Yokogawa MC1/AC1 Single Channel Calibration Unit For use with ZR402G /ZR22 User's Manual

User’s Manual MC1/AC1 Single Channel Calibration Unit For use with ZR402G IM 11M06D03-01E-A IM 11M06D03-01E-A Copyright 2007 4th Edition Feb 2013 User’s Manual MC1/AC1 Single Channel Calibration Unit For use with ZR402G I. Introduction............................................................................................4 II. Overview……………………………………………………………… .........4 III. 2.1 Principles of Calibration…………………………………………………..............................4 2.2 Gases………………………………………………………………………….........................5 2.2.1 Span/Reference Gas…………………………………………………………........................5 2.2.2 Calibration Gas (Zero Gas)………………………………………………….........................5 Specifications…………………………………………………................…6 3.1 Model MC1, Manual Calibration Panel…………………………………….........................6 3.1.2 Ordering Specifications……………………………………………………...........................7 3.2 Specifications, AC1…………………………………………………………..........................8 3.2.1 Model AC1, Single Point Automatic Calibration Unit……………………….. ...................8 3.2.2 AC1 Ordering Specifications………………………………………………..........................9 IV. Installation, Manual Calibration (MC1)………………………...…........10 4.1 Location…………………………………………………………………...............................10 4.2 Mounting the MC1…………………………………………………………..........................10 4.3 Piping…………………………………………………………………………........................10 4.3.1 Piping to the ZR22G Oxygen Probe………………………………………........................10 4.3.2 Connection to the Calibration Gas Inlet……………………………………......................10 4.3.3 Connection to the Reference Gas Inlet…………………………………...........................11 V. Setup Procedures, MC1…………………………………………….........12 VI. Installation, Automatic Calibration, AC1…………………….....…......13 5.1 5.2 5.3 Initial Flow Rate Setup………………………………………………………………............12 MC1 Flow Rate Setup……………………………………………………………….............12 Checking for leaks…………………………………………………………………...............12 6.1 Location…………………………………………………………………………...................13 6.2 Mounting the AC1………………………………………………………………..….............13 6.3 Piping………………………………………………………………………………................13 6.3.1 Piping to the ZR22G Oxygen Probe………………………………………...….................13 6.3.2 Connection to the Calibration Gas Inlet………………………………………..................13 6.3.3 Connection to the Reference Gas Inlet…………………………………...……................13 6.4. Wiring to the AC1, Automatic Calibration Unit……………………………………...........13 6.4.1 Wiring the AC1 to the ZR22G…………………………………………...……...................13 VII. Setup Procedures, AC1……………………………………………..........15 7.1 7.1.2 7.1.3 7.2 7.3 Initial Flow Rate Setup………………………………………………………………............15 Setting the Reference Air Flow Rates………………………………………….................15 Balancing Pressure Drops in the Calibration Lines……………………………...............15 Standard Operation…………………………………………………………………............15 Checking for leaks…………………………………………………………………...............16 VIII. Calibration Setup & Operation, ZR402G…………………………........17 8.1 8.2 8.2.1 8.2.2 8.2.3 8.3 8.4 8.5 ZR402G Touch Panel Switch Operations…………………………………………............17 Calibration…………………………………………………………………………................18 Mode Setting…………………………………………………………………......................18 Zero-gas Concentration………………………………………………………....................18 Span-gas Concentration………………………………………………………................... 19 Manual Calibration…………………………………………………………………..............19 Semi-automatic Calibration………………………………………………………...............19 Automatic Calibration……………………………………………………………................ 20 Appendix A, Spare Parts……………………………………………………....... 