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Yokogawa Model AV550G Zirconia Oxygen Analyzer Averaging Converter User's Manual
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User’s
Manual
Model AV550G
Zirconia Oxygen Analyzer
Averaging Converter
IM 11M12D01-01E
IM 11M12D01-01E
7th Edition
i
Introduction
The EXAxt Series AV550G Zirconia Oxygen Analyzer Averaging Converter is designed for oxygen
measurement at multiple points in flue 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
Specification 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 filter 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
IM 11M12D01-01E
ii
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 suffix codes or option codes
contain the code “Z” (made to customers’ specifications). 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 configuration
examples
2. Specifications
Standard specification, 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
configurations
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.
IM 11M12D01-01E
iii
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 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.
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 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 11M12D01-01E
iv
(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.
(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 Specification 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 specification matches the
order, and required accessories are not missing. Specifications can be checked by the model codes
on the nameplate. Refer to Chapter 2 Specifications for the list of model codes.
l Details 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.
l Product Disposal:
The instrument should be disposed of in accordance with local and national legislation/regulations.
IM 11M12D01-01E
v
CE marking products
n Authorized Representative in EEA
The Authorized Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2, 3825
HD Amersfoort, The Netherlands).
n Identification Tag
This manual and the identification tag attached on packing box are essential parts of the product.
Keep them together in a safe place for future reference.
n Users
This product is designed to be used by a person with specialized knowledge.
n How 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.office. 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.
IM 11M12D01-01E
vi
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 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 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 11M12D01-01E
Toc-1
Model AV550G
Zirconia Oxygen Analyzer Averaging Converter
IM 11M12D01-01E 7th Edition
CONTENTS
Introduction...............................................................................................................i
1. Overview..................................................................................................... 1-1
1.1
1.2
2.
System Configuration....................................................................................... 1-1
1.1.1
System Configuration Using Flow Setting Units for Manual Calibration....... 1-1
1.1.2
System Configuration to Perform Automatic Calibration.................... 1-2
System Components......................................................................................... 1-3
1.2.1
System Components and Their Applicability...................................... 1-3
1.2.2
Detectors and Accessories................................................................. 1-3
Specifications............................................................................................ 2-1
2.1
General Specifications...................................................................................... 2-1
2.2
General-purpose Separate type Detector and Related Equipment.............. 2-2
2.3
2.4
2.2.1
ZR22G General-purpose Separate type Detector............................. 2-2
2.2.2
ZO21R Probe Protector...................................................................... 2-7
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
AV550G Averaging Converter......................................................................... 2-11
2.4.1
Standard Specifications.................................................................... 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
IM 11M12D01-01E
Toc-2
3.2
3.3
3.4
3.5
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
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
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
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
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
4.2
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
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
IM 11M12D01-01E
General................................................................................................................ 5-1
5.1.1
Wiring Precautions.............................................................................. 5-1
5.1.2
Wiring Holes........................................................................................ 5-3
5.2
5.3
6.
5.1.3
External Wiring Connection Terminals of the Averaging Converter... 5-3
5.1.4
Types of Wiring and Cables................................................................ 5-4
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
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
Components.............................................................................................. 6-1
6.1
6.2
6.3
7.
Toc-3
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
AV550G Averaging Converter........................................................................... 6-3
6.2.1
Components and Function................................................................. 6-3
6.2.2
Touchpanel Switch Operations........................................................... 6-3
ZA8F Flow Setting Unit.................................................................................... 6-12
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
IM 11M12D01-01E
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8.
7.11.2
Checking contacts used to operate solenoid valves during automatic
calibration.......................................................................................... 7-12
7.11.3
Checking Contact Inputs................................................................... 7-12
Setting Operating Parameters - Detail, and Examples.......................... 8-1
8.1
8.2
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 Coefficient (Applies to All Analog Outputs).. 8-7
8.1.4
Setting Output Mode (Applies to All Analog Outputs)......................... 8-7
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
9.2
9.3
10.
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
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
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
Other Functions....................................................................................... 10-1
10.1 Display............................................................................................................... 10-1
IM 11M12D01-01E
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
Toc-5
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
10.3
10.4
10.5
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
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
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
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
IM 11M12D01-01E
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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
11.4
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
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
12.2
12.3
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
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
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
IM 11M12D01-01E
1-1
< 1. Overview >
1. Overview
Zirconia oxygen analyzers are used in combustion facilities to measure the flue 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 stratification
in the flue 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 field. 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 configurations with some typical examples.
1.1
System Configuration
The AV550G Zirconia Oxygen Analyzer Averaging Converter system can be configured by selecting
detectors and an averaging converter that meet the individual requirements and flow setting units for
calibration.
Subsection 1.1.1 presents a typical system configuration using flow setting units for manual
calibration. A typical system configuration to perform automatic calibration is provided in Subsection
1.1.2.
1.1.1 System Configuration Using Flow Setting Units for Manual Calibration
This system consists of detectors, an averaging converter, and flow 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 flow rate to the detectors. This reference gas
must be clean, dry air having a constant percentage of oxygen. Typically, instrument air that has been
dehumidified 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.
IM 11M12D01-01E
1-2
< 1. Overview >
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)
Model AV550G Averaging Converter
Analog outputs :
Averaged and individual outputs
4 to 20 mA DC
Digital output
Stop
Valve
or
Check
Valve
Contact output
Contact input
Power supply :
100 / 115 V AC, 230V AC
50 / 60 Hz±5%
Flowmeter
Reference gas
Air set
Calibration gas
Instrument air
Span gas (Calibration gas unit same as for zero gas)
Needle
Valve
Model ZA8F
flow setting unit
Pressure
reducing
valve
Calibration gas unit case
Zero gas cylinder
F1-1E.ai
Figure 1.1 Typical System Configuration Using Flow Setting Units for Manual Calibration
1.1.2 System Configuration to Perform Automatic Calibration
A typical system configuration to perform automatic calibration is illustrated in Figure 1.2. The system
consists of detectors, an averaging converter, solenoid valves, needle valves for flow control, and a
float-type flowmeter.
Averaging Converter (AV550G)
Detector
Output signal cable
Analog outputs:
Averaged and individual outputs
Digital output
Heater power
Solenoid valve
Contact output
Contact input
Calibration
contact outputs
Contact
output
Power supply
Calibration gas line
Flowmeter
Needle valve
Reference
gas line
Span gas cylinder
(Instrument air)
Solenoid valve
Needle valve
Flowmeter
Instrument air
Pressure reducing valve
Stop valve
Air set
Zero gas cylinder
Figure 1.2 Typical System Configuration to Perform Automatic Calibration
IM 11M12D01-01E
F1-2E.ai
1.2
1-3
< 1. Overview >
System Components
1.2.1 System Components and Their Applicability
Model, Part Number or
Specifications
Item
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 flow 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
G7013XF, G7014XF
zero gas cylinder
Zero gas cylinder
G7001ZC
: Items required for the above system example
() : Select either
1.2.2 Detectors and Accessories
Item
Temp.
Mounting Insertion
length
Horizontal
to
vertical
0.4
to
2m
Vertical
2.5 m
or more
Horizontal
to
vertical
3m
or less
Process gas temperature 0 to 700°C
General-purpose detector
Detector
(ZR22G)
Vertical
0.4
to
2m
2.5 m
or more
• Boiler
• Heating
furnace
Detector
(ZO21DW)
Probe Protector
(ZO21R)
Gas Flow
Detector
(ZR22G)
Sample inlet
Horizontal
to
vertical
Application
With dust filter
(K9471UA)
or
With dust guard
protector
(K9471UC)
Process gas temperature 700 to 1400°C
High temperature detector
Sample
outlet
*
Application
• Heating
furnace
Absorption
structure
High temperature
probe adapter
ZO21P
High
temperature
detector
Sample inlet
• For pulverized
coal boiler
with gas flow
velocity
10 m/sec or
more
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)
Pressure gauge assembly
Detector
(ZR22G)
• Black liquid
recovery boiler
• Cement Kiln
Ejector
Needle valve
Instrument
air
Tee
F1-3E.ai
IM 11M12D01-01E
Blank Page
2.
2-1
< 2. Specifications >
Specifications
This chapter describes the specifications for the following:
2.1
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)
General Specifications
n Standard Specifications
Measured Object:
Oxygen concentration in combustion exhaust gas and mixed gas
(excluding inflammable 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 field 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% O2 range
±1% Maximum value of set range;
0 to 25 vol% O2 or more and up to 0 to 100 vol% O2 range
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% O2 range
(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% O2 range
(Sample gas pressure: within ±0.49 kPa)
IM 11M12D01-01E
2-2
< 2. Specifications >
±5% Maximum value of set range ;
0 to 50 vol% O2 or more and up to 0 to 100 vol% O2 range
(Sample gas pressure: within ±0.49 kPa)
Drift:
(Excluding the first 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 fluctuation
in the furnace should be allowed.
Note:
Probe Length:
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.
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 dehumidified 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) (flange), Hastelloy B,
(Inconel 600, 601)
Construction:
IM 11M12D01-01E
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.)
Terminal Box Case:
2-3
< 2. Specifications >
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)
IM 11M12D01-01E
2-4
< 2. Specifications >
Model and Codes
Style : S2
Model
Suffix code
Option code
Description
ZR22G
----------------------------------
----------
Separate type Zirconia Oxygen Analyzer, Detector
Length
-015
-040
-070
-100
-150
-200
-250
-300
-360
-420
-480
-540
-------------------------------------------------------------------------------------------------------------
0.15 m (for high temperature use)
0.4 m
0.7 m
1.0 m
1.5 m
2.0 m
2.5 m
(*2)
3.0 m
(*2)
3.6 m
(*2)
4.2 m
(*2)
4.8 m
(*2)
5.4 m
(*2)
-------------------
SUS316
Stainless steel with Inconel calibration gas tube
-------------------------------------------------------------------------------------------------------------------------------
ANSI Class 150 2 RF SUS304
ANSI Class 150 3 RF SUS304
ANSI Class 150 4 RF SUS304
DIN PN10 DN50 A SUS304
DIN PN10 DN80 A SUS304
DIN PN10 DN100 A SUS304
JIS 5K 65 FF SUS304
JIS 10K 65 FF SUS304
JIS 10K 80 FF SUS304
JIS 10K 100 FF SUS304
JIS 5K 32 FF SUS304 (for high temperature use) (*4)
JPI Class 150 4 RF SUS304
JPI Class 150 3 RF SUS304
Westinghouse
----------------------------
Natural convection
External connection (Instrument air)
Pressure compensated
(*10)
-------------------
Rc 1/4
1/4 NPT(Female)
----------------------------------------------
G1/2
Pg13.5
M20 x1.5 mm
1/2 NPT
Quick connect
----------------------------
Japanese
English
Chinese
----------
Always -A
Wetted material
-S
-C
Flange
(*3)
-A
-B
-C
-E
-F
-G
-K
-L
-M
-P
-Q
-R
-S
-W
Reference gas
-C
-E
-P
Gas Thread
-R
-T
Connection box thread
-P
-G
-M
-T
-Q
Instruction manual
-J
-E
-C
—
-A
Options
*1
*2
*3
*4
*5
*6
*7
*8
*9
*10
(*9)
(*10)
(*8)
/C
Inconel bolt
(*5)
Valves
/CV
/SV
Check valve
Stop valve
(*6)
(*6)
Filter
/F1
/F2
Dust Filter
Dust Guard Protector
/SCT
/PT
Stainless steel tag plate
Printed tag plate
Tag plates
(*1)
(*7)
(*7)
Used with the ZO21P High Temperature Probe Adapter. Select flange (-Q).
When installing horizontally the probe whose insertion length is 2.5 meters or more, use the Probe Protector. Be sure to
specify ZO21R-L-200- . Specify the flange suffix code either -C or -K.
The thickness of the flange depends on its dimensions.
Not used in conjunction with -P (pressure compensation) for reference gas. The flange thickness does not conform to JIS
specification
Inconel probe bolts and U shape pipe are used. Use this option for high temperature use (ranging from 600 to 700°C).
Specify either /CV or /SV option code.
Specify either /SCT or /PT option code.
Not waterproof, avoid rain. Operating maximum temperature is 80°C. Available only in the U.S.
Recommended if sample gas contains corrosive gas like chlorine.
Piping for reference gas must be installed to supply reference gas constantly at a specified flow rate.
IM 11M12D01-01E
□
2-5
< 2. Specifications >
EXTERNAL DIMENSIONS
1. Model ZR22G Separate type Zirconia Oxygen Analyzer, Detectors
L
283 to 292
Unit : mm
85
Ø124
Ø50.8
t
L=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)
Rc1/4 or 1/4 NPT
Reference gas inlet
155 to 163
69
2-G1/2,2-1/2 NPT etc.
Cable connection port
C
48
25
ØA
ØB
Rc1/4 or 1/4 NPT
Calibration gas inlet
Flange
Flange
ANSI Class 150 2 RF SUS304
ANSI Class 150 3 RF SUS304
ANSI Class 150 4 RF SUS304
DIN PN10 DN50 A SUS304
DIN PN10 DN80 A SUS304
DIN PN10 DN100 A SUS304
JIS 5K 65 FF SUS304
JIS 10K 65 FF SUS304
JIS 10K 80 FF SUS304
JPI Class 150 3 RF SUS304
Westinghouse
JIS 10K 100 FF SUS304
JIS 5K 32 FF SUS304
JPI Class 150 4 RF SUS304
A
152.4
190.5
228.6
165
200
220
155
175
185
210
115
229
190
155
B
120.6
152.4
190.5
125
160
180
130
140
150
175
90
190.5
152.4
127
C
4 - Ø19
4 - Ø19
8 - Ø19
4 - Ø18
8 - Ø18
8 - Ø18
4 - Ø15
4 - Ø19
8 - Ø19
8 - Ø19
4 - Ø15
8 - Ø19
4 - Ø19
4 - Ø11.5
t
19
24
24
18
20
20
14
18
18
18
5
24
24
14
Flange
C
ØA
ØB
Flange
F2-1E.ai
IM 11M12D01-01E
2-6
< 2. Specifications >
2. Model ZR22G...-P (with pressure compensation) Separate type Zirconia Oxygen Analyzer,
Detectors
303
t
85
ø124
Ø50.8
L
L=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)
156
Rc1/4 or 1/4 NPT
Reference gas inlet
87
C
2-G1/2, 2-1/2 NPT etc.
Cable connection port
48
25
ØA
ØB
Reference gas outlet
Flange
PIPING
:B
PIPING : A
Flange
ANSI Class 150 2 RF SUS304
ANSI Class 150 3 RF SUS304
ANSI Class 150 4 RF SUS304
DIN PN10 DN50 A SUS304
DIN PN10 DN80 A SUS304
DIN PN10 DN100 A SUS304
JIS 5K 65 FF SUS304
JIS 10K 65 FF SUS304
JIS 10K 80 FF SUS304
JIS 10K 100 FF SUS304
JPI Class 150 4 RF SUS304
JPI Class 150 3 RF SUS304
Westinghouse
A
152.4
190.5
228.6
165
200
220
155
175
185
210
229
190
155
B
120.6
152.4
190.5
125
160
180
130
140
150
175
190.5
152.4
127
Rc1/4 or 1/4 NPT
Calibration gas inlet
Stop Valve
C
4 - Ø19
4 - Ø19
8 - Ø19
4 - Ø18
8 - Ø18
8 - Ø18
4 - Ø15
4 - Ø19
8 - Ø19
8 - Ø19
8 - Ø19
4 - Ø19
4 - Ø11.5
t
19
24
24
18
20
20
14
18
18
18
24
24
14
PIPING
A
B
B
A
B
B
A
A
B
B
B
B
A
Flange
C
ØA
ØB
Flange
F2-2E.ai
IM 11M12D01-01E
2-7
< 2. Specifications >
2.2.2 ZO21R Probe Protector
Used when sample gas flow velocity is approx. 10 m/sec or more and dust particles wears the
detector in cases such as pulverized coal boiler of fluidized bed furnace (or burner) to protect the
detector from wearing by dust particles. When probe insertion length is 2.5 m or more and horizontal
installation, specify the ZO21R-L-200- *B to reinforce the probe.
□
Insertion Length:
1.05, 1.55, 2.05 m.
Flange:
JIS 5K 65A FF equivalent. ANSI Class 150 4 FF (without serration)
equivalent or DIN PN10 DN50A equivalent. However, flange thickness is
different.
Material:
SUS316 (JIS), SUS304 (JIS) (Flange)
Weight:
1.05 m; Approx. 6/10/8.5 kg (JIS/ANSI/DIN),
1.55 m; Approx. 9/13/11.5 kg (JIS/ANSI/DIN),
2.05 m; Approx. 12/16/14.5 kg (JIS/ANSI/DIN)
Installation:
Bolts, nuts, and washers are provided for detector, probe protector and
process-side flange.
Model and Codes
Model
Suffix code
ZO21R
-L
Insertion
length
Flange ( *1)
Style code
Description
Probe Protector(0 to 700°C)
-100
-150
-200
----------------------------
1.05 m (3.5 ft)
1.55 m (5.1 ft)
2.05 m (6.8 ft)
-J
-A
-E
----------------------------
JIS 5K 65 FF SUS304
ANSI Class 150 4 FF SUS304
DIN PN10 DN50A
----------
Style B
*B
*1 Thickness of flange depends on dimensions of flange.
Unit: mm
Flange <1>
(with bolts, nuts and washers)
Gasket (Thickness 3.0)
Washer (M12)
Mounting nut (M12)
Gas flow
SUS316
ØB
ØA
Ø60.5
Option code
----------
D
t
ØB
l (Insert length)
C
l=1050,1550,2050
Dimensions of holes on opposing surface
Flange<1>
JIS 5K 65 FF SUS304
ANSI Class 150 4 FF SUS304
DIN PN10 DN50A SUS304
A
B
C
t
D
155
130
4 - Ø15
5
40
228.6
190.5
8 - Ø19
12
50
165
125
4 - Ø18
12
50
F2-3E.ai
IM 11M12D01-01E
2-8
< 2. Specifications >
2.3
Separate type Detector for High Temperature and
Related Equipment
2.3.1 ZR22G (0.15m) Separate type Detector for High Temperature
Standard Specifications
Construction:
Water-resistant, non-explosion-proof
Probe length:
0.15 m
Terminal box:
Aluminum alloy
Probe material in contact with gas: SUS 316 (JIS) (Probe), SUS 304 (JIS) (Flange), Zirconia (Sensor),
Hastelloy B, (Inconel 600, 601)
Weight:
Approx. 3 kg
Installation:
Flange mounting (The use of detector for high temperature, the ZO21P high
temperature probe adapter is necessary.)
Flange standard:
JIS 5 K 32 FF equivalent (thickness varies)
Mounting angle:
Any angle between horizontal and vertical (high temperature probe is
fitted with an adapter)
Reference gas and calibration gas piping connection: Rc 1/4 or 1/4 FNPT
Cable inlet:
G 1/2, Pg 13.5, M20 x 15, 1/2 FNPT
Ambient temperature: -20 to 150°C
Sample gas temperature: 0 to 700°C (temperature at the measuring point of the sampling gas)
When sample gas is 700°C to 1400°C, the high temperature probe
adapter is used.
Temperature of the high temperature probe adapter shall not exceed 300°C
to protect the gasket and avoid the bolts seizing together.
Sample gas pressure: -0.5 to +5 kPa: when used at the range of more than 0 to 25 vol% O2,
-0.5 to +0.5 kPa. (An ejector assembly is required for negative pressure
application.)
Model and Code:
Refer to “Model and Codes” in page 2-4.
External Dimensions:
Refer to the Figure in page 2-5.
IM 11M12D01-01E
2-9
< 2. Specifications >
2.3.2 ZO21P High Temperature Probe Adapter
Measuring O2 in the high temperature gases (exceeds 700°C) requires a general-purpose detector
ZR22G of 0.15 m length and a high temperature probe adapter.
Sample gas temperature: 0 to 1400°C (when using SiC probe)
0 to 800°C (when using SUS 310S probe)
Sample gas pressure: -0.5 to + 5 kPa. When using in the range of 0 to 25 vol% O2 or more,
the sample gas pressure should be in the range of -0.5 to +0.5 kPa.
(Where the sample gas pressure for the high temperature probe is
negative, an auxiliary ejector assembly is necessary.)
Insertion length:
0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5 m
Material in Contact with Gas: SUS 316 (JIS), SiC or SUS 310S, SUS 304 (JIS) (flange)
Probe Material:
SiC, SUS 310S (JIS)
Installation:
Flange mounting (FF type or RF type)
Probe Mounting Angle: Vertically downward within ± 5°. Where the probe material is SUS 310S,
horizontal mounting is available.
Construction:
Non-explosion-proof. Rainproof construction
Weight(example):
Insertion length of 1.0 m: approx. 5.3 kg (JIS) / approx. 11.3 kg (ANSI)
Insertion length of 1.5 m: approx. 5.8 kg (JIS) / approx. 11.8 kg (ANSI)
Model and Codes
Model
ZO21P
Material
Insertion
length
Flange
Style code
Option
Suffix code
Option code
-H
-A
-B
-050
-060
-070
-080
-090
-100
-150
-J
-N
-M
-L
-A
-R
-Q
-T
-S
-E
*B
Description
-------
High Temperature Probe Adapter
-------------
SiC
SUS 310S
------------------------------------
0.5 m
0.6 m
0.7 m
0.8 m
0.9 m
1.0 m
1.5 m
-------------------------------------------------------------
JIS 5K 50 FF SUS304
JIS 10K 65 FF SUS304
JIS 10K 80 FF SUS304
JIS 10K 100 FF SUS304
ANSI Class 150 4 RF SUS304
ANSI Class 150 2 1/2 RF SUS304
ANSI Class 150 3 RF SUS304
JPI Class 150 3 RF SUS304
JPI Class 150 4 RF SUS304
DIN PN10 DN50 A SUS304
-------
Style B
/EJ1
/EJ2
/SCT
Ejector Assy with E7046EC
Ejector Assy with E7046EN
Stainless steel tag plate
Note:The Insertion length 0.15 m of the ZR22G should be specified.
