YOKOGAWA EXAxt ZR22G User manual

User’s
Manual Model ZR22G, ZR402G
Separate type Zirconia
Oxygen/Humidity Analyzer
IM 11M12A01-02E
IM 11M12A01-02E
16th Edition

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IM 11M12A01-02E 16th Edition : Mar. 19, 2020-00
uIntroduction
Thank you for purchasing the ZR22G, ZR402G Separate type Zirconia Oxygen/Humidity
Analyzer.
Please read the following respective documents before installing and using the ZR22G, ZR402G
Separate type Zirconia Oxygen/Humidity Analyzer.
The related documents are as follows.
General Specications
Contents Document number Note
Model ZR22G, ZR402G, and ZR202G
Direct In Situ Zirconia Oxygen Analyzers and High
Temperature Humidity Analyzers
GS 11M12A01-01E
* the “E” in the document number is the language code.
User’s Manual
Contents Document number Note
Model ZR22G, ZR402G
Separate type Zirconia Oxygen/Humidity Analyzer IM 11M12A01-02E (This manual)
Model ZR22S, ZR402G
Separate type Explosion-proof Zirconia Oxygen Analyzer IM 11M13A01-02E
When you use the ZR22S
Explosion-proof detector,
read this manual.
Model ZR22A, ZR202A
Heater Assembly IM 11M12A01-21E
Model EXAxt ZR Series
HART Protocol IM 11M12A01-51E
Model AV550G Zirconia Oxygen Analyzer Averaging
Converter IM 11M12D01-01E
* the “E” in the document number is the language code.
An exclusive User’s Manual might be attached to the products whose su󰀩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 Zirconia Oxygen/Humidity Analyzer is usually the Oxygen
Analyzer which connected ZR402G converter and ZR22G detector together, but it is to the
High Temperature Humidity Analyzer when the option code “/HS (Set for Humidity Analyzer)” of
ZR402G is selected.
After that, in this manaul, the Humidity Analyzer refers to the thing which ZR22G combined with
ZR402G with “/HS”.
In addition, in this manual, the Oxygen Analyzer is mainly listed. When there are not mentions
such as “in the case of Humidity Analyzer”, it becomes same as the Oxygen Analyzer.
The EXAxt ZR Separate type Zirconia Oxygen/Humidity 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 Integrated type (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.>
Media No. IM 11M12A01-02E 16th Edition : Mar. 2020 (YK)
All Rights Reserved Copyright © 2000, Yokogawa Electric Corporation

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IM 11M12A01-02E 16th Edition : Mar. 19, 2020-00
Models and descriptions in this manual are listed below.
Models and descriptions in this manual
Model Product Name Description in this manual
Specication Installation Operation Maintenance CMPL
ZR22G General use detector ○○○○○
ZR22G High temperature detector (0.15m) ○○○○
ZR402G Converter ○○○○○
ZO21R Probe protector ○ ○
ZO21P High temperature probe adapter ○ ○ ○
ZH21B Dust protector (only for Humidity
analyzer) ○ ○
ZA8F Flow setting unit (for manual
calibration use) ○○○
ZR40H Automatic Calibration unit ○ ○ ○ ○
-
Auxiliary ejector for high
temperature use (Part No.
E7046EC, E7046EN)
○ ○ ○
-Calibration gas unit case (Part No.
E7044KF) ○ ○
-Check valve (Part No. K9292DN,
K9292DS) ○ ○
-Dust lter for the detector (Part
No. K9471UA) ○ ○
-Dust guard protector (Part No.
K9471UC) ○ ○
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 three standard system
congurations A C
5. Wiring Wiring procedures such as “Power supply
wiring”, “output signal wiring” or others A C
6. Components 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 A
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 B
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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n For the safe use of this equipment
WARNING
Handle it with care. 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 o󰀨 when connecting power supply.
Some sample gas is dangerous to people. When removing this equipment from the process line
for maintenance or other reasons, protect yourself from potential poisoning by using a protective
mask or ventilating the area well.
CAUTION
The cell (sensor) at the tip of the 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.
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.
l Details on operation parameters
When the EXAxt ZR Separate type Oxygen Analyzer arrives at the user site, it will operate
based on the operation parameters (initial data) set before shipping from the factory.
Ensure that the initial data is suitable for the operation conditions before conducting
analysis. Where necessary, set the instrument parameters for appropriate operation.
For details of setting data, refer to chapters 7 to 10.
When user changes the operation parameter, it is recommended to note down the changed
setting data.

