YOKOGAWA av550g User manual

User’s
Manual Model AV550G
Zirconia Oxygen Analyzer
Averaging Converter
IM 11M12D01-01E
IM 11M12D01-01E
7th Edition

i
IM 11M12D01-01E
<Introduction>
Introduction
The EXAxt Series AV550G Zirconia Oxygen Analyzer Averaging Converter is designed for oxygen
measurement at multiple points in ue ducts of industrial furnaces and can be used to optimize the
combustion process. For the AV550G system, various types of EXAxt ZR Series detectors as well as
optional accessories are available. The best measurement can be achieved by selecting instruments
appropriate to your application.
This manual provides information, such as installation, operation, inspection and maintenance
procedures, about the instruments used in the AV550G averaging converter measurement system.
Any sections concerning instruments not included in your system may be skipped.
Before using the instruments, read any descriptions related to your instruments and system to ensure
the best performance.
Regarding the HART communication, refer to IM 11M12D01-51E. IM 11M12D01-51E has been
published as “Model EXAxt AV550G HART protocol.”
Regarding the FOUNDATION Fieldbus communication, refer to IM 11M12D01-61E.
IM 11M12D01-61E has been published as “Model EXAxt AV550G Fieldbus communication.”
The models and description items in this manual are as follows:
Models and descriptions in this manual
Model Product Name Description in this manual
Specication Installation Operation Maintenance CMPL
ZR22G General-purpose detector     
ZR22G High temperature detector (0.15m)    
AV550G Averaging Converter     
ZO21R Probe protector  
ZO21P High temperature probe adapter   
ZA8F Flow setting unit
(for manual calibration use)   
–Auxiliary ejector assembly for high
temperature use
(Part No. E7046EC, E7046EN)
  
–Calibration gas unit case
(Part No. E7044KF)  
–Check valve
(Part No. K9292DN, K9292DS)  
–Dust lter for the detector
(Part No. K9471UA)  
–Dust guard protector
(Part No. K9471UC)  
CMPL : Customer Maintenance Parts List
Media No. IM 11M12D01-01E 7th Edition :May 2017 (YK)
All Rights Reserved Copyright © 2004, Yokogawa Electric Corporation

ii
IM 11M12D01-01E
<Introduction>
The related documents are as follows:
Model Title Manual No.
AV550G Model AV550G Zirconia Oxygen Analyzer
Averaging Converter
GS 11M12D01-01E
AV550G Model AV550G Zirconia Oxygen Analyzer
Averaging Converter
IM 11M12D01-01E (this manual)
AV550G-x-xx-x-x-E Model EXAxt AV550G HART Protocol IM 11M12D01-51E
AV550G-x-xx-x-x-F Model EXAxt AV550G Fieldbus
Communication Type
IM 11M12D01-61E
ZR22G Model ZR22G, ZR402G Zirconia Oxygen/
Humidity Analyzer
IM 11M12A01-02E
ZR22S Model ZR22S, ZR402G Separate type
Explosion-proof Zirconia Oxygen Analyzer
IM 11M13A01-02E
The “E” or “EN” in the document number is the language code.
An exclusive User’s Manual might be attached to the products whose sufx codes or option codes
contain the code “Z” (made to customers’ specications). Please read it along with this manual.
This manual consists of twelve chapters. Please refer to the reference chapters for installation,
operation and maintenance.
Table of Contents
Chapter Outline Release to
Installation Operation Maintenance
1. Overview Equipment models and system conguration
examples 
2. Specications Standard specication, 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
congurations 
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 AV550G.
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
Maintenance
How to conduct maintenance of AV550G and
procedures 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 
: 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.

iii
IM 11M12D01-01E
<Introduction>
For the safe use of this equipment
WARNING
The AV550G is very heavy. Handle it with care. Be sure not to accidentally drop it. Handle safely to
avoid injury. When carrying the AV550G Averaging Converter, make sure this is done by two or more
people.
Connect the power supply cord only after conrming that the supply voltage matches the rating of this
equipment. In addition, conrm 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.
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 installing 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 sample gas
may damage the sensor.
• The detector (especially at the tip) becomes very hot. Be sure to handle it with gloves.
(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 ofce.
• This manual does not cover the special specications. This manual may not be changed on any
change of specication, 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 specied in this manual, the safety of this product may be
impaired.

iv
IM 11M12D01-01E
<Introduction>
(2) Safety and Modication Precautions
• Follow the safety precautions in this manual when using the product to ensure protection 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.
WARNING
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.
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.
NOTE
This symbol draws attention to information essential for understanding the operation and functions.
NOTICE
l Specication 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 specication matches the
order, and required accessories are not missing. Specications can be checked by the model codes
on the nameplate. Refer to Chapter 2 Specications for the list of model codes.
lDetails on operation parameters
When the AV550G Averaging Converter arrives at the user site, it will operate based on the operation
parameters (initial data) set before 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.
lProduct Disposal:
The instrument should be disposed of in accordance with local and national legislation/regulations.