IM 11M12D01-01E
2-10
< 2. Specifications >
Unit: mm
Approx. 351
Flange (Thickness 5)
JIS 5K 32 FF equivalent
Gasket (Thickness 1.5)
180
t
110
ØA
85
Ø115
Ø60.5
Flange <1>
Approx. 48
Detector(ZR22G)
Flange provided by customer
Ø52 over
Reference gas inlet Rc1/4 or 1/4 NPT
69
25
High temperature
Probe SiC pipe
Ø30
48
170
Ø60.5
Approx. 100
L (Insertion length) (Note1)
Approx. 215
Rc1/2(Note2)
Ø124±3
Sample gas outlet
Pipe hole (2- G1/2, 2-1/2NPT, etc)
Calibration gas inlet Rc1/4 or 1/4 NPT
C
(Note 1) L= 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5(m)
(Note 2) Sample gas outlet
(if the sample gas pressure is negative,
connect the auxiliary ejector assembly.)
ØA
ØB
F2-4E.ai
Flange<1>
JIS 5K 50 FF SUS304
JIS 10K 65 FF SUS304
JIS 10K 80 FF SUS304
JIS 10K 100 FF SUS304
ANSI Class 150 4 RF SUS304
ANSI Class 150 3 RF SUS304
ANSI Class 150 2 RF SUS304
JPI Class 150 4 RF SUS304
JPI Class 150 3 RF SUS304
DIN PN10 DN50A SUS304
IM 11M12D01-01E
A
155
175
185
210
228.6
190.5
152.4
229
190
165
B
130
140
150
175
190.5
152.4
120.6
190.5
152.4
125
C
4 - Ø15
4 - Ø19
8 - Ø19
8 - Ø19
8 - Ø19
4 - Ø19
4 - Ø19
8 - Ø19
4 - Ø19
4 - Ø18
t
14
18
18
18
24
24
19
24
24
18
2.4
2-11
< 2. Specifications >
AV550G Averaging Converter
2.4.1 Standard Specifications
Compatibility of Detectors : ZR22G, ZO21D, ZO21DW
Number of Detectors : 1 to 8 (100 V type), Expandable up to 8
1 to 4 (200 V type), Expandable up to 4
(Note) Specify 4 Channel Base when 200V type is selected.
Averaging interval :
0.2 seconds
Display:
5.7 inches color LCD display of size 320 by 240 dot with touch screen
Output Signal:
4 to 20 mA DC (maximum load resistance 550 Ω)
Average-value Output; 3 points
(Note) Number of average-value output is 2 when suffix code “ -F” (FOUNDATION Fieldbus communication) is
selected.
(Note) When the individual insulation is specified, three points of average-value output and individual output are
insulated, but, between the three points of average-value are not insulated.
Independent Output; Output to each channel
Common isolation / Individual isolation selectable.
(Note) Used exclusively for communication when suffix code “ -F” (FOUNDATION Fieldbus communication) is
selected.
Digital Communication: FOUNDATION Fieldbus
HART; 250 to 550 Ω, depending on number of field devices connected to the
loop (multi-drop mode).
(Note) HART is a registered trademark of the HART Communication Foundation.
Contact Output:
Contact capacity 30V DC 3A, 250V AC 3A (resistive load)
Normally open / normally closed selectable
Common Contact Output; 5 points, Four of the output points can be selected to either normally
energized or normally deenergized status.
Contact output 5 is normally energized.
Contact Output for Individual Channel Fail; Output to each channel, Normally energized.
Solenoid Valve Contact Output: Contact capacity 30V DC 1A, 250V AC 1A, voltage free contacts,
DC 24V power supply (option). Maximam DC 300 mA
Contact Input:
2 points, voltage free contacts
Ambient Temperature: -5 to +50°C
Storage Temperature: -20 to +70°C
Humidity Range:
10 to 85%RH (non-condensing)
Installation Altitude:
2000 m or less
Category based on IEC 61010: II (Note)
Pollution degree based on IEC 61010:2 (Note)
Note: Installation category, called over-voltage category, specifies impulse withstand voltage. Category II is for electrical
equipment.
Pollution degree indicates the degree of existence of solid, liquid, gas or other inclusions which may reduce dielectric
strength. Degree 2 is the normal indoor environment.
Power Supply Voltage: Ratings; 100 / 115 V AC, 230 V AC
Acceptable range; 85 to 126.5 V AC, 195.5 to 253 V AC
Power Supply Frequency: Rating; 50/60 Hz
Acceptable range; 50 Hz±5%, 60 Hz±5%
Power Consumption: Max. 40 W + (120 W)×(Number of detectors) for steady operation (100 V type)
Max. 40 W + (220 W)×(Number of detectors) for warm-up (100 V type)
Max. 40 W + (140 W)×(Number of detectors) for steady operation (200 V type)
Max. 40 W + (220 W)×(Number of detectors) for warm-up (200 V type)
IM 11M12D01-01E
2-12
< 2. Specifications >
Safety and EMC conforming standards
Safety: Conforms to EN 61010-1, CAN/CSA-C22.2 No. 61010.1 certified,
UL Std. No. 61010-1 certified
EMC: Conforms to EN 61326-1 Class A, Table 2 *,
EN 61326-2-3, EN 61000-3-2, EN 61000-3-3
* : Influence of immunity environment (Criteria A ) : ±12.5% of F. S.
CE (Only HART communication type)
EMC Regulatory Arrangement in Australia and New Zealand (RCM)
EN61326-1 Class A
Korea Electromagnetic Conformity Standard Class A
RoHS: EN 50581
CAUTION
This instrument is a Class A product, and it is designed for use in the industrial environment. Please
use this instrument in the industrial environment only.
Maximum Distance between Probe and Converter: Conductor two-way resistance must be 10 Ω or
less (when a 1.25 mm2 cable or equivalent is used, 300 m or less)
Construction:
Indoor installation
Wiring Connection:
Number of wire holes 30 pieces
Wire hole size: Ø17 mm for grommet, Ø6 to Ø12 mm for cable gland (option).
Installation:
Wall mounting
Case:
Aluminum alloy (100 V type), Steel plate and Aluminum alloy (200 V type)
Paint Color:
Silver Gray (Munsell 3.2PB7.4/1.2)
Finish:
Polyurethane corrosion-resistance coating
Weight:
Approx. 13 kg (100 V type), Approx. 25 kg (200 V type)
2.4.2 Functions
Display Functions:
Value Display;
Displays values of the measured oxygen concentration, etc
Graph Display;
Displays trends of measured oxygen concentration
Data Display; Displays various useful data for maintenance, such as cell
temperature, reference junction temperature, maximum/minimum
oxygen concentration, or the like.
Status Message; Indicates an alarm or error occurrence with flashing of the
corresponding icon. Indicates status such as warming-up,
calibrating, or the like by icon.
Alarm, Error Display; Displays alarms such as “Abnormal cell e.m.f.” when any such
status occurs.
Calibration functions:
Auto-Calibration;
It calibrates automatically at specified intervals.
Semi-auto Calibration; Input calibration direction on the touch screen or contact, then it
calibrates automatically afterwards.
Manual Calibration; Calibration with opening/closing the valve of calibration gas in
operation interactively with an LCD touch screen.
IM 11M12D01-01E
< 2. Specifications >
2-13
Validation Function: Permits control room activation of zero, span or midpoint gas
concentrations without running an actual calibration.
Blow back Function:
Output through the contact in the set period and time. Auto/Semi-auto selectable.
Maintenance Functions: Can operate updated data settings in daily operation and checking. Display
data settings, calibration data settings, blow back data settings, current
output loop check, input/output contact check.
Setup Functions:
Initial settings suit for the plant conditions when installing the converter.
Equipment settings, current output data settings, alarm data settings, contact
data settings, other settings.
Self-diagnosis:
This function diagnoses conditions of the converter or the detector and
indicates when any abnormal condition occurs.
Password Functions:
Enter your password to operate the analyzer excepting data display.
Individual passwords can be set for maintenance and setup.
Display and Setting Content:
Measuring Related Items: Oxygen concentration (vol% O2)
Display Items:
Cell e.m.f. (mV), thermocouple e.m.f. (mV), cold junction resistance (Ω),
cell temperature (°C), cold junction temperature (°C),
span correction ratio (%), zero correction ratio (%), cell response time
(second), cell condition(in four grades), cell internal resistance (Ω),
next calibration estimate(year/month/day), heater on-time rate (%), time
(year/month/day, hour/minute), software revision, maximum/ minimum/
average oxygen concentration (vol%O2), calibration record (ten times),
internal temperature rise alarm record.
Calibration Setting Items: Span gas concentration(vol%O2), zero gas concentration(vol%O2),
calibration mode(auto, semi-auto, manual), calibration type and
method (zero-span calibration, zero calibration only, span calibration only),
stabilization time (minute/ second), calibration time (minute/second),
calibration period (day/hour), starting time (year/month/day, hour/minute)
Equipment Related Items: Measuring gas selection; wet/dry
Detector selection; ZR22/ZO21
Output Related Items:
Analog output/output mode selection, output conditions when warming- up/
maintenance/calibrating (during blow back)/abnormal, 4 mA/20 mA point
oxygen concentration (vol%O2), time constant, preset values when warmingup/ maintenance/calibrating during blow back abnormal, output preset
values on abnormal.
Alarm Related Items:
Oxygen concentration high alarm/high-high alarm limit values(vol% O2),
oxygen concentration low alarm/low-low alarm limit values (vol% O2),
oxygen concentration alarm hysteresis (vol% O2), oxygen concentration
alarm detection, alarm delay (seconds)
Converter Output:
mA analog output (4 to 20 mA DC (maximum load resistance of 550 Ω)).
Average-value output; 3 points (average value a, average value b, average value c=(a+b)/2)
Independent output; Output to each channel
Range; Any setting between 0 to 5 through 0 to 100 vol% O2 in 1 vol% O2, or partial
range is available (Maximum range value/minimum range value 1.3 or more)
For the log output, the minimum range value is fixed at 0.1 vol% O2.
4 to 20 mA DC linear or log can be selected.
Input/output isolation; Isolation between the input channel. Isolation between the output
channel (option).
IM 11M12D01-01E
2-14
< 2. Specifications >
Output damping; 0 to 255 seconds. Hold/non-hold selection, preset value setting
possible with hold.
Contact Output:
5 points, contact capacity 30 V DC 3 A, 250 V AC 3 A (resistive load)
Four of the output points can be selected to either normally energized
or normally deenergized status. Delayed functions (0 to 255 seconds)
and hysteresis function (0 to 9.9 vol%O2 can be added to high/low alarms.
The following functions are programmable for contact outputs.
(1) Abnormal, (2) High-high alarm, (3) High alarm, (4) Low-low alarm, (5)
Low alarm, (6) Maintenance, (7) Calibration, (8) Range switching
answerback, (9) Warm-up, (10) Calibration-gas pressure decrease
(answerback of contact input), (11) Blow back start, (12) Process alarm
(answerback of contact input), (13) Calibration coefficient alarm, (14) Internal
temperature rise alarm.
Contact output 5 is set to normally operated, fixed error status.
Contact Output for Individual Channel Fail: Output to each channel. Normally energized.
Each channel cards provides a failure contact output.
(1) Abnormal cell, (2) Abnormal cell temperature (high/low), (3) Abnormal
channel card, (4) Abnormal control card, (5) Abnormal card communication
Contact Input:
2 points, voltage-free contacts.
The following functions are programmable for contact inputs.
(1) Calibration-gas pressure decrease alarm, (2) Range switching,
(3) External calibration start, (4) Process alarm (if this signal is received,
the heater power turns off), (5) Validation start, (6) Blow back start
Self-diagnosis:
Abnormal cell, abnormal cell temperature (high/low), abnormal channel card,
abnormal control card, abnormal card communication
Calibration:
Method; zero/span calibration
Calibration mode; automatic, semi-automatic and manual (All are operated
interactively with an LCD touchscreen). Either zero or span can be skipped.
Zero calibration-gas concentration setting range; 0.3 to 100 vol% O2 (0.01
vol%O2 in smallest units).
Span calibration-gas concentration setting range; 4.5 to 100 vol% O2 (0.01
vol% O2 in smallest units).
Use nitrogen-balanced mixed gas containing 0 to 10 % scale of oxygen, and 80 to 100 %
scale of oxygen for standard zero gas and standard span-gas respectively.
Calibration period; date/time setting; maximum 255 days/23hours.
FOUNDATION Fieldbus communication function
The bi-directional digital communication as standard for FOUNDATION Fieldbus that is established by
Fieldbus foundation.
Interface :
FOUNDATION Fieldbus H1 (communication speed : 31.25 kb/s)
Physical layer type :
113 (standard-power signaling, bus powered, non I.S.)
Communication line condition: power supply----9 to 32 V DC, current supply----15 mA (Max)
Signal insulation :
Communication terminal to grand terminal, dielectric strength 500 Vrms
(50/60 Hz, 1 min).
Device :
Link master
IM 11M12D01-01E
2-15
< 2. Specifications >
Function block :
AI block ;
DI block ;
MAI block ;
MAO block ;
3 blocks (1 block for each channels)
Transfer the data of averaging oxygen concentration to other instruments.
2 blocks
Transfer the status of error and alarm to other instruments.
1 block (8 channels)
Transfer the data of oxygen concentration to other instruments.
1 block (8 channels)
Import the data of other instruments.
Model and Codes
Averaging Converter
Model
Suffix Code
Option Code
AV550G
---------------------------
-------------
Averaging Converter
Base (*1)
-A
-B
-------------------------
4 Channel Base
8 Channel Base
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1 Oxygen Channel Card, Common Isolation
2 Oxygen Channel Cards, Common Isolation
3 Oxygen Channel Cards, Common Isolation
4 Oxygen Channel Cards, Common Isolation
5 Oxygen Channel Cards, Common Isolation
6 Oxygen Channel Cards, Common Isolation
7 Oxygen Channel Cards, Common Isolation
8 Oxygen Channel Cards, Common Isolation
1 Oxygen Channel Card, Individual Isolation
2 Oxygen Channel Cards, Individual Isolation
3 Oxygen Channel Cards, Individual Isolation
4 Oxygen Channel Cards, Individual Isolation
5 Oxygen Channel Cards, Individual Isolation
6 Oxygen Channel Cards, Individual Isolation
7 Oxygen Channel Cards, Individual Isolation
8 Oxygen Channel Cards, Individual Isolation
-------------------------------------------------
Japanese
English
French
German
-------------------------
100 / 115 V AC
230 V AC (*3)
-------------------------
HART communication
FOUNDATION Fieldbus communication (*4)
/SCT- - - - - - - /24- - - - - - - - - /G- - - - - - -
Stainless steel tag plate
24 Voltage output for Solenoid valve
Cable gland (Numbers in (*5)
Number of Channel
Card (*2)
-A1
-A2
-A3
-A4
-A5
-A6
-A7
-A8
-B1
-B2
-B3
-B4
-B5
-B6
-B7
-B8
Display
-J
-E
-F
-G
Power supply
Communication
-1
-2
-E
-F
Options
Description
(*1) Select code “-B” (8 Channel Base) when future expansion exceeding 4 channels is expected.
By so doing, the expansion can be made economically.
(*2) Common isolation is recommended, when the same instrument receives the analog outputs from each channel card.
Individual isolation is recommended to prevent the trouble by mutual interference, when different instrument receives
the analog outputs from each channel card.
(*3) When suffix code “-2” (230 V AC) is selected, select code “-A” (4 Channel Base).
(*4) When suffix code “-F” (FOUNDATION Fieldbus communication) is selected, used exclusively for communication.
When using AV550G as CE marking compliance product, select HART communication.
(*5) Input 01 to 30 in .
Standard Accessories
Part No
Quantity
Remarks
Fuse
Name
A1112EF
2
2.5 A
Hexagonal Allen Wrench
L9827AS
1
For lock screw
IM 11M12D01-01E
2-16
< 2. Specifications >
Channel Card
Suffix Code
Option Code
AV55CM
Model
-------------
-------------
Channel Card
Number of
Channels (*1)
-A1
-A2
-A3
-A4
-A5
-A6
-A7
-A8
-B1
-B2
-B3
-B4
-B5
-B6
-B7
-B8
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1 Oxygen Channel Card, Common Isolation
2 Oxygen Channel Cards, Common Isolation
3 Oxygen Channel Cards, Common Isolation
4 Oxygen Channel Cards, Common Isolation
5 Oxygen Channel Cards, Common Isolation
6 Oxygen Channel Cards, Common Isolation
7 Oxygen Channel Cards, Common Isolation
8 Oxygen Channel Cards, Common Isolation
1 Oxygen Channel Card, Individual Isolation
2 Oxygen Channel Cards, Individual Isolation
3 Oxygen Channel Cards, Individual Isolation
4 Oxygen Channel Cards, Individual Isolation
5 Oxygen Channel Cards, Individual Isolation
6 Oxygen Channel Cards, Individual Isolation
7 Oxygen Channel Cards, Individual Isolation
8 Oxygen Channel Cards, Individual Isolation
-------------
Always -A
/K1- - - - - - - - - -
Expansion power supply unit for dry contact output
of solenoid valve output. (*2)
Expansion power supply unit for 24 volt output
of solenoid valve output. (*3)
—
Option
-A
/K2- - - - - - - - - -
Description
(*1) -A are common Isolation types -B are Individual Isolation types
Up to 4 channel cards can be added in the 230 V AC version.
(*2) Expansion power supply unit is required, when using the 4 channel base and extending the number of
channel cards to five or more.
The expansion power supply unit cannot be added in the 230 V AC version.
(*3) Expansion power supply unit is required, when using the 4 channel base and extending the number of
channel cards to five or more. Available only in U.S.
IM 11M12D01-01E
< 2. Specifications >
2-17
• External Dimensions
266.7
300
.5
165.1
35.5
R3
.5
R3
R3
17.3
150
R3
480 (without cable gland and grommet)
5
R3.
Unit: mm
480 (without knob)
465
166.5
457
4-knobs
Extension view
Distance between mounting hole
465
7
10-M5
holes
266.7
165.1
150
300
6
200
Maintenance space
200
800
300
200
F2-5E.ai
IM 11M12D01-01E
2-18
< 2. Specifications >
2.5
ZA8F Flow Setting Unit
ZA8F Flow Setting Unit
This flow setting unit is applied to the reference gas and the calibration gas in a system configuration
(System 1). Used when instrument air is provided.
This unit consists of a flowmeter and flow control valves to control the flow rates of calibration gas and
reference gas.
Standard Specifications
Construction:
Dust-proof and rainproof construction
Case Material:
SPCC (Cold rolled steel sheet)
Painting:
Baked epoxy resin, Dark-green (Munsell 2.0 GY 3.1/0.5 or equivalent)
FIowmeter Scale:
Calibration gas; 0.1 to 1.0 l/min.
Reference gas; 0.1 to 1.0 l/min.
Tube Connections:
Rc1/4 or 1/4 FNPT
Reference Gas pressure: Clean air supply of sample gas pressure plus approx. 50 kPa G
(or sample gas pressure plus approx. 150 kPa G when a check valve
is used). Pressure at inlet of the Flow Setting Unit.(Maximum 300 kPaG)
Reference Gas Consumption: Approx. 1.5 l/min
Calibration gas (zero gas, span gas) Consumption: Approx. 0.7 l/min (at calibration time only)
Weight:
Approx. 2.3 kg
NOTE
Use instrument air for span calibration gas, if no instrument air is available, contact Yokogawa.
Model and Codes
Model
Suffix code
Option code
ZA8F
--------
---------
Flow setting unit
Joint
-J
-A
-----------------
Rc 1/4
With 1/4 NPT adapter
---------
Style C
Style code
IM 11M12D01-01E
*C
Description
2-19
< 2. Specifications >
● External Dimensions
180
ø6 Hole
Unit : mm
140
7
REFERENCE CHECK
REFERENCE SPAN
235.8
JIS 50A (60.5mm)
mounting pipe
ZERO
222.8
Calibration gas outlet
Span gas inlet
Reference gas outlet
Zero gas inlet
32
Piping connection port A
REF
OUT
70
AIR
IN
CHECK
OUT
SPAN
IN
ZERO
IN
Model
35
20
35
35
7
35
35
20
Instrument air inlet
Piping connection port A
ZA8F-J*C
5 - Rc1/4
ZA8F-A*C
5 - 1/4 NPT
Weight : Approx. 2.3 kg
PIPNG INSIDE THE FLOW SETTING UNIT
REF
OUT
CHECK
OUT
Flowmeter
Flowmeter
AIR IN
ZERO
GAS IN
SPAN
GAS IN
Instrument air
Approx. 1.5 l/min.
Air Set
Air pressure ;
without check valve ; sample gas pressure + approx.50 kPaG
with check valve ; sample gas pressure + approx.150 kPaG
F2-6E.ai
IM 11M12D01-01E
2-20
< 2. Specifications >
2.6
Other Equipments
2.6.1 Dust Filter for the Detector (K9471UA)
This filter is used to protect the detector sensor from a corrosive dust components or high velocity
dust in recovery boilers and cement kilns.
