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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<Introduction>

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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

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<CONTENTS>
3. Installation................................................................................................. 3-1
3.1 Installation of ZR202G Zirconia Oxygen Analyzer ........................................3-1
3.1.1 Installation Location ........................................................................... 3-1
3.1.2 Probe Insertion Hole ..........................................................................3-2
3.1.3 Installation of the Probe .....................................................................3-2
3.1.4 Installation of the Dust Filter (K9471UA), Dust Guard Protector
(K9471UC) Probe Protector (ZO21R) ............................................... 3-3
3.2 Installation of ZA8F Flow Setting Unit............................................................ 3-5
3.2.1 Installation Location ........................................................................... 3-5
3.2.2 Mounting of ZA8F Flow Setting Unit..................................................3-6
3.3 Installation of ZR20H Automatic Calibration Unit .........................................3-7
3.3.1 Installation Location ........................................................................... 3-7
3.3.2 Mounting of ZR20H Automatic Calibration Unit.................................3-7
3.4 Installation of the Case Assembly (E7044KF) for
Calibration Gas Cylinder.................................................................................. 3-9
3.4.1 Installation Location ........................................................................... 3-9
3.4.2 Mounting ............................................................................................ 3-9
3.5 Insulation Resistance Test.............................................................................3-10
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...........................................................................................4-3
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 .......................................................................... 5-3
5.2.2 Wiring Procedure ............................................................................... 5-3

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<CONTENTS>
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 ..............................................................5-4
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 .......................................................................... 5-5
5.5.2 Wiring Procedure ............................................................................... 5-6
6. Components ............................................................................................. 6-1
6.1 ZR202G Zirconia Oxygen Analyzer.................................................................6-1
6.1.1 Integrated type Zirconia Oxygen Analyzer ........................................6-1
6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit ........................6-2
7. Startup ....................................................................................................... 7-1
7.1 Checking Piping and Wiring Connections..................................................... 7-2
7.2 Valve Setup ........................................................................................................ 7-2
7.3 Supplying Power to Converter ........................................................................ 7-2
7.4 Operation of Infrared Switch ........................................................................... 7-3
7.4.1 Display and Switches.........................................................................7-3
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 Minimum Current (4 mA) and Maximum Current (20 mA) Settings .. 7-9
7.8 Checking Current Loop.................................................................................. 7-11
7.9 Checking Contact I/O...................................................................................... 7-11
7.9.1 Contact Output Check .....................................................................7-12
7.9.2 Checking Calibration Contact Output ..............................................7-13
7.9.3 Checking Input Contacts..................................................................7-14
7.10 Calibration .......................................................................................................7-15
7.10.1 Calibration Setup .............................................................................7-15
7.10.2 Manual Calibration...........................................................................7-17

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<CONTENTS>
8. Detailed Data Setting ............................................................................... 8-1
8.1 Setting Display Item..........................................................................................8-1
8.2 Current Output Setting..................................................................................... 8-1
8.2.1 Setting Minimum Oxygen Concentration ( at 4 mA) and Maximum
Oxygen Concentration ( at 20 mA) .................................................... 8-2
8.2.2 Entering Output Damping Constants.................................................8-2
8.2.3 Selection of Output Mode .................................................................. 8-2
8.2.4 Default Values.................................................................................... 8-2
8.3 Output Hold Setting .......................................................................................... 8-3
8.3.1 Denition of Equipment Status .......................................................... 8-3
8.3.2 Preference Order of Output Hold Value............................................. 8-5
8.3.3 Output Hold Setting............................................................................8-5
8.3.4 Default Values.................................................................................... 8-5
8.4 Setting Oxygen Concentration Alarms........................................................... 8-6
8.4.1 Alarm Values...................................................................................... 8-6
8.4.2 Alarm Output Actions ......................................................................... 8-6
8.4.3 Alarm Setting...................................................................................... 8-7
8.4.4 Default Values.................................................................................... 8-8
8.5 Output Contact Setup....................................................................................... 8-8
8.5.1 Output Contact................................................................................... 8-8
8.5.2 Setting Output Contact ......................................................................8-9
8.5.3 Default Values..................................................................................8-10
8.6 Input Contact Settings.................................................................................... 8-11
8.6.1 Setting Input Contact ....................................................................... 8-11
8.6.2 Default Values.................................................................................. 8-11
8.7 Other Settings ................................................................................................. 8-12
8.7.1 Setting the Date-and-Time...............................................................8-12
8.7.2 Setting Periods over which Average Values are Calculated and Periods
over which Maximum and Minimum Values Are Monitored.............8-13
8.7.3 Setting Fuels ....................................................................................8-14
8.7.4 Setting Purging ................................................................................ 8-18
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.................................................................................... 9-2
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 Calibration.......................................................................................... 9-8

