ADDENDUM TO OPERATING INSTRUCTIONS

ZIRKOR200
ZIRKOR Series
SIL Safety Manual
Sensor Intelligence.

Doc.-ID: 8023xxx/0000/V1-0/2018-08 | SICK

About this Manual
This Manual contains important information concerning the design, installation, commissioning, operation, maintenance and
troubleshooting. Safe work with the ZIRKOR200 requires the users to become familiar with all warnings, safety instructions and
maintenance aspects of this Manual.

Symbols used in this Manual

Important information as well as safety instructions are emphasized by symbols below. Make sure that all safety advice and warnings
are observed at all times.

Warning Consider following information

Follow all instructions in this Manual Draws attention to important information which
must be noted before execution

Warning of hot surface Info

Warns of danger of burns which could occur from Contains further detailed information
hot system parts

Caution
Warns of risks which can severely damage the Protective grounding
system or its components or functionality

The content of this Manual, including all written content, pictures and illustrations is protected by copyright.
Alterations and errors reserved.

Safety instructions

This system is operated with line voltage. An electric shock hazard will occur when covers are removed while line voltage is still
connected,.
Only well trained and authorized personnel are allowed to conduct work on this system. Personnel have to understand all
precautions, safety instructions, installation and maintenance instructions in this Manual. The trouble free and safe operation of this
system requires safe transportation, professional storage, installation, operation and maintenance. Furthermore, all local safety
requirements have to be considered.
This system may not be used in the vicinity of combustible gases as parts of the system may cause a risk of explosion.

Manufacturer

SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Tel.: +49 7641 469-0
Fax: +49 7641 469-1149
E-mail: [email protected]

ADDENDUM TO OPERATING INSTRUCTIONS | ZIRKOR200 8023368/V1-0/2018-09 | SICK

 Contents

Contents
1 System description 2
1.1 Intended use ........................................................ 2
1.2 Safety hazards ...................................................... 2
1.3 Disruption of the process ...................................... 2
1.4 Storage instructions .............................................. 2
1.5 General ................................................................ 4
1.6 Purpose of this manual ......................................... 4
1.7 Related documentation ......................................... 4

2 General safety instructions 5

2.1 Safety-instrumented system .................................. 5
2.2 Measuring principle .............................................. 5
2.3 Definition: SIL ....................................................... 5

3 Device-specific safety instructions 6

3.1 Safety function ..................................................... 6
3.2 Initial setup .......................................................... 6
3.3 Checking the safety function ................................. 6
3.4 Maintenance intervals .......................................... 6
3.5 Maintenance recommendation.............................. 7
3.6 Troubleshooting .................................................... 7

8023368/V1-0/2018-09 | SICK ADDENDUM TO OPERATING INSTRUCTIONS | ZIRKOR200 1

System description

1 System description
1.1 Intended use
Info

ZIRKOR200 analyzer systems are for measurement of the oxygen concentration in flue gases and other non-combustible
gases. For reasons of safety and the possibility of accidents, unauthorized conversions and
modifications of the system are prohibited.

Warning

The systems cannot be used to determine the oxygen concentration of combustible gases or in a location where
combustible gases are present as the measuring cell temperature of 800 °C could present an explosion hazard!

Info
The minimum concentration of O2 in flue gas should not be less than 0.5% under normal process conditions.
If the O2 concentration is regularly below 0.5%, we recommend the option of LL² (Long Life²) to protect the O2 sensor.

Caution
Under no circumstance should the measuring probe be directly connected to the 230 V main power supply, as this will
immediately severely damage the probe heater element!

1.2 Safety hazards

Warning of hot surface
During operation, the temperature of the probe filter head and of other parts exposed to flue gas is 150 °C – 800 °C
(302°F – 1472 °F). Direct contact with the hot parts when dismantling or maintenance will cause severe burns!

The probe may only be removed with heat-insulated gloves. Before removing the probe, always switch off the supply voltage
of the electronic system. After removal, store the probe in a safe, protected place and wait until it has cooled down below
35 °C (95 °F).

1.3 Disruption of the process

The analyzer system has to be kept in operation also in the event of the process being disrupted or if the plant is powered
off temporarily (e.g. at night or during the weekend). Frequently cooling down and heating up of the probe results in thermal
stress of the hot probe parts (heater, thermocouple and sensor) and shortens their service life. Responsibility will not be
accepted for resultant damage.

1.4 Storage instructions

Equipment and spares are to be stored in a dry and ventilated environment. Paint fumes, silicone sprays, etc. must be
avoided in the storage environment.