21 Appendix B, Dimensional Drawings……………………………………….......24 Appendix C, Wiring Diagrams……………………………………………..........28 IM 11M06D03-01E-A 4th 3rd Edition Edition 3 IM 11M06D03-01E-A 4 I. INTRODUCTION There are two types of single channel calibration units offered by Yokogawa. These calibration units are used with the ZR402G Single Channel Oxygen Analyzer, to perform calibration of either ZR22G or ZO21D (obsolete) Oxygen Probes. The AC1 Automatic Calibration Unit utilizes electrical solenoids that are wired to and actuated by the ZR402G. Once activated by the ZR402G, the calibration gases flow to the ZR22 without the user opening valves or adjusting flow rates. The MC1 Manual Calibration Unit is not electronically controlled by the ZR402G. During calibration mode, the user must open valves and adjust the flow rates of the calibration gases. Both the MC1 and the AC1 provide a single point of control for the calibration system. II. OVERVIEW 2.1 CALIBRATION PRINCIPLES This section sets forth the principles of measurement with a Zirconia oxygen analyzer before detailing calibration. A solid electrolyte, such as Zirconia, allows the conductivity of oxygen ions at high temperatures. Therefore, when a Zirconia-plated element with platinum electrodes on both sides is heated up in contact with gases having different partial-oxygen pressures on each side, the element shows the action of the concentration cell. In other words, the electrode in contact with a gas with a higher partial-oxygen pressure acts as a negative electrode. As the gas comes in contact with the Zirconia element in this negative electrode, oxygen molecules in the gas acquire electrons and become ions. Moving in the Zirconia element, they eventually arrive at the positive electrode on the opposite side. There, the electrons are released and the ions return to the oxygen molecules. This reaction is indicated as follows: Negative electrode: O2 + 4e 2 O 2Positive electrode: 2 O 2- O2 + 4 e The electromotive force E (mV) between the two electrodes, generated by the reaction, is governed by Nernst’s equation as follows: E = -RT/nF ln PX/PA........................................Equation (1) Where, R: Gas constant T: Absolute temperature n: 4 F: Faraday’s constant Px: Oxygen concentration in a gas in contact with the positive Zirconia electrode (%) Pa: Oxygen concentration in a gas in contact with the negative Zirconia electrode (%) Assuming the Zirconia element is heated up to 750˚C, then we obtain equation (1) above. E = -50.74 log (Px/Pa) ................................. Equation (2) IM 11M06D03-01E-A 5 With this analyzer, the sensor (Zirconia element) is heated up to 750˚C, so Equation (2) is valid. At that point, the relationship as in Figure 2.1 is effected between the oxygen concentration of the measurement gas in contact with the positive electrode and the electromotive force of the sensor (= cell), where a comparison gas of air is used on the negative electrode side. Figure 2.1 2.2 CALIBRATION GASES 2.2.1 CALIBRATION (ZERO) GAS The calibration gas typically used is 1% oxygen balanced in nitrogen; however, an oxygen mixture between 0.4% and 8% is acceptable. A compressed gas cylinder is containing certified gas mixtures fitted with a dual stage regulator should be used. The maximum working pressure of the calibration systems (MC1 & AC1) is 35 psig. The reference gas should be clean, dry instrument air. 2.2.2 REFERENCE (SPAN) GAS Reference air is from the same source as the span gas. The reference air flows to the backside of the of the Zirconia cell, and is used at all times. The calibration units are plumbed to provide a continuous flow rate of the reference, as well as, calibration gas flow during calibration. A clean, dry air source is recommended, such as instrument air. Install an inline filter before the calibration unit to remove any moisture or dirt. A regulator must be attached to the