YOKOGAWA EXAxtZR User manual

Instruction
Manual
IM 11M12A01-02E
Model ZR22G, ZR402G
Separate type
Zirconia Oxygen Analyzer
IM 11M12A01-02E
3rd Edition

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IM 11M12A01-02E
IM 11M12A01-02E
3rd Edition: Sept. 2001 (YK)
All Rights Reserved, Copyright © 2000, Yokogawa Electric Corporation
Introduction
The EXAxtZR Separate type Zirconia Oxygen Analyzer has been developed for com-
bustion control in various industrial processes. This analyzer basically consists of a
detector and a converter. You can select between several versions, based upon your
application.
Optional accessories are also available to improve measurement accuracy and automate
calibration. An optimal control system can be realized by adding appropricate options.
This instruction manual refers to almost all of the equipment related to the EXAxtZR.
You may skip any section(s) on the 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 0 Model EXAxt ZR Series HART Protocol0 .
The all-in-one version (with sensor and analyzer integrated in one body) is described in
IM 11M12A01-04E
<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
EXAxtZR.>
Models and descriptions in this manual are as follows:
Models and descriptions in this manual
Description in this manual
Model Product Name Specification Installation Operation Maintenance CMPL
ZR22G General-use detector ss s ss
ZR22G High-temperature detector (0.15m) ssss
ZR402G Converter sssss
ZO21R-L Probe protector ss
ZO21P-H High-temperature probe adapter sss
ZA8F Flow setting unit (for manual calibration use) sss
ZR40H Automatic Calibration unit ssss
- Auxiliary ejector for high-temperature use
(Part No. E7046EC, EN) sss
- Calibration gas unit case (Part No. E7044KF) ss
- Check valve (Part No. K9292DN, K9292DS) ss
- Dust filter for the detector (Part No. K9471UA) ss
ZO21S Standard gas unit ssss
T.Int.1E
CMPL : Customer Maintenance Parts List

IM 1M12A01-02E
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This manual consists of twelve chapters. Please refer to the reference chapters for
installation, operation and maintenance.
Table of Contents
T.Int.2E
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Relates to
Chapter Outline Installation Operation Maintenance
1. Overview Equipment models and system configuration examples
2. Specifications Standard specification, model code (or part number),
dimension drawing for each equipment
3. Installation Installation method for each equipment
4. Piping Examples of piping in three standard system
configurations
5. Wiring Wiring procedures such as “Power supply wiring”, “output
signal wiring” or others
6. Components Major parts and function are described in this manual
7. Startup Basic procedure to start operation of EXAxtZR. Chapter 7
enables you to operate the equipment immediately.
8. Detailed Data Setting Details of key operations and displays
9. Calibration Describes the calibration procedure required in the course
of operation.
10. Other Functions Other functions described
11. Inspection and How to conduct maintenance of EXAxtZR and procedures
Maintenance for replacement of deteriorated parts
12. Troubleshooting This chapter describes measures to be taken when an
abnormal condition occurs.
CMPL (parts list) User replaceable parts list
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: Read and completely understand before operating the equipment.
: Read before operating the equipment, and refer to it whenever necessary.
: Recommended to read it at least once.
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IM 11M12A01-02E
rFor the safe use of this equipment
CAUTION
The cell (sensor) at the tip of the detector is made of ceramic (zirconia element). Do not
drop the detector or subject it to pressure stress.
• Do NOT allow the sensor (probe tip) to make contact with anything when installing
the detector.
• Avoid any water dropping directly on the probe (sensor) of the detector when install-
ing 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 measured gas may damage the sensor.
• The detector (especially at the tip) becomes very hot. Be sure to handle it with gloves.
DANGER
EXAxtZR is very heavy. Handle it with care. Do not drop it. Handle safely to avoid
injury.
Connect the power supply cord only after confirming that the supply voltage matches
the rating of this equipment. In addition, confirm that the power is switched off when
connecting power supply.
Some process gas is dangerous to people. When removing this equipment from the
process line for maintenance or other reasons, protect yourself from potential poisoning
by using a protective mask or ventilating the area well.
(1) About This Manual
• This manual should be passed on to the end user.
• The contents of this manual are subject to change without prior notice.
• The contents of this manual shall not be reproduced or copied, in part or in whole,
without permission.
• This manual explains the functions contained in this product, but does not warrant that
those will suit the particular purpose of the user.
• Every effort has been made to ensure accuracy in the preparation of this manual.
However, should any errors or omissions come to the attention of the user, please
contact the nearest Yokogawa Electric representative or sales office.
• This manual does not cover the special specifications. This manual may not be
changed on any change of specification, construction and parts when the change does
not affect the functions or performance of the product.
• If the product is used in a manner not specified in this manual, the safety of this
product may be impaired.

