Yokogawa Multi Channel Oxygen Analyzer System ZR22/AV550G User Manual
User's manual
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Table of contents
Document Outline
- Contents
- Introduction
- r For the safe use of this equipment
- r NOTICE
- r After-Sales Warranty
- 1. Overview
- 1.1 System Configuration
- 1.1.1 System Configuration Using Flow Setting Units for Manual Calibration
- 1.1.2 System Configuration to Perform Automatic Calibration
- 1.2 System Components
- 1.2.1 System Components and Their Applicability
- 1.2.2 Detectors and Accessories
- 2. Specifications
- 2.1 General Specifications
- 2.1.1 Standard Specifications
- 2.2 General-use Separate-type Detector and Related Equipment
- 2.2.1 ZR22G General-use Separate-type Detector
- 2.2.2 ZO21R-L Probe Protector
- 2.3 High-Temperature Separate-type Detector and Related Equipment
- 2.3.1 ZR22G (0.15m) High-Temperature Separate-type Detector
- 2.3.2 ZO21P-H Adapter for High-Temperature Probe
- 2.4 AV550G Averaging Converter
- 2.4.1 Standard Specification
- 2.4.2 Functions
- 2.5 ZA8F Flow Setting Unit
- 2.5.1 ZA8F Flow Setting Unit
- 2.6 Other Equipment
- 2.6.1 Dust Filter for the Detector (Part No.: K9471UA)
- 2.6.2 Dust Guard Protector (Part No.: K9471UC)
- 2.6.3 Auxiliary Ejector for High Temperature
- 2.6.4 Stop Valve (Part No. L9852CB or G7016XH)
- 2.6.5 Check Valve (Part No. K9292DN or K9292DS)
- 2.6.6 Air Set
- 2.6.7 Zero Gas Cylinder (Part No. G7001ZC)
- 2.6.8 Cylinder Regulator Valve (Part No. G7013XF or G7014XF)
- 2.6.9 Calibration Gas Unit Case (Part No. E7044KF)
- 2.6.10 Model ZR22A Heater Assembly
- 3. Installation
- 3.1 Installation of the Detector
- 3.1.1 Location
- 3.1.2 Probe Insertion Hole
- 3.1.3 Installation of the Detector
- 3.1.4 Installation of the Dust Filter( Part No K9471UA), etc
- 3.1.6 Detector with a probe protector
- 3.1.7 Detector with a probe protector
- 3.2 Installation of the Detector (Model ZR22G-015)
- 3.2.1 Installation Location
- 3.2.2 Usage of the High-temperature Probe Adapter (Model ZO21P-H)
- 3.2.3 Probe Insertion Hole
- 3.2.4 Mounting of the High-Temperature Detector
- 3.3 Installation of the Averaging Converter
- 3.3.1 Installation Location
- 3.3.2 Installation in an Instrument Panel
- 3.3.3 Outdoor Installation
- 3.4 Installation of ZA8F Flow Setting Unit
- 3.4.1 Location
- 3.4.2 Mounting of ZA8F Flow Setting Unit
- 3.5 Installation of the Calibration Gas Unit Case
- 3.5.1 Location
- 3.5.2 Mounting
- 4. Piping
- 4.1 Piping for a System Using Flow Setting Units for Manual Calibration
- 4.1.1 Parts Required for Piping in a System Using Flow Setting Units
- 4.1.2 Piping for the Calibration Gases
- 4.1.3 Piping for the Reference Gas
- 4.1.4 Piping to the High Temperature Probe Adapter
- 4.1.5 Piping for Blowback
- 4.1.6 Piping for Indication check
- 4.1.7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs
- 4.2 Piping for a System to Perform Automatic Calibration
- 4.2.1 Parts Required for Piping in a System to Perform Automatic
- 4.2.2 Piping for the Calibration Gases
- 4.2.3 Piping for the Reference Gas
- 4.2.4 Piping to the High Temperature Probe Adapter
- 4.2.5 Piping for Blowback
- 4.2.6 Piping for Indication Check
- 4.2.7 Piping to Introduce Purge Gas When a Process Gas Alarm Occurs
- 5. Wiring
- 5.1 General
- 5.1.1 Wiring Precautions
- 5.1.2 Wiring Holes
- 5.1.3 External Wiring Connection Terminals of the Averaging Converter
- 5.1.4 Types of Wiring and Cables
- 5.2 Wiring for the Averaging Converter and Peripheral Devices