v
IM 11M12D01-01E
<Introduction>
 CE marking products
nAuthorized 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.
nHow to dispose the batteries:
This is an explanation about the new EU Battery Directive (DIRECTIVE 2006/66/EC). 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.of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/EC.

vi
IM 11M12D01-01E
<Introduction>
After-Sales Warranty
nDo not modify the product.
n Yokogawa warrants the product for the period stated in the pre-purchase
quotation. Yokogawa shall conduct dened warranty service based on its
standard.
nDuring the warranty period, for repair under warranty carry or send the
product to the local sales representative or service ofce. Yokogawa will
replace or repair any damaged parts and return the product to you.
l 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.
l If we replace the product with a new one, we won’t provide you with a repair report.
nIn the following cases, customer will be charged repair fee regardless of
warranty period.
l Failure of components which are out of scope of warranty stated in instruction manual.
l Failure caused by usage of software, hardware or auxiliary equipment, which Yokogawa did not
supply.
l Failure due to improper or insufcient maintenance by user.
l Failure due to modication, misuse or outside-of-specications operation which Yokogawa does
not authorize.
l Failure due to power supply (voltage, frequency) being outside specications or abnormal.
l Failure caused by any usage out of scope of recommended usage.
l 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 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 ofce described in this instruction manual.

Toc-1
IM 11M12D01-01E
<CONTENTS>
Model AV550G
Zirconia Oxygen Analyzer Averaging Converter
CONTENTS
IM 11M12D01-01E 7th Edition
Introduction ..............................................................................................................i
1. Overview.................................................................................................... 1-1
1.1 System Conguration ...................................................................................... 1-1
1.1.1
System Conguration Using Flow Setting Units for Manual Calibration ...... 1-1
1.1.2 System Conguration to Perform Automatic Calibration ................... 1-2
1.2 System Components ........................................................................................ 1-3
1.2.1 System Components and Their Applicability ..................................... 1-3
1.2.2 Detectors and Accessories ................................................................ 1-3
2. Specications ........................................................................................... 2-1
2.1 General Specications..................................................................................... 2-1
2.2 General-purpose Separate type Detector and Related Equipment............. 2-2
2.2.1 ZR22G General-purpose Separate type Detector ............................ 2-2
2.2.2 ZO21R Probe Protector ..................................................................... 2-7
2.3 Separate type Detector for High Temperature and Related Equipment ..... 2-8
2.3.1 ZR22G (0.15m) Separate type Detector for High Temperature ........ 2-8
2.3.2 ZO21P High Temperature Probe Adapter ......................................... 2-9
2.4 AV550G Averaging Converter........................................................................ 2-11
2.4.1 Standard Specications ................................................................... 2-11
2.4.2 Functions.......................................................................................... 2-12
2.5 ZA8F Flow Setting Unit................................................................................... 2-18
2.6 Other Equipments........................................................................................... 2-20
2.6.1 Dust Filter for the Detector (K9471UA) ............................................ 2-20
2.6.2 Dust Guard Protector (K9471UC) ....................................................2-20
2.6.3 Ejector Assembly for High Temperature (E7046EC, E7046EN) ..... 2-21
2.6.4 Stop Valve (L9852CB, G7016XH) ................................................... 2-23
2.6.5 Check Valve (K9292DN, K9292DS) ................................................2-23
2.6.6 Air Set ...............................................................................................2-24
2.6.7 Zero Gas Cylinder (G7001ZC) ........................................................2-25
2.6.8 Cylinder Pressure Reducing Valve (G7013XF, G7014XF) ..............2-25
2.6.9 Case Assembly for Calibration Gas Cylinder (E7044KF) ................ 2-26
2.6.10 ZR22A Heater Assembly.................................................................. 2-26
3. Installation................................................................................................. 3-1
3.1 Installation of General-purpose Detector....................................................... 3-1