IM 1M12A01-02E
iv
(2) Safety and Modification Precautions
• Follow the safety precautions in this manual when using the product to ensure protec-
tion and safety of personnel, product and system containing the product.
(3) The following safety symbols are used on the product as well as in this manual.
DANGER
This symbol indicates that the operator must follow the instructions laid out in this
manual in order to avoid the risk of personnel injury electric shock, or fatalities. The
manual describes what special care the operator must exercise to avoid such risks.
WARNING
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 draws attention to information essential for understanding the operation and
functions.
Tip
This symbol gives information that complements the present topic.
SEE ALSO
This symbol identifies a source to which to refer.
Protective Ground Terminal
Function Ground Terminal (Do not use this terminal as the protective ground
terminal.)
Alternating current

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IM 11M12A01-02E
• Special descriptions in this manual
This manual indicates operation keys, displays and drawings on the product as follows:
• Operation keys, Enclosed in [ ], displays on the panel 0 0.
(Ex. [MODE] key)
(Ex. message display 0 BASE 0)
(Ex. data display 0 1020 lit, 0 1020flashing)
• Drawing for flashing
Indicated in light print. (Flashing) (lit)

IM 1M12A01-02E
vi
rNOTICE
• Specification check
When the instrument arrives, unpack the package with care and check that the
instrument has not been damaged during transportation. In addition, please check that
the specification matches the order, and required accessories are not missing. Specifi-
cations can be checked by the model codes on the nameplate. Refer to Chapter 2
Specifications for the list of model codes.
• 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 befor 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.
rAfter - Sales Warranty
dYokogawa warrants the product for the period stated in the quotation which was
delivered upon purchase. Yokogawa shall conduct defined warranty service based on
its standard. When the customer site is located out of the specified scope, a fee for
dispatching the maintenance engineer will be charged to the customer.
dIn the following cases, customer will be charged repair fee regardless of warranty
period.
• Failure of components which are out of scope of warranty stated in instruction
manual.
• Failure caused by usage of software, hardware or auxiliary equipment, which
Yokogawa Electric Corporation did not supply.
• Failure due to improper or insufficient maintenance by user.
• Failure due to modification, misuse or operation of specification which Yokogawa
does not authorize.
• Failure due to power supply (voltage, frequency) being outside specifications or
abnormal.
• Failure caused by any usage out of scope of recommended usage
• Any damage from fire, earthquake, a storm and flood, lightning, disturbance, riot,
warfare, radiation and other natural changes.
dYokogawa does not warrant conformance with the specific application at the user
site. Yokogawa will not bear direct/indirect responsibility for damage due to a specific
application.
dYokogawa Electric Corporation will not bear responsibility when the user configures
the product into systems or resells the product.
dMaintenance service and supplying repair parts will be covered for five years after
the production ends. For repair this product, please contact the nearest sales office
described in this instruction manual.

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IM 11M12A01-02E
Introduction........................................................................................................................... i
rFor the safe use of this equipment .......................................................................... iii
rNOTICE....................................................................................................................vi
rAfter - Sales Warranty..............................................................................................vi
1. Overview .......................................................................................................................1-1
1.1 < EXAxtZR > System Configuration ............................................................. 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 < EXAxtZR > System Components ............................................................... 1-4
1.2.1 System Components ................................................................................ 1-4
1.2.2 Detectors and Accessories....................................................................... 1-4
2. Specifications ................................................................................................................2-1
2.1 General Specifications .................................................................................... 2-1
2.1.1 Standard Specifications ........................................................................... 2-1
2.2 General-use Separate-type Detector and Related Equipment ........................ 2-3
2.2.1 ZR22G General-use Separate-type Detector........................................... 2-3
2.2.2 ZO21R-L Probe Protector ....................................................................... 2-8
2.3 High-Temperature Separate-type Detector and Related Equipment .............. 2-9
2.3.1 ZR22G (0.15m) High-Temperature Separate-type Detector .................. 2-9
2.3.2 ZO21P-H Adapter for High-Temperature Probe .................................. 2-10
2.4 ZR402G Separate-type Converter................................................................. 2-12
2.4.1 Standard Specification........................................................................... 2-12
2.4.2 Functions................................................................................................ 2-13
2.5 ZA8F Flow Setting Unit and ZR40H Automatic Calibration Unit ............. 2-17
2.5.1 ZA8F Flow Setting Unit........................................................................ 2-17
2.5.2 ZR40H Automatic Calibration Unit...................................................... 2-19
2.6 ZO21S Standard Gas Unit ............................................................................ 2-22
2.7 Other Equipment ........................................................................................... 2-24
2.7.1 Dust Filter for the Detector (Part No.: K9471UA)............................... 2-24
2.7.2 Auxiliary Ejector for High Temperature
(Part No. E7046EC or E7046EN)........................................................ 2-25
2.7.3 Stop Valve (Part No. L9852CB or G7016XH) .................................... 2-27
2.7.4 Check Valve (Part No. K9292DN or K9292DS) ................................. 2-28
2.7.5 Air Set (Part No. G7011XF or E7040EL) ............................................ 2-29
2.7.6 Zero Gas Cylinder (Part No. G7001ZC)............................................... 2-29
2.7.7 Cylinder Regulator Valve (Part No. G7013XF or G7014XF) ............. 2-30
2.7.8 Calibration Gas Unit Case (Part No. E7044KF) .................................. 2-30
2.7.9 Model ZR22A Heater Assembly........................................................... 2-31
Contents

