardshockorreintheinstrument
may be caused.
WARNING
PurgenotonlyinsideofIR400butallmeasuringgaslineswithzerogassu󰀩ciently,whenyou
provide maintenance or inspection on IR400 with its cover or door open. Otherwise it may cause
hazardousaccidentssuchasgasleakage,reandexplosion.
CAUTION
Do not operate the analyzer for a long time with its cover or door left open. Otherwise, dust, for-
eign matter, etc. may stick on internal walls, thereby causing faults.
CAUTION
• Be sure to observe the following for safe operation avoiding the shock hazard and injury.
• Replacement parts such as a maintenance part should be disposed of as incombustibles. For
details, follow the local ordinance.
lInspection of product
On receipt of the product, inspect the package and note it has no damage caused by the delivery.
Conrmthespecicationoftheproductcomformswithyourorderandaccessoriesarealldeliv-
ered. Check the product code labeld on a model plate is correct.

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IM 11G02N01-01E
<Preface>
uSafety Precautions
n Safety,Protection,andModicationoftheProduct
• This manual is intended for the following personnel :
• Engineers responsible for installation, wiring, and maintenance of the equipment
• Personnel responsible for normal daily operation of the equipment.
• In order to protect the system controlled by the product and the product itself and ensure safe
operation, observe the safety precautions described in this user’s manual. We assume no liabil-
ity for safety if users fail to observe these instructions when operating the product.
• Ifthisinstrumentisusedinamannernotspeciedinthisuser’smanual,theprotectionprovided
by this instrument may be impaired.
• If any protection or safety circuit is required for the system controlled by the product or for the
product itself, prepare it separately.
• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter simply
referred to as YOKOGAWA) when replacing parts or consumables.
• Modicationoftheproductisstrictlyprohibited.
• The following safety symbols are used on the product as well as in this manual.
WARNING
This symbol indicates that an operator must follow the instructions laid out in this manual
in order to avoid the risks for the human body and health including risk of injury, electric
shock, or fatalities. or the damages to instruments. The manual describes what special
care the operator must take to avoid such risks.
CAUTION
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.
The following are signal words to be found only in our instruction manuals.
CAUTION
This symbol gives information essential for understanding the operations and functions.
NOTE
This symbol indicates information that complements the present topic.
nNotes on Handling User’s Manuals
• Please hand over the user’s manuals to your end users so that they can keep the user’s manu-
als on hand for convenient reference.
• Please read the information thoroughly before using the product.
• The purpose of these user’s manuals is not to warrant that the product is well suited to any par-
ticular purpose but rather to describe the functional details of the product.
• No part of the user’s manuals may be transferred or reproduced without prior written consent
from YOKOGAWA.
• YOKOGAWA reserves the right to make improvements in the user’s manuals and product at any
time, without notice or obligation.
• Ifyouhaveanyquestions,oryoundmistakesoromissionsintheuser’smanuals,pleasecon-
tact our sales representative or your local distributor.
• This manual is an essential part of the product ; keep it in a safe place for future reference.

iv
IM 11G02N01-01E
<Preface>
nDrawing Conventions
Somedrawingsmaybepartiallyemphasized,simplied,oromitted,fortheconvenienceofde-
scription.
Somescreenimagesdepictedintheuser’smanualmayhavedi󰀨erentdisplaypositionsor
character types (e.g., the upper / lower case). Also note that some of the images contained in this
user’s manual are display examples.
n AuthorizedRepresentativeinEEA
The Authorized Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2,
3825 HD Amersfoort, The Netherlands).
nTrademark Acknowledgments
• All other company and product names mentioned in this user’s manual are trademarks or
registered trademarks of their respective companies.
• We do not use TM or ® mark to indicate those trademarks or registered trademarks in this user’s
manual
Notes on Use in Korea
The AC cord with the following products is not compliant with the safety standards in Korea.
Please do not use it to connect household appliances in Korea.
It is prohibited to use an adapter connector to change the plug shape for the AC cord of the
following products.
• IR400--J/
• IR400--E/

