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instruction manual ZA8 zirconia oxygen analyzer im 11m6a2-yia 2nd edition, february 1999 printed in u.s.a. free datasheet http://www.datasheetlist.com/
table of contents im 11m6a2-yia 2nd edition, february 1999 i i. introduction ................................................................................................................. ............ 1 1.1 general ............................................................................................................................. 1 1.2 overview ............................................................................................................................. 1 1.3 system configuration .................................................................................................................. 2 1.3.1 detectors and accessories ................................................................................................. 2 1.3.2 features ............................................................................................................................. 2 1.4 standard specifications ............................................................................................................... 3 ii. standard converter, detector and calibration units ................................. 4 2.1 ZA8c converter ......................................................................................................................... 4 2.2 mc1, manual calibration plate ................................................................................................ 10 2.3 ac1 single point automatic calibration .................................................................................. 11 2.4 zo21d-l standard detector ..................................................................................................... 14 2.5 zo21d-h high temperature detector with zo21p-h adapter ............................................... 18 2.5.1 zo21p adapter for the high temperature probe ............................................................ 20 2.5.2 temperature controller (/ht) ......................................................................................... 24 2.5.3 water eductor (/we) ...................................................................................................... 24 2.5.4 auxiliary ejector assembly for high temperature use (m1132ke) .............................. 25 2.6 zo21d-w pressure compensating oxygen detector ............................................................... 27 2.6.1 zo21d-w reference air system, model ZA8r ............................................................. 29 2.7 accessories ........................................................................................................................... 29 2.7.1 zo21r probe protector .................................................................................................. 30 2.7.2 zo21v, probe support .................................................................................................... 32 2.7.3 check valve, m1132kn ................................................................................................. 33 2.7.4 silicon carbide filter & dust guard, e7042uq and e7042uu .................................... 33 2.7.5 fly ash filter, m1100da ............................................................................................... 34 2.7.6 hastelloy x sintered filter assembly, m1 100da-2 ....................................................... 35 2.7.7 quick disconnect cable (/a option on probe) ................................................................. 35 2.7.8 flexible metallic conduit, wz-fc ................................................................................. 38 iii. quick start-up programming for ZA8c single point o 2 system ............... 39 3.1 installation of the zo21d-l detector ....................................................................................... 39 3.1.1 installation site ............................................................................................................... 39 3.1.2 probe insertion hole ........................................................................................................ 39 3.1.3 zo21d-l detector installation ....................................................................................... 40 3.1.4 installation of zo21d-l accessories .............................................................................. 41 3.1.5 silicon carbide filter and dust guard installation ......................................................... 41 3.1.6 fly ash filter installation ................................................................................................ 42 3.1.7 flame arrestor ................................................................................................................. 42 3.1.8 detector with probe support or protector ........................................................................ 42 3.2 installation of the high-temperature detector .......................................................................... 44 3.2.1 installation site ............................................................................................................... 44 3.2.2 probe insertion hole ........................................................................................................ 44 3.2.3 mounting the zo21d-h detector and zo21p adapter tee ............................................... 45 3.2.4 installation of the zo21d-h high temperature system ................................................. 46 3.2.5 auxiliary ejector assembly, m1 132ke .......................................................................... 46 3.3 installation of the ZA8c converter ........................................................................................... 47 3.3.1 location .......................................................................................................................... 47 3.3.2 mounting ......................................................................................................................... 47 free datasheet http://www.datasheetlist.com/
table of contents im 11m6a2-yia 2nd edition, february 1999 ii 3.4 mounting of the calibration system (ac1 or mc1) ................................................................ 49 3.4.1 location .......................................................................................................................... 50 3.4.2 mounting (ac1) .............................................................................................................. 50 3.4.3 mounting (mc1) ............................................................................................................. 50 iv. calibration and piping ....................................................................................................... 51 4.1 piping ........................................................................................................................... 51 4.2 air purge fitting in the converter ............................................................................................ 52 4.3 calibration gas ......................................................................................................................... 53 4.3.1 zero gas .......................................................................................................................... 53 4.3.2 span gas ......................................................................................................................... 53 4.3.3 reference gas ................................................................................................................. 53 4.3.4 piping of gases to cal unit ............................................................................................ 53 4.4 piping to zo21d probe ............................................................................................................ 54 4.5 initial flow rate setup (ac1) ................................................................................................... 54 4.5.1 setting of reference air flow rate ................................................................................ 55 4.5.2 balancing pressure drops in the cal lines ........................................................................ 55 4.6 checking for leaks ................................................................................................................... 55 4.7 mc1 flow rate setup .............................................................................................................. 55 v. wiring ........................................................................................................................... 57 5.1 overview of types of wires ....................................................................................................... 57 5.1.1 initial preparations .......................................................................................................... 58 5.1.2 safety precaution during wiring ..................................................................................... 58 5.1.3 power and ground w iring ............................................................................................... 58 5.1.4 wiring for the detector ................................................................................................... 59 5.1.5 quick disconnect w iring ................................................................................................ 62 5.2 analog output wiring ............................................................................................................... 62 5.3 solenoid wiring for calibration unit ........................................................................................ 63 5.4 contact output w iring ............................................................................................................... 64 5.4.1 changing relay contact for contact output ................................................................... 65 5.5 contact input wiring ................................................................................................................. 66 5.6 temperature input signal wiring .............................................................................................. 66 vi. programming ........................................................................................................................... 68 6.1 quick start-up programming for ZA8c single point o 2 system ............................................. 68 6.1.1 configuring the ZA8c converter ................................................................................ 68 6.1.2 power up ZA8c ........................................................................................................... 68 6.1.3 procedure to enter maintenance mode ........................................................................ 69 6.1.4 procedure to set internal date and time ........................................................................ 69 6.1.5 procedure to enter calibration gas values ..................................................................... 70 6.1.6 procedure to set up calibration mode for manual or auto calibration systems ............. 71 6.1.7 procedure to configure (0 to 100%) ............................................................................. 71 6.1.8 procedure to set up alarm setpoints ............................................................................. 72 6.1.9 procedure to perform a manual calibration and record diagnostic parameters ............ 72 6.1.10 table of diagnostic values .......................................................................................... 74 free datasheet http://www.datasheetlist.com/
table of contents im 11m6a2-yia 2nd edition, february 1999 iii 6.2 operating keys ......................................................................................................................... 76 6.2.1 types and functions of operating keys ...................................................................... 76 6.2.2 examples of applications of the operating keys ........................................................ 76 6.3 readout displays ...................................................................................................................... 83 6.3.1 status display .............................................................................................................. 83 6.3.2 data display ................................................................................................................ 84 6.3.3 message display .......................................................................................................... 84 6.4 start-up ........................................................................................................................... 95 6.4.1 supplying power to converter ..................................................................................... 95 6.4.2 during warm-up ......................................................................................................... 95 6.4.3 data setting configuration .......................................................................................... 96 6.4.4 calibration ................................................................................................................. 115 6.5 stationary operations ............................................................................................................. 116 6.5.1 collection of control data ......................................................................................... 116 6.5.2 troubleshooting ......................................................................................................... 116 6.5.3 checking operating conditions ................................................................................. 117 6.5.4 frequent stopping and restarting operations ........................................................... 117 6.6 calibration from the ZA8c converter .................................................................................... 118 6.6.1 set-up menus for calibration .................................................................................... 118 vii. serial communication ...................................................................................................... 119 7.1 wiring with rs-232c communications cable ....................................................................... 119 7.2 wiring with rs-422a communications cable ....................................................................... 119 7.3 specifications for ZA8c converter communications ............................................................. 121 viii. calibration ......................................................................................................................... 129 8.1 calibration procedures ............................................................................................................ 129 8.1.1 principles of the zirconia oxygen analyzer .............................................................. 129 8.1.2 calibration gas .......................................................................................................... 130 8.1.3 compensation ............................................................................................................. 131 8.1.4 diagnostic data from a sensor measured during calibration .................................. 132 8.1.5 operation flowchart section ..................................................................................... 132 8.1.6 operation flowchart of semi-automatic and automatic calibrations ...................... 133 8.1.7 operation flowchart of one-touch calibrations ....................................................... 134 ix. inspection and maintenance ........................................................................................ 136 9.1 inspection and maintenance of the detector ........................................................................... 136 9.1.1 precautions for inspecting the detector ..................................................................... 136 9.1.2 cleaning the filter in the sensor assembly ................................................................ 136 9.1.3 cleaning the calibration gas tube ............................................................................ 136 9.1.4 replacing the sensor assembly ................................................................................. 137 9.1.5 cleaning the high temperature probe adapter .......................................................... 138 9.2 inspection and maintenance of the converter ......................................................................... 138 9.2.1 replacing fuses ......................................................................................................... 139 9.2.2 replacing the message display unit ......................................................................... 140 free datasheet http://www.datasheetlist.com/
table of contents im 11m6a2-yia 2nd edition, february 1999 iv x. troubleshooting ................................................................................................................ 143 10.1 error code descriptions ......................................................................................................... 143 10.1.1 types of error codes ................................................................................................. 143 10.1.2 causes of "e-1 sensor (cell) failure" and procedure for restoration ....................... 144 10.1.3 causes of "e-2 sensor temperature error (low)" and procedure for restoration .... 145 10.1.4 causes of "e-3 sensor temperature error (high)" and procedure for restoration ... 146 10.1.5 causes of "e-4 a/d (analog circuit) failure" and procedure for restoration .......... 148 10.1.6 causes of "e-5 calibration value error (zero)" and procedure for restoration ....... 148 10.1.7 causes of "e-6 calibration value error (span)" and procedure for restoration ....... 149 10.1.8 causes of "e-7 emf stabilization time over" and procedure for restoration ......... 150 10.1.9 causes of "e-8 rom and ram failure" and procedure for restoration ................. 150 10.1.10 causes of display disappearance (data display) and procedure for restoration .... 150 10.2 measures when measured value shows and error ................................................................ 151 10.2.1 measured value higher than true v alue .................................................................. 151 10.2.2 measured value lower than true v alue ................................................................... 152 10.2.3 measured value sometimes show abnormal values ................................................. 152 xi. spare parts ......................................................................................................................... 153 11.1 model zo21d-l ..................................................................................................................... 153 11.2 model zo21p ......................................................................................................................... 154 11.3 ZA8c spare parts ........................................................................................................... ........ 155 appendices .......................................................................................................................... a1 figures .......................................................................................................................... a1 tables .......................................................................................................................... a2 free datasheet http://www.datasheetlist.com/
introduction im 11m6a2-yia page 1 i. introduction 1.1 g eneral the ZA8c in-situ zirconia oxygen analyzer has been designed to measure excess oxygen in a wide variety of combustion processes. it is an outstanding unit for monitoring oxygen concentrations in combustion gas of large or small boilers, industrial furnaces and combustion processes or for the control of low percent oxygen combustion. the analyzer consists of a detector, converter and calibration unit. optional accessories may be selected to enhance installation, add system care, minimize maintenance and automate calibration. an optimal control system can be realized if the appropriate supplemental equipment is selected. the ZA8c converter utilizes a high performance microprocessor-based electronics unit incorporating the latest technology. when combined with the proven, reliable output of the zo21d zirconia oxide detector, the user receives an accurate, dependable oxygen concentration measurement needed for control and monitoring capabilities. featuring a single chip microprocessor, the ZA8c incorporates the industry's latest technological advances. reliable and simple one-chip operating is achieved through interactive operation with the microcomputer. a backlit, 40-dot matrix, liquid crystal display provides excellent readability of data while reduced components create an easy to handle, lightweight design. 1.2 o verview the ZA8c in-situ type zirconia oxygen analyzer is used to monitor and control the excess oxygen concentration in combustion gases of boilers, incinerators and other industrial furnaces. two types of detectors are available for the ZA8c: a low temperature detector (model zo21d-l) sampling gases up to 1200of (700oc) and a high temperature detector (model zo21d-h) to sample gases up to 3400of (1871oc). the flue gas temperature determines which detector will give the best oxygen measurement for combustion control, as the detector is inserted into the flue via flange and spool piece attached to the flue wall. the ZA8c is equipped with user friendly displays, featuring measurement information, cell diagnostics and help functions. because of an easily accessible pre-configured display menu, values such as display menu, min/max values of o 2 concentration, averaging values, air ratio and more are displayed on the lcd with the push of a button. the ZA8c lets the user select the calibration method: automatic (with an ac1 unit) or manual (with a mc1 unit). the converter is equipped with various functions which perform such tasks as measurement and calculation as well as maintenance functions, including self-diagnostics. free datasheet http://www.datasheetlist.com/
introduction im 11m6a2-yia page 2 1.3 s ystem c onfiguration the basic system consists of a detector, converter and calibration unit. 1.3.1 detectors and accessories meas maint alm fail data vol%o 2 detector reference air piping heater power supply wiring converter analog output (o concentration) 2 digital communication contact output temperature input contact input this panel before opening isolate mains hazardous voltages warning o calibration system 2 ZA8c zo21d (1 pair, twisted with overall shield) sensor signal wiring (3 pair, twisted with overall shield) calibration gas piping ac1 reference air zero gas check valve (optional) incoming ac power figure 1: typical system configuration 1.3.2 features repeatability: 0.5% full scale linearity: 1% full scale (for a maximum range of 0 to 25 vol% o 2 ) drift: span -0.8% of full scale/month; zero 0.7% of full scale/month response: 90% response within five seconds (measured from the time gas is switched on at the detector calibration gas inlet until the analog output signal starts to vary) free datasheet http://www.datasheetlist.com/
introduction im 11m6a2-yia page 3 1.4 s tandard s pecifications measurement: % oxygen concentration measurement method: zirconium oxide measurement range: 0 to 100 vol% o 2 output: 0 to 5 vol% o 2 to 0 to 100 vol% o 2 warm up time: 10 minutes (4 hours for stability) wiring between the detector and converter: 1. separate conduits are required for the signal cable and heater cable. 2. probe signal cable should be three pair twisted, with overall shield. 3. probe heater cable should be one pair twisted, with overall shield. 4. the maximum distance between the detector and converter is 1500 feet using 16# awg shielded wire; however, the electrical resistance of cable is less than 10 w of loop resistance. power requirements: 110 (standard), 115, 220, 240 vac (-15%, +10%) 50/60 hz. power consumption: 1. approximately 80 va during normal operation. 2. during start-up, maximum 270 va are required. free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 4 ii. standard converter, detector and calibration units 2.1 ZA8c converter ?external dimensions 1.0 4.7 4- ?0.24(6) hole 2.0 5.9 2.1 2-inch pipe 5.0 purge air connection electrical connections 2-pt 1/8 female screw ?1.1(27.5), 7 holes (with rubber cap) (with plug) panel face mounting hole 4.3 1.3 13.4 0.03(1) to 0.23(6) (panel thickness) 3.5 3.5 9.4 0.5 1.5 1.4 10.2 (340) (260) (54) (149) (33) (52) (108) (120) (126.5 ) (25) (25) 1.0 (25) 1.0 (25) 1.0 (25) 1.0 (25) 1.0 (90) (90) (238) (12) (37) (36) meas maint alm fail data vol%o 2 figure 2: ZA8c free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 5 ?standard specifications construction: dust-proof, watertight (by sealing the wiring port) nema 4 case material: aluminum alloy coating: epoxy resin, baked finish color: mansell 2.5gy5.01/1.0 equivalent installation: attached to 2" pipe, wall or panel weight: 26 lbs ambient temperature: -4o to 131of (-20o to 55oc) storage temperature: -4o to 140of (-20o to 60oc) power source: 110, 115, 220, or 240 vac (-15%, +10%), 50/60 hz display: dual display - lcd and led data display: 40 dot matrix lcd; 4 digit led oxygen concentration: 0.0 to 100.0 vol% o 2 error codes: e--1 cell failure e--2 cell temperature low e--3 cell temperature high e--4 a/d failure e--5 calibration failure of the zero gas e--6 calibration failure of the span gas e--7 s tabilizing time too short e--8 rom, ram failure (no display) digital circuit failure, or power disconnected status display: the operational status is identified by backlit indicators as follows: operation mode: green pilot lamp is on meas (measurement mode) maint (maintenance, data-setting mode) error mode: red pilot lamp is on alm (contact signal of upper or lower limit alarm is output.) fail (an error was detected during the self-test.) free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 6 message display: dot matrix lcd, 40 characters group a (1st level) a-0 analog bar-graph, output range, preset alarm output value a-1 maximum and minimum oxygen concentration within a specified time interval a-2 average oxygen concentration within a specified time interval a-3 cell emf in mv a-4 cell temperature in of/oc, thermocouple emf in mv a-5 output current in ma, output range in vol% o 2 a-6 year, month, date, hour, minute a-7 air ratio group b (2nd level) b-0 history of the span calibration b-1 history of the zero calibration b-2 cell response time in seconds b-3 cell internal resistance in ohms b-4 cell health status b-5 thermocouple cold junction temperature in of/oc b-6 cell heater on time b-7 dry oxygen concentration/wet oxygen concentration b-8 exhaust gas temperature, combustion ef ficiency note: for groups c through j, refer to table 14 ?configurable items and their defaults?. analog output: 1 output point range: two ranges can be specified, each within 0 to 5, 100 vol% o 2 . (range switching may be local or remote by contact input.) output: 4 to 20 ma or 0 to 20 madc; maximum load resistance: 550 w ; input/ output isolated characteristic: linear or log (0.1 to 5, 0.1 to 10, 0.1 to 25, or 0.1 to 100 vol% o 2 range) contact output: three output points contact capacity: 30 vdc 2a, 250 vac 2a: resistance load relay status: normally energized or normally de-energized can be programmed. (the contact status is selected with a jumper pin). application: the following functions can be configured for contact outputs #1 to #3: ? errors ? entry in progress; range switching instruction answer back; warm-up in progress; calibration in progress; blow back initiated; calibration gas pressure low; abnormal process gas temperature ?o 2 alarm low-low; low; high-high; high relay output status (factory default configuration) ? contact output #1 - nc (relay coil is normally ener gized) ? contact output #2 - no (relay coil is normally non-ener gized) ? contact output #3 - no (relay coil is normally non-ener gized) free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 7 digital communication: serial communication using rs-232c or rs-422a (driver not included) communication specifications (rs-232c or rs-422a): transmission items: time, o 2 concentration (wet and dry), cell emf, cell temperature, fail code, alarm code, status number, calibration coefficient, cell resistance, response time, cell life, measuring gas temperature, average oxygen concentration, average computing time, maximum and minimum oxygen concentration, output current and calibration start day/time. communication: start-stop system, half duplex rs-232c two-wire system rs-422a four -wire, multi-drop system communication rate: 9600, 4800, or 2400 bps may be selected transmission: transferable between no procedure and handshaking (no procedure is only for data transmission) data length: 8 bits parity: no start bit: 1 stop bit: 1 comm. code: ascii comm. format: (refer to section 7.4) analog input signal: temperature input: (1 point) 4-20 madc (measurement range 0 to 3000 of/oc) note: this input can be used for the boiler efficiency calculation as well as controlling an alarm output. contact input: two points, isolated input: contact (resistor) input or voltage input 1) contact (resistor) input on (maximum 220 w) off (minimum 100 kw) 2) voltage input on -1 to 1 vdc off 4.5 to 25 vdc application: one of the following can be specified: ? calibration gas pressure low ? range switching ? calibration start command ? process gas failure alarm (see note) ? blow back start command note: when process gas failure is specified, the alarm contact will cut off heater power. free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 8 self-test ? cell temperature low ? cell temperature high ? a/d analog circuit failed ? calibration value was incorrect ? rom or ram failed ? digital circuit failed ?power supply was switched off calibration: operation: one-touch calibration, automatic, semi-automatic 1) automatic - all calibration procedures are executed according to the sequence specified. 2) semi-automatic - pressing the "cal" key initiates the automatic calibration sequence. 3) one-touch calibration - calibration gas flow and key operation are executed manually according to the message displayed. oxygen concentration of the calibration gas: 0.3 to 21 vol% o 2 contact signal for the auto calibration unit: one each no contact for zero gas and span gas normally de-energized air purge: possible (optional) piping connection: 1/8? npt by 1/4? npt air qualification: instrument air air consumption: approximately 2 scfh at 5 psig free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 9 ?model and code for ZA8c converter single point analyzer z a8c- s m odel num ber approval -s standard - no approval -e csa & ce mark power supply -3 220 vac, 50/60 hz -4 240 vac, 50/60 hz -4 100 vac, 50/60 hz -8 115 vac, 50/60 hz digital communications -n not required -a rs-232c (ZA8c-s only) -b rs-422a digital input -0 not included -1 included process tem perature input -n none -a 4-20 ma (ZA8c-s only) auto calibration 0 not included -1 included language -j japanese -e english -g german -f french style *b style b air purge fit t ing size /ap1 rc1/4 (f) /ap2 1/4 npt (f) water tight cable glands /ecg jis a20 (7) /pat paper tag /sct stainless steel tag (attached w ith w ire) free datasheet http://www.datasheetlist.com/