Sample gas flow rate is needed to be 1 m/sec or more to replace gas inside zirconia sensor.
• Standard specification
Applicable detector:
Standard-type detector for general-purpose (the sample gas flow should
be approximately perpendicular to the probe.)
Material:
Carborundum (Filter), SUS316 (JIS)
Mesh:
30 microns
Weight:
Approx. 0.2 kg
Part No.
Description
K9471UA
Filter
K9471UX
Tool
Unit : mm
Carborundum filter (SiC)
Detector
Ø51
32
Screw
10
Increasing of insertion length
Attach the filter unit to the tip of
the detector by screwing it clockwise.
F2-7E.ai
2.6.2 Dust Guard Protector (K9471UC)
Recommended to be used when sample gas is likely to flow directly into the cell due to its flow
direction in the stack or the like, flammable dust may go into the cell, or water drops are likely to fall
and remain in the cell during downtime or the like due to the installation position.
Material:
SUS316(JIS)
Weight:
Approx. 0.3 kg
Increasing of insertion length
Ø50.8
100
4-Ø6
122
F2-8E.ai
IM 11M12D01-01E
< 2. Specifications >
2-21
2.6.3 Ejector Assembly for High Temperature (E7046EC, E7046EN)
This ejector assembly is used where pressure of sample gas for high temperature detector is
negative. This ejector assembly consists of an ejector, a pressure gauge assembly and a needle
valve.
Standard Specifications
Needle Valve
Connection:
Rc1/4 or 1/4 FNPT
Material:
SUS316 (JIS)
Pressure Gauge Assembly
A 1.6 3/8 x75 x100 kPa (JIS B7505)
Type:
Material in Contact with Gas: SUS316 (JIS)
Case Material:
Aluminum alloy (Paint color; black)
Connection:
R1/4 or 1/4 NPT, SUS304 (JIS) (with Bushing G3/8 x R1/4 or
1/4 FNPT)
0 to 100 kPa G
Scale:
Ejector
Ejector Inlet Air Pressure: 29 to 68 kPa G
Air Consumption:
Approx. 30 to 40 l/min
Suction gas flow rate:
3 to 7 l/min
Connection to Blow:
Rc1/4, SUS304 (JIS)
Tube Connection:
Φ 6 / Φ 4 mm or 1/4 inch copper tube (stainless tube)
(Note) Pipe and connections are not provided.
Part No.
Description
E7046EC
Needle valve; Rc1/4, Ejector; Ø6 / Ø4 TUBE joint, Pressure gauge; R1/4
E7046EN
Needle valve; 1/4 FNPT, Ejector; 1/4 TUBE joint, Pressure gauge; 1/4 NPT
Dimension
Pressure gauge assembly
39
Pressure gauge
Instrument air inlet
<1>
40
Approx. 88
Approx. 67
Ø43
Full open
height
Connector (Tee) is not
included in ejector assembly.
<3>
<2>
Nozzle (Note1)
R1/2
Approx. 70
38
Ejector
Needle valve
Detector
20
Tee
Blow Rc1/4
(Note1) The connecter of ejector is a dedicated
connecter with nozzle function.
<1> Rc1/4 or 1/4 FNPT
<2> Ø6/Ø4 or 1/4 inch copper tube (stainless)
with ejector to connect
<3> R1/4 or 1/4 NPT
F2-9E.ai
IM 11M12D01-01E
2-22
< 2. Specifications >
Needle valve
Pressure gauge
Po
Qa
Air source
L
Ejector
Pg
Qg
Graph 1
Po (kPa)
200
100
Graph 2
Qa (l/min)
40
P= 0.5
30
0
5
10
15
0
40
P (kPa)
L (m)
Pressure setting characteristics
Graph 3
Pg (kPa)
60
80
Air consumption characteristics
-1.0
Qg (l/min)
8
-0.5
4
0
0
Graph 4
Gas pressure: 0 kPa
Sample Gas
Po (kPa)
P
(kPa)
Pg (kPa)
Qa (l/min)
Qg (l/min)
L
(m)
Gas pressure : -150 Pa
40
60
80
P (kPa)
Suction pressure characteristics
40
60
: Pressure setting
: Drive pressure (at the ejector entrance)
: Suction pressure
: Air consumption
: Suction flow
: Distance between the ejector and the pressure
gauge
80
P (kPa)
Suction flow characteristics
F2-10E.ai
< Pressure setting for the ejector for high temperature use >
Pressure supply for the ejector should be set so that the suction flow of the sample gas becomes
approximately 5 l/min.
To set this, proceed as follows:
(1) In Graph 4, draw a horizontal line from the 5 l/min point on the vertical axis (Suction flow: Qg)
toward the gas pressure line to be used, to find the point of intersection. Draw a line vertically
down from the point of intersection to the axis to find the drive pressure, P (at the ejector
entrance).
(2) In Graph 1, determine Po (pressure setting) from L (the distance between the ejector and the
pressure gauge).
(3) Open the needle valve to supply air for the ejector to the pressure gauge until it indicates the
pressure setting, Po.
NOTE
Qg (the suction flow) may require change according to the conditions of use. Refer to Subsection
3.2.2 and Subsection 4.1.4 for details.
Graph explanation
1)
Graph 1 is to compensate for pressure loss in piping between the ejector and the pressure
gauge, and find Po (pressure setting).
2)
Graph 2 shows correlation between P (drive pressure) and Qa (air consumption).
3)
Graph 3 shows correlation between P (drive pressure) and Pg (suction pressure; when the
sample gas inlet of the ejector is closed).
4) Graph 4 shows correlation between P (drive pressure) and Qg (suction flow) for each gas
pressure.
IM 11M12D01-01E
< 2. Specifications >
2-23
2.6.4 Stop Valve (L9852CB, G7016XH)
This valve mounted on the calibration gas line in the system using ZA8F flow setting unit for manual
calibration.
Standard Specifications
Material:
SUS 316 (JIS)
Connection:
Rc 1/4 or 1/4 FNPT
Weight:
Approx. 80 g
Part No.
Description
L9852CB
Joint: Rc 1/4, Material: SUS316 (JIS)
G7016XH
Joint: 1/4 FNPT, Material: SUS316 (JIS)
Unit: mm
55
Rc1/4 or 1/4 FNPT
(Full open length)
Ø43
40
F2-11E.ai
2.6.5 Check Valve (K9292DN, K9292DS)
This valve is mounted on the calibration gas line (directly connected to the detector).
This valve prevents the sample gas from entering the calibration gas line. Although it functions as
a stop valve, operation is easier than a stop valve as it does not require opening/closing at each
calibration.
Screw a check valve, instead of a stop valve into the calibration gas inlet of the detector.
Standard Specifications
Material:
SUS304 (JIS)
Connection:
Rc1/4 or 1/4 FNPT
Pressure:
150 kPa G or more and 350 kPa G or less
Weight:
Approx. 40 g
Part No.
Description
K9292DN
Joint: Rc 1/4, Material: SUS304 (JIS)
K9292DS
Joint: 1/4 FNPT, Material: SUS304 (JIS)
K9292DN : Rc 1/4(A),R 1/4(B)
K9292DS : 1/4 FNPT(A),1/4 NPT(Male)(B)
Unit: mm
A
Approx. 19
B
Approx. 54
F2-12E.ai
IM 11M12D01-01E
2-24
< 2. Specifications >
2.6.6 Air Set
This set is used to lower the pressure when instrument air is used as the reference and span
gases.
Standard Specifications
• G7003XF, K9473XK
Primary Pressure:
Max. 1 MPa G
Secondary Pressure: 0.02 to 0.2 MPa G
Connection:
Rc1/4 or 1/4 FNPT (with joint adapter)
Weight:
Approx.1 kg
Part No.
Description
G7003XF
Joint: Rc 1/4, Material: Zinc alloy
K9473XK
Joint: 1/4 FNPT (with joint adapter), Material: Zinc alloy, Adapter: SUS 316
• G7004XF, K9473XG
Primary Pressure:
Max. 1 MPa G
Secondary Pressure: 0.02 to 0.5 MPa G
Connection:
Weight:
Rc1/4 or 1/4 FNPT with joint adapter
Approx. 1 kg
Part No.
Description
G7004XF
Joint: Rc 1/4, Material: Zinc alloy
K9473XG
Joint: 1/4 FNPT (with joint adapter), Material: Zinc alloy, Adapter: SUS 316
External Dimensions
Unit : mm
View A
Panel cut dimensions
Horizontal
mounting
22 ø15
Vertical
mounting
40
+0.5
2-ø2.2-0
40
2-ø6.5
max. 55
2-ø6 screw depth 8
Secondary
pressure
gauge
Secondary
G7003XF, G7004XF: Rc 1/4
K9473XK, K9473XG: 1/4 FNPT
(with joint adapter)
Approx. 122
IM 11M12D01-01E
Panel (Vertical mounting)
A
88
Primary
Max. 210
Ø74
Panel (Horizontal mounting)
F2-13E.ai
2-25
< 2. Specifications >
2.6.7 Zero Gas Cylinder (G7001ZC)
The gas from this cylinder is used as the calibration zero gas and detector purge gas.
Standard Specifications
Capacity:
3.4 l
Filled Pressure:
9.8 to 12 MPa G
Composition:
0.95 to 1.0 vol% O2 in N2
Weight:
Approx. 6 kg
(Note) Export of such high pressure filled gas cylinder to most countries is prohibited or restricted.
325
485
Unit : mm
Ø140
F2-14E.ai
2.6.8 Cylinder Pressure Reducing Valve (G7013XF, G7014XF)
This pressure reducing valve is used with the zero gas cylinders.
Standard Specifications
Primary Pressure:
Max. 14.8 MPa G
Secondary Pressure:
0 to 0.4 MPa G
Connection:
Inlet; W22 14 threads, right hand screw
Outlet; Rc1/4 or 1/4 FNPT
Material:
Brass body
Unit : mm
Approx.112
Secondary pressure gauge
Primary pressure gauge
Reducing valve handle
W22 (Right hand screw)
Inlet
ACH
O
IH
TAK
Stop valve
Secondary
safety valve
* Outlet
Primary safety valve
Approx. 59
Approx. 82
Approx. 174
Approx. 163
Part No.
* Outlet
G7013XF
Rc1/4
G7014XF
1/4 NPT female with adapter
F2-15E.ai
IM 11M12D01-01E
2-26
< 2. Specifications >
2.6.9 Case Assembly for Calibration Gas Cylinder (E7044KF)
This case assembly is used to store the zero gas cylinders.
Standard Specifications
Installation:
JIS 50A (Ø 60.5 mm) pipe mounting
Material:
SPCC (Cold rolled steel sheet)
Case Paint:
Baked epoxy resin, Jade green (Munsell 7.5 BG 4/1.5)
Weight:
Approx. 3.6 kg, Approx. 10 kg with gas cylinder
(Note) Export of such high pressure filled gas cylinder to most countries prohibited or restricted.
Unit : mm
Pressure reducing valve
225
180
( G7013XF / G7014XF )
324
Zero gas cylinder
496
(G7001ZC)
(158.3)
(160)
JIS 50A mounting pipe
( Ø60.5 )
The oblique line is an opening portion.
F2-16E.ai
(Note) The zero gas cylinder and the reducing valve are not included in the E7044KF (case assembly)
2.6.10 ZR22A Heater Assembly
Model and Codes
Model
Style: S2
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 (*2)
None
-------------------------------
Natural convention, Instrument air
Pressure compensated (for ZR22G S2)
Pressure compensated (for ZR22G S1)
Jig for change
Reference gas (*3)
-A
-N
-A
-B
-C
Description
*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.
IM 11M12D01-01E
< 2. Specifications >
2-27
Unit : mm
30
Ø45
(K9470BX)
K9470BX
Jig for change
Ø21.7
• External Dimensions
L ± 12
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
F2-17E.ai
IM 11M12D01-01E
Blank Page
3-1
< 3. Installation >
3. Installation
This chapter describes installation of the following equipment:
3.1
Section 3.1
General-purpose Detector (except ZR22G-015)
Section 3.2
High Temperature Detector (ZR22G-015)
Section 3.3
AV550G Averaging Converter
Section 3.4
ZA8F Flow Setting Unit
Section 3.5
Case Assembly (E7044KF)
Installation of General-purpose Detector
3.1.1 Installation Location
The following should be taken into consideration when installing the detector:
(1) Easy and safe access to the detector for checking and maintenance work.
(2) An ambient temperature of not more than 150 °C, and the terminal box should not be affected by
radiant heat.
(3) A clean environment without any corrosive gases.
NOTE
A natural convection type detector (model ZR22G----C), which uses ambient air as reference
gas, requires that the ambient oxygen concentration be constant.
(4) No vibration.
(5) The sample gas satisfies the specifications described in Chapter 2.
3.1.2 Probe Insertion Hole
Includes those analyzers equipped with a dust filter, a dust guard protector and probe protector.
When preparing the probe insertion hole, the following should be taken into consideration:
CAUTION
• The outside dimension of detector may vary depending on its options. Use a pipe that is large
enough for the detector. Refer to Figure 3.1 for the dimensions.
• If the detector is mounted horizontally, the calibration gas inlet and reference gas inlet should
face downwards.
• When using the detector with pressure compensation, ensure that the flange gasket does not
block the reference gas outlet on the detector flange. If the flange gasket blocks the outlet, the
detector cannot conduct pressure compensation. Where necessary, make a notch in the flange
gasket. Confirm the external dimensions of the detector in Section 2.2 before installation.
• The sensor (zirconia cell) at the tip of the detector may deteriorate due to thermal shock if water
drops are allowed to fall on it, as it is always at high temperature.
IM 11M12D01-01E
3-2
< 3. Installation >
(1) Do not mount the probe with the tip higher than the probe base.
(2) If the probe length is 2.5 meters or more, the detector should be mounted vertically
(no more than a 5° tilt).
(3) The detector probe should be mounted at right angles to the sample gas flow or the probe tip
should point downstream.
(vertical)
Bounds of the probe
insertion hole location
Flange matches
the detector size
100 mm
*1
Type
Outside diameter of detector
Standard
50.8 mm in diameter (Note)
With dust filter
51 mm in diameter (Note)
With probe protector 60.5 mm in diameter (Note)
(horizontal)
*1
Note
100 mm
Four-hole flange
Eight-hole flange
F3-1E.ai
(Note)
When using the detector with pressure compensation, ensure that the flange gasket does not block the reference gas outlet on
the detector flange. If the flange gasket blocks the outlet, the detector cannot perform pressure compensation.
Where necessary, make a notch in the flange gasket. Confirm the outside dimensions of the detector in Section 2.2 before
installation.
Figure 3.1 Example of the probe insertion hole.
3.1.3 Installation of the Detector
CAUTION
• The cell (sensor) at the tip of the detector is made of ceramic (zirconia). Do not drop the detector,
as impact will damage it.
• A gasket should be used between the flanges to prevent gas leakage. The gasket material
should be heatproof and corrosion-proof, suited to the characteristics of the sample gas.
The following should be taken into consideration when mounting the general-purpose detector:
(1) Make sure that the cell mounting screws (four bolts) at the tip of the detector are not loose.
If a dust filter (see Subsection 2.6.1) is used, make sure it is properly attached to the detector.
Refer to Subsection 3.1.4 for installation of the dust filter.
(2) Where the detector is mounted horizontally, the calibration gas inlet and the reference gas inlet
should face downward.
IM 11M12D01-01E
3-3
< 3. Installation >
3.1.4 Installation of the Dust Filter (K9471UA), Dust Guard Protector (K9471UC),
Probe Protector ZO21R
CAUTION
• The dust filter is used to protect the Zirconia sensor from corrosive dust or a high concentration
of dust such as in utility boilers and cement kilns. If a filter is used in combustion systems other
than these, it may have adverse effects such as response delay. These combustion conditions
should be examined carefully before using a filter.
• The dust filter requires gas flow of 1 m/sec or faster at the front surface of the filter.
When you specify option code /F1, the detector is shipped with the dust filter mounted.
Follow this procedure replace the filter on the detector . It is recommended that you read Chapter 11
prior to filter mounting, for it is necessary to be familiar with the detector’s construction, especially the
sensor assembly.
(1) Mount the dust filter assembly by putting it on the end of the detector and screw the assembly
clockwise. Put a hook pin wrench (K9471UX), Φ52 to 55 in diameter, into the hole on the
assembly to fasten or remove it. Apply a heat-resistant coating (see Note 1) to the threads on
the detector. When remounting filter assembly after having once removed it from the detector,
reapply the heat-resistant coating.
Note 1:
As the detector is heated to 700 °C, it is recommended to use heat-resistant coating on the threads to prevent seizing up.
Name of the heat-resistant coating material: NEVER SEEZ Nickel Special”.
32
Detector
Unit : mm
Ø51
Carborundum filter (SiC)
Attach the filter unit to
the tip of the detector
by screwing it clockwise.
Screw
10
Increasing of insertion length
F3-2E.ai
Figure 3.2.1 Installation of the dust filter
< Procedures for installation of the dust guard protector (K9471UC)>
The ZR22G detector is shipped with the dust guard protector when the option code / F2 is specified in
case of ordering the detector. The protector should be used when preventing dusts and water drops
from lowering the detector performance is desired.
Screw the protector on the top of the detector so as to cover the top. When attaching or detaching the
protector, perform by hooking holes of its side with a hook pin wrench for Φ52-55 hole (Pin diameter
4.5 mm: P/N K9471UX or the like) or by pass a screwdriver through the holes. When re-attaching the
protector after detaching it, apply the “NEVER SEEZ Nickel Special” to it.
IM 11M12D01-01E
3-4
< 3. Installation >
Unit : mm
Ø50.8
Increasing of insertion length
100
4-Ø6
122
F3-3E.ai
Figure 3.2.2 Installation of the dust guard protector
The detector is used with a probe protector to support the probe (ZR22G) when the probe length is 2.5
m or more and it is mounted horizontally.
(1) Put a gasket (provided by the user) between the flanges, and mount the probe protector in the
probe insertion hole.
(2) Make sure that the sensor assembly mounting screws (four bolts) at the tip of the detector are
not loose.
(3) Mount the detector so that the reference gas and calibration gas inlet faces downward.
Figure 3.3 Probe protector (supporting the mounting strength)
Flow direction of the sample gas
Unit: mm
Gasket (Thickness 3.0)
2050
Ø60.5
Notch
Probe top
Reference gas inlet
Calibration gas inlet
F3-4E.ai
The detector is used with a probe protector to prevent the sensor from being worn by dust particles
when there is a high concentration of dust and gas flow exceeds 10 m/sec (pulverized coal boiler or
fluidized-bed furnace).
(1) Put a gasket (provided by the user) between the flanges, and mount the probe protector in the
probe insertion hole. The probe protector should be installed so that the notch is downstream of
the sample gas flow.
(2) Make sure that the sensor assembly mounting screws (four bolts) at the probe tip are not loose.
(3) Where the detector is mounted horizontally, the reference gas and calibration gas inlet should
face downward.
When the probe length of the ZR22G is more than 2m, consult Yokogawa.
NOTE
When the probe protector is used in the ZR22G with pressure compensation (-P), instrument air
leaking from the probe protector may affect the measured value.
IM 11M12D01-01E
3-5
< 3. Installation >
1050,1550,2050
Gasket (Thickness 3.0)
Unit: mm
Flow direction of the sample gas
Probe top
Mount the protector so that the notch is
the downstream side of the gas flow.
F3-5E.ai
Reference gas inlet
Calibration gas inlet
Figure 3.4 Probe protector (for dust wear protect)
3.2
Installation of High Temperature Detector
(ZR22G-015)
3.2.1 Installation Location
This detector is used with the High Temperature Probe Adapter (Model ZO21P) when the temperature
of sample gas exceeds 700 °C, or when it is required due to maintenance spaces.
The following should be taken into consideration when installing the detector:
(1) Easy and safe access to the detector for checking and maintenance work.
(2) Ambient temperature of not more than 150 °C and the terminal box should not be exposed to
radiant heat.
(3) A clean environment without any corrosive gases.
(4) No vibration.
(5) The sample gas should satisfy the specifications described in Chapter 2.
3.2.2 Usage of the High Temperature Probe Adapter (ZO21P)
During analysis, the surface temperature of the probe adapter should be within the range from
more than the dew point of the sample gas and 300 °C or less to prevent ejector clogging, gasket
deterioration or bolt scoring.
Where the dew point of the sample gas is not known, keep within the range of more than 200 °C to
less than 300 °C.
The temperature shall be measured at the probe in the probe adapter and the surface of the blind
flange at the opposite side.
When the surface temperature is not within the above range, the following measures can be taken to
change the temperature.
(1) When the furnace pressure is negative, lower the pressure setting to reduce induction flow
of the sample gas. Refer to Subsection 2.6.3, Ejector Assembly for High Temperature, for the
setting of induction flow. When you reduce induction flow, ensure that the ejector inducts air
when the furnace pressure fluctuates.
(2) When the furnace pressure is positive, close the needle valve for the sample gas outlet to
reduce the exhaust gas flow. Refer to Subsection 4.1.4, Piping to the High Temperature Probe
Adapter.
IM 11M12D01-01E
3-6
< 3. Installation >
(3) When the probe adapter is surrounded by a heat insulator, remove the heat insulator. Ensure
that the temperature of the probe adapter does not fall below the dew point of the gas in winter.
(4) To prevent temperature rises due to radiant heat, insert heat insulator between the wall of the
furnace and the probe adapter.
(5) To prevent temperature rises from thermal conduction, place the mounting flange as far from the
wall of the furnace as possible.
