YOKOGAWA ZR402G, ZR22A, ZR202G, ZR202A, ZR22G User Manual

User ’s
Manual

Model ZR202G
Integrated type Zirconia
Oxygen/Humidity Analyzer

IM 11M12A01-04E

IM 11M12A01-04E

11th Edition

u Introduction

Thank you for purchasing the ZR202G Integrated type Oxygen/Humidity Analyzer.

Please read the following respective documents before installing and using the ZR202G
Integrated type Oxygen/Humidity Analyzer.

The related documents are as follows.

General Specications

Contents Document number Note

Model ZR22G, ZR402G, and ZR202G
Direct In Situ Zirconia Oxygen Analyzers and High
Temperature Humidity Analyzers

* the “E” in the document number is the language code.

User’s Manual

Contents Document number Note

Model ZR202G
Integrated type Oxygen/Humidity Analyzer

Model ZR22A, ZR202A
Heater Assembly

Model EXAxt ZR Series
HART Protocol

* the “E” in the document number is the language code.

i

GS 11M12A01-01E

IM 11M12A01-04E (This manual)

IM 11M12A01-21E

IM 11M12A01-51E

An exclusive User’s Manual might be attached to the products whose sufx codes or option
codes contain the code “Z” (made to customers’ specications). Please read it along with this

manual.

The EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer is usually the Oxygen
Analyzer, but it is to the High Temperature Humidity Analyzer when the option code “/HS (Set for
Humidity Analyzer)” is selected.

In this manual, the Oxygen Analyzer is mainly listed. When there are not mentions such as “in the
case of Humidity Analyzer”, it becomes same as the Oxygen Analyzer.

The EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer has been developed for
combustion control in various industrial processes. There are several version of this analyzer so
you can select one that matches your application.

Optional accessories are also available to improve measurement accuracy and automate
calibration. An optimal control system can be realized by adding appropriate options.

This instruction manual describes almost all of the equipment related to the EXAxt ZR. You may
skip any section(s) regarding equipment which is not included in your system.

Regarding the HART Communication Protocol, refer to IM 11M12A01-51E.

IM 11M12A01-51E has been published as ‘’Model EXAxt ZR series HART protocol’’.

Regarding Separate type Zirconia Oxygen Analyzer, refer to IM 11M12A01-02E.

<Before using the equipment, please read any descriptions in this manual related to the
equipment and system that you have, on appropriate use and operation of the EXAxt ZR.>

No. IM 11M12A01-04E 11th Edition : Jul. 2017 (YK)
All Rights Reserved Copyright © 2000, Yokogawa Electric Corporation

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

Models and descriptions in this manual are listed below.

Models and descriptions in this manual

Model Product Name

ZR202G Integrated type Oxygen

ZO21R Probe protector ○ ○

ZH21B

ZA8F

ZR20H Automatic Calibration unit ○ ○ ○ ○

ZO21S Standard gas unit ○ ○ ○ ○

CMPL: Customer Maintenance Parts List

Analyzer

Dust protector (only for Humidity
analyzer)

Flow setting unit (for manual
calibration use)

Case Assembly for calibration

­gas cylinder (Part No. E7044KF)

Check valve (Part No.

­K9292DN, K9292DS)

Dust lter for the detector (Part

­No. K9471UA)

Dust guard protector (Part No.

­K9471UC)

Specication

○ ○ ○ ○ ○

○ ○

○ ○ ○

○ ○

○ ○

○ ○

○ ○

Description in this manual

Installation Operation

Maintenance

ii

CMPL

This manual consists of twelve chapters. Please refer to the reference chapters for installation,
operation and maintenance.

Table of Contents

Chapter Outline

1. Overview

2. Specications

3. Installation Installation method for each equipment A C

4. Piping

5. Wiring

6. Components

7. Startup

8. Detailed Data Setting Details of key operations and displays B C

9. Calibration

10. Other Functions Other functions described B C

11. Inspection and
Maintenance

12. Troubleshooting

CMPL (parts list) User replaceable parts list C B

A: Read and completely understand before operating the equipment.
B: Read before operating the equipment, and refer to it whenever necessary.
C: Recommended to read it at least once.

Equipment models and system

conguration examples
Standard specication, model code (or

part number), dimension drawing for each
equipment

Examples of piping in three standard system

congurations

Wiring procedures such as “Power supply
wiring”, “output signal wiring” or others

Major parts and function are described in
this manual

Basic procedure to start operation of EXAxt
ZR. Chapter 7 enables you to operate the
equipment immediately.

Describes the calibration procedure
required in the course of operation.

How to conduct maintenance of EXAxt
ZR and procedures for replacement of
deteriorated parts

This chapter describes measures to be
taken when an abnormal condition occurs.

Installation Operation

B C B

A B B

A C

A C

C B B

Relates to

Maintenance

A C

B C

B A

C A

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

n For the safe use of this equipment

WARNING

Be sure not to accidentally drop it. Handle safely to avoid injury.

Connect the power supply cord only after conrming that the supply voltage matches the rating of
this equipment. In addition, conrm that the power is switched off when connecting power supply.

Some sample gas is dangerous to people. When removing this equipment from the process line
for maintenance or other reasons, protect yourself from potential poisoning by using a protective
mask or ventilating the area well.

CAUTION

The cell (sensor) at the tip of the probe is made of ceramic (zirconia element). Do not drop the
equipment or subject it to pressure stress.

• Do NOT allow the sensor (probe tip) to make contact with anything when installing the

analyzer.

• Avoid any water dropping directly on the probe (sensor) of the analyzer when installing it.

• Check the calibration gas piping before introducing the calibration gas to ensure that there

is no leakage of the gas. If there is any leakage of the gas, the moisture drawn from the
sample gas may damage the sensor.

• The probe (especially at the tip) becomes very hot. Be sure to handle it with gloves.

iii

n NOTICE

l Specication check

When the instrument arrives, unpack the package with care and check that the instrument

has not been damaged during transportation. In addition, please check that the specication
matches the order, and required accessories are not missing. Specications can be
checked by the model codes on the nameplate. Refer to Chapter 2 Specications for the list

of model codes.

l Details on operation parameters

When the EXAxt ZR Separate type Oxygen Analyzer arrives at the user site, it will operate

based on the operation parameters (initial data) set before shipping from the factory.
Ensure that the initial data is suitable for the operation conditions before conducting
analysis. Where necessary, set the instrument parameters for appropriate operation.
For details of setting data, refer to chapters 7 to 10.
When user changes the operation parameter, it is recommended to note down the changed
setting data.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

u Safety Precautions

n Safety, Protection, and Modication of the Product

• In order to protect the system controlled by the product and the product itself and ensure

safe operation, observe the safety precautions described in this user’s manual. We assume
no liability for safety if users fail to observe these instructions when operating the product.

• If this instrument is used in a manner not specied in this user’s manual, the protection

provided by this instrument may be impaired.

• If any protection or safety circuit is required for the system controlled by the product or for

the product itself, prepare it separately.

• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter

simply referred to as YOKOGAWA) when replacing parts or consumables.

• Modication of the product is strictly prohibited.

• The following safety symbols are used on the product as well as in this manual.

WARNING

This symbol indicates that an operator must follow the instructions laid out in this manual in order
to avoid the risks, for the human body, of injury, electric shock, or fatalities. The manual describes
what special care the operator must take to avoid such risks.

iv

CAUTION

This symbol indicates that the operator must refer to the instructions in this manual in order to
prevent the instrument (hardware) or software from being damaged, or a system failure from
occurring.

CAUTION

This symbol gives information essential for understanding the operations and functions.