specifica tions im 11m6a2-yia page 10 2.2 mc1 m anual c alibra tion p la te the mc1 is the manual calibration unit for a single oxygen probe. it provides flowrate regulation of the reference air and cal gas, allowing the operator to easily interface with ZA8c commands during calibration. separate flowmeters are used to set cal gas and reference air flowrates. ?external dimensions figure 3: manual calibration unit free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 11 ?standard specifications flowrates: cal gas - 0.6 lpm (1.3 scfh); reference air - 0.8 lpm (1.7 scfh) note: exceeding recommended flowrates may damage the detector cell. maximum pressure: 35 psig cal plate: stainless steel connection : 1/4? fnpt cal tubing: 1/4? copper (standard); 1/4? stainless steel (optional) weight: approximately 4.4 lb (2 kg) ambient temperature: 176of (80oc) maximum ?model and code for mc1 cal unit singl e channel o 2 m anual cal ibrat ion m c1 m odel num ber tubing/fittings -c 1/4" copper tubing and brass f ittings -s 1/4" stainless steel tubing and fittings reference air fl owm et er -r*u reference air flow meter 2.3 ac1 s ingle p oint a utomatic c alibration the ac1 automatic calibration system is designed to work with the ZA8c oxygen converter to provide accurate, automatic or semi-automatic calibration of the zo21d oxygen detector. the solenoids of the ac1 are sequentially activated by internal contacts at the ZA8c converter. calibration is achieved using instrument air and a compressed gas composed of oxygen balanced in nitrogen (typically 1%). the ac1 unit controls the flow of calibration gases and reference air. to simplify operation of your o 2 monitoring system, the ac1 comes fully assembled with plumbing, flow control hardware, and solenoid wiring for calibrating the oxygen probe. all the user need provide is plumbing to the zo21d probe and plumbing of the gases to the ac1, along with regulators and interconnecting wiring between the ac1 and ZA8c. the ac1 requires 120 vac. the ac1 calibration unit is available with a choice of stainless steel fittings and tubing or brass fittings and copper tubing. reference air flow control is a standard feature of the ac1, with separate flow indicators for cal gas and reference air. a clean, dry air source such as instrument air is used as both span gas and reference air. the ac1 enclosure is available in nema 4 or 4x rating. initial setup of the auto calibration unit is simplified by the use of manual overrides for all solenoids. the overrides allow for a quick balancing of the calibration gas, without the use of power. free datasheet http://www.datasheetlist.com/
specifica tions im 11m6a2-yia page 12 ?e xternal d imensions figure 4: auto calibration unit figure 4 shows the mounting dimensions for the unit. it should be located in an accessible spot as close to the oxygen probe as possible. even though the enclosure is rated for nema 4 or 4x, it is advisable to keep the unit out of direct rain. all external tubing should be 1/4? stainless steel or copper. connections to the unit are 1/4? fnpt. ?standard specifications operating pressure: up to 35 psi maximum pressure: 50 psi flowmeter range: 0.15 to 1 lpm (separate flowmeter for cal gas and reference air) flowrate: cal gas - 0.6 lpm; reference air - 0.8 lpm cal tubing: 1/4? copper (standard); 1/4? stainless steel (optional) gas connection: 1/4? fnpt voltage: 110 vac, 50/60 hz (standard) ambient temperature: 176of (80oc) maximum free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 13 ?model and code for ac1 auto-cal unit single channel o 2 auto calibration ac1 m odel num ber encl osure -4 nema 4, metal enclosure -5 nema 4x, f iberglass enclosure t ubing/fitt ings -c 1/4" copper tubing and brass fittings -s 1/4" stainless steel tubing and f ittings reference air flowm et er -r*u reference air flow meter free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 14 2.4 zo21d-l s tandard d etector the zo21d-l general purpose low temperature detector is a direct insertion (in-situ) type oxygen detector used to continuously monitor the oxygen concentration of combustion gas. a zirconia cell maintained by an internal heater at 1382of (750oc) is the measuring sensor. detector options include a check valve, flame arrester (for fm approval), derakane coating and quick disconnect cabling. ?external dimensions 7.4 4.75 0.3 inlet-1/8 fnpt 1.7 cal. gas inlet-1/8 nptf wiring hole 2-1.06 (27) 4.7 (188) (8) (120.7) (120) (42) with rubber plug 78 6 5 4 3 2 1 +- htr cj + - tc + - cell + - gnd 1.2 2.1 (30) (53) 1.69 (42.9) 0.5(12.7) with cover removed. this view shown check valve optional flame arrestor (42.4) ?1.67 ?6.1(155.0) on a ?5.0(127.0) bc 4-?0.45(11.5) holes "l" on the cal. gas inlet 8-?0.75(19.1) holes on a ?7.5(190.5) bc ?9.0(228.6) ansi class 4", 150# ff flange on a ?6.0(152.4) bc 4-?0.75(19.1) holes ?7.5(190.5) ansi class 3", 150# ff flange ?6.0(152.4) on a ?4.75(120.7) bc 4-?0.75(19.1) holes ansi class 2", 150# ff flange westinghouse flange reference air jis flange figure 5: standard detector free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 15 zo21d with tri-clamp fitting 120 [4.7] 5 [0.2] 78.9 [?3.11] 77.4 [3.05] figure 6: zo21d detector w/t ri-clamp ?standard specifications type: general purpose, direct insertion, water resistant lengths: (1.3, 1.5, 2.1, 2.5, 3.3, 5.0, 6.6, 8.0, 10.0, 12.0, 14.0, 16.0 and 18.0 feet). custom lengths are also available from the factory. weight (shipping): insertion length (l) approx. weight 1.3 f t (0.4 m) 7.7 lb (3.5 kg) 1.5 f t (0.46 m) 8.0 lb (3.8 kg) 2.1 f t (0.6 m) 9.2 lb (4.2 kg) 2.5 f t (0.8 m) 10.0 lb (4.6 kg) 3.3 f t (1.0 m) 15.0 lb (7.0 kg) 5.0 f t (1.5 m) 22.0 lb (10.0 kg) 6.6 f t (2.0 m) 29.0 lb (13.0 kg) 10.0 ft (3.0 m) 35.0 lb (16.0 kg) 12.0 ft (3.6 m) 48.0 lb (22.0 kg) 14.0 ft (4.2 m) 56.0 lb (25.5 kg) 16.0 ft (4.8 m) 64.0 lb (29.0 kg) 18.0 ft (5.4 m) 72.0 lb (33.0 kg) table 1: approximate weight of zo21d detector w/4", 150# ansi flange free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 16 material: terminal box - 304ss probe - 316ss probe flange - 304ss zirconium oxide sensor installation: flange mounting flange specs: 4 ansi, class 150# ff reduced bulk 3 ansi, class 150# ff reduced bulk 2 ansi, class 150# ff reduced bulk 2?" tri-clover westinghouse flange note: custom flanges are available upon request. mounting angle: the probe may be mounted vertically with cell end down or any angle to horizontal. a probe support (or protector) is required for all probes longer than two meters. reference air and calibration gas inlets: 1/8? npt female cable inlet: 27 mm (2 locations) ambient temperature: 14o to 176of (-10o to 80oc) sample temperature: 0o to 1230of (0o to 700oc) sample gas pressure: 0.7 psig (500 mm h 2 o) free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 17 ?model and code l ow t em pera t ure det ec t or zo21d-l general purpose zo21d-e ce mark insert ion l engt h 1 -040 0.40 m (1.3', 15.6") -046 0.46 m (1.5', 18") zo21d-l only -064 0.64 m (2.1', 25") zo21d-l only -076 0.76 m (2.5', 30") zo21d-l only -100 1.0 m (3.3') -150 1.5 m (5.0') -200 2.0 m (6.6') -245 2.45 m (8.0') zo21d-l only -300 3.0 m (10.0') -360 3.6 m (12.0') these detector lengths zo21d-l only -420 4.2 m (14.0') these detector lengths zo21d-l only -480 4.8 m (16.0') these detector lengths zo21d-l only -540 5.4 m (18.0') zo21d-l only flange m ounting 3, 6 -a*u ansi 4", 150# ff flange 5 -b*u ansi 3", 150# ff flange zo21d-l only -c*u ansi 2", 150# ff flange zo21d-l only -j*u jis 5k, 65a ff f lange -t*u 2?" tri-clamp flange zo21d-l only -w*u westinghouse flange zo21d-l only options (can select more than one) /a quick disconnects (male portion) /c check valve (m1132kn) /d derakane coating 4 /f flame arrester 2 /pat paper tag (attached w ith w ire) /sct stainless steel tag (attached w ith w ire) /t welded npt collar w ithout flame arrester not es: 1) for special detector lengths and flanges contact yokogaw a corporation of america. 2) the filter assemblies (e7042uq and m1100da or da-2) are not compatible w ith, nor required w hen the flame arrester option is selected. the f lame arrester includes its ow n f ilter. replacement part number for f lame arrester filter is e7042vg. filter assemblies and/or f lame arrester option w ill not fit through a 2", ansi mounting f lange (-c*u) or 2?" tri-clamp (-t*u). 3) the (*u) portion of the part number indicates that the detector is made in the united states at yokogaw a corporation of america, new nan, georgia. 4) derakane coating is recommended for any application up to 390 f (200o c) w here elements corrosive to the detector may be present, such as those found in chemical incinerators. 5) the 4" ansi flange (-a*u) is suggested f or probe lengths 2 m or greater. 6) detector lengths greater than 10.0 ft (3.0 m) use a rf f lange instead of a ff flange. 7) only available w ith -040 and -100 lengths. free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 18 2.5 zo21d-h h igh t emperature d etector with zo21p-h a dapter the high temperature detector is a general purpose probe utilized in conjunction with a high temperature adapter tee (zo21p) in applications with temperatures ranging between 1200of and 3400of . the detector is mounted to an adapter reducing the heat of the process gas through conduction. probe options include derakane coating, flame arrester (for fm approval), and quick disconnect wiring. ?external dimensions flange (with rubber plug) 2-?1.06 (?27) wiring holes calibration gas inlet (38) 1/8 fnpt ?1.7[43.2] 4-?0.63(?16.0) holes on a 3.54 (89.9) dia bolt circle ?4.50 (?114.3) 2.1 (53) 1.5 1.7 (43) ?1.7 (?43) (150) 0.2 (5) 4.7 (120) 0.31 (8) this view shown with cover removed. gnd tc cell + 1 - 2 + 3 htr + 7 cj - 8 - 4 + 5 - 6 (168) 5.9 6.6 reference air inlet 1/8 fnpt figure 7: zo21d-h-015-k-u high t emperature detector with 150# jis flange and junction box free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 19 ansi 3" 150lb ff flange (with rubber plug) 2-?1.06 (?27) wiring holes calibration gas inlet (38) 1/8 fnpt flame arrestor ?1.7[43.2] 4-?0.75 (?19.1) holes on a ?6.00 (152.4)dia bolt circle ?7.50 (?190.5) 2.1 (53) 1.5 1.7 (43) ?1.7 (?43) 0.2 (5) 0.38 (9.5) 4.7 (120) 1.0 (25.4) this view shown with cover removed. gnd tc cell + 1 - 2 + 3 htr + 7 cj - 8 - 4 + 5 - 6 (?60) ?2.38 7.13 (181) 3.25 max. (83 max.) (173) 6.8 6.6 (168) reference air inlet 1/8 fnpt figure 8: zo21d-h-017-l*u/f high t emperature detector with junction box and flange ?standard specifications type: general purpose, water-vapor resistant material: terminal box- 304ss probe - 316ss flange - 304ss zirconium oxide sensor weight: 7 lbs (3.2 kgs); /f option - add 8 lbs (3.6 kgs) installation: flange mounting with the high temperature probe adapter any angle from vertical to horizontal. reference air and calibration gas inlet: 1/8? npt female fittings cable inlet: two holes of 27 mm free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 20 ambient temperature: 14o to 302of (-10o to 150oc) sample gas temp: 32o to 1230of (0o to 700oc) when no adapter is used and 32o to 3600of (0o to 1400oc) when probe adapter is used. sample gas pressure: 0.7 psi (500 mm h 2 o) optional quick disconnects: (refer to sections 2.7.6 and 2.7.7) ?model and code high t em perat ure detect or m odel num ber descript ion zo21d-h-015-k*u high temperature detector includes a jis5k32a f lange zo21d-h-017-k*u high temperature detector for flame arrester includes a 3" ansi f lange 1 zo21d-f-015-k*u ce mark options (can select m ore than one) /a quick disconnects (male portion) (not available on zo21d-f) /c check valve (m1132kf) /d derakane coating 2 /f flame arrester (zo21d-h-017 only) 1 /sct stainless steel tag (attached w ith w ire) /pat paper tag (attached w ith w ire) /t welded npt collar w ithout flame arrester 1 not es: 1) /f version - order zo21d-h-017-l*u/f f or probe w ith preattached f lame arrester. probe adapter zo21p-f is used w ith flame arrester option. /t on a probe includes the mounting threads w ithout the f lame arrester. do not specify /t/f. 2) /d derakane c oating - used for corrosive applications. cannot be used if the tee temperature is maintained above 390o f (200o c). 2.5.1 zo21p adapter for the high t emperature probe the probe adapter is used to reduce the sample gas temperature below 1230of (700oc) before it is measured by the detector. the adapter tee cools the process gas through conduction, preventing overheating of the cell. a transport tube and eductor assembly provide the extraction of the process gas in negative pressure applications. a heated eductor option helps prevent condensation from forming in the ejector assembly. see table 2 for the transport tube material and insertion lengths. in applications prone to blockage, an optional manual ?blow back? system is used. instrument air is blown through the transport tube, removing possible obstructions. refer to im 11m6z2-yia for details regarding the "blow back" system. free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 21 ?external dimensions 1/4 fnpt (?60) 4 - ?0.63(?16.0) hole s on a 3.54 (89.9) dia bolt circle 3/4 fnpt 6.1 9.7 11.7 notes: 1. material is 316 sst, except for ansi flange which is 304 sst. 2. weight: 24.3 lbs(11 kg) (?114.3) 0.38(9.7) thk flange (193) (?228.6) 8 - ?0.75(4819.1) holes on a 7.50(190.5)dia bolt circle 0.94(23.8) thk flange 4" ansi 150# raised face flange (297) (246) ?2.4 (155) (2 places) [1.0m] 7.60 ?9.00 3.3ft ?4.50 figure 9: zo21p-h high t emperature adapter tee 11.8 (301) 9.1 (232) ?4.5 (?114) 5.7 (145) 1/4 fnpt 4 - ?0.75(?19.1) holes on a 6.00(152.4) dia bolt circle ?7.5 (?191) 0.38 (9.7) thk flange 10.4 (265) 3/4 fnpt ?9.0 (?228.6) 8 - ?0.75(?19) holes ?7.50[ 190.5] bolt circle 0.94(23.8) thk flange 4" ansi 150# raised face flange 3" ansi 150# raised face flange [1.0m] 3.3ft ?0.8 [?20] ?1.9 (?48) 2.5 (64) figure 10: zo21p-f high temperature adapter for the flame arrester free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 22 ?standard specifications insertion length: refer to table 1, "material reference chart for transport tube" materials: adapter = 316 stainless steel flange = 304 stainless s teel transport tube = see table 1 weight: 24 lbs; /f option - add 5 lbs; /be option - add 5 lbs; /bh option - add 5 lbs; /b option - add 2 lbs installation: flange mounting flange specifications: 4? ansi class 150# rf flange mounting angle: vertical (can also be attached horizontally if the probe material is 310ss) sample gas exhaust: npt 1/4? female process temperature: 32o to 3000of (0o to 1650oc) for exalloy transport tube operation pressure: 0.7 psi (500 mm h 2 o) (eductor is required for negative pressure) table 2: material reference chart for transport t ubes material length (l) part number max. tem perature weight tube diameter o.d. silicon carbide 0.3 m (1.0 f t) e7046al-j01 2600of (1427o c) 2 lb (0.9 kg) 1.3 in. silicon carbide 0.5 m (1.5 f t) e7046al-j02 2600of (1427o c) 2.4 lb (1.0 kg) 1.3 in. silicon carbide 1.0 m (3.3 f t) e7046al-j03 2600of (1427o c) 5 lb (2.3 kg) 1.3 in. silicon carbide 1.5 m (5.0 f t) e7046al-j04 2600of (1427o c) 7 lb (3.2 kg) 1.3 in. 310 s stainless steel 0.3 m (1.0 f t) e7046ap-j01 1980of (1082o c) 1.5 lb (0.7 kg) 1.1 in. 310 s stainless steel 0.5 m (1.5 f t) e7046ap-j02 1980of (1082o c) 2.2 lb (1.0 kg) 1.1 in. 310 s stainless steel 1.0 m (3.3 f t) e7046ap-j03 1980of (1082o c) 6 lb (2.7 kg) 1.1 in. 310 s stainless steel 1.5 m (5.0 f t) e7046ap-j04 1980of (1082o c) 8 lb (3.6 kg) 1.1 in. 310 s stainless steel 3.0 m (9.8 f t) e7046ap-j05 1980of (1082o c) 12.6 lb (5.7 kg) 1.1 in. alumina 0.3 m (1.0 f t) m1132za-01 3400of (1871o c) 1.2 lb (0.5 kg) 0.8 in. alumina 0.5 m (1.5 f t) m1132za-02 3400of (1871o c) 2 lb (0.9 kg) 0.8 in. alumina 1.0 m (3.3 f t) m1132za-03 3400of (1871o c) 5 lb (2.3 kg) 0.8 in. alumina 1.5 m (5.0 f t) m1132za-04 3400of (1871o c) 7 lb (3.2 kg) 0.8 in. hr160 0.3 m (1.0 f t) m1132xa-01 2000of (1100o c) 1.6 lb (0.7 kg) 1.1 in. hr160 0.5 m (1.5 f t) m1132xa-02 2000of (1100o c) 2.2 lb (1.0 kg) 1.1 in. hr160 1.0 m (3.3 f t) m1132xa-03 2000of (1100o c) 6 lb (2.7 kg) 1.1 in. hr160 1.5 m (5.0 f t) m1132xa-04 2000of (1100o c) 8 lb (3.6 kg) 1.1 in. hr160 3.0 m (9.8 f t) m1132xa-05 2000of (1100o c) 12.6 lb (5.7 kg) 1.1 in. exalloy ceramic 0.3 m (1.0 f t) m1233ka-01 3000of (1650o c) 1.5 lb (0.7 kg) 1.3 in. exalloy ceramic 0.5 m (1.5 f t) m1233ka-02 3000of (1650o c) 1.9 lb (0.8 kg) 1.3 in. exalloy ceramic 1.0 m (3.3 f t) m1233ka-03 3000of (1650o c) 3 lb (1.4 kg) 1.3 in. exalloy ceramic 1.5 m (5.0 f t) m1233ka-04 3000of (1650o c) 4.4 lb (2.0 kg) 1.3 in. exalloy ceramic 3.0 m (9.8 f t) m1233ka-05 3000of (1650o c) 7.8 lb (3.5 kg) 1.3 in. free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 23 ? model and code high temperature probe adapter z o2 1 p m odel num ber t ee configurat ion 1 -h basic design (side eductor port) -t basic design (bottom port) -s split design (f or blow back) -f oversized design (for flame arrester, includes studs) -c all hastelloy c (configured as -t only) transport tube material -a silicon carbide (sic) (up to 2600of/1427oc) -b 310 stainless steel (up to 1980of/1082oc) -c alumina ceramic (up to 3400of/1871oc) -h hr160 stainless steel (up to 2000of/1100oc) -x exalloy ceramic (up to 3000of/1650oc) - n no tra nsport tube insertion length -033 0.3 m (13") -050 0.5 m (20") -100 1.0 m (3.3') -150 1.5 m (5.0') -300 3.0 m (9.8') (not for -a or -c tubes) -nnn no tra nsport tube flange connection -a*u ansi 4", 150# rf options (m ay select one from each group) options heater system /ht aux heater system (to 600o f) [includes controller and heaters] blowback block valve (for zo21p-s) /av automatic valve /mv manual valve ed u c t o r /be wrapped air eductor pre-attached w ith regulator and gauge (f or zo21p-h w ithout /ht only) /er air ejector w /return exhaust pre- attached w ith regulator and gauge (for zo21p-h or zo21p-s only) /se separate air ejector, regulator and gauge (not preattached) /we self -cleaning w ater ejector (regulator and gauge not included) /e4 tag /sct stainless steel tag (attached w ith w ire) /pat paper tag (attached w ith w ire) notes: 1) the -h option is the standard tee. t-eductor port is mounted on the side - (180o f rom the probe.) -s i desi g ned f or applications that require blow back to keep the transport tube clean. it must have a val v installed (1" npt, full port, high temp). customer must specify option /mv or /av. -f is an oversized tee f or applications requiring a f lamer arrester. free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 24 2.5.2 t emperature controller (/ht) controller is installed in nema 4x enclosure, and is preconfigured with a setpoint value of 600of with 700of alarm. ?standard specifications supply voltage: 85 to 264 vac; 50/60 hz; rating: 100 to 240 vac thermocouple: type j included, preset @ 600of (316oc) setpoint power consumption: less than 17 va for standard ac type. operating environment: 30o to 122of (0o to 50oc); 45 to 85% rh control: preset for pd control. alarm: heater break alarm preset at 700of (371of) net weight: 6 oz (0.17 kg) certification: ul recognized; csa listing. 2.5.3 water eductor (option /we ) used as the pumping mechanism for obtaining a sample from the process, water is used to create a vacuum, thereby directing the sample through the adapter tee. ?standard specifications water pressure: 20 psi minimum water consumption: 2.5 gpm water vacuum flow: .56 gpm air vacuum flow: .08 scfm vacuum force: 29" hg material: anodized aluminum weight: 6 oz 1/4" mnpt p/n m1133cw mounting plate water supp l 1/8" fnpt 1/8" fnpt figure 11: water eductor ejector assembly free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 25 2.5.4 auxiliary ejector assembly for high t emperature use (m1132ke) high temperature applications require the use of the auxiliary ejector assembly in negative pressure installations. using instrument air, the auxiliary ejector draws a sample through the adapter tee without mechanical assistance. the assembly includes an ejector , regulator and pressure gauge and is included in the heated eductor (/be option) for the zo21p high temperature adapter tee. ?external dimensions 0 30 25 20 15 10 5 bar 100 x kpa psi 0.5 1.0 1.5 2.0 2.50 [63.5] 5.63 [143.0] in in from probe adapter 1/4 npt female 1/4 npt female 1/8 npt female (2) 10-24 unc mounting holes out exhaust 1/4 npt male (typ ea end) exhaust sample figure 12: auxiliary ejector assembly ?standard specifications ejector (m1132ka): material: 316ss air supply: 1/8? npt female air consumption: 1.7 scfm exhaust: 1/4? npt male straight vacuum force: 7.6? hg vacuum flow: 2.4 scfm air consumption: 1.7 scfm weight: 6 oz. (170 kg) free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 26 vacuum: 1/4? npt male connection to high-temp probe adapter: 1/4? npt piping connection: 1/4? npt female connection tube: 1/4? stainless pipe pressure gauge (m1132cg): indicates the pressure of instrument air flowing into the eductor. gauge size: 2? measuring range: 0 to 60 psi piping connection: 1/4? npt male scaling: 0 to 30 psig (0 to 2 bar) ambient temperature: 140of (40oc) at maximum pressure regulator (m1132kd): this general purpose regulator is used to adjust the flow of instrument air entering the ejector. made of durable materials and corrosion resistant construction, it provides reliable operation in harsh industrial environments. flow capacity: 20 scfm (33.6 m 3 /hr) at 100 psig (700 kpa) supply - 20 psig (140 kpa) outlet. exhaust capacity: 0.1 scfm (0.17 m 3 /hr) - downstream pressure 5 psig (35 kpa) above setpoint. sensitivity: 1? h 2 o (25.4 mm) effect of supply pressure variation: less than 0.2 psig (1.4 kpa) for 25 psi (170 kpa) change maximum supply pressure: 250 psig (1700 kpa) air consumption: less than 6 scfh (0.17 m 3 /hr) output range: 0 to 60 psi (0-400 kpa) port size: 1/4? npt materials: body - die cast aluminum alloy; diaphragm - nitrile elastomer and nylon fabric; trim - brass, zinc plated steel, acetal. weight: 4.0 lbs (1.8 kgs) free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 27 2.6 zo21dw p ressure c ompensating o xygen d etector the zo21dw is a pressure compensating type oxygen detector used in applications with positive pressures exceeding 0.7 psig (500 mm h 2 0). because the zirconia cell measures the ratio of the oxygen partial pressures between the measuring and reference sides of the zirconia cell, uncompensated positive pressure differences exceeding 0.7 psig (500 mm h 2 0) may create errors with the standard oxygen detectors (zo21d-l and zo21d-h). compensation is accomplished via a specially designed reference system using dry instrument air (see note below). options include flame arrester, check valve, and derakane coating. note : user must supply a pressure compensated reference air system with any zo21dw detector. the zo21dw is not used in nega tive pr essur e applications. ?external dimensions 1.69 (42.9) 4" raised face flange ?6.19 150 lb ansi 0.94(23.9) 0.06(1.5) 3.3 ft ?9.0(228.6) on a ?7.5(190.5) bc 8-?0.75(19.1) holes check valve flame arrestor (?42.4) ?1.67 weld typ. + + tc tc-in - - cell + htr + - + cj - - 12.3 (312.4) this view shown with cover removed ?6.00 (?152.4) 2.00 (50.8) 2.75 3.19 (69.9) (81.0) 1.75 (44.5) 6.13 (155.7) ref. air inlet 1/8 fnpt check gas inlet 1/8fnpt ref. air outlet conduit 3/4"mnpt (?157.2) (1.0 m) 3.25 max. (83 max.) 7.13 (181) 1.33 (33) figure 13: pressure compensating oxygen detector ?standard specifications sample gas temperature: 32o to 1112of (0o to 600oc) sample gas pressure: maximum duct pressure, 35 psig (24,607 mm h 2 0) (not recommended for negative gas pressures) reference gas flowrate: 0.6 lpm (1.3 scfh) free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 28 insertion length and weight: length (l) weight 1.3 f t (0.4 m) 14 lb (6.5 kg) 3.3 f t (1.0 m) 22 lb (10 kg) 5.0 f t (1.5 m) 29 lb (13 kg) 6.6 f t (2.0 m) 37 lb (17 kg) 10 f t (3.0 m) 44 lb (20 kg) 12 f t (3.6 m) 52 lb (23.5 kg) table 3: probe lengths and weights for zo21dw ambient temperature: 14o to 176of (-10o to 80oc) material in contact with gas: terminal box: aluminum casting; probe: 316ss; flange: 304ss; sensor: zirconia construction: water-resistant, direct insertion installation: flange mounted, ansi class 4?, 150# rf flange flange connection: 1/8? fnpt fitting with npsm 3/4? conduit fitting. probe mounting angle: vertically with cell end down or horizontally, or at an angle in between. when probe length is greater than 2.0 m, use a probe support or probe protector (see accessories). wiring: for description, refer to accessories. ?model and code pressure compensating (low temperature) z o21dw-l m odel num ber insert ion l engt h 1 -040 0.40 m (1.3', 15.6") -100 1.0 m (3.3') -150 1.5 m (5.0') -200 2.0 m (6.6') -300 3.0 m (10.0') these detector lengths require a probe -360 3.6 m (12.0') support or probe protector. flange connection -a*a ansi 4", 150# rf flange flange connection -npt 1/8" fnpt fitting w ith npsm 3/4" conduit fitting options (can select more than one) /c check valve (required) /d derakane coating 1 /f flame arrestor /sct stainless steel tag (attached w ith w ire) /pat paper tag (attached w ith w ire) /t welded npt collar w ithout f lame arrester not es: 1 ) derakane coatin g is recommended f or applications up to 390o f (200o c) w here elements corrosive to the detector may be present. such as those found in chemical incinerators. free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 29 2.6.1 zo21dw reference air system, model ZA8r the model ZA8r is a dual calibration unit that in addition to performing automatic calibration, also provides pressure compensation for the model zo21dw pressure compensating detector. optionally, instrument air may be used to provide safety blowback. consult factory for more detailed information. ?standard specifications calibration air: clean dry instrument grade air flowmeter range : 0.15 to 1 lpm flowrate : cal gas - 0.6 lpm (1.3 scfh) reference air - 0.8 lmp (1.7 scfh) operating pressure : pressure setting for cal gas and reference air is approximately 14 psig above wind box pressure. maximum pressure : 35 psig operating pressure: 0.7 to 35 psig gas connection : 1/4? fnpt voltage : 110 vac, 50/60 hz (standard) 220 vac, 50/60 hz (optional) ambient temperature : 14o to 176of (-10o to 80oc) 2.7 a ccessories accessory description zo21d-l zo21d-h probe protector zo21r x probe support zo21v x low temp sintered ss filter m1100da (to 500o f) x hastelloy x filter m1100da-2 (to 1250o f) x ceramic filter & dust guard e7042uq (uu) x x check valve m1132kn (/c option on probe) x x flame arrestor e7042vp (/f option on probe) x x derakane coating (/d option on probe) x x zirconia cell assembly e7042ud x x table 4: accessories free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 30 2.7.1 zo21r probe protector a probe protector is required for most coal fired boilers, lime kilns, cement kilns and incinerators where the abrasive particles in the flue gas may erode the wall of the oxygen detector. probe protectors may only be used in conjunction with the zo21d-l. ?external dimensions detector probe protector 316 ss 3.3 id (83.82) "a" "b" fly ash filter 4.0 (101.6) ansi class 2", 150# ff flange 4-?0.75(19.1) holes on a ?4.75(120.7) bc ?6.0(152.4) jis flange westinghouse flange ?6.1(155.0) 4-?0.45(11.5) holes on a ?5.0(127.0) bc 0.70(17.8) w/ ?1.38(35.1) ansi 4" 150 lb flange 4-?0.75(19.1) holes evenly spaced on a ?7.5(190.5) bc on a ?7.5(190.5) bc 4-?0.75(19.1) holes counter sunk ?9.0(228.6) ansi class 3", 150# ff flange ?7.5(190.5) 4-?0.75(19.1) holes on a ?6.0(152.4) bc figure 14: probe protector note: when probe is longer than 10 feet, clamps are used to center the probe. ?standard specifications material: 316ss pipe 304ss, ansi 4? 150# flange installation: flange mount (ff type) length/weight: for custom lengths, please contact your local yokogawa industrial automation representative. free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 31 insertion length (l) approx. weight 1.3 ft (0.4 m) 15 lb (7 kg) 1.5 f t (0.46 m) 18 lb (8.2 kg) 2.1 f t (0.64 m) 20 lb (9.1 kg) 2.5 f t (0.76 m) 21 lb (9.5 kg) 3.3 ft (1.0 m) 22 lb (10 kg) 5.0 ft (1.5 m) 29 lb (13 kg) 6.6 ft (2.0 m) 35 lb (16 kg) 10.0 f t (3.0 m) 48.5 lb (22 kg) table 5: approximate length and weight of zo21r-l probe protector w/4", 150# ansi flange ?model and code low temperature probe protector zo21r-l model num ber insert ion lengt h -040 0.40 m (1.3', 15.6") -046 0.46 m (1.5', 18") -064 0.64 m (2.1', 25") -076 0.76 m (2.5', 30") -100 1.0 m (3.3') -150 1.5 m (5.0') -200 2.0 m (6.6') -300 3.0 m (10.0') flange connection -a*u ansi 4", 150# ff flange -b*u ansi 3", 150# ff flange -c*u ansi 2", 150# ff flange -j*u jis 5k, 65aff flange -w*u westinghouse f lange free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 32 2.7.2 zo21v probe support a probe support is required for detector lengths of 10 feet (3 meters) or greater. probe supports may only be used in conjunction with the zo21d-l low temperature detector. ?external dimensions clamp (1.5 m) 5 ft (?89) ansi 4" 150#, 1" thk flange zo21d-l termperature probe ?3.5 ansi 4" 150 lb flange ?9.0(228.6) 4-?0.75(19.1) holes evenly spaced on a ?7.5(190.5) bc counter sunk 4-?0.75(19.1) holes on a ?7.5(190.5) bc 0.70(17.8) w/ ?1.38(35.1) ?6.1(155.0) on a ?5.0(127.0) bc 4-?0.45(11.5) holes on a ?6.0(152.4) bc 4-?0.75(19.1) holes ?7.5(190.5) ansi class 3", 150# ff flange ?6.0(152.4) on a ?4.75(120.7) bc 4-?0.75(19.1) holes ansi class 2", 150# ff flange westinghouse flange jis flange figure 15: probe support ?standard specifications material: sus316 (support) sus304 (flange) supporter length: 5 ft (1.5 m) for use with a 10 ft (3.0 m) probe weight: approx. 22 lbs (10 kgs) when jis flange is used. approx. 28 lbs (12.7 kgs) when ansi flange is used. installation: flange mounting (ff type) with an internal spacer to position detec- tor. ?model and code low tem perature probe support zo21v model number insert ion lengt h -150 5.0 f t (1.5 m) [f or use w ith 10 ft (3 m) probe] flange connection -a*u ansi 4", 150# ff flange -j*u jis 5k, 65ff flange -w*u westinghouse f lange free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 33 2.7.3 check v alve, m1132kn the check valve prevents water vapor in the process from diffusing down the calibration line where it may condense and cause the cell to crack. a check valve should be used on all natural gas and positive pressure applications as well as any time with long periods (>3 months) of time between calibrations. ?external dimensions 1.77 (45) 1/8 male npt 1/8 female npt 0.551 (14) figure 16: check valve ?standard specifications connection: 1/8? fnpt inlet; 1/8? mnpt outlet material: 304ss cracking pressure: 1 psi weight: approximately 0.1 lb (50 g) note: the check valve is not a substitution for an in-line filter for removing moisture from instrument air source. 2.7.4 s ilicon c arbide f ilter & d ust g uard , e7042uq and e7042uu this assembly protects the zirconia cell from fine particulate components in the flue gas which may poison or reduce the life of the cell (not used with the flame arrester). free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 34 ?external dimensions 120? 90? gas flow 2.36 (60.0) 3.15 (80.0) 1.70 (43.3) 1.91 (48.6) 1.73 (44.0) 2-m6 carborundum filter (e7042uq) guard (e7042uu) filter and guard figure 17: filter and dust guard ?standard specifications mesh: 70 micron (filter) material: carborundum (filter), 316ss max. temperature rating: 932of (500oc) connection: stainless steel bolts weight: approximately 1.6 lbs 2.7.5 fly ash filter, m1100da the fly ash filter is for high dust applications such as coal fired boilers, kilns and bark boilers. ?external dimensions (ref) 2.60 8.10 (ref) (ref) end of o probe 2 7.0 this view shows the as it is installed. (process flow will be down) side view of the filter flow c-clamp connection figure 18: fly ash filter free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 35 ?standard specifications mesh: 10 micron (filter) material: 316 sintered stainless steel max. temperature rating: 572of (300oc) connection: stainless steel c-clamp with bolt weight: approximately 1.5 lbs 2.7.6 h astelloy x s intered f ilter a ssembly , m1100da-2 designed for use in applications above 572of (300oc), this filter addresses blockage and coating problems experienced by tough applications. ?external dimensions refer to figure 17 ?standard specifications mesh: 10 micron (filter) material: hastelloy x (see note) max. temperature rating: 1292of (700oc) connection: stainless steel c-clamp with bolts weight: approximately 1.8 lbs note: m1100da-2 is not suitable for recovery boiler applications. 2.7.7 quick disconnect cable (/a option on probe) quick disconnect connectors are used on the detector?s heater and signal cables for easy wire installations and maintenance. see model zo21d detectors for pre-attached male connectors in section 1 (/a options shown). field connectors must be ordered separately (wz... options shown). free datasheet http://www.datasheetlist.com/