(1) When the furnace pressure is negative, raise the pressure setting to increase induction flow
of the sample gas. Refer to Subsection 2.6.3, Ejector Assembly for High Temperature, for the
setting of induction flow. If there is much dust in the gas, the ejector may become clogged as
induction flow increases.
(2) When the furnace pressure is positive, open the needle valve of the sample gas outlet to
increase the gas flow. Refer to Subsection 4.1.4, Piping to the High Temperature Probe Adapter.
(3) Warm the probe adapter. Refer to Subsection 4.1.4, Piping to the High Temperature Probe
Adapter.
(4) When the surface temperature is still less than 200 °C or below the dew point of the sample gas,
even if the above measures have been taken, warm the probe adapter using a heat source such
as steam.
3.2.3 Probe Insertion Hole
A high temperature detector consists of a ZR22G-015 Detector and ZO21P High Temperature Probe
Adapter. When forming the probe insertion hole, the following should be taken into consideration:
(1) If the probe of the ZO21P is made of silicon carbide (SiC), the probe hole should be formed so
that the probe is mounted vertically (within ± 5° tilt).
(2) In the case where the probe of the ZO21P is made of stainless steel and the high temperature
probe adapter (ZO21P-H-B) is to be mounted horizontally, the probe hole should be formed so
that the probe tip is not higher than the probe base.
JIS 5K 50 FF (equivalent) or
ANSI Class 150 4 RF
(equivalent) flange
100mm
A space of 52 mm or more
in diameter, and long enough
for the length of the probe
The allowable margin for probe
tilt is within ± 5°.
An SiC probe shall be mounted vertically.
100mm
A space of 52 mm or
more in diameter, and
long enough for the length JIS 5K 50 FF (equivalent)
of the probe
or ANSI Class 150 4 RF
(equivalent) flange
Never mount the probe
with its tip higher than
the base
Horizontal mounting is used with a SUS probe.
F3-6E.ai
Figure 3.5 Examples of the probe insertion hole
3.2.4 Mounting of the High Temperature Detector
CAUTION
• Ceramic (zirconia) is used in the sensor (cell) portion on the detector probe tip. Care should be
taken not to drop the detector during installation.
IM 11M12D01-01E
3-7
< 3. Installation >
• The same applies to the high temperature probe adapter with a probe made of silicon carbide
(SiC).
• A gasket should be used on the flange surface to prevent gas leakage. The gasket material
should be selected depending on the characteristics of the sample gas. It should be heatproof and
corrosion-proof. The parts, which should be supplied by the user, are listed in Table 3.1.
Table 3.1 Accessories for mounting high temperature probe adapter
Mounting flange specification
JIS 5K 50 FF (equivalent)
ANSI Class 150 4 RF
(equivalent)
Parts name
Q’ty
Note
Gasket
1
Heatproof and corrosion-proof
Bolt (M12 by 50)
4
Nut (M12)
4
Washer (for M12)
8
Gasket
1
Bolt (M16 by 60)
8
Nut (M16)
8
Washer (for M16)
16
Heatproof and corrosion-proof
A high temperature detector should be mounted as follows:
(1) It is recommended to mount the detector vertically. When it is impossible due to the physical
arrangements and the detector is mounted horizontally, ensure that the probe tip be placed no
higher than the probe base.
(2) When mounting a high temperature probe adapter, be sure to insert a gasket between the
flanges to prevent gas leakage. When the furnace pressure is negative, ensure that there is no
leakage of air into the detector.
(3) When mounting the detector in a position other than vertical, the cable inlet should face
downward.
(4) When installing the detector in a low-temperature location such as in the open air, cover the
probe adapter including the ejector with a heat insulator (e.g. ceramic wool) to keep it warm and
to prevent condensation of drain on the ejector.
Wiring connection
Mounting the detector
vertically, probe tip
faces downward.
Wiring connection
When using an SiC probe, mount the probe vertically
with an allowable tilt of ± 5°.
F3-7E.ai
Figure 3.6 Mounting of the High Temperature Detector
IM 11M12D01-01E
3-8
< 3. Installation >
3.3
Installation of the Averaging Converter
The averaging converter is designed for indoor installation and should be installed in the instrument
panel in a control room. For outdoor installation, the averaging converter should be installed in an
outdoor instrument panel protected from direct sunlight and the weather.
WARNING
High voltages are present inside the averaging converter. To prevent unintentional opening of the front
cover, it is securely attached by a lock screw on the right side of the case. Loosen the lock screw to
remove the front cover, and securely tighten the lock screw after the front cover has been attached.
How to remove the front cover
• Loosen the 4 knob bolts by hand, and then loosen the lock screw with the Allen wrench supplied.
• Remove the front cover by lifting up slightly then pulling away from the case.
How to attach the front cover
• Attach the front cover, aligning the slots on the sides of the cover with the knob bolts on the case,
and then pull the cover down until it is seated firmly.
• Hand tighten the knob bolts, and then securely tighten the lock screw with the Allen wrench
supplied.
Knob Bolt
Lock Screw
F3-8E.ai
Figure 3.7 How to Remove/Attach the Front Cover
3.3.1 Installation Location
Follow the guidelines below when selecting a location for the averaging converter.
(1) The touch screen display should be clearly visible and easily accessible for key operation: the
display at eye level is recommended.
(2) A wall or construction should be strong enough to support the weight of the converter.
(3) The converter should be easily accessible for inspections and maintenance.
(4) The ambient temperature should be in the range of -5 to 50°C and the temperature variation
should be small: the daily temperature range within 15°C is recommended.
(5) The humidity should be in the range of 10 to 85%RH and no condensation may occur.
(6) No corrosive gases are present.
(7) No dust exists.
(8) There is minimal vibration.
IM 11M12D01-01E
3-9
< 3. Installation >
(9) The converter should be near the detectors: the two-way resistance between detector and
converter should not exceed 10Ω.
WARNING
The averaging converter is heavy. Take extra care not to accidentally drop it. Installation work should
be done by an adequate number of people.
CAUTION
The averaging converter is heavy (100/115 V AC version: approx. 13 kg, 230 V AC version: approx. 25
kg) so needs to be installed on a wall or construction strong enough to support.
3.3.2 Installation in an Instrument Panel
When installing the averaging converter in an instrument panel, operability, maintainability, and
environmental resistance should be considered.
(1) Installation Space and Relationship to Peripheral Devices
Follow the instructions below to determine the positions of the averaging converter and peripheral
devices.
• Do not place heat-generating devices in close proximity of the averaging converter:
specially, avoid a place under the averaging converter.
• Do not place power related devices such as transformers or electromagnetic switches in close
proximity of the averaging converter.
• Segregate wiring ducts for signal lines and those for power lines and do not place in close
proximity.
Figure 3.8 shows the requirements for the mounting holes for the averaging converter.
See Section 2.4 for the dimensions of the averaging converter and maintenance clearance.
6-M5 screws
Unit: mm
300 267
150
465
165
F3-9E.ai
Figure 3.8 Mounting holes
IM 11M12D01-01E
3-10
< 3. Installation >
(2) Preventing Excessive Temperature Rise in an Instrument Panel
Use a cooling method such as one of those shown in Figure 3.9 if there is a danger of the temperature
inside an instrument panel exceeding the temperature range limits.
▲
∞
▲
▲
▲
Fan
▲
∞
▲
▲
▲
▲
▲
▲▲▲
AV550G
AV550G
AV550G
▲▲
▲
▲
▲
▲
▲
▲
▲
▲
Natural air cooling
○
○
○
○
○
○
○
○
▲
▲ ▲ ▲
▲
▲
Air Filter
Forced air ventilation
F3-10E.ai
Forced air circulation
Figure 3.9 Preventing Excessive Temperature Rise in Panel
CAUTION
If an internal temperature rise alarm occurs, use a more effective method to cool the inside of an
instrument panel down to within the converter operating temperature range.
3.3.3 Outdoor Installation
The averaging converter is designed for indoor installation. For outdoor installation, the averaging
converter should be housed in an outdoor case protected from direct sunlight and the weather. The
outdoor case should be equipped with a cooling system for controlling the internal temperature, if
necessary. Also, the outdoor case should be installed in a location that keeps the case free from
corrosive gases or dust.
CAUTION
If an internal temperature rise alarm occurs, use a more effective method to cool the inside of an
instrument panel down to within the converter operating temperature range.
IM 11M12D01-01E
3.4
< 3. Installation >
3-11
Installation of ZA8F Flow Setting Unit
3.4.1 Installation Location
The following should be taken into consideration:
(1) Easy access to the unit for checking and maintenance work.
(2) Near to the detector or the converter.
(3) No corrosive gas.
(4) An ambient temperature of not more than 55 °C and little changes of temperature.
(5) No vibration.
(6) Little exposure to rays of the sun or rain.
3.4.2 Mounting of ZA8F Flow Setting Unit
The flow setting unit can be mounted either on a pipe (nominal JIS 50A) or on a wall. It should be
positioned vertically so that the flowmeter works correctly.
(1) Prepare a vertical pipe of sufficient strength (nominal JIS 50A: O.D. 60.5 mm) for mounting the
flow setting unit. (The unit weighs approximately 2 to 3.5 kg.)
(2) Mount the flow setting unit on the pipe by tightening the nuts with the U-bolt so that the metal
fitting is firmly attached to the pipe.
F3-11E.ai
Figure 3.10 Pipe Mounting
(1) Make a hole in the wall as illustrated in Figure 3.11.
(2) Mount the flow setting unit. Remove the pipe mounting parts from the mount fittings of the flow
setting unit and attach the unit securely on the wall with four screws.
Unit : mm
223
140
F3-12E.ai
Figure 3.11 Mounting holes
4 - Ø6 hole, or M5 screw
F3-13E.ai
Figure 3.12 Wall mounting
IM 11M12D01-01E
3-12
< 3. Installation >
3.5
Installation of the Case Assembly(E7044KF)
The case assembly is used to store the G7001ZC zero gas cylinders.
3.5.1 Installation Location
The following should be taken into consideration:
(1) Easy access for cylinder replacement.
(2) Easy access for checking.
(3) Near to the detector or converter as well as the flow setting unit.
(4) The temperature of the case should not exceed 40 °C due to rays of the sun or radiated heat.
(5) No vibration.
3.5.2 Mounting
Mount case assembly on a pipe (nominal JIS 50A) as follows:
(1) Prepare a vertical pipe of sufficient strength (nominal JIS 50A: O.D. 60.5 mm) for mounting
the case assembly. (The sum of the case assembly and the calibration gas cylinder weights
approximately 4.2 kg.)
(2) Mount the case assembly on the pipe by tightening the nuts with the U-bolt so that the metal
fitting is firmly attached to the pipe.
225
180
A pipe to be mounted
(nominal JIS 50A : O.D. 60.5 mm)
Figure 3.13 Pipe Mounting
IM 11M12D01-01E
Unit: mm
F3-14E.ai
4-1
< 4. Piping >
4. Piping
This chapter describes piping procedures for the AV550G Zirconia Oxygen Analyzer Averaging
Converter system based on two typical system configurations.
4.1
Piping for a System Using Flow Setting Units for
Manual Calibration
The piping for a system using flow setting units for manual calibration is shown in Figure 4.1.
ZR22G Detector (max. 8 detectors)
Output signal cable (Cell output,
thermocouple output, cold contact
compensation)
(0.75mm2, 6-core shield cable)
Model AV550G Averaging Converter
Analog outputs :
Averaged and
individual outputs
4 to 20 mA DC
Digital output
Heater power
(1.25mm2, 2-core shield cable)
Stop Valve
or
Check Valve
Contact output
Contact input
Reference gas
Needle
Flowmeter Valve
Calibration gas
Air set
Power supply :
100 / 115 V AC,
50 / 60 Hz±5%
Instrument air
Span gas (Calibration gas unit same as for zero gas)
ZA8F
flow setting unit
Calibration gas unit case
Pressure
reducing
valve
Zero
gas cylinder
F4-1E.ai
Figure 4.1 Typical Piping for System Using Flow Setting Units for Manual Calibration
The following outlines some points to note regarding the piping for this system.
• Install a stop valve or a check valve through a nipple on the calibration gas inlet of the detector.
CAUTION
The stop valve should be connected directly to the detector. If any piping is present between the
detector and the stop valve, condensation may develop in the pipe, causing damage to the detector
by rapid cooling when the calibration gas is introduced.
• When a high temperature detector is used and the pressure of a sample gas is negative, connect
an ejector assembly on the sample gas outlet of the high temperature probe adapter. (See Figure
4.3 in Subsection 4.1.4.)
• When a high temperature detector is used and the pressure of a sample gas is 0.49 kPa or higher,
it is recommended that a throttle (e.g., needle valve) be installed on the sample gas outlet of the
high temperature probe adapter. (See Figure 4.4 in Subsection 4.1.4.)
IM 11M12D01-01E
4-2
< 4. Piping >
CAUTION
This is to lower the temperature of a sample gas below 700°C. When both the temperature and the
pressure of a sample gas are high, the temperature of the sample gas may not fall below 700°C
before the gas reaches the detector. On the other hand, the temperature of a sample gas may drop
too much and thus condensation develops in the high temperature probe adapter. During wintertime,
it is recommended that the high temperature probe adapter be protected with an insulating material to
prevent condensation.
• When a high temperature detector is used and blow back is required to eliminate dust
accumulating in the probe of the high temperature probe adapter, air supply piping for purging
should be installed.
CAUTION
If a sample gas contains much dust (e.g., in recovery boilers or cement kilns), the probe is more likely
to become clogged. To eliminate this dust accumulation using air pressure, piping is generally installed
from an air source only when cleaning is performed. Some cases, however, may need a permanent
installation of the blow back piping. See Subsection 4.1.5 for the installation of blow back piping.
4.1.1 Parts Required for Piping in a System Using Flow Setting Units for Manual
Calibration
Referring to Table 4.1, check that the parts required for your system are ready.
Table 4.1 Parts Required for Piping in a System Using Flow Setting Units for Manual
Calibration
Detector
Piping Location
General-purpose Calibration gas
detector
inlet
Reference gas
inlet
High
Calibration gas
temperature
inlet
detector (0.15 m)
Reference gas
inlet
Sample gas
outlet
Parts Name
Remark
Stop valve or
Check valve
Yokogawa recommended: L9852CB/G7016XH or
K9292DN/K9292DS
* Nipple
R1/4 or 1/4 NPT (male-male)
General parts
Tube fitting
R1/4 (or 1/4 NPT) for a Ø6 Ø4
mm soft tube
General parts
Air set
Yokogawa recommended: G7003XF/K9473XK or
G7004XF/K9473XG
Connection fitting
R1/4 or 1/4 NPT (male)
Stop valve or
Check valve
Yokogawa recommended: L9852CB/G7016XH or
K9292DN/K9292DS
* Nipple
R1/4 or 1/4 NPT (male-male)
General parts
Tube fitting
R1/4 (or 1/4 NPT) for a Ø6 Ø4
mm soft tube
General parts
Air set
Yokogawa recommended: G7003XF/K9473XK or
G7004XF/K9473XG
Connection fitting
R1/4 or 1/4 NPT (male)
* Auxiliary ejector
assembly
Yokogawa recommended: E7046EC or E7046EN
* Equal tee,
connection fitting
Rc1/4 or 1/4 NPT (female)
* Needle valve
Rc1/4 or 1/4 NPT
General parts
* Reducing nipple
R1/2 to R1/4 or R1/2 to 1/4 NPT
General parts
Note: Parts marked with an asterisk (*) are used when required. General parts can be found on the local market.
IM 11M12D01-01E
General parts
General parts
General parts
4-3
< 4. Piping >
4.1.2 Piping for the Calibration Gas Inlet
This piping is to be installed between the zero gas cylinder and the ZA8F flow setting unit, and
between the ZA8F flow setting unit and the ZR22G detector.
The cylinder should be placed in a calibration gas unit case or the like to avoid any direct sunlight
or radiant heat so that the gas cylinder temperature does not exceed 40°C. Mount a regulator valve
(specified by Yokogawa) on the cylinder.
Mount a check valve or stop valve (specified by Yokogawa) on the nipple (found on the local market)
at the calibration gas inlet of the detector as illustrated in Figure 4.2.
(The check valve or the stop valve may have been mounted on the detector when shipped.)
Connect the flow setting unit and the detector to a stainless steel pipe 6 mm (O.D.) x 4 mm or larger
(I.D.) (or nominal size 1/4 inch).
Stop valve or Check valve
Piping for the calibration gas, 6 mm (O.D.)
by 4 mm (I.D.) Stainless steel pipe
Piping for the reference gas, 6 mm (O.D.)
by 4 mm (I.D.)Stainless steel pipe
F4-2E.ai
Figure 4.2 Piping for the calibration gas inlet
4.1.3 Piping for the Reference Gas Inlet
Reference gas piping is required between the air source (instrument air) and the ZA8F flow setting
unit, and between the ZA8F flow setting unit and the ZR22G detector.
Insert the air set next to the flow setting unit in the piping between the air source and the flow setting unit.
Use a 6 mm (O.D.) x 4 mm or larger (I.D.) (or nominal size 1/4 inch) stainless steel pipe between the
flow setting unit and the detector.
4.1.4 Piping to the High Temperature Probe Adapter
A sample gas should be at a temperature below 700°C before it reaches the detector. Also, a sample
gas needs to be sucked if its pressure is negative. The piping for these purposes should be connected
to the high temperature probe adapter. For the use of the high temperature probe adapter when the
high temperature detector is used, refer to Subsection 3.2.2.
• If the pressure of a sample gas is negative, connect an ejector assembly (E7046EC/ E7046EN) as
shown in Figure 4.3. Mount the pressure gauge as close as possible to the ejector. However, if the
ambient temperature is too high, mount the gauge in a location with a temperature below 40°C.
Pressure gauge
Ejector
Ejector assembly for
high temperature
Detector
High temperature
probe adapter
F4-3E.ai
Figure 4.3 Mounting the ejector assembly
IM 11M12D01-01E
4-4
< 4. Piping >
• If the temperature of a sample gas is high and its pressure exceeds 0.49 kPa, the temperature
of the sample gas at the detector may not be below 700°C. In this case, connect a needle valve
(found on the local market) through a nipple (found on the local market) to the sample gas outlet
(Rc1/2) of the probe adapter so that the sample gas exhaust volume can be restricted. In cases
where condensation is likely to occur in the probe adapter when the sample gas is cooled, protect
the probe adapter with an insulating material as shown in Figure 4.5.
Reducing nipple
(R1/2-R1/4 or R1/2-1/4 NPT)
Needle valve
(Rc1/4 or 1/4 NPT)
F4-4E.ai
Figure 4.4 Mounting the needle valve for restricting exhaust flow of the sample gas
Cover flange
Sample gas outlet
High temperature probe adapter
Detector
Insulating material
Probe
F4-5E.ai
Figure 4.5 Preventing to condensation
IM 11M12D01-01E
4-5
< 4. Piping >
4.1.5 Piping for Blow back
This piping is required when the blow back function is carried out. The piping described below
provides automatic blow back operation when the “ blow back start “ command is entered to the
converter.
Blow back air
Reducing valve
Solenoid valve
Solenoid valve
Pipe coupling
Note
Blow pipe
If blow back is done under
control of a contact output
from the averaging converter,
a hold is placed on analog
output signals from all detector
while blow back is in progress.
See Section 10.5 for details on
the blow back function. Wiring
for solenoid valves is described
in Section 5.3.
F4-6.ai
Figure 4.6 Blow back Piping
The following parts are required for blow back piping.
• Blow pipe (to be prepared as illustrated in Figure 4.7.)
• Two-way solenoid valve: “ Open “ when electric current is on. (Found on the local market)
• Air set (Yokogawa recommended: G7003XF / K9473XK or G7004XF / K9473XG)
Manufacture the blow pipe as illustrated in Figure 4.7, and mount it on the high temperature probe
adapter.
Unit : mm
Φ
90
4-Φ9
8 ~ 10
Rc1/4
Blind flange of the
high temperature probe adapter
Φ73
Welded
Approximately
200
8 (O.D.) by 6 (I.D.) Stainless steel pipe
F4-7E.ai
Figure 4.7 Blow pipe Construction
IM 11M12D01-01E
4-6
< 4. Piping >
4.1.6 Piping for Indication check
To perform an indication check using the third check gas, the piping to allow the third gas to flow
into the calibration gas line is required for the ZA8F Flow Setting Unit in addition to the system
configuration shown in Figure 4.1.
Connect the piping from the third check gas cylinder through a pressure reducing valve and a stop
valve, along with the span gas line, to the zero gas inlet of the ZA8F Flow Setting Unit. To perform an
indication check, open the stop valve on the line from the third check gas cylinder, while open the stop
valve on the span gas line to perform span calibration.
Flowmeter
Reference
gas line
Needle valve
Calibration
gas line
ZA8F flow setting unit
Flowmeter
Reference
gas line
Needle valve
Air Set
Pressure reducing valve
Calibration
gas line
Instrument air
Span gas cylinder
(Instrument air)
ZA8F flow setting unit
Zero gas cylinder
Stop valve
Third check gas cylinder
F4-8E.ai
Figure 4.8 Piping to ZA8F Flow Setting Unit for Indication Check Using 3rd Check Gas
IM 11M12D01-01E
4-7
< 4. Piping >
4.1.7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs
When a process gas alarm (an input contact signal of unburnt gas detection) occurs, the averaging
converter will cut off the power supply to the heater of the detector, and at the same time it will send a
contact output to activate a solenoid valve for introducing a purge gas to the detector.
In addition to the system configuration shown in Figure 4.1, a purge gas cylinder and a pressure
reducing valve, and where necessary, a stop valve, a flowmeter, and a needle valve are required.