NOTE

This symbol indicates information that complements the present topic.

This symbol indicates Protective Ground Terminal.

This symbol indicates Function Ground Terminal. Do not use this terminal as the protective
ground terminal.

n Warning and Disclaimer

The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor
responsibility to any person or entity with respect to any direct or indirect loss or damage arising
from using the product or any defect of the product that YOKOGAWA can not predict in advance.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

n Notes on Handling User’s Manuals

• Please hand over the user’s manuals to your end users so that they can keep the user’s

manuals on hand for convenient reference.

• Please read the information thoroughly before using the product.

• The purpose of these user’s manuals is not to warrant that the product is well suited to any

particular purpose but rather to describe the functional details of the product.

• No part of the user’s manuals may be transferred or reproduced without prior written

consent from YOKOGAWA.

• YOKOGAWA reserves the right to make improvements in the user’s manuals and product at

any time, without notice or obligation.

• If you have any questions, or you nd mistakes or omissions in the user’s manuals, please

contact our sales representative or your local distributor.

n Drawing Conventions

Some drawings may be partially emphasized, simplied, or omitted, for the convenience of

description.

Some screen images depicted in the user’s manual may have different display positions or
character types (e.g., the upper / lower case). Also note that some of the images contained in this
user’s manual are display examples.

v

In the gure listed in this manual, the example of the oxygen analyzer is shown mainly.
In the case of the humidity analyzer, unit indication may be different. Please read it appropriately.

n Product Disposal

The instrument should be disposed of in accordance with local and national legislation/regulations.

n Trademark Acknowledgments

• All other company and product names mentioned in this user’s manual are trademarks or

registered trademarks of their respective companies.

• We do not use TM or ® mark to indicate those trademarks or registered trademarks in this

user’s manual.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

n Special descriptions in this manual

This manual indicates operation keys, displays and drawings on the product as follows:

l Operation keys, displays on the panel

Enclosed in [ ]. (Ex. “MODE” key)

(Ex. message display → “BASE”)

(Ex. data display → “102” lit, “102” ashing)

l Drawing for ashing

Indicated by gray characters (Flashing) (lit)

l Displays on the LCD display panel

Alphanumerics Alphanumerics AlphanumericsLED Display LED Display LED Display

vi

A

B

C

D

E

F

G

H

I

J

K

L

O

Q

W

N

P

R

S

T

U

V

Y

Z

0

1

2

3

4

5

6

7

8

9

M

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

u CE marking products

n Authorised Representative in EEA

The Authorised Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2,
3825 HD Amersfoort, The Netherlands).

n Identication Tag

This manual and the identication tag attached on packing box are essential parts of the product.

Keep them together in a safe place for future reference.

n Users

This product is designed to be used by a person with specialized knowledge.

n How to dispose the batteries:

This is an explanation about the EU Battery Directive. This directive is only valid in the EU.

Batteries are included in this product. Batteries incorporated into this product cannot be removed
by yourself. Dispose them together with this product.

vii

When you dispose this product in the EU, contact your local Yokogawa Europe B.V.ofce. Do not

dispose them as domestic household waste.

Battery type: Manganese dioxide lithium battery

Notice:

The symbol (see above) means they shall be sorted out and collected as ordained in the EU
Battery Directive.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

Blank Page

Model ZR202G
Integrated type
Oxygen/Humidity Analyzer

IM 11M12A01-04E 11th Edition

CONTENTS

u Introduction ....................................................................................................i

u Safety Precautions ......................................................................................iv

u CE marking products .................................................................................vii

1. Overview .................................................................................................... 1-1

1.1 < EXAxt ZR > System Conguration ............................................................... 1-1

1.1.1 System 1 ............................................................................................ 1-1

1.1.2 System 2 ............................................................................................ 1-2

1.1.3 System 3 ............................................................................................ 1-3

1.2 < EXAxt ZR > System Components ................................................................1-4

1.2.1 System Components ......................................................................... 1-4

1.2.2 Oxygen/Humidity Analyzer and Accessories ..................................... 1-4

Toc-1

2. Specications ........................................................................................... 2-1

2.1 General Specications ..................................................................................... 2-1

2.1.1 Standard Specications ..................................................................... 2-1

2.1.2 ZR202G Integrated type Zirconia Oxygen Analyzer ..........................2-2

2.1.3 ZO21R Probe Protector ..................................................................... 2-9

2.1.4 ZH21B Dust Protector ...................................................................... 2-10

2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit ................ 2-11

2.2.1 ZA8F Flow Setting Unit .................................................................... 2-11

2.2.2 ZR20H Automatic Calibration Unit ................................................... 2-14

2.3 ZO21S Standard Gas Unit .............................................................................. 2-16

2.4 Other Equipment ............................................................................................. 2-17

2.4.1 Dust Filter for Oxygen Analyzer (part no. K9471UA) ....................... 2-17

2.4.2 Dust Guard Protector (K9471UC) .................................................... 2-17

2.4.3 Stop Valve (part no. L9852CB or G7016XH) ................................... 2-18

2.4.4 Check Valve (part no. K9292DN or K9292DS) ................................ 2-18

2.4.5 Air Set ............................................................................................... 2-19

2.4.6 Zero Gas Cylinder (part no. G7001ZC) ........................................... 2-20

2.4.7 Pressure Regulator (G7013XF or G7014XF) for Gas Cylinder ....... 2-21

2.4.8 Case Assembly (E7044KF) for Calibration gas Cylinder ................. 2-21

2.4.9 ZR202A Heater Assembly ............................................................... 2-22

3. Installation ................................................................................................. 3-1

3.1 Installation of ZR202G Zirconia Oxygen/Humidity Analyzer ....................... 3-1

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

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3.1.1 Probe Insertion Hole .......................................................................... 3-1

3.1.2 Installation of the Probe ..................................................................... 3-2

3.1.3 Installation of the Dust Filter (K9471UA), Dust Guard Protector

(K9471UC) Probe Protector (ZO21R) ............................................... 3-2

3.1.4 Installation of ZH21B Dust Protector ................................................. 3-4

3.2 Installation of ZA8F Flow Setting Unit ............................................................ 3-5

3.3 Installation of ZR20H Automatic Calibration Unit ......................................... 3-6

3.4 Installation of the Case Assembly (E7044KF) for Calibration Gas Cylinder 3-7

3.5 Insulation Resistance Test ............................................................................... 3-8

4. Piping ......................................................................................................... 4-1

4.1 Piping for System 1 ........................................................................................... 4-1

4.1.1 Piping Parts for System 1 .................................................................. 4-2

4.1.2 Piping for the Calibration Gas ............................................................ 4-2

4.1.3 Piping for the Reference Gas............................................................. 4-2

4.2 Piping for System 2 ........................................................................................... 4-2

4.2.1 Piping Parts for System 2 .................................................................. 4-3

4.2.2 Piping for the Calibration Gas ............................................................ 4-3

4.2.3 Piping for the Reference Gas............................................................. 4-4

4.3 Piping for System 3 ........................................................................................... 4-4

4.4 Piping for the Oxygen Analyzer with Pressure Compensation ................... 4-6

4.4.1 Piping Parts for Oxygen Analyzer with Pressure Compensation ...... 4-8

4.4.2 Piping for the Calibration Gas ............................................................ 4-8

4.4.3 Piping for the Reference Gas............................................................. 4-8

5. Wiring ......................................................................................................... 5-1

5.1 General ............................................................................................................... 5-1

