YOKOGAWA OX100 User manual

User’s
Manual OX100
General-Purpose Oxygen Analyzer
IM 11M10A01-01E
IM 11M10A01-01E
4th Edition

i
IM 11M10A01-01E
uSafety Precautions
n Safety,Protection,andModicationoftheProduct
• 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 liability 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.
nWarning and Disclaimer
The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor
responsibility to any person or entity with respect to any direct or indirect loss or damage arising
from using the product or any defect of the product that YOKOGAWA can not predict in advance.
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
manuals 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
particular 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
contact our sales representative or your local distributor.
Media No. IM 11M10A01-01E 4th Edition : Oct. 2019 (YK)
All Rights Reserved Copyright © 2000, Yokogawa Electric Corporation
4th Edition : Oct. 23, 2019-00

ii
IM 11M10A01-01E-
WARNING
 Hightemperature,takecare
When the sensor is powered on, the sensor tip gets very hot. Be careful not to touch it.
4-20mA
ENT.
%
ppm
FAILALM
1000ppmAIR
MODE
SET
Caution: Sensor is HOT
F1.EPS
Power
Be sure to check the power supply voltage before turning on the power.
Grounding
Be sure to connect a Class D (100 or less) ground before turning on the power, to minimize the
possibility of shock.
Need for Grounding
Do not cut the internal or external protective ground wire, or remove the ground wire from the
terminal. This creates a shock hazard.
DonotOperatewithoutProtectiveGroundingandFuse
Do not operate the instrument without protective grounding and correct fuse.
Fuse
For safety, this product is fused internally. It is recommended that you ask the local service
representative to change the fuse; do not either change it yourself, or open the case to check the
fuse.Turno󰀨thepowerswitchanddisconnecttheinstrumentfromthepowerbeforechanging
thefuse.Donotuseafuseofdi󰀨erenttypeorsize,orshortcircuitthefuseholder.
EnvironmentalRestrictions
Danger:Donotusethisinstrumentinaammable,explosive,orsteamyenvironment.Donottry
to measure gases with traces of redox gas, corrosive gas, or organic silicone gas.
Keep Hands Out
While voltage is applied, keep hands out. Internal parts should be replaced by our service
representative, or by an authorized person.
External Connections
Before wiring, to minimize the possibility of shock, disconnect power from the instrument.
Also check ground connection to this instrument, to the system being measured, and to any
associated external control equipment.
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IM 11M10A01-01E
uAfter-sales Warranty
nDonotmodifytheproduct.
nDuringthewarrantyperiod,forrepairunderwarranty,carryorsendtheproduct
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.
• Yokogawa warrants the product for the period stated in the pre-purchase quotation
Yokogawashallconductdenedwarrantyservicebasedonitsstandard.Whenthe
customer site is located outside of the service area, a fee for dispatching the maintenance
engineer will be charged to the customer.
nIn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 did not supply.
• Failureduetoimproperorinsu󰀩cientmaintenancebyuser.
• Failureduetomodication,misuseoroutside-of-specicationsoperation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,stormsandoods,lightning,disturbances,riots,warfare,
radiation and other natural changes.
n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specicapplication.
nYokogawaElectricwillnotbearresponsibilitywhentheuserconguresthe
productintosystemsorresellstheproduct.
nMaintenanceserviceandsupplyingrepairpartswillbecoveredforveyears
aftertheproductionends.Forrepairforthisproduct,pleasecontactthe
nearestsaleso󰀩cedescribedinthisinstructionmanual.
uNotes on Use
• Donotdroporjolttheequipment,oritsaccuracymaybeadverselya󰀨ected.
• Do not attempt to disassemble the equipment, or it may malfunction.
• As far as possible, install the equipment horizontally. The sensor should be installed
securely so that it does not vibrate. Avoid installing the equipment in places where the
temperature exceeds 70°C.
• Avoid installing the equipment where it would be exposed to direct sunlight, radiant heat,
or the weather, and where vibration exists.
• Avoid installing the equipment in atmospheres containing corrosive gases, gas atmos-
pheres out of measuring scope, or atmospheres where the sensor is exposed to silicone
vapor.
4th Edition : Oct. 23, 2019-00

