Yokogawa Model ZR22A, ZR202A Heater Assembly User's Manual

User’s Manual Model ZR22A, ZR202A Heater Assembly IM 11M12A01-21E R IM 11M12A01-21E 3rd Edition i Introduction The ZR22A and ZR202A Heater Assemblies for ZR22G, ZR22S, ZR202G and ZR202S are described here. The ZR22G, ZR22S, ZR202G and ZR202S manuals are listed below. User’s Manual IM No. Model ZR22G, ZR402G Separate type Zirconia Oxygen Analyzer IM11M12A01-02E Model ZR22G, ZR402G Separate type Zirconia High Temperature Humidity Analyzer IM11M12A01-03E Model ZR202G Integrated type Zirconia Oxygen Analyzer IM11M12A01-04E Model ZR202G Integrated type Zirconia High Temperature Humidity Analyzer IM11M12A01-05E Model ZR22S, ZR402G Separate type Explosion-proof Zirconia Oxygen Analyzer IM11M13A01-02E Model ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer IM11M13A01-04E The heater assembly is a replaceable part. After unpacking, check the following. If any problems are found, contact our sales office (do not install if problems are found). Our warranty does not apply if user replaces the heater. • Check after unpacking Do a visual inspection to check that bracket is not bent, and insulator element is not chipped or broken. • Measure resistance of heater and thermocouple (using a tester or the like): < ZR22A (Separate type) heater assembly > Insulator Bracket Check that heater resistance is 90 Ω or less. Check that resistance of thermocouple 5 Ω or less. < ZR202A (Integrated type) heater assembly > Insulator Check that heater resistance is 90 Ω or less. Bracket Check that thermocouple resistance (between terminals 3, 4) of 5 Ω or less. Yellow Green Red White Media No.IM 11M12A01-21E (CD) 3rd Edition :July 2012 (YK) All Rights Reserved Copyright © 2001, Yokogawa Electric Corporation 1 2 3 4 IM 11M12A01-21E ii CAUTION The cell (sensor) at the tip of the probe is made of ceramic (zirconia element). Do not drop the equipment or subject it to pressure stress. • Do NOT allow the sensor (probe tip) to make contact with anything when installing the analyzer. • Avoid water dropping directly on the probe (sensor) of the analyzer 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 probe (especially at the tip) becomes very hot. Be sure to handle it with gloves. WARNING Heater Assembly is very heavy. Be sure not to accidentally drop it. Handle safely to avoid injury. Connect the power supply cord only after confirming that the supply voltage matches the rating of this equipment. In addition, confirm that the power is switched off when connecting power supply. Some process gas is dangerous to people. When removing this equipment from the process line for maintenance or other reasons, protect yourself from potential poisoning by using a protective mask or ventilating the area well  For the safe use of this equipment (1) About This Manual  The contents of this manual shall not be reproduced or copied, in part or in whole, without permission.  This manual explains the functions contained in this product, but does not warrant that those will suit the particular purpose of the user.  Every effort has been made to ensure accuracy in the preparation of this manual. However, should any errors or omissions come to the attention of the user, please contact the nearest Yokogawa Electric representative or sales office.  This manual does not cover the special specifications. This manual may not be changed on any change of specification, construction and parts when the change does not affect the functions or performance of the product.  If the product is used in a manner not specified in this manual, the safety of this product may be impaired. IM 11M12A01-21E iii (2) Safety and Modification 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.  The following safety symbols and wordings are used on the product as well as in this manual. (3) The following safety symbols are used in this manual. Throughout this user’s manual, you will find several different types of symbols are used to identify different sections of text. This section describes these icons. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. NOTE Draws attention to information essential for understanding the operation and features. IM 11M12A01-21E iv  After-Sales Warranty n Do not modify the product. n Yokogawa warrants the product for the period stated in the pre-purchase quotation. Yokogawa shall conduct defined warranty service based on its standard. n During the warranty period, for repair under warranty carry or send the product to the local sales representative or service office. 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. n In 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 Electric did not supply. l Failure due to improper or insufficient maintenance by user. l Failure due to modification, misuse or outside-of-specifications operation which Yokogawa does not authorize. l Failure due to power supply (voltage, frequency) being outside specifications or abnormal. l Failure caused by any usage out of scope of recommended usage. l Any damage from fire, earthquake, storms and floods, lightning, disturbances, riots, warfare, radiation and other natural changes. n Yokogawa does not warrant conformance with the specific application at the user site. Yokogawa will not bear direct/indirect responsibility for damage due to a specific application. n Yokogawa Electric will not bear responsibility when the user configures the product into systems or resells the product. n Maintenance service and supplying repair parts will be covered for five years after the production ends. For repair for this product, please contact the nearest sales office described in this instruction manual. IM 11M12A01-21E  Toc-1 Model ZR22A, ZR202A Heater Assembly IM 11M12A01-21E 3rd Edition CONTENTS Introduction...............................................................................................................i  For the safe use of this equipment................................................................................ ii  After-Sales Warranty...................................................................................................... iv 1. 2. Specifications............................................................................................ 1-1 1.1 Model ZR22A Heater Assembly........................................................................ 1-1 1.2 Model ZR202A Heater Assembly...................................................................... 1-2 Instruction for Replacement of the Heater Unit..................................... 2-1 2.1 2.2 Instruction for Replacement of Model ZR22A Heater Unit............................ 2-1 2.1.1 Removal Procedures for Sensor Assembly........................................ 2-1 2.1.2 Replacement of the Heater Unit......................................................... 2-2 2.1.3 Part Assembly Procedure of Sensor Assembly.................................. 2-5 Instruction for Replacement of Model ZR202A Heater Unit.......................... 2-6 2.2.1 3. Replacement of the Heater Unit......................................................... 2-7 Checking After Replacing Heater Unit.................................................... 3-1 3.1 Checking Wiring................................................................................................. 3-1 3.2 Checking Heater Operation.............................................................................. 3-1 Revision Information................................................................................................i IM 11M12A01-21E Blank Page  <1. Specifications> 1. Specifications 1.1 Model ZR22A Heater Assembly 1-1  Model and Codes Style: S2 Model Suffix code Option code ZR22A --------- ----------- Heater Assembly for ZR22G Length (*1) -015 -040 -070 -100 -150 -200 -250 -300 --------------------------------------------------------------------------------- 0.15 m 0.4 m 0.7 m 1m 1.5 m 2m 2.5 m 3m --------------------- With Jig None -A ----------- -B -C --------------------- Natural convention, External connection (Instrument air) Pressure compensated (for ZR22G S2) Pressure compensated (for ZR22G S1) Jig for change -A -N Reference gas (*3) Description (*2) *1 Suffix code of length should be selected as same as ZR22G installed. *2 Jig part no. is K9470BX to order as a parts after purchase. *3 Select appropriately among “-A”, “-B”, “-C” according to the reference gas supply method and style. (Note) The heater is made of ceramic, do not drop or subject it to pressure stress.  