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

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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.

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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.

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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.

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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.

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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.

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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

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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

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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

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IM 11M12D01-01E
<CONTENTS>
7.11.2 Checking contacts used to operate solenoid valves during automatic
calibration ......................................................................................... 7-12
7.11.3 Checking Contact Inputs .................................................................. 7-12
8. Setting Operating Parameters - Detail, and Examples......................... 8-1
8.1 Setting Analog Outputs.................................................................................... 8-1
8.1.1 Analog Output Range (Per-Channel) ................................................ 8-1
8.1.2 Setting Output Hold (Applies to All Outputs) ...................................... 8-3
8.1.3
Setting Output Smoothing Coefcient (Applies to All Analog Outputs) . 8-7
8.1.4 Setting Output Mode (Applies to All Analog Outputs) ........................ 8-7
8.2 Setting Oxygen Concentration Alarms........................................................... 8-8
8.2.1 Setting the Alarm Values (Individual Settings) ................................... 8-8
8.2.2 Alarm Delay Time and Hysteresis (Applies to All Alarm Settings) ..... 8-8
8.3 Setting Contact Outputs................................................................................. 8-11
8.4 Setting Contact Inputs.................................................................................... 8-13
8.5 Other Settings ................................................................................................. 8-14
8.5.1 Date and Time .................................................................................. 8-14
8.5.2 Average Value / Max. and Min. Monitoring Time ............................. 8-14
8.5.3
“Fuel” Setup: Humid Exhaust Gas or “Dry” Equivalent Oxygen Content .... 8-15
8.5.4 Setting Password ............................................................................. 8-20
9. Calibration................................................................................................. 9-1
9.1 Calibration Briefs .............................................................................................. 9-1
9.1.1 Principle of Measurement .................................................................. 9-1
9.1.2 Calibration Gas .................................................................................. 9-2
9.1.3 Compensation .................................................................................... 9-3
9.1.4 Characteristic Data from a Sensor Measured During Calibration ..... 9-4
9.2 Calibration Setup .............................................................................................. 9-4
9.2.1 Mode .................................................................................................. 9-4
9.2.2 Calibration Setup Procedure.............................................................. 9-5
9.2.3 Zero Gas Concentration .................................................................... 9-5
9.2.4 Span Gas Concentration ................................................................... 9-6
9.2.5 Calibration Time Setting ..................................................................... 9-6
9.3 Performing Calibration..................................................................................... 9-9
9.3.1 Performing Manual Calibration .......................................................... 9-9
9.3.2 Semi-Automatic Calibration ............................................................... 9-9
9.3.3 Starting Automatic Calibration ......................................................... 9-10
10. Other Functions...................................................................................... 10-1
10.1 Display.............................................................................................................. 10-1
10.1.1 Cell Voltage ......................................................................................10-1
10.1.2 Thermocouple Voltage ..................................................................... 10-1
10.1.3 Cold Junction Resistance (C.J. Voltage) .........................................10-2
10.1.4 Cell temperature .............................................................................. 10-2
10.1.5 C. J. Temperature.............................................................................10-2