- 5.2.1 Preparation for Wiring to the Averaging Converter
- 5.2.2 Preparation for Wiring to Detectors
- 5.2.3 Power and Ground Wiring
- 5.2.4 Power Wiring to Detector Heaters
- 5.2.5 Signal Wiring to Detectors
- 5.2.6 Ground Wiring of Detectors
- 5.2.7 Wiring for Individual and Average Concentration Analog Outputs
- 5.2.8 Wiring for Solenoid Valve for Automatic Calibration
- 5.2.9 Wiring for Individual/Common Error Contact Outputs
- 5.2.10 Wiring for Contact Inputs
- 5.3 Wiring and Piping Examples
- 5.3.1 Wiring and Piping for Automatic Calibration
- 5.3.2 Wiring and Piping for Automatic Calibration and 3rd Gas Indication
- 5.3.3 Wiring and Piping for Blowback
- 5.3.4 Wiring and Piping for Automatic Calibration and Blowback
- 6. Components
- 6.1 ZR22G Detector
- 6.1.1 General-purpose Detector (except for Model ZR22G-015)
- 6.1.2 High-Temperature Detector (Model ZR22G-015)
- 6.2 AV550G Averaging Converter
- 6.2.1 Components and Function
- 6.2.2 Touchpanel Switch Operations
- 6.2.2.1 Panels and Switches
- 6.2.2.2 Switches and Their Functions
- 6.2.2.3 Display Configuration
- 6.2.2.4 Display Functions
- 6.2.2.5 Entering Numeric and Text Data
- 6.3 ZA8F Flow Setting Unit
- 7. Startup
- 7.1 Startup procedure
- 7.2 Check Piping and Wiring
- 7.3 Set Valve type
- 7.4 Setting Detector model
- 7.5 Supply Power to Averaging Converter
- 7.6 Selection of Gas to be Measured
- 7.7 Current Output Range Setting
- 7.8 Averaging Group Setting
- 7.9 Calibration
- 7.9.1 Setting Calibration Gas Concentration
- 7.9.2 Performing Manual Calibration
- 7.10 Analog Output Current Loop Check
- 7.11 Checking Operation of Contact Input, Contact Output
- 7.11.1 Contact Output Operation Check
- 7.11.2 Checking contacts used to operate solenoid valves during autocalibration
- 7.11.3 Checking Contact Inputs
- 8. Setting Operating Parameters - Detail, and Examples
- 8.1 Setting Analog Outputs
- 8.1.1 Analog Output Range (Per-Channel)
- 8.1.2 Output Hold Setting (Applies to All Outputs)
- 8.1.3 Setting Output Smoothing Coefficient
- 8.1.4 Setting Output Mode (Applies to All Analog Outputs)
- 8.2 Oxygen Concentration Alarm Setting
- 8.2.1 Setting the Alarm Values (Individual Settings)
- 8.2.2 Alarm Delay Time and Hysteresis (Applies to All Alarm Settings)
- 8.3 Assigning Contact Outputs
- 8.4 Assigning Contact Inputs
- 8.5 Other Settings
- 8.5.1 Date and Time
- 8.5.2 Average Value / Max. and Min. Monitoring Time
- 8.5.3 "Fuel" Setup: Humid Exhaust Gas or "Dry" Equivalent Oxygen
- 8.5.4 Setting Password
- 9. Calibration
- 9.1 Calibration Briefs
- 9.1.1 Principle of Measurement
- 9.1.2 Calibration Gas
- 9.1.3 Compensation
- 9.1.4 Characteristic Data from a Sensor Measured During Calibration
- 9.2 Calibration Setup
- 9.2.1 Mode
- 9.2.2 Calibration Setup Procedure
- 9.2.3 Zero Gas Concentration
- 9.2.4 Span Gas Concentration
- 9.3 Performing Calibration
- 9.3.1 Performing Manual Calibration
- 9.3.2 Semi-Automatic Calibration
- 9.3.3 Starting AutoCalibration
- 10. Other Functions
- 10.1 Display
- 10.1.1 Cell Voltage
- 10.1.2 Thermocouple Voltage
- 10.1.3 Cold Junction Resistance (C.J. Voltage)
- 10.1.4 Cell temperature
- 10.1.5 C. J. Temperature
- 10.1.6 Span-gas and Zero-gas Correction Ratios
- 10.1.7 Cell Response Time
- 10.1.8 Robustness of a Cell
- 10.1.9 Cell’s Internal Resistance
- 10.1.10 Recommended Next Calibration Date
- 10.1.11 Heater On-Time Ratio
- 10.1.12 Time
- 10.1.13 Ch. card Rev., Ctrl. card Rev.