External Dimensions Φ 45 Unit : mm L±12 (K9470BX) K9470BX Jig for change Φ 21.7 L : length 30 F1-1-1E.ai Model & Codes L Weight (kg) ZR22A-015 302 Approx. 0.5 ZR22A-040 552 Approx. 0.8 ZR22A-070 852 Approx. 1.2 ZR22A-100 1152 Approx. 1.6 ZR22A-150 1652 Approx. 2.2 ZR22A-200 2152 Approx. 2.8 ZR22A-250 2652 Approx. 3.4 ZR22A-300 3152 Approx. 4.0 Figure 1.1 External Dimensions of ZR22A IM 11M12A01-21E 1-2 <1. Specifications> 1.2 Model ZR202A Heater Assembly  Model and Codes Model Suffix code Option code Description ZR202A --------- ----------- Heater Assembly for ZR202G Length (*1) -040 -070 -100 -150 -200 -250 -300 ----------------------------------------------------------------------- 0.4 m 0.7 m 1m 1.5 m 2m 2.5 m 3m --------------------- With Jig None ----------- Always -A Jig for change -A -N - -A (*2) *1 Suffix code of length should be selected as same as ZR202G installed. *2 Jig part no. is K9470BX to order as a parts after purchase. (Note) The heater is made of ceramic, do not drop or subject it to pressure stress.  External Dimensions Ø 45 Unit : mm L±12 (K9470BX) K9470BX Jig for change Ø 21.7 L: length 30 F1-2-1.EPS Figure 1.2 External Dimensions of ZR202A IM 11M12A01-21E Weight (kg) Model & Codes L ZR202A-040 552 Approx. 0.8 ZR202A-070 852 Approx. 1.2 ZR202A-100 1152 Approx. 1.6 ZR202A-150 1652 Approx. 2.2 ZR202A-200 2152 Approx. 2.8 ZR202A-250 2652 Approx. 3.4 ZR202A-300 3152 Approx. 4.0  2-1 <2. Instruction for Replacement of the Heater Unit> 2. Instruction for Replacement of the Heater Unit 2.1 Instruction for Replacement of Model ZR22A Heater Unit CAUTION • Allow adequate time for the sensor (cell) and heater assembly to cool before replacing them, or you may get burnt. • When removing the cell, the metal O-ring should be replaced with a new one. Never reuse a metal O-ring. Once-used metal O-ring should be replaced with a new one. • The grease used for rubber O-rings lubricant see ⑭ , ㉑ , ㉒ etc. in Figure 2.2, 2.3 makes poisonous gas when heated to more than 250ºC. Wash your hands thoroughly after work! Especially be careful if you smoke. 2.1.1 Removal Procedures for Sensor Assembly (1) Remove the four bolts and associated washers from the tip of the detector probe. (2) Remove the U-shaped pipe support together with the U-shaped pipe. Remove filter also. (3) Pull the sensor assembly toward you while turning it clockwise. Also, remove the metal O-ring between the sensor assembly and the probe. When replacing the sensor assembly, be careful not to scratch or dent the tip of the probe with which the metal O-ring comes in contact (the surface with which the sensor flange also comes in contact). Otherwise, the measurement gas will not be sealed. (4) Use tweezers to pull the contact out of the groove in the tip of the probe. (5) Clean the sensor assembly, especially the metal O-ring contact surface to remove any contaminants adhering to that part. If you can use any of the parts from among those removed, also clean them up to remove any contaminants adhering to them. Once the metal O-ring has been used, it cannot be reused. So, be sure to replace it. Metal O-ring Sensor (cell) Dust filter (optional) Bolts (four) U-shaped pipe support Contact Probe Screw Filter U-shaped pipe Washers (four) 1/8 turn – tighten bolts 1/8 turn (approximately 45°) each F2.1E.ai Figure 2.1 Exploded View of Sensor Assembly IM 11M12A01-21E 2-2 <2. Instruction for Replacement of the Heater Unit> CAUTION If the heater strut assembly cannot be removed because a screw has fused to its thread, one of our service representatives can fix it. 2.1.2 Replacement of the Heater Unit 1. Removing of the Sensor (Cell) Remove the U-shaped pipe support, the U-shaped pipe, the Filter and the Sensor (Cell) according to Sec. 2.1.1 “Removal procedures for Sensor Assembly”. 