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IM 11G02N01-01E
<Preface>
uCE marking products
n AuthorizedRepresentativeinEEA
The Authorized Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2,
3825 HD Amersfoort, The Netherlands).
n IdenticationTag
Thismanualandtheidenticationtagattachedonpackingboxareessentialpartsoftheproduct.
Keep them together in a safe place for future reference.
nUsers
This product is designed to be used by a person with specialized knowledge.
n Howtodisposethebatteries
This is an explanation about the new EU Battery Directive. This directive is only valid in the EU.
Batteries are included in this product. Batteries incorporated into this product cannot be removed
by yourself. Dispose them together with this product.
WhenyoudisposethisproductintheEU,contactyourlocalYokogawaEuropeB.V.o󰀩ce.
Do not dispose them as domestic household waste.
Battery type: Manganese dioxide lithium battery
Notice:
The symbol (see above) means they shall be sorted out and collected as ordained inANNEX II in DIRECTIVE 2006/66
n InformationoftheWEEEDirective
Thisproductispurposelydesignedtobeusedinalargescalexedinstallationsonlyand,
therefore, is out of scope of the WEEE Directive. The WEEE Directive does not apply. This
product should be disposed in accordance with local and national legislation/regulations.
The WEEE Directive is only valid in the EU.

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IM 11G02N01-01E
<Preface>
uAfter-Sales Warranty
Donotmodifytheproduct.
Yokogawawarrantstheproductfortheperiodstatedinthepre-purchasequo-
tation.Yokogawashallconductdenedwarrantyservicebasedonitsstand-
ard.Whenthecustomersiteislocatedoutsideoftheservicearea,afeefor
dispatchingthemaintenanceengineerwillbechangedtothecustomer.
Duringthewarrantyperiod,forrepairunderwarrantycarryorsendtheprod-
ucttothelocalsalesrepresentativeorserviceo󰀩ce.Yokogawawillreplaceor
repairanydamagedpartsandreturntheproducttoyou.
Before returning a product for repair under warranty, provide us with the model name and serial
number and a description of the problem. Any diagrams or data explaining the problem would
also be appreciated.
If we replace the product with a new one, we won’t provide you with a repair report.
Inthefollowingcases,customerwillbechargedrepairfeeregardlessofwar-
ranty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 did not
supply.
Failureduetoimproperorinsu󰀩cientmaintenancebyuser.
Failureduetomisoperation,misuseormodicationwhichYokogawadoesnotauthorize.
Failureduetopowersupply(voltage,frequency)beingoutsidespecicationsorabnormal.
Failure caused by any usage out of scope of recommended usage
Anydamagefromre,earthquake,astormandood,lightning,disturbance,riot,warfare,
radiation and other natural changes.
Yokogawadoesnotwarrantconformancewiththespecicapplicationatthe
usersite.
Yokogawawillnotbeardirect/indirectresponsibilityfordamageduetoaspe-
cicapplication.
Yokogawawillnotbearresponsibilitywhentheusercongurestheproduct
intosystemsorresellstheproduct.
Maintenanceserviceandsupplyingrepairpartswillbecoveredforveyears
aftertheproductionends.Forrepairthisproduct,pleasecontactthenearest
saleso󰀩cedescribedinthisinstructionmanual.

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IM 11G02N01-01E
<CONTENTS>
Model IR400
Infrared Gas Analyzer
CONTENTS
IM11G02N01-01E7thEdition
uPREFACE........................................................................................................i
uSafety Precautions......................................................................................iii
uCE marking products ..................................................................................v
uAfter-Sales Warranty...................................................................................vi
1. OVERVIEW................................................................................................ 1-1
1.1 Nameanddescriptionofmainunit................................................................. 1-2
1.2 Input/Outputterminalmodule......................................................................... 1-3
2. SPECIFICATIONS..................................................................................... 2-1
2.1 StandardSpecications................................................................................... 2-1
2.2 ModelandSu󰀩xcodes.................................................................................... 2-6
2.3 ExternalDimensions...................................................................................... 2-13
3. INSTALLATION......................................................................................... 3-1
3.1 Installationconditions...................................................................................... 3-1
3.2 Installation......................................................................................................... 3-2
3.2.1 Installation of analyzer main frame .................................................... 3-2
3.2.2 Mounting input/output terminal module ............................................. 3-3
3.3 Piping................................................................................................................. 3-4
3.4 Sampling............................................................................................................ 3-7
3.4.1 Conditions of sampling gas................................................................ 3-7
3.4.2 Samplinggasow.............................................................................. 3-7
3.4.3 Preparation of standard gas .............................................................. 3-7
3.4.4 Reduction of moisture interference.................................................... 3-7
3.4.5 Purging of instrument inside .............................................................. 3-8
3.4.6 Pressure at sampling gas outlet ........................................................ 3-8
3.4.7 Examplecongurationofgassamplingsystem ................................ 3-9
3.5 Wiring............................................................................................................... 3-10
3.5.1 Power inlet ....................................................................................... 3-10
3.5.2 Input/Output terminal module .......................................................... 3-10
4. OPERATION.............................................................................................. 4-1
4.1 Warm-upoperationandregularoperation..................................................... 4-1
4.2 Nameanddescriptionofoperationpanel...................................................... 4-2
4.3 Overviewofdisplayandoperationpanels..................................................... 4-3
4.4 Outlineofdisplayscreen................................................................................. 4-4