2 ADDENDUM TO OPERATING INSTRUCTIONS | ZIRKOR200 8023368/V1-0/2018-09 | SICK

 System description

Abbreviations

Abbreviation Full form Definition

SIL Safety integrity level Safety integrity level (SIL) is a relative level of risk-reduction provided
by a safety function, or to specify a target level of risk.
Based on the IEC 61508 standard, four discrete Safety Integrity
Levels (SIL 1 to SIL 4) are defined with SIL 4 the most dependable
and SIL 1 the least dependable

PFD Probability of Failure on Demand Probability of dangerous safety function failures occurring on
demand.
PFDavg Probability of Failure on Demand Average probability that a system will fail dangerously, and is not
average able to perform its safety function when required

PFH Probability of a dangerous Failure Probability of Failure per Hour for the safety function
per Hour
SFF Safe Failure Fraction Ratio of safe and dangerous detected failures to the total failure rate

λS Rate of safe failures Non-dangerous failures per hour

λSU Rate of safe undetected failures Undetected non-dangerous failures per hour

λSD Rate of safe detected failures Detected non-dangerous failures per hour

λD Rate of dangerous failures Dangerous failures per hour

λDU Rate of dangerous undetected Undetected dangerous failures per hour

failures
λDD Rate of dangerous detected Detected dangerous failures per hour
failures
DC Diagnostic Coverage of dangerous Diagnostic coverage: DC = λDD / (λDU + λDD)
failures
HFT Hardware Fault Tolerance Hardware fault tolerance: Capability of a functional unit to continue
the execution of the demanded function in case of faults or
deviations
MTBF Mean Time Between Failures Average time between two failures
MTTR Mean Time To Repair Average time between the occurrence of a failure in a device or
system and its repair
FIT Failure In Time 1 x 10-9 failures per hour
TI Test Interval between life testing of Time interval between the functional tests of the safety function
the safety function
XooYD X out of Y Voting (e.g. 1oo3) Classification and description of the safety-related system regarding
redundancy and the selection procedure used.
“Y“ indicates how often the safety function is carried out
(redundancy). “X“ determines how many channels must work
properly. Example (temperature measurement): 1oo2 architecture.
When one out of two temperature sensors reaches a defined limit
value, the safety-related system decides that the temperature limit
has to be considered as exceeded. In a system with a 1oo1
architecture, there is only one temperature sensor.
“D“ indicates that the system provides a diagnostic function.

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System description

1.5 General
The SIL certification covers the ZIRKOR200 with the capability of automatic calibration.

1.6 Purpose of this manual

This Manual contains information and instructions which are required when using ZIRKOR200 analyzers in a SIL
configuration and must be used by all relevant personnel.

1.7 Related documentation

This Manual covers the ZIRKOR200 analyzers as part of a safety function and must be used in in conjunction with the
relevant Installation and Operating Instructions of the respective analyzers.

4 ADDENDUM TO OPERATING INSTRUCTIONS | ZIRKOR200 8023368/V1-0/2018-09 | SICK

 General safety instructions

2 General safety instructions

2.1 Safety-instrumented system
Note

The ZIRKOR200 O2 analyzer system acts as part of a safety function.

2.2 Measuring principle

ZIRKOR200 O2 analyzer systems consists of an in-situ probe installed in a duct to measure non-combustible process gases
and of an electronic unit for voltage and gas supply, as well as for signal processing.
The oxygen sensor is at the tip of the probe and is regulated to 800 °C, and works on the zirconium oxide principle of
measurement. Here, an mV signal between the reference gas side of the sensor (inside, instrument air 20.95% O2) and the
measured gas side is measured, which depends logarithmically on the ratio of oxygen partial pressures on both sides of the
sensor.
The mV signal is converted according to the Nernst equation into oxygen partial pressure within the process gas, whereby
the O2 concentration is determined in the process gas. Gas-tight separation of reference air and process gas is of particular
importance.
The measured O2 value is converted to the isolated 4 … 20 mA analog output (NAMUR).

2.3 Definition: SIL

Four SIL levels are defined based on the IEC 61508 standard, SIL 4 being the most dependable and SIL 1 the least
dependable. A SIL is determined based on a number of quantitative factors in combination with qualitative factors such as
development process and safety life cycle management.
The achievable SIL is determined by the following safety characteristics:
• Average probability of dangerous failure of a safety function in case of demand (PFDAVG)
• Hardware fault tolerance (HFT)
• Safe failure fraction (SFF)
Description
The following Table shows the dependency of the SIL on the average probability of dangerous failures of a safety function
of the entire safety-instrumented system (PFDAVG). The Table covers “Low demand mode”, i.e. the safety function is
required a maximum of once per year on average.

