YOKOGAWA ZR22S User manual

User’s
Manual Model ZR22S, ZR402G
Separate type Explosion-proof
Zirconia Oxygen Analyzer
IM 11M13A01-02E
IM 11M13A01-02E
7th Edition

i
IM 11M13A01-02E
Introduction
Thank you for purchasing the ZR22S, ZR402G Separate type Explosion-proof Zirconia Oxygen
Analyzer.
Please read the following respective documents before installing and using the ZR22S, ZR402G
Separate type Explosion-proof Zirconia Oxygen Analyzer.
The related documents are as follows.
General Specications
Contents Document number Note
Model ZR22S and ZR202S Explosion-proof Direct In Situ
Zirconia Oxygen Analyzers GS 11M13A01-01E
* the “E” in the document number is the language code.
User’s Manual
Contents Document number Note
Model ZR22S, ZR402G Separate type Explosion-proof
Zirconia Oxygen Analyzer IM 11M13A01-02E (This manual)
Model ZR22A, ZR202A
Heater Assembly IM 11M12A01-21E
Model EXAxt ZR Series
HART Protocol IM 11M12A01-51E
* the “E” in the document number is the language code.
An exclusive User’s Manual might be attached to the products whose sufx codes or option
codes contain the code “Z” (made to customers' specications). Please read it along with this
manual.
The EXAxt ZR Separate type Explosion-proof Zirconia Oxygen Analyzer has been developed for
combustion 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 appropriate options.
This instruction manual refers to almost all of the equipment related to the EXAxt ZR.
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 " Model EXAxt ZR Series HART Protocol" .
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 EXAxt ZR.>
Models and descriptions in this manual
Model Product Name Description in this manual
Specication Installation Operation
Maintenance CMPL
ZR22S General-purpose detector     
ZR22S High temperature detector
(0.15 m)    
ZR402G Converter     
ZO21R Probe protector  
ZO21P High temperature probe
adapter   
Media No. IM 11M13A01-02E 7th Edition : Jul. 2017 (YK)
All Rights Reserved Copyright © 2005, Yokogawa Electric Corporation

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IM 11M13A01-02E
ZA8F Flow setting unit
(for manual calibration use)    
ZR40H Automatic Calibration unit    
-Auxiliary ejector assembly for
high temperature use
(Part No. E7046EC, E7046EN)
  
-Calibration gas unit case
(Part No. E7044KF)  
-Check valve
(Part No. K9292DN, K9292DS)  
ZO21S Standard gas unit    
CMPL : Customer Maintenance Parts List
This manual consists of twelve chapters. Please refer to the reference chapters for installation,
operation and maintenance.
Table of Contents
Chapter Outline Relates to
Installation Operation Maintenance
1. Overview Equipment models and system conguration
examples B C B
2. Specications Standard specication, model code (or
part number), dimension drawing for each
equipment
A B B
3. Installation Installation method for each equipment A C
4. Piping Examples of piping in two standard system
congurations A C
5. Wiring Wiring procedures such as “Power supply
wiring”, “output signal wiring” or others A C
6. Components and
Their Functions
Major parts and function are described in this
manual C B B
7. Startup Basic procedure to start operation of EXAxt
ZR.
Chapter 7 enables you to operate the
equipment immediately.
A C
8. Detailed Data Setting Details of key operations and displays B C
9. Calibration Describes the calibration procedure required in
the course of operation. B C
10. Other Functions Other functions described B C
11. Inspection and
Maintenance
How to conduct maintenance of EXAxt ZR and
procedures for replacement of deteriorated
parts
B A
12. Troubleshooting This chapter describes measures to be taken
when an abnormal condition occurs. C A
CMPL (parts list) User replaceable parts list C B
A : Read and completely understand before operating the equipment.
B : Read before operating the equipment, and refer to it whenever necessary.
C : Recommended to read it at least once.