Also, a check valve should be installed on the calibration gas inlet of the detector. A typical piping
diagram for purging is shown in Figure 4.9.
It is recommended that each instrument be installed to allow for minimum piping between the ZA8F
Flow Setting Unit and the detector and between the solenoid valve for introducing the purge gas and
the detector.
Averaging Converter (AV550G)
Detector
Signal
Check valve
Calibration gas line
Analog outputs:
(Averaged and
individual outputs)
Contact output
Heater
Contact input
To ZA8F
Reference gas line
Contact output
Check valve
Power supply
Calibration gas line
To ZA8F
Reference gas line
Flowmeter
Solenoid valve
Needle valve
Stop valve
Pressure
reducing valve
Purge gas cylinder
F4-9E.ai
Figure 4.9 Typical Piping for Purging
IM 11M12D01-01E
4-8
< 4. Piping >
4.2
Piping for a System to Perform Automatic Calibration
The piping for a system to perform automatic calibration is shown in Figure 4.10.
Averaging Converter (AV550G)
Detector
Signal
Analog outputs:
Averaged and
individual outputs
Heater
Solenoid valve
Contact output
Contact input
Calibration
Contact
contact outputs output
Power supply
Calibration gas line
Flowmeter
Needle valve
Reference
gas line
Span gas cylinder
(Instrument air)
Solenoid valve
Needle valve
Flowmeter
Instrument air
Pressure reducing valve
Stop valve
Air set
Zero gas cylinder
F4-10E.ai
Figure 4.10 Typical Piping for a System to perform Automatic Calibration
The following outlines some points to note regarding the piping for this system.
• Install a solenoid valve through a nipple on the calibration gas inlet of the detector.
CAUTION
The solenoid valve should be connected directly to the detector. If any piping is present between
the detector and the solenoid valve, condensation may develop in the pipe, causing damage to the
detector by rapid cooling when the calibration gas is introduced.
• When a high temperature detector is used and the pressure of a sample gas is negative, connect
an ejector assembly on the sample gas outlet of the high temperature probe adapter. (See
Figure 4.3 in Subsection 4.1.4.)
• When a high temperature detector is used and the pressure of a sample gas is 0.49 kPa or
higher, it is recommended that a throttle (e.g., needle valve) be installed on the sample gas outlet
of the high temperature probe adapter. (See Figure 4.4 in Subsection 4.1.4.)
IM 11M12D01-01E
< 4. Piping >
4-9
CAUTION
• This is to lower the temperature of a sample gas below 700°C. When both the temperature and
the pressure of a sample gas are high, the temperature of the sample gas may not fall below
700°C before the gas reaches the detector. On the other hand, the temperature of a sample gas
may drop too much and thus condensation develops in the high temperature probe adapter.
During wintertime, it is recommended that the high temperature probe adapter be protected with
an insulating material to prevent condensation.
• If optional 24 V outputs are specified for solenoid valves (Option Code “/24”), no external
power supply for solenoid valve is required. The solenoid valves are powered from the AV550G
Averaging Converter. Never connect external power sources in the wiring for solenoid valves.
• When a high temperature detector is used and blow back is required to eliminate dust
accumulating in the probe of the high temperature probe adapter, air supply piping for purging
should be installed.
CAUTION
If a sample gas contains much dust (e.g., in recovery boilers or cement kilns), the probe is more likely
to become clogged. To eliminate this dust accumulation using air pressure, piping is generally installed
from an air source only when cleaning is performed. Some cases, however, may need a permanent
installation of the blow back piping. See Subsection 4.1.5 for the installation of blow back piping.
IM 11M12D01-01E
4-10
< 4. Piping >
4.2.1 Parts Required for Piping in a System to Perform Automatic Calibration
Referring to Table 4.2, check that the parts required for your system are ready.
Table 4.2 Parts Required for Piping in a System to Perform Automatic Calibration
Detector
Piping Location
General-purpose Calibration gas
detector
inlet
Parts Name
Description
Solenoid valve
Yokogawa recommended: E7057GS, E7057GT,
E7057GR, G7001XP, G7002XP, G7003XP
* Nipple
R1/4 or 1/4 NPT (male-male)
General parts
Flowmeter
0 to 1 L /min
General parts
Needle valve
For flow control
General parts
Tee fitting
For branch connection. Manifold
substitutable
General parts
Solenoid value
3-way valve for zero/span gas
switching
General parts
* Check valve
Yokogawa recommended: K9292DN, K9292DS
* Stop valve
Reference gas
inlet
Calibration gas
High
inlet
temperature
detector (0.15 m)
—
Zero gas cylinder
Yokogawa recommended: G7001ZC
Pressure
reducing valve
Yokogawa recommended: G7013XF or G7014XF
Connection fitting
R1/4 or 1/4 NPT (male)
General parts
Flowmeter
0 to 1 L /min
General parts
* Needle valve
For flow control. Unnecessary if
supplied with flowmeter
General parts
Air set
Yokogawa recommended: G7003XF/K9473XK or
G7004XF/K9473XG
Connection fitting
R1/4 or 1/4 NPT (male)
Solenoid valve
Yokogawa recommended: E7057GS, E7057GT,
E7057GR, G7001XP, G7002XP, G7003XP
* Nipple
R1/4 or 1/4 NPT (male-male)
General parts
Flowmeter
0 to 1 L /min
General parts
Needle valve
For flow control
General parts
Tee fitting
For branch connection. Manifold
substitutable
General parts
Solenoid valve
3-way valve for zero/span gas
switching
General parts
* Check valve
Yokogawa recommended: K9292DN, K9292DS
* Stop valve
Reference gas
inlet
Sample gas
outlet
—
General parts
General parts
Zero gas cylinder
Yokogawa recommended: G7001ZC
Pressure
reducing valve
Yokogawa recommended: G7013XF or G7014XF
Connection fitting
R1/4 or 1/4 NPT (male)
General parts
Flowmeter
0 to 1 L /min
General parts
* Needle valve
For flow control. Unnecessary if
supplied with flowmeter
General parts
Air set
Yokogawa recommended: G7003XF/K9473XK or
G7004XF/K9473XG
Connection fitting
R1/4 or 1/4 NPT (male)
General parts
* Ejector assembly Yokogawa recommended: E7046EC or E7046EN
General parts
* Equal tee,
connection fitting
Rc1/4 or 1/4 NPT (female)
* Needle valve
Rc1/4 or 1/4 NPT
General parts
* Reducing nipple
R1/2-R1/4 or R1/2-1/4 NPT
General parts
Note: Parts marked with an asterisk (*) are used when required. General parts can be found on the local market.
IM 11M12D01-01E
General parts
< 4. Piping >
4-11
4.2.2 Piping for the Calibration Gases
The piping for the calibration gases should be installed between the calibration gas cylinders (or
instrument air source) and the detectors with a flowmeter, solenoid valves, needle valves, and stop
valves for performing automatic calibration.
• Place the calibration gas cylinders in a place not exposed to direct sunlight as much as possible,
e.g., house in a gas unit case. The cylinder should be equipped with a pressure reducing valve
(Yokogawa recommended part) and where necessary, a stop valve.
• Install a normally closed solenoid valve (Yokogawa recommended part) through a nipple (found on
the local market) on the calibration gas inlet of the detector as shown in Figure 4.11. This solenoid
valve is activated by a contact signal from the averaging converter. (Power wiring is separately
required.)
CAUTION
If the solenoid valve cannot be connected directly to the calibration gas inlet of the detector, install a
dedicated check valve (K9292DN or K9292DS) on the inlet and then route the piping to the solenoid
valve.
• After installing the solenoid valve on the calibration gas inlet of the detector, route the piping
through a needle valve, a flowmeter, a solenoid valve for switching zero and span gases, a stop
valve, and a pressure reducing valve for the cylinder, in this order, to the cylinder.
• Install the piping for the solenoid valve for switching zero and span gases so that the zero gas is
introduced to the detector when powered. This solenoid valve is activated by a contact signal from
the averaging converter. (Power wiring is separately required.)
• Install the needle valve and flowmeter in close proximity as much as possible.
• Use stainless steel pipes with 6 OD x 4 ID mm (or nominal 1/4 inch) or larger inside diameter for
the piping for the calibration gases.
Solenoid valve (normal close)
Connect directly to piping inlet
Nipple
Calibration gas piping
Ø6 × Ø4mm stainless steel pipe
F4-11E.ai
Reference gas piping
Ø6 × Ø4mm
(or nominal 1/4-inch) stainless steel pipe
Figure 4.11 Piping for the Calibration Gas Inlet
4.2.3 Piping for the Reference Gas
The piping for the reference gas should be installed between the air source (instrument air) and the
detector through flowmeters, needle valves and an air set for flow control of the reference gas.
• Install the piping from the reference gas inlet of the detector to the air source with a flow meter, a
needle valve where necessary, and an air set in this order.
• Install the flowmeter, needle valve and air set in close proximity.
• Use stainless steel pipes with 6 OD x 4 ID mm (or nominal 1/4 inch) or larger inside diameter for
the piping for the reference gas.
IM 11M12D01-01E
4-12
< 4. Piping >
4.2.4 Piping to the High Temperature Probe Adapter
The piping to the high temperature probe adapter is required when a high temperature detector is
used.
This piping is the same as the one in the system using flow setting units for manual calibration. See
Subsection 4.1.4.
4.2.5 Piping for Blow back
The piping for blow back is required only when the blow back is conducted in a system using a high
temperature detector. This piping is the same as the one in the system using flow setting units for
manual calibration. See Subsection 4.1.5.
4.2.6 Piping for Indication Check
To perform an indication check using the third check gas, the piping to allow the third gas to flow into
the calibration gas line is required in addition to the system configuration shown in Figure 4.10.
Route the piping from the third check gas cylinder through a pressure reducing valve and a stop valve
to the solenoid valve for switching the span gas and the third check gas, as shown in Figure 4.12.
It is recommended that the piping and wiring for the solenoid valve for switching the span gas and the
third check gas be installed to allow the third check gas to be introduced when powered. This solenoid
valve is activated by a contact signal from the averaging converter (Power wiring is separately
required.)
Detector
Averaging converter(AV550G)
Analog outputs:
(Averaged and
individual output)
Signal
Heater
Contact output
Solenoid valve
Calibration
Contact
contact outputs output
Contact input
Power supply
*
Calibration gas line
Flowmeter
Needle valve
Pressure
reducing valve
Needle valve
Reference
gas line
Fig4-12E.ai
*
*
Span gas cylinder
(Instrument air)
Flowmeter Solenoid
valve
Air set
Instrument air
Stop valve
Zero gas cylinder
Third check gas cylinder
*: If optional 24 V outputs are specified for solenoid valve (MS Code "/24"), no external power supply for solenoid valves is required.
The solenoid valves are powered from the AV550G Averaging Converter. Never connect external power sources in the wiring for
solenoid valves.
Figure 4.12 Piping for Automatic Indication Check Using 3rd Check Gas
IM 11M12D01-01E
4-13
< 4. Piping >
4.2.7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs
When a process gas alarm (an input contact signal of unburnt gas detection) occurs, the averaging
converter will cut off the power supply to the heater of the detector, and at the same time it will send a
contact output to activate a solenoid valve for introducing a purge gas to the detector.
The piping for purging in a system to perform automatic calibration is the same as the one in the
system using flow setting units for manual calibration. As instructed in Subsection 4.1.7, this piping
also requires that a check valve be installed on the calibration gas inlet of the detector. A typical piping
diagram for purging is shown in Figure 4.13.
It is recommended that each instrument be installed to allow for minimum piping between the solenoid
valve for introducing the calibration gases and the check valve, and between the solenoid valve for
introducing the purge gas and the check valve.
Averaging converter (AV550G)
Detector
Signal
Check valve
Analog output
(Averaged and
individual outputs)
Heater
Contact output
Solenoid valve
Calibration
gas line
Reference gas line
Calibration
Contact
contact outputs output
To calibration gas flow setting
needle valve and flowmeter.
To reference gas flow setting
flowmeter and needle valve.
Contact input
Power supply
*
Check valve
Calibration
gas line
To calibration gas flow setting
needle valve and flowmeter.
Reference
gas line
To reference gas flow setting
flowmeter and needle valve.
Flowmeter
Solenoid valve
Needle valve
*
Stop valve
Pressure reducing
valve
F4-13E.ai
Purge gas cylinder
* : If optional 24 V outputs are specified for solenoid valve (MS Code "/24"), no external power supply for solenoid valves is required.
The solenoid valves are powered from the AV550G Averaging Converter. Never connect external power sources in the wiring for
solenoid valves.
Figure 4.13 Typical Piping for Purging
IM 11M12D01-01E
Blank Page
5-1
< 5. Wiring >
5. Wiring
This chapter describes the wiring connections to the AV550G Averaging Converter.
5.1
General
WARNING
Never apply power to the averaging converter and other instruments connected to the averaging
converter until all wiring is completed.
CAUTION
This product complies with the CE marking. Where compliance with the CE marking is necessary, the
following wiring is required.
1. Install an external switch or circuit breaker to the power supply of the averaging converter.
2. Use an external switch or circuit breaker rated 20A and conforming to IEC 947-1 or IEC 947-3.
3. It is recommended that the external switch or circuit breaker be installed in the same room as the
averaging converter.
4. The external switch or circuit breaker should be installed within reach of the operator and
identified with marking as a power supply switch to the averaging converter.
5. Power lines such as power cables and heater wires should be fixed securely onto a wall
or construction using cable racks, conduit tubing, nylon bands or other appropriate ways.
Accidental removal from terminals by pulling may result in electric shock.
5.1.1 Wiring Precautions
Precautions Concerning the Correspondence Between Detectors and Channel Cards
Multiple detectors are connected to the averaging converter. Make sure that the wiring is run properly
between the detector and its corresponding channel card on the averaging converter. Special care
should be exercised so that the channel number of the detector signal line from the channel card
corresponds the one of the detector heater line from the power supply unit. Disagreement may result
in malfunction of the detector as well as invalid operation. (A channel number is indicated in the
channel card slot.)
The specified number of channel cards per purchase order is factory installed in channels in order
from CH1. The factory-installed channels can be changed as desired. All the channels are the same.
Note that in a 4-channel base averaging converter (AV550G-A-), channels CH5 to CH8 cannot be
used.
To remove a channel card, loosen the 2 screws attached to the top and bottom of the card, and then
while holding the loosened screws, pull straight away from the slot. To install a channel card, insert the
card by sliding along the guide rail in the slot, and then securely tighten the 2 screws.
IM 11M12D01-01E
5-2
< 5. Wiring >
WARNING
Cables that withstand temperatures of at least 80°C should be used for wiring.
CAUTION
Using a channel card installed without 2 screws tightened, may result in poor resistance to noise.
Precautions in Processing Shields
When a shielded cable is required for wiring, follow the instructions below to process the shield.
(1) All the shields should be connected on the averaging converter side: Connect to the cable shield
ground terminals inside the averaging converter.
(2) The shields should not be connected on the other side of the cable. To avoid any possible
contact with housings of instruments connected or metal parts, conductors of the shields should
be processed using insulating tapes or in an appropriate way.
(3) The shields should be connected to the cable shield ground terminals immediately after the
cable is inserted into the averaging converter through the wiring hole.
Having a long distance between the wiring hole and the cable end where the shield goes out,
may result in poor resistance to noise.
Good
Cores
Bad
To Terminals
To Terminals
Shield
Cable Shield Ground
Terminal
Long
Short
Cable Sheath
Wiring Holes
Figure 5.1
F5-1E.ai
Shield Processing
Cable Shield Ground Terminals (M4)
F5-2E.ai
Figure 5.2 Cable Shield Ground Terminals
IM 11M12D01-01E
5-3
< 5. Wiring >
5.1.2 Wiring Holes
The averaging converter has 30 wiring holes. Use holes near the rear for power wiring (e.g., power
cables, detector heater wires, and wiring for solenoid valve contacts and other contact outputs). For
signal wiring (e.g., detector signal lines and analog output signal lines), use holes near the front.
If more than 30 cables are used and thus more than one cable has to be passed through one wiring
hole, do not allow signal lines and power lines to pass the same hole. Also, in the averaging converter,
the signal lines and power lines should be routed so they can avoid contact and interference.
A grommet is attached, as standard, to the wiring hole of the averaging converter. An optional cable
gland is available. When a cable gland is not used, make a cable hole in a grommet.
Wiring Connections:
30 holes
Applicable Cable Hole: Ø17 mm maximum for grommet
Ø6 to Ø12 mm for cable gland (optional)
5.1.3 External Wiring Connection Terminals of the Averaging Converter
The connection diagram of the averaging converter is shown in Figure 5.3.
The terminal numbers are indicated on the converter. Care should be taken to make the wiring
connections correctly.
If 230 V AC is selected, channel cards are expandable up to 4.
Control Card
*1
Ave-a
Ave-b
Averaged
Analog
Outputs *2
Ave-c
Contact
Input
Channel Card (CH4)
Channel Card (CH1)
+
1
-
2
+
3
-
4
+
5
-
6
DI1
7
DI2
8
COM
9
CELL
Detector
Output TC
Signals
CJ
Individual
Analog AO
Output
+
1
-
2
+
3
-
4
+
5
-
6
+
7
-
8
CELL
Detector
Output
Signals
TC
CJ
Individual
AO
Analog
Output
+
1
-
2
+
3
-
4
+
5
-
6
+
7
-
8
Channel Card (CH5)
CELL
Detector
Output
Signals
TC
CJ
Individual
Analog AO
Output
+
1
-
2
+
3
-
4
+
5
-
6
+
7
-
8
DO1
DO2
Common Error Solenoid Valve
Contact Output Contact Output
DO5
DO4
DO3
SV-CH1 SV-CH2
Power
Supply
Ground
External
Ground
Terminal
L
N
G
+
CELL
TC
CJ
Individual
Analog AO
Output
1
-
2
+
3
-
4
+
5
-
6
+
7
-
8
M3.5 screws
Solenoid Valve
Contact Output
Individual Error Contact Output
DO-CH5
DO-CH6
SV-CH5 SV-CH6
C NC NO C NC NO
COM NC NO COM NC NO COM NC NOCOM NC NO COM NC NO
11 12 13 14 15 16 17 18
Detector
Output
Signals
Expansion Power Unit
Basic Power Unit
Functional Contact Output
Channel Card (CH8)
19 20 21 22 23
24 25 26 27 28 29
61 62 63 64 65 66 67 68 69 70 71 72
31 32 33 34 35 36 37 38 39 40 41 42 43
44 45 46 47 48 49
81 82 83 84 85 86 87 88 89 90 91 92
COM NC NO COM NC NO COM NC NO COM NC NO
DO-CH1
DO-CH2
DO-CH3
Individual Error Contact Output
51 52
HTR1
C NC NO C NC NO
DO-CH4
SV-COM SV-CH3 SV-CH4
Solenoid Valve Contact Output
DO-CH7
HTR3
M4 screws
SV-CH7 SV-CH8
Individual Error Contact Output Solenoid Valve Contact Output
101 102 103 104 105 106 107 108
53 54 55 56 57 58
HTR2
DO-CH8
HTR5
HTR4
Cell Heater
HTR6
HTR8
HTR7
Cell Heater
Grounding plate
G terminal and
terminal are connected by jumper plate.
1
2
3
4
7
8
5
6
1
2
3
4
7
8
5
6
Power supply and Ground terminals are M4 screw.
*1 Averaged analog output with digital communication (HART) when
suffix code “-E” (HART communication) is selected.
*2 Used exclusively for communication when suffix code “-F” (FOUNDATION
Fieldbus communication) is selected.
Detector CH1
Detector CH5
F5-3E.ai
Figure 5.3 External Wiring Connection Terminals of the Averaging Converter
IM 11M12D01-01E
5-4
< 5. Wiring >
5.1.4 Types of Wiring and Cables
Types of wiring and cables to be used are listed in Table 5.1. The purpose of a shield is not only to
prevent the effect from noise disturbance but also to restrict the noise emitted from the converter.
Specified cables must be used.
Table 5.1 Types of Wiring and Cables
Terminal
Power,
Internal grounding
Indication
L, N,
External ground
terminal
Shield
Number of
Requirement
Cores
Requirement
Unshielded
2 or 3
Size: 2 mm2 (14 AWG) or larger per core
Unshielded
—
Either internal grounding or external
grounding will do.
Cell heater
HTR1 to HTR8
Shielded
2
Size: 1.25 mm2 (16 AWG) or larger,
Conductor two-way resistance: 10 Ω or less
Detector output
signal
CELL, TC, CJ
Shielded
6
Conductor two-way resistance: 10 Ω or less
Individual analog
output
AO
Shielded
2
Averaged analog
output
Ave-a, Ave-b, Ave-c
Shielded
Note
Solenoid valve
contact output
SV-COM,
SV-CH1 to SV-CH8
Shielded
Note
Individual error
contact output
DO-CH1 to
DO-CH8
Unshielded
Note
Functional contact
output
DO1 to DO4
Unshielded
Note
Common error
contact output
DO5
Unshielded
Note
Contact input
DI1, DI2, COM
Unshielded
2 or 3
550 Ω or less, including load resistance
Note: The number of cores is determined by number of outputs to be used.
IM 11M12D01-01E
—
—
—
—
Loop resistance when contact is closed:
200 Ω or less
5.2
5-5
< 5. Wiring >
Wiring for the Averaging Converter and Peripheral
Devices
5.2.1 Preparation for Wiring to the Averaging Converter
Follow the instructions below when connecting cables to the averaging converter.