IM 1M12A01-02E
viii
3. Installation .................................................................................................................... 3-1
3.1 Installation of the Detector ............................................................................. 3-1
3.1.1 Location ................................................................................................... 3-1
3.1.2 Probe Insertion Hole................................................................................ 3-1
3.1.3 Installation of the Detector...................................................................... 3-2
3.1.4 Installation of the Dust Filter( Part No K9471UA)................................ 3-3
3.2 Installation of the Detector (Model ZR22G-015)........................................... 3-5
3.2.1 Installation Location ................................................................................ 3-5
3.2.2 Usage of the High-temperature Probe Adapter (Model ZO21P-H) ....... 3-5
3.2.3 Probe Insertion Hole................................................................................ 3-7
3.2.4 Mounting of the High-Temperature Detector ......................................... 3-7
3.3 Installation of the Converter ........................................................................... 3-9
3.3.1 Location ................................................................................................... 3-9
3.3.2 Mounting of the Converter...................................................................... 3-9
3.4 Installation of ZA8F Flow Setting Unit ....................................................... 3-12
3.4.1 Location ................................................................................................. 3-12
3.4.2 Mounting of ZA8F Flow Setting Unit .................................................. 3-12
3.5 Installation of ZR40H Automatic Calibration Unit...................................... 3-14
3.5.1 Location ................................................................................................. 3-14
3.5.2 Mounting of ZR40H Automatic Calibration Unit ................................ 3-14
3.6 Installation of the Calibration Gas Unit Case (E7044KF) ........................... 3-16
3.6.1 Location ................................................................................................. 3-16
3.6.2 Mounting................................................................................................ 3-16
3.7 Insulation Resistance Test............................................................................. 3-17
3.8 External Dimensions of Detectors with Pressure Compensation................. 3-18
4. Piping............................................................................................................................. 4-1
4.1 Piping for System 1 ........................................................................................ 4-1
4.1.1 Parts Required for Piping in System 1 ................................................... 4-2
4.1.2 Connection to the Calibration Gas Inlet ................................................. 4-3
4.1.3 Connection to the Reference Gas Inlet ................................................... 4-3
4.1.4 Piping to the High-temperature Probe Adapter ...................................... 4-4
4.2 Piping for System 2 ........................................................................................ 4-6
4.2.1 Piping Parts for System 2........................................................................ 4-7
4.2.2 Piping for the Calibration Gas ................................................................ 4-8
4.2.3 Piping for the Reference Gas .................................................................. 4-8
4.2.4 Piping to the High-temperature Probe Adapter ...................................... 4-8
4.3 Piping for System 3 ........................................................................................ 4-9
4.3.1 Blow Back Piping.................................................................................. 4-10
4.4 Piping for the Detector with Pressure Compensation .................................. 4-12
4.4.1 Piping Parts for a System using Detector with Pressure Compensation4-14
4.4.2 Piping for the Calibration Gas .............................................................. 4-14
4.4.3 Piping for the Reference Gas ................................................................ 4-14
5. Wiring ........................................................................................................................... 5-1
5.1 General ............................................................................................................ 5-1
5.1.1 Terminals for the External Wiring in the Converter .............................. 5-2
5.1.2 Wiring ...................................................................................................... 5-3
5.1.3 Mounting of Cable Gland........................................................................ 5-4
5.2 Wiring for Detector Output............................................................................. 5-5
5.2.1 Cable Specifications ................................................................................ 5-5
5.2.2 Connection to the Detector...................................................................... 5-6
5.2.3 Connection to the Converter ................................................................... 5-7

