YOKOGAWA ZR202G User manual

User’s
Manual
R
Model ZR202G
Integrated type
Zirconia Oxygen Analyzer
IM 11M12A01-04E
IM 11M12A01-04E
7th Edition

i
IM 11M12A01-04E
<Introduction>
Introduction
The EXAxt ZR Integrated type Zirconia Oxygen 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.
IM11M12A01-51E 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. >
Models and descriptions in this manual are listed below.
Model Product Name Description in this manual
Specication Installation Operation Maintenance CMPL
ZR202G Integrated type Oxygen Analyzer
ZO21R Probe Protector
ZA8F Flow Setting Unit (for manual
calibration use)
ZR20H Automatic Calibration Unit
— Case Assembly for calibration
gas cylinder (Part No. E7044KF)
— Check valve (Part No. K9292DN,
K9292DS)
— Dust Filter for the detector (Part
No. K9471UA)
— Dust Guard Protector (Part No.
K9471UC)
ZO21S Standard Gas Unit
CMPL: Customer Maintenance Parts List
Media No.IM 11M12A01-04E (CD) 7th Edition :March 2012 (YK)
All Rights Reserved Copyright © 2000, Yokogawa Electric Corporation

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IM 11M12A01-04E
<Introduction>
This manual consists of twelve chapters. Please refer to the reference chapters for installation, opera-
tion and maintenance.
Chapter Outline Relates to
Installation Operation Maintenance
1. Overview Equipment models and system conguration
examples
2. Specications Standard specication, 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
congurations
5. Wiring Wiring procedures such as “Power supply wiring”,
“output signal wiring” or others
6. Components Major parts and functions are described
7. Startup Basic procedure to start operation of EXAxt ZR.
Chapter 7enables 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
Maintenance
How to conduct maintenance of EXAxt ZR and
procedures for replacement of deteriorated parts
12. Troubleshoot-
ing
This chapter describes measures to be taken when an
abnormal condition occurs.
CMPL (parts list) User replaceable parts list
: Read and completely understand before operating the equipment.
: Read before operating the equipment, and refer to it whenever necessary.
: Recommended to read at least once.

iii
IM 11M12A01-04E
<Introduction>
For the safe use of this equipment
WARNING
EXAxt ZR is very heavy. 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 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
CAUTION
The cell (sensor) at the tip of the probe is made of ceramic (zirconia element). Do not drop the equip-
ment or subject it to pressure stress.
• Do NOT allow the sensor (probe tip) to make contact with anything when installing the analyzer.
• Avoid 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.
(1) About This Manual
The contents of this manual shall not be reproduced or copied, in part or in whole, without per-
mission.
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 ofce.
This manual does not cover the special specications. This manual may not be changed on any
change of specication, 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 specied in this manual, the safety of this product may be
impaired.

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IM 11M12A01-04E
<Introduction>
(2) Safety and Modication Precautions
Follow the safety precautions in this manual when using the product to ensure protection and
safety of personnel, product and system containing the product.
The following safety symbols and wordings are used on the product as well as in this manual.
(3) The following safety symbols are used in this manual.
Throughout this user’s manual, you will find several different types of symbols are used to identify
different sections of text. This section describes these icons.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices.
IMPORTANT
Indicates that operating the hardware or software in this manner may damage it or lead to system
failure.
NOTE
Draws attention to information essential for understanding the operation and features.
TIP
Identies additional information.
SEE ALSO
Identies a source to be referred to.
Clicking a reference displayed in green can call up its source, while clicking a reference displayed
in black cannot.