5.1.1 Terminals for the External Wiring ....................................................... 5-2

5.1.2 Wiring ................................................................................................. 5-2

5.1.3 Mounting of Cable Gland ................................................................... 5-3

5.2 Wiring for Analog Output ................................................................................. 5-3

5.2.1 Cable Specications .......................................................................... 5-4

5.2.2 Wiring Procedure ............................................................................... 5-4

5.3 Wiring Power and Ground Terminals ............................................................. 5-4

5.3.1 Wiring for Power Line ......................................................................... 5-4

5.3.2 Wiring for Ground Terminals .............................................................. 5-5

5.4 Wiring for Contact Output ................................................................................ 5-5

5.4.1 Cable Specications .......................................................................... 5-5

5.4.2 Wiring Procedure ............................................................................... 5-5

5.5 Wiring for Contact Input ................................................................................... 5-5

5.5.1 Cable Specications .......................................................................... 5-6

5.5.2 Wiring Procedure ............................................................................... 5-6

6. Components ............................................................................................. 6-1

6.1 ZR202G Zirconia Oxygen/Humisity Analyzer ................................................ 6-1

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

Toc-3

6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit ........................ 6-2

7. Startup ....................................................................................................... 7-1

7.1 Checking Piping and Wiring Connections ..................................................... 7-1

7.2 Valve Setup ........................................................................................................ 7-1

7.3 Supplying Power to Converter ........................................................................ 7-2

7.4 Operation of Infrared Switch ........................................................................... 7-2

7.4.1 Display and Switches ......................................................................... 7-2

7.4.2 Display Conguration ......................................................................... 7-4

7.4.3 Entering Parameter Code Selection Display ..................................... 7-5

7.4.4 Selecting Parameter Codes ............................................................... 7-6

7.4.5 Changing Set Values ......................................................................... 7-6

7.5 Conrmation of Equipment Type Setting ....................................................... 7-8

7.6 Selection of Measurement Gas ....................................................................... 7-9

7.7 Output Range Setting ....................................................................................... 7-9

7.7.1 Oxygen Analyzer -Minimum Current (4 mA) and Maximum Current (20

mA) Settings....................................................................................... 7-9

7.7.2 Output Range Setting ...................................................................... 7-11

7.7.3 Humidity Analyzer -Minimum Current (4 mA) and Maximum Current (20

mA) Settings..................................................................................... 7-11

7.8 Setting Display Item ........................................................................................ 7-12

7.8.1 Oxygen Analyzer - Setting Display Item ..........................................7-12

7.8.2 Humidity Analyzer - Setting Display Item ......................................... 7-13

7.9 Checking Current Loop .................................................................................. 7-13

7.10 Checking Contact I/O ......................................................................................7-14

7.10.1 Contact Output Check ..................................................................... 7-14

7.10.2 Checking Calibration Contact Output .............................................. 7-15

7.10.3 Checking Input Contacts .................................................................. 7-16

7.11 Calibration .......................................................................................................7-16

7.11.1 Calibration Setup .............................................................................7-16

7.11.2 Manual Calibration ........................................................................... 7-19

8. Detailed Data Setting ............................................................................... 8-1

8.1 Current Output Setting ..................................................................................... 8-1

8.1.1 Oxygen Analyzer_Current Output Setting ......................................... 8-1

8.1.2 Oxygen Analyzer_Analog Output Setting .......................................... 8-1

8.1.3 Setting Minimum Oxygen Concentration (at 4 mA) and Maximum Oxygen

Concentration (at 20 mA) ................................................................... 8-2

8.1.4 Minimum and Maximum Settings Corresponding to 4 mA and 20 mA 8-2

8.1.5 Input Ranges ...................................................................................... 8-2

8.1.6 Entering Output Damping Constants ................................................. 8-5

8.1.7 Selection of Output Mode .................................................................. 8-5

8.1.8 Default Values .................................................................................... 8-5

8.2 Output Hold Setting .......................................................................................... 8-5

8.2.1 Denition of Equipment Status .......................................................... 8-6

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

Toc-4

8.2.2 Preference Order of Output Hold Value ............................................. 8-7

8.2.3 Output Hold Setting ............................................................................ 8-7

8.2.4 Default Values .................................................................................... 8-7

8.3 Setting Alarms ................................................................................................... 8-8

8.3.1 Alarm Values ...................................................................................... 8-8

8.3.2 Alarm Output Actions ......................................................................... 8-8

8.3.3 Alarm Setting...................................................................................... 8-9

8.3.4 Default Values .................................................................................. 8-10

8.4 Output Contact Setup ..................................................................................... 8-10

8.4.1 Output Contact ................................................................................. 8-10

8.4.2 Setting Output Contact .................................................................... 8-11

8.4.3 Default Values .................................................................................. 8-12

8.5 Input Contact Settings .................................................................................... 8-12

8.5.1 Input Contact Functions ................................................................... 8-12

8.5.2 Setting Input Contact ....................................................................... 8-13

8.5.3 Default Values .................................................................................. 8-13

8.6 Other Settings .................................................................................................8-13

8.6.1 Setting the Date-and-Time ............................................................... 8-13

8.6.2 Setting Periods over which Average Values are Calculated and Periods

over which Maximum and Minimum Values Are Monitored.............8-14

8.6.3 Setting Fuels .................................................................................... 8-15

8.6.4 Setting Measurement Gas Temperature and Pressure ................... 8-19

8.6.5 Setting Purging ................................................................................ 8-20

9. Calibration ................................................................................................. 9-1

9.1 Calibration Briefs .............................................................................................. 9-1

9.1.1 Principle of Measurement with a zirconia oxygen analyzer .............. 9-1

9.1.2 Measurement Principle of Zirconia Humidity Analyzer ...................... 9-2

9.1.3 Calibration Gas .................................................................................. 9-4

9.1.4 Compensation .................................................................................... 9-4

9.1.5 Characteristic Data from a Sensor Measured During Calibration ..... 9-5

9.2 Calibration Procedures ....................................................................................9-6

9.2.1 Mode .................................................................................................. 9-6

9.2.2 Calibration Procedure ........................................................................ 9-6

9.2.3 Zero gas Concentration ..................................................................... 9-7

9.2.4 Span gas Concentration .................................................................... 9-7

9.2.5 Calibration Time ................................................................................. 9-7

9.3 Calibration ......................................................................................................... 9-9

9.3.1 Manual Calibration ............................................................................. 9-9

9.3.2 Semi-automatic Calibration ............................................................... 9-9

9.3.3 Automatic Calibration ....................................................................... 9-10

10. Other Functions ...................................................................................... 10-1

10.1 Detailed Display ..............................................................................................10-1

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

Toc-5

10.1.1 Oxygen Concentration ..................................................................... 10-2

10.1.2 Humidity ........................................................................................... 10-2

10.1.3 Mixing Ratio ..................................................................................... 10-2

10.1.4 Relative Humidity ............................................................................. 10-2

10.1.5 Dew Point ......................................................................................... 10-2

10.1.6 Air Ratio............................................................................................10-3

10.1.7 Cell Temperature .............................................................................. 10-3

10.1.8 Process Gas Temperature ............................................................... 10-3

10.1.9 C. J. Temperature............................................................................. 10-3

10.1.10 Amount of Water Vapor in Exhaust Gas .......................................... 10-3

10.1.11 Cell Voltage ...................................................................................... 10-4

10.1.12 Thermocouple Voltage ..................................................................... 10-4

10.1.13 Cold Junction Voltage ...................................................................... 10-4

10.1.14 Current Output .................................................................................10-4

10.1.15 Response Time ................................................................................ 10-4

10.1.16 Cell’s Internal Resistance ................................................................10-5

10.1.17 Robustness of a Cell ........................................................................ 10-5

10.1.18 Heater On-Time Ratio ...................................................................... 10-5

10.1.19

10.1.20 Maximum Oxygen Concentration, Humidity, and Mixing Ratio ...... 10-6

10.1.21 Minimum Oxygen Concentration, Humidity, and Mixing Ratio ........ 10-6

10.1.22 Average Oxygen Concentration, Humidity, and Mixing Ratio ......... 10-6

10.1.23 Span and Zero Correction Ratios .................................................... 10-6

10.1.24 History of Calibration Time ............................................................... 10-7

10.1.25 Time .................................................................................................10-7

10.1.26 Software Revision ............................................................................ 10-7

10.2 Operational Data Initialization ...................................................................... 10-7

10.3 Initialization Procedure .................................................................................. 10-8

10.4 Reset ................................................................................................................. 10-8