iv
IM 11M10A01-01E-
• Keep the equipment away from noise-generating devices to minimize the possibility of
malfunction, although it is designed to cope with noise.
• The sensor has a limited life, which varies depending on operating conditions. It is
strongly recommended that you replace the sensor once a year from a preventive main-
tenance standpoint, even if sensor deterioration is not observed.
• Keep this instruction manual handy for your quick reference during operation and main-
tenance.
uRestrictions on Use
• Donotusetheequipmentinatmospherescontainingcombustible,corrosive,oruegases,
or organic compounds.
• Ifitisusedinsilicongasatmospheres,inowfurnacesornitrogenreowfurnaces,the
equipment must be used in the following system:
• The sampling unit, K9424GA, must be used.
• The sampling unit requires appropriate maintenance, which is determined by gas
conditions. Filters and activated carbon packs should be replaced at intervals which depend
on the operating conditions.
For best measurement, use new activated carbon packs. Using expired packs may result in
invalid measurement results, or even sensor deterioration.
• If you have any questions, please contact your Yokogawa representative.
uHowtoUseThisManual
The structure of this manual is as shown in the table below. This table shows which chapters you
are recommended to read when performing the corresponding tasks.
Chapter to refer to:Unpacking
installation
Initial
setting
Daily
operation
Changing
settings
Maintenance
Maintenance
troubleshooting
Chapter 1. Overview
Chapter 2. Installation
Chapter 3. Operation
Chapter 4. Troubleshooting
Appendix 1. Sampling Unit
Appendix 2. Calibration Gas Kits
Safety precautions
CMPL (Parts List)
: Read and completely understand before operating the equipment.
: Read before operating the equipment, and refer to it whenever necessary.
4th Edition : Oct. 23, 2019-00

Toc-1
IM 11M10A01-01E
OX100
General-Purpose Oxygen Analyzer
CONTENTS
IM11M10A01-01E4thEdition
uSafety Precautions........................................................................................i
1. Overview.................................................................................................... 1-1
1.1 CautionsRegardingUse.................................................................................. 1-1
1.2 StandardSpecications................................................................................... 1-1
1.3 ModelandSu󰀩xCodes................................................................................... 1-3
1.4 ExternalDimensions........................................................................................ 1-4
1.5 SensorOperatingPrinciples........................................................................... 1-6
2. Installation................................................................................................. 2-1
2.1 NamesandFunctionsofParts........................................................................ 2-1
2.1.1 Sensor................................................................................................ 2-1
2.1.2 Instrument Body................................................................................. 2-1
2.2 InstallationLocationfortheInstrument......................................................... 2-4
2.3 InstallingtheInstrument.................................................................................. 2-5
2.4 Wiring................................................................................................................. 2-6
2.4.1 Power Wiring...................................................................................... 2-6
2.4.2 Connecting to an External Instrument ............................................... 2-7
2.5 InstallationofSensor....................................................................................... 2-7
2.6 InstallingtheOptionalSamplingUnit(K9424GA)....................................................... 2-8
2.7 CalibrationKit(Optional)............................................................................... 2-10
3. Operation................................................................................................... 3-1
3.1 Calibration......................................................................................................... 3-1
3.1.1 One-point Calibration in Atmospheric Air (Span Calibration)........................ 3-1
3.1.2 When Measuring on 0 to 1000 ppm O2Range.................................. 3-2
3.1.3 Setting Error Display .......................................................................... 3-2
3.2 AlarmSetting..................................................................................................... 3-3
3.3 AlarmsandAlarmOutput................................................................................ 3-3
3.4 Setting4to20mADCOutput.......................................................................... 3-3
4. Troubleshooting....................................................................................... 4-1
uAppendix1.SamplingUnit....................................................................... App.-1
1. Specications..............................................................................................App.-1
2. Installation...................................................................................................App.-2
3. OperatingProcedures................................................................................App.-3
uAppendix2.CalibrationGasKits............................................................. App.-5
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IM 11M10A01-01E
1. ConnectingtheNeedleValveAssemblytotheGasCylinder................App.-5
2. SupplyingtheCalibrationGas..................................................................App.-6
3. StoppingSupplyingtheCalibrationGas..................................................App.-6
CustomerMaintenancePartsList......................................CMPL11M10A01-01E
RevisionInformation...............................................................................................i
4th Edition : Oct. 23, 2019-00