- 10.1.14 Maximum Oxygen Concentration
- 10.1.15 Minimum Oxygen Concentration
- 10.1.16 Average Oxygen Concentration
- 10.1.17 History of Calibration Time
- 10.1.18 Internal Temperature Alarm Logging
- 10.2 Trend Graphs
- 10.2.1 Trend Graph Screen
- 10.2.2 Time Axis of Trend Graph
- 10.2.3 Trend Graph Display Settings
- 10.3 Other Display-related Functions
- 10.3.1 Auto-return Time
- 10.3.2 Selecting Language
- 10.3.3 LCD Auto Off
- 10.3.4 Display Contrast Adjustment
- 10.3.5 Tag Name Entry
- 10.4 Indication Check
- 10.4.1 Mode
- 10.4.2 Procedure for Performing an Indication Check
- 10.4.3 Setting Contacts for Operating Third Check Gas Solenoid Valve
- 10.4.4 Setting Indication Check Timing
- 10.4.5 Running an Indication Check
- 10.4.6 Starting Auto Indication Check
- 10.5 Blowback
- 10.5.1 Mode
- 10.5.2 Setting Contacts for Operating Solenoid Valves
- 10.5.3 Setting Blowback Start Time
- 10.5.4 Operation of Blowback
- 10.5.5 Performing Blowback
- 10.6 Purging
- 10.7 Parameter Initialization
- 10.8 Methods of Operating Valves in the ZA8F Flow Setting Unit
- 10.8.1 Preparation Before Calibration
- 10.8.2 Operating the Span Gas Flow Setting Valve
- 10.8.3 Operating the Zero Gas Flow Setting Valve
- 10.8.4 Operation After Calibration
- 11. Inspection and Maintenance
- 11.1 Removing and Attaching the Front Cover
- 11.1.1 Removing the Front Cover
- 11.1.2 Attaching the Front Cover
- 11.2 Hot Swap Function
- 11.3 Inspection and Maintenance of the Detector
- 11.3.1 Cleaning the Filter in Sensor Assembly
- 11.3.2 Cleaning the Calibration Gas Tube
- 11.3.3 Replacing the Sensor Assembly
- 11.3.4 Replacement of the Heater Unit
- 11.3.5 Replacement of filter assembly
- 11.3.6 Replacement of O-ring
- 11.3.7 Cleaning the High-temperature Probe Adapter
- 11.3.8 Stopping and Re-starting Operation
- 11.4 Inspection and Maintenance of the Averaging Converter
- 11.4.1 Fuse Replacement
- 11.4.2 Cleaning
- 11.5 Adding Channel Cards
- 11.6 Adding the Expansion Power Supply Unit
- 11.7 Replacing Limited Life Components
- 12. Troubleshooting
- 12.1 Displays and Remedies When Errors Occur
- 12.1.1 Error Types
- 12.1.2 Operations When an Error Occurs
- 12.1.3 Error Displays
- 12.1.4 Remedies When an Error Occurs
- 12.2 Displays and Remedies When Alarms are Generated
- 12.2.1 Alarm Types
- 12.2.2 Alarm Displays
- 12.2.3 Remedies when Alarms are Generated
- 12.3 Countermeasures When Measured Value Shows Error
- 12.3.1 Measured Value Higher Than True Value
- 12.3.2 Measured Value Lower Than True Value
- 12.3.3 Measurements Sometimes Show Abnormal Values
- Revision Record