10.5 Handling of the ZO21S Standard Gas Unit .................................................10-21

10.5.1 Standard Gas Unit Component Identication ................................ 10-21

10.5.2 Installing Gas Cylinders ................................................................. 10-21

10.5.3 Calibration Gas Flow ......................................................................10-22

10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit ................... 10-23

10.6.1 Preparation Before Calibration ......................................................10-24

10.6.2 Operating the Span Gas Flow Setting Valve .................................10-24

10.6.3 Operating the Zero Gas Flow Setting Valve ..................................10-24

10.6.4 Treatment After Calibration ............................................................ 10-24

Oxygen Concentration (with time constant), Humidity (with time constant), and

Mixing Ratio (with time constant) ............................................................. 10-6

11. Inspection and Maintenance ................................................................. 11-1

11.1 Inspection and Maintenance of the Detector ............................................... 11-1

11.1.1 Cleaning the Calibration Gas Tube .................................................. 11-1

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

Toc-6

11.1.2 Replacing the Sensor Assembly ...................................................... 11-2

11.1.3 Replacement of the Heater Assembly ............................................. 11-4

11.1.4 Replacement of Dust Filter .............................................................. 11-6

11.1.5 Replacement of O-ring ..................................................................... 11-6

11.1.6 Stopping and Re-starting Operation ................................................ 11-7

11.2 Inspection and Maintenance of the Converter ............................................ 11-7

11.3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit .......... 11-9

12. Troubleshooting ..................................................................................... 12-1

12.1 Displays and Measures to Take When Errors Occur .................................. 12-1

12.1.1 What is an Error? ............................................................................. 12-1

12.1.2 Measures to Take When an Error Occurs ....................................... 12-2

12.2 Displays and Measures to Take When Alarms are Generated ................... 12-4

12.2.1 What is an Alarm? ............................................................................ 12-4

12.2.2 Measures Taken When Alarms are Generated ...............................12-4

12.3 Measures When Measured Value Shows an Error ...................................... 12-8

12.3.1

12.3.2

12.3.3 Measurements Sometimes Show Abnormal Values ..................... 12-10

Measured Value Higher (Lower for Humidity Analyzer) Than True Value

Measured Value Lower (Higher for Humidity Analyzer) Than True Value

.. 12-8

.. 12-9

Customer Maintenance Parts List ......................................CMPL 11M12A01-04E

Customer Maintenance Parts List ......................................CMPL 11M12A01-12E

Customer Maintenance Parts List ..........................................CMPL 11M3D1-01E

Revision Information ...............................................................................................i

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<1. Overview>

1. Overview

The EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer is used to monitor and
control the oxygen concentration in combustion gases, in boilers and industrial furnaces, for
wide application in industries which consume considerable energy-such as steel, electric power,
oil and petrochemical, ceramics, pulp and paper, food, or textiles, as well as incinerators and
medium/small boilers. It can help conserve energy in these industries. The EXAxt ZR also
contributes to preservation of the earth’s environment in preventing global warming and air
pollution by controlling complete combustion to reduce CO

The EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer integrates both probe and
converter. The analyzers need not use a sampling device, and allow direct installation of the

probe in the wall of a ue or furnace to measure the concentration of oxygen in the stack gas of

the temperature up to 700°C.

The EXAxt ZR Integrated-type Zirconia High-temperature Humidity Analyzer integrates
the detector and the converter in one unit. This analyzer can measure humidity of hot air
continuously, so can be used to measure humidity of air in driers which are heated by steam or

electricity. It can also be used in a variety of manufacturing applications with humidiers, as well

as with driers, for humidity measurement and control. It can help improve productivity in these

application elds.

The probe uses a high-reliability Zirconia sensor and a heater assembly that can be replaced on
site.

The analyzer is equipped with three infrared switches, which enable the user to operate the
equipment without opening the cover on site. Analyzer calibration can also be fully automated
and the automatic calibration unit is provided. Choose the equipment which best suits your needs
so that an optimal combustion control system can be obtained.

Some examples of typical system conguration are illustrated below:

, SOx and NOx.

2

1-1

1.1 < EXAxt ZR > System Conguration

The system conguration should be determined by the conditions; e.g. whether the calibration
is to be automated, and whether ammable gas is present and requires safety precautions. The
system conguration can be classied into three basic patterns as follows:

1.1.1 System 1

This is the simplest system consisting of an integrated type analyzer. This system can be
implemented for monitoring oxygen concentration in the combustion gases boiler, and can be
implemented for monitoring humidity in a production process such as food production.

No piping is required for the reference gas (air) which is fed in at the installation site. The ZO21S
standard gas unit is used for calibration.

Zero gas from this unit and span gas (air) is sent to the probe through a tube which is connected
during calibration.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<1. Overview>

ZR202G Integrated type
Zirconia Oxygen/Humidity Analyzer

1-2

Stop valve

Calibration gas

Figure1.1 Example of System 1

NOTE

• As this system uses ambient air for the reference gas, measuring accuracy will be affected

by the installation location.

• A stop valve should be connected to the calibration gas inlet of the equipment. The valve

should be fully closed unless calibration is in progress.

1.1.2 System 2

This system is for monitoring and controlling oxygen concentration in the combustion gases of
a large-size boiler or heating furnace. Instrument air (clean and dry air of oxygen concentration
21%) is used as the reference gas and the span gas for calibration. Zero gas is fed from a
cylinder during calibration.

In case of humidity analyzer, this system is for accurate monitoring and controlling humidity when
the installation environment is polluted with gases other than the air.

Instrument air (clean and dry air of oxygen concentration 21%) is used for the reference gas and
the span gas for calibration.

The gas ow is controlled by the ZA8F ow setting unit (for manual valve operation).

100 to 240 V AC

~

Contact input
Analog output, contact output

Digital output (HART)

ZO21S Standard gas unit

100/110/115
200/220/240 V AC

~

F1.1E.ai

ZR202G Integrated type
Zirconia Oxygen/Humidity Analyzer

Stop valve

or

Check valve

Reference gas

Calibration gas

Figure1.2 Example of System 2

100 to 240 V AC

~

Contact input

Analog output, contact output
Digital output (HART)

Flowmeter

ZA8F flow setting unit

Needle

valve

Air Set

Instrument air

Span gas(Same as Zero gas calibration)

Calibration

gas pressure

regulator

Calibration gas unit case

Zero gas cylinder

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

F1.2E.ai

<1. Overview>

1.1.3 System 3

This example, System 3, represents typical applications in large boilers and heating furnaces,
where is a need to monitor and control oxygen concentration. The reference gas and calibration­time span gas are (clean, dry) instrument air. Zero gas is supplied from a gas cylinder.

System 3 uses the ZR20H automatic calibration unit, with auto-switching of the calibration gas.

A “combustible gas detected” contact input turns off power to the heater. There’s also contact
output from the converter that can be used to operate a purge gas valve to supply air to the
sensor.