2. Removing of the Terminal Box (1) Open the terminal box ⑯ and remove the three terminal connections (CELL+, TC+ and TC-). (2) To disconnect the HTR terminals, remove the terminal block screw ㉘. The other terminal connections remain connected; disconnect the two HTR connections. (These terminals have no polarity.) (3) Remove the two screws ⑮ that fasten the cover ⑫ and slide it to the flange side. (4) Remove the four bolts ⑩ and the terminal box ⑯ with care so that the already disconnected wire will not get caught in the terminal box. 3. Replacement of Heater Strut Assembly (1) Loosen screw ⑲ until heater strut assembly’s plate ⑰ can be removed. There’s no need to remove O-ring ⑱ which prevents screw ⑲ from coming out. Pull out connector ⑬. (2) Loosen and remove the screw ⑧ with a special tool (part no. K9470BX or equivalent) and then remove the heater strut assembly ㉓ from the detector ㉔. (3) To reassemble the heater strut assembly, reverse the above procedure: Insert the heater strut assembly ㉓ into the detector ㉔, while inserting the calibration pipe in the detector ㉔ into the heater section in the heater strut assembly ㉓ as well as in the bracket hole. Coat the screw ⑧ with grease (NEVER SEEZ: G7067ZA) and tighten the screw ⑧ with a special tool (part no. K9470BX or equivalent) with a tightening torque of 12N · m ±10%. (screw ⑧ attached with heater strut assembly ㉓ is shipped with coating.) 4. Assembling of Connector (1) To install the O-rings ㉒ on the calibration gas and reference gas pipes, disassemble the connector ⑬ in the following procedure. Remove the screw ㉕ and then remove the plate ⑰ and two caps ⑳. If the O-ring ㉒ remains in the hole, pull them out from the back. (2) Pass the heater and thermocouple lead-wire through the connector ⑬. Also, pass the calibration gas and reference gas pipes through the holes of the connector ⑬ . (3) Insert the calibration gas and reference gas pipes into O-rings ㉒ after confirming no damage to O-rings. If the O-ring ㉒ fails, replace it with a new one. (4) Push the two caps ⑳ into the associated opening of the connector ⑬ . Insert the plate ⑰, aligning it with the groove of the cap ⑳, and tighten it with the screw ㉕. If you attempt to insert the calibration gas and reference gas pipes into the connector ⑬ without disassembling the connector ⑬, the O-ring may be damaged. (5) Tighten the screw ⑲ in heater strut assembly ㉓ until connector ⑬ cannot move. IM 11M12A01-21E  2-3 <2. Instruction for Replacement of the Heater Unit> 5. Assembling of Terminal Box and Wiring Reassemble in reverse order to the above disassembly procedure. How to identify the wires from the heater strut assembly : Two wires coming from the ceramic insulator are heaters’. Single-core wire is CELL+. One of two-core wires with semitransparent silicone tube is TC+ and the other is TC-. (If wire markers are attached to each wire, connect wires to the corresponding terminal. 6. Installing of the Sensor (Cell) Install the U-shaped pipe support, the U-shaped Pipe, the Filter and the Sensor (Cell) according to Section 2.1.3 ” Part Assembly Procedure of Sensor Assembly”. Heater strut assembly ㉓ is shipped with a new contact. A ⑯ ⑭ ⑩ ⑪ ⑫ Grip jig in spanner and turn to unscrew ⑬ A ⑮ Turn to remove screw Contact Index jig with notches in screw ⑧ Metal O-ring Bolt U-shaped pipe U-shaped pipe support Washer ① Sensor (Cell) Filter TC+ CELL+ View A-A TC- ⑰ ⑱ 1CELL 23 TC45 CJ6 ⑲ ⑬ 7HTR8 ⑭ Figure 2.2 ⑳ F2.2.1E.ai Installation of Model ZR22A HEATER UNIT when reference gas is natural convection or instrument air (suffix code-A) IM 11M12A01-21E 2-4 <2. Instruction for Replacement of the Heater Unit> ⑯ A ⑭ ⑭ ⑭ ⑩ ⑪ ⑫ A ⑬ ⑮ Grip jig in spanner and turn to unscrew Contact Metal O-ring Bolt U-shaped U-shaped pipe pipe support Washer Index jig with notches in screw Turn to remove screw ⑧ Sensor (Cell) ① Filter TC+ View A-A CELL + TC - ⑰⑱ 1CELL 23 TC45 CJ6 ⑲ ⑬ 7HTR8 ⑭ ⑳ F2.2.2E.ai Figure 2.3 IM 