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IM 11M12A01-02E
5.3 Wiring for Power to Detector Heater ............................................................. 5-8
5.3.1 Cable Specifications ................................................................................ 5-8
5.3.2 Connection to Detector............................................................................ 5-8
5.3.3 Connection to Converter ......................................................................... 5-9
5.4 Wiring for Analog Output............................................................................. 5-10
5.4.1 Cable Specifications .............................................................................. 5-10
5.4.2 Wiring Procedure................................................................................... 5-10
5.5 Power and Grounding Wiring....................................................................... 5-11
5.5.1 Power Wiring......................................................................................... 5-11
5.5.2 Grounding Wiring ................................................................................. 5-11
5.6 Contact Output Wiring.................................................................................. 5-12
5.6.1 Cable Specifications .............................................................................. 5-12
5.6.2 Wiring Procedure................................................................................... 5-12
5.7 Wiring for ZR40H Automatic Calibration Unit ........................................... 5-13
5.7.1 Cable Specifications .............................................................................. 5-13
5.7.2 Wiring Procedure................................................................................... 5-14
5.8 Contact Input Wiring .................................................................................... 5-15
5.8.1 Cable Specifications .............................................................................. 5-15
5.8.2 Wiring Procedure................................................................................... 5-15
6. Components ..................................................................................................................6-1
6.1 ZR22G Detector .............................................................................................. 6-1
6.1.1 General-purpose Detector (except for Model ZR22G-015) ................... 6-1
6.1.2 High-Temperature Detector (Model ZR22G-015).................................. 6-2
6.2 ZR402G Converter.......................................................................................... 6-3
6.3 ZA8F Flow Setting Unit, ZR40H Automatic Calibration Unit ..................... 6-4
7. Startup...........................................................................................................................7-1
7.1 Checking Piping and Wiring Connections ..................................................... 7-1
7.2 Checking Valve Setup..................................................................................... 7-1
7.3 Supplying Power to the Converter.................................................................. 7-2
7.4 Touchpanel Switch Operations ....................................................................... 7-3
7.4.1 Basic Panel and Switch ........................................................................... 7-3
7.4.2 Display Configuration (for Oxygen Analyzer) ....................................... 7-4
7.4.3 Display Functions .................................................................................... 7-5
7.4.4 Entering Numeric and Text Data ............................................................ 7-5
7.5 Confirmation of Converter Type Setting........................................................ 7-7
7.6 Confirmation of Detector Type Setting .......................................................... 7-8
7.7 Selection of Measurement Gas ....................................................................... 7-8
7.8 Output Range Setting ...................................................................................... 7-8
7.8.1 Minimum Current (4 mA) and Maximum Current (20 mA) Settings ... 7-8
7.9 Setting Display Item ....................................................................................... 7-9
7.10 Checking Current Loop................................................................................. 7-11
7.11 Checking Contact I/O ................................................................................... 7-12
7.11.1 Checking Contact Output ...................................................................... 7-12
7.11.2 Checking Calibration Contact Output ................................................... 7-13
7.11.3 Checking Input Contacts ....................................................................... 7-13
7.12 Calibration ..................................................................................................... 7-14
7.12.1 Calibration Setup ................................................................................... 7-14
7.12.2 Manual Calibration ................................................................................ 7-15