specifica tions im 11m6a2-yia page 36 type awg no. conductors insulation shield jacket voltage/ weight/ cable (material, thickness) temp 1,000 ft high temp signal 3 pair, twisted; fep aluminum mylar; fep.010" wall/ 300 volts/ 35 lb wz-h-6s black/white/red/green awg 18/7 tc drain .268" od 392o f (200oc) (15.9 kg) low temp signal 16 3 pair, twisted; polyethylene aluminum polyester foil; pvc.035" wall/ 300 volts/ 125 lb wz-l-6s black/white/red/green stranded tinned copper drain .475" od -4o to 140o f/ (56.7 kg) (-20o to 60o c) high temp heater 2 conductor fep aluminum mylar; fep.010" wall/ 300 volts/ 35 lb wz-h-3h black/red awg 16/19 tc drain .182" od 392o f (200oc) (15.9 kg) low temp heater 14 2 conductor polyethylene aluminum polyester foil; pvc.035" wall/ 300 volts/ 72 lb wz-l-3h black/natural stranded tinned copper drain. .350" od -4o to 140o f/ (32.6 kg) (-20o to 60o c) table 6: quick disconnect cable specifications ?external dimensions figure 19: wz.../qc or /qf figure 20: zo21d.../a free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 37 ?model and code z o21d wiring - signal c abl e ca bl e t em perat ure ra t ing wz -h high temp cable (fep jacket (up to 390o f) (200o c)) wz-l low temp cable (pvc jacket (up to 140o f (60o c)) cable length (feet) -3h-0005 5' heater cable (3-conductor) -6s-0005 5' signal cable (6-conductor) -3h-0010 10' heater cable (3-conductor) -6s-0010 10' signal cable (6-conductor) -3h-0015 15' heater cable (3-conductor) -6s-0015 15' signal cable (6-conductor) -3h-0020 20' heater cable (3-conductor) -6s-0020 20' signal cable (6-conductor) -3h-0025 25' heater cable (3-conductor) -6s-0025 25' signal cable (6-conductor) -3h-0030 30' heater cable (3-conductor) -6s-0030 30' signal cable (6-conductor) -3h-0040 40' heater cable (3-conductor) -6s-0040 40' signal cable (6-conductor) -3h-0050 50' heater cable (3-conductor) -6s-0050 50' signal cable (6-conductor) -3h-0100 100' heater cable (3-conductor) -6s-0100 100' signal cable (6-conductor) -3h-0200 200' heater cable (3-conductor) -6s-0200 200' signal cable (6-conductor) -3h-0500 500' heater cable (3-conductor) -6s-0500 500' signal cable (6-conductor) connection 1 /qc quick disconnect w /cable clamp 1 /qf quick disconnect w /flex conduit adapter (1/2" nptm) 2, 3 ca ut ion: wz-h-6s-0500/qf w ill add a soldered quick disconnect f itting to the end of the 500 f oot low temperature cable, w ith 2 separate flex conduit adapter f ittings (1/2" npt). the customer w ill probably use a junction box close to the probe, and run the remainder several hundred feet from the junction box to the convert e not es: 1) must select /a option f or the zo21d probe quick disconnects. 2) the quick disconnect w ith cable clamp (/qc option) can only be used w ith the low temperature (wz-l...) cable. 3) the quick disconnect w ith f lex conduit adapter (/qf) f ittings can only be used w ith the high temperature (wz-h..) cable. 4) the 1/2" f lex conduit must be ordered separately. see wz-fc inf ormation. free datasheet http://www.datasheetlist.com/
specifications im 11m6a2-yia page 38 2.7.8 flexible metallic conduit, wz-fc this jacketed, liquid-tight, flexible metallic conduit provides complete protection from liquids and vapors. it has an absorbing motion and withstands severe vibration and tight bending. the conduit jacket is a special thermoplastic rubber compound. its applicable temperature range is from -76o to 302of (-60o to 150oc), with intermittent excursions to 329of (165oc). ?standard specifications size : 0.5 inches id : 0.622 min / 0.642 max od : 0.820 min / 0.840 max inside bend radius : 0.2 inch weight per 100 feet : 27 pounds ?model and code part num ber opt ional it em s m1132xp 1/2" flexible conduit (order quantity is conduit length in f eet) free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 39 iii. installation 3.1 i nstallation of the zo21d-l d etector 3.1.1 installation site note the following when installing the detector: 1) easy access to the detector for maintenance work. 2) ambient temperature does not exceed 176of (80oc). 3) a clean environment free of corrosive gases. 4) minimum vibration. 3.1.2 probe insertion hole includes those analyzers equipped with a probe supporter and probe protector. when preparing the probe insertion hole, the following should be taken into consideration: 1) the detector probe tip should not be mounted above the horizontal. 2) if the probe length is greater than 2 meters (10 feet), the detector requires a probe support or protector. 3) the probe should be situated so that the sensor is at a right angle to the gas flow note: to prevent the sensor from deterioration due to condensation, do not mount the probe above the horizontal. within this angle (vertical) (horizontal) ansi class 150#, or jis flange 3.94 (100) (52 min.) 3.94 (100) 2.05" min. westinghouse flange ansi class 3", 150# ff flange 4-?0.75(19.1) holes on a ?6.0(152.4) bc 4-?0.45(11.5) holes on a ?5.0(127.0) bc ansi class 2", 150# ff flange 4-?0.75(19.1) holes on a ?4.75(120.7) bc ?6.0(152.4) ansi class 4", 150# ff flange jis flange on a ?7.5(190.5) bc 8-?0.75(19.1) holes ?9.0(228.6) ?6.1(155.0) ?7.5(190.5) figure 21: probe insertion hole free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 40 3.1.3 zo21d-l detector installation the cell (sensor) at the tip of the detector is made of ceramic (zirconia). the heater is made of a quartz type material; therefore, care should be taken to avoid any mechanical shock or jarring to the probe such as dropping. use a suitable gasket on the flange surface to prevent gas leakage. the gasket material should be heatproof and corrosion-proof. if corrosion is a prevalent problem at the flange, request derakane coating when ordering probes. see accessories. the following should be taken into consideration when mounting the detector. 1) the zirconia cell is packaged inside of the zo21d detector box, in a styrofoam cup. remove the cell, and using a 5/16" wrench, secure the cell as shown in figure 22. the bolts are tightened according to the sequence shown. use approximately 52 lb?in (60 kg?cm) of torque. please note that bolts are pre-attached to the zo21d detector, and are not inside of the styrofoam cup with the zirconia cell. 2) accessories (optional) attach filter to detector, if purchased, according to instructions found in section 3.1.5. install probe protector, or support, according to instructions found in section 3.1.8. 3) place gasket between probe and process flange connection. the gasket is used to prevent leaks. if a protector or support is used, also place gasket between all flange surfaces to prevent leaks. 4) carefully insert the probe into the process, and secure the bolts and washers of the flange using a wrench. if a filter or probe protector is used, note the probe positioning as de- scribed in section 3.1.5 for the filter, and section 3.1.8 for the probe protector. 5) in a case where the detector is mounted horizontally, the cable lead-in hole on the junc- tion box of the detector should face downward. flange specification part nam e quantity gasket (same hole pattern as f lange) 1 ansi 4", 150# ff bolts (5/8 - 11 unc x 2-1/2") 8 nuts ( 5/8 - 11 unc) 8 washers (5/8") 16 gasket (same hole pattern as f lange) 1 ansi 3", 150# ff bolts (5/8 - 11 unc x 2-1/2") 4 nuts ( 5/8 - 11 unc) 4 washers (5/8") 8 gasket (same hole pattern as f lange) 1 jis 5k - 65 bolts (m12 x 50) (1/2 - 13 unc x 2") 4 nuts (m10) (3/8 - 16 unc) 4 washers (12 mm) (5/8") 8 gasket (same hole pattern as f lange) 1 westinghouse flange bolts (m10 x 50) (3/8 - 16 x 2") 4 nuts (m10) (3/8 - 16 unc) 4 washers (10mm) (3/8") 8 table 7: mounting parts required free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 41 bolt spring washer filter retainer filter sensor (cell) calibration gas tube contact o ring (metallic) u-shaped pipe figure 22: parts in sensor assembly 3.1.4 installation of zo21d-l accessories in order to extend the useful life of the probe, accessories are used. the following is a list of accessories for the low temperature detector, model zo21d-l, along with installation instructions. all instructions assume that the zirconia cell has been previously installed, as described above in section 3.1.3. 3.1.5 silicon carbide filter (e7042uq) and dust guard (e7042uu) installation the dust filter (e7042uq) is used to protect the sensor from low concentrations of dust. install the filter as follows: 1) remove the sensor bolts (4) and washers . these bolts are not used with filter mounting. the filter assembly includes bolts. it is recommended that you keep the original bolts since operation without a filter may be required in the future. figure 23: dust filter and guard 2) mount the dust filter as follows: attach the filter with the supplied bolts and washers. tighten each bolt to 52 lb?in (60 kg?cm) torque. 3) if dust concentration is high and gas flow exceeds 10 m/sec, a dust guard (e7042uu) is recommended. attach the dust guard with the open side away from the flow mount to the detector probe with two screws. tighten the screws, matching them with the probe grooves. 4) position the probe's dust guard upstream and perpendicular to the gas flow. free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 42 3.1.6 fly ash filter installation (m1100da or m1100da-2) 1) carefully note direction of flow and place filter over end of probe. locate the c-clamp approximately 7.0 in (17.78 cm) from the probe tip. 2) after filter is located over the probe, tighten the socket head bolt until the filter will not move. do not overtighten. 3) put the hexhead cap screws (2) through the washers into the filter holes and securely tighten each bolt. 4) mark the flange to show the position of the filter shield. position the probe so that the shield portion of the filter upstream and perpendicular to the gas flow. (ref) 2.60 8.10 (ref) (ref) end of o probe 2 7.0 this view shows the as it is installed. (process flow will be down) side view of the filter flow c-clamp connection figure 24: fly ash filter 3.1.7 flame arrester (/f option) if a flame arrester is used with the probe, a filter is not required. the flame arrester extinguishes flames generated by the zirconia cell (maintained at 1382of (750oc)) and cools the hot gases before they escape, thereby preventing the detector from causing an explosion or fire in the duct. 1) thread the flame arrester to the zo21d probe near the tip. 2) thread the 2 bolts to the flame arrester in the holes provided in order to prevent any movement of the flame arrester. 3.1.8 detector with probe support or protector 1) attach the guide ring of the probe support to the detector 1.5 m from the probe flange, and affix it with two screws. tighten the screws firmly. 2) insert the gasket supplied by the user between the flange surfaces and mount the probe support. mount the probe protector so that the opening at the tip is located on the down- stream side of the gas to be analyzed. 3) make sure the 4 bolts used to attach the zirconia cell to the probe are tightly secured. 4) for probe supports, install the support collar 57 inches (1447 mm) from the face of the flange. tighten screws to a 52 lb?in (60 kg?cm) torque. if a probe protector is used instead of a support, install the support collar 9 inches (228 mm) from the probe tip. note: clamps are used to prevent damage to the probe and to allow easy removal of the probe. free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 43 ? ? figure 25: zo21d with probe support (zo21v) 5) install a gasket between all flange surfaces in order to prevent leaks. 6) if the detector is mounted horizontally, position it so that the cable lead-in hole (gland) is located at the bottom. 7) mount probe support perpendicular to gas flow. if probe protector is used instead of support, take care to position the notched edge of protector upstream from the gas flow, as shown in figure 24. 8) the 4", 150# ansi flange has 4 of the 8 bolt holes recessed. the recessed bolt holes should be attached to the process flange connection. the remaining holes should be attached to the probe. secure all bolts tightly. l1 l2 7.8 (198) (?89) ?3.5 ansi 4" 150#, 1" thk flange zo21d-l termperature probe figure 26: zo21d with probe protector (zo21r) free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 44 3.2 i nstallation of the h igh -t emperature d etector 3.2.1 installation site the following should be taken into consideration. 1) easy access to the detector for inspection and maintenance work. 2) the ambient temperature should not be too high (below 300of (150oc)) nor should the terminal box be subjected to radiant heat. 3) no corrosive gas present in surrounding atmosphere. 4) no vibration should be allowed. 5) the gas should satisfy the conditions as described in the specifications chapter. 3.2.2 probe insertion hole a high-temperature detector consists of a detector zo21d-h and high temperature probe adapter (zo21p) and the auxiliary ejector. the probe insertion hole should be prepared as follows: 1) if the transport tube is made of silicon carbide (sic), the probe hole should be prepared so that the tube is placed vertically (no more than a 5o tilt.) 2) if the transport tube is made of stainless steel and the probe adapter positioned horizon- tally, it is important that the probe tip remains below the probe base. transport tube made of 310 ss, or silicon carbide (sic) 3.3ft(1.0m) or 5.0ft(1.5m) length. high-temperature detector installed where the ambient temperature is less than 302?f (150?c). its structure is the same as that of a general purpose detector (except for the flange size). probe length is 6" (150mm). sample gas outlet port when the pressure of the measurement gas is negative, connect the ejector assembly here. if the temperature does not decrease to less than 1112? (600?c) under high pressure, connect a needle valve. mounting flange 4" ansi 150# flange figure 27: zo21ph high temperature tee adapter free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 45 3.2.3 mounting the zo21d-h detector and zo21p adapter tee ceramic (zirconia) used in the sensor (cell) portion on the detector probe tip and heater is made of a quartz crystal. care should be taken not to drop the detector during installation. the same applies to a transport tube made of silicon carbide (sic) or alumina ceramic. wiring port tilt of no more the 5? from vertical should be observed for wiring port face the tip of the probe downward. silicon carbide transport tube. the insertion hole may be horizontal if stainless steel transport tube is used, vertical installation horizontal installation units: inches (mm) or vertical. figure 28: installation into probe insertion hole a gasket should be used at the flange surface to prevent gas leakage. the gasket material should be selected depending on the characteristics of the sample. the gasket must be heatproof and corrosion- proof. 1) zirconia cell is packaged inside of detector box, in a styrofoam cup. remove cell and using 5/16 wrench, secure cell according to instructions included with the cell. use approximately 30 to 40 in/lb of torque. please note that bolts are pre-attached to probe and are not in the styrofoam cup with cell. if a flame arrester is used with the probe, thread the flame arrester to the zo21d-h-017-l*u/f probe. thread the 2 bolts to the flame arrester in the 2 holes provided in order to prevent any movement of the flame arrester. 2) the zo21d-h is flange mounted to the zo21p adapter tee, placing a gasket between the probes flange and zo21p adapter. cable glands on the probes junction box should face downward if the probe is mounted horizontally. 3) attach the transport tube to the zo21p adapter. the probe hole should be prepared so that the probe tip is not higher than the probe base. note: it is important that the probe tip (where zirconia cell is attached ) is not higher than probe base (where terminals are enclosed in junction box). condensation will form inside the cell, if the tip is mounted higher than the base. 4) place gasket between zo21p and process flange connection. the gasket is used to prevent leaks. free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 46 5) if transport tube is mounted horizontally, and extends longer than 1 meter, a support tube must be used (3" o.d. minimum). 6) carefully insert the transport tube into the process, and secure the bolts and washers of the zo21p flange using a wrench. 7) insulate zo21p and all metal surfaces. 8) if the process duct pressure is negative, attach an eductor to the zo21p adapter as shown in figure 29. however, if the pressure exceeds 2 inh 2 o (50 mmh 2 o), connect a needle valve at the 1/4" fnpt fitting for the eductor port so that the sample gas exhaust volume can be controlled. 3.2.4 installation of zo21d-h high temperature system: when the sample exceeds 1200 of (650 oc), a probe adapter tee is used to cool the sample via natural convection before reaching the probe. 0 10 bar 100 x kpa psi 1.0 20 30 2.0 60 50 4.0 3.0 40 sample exhaust "a" "a" instrument air supply regulator should be connected to incoming clean, dry instrument air set at 60 psi max. regulator not to scale exhaust outlet 1/4" mnpt air eductor to regulator (see view "a-a") vacuum inlet 1/8" fnpt figure 29: zo21p high temperature adapter tee 3.2.5 auxiliary ejector assembly, m1132ke ejector installation when the process pressure is negative or equal to that of atmosphere, an ejector is used to create a positive force that draws a sample through the high temperature assembly. there is a choice of either an air or water ejector. water is self-cleaning, and is used when the sample contains a large volume of particulates that would cause the exhaust of the eductor to plug if air were used. the ejector is attached to the high temperature adapter?s eductor port fitting, which is a 1/4" fnpt connection. when the eductor return option (/er) is selected, an air eductor is pre-attached to the zo21p adapter, and the exhaust is returned to the process via 316 stainless steel tubing. however, for all other options, the user must provide the exhaust plumbing to atmosphere, drain, etc. note the following procedure for installing an eductor (refer to figure 29): free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 47 1) attach the eductor to the adapter tees 1/4" fnpt port. use teflon tape or a suitable alternate on the threads in order to prevent leaks. also, install all compression fittings correctly. take care to attach the inlet of the eductor to the adapter, and not the exhaust! 2) use 316 stainless steel tubing to attach the supply (either water or air as determined by eductor selection) to the eductor. a regulator is used between the supply and eductor in order to adjust the pressure of the supply (air or water). for air, a 0 to 60 psi regulator is sufficient. for water, a 0 to 50 gpm regulator is recommended. do not start the eductor supply until the exhaust has been piped appropriately for the application. 3) use 316 ss tubing to pipe the sample that exits the exhaust of the eductor to drain, atmosphere, or others as determined by the safety procedures dictated by the application. use a teflon tape or suitable alternate on the threads in order to prevent leaks. determining the eductor flowrate/pressure in order to determine the flowrate or pressure of the supply (either water or air), the ZA8c analyzer must be completely wired to the probe. it is recommended that all parts are wired and plumbed appropriately, which includes the ZA8c analyzer, zo21d probe, and calibration unit (either mc1 or ac1). if the installation of all components is completed, turn on the ZA8c analyzer. after the analyzer is no longer in the ?warm up? mode and the led begins to display the o2 value (typically 20.6 vol % o2), turn on the supply to the eductor, starting with a low setting and gradually increase the regulator setting until the o2 reading displayed on the led of the ZA8c begins to drop. do not increase the flow or pressure past this value. wait until the reading begins to stabilize. if the reading does not stabilize after a few minutes, reduce the flow or pressure slowly until the reading stabilizes. once the reading has stabilized, this is the setpoint for the supply to the eductor. important note: the supply to the eductor must remain at this setting in order for the sample to continuously flow from the process. 3.3 i nstallation of the ZA8c c onverter 3.3.1 l ocation install the converter to meet the following: 1) easy access to displays and keyboard entry. 2) maintenance and inspection are easily carried out. 3) ambient temperature does not exceed 131of (55oc) and temperature variations are minimal. 4) humidity is moderate (40 to 75% rh) and no corrosive gases are present. 5) where vibration is limited. 6) the detector is installed within 1,500 feet maximum. note: if the ambient atmosphere contains corrosive gases, install air purging. 3.3.2 mounting the converter may be pipe, wall or panel mounted. ?pipe mounting mount the converter as described below: 1) use a vertical pipe (o.d. approximately 2") of sufficient strength for mounting the converter. 2) attach firmly to the pipe in the procedure shown in figure 30 using the enclosed mounting hardware. a. screw four bolts into the mounting bracket. b. hold the pipe between the bracket and mounting fitting, passing bolts through the bracket holes. free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 48 c. clamp the mounting fitting to the pipe. set washers onto the bolts and fully fasten the nuts. figure 30: pipe mounting procedure ?wall mounting 1) drill mounting holes as shown below. figure 31: drilling mounting holes 2) secure the converter on the wall using four screws. figure 32: mounting to the wall note: for wall mounting, the pipe bracket and bolts are not used. free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 49 ?panel mounting 1) cut out the panel according to the figure below. figure 33: panel cut dimensions 2) remove the mounting fitting from the converter by loosening the four screws. 3) insert the converter case into the cutout of the panel. 4) attach the mounting fitting removed in step (2) to the converter. 5) firmly fix the converter to the panel. secure the two clamp screws to hold the panel with the fitting. figure 34: mounting to the panel 3.4 m ounting of the c alibration s ystem (ac1 or mc1) there are two types of calibration systems. the auto calibration unit, model ac1, uses solenoids that automate the calibration system. the solenoids are wired to the ZA8c, and during the calibration mode, the solenoids are activated by the ZA8c, and the gas flows to the zo21d detector, without the user opening the valve or adjusting flowrates. the manual calibration unit, model mc1, is not electrically activated by the ZA8c. during the calibration mode, the user opens the valve and adjusts the flowrate of the gas, as instructed by the ZA8c. both the mc1 and ac1 calibration units provide one point of control for the calibration system. free datasheet http://www.datasheetlist.com/
inst alla tion im 11m6a2-yia page 50 3.4.1 l ocation the following guidelines should be used when selecting a location for the calibration unit. 1) easily accessible for maintenance and inspections. 2) as close to the zo21d probes as practical, which will minimize the amount of tubing required for plumbing. the mc1 is mounted near the ZA8c converter. 3) ambient temperature does not exceed 131of (55oc). 4) humidity is moderate and no corrosive gases are present. note : use air purge for the ac1 enclosure if corrosive gas or high dust present. 5) minimal vibration area. 6) instrument air is available. 3.4.2 mounting (ac1) the ac1 unit is designed for wall mounting by securing the four standoffs with bolts. allow sufficient room to connect the cal gas and reference air tubing. input gases (zero gas and instrument air) are connected to the left side, while all probe connections (cal lines and reference air) are on the side. mount the unit so that the terminal strip is easily visible for wiring purposes. the ac1 unit is available with nema 4 or nema 4x enclosures and is provided with a key. important note: unit must be mounted level, to ensure the accuracy of flowrates. 3.4.3 mounting (mc1) the mc1 unit should be mounted as close as practical to the ZA8c oxygen converter, since the ZA8c displays calibration instructions for opening valves during a calibration. the mc1 unit is designed for wall mounting by securing the four standoffs with bolts. allow sufficient room to connect cal gas and reference air tubing. input gases (zero gas and instrument air) are connected to the right side, while all probe connections (cal lines and reference air) are on the left side. important note: unit must be mounted level, to ensure the accuracy of flowrates. free datasheet http://www.datasheetlist.com/
piping im 11m6a2-yia page 51 iv. calibration and piping 4.1 p iping cal gas adjust 0.6lpm ref air adjust 0.8lpm figure 35: mc1 piping diagram cal gas port ref gas to air in port cal gas to chk gas port free datasheet http://www.datasheetlist.com/
piping im 11m6a2-yia page 52 detector piping parts required description check valve recommended by yia (m1132kf) nipple 1/8" npt (on open market) low temp calibration gas zero gas cylinder 1% oxygen in nitrogen (on open mar ke t .) detector cylinder 2 stage regulator by yia (m1132zx w / cga 580) or on open market. piping connection 1/4" npt (on open market) at the reference instrument air supplied by customer gas inlet piping connection 1/8" npt (on open market) check valve recommended by yia (m1132kf) nipple 1/8" npt (on open market) high temp calibration gas zero gas cylinder 1% oxygen in nitrogen (on open mar ke t .) detector cylinder 2 stage regulator by yia (m1132zx w / cga 580) or on open market. piping connection 1/4" npt on (on open market) at the reference gas instrument air supplied by customer inlet and purge gas piping connection 1/8" npt (on open market) (air) ejector assembly water eductor recommended by yia m1132ke (air) m1132cw (w ater) eductor supply supply piping connection 1/8" npt(on open market) and exhaust exhaust piping connection 1/4" npt(on open market) calibration unit tubing 316 stainless steel, 1/4" o.d. (on open mar ke t ) tef lon tape sealant f or all npt connections.(on open market) table 8: piping 4.2 a ir p urge f itting in the c onverter it is recommended that air purging is used when the converter is to be installed in a place where the atmospheric gas is corrosive. the converter is shipped with air purge joints (each one with air supply and venting ports.) attach the purge fittings and connect tubing as described below. 1) the air supply joint has a different diameter for air hole from that of the air venting joint. be sure to use the joint having the 0.5mm diameter hole for the air supply port. 2) use clean, dry air source, such as instrument air. air consumption is approximately 5 lpm when the supply air pressure is 0.5 kgf/cm 2 . 3) remove each tapered plug with hexagon socket attached to two air purge joint connections at the bottom of the converter case, and connect the attached joints. connect air supply to the air purge supply port with a nominal size ?" tube through a pressure regulator. normally, the venting joint does not require tubing. free datasheet http://www.datasheetlist.com/
piping im 11m6a2-yia page 53 4.3 c alibration g as 4.3.1 zero gas never use pure nitrogen. typically, 1% oxygen balanced in nitrogen is used, however, an oxygen mixture between 0.4 % and 8% is acceptable. a compressed gas cylinder containing certified gas mixtures fitted with a dual stage regulator should be used. the maximum working pressure of the calibration box is 35 psi. ( see figure 35) note: compressed gas cylinder must have the same cga connection fitting as the dual stage regulator (see accessories). set all switches to auto for normal operation auto span gas lpm air zero gas auto manual manual block manual .2 auto lpm air .2 .4 .6 .4 2 figure 36: ac1 piping diagram 4.3.2 span gas a clean, dry air source is recommended, such as instrument air. install an in-line filter before the calibration unit to remove any moisture or dirt. a regulator must be attached to the instrument air source to provide the appropriate working pressure for the calibration unit. the maximum pressure is 35 psi. 4.3.3 reference gas reference air is from the same source as the span gas, which is clean, dry instrument air. the reference air flows to the back side of the zirconia cell, and is used at all times. the calibration unit is plumbed to provide a continuous flow rate of the reference air, as well as, calibration gas flow during calibration 4.3.4 piping of gases to cal unit plumbing is required from the instrument air line and zero gas cylinder to the calibration unit. standard 1/4? o.d. is recommended, stainless steel is preferred. separate tubing for both the instrument air and zero gas are connected to the 1/4? fnpt fittings on the left side of the calibration unit. air in port cal gas to chk gas port ref gas to air in port free datasheet http://www.datasheetlist.com/
piping im 11m6a2-yia page 54 4.4 p iping to zo21d probe tubing to the zo21d probe is from the right side of the calibration unit. run ?" tubing from the auto cal unit to the 1/8? fnpt fitting on the zo21d probe. the reference air tubing is connected to the air in port at the probe, and the cal gas tubing is connected to the chk gas port on the probe. the air in and chk gas ports are located on the bottom of the probe junction box near the cable gland holes. these ports require a 1/8? npt fitting. any unused ports must have a t eflon taped plug. all probes have independent plumbing from other probes and are not to be teed at any point. teflon tape or a suitable substitute is required to make an air tight seal. important note: to prevent leakage, all threaded fittings should have teflon tape (or suitable alternate) and all compression fittings should be installed per manufacturer?s recommendations. in addition, a check valve is usually installed on the cal gas inlet of the probe to protect the cal tubing from moisture contamination. 4.5 initial flow rate setup (ac1) ensure that the cal gas and reference air are properly plumbed to the left side of the ac1 auto cal unit. the zero gas and instrument air should be set at approximately 20 + 2 psig. power is not needed to set the flow rates. [8.15] [1.50] reference air outlet zero gas inlet [5.90] [7.71] [9.84] [1.25] [13.77] [14.57] [6.97] to probes cal. gas [4.00] inlet span gas 101.6 177.0 250.0 370.0 31.8 206.9 38.1 349.8 150.0 195.7 mm [inches] units: .5 1.0 2.5 3.0 3.0 3.0 .5 1.0 2.5 3.0 3.0 3.0 figure 37: ac1 piping free datasheet http://www.datasheetlist.com/