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IM 11M13A01-02E
nATEX Documentation
This procedure is only applicable to the countries in European Union.
GB
DK
I
E
NL
SF
P
F
D
S
LT
LV
PL
EST
SLO
H
BG
RO
M
CZ
SK
GR

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IM 11M13A01-02E
nPrecautions in Handling Explosion-proof Zirconia Oxygen Analyzer
The explosion-proof zirconia oxygen analyzer (Model ZR22S) are designed as explosion-proof
instruments.
When using either of these instruments in an explosion-susceptible hazardous area, note the
following and observe the given precautions:
Use only the supplied, the explosion-proof zirconia oxygen analyzer (Model ZR22S) and
accessories, or any explosion-proof certication may be invalidated.
For the details, refer to the system congurations in the manual.
CAUTION
Only trained persons use this instrument in industrial locations.
Explosion-proof Approval followings:
ZR22S-A (ATEX); Ex db IIB+H2T2 Gb, Ex tb IIIC T300°C Db
ZR22S-B (FM); Class I, Division 1, Groups B, C and D, Class II/III, Division 1,
Groups E, F and G, T2
ZR22S-C (CSA); Class I, Division 1, Groups B, C and D, Class II/III, Division 1,
Groups E, F and G, T2
ZR22S-D (IECEx);Ex db IIB+H2T2 Gb, Ex tb IIIC T300°C Db
nFor the safe use of this equipment
WARNING
EXAxtZR is very heavy. Handle it with care. Do not 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
Requirements for explosion-proof use:
The ZR22S is connected to a ZR402G or AV550G*1that is mounted in a non-hazardous area.
The ambient temperature is in the range -20 to +60°C. The surface temperature of the ZR22S is
not over the temperature class T2 (300°C)*2.
*1: Refer to IM 11M12D01-01E
*2: The terminal box temperature does not exceed 150ºC
Oxygen concentration of sample/reference /calibration gas shall not exceed that found in normal
air, typically 21 vol%.

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IM 11M13A01-02E
NOTE
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 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 detector (especially at the tip) becomes very hot. Be sure to handle it with gloves.
(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 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.
NOTE
This instrument is tested and certicated as explosion-proof type. Please note that the
construction of the instrument, installation, external wiring, maintenance or repair is strictly
restricted, and non-observation or negligence of this restriction would result in dangerous
condition.
(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.

vi
IM 11M13A01-02E
(3) The following safety symbols are used on the product as well as in this manual.
WARNING
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.
CAUTION
This symbol indicates that the operator must refer to the instructions in this manual in order to
prevent the instrument (hardware) or software from being damaged, or a system failure from
occurring.
NOTE
This symbol draws attention to information essential for understanding the operation and
functions.
Protective Ground Terminal
Function Ground Terminal (Do not use this terminal as the protective
ground terminal.)
Alternating current
• 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 “ “.
(Ex. [MODE] key)
(Ex. selection display “ BASE “)
(Ex. data display “ 102” lit, “ 102” ashing)
• Drawing for ashing
Indicated in light print. (Flashing) (lit)

vii
IM 11M13A01-02E
nNOTICE
l Specication check
When the instrument arrives, unpack the package with care and check that the instrument has
not been damaged during transportation. In addition, please check that the specication matches
the order, and required accessories are not missing. Specications can be checked by the model
codes on the nameplate. Refer to Chapter 2 Specications for the list of model codes.
lDetails on operation parameters
When the EXAxt ZR Separate type Oxygen Analyzer arrives at the user site, it will operate based
on the operation parameters (initial data) set before shipping from the factory.
Ensure that the initial data is suitable for the operation conditions before conducting analysis.
Where necessary, set the instrument parameters for appropriate operation.
For details of setting data, refer to chapters 7 to 10.
When user changes the operation parameter, it is recommended to note down the changed
setting data.
lProduct Disposal:
The instrument should be disposed of in accordance with local and national legislation/
regulations.
n Trademark Acknowledgments
• All other company and product names mentioned in this user’s manual are trademarks or
registered trademarks of their respective companies.
• We do not use TM or ® mark to indicate those trademarks or registered trademarks in this
user’s manual.

viii
IM 11M13A01-02E
u CE marking products
nAuthorized Representative in EEA
The Authorized Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2,
3825 HD Amersfoort, The Netherlands).
n Identication Tag
This manual and the identication tag attached on packing box are essential parts of the product.
Keep them together in a safe place for future reference.
nUsers
This product is designed to be used by a person with specialized knowledge.
lHow to dispose the batteries:
This is an explanation about the EU Battery Directive. This directive is only valid in the EU.
Batteries are included in this product. Batteries incorporated into this product cannot be removed
by yourself. Dispose them together with this product.
When you dispose this product in the EU, contact your local Yokogawa Europe B.V.ofce. Do not
dispose them as domestic household waste.
Battery type: Manganese dioxide lithium battery
Notice:
The symbol (see above) means they shall be sorted out and collected as ordained in the EU
Battery Directive.