IM 1M12A01-02E
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8. Detailed Data Setting................................................................................................... 8-1
8.1 Current Output Setting .................................................................................... 8-1
8.1.1 Setting Minimum Current (4 mA) and Maximum Current (20 mA) ..... 8-1
8.1.2 About Input Ranges................................................................................. 8-1
8.1.3 Entering Output Damping Constants ...................................................... 8-2
8.1.4 Selection of Output Mode ....................................................................... 8-2
8.1.5 Default Values ......................................................................................... 8-3
8.2 Output Hold Setting ........................................................................................ 8-4
8.2.1 Definition of Equipment Status............................................................... 8-4
8.2.2 Preference Order of Output Hold Value ................................................. 8-5
8.2.3 Output Hold Setting................................................................................. 8-6
8.2.4 Default Values ......................................................................................... 8-6
8.3 Setting Oxygen Concentration Alarms ........................................................... 8-7
8.3.1 Alarm Values ........................................................................................... 8-7
8.3.2 Alarm Output Actions ............................................................................. 8-7
8.3.3 Alarm Setting Procedure ......................................................................... 8-8
8.3.4 Default Values ......................................................................................... 8-9
8.4 Output Contact Setup .................................................................................... 8-10
8.4.1 Output Contact....................................................................................... 8-10
8.4.2 Setting Procedure................................................................................... 8-10
8.4.3 Default Values ....................................................................................... 8-13
8.5 Input Contact Settings................................................................................... 8-14
8.5.1 Input Contact Functions ........................................................................ 8-14
8.5.2 Setting Procedure................................................................................... 8-15
8.5.3 Default Values ....................................................................................... 8-15
8.6 Other Settings................................................................................................ 8-16
8.6.1 Setting the Date-and-Time .................................................................... 8-16
8.6.2 Setting Periods over which Average Values Are Calculated and
Periods over which Maximum and
Minimum Values Are Monitored.......................................................... 8-16
8.6.3 Setting Fuels .......................................................................................... 8-17
8.6.4 Setting Passwords .................................................................................. 8-22
9. Calibration .................................................................................................................... 9-1
9.1 Calibration Briefs ............................................................................................ 9-1
9.1.1 Principle of Measurement ....................................................................... 9-1
9.1.2 Calibration Gas ........................................................................................ 9-2
9.1.3 Compensation .......................................................................................... 9-3
9.1.4 Characteristic Data from a Sensor Measured During Calibration.......... 9-4
9.2 Calibration Procedures .................................................................................... 9-5
9.2.1 Calibration Setting................................................................................... 9-5
9.2.2 Default Values ......................................................................................... 9-8
9.2.3 Calibration ............................................................................................... 9-9
10. Other Functions ................................................................................................ 10-1
10.1 Display........................................................................................................... 10-1
10.1.1 Detailed Display .................................................................................... 10-1
10.1.2 Trend Graph........................................................................................... 10-5
10.1.3 Auto(matic) Revert Time ...................................................................... 10-7
10.1.4 Entering Tag Name ............................................................................... 10-7
10.1.5 Language Selection ............................................................................... 10-7
10.2 Blowback....................................................................................................... 10-8
10.2.1 Blowback Setup..................................................................................... 10-8

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IM 11M12A01-02E
10.3 Operational Data Initialization.................................................................... 10-11
10.4 Reset ............................................................................................................ 10-14
10.5 Handling of the ZO21S Standard Gas Unit................................................ 10-15
10.5.1 Standard Gas Unit Component Identification..................................... 10-15
10.5.2 Installing Gas Cylinders ...................................................................... 10-16
10.5.3 Calibration Gas Flow........................................................................... 10-16
10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit.................. 10-19
10.6.1 Preparation Before Calibration............................................................ 10-19
10.6.2 Operating the Span Gas Flow Setting Valve ...................................... 10-19
10.6.3 Operating the Zero Gas Flow Setting Valve ...................................... 10-20
10.6.4 Operation After Calibration................................................................. 10-20
11. Inspection and Maintenance ........................................................................... 11-1
11.1 Inspection and Maintenance of the Detector ................................................ 11-2
11.1.1 Cleaning the Calibration Gas Tube....................................................... 11-2
11.1.2 Replacing the Sensor Assembly............................................................ 11-3
11.1.3 Replacement of the Heater Unit............................................................ 11-5
11.1.4 Replacement of filter assembly ............................................................. 11-8
11.1.5 Replacement of O-ring .......................................................................... 11-8
11.1.6 Cleaning the High-temperature Probe Adapter..................................... 11-8
11.2 Inspection and Maintenance of the Converter.............................................. 11-9
11.2.1 Replacing Fuses..................................................................................... 11-9
11.2.2 Cleaning ............................................................................................... 11-10
11.3 Replacing Flowmeter in ZR40H Autocalibration Unit .............................. 11-11
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..................... 12-5
12.2.1 What is an Alarm?................................................................................. 12-5
12.2.2 Measures Taken When Alarms are Generated ..................................... 12-6
12.3 Countermeasures When Measured Value Shows Error ............................. 12-11
12.3.1 Measured Value Higher Than True Value.......................................... 12-11
12.3.2 Measured Value Lower Than True Value .......................................... 12-12
12.3.3 Measurements Sometimes Show Abnormal Values ........................... 12-12
Customer Maintenance Parts List ...................................................................................... i
Revision Record .................................................................................................................... i