1-3

*2

Automatic calibration unit

ZR20H

Reference gas

Span gas

Calibration gas (Zero)

Note:
The installation temperature limits range for integrated type analyzer is -20 to 55°C.

*1 Shield cable:

Use shielded signal cables, and connect the shields to the FG terminal of the converter.

*2 Select the desired probe from the Probe Conguration table on page 1-4.

*3 When a zirconia oxygen analyzer is used, 100% N2 gas cannot be used as the zero gas.

Use approx. 1 vol% O

gas (N2-based).

2

ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer

with automatic calibration unit (ZR202G-

100 to 240 V AC

~

Calibration

gas pressure

regulator

*3

Calibration gas unit case

*1

Contact input
Analog output, contact output

Digital output (HART)

Air Set

Instrument air

Zero gas cylinder

Figure1.3 Example of System 3

□-□-□-A-□-□-□-□-A)

F1.3E.ai

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

<1. Overview>

1.2 < EXAxt ZR > System Components

1.2.1 System Components

1-4

System Components

Separate type

System cong.

Ex.1 Ex.2 Ex.3

Oxygen
Analyzer

Model ZR202G Integrated type Zirconia Oxygen Analyzers A A A A A
Model ZO21R Probe Protector for Zirconia Oxygen Analyzers B B B B
K9471UA Dust Filter for Oxygen Analyzer B B B B
K9471UC Dust Guard Protector B B B B B
ZH21B Dust protector (only for Humidity Analyzer) B B B B
Model ZO21S Standard Gas Unit A B B
Model ZA8F Flow Setting Unit for manual calibration A B B
Model ZR20H Automatic Calibration Unit for Integrated type Analyzer A B B
L9852CB, G7016XH Stop Valve for Calibration gas line A (A) B B
K9292DN,K9292DS Check Valve for Calibration gas line (A) B B
G7003XF/K9473XK, G7004XF/K9473XG Air Set A A B B
G7001ZC Zero gas Cylinder A A B B
G7013XF, G7014XF Pressure Reducing Valve for Gas Cylinder A A B B
E7044KF Case Assembly for Calibration gas Cylinder A A B B
Model ZR202A Heater Assembly (Spare Parts for ZR202G) B B B B B

A: Items required for the above system example
B: To be selected depending on each application. For details, refer to corresponding chapter.
(A): Select either

1.2.2 Oxygen/Humidity Analyzer and Accessories

Sample gas temperature 0 to 700°C

Mounting Insertion length

Horizontal

to

vertical

Vertical

Horizontal

to

vertical

Horizontal

to

vertical

Vertical

0.4
to

2 m

2.5 m

or more

3 m

or less

0.4

to

2 m

2.5 m

or more

General-use Probe

Dust protector

(ZH21B)

Humidity analyzer use

Probe Protector

(ZO21R)

Gas Flow

Sample inlet

Dust Filter

(K9471UA)

or

Dust Guard

Protector

(K9471UC)

ZR202G

Only

ZR22G-040

Detector
(ZR202G)

Detector(ZR202G)

+

Application

• Boiler

• Heating furnace

• For pulverized coal boiler with gas flow velocity

10 m/sec or more

• Cement Kiln

• Black liquid recovery boiler

• Cement Kiln

Humidity
Analyzer

F1.4E.ai

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

2. Specications

This chapter describes the specications for the following:

ZR202G General-use Integrated type Zirconia Oxygen Analyzer (See Section 2.1.2)

ZO21R-L Probe protector (See Section 2.1.3)

ZH21B Dust protector (See Section 2.1.4)

ZA8F Flow setting unit (See Section 2.2.1)

ZR20H Automatic calibration unit (See Section 2.2.2)

ZO21S Standard gas unit (See Section 2.3)

K9471UA Dust Filter for Oxygen Analyzer (See Section 2.4)

2.1 General Specications

2.1.1 Standard Specications

Measured Object: Oxygen concentration in combustion exhaust gas and mixed gas

(excluding inammable gases). May not be applicable corrosive gas

such as ammonia, chlorine is present-check with YOKOGAWA.)
(In case of Humidity Analyzer, Water vapor (in vol%) in mixed gases (air
and water vapor))

Measured System: Zirconia system

Measurement Range: 0.01 to 100 vol%O
(In case of Humidity Analyzer, 0 to 100 vol% H

Output Signal: 4 to 20 mA DC (maximum load resistance 550 Ω)

Setting Range: Any setting in the range of 0 to 5 through 0 to 100 vol%O

or partial range
In case of Humidity Analyzer,
Moisture quantity: 0 to 25 through 0 to 100 vol% H

Mixture ratio; 0 to 0.2 through 0 to 1.000 kg/kg (in 0.001 kg/kg), or

Digital Communication (HART): 250 to 550 Ω, depending on number of eld devices connected

to the loop (multi-drop mode).

Note: HART is a registered trademark of the HART Communication Foundation.

2

partial range.

partial range.

O or 0 to 1.000 kg/kg)

2

O (in 1 vol% H2O), or

2

2-1

(in 1 vol%O2),

2

Display Range: Oxygen concentration; 0 to 100 vol%O2

In case of Humidity Analyzer,

Moisture quantity; 0 to 100 vol% H

O, Mixture ratio; 0 to 1 kg/kg, Relative

2

humidity; 0 to 100% RH (Note), Dew point; -40 to 370°C (Note)

Note: These values are affected by temperature and absolute pressure, So accurate temperature

and pressure values must be inputted to the converter.

Warm-up Time: Approx. 20 min.

These characteristics are calculated by oxygen concentration measured in air which include
water vapor.

Repeatability: (Excluding the case where the reference gas is by natural convection)

±0.5% Maximum value of set range; less than 0 to 25 vol%O
±1% Maximum value of set range; 0 to 25 vol%O

or more and up

2

to 0 to 100 vol%O

range

2

range

2

In case of Humidity Analyzer, ± 1 vol% H2O; (Sample gas pressure 2

kPa or less)

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Linearity: (Excluding standard gas tolerance)

(Excluding the case where the reference gas is by natural convection)
(Use oxygen of known concentration (within the measuring range) as the
zero and span calibration gases.)

±1% Maximum value of set range;
less than 0 to 25 vol%O

range

2

(Sample gas pressure: within ±4.9 kPa)

±3% Maximum value of set range;
0 to 25 vol%O

or more and less than 0 to 50 vol%O2 range

2

(Sample gas pressure: within ±0.49 kPa)

±5% Maximum value of set range;
0 to 50 vol%O

or more and up to 0 to 100 vol%O2 range

2

(Sample gas pressure: within ±0.49 kPa)

In case of Humidity Analyzer,

± 2 vol% H
± 3 vol% H

O; (Sample gas pressure: within ± 0.49 kPa)

2

O; (Sample gas pressure: 2 kPa or less)

2

Drift: (Excluding the rst two weeks in use)

(Excluding the case where the reference gas is by natural convection.)
Both zero and span ±2% Maximum value of set range/month

In case of Humidity Analyzer,

Both zero and span ± 3 vol% H

O/month

2

Response Time: Response of 90% within 5 seconds. (Measured after gas is introduced

from calibration gas inlet and analog output start changing.)

2-2

Installation Altitude: 2000 m or less

Category based on IEC 61010: II (Note)

Pollution degree based on IEC 61010: 2 (Note)

Note: Installation category, called over-voltage category, species impulse withstand voltage. Category II is for electrical equipment.

Pollution degree indicates the degree of existence of solid, liquid, gas or other inclusions which may reduce dielectric strength.

Degree 2 is the normal indoor environment.