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<CONTENTS>
10. Other Functions...................................................................................... 10-1
10.1 Detailed Display ..............................................................................................10-1
10.1.1 Air Ratio............................................................................................10-3
10.1.2 Cell Temperature..............................................................................10-3
10.1.3 C. J. Temperature.............................................................................10-3
10.1.4 Amount of Water Vapor in Exhaust Gas ..........................................10-3
10.1.5 Cell Voltage......................................................................................10-4
10.1.6 Thermocouple Voltage.....................................................................10-4
10.1.7 Cold Junction Voltage ......................................................................10-4
10.1.8 Current Output .................................................................................10-4
10.1.9 Response Time................................................................................10-5
10.1.10 Cell’s Internal Resistance ...............................................................10-5
10.1.11 Robustness of a Cell....................................................................... 10-5
10.1.12 Heater On-Time Ratio.....................................................................10-6
10.1.13 Oxygen Concentration (with time constant)....................................10-6
10.1.14 Maximum Oxygen Concentration...................................................10-6
10.1.15 Minimum Oxygen Concentration ....................................................10-6
10.1.16 Average Oxygen Concentration...................................................... 10-6
10.1.17 Span and Zero Correction Ratios ...................................................10-6
10.1.18 History of Calibration Time..............................................................10-7
10.1.19 Time.................................................................................................10-7
10.1.20 Software Revision ........................................................................... 10-7
10.2 Operational Data Initialization ......................................................................10-7
10.3 Initialization Procedure ..................................................................................10-8
10.4 Reset.................................................................................................................10-9
10.5 Handling of the ZO21S Standard Gas Unit.................................................10-16
10.5.1 Standard Gas Unit Component Identication................................10-16
10.5.2 Installing Gas Cylinders .................................................................10-16
10.5.3 Calibration Gas Flow......................................................................10-17
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 ..................................10-19
10.6.4 Treatment After Calibration............................................................ 10-20
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
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................................................ 11-6

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<CONTENTS>
11.2 Inspection and Maintenance of the Converter ............................................ 11-8
11.2.1 Replacing Fuses .............................................................................. 11-8
11.3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit ........ 11-10
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
12.3 Measures When Measured Value Shows an Error......................................12-9
12.3.1 Measured Value Higher Than True Value........................................12-9
12.3.2 Measured Value Lower Than True Value ......................................12-10
12.3.3 Measurements Sometimes Show Abnormal Values .....................12-10
Customer Maintenance Parts List ........................................CMPL 11M12A01- 04E
Customer Maintenance Parts List ........................................CMPL 11M12A01-12E
Customer Maintenance Parts List ...........................................CMPL 11M3D1- 01E
Revision Information ...............................................................................................i

<1.Overview> 1-1
IM 11M12A01-04E
1. Overview
The EXAxt ZR Integrated type Zirconia 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 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 CO2, SOx
and NOx.
The EXAxt ZR Integrated type Zirconia Oxygen 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 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:
1.1 <EXAxtZR>SystemConguration
The system configuration should be determined by the conditions; e.g. whether the calibration is to
be automated, and whether flammable 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. 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.
~
ZR202G Integrated type Zirconia Oxygen Analyzer
ZO21S Standard gas unit
Stop valve
Calibration gas
F1.1E.ai
~
100 to 240 V AC
100/110/115
200/220/240 V AC
Contact input
Analog output, contact output
Digital output (HART)
Figure1.1 ExampleofSystem1