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u Safety Precautions
n Safety, Protection, and Modication of the Product
• In order to protect the system controlled by the product and the product itself and ensure
safe operation, observe the safety precautions described in this user’s manual. We assume
no liability for safety if users fail to observe these instructions when operating the product.
• If this instrument is used in a manner not specied in this user’s manual, the protection
provided by this instrument may be impaired.
• If any protection or safety circuit is required for the system controlled by the product or for
the product itself, prepare it separately.
• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter
simply referred to as YOKOGAWA) when replacing parts or consumables.
• Modication of the product is strictly prohibited.
• The following safety symbols are used on the product as well as in this manual.
WARNING
This symbol indicates that an operator must follow the instructions laid out in this manual in order
to avoid the risks, for the human body, of injury, electric shock, or fatalities. The manual describes
what special care the operator must take to avoid such risks.
CAUTION
This symbol indicates that the operator must refer to the instructions in this manual in order to
prevent the instrument (hardware) or software from being damaged, or a system failure from
occurring.
CAUTION
This symbol gives information essential for understanding the operations and functions.
NOTE
This symbol indicates information that complements the present topic.
This symbol indicates Protective Ground Terminal.
This symbol indicates Function Ground Terminal. Do not use this terminal as the protective
ground terminal.
n Warning and Disclaimer
The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor
responsibility to any person or entity with respect to any direct or indirect loss or damage arising
from using the product or any defect of the product that YOKOGAWA can not predict in advance.

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n Notes on Handling User’s Manuals
• Please hand over the user’s manuals to your end users so that they can keep the user’s
manuals on hand for convenient reference.
• Please read the information thoroughly before using the product.
• The purpose of these user’s manuals is not to warrant that the product is well suited to any
particular purpose but rather to describe the functional details of the product.
• No part of the user’s manuals may be transferred or reproduced without prior written
consent from YOKOGAWA.
• YOKOGAWA reserves the right to make improvements in the user’s manuals and product at
any time, without notice or obligation.
• If you have any questions, or you nd mistakes or omissions in the user’s manuals, please
contact our sales representative or your local distributor.
n Drawing Conventions
Some drawings may be partially emphasized, simplied, or omitted, for the convenience of
description.
Some screen images depicted in the user’s manual may have di󰀨erent display positions or
character types (e.g., the upper / lower case). Also note that some of the images contained in this
user’s manual are display examples.
In the gure listed in this manual, the example of the oxygen analyzer is shown mainly.
In the case of the humidity analyzer, unit indication may be di󰀨erent. Please read it appropriately.
n Product Disposal:
The instrument should be disposed of in accordance with local and national legislation/regulations.
n Trademark Acknowledgments
• All other company and product names mentioned in this user’s manual are trademarks or
registered trademarks of their respective companies.
• We do not use TM or ® mark to indicate those trademarks or registered trademarks in this
user’s manual.