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IM 11M12A01-04E
<Introduction>
Special descriptions in this manual
This manual indicates operation keys, displays and drawings on the product as follows:
• Operation keys, displays on the panel
Enclosed in [ ]. (Ex. "MODE" key)
(Ex. message display → "BASE")
(Ex. data display → "102" lit, "102" ashing)
• Drawing for ashing
Indicated by gray characters (Flashing) (lit)
• Displays on the LCD display panel
9
8
7
6
5
4
3
2
1
0
W
V
U
T
S
R
Q
P
O
N
M
L
K
J
I
H
G
F
E
D
C
B
A
Alphanumerics Alphanumerics AlphanumericsLED Display LED Display LED Display
Z
Y

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IM 11M12A01-04E
<Introduction>
NOTICE
• 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.
• Details on operation parameters
When the EXAxt ZR Integrated type Zirconia 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 on setting data,
refer to Chapters 7 to 10.
When user changes the operation parameter, it is recommended to note down the changed setting
data.
• How to dispose the batteries:
This is an explanation about the new EU Battery Directive (DIRECTIVE 2006/66/EC). 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.
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: silver oxide battery
Notice:
The symbol (see above) means they shall be sorted out and collected as ordained in ANNEX II in
DIRECTIVE 2006/66/EC

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IM 11M12A01-04E
<Introduction>
After-Sales Warranty
Do not modify the product.
During the warranty period, for repair under warranty carry or send the product to the local sales
representative or service ofce. Yokogawa will replace or repair any damaged parts and return
the product to you.
Before returning a product for repair under warranty, provide us with the model name and serial
number and a description of the problem. Any diagrams or data explaining the problem would
also be appreciated.
If we replace the product with a new one, we won’t provide you with a repair report.
Yokogawa warrants the product for the period stated in the pre-purchase quotation. Yokogawa
shall conduct dened warranty service based on its standard. When the customer site is located
outside of the service area, a fee for dispatching the maintenance engineer will be charged to the
customer.
In 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 Elec-
tric did not supply.
• Failure due to improper or insufcient maintenance by user.
• Failure due to modication, misuse or outside-of-specications operation which Yokogawa
does not authorize.
• Failure due to power supply (voltage, frequency) being outside specications or abnormal.
• Failure caused by any usage out of scope of recommended usage.
• Any damage from re, earthquake, storms and oods, lightning, disturbances, riots, warfare,
radiation and other natural changes.
Yokogawa does not warrant conformance with the specic application at the user site. Yokogawa
will not bear direct/indirect responsibility for damage due to a specic application.
Yokogawa Electric will not bear responsibility when the user congures the product into systems
or resells the product.
Maintenance service and supplying repair parts will be covered for ve years after the production
ends. For repair for this product, please contact the nearest sales ofce described in this instruc-
tion manual.

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IM 11M12A01-04E
<Introduction>

Toc-1
IM 11M12A01-04E
<CONTENTS>
Model ZR202G
Integrated type Zirconia Oxygen Analyzer
CONTENTS
IM 11M12A01-04E 7th Edition
Introduction ..............................................................................................................i
For the safe use of this equipment.............................................................................. iii
NOTICE ........................................................................................................................... vi
After-Sales Warranty .................................................................................................... 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 Analyzer and Accessories ....................................................1-4
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
2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit................ 2-10
2.2.1 ZA8F Flow Setting Unit....................................................................2-10
2.2.2 ZR20H Automatic Calibration Unit...................................................2-12
2.3 ZO21S Standard Gas Unit .............................................................................. 2-14
2.4 Other Equipment.............................................................................................2-15
2.4.1 Dust Filter for Oxygen Analyzer (part no. K9471UA).......................2-15
2.4.2 Dust Guard Protector (part no. K9471UC) ......................................2-15
2.4.3 Stop Valve (part no. L9852CB or G7016XH)...................................2-16
2.4.4 Check Valve (part no. K9292DN or K9292DS)................................2-16
2.4.5 Air Set............................................................................................... 2-17
2.4.6 Zero Gas Cylinder (part no. G7001ZC) ........................................... 2-18
2.4.7 Pressure Regulator (G7013XF or G7014XF) for Gas Cylinder....... 2-18
2.4.8 Case Assembly (E7044KF) for Calibration gas Cylinder................. 2-19
2.4.9 ZR202A Heater Assembly ...............................................................2-19