<1. Overview>
1-2
IM 11M12A01-04E
CAUTION
• 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. The gas ow is controlled by the ZA8F ow setting unit (for manual valve operation).
~
ZR202G Integrated type Zirconia Oxygen Analyzer
F1.2E.ai
ZA8F flow setting unit
Reference gas
Calibration gas
Needle
valve
Flowmeter
Instrument air
Air Set
Calibration
gas pressure
regulator
Zero gas cylinder
Calibration gas unit case
Stop valve
or
Check valve
Span gas(Same as Zero gas calibration)
100 to 240 V AC
Contact input
Analog output, contact output
Digital output (HART)
Figure 1.2 Example of System 2

<1.Overview> 1-3
IM 11M12A01-04E
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 calibration-time 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.
~100 to 240 V AC
Automatic calibration unit
Reference gas
Calibration gas (Zero)
Contact input
Analog output, contact output
Digital output (HART)
Air Set
Instrument air
Calibration gas unit case
Calibration
gas pressure
regulator
Zero gas cylinder
ZR202G Integrated type Zirconia Oxygen Analyzer
with automatic calibration unit (ZR202G-□-□-□-A-□-□-□-□-A)
F1.3E.ai
Span gas
ZR20H
*3
Note:
The installation temperature limits range for integrated type analyzer is -20 to 55°C.
*2
*1
*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% N2gas cannot be used as the zero gas.
Use approx. 1 vol% O2gas (N2-based).
Figure 1.3 Example of System 3

<1. Overview>
1-4
IM 11M12A01-04E
1.2 < EXAxt ZR > System Components
1.2.1 System Components
System Components
ZR202G Integrated type Zirconia Oxygen Analyzers
ZO21R Probe Protector for Zirconia Oxygen Analyzers
K9471UA Dust Filter for Oxygen Analyzer
ZO21S Standard Gas Unit
ZA8F Flow Setting Unit for manual calibration
ZR20H Automatic Calibration Unit for Integrated type Analyzer
L9852CB, G7016XH Stop Valve for Calibration gas line
K9292DN,K9292DS Check Valve for Calibration gas line
G7003XF/K9473XK, G7004XF/K9473XG Air Set
G7001ZC Zero gas Cylinder
G7013XF, G7014XF Pressure Regulator for Gas Cylinder
E7044KF Case Assembly for Calibration gas Cylinder
Integrated type
System configuration
Example 3
Example 1 Example 2
( )
( )
T1.1.ai
: Items required for the above system example
: To be selected depending on each application. For details, refer to corresponding chapter.
: Select either
( )
ZR202A Heater Assembly (Spare Parts for ZR202G)
K9471UC Dust Guard Protector
1.2.2 Oxygen Analyzer and Accessories
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Detector
(ZR202G)
Detector
(ZR202G)
Detector(ZR202G)
Probe Protector
(ZO21R)
Dust Filter
(K9471UA)
or
Dust Guard
Protector
(K9471UC)
+
Sample gas temperature 0 to 700°C
Mounting Insertion length General-use Probe 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/sec or more
• Cement Kiln
• Black liquid recovery boiler
• Cement Kiln
Gas Flow
Sample inlet

<2. Specications> 2-1
IM 11M12A01-04E
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)
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.)
Measured System: Zirconia system
Oxygen Concentration: 0.01 to 100 vol% O2
Output Signal: 4 to 20 mA DC (maximum load resistance 550Ω)
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 550Ω, depending on number of eld 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 gas is by natural convection)
± 0.5% Maximum value of set range; less than 0 to 25 vol% O2range
± 1 % Maximum value of set range; 0 to 25 vol% O2or more and up to 0 to
100 vol% O2range
Linearity: (Excluding standard gas tolerance)
(Excluding the case where the reference gas is by natural convection)
(Use oxygen of known concentration (with in the measuring range) as the
zero and span calibration gases.)
± 1% Maximum value of set range; less than 0 to 25 vol% O2range
(Sample gas pressure: within ± 4.9 kPa)
± 3% Maximum value of set range; 0 to 25 vol% O2or more and less than 0
to 50 vol% O2range
(Sample gas pressure: within ± 0.49 kPa)
± 5% Maximum value of set range; 0 to 50 vol %O2or more and up to 0 to
100 vol% O2range
(Sample gas pressure: within ± 0.49 kPa)