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IM 11M13A01-02E
uAfter-Sales Warranty
lDo not modify the product.
lYokogawa warrants the product for the period stated in the pre-purchase
quotation. Yokogawa shall conduct dened warranty service based on its
standard.
lDuring 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.
lIn 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 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.
lYokogawa 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.
lYokogawa will not bear responsibility when the user congures the product
into systems or resells the product.
lMaintenance 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 instruction manual.

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IM 11M13A01-02E
Model ZR22S, ZR402G
Separate type Explosion-proof
Zirconia Oxygen Analyzer
CONTENTS
IM 11M13A01-02E 7th Edition
Introduction ..............................................................................................................i
u CE marking products................................................................................viii
uAfter-Sales Warranty...................................................................................ix
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
1.2 < EXAxt ZR > System Components ................................................................ 1-3
1.2.1 System Components ......................................................................... 1-3
1.2.2 Detectors and Accessories ................................................................ 1-3
2. Specications ........................................................................................... 2-1
2.1 General Specications ..................................................................................... 2-1
2.2 Separate type Explosion-proof Detector and Related Equipment.............. 2-3
2.2.1 ZR22S Separate type Explosion-proof Detector............................... 2-3
2.2.2 ZO21R Probe Protector.....................................................................2-8
2.3 Separate type Explosion-proof Detector for High Temperature and Related
Equipment.......................................................................................................... 2-9
2.3.1 ZR22S (0.15 m) Separate type Explosion-proof Detector for High
Temperature....................................................................................... 2-9
2.3.2 ZO21P High Temperature Probe Adapter ......................................2-10
2.4 ZR402G Separate type Converter ................................................................. 2-12
2.4.1 Standard Specication..................................................................... 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 .............................................................................. 2-21
2.7 Other Equipments........................................................................................... 2-22
2.7.1 Ejector Assembly for High Temperature (E7046EC, E7046EN) .....2-22
2.7.2 Stop Valve (L9852CB, G7016XH) ...................................................2-23
2.7.3 Check Valve (K9292DN, K9292DS)................................................2-24
2.7.4 Air Set...............................................................................................2-25
2.7.5 Cylinder Pressure Reducing Valve (G7013XF, G7014XF)..............2-26
2.7.6 ZR22A Heater Assembly..................................................................2-27

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IM 11M13A01-02E
3. Installation................................................................................................. 3-1
3.1 Installation of General-purpose Detector....................................................... 3-2
3.1.1 Installation Location ........................................................................... 3-2
3.1.2 ATEX Flameproof Type...................................................................... 3-2
3.1.3 FM Explosion-proof Type................................................................... 3-3
3.1.4 CSA Explosion-proof Type................................................................. 3-4
3.1.5 IECEx Flameproof Type..................................................................... 3-5
3.1.6 Probe Insertion Hole .......................................................................... 3-7
3.1.7 Installation of the Detector ................................................................. 3-7
3.1.8 Installation of Probe Protector (ZO21R) ............................................ 3-8
3.2 Installation of High Temperature Detector (Model ZR22S--015)............... 3-8
3.2.1 Installation Location ........................................................................... 3-8
3.2.2 Usage of High Temperature Probe Adapter
(Model ZO21P) .................................................................................. 3-9
3.2.3 Probe Insertion Hole ........................................................................ 3-10
3.2.4 Mounting of High Temperature Detector.......................................... 3-11
3.3 Installation of ZR402G Converter.................................................................. 3-12
3.3.1 Installation Location ......................................................................... 3-12
3.3.2 Mounting of the Converter ...............................................................3-12
3.4 Installation of ZA8F Flow Setting Unit .......................................................... 3-14
3.4.1 Installation Location ......................................................................... 3-14
3.4.2 Mounting of ZA8F Flow Setting Unit................................................3-14
3.5 Installation of ZR40H Automatic Calibration Unit ....................................... 3-15
3.5.1 Installation Location ......................................................................... 3-15
3.5.2 Mounting of ZR40H Automatic Calibration Unit...............................3-15
3.6 Insulation Resistance Test............................................................................. 3-17
4. Piping......................................................................................................... 4-1
4.1 Piping for a System Using Flow Setting Unit for Manual Calibration ........ 4-2
4.1.1 Parts Required for Piping in a System Using Flow Setting Units for
Manual Calibration............................................................................. 4-3
4.1.2 Piping for the Calibration Gas Inlet .................................................... 4-4
4.1.3 Piping for the Reference Gas Inlet..................................................... 4-4
4.1.4 Piping for the Reference Gas Outlet.................................................. 4-4
4.1.5 Piping to the High Temperature Probe Adapter................................. 4-4
4.2 Piping for a System to Perform Automatic Calibration ................................ 4-6
4.2.1 Parts Required for Piping in a System to Perform Automatic Calibration
4-7
4.2.2 Piping for the Calibration Gases ........................................................ 4-8
4.2.3 Piping for the Reference Gas............................................................. 4-8
4.2.4 Piping to the High Temperature Probe Adapter................................. 4-9
4.2.5 Piping for Blow back...........................................................................4-9
5. Wiring......................................................................................................... 5-1
5.1 General............................................................................................................... 5-1