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u CE marking products
n Authorized 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.
n Users
This product is designed to be used by a person with specialized knowledge.
n How to dispose the batteries:
This is an explanation about the EU Battery Directive. This directive is only valid in the EU.
Batteries are included in this product. Batteries incorporated into this product cannot be removed
by yourself. Dispose them together with this product.
When you dispose this product in the EU, contact your local Yokogawa Europe B.V.o󰀩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 11M12A01-02E 16th Edition : Mar. 19, 2020-00
Model ZR22G, ZR402G
Separate type Zirconia
Oxygen/Humidity Analyzer
CONTENTS
IM 11M12A01-02E 16th Edition
uIntroduction....................................................................................................i
u Safety Precautions ......................................................................................iv
u CE marking products..................................................................................vi
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 Detectors and Accessories ................................................................ 1-4
2. Specications ........................................................................................... 2-1
2.1 General Specications ..................................................................................... 2-1
2.2 General use Separate type Detector and Related Equipment ..................... 2-3
2.2.1 ZR22G General use Separate type Detector .................................... 2-3
2.2.2 ZO21R Probe Protector ..................................................................... 2-8
2.2.3 ZH21B Dust Protector........................................................................ 2-9
2.3 Separate type Detector for High Temperature and Related Equipment ... 2-10
2.3.1 ZR22G (0.15m) Separate type Detector for High Temperature ...... 2-10
2.3.2 ZO21P High Temperature Probe Adapter ....................................... 2-11
2.4 ZR402G Separate type Converter ................................................................. 2-13
2.5 ZA8F Flow Setting Unit and
ZR40H Automatic Calibration Unit ................................................................ 2-18
2.5.1 ZA8F Flow Setting Unit .................................................................... 2-18
2.5.2 ZR40H Automatic Calibration Unit................................................... 2-20
2.6 ZO21S Standard Gas Unit .............................................................................. 2-22
2.7 Other Equipments........................................................................................... 2-23
2.7.1 Dust Filter for the Detector (K9471UA)............................................ 2-23
2.7.2 Dust Guard Protector (K9471UC).................................................... 2-24
2.7.3 Ejector Assembly for High Temperature (E7046EC, E7046EN) ..... 2-24
2.7.4 Stop Valve (L9852CB, G7016XH) ................................................... 2-27
2.7.5 Check Valve (K9292DN, K9292DS) ................................................ 2-27
2.7.6 Air Set............................................................................................... 2-28
2.7.7 Zero Gas Cylinder (G7001ZC) ........................................................ 2-29

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2.7.8 Cylinder Pressure Reducing Valve (G7013XF, G7014XF) ................2-29
2.7.9 Case Assembly for Calibration Gas Cylinder (E7044KF)................ 2-30
2.7.10 ZR22A Heater Assembly.................................................................. 2-31
3. Installation................................................................................................. 3-1
3.1 Installation of General-purpose Detector....................................................... 3-1
3.1.1 Probe Insertion Hole .......................................................................... 3-1
3.1.2 Installation of the Detector ................................................................. 3-2
3.1.3 Installation of the Dust Filter (K9471UA), Dust Guard Protector
(K9471UC), Probe Protector ZO21R................................................. 3-2
3.1.4 Installation of ZH21B Dust Protector ................................................. 3-4
3.2 Installation of High Temperature Detector
(ZR22G-015)....................................................................................................... 3-5
3.2.1 Usage of the High Temperature Probe Adapter (ZO21P-H).............. 3-5
3.2.2 Probe Insertion Hole .......................................................................... 3-6
3.2.3 Mounting of the High Temperature Detector...................................... 3-7
3.3 Installation of the ZR402G Converter ............................................................. 3-8
3.4 Installation of ZA8F Flow Setting Unit .......................................................... 3-10
3.5 Installation of ZR40H Automatic Calibration Unit ....................................... 3-11
3.6 Installation of the Case Assembly (E7044KF) ...............................................3-12
3.7 Insulation Resistance Test............................................................................. 3-13
4. Piping......................................................................................................... 4-1
4.1 Piping for System 1........................................................................................... 4-1
4.1.1 Parts Required for Piping in System 1............................................... 4-2
4.1.2 Connection to the Calibration Gas Inlet ............................................. 4-3
4.1.3 Connection to the Reference Gas Inlet ............................................. 4-3
4.1.4 Piping to the High Temperature Probe Adapter ................................. 4-3
4.2 Piping for System 2........................................................................................... 4-5
4.2.1 Piping Parts for System 2 .................................................................. 4-6
4.2.2 Piping for the Calibration Gas ............................................................ 4-6
4.2.3 Piping for the Reference Gas............................................................. 4-7
4.2.4 Piping to the High Temperature Probe Adapter ................................. 4-7
4.3 Piping for System 3........................................................................................... 4-7
4.4 Piping for the Detector with Pressure Compensation.................................. 4-9
4.4.1 Piping Parts for a System using Detector with Pressure Compensation
4-11
4.4.2 Piping for the Calibration Gas .......................................................... 4-11
4.4.3 Piping for the Reference Gas........................................................... 4-11
5. Wiring......................................................................................................... 5-1
5.1 General............................................................................................................... 5-1
5.1.1 Terminals for the External Wiring in the Converter ............................ 5-2
5.1.2 Wiring ................................................................................................. 5-3
5.1.3 Mounting of Cable Gland ................................................................... 5-4
5.2 Wiring ................................................................................................................. 5-5