IM 11M12A01-02E 1-1
1. Overview
1. Overview
The EXAxtZR Separate-type Zircon Oxygen 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 energy2such as steel, electric
power, oil and petrochemical, ceramics, paper and pulp, food, or textiles, as well as
incinerators and medium/small boilers. It can help conserve energy in these industries.
The EXAxtZR also contributes to preservation of the earth’s environment in preventing
global warming and air pollution by controlling complete combustion to reduce CO2,
SOx and NOx.
ZR22G Separate-type Detector uses a high-reliability Zirconia sensor, and its heater
assembly can be replaced on site. The detector is mounted, for example, on the wall of a
flue and can measure the gases directly.
For use in combustion gases at temperatures up to 1400°C, choose the general-use
0.15m long detector, which is combined with ZO21P-H, the high-temperature probe
protector. The converter is equipped with an LCD touch screen which has various
setting displays, a calibration display, oxygen concentration trend display, with easier
operation and improvement of display functions. The converter is equipped with various
standard functions such as measurement and calculation as well as maintenance func-
tions including self-test. Analyzer calibration can also be fully automated2and ZR40H,
an automatic calibration unit, is available. Choose the detector version which best suits
your needs so that an optimal combustion control system can be obtained.
Some examples of typical system configurations are illustrated below:
1.1 < EXAxtZR > System Configuration
The system configuration should be determined by the conditions; e.g. whether calibra-
tion is to be automated, and whether flammable gas is present and requires safety
precautions. The system configuration can be classified into three basic patterns as
follows:
1.1.1 System 1
This is the simplest system consisting of a detector and a converter. This system can be
implemented for monitoring oxygen concentration in the combustion gases of a package
boiler. No piping is required for the reference gas (air) which is fed in at the installation
site. The handy ZO21S standard gas unit is used for calibration.
Zero gas from this unit and span gas (air) is sent to the detector through a tube which is
connected during calibration. A needle (stop) valve should be connected to the calibra-
tion gas inlet of the detector. The valve should be fully closed unless calibration is in
progress.
CAUTION
• As this system uses ambient air for the reference gas, measuring accuracy will be
affected by the installation location.

IM 11M12A01-02E
1-2
EXAZR402G
Model ZR22G Separate type Zirconia Oxygen
Analyzer, Detector
Model ZR402G Converter
Stop valve
Calibration gas
Model ZO21S Standard gas unit
,
,
100 to
240 V AC
F1.1E.EPS
Contact input
Analog output, contact output
(Digital output HART)
Signal
(6-core shield cable)
Heater(2-core)
Figure1.1
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. Clean (dry) air (21% O2) is used as the
reference gas and the span gas for calibration. Zero gas is fed in from a cylinder during
calibration. The gas flow is controlled by the ZA8F flow setting unit (for manual valve
operation).
F1.2E.EPS
,
Model ZR402G Converter
Check valve
or Stop Vallve
Model ZA8F flow setting unit
EXAZR402G
Model ZR22G Separate type Zirconia Oxygen
Analyzer, Detector
100 to
240 V AC
Air Set
Instrument air
Calibration gas
Reference
gas Flowmeter Needle
valve
Calibration gas pressure regulator
Calibration gas
unit case
Zero gas
cylinder
Span gas (Same as Zero gas calibration unit)
Contact input
Analog output, contact output
(Digital output HART)
Signal
(6-core shield cable)
Heater(2-core)
Figure1.2

IM 11M12A01-02E 1-3
1. Overview
1.1.3 System 3
This example, System 3, represents typical applications in large boilers and heating
furnaces, where there is a need to monitor and control oxygen concentration. The
reference gas and calibration-time span gas are (clean, dry) instrument air. Zero gas is
supplied from a gas cylinder.
System 3 uses the ZR40H autocalibration 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.
F1.3E.EPS
Model ZR22G Separate type Zirconia OxygenAnalyzer
Detector Model ZR402G Converter
Signal
(6-core shield cable)
Heater (2-core)
Reference gas
Calibration gas
FlowmeterNeedle
vaive
Calibration gas
unit case
Zero gas cylinder
100 to 240 V AC
*3
Check valve
Model ZR40H Aoto-Calibration unit
Contact input
Analog output, contact output
Digital output (HART)
Air Set
lnstrument air
Calibration gas pressure regulator
EXAZR402G
,
*1
*2
*1 Shield cable;
Use shielded signal cables, and connect the shield to the FG terminal of the con-
verter.
*2 Select the desired probe from the Probe Configuration table on page 1-4.
*3 When a zirconia oxygen analyzer is used, 100% N2gas cannot be used as the zero
gas. Use approximately 1% of O2gas (N2-based).
Figure1.3