instrument air source to provide the appropriate working pressure for the calibration unit. The maximum pressure is 35 psig. NOTE Never use pure nitrogen for calibration. NOTE Compressed gas cylinders must have the same CGA connection as the dual stage regulator. Refer to the Appendix A (Spare Parts section) of this manual for the Dual Stage Regulator (M1132ZX) and the Zero Pressure Switch (M1133AR). IM 11M06D03-01E-A 6 III. SPECIFICATIONS, MC1 3.1 MODEL MC1, MANUAL CALIBRATION PANEL The MC1 is the manual calibration unit for a single oxygen probe. It provides regulation of the reference air and calibrations gas while allowing the operator to select zero or span gas for calibration. Separate flow meters are used to set cal gas flow rates and reference air. Figure 3.1 Maximum pressure: Calibration Plate: Connections: Calibration Tubing: Weight: 35 psig Stainless Steel ¼” FNPT ¼” Copper (standard); ¼” Stainless Steel (optional) Approximately 4.4 lbs. (2 kg) Flow rates: Calibration gas – 0.6 LPM Reference Air – 0.8 LPM NOTE Exceeding the recommended flow rates will damage the detector cell. IM 11M06D03-01E-A 7 3.1.2 ORDERING SPECIFICATIONS: SINGLE CHANNEL O2 MANUAL CALIBRATION MC1 MODEL NUMBER TUBING/FITTINGS -C 1/4” Copper Tubing and Brass Fittings -S 1/4” Stainless Steel Tubing and Fittings CODE B REFERENCE AIR FLOW METER -R*U Reference Air Flow meter Table 3.1 IM 11M06D03-01E-A 8 3.2. SPECIFICATIONS, AC1 3.2.1 MODEL AC1, SINGLE POINT AUTOMATIC CALIBRATION UNIT The AC1 provides control of reference air and cal gas flow rates while maintaining a constant regulation of gases. The AC1 includes individual span, zero and block solenoids with manual overrides for easy setup of flow rates. The user has a choice of copper or stainless steel tubing in addition to NEMA 4 or NEMA 4X enclosures. . It also contains a 1 amp fuse with an LED indicator to indicate a power surge. Figure 3.2 NOTE: Cutaway shows internal flow meters and solenoids Operating Pressure: Maximum Pressure: Flow meter Range: Tubing: Gas Connections: Voltage: 20 psig 35 psig 0.15 to 1.0 LPM (separate flow meter for cal gas and reference air). 1/4” Copper (standard); 1/4” Stainless Steel (optional). 1/4” FNPT 110 VAC, 50/60 Hz (standard). Flow rates: Calibration gas – 0.6 LPM Reference Air – 0.8 LPM NOTE Exceeding the recommended flow rates will damage the detector cell. IM 11M06D03-01E-A 9 3.2.2 AC1 ORDERING SPECIFICATIONS SINGLE CHANNEL O2 AUTO CALIBRATION AC1 MODEL NUMBER CODE A ENCLOSURE -4 NEMA 4, Metal Enclosure -5 NEMA 4X, Fiberglass Enclosure CODE B TUBINGS/FITTINGS -C 1/4” copper Tubing and Brass Fittings -S 1/4” Stainless Steel Tubing and Fittings CODE C POWER SUPPLY -A For use with ZA8C -D For use with ZR402G (requires 110 VAC) CODE D REFERENCE AIR CONNECTION -R*U Reference Air Connection Table 3.2 IM 11M06D03-01E-A 10 IV. INSTALLATION, MANUAL CALIBRATION (MC1) 4.1 LOCATION The following guidelines should be used when selecting a location for the calibration unit: 1) 2) 3) 4) 5) 6) Easily accessible for maintenance and inspections. Locating the MC1 close to the ZR22 probe minimizes the amount of tubing required for plumbing. Conversely, mounting the MC1 close to the ZR402G eliminates the need for two technicians to accomplish the calibration. Ambient temperature should not exceed 55˚C (131˚F). Humidity is moderate and no corrosive gases are present Minimal vibration Clean, dry instrument air is available 4.2 MOUNTING THE MC1 The MC1 unit is designed for wall mounting, and can be secured using four (4) standoff and four bolts. Sufficient room should be made available for connecting the calibration and reference gas tubing. NOTE The unit must be mounted as level as possible to ensure the accuracy of the flow rates 4.3 PIPING Plumbing is required from the instrument air line and zero