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<CONTENTS>
10.1.6 Span gas and Zero gas Correction Ratios ......................................10-2
10.1.7 Cell Response Time .........................................................................10-3
10.1.8 Robustness of a Cell ........................................................................ 10-3
10.1.9 Cell’s Internal Resistance ................................................................ 10-3
10.1.10 Recommended Next Calibration Date ..............................................10-4
10.1.11 Heater ON-Time Ratio ....................................................................... 10-4
10.1.12 Time ................................................................................................... 10-4
10.1.13 Ch. card Rev., Ctrl. card Rev. ............................................................ 10-4
10.1.14 Maximum Oxygen Concentration ..................................................... 10-5
10.1.15 Minimum Oxygen Concentration ...................................................... 10-5
10.1.16 Average Oxygen Concentration ........................................................ 10-5
10.1.17 History of Calibration Time ................................................................ 10-5
10.1.18 Internal Temperature Alarm Logging ................................................. 10-5
10.2 Trend Graphs................................................................................................... 10-6
10.2.1 Trend Graph Screen ........................................................................ 10-6
10.2.2 Time Axis of Trend Graph ................................................................ 10-7
10.2.3 Trend Graph Display Settings .......................................................... 10-7
10.3 Other Display-related Functions................................................................... 10-9
10.3.1 Auto-return Time ..............................................................................10-9
10.3.2 Selecting Language .........................................................................10-9
10.3.3 LCD Auto Off ..................................................................................10-10
10.3.4 Display Contrast Adjustment..........................................................10-10
10.3.5 Tag Name Entry .............................................................................10-10
10.4 Indication Check ........................................................................................... 10-11
10.4.1 Mode .............................................................................................. 10-11
10.4.2 Procedure for Performing an Indication Check .............................10-12
10.4.3 Setting Contacts for Operating Third Check Gas Solenoid Valve . 10-12
10.4.4 Setting Indication Check Timing .................................................... 10-13
10.4.5 Running an Indication Check .........................................................10-15
10.5 Blow back ...................................................................................................... 10-19
10.5.1 Mode ..............................................................................................10-19
10.5.2 Setting Contacts for Operating Solenoid Valves............................10-20
10.5.3 Setting Blow back Start Time ......................................................... 10-21
10.5.4 Operation of Blow back .................................................................. 10-22
10.5.5 Performing Blow back ....................................................................10-23
10.6 Purging........................................................................................................... 10-24
10.7 Parameter Initialization.................................................................................10-26
10.8 Methods of Operating Valves in the ZA8F Flow Setting Unit...................10-29
10.8.1 Preparation Before Calibration ......................................................10-29
10.8.2 Operating the Span Gas Flow Setting Valve .................................10-29
10.8.3 Operating the Zero Gas Flow Setting Valve .................................. 10-30
10.8.4 Operation After Calibration ............................................................10-30

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IM 11M12D01-01E
<CONTENTS>
11. Inspection and Maintenance................................................................. 11-1
11.1 Removing and Attaching the Front Cover ................................................... 11-2
11.1.1 Removing the Front Cover ............................................................... 11-2
11.1.2 Attaching the Front Cover ................................................................ 11-2
11.2 Hot Swap Function ......................................................................................... 11-2
11.3 Inspection and Maintenance of the Detector............................................... 11-4
11.3.1 Cleaning the Filter in Sensor Assembly ........................................... 11-4
11.3.2 Cleaning the Calibration Gas Tube .................................................. 11-4
11.3.3 Replacing the Sensor Assembly ...................................................... 11-4
11.3.4 Replacement of the Heater Unit ...................................................... 11-7
11.3.5 Replacement of Dust Filter .............................................................. 11-9
11.3.6 Replacement of O-ring ................................................................... 11-10
11.3.7 Cleaning the High Temperature Probe Adapter ............................. 11-10
11.3.8 Stopping and Re-starting Operation ...............................................11-11
11.4 Inspection and Maintenance of the Averaging Converter........................ 11-12
11.4.1 Fuse Replacement ......................................................................... 11-12
11.4.2 Cleaning ......................................................................................... 11-13
11.5 Adding Channel Cards ................................................................................. 11-14
11.6 Adding the Expansion Power Supply Unit................................................. 11-15
11.7 Replacing Limited Life Components .......................................................... 11-16
12. Troubleshooting ..................................................................................... 12-1
12.1 Displays and Remedies When Errors Occur ............................................... 12-1
12.1.1 Error Types ....................................................................................... 12-1
12.1.2 Operations When an Error Occurs .................................................. 12-1
12.1.3 Error Displays...................................................................................12-2
12.1.4 Remedies When an Error Occurs .................................................... 12-3
12.2 Displays and Remedies When Alarms are Generated................................ 12-6
12.2.1 Alarm Types ..................................................................................... 12-6
12.2.2 Alarm Displays ................................................................................. 12-7
12.2.3 Remedies when Alarms are Generated .......................................... 12-7
12.3 Countermeasures When Measured Value Shows Error........................... 12-14
12.3.1 Measured Value Higher Than True Value ...................................... 12-14
12.3.2 Measured Value Lower Than True Value ......................................12-15
12.3.3 Measurements Sometimes Show Abnormal Values .....................12-15
Customer Maintenance Parts List......................................CMPL 11M12D01-01E
Customer Maintenance Parts List......................................CMPL 11M12A01-02E
Customer Maintenance Parts List......................................CMPL 11M06B02-01E
Customer Maintenance Parts List......................................CMPL 11M03B01-10E
Customer Maintenance Parts List......................................CMPL 11M03B01-05E
Revision Information ...............................................................................................i