piping im 11m6a2-yia page 55 4.5.1 setting the reference air flow rate locate the reference air flowmeters. adjust the flow adjustment knob on the reference air flowmeter to 0.8 lpm or 800 ml/min. 4.5.2 balancing pressure drops in the cal lines for accurate calibrations, the auto cal system must provide a fixed flow of zero gas and span gas (0.6 lpm or 600 ml/min). to balance the pressure drops, perform the following steps: these adjustments can be made with a flat tip screwdriver. 1. locate the block and span gas solenoid. using a screwdriver, turn the override screw to the manual position. 2. use the flow regulator knob on the cal gas flowmeter to adjust the flow to 1.0 lpm. 3. switch the override screw of the span gas solenoid to aut o. turn the override screw for the zero gas solenoid to manual. 4. adjust the pressure regulator on the zero gas cylinder for a flow of 1.0 lpm on the calibra- tion gas flowmeter. important: do not use the flow regulator knob of the flowmeter to achieve this flow rate! 5. adjust the flow regulator knob on the calibration gas flowmeter until the flowmeter reads 0.6 lpm. 6. verify that all the manual overrides are set back to auto. standard operation the reference air flowmeter indicates 0.8 lpm during normal operation and calibration. all manual overrides are set to the auto position. the calibration gas flowmeter will show a flow of 0.6 lpm during calibration only. before considering your calibration unit automated, it is a good practice to check for leaks along the full distance of the cal line tubing in addition to doing a cal check to confirm that the gases are plumbed correctly to each probe. 4.6 c hecking for l eaks 1) locate the block solenoid. turn the override screw on the block solenoid and span solenoid to the manual position. 2) use leak detection spray on all compression fittings and bends of the cal and reference line tubing. 3) inspect the full length of the cal line to determine if there is a leak. repair any leaks. 4) after repairing the leaks, if any, return all solenoids to the auto position. note: for ZA8c programming values, see section 6.3. 4.7 mc1 f low r at e s etup performing a calibration for accurate calibrations, the manual cal system must provide a fixed flow of zero gas and span gas (0.6 lpm or 600 cc/min) during calibration. there are two flowmeters and one hand valve adjuster for the mc1. the hand valve is used only during calibration to flow either span gas or zero gas to the probe, using the cal gas flowmeter to indicate the flowrate. the reference air flowmeter is used to free datasheet http://www.datasheetlist.com/
piping im 11m6a2-yia page 56 flow the reference air for the zo21d probe, and remains flowing at all times with a flowrate of 0.8 lpm. the ZA8c display will prompt the user to perform the following steps, when programmed for one touch (tch) calibration as follows (refer to figure 35): 1) position the valve knob to span gas on. this will start the flow of span gas (or air) to the probe. 2) adjust the cal gas flowmeter to show 0.6 lpm as the flowrate. also, if necessary, adjust the reference flowmeter to show 0.8 lpm 3) to stop the flow of span gas, position the valve knob to the off position. 4) to start the flow of zero gas to the probe, position the valve knob to zero gas on. 5) adjust the cal gas flowmeter to show 0.6 lpm as a flowrate. also, if necessary, adjust the reference flowmeter to show 0.8 lpm. 6) to stop the flow of zero gas, position the valve knob to the off position. warning: if reference air is used during calibration, the reference air must be left on after calibra- tion!! checking for leaks for mc1 1) position the valve to span. 2) apply a leak detection spray on all compression fittings and bends of the cal line tubing for the probe, the cal unit inlet, cal unit outlet, probe inlet for cal gas and reference air. spray both the reference air and cal gas line. 3) inspect the full length of the cal line to determine if there is a leak. repair any leaks. 4) after repairing the leaks, if any, return the valve to the off position. set reference air flow- meter to 0.8 lpm. note: for ZA8c programming values, see section 6.3. free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 57 v. wiring 5.1 o verview of types of wires your new ZA8c converter is capable of expanding to fit your future needs. this section provides detailed information on wiring the ZA8c converter to any type of system configuration. each channel is labeled on the ZA8c?s terminal board. operation panel cable lead-in hole (seven places) outside wiring terminal power terminal (for 100v power) power terminal (for 200v power) (see note) front door note: in case of converters for 220 v or 240 v ac power, an exclusive terminal is prepared in the left inside corner. figure 38: ZA8c wiring channel description of wiring required cable optional cable purpose 1 detector signal x connects the converter w ith detector's cell, cold junction, and thermocouple signals 2 detector heater x connects the converter w ith detectors heater 3 analog output x provides analog output to auxiliary equipment 4 pow er & ground x pow er & ground wiring for the converter only 5 serial communic ation (optional) x digital communic ation 6 contact output (optional) x dry contact outputs (3) 7 contact input (optional) x contact input (2) 8 solenoid valve (optional) x x calibration via solenoid valves. not used w ith manual calibration unit 9 temperature input (optional) x gas temperature input from external temperature source table 9: wiring channels free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 58 there are 7 cable wiring ports (i.e. rubber glands) on the bottom of the ZA8c converter. keep the detector signal cable separate at all times from the power and heater cables. the ac voltage cables must be kept separate from dc voltage cables at all times in order to prevent electrical noise problems. 5.1.1 initial preparations the oxygen converter, detector, and auto calibration units are supplied with rubber plugs already installed in the cable ports. if corrosive gas is present, it may be necessary to purge the enclosures of the converter and calibration units. in such an instance, a watertight gland is used instead of the rubber plug. the ZA8c converter is shipped with purge connection pre-attached. the ac1 calibration unit does not have a purge connection. when using wire conduit, the gland is removed, and a standard 3/4? (19 mm) conduit fitting is used. note the following procedure for using the plastic watertight cable gland. 1. remove the rubber plug. 2. remove the nut from the cable gland and set the nut in the keyway inside of the cable bushing. 3. thread the gland over the cable, in the correct sequence. 4. screw the gland onto the nut from the outside, using a gasket to seal completely the space be- tween the ZA8c case hole and the gland. the zo21d detector is supplied with 2 rubber plugs installed in the cable ports. the diameter of the cable bushing hole in the detector is 1.06 in (27 mm) if necessary, protect the cable by using a flexible wire conduit of nominal diameter 3/4? (19 mm) the detector may need to be removed in the future for maintenance, so be sure to allow a sufficient cable length. 5.1.2 safety precaution during w iring never apply power to the converter or any other device constituting a power circuit in combination with the converter, until all wiring is completed. 5.1.3 power and ground w iring this wiring provides the converter with ac power and ground the converter. the detector and auto calibration units are powered from the ZA8c converter. case ground 34 32 33 ZA8c converter case ground zo21d detector power: 100, 110, 115 vac, 50/60 hz or, 220, 240 vac, 50/60 hz figure 39: power w iring free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 59 power wiring connect the power wiring at the appropriate terminals of the converter, as shown in figure 38. note the following when installing the wiring: 1. use 14 awg, 2 conductor, shielded cable. the size of the converter terminal screw threads is m4. ground wiring case ground wiring ground term inal ground wiring cr imp term inal l ock wash er figure 40: case gr ound wiring for the ground wiring, it is a general rule that wires should be installed from the ground terminal of the detector case or the converter case. be careful of the following when wiring: 1. keep the ground resistance less than 100 ohms. 2. connect the cable to the converter case ground terminal so that the lock washer makes contact with the case as shown in figure 40. 5.1.4 wiring for the detector the wiring of the detector requires two cables: a signal cable and a heater cable, as specified in the following table. type awg no. conductors insulation shield jacket voltage/ weight/ cable (material, thickness) temp 1,000 ft high temp signal 3 pair, tw isted; fep aluminum mylar; fep.010" w all/ 300 volts/ 35 lb wz-h-6s black/white/red/green awg 18/7 tc drain .268" od 392o f (200o c) (15.9 kg) low temp signal 16 3 pair, tw isted; polyethylene aluminum polyester f oil; pvc.035" w all/ 300 volts/ 125 lb wz-l-6s black/white/red/green stranded tinned copper drain .475" od -4o to 140o f/ (56.7 kg) (-20o to 60o c) high temp heater 2 conductor fep aluminum mylar; fep.010" w all/ 300 volts/ 35 lb wz-h-3h black/red awg 16/19 tc drain .182" od 392o f (200o c) (15.9 kg) low temp heater 14 2 conductor polyethylene aluminum polyester f oil; pvc.035" w all/ 300 volts/ 72 lb wz-l-3h black/natural stranded tinned copper drain. .350" od -4o to 140o f/ (32.6 kg) (-20o to 60o c) table 10: specifications of signal and heater cables signal cable this wiring is used to transmit the mv dc outputs from the detector: the cell output, type k thermocouple cell temperature, and the compensating cold junction. typically a 16 awg, 3 twisted pair cable with drain is used as signal cable. install wires that allow for no greater than 10 ohms of loop resistance. it is important to install these wires separate from the power and heater wiring. connect the shield (or drain) for the signal cable at the zo21d detector?s ground terminal, and not at the converter?s ground terminal as shown in figures 41 and 42. note that the ambient temperature at the detector determines the wire configuration. no thermocouple cable is used between the detector and converter due to the use of a cold junction compensator at the detector?s junction box. free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 60 note: thermocouple cable is not required. however, if type k cable is already available and installed, remove the cold junction compensator thermistor from the probe junction box and attach to the corresponding terminals at the ZA8c converter. cell + cell - tc + tc - cj + cj - cell + cell - tc + tc - cj + cj - 3 4 5 6 7 8 1 2 3 4 5 6 zo21d detector ZA8c converter figure 41: detector signal output -112of ( -80oc) or less ambient cell + cell - tc + tc - cj + cj - cell + cell - tc + tc - cj + cj - 3 4 5 6 7 8 1 2 3 4 5 6 junction box high temperature cable zo21d detector ZA8c converter figure 42: detector signal output - between 176o and 302of (80o and 150oc) at the detector heater cable this wiring is used to transmit the 110 vac output from the convert to the detector?s heater. the power consumption of the heater is 80 va normal, and 270 va maximum. typically a 14 awg, 1 twisted pair cable with drain is used for the heater. connect the heater cable?s shield (or drain) at the ground terminal of the converter, and not the detector as shown in figures 43 and 44. note that the ambient temperature at the detector determines the wire configuration. again, the heater cable must remain separate from the signal cable. free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 61 heater 8 7 gnd 16 17 32 zo21d detector ZA8c converter heater cable: 14 awg, 1 twisted pair w/separate shield figure 43: detector heater output - maximum 112of (80oc) ambient heater cable: 14 awg, 1 twisted pair w/separate shield high temperature cable case ground ZA8c converter heater 8 7 gnd 16 17 32 zo21d detector junction box figure 44: detector heater output - between 176o and 302of (80o and 150oc) at the detector free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 62 5.1.5 quick disconnect wiring (optional) yokogawa industrial automation offers ?quick disconnect? wiring for the detector heater and signal cables. the cable is pre-attached to connectors so that all the user need perform is match the connectors for the heater (a 3 pin connector) and signal (a 7 pin connector) male and female connectors. during maintenance, detaching the cable at the detector is quick and easy. ref. air inlet-1/8 nptf 1.7 cal. gas inlet-1/8 nptf 4.7 (120) (42) 1.2 2.1 (30) (53) 1.69 (42.9) 150 lb ansi 4" flat face flange 7 and 3 pin quick disconnects figure 45: quick disconnect 5.2 a nalog o utput w iring this wiring is used to transmit the 4 to 20 ma dc or 0 to 20 ma dc output signal to a peripheral device, such as a recorder. a 16 awg cable, 2 conductor with shield is recommended. maximum load resistance is 550 ohms. (+)26 (-)27 + - ZA8c converter receiver figure 46: w iring for analog output the terminal screw thread is m4 at the ZA8c converter. connect the shield of the cable generally on the side of the device receiving the analog signal, i.e. the recorder as shown in figure 45. it is important to connect the polarities correctly. free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 63 5.3 s olenoid w iring for c alibration u nit (ac1) the ac1 is the automated calibration unit for the ZA8c which uses solenoids to control the flowrate of the calibration gas and reference air. the solenoids are powered from the ZA8c unit. all adjustments of flowrates for calibration gases can be performed without ac power. 14 awg, 4 conductor is recommended, run in conduit separate from detector cables. if conduit is not used, wiring should have a suitable jacket to meet environmental and regulatory codes. the ?jumper? shown in the drawing is used to wire all solenoids at the ZA8c common (120 vac). note the manual calibration unit, model mc1, does not use solenoids, and therefore does not require cable. note: to prevent noise from solenoids from interfering with surrounding electrical lines, we recommend the use of metal conduit or shielded cable grounded at the auto cal unit. 28 29 30 31 32 33 34 zero span zero 28 span 30 gnd 32 com 34 ac1 auto cal ZA8c converter power supply input (110v ac) gnd l1 l2 jumper figure 47: interconnect wiring for ac1 & ZA8c free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 64 ac1 auto cal ZA8c converter 28 29 30 31 zero span zero 28 span 30 gnd 32 com 34 32 33 34 32 33 34 gnd l1 l2 jumper power supply input 220v ac (separate terminal block) figure 48: inter connect wiring for 220 v ac ZA8c & ac1 5.4 c ontact o utput w iring (o ptional ) the converter can output a maximum of 3 contact signals. the function of the output signals is determined from a menu of 13 parameters, as described in the g0 through g3 menu (i.e. ?low limit alarm? or ?high limit alarm?). see figure 49 for wiring details. use a cable suitable to safely transmit the signal based on the following: 30 vdc 2a and 250 vac 2a. grouping the conductors into 1 cable jacket is recommended when using multiple contacts, using either a 2, 4, or 8 conductor cable and dividing the signal after the junction box, as shown in figure 49. 10 11 14 15 output #1 12 13 output #2 output #3 junction box ZA8c figure 49: contact output w iring free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 65 5.4.1 changing relay contact for contact output contact status (normally open or normally closed) of the contact outputs selecting applications with function no. g-0, g-1, or g-2 is determined by the selected relay operation (normally energized or de- ener gized) and types of relay contact (?make? contact or ?break? contact). note: no of the contact status means the contact operating status where the contact is ?closed? when a contact signal is output (nc is its inversion). ?make? contact in the types of relay contact means the contact which is closed when the relay coil is energized. re lay ope ration type of relay contacts contact status when contact signal no r m al condtion power off nor mally energized break contact (shortcircuiting jumpers 1 and 2) [closed] [open] [closed] make contact (shortcircuiting jumpers 3 and 4) [open] [closed] [open] nor mally deenergized break contact (shortcircuiting jumpers 1 and 2) [open] [closed] [closed] make contact (shortcircuiting jumpers 3 and 4) [closed] [open] [open] table 11: contact states classified with relay operation and types of contact on shipment, the relays are set as shown below. ?function no. g-0 (contact output #1, contact status no): normally energized, break contact ?function no. g-1 (contact output #2, contact status no): normally de-energized, make contact ?function no. g-2 (contact output #3, contact status no): normally de-energized, make contact if the type of contact is necessary to be changed, do it in the following procedure. the relay operation can be set to function no. g-0, no. g-1, or no. g-2 with key operation. (1) turn off the power switch in the converter. (2) open the operating panel and remove the pcb cover. remove screw 1 in figure 50, and also loosen screws 2 and 3. (3) set the corresponding jumper connector position again and change the type of contact. for obtaining a make contact, set the jumper connector to pins 2 and 3, while for obtaining a break contact, set the jumper connector to pins 1 and 2. when the set work has been done, reinstall the pcb cover and turn on the power switch. free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 66 + + + + + + + + wiring terminal board screw 2 operation panel screw 1 screw 3 printed circuit board cover setting jumper connector (cn5, cn6, or cn7) cn5(for rl1) cn6(for rl2) cn7(for rl3) relay rl1(output signal #1) relay rl2(output signal #2) relay rl3(output signal #3) break contact make contact 1 2 33 1 2 mounting position or jumper connectors (cn5, cn6, or cn7) figure 50: ZA8c relational diagram 5.5 c ontact i nput w iring (o ptional ) (+)22 (-)23 input #1 (+)24 (-)25 input #2 junction box ZA8c (expanded) converter figure 51: contact input w iring the wiring for the contact inputs is either a 2 conductor cable for use of 1 contact or a 4 conductor cable, for 2 contact inputs. use a cable suitable to transmit the parameters shown in the table below: description on electrical values off electrical values resistance (contact) less than 200 ohms greater than 100 k ohms voltage -1 to 1 v dc 4.5 to 25 v dc table 12: contact input on/off electrical parameters free datasheet http://www.datasheetlist.com/
wiring im 11m6a2-yia page 67 5.6 t emperature i nput s ignal w iring (o ptional ) the ZA8c converter can accept a 4 to 20 madc temperature input corresponding to the temperature range of a thermocouple. this temperature input is used by the ZA8c to calculate the boiler ef ficiency or to trigger an alarm whenever the process gas exceeds the setpoint. 2 conductor shielded cable is recommended that conforms to electrical standards. ground the cable shield at the device that transmits the temperature signal to the converter. (+)1 (-)2 (+) (-) ZA8c (expanded) converter temperature transmitter transmits 4 to 20 ma temperature signal only figure 52: measurement gas t emperature input free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 68 vi. programming in this chapter, the basic operation methods for the ZA8c in-situ type zirconia oxygen analyzer are described. 6.1 q uick s tart -up programming for ZA8c s ingle p oint o 2 s ystem 6.1.1 configuring the ZA8c converter this is the final stage of the installation of your new single point oxygen measuring system. at this stage you should have completed the following: ?detector installation ?converter installation ?calibration unit installation ?wiring/t ubing ?setting flow rates for calibration unit. if you have not completed any of the above, please do so before proceeding. please confirm the following: 1) there is a wire connected to all the terminals labeled in white (excluding shields) on the ZA8c. open the front panel to perform this quick check. if there is a wire missing on any one of these white terminals then your ZA8c will not function properly (excluding analog output). 2) verify that the zirconia cell was removed from its foam package and installed in the zo21d detector. 3) please record the mix of the calibration gases that you are using as follows: zero gas: _________ % vol o 2 span gas: __ 21 ___ % vol o 2 note: the span is usually instrument air, which is between 19.0% and 21% vol o 2 . also, record the high and low set point values below. hh: _________ % vol o 2 h: _________ % vol o 2 ll: _________ % vol o 2 l: _________ % vol o 2 record the range of normal operation, and an alternate range: (normal 4 to 20 ma range) range 1: _________ % vol o 2 to _________ % vol o 2 range 2: _________ % vol o 2 to _________ % vol o 2 6.1.2 power up ZA8c 1) open the front panel of the ZA8c and turn on the power. this button is located in the lower left hand corner. 2) close the front panel. your led display will flash uuuuu and numbers. the number is the temperature of the o 2 cell in degrees celsius. the lcd will display warming up. now is the time to begin configuring the ZA8c. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 69 6.1.3 procedure to enter maintenance mode enter yes enter 16 as password using arrow keys enter step 1: press enter lcd will display ?maintenance mode/entry model ? note the green light to the left of the lcd. step 2: press yes lcd will display ?password?? step 3: use arrow ( ) keys to enter your 2 digit password number which is on the inside door on the ZA8c. your number is probably 16. step 4: press enter this will enter your password number. if your password is correct, the display will show the c0 menu. if the password is not accepted, the unit will return to step 1 above. 6.1.4 pr ocedure to set internal date and time step 1: press the up arrow ( ) key 3 times for the fo clock entry menu. step 2: use the arrow keys ( ) to set the date as yy/mm/dd by placing the flashing indicator on the digit you wish to change. step 3: press enter. step 4: also, enter the (military) time as hh:mm. remember to press the enter key. goto the f0 menu for clock entry using the arrow keys. set the date using the arrow keys as follows: yy/mm/dd set the (military) time using the arrow keys as follows: hh:mm enter enter free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 70 6.1.5 pr ocedure to enter calibration gas values begin entering the calibration gas and reference air values from the data that was recorded earlier in section 6.1.1. step 1: the flashing cursor must highlight the character you wish to change. to change press up arrow key ( ) until the display shows c0, span value menu. step 2: normally, if instrument air is used the span value is between 19% and 21%. use arrow keys ( ) to enter 21%. remember to press the enter key. step 3: press right arrow ( ) key 1 time, then press up arrow key ( ) 1 time for the c1, zero value menu. step 4: use the arrow keys to enter your vol% o 2 value for your zero gas cylinder. remember to press the enter key. go to c0 menu using arrow keys enter span gas % vol o2 value. for instrument air, using arrow keys. enter go to c1 menu using arrow keys enter zero gas % vol o2 value, using arrow keys. if using instrument air for span, then max zero value is 8%. enter span set up zero set up the following is a list of values that must be programmed in order for the calibration system to work properly at the ZA8c. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 71 6.1.6 pr ocedure to set up calibration mode for manual or auto calibration systems goto the c2 calibration mode menu using the arrow keys using arrow keys, place flashing cursor on 2 in 2: tch verify that the 2 is displayed below c2 as follows: c2 2 enter using arrow keys, place flashing cursor on 1 in 1: semi verify that the 1 is displayed below c2 as follows: c2 1 enter are you using a manual calibration system? yes no step 1: press right arrow key ( ) 1 time, then press up arrow key 1 time for c2 menu , where we indicate the type of calibration system in use. step 2: if you are using a manual calibration system (i.e. no solenoids) enter touch. use the arrow keys to put the flashing indicator on the number 2, then press enter. the very left position should show the number 2. step 3: if you are using autocal, for now enter semi-auto, which will allow us to calibrate at the push of a button. use the arrow keys to put the flashing indicator on the number 1, then press enter. the very left position should show the number 1. 6.1.7 procedure to configure (0 to 100%) go to the d0 output range 1 menu. this range is for the 4 to 20 (0 to 20) ma signal use the arrow keys. note: minimum range is 0 to 5% o2 use the arrow keys to enter your % o2 range. enter step 1: press the up arrow key 1 time for the d0 menu. enter the normal range for your o 2 . example: if you are controlling around 8% o 2 and never get above 10%, set a range of 0 to 15%. this is your 4 to 20 ma (or 0 to 20 ma) signal. step 2: use the arrow keys to enter your range. remember to press the enter key. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 72 6.1.8 pr ocedure to set up alarm setpoints goto the e0 alarm set pt menu using the arrow keys. enter the high set point values using the arrow keys. note: hh is the absolute high value enter goto the e1 alarm set pt menu using the arrow keys. enter the low set point values using the arrow keys. note: ll is the absolute low value enter step 1: using the arrow ( ) keys, go to the e0 alarm set points menu. step 2: enter the high set point values using the arrow keys. don?t forget to press enter. step 3: using the arrow keys, go to the e1 alarm set points menu. step 4: enter the low set point values using the arrow keys. don?t forget to press enter. 6.1.9 procedure to perform a manual calibration and record diagnostic parameters step 1: exit the maintenance mode by pressing the disp (display) key. this returns the unit to the measurement mode. step 2: to begin a calibration, press the cal key. the display will ask if you want to begin a span calibration, ?span cal y/n?? step 3: press the yes key. step 4: if you are using a manual calibration system, begin the flow of span gas. step 5: wait until the o 2 reading has stabilized. step 6: press the yes key. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 73 yes span cal y/n ? please confirm span gas = x% o2 introduce span gas flow rate = 600 ml/min span valve open y? span display flowchart zero display flowchart zero cal y/n ? please confirm zero gas = x% o2 introduce zero gas flow rate = 600 ml/min zero valve open y? wait until reading is stabilized,then enter yes. cal manual cal users should begin the flow of span gas at this point manual cal users should begin the flow of zero gas at this point yes span cal good wait until reading is stabilized,then enter yes. zero cal good cal good stabilization time close zero valve close span valve note: at this point the unit will read the span gas and then prompt the manual calibration user to close the span valve. to complete the calibration, you must do a zero cal. step 7: the unit will ask if you want to do a zero cal, ?zero cal y/n?? step 8: press the yes key. step 9: if you are using a manual calibration system, begin the flow of zero gas. step 10: wait until the o 2 reading has stabilized. step 11: press the yes key. note: at this point the unit will read the zero gas and then prompt the manual calibration user to close the zero valve. when the display asks if you want to do a span cal, press the no key until the bar graph is displayed. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 74 6.1.10 t able of d iagnostic v alues to provide an effective preventive maintenance record of your zirconia cell, it is recommend that the user keep a log of diagnostic values, which is updated after each two (2) point calibration is performed. please note the following: ce ll no . date o f b0 b1 b3 b4 a3 calibration (span correction) (zero correction) (resistance) (cell life) (emf) table 13: diagnostic v alues the ZA8c converter is a microprocessor based oxygen converter capable of more than the standard 4 to 20 ma analog output. the following provides a brief description of a few features that are standard to the ZA8c converter that the user may want to utilize. the ZA8c converter allows the user to program two different ranges for the 4 to 20 ma signal. this gives the operator a backup for an emergency situation where the unit has surpassed the 20 ma max . instead of having the display lockup at 20 ma, the unit will use an alternate, predetermined range that is greater than the original setup. in addition, the unit will alert the user with an ?answer back? contact output function, which forces the operator to acknowledge that the range has changed. additionally, the user has two low alarm values. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 75 setup optional range 2 enter enter password #16 use the arrow keys to goto menu d1 output range 2, the alternate range. use the arrow keys to enter your % o2 range of measurement. enter enter yes program range answerback contact output use the arrow keys to goto menu g0 contact output. enter the following setup using the arrow keys to change 0 to 1. 01111101100000 enter enter enter password #16 enter yes when a calibration is initiated, you can hold the output value prior to the calibration, or set a preset value until the calibration is completed. should an error occur during calibration, the unit will remain in hold until the cause of the error is eliminated. hold last measured value use arrow keys to goto menu d2 output hold position cursor on the 1 in 1: hld enter enter enter password #16 enter yes hold pre-determinedvalue use arrow keys to goto menu d2 output hold position cursor on the 2 in 2: p - hold enter use arrow keys to enter % o2 value to hold during calibration enter enter enter password #16 enter yes the ZA8c has a total of 4 contact outputs, which the user can choose to represent up to 14 different situations. we recommend that the user use at least the following conditions for led alarm contacts: free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 76 1) error 2) high and low setpoints 3) range selection answerback 4) calibration 5) cal gas pressure (see contact output section) 6.2 o perating k eys 6.2.1 types and functions of operating keys there are nine set keys on the operation panel of the converter. you can select an operation mode (measurement or maintenance), register temporary data, display various measurements or calculated data using these nine keys. to operate the keys, press the center of each key. key nam e functions/applications yes interactive key (yes) used for replying "yes" to an inquiry (y/n?) no interactive key (no) used for replying "no" to an inquiry (y/n?) help sub-message display keycalibration start key used for displaying sub-messages.used f or suspending c alibration. cal calibration start key. used for starting calibration in one-touch or semi- automatic calibration. disp measurement mode select key. calibration data display key. used for returning the mode from the setting mode, etc. to an analog bar display (measurement mode). used for monitoring various data during calibration. enter entry key.setting-mode select key. used for registering data in setting mode. used f or changing f rom the measurement mode to the setting mode. > cursor key.message cos key used for moving the cursor to the number or letter to be changed or registered. used f or the display continuation of a message on 2 or more screens. ^ number increase key.number forw ard key. used for increasing a number on the cursor. used f or changing f rom one function to the next. > number decrease key.number backw ard key. used for decreasing a number on the cursor. used for returning f rom one function to the next. 6.2.2 examples of applications of the operating keys this section describes how to operate the keys with the following examples of operations. for displays, see chapter 7. 1) change over from the measurement mode to the setting mode 2) reply to inquiry 3) entering the password 4) selection of function no. (selection of number) 5) selection of function no. (selection of group symbol) free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 77 6) entering the setting data (selection of setting details) 7) entering the setting data (input of data values) 8) change over from the setting mode to the measurement mode 9) changing displayed data 10) calibration start or suspension instructions 11) displaying the data values in the calibration mode 1) change over from the measurement mode to the setting mode used as the setting mode selection key (entry key) maintenance mode entry mode ? a2 average (024 hour) =011.52% o2 display of function no. a-2 inquiry display example enter measurement mode: "meas" lights up on the display. setting mode: "maint" lights up on the display. reply to the inquiry by pressing the interactive key (yes or no). (fo r more details, see the following example.) 