11M12A01-21E Installation of Model ZR22A HEATER UNIT when reference gas is pressure compensated (suffix code-B or -C)  2-5 <2. Instruction for Replacement of the Heater Unit> 2.1.3 Part Assembly Procedure of Sensor Assembly (1) First, install the contact. Being careful not to cause irregularities in the pitch of the coil spirals (i.e., not to bend the coil out of shape), place it in the ringed groove properly so that it forms a solid contact. Groove in which the contact (E7042BS) is placed. Metal O-ring Sensor (cell) Dust filter (optional) Bolts (four) U-shaped pipe support Contact Probe Screw Filter U-shaped pipe Washers (four) 1/8 turn – tighten bolts 1/8 turn (approximately 45°) each F2.3E.ai Figure 2.4 Installing the Contact (2) Next, make sure that the O-ring groove on the flange surface of the sensor (cell) is clean. Install the metal O-ring in that O-ring groove, and then insert the sensor (cell) in the probe while turning it clockwise. After inserting it until the metal O-ring comes in contact with the probe’s O-ring contact surface, properly align the U-shaped pipe insertion holes with the bolt openings. (3) Attach the U-shaped pipe to its support with filter, then fully insert the U-shaped pipe and its support into the probe. (4) Coat the threads of the four bolts with antiseize grease and then screw them in along with the washers. First, tighten the four bolts uniformly by hand, and then use a torque wrench to tighten all areas of the metal O-ring uniformly, that is, to make sure the sensor flange is perfectly parallel to the O-ring’s working face in the probe. This is done by tightening first one bolt and then its opposing bolt each 1/8 turn, and then one of the other bolts followed by its opposing bolt, each also 1/8 turn. This continues in rotating fashion until they are all fully tightened with the torque wrench preset to approximately 5.9 N · m. If they are not uniformly tightened, the sensor or heater may be damaged. Replacement of the sensor assembly is now complete. Install the detector and restart operation. Calibrate the instrument before making a measurement. IM 11M12A01-21E 2-6 <2. Instruction for Replacement of the Heater Unit> 2.2 Instruction for Replacement of Model ZR202A Heater Unit CAUTION • Allow adequate time for the sensor (cell) and heater assembly to cool before replacing them, or you may get burnt. • When removing the cell, the metal O-ring should be replaced with a new one. Never reuse a metal O-ring. Once-used metal O-ring should be replaced with a new one. • The grease used for rubber O-rings lubricant see ⑭ , ㉑ , ㉑ etc. in Figure 2.5 makes poisonous gas when heated to more than 250ºC. Wash your hands thoroughly after work! Especially be careful if you smoke. IM 11M12A01-21E  2-7 <2. Instruction for Replacement of the Heater Unit> 2.2.1 Replacement of the Heater Unit 1. Removing of the Sensor (Cell) Remove the U-shaped pipe support, the U-shaped pipe, the Filter and the Sensor (Cell) according to chapter 2.11 ”Removal procedures of the sensor assembly”. 2. Removing of the Converter Case (1) Remove the two screws ⑮ that fasten the cover ⑫ and slide it to the flange side. (2) Remove the four bolts ⑩ and the converter ⑯. Then remove the three connectors to which leadwire from the heater, CELL+ signal and thermocouple are connected. If the automatic calibration unit is attached, the wires from solenoid valves are connected to the converter with connectors. 3. Replacement of Heater Strut Assembly (1) Loosen screw ⑲ until heater strut assembly’s plate ⑰ can be removed. There’s no need to remove O-ring ⑱ which prevents screw ⑲ from coming out. Pull out connector ⑬. (2) Loosen and remove the screw ⑧ with a special tool (part no. K9470BX or equivalent) and then remove the heater strut assembly ㉓ from the detector ㉔. (3) To reassemble the heater strut assembly, reverse the above procedure: Insert the heater strut assembly ㉔ into the detector ㉔, while inserting the calibration pipe in the detector ㉔ into the heater section in the heater strut assembly ㉓ as well as in the bracket hole. Coat the screw ⑧ with grease (NEVER SEEZ: G7067ZA) and tighten the screw ⑧ with a special tool (part no. K9470BX or equivalent) with a tightening torque of 12N•m10%. (screw ⑧ attached with heater strut assembly ㉓ is shipped with coating.) 