< 1. Overview > 1-1
IM 11M12D01-01E
1. Overview
Zirconia oxygen analyzers are used in combustion facilities to measure the ue gas oxygen
concentration. Boiler operators use the oxygen measurement to optimize fuel usage, minimize
atmospheric emissions and reduce energy consumption.
A multiple point oxygen measurement system may be required for situations when gas stratication
in the ue duct affects combustion control. The AV550G Averaging Converter can accept inputs from
up to eight zirconia oxygen detectors. It sends output signals for the individual as well as averages of
multiple oxygen concentrations. A robust multipoint converter reduces installation and maintenance
costs.
A large 5.7-inch color LCD display shows various measurement, setup, calibration, and trend screens.
Its intuitive touch screen is easy to read and makes set up and maintenance simple. Other standard
features include new self-diagnostics and a hot swap function that allows a desired probe to be
disconnected/reconnected for inspection or maintenance just by turning off the power of the relevant
channel.
The ZR22G separate type detector uses a highly reliable zirconia sensor and its heater assembly
can be replaced in the eld. The in situ probe is mounted on the duct wall and directly measures
the oxygen concentration of a sample gas at a temperature of up to 700°C. For higher temperature
applications up to 1400°C, the ZO21P High Temperature Probe Adapter is available for use in
conjunction with a 0.15 m ZR22G general-purpose detector.
The averaging converter system is ideal for combustion control in large utility boilers or various
industrial furnaces.
This chapter explains system congurations with some typical examples.
1.1 System Conguration
The AV550G Zirconia Oxygen Analyzer Averaging Converter system can be congured by selecting
detectors and an averaging converter that meet the individual requirements and ow setting units for
calibration.
Subsection 1.1.1 presents a typical system conguration using ow setting units for manual
calibration. A typical system conguration to perform automatic calibration is provided in Subsection
1.1.2.
1.1.1 System Conguration Using Flow Setting Units for Manual Calibration
This system consists of detectors, an averaging converter, and ow setting units (Model ZA8F), as
shown in Figure 1.1. Note that the ZA8F Flow Setting Units are required as many as the detectors
connected to the averaging converter.
A reference gas needs to be supplied at a constant ow rate to the detectors. This reference gas
must be clean, dry air having a constant percentage of oxygen. Typically, instrument air that has been
dehumidied down to a dew point of approximately -20°C and is free from oil mist or dust, is used as
the air source. This air is also used as a span gas for the detectors during calibration. A zero gas for
calibration is supplied from a cylinder to the detectors.

< 1. Overview >
1-2
IM 11M12D01-01E
F1-1E.ai
ZR22G Detector (max. 8 detectors)
Output signal cable (Cell output, thermocouple output, cold contact compensation)
(0.75mm2, 6-core shield cable)
Heater power
(1.25mm2, 2-core shield cable)
Analog outputs :
Averaged and individual outputs
4 to 20 mA DC
Digital output
Power supply :
100 / 115 V AC, 230V AC
50 / 60 Hz±5%
Stop
Valve
or
Check
Valve
Reference gas
Flowmeter
Air set
Needle
Valve
Calibration gas
Zero gas cylinder
Pressure
reducing
valve Calibration gas unit case
Span gas (Calibration gas unit same as for zero gas)
Instrument air
Model ZA8F
flow setting unit
Model AV550G Averaging Converter
Contact input
Contact output
Figure 1.1 Typical System Conguration Using Flow Setting Units for Manual Calibration
1.1.2 System Conguration to Perform Automatic Calibration
A typical system conguration to perform automatic calibration is illustrated in Figure 1.2. The system
consists of detectors, an averaging converter, solenoid valves, needle valves for ow control, and a
oat-type owmeter.
Averaging Converter (AV550G)
Heater power
Output signal cable
Calibration
contact outputs
Contact
output
Span gas cylinder
(Instrument air)
Zero gas cylinder
Flowmeter Solenoid valve
Needle valve
Air set
Pressure reducing valve
Needle valve
Flowmeter
Reference
gas line
Calibration gas line
Solenoid valve
Detector
Power supply
Instrument air
Contact input
Contact output
Analog outputs:
Averaged and individual outputs
Digital output
Stop valve
F1-2E.ai
Figure 1.2 Typical System Conguration to Perform Automatic Calibration

< 1. Overview > 1-3
IM 11M12D01-01E
1.2 System Components
1.2.1 System Components and Their Applicability
Item Model, Part Number or
Specications
System 1
Manual Calibration
System 2
Automatic Calibration
Averaging Converter AV550G- (A or B)  
Detector See Chapter 1.2.2  
Flow setting unit ZA8F 
Needle valve For ow control 
Flowmeter 0 to 1 L/min 
Solenoid valve
E7057GS, E7057GT,
E7057GR, G7001XP,
G7002XP, G7003XP