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IM 11M13A01-02E
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 Specications .......................................................................... 5-5
5.2.2 Connection to the Detector ................................................................ 5-6
5.2.3 Connection to the Converter.............................................................. 5-6
5.3 Wiring for Power to Detector Heater............................................................... 5-7
5.3.1 Cable Specications .......................................................................... 5-7
5.3.2 Connection to Detector ...................................................................... 5-7
5.3.3 Connection to Converter.................................................................... 5-8
5.4 Wiring for Analog Output ................................................................................. 5-9
5.4.1 Cable Specications .......................................................................... 5-9
5.4.2 Wiring Procedure ............................................................................... 5-9
5.5 Power and Grounding Wiring.......................................................................... 5-9
5.5.1 Power Wiring...................................................................................... 5-9
5.5.2 Grounding Wiring.............................................................................5-10
5.6 Contact Output Wiring.................................................................................... 5-10
5.6.1 Cable Specications ........................................................................5-10
5.6.2 Wiring Procedure ............................................................................. 5-11
5.7 Wiring for ZR40H Automatic Calibration Unit.............................................. 5-11
5.7.1 Cable Specications ........................................................................ 5-11
5.7.2 Wiring Procedure ............................................................................. 5-12
5.8 Contact Input Wiring....................................................................................... 5-12
5.8.1 Cable Specications ........................................................................5-12
5.8.2 Wiring Procedure ............................................................................. 5-12
6. Components and Their Functions.......................................................... 6-1
6.1 ZR22S Detector ................................................................................................. 6-1
6.1.1 General-purpose Explosion-proof Detector (except for ZR22S--015)6-1
6.1.2 High Temperature Detector (ZR22S--015)..................................... 6-2
6.2 ZR402G Converter ............................................................................................ 6-3
6.3 Touchpanel Switch Operations ....................................................................... 6-4
6.3.1 Basic Panel and Switch ..................................................................... 6-4
6.3.2 Display Conguration (for Oxygen Analyzer) .................................... 6-5
6.3.3 Display Functions............................................................................... 6-6
6.3.4 Entering Numeric and Text Data........................................................ 6-6
6.4 ZA8F Flow Setting Unit, ZR40H Automatic Calibration Unit ........................ 6-8
7. Startup ....................................................................................................... 7-1
7.1 Startup Procedure............................................................................................. 7-1
7.2 Checking Piping and Wiring Connections..................................................... 7-1
7.3 Checking Valve Setup....................................................................................... 7-2