gas cylinders to the calibration unit. Standard 1/4” Stainless Steel tubing is recommended. Separate tubing for the instrument air and zero gas are connected to the 1/4” FNPT fittings on the LEFT side of the calibration unit. The input/output fittings are all 1/4”FNPT fittings, and are available in brass or stainless steel. The probe connections (calibration and reference) are located on the RIGHT. See figure 4.1 NOTE Never use pure nitrogen for calibration. NOTE Compressed gas cylinders must have the same CGA connection as the dual stage regulator. Refer to the Appendix A (Spare Parts section) of this manual for the Dual Stage Regulator (M1132ZX) and the Zero Pressure Switch (M1133AR). 4.3.1 PIPING TO THE ZR22G OXYGEN PROBE 4.3.2 Connection to the Calibration Gas Inlet Connect the tubing from the Zero (cal) gas output, shown in Figure 3.1, to the CAL IN side of the ZR22 probe. If the process is a positive pressure application, ensure that a check valve (Yokogawa Part Number M1234VV-A) is installed between the CAL IN port and the 1/4” tubing. The check valve may already be installed on the detector prior to shipping. IM 11M06D03-01E-A 11 4.3.3 CONNECTION TO THE REFERENCE GAS INLET Connect the tubing from the Reference gas output, shown in Figure 4.3, to the REF IN side of the ZR22 probe. Clean, dry instrument air is recommended as a reference (span) gas; however, ambient air may be used as a substitute. ZERO (CAL) GAS INPUT INSTRUMENT AIR INPUT REFERENCE AIR OUTPUT CALIBRATION GAS OUTPUT Figure 4.1 A list of recommended part for piping to the MC1 or AC1 units is listed below in Table 3.1 Calibration Unit Piping Location Parts Check valve Nipple MC1 Manual Calibration Unit Calibration Gas Inlet AC1 Single Channel Automatic Calibration Unit Reference gas inlet Zero Gas Cylinder Notes Recommended by Yokogawa for positive pressure applications: M1234VV-A. Available through Yokogawa General Rc 1/4 or 1/4 inch MNPT parts User’s Scope Gas Pressure Regulator Recommended by Yokogawa: M1132KD Regulator, and M1132ME Gauge. Available through Yokogawa Zero Gas Pressure Switch Recommended by Yokogawa: M1133AR Available through Yokogawa Joint for tube connection Rc 1/4 or 1/4 inch MNPT General parts Figure 4.1 IM 11M06D03-01E-A 12 V. SETUP PROCEDURES, MC1 5.1 INITIAL FLOW RATE SETUP Locate the reference air flow meters, and adjust the flow adjustment knobs as outlined below: Reference Air: 0.8 LPM Calibration Gas: 0.6 LPM CAUTION The maximum working pressure of the MC1 and AC1 unit is 35 psi. Excessive pressure can damage the Zirconia cell of the ZR22G Oxygen Probe. 5.2 MC1 FLOW RATE SETUP Performing a calibration For accurate calibrations, the manual calibration system must provide a fixed flow of zero and span gas during calibration. There are two flow meters and one hand valve for the MC1. The hand valve is used only during calibration to flow either span gas or zero gas to the probe, using the CAL GAS flow meter to indicate the flow rate. The REF AIR flow meter is used to flow the reference air for the ZR22 probe, and remains flowing at all times, with a flow rate of 0.8 LPM. The ZR402 display will prompt the user to perform the following steps, when programmed for One Touch (TCH) calibration: 1. 2. 3. 4. 5. 6. Position the valve knob to SPAN GAS ON. This will start the flow of Span Gas to the probe. Adjust the CAL GAS flow meter to show 0.6 LPM as the flow rate. If necessary, adjust the reference flow meter to show 0.8 LPM. To stop the flow of Span gas, position the valve knob to the OFF position. To start the flow of Zero gas to the probe, position the valve knob to ZERO GAS ON. Adjust the CAL GAS flow meter to show 0.6 LPM as a flow rate. If necessary, adjust the reference flow meter to show 0.8 LPM. To stop the flow of Zero gas, position the valve to the OFF position. WARNING If reference air is used during calibration, the reference air must be left ON after calibration. 