(1) The terminal screws on the control and channel cards are M3.5, and all the other terminal screws
are M4. Each wire should be terminated with a crimp terminal appropriate to the screw.
(2) If a silicone rubber insulated glass fiber braided wire is used for wiring to the detector, run the
wiring through a terminal box. It is recommended that a cable that withstand temperatures of
at least 80°C be used between the terminal box and the averaging converter. This is to prevent
moisture or corrosive gases from entering into the averaging converter and to ensure the
grounding of the detector.
5.2.2 Preparation for Wiring to Detectors
Follow the instructions below when connecting cables to detectors.
(1) Install a conduit or cable gland appropriate to the specified screw size to the cable inlet of a
detector. Allow for the sufficient length of a cable in case that the detector needs to be removed
for maintenance.
(2) If the ambient temperature around the wiring lines exceeds 75°C, a flexible metal conduit tube
must be used. If an unshielded 600 V silicon rubber insulated glass fiber braided wire is used,
keep the wire away from noise sources to avoid noise interference.
(3) Figure 5.4 shows the layout of the detector terminals.
The sizes of the terminal screws are M3.5. Each wire should be terminated with a crimp terminal
appropriate to the screw.
If the ambient temperature at the detector installation site exceeds 60°C, use a “burl crimp-on
terminal”.
TC +
TC –
CELL +
CELL CELL
(+)
(-)
TC
(+)
TC
(-)
CJ
(+)
CJ
(-)
HTR HTR
1
CELL
2 3
TC
4 5
7
CJ
H T R
6
8
To Converter,
To Converter,
To Ground
or
or
Terminal Box
Terminal Box
F5-4E.ai
Figure 5.4
Detector Terminals
IM 11M12D01-01E
5-6
< 5. Wiring >
Notice when closing the cover of the detector.
CAUTION
• Before opening the detector cover, loosen the lock screw. If the screw is not loosened first, the
screw will damage the cover, and the terminal box will require replacement.
When opening and closing the cover, remove any sand particles or dust to avoid gouging the
thread.
• After screwing the cover in the detector body, secure it with the lock screw.
Lock Screw
Detector Cover
F5-5E.ai
Figure 5.5
5.2.3 Power and Ground Wiring
Connect the power wiring to the L and N terminals in the averaging converter. Use wires with a size
of 2 mm2 (14 AWG) or larger. If a cable gland is not installed on the wiring hole of the averaging
converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an
outside diameter of 6 to 12 mm. A lock washer must be installed.
Connect the ground wiring to the protective ground terminal in the averaging converter or the external
ground terminal on the side of the case. Run the ground wiring so the ground resistance is 100 Ω or
less (equivalent to Class D grounding).
Make sure that the jumper plate is connected between the G terminal and the protective ground
terminal.
Grounding to the ground terminal
on the Averaging converter case
Converter Case
Crimp Terminal
FG Terminal
Lock Washer
F5-6E.ai
Figure 5.6 Grounding to the Ground Terminal
CAUTION
Operating the instrument with the jumper plate disconnected may result in poor resistance to noise.
IM 11M12D01-01E
5-7
< 5. Wiring >
5.2.4 Power Wiring to Detector Heaters
This wiring provides electric power from the averaging converter to the heater for heating the sensor
in a detector. Use 2-core shielded cables that withstand temperatures of at least 80°C. The wire size
should be 1.25 mm2 (16 AWG) or larger and the conductor two-way resistance should be 10 Ω or less.
If a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside
diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm. The
shields should be connected to cable shield ground terminals on the case of the averaging converter.
Detector for CH1
Averaging Converter
Basic Power Unit
CH1
CH2
CH3
ZR22G / ZO21D
CH4
51 52 53 54 55 56 57 58
7
8
Shield
To Detector for CH2
To Detector for CH3
To Detector for CH4
F5-7E.ai
Figure 5.7 Power Wiring to Detector Heaters
If the ambient temperature at the detector installation site exceeds 75°C, install a terminal box
and connect to the detector using 600 V silicon rubber insulated glass braided wires. The distance
between the detector and the terminal box should be minimized.
Detector for CH1
Averaging Converter
Basic Power Unit
CH1
CH2
CH3
CH4
51 52 53 54 55 56 57
ZR22G / ZO21D
58
7
Shield
8
Terminal Box
Silicon Rubber Insulated Glass Braided Wire
To Detector for CH2
To Detector for CH3
To Detector for CH4
F5-8E.ai
Figure 5.8 Power Wiring to Detector Heaters (Using Terminal Box)
IM 11M12D01-01E
5-8
< 5. Wiring >
5.2.5 Signal Wiring to Detectors
This wiring is for transmitting signals of cell electromotive force, thermocouple output and cold junction
compensation from a detector to the averaging converter. Use 6-core shielded cables that withstand
temperatures of at least 80°C. The conductor two-way resistance should be 10 Ω or less. Keep the
cables away from the power wiring. If a cable gland is not installed on the wiring hole of the averaging
converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an
outside diameter of 6 to 12 mm. The shields should be connected to cable shield ground terminals on
the case of the averaging converter.
Averaging Converter
Detector for CH1
Channel Card
CH1
+ 1
– 2
+ 3
– 4
+ 5
– 6
CELL
TC
CJ
CH2
CH3
CH4
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
ZR22G / ZO21D
1
2
3
4
5
6
Shield
To Detector for CH2
F5-9E.ai
Figure 5.9 Signal Wiring to Detectors
If the ambient temperature at the detector installation site exceeds 75°C, install a terminal box
and connect to the detector using 600 V silicon rubber insulated glass braided wires. The distance
between the detector and the terminal box should be minimized.
Averaging Converter
Detector for CH1
Channel Card
CH1
CH2
CH3
CH4
+
1
1
1
1
–
2
2
2
2
+
3
3
3
3
–
4
4
4
4
+
5
5
5
5
–
6
6
6
6
CELL
TC
CJ
ZR22G / ZO21D
1
2
3
4
5
6
Shield
Silicon Rubber Insulated Glass Braided Wire
Terminal Box
Figure 5.10 Signal Wiring to Detectors (Using Terminal Box)
IM 11M12D01-01E
To Detector for CH2
F5-10E.ai
5-9
< 5. Wiring >
5.2.6 Ground Wiring of Detectors
Connect the ground wiring to the external ground terminal on the detector case or the internal ground
terminal. Follow the instructions below. The ground terminal screw is M4.
(1) The ground resistance should be 100 Ω or less (equivalent to Class D grounding).
(2) If the ambient temperature of the wiring installation exceeds 75°C, use appropriate heat resistant
wires.
CAUTION
The flange bolts alone do not provide durable grounding of the detector. Be sure to grounded the
ground terminal.
5.2.7 Wiring for Individual and Average Concentration Analog Outputs
For the signal wiring to analog outputs, use shielded cables that withstand temperatures of at least
80°C. The number of cores is determined by the number of outputs. If a cable gland is not installed on
the wiring hole of the averaging converter, use a wire with an outside diameter of 17 mm or smaller.
If installed, use a wire with an outside diameter of 6 to 12 mm. Like the signal wiring to detectors, the
shields should be connected to cable shield ground terminals on the case of the averaging converter.
The load resistance from the averaging converter, including the wiring resistance, should be 550 Ω or
less.
Averaging Converter
+
1
–
2
+
3
–
4
+
5
–
6
Channel Card
CH2
CH1
Ave-a
CH3
CH4
+
Individual Analog output
Averaged Analog Output
Control Card
Receiver
Ave-b
Ave-c
+
7
–
8
AO
–
+
–
+
–
7
7
7
8
8
8
+
–
Shield
Shield
F5-11E.ai
Figure 5.11 Wiring for Individual and Average Concentration Analog Outputs
IM 11M12D01-01E
5-10
< 5. Wiring >
5.2.8 Wiring for Solenoid Valve for Automatic Calibration
This wiring is for operating the solenoid valve to switch zero and span gases during calibration in the
automatic calibration system and for operating the solenoid valve installed on the calibration gas line
to the detector of each channel. The contact output for solenoid valve is also used for operating the
solenoid valve on the blow back piping. For the wiring and piping of the system, refer to Section 5.3,
Wiring and Piping Examples.
Use shielded cables that withstand temperatures of at least 80°C for the wiring for solenoid valves.
The shields should be connected to cable shield ground terminals on the case of the averaging
converter.
If a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside
diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm. Like the
signal wiring to detectors, the shields should be connected to cable shield ground terminals on the
case of the averaging converter.
All contact outputs for solenoid valves are voltage free, dry contacts (mechanical relay contact
outputs). The contacts are open under normal conditions (when deenergized).
The contact rating is 250 V AC, 1A or 30 V DC, 1A.
If optional 24 V outputs are specified for solenoid valves (Option Code “/24”), no external power
supply for solenoid valves is required. The solenoid valves are powered from the AV550G Averaging
Converter. The maximum current that can be supplied to the solenoid valve is 50 mA. Use solenoid
valves that consume not more than 1.2 W to operate.
Averaging Converter
Basic Power Unit
Expansion Power Unit
26 27 28 29
44 45 46 47 48 49
69
70 71 72
89 90 91 92
Solenoid Valve for Switching
Zero/Span Gases
*
Power Supply to Solenoid Valve
Shield
Solenoid Valve for Calibration Gas
to Detector CH1
*
Power Supply to Solenoid Valve
Solenoid Valve for Calibration Gas
to Detector CH2
*
Power Supply to Solenoid Valve
*
F5.-12E.ai
: If optional 24 V outputs are specified for solenoid valves (Option Code "/24"), no external power
supply for solenoid valves is required. The solenoid valves are powered from the AV550G
Averaging Converter. Never connect external power sources in the wiring for solenoid valves.
Figure 5.12 Wiring for Solenoid Valve for Automatic Calibration
IM 11M12D01-01E
< 5. Wiring >
5-11
5.2.9 Wiring for Individual/Common Error Contact Outputs and Functional Contact
Outputs
The averaging converter has the following contact outputs.
(1) Functional contact outputs (DO1 to DO4): User specified functions can be assigned.
(2) Common error contact output (DO5): Activated when any error occurs.
(3) Individual error contact outputs (DO-CH1 to DO-CH8): Channel-specific contacts.
One output is provided per channel.
For details on errors, refer to Section 12.1, “Displays and Remedies When Errors Occur.”
All contact outputs are Form C (transfer contact) and consist of 3 terminals of COM, NC, and NO. All
contacts are voltage free, dry contacts (mechanical relay contact outputs). The contact rating is 250 V
AC, 3A or 30 V DC, 3A.
The individual and common error contacts are set to normally energized and cannot be changed. The
“NC” and “NO” indications on the terminal show energized states. States of functional contact outputs
DO1 to DO4 are user selectable: normally energized or normally deenergized. The “NC” and “NO”
indications on the terminal show deenergized states.
Use cables that withstand temperatures of at least 80°C for the wiring for these outputs. There is
no need to use shielded cables. If a cable gland is not installed on the wiring hole of the averaging
converter, use a wire with an outside diameter of 17 mm or smaller. If installed, use a wire with an
outside diameter of 6 to 12 mm.
Averaging Converter
Basic Power Unit
Expansion Power Unit
11 12 13 14 15 16 17 18 19 20 21 22 23 24
61 62 63 64 65 66
31 32 33 34 35 36 37 38 39 40 41 42 43 44
81 82 83 84 85 86
CH1
Error
CH2
Error
CH3
Error
Annunciator, etc.
CH4
Error
F5-13E.ai
Figure 5.13 Wiring for Individual/Common Error Contact Outputs and Functional Contact
Outputs
IM 11M12D01-01E
5-12
< 5. Wiring >
5.2.10 Wiring for Contact Inputs
The averaging converter receives contact inputs to perform the specified functions.
Follow the instructions below to run the wiring for contact inputs.
Use 2-core or 3-core cable that withstand temperatures of at least 80°C for this wiring. The number of
cores is determined by the number of contacts to be used. There is no need to use shielded cables. If
a cable gland is not installed on the wiring hole of the averaging converter, use a wire with an outside
diameter of 17 mm or smaller. If installed, use a wire with an outside diameter of 6 to 12 mm. Like the
signal wiring to detectors, the shields should be connected to cable shield ground terminals on the
case of the averaging converter.
Contact inputs should be voltage free. The open/closed state of the contact is determined by the
resistance from the averaging converter side. Note that the resistance should include the wiring
resistance.
Closed contact: 200 Ω or less
Open contact:
100 kΩ or more
Averaging Converter
Control Card
DI1
7
DI2
8
COM
9
Contact Input 1
Contact Input 2
F5-14E.ai
Figure 5.14 Wiring for Contact Inputs
IM 11M12D01-01E
5.3
5-13
< 5. Wiring >
Wiring and Piping Examples
5.3.1 Wiring and Piping for Automatic Calibration
Averaging Converter (AV550G)
Detector
Analog Output
(Averaged and Individual Output)
CH1
Contact Output
Solenoid
Valve
SV-CH1
*
CH8
Calibration Gas Line
SV-COM
SV-CH8
Power Supply
*
Needle Valve
*
Solenoid
Valve
Reference
Gas Line
Span Gas Cylinder
(Instrument Air)
Pressure Reducing Valve
Flowmeter
Flowmeter
Contact Input
Instrument Air
Stop Valve
Air Set
Zero Gas Cylinder
Needle Valve
*
F5-15E.ai
: If optional 24 V outputs are specified for solenoid valves (Option Code "/24"), no external
power supply for solenoid valves is required. The solenoid valves are powered from the AV550G
Averaging Converter. Never connect external power sources in the wiring for solenoid valves.
Figure 5.15 Typical Diagram for Automatic Calibration
5.3.2 Wiring and Piping for Automatic Calibration and 3rd Gas Indication Check
Averaging Converter (AV550G)
Detector
Analog Output
(Averaged and Individual Output)
CH1
Solenoid
Valve
Contact Output
SV-CH1
SV-CH8
*
CH8
Calibration Gas Line Needle Valve
Reference
Gas Line
DO1～4
*
Instrument Air
Air Set
Needle Valve
Contact Input
Power Supply
*
Span Gas Cylinder
(Instrument Air)
Pressure Reducing Valve
Flowmeter
Flowmeter
SV-COM
Solenoid
Valve
Stop Valve
Zero Gas Cylinder
Third Check Gas Cylinder
F5-16E.ai
*
: If optional 24 V outputs are specified for solenoid valves (Option Code "/24"), no external
power supply for solenoid valves is required. The solenoid valves are powered from the AV550G
Averaging Converter. Never connect external power sources in the wiring for solenoid valves.
Figure 5.16 Typical Diagram for Automatic Calibration and 3rd Gas Indication Check
IM 11M12D01-01E
5-14
< 5. Wiring >
5.3.3 Wiring and Piping for Blow back
Averaging Converter (AV550G)
Blow back Solenoid Valve
Analog Output
(Averaged and Individual Output)
High Temperature
Detector
Contact Output
SV-CH1
Stop Valve
Power Supply
*
Calibration
Gas Line
Reference
Gas Line
Calibration
Gas Line
Reference
Gas Line
*
To ZA8F Flow Setting Unit
To ZA8F Flow Setting Unit
Instrument Air
Air Set
*
Contact Input
SV-CH8
F5-17.ai
: If optional 24 V outputs are specified for solenoid valves (Option Code "/24"), no external
power supply for solenoid valves is required. The solenoid valves are powered from the AV550G
Averaging Converter. Never connect external power sources in the wiring for solenoid valves.
Figure 5.17 Typical Diagram for Blow back
5.3.4 Wiring and Piping for Automatic Calibration and Blow back
Blow back Solenoid Valve
Averaging Converter (AV550G)
High Temperature
Detector
Solenoid
Valve
Analog Output
(Averaged and
Individual Output)
Contact Output
Contact Input
DO1~4
SV-COM
SV-CH8
SV-CH1
Power Supply
Calibration Gas Line
Needle Valve
Span Gas Cylinder
(Instrument Air)
Flowmeter
Reference
Gas Line
Solenoid
Valve
Flowmeter
Air Set
Needle Valve
Pressure Reducing Valve
Instrument Air
Zero Gas Cylinder
F5-18E.ai
Note : If optional 24 V outputs are specified for solenoid valves (Option Code "/24"), this system cannot be established.
This is because the contact to activate a solenoid valve is used in common for automatic calibration and blow back.
Figure 5.18 Typical Diagram for Automatic Calibration and Blow back
IM 11M12D01-01E
6-1
< 6. Components >
6. Components
In this Chapter, the names and functions of components are described for the major equipment of the
AV550G Averaging Converter.
6.1
ZR22G Detector
6.1.1 General-purpose Detector (except for Model ZR22G-015)
Terminal box,
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.)
Flange used to mount the detector.
Select from JIS, ANSI DIN standard models.
Probe
this part is inserted in the furnace.
Select length from 0.4,
0.7, 1.0, 1.5, 2.0, 2.5 or 3.0
3.6, 4.2, 4.8 or 5.4 m.
Contact
Metal O-ring
Pipe support
Dust filter mounting screw
Calibration gas
pipe opening
U-shaped pipe
Bolt
Probe
Sensor (cell)
Filter
F6-1E.ai
Washer
Figure 6.1 General-purpose Detector (standard type)
IM 11M12D01-01E
6-2
< 6. Components >
6.1.2 High Temperature Detector (Model ZR22G-015)
Sample gas outlet
When a negative measurement gas
pressure is used, connect the auxiliary
ejector assembly.
When the measurement gas is
high temperature and high-pressure,
and does not fall below 700°C,
connect a pressure control valve
(e.g. a needle valve).
Separate type High temperature Detector (ZR22G-015)
When the temperature of the measurement gas is
between 700°C and 1400°C, mount this detector
with a ZO21P high temperature probe adapter.
Flange
Selectable from JIS standards,
ANSI standards or DIN standards
High Temperature Probe Adapter (ZO21P)
The probe is made of either SUS 310S or silicon carbide (SiC).
Its length is 0.5, 0.6, 0.7, 0.8, 0.9, 1.0 and 1.5 m.
When using an SiC probe, mount it vertically downward.
F6-2E.ai
Figure 6.2 High Temperature Detector
IM 11M12D01-01E
6.2
6-3
< 6. Components >
AV550G Averaging Converter
6.2.1 Components and Function
Control Card
Channel Cards
Status Display Lamps
Controls averaging
calculations, autocalibration
and display functions
Frame
Specified number of channel cards is
installed. Send output signals for
individual oxygen concentrations.
Green, continuous: Channel card is active
Orange, continuous: Alarm condition
Displays data and allows Orange, flashing: Calibration in progress
interactive touch screen Red, continuous: Error condition
operation.
Touch Screen Display
Channel Slot Covers
Covers unused channel slots.
Basic Power Supply Unit
Carries heater terminals
and contact terminals for
CH1 to CH4
+1
Ave-a
-2
+3
Ave-b
-4
+5
Ave-c
-6
DI1 7
DI2 8
COM9
DO1
COM NC NO
11
12
13
DO-CH1
COM NC NO
31
32
33
+1
CELL
-2
+1
CELL
-2
+1
CELL
-2
+1
CELL
-2
+1
CELL
-2
+1
CELL
-2
+3
TC
-4
+3
TC
-4
+3
TC
-4
+3
TC
-4
+3
TC
-4
+3
TC
-4
+5
CJ
-6
+5
CJ
-6
+5
CJ
-6
+5
CJ
-6
+5
CJ
-6
+5
CJ
-6
+7
AO
-8
+7
AO
-8
+7
AO
-8
+7
AO
-8
+7
AO
-8
+7
AO
-8
DO2
COM NC NO
14
15
16
DO-CH2
COM NC NO
34
35
36
DO3
COM NC NO
17
18
19
DO-CH3
COM NC NO
37
38
39
DO4
COM NC NO
20
21
22
DO-CH4
COM NC NO
40
41
42
DO5
COM NC NO
23
24
25
SV-COM
26
27
SV-CH3
28
29
SV-CH4
43
46
48
44
45
SV-CH1
47
SV-CH2
49
DO-CH5
COM NC NO
61
62
63
DO-CH7
COM NC NO
81
82
83
Expansion Power
Supply Unit
Carries heater terminals
and contact terminals
for CH5 to CH8.
DO-CH6
COM NC NO
64
65
66
DO-CH8
COM NC NO
84
85
86
SV-CH5
FUSE
HTR1
FUSE
HTR1
HTR1
51
52
Power Switch
Main Power Supply
External Protective
Ground Terminal
FUSE
HTR2
FUSE
HTR2
HTR2
53
54
FUSE
HTR3
FUSE
HTR3
HTR3
55
56
FUSE
HTR4
FUSE
HTR4
HTR4
57
58
*Cable Shield* Ground Terminals
• L
• N
• G (connected to internal protective ground
terminal by jumper plate)
• Internal protective ground terminal
SV-CH6
67
68
69
70
SV-CH7
71
72
SV-CH8
87
88
89
91
250V T2.5A X 8
90
92
250V T2.5A X 8
FUSE
HTR5
FUSE
HTR5
HTR5
101 102
FUSE
HTR6
FUSE
HTR6
HTR6
103 104
FUSE
HTR7
FUSE
HTR7
HTR7
105 106
FUSE
HTR8
FUSE
HTR8
HTR8
107 108
Protection Covers for Heater
Terminals
F6-3E.ai
Figure 6.3 Components and Function of AV550G
6.2.2 Touchpanel Switch Operations
Panels and Switches
The averaging converter uses touchpanel switches which can be operated by just touching the panel
display. The display viewed upon power up or during oxygen concentration measurement varies
depending on the number of channel cards installed in an averaging converter. Data of 4 channels will
be displayed if 1 to 4 channel cards are installed. If more than 4 channel cards are installed, data of 8
channels will be displayed.