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IM 11M13A01-02E
7.4 Supplying Power to the Converter.................................................................. 7-2
7.5 Conrmation of Converter Type Setting ........................................................ 7-3
7.6 Conrmation of Detector Type Setting........................................................... 7-4
7.7 Selection of Sample Gas.................................................................................. 7-4
7.8 Output Range Setting....................................................................................... 7-4
7.9 Setting Display Item.......................................................................................... 7-5
7.10 Checking Current Loop.................................................................................... 7-6
7.11 Checking Contact I/O........................................................................................ 7-7
7.11.1 Checking Contact Outputs................................................................. 7-7
7.11.2 Checking Calibration Contact Outputs .............................................. 7-8
7.11.3 Checking Contact Inputs.................................................................... 7-8
7.12 Calibration ......................................................................................................... 7-9
7.12.1 Calibration Setup ............................................................................... 7-9
7.12.2 Manual Calibration........................................................................... 7-10
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 Input Ranges...................................................................................... 8-1
8.1.3 Setting Output Smoothing Coefcient ............................................... 8-2
8.1.4 Selection of Output Mode .................................................................. 8-2
8.1.5 Default Values.................................................................................... 8-2
8.2 Output Hold Setting .......................................................................................... 8-3
8.2.1 Denition of Equipment Status .......................................................... 8-3
8.2.2 Preference Order of Output Hold Value............................................. 8-4
8.2.3 Output Hold Procedure...................................................................... 8-4
8.2.4 Default Values.................................................................................... 8-5
8.3 Oxygen Concentration Alarms Setting........................................................... 8-6
8.3.1 Setting the Alarm Values.................................................................... 8-6
8.3.2 Alarm Output Actions ......................................................................... 8-6
8.3.3 Alarm Setting Procedure.................................................................... 8-7
8.3.4 Default Values.................................................................................... 8-8
8.4 Contact Output Setting..................................................................................... 8-8
8.4.1 Contact Output .................................................................................. 8-8
8.4.2 Setting Procedure .............................................................................. 8-9
8.4.3 Default Values.................................................................................. 8-11
8.5 Contact Input Setting...................................................................................... 8-12
8.5.1 Contact Input Functions................................................................... 8-12
8.5.2 Setting Procedure ............................................................................ 8-13
8.5.3 Default Values..................................................................................8-13
8.6 Other Settings ................................................................................................. 8-14
8.6.1 Setting the Date-and-Time...............................................................8-14

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IM 11M13A01-02E
8.6.2 Setting Periods over which Average Values Are Calculated and Periods
over which Maximum and Minimum Values Are Monitored.............8-14
8.6.3 Setting Fuels .................................................................................... 8-15
8.6.4 Setting Purging ................................................................................8-20
8.6.5 Setting Passwords ........................................................................... 8-21
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 Detailed-data Display...................................................................................... 10-1
10.1.1 Cell Voltage......................................................................................10-1
10.1.2 Thermocouple Voltage.....................................................................10-2
10.1.3 Cold Junction Resistance (C.J. Voltage) ......................................... 10-2
10.1.4 Cell’s Internal Resistance ................................................................10-2
10.1.5 Software Revision............................................................................ 10-2
10.1.6 Span gas and Zero gas Correction Ratios ......................................10-2
10.1.7 Cell Response Time.........................................................................10-3
10.1.8 Robustness of a Cell........................................................................10-3
10.1.9 Cell Temperature..............................................................................10-3
10.1.10 C. J. Temperature.............................................................................10-4
10.1.11 Maximum Oxygen Concentration....................................................10-4
10.1.12 Minimum Oxygen Concentration..................................................... 10-4
10.1.13 Average Oxygen Concentration ......................................................10-4
10.1.14 Heater On-Time Ratio......................................................................10-4
10.1.15 Time .................................................................................................10-4
10.1.16 History of Calibration Time...............................................................10-4
10.1.17 Power Supply Voltage......................................................................10-4
10.1.18 Power Frequency.............................................................................10-4
10.2 Trend Graph..................................................................................................... 10-5
10.2.1 Setting Display Items .......................................................................10-5
10.2.2 Sampling Interval ............................................................................. 10-5
10.2.3 Setting Upper and Lower Limit Values on Graph ............................10-6
10.2.4 Default Setting..................................................................................10-6
10.3 Other Display-related Functions................................................................... 10-7
10.3.1 Auto-Return Time............................................................................. 10-7