2) reply to inquiry use an interactive key (yes or no key). maintenance mode entry mode ? nnnnnnnnnnnooooooooo 0 1 1 2 5 yes no pass word ?? message display for changing to the setting mode message display for entering the password display of function no. a-0 analog bar-graph status, after the reply to the inquiry, differs according to the message details. when password input message is displayed, enter "16". for the more detailed procedure, see (3). measurement mode is displayed. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 78 3) entering the password (16) to assign a function in the setting mode, enter the password. the password is 16, as shown on the label attached to the inside door of the ZA8c. to do so, use the number increase/decrease key, cursor movement key, and the entry key. the flashing indicator is positioned on the item that can be changed with the arrow keys. enter a co cal gas conc (%o2) span = 021.00 (two times) cursor moves to "?" on the right side. press enter after "16" is displayed. the first function no. in the setting mode is displayed. display of function no., c-0 display of password - entering message 1 ? pass word ? pass word ? pass word 1 ? free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 79 4) selection of the function no. (selection of number) the number increase key, number decrease key and the cursor key are used. the commonly used functions are silk-screened on the front of the ZA8c converter for easy operation without an instruction manual. however, the programming of the contact inputs and outputs, along with the efficiency parameters are only found in this manual. a disp nnnnnnnnnnnooooooooo 0 1 1 2 5 c1 cal gas conc (% o2) zero = 001.00 co cal gas conc (% o2) span = 021.00 display of function no., c-0 no. decreases. no. increases. number is changed from 0 to 1. cursor moves over to the next number. data-entering status is effected. the mode changes to the measurement mode and displays an analog bar-graph. (note 1) if the entry key "enter" is pressed when the cursor resides in a function no. position, note that "0:at (automatic calibration)" is automatically set as the calibration mode. o cal gas conc (% o2) span = 021.00 c c cal gas conc (% o2) span = 021.00 0 (note 1) 2 c calibration mode 0: at 1:sem1 2:tch c cal gas conc (% o2) zero = 001.00 1 free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 80 5) selection of function no. (selection of group symbol) use the number increase key, number decrease key, entry key, etc. to select a group symbol. the type of key you select is dependent on the current operating state in which you are working (i.e., the operation mode and the position of the cursor). display of function no., d-0 enter a the displayed data are registered and the cursor moves to the upper left. the function group changes from group c to d. the cursor moves over to the no. the no. decreases. display of function no. c-1 c1 cal gas conc (% o2) zero = 00 .00 1 cal gas conc (% o2) zero = 001.00 c d 1 output range 2 000 - 25 % o2 1 d output range 2 000 - 25 % o2 0 d output range 1 000 - 010 % o2 1 6) entering the setting data (selection of setting details) use the number increase key, number decrease key, entry key, etc. for setting details. the type of key you select is dependent on the current operating state in which you are working (i.e., the operation mode and the position of the cursor). display of function no., d-0 enter the displayed data are registered and the cursor moves to the upper left. display of function no. d-0 the cursor moves over to the no. press this key twice. the cursor moves over to "1". enter registered. (note) presently set item is displayed by the number of left side in the lower line. press this key twice (d-1 comes up if you press this key only once.) d0 output range 1 000 - 010 % o2 d0 output range 1 000 - 010 % o2 d output range 1 000 - 010 % o2 d output hold 0 0:n 1: hld 2:p - hld 0 2 d2 output hold 0 0:n : hld 2:p - hld 1 free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 81 7) entering the setting data (input of data values) use the number increase key, number decrease key, cursor key, entry key, etc. which keys you use depend on the present state you are in (i.e., the operation mode and the position of the cursor). display of function no. c-0 set range exceeded a enter press the key 4 times to move the cursor to the 1 from the c. the 1 changed to 0 to come up with the figure 20.00 o cal gas conc (% o2) span = 020.00 c 1 co cal gas conc (% o2) span = 02 .00 co cal gas conc (% o2) span = 02 .00 0 o cal gas conc (% o2) span = 021.00 c 8) change over from the setting mode to the measurement mode use the measurement mode select key. display of function no. d-0 disp d0 output range 1 000 -050 % o2 the mode is changed over to the measurement mode and the analog bar-graph is displayed. 0 1 1 25 nnnnnnnnnoooooooo free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 82 9) changing displayed data use the number increase key to change the function number. use the cursor key to change to another function group or to move to the next screen. display of function no. a-0 0 1 1 25 a7 excess air ratio = 01.40 b0 span (0) = 099.7 % 89/04/26 14:30 h the display changes from group a to group b. nnnnnnnnnnnooooooooo when there are 2 or more component screens, h shows in the lower, right position. the second (or next) screen can be displayed by pressing the help key. 10) calibration start or suspension instructions use the calibration start or suspension key. for more details on the calibration keys, see chapter ix. display of function no. a-0 calibration y ? calibration y ? cal disp no yes help help the mode changes from the measurement mode to the calibration mode. upon pressing the key, the solenoid valve in the calibration gas line is closed. after the stability time as set in function no. c-4 elapses, the mode changes back to the measurement mode. if changing another display in the measurement mode to an analog bar-graph, press [disp] key. span cal on zero cal on 0 1 1 25 nnnnnnnnnnnooooooooo 0 1 1 25 0 1 1 25 nnnnnnnnnnnooooooooo 0 1 1 25 nnnnnnnnnnnooooooooo free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 83 11) displaying the data values in the calibration mode you can display the readout from function no. a-0. you can also display the set data in function no. c-0 and subsequent functions. however, no data is settable. display of function no. a-0 0 1 1 25 0 1 1 25 calibration y ? 0 1 1 25 disp on span cal yes yes calibration mode is off. the readout changes the data display. the readout again indicates calibration is under way. if calibration was already completed, calibration begins again. cal nnnnnnnnnnnooooooooo nnnnnnnnnnnooooooooo 6.3 r eadout d isplays there are three kinds of readouts: a status display, data display and message display on the operation panel of the converter. in the status readout, the operation mode and the error alarm (if any) are displayed. in the data readout, the measured oxygen concentration and the details of any error which has occurred are displayed. in the message readout, various measured data, set data and messages are displayed. 6.3.1 status display the related operation mode and the occurrence of an alarm, etc. are indicated by illuminated lights. meas: lights up in the measurement mode. maint: lights up in the calibration mode or setting mode. this light also glows when an error occurs with the instrument stopping measurement operations. alm: lights up when an alarm is issued according to the details set in function nos. g-0 to g-2. the operation mode changes from the measurement mode to the maintenance mode depending on the type of alarm. fail: lights up when an error occurs while stopping the measurement operations of the instrument. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 84 6.3.2 data display this display incorporates a large 4-digit led. items displayed here are the warm-up state (warm-up symbol on and the current temperature of the sensor), measured oxygen concentration (vol% o 2 ) and the error code. normally, just the measured oxygen concentration is displayed. ?example of warm-up state display xxxx alternately displayed current temperature of sensor in oc ?example of measured oxygen concentration display note: measured value is displayed. thus, even if "1" (oxygen concentration in dry gas) is selected in function no. d-6, indication in the data display is the oxygen concentration in wet gas. ?example of error occurrence display ( note: an error display "e--5", "e--6" or "e--7" generated in calibration is indicated alternately with the oxygen concentration display. 6.3.3 message display the message display incorporates the dot matrix lcd of 40 characters (20 characters x two lines). this readout displays the following messages: to display the message of a value-setting group, you have to enter the specified password. the password is the 2-digit number ?16?. 1) measurement value group a (function no. a-0 - a-7) 2) measurement value group b (function no. b-0 - b-8) 3) value-setting group c (function no. c-0 - c-7) 4) value-setting group d (function no. d-0 - d-6) 5) value-setting group e (function no. e-0 - e-2) 6) value-setting group f (function no. f-0 - f-5) 7) value-setting group g (function no. g-0 - g-4) 8) value-setting group h (function no. h-0 - h-1) 9) value-setting group j (function no. j-0 - j-7) 10) status message group 11) interactive message group 12) sub-message group free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 85 among other message groups, the value-setting group has already been described in 7.1.5. for the status, interactive and sub-message groups to be displayed automatically, the relevant descriptions will be given when required (e.g., ?calibration? in chapter 9). therefore, the following description describes only the messages in the measurement value groups (1) and (2): {displaying measurement value group messages} a-0 display of an analog bar-graph when you press the measurement mode select key, an analog bar-graph is first displayed. on the top line is displayed the analog bar-graph showing the oxygen concentration of the measurement span. on the bottom line are displayed the minimum and maximum values of the measurement range and arrows indicating the lower limit alarm set value (lo) and the upper limit alarm set value (hi). when an error occurs, a message is also displayed. if there are multiple messages, ?h? is displayed at the bottom right part of the display. thus, in this case, display auxiliary messages using [help] key to confirm the contents. 1) the minimum unit on the analog bar-graph corresponds to 2.5% created by dividing the 100% of measurement span by 40. there is one displayed value after being smoothed. 2) displayable alarm set values (indexes) are those only for the lower and upper limits. the extreme upper and extreme lower limits, if any, are not displayed. in addition, if the lower or upper alarm set value is set in excess of the measurement range, it is not dis- played either. 3) if the alarm set value indication (index) overlaps the display unit of the minimum of maximum value in the measurement range, it is not displayed. 4) if the analog bar-graph indicates the hold value (preset or preceding value), hold is displayed in the lower line. nnnnnnnnnnnooooooooo nnnnnnnnnnnooooooooo nnnnnnnnnnnooooooooo (note 1) the value corresponding to the output current is shown in the analog bar-graph. therefore, when "1" is selected with function no. d-4, logarithmic indication of the current is displayed. when "1" is selected with function no. d-6, oxygen concentration in dry gas is displayed. (note 2) if a hold value is displayed, "hold" is also displayed. (example 2): in hold state display of analog bar-graph (example 1) 0 l l 25 l h 0 l l 25 l hold h free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 86 poor or nc in outlne cell brkn or dmgd h pls read inst manual "troubleshooting" when more than one error occurs, "h" is displayed. sequentially transfer the display using the auxiliary message display key. cell failure - cause? incor wrg (conv > det) h *error code "e---2" pls read inst manual "troubleshooting" display when an error occurs (example 1) display when an error occurs (example 2) temp too lo - cause? incor or brkn wrg h cldjct ckt, e + c - abnl htr or tc lne brkn h pls read inst manual "troubleshooting" blwn fu or poor cont short in tc h free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 87 *error code "e---3" pls read inst manual "troubles hooting" display when an error occurs (example 3) pls read inst manual "troubles hooting" *error code "e---4" display when an error occurs (example 4) *error code "e---5" display when an error occurs (example 5) *error code "e---6" display when an error occurs (example 6) temp too hi - cause? incor or brkn wrg h cldjct ckt, e + c - abnl htr or tc lne brkn h blwn fu or poor cont short in tc h analog ckt failure ad conv defective h cust rpr impossible cont jyc svce dept cal val abnl ( 0 pt ) cause? cell dmgd h cal gas fltr < ind ' d possible leak h wrng gas - chng span --> 0 diff conc & mem val h cal val abnl - span pt cause ? cell dmgd h cal gas fltr < ind ' d possible leak h wrng gas - chng 0 --> span diff conc & mem val h pls read inst manual "troubles hooting" yia free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 88 *error code "e---7" display when an error occurs (example 7) stab t fnshd -- cause? t ov b f r out stbln h cal gas flrt < ind 'd pos lkg / cell dmgd h pls read inst manual "troubleshooting" display when an error occurs (example 8) *error code "e---8" memory failure in rom/ram h cust rpr impossible cont jyc svce dept a-1 maximum or minimum o 2 concentration the maximum and minimum values of measured oxygen concentrations are stored and updated according to the time intervals set in function no. f-2. in function no. a-1, the latest values are displayed. by subsequently pressing ?help?, the auxiliary message display key, generated data and time of those values are displayed. display of maximum and minimum o2 concentrations (example) a1 max = 19.32 %o2 min = 15.48 %o2 h a-2 mean o 2 concentration the mean value of the measured oxygen concentration is stored and updated according to the time intervals set in function no. f-1. in function no. a-2, the latest value is displayed. a2 average (024 hour) 016.92 %o2 display of mean o2 concentration (example) yia free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 89 a-3 cell voltage cell (sensor) voltage is an index for noting the deterioration of the sensor. in function no. a-3, the cell voltage at the oxygen concentration presently measured is displayed. the sensor is judged to be normal if the measured value agrees with the theoretical value at the same oxygen concentration. e= -50.74 log (px /pa) [mv] where px: o 2 concentration in the measurement gas pa: o 2 concentration in the comparison gas (21 vol% o 2 ) % o 2 mv 0.1 117.83 0. 2 102.56 0.3 93.62 0.4 87 . 2 8 0.5 82.36 0. 6 78.3 5 0.7 74.95 0.8 72 . 0 1 0.9 69.41 % o 2 mv 10 16.35 21.0 0 30 -7 .86 40 -14.2 50 -19 .2 60 -23.1 70 -2 6.5 80 -29.5 90 -32.1 % o 2 mv 1 67.09 2 51.82 3 42 . 8 8 4 36.54 5 31.62 6 27.61 7 24 . 2 1 8 21.27 9 18.67 % o 2 mv 100 -34 .4 figure 53: oxygen concentration, v ol% o 2 vs cell voltage mv (cell temperature 750o c) a3 cell emf = 018.3 mv display of cell voltage (example) a-4 cell temperature/thermocouple voltage cell temperature is measured using a type k (chromel-alumel) thermocouple. the cold junction of this thermocouple is located at the terminal end of the detector. the temperature at this cold junction is measured with a transistor. in function no. a-4, displayed is a voltage affected by the temperature at the cold junction terminal. if the cell temperature is higher than 780o c (1436o f), error ?e?3? is effected, while error ?e?2? is displayed at 730o c (1346o f) or less. note: when the cell temperature is to be determined based on the displayed voltage, compensate for voltage error due to the temperature at the cold junction. a4 cell temp = 0750oc tc (k) emf = 030.4 mv display of cell temperature/ thermocouple voltage (example) free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 90 a-5 output current/output (measurement) range the current output value (ma) of the output signal and the measurement range (vol% o 2 ) are displayed. a5 output = 10.4 madc range = 000 - 025% o2 display of output current/ measurement range (example) note: the relationship between the output values of the current (madc) and the oxygen concentration (vol% o 2 ) is as shown below: (1) for a linear output signal of 0 to 20 madc: output current (ma) = 20 x (px/range h) (2) for a linear output signal of 4-20 madc: output current (ma) = 16 x (px/range h) + 4 (3) for a logarithmic output signal of 0 to 20 madc; output current (ma) = 20 x {(1/log(range h/0.1)}{log(px/0.1)} (4) for a logarithmic output signal of 4-20 madc: output current (ma) = 16 x {(1/log(range h/0.1)}{log(px/0.1)} + 4 where, px: oxygen concentration (vol% o 2 ) range h: maximum value of measurement range (vol% o 2 ) 0.1 20 18 16 14 12 10 8 6 4 2 0 1 0.5 5 10 100 50 0. 1 t o 100 0.1 to 25 0. 1 t o 10 range 0.1 to 5 1 (m a) i = 16 x {(1/log(rangeh/0.1)} {log(px/0.1)} + 4 px (vol% o 2 ) figure 54: relationship between each range and the logarithmic output signal (4-20 madc) free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 91 a-6 time the time is displayed by the clock function of the converter (year, month, day, hour, minute). if correction of this time is required, enter the correct time in function no. f-0. a6 present time 90/05/26 13:00 display of time (example) note: clock function must be reset when power is removed from the analyzer. a-7 air ratio the current air ratio, obtained by calculation, is displayed. if you use this air ratio data for estimating the combustion efficiency, etc., check that there is no air leaking in beforehand and that the measured value has not been affected by any interference gas (ch 4 , co, h 2 , etc.) air ratio m is calculated by the following formula: m={1/(21-oxygen concentration)} x 21 a7 excess air ratio 03.59 display of air ratio (example) note: a-7 is the last message in the measured value group a. if you want to display messages in measured value group b, press the cursor { > } key. b-0 span point correction ratio record the span point correction ratio, obtained every time the span point is calibrated, is displayed. you can determine the degree of deterioration in the cell (sensor) from this value. you can display the data record for the previous ten times including the latest data. to display each datum on the screen, call up the next screen by pressing the message ?help? key. you can have the span point correction ratio as follows: color the correctable range of the span point is 0 18% (corresponding to a voltage at a span point of about 15 mv). zero origin a b span origin c 0 es e1 p1 20.6 (span gas concentration) p2 (zero gas concentration) 0.51 corrected (theoretical) calibration curve calibrati on curve be for e c orr ec tion e2 ez 81.92 cell vol tage mv figure 55: span point correction ratio free datasheet http://www.datasheetlist.com/
configura tion im 11m6a2-yia page 92 zero point correction factor = (b/a) x 100 (%) correctable range: 100 30% span point correction factor = (c/a) x 100 (%) correctable range: 0 18% b0 span (0) = 001.5% 89/04/30 09:30 h display of the span point correction ratio record (1) (example) b-1 zero point correction ratio record the zero point correction ratio, obtained every time the zero point is calibrated, is displayed. you can determine the degree of cell (sensor) deterioration from this value. you can display the data record for the previous ten times including the latest data. to display each data display screen, call up the next screen by pressing the message ?help? key. you can get the zero point correction ratio by the method in figure 54. the correctable range for the zero point is 100 30%. b1 zero (0 = 098.7% 89/04/30 09:30 h display of the zero point correction ratio record (1) (example) b-2 response time response time, displayed in function no. b-2, can be obtained during calibration by the method in figure 55. note: if the zero point or the span point is skipped, it is not executed as in the one-touch calibration mode. figure 56: calculation of response time response time is calculated after the corrected calibration curve is obtained. with a starting point where a voltage corresponding to 10% of the corrected calibration curve span is found, the time that it takes for the voltage to reach the 90% mark of a 100% voltage corresponding to the oxygen concentration of a calibration gas (zero gas) set in the converter is calculated. in other words, the response time for the above is in the range from 10 to 90%. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 93 b2 cell respoinse (10 - 90%) = 003 sec display of response time (example) b-3 resistance in the cell a new cell (sensor) has an internal resistance of less than 200 w . the resistance increases as the cell deteriorates. therefore, the internal resistance of a cell is an index for indicating the degree of the sensor deterioration. in function no. b-3, the value obtained at the most recent calibration is displayed. b3 cell resistance 00175 ohm display of inner resistance of cell (example) b-4 robustness of the cell the robustness of the cell, an index for estimating the remaining life of the cell (sensor) is classified by a number from five (good) to one (poor). this robustness is determined after comprehensively evaluating various data monitored during calibration (e.g., the response time, the internal resistance of the cell, and the calibration coefficient.). however, when the zero point or span is skipped, no response time is measurable. thus, cell robustness is obtained from the other evaluation items. b4 sell robustness (5) life > 12 month display of cell robustness (example) b-5 temperature at the cold junction on a thermocouple the temperature at the cold junction terminal, measured with a transistor, is displayed. the highest permissible temperature of the terminal is 80o c (176o f). if this temperature is exceeded, it must be lowered by shielding the detector terminal box from radiation heat, etc. b5 cj temp = 026oc display of the temperature at the cold junction on a thermocouple (example) b-6 heater on time ratio the sensor in the detector is heated up to and maintained at a temperature of 750o c (1382o f) by the heater. the higher the temperature of the measurement gas, the less the on time of the heater becomes. however, if this time becomes too short, the temperature of the measurement gas might exceed the limit temperature of 600o c (1100o f), which is not recommended for the detector. the heater on time ratio is an index for monitoring an abnormal temperature rise in the measurement gas. however, its critical temperature rise varies depending on the conditions in individual processes. therefore, no definite specifications are given herein; however, a general guideline is about 20 to 30%. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 94 b6 cell heater duty 037.5% display of the heater on time ratio (example) b-7 dry o 2 concentration/moisture content when data corresponding to function no. j-0 to j-7 are set, the captioned values are calculated based on the data while displaying the dry o 2 concentration (vol% o 2 ) and the moisture content (% h 2 0) in the exhaust gas as follows: b7 dry o2 = 097.51 %o2 set h20 = 0010.5 %h20 display of the dry o2 concentration/moisture content (example) b-8 combustion efficiency the combustion efficiency is an effective operation control item even with a small boiler such as, a package boiler. when the data related to function no. j-0 to j-7 are set, an approximate combustion efficiency is calculated based on the data and is displayed by function no. b-8. when 0o c (o f) is assigned in function f-4, ?range input temperature?, the value j6 is displayed directly as the temperature of the exhaust gas. b8 gas temp = 0450oc comb eff = 076.0% display of combustion efficiency (example) note: the readouts of all the messages in measured value group b have been described on the preceding pages. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 95 6.4 s tart -u p the general procedures for starting up are as follows: supply power to the converter calibrate normal operation note: also check for normal operation of alarm output, etc. before starting up stationary operation. warm up and configure data inspect piping & wiring 6.4.1 supplying power to converter check that the supplied voltage meets the specifications of your converter (see 2.1) and then turn on the power to the converter (on the left side of the external wire terminals.) at that time, the converter will begin to operate. measurement will not take effect for approximately ten minutes or until the sensor reaches the specified temperature (750o c). all of the set parameters will be in a default state. the display will be as shown below immediately after the power is turned on. indication of warm-up t emperature of sensor (o c) alternately displayed 6.4.2 during warm-up the war-up period is about ten minutes. since measuring operations are suspended during this time, you can take this opportunity to set the data as explained in the quick start-up in section 6.1. the analog output signal during the warm-up period reads 0% o 2 . after completion of the warm-up period, the data display indicates the measured oxygen concentration. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 96 6.4.3 data setting configuration the ZA8c in-situ type zirconia oxygen analyzer allows custom configuration functions for your individual application. basic data, e.g., parameters required for operation, are stored in eeprom in the converter. temporary data, as set forth individually, are stored in the ram. the temporary data, read in the ram, are preserved through the backup of an electric double-layer capacitor for a short time even if the main power supply fails. after that, however, the data in the ram is lost while the stored data in the converter changes to a default state. upon shipment, the data loaded into the converter are in the default state. when operation begins, set the data to match each operation. the following table shows the default values. menu groups a & b are display functions which are discussed later in this chapter. the following menus are set up parameters required for accurate operation of your oxygen analyzer system. group c (0 through 7) c-0 s pan g as c oncentration set the oxygen concentration for the span gas used in calibration. if, for example, instrument air is used as a span gas, set the value at 20.6 vol% o 2 by entering ?020.6?. message display (example) c0 cal gas conc (%o2) span = 020.60 c-1 z ero g as c oncentration set the oxygen concentration for the zero gas used for calibration. set it for the certified gas value in the cylinder you are using at present. if, for example, the concentration is 1 vol% o 2 enter ?001.00?. message display (example) c1 cal gas conc (%o2) zero = 001.00 free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 97 group no. setting range or default details default lcd display setting c-0 span gas concentration: 4.5 to 100 vol% o 2 21.00% o 2 21 c-1 zero gas concentration: 0.3 to 100 vol% o 2 1.00% o 2 1 c-2 mode: one-touch(tch)/semi-auto(semi)/auto(at) tch 2: tch calibration c-3 stabilizing time: 0 to 10 minutes 3.0 min 3.0 minutes c-4 calibration time: 0 to 10 minutes 3.0 min 3.0 minutes c-5 calibration schedule: 0 to 255 day or 0 to 23 hours 1 day 1 day c-6 calibration start time: month, day, hour, minute c-7 skip: none(0), span(1), zero(2) 0: none 0: none d-0 range 1: (0 to 5) to (0 to 100) vol% o 2 0 to 10% o 2 000-010% o 2 d-1 range 2: (0 to 5) to (0 to 100) vol% o2 0 to 25% o 2 000-025% o 2 d- 2 hold: none( n), hld, p-hld hold 1: hld analog d-3 selection: 4 to 20 ma or 0 to 20 ma 4 to 20 ma dc 0: 4-20 ma output d-4 output characteristic selection: linear/log linear 0: linear d-5 smoothing constant: 0 to 255 sec. 0 sec 000 sec d-6 wet gas o 2 /dry gas o 2 wet gas o 2 0: wet e-0 extreme upper limit/upper limit: 0 to 100.0% o 2 both 0 (none) hh=0, hi=0 alarm e-1 extreme low er limit/low er limit: 0 to 100.0% o 2 both 0 (none) ll=0, lo=0 e-2 contact delay: sec, hysteresis: %o 2 3 sec, 0.1% o 2 3 sec, 0.1% o 2 f-0 hour-meter setting: day/hour, minute time m atching, f-1 o2 concentration averaging time: 1 to 255 hour 1 hr 1 hr temperature f-2 max/min o2 averaging time: 1 to 255 hour 24 hr 24 hr unit assigning, f- 3 temperature unit specif ication: oc, o f oc 0:oc etc. f-4 input temperature range: 0 to 3000oc/o f none (note 1) f-5 high-limit alarm value of the input temperature 0oc (none) 0:oc g-0 contact output 1 ne/f contact output g-1 contact output 2 nde/e+c+w g-2 contact output 3 nde/h+l contact input g-3 contact input 1 r 1: r g-4 contact input 2 r 1:r h-0 communication mode: f reew heel/handshake handshake handshake communication h-1 baud rate: 9600 b/s, 4800 b/s, 2400 b/s 4800 bps 1:48 j-0 types of f uels j-1 moisture content in exhaust gas: 0 to 5 m 3 /kg(m 3 ) fu e l j-2 theoretical air quantity: 1 to 20 m 3 /kg(m 3 ) calculation j-3 net calorif ic value: 0 to 15000 kcal/kg(m 3 ) data j-4 x value (x=a+b*h1) j-5 absolute humidity of atmosphere: 0 to 1 kg/kg j-6 temperature of exhaust gas: 0 to 2000o c j-7 temperature of atmosphere: -50 to 60oc p: pr ocess gas err or al ar m, b : inst r uctio ns fo r st ar t o f b l ow- back, g : c al ib r at io n g as under pr essure al ar m, r: inst r uctio ns fo r chang e in measur ement r ang e, c : inst r uctio n for st art of cal ib r at io n table 14: configurable items and their defaults free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 98 c-2 c alibration m ode select mode from auto (a t), semi-auto (semi) and one-touch (tch). set the cursor to the corresponding number. the calibration mode presently set is expressed with the member displayed under the function number. message display (example) c2 calibration mode 2 0: at 1: semi 2: tch number of mode presently set. c-3 s tabilizing t ime set a waiting period from the completion of the calibration to the beginning of measurements again, in minutes. set an interval for the time between stopping the flow of the calibration gas and completing the replacement of the calibration gas with measurement gas. if, for example, it is 3 minutes 30 seconds enter ?03.5?. the operation mode, switched to the maintenance mode (maint) during calibration operations, will return to the measurement mode (meas) after the stabilizing time has passed. message display (example) c3 stabilizing time 03.5 minutes c-4 c alibration t ime set a time after which the converter reads the oxygen concentration of a calibration gas (span gas or zero gas). in automatic or semiautomatic calibration mode, set a time (in minutes) from which the converter turns on the appropriate solenoid valve causing the calibration gas to flow to the probe. in one-touch calibration, set a permissible maximum interval (in minutes) for the time between when you enter a positive answer (by pressing the ?yes? key) in reply to the message ?span (or zero) valve open y?? shown in the message display, and when the calibration value is completely read. if, for example, for five minutes enter ?05.0?. upon the completion of the calibration time interval, you will see the message, ?span (or zero) cal good?. message display (example) c4 calibration time 05.0 minutes free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 99 c-5 c alibration f requency in automatic calibration, you can set the interval from the time of starting a calibration to the time of starting the next calibration. set in days or hours, according to the calibration frequency of your process conditions. it is normally recommended that intervals of one to three months (30 to 90 days) be used. if a calibration interval of 60 days is to be set, select ?0? from the settable-item selection messages thereby displaying the day-setting message and set 60 days by entering ?060?. if you want to set 12 hours select ?1? from the settable-item selection messages and enter 12 hours with ?12?. message display (example) c5 cal interval 0: day 1: hr c5 cal interval (1) 12 hr c5 cal interval (0) 060 day when "0" is selected from when "1" is selected from c-6 c alibration s tart t ime set the date and time at which the first automatic calibration is to start. if is it 4:30 p.m., july 15, 1994 set the date by entering ?94/07/15 16:30?. message display (example) c6 cal start time 94/07/15 16:30 note: if you change any parameters in c-0 through c-5 and are operating in the auto-cal mode, you must enter a cal start time in c-6 later than present time and date. c-7 s kip calibration is normally performed for both zero and span points. however, either of them may be skipped (but both zero and span points should be calibrated once). if you do not want to skip either, select ?0?. for skipping span or zero point, select ?1? or ?2?, respectively. these assignments are effective for semiautomatic and automatic calibrations. you cannot omit them in one-touch calibration. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 100 message display (example) c7 skip 0 0: none 1: spn 2: zr group d d-0 o utput r ange 1 set the range of oxygen concentration to correspond to the analog output signal (4-20 ma or 0 to 20 madc). you can set a free range from 0 to 5 vol% o 2 to 0 to 100 vol% o 2 . also, a partial range is selectable provided the minimum operating span is 5 vol% o 2 under the condition that the ratio of ?maximum/minimum? is ?1.3:1? or greater. note: if the output mode is set to ?logarithm? in function no. d-4, the minimum value of the output range is always ?0.1? regardless of this setting. message display (example) d0 output range 1 000 - 010 %o2 d-1 o utput r ange 2 output range 2 can be output only when the converter has the functions of ?contact input? or ?digital communication? by the ?range change command?. similar to output range 1, set the oxygen concentration range correspondent to the analog output signal (4-20 madc or 0 to 20 madc). any range from 0 to 5 vol% o 2 up to 0 to 100 vol% o 2 can be set. in addition, if the ?range selection command? is to be made with a contact input, select change in measurement range in function no. g-3 or g-4. however, if the command is made via digital communications, do not select change in measurement range. if selected, a command via digital communications cannot be received. message display (example) d1 output range 2 010 - 025 %02 d-2 o utput s ignal h old you can select what the 4-20 ma output will do when the analyzer is not in the "meas" mode. you can have the output track the o 2 level, hold at last reading or go to a predetermined level. "?" will track, "1" will hold last value and "2" will prompt you for the value you want the reading to go to. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 101 when ?2? is selected, a message for setting a preset value is then displayed, enter the value from the keypad. preset values are in vol% o 2 units. if you want 5% (corresponding to 12 madc on a 0-10% range), select ?005?. note: the output signal in a state other than normal operation, such as in data setting mode or during warm up, shows the value either for holding the preceding value for preset holding (where ?2? is set), even if ?0? is set. if the preset value is not set in the preset hold mode, the preceding value holds. message display (example) d2 output hold (2 ) preset hold = 000% when "2" is assigned d2 output hold 2 0:n 1: hld 2: p - hld note: this option only affects the 4-20 ma signal. the red led on the analyzer will always display actual o 2 levels (wet basis). d-3 t ypes of o utput s ignals assign the analog output signals to match your dcs or recorder's specifications. enter ?0? or ?1? for 4-20 madc or 0 to 20 madc, respectively. message display (example) d3 current output 0 0" 4-20 ma 1: 0-20 ma d-4 o utput s ignal c haracteristics the relationship between the 4-20 madc or 0 to 20 madc analog output signal and oxygen concentration is normally linear. however, you can modify it to logarithmic. for a linear or logarithmic relationship, assign ?0? or ?1?, respectively. note: for the ?relationship between the output current and oxygen concentration? when selecting ?log? see the description of function no. a-5. message display (example) d4 output scale 0 0:linear 1:log free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 102 d-5 o utput s moothing c onstant if the oxygen concentration of the measured gas changes suddenly, and you use these measured values directly to control operations, problems (e.g., frequent turning on/off of operations) might occur. to avoid such situations, you can introduce a time constant in order to smooth out the signal variations. you can set a time constant of up to 255 seconds, enter a suitable value from the keypad. if it is 30 seconds, enter ?030?. message display (example) d5 signal damping 030 sec d-6 m oisture b ase in m easurement g as combustion gases contain moisture created by burning hydrogen in the fuel. if this moisture is removed, the oxygen concentration will be higher than before. you can select whether the oxygen concentration is wet or dry value before use. for wet or dry conditions, assign ?0? or ?1?, respectively. set the moisture content required for the calculation according to function no. j-1 through j-7. message display (example) d6 wet/dry 02 select 0 0:wet 1:dry group e e-0 s etting of h igh h igh -l imit /h igh -l imit a larms set the level(s) for contact output signals for the high high-limit (hh) and/or high-limit (hl) alarms. if, for instance, you want to have an alarm set at an oxygen high-limit of 7.5 vol% o 2 but deactivate the high high-limit alarm, enter ?000.0? for the high high-limit alarm (hh=) and ?007.5? for the high- limit alarm (hi=). for an alarm contact output, refer to function no. g-0 through g-2. note: the analog bargraph (function a-0) will display the limit alarms under the bar graph. message display (example) e0 alarm set pt (%o2) hh = 000.0 hi = 007.5 free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 103 e-1 s etting of l ow l ow -l imit /l ow -l imit a larms set the level(s) of contact output signals for the low low-limit (ll) and/or low-limit (lo) alarms. if you want to have an alarm set at an oxygen extreme low limit of 2.5% and activate a low-limit alarm of 4.9%, enter ?002.5? for the low low-limit alarm (ll=) and ?004.9? for the low-limit alarm (lo=). for an alarm contact output, refer to function no. g-0 through g-2. note: the analog bargraph (function a-0) will display the limit alarms under the bar graph. message display (example) e1 alarm set pt (%o2) ll = 002.5 lo = 004.9 e-2 c ontact o peration of a larm o utput when measured values return to a stationary range after leaving the alarm range, it is sometimes desirable for existing alarm output to be reset conditionally instead of being reset immediately. you can set such conditions, i.e., operation delay and hysteresis. the operation delay, once set here, is effective even after measured values shift from the stationary range to the alarm range. set the operation delay (in ?seconds?) and the hysteresis in the oxygen concentration (vol% o 2 ), respectively. to set an operation delay of five seconds and a hysteresis in the oxygen concentration of 2.0 vol% o 2 , enter ?005? and ?2.0? on the keypad. note: the operation delay set here is applied to all contact signals selected with function numbers g-0 to g-2. message display (example) e2 rl delay = 005sec rl hys =2.0 %o2 group f f-0 s etting of d ate and t ime set the clock to the present date and time. if the present date/time is april 26, 1994/6:45 p.m., enter ?94/04/26 18:45? and press the ?enter? key to activate the date and time. message display (example) f0 clock entry 94/04/26 18:45 free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 104 f-1 m ean o 2 c oncentration c alculation t ime set the time for collecting data in order to calculate the mean oxygen concentration (indicated when you access function no. a-2). measured data are collected and summarized in 60 second intervals, while averages are calculated every time a datum is collected. after the set time expires, the calculated mean value is reset and the operation of calculating a new mean value begins all over again. if you want to update accumulated data every 24 hours, set this function at ?024?. accumulation of data begins from the time you press the entry key. note: the calculation of the mean value is activated every time a datum is collected. so, the longer the calculation time is extended, the more data which are used in averaging are collected. if you use a mean data periodically, you should take notice of this. message display (example) f1 average interval 024 hr f-2 t ime i nterval for m onitoring m aximum /m inimum o 2 the converter stores the maximum and minimum values of measured oxygen concentrations within a set time period. these values are displayed by accessing function no. a-1. you can set the time period for storing these maximum and minimum values. if you want to store them for a week, enter ?168? (hr). the storage of data begins when you press the entry key. s tored maximum and minimum values are updated by comparing them with the new data periodically. when the set time expires, the stored values are reset and new maximum and minimum value storage begins all over again. message display (example) f2 max, min interval 168 hr f-3 s electing i nput t emperature s cale (o f/o c) set the temperature scale to be o f or o c. if o f is selected you must enter a value of 32o f in function f5, otherwise, the alarm lamp will remain in effect. message display (example) f3 temperature unit 1 0: oc 1: of free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 105 f-4 i nput t emperature r ange you assign the temperature range of the process gas, corresponding to the analog input signal of 4-20 ma. if your range is 0o to 1000o f (537o c), enter ?1000?. at that time, check the temperature scale readout on the message display (the scale as assigned in function no. f-3 will be indicated). the maximum setting value is 3000o regardless of the temperature scale. note: the minimum input temperature is 32o f (0o c). therefore, when a temperature decreases below 32o f, alm lamp is lit. similarly, if the input signal decreases to 4 ma or less for some reasons, alm lamp is also lit. if no temperature input is used, value must be set to 32o f. message display (example) f4 flue gas temp spn 1000 of f-5 h igh a larm i nput t emperature set the high-limit temperature of the process gas. set a desired temperature within the measurement range. if the alarm value is 600o c (1100o f), set ?0600? (o c). if no high-limit alarm is required, enter ?000?. message display (example) f5 flue gas temp hi alm set = 0600 oc this alarm output is available as a contact output when you select the ?process gas temperature high- limit alarm setting? in function no. g-0, g-1, or g-2. note: if no temperature input is used, value must be set to 0o c or 32o f. g-0, g-1, g-2 c ontact o utputs , 1,2,3 output any contact signal selected out of 13 specified types. you select this together with the assignment of the relay contact operation (normally energized or de-energized) in function no. g-0, g- 1 and g-2. message display (example) -- see note 1 g o ry1 cont o u t p u t 100000000 00010 : 12345678910 11 12 13 14 digit no. 1: relay operation digit no. 2 to 14: section of contact signal to be used (to use =1, don?t use =0) digit no. 1) relay operation: relay operation is selected whether it is normally energized or de-energized. 0: normally energized (ne) 1: normally de-energized (nde) free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 106 digit no. 2) error occurrence: relays operate when an error (code ?e?1? through ?e?8?) occurs. digit no. 3) high-high alarm (hh): relay operates when the high-high limit set- point set with function no. e-0 is reached. (note 2) digit no. 4) high alarm (h): relay operates when the high limit set-point set with function no. e-0 is reached . (note 2) digit no. 5) low alarm (l): relay operates when the low limit set-point set with function no. e-1 is reached. (note 2) digit no. 6) low-low alarm (ll): relay operates when the low-low limit set- point set with function no. e-1 is reached. (note 2) digit no. 7) entry (e): relay operates when the maintenance mode is set. digit no. 8) in calibration (c): relay operates when calibration action is selected. digit no. 9) range selection answerback (r): relay operates when the selection command is input in a state where the range selection command (r) is set in function no. g-3 or no. 14. digit no. 10) in warm-up (w): relay operates when the detector is warmed up. digit no. 11) lo - calibration gas pressure (g): relay operates when the optional pressure switch input is set in function g-3 or g-4 and switch closes. digit no. 12) process gas temperature high alarm (t): relay operates when process gas rises above the input temperature high limit alarm set- point set with function no. f-5. digit no. 13) solenoid valve assembly drive (p): relay operates when the process gas failure alarm is input in the state where the process gas failure alarm input (p) is set with function no. g-3 (note 3) and the input closes. digit no. 14) blowback (b): relay operates when blowback state command input is set with function g-3. note 1: when a function is to be used, it is specified by setting the corresponding digit to 1. the default status is those shown below: g-0: (0) 1 0 0 0 0 0 0 0 0 0 0 0 0 g-1: (1) 0 0 0 0 0 1 1 0 1 0 0 0 0 g-2: (1) 0 0 1 1 0 0 0 0 0 0 0 0 0 note 2: the relay is energized corresponding to the operation delay and hysteresis valve set in function no. e-2. note 3: ?solenoid valve assembly drive? is a function for driving a solenoid valve which supplies purge gas to the detector when gases not yet burned are mixed into the measuring gas. this function can also be applied to the cases where a sensor breakage accident due to condensed water should be prevented by purging the calibration gas tubing at the restart of operation. note 4: on shipment, relay contacts for contact output relays are set as shown below. function no. g-0 (contact output #1) relay contacts: ?break contact? (closed when de- energized) function no. g-1 (contact output #2) relay contacts: ?make contact? function no. g-2 (contact output #3) relay contacts: ?make contact" free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 107 the contact type can be changed be resetting the jumper connector positions on the pcb. if ?break contact? (open when energized) is necessary, change it referring to subsection 6.1.6. g-3 c ontact i nput 1 the instrument can accept a total of two contact inputs assigned in functions no. g-3 and g-4. you select them from the following five types in function g-3: 0: calibration gas under pressure alarm (g) 1: instructions for change in measurement range (r) 2: instructions for start of calibration (c) 3: process gas error alarm (p) (g-3 only) 4: instructions for start of blow-back (b) (g-3 only) note: the blowback start command is valid when blowback is specified for function no. g-0 (or g-1 or g-2). the blowback start command contact input must be made for more than one second. when the converter receives the blowback start command, it outputs a contact signal which turns on and off about every ten seconds for an interval the same as the ?calibration time? set for function no. c-4, starting at 1 to 11 seconds after receiving the command. 1) blowback can be stopped with the help key. 2) blowback is not started during calibration because the calibration-start commands (auto, semi-auto, one touch) and calibrating action have priority. 3) the ?blowback signal? time does not include the stabilizing time set for function no. c-3. 4) the analog output at the blowback operation becomes the mode specified for function no. d-2 (non-hold, hold, or preset hold). blowback start command (contact input) on off on off on off about ten seconds by pressing the help key, the operation can be stopped in mid-stream. 1 to 11 seconds (start timing) time interval set to function no. c-4 one second or more blowback signal (contact output) free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 108 readout on the message display (example) g3 ry 1 cont input 3 0 : g 1 : r 2 : c 3 : p 4 : b g-4 c ontact i nput 2 in function no. g-4, select the contact input signal from the following three types: 0: calibration gas under pressure alarm (g) 1: instructions for change in measurement range (r) 2: instructions for start of calibration (c) if the measurement range change instruction is assigned, move the cursor with the keys to ?2?. readout on the message display (example) g4 ry 2 cont input 2 0:g 1:r 2:c group h h-0 c ommunication m ode the communication mode should be specified only when digital communications are achieved. when ?1? is specified, ?set ZA8c converter channel number (ch=)? appears. enter channel numbers 1 thorough 8 for the individual converters. note: when an rs-422a communication interface is used, up to eight converters can be connected to one computer. channel numbers are used to identify the converters, so set channel numbers which are different for each converter. readout on the message display (example) ho comm mode 0 0 : free 1 : hand when "1" is assigned. ho comm mode (1) hand shake: ch3 h-1 b aud r ate (d ata c ommunication r ate ) a ssignment assign operating digital communications. for a data communication rate of 9600 bps or 4800 bps, enter ?0? or ?1?, respectively. for 2400 bps, select ?2? from the keypad. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 109 readout on the message display (example) h1 baud rate (bps) 2 0:96 1:48 2:24 (note) disp key h1 baud rate (bps) (2) 2400 bits/sec group j j-0 t ypes of f uels you can select a type of fuel for obtaining combustion ef ficiency, etc. select and assign in function no. j-0 what fuel you are using from the following five types: 0: heavy oil a (a) 1: heavy oil b (b) 2: heavy oil c (c) 3: gas (g) 4: coal (x) if your oil in use is heavy oil (c), move the cursor to "2" with the keys. j0 fuel grade 2 0 : a 1 : b 2 : c 3 : g 4 : x readout on the message display (ex.) j-1 m oisture content in exhaust gas you can set the amount of moisture contained in the combustion exhaust gas of the fuel used in the measurement process (in terms of n m 3 /kg or m 3 /m 3 in proportion to the unit volume of the fuel.) look up the setting value from table 15. if there are no relevant descriptions for your fuel, calculate the value using the formula shown on page 119. if the moisture content is 1.27 n m 3 /kg, for example enter "01.27". j1 h20 in fuel 01 . 27 m3 / kg (m3) readout on the message display (ex.) readout on the message display (ex.) free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 110 j-2 t heoretical air quantity you can set the theoretical air quantity required for the fuel used in the measurement process to ignite (n m 3 /kg or m 3 /m 3 ). look up the setting value from table 15. if there are no relevant descriptions for your fuel, calculate the value using the formula shown on page 119. if the theoretical quantity is 10.7 n m 3 /kg, enter "10.70". j2 theoritical air 10 . 70 m3 / kg (m3) readout on the message display (ex.) j-3 n et calorific value you can set the net calorific value of the fuel used in the measurement process to ignite (kcal/kg or kcal/m 3 ). look up the setting value from table 15. if there are no relevant descriptions for your fuel, calculate the value using the formula shown on page 119. if the net calorific value is 9860 kcal/kg, enter "09860". j3 net calorific val 09860 kcal / kg (m3) readout on the message display (ex.) j-4 x value (x = a + b * h 1 ) the x value (n m 3 /kg or m 3 /m 3 ) is the coefficient provided with each fuel. look up the x value of the fuel used from table 15. if there are no relevant descriptions for your fuel, calculate the value using the formula shown on page 119. if the x value is 0.773 (m 3 /kg), for instance, round off the value to the second decimal place and enter "00.77". j4 value of x 00 . 77 m3 / kg (m3) readout on the message display (ex.) j-5 a bsolute humidity of atmosphere you can set the absolute humidity of the atmosphere used in igniting (moisture: kg/dry air :kg). if the absolute humidity is 0.021 kg/kg, enter "0.021". for your reference, a graph for determining absolute humidity by the temperature indications of a psychrometer is shown in figure 57. it is a little inferior in accuracy. if the exact humidity is required, determine the value by referring to references such as jis b8222, "heat balancing of boilers for land use." free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 111 j5 abs hmd of air 0 . 0210 kg / kg readout on the message display (ex.) j-6 t emperature of exhaust gas you can set the temperature of the exhaust gas in the actual combustion process (o c). if the temperature of the exhaust gas is 450o c, enter "0450". j6 fuel gas temp 0450 o c readout on the message display (ex.) j-7 t emperature of atmosphere you can set the temperature of the atmosphere taken in for igniting (o c). measure the temperature of the atmosphere at a place as close to the air intake port as possible. if the temperature is minus 1o c, for instance, enter "-001". you can alternately display plus and minus signs by pressing the increase key. j7 amb air temp - 001 o c readout on the message display (ex.) free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 112 j-2 : theor et ic al air qt yj-4 : x val ue ?liquid fuels fuel specific chemical components heat value the o retical combus tio n gas qty x p ro pertie s weight (% by weight) kc al/kg co mb us tio n n m 3 /k g v a lue type kg/l c h on s w as h high lo w nm 3 /kg c o 2 h 2 oso 2 n 2 to ta l kerosene 0.78~ 0.83 85.7 14.0 - - 0.5 0.0 0.0 11100 10400 11.4 1.59 1.56 0.00 9.02 12.17 0.96 light oil 0.8 1~ 0.84 85 .6 13 .2 - - 1.2 0.0 0.0 109 6 0 1028 0 11.2 1.59 1.47 0.00 8 .87 11.9 3 0.9 1 a heavy oil n o. 1 0.85~ 0.88 85.9 12.0 0.7 0.5 0.5 0.3 0.05 10880 10210 10.9 1.60 1.34 0.00 8.61 11.55 0.89 class 1 n o. 2 0.83~ 0.89 84.6 11.8 0.7 0.5 2.0 0.3 0.05 0.780 10110 10.8 1.58 1.32 0.01 8.53 11.44 0.86 b heavy oil class 2 0.90~ 0.93 84.5 11.3 0.4 0.4 3.0 0.4 0.05 0.470 9860 10.7 1.58 1.27 0.02 8.44 11.31 0.77 n o. 1 0.93~ 0.95 86.1 10.9 0.5 0.4 1.5 0.5 0.1 0.500 9900 10.7 1.61 1.22 0.01 8.43 11.27 0.79 c heavy oil n o. 2 0.94~ 0.96 84.4 10.7 0.5 0.4 3.5 0.5 0.1 0.300 9710 10.5 1.58 1.20 0.02 8.32 11.12 0.72 class 2 n o. 3 0.92~ 1.00 86.1 10.9 0.5 0.4 1.5 0.6 0.1 0.430 9840 10.7 1.61 1.22 0.01 8.43 11.27 0.77 n o. 4 0.94~ 0.97 83.0 10.5 0.5 0.4 3.5 2.0 0.1 0.280 9700 10.3 1.55 1.18 0.02 8.18 10.93 0.72 j-3: net cal or ific val ue o f fu e l in us e j - 1: m o is t ur e cont ent in e xhaus t gas j-2 : theor et ic al air qt yj-4 : x val ue ?g a s f u e l s fuel specific chemical components heat value the o retical combus tio n gas qty x p ro pertie s weight (% by weight) kc al/kg co mb us tio n n m 3 /m 3 value type kg/l c h 2 co 2 ch 4 c m h n o 2 n 2 hig h lo w nm 3 /m 3 co 2 h 2 on 2 to ta l coke oven gas 0.544 9.0 50.5 2.6 25.9 3.9 0.1 8.0 4880 4350 4.455 0.45 1.10 3.60 5.15 0.46 blast furnace gas 0.3 69 25 .0 2 .0 20.0 - - - 5 3 .0 810 8 00 0.6 03 0.45 0.02 1.01 1.48 0.08 natural gas 0.7 9 6 - - 2 .0 88 .4 3 .2 1.6 4.2 9 05 0 8 140 9 .015 0.9 8 1.8 8 7 .17 10.03 0.86 propane 2.030 c 3 h 8 90%, c 4 h 10 10% 24380 22450 24.63 3.10 4.10 19.5 26.7 2.36 butane 2.530 c 3 h 8 10%, c 4 h 10 90% 29980 27680 30.37 3.90 4.90 24.0 32.8 2.91 (gases) (m ol ecul ar for mul a) oxygen 1.43 o 2 -- - - - -- - nitrogen 1.2 5 n 2 -- - - - -- - hydrogen 0.09 h 2 3050 2570 2.390 - 1.0 1.89 2.89 0.27 carbon monoxide 1.25 c o 3020 3020 2.390 1.0 - 1.89 2.89 0.32 carbon dixoide 1.9 6 co 2 -- - - - -- - methane 0.7 2 ch 4 9496 8557 9.570 1.0 2.0 7.57 10.6 0.90 et h an e 1.34 c 2h6 16636 15228 16.74 2.0 3.0 13.2 18.2 1.60 ethylene 1.25 c 2h 4 15048 14109 14.35 2.0 2.0 11.4 15.4 1.48 propane 1.97 c 3h8 23667 21800 23.91 3.0 4.0 18.9 25.9 2.29 butane 2.59 c 4h10 30685 28338 31.09 4.0 5.0 24.6 33.6 2.98 j-3: net cal or ific val ue o f fu e l in us e j - 1: m o is t ur e cont ent in e xhaus t gas table 15: various values of fuels free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 113 if you use a fuel not described in table 15, calculate the set values for function nos. j-1 to j-4 using the following formula: ?liquid fuels moisture content in exhaust gas = 1/100 {1.24 (9 h + w )} [m 3 /kg] theoretical air quantity = 12.38/10000 x h 1 - 1.36 [m 3 /kg] net calorific value = h 1 x value = 3.37/10000 x h x - 2.55 [m 3 /kg] where, h 1 : net calorific value of fuel h : hydrogen in fuel (% by weight) w : moisture content in fuel (% by weight) h x : same as h 1 ?gas fuels moisture content in exhaust gas = 1/100 {(h 2 ) + 1/2 s y (c x h y ) + w} [m 3 /m 3 ] theoretical air quantity = 11.2 x h 1 /10000 [m 3 /m 3 ] net calorific value = h 1 x value = 1.05/10000 x h x [m 3 /m 3 ] where, h 1 : net calorific value of fuel h : hydrogen in fuel (% by weight) w : moisture content in fuel (% by weight) h x : same as h 1 ?solid fuels moisture content in exhaust gas = 1/100 {1.24 (9 h + w )} [m 3 /kg] theoretical air quantity = 1.01 x h 1 /1000 + 0.56 [m 3 /kg] net calorific value = h 1 = h h - 5.9 (9 h + w ) [kcal/kg] x value = 1.11 - (0.106/1000) x h x [m 3 /m 3 ] where, w : total moisture content during use (% by weight) h : hydrogen content (% by weight) mean hydrogen content of domestic coal (moisture - /ash-free) is 5.7%. therefore, h is approximated by the following formula: h = 5.7 x [ {100 - ( w + a)} / 100] x (100 - w ) / (100 - w 1 ) where, a : ash content [%] w 1 : moisture content based on industrial analysis (constant - humidity base ) [%] h h : high heat value of fuel [kcal/kg] h 1 : low heat value of fuel [kcal/kg] h x : same as h 1 free datasheet http://www.datasheetlist.com/
configura tion im 11m6a2-yia page 114 figure 57: absolute humidity of air free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 115 6.4.4 calibration the calibration of this instrument is carried out by comparing either the oxygen concentration of the zero gas or of the span gas with the measured value of the relevant calibration gas. the reference oxygen concentration (set in c-0 and c-1) is already read into the memory of the converter. the converter detects the deviation of the measured result from this value and automatically corrects it. the following three methods of calibration are available; further calibrations can be carried out periodically or occasionally, and the calibration gas for these later calibrations can be automatically or manually introduced. you can select any of these methods by registering it in the converter. 1) automatic calibration a calibration operation begins when you set the calibration start time and the calibration fre- quency, and then press the key (or enter an external contact signal) to begin. all operations related to calibration (e.g., calibration time, opening/closing of the solenoid valve and sequence) are automatically activated based on the data set in the converter. note: if you manually start a calibration from the keypad, digital input or serial communication, the automatic sequence is aborted. a new start time must be entered in c-6. 2) semiautomatic calibration in this mode, calibration begins only when the converter is operated with the keys or receives starting instructions from a contact signal through an external circuit. the other details are the same as those for automatic calibration. 3) one-touch calibration in this mode, operate keys to send the calibration gas or for other procedures depending on the readout on the message display on the converter after you have given the calibration start instruc- tions (in the same way as for semiautomatic calibration). other calibration operations are auto- matically processed by the converter. ?preparation for calibration (1) (2) (3) (4) adjust opening in the valve for calibration gas (automatic or semi-automatic calibration) check the set calibration data check calibration operation execute calibration ? checking the set calibration data sequentially display the data from codes c-0 to c-7 on the message display of the converter and check for errors in the set data (e.g., the selected calibration method and the concentration of the calibration gas). free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 116 6.5 s tationary o peration 6.5.1 collection of control data you can display ?maximum/minimum o 2 concentration? of function no. a-1 or ?mean o 2 concentration? of a-2 on the message display. 6.5.2 troubleshooting if an error occurs: 1) a fail led on the converter status display lights up; 2) an error code appears in the data display area; 3) error messages appear in the message display area. if the error messages do not appear, push the "disp" key. every time an error occurs, immediately correct it according to the instructions in chapter 11. the following error codes are operable. er r o r c o d e er r o r de t a il er r o r st a t u s e--1 sensor (cell) error goes into f ail mode, automatically turning off the pow er supply to the detector heater. e--2 sensor temp "low" goes into f ail mode, automatically turning off the pow er supply to the detector heater. e--3 sensor temp "high" goes into f ail mode, automatically turning off the pow er supply to the detector heater. e--4 a/d (analog circuit) error goes into f ail mode, automatically turning off the pow er supply to the detector heater. e--5 calibration value "zero" (displayed during calibration) the present zero point calibration v alue is not af f ected. e--6 calibration value "span" (displayed during calibration) the present zero point calibration v alue is not af f ected. e--7 start pow er stability time over (displayed during calibration) the present zero point calibration v alue is not af f ected. e--8 rom, ram error goes into f ail mode, automatically turning off the pow er supply to the detector heater. ooo (display erased) digital circuit error pow er f ailure goes into f ail mode, automatically turning off the pow er supply to the detector heater. (displayed upon restart after remedying the pow er f ailure). data values default. table 16: error codes, details and status note: e--5, e--6 or e--7 is displayed alternately with the o 2 concentration. 6.5.3 checking operating conditions in order to maintain normal operating conditions, determine which items are to be inspected periodically, and check them regularly for errors. free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 117 items recommended for periodic inspections are listed below for your reference. for maintaining or recovering performance, see chapter 10. inspection item purpose & detail of inspection inspection interval complete closing of c alibration gas inlet to prevent condensation w hich ma y break sensor. check f or a complete closing of needle valve. 1 to 7 days set f low rate of f low setting unit check that f low is about 600 ml/min. for both the ref erence & calibration gases, f or correctly measured and calibrated values. 1 to 7 days cell voltage (function no. a -3) to know the extent of deterioration of the sensor (cell). compare the displayed value w ith theoretical one. 1 to 2 w eeks pressure in the calibration gas cylinder to determine the intervals betw een replacement of calibration gas (zero gas) cylinders. specify min. pressure and check for higher pressure. 1 to 2 w eeks set value of oxygen concentration f or calibration gas (zero) to obtain a correct calibrated value. check f or complete setting of oxygen conc in the calibration gas (zero) in use. upon replacement digital circuit error pow er failure to determine the intervals betw een replacement of purge gas cylinders. determine min. pressure and check f or higher pressure. 1 to 2 w eeks table 17: example of items for periodic inspection 6.5.4 frequent stopping and restarting operations if you stop the operation of the zirconia oxygen analyzer at the same time as the boiler, furnace, etc., condensation forms in the sensor and dust may adhere to it. if you restart operations with the sensor in this state, as it heats up to 750o c (1382o f), it causes dust to accumulate which significantly deteriorates its performance. in an extreme case with a lot of condensation, the analyzer may break, or the zirconia cell may crack due to thermal shock. to prevent such an occurrence, take the following steps to stop the equipment. 1) keep the power supply to the analyzer on as long as possible. if this is impossible, remove the detector. 2) if both of the above are impossible, keep air flowing into the calibration gas piping at a rate of about 600 ml/min. ?operation restart if none of the above precautions for stopping operations can be done, supply air into the calibration gas piping for five to ten minutes at a rate of about 600 ml/min. after stopping operations for a long period of time, set the necessary data again. 6.6 c alibration from the ZA8c c onverter 6.6.1 set-up menus for calibration in order to fully employ the use of an auto calibration system, the appropriate parameters must be entered into your ZA8c converter. entering this information will give an accurate calibration, thereby providing correct diagnostics values for span correction, zero correction, etc. every time a 2 point free datasheet http://www.datasheetlist.com/