Even if the number of channel cards is 4 or less, data of 8 channels will be displayed if an expansion
power supply unit is mounted and a card is installed on any of channels CH5 to CH8. The display
“---” means a channel no card is installed in the channel. As shown in upper left and right displays in
Figure 6.4, data of multiple channels can be viewed in a single screen, which is called a multi-channel
display.
IM 11M12D01-01E
6-4
< 6. Components >
On this display, touch the indication area (enclosed by dotted line) of the desired channel. A display
shown in bottom in Figure 6.4 will appear. This display will show the oxygen concentration (or cell
temperature during warm-up) and average concentration data (groups a, b, and c) (show “---” if all
channels are in warm-up period) of the selected channel, which is called a single-channel display. To
return to the previous multi-channel display, touch the area enclosed by dotted line.
The operation status of the averaging converter is indicated by yellow marking at the bottom of the
display. Table 6.1 shows the types and conditions of the markings.
Switch Indication Area
Tag:
Tag:
Ch1
Ch2
Ch3
Ch4
Ch1
514°C
Ch2
515°C
Ch3
513°C
Ch4
514°C
Warmup
Hold
515°C
513°C
514°C
Ch6
Ch7
Ch8
Average Oxygen Concentrations
514°C
514°C
513°C
--Hold
8-channel Multi-channel Display
514
Ave-a
Ave-b
Ave-c
Warmup
-------
°C
Hold
Status Indication Markings
Single-channel Display
Figure 6.4 Multi-channel Display and Single-channel Display
IM 11M12D01-01E
Ch5
Warmup
4-channel Multi-channel Display
Tag:
Ch1
514°C
F6-4E.ai
6-5
< 6. Components >
Table 6.1 Types of Status Indication Markings
Marking
Condition
Displayed if any of the calibration gas channels is being purged.
Purge
Warmup
Displayed if any channel is in warmup status. If any other channel
is in Purge status then Purge status display takes preference.
CAL.TIME
Channel is in calibration period: calibration gases are being
introduced.
CHK.TIME
CAL.TIME
Channel is in check period: check gases (including 3rd check
gas) are being introduced.
BLOW TIME
Blow back is being performed.
HOLD TIME
Channel is in stabilization period after calibration,
indication check, or blow back.
Hold
Range
Output is being held.
Range is being switched by contact input.
Switches and Their Functions
Switch icons displayed on the right side of the display vary depending on the panel display, allowing all
switch operations. Table 6.2 shows the functions of the switches.
Table 6.2 Switches and Their Functions
Home key:
Returns to the Execution/Setup display.
Reject key:
Moves back to the previous display.
Cursor key:
Moves the cursor downward.
Graph display:
Displays a trend graph.
Alarm:
Displayed if an alarm arises.
Page scroll key:
In detailed data display, scrolls
up/down one page.
Update key:
In error or alarm display, updates the
information displayed.
Enter key:
Enter
Confirms data entry or selected item.
Setup key:
Moves to the Execution/Setup display.
Detailed data key:
Displays detailed operation data.
Graph display key:
Displays a trend graph in cascade
pattern.
Error:
Displayed if an error occurs.
Channel scroll key:
In detailed data display or data setup
display, moves to the previous/next
channel.
Cursor:
Points to the currently selected item.
T6-2E.ai
IM 11M12D01-01E
6-6
< 6. Components >
Display Configuration
Display configuration is shown below.
Tag:
Ch1
Tag:
21.0
Ave-a
Ave-b
Ave-c
Ch1
Ch2
Ch3
%O2
21.0 %O2
21.0 %O2
21.0 %O2
Ch4
21.0%
21.0%
21.0%
21.0%
Ch5
Ch6
Ch7
Ch8
21.0%
21.0%
21.0%
20.7%
+ Channel Indication Area
Execution/Setup
25%O2
Ch1
Execution
0 . 9 mV
Cell voltage:
2 9 . 4 mV
Thermo voltage:
C.J.resistance: 1 1 7 0 . 2 Ω
Cell temperature:
7 5 0 °C
C.J.temperature:
4 3 °C
Calibration
Indication check
Blow back
Setup
Maintenance
Commissioning
0%O2
Enter
Hol d
Commissioning
Calibration
Indication check
Blow back
Maintenance
Entry your password
Entry your password
0-9
A
B C
D
E F
G
H I
other
J
K L
M
N O
P
Q R
Space
- S
S
T U
V
W X
Y
Z @
Password entry display will appear
only if the desired operation is
protected by password. Password
protection is factory set to
disabled.
Enter
0-9
A
B C
D
E F
G
H I
other
J
K L
M
N O
P
Q R
Space
- S
S
T U
V
W X
Y
Z @
Enter
Password Entry for Commissioning
Password Entry for Maintenance
Calibration
Maintenance
Manual calibration
Semi-auto calibration
Enter
Display setup
Calibration setup
Indication check setup
Blow back setup
mA-output loop check
Contact check
Channel card power
Commissioning
Enter
Basic setup
mA-output setup
Alarm setup
Indication check
Contact setup
Blow back
Manual ind. check
Start blow back
Semi-auto ind. check
Cancel blow back
Enter
Average group setup
Others
Enter
Enter
F6-5E.ai
Figure 6.5 Display Configuration of AV550G
IM 11M12D01-01E
6-7
< 6. Components >
Display Functions
1) Basic panel display (Displays measured oxygen concentrations, and cell temperatures during
warm-up period.)
The basic panel display consists of a multi-channel display and a single-channel display.
The multi-channel display screen shows cell temperatures during warm-up period and oxygen
concentrations afterward. The single-channel display screen shows the data of the selected channel
— the cell temperature or oxygen concentration and average concentrations of each group. If an error
or alarm occurs, a relevant icon will be flashing in its display area. If an error and an alarm occurs
at the same time, the error icon display takes precedence. For details on errors and alarms, refer to
Chapter 12, Troubleshooting.
Tag:
Ch1
Tag:
Ch1
Ch2
Ch3
Ch4
21.0%
21.0%
21.0%
21.0%
Ch5
Ch6
Ch7
Ch8
21.0
21.0%
21.0%
21.0%
20.7%
Multi-channel Display Showing
Oxygen Concentration
Ave-a
Ave-b
Ave-c
%O2
21.0 %O2
21.0 %O2
21.0 %O2
Single-channel Display Showing
Oxygen Concentration
Red error code is indicated on a
relevant channel.
Tag:
Ch1
Tag:
Ch1
Ch2
Ch3
Ch4
Err2
0.96%
0.96%
0.96%
Ch5
Ch6
Ch7
Ch8
0.96%
Err1
0.96%
0.94%
Hold
Multi-channel Display When Error Occurs
Err2
Ave-a
Ave-b
Ave-c
0.96 %O2
0.95 %O2
0.96 %O2
Hold
Single-channel Display When Error Occurs
F6-6E.ai
Figure 6.6 Basic Panel Displays
IM 11M12D01-01E
6-8
< 6. Components >
2) Detailed data display
To move to the detailed data display, touch the Detailed data key and then touch the indication area of
the desired channel in the multi-channel display, or simply touch the Detailed data key in the singlechannel display. The detailed data display shows maintenance data, such as cell electromotive force,
cell temperature, and calibration history, per channel.
Tag:
Ch1
Ch2
Ch3
Ch4
21.0%
21.0%
21.0%
21.0%
Ch5
Ch6
Ch7
Ch8
Tag:
Ch1
21.0%
21.0%
21.0%
21.0
Ave-a
Ave-b
Ave-c
20.7%
%O2
21.0 %O2
21.0 %O2
21.0 %O2
Ch1
Cell voltage:
0 . 9 mV
2 9 . 4 mV
Thermo voltage:
C.J.resistance: 1 1 7 0 . 2 Ω
Cell temperature:
7 5 0 °C
C.J.temperature:
4 3 °C
F6-7E.ai
Figure 6.7 Detailed Data Display
3) Trend graph display
Up to 11 user-selected data from among the individual outputs from each channel and average
concentration outputs, groups a, b, and c, can be viewed in graphical format at a time in a single
screen. To move to the trend graph display, touch the graph display key on a basic panel display. The
cascade function may be used to view each trend line of channels clearly in the trend graph display.
The function offsets the axes so that trend lines do not overlap.
1 2 3 4 5 6 7 8 a b c
25.0 %O2
30min./div.
1 2 3 4 5 6 7 8 a b c
30min./div.
0.0 %O2
F6-9E.ai
F6-8E.ai
Figure 6.8 Trend Graph Display
IM 11M12D01-01E
Figure 6.9 Cascade Display
< 6. Components >
6-9
4) Execution/Setup display
Touch the Setup key on the basic panel display. The Execution/Setup display will appear. From the
menu items — calibration, indication check, blow back, maintenance, or commissioning, select the
desired item to perform.
Execution/Setup
Execution
Calibration
Indication check
Blow back
Setup
Maintenance
Commissioning
Enter
F6-10E.ai
Figure 6.10 Execution/Setup Display
5) Calibration display
From the menu on the Execution/Setup display, select Calibration. The Calibration display will appear.
Calibration can be performed from the menu on this display.
Calibration
Manual calibration
Semi-auto calibration
Enter
F6-11E.ai
Figure 6.11 Calibration Display
6) Indication check display
From the menu on the Execution/Setup display, select Indication check. The Indication check display
will appear. Indication check can be performed from the menu on this display.
7) Blow back display
From the menu on the Execution/Setup display, select Blow back. The Blow back display will appear.
Blow back can be performed from the menu on this display.
Indication check
Blow back
Manual ind. check
Semi-auto ind. check
Start blow back
Cancel blow back
Enter
F6-12E.ai
Figure 6.12 Indication Check Display
Enter
F6-13E.ai
Figure 6.13 Blow Back Display
IM 11M12D01-01E
6-10
< 6. Components >
8) Maintenance display
From the menu on the Execution/Setup display, select Maintenance. The Maintenance display will
appear. The following can be performed from the menu on this display.
1.
2.
3.
4.
Display setup
Calibration, Indication check, and Blow back setups
mA-output loop and Contact checks
Channel card power
9) Commissioning display
From the menu on the Execution/Setup display, select Commissioning. The Commissioning display
where parameter setups can be selected will appear. The following can be selected from the menu on
this display.
1.
2.
3.
4.
5.
6.
Selection of detectors and sample gases
Analog output setup
Alarm setup
Contact input/output setup
Average group setup
Others — clock setup, password setup, etc.
Commissioning
Maintenance
Basic setup
Display setup
Calibration setup
Indication check setup
Blow back setup
mA-output loop check
Contact check
Channel card power
mA-output setup
Alarm setup
Contact setup
Average group setup
Others
Enter
Enter
F6-15E.ai
F6-14E.ai
Figure 6.14 Maintenance Display
Figure 6.15 Commissioning Display
Entering Numeric and Text Data
This section sets out how to enter numeric and text data. If only numeric values are entered, a
numeric-data entry display as in Figure 6.16 then appears. Press the numeral keys to enter numeric
values. If those values include a decimal point as in Figure 6.16, the decimal point need not be
entered because the decimal point position is already fixed, so just enter 00098.
New value:
0
000.98 % O2
7
8
9
4
5
6
1
2
3
Enter
F6-16E.ai
Figure 6.16 Numeric-data Entry Display
IM 11M12D01-01E
< 6. Components >
6-11
To enter a password (in combination with text data, numeric values and codes), the alphabetic
character entry panel display first appears. If you press any numeral key (0 to 9), the current display
then changes to the numeric-value entry panel display, enabling you to enter numeric values. If you
press the “other” key, the current display then changes to the code-entry display, enabling you to enter
codes. These displays alternate between the three. Figure 6.17 shows the relationship between these
three displays.
Three alphabetic characters and three codes are assigned for each individual switch. If the alphabetic
character key is pressed and held, three characters appear in turn. Move the cursor to the desired
character and release the key to enter it. If an incorrect character is entered, move the cursor to reenter the characters. The following shows an example of entering “abc%123.”
Operation
Press the [ABC] key once.
Press and hold the [ABC] key.
Display
A
AA
B
C
Release the [ABC] key when the character B
appears in the cursor position.
Enter the character C in the same manner
as above.
Press the [other] key.
AB
Press and hold the [$%&] key and enter “%.”
Then press the [0-9] key.
ABC%
Enter the numeric characters 1, 2 and 3 in turn.
Press the Enter key to complete the entry.
ABC%123
ABC
Enter your password
0-9
A
B C
D
E F
G
H I
other
J
K L
M
N O
P
Q R
Space
- $
S
T U
V
W X
Y
Z @
Enter your password
Enter
Enter your password
A-Z
7
8
9
A-Z
other
4
5
6
0-9
0
1
2
3
Enter
[
{
}
!
$
% &
'
( )
*
+ ,
–
. /
:
; <
>
? @
[
\ ]
^
_ `
#
Enter
F6-17E.ai
Figure 6.17 Text Entry Display
IM 11M12D01-01E
6-12
< 6. Components >
6.3
ZA8F Flow Setting Unit
Reference gas flow
setting valve
Span gas flow
setting valve
Zero gas flow
setting valve
Flowmeter for
reference gas
Flowmeter for
calibration gas
Figure 6.18 ZA8F Flow Setting Unit
IM 11M12D01-01E
F6-18E.ai
7.
< 7. Startup >
7-1
Startup
This Chapter explains the startup procedures for the Averaging Converter: supplying power, setting
parameters as required, and performing manual calibration.
7.1
Startup Procedure
The startup procedure is as follows:
CAUTION
If you connect Model ZO21D detectors, then you need to change the detector parameters.
Before connecting power, refer to: Section 7.4 Setting Detector Model.
Check settings
Check piping & wiring
Check valve type setting
If connecting ZO21D
Briefly power on
Set detector to ZO21D
(front panel)
If all detectors are ZR22G
Power OFF
Permanent power wiring
Start set parameters
Warmup, then calibrate
F7-1E.ai
Figure 7.1 Startup Procedure
7.2 Check Piping and Wiring
Check piping and wiring (refer to Chapter 4 for piping, and Chapter 5 for wiring).
IM 11M12D01-01E
7-2
< 7. Startup >
7.3
Set Valve Type
Set valves (which depend on your system configuration) as follows:
1) If there is a shut-off valve at the calibration gas inlet, shut it.
2) Assuming that instrumentation air supply is used as the reference gas, adjust air set secondary
pressure to approximately 50 kPa above that of the sample gas -- if there is a check valve, then
adjust it to approximately 150 kPa above that of the sample gas (but pressure should be no
greater than 300 kPa). Adjust reference gas flow so that it is in the range 800~1000 ml/min.
7.4
Setting Detector Model
The default detector model set before shipment from the factory is ZR22G. If you plan to use the
ZO21D then before starting warmup you need to change the default setting. If you do not change the
setting before starting warmup then detector temperature control will not work properly and serious
damage to the detector may result.
There are two ways of changing this setting before warmup, as follows:
[ How to use Channel-card “Hot Swap” feature ]
This converter allows you to toggle the power supply of individual channel cards OFF/ ON while power
to the converter is applied. This method also allows you change the detector model settings without
detector warm up.
1) Touch the Setup key, and the [Execution/Setup] display appears.
2) Use the pointer cursor key to move the pointer to [Maintenance] and touch the Enter key.
3) On the Maintenance display, select [Channel card power] and touch the Enter key. A display like
that shown in Figure 7.3 appears.
4) On the [Channel card power] display, select the channel no. of a channel connected to a ZO21D
then touch the Enter key.
5) A [Disable/Enable] selection window is displayed. Select [Disable] and touch the Enter key.
Confirm that the status display lamp of the corresponding channel turns off.
6) Repeat the above procedure for each channel connected to a ZO21D and disable power.
7) Touch the Home key to return to the [Execution/Setup] display.
8) Select [Commissioning] --> [Basic setup] --> [Detector], then the Detector Selection display
appears.
9) Select each channel to be connected to a ZO21D and change the ZR22G default to ZO21D.
10) After changing the settings for all channels to be connected to ZO21D detectors, turn off
converter power.
Channel card power
Detector
Ch1 : ZR22G
Ch2 : ZO21D
Ch3 : ZR22G
Ch4 : ZO21D
Ch5 : ZR22G
Ch6 : ZO21D
Ch7 : ZR22G
Ch8 : ZO21D
Enter
F7-2E.ai
Figure 7.2 Detector Selection
IM 11M12D01-01E
Ch1 : Disable
ZR22G
Ch2 : Enable
Ch3 : Enable
Ch4 : Enable
Ch5 : Enable
Ch6 : Enable
Ch7 : Enable
Ch8 : Enable
Enter
F7-3E.ai
Figure 7.3 Channel Card Power Setting
7-3
< 7. Startup >
[Disconnect power to the heater; this will generate an error ]
If you disconnect the signal wiring from the detector then this will generate an error, but this allows you
to change the detector model settings without detector warm up.
1) Remove all thermocouple (TC) signal wiring from channel cards which connect to ZO21D
detectors.
2) Apply power to the averaging converter.
3) Error messages are displayed for these channels, but you can set their parameters.
4) Touch the Setup key, and the [Execution/Setup] display appears.
5) Select [Commissioning] --> [Basic setup] --> [Detector], then the Detector Selection display
(Figure 7.2) appears.
6) Select channels to be connected to ZO21D, and change [ZR22G] to read [ZO21D].
7) After changing the channels settings of all channels to be connected to ZO21D detectors, turn off
converter power.
8) Reconnect the removed thermocouple (TC) signal wiring to the channel cards.
IM 11M12D01-01E
7-4
< 7. Startup >
7.5
Supply Power to Averaging Converter
CAUTION
To avoid temperature changes around the sensor, it is recommended that (rather than turning it on
and off) power be continuously supplied to the Averaging Converter if it is used in an application where
it is used periodically.
It is also recommended to flow a span gas (instrument air) beforehand.
Before connecting power check that power switch is set to “O (Off)”. After connecting power, turn
power switch to “I (On)”. The startup display is displayed for about 10 seconds then the multi-channel
cell temperature display shown in Figure 7.4 appears.
Confirm that the displayed temperatures of each channel gradually increase.
After the cell temperatures reach their target setting of 750°C and stabilize, the display switches to
show oxygen concentration. When all the channels have switched to display oxygen concentration,
the red [Warmup] and [Hold] alarm marks at the bottom of the display disappear.
Tag:
Ch1
Ch2
Ch3
Ch4
514°C
515°C
513°C
514C
Warmup
Ch5
Ch6
Ch7
Ch8
Measurement gas
514°C
See Manual for details !
514°C
Select measurement gas:
Wet
Dry
513°C
519°C
Hold
Enter
F7-4E.ai
Figure 7.4 Display during warmup
F7-5E.ai
Figure 7.5 Measurement gas selection
NOTE
Depending on furnace conditions, the cell temperature may overshoot the target by 10~15°C during
the warmup phase. This is not an abnormality.
IM 11M12D01-01E
7.6
7-5
< 7. Startup >
Selection of Gas to be Measured
Exhaust gas includes steam resulting from combustion of hydrogen and oxygen. You may choose
whether to display the oxygen concentration including the oxygen contained in the steam, or display
the computed “dry” oxygen concentration (a value compensated for the oxygen in steam) which
results in a higher concentration value. For details, refer to “ Fuel Setup” in Subsection 8.5.3.
1) Touch the Setup key to switch to the [Execution/Setup] display.
2) Select [Commissioning] --> [Basic setup] --> [Select measurement gas] and the [Measurement
gas] display appears.
3) Touch the Enter key and the Measurement gas selection window opens for you to select the
measurement gas.
The Measurement gas selection applies to all channels, you cannot specify it on a channel-bychannel basis.
7.7
Current Output Range Setting
The output ranges (two ranges) of each channel are independently settable. Ranges are switched by
contact input. Contact OFF results in Range 1, and contact ON results in range 2. For details, refer
to Section 8.4 Setting Contact Inputs. Shipping time default is for each range to be set to 0 to 25%
O2. The ratio of the maximum range setting to the minimum is restricted as described in Section 8.1
Setting Analog Outputs.
1) Touch the Setup key to switch to the [Execution/Setup] display.
2) From the [Commissioning] display select [mA-output setup], then [Set range]. (See Figure 7.6).
3) Use [ ] and [] keys to select the channel.
4) Set [min] O2 concentration corresponding to 4 mA output, then set [max] O2 concentration
corresponding to 20 mA output (select, then touch the Enter key).
5) The numeric data entry display shown in Figure 7.7 appears; enter the desired oxygen
concentration setting. To set 10% O2, input [010] and touch the Enter key.
6) As necessary, repeat for averaging output a, b and c and other channels.
New value: 025 %O2
mA-output range
Ch1
Range1
max:
min:
Range2
max:
min:
25 %O2
0 %O2
25 %O2
0 %O2
Enter
0
7
8
9
4
5
6
1
2
3
F7-6E.ai
Figure 7.6 Current-output range
Enter
F7-7E.ai
Figure 7.7 Numerical entry
IM 11M12D01-01E
7-6
< 7. Startup >
7.8
Averaging Group Setting
The AV550G can determine oxygen concentration average for three averaging groups a, b, and c.
a and b can each be arbitrary channel groupings, and the corresponding averages are output.
c output is (a+b) /2. Select the groupings for a and b as per the procedure below.
1) Touch the Setup key to switch to the [Execution/Setup] display.
2) From the [Commissioning] display select [Average group setup], then [Average group -a].
Figure 7.8 shows the display.
3) Select the group to set (a or b) then touch the Enter key. Channels that you can select are
displayed.