Solenoid valve for
zero/span switching
Solenoid valve for
switching two streams 
Stop valve L9852CB, G7016XH ()
Check valve K9292DN, K9292DS ()
Air set G7003XF, K9473XK,
G7004XF, K9473XG  
Pressure reducing valve for
zero gas cylinder
G7013XF, G7014XF  
Zero gas cylinder G7001ZC  
 : Items required for the above system example
() : Select either
1.2.2 Detectors and Accessories
Detector
(ZR22G)
Detector
(ZR22G)
Detector
(ZR22G)
Probe Protector
(ZO21R)
Gas Flow
F1-3E.ai
With dust filter
(K9471UA)
or
With dust guard
protector
(K9471UC)
Process gas temperature 0 to 700°C Process gas temperature 700 to 1400°C
Mounting
Item Temp.
Insertion
length General-purpose detector High temperature detector
Application
Application
Horizontal
to
vertical
Horizontal
to
vertical
Horizontal
to
vertical
Vertical
Vertical
0.4
to
2 m
0.4
to
2 m
2.5 m
or more
3 m
or less
2.5 m
or more
• Boiler
• Heating
furnace
• For pulverized
coal boiler
with gas flow
velocity
10 m/sec or
more
• Black liquid
recovery boiler
• Cement Kiln
Sample inlet
Sample
outlet
*
Sample inlet
High
temperature
detector
• Heating
furnace
Probe material and Temperature
SUS310S: 800°C, SiC: 1400°C
Mounting: Vertical downwards
Insertion length: 0.5, 0.6, 0.7, 0.8, 0.9,
1.0, 1.5m
When duct pressure is atmospheric
or negative, attach ejector assembly.
* Ejector assembly for high temperature
(E7046EC, E7046EN)
Absorption
structure
High temperature
probe adapter
ZO21P
Detector
(ZO21DW)
Needle valve
Pressure gauge assembly
Ejector
Tee
Instrument
air

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< 2. Specications > 2-1
IM 11M12D01-01E
2. Specications
This chapter describes the specications for the following:
ZR22G General-purpose separate type detector (See Subsection 2.2.1)
ZO21R Probe protector (See Subsection 2.2.2)
ZR22G (0.15 m) Separate type detector for high temperature (See Subsection 2.3.1)
ZO21P High temperature probe adapter (See Subsection 2.3.2)
AV550G Averaging converter (See Section 2.4)
ZA8F Flow setting unit (See Subsection 2.5.1)
– Other equipment (See Section 2.6)
2.1 General Specications
n Standard Specications
Measured Object: Oxygen concentration in combustion exhaust gas and mixed gas
(excluding inammable gases, may not be applicable corrosive gas such
as ammonia is present — check with Yokogawa)
Measurement System: Zirconia system
Oxygen concentration: 0.01 to 100 vol% O2
Output Signal: 4 to 20 mA DC (maximum load resistance 550 Ω)
Measurement Range: Any setting in the range of 0 to 5 through 0 to 100 vol% O2
(in 1 vol% O2), or partial range
Digital Communication (HART): 250 to 550 Ω, depending on number of eld devices connected
to the loop (multi-drop mode).
Note: HART is a registered trademark of the HART Communication Foundation.
Display Range: 0 to 100 vol% O2
Warm-up Time: Approx. 20 min.
Repeatability: (Excluding the case where the reference gas is by natural convection)
±0.5% Maximum value of set range;
0 to 5 vol% O2 or more and less than 0 to 25 vol% O2range
±1% Maximum value of set range;
0 to 25 vol% O2 or more and up to 0 to 100 vol% O2range
Linearity: (Excluding standard gas tolerance)
(Excluding the case where the reference gas is by natural convection)
(Use oxygen of known concentration (within the measuring range) as the
zero and span calibration gases.)
±1% Maximum value of set range ;
0 to 5 vol% O2 or more and less than 0 to 25 vol% O2range
(Sample gas pressure: within ±4.9 kPa)
±3% Maximum value of set range ;
0 to 25 vol% O2 or more and less than 0 to 50 vol% O2range
(Sample gas pressure: within ±0.49 kPa)