5.3 CHECKING FOR LEAKS 1. 2. 3. 4. 5. 6. Position the valve to SPAN Apply a leak detection spray on all compression fittings and bends of the cal line tubing for the probe, the MC1 gas inlets/outlets, and the probe inlets for CAL and REF gas. Inspect the full length of the CAL and REF lines for leaks. Repair leaks as necessary, and within applicable guidelines After repairing the leaking areas, repeat the inspection instructions above for the affected areas. Upon completion, return the valve to the OFF position, and set the Reference and Cal gas flow rates to 0.8 LPM and 0.6 LPM respectively IM 11M06D03-01E-A 13 VI. INSTALLATION, AUTOMATIC CALIBRATION, AC1 6.1 LOCATION The following guidelines should be used when selecting a location for the calibration unit: 1) 2) 3) Easily accessible for maintenance and inspections. As close to the ZR22 probe as practical. This will minimize the amount of tubing required for plumbing, and decrease calibration times. Ambient temperature should not exceed 55˚C (131˚F). Humidity is moderate and no corrosive gases are present NOTE Use an air purge for the AC1 enclosure if the corrosive gases or high dust content is present. 4) Minimal vibration 5) Clean, dry instrument air is available 6.2 MOUNTING THE AC1 The AC1 is available in a NEMA and NEMA 4X, lockable enclosure, and the unit is designed for wall mounting. It can be secured using four (4) standoffs and four (4) bolts. Mount the AC1 unit so that the terminal strip is easily visible for wiring purposes. Sufficient room should be made available for connecting the calibration and reference gas tubing. NOTE The unit must be mounted as level as possible to ensure the accuracy of the flow rates 6.3 PIPING A list of recommended part for piping to the MC1 and AC1 units is listed previously in Table 4.1 6.3.1 PIPING TO THE ZR22G OXYGEN PROBE 6.3.2 CONNECTION TO THE CALIBRATION GAS INLET Connect the tubing from the Zero (cal) gas output, shown in Figure 5.1, to the CAL IN side of the ZR22 probe. If the process is a positive pressure application, ensure that a check valve (Yokogawa Part Number M1234VV-A) is installed between the CAL IN port and the 1/4” tubing. The check valve may already be installed on the detector prior to shipping. 6.3.3 CONNECTION TO THE REFERENCE GAS INLET Connect the tubing from the Reference gas output, shown in Figure 5.1, to the REF IN side of the ZR22 probe. Clean, dry instrument air is recommended as a reference (span) gas; however, ambient air may be used as a substitute. 6.4. WIRING TO THE AC1, AUTOMATIC CALIBRATION UNIT 6.4.1 WIRING THE AC1 TO THE ZR22G The solenoids of the AC1 are powered by 24VDC from the ZR402G Oxygen Converter. The AC1 itself can be powered by the ZR402G if the ZR402G is using 120VAC, 60Hz. Supply voltage for the AC1 can be obtained from terminals “L, N & G” on the ZR402G. Please refer to the wiring diagram located in Appendix C. IM 11M06D03-01E-A 14 WARNING When wiring electrical components, verify that electrical current and all applicable circuit breakers are de-energized prior to wiring the AC1 and ZR402G. Ensure that all applicable “Lock Out” and “Tagging” procedures have been adhered to. Verify the integrity of ALL electrical connections and terminations prior to energizing the system. A 16 AWG, 4 conductor cable is recommended for use between the ZR402G and the AC1 Unit. The cable should be run in a separate conduit from the detector cables. If a conduit is not used, the wiring should have a suitable jacket to meet environmental and regulatory codes. NOTE To prevent noise from interfering with surrounding electrical lines, we recommend the use of shielded cable ground at the ZR402G. Figure 6.1 IM 11M06D03-01E-A 15 VII. SETUP PROCEDURES, AC1 Locate the reference air flow meters, and adjust the flow adjustment knobs as outlined below: Reference Air: 0.8 LPM Calibration Gas: 0.6 LPM CAUTION The maximum working pressure of the MC1 and AC1 unit is 35 psi. Excessive pressure can damage the Zirconia cell of the ZR22G Oxygen Probe. 