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<CONTENTS>
4.5 Generaloperation............................................................................................. 4-7
5. SETTINGANDCALIBRATION................................................................. 5-1
5.1 Switchofrange................................................................................................. 5-1
5.1.1 Setting of range switch mode............................................................. 5-1
5.1.2 Manual range switch .......................................................................... 5-2
5.2 Calibrationsetting............................................................................................ 5-3
5.2.1 Setting of calibration concentration.................................................... 5-3
5.2.2 Setting of manual zero calibration ..................................................... 5-5
5.2.3 Setting of calibration range ................................................................ 5-7
5.2.4 Setting of auto calibration component/range..................................... 5-9
5.3 Alarmsetting................................................................................................... 5-11
5.3.1 Setting of alarm values .................................................................... 5-11
5.3.2 Hysteresis setting............................................................................. 5-13
5.4 Settingofautocalibration.............................................................................. 5-14
5.4.1 Auto calibration ................................................................................ 5-14
5.4.2 Forced run/stop of auto calibration .................................................. 5-17
5.5 Settingofautozerocalibration..................................................................... 5-20
5.5.1 Auto zero calibration ........................................................................ 5-20
5.5.2 Forced run/stop of auto zero calibration .......................................... 5-22
5.6 Peakalarmsetting.......................................................................................... 5-25
5.7 Parametersetting............................................................................................ 5-27
5.8 Maintenancemode......................................................................................... 5-34
5.9 Calibration....................................................................................................... 5-40
5.9.1 Zero calibration ............................................................................... 5-40
5.9.2 Span calibration ............................................................................... 5-41
6. MAINTENANCE......................................................................................... 6-1
6.1 Dailycheck........................................................................................................ 6-1
6.2 Dailycheckandmaintenanceprocedures..................................................... 6-2
6.3 Maintenanceofanalyzerunit........................................................................... 6-2
6.3.1 Cleaning method for sample cell (pipe cell)....................................... 6-2
6.3.2 Cleaning method for sample cell (block cell) ..................................... 6-4
6.3.3 Optical zero adjustment method (optical balance adjustment) ......... 6-6
6.3.4 Moisture interference compensation adjustment method ................. 6-7
6.3.5 Replacement of fuse on analyzer unit ............................................... 6-8
6.4 Inspectionandmaintenanceoflimitedservice-lifecomponents............... 6-9
7. TROUBLESHOOTING............................................................................. 7-1
7.1 Errormessage................................................................................................... 7-1
7.2 Troubleshooting................................................................................................ 7-3
Revision Information...............................................................................................i

<1. OVERVIEW> 1-1
IM 11G02N01-01E
1. OVERVIEW
This infrared gas analyzer (type: IR400) measures the concentration of NO, SO2, CO2, CO and
CH4containedinsamplinggasontheprinciplethatdi󰀨erentatomicmoleculeshaveanabsorption
spectrum in the wave band of infrared rays, and the intensity of absorption is determined by the
Lambert-Beer law.
Since this instrument incorporates a compact paramagnetic O2sensor, it allows measuring up to
5 components simultaneously by using the built-in O2sensor (up to 4 components if O2sensor is
excluded).
Furthermore, use of a microprocessor or large sized liquid crystal display realizes improvement of
operability, accuracy and multi-functions.
This instrument is optimum for measuring combustible gas exhausted from boilers or incinerators, and
itise󰀨ectiveforsteelgasanalysis(blastfurnace,steelconverter,thermaltreatmentfurnace,sintering
(Pellet equipment), coke furnace), storage and maturity of vegetable and fruit, biochemistry (microbe),
[fermentation], air pollution [incinerator, exhaust gas desulfurization, denitration], automotive emission
(excluding tester), protection against disasters [detection of explosive gas and toxic gas, combustion
gasanalysisofnewbuildingmaterial],growthofplants,chemicalanalysis[petroleumreneryplant,
petroleum chemistry plant, gas generation plant], environment [landing concentration, tunnel
concentration, parking lot, building management] and various physical and chemical experiments.