configuration im 11m6a2-yia page 118 (span and zero) calibration is performed. the timing sequence of the ac1 auto calibration unit is controlled by the ZA8c converter. you must configure the ZA8c parameters, as described in this section. refer to section 6.1 for detailed information. ZA8c menu description default setting typical setting f-3 date/time yy/mm/dd hh:mm c0 span gas concentration 21.00% 20.60% c1 zero gas concentration 1.00% betw een 0.5 and 5 % c2 calibration mode 2-one touch 0-automatic (for ac1) 0- automatic or 2-one touch (for mc1) 1-semi-automatic 2-one touch c3 stabilization time 3 minutes 3 to 5 minutes c4 calibration time 3 to 5 minutes c5 calibration frequency 1 day 1/month c6 calibration start time yy/mm/dd hh:mm table 18: setup parameters for calibration free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 119 vii. serial communication to allow for rs-232c or rs-422a communications, you must connect the converter to a pc. 7.1 w iring with rs-232c c ommunica tions c able figure x shows terminal connections of rs-232c communication cable. rs-232c communications are carried out by connecting only one converter to one computer. figure 58: w iring of rs-232c communications cable use a three-conductor - (nominal cross section: 0.2 mm 2 ) or two twisted pair (24 awg or thicker) - shielded cable for rs-232c communications wiring. in addition, the cable length is limited up to 15 m. in end-treating the cable, attach crimping type solderless terminal lugs matching m4 (4 mm) screws to the cable end to be connected to the converter terminals. 7.2 w iring with rs-422a c ommunica tions c able rs-422a communication can be carried out by connecting up to eight converters to one computer. in the ZA8c converter, communication i/o signals are not isolated. if the computer is distant (communication cable length is 15 m or more as a guideline) from the converter and thus their ground potentials cannot be equalized, use a computer having i/o signal isolating type interface. figure 51 shows terminal connections of rs-422a communication cable. 1) communication cables away from power cables which may become noise sources. in addition, cables so that adjacent cables are not in parallel with each other. 2) if more than one converter is to be connected to a computer, ground wiring should be such that the ground potentials of each converter are equal. free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 120 figure 59: connections for rs-422a communications for rs-232c communication cable, use two twisted pair (24 awg or thicker) shielded cables of ?8 to ?11 mm o.d. so that the cable impedance is 100 w and cable capacitance is 50 pf/m or less. it is recommended that the cable length be within 15 m to balance ground potentials. however, if a computer having i/o signal isolating interface is used, the cable length may be extended up to 500 m. in this case, the ground system wiring should be made in a procedure shown in figure 59. as end treatment of the cable, attach the crimping type solderless terminal lugs matching m4 (4 mm) screws to the end of the cable to be connected to the converter terminals. expose the conductors from the cable shield as short as possible. figure 60: connections for rs-422a communications (when using an i/o isolating computer) free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 121 7.3 s pecifica tions for ZA8c c onverter c ommunica tions (rs-232c or rs-422a) classifications item description signal level conforming to eia rs-232c or rs-422a standards i/o signal not isolated communication system start-stop system, half duplex ?rs-232c: tw o-w ire system ?rs-422a: four-w ire system, multi-drop connection - number of computer converters = 1: n (n = 1 to 8) communication distance ?rs-232c: up to 15m?rs-422a: up to 500m (betw een i/o isolated computer and ZA8c converter) spe cifications communication rate 2,400, 4,800, 9,600 bps sw itching transmission procedure no procedure, handshaking transfer. in the case of "no procedure" data transmission only (transmission period: 10 seconds) data length 8 bits parity none start bit 1 stop bit 1 communication code ascii code reception (1) zero and span calibration request, calibration abort request(2) analog output range selection signal contents transmission time, o2 concentration (w et and dry), cell emf , cell temperature, error codes, alarm number, status number, calibration coef ficient, cell resistance, response time, cell life, exhaust gas temperature, o2 average value, o2 averaging time, max. and min. o2 table 19: communication specifications free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 122 free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 123 free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 124 free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 125 free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 126 free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 127 free datasheet http://www.datasheetlist.com/
serial communication im 11m6a2-yia page 128 free datasheet http://www.datasheetlist.com/
calibra tion im 11m6a2-yia page 129 viii. calibra tion 8.1 c alibra tion p rocedures 8.1.1 principles of the zirconia oxygen analyzer before detailing calibration, the principles of measuring with a zirconia oxygen analyzer will be described. a solid electrolyte such as zirconia allows the conductivity of oxygen ions in a high temperature state. therefore, when a zirconia-plated element with platinum electrodes on both sides is heated up in contact with gases having different partial-oxygen pressures on each side, the element shows the action of the concentration cell. in other words, the electrode in contact with a gas with a higher partial-oxygen pressure acts as a negative electrode. as the gas comes in contact with the zirconia element in this negative electrode, oxygen molecules in the gas acquire electrons and become ions. moving in the zirconia element, they eventually arrive at the positive electrode on the opposite side. there, the electrons are released and the ions return to oxygen molecules. this reaction is indicated as follows: negative electrode: o 2 + 4e ? 2 o 2- positive electrode: 2 o 2- ? o 2 + 4e the electromotive force e (mv) between the two electrodes, generated by the reaction, is governed by nernst's equation as follows: ....................(1) where: r: gas constant t : absolute temperature n : 4 f : the faraday constant p x : oxygen concentration in the gas in contact with the negative zirconia electrode (%) p a : oxygen concentration in the gas in contact with the positive zirconia electrode (%) assuming the zirconia element is heated up to 750oc, then the equation (1) becomes: ....................(2) with this analyzer, the sensor (zirconia element) is heated up to 750oc, so the relationship of equation (2) remains valid. at that time, a relationship, as in figure x, is effected between the oxygen concentration of the sample gas in contact with the positive electrode and the electromotive force of the sensor (= cell), where a comparison gas of reference air is used on the negative electrode side. free datasheet http://www.datasheetlist.com/
calibration im 11m6a2-yia page 130 figure 61: oxygen concentration in measurement gas vs cell v oltage (21.0% o 2 equivalent) measurement principles of a zirconia oxygen analyzer have been described above. however, the relationship between oxygen concentration and the electromotive force of a cell is only a theoretical one. usually, a practical sensor shows a slight deviation from the theoretical value. this is the reason why calibration is required. it's performed to obtain a calibration curve for correcting a deviation from a theoretical cell electromotive force. 8.1.2 calibration gas a gas with a known oxygen concentration is used for calibration. normal calibration is performed using 2 different gases: a zero gas of low oxygen concentration and a span gas of high oxygen concentration. in some cases, only one or the other gas may 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 vol% o 2 with a balance of nitrogen gas (n 2 ). the span gas widely used is clean air (i.e., instrument air). free datasheet http://www.datasheetlist.com/
calibration im 11m6a2-yia page 131 8.1.3 compensation the deviation of a measured value from the theoretical cell electromotive force is checked by the method in figures 61 or 62. figure 61 shows a 2-point calibration using 2 gases: zero and span. cell electromotive forces for a span gas with an oxygen concentration p1 and a zero gas with an oxygen concentration p2 are measured while determining a calibration curve passing between these 2 points. the oxygen concentration of the measurement gas is determined from this calibration curve. in addition, the calibration curve corrected by calibration is compared with the theoretical calibration curve for determining the zero point correction ration represented by b/a x 100(%) on the basis of a, b and c shown in figure xa and the span point correction ration of c/a x 100(%). if the zero point correction ratio exceeds a range of 100 30% or the span point correction ratio becomes larger than 0.18%, calibration of the sensor become impossible. figure 62: calculation of a calibration curve and correction factor in a 2-point calibration using zero and span gases figure 62 shows a 1-point calibration using only a span gas. in this case, only the cell electromotive force for a span gas with an oxygen concentration p1 is measured. the cell electromotive force for the zero gas is carried over from a previous measurement to obtain the calibration curve. the principles of calibration using only a span gas also applies to the 1-point calibration method using a zero gas only. free datasheet http://www.datasheetlist.com/
calibration im 11m6a2-yia page 132 figure 63: calculation of a calibration curve and correction factor in a 1-point calibration using a span gas 8.1.4 diagnostic data from a sensor measured during calibration during calibration, the following data for monitoring the conditions of the sensor are collected, as well as calibration data. however, if calibration is not properly executed (errors may occur in automatic or semi-automatic calibration), these data are not collected in the current calibration. also, if one of the calibration gases is skipped, the data is not collected. record of span correction factor you can monitor values acquired from the past 10 calibrations using function no. b-0. record of zero correction factor you can monitor values acquired from the past 10 calibrations using function no. b-1. response time you can monitor the response time provided that a 2-point calibration has performed. these values can be monitored using function no. b-2. internal resistance of a cell internal resistance gradually increases as the cell (sensor) deteriorates. you can monitor the value measured during the latest calibration using function no. b-3. robustness of a cell the robustness of a cell is an index for predicting the remaining life of a sensor and is expressed in a number on 5 levels. you can monitor cell robustness using function no. b-4. 8.1.5 operation flowchart of semi-automatic and automatic calibrations in this section, the procedures for operating semi-automatic, automatic and one-touch calibrations are described using flowcharts. free datasheet http://www.datasheetlist.com/
calibration im 11m6a2-yia page 133 8.1.6 operation flowchart of semi-automatic and automatic calibration cal disp yes nnnnnnnnnooooooooooo calibration y/n? also instructable through an external contact signal. (note 1) (note 3) the mode changes to a semi-automatic calibration. automatic calibration starts. (note 1) "warm-up on" is displayed while warming up. displayed only during the time set in c-3 0 25 setting of c-7 "1" (skip span) setting of c-7 "0" (skip none) setting of c-7 "2" (skip zero) (note 2) (note 2) (note 3) ledger: skip span gas skip zero gas skip none span gas solenoid valve "open" on span cal help span point calibration span gas solenoid valve "close" zero gas solenoid valve "open" on zero cal set skip help zero point calibration zero gas solenoid valve "close" calibration over stabilizing time! free datasheet http://www.datasheetlist.com/
calibration im 11m6a2-yia page 134 please set c4 span cal y/n? zero cal y/n? please confirm span gas = 20.90% o2 introduce span gas flow rate = 600 ml/min span valve open y? flow of span gas at 600 ml/min on span cal stability error try again y/n? span point is calibrated. normally calibrated? span cal error try again y/n? (note 2) zero cal y/n? stop span gas flow. cal no yes disp help no help yes no yes no yes no yes (note 2) the following messages are displayed depending on the calibrated results. "span cal good span valve close y?" "span cal error try again y/n?" "stability error try again y/n?" to a continued on next page no is output stabilized? yes no no yes yes a to on the next page. 2 displayed only 5 sec displayed only 5 sec (note 1) mode changed to calibration. (note 1) if 00.0 min. is set in c-4, this message is displayed, prohibiting calibration. "warm-up on" is displayed while warming up. 1 to on the next page. did calibration time expire? 0 25 nnnnnnnnnooooooooooo 8.1.7 operation flowchart of one-touch calibration free datasheet http://www.datasheetlist.com/
calibration im 11m6a2-yia page 135 no yes span cal good span valve close? help no help no zero valve open y? did calibration time expire? on zero cal zero point calibration normally calibrated? stability error try again y/n? zero cal error try again y/n? flow of zero gas at 600 ml/min stop zero gas flow (note 3) span cal y/n? yes no yes no yes no yes span cal y/n? stabilizing time! yes continued from the previous page please confirm zero gas = 01.00 % o2 2 to to 2 introduce span gas flow rate = 600 ml/min 1 displayed only 5 sec displayed only 5 sec yes no yes yes no no is output stabilized? b to (note 3) the following messages are displayed depending on the calibrated results. "zero cal good zero valve close y?" "zero cal error try again y/n?" "stability error try again y/n?" displayed only during the time set in c-3 b 2 the one-touch calibration procedure above finishes. select the function no. a-0 display by pressing the measurement mode select key. free datasheet http://www.datasheetlist.com/
inspection and maintenance im 11m6a2-yia page 136 ix. inspection and maintenance in this chapter, inspection and maintenance for keeping or recovering the measuring performances of the ZA8c in-situ type zirconia oxygen analyzer is described: 9.1 i nspection and m aintenance of the d etector 9.1.1 precautions for inspecting the detector 1) be careful not to touch any hot parts. the sensor at the tip of the detector probe is heated up to 750oc (1382of) during opera- tion. if an operation is carried out immediately before inspection, be careful not to touch the probe with your finger tips. 2) do not drop, bump or cause any great impact on the sensor assembly. the sensor is made of ceramic (zirconia). if the detector is dropped or hit with something, the sensor will be damaged and no longer work. 9.1.2 cleaning the filter in the sensor assembly if the filter at the back of the detector probe becomes clogged with dust, measurement problems occur. if dust blocks the flow of gas, wipe off the dust with a brush. 9.1.3 cleaning the calibration gas tube calibration gas, supplied from the calibration gas inlet of the terminal box into the detector, flows through the tube and comes out at the tip of the probe. the tube might become clogged with dust from the measurement gas. if you become aware of clogging, such as when a higher pressure is required to achieve a specified flow rate, clean the calibration gas tube. clean the calibration gas tube in the following manner: 1) remove the detector. 2) remove the four bolts (and the spring washers) attaching the sensor assembly from the top of the detector probe. 3) remove the filter. remove the filter hold plate assembly together with the u-shaped pipe. 4) clean the calibration gas tube equipped in the probe, using a rod of 2 to 2.5 mm in diameter (see figure 56). keep air flowing from the calibration gas inlet at about 600 ml/ min and insert the rod into the tube (3 mm in inside diameter). however, be careful not to insert the rod deeper than 40 cm for the general-purpose detector, or 15 cm for the high- temperature detector. 5) clean the filter and the u-shaped pipe, as removed in (3). the u-shaped pipe can be rinsed with water. however, it should be dried out before reassembly. 6) reassemble the parts removed for cleaning. replace the filter with the fine-meshed ring element side facing the sensor. coat the screw threads of the bolts with a heat-resistant agent (such as never seize) and then screw them in. free datasheet http://www.datasheetlist.com/
inspection and maintenance im 11m6a2-yia page 137 tighten each bolt with a torque of about 60 kgf ? cm (52 in ? 16) uniformly. rod(?0.079-?0.098in) (?2-?2.5mm) calibration gas tube figure 64: cleaning of calibration gas tube 9.1.4 replacing the sensor assembly the performance of the sensor (cell) deteriorates as the surface becomes soiled during operation. therefore, you have to replace the sensor when its life expectancy expires, namely when it can no longer satisfy the range of the zero point correction factor of 100 30% or the range of the span point correction factor of 0 15%, and so on. in addition, the sensor assembly is to be replaced also when it is damaged and can no longer work normally in measuring. when the sensor is no longer operable (for example, due to breakage), investigate the cause and remedy the problem as far as possible to prevent its reoccurrence. replace the sensor assembly as follows: 1) in order not to lose or damage disassembled parts, identify the parts to be replaced from among all the parts in the sensor assembly. normally, replace the sensor, filter, metal o- ring and the contact together at the same time. if required, also replace the u-shaped filter hold plate, bolts and the spring washers. bolt spring washer filter retainer filter sensor (cell) calibration gas tube contact o ring (metallic) u-shaped pipe figure 65: parts in a sensor assembly free datasheet http://www.datasheetlist.com/
inspection and maintenance im 11m6a2-yia page 138 2) remove the bolts from the back of the detector probe, together with the washers. 3) remove the filter hold plate with the u-shaped pipe. at this point, the filter can also be separated from the detector probe. 4) remove the sensor and the metal o-ring (embedded in a groove on the flange surface of the sensor). pull the sensor out by twisting it slightly. 5) remove the contact using tweezers to pull it out of the groove. 6) if you can use any of the parts from among those removed, clean them with solvent to remove any contaminants adhering to them. also, clean the parts used for mounting the detector probe, as they may also be soiled with the measurement gas. 7) the parts are to be assembled sequentially. first, replace the contact. being careful not to cause irregularities in the pitch of the coil spirals (i.e., not to bend the coil out of shape), place it in the ringed groove so that it forms a solid contact. 8) next, set the metal o-ring in the o-ring groove on the flange surface of the sensor and then mount the sensor. to insert the sensor, turn it clockwise. after inserting it all the way to its base, adjust its position so that the u-shaped pipe insertion holes of the sensor and of the probe are properly aligned. 9) replace the filter, the filter hold plate and the u-shaped pipe. to mount the u-shaped pipe, attach the pipe to the filter hold plate and then insert the assembly into the u-shaped pipe insertion hole. in addition, mount the filter with the fine-meshed ring-shaped element side facing and forming a contact with the sensor. 10) attach the reassembled parts with the four bolts. coat the threads of the bolts with a heat- resistant agent (such as never seize) and then screw then in along with the washers. tighten all four bolts with a torque of about 60 kgf ? cm (52 in ? lb). the work of replacing the sensor assembly is now complete. mount the detector and restart the operation. however, be sure to calibrate the instrument before beginning a measurement. 9.1.5 cleaning the high t emperature pr obe adapter the high-temperature detector is structured so that the gas to be measured is directed toward the detector with a high-temperature probe adapter. therefore, if the probe or the sample gas outlet clogs, a precise measurement is no longer possible because of no gas flow. therefore, if a high-temperature detector is used you must inspect it periodically and, if any part of it is significantly clogged with dust, clean it. dust sticking to the probe should be blown off. if any dust still remains after blowing, clean it with a metal rod. in addition, if dust is found on the auxiliary ejector at the sample gas outlet, remove these parts from the high-temperature probe adapter and then clean them. to remove dust, blow them with air or rinse them with water. if the ejector is plugged, replace it with a new ejector. if the transport tube is clogged, remove particulates with a metal rod. 9.2 i nspection and m aintenance of the c onverter you need not inspect or perform maintenance work on the converter daily or periodically. if the converter fails to work properly, check for the correct input voltage or a brown fuse. free datasheet http://www.datasheetlist.com/
inspection and maintenance im 11m6a2-yia page 139 9.2.1 replacing fuses the converter incorporates a total of four fuses: two for the detector heater and two for the electric circuit in the converter. if any fuse burns out, replace it in the following manner. however, it is recommended that the fuses for the detector heater (f1, f2) be replaced every two years even if they are not burned out. note: if a replaced fuse blows out immediately, a problem may exist in the circuit. completely go over the circuit to find out why the fuse blew. main switch f1, f2 fuses f3, f4 fuses (inside of cover) when converter for 100 to 115 v power when converter for 200 to 240 v power (inside of cover) f3, f4 fuses main switch f1, f2 fuses figure 66: positions for installing fuses in a converter ?replacement of detector heater fuses (f1, f2) the location of the fuse and power switch is different in converters for a 115 v series power supply than for a 220 v series power supply. replace the fuses for the detector heater in the following manner: 1) turn off the power to the converter for safe replacement work. 2) remove the fuses from the fuse holders. for 115 v series power converters, turn the fuse holder cap 90o counterclockwise using a flat blade screwdriver that just fits the holder cap slot. in this state, the fuse can be pulled out together with the cap. for 220 v series power converters, the use of a tool is not necessary. 3) after checking that the new fuse has the specified rating (3 a), place this new fuse (cartridge glass-tube fuse) in the holder. in 100 v series power converters, insert the fuse into the cap and then both into the holder. turn the cap 90o clockwise while pushing it at the same time with a flat blade screwdriver. free datasheet http://www.datasheetlist.com/
inspection and maintenance im 11m6a2-yia page 140 ?replacing the fuse (f3, f4) to protect the electric circuit in a converter 1) turn off the main switch of the converter to maintain safety while replacing the fuse. 2) remove the fuse. fuses f3, f4 are cartridge socket types in which two prongs of the fuse are inserted into the socket on the printed circuit board. if you cannot remove fuses f3, f4 easily with your hand, use a tool such as a long nose or needle nose pliers. 3) check the new fuse for the specified rating (0.2 a) before installing it. hold the body of the fuse gently with a pair of pliers and fully insert the two prongs into the socket on the printed circuit board. be careful not to bend the prongs during installation (otherwise, the fuse may be damaged). 9.2.2 replacing the message display unit the dot matrix lcd, incorporated in the message display unit, should provide long term operation. however, over time, the performance deteriorates gradually and unavoidably (i.e., giving ambiguous readouts, etc.). if the readout on the display becomes unreadable, replace the lcd assembly. free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 141 x. troubleshooting this chapter describes the checking and restoring methods when the ZA8c converter self-diagnosis function detected errors or other troubles occur. 10.1 e rror c ode d escriptions 10.1.1 types of error codes there are nine types of error that can be detected with the self-diagnostics function of the ZA8c converter. when these errors occur (except for digital circuit failures), the corresponding error codes are displayed in the data display. in the lcd display, error messages are also displayed. in addition, if more than one error occurs simultaneously, the letter ?h? is also displayed in the lower right corner of the lcd display. in this case, by selecting the displayed message using the auxiliary message display key ?help?, suggested causes of the error are displayed. error code error detail error status e--1 sensor (cell) error goes into f ail mode, automatically turning off the pow er supply to the detector heater. e--2 sensor temp "low" goes into f ail mode, automatically turning off the pow er supply to the detector heater. e--3 sensor temp "high" goes into f ail mode, automatically turning off the pow er supply to the detector heater. e--4 a/d (analog circuit) error goes into f ail mode, automatically turning off the pow er supply to the detector heater. e--5 calibration value "zero" (displayed during calibration) the present zero point calibration value is not aff ected. e--6 calibration value "span" (displayed during calibration) the present zero point calibration value is not aff ected. e--7 start pow er s tability time over (displayed during calibration) the present zero point calibration value is not aff ected. e--8 rom, ram error goes into f ail mode, automatically turning off the pow er supply to the detector heater. ooo (display erased) digital circuit error pow er failure goes into f ail mode, automatically turning off the pow er supply to the detector heater. (displayed upon restart af ter remedying the pow er f ailure). data values def ault. table 20: error codes, their contents and status when each error occurs errors displayed with error code ?e?5?, ?e?6?, or ?e?7? are those generated in carrying out automatic or semi-automatic calibration. if these errors occur, that error code and oxygen concentration valve are alternately displayed in the data display. the error is released when the analyzer returns to the measurement mode and, at the same time, the error code display disappears. the error message display is cleared by pressing the measurement mode select key ?disp?. free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 142 note: re-calibration after an error occurred should be performed after examining that set points and piping conditions are not improper. errors displayed with error code ?e?1?, ?e?2?, ?e?3?, ?e?4?, or ?e?8? including digital circuit failure are caused by equipment failures. if these errors occur, the converter stops the supply of power to the detector heater and holds the output signal at the value immediately before the error occurrence (preset value if ?2? is set with function no. d-2). when these errors occur, turn off the converter power and begin restoration. the error code display is released after the equipment is restored and operates normally. 10.1.2 causes of ?e?1 sensor (cell) failure? and procedure for restoration ?causes 1) failure in wiring between the converter and the detector (poor contact of terminal connec- tions, disconnection, etc.) 2) sensor (cell) assembly failure (damage, deterioration) 3) failure in the sensor (cell) assembly mounting part (poor continuity between the sensor electrode and the contact, etc.) 4) wiring system failure inside the detector (disconnection, etc.) is an error displayed? turn off the power to the converter end. set temporary data. replace the wiring cables. is the sensor extremely dirty, corrosive, or damaged? the analyzer operates properly. yes yes yes yes yes no no no no no no yes temporarily operate the analyzer by mounting the spare sensor assembly. is there any breakage or poor contact in wiring to the converter terminals? is there any place of disconnection or poor continuity in wiring between the converter and detector? is there any breakage or poor contact in wiring to the detector terminals? *remove the wiring conductors from detector terminals 1 and 2 and short the conductors removed. measure the resistance of this conductor on the converter side. resistance value is normal if it indicates 10 ohms or less. *examine the wiring connection to converter terminals 3 and 4. if the repeater terminal box is used, also check wiring connection there. replace the damaged parts. replace the damaged parts. *examine the wiring connection to detector terminals 1 and 2. also check that terminals and cable conductors are not corroded. *remove the sensor assembly from the detector and check for any corrosion that may cause poor contact between the electrode and contact. sensor assemblies with no failure may be used again replace the sensor assembly. *turn on the power switch to put the analyzer in operation. inside of the converter or detector is suspected of failure. contact yokogawa. free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 143 10.1.3 causes of ?e?2 sensor t emperature error (low)? and procedure for restoration this error occurs when the sensor temperature after warm-up (in steady state operation) is lower than 730oc (1346of). ?causes 1) fuse (f1 and/or f2) for the detector heater in the converter is blown. 2) failure in wiring between the converter and the detector (poor contact of terminal connec- tions, disconnection, short circuiting, etc.). 