< 2. Specications >
2-2
IM 11M12D01-01E
±5% Maximum value of set range ;
0 to 50 vol% O2 or more and up to 0 to 100 vol% O2range
(Sample gas pressure: within ±0.49 kPa)
Drift: (Excluding the rst two weeks in use)
(Excluding the case where the reference gas is by natural convection.)
Both zero and span ±2% Maximum value of set range/month
Response Time : Response of 90% within 5 seconds. (Measured after gas is introduced
from calibration gas inlet and analog output start changing.)
2.2 General-purpose Separate type Detector and
Related Equipment
General-purpose separate type detector ZR22G can be used in combination with the probe protector
ZO21R (see Subsection 2.2.2).
2.2.1 ZR22G General-purpose Separate type Detector
Sample Gas Temperature:0 to 700 °C (Probe only)
It is necessary to mount the cell using Inconel cell-bolts when the
temperature is greater than 600 °C.
700 to 1400 °C (with High Temperature Probe Adapter)
For high temperature sample gas, apply 0.15 m long probe and High
Temperature Probe Adapter ZO21P.
Sample Gas Pressure: -5 to +250 kPa (When the pressure in the furnace exceeds 3 kPa,
it is recommended that you compensate the pressure. When the
pressure in the furnace exceeds 5 kPa, you must perform pressure
compensation.) For 0.15 m probe, 0.5 to 5 kPa. No pressure uctuation
in the furnace should be allowed.
Note: When the detector is used in conjunction with a check valve and a ZA8F Flow Setting Unit,
the maximum pressure of sample gas is 150 kPa. When with a check valve and a ZR40H
Automatic Calibration Unit, it is 200 kPa. If the pressure of your sample gas exceeds these
limits, consult with Yokogawa.
Probe Length: 0.15, 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0, 3.6, 4.2, 4.8, 5.4 m
Probe Material: SUS 316 (JIS)
Ambient Temperature: -20 to +150 °C
Reference Gas System: Natural Convection, Instrument Air, Pressure Compensation
(other than for probe length 0.15 m)
Instrument Air System (excluding Natural Convection) :
Pressure; 200 kPa + the pressure inside the furnace (It is recommended
to use air which has been dehumidied by cooling to dew point -20
°C or less, and dust or oil mist removed.)
Consumption; Approx. 1 Nl/min
Material in Contact with Gas: SUS 316 (JIS), Zirconia, SUS 304 (JIS) (ange), Hastelloy B,
(Inconel 600, 601)
Construction: Heater and thermocouple replaceable construction.
Non-explosion-proof JIS C0920 / equivalent to IP44D.
Equivalent to NEMA 4X/IP66 (Achieved when the cable entry is
completely sealed with a cable gland in the recirculation pressure
compensated version.)

< 2. Specications > 2-3
IM 11M12D01-01E
Terminal Box Case: Material; Aluminum alloy
Terminal Box Paint Color: Case; Mint green (Munsell 5.6BG3.3/2.9)
Cover; Mint green (Munsell 5.6BG3.3/2.9)
Finish: Polyurethane corrosion-resistant coating
Gas Connection: Rc1/4 or 1/4 FNPT
Wiring Connection: G1/2, Pg13.5, M20 by 1.5 mm, 1/2 NPT
Installation: Flange mounting
Probe Mounting Angle: Horizontal to vertically downward.
When the probe insertion length is 2 m or less, installing at angles from
horizontal to vertically downward is available.
When the probe insertion length is exceeds 2.5 m, mount vertically
downward (within ±5°), and use a probe protector.
Weight: Insertion length; 0.4 m: approx. 6 kg (JIS 5K 65) / approx. 11 kg (ANSI 150 4)
1.0 m: approx. 8 kg (JIS 5K 65) / approx. 13 kg (ANSI 150 4)
1.5 m: approx. 10 kg (JIS 5K 65) / approx. 15 kg (ANSI 150 4)
2.0 m: approx. 12 kg (JIS 5K 65) / approx. 17 kg (ANSI 150 4)
3.0 m: approx. 15 kg (JIS 5K 65) / approx. 20 kg (ANSI 150 4)
3.6 m: approx. 17 kg (JIS 5K 65) / approx. 22 kg (ANSI 150 4)
4.2 m: approx. 19 kg (JIS 5K 65) / approx. 24 kg (ANSI 150 4)
4.8 m: approx. 21 kg (JIS 5K 65) / approx. 26 kg (ANSI 150 4)
5.4 m: approx. 23 kg (JIS 5K 65) / approx. 28 kg (ANSI 150 4)