<1. Overview>1-1
IM 11M10A01-01E
1. Overview
1.1 CautionsRegardingUse
CAUTION
· This is a precision instrument; be careful not to drop it.
· Do not disassemble it, as it may stop operating normally.
· As far as possible, mount horizontally. Secure the sensor so that it can’t vibrate. Avoid
installing in places where the temperature exceeds 70°C.
· Do not mount this instrument in a place that is exposed to direct sunlight, or to direct
radiation from a furnace, boiler or the like, in a windy place, or in a location that is subject to
vibration.
· Avoid mounting in a location where there may be corrosive gases, gases other than the
measured gas, or organic silicon vapor.
· Wherethefurnacegasofanitrogenreowfurnacecontainsorganicsolventatafewppmto
percentage level, the sensor should be used with the optional sampling system (K9424GA),
to avoid contact with the solvent.
· This instrument was designed to be resistant to electrical noise, but to avoid invalid readings
it would be wise to avoid using electrically noisy devices in the vicinity.
· The sensor is a consumable. Its life depends on usage and environment, but is about one
year.
· Be sure to keep this manual in a handy place when using this instrument.
1.2 StandardSpecications
Measured gas: Measures O2in N2or mixed gases; can’t contain silicone vapor,
ammablegasororganicsolvent.
Measuring principle: Current-limited Zirconia sensor
Measuring range: 0 to 1000 ppm O2, 0.1 to 25% O2(measuring range autoswitching)
Note: If you want an oxygen (concentration) control range of 0.2 to 0.5%,please consult with us, or your Yokogawa
salesperson or representative.
Samplingmethod: Naturaldi󰀨usion(directinput)
Linearity : ±5% of span (for 0-1000 ppm range, with O2being in the range 0 to 100
ppm). ±3% of span (for 0-1000 ppm range, with O2being in the range
100 to 1000 ppm). ±2% of span (for 0.1 to 25% range, with O2being in
the range 100 to 1000 ppm).
Repeatability : ±5% of span (for 0-1000 ppm range, withO2being in the range 0 to 100
ppm). ±2% of span (for 0-1000 ppm range, with O2being in the range
100 to 1000 ppm). ±2% of span (for 0.1 to 25% range, with O2being in
the range 100 to 1000 ppm).
Stability (Drift): ±2% of span per week.
Display: LED digital display
Output signal: 4-20 mA DC isolated (measuring range: 0 to 1000 ppm or 0.1 to 25%).
Contact outputs (relay) : Closed if fail, contact rating 250 V AC / 3A
Closed if alarm, contact rating 250 V AC / 3A.
4th Edition : Oct. 23, 2019-00

<1. Overview>1-2
IM 11M10A01-01E
Operating temperature range: Sensor 0 to 250°C (within 5 cm of tip, the rest 0 to 70°C )
Converter 0 to 50°C
Measurementgasconditions:  Atmosphericpressure,temperature0to70°C,gasow
up to 1 m/s, no corrosive gases like SO2(can’t be used
inatmospherewithammablegases,corrosivegases,
or silicone vapor.
Power consumption: up to 15 VA.
Power supply : 100 V AC ±10% 50/60 Hz.
Weight : Body approx. 600 g, sensor approx 150 g.
Accessories : Oxygen sensor assembly (1), nipple (1), bracket (2),
extension cable(1), instruction manual (1), warranty
CARD (1)
4th Edition : Oct. 23, 2019-00

<1. Overview>1-3
IM 11M10A01-01E
1.3 ModelandSu󰀩xCodes
• OX100 Current limited Zirconia Oxygen Analyzer
Model Su󰀩xCode Option code Specications
OX100 ............................ ...................... General purpose Oxygen analyzer
Application -1
-2
-3
......................
......................
......................
Oxygenanalyzer(Can’tuseanactivatedcarbonlter)*1
For (N2)reowfurnace(Specifyincaseofusinganactivated
carbonlter)*1
MonitoringfordeciencyofOxygenwithlowalam,Measuring
range 0-25%
Measuring Range 1...................... 0-1000 ppm/ 0-25% O2
Power Supply 5...................... 100 V AC ±10%, 50/60 Hz
Sensor 1
N
......................
......................
Sensor assy. cable 3m + extension 2 m
No sensor assembly
Manual E
J
......................
......................
English
Japanese
L9811LA plastic resin sensor holder is provided as standard accessory.
*1Formeasurementintherangeof1500to4500ppm,usetheOX102.
•Samplingunit,calibrationkit
Part Number Specications
K9424GA Sampling unit
K9424JA Calibrationkit:Six1-literasks,1000ppmO2/N2gasoutletcock(withowadjuster)
K9424JB Calibrationkit:Six1-literasks,1000ppmO2/N2gasoutletcock(withoutowadjuster)
K9424JR Calibrationkit:Six1-literasks,10000ppmO2/N2gasoutletcock(withowadjuster)
K9424JS Calibrationkit:Six1-literasks,10000ppmO2/N2gasoutletcock(withoutowadjuster)
•Accessories
Part Number Specications
K9346WM Activatedcarbonelement,veperpack:forsamplingunit
K9424JC Gasoutletcock(withowadjuster):qty.one
K9424JD Gasoutletcock(withoutowadjuster):qty.one
K9424JP Standard gas cylinder (1000 ppm O2/N2): qty. six
K9424JQ Standard gas cylinder (10000 ppm O2/N2): qty. six
K9424BA Sensorassy.cable3mforOX100only
K9424CA Extensioncable,2m:forOX100only
B9877BA BracketformountingOX100,twoperset.
K9424DB Sensorholder(metal)forOX100orOX102
L9811LA Sensorholder(plastic)forOX100orOX102
K9424GQ Disklter
K9424WH Feltlter
4th Edition : Oct. 23, 2019-00