Safety, EMC and RoHS conforming standards the ZR202G

Safety: EN 61010-1, EN 61010-2-030, CAN/CSA-C22.2 No. 61010-1,

UL Std. No. 61010-1

EMC: EN 61326-1 Class A*, Table 2,
EN 61326-2-3, EN 61000-3-2

*: Inuence of immunity environment (Criteria A ): ±20% of F. S.

EMC Regulatory Arrangement in Australia and New Zealand (RCM)

EN61326-1 Class A

Korea Electromagnetic Conformity Standard

Note: This instrument is a Class A product, and it is designed for use in the industrial environment. Please use this

instrument in the industrial environment only.

RoHS: EN 50581

2.1.2 ZR202G Integrated type Zirconia Oxygen Analyzer

Can be operated in the eld without opening the cover using optical switches.

Display: 6-digit LCD

Switch: Three optical switches

Output Signal: 4 to 20 mA DC, one point (maximum load resistance 550 Ω)

Digital Communication (HART): 250 to 550 Ω, depending on quantity of eld devices connected

to the loop (multi-drop mode).

Contact Output Signal: Two points (one is fail-safe, normally open)

Contact Input Signal: Two points

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Sample Gas Temperature: 0 to 700°C

It is necessary to mount the cell using inconel cell-bolts when the
temperature is greater than 600°C.

High temperature service ― greater than 700°C ― is not

available.

Sample Gas Pressure: -5 to +250 kPa (When the pressure in the furnace exceeds 3 kPa, it is

recommended to use pressure compensated type. When the pressure in
the furnace exceeds 5 kPa, pressure compensated type is required.)

No pressure uctuation in the furnace should be allowed.

Note: When the detector is used in conjunction with a check valve and the ZA8F Flow Setting Unit, the maximum pressure of sample

gas is 150 kPa. When with a check valve and the ZR20H Automatic Calibration Unit, it is 200 kPa. If the pressure of your sample
gas exceeds these limits, consult with Yokogawa.

Probe Length: 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 m

Probe Material: SUS 316 (JIS)

Ambient Temperature: -20 to +55°C (- 5 to +70°C on the case surface)

Storage Temperature: -30 to +70°C

Humidity Range: 0 to 95%RH (non-condensing)

Power Supply Voltage: Ratings; 100 to 240 V AC
Acceptable range; 85 to 264 V AC

Power Supply Frequency: Ratings; 50/60 Hz
Acceptable range; 45 to 66 Hz

Power Consumption: Max. 300 W, approx. 100 W for ordinary use.

Reference Gas System: Natural Convection, Instrument Air, or Pressure Compensated

Instrument Air System (excluding Natural Convection):
Pressure; 200 kPa + the pressure inside the furnace (It is recommended to use air

which is dehumidied by cooling to dew point -20°C or less, and dust or

oil mist are removed.)

Consumption; Approx. 1Nl/min

Wetted Material: SUS 316 (JIS), Zirconia, SUS304 (JIS) or ASTM grade 304 (ange),

Hastelloy B, (Inconel 600, 601)

Construction: Heater and thermocouple replaceable construction. Non explosion-proof JIS

C0920 / equivalent to IP44D. Equivalent to NEMA 4X/IP66 (Achieved when the
cable entry is completely sealed with a cable gland in the recirculation pressure
compensated version.)

Gas Connection: Rc1/4 or 1/4NPT(F)

Wiring Connection: G1/2, Pg13.5, M20 x 1.5mm, 1/2NPT select one type (4 pieces)

Installation: Flange mounting

Probe Mounting Angle: Horizontal to vertically downward.

When the probe insertion length is 2 m or less, installing at angles from
horizontal to vertically downward is available.
When the probe insertion length is 2.5m or more, mount vertically
downward (within ± 5°), and if installing at angles from horizontal to
vertically downward (within ± 5°), use a probe protector.

Case: Aluminum alloy

Paint Color: Cover; Mint green (Munsell 5.6BG3.3/2.9)
Case; Mint green (Munsell 5.6BG3.3/2.9)

Finish: Polyurethane corrosion-resistance coating

Weight: Insertion length of 0.4m: approx. 8 kg (JIS 5K 65) / approx. 13 kg (ANSI 150 4)

Insertion length of 1.0m: approx. 10 kg (JIS 5K 65) / approx. 15 kg (ANSI 150 4)
Insertion length of 1.5m: approx. 12 kg (JIS 5K 65) / approx. 17 kg (ANSI 150 4)
Insertion length of 2.0m: approx. 14 kg (JIS 5K 65) / approx. 19 kg (ANSI 150 4)
Insertion length of 3.0m: approx. 17 kg (JIS 5K 65) / approx. 22 kg (ANSI 150 4)

2-3

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Functions (inclused Humidity Analyzer)

Display Function: Displays values of the measured oxygen concentration, moisture

quantity, mixture ratio, etc.

Alarm, Error Display: Displays alarms such as “AL-06” or errors such as “Err-01” when any

such status occurs.

Calibration Functions:

Automatic calibration; Requires the Automatic Calibration Unit. It calibrates

automatically at specied intervals.

Semi-auto Calibration; Requires the Automatic Calibration Unit. Input calibration start

signal by optical switch or contact, then it calibrates automatically
afterwards.

Manual Calibration; Calibration with opening/closing the valve of calibration gas in

operation interactively with the optical switch.

Maintenance Functions: Can operate updated data settings in daily operation and

checking. Display data settings, calibration data settings, test
settings (current output loop check, input/output contact check).

Setup Functions: Initial settings suit for the plant conditions when installing the converter.

Current output data settings, alarm data settings, contact data settings,
other settings.

Display and setting content:

Display Related Items: Oxygen concentration (vol% O

moisture quantity (in hot gases) (vol% H

), output current value (mA), air ratio,

2

O), mixture ratio(kg/kg), relative

2

humidity(%RH), dew point (°C), Cell temperature (°C ), thermocouple
reference junction temperature (°C ), maximum/minimum/average
oxygen concentration (vol% O
quantity (vol% H

O), maximum/minimum/average mixture ratio (kg/

2

), maximum/ minimum/average moisture

2

kg), cell e.m.f. (mV), cell internal resistance (Ω), cell condition (in four

grades), heater on-time rate (%), calibration record (ten times), time
(year/month/day/hour/minute), output 1, 2 current (mA), cell response
time (seconds),

Calibration Setting Items:

Span gas concentration (vol% O2), zero gas concentration (vol%O2),

calibration mode (auto, semi-auto, manual), calibration type and method
(zero-span calibration, zero calibration only, span calibration only),
stabilization time (min.sec), calibration time (min.sec), calibration interval
(day/hour), starting time (year/month/day/hour/minute)

Output Related Items: Analog output/output mode selection, output conditions when warming-

up/maintenance/calibrating/abnormal, 4 mA/20 mA point oxygen
concentration (vol% O

), time constant, preset values when warming-up/

2

maintenance/calibrating/abnormal, output preset values on abnormal

Alarm Related Items: Oxygen concentration high alarm/high-high alarm limit values (vol% O

oxygen concentration low alarm/low-low alarm limit values (vol% O
oxygen concentration alarm hysteresis (vol% O
alarm/ high-high alarm limit values (vol% H
alarm/ low-low alarm limit values (vol% H

2

), moisture quantity high

2

O), moisture quantity low

2

O), mixture ratio high alarm/
high-high alarm limit values (kg/kg), mixture ratio low alarm/ low-low
alarm limit values (kg/kg), moisture quantity alarm hysteresis (vol%
H

O), mixture ratio alarm hysteresis (kg/kg), oxygen concentration/

2

moisture quantity/mixture ratio alarm detection,alarm delay (seconds)

Contact Related Items: Selection of contact input 1 and 2, selection of contact output 1 and

2 (abnormal, high-high alarm, high alarm, low alarm, low-low alarm,
maintenance, calibrating, range switching, warming-up, calibration gas

pressure decrease, ameout gas detection (answer-back of contact

input)

2

2-4

),

),

2

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Converter Output: One mA analog output point (4 to 20 mA DC (maximum load resistance

of 550Ω)) with mA digital output point (HART) (minimum load resistance
of 250Ω).