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5.2.1 Connection to Converter.................................................................... 5-5
5.2.2 Connection to Detector ...................................................................... 5-5
5.2.3 Power and Grounding Wiring............................................................. 5-6
5.2.4 Wiring for Power to Detector Heater.................................................. 5-7
5.2.5 Wiring for Detector Output ................................................................. 5-7
5.2.6 Wiring for Analog Output.................................................................... 5-9
5.2.7 Contact Output Wiring........................................................................ 5-9
5.2.8 Contact Input Wiring ........................................................................ 5-10
5.2.9 Wiring for ZR40H Automatic Calibration Unit .................................. 5-11
5.2.10 Temperature Input Wiring ................................................................ 5-12
6. Components ............................................................................................. 6-1
6.1 ZR22G Detector................................................................................................. 6-1
6.1.1 General-purpose Detector (except for ZR22G-015).......................... 6-1
6.1.2 High Temperature Detector (ZR22G-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......................................................................... 6-4
6.3.3 Display Functions............................................................................... 6-5
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..................................................... 7-2
7.3 Checking Valve Setup....................................................................................... 7-2
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
7.8.1 Oxygen Analyzer - Minimum Current (4 mA) and Maximum Current (20
mA) Settings....................................................................................... 7-4
7.8.2 Humidity Analyzer - Analog Output Setting........................................ 7-5
7.8.3 Humidity Analyzer - Minimum Current (4 mA) and Maximum Current (20
mA) Settings....................................................................................... 7-5
7.9 Setting Display Item.......................................................................................... 7-6
7.9.1 Oxygen Analyzer - Setting Display Item ............................................ 7-6
7.9.2 Humidity Analyzer - Setting Display Item........................................... 7-8
7.10 Checking Current Loop.................................................................................. 7-10
7.11 Checking Contact I/O...................................................................................... 7-10
7.11.1 Checking Contact Output................................................................. 7-10
7.11.2 Checking Calibration Contact Output .............................................. 7-11
7.11.3 Checking Input Contacts.................................................................. 7-11