4) Channels that are set to [ON] belong to that group. Use the pointer cursor keys to move the
pointer to any channel whose status you want to toggle, then touch the Enter key. The ON/OFF
selection window opens, and you can toggle status.
5) Any or all channels may belong to both groups a and b.
Average group-a
Ch1
Ch2
Ch3
Ch4
Ch5
Ch6
Ch7
Ch8
ON
ON
ON
ON
OFF
OFF
OFF
OFF
Enter
F7-8E.ai
Figure 7.8 Setting Averaging Group
< Shipping-time defaults >
At shipping time, averaging groups a and b contain all channels (all channels [ON]).
NOTE
If you set all channels in a group to [OFF] then the averaged output will be held at the current set by
[Ave group invalid] on the [mA-outputs hold] display. In this case, the status mark at the bottom of
the display will be [HOLD]. For details, refer to Subsection 8.1.2 Output Hold Setting (Applies to All
Outputs).
IM 11M12D01-01E
7.9
< 7. Startup >
7-7
Calibration
To calibrate this instrument, the procedure is to measure zero gas and span gas and set the
instrument to read the known concentrations. The procedure for both zero and span calibration,
or for either zero or span calibration, can be performed manually from the touch display, or can
be performed semi-automatically using contact signal inputs to start calibration, (allowing preset
calibration and stabilization times), or it can be performed automatically at preset intervals. Here we
explain manual calibration.
7.9.1 Setting Calibration Gas Concentration
Before calibrating, you need to set the (oxygen) concentration of the gas you will use for calibration.
Here we explain how to do this. Note that calibration-related settings apply to all channels, you can’t
set different values for individual channels.
A gas with a known oxygen concentration is used for calibration. Normal calibration is performed
using two different gases: a zero gas of low oxygen concentration and a span gas of high oxygen
concentration. In some cases, only one of the gases needs to be used for calibration. However, even if
only one of the gases is normally used, calibration using both gases should be done at least once.
The zero gas normally used has an oxygen concentration of 0.95 to 1.0 percent oxygen by volume
with a balance of nitrogen gas (N2). The span gas widely used is clean air (at a dew-point temperature
below -20°C and free of oily mist or dust, as in instrument air).
For best accuracy, as the span gas use oxygen whose concentration is near the top of the
measurement range, in a nitrogen mixture.
Shipping-time default setting for zero gas is 1.0% O2, and for span gas is 21.0% O2.
1) Touch the Setup key to switch to the [Execution/Setup] display.
2) Select [Maintenance] to display the Maintenance display.
3) From the Maintenance display, select [Calibration setup].
4) Select [Zero gas conc] and touch the Enter key to display the numerical entry display. Enter the
oxygen concentration of the zero gas you plan to use. To enter a concentration of 0.98% O2,
enter 00098.
5) Select and set the Span Gas in the same manner.
Calibration setup
Mode: Auto
Points: Span-Zero
Zero gas conc:
0.98%
Span gas conc: 2 1 . 0 0 %
Timing
Cal. history initialize
Enter
F7-9E.ai
Figure 7.9 Calibration Setting
NOTE
If instrument air is used for the span gas, dehumidify the air by cooling to the dew point of -20°C and
remove any oil mist or dust
IM 11M12D01-01E
7-8
< 7. Startup >
7.9.2 Performing Manual Calibration
1) Confirm that the zero gas flow setting valve is fully closed, then adjust supply gas pressure to
measurement gas pressure + 50kPa (but a maximum of 300 kPa) using the valve on the gas
cylinder.
2) Touch the Setup key to switch to the [Execution/Setup] display.
3) Select [Calibration] and the Calibration display appears.
4) Select [Manual calibration] then touch the Enter key. The Channel Select display shown in Figure
7.10 appears.
Manual cal.
Select calibration channel
Ch1
Ch2
Ch3
Ch4
Ch5
Ch6
Ch7
Ch8
Enter
F7-10E.ai
Figure 7.10 Channel Select for Manual Calibration
5) Select the channels to be calibrated (channels in warmup or error status can’t be selected). Here
we describe the situation for Channel 1.
6) Select [Span calibration] and touch the Enter key. A display like Figure 7.11 appears.
Ch1
Manual cal.
Check the span gas
concentration value.
Next
Cancel calibration
Change value: 2 1 . 0 0%
Enter
F7-11E.ai
Figure 7.11 Span Calibration setup
7) Select [Next] and touch the Enter key. The display in Figure 7.12 appears. If wiring and piping for
automatic calibration has been done, span gas will start flowing at this point.
Ch1
Manual cal.
Open span gas valve.
Set flow span gas to
600ml/min.
Valve opened
Cancel calibration
Enter
F7-12E.ai
Figure 7.12 Span Calibration start
IM 11M12D01-01E
7-9
< 7. Startup >
8) Open the span gas flow setting valve, and adjust flow to 600 ± 60 ml/min.
9) Select [Valve opened (Start Calibration)] and touch the Enter key. An oxygen concentration
graph like Figure 7.13 is displayed, and [CAL.TIME] status mark flashes.
Wait for the graph measured value trace to stabilize. Calibration has not yet been performed,
so it is not a problem if the displayed value is different from the correct value of span gas
concentration.
Channel No.
under calibration
Setting value of
span gas concentration
Manual cal.
Ch1
1min./div.
21.00%
Setting value of
zero gas concentration
Actual measurement value
0.98%
21.0 %O2
CAL. TIME
Enter
F7-13E.ai
Figure 7.13 Display during calibration
10) When the graph trace stabilizes, touch the Enter key. The display changes to like Figure 7.14.
The measured value is adjusted to read the same as the span gas concentration set value, and
a check mark appears in the check box beside Span calibration.
Close the span gas flow setting valve and tighten the lock nut used to prevent it from loosening
during measurement.
Even if span calibration is executed, the span calibration will not be completed normally if a
check mark is not placed in the [Span calibration] box on the Zero calibration Start Display
shown in Figure 7.14. Even if zero calibration is executed subsequently, the results will not be
applied.
11) Next perform zero calibration. Select [Zero calibration] and touch the Enter key.
12) Select [Next] and touch the Enter key.
Ch1
Manual cal.
Manual cal.
Ch1
Span calibration
21.00%
Zero calibration
Close the span gas valve.
Zero calibration
End
1min./div.
0.98%
Enter
0.98 %O2
CAL. TIME
F7-14E.ai
Figure 7.14 Zero calibration start display
Enter
F7-15E.ai
Figure 7.15 Display during calibration
13) Open the zero gas flow setting valve, and adjust flow to 600 ± 60 ml/min.
14) Select [Valve opened (Start Calibration)] and touch the Enter key. An oxygen concentration
graph like Figure 7.15 is displayed, and [CAL.TIME] status mark flashes.
Wait for the graph measured value trace to stabilize. Calibration has not yet been performed,
so it is not a problem if the displayed value is different from the correct value of zero gas
concentration.
IM 11M12D01-01E
7-10
< 7. Startup >
15) When the graph trace stabilizes, touch the Enter key. The display changes to like Figure 7.16.
The measured value is adjusted to read the same as the zero gas concentration set value, and a
check mark appears in the check box beside Zero calibration.
Close the zero gas flow setting valve and tighten the lock nut used to prevent it from loosening
during measurement.
Ch1
Manual cal.
Span calibration
Zero calibration
Close the zero gas valve.
Span calibration
End
Enter
F7-16E.ai
Figure 7.16 Calibration complete
16) Select [End] and touch the Enter key. The oxygen concentration graph is displayed and
the [HOLD TIME] status mark appears. The graph trace changes gradually from zero gas
concentration to sample gas concentration. During this “Output stabilization (settling) time” if
“Output hold” is set, then the analog output is held at the corresponding preset value. For details
of “Output hold” refer to “Subsection 8.1.2 Output Hold Setting”.
Shipping-time default setting is for stabilization (settling) time to be set to 3 minutes. After the
stabilization (settling) time has elapsed then the display reverts to channel select (Figure 7.10) so
that you can select another channel for calibration. If you touch the enter key during stabilization
(settling) time then stabilization (settling) time is skipped and you are returned to the channel
select display.
7.10 Analog Output Current Loop Check
After wiring the cables you can perform a loopback check to check if you can output a specified
current from the analog output terminals.
1) Touch the Setup key to switch to the [Execution/Setup] display.
2) Select [Maintenance] and touch the Enter key.
3) From the Maintenance display select [mA-output loop check], and touch the Enter key.
4) The “mA-output loop check” channel-select display appears (Figure 7.17).
mA-output loop check
Ch1
Ch2
Ch3
Ch4
Ch5
Ch6
Ch7
Ch8
Ave-a
Ave-b
Ave-c
Enter
F7-17E.ai
Figure 7.17
IM 11M12D01-01E
Analog output select
7-11
< 7. Startup >
5) Select the Analog output to perform Loop check on, and touch the Enter key.
6) The numerical entry display appears. Set output current somewhere in the range 4 to 20 mA.
Touching the Entry key outputs this current value.
7) Touching the Reject key (door with arrow) from the numerical entry display returns you to the
“mA-output loop check” channel-select display.
8) You can then perform a loop check on other analog outputs in the same manner.
7.11 Checking Operation of Contact Input, Contact
Output
After wiring the cables you can perform a contact I/O check to display the status of contact inputs and
to check the operation of contact outputs including contact outputs to operate solenoid valves during
automatic calibration.
7.11.1 Contact Output Operation Check
1) Touch the Setup key to switch to the [Execution/Setup] display.
2) Select [Maintenance] and touch the Enter key.
3) From the Maintenance display select [Contact check], and touch the Enter key.
4) The Contact check display shown in Figure 7.18 allows you to select contacts to check.
To check the individual error contacts for channels 1 to 8, select [Output contact ch(Channel
contact output)] or to select Function contacts (contacts 1 to 5) select [Output contact
ctrl(Common contact outputs)].
5) Next the Contact no. select display is displayed. Select the contact you want to check, then touch
the Enter key, and the [OFF] / [ON] selection window opens. Select then touch the Enter key to
open or close the corresponding contact output.
Output contact ch
Contact check
Output contact ch
Output contact ctrl
Solenoid valve contacts
Input contacts
Enter
F7-18E.ai
Figure 7.18 Contact check display
Ch1 :
Ch2 :
Ch3 :
Ch4 :
Ch5 :
Ch6 :
Ch7 :
Ch8 :
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
Enter
F7-19E.ai
Figure 7.19 Contact select display
CAUTION
1) Individual error contacts do not operate if corresponding channel is not installed.
2) If you perform a Channel contact output Open / Close check then Error2 is generated. The
reason is that Channel contact output is used as Sensor heater power safety switch, and this
turns off power to the heater. If this error occurs, to reset it remove the channel card then reinsert
it (hot swap functions), or turn power OFF then back ON.
IM 11M12D01-01E
7-12
< 7. Startup >
7.11.2 Checking contacts used to operate solenoid valves during automatic
calibration
1) From the Contact check display of Figure 7.18 select [Solenoid valve contacts]. From the
corresponding Solenoid valve contacts select display of Figure 7.20 select the solenoid to check.
To check the automatic calibration gas switching valve, select [Com].
Touching the Enter key opens the [Span] (Span valve open) / [Zero] (Zero valve open) selection
window. Selecting an output and touching Enter key allows you to test Open / Close the
corresponding solenoid valve.
2) To check a channel switching valve, select its channel [Ch1] through [Ch8] and touch the Enter
key to open the [OFF] (valve closed) / [ON] (valve open) selection window.
Selecting an output and touching Enter key allows you to test Open / Close the corresponding
solenoid valve.
NOTE
You cannot check a Channel Select valve if the corresponding Channel unit is not installed.
Solenoid valve contacts
Com:
Ch1 :
Ch2 :
Ch3 :
Ch4 :
Ch5 :
Ch6 :
Ch7 :
Ch8 :
Span
Zero
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Enter
F7-20E.ai
Figure 7.20 Solenoid valve contact selects
7.11.3 Checking Contact Inputs
1) From the Contact check display of Figure 7.18 select [Input contacts] then touch the Enter key.
The display of Figure 7.21 appears.
2) The input contact status [Open] or [Closed] is displayed in real time.
Input contacts
Contact 1 : Open
Contact 2 : Open
Enter
F7-21E.ai
Figure 7.21 Contact input check
IM 11M12D01-01E
8-1
<8. Detailed Data Setting>
8.
Setting Operating Parameters - Detail,
and Examples
8.1
Setting Analog Outputs
8.1.1 Analog Output Range (Per-Channel)
The analog output range is defined by setting the oxygen concentration value corresponding to the
range minimum oxygen concentration (corresponding to 4 mA output) and the oxygen concentration
value corresponding to the range maximum oxygen concentration (corresponding to 20 mA output).
For each channel the range settings can be set independently. You can have two ranges for each
output, switched by contact input: Contact OFF results in Range 1, and contact ON results in range
2. For details, refer to Section 8.4 Setting Contact Inputs. Factory default setting is 0 to 25% O2 for all
ranges.
1) Touch the Setup key, and the [Execution/Setup] display appears.
2) From the [Commissioning] display select [mA-output setup] then [Set range]. (See Figure 8.1).
3) Use [ ] and [
] keys to select the channel.
4) Set [min] O2 concentration corresponding to 4 mA output, then set [max] O2 concentration
corresponding to 20 mA output (select, then touch the Enter key).
5) The numeric data entry display shown in Figure 8.2 appears; enter the desired oxygen
concentration setting. To set 10% O2, input [010] and touch the Enter key.
6) As necessary, repeat for averaging output a, b and c and other channels.
New value: 025 %O2
mA-output range
Ch1
Range1
max:
min:
Range2
max:
min:
25 %O2
0 %O2
25 %O2
0 %O2
Enter
0
7
8
9
4
5
6
1
2
3
F8-1E.ai
Figure 8.1 Current-output range
Enter
F8-2E.ai
Figure 8.2 Numerical entry
IM 11M12D01-01E
8-2
<8. Detailed Data Setting>
The range low and high values are restricted as follows:
The range min. O2 concentration value (corresponding to 4 mA output) can be set to either 0% O2 or
in the range 6 to 76% O2.
The range max. O2 concentration value (corresponding to 20 mA output) can be set to any value in the
range 5 to 100% O2, however the range max. setting must be at least 1.3 times the range min. setting.
If you do not observe this restriction, the measurement will be invalid, and any previous valid value will
be used. The gray area in figure represents the valid setting range.
Setting example 1: If the range minimum (corresponding to 4 mA output) is set to 10% O2 then range
maximum (corresponding to 20 mA output) must be at least 13% O2.
Setting example 2: If the range minimum (corresponding to 4 mA output) is set to 75% O2 then range
maximum (corresponding to 20 mA output) must be at least 75x1.3=98% O2
(rounding decimal part up).
95
Maximum oxygen concentration, %O2
(for a maximum current of 20mA)
85
Ranges over which oxygen
concentrations can be set
75
65
55
45
Outside ranges
35
25
15
5
5
15
25
35
45
55
65
75
Minimum oxygen concentration, %O2 (for a minimum current of 4mA)
F8-3E.ai
Figure 8.3 Minimum-Maximum setting range of oxygen concentration
< Default setting>
Both range 1 and the second range range 2 are set to 0 to 25% O2 prior factory shipment.
IM 11M12D01-01E
8-3
<8. Detailed Data Setting>
8.1.2 Setting Output Hold (Applies to All Outputs)
During warmup, during calibration, and when an error occurs, output hold status applies: the analog
output is held at a preset value. In this instrument, the permissible hold values which may be set are
shown in Table 8.1 . The hold setting applies to the outputs of all channels.
[Warmup], [Calibration / Indication check / Blow back], or [Error] statuses may occur independently
for each channel; only the outputs of any channels in these statuses are in [HOLD] status. However
the [Error] status, [Control Card Abnormal], causes *all* the individual channel outputs and *all* the
averaging outputs to be in [HOLD] status. Both [(Under) Maintenance] and [Process Gas Alarm]
statuses also apply to the whole system and cause *all* the individual channel outputs and *all* the
averaging outputs to be in [HOLD] status.
“Averaging Group Invalid” status applies to individual averaging groups;
it means that either no channels are assigned to an averaging group, or that the status of all channels
in the averaging group is set to “disabled”; and the output of groups in this status will be in HOLD
status.
CAUTION
[Disable] means setting channel card power “OFF” so that card may be swapped. Refer to “Section
11.2 Hot Swap Function”.
Table 8.1
Status
Valid output
hold values
Warmup, Purging
4mA
20mA
(Under) Maintenance
Don’t
hold
Hold last
value
Preset value
(2.4-21.6mA)
(Under) Calibration
Indication Check
Blow back
Process Gas Alarm
Error
Averaging Group Invalid
< Definition of Statuses >
1) Warmup period, Purging
Warmup period means the status from power on until cell temperature stabilizes at 750° C and the
instrument switches to measurement mode. The basic panel display shows cell temperature during
warmup period.
“Purging” is the passing of calibration gas through the calibration gas piping before warmup, to
remove any condensate in the piping. Refer to Section 10.6 Purging. Warmup does not start until after
purging ends.
2) (Under) Maintenance
“Under maintenance” is the time that starts when you move to the [Execution/Setup] display by
touching the Setup key on the basic panel display and ends when you return to the basic panel
display. It includes when you operates keys on lower level menu displays of the [Execution/Setup]
display.
IM 11M12D01-01E
8-4
<8. Detailed Data Setting>
3) (Under) Calibration
For Manual Calibration
“Under calibration” is the time that starts when you move to the [Manual cal.] display (Figure 8.4) from
the Calibration display, lasts while you are operating keys for performing calibration manually, and
ends when you press the End key and after a preset hold time has elapsed.
For Semi-Automatic Calibration
When calibration is started from the Calibration display, “under calibration” is the time that starts when
you touch the Enter key on the [Semi-auto cal.] display with Start calibration selected (Figure 8.5),
lasts while calibration is being performed, and ends after a preset hold time has elapsed.
When calibration is started by a contact input, calibration is performed for all installed channels.
“Under calibration” is the time that starts when calibration is started by the contact input, lasts while
calibration is being performed sequentially, and ends after a preset hold time for the last calibrated
channel has elapsed.
Ch1
Manual cal.
Ch1
Open span gas valve.
Set flow span gas to
600ml/min.
Semi-auto cal.
Check settings
Span gas conc: 2 1 . 0 0 %
Zero gas conc:
0.98%
Cal. time: 2 min 0 0 s
Points: Span-Zero
Go to setup to change value.
Valve opened
Cancel calibration
Start calibration
Cancel calibration
Enter
F8-4E.ai
Figure 8.4 Manual Calibration display
Enter
F8-5E.ai
Figure 8.5 Semi-Automatic Calibration display
For Automatic Calibration
“Under calibration” is the time that starts when calibration is started at a preset timing, lasts while
calibration is being performed sequentially, and ends after a preset hold time for the last calibrated
channel has elapsed.
4) Under Indication Check
For Manual Indication Check
“Under indication check” is the time that starts when you move to the [Manual ind. check] display
(Figure 8.6) from the Indication check display, lasts you operating keys for performing indication check
manually, and ends when a preset hold time has elapsed.
For Semi-Automatic Indication Check
When indication check is started from the [Indication check] display, “under indication check” is the
time that starts when you touch the Enter key on the [Semi-auto ind. chk] display with Start ind. check
selected (Figure 8.7), lasts while indication check is being performed, and ends after a preset hold
time has elapsed.
When indication check is started by a contact input, indication check is performed for all installed
channels. “Under indication check” is the time that starts when indication check is started by the
contact input, lasts while indication check is being performed sequentially, and ends after preset hold
time for the last checked channel has elapsed.
IM 11M12D01-01E
8-5
<8. Detailed Data Setting>
Ch1
Manual ind. check
Ch1
Open span gas valve.
Set flow span gas to
600ml/min.
Semi-auto ind. chk
Check settings
Span gas conc: 2 1 . 0 0 %
Zero gas conc:
0.98%
Check time: 2 min 0 0 s
Points: Span- Zero-Third
Go to setup to change value.
Start ind. check
Cancel ind. check
Start ind. check
Cancel ind. check
Enter
Enter
F8-7E.ai
F8-6E.ai
Figure 8.6 Manual Indication Check
Figure 8.7 Semi-Automatic Indication Check
For Automatic Indication Check
“Under indication check” is the time starts when indication check is started at a preset timing, lasts
while indication check is being performed sequentially, and ends after a preset hold time for the last
checked channel has elapsed.
5) During Blow back
For Semi-Automatic Blow back
When blow back is started from the Blow back display, “during blow back” is the time that starts when
you touch the Enter key on the Blow back display with Start blow back selected (Figure 8.8), lasts
while blow back is being performed for all installed channels, and ends after a preset hold time has
elapsed.
When blow back is started by a contact input, “during blow back” is the time that starts when blow
back is started by the contact input, lasts while blow back is being performed sequentially for all
installed channels, and ends after a preset hold time for the last performed channel has elapsed.
For Automatic Blow back
“During blow back” is the time that starts when blow back is started at a preset timing, lasts while blow
back is being performed sequentially, and ends after a preset hold time for the last performed channel
has elapsed.
Blow back
Start blow back
Cancel blow back
Enter
F8-8E.ai
Figure 8.8 Blow back display
6) Process Gas Alarm
Process gas alarm status lasts from when a contact input representing the process gas alarm occurs
until the input turns off.
7) Error
Error status exists from when the error occurs until it is cleared.
IM 11M12D01-01E
8-6
<8. Detailed Data Setting>
8) Averaging group invalid
When no channels are assigned to an averaging group, or when the statuses of allocated channels
are “Disabled”, “Error”, “Warmup” or the like, so that no valid channel average value can be calculated.