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IM 11M13A01-02E
10.3.2 Entering Tag Name ..........................................................................10-7
10.3.3 Language Selection.........................................................................10-7
10.4 Blow Back ........................................................................................................ 10-8
10.4.1 Mode of Blow back...........................................................................10-8
10.4.2 Operation of Blow back....................................................................10-8
10.4.3 Setting Output Hold Time and Blow back Time ...............................10-9
10.4.4 Setting Interval, Start Date, and Start Time .....................................10-9
10.4.5 Default Setting................................................................................10-10
10.5 Parameter Initialization.................................................................................10-10
10.6 Reset............................................................................................................... 10-13
10.7 Handling of the ZO21S Standard Gas Unit.................................................10-14
10.7.1 Standard Gas Unit Component Identication................................10-14
10.7.2 Installing Gas Cylinders.................................................................10-15
10.7.3 Calibration Gas Flow......................................................................10-15
10.8 Methods of Operating Valves in the ZA8F Flow Setting Unit ................... 10-18
10.8.1 Preparation Before Calibration ...................................................... 10-18
10.8.2 Operating the Span Gas Flow Setting Valve .................................10-18
10.8.3 Operating the Zero Gas Flow Setting Valve ..................................10-18
10.8.4 Operation After Calibration ............................................................10-19
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...................................................... 11-2
11.1.3 Replacement of the Heater Unit (Assembly) ................................... 11-5
11.1.4 Replacement of Flame Arrestor Assembly ...................................... 11-8
11.1.5 Replacement of O-ring..................................................................... 11-8
11.1.6 Cleaning the High Temperature Probe Adapter............................... 11-9
11.1.7 Stopping and Re-starting Operation................................................ 11-9
11.2 Inspection and Maintenance of the Converter .......................................... 11-10
11.2.1 Replacing Fuses ............................................................................ 11-10
11.2.2 Cleaning..........................................................................................11-11
11.2.3 Adjust LCD screen contrast............................................................11-11
11.3 Replacing Flowmeter in ZR40H Automatic Calibration Unit.................... 11-12
12. Troubleshooting ..................................................................................... 12-1
12.1 Displays and Remedies When Errors Occur ............................................... 12-1
12.1.1 Error Types....................................................................................... 12-1
12.1.2 Remedies When an Error Occurs....................................................12-2
12.2 Displays and Remedies When Alarms are Generated................................ 12-5
12.2.1 Alarm Types ..................................................................................... 12-5
12.2.2 Remedies 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

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IM 11M13A01-02E
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 .....................................CMPL 11M13A01-02E
Customer Maintenance Parts List .....................................CMPL 11M12C01-01E
Customer Maintenance Parts List .....................................CMPL 11M12A01-11E
Customer Maintenance Parts List .....................................CMPL 11M03B01-10E
Customer Maintenance Parts List .....................................CMPL 11M03B01-05E
Customer Maintenance Parts List .........................................CMPL 11M3D1-01E
Revision Information ...............................................................................................i

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<1. Overview> 1-1
IM 11M13A01-02E
1. Overview
The EXAxtZR Separate type Explosion-proof 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, 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.
ZR22S Separate type Explosion-proof 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
ue and can measure the gases directly.
For use in combustion gases at temperatures up to 1400°C, choose the general-purpose 0.15
m long detector, which is combined with ZO21P, 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 functions including self-test. Analyzer calibration can
also be fully automated ─and 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 congurations are illustrated below:
1.1 < EXAxt ZR > System Conguration
The system conguration should be determined by the conditions; e.g. whether calibration is
to be automated, and whether ammable gas is present and requires safety precautions. The
system conguration can be classied into three basic patterns as follows:
1.1.1 System 1
This 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 ow is
controlled by the ZA8F ow setting unit (for manual valve operation).
ZA8F
Flow Setting Unit
ZR22S Separate type Explosion-proof ZR402G Converter
Reference gas
Calibration gas
Stop valve
or
Check valve
Needle
valve
Flowmeter
Instrument air
Air Set
Pressure
reducing
valve
Zero gas
cylinder
F01-1E.ai
Span gas (*)
* Calibration gas unit same as for zero gas.
Zirconia Oxygen Analyzer, Detector
Calibration gas
unit case
EXAZR402G
Non-hazardous Area
Hazardous Area
~
100 to 240 V AC
Contact input
Analog output,
contact output
Digital output
(HART)
*1
Figure 1.1 System conguration 1