7.1 INITIAL FLOW RATE SETUP Ensure that the calibration gas and reference air lines are properly plumbed to the left side of the AC1 Auto Cal Unit. The zero gas and instrument air should be set at approximately 20 psi (± 2 psi). Power is not required to set the flow rates. 7.1.2 SETTING THE REFERENCE AIR FLOW RATES Locate the reference flow meters. Adjust the flow adjustment knob on the REFERNCE AIR FLOW METER to 0.8 LPM or 800ml/min. 7.1.3 BALANCING PRESSURE DROPS IN THE CALIBRATION LINES For accurate calibrations, the auto cal system must provide a fixed flow of Zero gas and Span gas. To balance the pressure drops perform the following steps: 1) 2) 3) 4) 5) Locate the BLOCK and SPAN GAS SOLENOID. Using a screwdriver, turn the override screw to the manual position. See Figure 5.2 Use the flow regulator knob on the CAL GAS FLOW METER to adjust the flow to 1.0 LPM. Switch the override screw of the SPAN GAS solenoid to AUTO. Turn the override screw for the ZERO GAS solenoid to MANUAL. Adjust the pressure regulator on the zero gas cylinder for a flow of 1.0 LPM on the Calibration Gas flow meter. CAUTION DO NOT USE the flow regulator knob of the flow meter to achieve this flow level. 6) Adjust the flow regulator knob on the Calibration Gas flow meter until the flow meter reads 0.6 LPM. 7) Verify that all the manual overrides are set back to AUTO. 7.2 STANDARD OPERATION • The Reference Air Flow meter indicates 0.8 LPM during normal operation and calibration. • All manual overrides are set to the AUTO position. • The Calibration Gas flow meter will show a flow of 0.6 LPM during Calibration only. Before considering your calibration unit automated, it is good practice to check for leaks along the full distance of the calibration line tubing, in addition to performing a CAL CHECK to confirm that the gases are plumbed correctly to each probe. IM 11M06D03-01E-A 16 7.3 CHECKING FOR LEAKS NOTE To prevent leakage, all threaded connections should have Teflon tape (or suitable alternative) and all compression fittings should be installed per manufacturer’s recommendations. 1. 2. 3. 4. 5. 6. Locate the BLOCK SOLENOID. Turn the override screw on the BLOCK SOLENOID and SPAN SOLENOID to the manual position. Use leak detection spray on all compression fittings and bends of the cal and reference line tubing. Inspect the full length of the tubing to determine if there is a leak. Repair leaks as necessary, and within applicable guidelines. After repairing the leaking areas, repeat the inspection instructions above for the affected areas. Upon completion of repairing the leaks, return all solenoids to the AUTO position. IM 11M06D03-01E-A 17 VIII. CALIBRATION SETUP & OPERATION, ZR402G 8.1 ZR402G TOUCH PANEL SWITCH OPERATIONS The converter uses a touch panel switch which can be operated by just touching the panel display. Figure 8.1 shows the basic panel display. The switches that appear in the switch display area vary depending on the panel display, allowing all switch operations. Figure 8.2 shows the switch functions. FIGURE: 8.1 Tag name display area: Primary to tertiary display items: Switch display area: Alarm and error display area: Displays the set tag name (Refer to Section 10.1.4, “Entering Tag Name”). Displays the selected item. (Refer to Section 7.9, “Setting Display Item”.) Displays switches and functions selected according to the panel display. Displays an error if an alarm or error occurs. If you touch this area, the