3) failure of sensor for cold junction compensation at the detector terminal board (poor contact in terminal connections, or failure). 4) failure of thermocouple in the detector (disconnection, short circuiting in wiring inside the detector). 5) failure of the heater inside the detector (disconnection, etc.). 6) electronic circuit failure inside the converter. turn off the power to the converter does the thermocouple in the detector fail? does the detector heater fail? is the error displayed? replace the cold junction compensating sensor. end. set temporary data. yes yes yes yes yes yes no no no does the cold junction compensating sensor fail? no no no *examine that the cold junction compensating sensor leadwires connected to wiring terminals 7 and 8 in the detector are not disconnected. if the cold junction compensating sensor is normal, the voltage across terminals 7 and 8 is about 0.4 to 0.7 v (varies with ambient temperatures). *remove the wiring to converter terminals 5 and 6 and measure resistance between these leadwires. if it is 15 ohms or lower, it is normal. in addition, lead resistances between the converter and detector are normal if they are 10 ohms or less. *examine the wiring connection to detector terminals 3, 4, 5, 6, 7 and 8. check if the terminal and cable conductors are not corroded. also check that wiring is not short circuited between the converter and detector. *examine fuses (f1 and f2) for the detector heater regardless of appearance. check wiring connections to converter terminals 5, 6, 7, 8, 16 and 17. if the repeater terminal box is used, also check the connections inside the box. is there any breakage or poor contact in wiring to the converter terminals? is there any breakage or poor contact in wiring to the detector terminals? *temporarily operate the converter by turning its power switch. *remove wiring to the converter terminals 16 and 17 and measure resistance between these leadwires. if it is 90 ohms or lower, it is normal. in addition, lead resistances between the converter and detector are normal if they are 10 ohms or less. replace the damaged parts. replace the damaged parts. as it cannot be restored, replace the detector. as it cannot be restored, replace the detector. the electronic circuit in the converter may possibly be failed. contact yokogawa. free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 144 10.1.4 causes of ?e?3 sensor t emperature error (high)? and procedure for restoration this error occurs when the converter detects that the sensor temperature is higher than 780oc (1486of). it also occurs if the converter detects failure of the heater circuit and temperature measuring and controlling circuit during warm-up. ?causes if the error code is displayed in steady state operation, the following are considered as the possible causes: 1) cold junction compensating sensor failure at the detector terminal board. 2) failure of thermocouple in the detector. 3) failure of electronic circuits in the converter. next, if the error code is displayed during warm-up, the following are considered as the possible causes: 1) fuses (f1 and/or f2) in the converter for the detector heater are blown. 2) wiring failure between the converter and the detector (poor contact at the terminal connec- tions, disconnection, short circuiting, etc.). 3) failure of the heater in the detector (disconnection, etc.). free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 145 turn off the power to the converter does the thermocouple in the detector fail? is the error displayed? replace the cold junction compensating sensor. end. set temporary data. yes yes yes yes yes yes no no no does the cold junction compensating sensor fail? no no no is there any breakage or poor contact in wiring to the converter terminals? ** ** does the detector heater fail? ** is there any breakage or poor contact in wiring to the detector terminals? *examine fuses (f1 and f2) for the detector heater regardless of appearance. check wiring connections to converter terminals 5, 6, 7, 8, 16 and 17. if the repeater terminal box is used, also check the connections inside the box. *examine the wiring connection to detector terminals 3, 4, 5, 6, 7 and 8. check if the terminal and cable conductors are not corroded. also check that wiring is not short circuited between the converter and detector. *remove the wiring to converter terminals 5 and 6 and measure resistance between these leadwires. if it is 15 ohms or lower, it is normal. in addition, lead resistances between the converter and detector are normal if they are 10 ohms or less. *examine that the cold junction compensating sensor leadwires connected to wiring terminals 7 and 8 in the detector are not disconnected. if the cold junction compensating sensor is normal, the voltage across terminals 7 and 8 is about 0.4 to 0.7 v (varies with ambient temperatures). *temporarily operate the converter by turning its power switch. note: items marked with ** should be checked when the error occurs during warm-up. replace the damaged parts. replace the damaged parts. as it cannot be restored, replace the detector. *remove wiring to the converter terminals 16 and 17 and measure resistance between these leadwires. if it is 90 ohms or lower, it is normal. in addition, lead resistances between the converter and detector are normal if they are 10 ohms or less. as it cannot be restored, replace the detector. the electronic circuit in the converter may possibly be failed. contact yokogawa. free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 146 10.1.5 causes of ?e?4 a/d (analog cir cuit) failure? and procedure for restoration this error occurs when the electric circuit of the converter does not operate normally. ?causes 1) the analog circuits of the converter contains a failure. 2) the supply voltage significantly drops (15% or more of the rating). ?locating the failures and measures turn the converter power switch off and back on again. next, check to see if operation is normal. if operation is normal, the error is considered to be caused by temporary failure of the power system, such as voltage drop or influence of noise. if the cause is clear, take suitable measures to prevent reoccurrence of the same problem. if the error occurs again, it may be caused by the converter?s electric circuits, such as a cpu card. in this case, it is not as easy to locate and restore the failed part. if the error occurs again, contact yokogawa industrial automation. however, first confirm by checking the power supply that the power system is not at fault. 10.1.6 causes of ?e?5 calibration v alue error (zero)? and procedure for restoration this error occurs when the zero point correction factor exceeds the range 100 30% in the automatic and semi-automatic calibrations. ?causes 1) the oxygen concentration of zero gas and the value set with function no. c-1 do not agree or the span gas is accidentally used as the zero gas. 2) the zero gas does not flow by the specified quantity (about 600 ml/min). 3) the sensor (cell) is damaged and the cell emf contains an error. ?locating the cause of failure and taking measures 1) to make sure, carry out the calibration once more. before calibration, examine the following. if they are not in normal state, correct them. ?does the value set in the function no. c-1 agree with the zero gas oxygen concentration? ?does the calibration gas tubing have measures to no zero gas leakage? 2) if the error does not occur in re-calibration, it is considered as the cause of the error in the first calibration that the calibrating conditions were not proper. in this case, no particular restoration is necessary. restart the steady state operation. if the error also occurs in re-calibration, it is considered as the cause of error occurrence that the sensor is deteriorated or is damaged. confirm that the error corresponds to one or more of the following phenomena and replace it with a new sensor (see 10.1.4). ?when zero gas is passed, the sensor (cell) emf indicated with function no. a-3 greatly differs from the theoretical value in that oxygen concentration. ?when three kinds of gas (zero gas, span gas, and the gas having approximately middle oxygen concentration between the above two) are measured, correlation cannot be found in these measured data for oxygen concentration. free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 147 in addition, check the sensor deterioration for damage which caused the error occurrence whether or not it abruptly occurs by the following phenomena. if abrupt occurrence may be suspected, check the check valve located at the inlet of detector calibration gases whether or not the valve has failed. check valve failure causes condensed water in the calibration gas tubing, which is the cause of sensor breakage. ?examine historical data of the zero point correction factor displayed with function no. b-1. permissible range of the zero point correction factor is 100 30%. ?examine the sensor (cell) internal resistance displayed with function no. b-3. a new sensor shows the value of 200 ohms or less. while the dissipated sensor approaching to the end of the life indicates the value of 3 to 10 k ohms. ?examine the sensor integrity data (five grade evaluation of five to one) displayed with function no. b-4. a sensor in good state shows ?5?. 10.1.7 causes of ?e?6 calibration v alue error (span)? and procedure for restoration this error occurs when the span point correction factor exceeds the range 0 18% in the automatic and semi-automatic calibrations. ?causes 1) the oxygen concentration of span gas and the value set with function no. c-0 do not agree or the zero gas is accidentally used as the span gas. 2) the span gas does not flow by the specified quantity (about 600 ml/min). 3) the sensor (cell) is damaged and the cell emf contains an error. ?locating the cause of failure and taking measures 1) to make sure, carry out the calibration once more. before calibration, examine the following. if they are not in normal state, correct them. ?does the value set in the function no. c-0 agree with the span gas oxygen concentration? ?is there a leak in the span gas tubing or connections? 2) if the error does not occur in re-calibration, it is considered as the cause of the error in the first calibration that the calibration conditions were not proper. in this case, no particular restoration is necessary. restart the steady state operation. if the error also occurs in re-calibration, it is considered as the cause of error occurrence that the sensor has deteriorated or is damaged. confirm that the error corresponds to one or more of the following phenomena and replace it with a new sensor (see section 10.1.4). 1) when span gas is passed, the sensor (cell) emf indicated with function no. a-3 greatly differs from the theoretical value in that oxygen concentration. 2) when three kinds of gas (zero gas, span gas, and the gas having approximately middle oxygen concentration between the above two) are measured, correlation cannot be found in these measured data for oxygen concentration. in addition, check the sensor deteriora- tion or damage which caused the error occurrence may be suspected, check the check valve located at the inlet of the detector calibration gases whether or not the valve has failed. check valve failure causes condensed water in the calibration gas tubing, which is the cause of sensor breakage. ?examine historical data of the span point correction factor displayed with function no. b-0. permissible range of the span point correction factor is 0 18%. ?examine the sensor (cell) internal resistance displayed with function no. b-3. a new sensor shows the value of 200 ohms or less. free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 148 3) while the displayed sensor approaching to the end of the life indicates the value of 3 to 10 k ohms. ?examine the sensor integrity data (five grade evaluation five to one) displayed with function no. b-4. a sensor in good state shows ?5?. 10.1.8 causes of ?e?7 emf s tabilization time over? and procedure for restoration this error occurs when the sensor (cell) emf is not stabilized even if the calibration time is over because the sensor part of the detector is not filled with calibration gas (zero and span gases) at the one-touch calibration. ?causes 1) flow of the calibration gas is small (specified flow: about 600 ml/min). 2) measuring gas flows toward the tip of the detector probe. 3) sensor (cell) response is deteriorated. ?locating the cause of failure and taking measures 1) examine the setting time with function no. c-4 whether or not it is suitable. if not suitable, modify the setpoint and perform re-calibration again. carry out re-calibration after confirming that the tubing does not leak and flowing calibration gas by the specified rate (about 600 ml/min). 2) when calibration is normally carried out, continue the steady state operation. if the error occurs again, replace the sensor assembly after checking that whether or not the error corresponds to the following. ?dust significantly sticks to the detector probe tip. if dust sticks, clean it (see chapter 10). if the error occurs in calibration even after the sensor assembly is replaced, influence of measuring gas flow is considered as the cause. if this occurs, stop the measuring gas form flowing toward the detector probe tip by changing the mounting position of the detector. 10.1.9 causes of ?e?8 rom and ram failure? and procedure for restoration this error occurs when rom contents reading and/or writing memory to ram are not possible. ?causes 1) rom and ram pins are not fully inserted into the socket. 2) high supply voltages exceeding the specifications are applied or the effect of noise is given to rom and ram. 3) rom and/or ram failed. 4) failure occurred in digital circuits on the cpu board and others. ?locating the cause of failure and taking measures turn off the converter power switch. after confirming that the supply voltage satisfies the specification, turn on the power switch again to operate the converter. if the error repeats, repair is necessary. contact yokogawa industrial automation. 10.1.10 causes of display disappearance (data display) and pr ocedure for restoration operation of the converter digital circuits is being self-checked with the watchdog timer (wdt) or clock monitor. free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 149 this error occurs when power is turned on again after power supply to the converter electrical circuit is interrupted due to power failure, when the electrical circuit is interrupted due to power failure, or when the converter digital circuits fail, such as time-up of the watchdog timer normally reset in a fixed period. in any case, if the error occurs, on-screen information in the data display disappears. next, measures when the error occurs due to the digital circuit operation failure will be described. ?causes 1) low supply voltages exceeding the specifications are applied or the effect of noise is given to digital circuits. 2) digital circuit failure. ?locating the cause of the failure and taking measures once the converter is turned off, the likelihood of explosion is eliminated. make sure the supply voltage satisfies the specification and then turn on the power switch on to begin operation of the converter. if the error occurs again, repair is necessary. contact yokogawa industrial automation. 10.2 measures when measured value shows an error when measured values are abnormal, the cause is not always due to instrument failure. there are many cases when the measuring gas itself is in an abnormal state or external causes, which disturb the instrument operation, exist. in this section, we present cases where measured values show the following phenomena: 1) the measured value is higher than the true value. 2) the measured value is lower than the true value. 3) the measured value sometimes show abnormal values. 10.2.1 measured value higher than true v alue ?causes and measures 1) the measuring gas pressure becomes higher. the measured oxygen concentration value x (vol% o 2 ) is expressed as shown below, when the measuring gas pressure is higher than that in calibration by d p (mm h 2 0). x=y [1 + ( d p/10336)] where y: measured oxygen concentration value at the same pressure as in calibration (vol% o 2 ). when an increment of the measured value by pressure change cannot be neglected, mea- sures must be taken. investigate the following points to perform improvement available in each process. ?is improvement in facility?s aspect available so that pressure change does not occur? ?is performing calibration available under the averaging measuring gas pressure (internal pressure of a furnace)? free datasheet http://www.datasheetlist.com/
troubleshooting im 11m6a2-yia page 150 2) moisture content in a reference gas changes (increase) greatly. when this error is not ignored, use a gas in which moisture content is constant such as instrument air in almost dry condition as a reference gas. in addition, change of moisture content in exhaust gas after combustion is also considered as a cause of error. however, normally this error is negligible. 3) calibration gas (span gas) is mixing into the detector due to leakage. if the span gas is mixing into the detector due to leakage for the reason of failure of the valve provided in the calibration gas tubing system, the measured value shows a value a little higher than normal. check valves in the calibration gas tubing system for leakage. for manual valves, check them after confirming that they are in a fully closed state. 4) the reference gas is mixing into the measuring gas and vice versa. since the difference between oxygen partial pressures on the sensor anode and cathode sides becomes smaller, the measured value shows a higher value. an error which does not appear as the error ?e?1? may occur in the sensor. visually inspect the sensor. if any crack is recognized, replace it with a new sensor assembly. 5) the fly ash filter is clogged with ash, and requires replacement. note: data such as cell integrity displayed with function no. b-4 should also be used for deciding sensor quality. 10.2.2 measured value lower than true v alue ?causes and measures 1) the measuring gas pressure becomes lower. where an increment of the measured value by pressure change cannot be neglected, follow the steps as described in subsection 10.1.1 (1). 2) moisture content in a reference gas changes (decreases) greatly. if air at the detector installation site is used for the reference gas, a large change of moisture in the air may cause an error in measured oxygen concentration value (vol% o 2 ). to correct this error, use a gas with little or no moisture content. another cause of error may be the sudden change in moisture content of the exhaust gas after combustion. however, normally this error is negligible. 3) calibration gas (zero gas) is mixed into the detector due to leakage. if zero gas leakage into the detector is the cause of failure, the measured value will show a value a lower than normal. check the valves in the calibration gas tubing system for leakage. for manual valves, check them after confirming that they are in fully closed state. 10.2.3 measured value sometimes show abnormal values ?causes and measures 1) noise is mixed into the converter from the detector output wiring. shield the wiring to eliminate noise mixing into the converter. 2) the converter is affected with noises from the power supply. insert the line filter in the power line. 3) the cell leads are incorrectly wired on the signal cable. 4) the calibration gas for zero gas may not correspond to the certified value listed on the cylinder. reprogram menu c-1 and calibrate the sensor. free datasheet http://www.datasheetlist.com/
sp are p arts im 11m6a2-yia page 151 xi. sp are p ar ts 1 1.1 model zo21d-l low tempera ture detect or with f lame a rrest or , c heck v al ve and f langes item part no. description 1 e7042ud *cell assembly kit 2 k9119en *cell parts (without cell) kit a y9512ru *bolt (12 mm) (5) b y9500su *washer (5) c e7042bq *pipe d e7042br plate e e7042ay filter assembly f g7048xl metal o-ring g e7042bs contact h e7042au cold junction i m1132kn check valve j e7042vg replacement filter for flame arrestor (does not include flame arrestor). e7042vp flame arrestor assembly note: *denotes typical spare part. free datasheet http://www.datasheetlist.com/
spare parts im 11m6a2-yia page 152 11.2 model zo21p a dapter t ee s pare p arts par t number description m1100hh adapter tee (zo21p-h) m1132fh adapter tee (zo21p-f) m1100hf plate m1133ft gasket (jis 5k32a) for zo21p-h, t, s or c m1132hp gasket (3" ansi) f or zo21p-f y9121bu nut y9120wu washer m1132ky bolt 11.3 ZA8c s pare p arts 1/4 fnpt (?60) 4 - ?0.63(?16.0) hole s on a 3.54 (89.9) dia bolt circle 3/4 fnpt 6.1 9.7 11.7 notes: 1. material is 316 sst, except for ansi flange which is 304 sst. 2. weight: 24.3 lbs(11 kg) (?114.3) 0.38(9.7) thk flange (193) (?228.6) 8 - ?0.75(4819.1) holes on a 7.50(190.5)dia bolt circle 0.94(23.8) thk flange 4" ansi 150# raised face flange (297) (246) ?2.4 (155) (2 places) [1.0m] 7.60 ?9.00 3.3ft ?4.50 free datasheet http://www.datasheetlist.com/
spare parts im 11m6a2-yia page 153 part no. description m1132zx dual stage regulator f or zero gas cylinders, 316l stainless steel, cga 580, and 3000 ps i inlet. m1133ar zero gas pressure sw itch, spdt 1/8 nptf. m1132kd ref erence air regulator m1132cg ref erence air gauge 0 -30 psi k9290ua pcb2 k9290uh lcd assembly k9290xc panel k9290xl cpu assembly (extended version) k9290xq cpu assembly (basic version) a1113ef fuse, 3a (in-line) (pkg. of 5) l9021ef fuse, 0.5a (plug-in) (pkg. of 5) l9811fp watertight glands (each) free datasheet http://www.datasheetlist.com/
appendix a im 11m6a2-yia appendix a. figures and tables a.1 f igures figure description page number figure 1 typical system configuration ............................................................................... 2 figure 2 ZA8c ..................................................................................................................... 4 figure 3 mc1 manual calibration unit ............................................................................ 10 figure 4 ac1 automatic calibration unit ......................................................................... 12 figure 5 zo21d-l standard detector ............................................................................... 14 figure 6 zo21d detector w/ tri clamp ........................................................................... 15 figure 7 zo21d-h high temperature detector w/150# jis flange and junction box ...... 18 figure 8 zo21d-h high temperature detector with junction box and flange ................. 19 figure 9 zo21p-h high temperature adapter tee ............................................................ 21 figure 10 zo21p-f high temperature adapter for the flame arrestor ............................. 21 figure 11 water eductor assembly ..................................................................................... 24 figure 12 auxiliary ejector assembly ................................................................................. 25 figure 13 pressure compensating oxygen detector ........................................................... 27 figure 14 probe protector .................................................................................................... 32 figure 15 probe support ...................................................................................................... 34 figure 16 check valve ......................................................................................................... 33 figure 17 filter and dust guard .......................................................................................... 34 figure 18 fly ash filter ....................................................................................................... 34 figure 19 wz.../qc or /qf ................................................................................................. 36 figure 20 zo21d.../a ......................................................................................................... 36 figure 21 probe insertion hole ............................................................................................ 39 figure 22 parts in sensor assembly .................................................................................... 41 figure 23 dust filter and guard .......................................................................................... 41 figure 24 fly ash filter ....................................................................................................... 42 figure 25 zo21d with probe support (zo21v) ................................................................. 43 figure 26 zo21d with probe protector (zo21r) ............................................................... 43 figure 27 zo21ph high temperature tee adapter ............................................................ 44 figure 28 installation into probe insertion hole ................................................................... 45 figure 29 zo21p high temperature adapter tee ............................................................... 46 figure 30 pipe mounting procedure .................................................................................... 48 figure 31 drilling mounting holes ...................................................................................... 48 figure 32 mounting to the wall ........................................................................................... 48 figure 33 panel cut dimensions ......................................................................................... 49 figure 34 mounting to the panel ......................................................................................... 49 figure 35 mc1 piping ......................................................................................................... 51 figure 36 ac1 piping .......................................................................................................... 53 figure 37 ac1 piping .......................................................................................................... 54 figure 38 ZA8c ................................................................................................................... 57 figure 39 power w iring ....................................................................................................... 58 figure 40 case ground w iring ............................................................................................ 59 figure 41 detector signal output -112of ( -80oc) or less ambient ..................................... 60 figure 42 detector signal output - between 176o and 302of (80o and 150oc) .................. 60 free datasheet http://www.datasheetlist.com/
appendix a im 11m6a2-yia figure 43 detector heater output - maximum 112of (80oc) ambient ................................ 61 figure 44 detector heater output - between 176o and 302of (80o and 150oc) .................. 61 figure 45 quick disconnect ................................................................................................ 62 figure 46 wiring for analog output ................................................................................... 62 figure 47 interconnect wiring for ac1 & ZA8c ................................................................ 63 figure 48 interconnect wiring for 220 v ac ZA8c & ac1 ............................................... 64 figure 49 contact output w iring ........................................................................................ 64 figure 50 ZA8c relational diagram .................................................................................. 66 figure 51 contact input w iring ........................................................................................... 66 figure 52 measurement gas temperature input ................................................................. 67 figure 53 oxygen concentration ......................................................................................... 89 figure 54 relationship between range and logarithmic output signal (4-20 madc) .......... 90 figure 55 span point correction ratio ................................................................................ 91 figure 56 calculation of response time ............................................................................... 92 figure 57 absolute humidity of air .................................................................................. 114 figure 58 wiring of rs-232c communications cable ..................................................... 119 figure 59 connections for rs-422a communications ...................................................... 120 figure 60 connections for rs-422a communications (when using an i/o isolating computer) ... 120 figure 61 o2 concentration in measurement gas vs cell voltage (21.0% o 2 equivalent) ...... 130 figure 62 calculation of a calibration curve and correction factor in a 2-point calibration using zero and span gases .............................................................................. 131 figure 63 calculation of a calibration curve and correction factor in a 1-point calibration using a span gas .............................................................................................. 132 figure 64 cleaning of calibration gas tube ..................................................................... 138 figure 65 parts in a sensor assembly ............................................................................... 138 figure 66 positions for installing fuses in a converter ...................................................... 140 a.2 t ables table 1 approximate weight of zo21d detector w/4", 150# ansi flange ..................... 15 table 2 material reference chart for transport t ubes ................................................... 22 table 3 probe lengths and weights for zo21dw ............................................................ 28 table 4 zo21dw accessories ......................................................................................... 29 table 5 length and weight of zo21r-l probe protector w/4", 150# ansi flange ........ 31 table 6 quick disconnect cable specifications ............................................................... 38 table 7 mounting parts required ...................................................................................... 40 table 8 piping ................................................................................................................... 52 table 9 wiring channels .................................................................................................. 57 table 10 specifications of signal and heater cables ........................................................ 59 table 11 contact states classified with relay operation and types of contact .............. 65 table 12 contact input on/off electrical parameters .................................................... 66 table 13 diagnostic values ................................................................................................ 74 table 14 configurable items and their defaults ............................................................... 97 table 15 various values and fuels ................................................................................... 112 table 16 error codes, details and s tatus ........................................................................ 116 table 17 example of items for periodic inspection ......................................................... 117 table 18 setup parameters for calibration ...................................................................... 118 table 19 communication specifications .......................................................................... 121 table 20 error codes, contents and s tatus ..................................................................... 141 free datasheet http://www.datasheetlist.com/

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