4. Assembling of Connector (1) To install the O-rings ㉒ on the calibration gas and reference gas pipes, disassemble the connector ⑬ in the following procedure. Remove the screw ㉕ and then remove the plate ⑰ and two caps ⑳. If the O-ring ㉒ remains in the hole, pull them out from the back. (2) Pass the heater, CELL+ and thermocouple lead-wire through the connector ⑬. Also, pass the calibration gas and reference gas pipes through the holes of the connector ⑬. (3) Insert the calibration gas and reference gas pipes into O-rings ㉒ after confirming no damage of O-rings. If the O-ring ㉒ fails, replace it with a new one. (4) Push the two caps ⑳ into the associated opening of the connector ⑬. Insert the plate ⑰, aligning it with the groove of the cap ⑳, and tighten it with the screw ㉕. At this time, fix the terminal of the end of green wire from the four core connectors to connector ⑬ by screw ㉕. If you attempt to insert the calibration gas and reference gas pipes into the connector ⑬ without disassembling the connector ⑬, the O-ring may be damaged. (5) Tighten the screw ⑲ in heater strut assembly ㉓ until connector ⑬ cannot move. 5. Assembling of Converter and Wiring Reassemble in reverse order to the above disassembly procedure. Each connector from the heater strut assembly is identified by its size and the number of cores. Insert them fully by taking care of their size and direction. The connectors from solenoid valves are marked “ZERO” or “Z” and “SPAN” or “S”, so correspond each marking with converter’s. 6. Installing of the Sensor (Cell) Install the U-shaped pipe support, the U-shaped pipe, the Filter and the Sensor (Cell) according to section 2.1.3 ”Part assembly of the sensor assembly”. heater strut assembly ㉓ is shipped with a new contact. IM 11M12A01-21E 2-8 <2. Instruction for Replacement of the Heater Unit> ⑱ ⑪ ⑩ ⑭ A ⑫ ⑬ ⑮ A Contact Metal O-ring Grip jig in Spanner and turn to unscrew Turn to remove screw Index jig with notches in screw ⑧ U-shaped pipe support U-shaped pipe Washer Bolt Sensor (Cell) ① Filter View A-A ⑰ ⑱ ⑲ ⑬ ⑭ ⑳ Figure 2.5 Installation of Model ZR202A HEATER UNIT IM 11M12A01-21E F2.4E.ai  3-1 <3. Checking After Replacing Heater Unit> 3. Checking After Replacing Heater Unit 3.1 Checking Wiring Model ZR22A (Separate type heater) uses screw termination. TC + TC – CELL + 1 CELL 2 3 TC 4 5 7 HEATER CJ H TR 6 8 F3.1E.ai Figure 3.1 Model ZR22A Terminal wiring diagram Model ZR202A (Integrated type heater) uses a connector. Signal connector Connector for heater Solenoid valve connector when ZR20H automatic calibration unit used. Zero Span F3.2E.ai Figure 3.2 Bottom view of Model ZR202A Connector wiring diagram 3.2 Checking Heater Operation After turning on the power, check that heater heats up normally. For separate type (ZR22A) see IM11M12A01-02E, 03E section 7.3, and for integrated type (ZR202A) see IM11M12A01-04E, 05E section 7.3 “Supplying Power to Converter Unit”. After confirming that operation is satisfactory, return detector to operation. Calibrate before taking measurements. IM 11M12A01-21E Blank Page i Revision Information Model ZR22A, ZR202A Heater Assembly  Title:  Manual No.: IM 11M12A01-21E Edition Date 1st Aug. 2001 Remark (s) Newly published 2nd July 2003 Revised Section Style of ZR22A changed to S2 3.1 Instruction for replacement for ZR22A Heater Unit some changed. 3rd July 2012 Revised and Corrected over all IM 11M12A01-21E ii n If you want have more information about Yokogawa products, you can visit Yokogawa’s home page at the following website. Home page: http://www.yokogawa.com/an/ n Written by Environmental & Analytical Products PMK Dept. IA Div., Product Business Center Yokogawa Electric Corporation n Published by Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, JAPAN n Printed by KOHOKU PUBLISHING & PRINTING INC. IM 11M12A01-21E