Oxygen analyzer; Range; Any setting between 0 to 5 through 0 to 100 vol% O

1 vol% O

, and partial range is available (Maximum range value/

2

minimum range value 1.3 or more)

For the log output, the minimum range value is xed at 0.1 vol%

O

.

2

4 to 20 mA DC linear or log can be selected. Input/output
isolation.

Humidity analyzer; Range; Any setting between 0 to 5 through 0 to 100 vol% O

1 vol% O

, and partial range is available (Maximum range value/

2

minimum range value 1.3 or more)

For the log output, the minimum range value is xed at 0.1 vol%

O

.

2

4 to 20 mA DC linear or log can be selected. Input/output
isolation.

Output damping; 0 to 255 seconds.

Hold/non-hold selection, preset value setting possible with hold.

Contact Output: Two points, contact capacity 30V DC 3A, 250V AC 3A (resistive load)

One of the output points can be selected to ether normally energized or
normally de-energized status.
Delayed functions (0 to 255 seconds) and hysteresis function (0 to 9.9
vol% O

) can be added to high/low alarms.

2

The following functions are programmable for contact outputs.
(1) Abnormal, (2) High-high alarm, (3) High alarm, (4) Low-low alarm,
(5) Low alarm, (6) Maintenance, (7) Calibration, (8) Range switching
answer-back, (9) Warm-up, (10) Calibration gas pressure decrease
(answer-back of contact input), (11) Flameout gas detection (answer­back of contact input).

Contact Input: Two points, voltage-free contacts

The following functions are programmable for contact inputs:
(1) Calibration gas pressure decrease alarm, (2) Range switching

(switched range is xed), (3) External calibration start, (4) Process alarm

(if this signal is received, the heater power turns off)

Contact capacity: Off-state leakage current: 3 mA or less

Self-diagnosis: Abnormal cell, abnormal cell temperature (low/high), abnormal

calibration, A/D converter abnormal, digital circuit abnormal

Calibration:

Method; zero/span calibration
Calibration mode; Auto, semi-auto and manual (All are operated using optical switches).

Either zero or span can be skipped.

Zero calibration gas concentration setting range;

0.3 to 100 vol% O

(minimum setting: 0.01 vol% O2).

2

Span calibration gas concentration setting range;

4.5 to 100 vol% O

(minimum setting: 0.01 vol% O2).

2

Use nitrogen-balanced mixed gas containing 0 to 10 vol% O

oxygen for standard zero gas and 80 to 100 vol% O

scale of oxygen for

2

standard span gas.

Calibration interval; date/time setting: maximum 255 days

scale of

2

2

2

in

2-5

in

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  <2.Specications>

l Model and Codes

Model Sufx code

ZR202G - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Length -040

Wetted
material

Flange
(*2)

Auto Calibration -N

Reference gas -C

Gas Thread -R

Connection box thread -P

Instruction manual -J

— -A - - - - - - - - - - Always -A
Options

*1 For the horizontally installed probe whose insertion length is 2.5 m or more, use the Probe Protector. Be sure to specify

*2 The thickness of the ange depends on its dimensions.

*3 Inconel probe bolts and U shape pipe are used. Use this option for high temperature use (ranging from 600 to 700°C).
*4 For humidity measurements, be sure to specify /HS options. Pressure compensation of reference gas can not be selected.
*5 Specify either /CV or /SV option code.
*6 Not used with the high temperature humidity analyzer.
*7 Specify either /SCT or /PT option code.
*8 No need to specify the option codes, /CV and /SV, since the check valves are provided with the Automatic Calibration Unit.
Automatic calibration cannot be used when natural convection is selected as reference air.
*9 Sun shield hood is still effective even if scratched. Hood is necessary for outdoor installation out of sun shield roof.
*10 Recommended if sample gas contains corrosive gas like chlorine.

*11 Piping for reference gas must be installed to supply reference gas constantly at a speci ed  ow rate.

*12 Output signal limits: 3.8 to 20.5 mA. Specify either /C2 or /C3 option code.

-070

-100

-150

-200

-250

-300

-S

-C

ZO21R-L-200-

-A

-B

-C

-E

-F

-G

-K

-L

-M

-P

-R

-S

-W

-A

-B

-E

-P

-T

-G

-M

-T

Tag plates

NAMUR NE43 compliant

□. Specify the ange sufx code either -C or -K.

-E

-C

Valves

Filter

Option code

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

- - - - - - - - - -

/C
/HS
/CV
/SV
/H
/F1
/F2
/SCT
/PT
/C2

/C3

Description

Integrated type Zirconia Oxygen/ Humidity Analyzer

0.4 m

0.7 m

1.0 m

1.5 m

2.0 m

2.5 m (*1)

3.0 m (*1)
Stainless steel (SUS316)

Stainless steel with Inconel calibration gas tube (*10)
ANSI Class 150 2 RF

ANSI Class 150 3 RF
ANSI Class 150 4 RF
DIN PN10 DN50 A
DIN PN10 DN80 A
DIN PN10 DN100 A
JIS 5K 65 FF
JIS 10K 65 FF
JIS 10K 80 FF
JIS 10K 100 FF
JPI Class 150 4 RF
JPI Class 150 3 RF
Westinghouse

Not required
Horizontal mounting (*8)
Vertical mounting (*8)

Natural convection
External connection (Instrument air) (*11)
Pressure compensated (*11)

Rc1/4
1/4NPT (Female)

G1/2
Pg13.5
M20 x1.5 mm
1/2NPT

Japanese
English
Chinese

Inconel bolt (*3)
Set for Humidity Analyzer (*4)
Check valve (*5)
Stop valve (*5)
Hood (*9)
Dust Filter (*6)
Dust Guard Protector (*6)
Stainless steel tag plate (*7)
Printed tag plate (*7)
Failure alarm down-scale: Output status at CPU failure and
hardware error is 3.6 mA or less (*12)
Failure alarm up-scale: Output status at CPU failure and
hardware error is 21.0 mA or more (*12)

2-6

Style : S1

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

338 to 351

l EXTERNAL DIMENSIONS

Model ZR202G Integrated type Zirconia Oxygen/Humidity Analyzers

2-7

Unit: mm

L= 0.4, 0.7,

1.0, 1.5, 2.0,

2.5, 3.0 (m)

Ø50.8

L

t

Rc1/4 or 1/4NPT
Reference gas inlet

25

153 to 164

252 to 265

4-G1/2,2-1/2NPT etc.
Cable connection port

49

Rc1/4 or 1/4NPT
Calibration gas inlet

Ø123

Display side

122

48.5

125

Terminal side

170

C

ØA

ØB

Flange

Flange

ANSI Class 150 2 RF
ANSI Class 150 3 RF
ANSI Class 150 4 RF
DIN PN10 DN50 A
DIN PN10 DN80 A
DIN PN10 DN100 A
JIS 5K 65 FF
JIS 10K 65 FF
JIS 10K 80 FF
JIS 10K 100 FF
JPI Class 150 4 RF
JPI Class 150 3 RF
Westinghouse