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7.12 Calibration ....................................................................................................... 7-12
7.12.1 Calibration Setup ............................................................................. 7-12
7.12.2 Manual Calibration........................................................................... 7-13
8. Detailed Data Setting ............................................................................... 8-1
8.1 Current Output Setting ..................................................................................... 8-1
8.1.1 Oxygen Analyzer - Setting Minimum Current (4 mA) and Maximum
Current (20 mA) ................................................................................. 8-1
8.1.2 Humidity Analyzer - Setting Minimum Current (4 mA) and Maximum
Current (20 mA) ................................................................................. 8-1
8.1.3 Input Ranges...................................................................................... 8-1
8.1.4 Setting Output Smoothing Coe󰀩cient ............................................... 8-4
8.1.5 Selection of Output Mode .................................................................. 8-4
8.1.6 Default Values.................................................................................... 8-4
8.2 Output Hold Setting .......................................................................................... 8-4
8.2.1 Denition of Equipment Status .......................................................... 8-5
8.2.2 Preference Order of Output Hold Value............................................. 8-5
8.2.3 Output Hold Setting............................................................................ 8-6
8.2.4 Default Values.................................................................................... 8-6
8.3 Alarms Setting................................................................................................... 8-6
8.3.1 Setting the Alarm Values.................................................................... 8-7
8.3.2 Alarm Output Actions ......................................................................... 8-7
8.3.3 Alarm Setting Procedure.................................................................... 8-8
8.3.4 Default Values.................................................................................... 8-9
8.4 Output Contact Setup....................................................................................... 8-9
8.4.1 Output Contact................................................................................... 8-9
8.4.2 Setting Procedure ............................................................................ 8-10
8.4.3 Default Values.................................................................................. 8-12
8.5 Input Contact Settings.................................................................................... 8-12
8.5.1 Input Contact Functions................................................................... 8-12
8.5.2 Setting Procedure ............................................................................ 8-13
8.5.3 Default Values.................................................................................. 8-14
8.6 Other Settings ................................................................................................. 8-14
8.6.1 Setting the Date-and-Time............................................................... 8-14
8.6.2 Setting Periods over which Average Values Are Calculated and Periods
over which Maximum and Minimum Values Are Monitored............. 8-14
8.6.3 Setting Fuels .................................................................................... 8-15
8.6.4 Setting Measurement Gas Temperature and Pressure................... 8-19
8.6.5 Setting Purging ................................................................................ 8-21
8.6.6 Setting Passwords ........................................................................... 8-22
9. Calibration................................................................................................. 9-1
9.1 Calibration Briefs .............................................................................................. 9-1
9.1.1 Principle of Measurement with a zirconia oxygen analyzer .............. 9-1
9.1.2 Measurement Principle of Zirconia Humidity Analyzer...................... 9-2

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9.1.3 Calibration Gas .................................................................................. 9-4
9.1.4 Compensation.................................................................................... 9-4
9.1.5 Characteristic Data from a Sensor Measured During Calibration ..... 9-5
9.2 Calibration Procedures .................................................................................... 9-6
9.2.1 Mode .................................................................................................. 9-6
9.2.2 Calibration Procedure ........................................................................ 9-7
9.2.3 Zero gas Concentration ..................................................................... 9-7
9.2.4 Span gas Concentration .................................................................... 9-7
9.2.5 Setting Calibration Time..................................................................... 9-8
9.3 Calibration ......................................................................................................... 9-9
9.3.1 Manual Calibration............................................................................. 9-9
9.3.2 Semi-automatic Calibration ............................................................. 9-10
9.3.3 Automatic Calibration....................................................................... 9-10
10. Other Functions...................................................................................... 10-1
10.1 Detailed-data Display...................................................................................... 10-1
10.1.1 Span gas and Zero gas Correction Ratios ...................................... 10-1
10.1.2 Cell Response Time......................................................................... 10-2
10.1.3 Robustness of a Cell........................................................................ 10-2
10.1.4 Cell Temperature.............................................................................. 10-2
10.1.5 C. J. Temperature............................................................................. 10-2
10.1.6 Cell Voltage ...................................................................................... 10-3
10.1.7 Thermocouple Voltage..................................................................... 10-3
10.1.8 Cold Junction Resistance (C.J. Voltage) ......................................... 10-3
10.1.9 Cell’s Internal Resistance ................................................................ 10-3
10.1.10 Software Revision............................................................................ 10-3
10.1.11 Maximum Oxygen Concentration, Humidity and Mixing Ratio........ 10-4
10.1.12 Minimum Oxygen Concentration, Humidity and Mixing Ratio......... 10-4
10.1.13 Average Oxygen Concentration, Humidity and Mixing Ratio .......... 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..................................................................................................... 10-4
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
10.3.2 Entering Tag Name .......................................................................... 10-7
10.3.3 Language Selection ......................................................................... 10-7