IM 11M12A01-02E
1-4
1.2 < EXAxtZR > System Components
1.2.1 System Components
T1.1E.EPS
System Components
Model ZR22G Separate type Zirconia Oxygen Analyzers ,Detector
Model ZR402G Separate type Zirconia Oxygen Analyzer, Converter
Model ZO21P-H Adapter for High temperature Probe of separate type Zirconia Oxygen Analyzer
E7046EC, E7046EN Auxiliary Ejector for High temperature of separate type Oxygen Analyzer
Model ZO21R-L Probe Protector for Zirconia Oxygen Analyzers
K9471UA Filter for Oxygen Analyzer
Model ZO21S Standard Gas Unit
Model ZA8F Flow setting unit for manual calibration
Model ZR40H Automatic Calibration Unit for Separate type Analyzer
L9852CB, G7016XH Stop Valve for Calibration-gas line
K9292DN,K9292DS Check Valve for Calibration-gas line
G7011XF, E7040EL Air Set
G7001ZC Zero-gas Cylinder
G7013XF, G7014XF Pressure Regulator for Gas Cylinder
E7044KF Case Assembly for Calibration-gas Cylinder
Sparate type
Ex.1 Ex.2 Ex.3
System config.
: Items required for the above system example
: To be selected depending on each application. For details, refer to corresponding chapter.
: Select either
( )
( )
( )
Model ZR22A, ZR202A Heater Assembly (Spare Parts for Model ZR22G)
1.2.2 Detectors and Accessories
Detector
(ZR22G)
Detector
(ZR22G)
Detector (ZR22G)
Probe Protector
(ZO21R)
Gas Flow
F1.4E.EPS
Filter
(K9471UA)
+
Process gas temperature 0 to 7008C Process gas temperature 0 to 14008C
Mounting Insertion
length General-use Probe High temperature detector
Application Application
Horizontal
to
vertical
Horizontal
to
vertical
Horizontal
to
vertical
Vertical
Vertical
0.4
to
2 m
0.4
to
2 m
2.5 m
or more
3 m
or less
2.5 m
or more
Boiler
Heating
furnace
For pulverized
coal boiler
with gas flow
velocity
10 m/s or more
Black liquid
recovery boiler
Cement
Kiln
Sample inlet
Sample
outlet
Sample inlet
High
temperature
detector
Heating
furnace
Temperature:
Probe material SUS310S 8008C
Probe material SiC 14008C
Mounting:Vertical downwards
Insertion length: 1.0m, 1.5m
When duct pressure is atmospheric
or negative, attach air ejector.
High temperature auxiliary
ejector (E7046EC, E7046EN)
Pressure gauge
Needle
valve
Absorption
structure
Inlet
Ejector
assy.
Probe protector
for high
temperature use
ZO21P-H
Blow

IM 11M12A01-02E 2-1
2. Specifications
2. Specifications
This chapter describes the specifications for the following:
ZR22G General-use separate-type detector (See Section 2.2.1)
ZO21R-L Probe protector (See Section 2.2.2)
ZR22G (0.15 m) High-temperature separate-type detector (See Section 2.3.1)
ZO21P-H Adapter for High temperature probe (See Section 2.3.2)
ZR402G Separate type converter (See Section 2.4)
ZA8F Flow setting unit (See Section 2.5.1)
ZR40H Automatic calibration unit(See Section 2.5.2)
ZO21S Standard gas unit (See Section 2.6)
2.1 General Specifications
2.1.1 Standard Specifications
Measured Object: Oxygen concentration in combustion exhaust gas and mixed gas
(excluding inflammable gases, may not be applicable corrosive gas such as
ammonia is present2check with YOKOGAWA)
Measurement System: Zirconia system
Oxygen concentration: 0.01 to 100 vol% O2
Output Signal: 4 to 20 mA DC (maximum load resistance 550V)
Measurement Range: Any setting in the range of 0 to 5 through 0 to 100 vol% O2(in
1 vol% O2), or partial range
Digital Communication (HART): 250 to 550V, depending on number of field devices
connected to the loop (multi-drop mode).
Note: HART is a registered trademark of the HART Communication Foundation.
Display Range: 0 to 100 vol% O2
Warm-up Time: Approx. 20 min.
Repeatability: (Excluding the case where the reference air is by natural convection)
60.5% Maximum value of range setting. (range up to 0 to 25 vol% O2)
61% Maximum value of range setting.
(range from 0 to 25 vol% O2up to 0 to 100 vol% O2)
Linearity: (Excluding standard gas tolerance)
(Excluding the case where the reference air flow is natural convection)
(Use oxygen of known concentration (in the measuring range) as the zero and
span calibration gas.)
61% Maximun value of range setting ; from 0 to 5 vol% O2to 0 to 25
vol% O2range