A B C

152.4

190.5

228.6
165
200
220
155
175
185
210
229
190
155

l Standard Accessories

Item Parts. No. Q'ty Description

Fuse A1113EF 1 3.15 A
Allen wrench L9827AB 1 For lock screw

120.6

152.4

190.5
125
160
180
130
140
150
175

190.5

152.4
127

4 - Ø19
4 - Ø19
8 - Ø19
4 - Ø18
8 - Ø18
8 - Ø18
4 - Ø15
4 - Ø19
8 - Ø19
8 - Ø19
8 - Ø19
4 - Ø19

4 - Ø11.5

19
24
24
18
20
20
14
18
18
18
24
24
14

Flange

C

t

ØA

ØB

Flange

F11_01.ai

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Model ZR202G...-P Integrated type Zirconia Oxygen/Humidity Analyzer with pressure
compensation

L

t

L= 0.4, 0.7,

1.0, 1.5, 2.0,

2.5, 3.0 (m)

342 ± 4

Rc1/4 or 1/4NPT
Reference gas inlet

2-8

Unit: mm

Ø123

Display side

122

Ø50.8

Reference gas outlet

Flange

ANSI Class 150 2 RF
ANSI Class 150 3 RF
ANSI Class 150 4 RF
DIN PN10 DN50 A
DIN PN10 DN80 A
DIN PN10 DN100 A
JIS 5K 65 FF
JIS 10K 65 FF
JIS 10K 80 FF
JIS 10K 100 FF
JPI Class 150 4 RF
JPI Class 150 3 RF
Westinghouse

25

PIPING

:B

PIPING:A

156 ± 3

256 ± 4

Flange

A B C

152.4

190.5

228.6
165
200
220
155
175
185
210
229
190
155

120.6

152.4

190.5

190.5

152.4

125
160
180
130
140
150
175

127

Stop

valve

49

Rc1/4 or 1/4NPT
Calibration gas inlet

4 - Ø19
4 - Ø19
8 - Ø19
4 - Ø18
8 - Ø18
8 - Ø18
4 - Ø15
4 - Ø19
8 - Ø19
8 - Ø19
8 - Ø19
4 - Ø19

4 - Ø11.5

4-G1/2,2-1/2NPT etc.
Cable connection port

t

PIPING
19
24
24
18
20
20
14
18
18
18
24
24
14

A
B
B
A
B
B
A
A
B
B
B
B
A

48.5

ØA

ØB

ØA

ØB

Terminal side

170

C

Flange

Flange

125

C

F11_02.EPS

l Standard Accessories

Item Parts. No. Q'ty Description

Fuse A1113EF 1 3.15 A
Allen wrench L9827AB 1 For lock screw

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

274

l Hood (Option code /H)

± 4

± 3

150

150

± 3

2-9

Unit: mm

Material of HOOD : Aluminum Food Weight : Approx. 800g

2.1.3 ZO21R Probe Protector

Used when sample gas ow velocity is approx. 10 m/sec or more and dust particles wears the
detector in cases such as pulverized coal boiler of uidized bed furnace (or burner) to protect the

detector from wearing by dust particles.

When probe insertion length is 2.5 m or more and horizontal installation, specify the ZO21R-L-

200-□*B to reinforce the probe.

Insertion Length: 1.05 m, 1.55 m, 2.05 m.

Flange: JIS 5K 65A FF equivalent, ANSI Class 150 4 FF (without serration)

equivalent . However, ange thickness is different.

Material: SUS316 (JIS), SUS304 (JIS) or ASTM grade 304 (Flange)

Weight: 1.05m; Approx. 6/10 kg (JIS/ANSI),

1.55 m; Approx. 9/13 kg (JIS/ANSI),

2.05 m; Approx. 12/16 kg (JIS/ANSI)

Installation: Bolts, nuts, and washers are provided for detector, probe adapter and

process-side ange.

l Model and Codes

Model Sufx code

ZO21R -L - - - - - - Probe Protector (0 to 700 °C)

Insertion
length

Flange ( *1) -J

Style code *B - - - - - - Style B

*1 Thickness of ange depends on dimensions of ange.

-100

-150

-200

-A

Option

code

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1.05 m

1.55 m

2.05 m
JIS 5K 65 FF

ANSI Class 150 4 FF

F13.ai

Description

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

l EXTERNAL DIMENSIONS

Flange <1>
(with bolts, nuts and washer)

Washer (12)

Gas flow

JIS 5K 65 FF 155 130 4 - Ø15 5 40

ANSI Class 150 4 FF 228.6 190.5 8 - Ø19 12 50

Mounting nut (M12)

SUS316

Ø60.5

D

l (Insert length)

l=1050,1550,2050

Flange<1> A B C t D

gasket (t3.0)

B

ØA

t

Dimensions of
holes on opposing surface

Ø

B

Ø

C

F2-3E.ai

2-10

Unit: mm

2.1.4 ZH21B Dust Protector

This protector is designed to protect the probe output from dust agitation (i.e., to prevent
combustible materials from entering the probe cell where humidity measurements are made) in a
dusty environment.

Insertion length: 0.428m

Flange: JIS 5K 80 FF or ANSI Class 150 4 FF (However, ange thickness is

different)

Material: SUS 316(JIS), SUS304 (JIS) or ASTM grade 304 (ange)

Weight: Approximately 6kg (JIS), approximately 8.5kg (ANSI)

Mounting: Mounted on the probe or process ange with bolts and associated nuts

and washers.

l Model and Codes

Model Sufx code

ZH21B - - - - - - - - - - - - - - - - - - - Dust Protector (0 to 600 °C)

Insertion length -40 - - - - - - 0.428 m

Flange ( *1) -J

-A

Style code *B - - - - - - Style B

Note: The ange thickness varies.

(*1) Specify the probe ZR22G-040-h-K
(*2) Specify the probe ZR22G-040-h-C

Option

code

- - - - - -

- - - - - -

JIS 5K 80 FF (*1)
ANSI Class 150 4B FF (*2)

Description

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00

  <2.Specications>

Unit: mm

428 (Insertion length)

t

øA

ø72

JIS flange

Install facing upwards

ø76.3

D

ANSI flange

øB

2-11

øB

C

Flange A B C t D

JIS 5K 80 FF 180 145 4 - Ø19 12 40

ANSI Class 150 4B FF 228.6 190.5 8 - Ø19 12 50

øB

C

ZH21B.ai

2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit

2.2.1 ZA8F Flow Setting Unit

This ow setting unit is applied to the reference gas and the calibration gas in a system
conguration (System 2). Used when instrument air is provided.

This unit consists of a owmeter and ow control valves to control the ow of calibration gas and

reference gas.

Standard Specications

FIowmeter Scale: Calibration gas; 0.1 to 1.0 l/min. Reference gas; 0.1 to 1.0 l/min.

Construction: Dust-proof and rainproof construction

Case Material: SPCC (Cold rolled steel sheet)

Painting: Baked epoxy resin, Dark-green (Munsell 2.0 GY 3.1/0.5 or equivalent)

Tube Connections: Rc1/4 or 1/4NPT (Female)

Reference Gas Pressure:

Air Consumption: Approx. 1.5 l/min

Weight: Approx. 2.3 kg

Calibration gas (zero gas, span gas) Consumption: Approx. 0.7 l/min (at calibration time only)

Clean air supply of sample gas pressure plus approx. 50 kPa G (or

sample gas pressure plus approx.150 kPa when a check valve is used.)

Pressure at inlet of the  ow setting unit. (Max. 300 kPa G)

NOTE

Use instrument air for span calibration gas, if no instrument air is available, contact YOKOGAWA.

IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00