details of the error or alarm are then displayed. FIGURE: 8.2 IM 11M06D03-01E-A 18 8.2 CALIBRATION The converter is calibrated in such a way that the actual zero and span gases are measured and those measured values are used to agree with the oxygen concentrations in the respective gases. There are three types of calibration procedures available: Manual calibration: conducting zero and span calibrations, or either of these calibrations in turn. Manual calibration needs the MC1 Manual Calibration Unit to allow manual supply of the calibration gases. Semi-automatic calibration which uses the touch panel or a contact input signal and conducts calibration operations based on a preset calibration time and stable time. Automatic calibration conducted at preset intervals. Semi-automatic and automatic calibration needs the AC1 Automatic Calibration Unit to allow automatic supply of the calibration gases. The following sections set forth the manual calibration procedures. For details on semi-automatic and automatic calibrations, consult Chapter 9, “Calibration,” in the ZR22G/ZR402G Instruction Manual. 8.2.1 MODE SETTING For the mode setting, do the following: 1) Press the Setup key in the basic panel display to display the Execution/Setup display. 2) Select Maintenance in the Execution/Setup display to display the Maintenance panel display. 3) Then select Calibration setup to display the Calibration setup display as Figure 8.3 shows. 4) Select Mode in this panel, and then select “Manual,” “Semi-Auto” or “Auto.” Figure 8.3 8.2.2 ZERO-GAS CONCENTRATION Set the oxygen concentration for zero-point calibration. Enter the oxygen concentration for the zero gas in the cylinder used in the following procedures: 1) 2) 3) Select Zero gas conc. from the Calibration setup display. The numeric-data entry display then appears. Enter the desired oxygen concentration for the zero-point calibration. (The zero-gas set ranges from 0.3 to 100 %O2.) Enter 00098 for an oxygen concentration of 0.98 vol % O2. IM 11M06D03-01E-A 19 8.2.3 SPAN-GAS CONCENTRATION Set the oxygen concentration for span calibration. If instrument air is used as the span gas, enter 21 %O2. 1) Select Span gas conc. from the Calibration setup display. 2) Enter the desired span-gas oxygen concentration from the numeric-data entry display. (The span-gas set ranges from 4.5 to 100 %O2.) 3) Enter 02100 for an oxygen concentration of 21 vol%O2.Instrument air is here defined as dry air with a dew-point temperature of no higher than -208˚C. If the dew-point temperature is higher than -208˚C, use a hand-held oxygen analyzer to measure the actual oxygen concentration. CAUTION (1) When instrument air is used for the span calibration, remove the moisture from the instrument air at a dew-point temperature of -208C and also remove any oily mist and dust from that air. (2) If dehumidifying is not enough, or if foul air is used, the measurement accuracy will be adversely affected. 8.3 MANUAL CALIBRATION For manual calibration, consult Section 7.12, “Calibration,” In the ZR22G / ZR402G Instruction Manual (IM 11M12A01-02E) 8.4 SEMI-AUTOMATIC CALIBRATION To start calibration, follow these steps: (1) Press the Setup key in the basic panel display to display the Execution/Setup display. (2) Then select Calibration from the Execution/Setup display. The Calibration display shown in Figure 8.4 appears. (3) (2) Select Semi-auto calibration to display the Semi-automatic calibration display shown in Figure 8.4 (4) (3) Select Start calibration. The display shown in Figure 8.4 appears, and then start calibration. Figure 8.4 IM 11M06D03-01E-A 20 To start calibration using an input contact, follow these steps: (1) Make sure that Calibration start has been selected in the Input contacts display (2) Apply an input contact to start calibration. To stop calibration midway, follow these steps: (1) Press the Return key. If this key is pressed midway during calibration, the calibration will stop and the output stabilization time will be set up. (2) Press the Return key once again to return to the basic panel display and the analyzer will be in normal measurement. 