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10.4 Blow Back ........................................................................................................ 10-8
10.4.1 Mode ................................................................................................ 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............................................................................................................... 10-17
10.7 Handling of the ZO21S Standard Gas Unit.................................................10-17
10.7.1 Standard Gas Unit Component Identication................................10-18
10.7.2 Installing Gas Cylinders ................................................................. 10-19
10.7.3 Calibration Gas Flow......................................................................10-19
10.8 Methods of Operating Valves in the ZA8F Flow Setting Unit................... 10-21
10.8.1 Preparation Before Calibration ......................................................10-22
10.8.2 Operating the Span Gas Flow Setting Valve .................................10-22
10.8.3 Operating the Zero Gas Flow Setting Valve ..................................10-22
10.8.4 Operation After Calibration ............................................................ 10-23
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 Unit ...................................................... 11-4
11.1.4 Replacement of Dust Filter .............................................................. 11-6
11.1.5 Replacement of O-ring..................................................................... 11-6
11.1.6 Cleaning the High Temperature Probe Adapter............................... 11-7
11.1.7 Stopping and Re-starting Operation ................................................ 11-7
11.2 Inspection and Maintenance of the Converter ............................................ 11-8
11.2.1 Replacing Fuses .............................................................................. 11-8
11.2.2 Cleaning........................................................................................... 11-9
11.2.3 Adjust LCD screen contrast ............................................................. 11-9
11.3 Replacing Flowmeter in ZR40H Automatic Calibration Unit...................... 11-9
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................................ 12-4
12.2.1 Alarm Types ..................................................................................... 12-4
12.2.2 Remedies When Alarms are Generated.......................................... 12-5
12.3 Countermeasures When Measured Value Shows Error........................... 12-11
12.3.1 Measured Value Higher (Lower for Humidity Analyzer)Than True Value . 12-11
12.3.2 Measured Value Lower (Higher for Humidity Analyzer) Than True Value 12-12
12.3.3 Measurements Sometimes Show Abnormal Values ..................... 12-13

Toc-7
IM 11M12A01-02E 16th Edition : Mar. 19, 2020-00
Customer Maintenance Parts List......................................CMPL 11M12A01-02E
Customer Maintenance Parts List......................................CMPL 11M12C01-01E
Customer Maintenance Parts List......................................CMPL 11M03B01-10E
Customer Maintenance Parts List......................................CMPL 11M03B01-05E
Customer Maintenance Parts List......................................CMPL 11M12A01-11E
Customer Maintenance Parts List..........................................CMPL 11M3D1-01E
Revision Information ...............................................................................................i

Blank Page

<1. Overview> 1-1
IM 11M12A01-02E 16th Edition : Mar. 19, 2020-00
1. Overview
The EXAxt ZR Separate type Zircon Oxygen/Humidity Analyzer is used to monitor and control
the oxygen concentration in combustion gases, in boilers and industrial furnaces, for wide
application in industries which consume considerable energy — such as steel, electric power,
oil and petrochemical, ceramics, paper and pulp, 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 ZR22G Separate type Detector uses a high-reliability Zirconia sensor, and its heater
assembly can be replaced on site. The detector is mounted, for example, on the wall of a ue and
can measure the gases directly.
For use in combustion gases at temperatures up to 1400°C, choose the general use 0.15 m long
detector, which is combined with the ZO21P, the high temperature probe protector.
The EXAxt ZR Separate-type Zirconia Humidity Analyzer is used to measure the humidity of hot
gases continuously in driers which use hot gas or electricity as the heat source. It can also be
used in a variety of manufacturing applications in humidiers, as well as in driers, for humidity
measurement and control. It can help improve productivity in these application elds.
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 the 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 is the simplest system consisting of a detector and a converter. This system can be
implemented for monitoring oxygen concentration in the combustion gases of a package
boiler, and can be implemented for monitoring humidity in a production process such as food
production.
No piping is required for the reference gas (air) which is fed in at the installation site. The handy
the ZO21S standard gas unit is used for calibration.
Zero gas from this unit and span gas (air) is sent to the detector through a tube which is
connected during calibration.