IM 11M12A01-02E
2-2
(Sample gas pressure: within 64.9 kPa)
63% Maximun value of range setting ; from 0 to 25 vol%O2to 0 to 50 vol%
O2range
(Sample gas pressure: within 60.49 kPa)
65% Maximum value of range setting ; from 0 to 50 vol% O2to 0 to 100 vol%
O2range (Sample gas pressure: within 60.49 kPa)
Drift: (Excluding the first two weeks in use)
(Excluding the case where the reference air flow is natural convection.)
Both zero and span 62% Maximum value of range setting/month
Response Time : Response of 90% within 5 seconds. (Measured from when gas is
introduced from calibration gas inlet and analog output start changing.)

IM 11M12A01-02E 2-3
2. Specifications
2.2 General-use Separate-type Detector and Related
Equipment
General-use separate-type detector ZR22 can be used in combination with the probe
protector ZO21R-L (see Section 2.2.2).
2.2.1 ZR22G General-use Separate-type Detector
Sample Gas Temperature: 0 to 7008C (Probe only)
It is necessary to mount the cell using Inconel cell-bolts when the temperature
is 6008C or greater.
700 to 14008C (with High Temperature Probe Adapter)
For high-temperature sample gas, apply 0.15 m length probe and High tempera
ture Probe Adapter ZO21P-H.
Sample Gas Pressure: -5 to +250 kPa (When the pressure in the furnace exceeds 3 kPa,
it is recommended that you compensate for this pressure. When the pressure in
the furnace exceeds 5 kPa, you must perform pressure compensation.)
For 0.15m probe, 0.5 to 5kPa.
No pressure fluctuation in the furnace should be allowed.
Probe Length: 0.15, 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0, 3.6, 4.2, 4.8, 5.4 m
Probe Material: SUS 316 (JIS)
Ambient Temperature: -20 to +1508C
Reference Air System: Natural Convection, Instrument Air, Pressure Compensation
(other than for probe length 0.15 m)
Instrument Air System (excluding Natural Convection) :
Pressure; 200 kPa + the pressure inside the furnace (It is recommended to use
air which has been dehumidified by cooling to dew point -208C or less, and had
dust or oil mist removed.)
Consumption; Approx. 1 Nl/min
Material in Contact with Gas: SUS 316 (JIS), Zirconia, SUS 304 (JIS) (flange),
Hastelloy B, (Inconel 600, 601)
Construction: Heater and thermocouple replaceable construction. Non explosionproof.
Equivalent to NEMA 4X/IP66 (recirculation to furnace with pressure compen
sation only)
Terminal Box Case: Material; Aluminium alloy
Terminal Box Paint Color:
Case; Off-white (Munsell 0.6GY3.1/2.0)
Cover; Moss green (Munsell 2.5Y8.4/1.2)
Finish: Polyurethane corrosion-resistant coating
Gas Connection: Rc1/4 or 1/4FNPT
Wiring Connection: G1/2, Pg13.5, M20 by 1.5 mm, 1/2 NPT

IM 11M12A01-02E
2-4
Installation: Flange mounting
Probe Mounting Angle: Horizontal to vertically downward.
When the probe insertion length is 2 m or less, can install at angles from
horizontal to vertically downward.
When the probe insertion length is 2.5 or more, mount vertically downward
(within 658), and if using a probe protector install at angles between horizontal
and vertically downward (within 658).
Weight:
Insertion length of 0.4 m: approx. 6 kg (JIS 5K-65) / approx. 11 kg (ANSI 150-4)
Insertion length of 1.0 m: approx. 8 kg (JIS 5K-65)) / approx. 13 kg (ANSI 150-4)
Insertion length of 1.5 m: approx. 10 kg (JIS 5K-65)) / approx. 15 kg (ANSI 150-4)
Insertion length of 2.0 m: approx. 12 kg (JIS 5K-65)) / approx. 17 kg (ANSI 150-4)
Insertion length of 3.0 m: approx. 15 kg (JIS 5K-65)) / approx. 20 kg (ANSI 150-4)
Insertion length of 3.6 m: approx. 17 kg (JIS 5K-65)) / approx. 22 kg (ANSI 150-4)
Insertion length of 4.2 m: approx. 19 kg (JIS 5K-65)) / approx. 24 kg (ANSI 150-4)
Insertion length of 4.8 m: approx. 21 kg (JIS 5K-65)) / approx. 26 kg (ANSI 150-4)
Insertion length of 5.4 m: approx. 23 kg (JIS 5K-65)) / approx. 28 kg (ANSI 150-4)