SIL PFDAVG PFDAVG (power)

−1 −2
1 0.1 – 0.01 10 – 10
−2 −3
2 0.01 – 0.001 10 – 10
−3 −4
3 0.001 – 0.0001 10 – 10
−4 −5
4 0.0001 – 0.00001 10 – 10

Table 2-1 Safety Integrity Level

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Device-specific safety instructions

3 Device-specific safety instructions

3.1 Safety function
ZIRKOR200 analyzers are mainly used for user defined threshold monitoring. Only the analog output 4...20 mA (NAMUR) is
considered as the safety function. The dangerous failure is a deviation of the output current of ±2% full span.

3.2 Initial setup

After installation and commissioning in accordance with the Operating Instructions, make sure that the following are set
within the software menu:
Set the mA output type to 4 – 20 mA
SYS-MENU -> System configuration -> O2 measuring ranges -> mA output type -> 4 - 20 mA

Set automatic calibration at an interval of 3 days

SYS-MENU -> System configuration -> Calibration settings - > Auto.calibration -> ON
-> Calibration method -> O2 1-point
-> Start by -> Time
-> Interval (days) -> 3
Prevent changes to the settings
After commissioning the system, set a customized system code to prevent unauthorized changes to the settings.

Initial calibration after installation

Wait for the system to reach its operating temperature. Carry out an O2 two point calibration after
24 hours of operation in accordance with the Operating Instructions.
CAL-MENU -> 2-point calibration, O2

3.3 Checking the safety function

To check whether the analyzer enters a safe state in the event of a failure, carry out the following steps:
1 Take action to prevent a false trip e.g. Bypass the safety PLC
2 Access the connection terminal of the electronic unit according to the Operating Instructions
3 Disconnect the wire X4:12 (O2 sensor signal +) at the terminal
4 The error LED should be on after a short while and an error message should be present
5 Measure the mA output at terminal X5:17 A/B with a suitable ampere meter, the output should be 2 mA
± 0,05 mA.
6 Reconnect the wires and confirm the error message
7 Measure the mA output, while it is adjusted to the values 4 mA, 12 mA and 20 mA in the software
menu SYS-MENU -> System checks -> Check mA output. The measured value and setpoint should be in
the range of ± 0,05 mA.
8 Undo the PLC bypass or other measures taken in point 1

3.4 Maintenance intervals

In general, maintenance as well as the maintenance intervals always depend on the flue or process gas conditions in which
the probe is installed. Maintenance intervals may therefore vary between a few months up to a few years.
The biggest influencing factors are the presence of corrosive ingredients such as SO2 or HCl, a continuous reducing
atmosphere (reduced oxygen concentration, increased levels of combustibles) and the characteristics of the solid
components in the flue gas.
These may have the following effects: Severe chemical or mechanical damage to the probe, clogging of the filter element or
accelerated aging of the sensor. This may lead to a distortion of the measured values as well as an increase in the
response time, which can in turn lead to false process operation afterwards.
For this reason, a sensor check is recommended with test gas and test air every six months. If a significant deviation
between the values obtained and those presently anticipated, a 2-point calibration should be carried out. A visual
inspection of the probe, which includes cleaning of the filter element if necessary, should be conducted at least annually.
Notwithstanding these recommendations, the operator must define an appropriate maintenance interval which reflects the
criticality of the measurement and the process.

6 ADDENDUM TO OPERATING INSTRUCTIONS | ZIRKOR200 8023368/V1-0/2018-09 | SICK

 Device-specific safety instructions

3.5 Maintenance recommendation

Monthly 1/2 year Yearly

Visual examination
Check for plausible measured values X X X
Visual check electronic unit, sensor, cables and hoses for external X
damage.

Electronic unit
Check sensor values with test air and test gas (SIL safety
relevance) X X
Sensor calibration (If required) X X
Check mA and relay outputs (SIL safety relevance) X
Check for next required calibration of the HCU (ATEX only) X

Probe
Check, and if necessary clean the probe and filter head X
Check the probe for corrosion (flange process side) X

System
Check safety function (SIL safety relevance) X X
Log all work carried out incl. measurement values X X
Complete Service Report and Log Sheet X X

3.6 Troubleshooting
In case of failed tests of the safety function, refer to the Troubleshooting Section of the Operating Instructions.
Contact the manufacturer for support or repairs if necessary.

8023368/V1-0/2018-09 | SICK ADDENDUM TO OPERATING INSTRUCTIONS | ZIRKOR200 7

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SICK AG | Waldkirch | Germany | www.sick.com