8.5 AUTOMATIC CALIBRATION No execution operations are required for automatic calibration. Automatic calibration starts in accordance with a preset start day and time. Calibration is then executed at preset intervals. CAUTION Before conducting a semi-automatic or automatic calibration, run the automatic calibration unit beforehand to obtain a calibration flow of 600 ± 60 ml/min. IM 11M06D03-01E-A 21 APPENDIX A SPARE PART IM 11M06D03-01E-A 22 MODEL MC1 1. 2. 3. M1132CC M1132ZC M1132YL M1132GC M1132RS Flow meter, Brass (2) Flow Meter, SS (2) 3-Way Ball Valve (1) BRASS 1/4” FNPT CONNECTION (4) SS 1/4” FNPT CONNECTION (4) IM 11M06D03-01E-A 23 MODEL AC1 1. 2. 3. 4. 5. M1132YX M1132PF M1132PB M1132CC M1132ZC M1132GC M1132RS NEMA 4 STEEL ENCLOSURE (1) NEMA 4X FIBERGLASS ENCLOSURE (1) 3-WAY BLOCK MANIFOLD & SOLENOIDS (1) FLOW METER, BRASS CONNECTIONS (2) FLOW METER, SS CONNECTIONS (2) BRASS 1/4” FNPT CONNECTION (4) SS 1/4” FNPT CONNECTION (4) IM 11M06D03-01E-A 24 Zero Gas Regulator, M1132ZX This regulator controls the gas pressure of the zero gas cylinders before it reaches the calibration unit. The dual stage regulator is highly recommended for services which require a near constant delivery pressure as the calibration source decays (See M1133AR). Air diffusion and absorption, desorption and off gassing are minimized because of its stainless steel construction. NOTE This regulator is used on a “zero gas” cylinder with a CGA 580 connection. The Cylinder connection must be CGA580 (used for <5% oxygen balanced in nitrogen). FRONT ISOMETRIC Zero Gas Regulator, M1132ZX Maximum Inlet Pressure: 3,000 psig Operating Temperature Range: -40ºF to 200 ºF Bonnet Vents: 1/8” NPTF Inlet/Outlet Connection: CGA 580 with ¼” NPTM Purge Ports: ¼” NPT Female Weight: 4.7 lbs (1.75 kg) Material of Construction: Body - 316L Stainless Steel Diaphragm - 316L Stainless Steel Seat/Seal – Tetzel/Teflon, Kel-F Gauges - 316L Stainless Steel Bonnet – brass, nickel-plated Delivery pressure Range: 2 to 75 psig Flow Capacity Air: 300 scfh Gauges: Delivery, 0 to 100 psig; Cylinder pressure, 0 to 3,000 psig 2” diameter IM 11M06D03-01E-A 25 Zero Pressure Switch, M1133AR The pressure switch is used to alert the Operator via a contact input that the zero gas cylinder needs to be replaced before the cylinder is empty. The recommended connection is to the high pressure side of the zero gas regulator. Refer to Figure 4.1. Zero Pressure Switch, M1133AR Adjustable Set Point Ranges: 30 to 575 psi on fall; 50 to 600 psi on rise. Dead Band: 8 to 60 psi Over Range: 2,500 psi Proof Pressure: 3,000 psi Storage Temperature: -40ºF to 180ºF (-40 ºC to 82 ºC) Ambient Temperature: 0 ºF to 160 ºF (-18 ºC to 71 ºC) Set Point Repeatability: 1% of span Switch Output: One SPDT (either NC or NO) Electrical Rating: Rated to 5 amps resistive and 15 amps inductive (75% PF), at 125 and 120 VAC, ¼” HP Enclosure: Aluminum with irradiate finish rated for 100 hours of salt spray Electrical Connection: One SPDT output; ½” NPTF, 5ft cable Pressure Connection: 1/8” NPTM Mounting: NPTM pressure connection Weight: 12oz (340g) Approvals: UL 508 listed, E42272; CSA C22.2, No 14-1987: LR 9690 IM 11M06D03-01E-A 26 APPENDIX B DIMINSIONAL DRAWINGS IM 11M06D03-01E-A 27 MC1 MC1 IM 11M06D03-01E-A 28 AC1-4 NEMA 4 AC1-4, with NEMA 4 Enclosure IM 11M06D03-01E-A 29 AC1-5, NEMA 4X AC1-5, with NEMA 4X Enclosure IM 11M06D03-01E-A 30 APPENDIX C WIRING DIAGRAM IM 11M06D03-01E-A 31 IM 11M06D03-01E-A 32 IM 11M06D03-01E-A