Toc-2
IM 11M12D01-01E
<CONTENTS>
3.1.1 Installation 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 (K9471UA), Dust Guard Protector
(K9471UC), Probe Protector ZO21R ................................................. 3-3
3.2 Installation of High Temperature Detector
(ZR22G-015)....................................................................................................... 3-5
3.2.1 Installation Location ........................................................................... 3-5
3.2.2 Usage of the High Temperature Probe Adapter (ZO21P) ................. 3-5
3.2.3 Probe Insertion Hole .......................................................................... 3-6
3.2.4 Mounting of the High Temperature Detector ...................................... 3-6
3.3 Installation of the Averaging Converter.......................................................... 3-8
3.3.1 Installation Location ........................................................................... 3-8
3.3.2 Installation in an Instrument Panel ..................................................... 3-9
3.3.3 Outdoor Installation .......................................................................... 3-10
3.4 Installation of ZA8F Flow Setting Unit .......................................................... 3-11
3.4.1 Installation Location ......................................................................... 3-11
3.4.2 Mounting of ZA8F Flow Setting Unit ................................................ 3-11
3.5 Installation of the Case Assembly(E7044KF) .............................................. 3-12
3.5.1 Installation Location .........................................................................3-12
3.5.2 Mounting ..........................................................................................3-12
4. Piping......................................................................................................... 4-1
4.1 Piping for a System Using Flow Setting Units for Manual Calibration ...... 4-1
4.1.1 Parts Required for Piping in a System Using Flow Setting Units for
Manual Calibration ............................................................................. 4-2
4.1.2 Piping for the Calibration Gas Inlet .................................................... 4-3
4.1.3 Piping for the Reference Gas Inlet ..................................................... 4-3
4.1.4 Piping to the High Temperature Probe Adapter ................................. 4-3
4.1.5 Piping for Blow back........................................................................... 4-5
4.1.6 Piping for Indication check ................................................................. 4-6
4.1.7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs 4-7
4.2
Piping for a System to Perform Automatic Calibration .........................................4-8
4.2.1 Parts Required for Piping in a System to Perform Automatic Calibration ... 4-10
4.2.2 Piping for the Calibration Gases ...................................................... 4-11
4.2.3 Piping for the Reference Gas........................................................... 4-11
4.2.4 Piping to the High Temperature Probe Adapter ...............................4-12
4.2.5 Piping for Blow back.........................................................................4-12
4.2.6 Piping for Indication Check .............................................................. 4-12
4.2.7
Piping to Introduce Purge Gas When a Process Gas Alarm Occurs 4-13
5. Wiring......................................................................................................... 5-1
5.1 General............................................................................................................... 5-1
5.1.1 Wiring Precautions ............................................................................. 5-1
5.1.2 Wiring Holes ....................................................................................... 5-3

Toc-3
IM 11M12D01-01E
<CONTENTS>
5.1.3 External Wiring Connection Terminals of the Averaging Converter .. 5-3
5.1.4 Types of Wiring and Cables ............................................................... 5-4
5.2 Wiring for the Averaging Converter and Peripheral Devices....................... 5-5
5.2.1 Preparation for Wiring to the Averaging Converter ............................ 5-5
5.2.2 Preparation for Wiring to Detectors ................................................... 5-5
5.2.3 Power and Ground Wiring ................................................................. 5-6
5.2.4 Power Wiring to Detector Heaters ..................................................... 5-7
5.2.5 Signal Wiring to Detectors ................................................................. 5-8
5.2.6 Ground Wiring of Detectors ............................................................... 5-9
5.2.7 Wiring for Individual and Average Concentration Analog Outputs .... 5-9
5.2.8 Wiring for Solenoid Valve for Automatic Calibration ........................5-10
5.2.9 Wiring for Individual/Common Error Contact Outputs and Functional
Contact Outputs ............................................................................... 5-11
5.2.10 Wiring for Contact Inputs ................................................................. 5-12
5.3 Wiring and Piping Examples ......................................................................... 5-13
5.3.1 Wiring and Piping for Automatic Calibration .................................... 5-13
5.3.2
Wiring and Piping for Automatic Calibration and 3rd Gas Indication Check .. 5-13
5.3.3 Wiring and Piping for Blow back ......................................................5-14
5.3.4 Wiring and Piping for Automatic Calibration and Blow back ............ 5-14
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 AV550G Averaging Converter.......................................................................... 6-3
6.2.1 Components and Function ................................................................6-3
6.2.2 Touchpanel Switch Operations .......................................................... 6-3
6.3 ZA8F Flow Setting Unit................................................................................... 6-12
7. Startup ....................................................................................................... 7-1
7.1 Startup Procedure............................................................................................. 7-1
7.2 Check Piping and Wiring.................................................................................. 7-1
7.3 Set Valve Type ................................................................................................... 7-2
7.4 Setting Detector Model..................................................................................... 7-2
7.5 Supply Power to Averaging Converter ........................................................... 7-4
7.6 Selection of Gas to be Measured .................................................................... 7-5
7.7 Current Output Range Setting......................................................................... 7-5
7.8 Averaging Group Setting ................................................................................. 7-6
7.9 Calibration ......................................................................................................... 7-7
7.9.1 Setting Calibration Gas Concentration .............................................. 7-7
7.9.2 Performing Manual Calibration .......................................................... 7-8
7.10 Analog Output Current Loop Check ............................................................. 7-10
7.11 Checking Operation of Contact Input, Contact Output .............................. 7-11
7.11.1 Contact Output Operation Check .................................................... 7-11