<1. Overview> 1-2
IM 11M12A01-02E 16th Edition : Mar. 19, 2020-00
EXAZR402G
ZR22G Separate type
Zirconia Oxygen/Humidity Analyzer, Detector
ZR402G Converter
Stop valve
Calibration gas
ZO21S Standard gas unit
~100 to
240 V AC
F1-1E.ai
Contact input
Analog output, contact output
(Digital output HART)
Signal
(6-core shield cable)
Heater(2-core)
~
Figure1.1
NOTE
• As this system uses ambient air for the reference gas, measuring accuracy will be a󰀨ected
by the installation location.
• A needle (stop) valve should be connected to the calibration gas inlet of the detector.
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. Clean (dry) air (21 vol%O2) is used as the reference gas and
the span gas for calibration.
In case of humidity analyzer, this system is for accurate monitoring and controlling humidity when
the installation environment is polluted with gases other than the air. Instrument air (clean and dry
air of oxygen concentration 21%) is used for the reference gas and the span gas for calibration.
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).

<1. Overview> 1-3
IM 11M12A01-02E 16th Edition : Mar. 19, 2020-00
F1-2E.ai
ZR402G Converter
Check valve
or Stop Valve
ZA8F Flow Setting Unit
EXAZR402G
ZR22G Separate type
Zirconia Oxygen/Humidity Analyzer, Detector
100 to
240 V AC
Air Set
Instrument air
Calibration gas
Reference
gas
Flowmeter Needle
valve
Calibration gas
unit case
Zero gas
cylinder
Span gas
(Same as Zero gas calibration unit)
Contact input
Analog output, contact output
(Digital output HART)
Signal
(6-core shield cable)
Heater(2-core)
~
Pressure
reducing
valve
Figure1.2
1.1.3 System 3
This example, System 3, represents typical applications in large boilers and heating furnaces,
where there is a need to monitor and control oxygen concentration. The reference gas and
calibration-time span gas are (clean, dry) instrument air. Zero gas is supplied from a gas cylinder.
System 3 uses the ZR40H automatic calibration unit, with auto-switching of the calibration gas.
A “combustible gas detected” contact input turns o󰀨 power to the heater. There’s also contact
output from the converter that can be used to operate a purge gas valve to supply air to the
sensor.
F1-3E.ai
ZR22G Separate type
Zirconia Oxygen/Humidity Analyzer, Detector ZR402G Converter
Signal
(6-core shield cable)
Heater (2-core)
Reference gas
Calibration gas
Flowmeter Needle
valve
Zero gas cylinder
100 to 240 V AC
*3
Check valve
Contact input
Analog output, contact output
Digital output (HART)
Air Set
lnstrument air
Pressure
reducing
valve
EXAZR402G
*1
*2
~
Calibration gas
unit case
ZR40H
Automatic Calibration Unit
*1 Shield cable ; Use shielded signal cables, and connect the shield 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 approximately 1% of O2gas (N2-
based).
Figure1.3

<1. Overview> 1-4
IM 11M12A01-02E 16th Edition : Mar. 19, 2020-00
1.2 < EXAxt ZR > System Components
1.2.1 System Components
System Components
Separate type
Oxygen
Analyzer
Humidity
Analyzer
System cong.
Ex.1 Ex.2 Ex.3
Model ZR22G Separate type Zirconia Oxygen Analyzers ,Detector A A A A A
Model ZR402G Separate type Zirconia Oxygen Analyzer, Converter A A A A A
Model ZO21P Adapter for High Temperature Probe of separate type
Zirconia Oxygen Analyzer B B B B
E7046EC, E7046EN Ejector Assembly for High temperature of separate
type Oxygen Analyzer
B B B B
Model ZO21R Probe Protector for Zirconia Oxygen Analyzers B B B B B
K9471UA Dust Filter for Oxygen Analyzer B B B B
K9471UC Dust Guard Protector B B B B B
ZH21B Dust protector (only for Humidity Analyzer) B B B B
Model ZO21S Standard Gas Unit A B B
Model ZA8F Flow Setting Unit for manual calibration A B B
Model ZR40H Automatic Calibration Unit for Separate type Oxygen
Analyzer A B B
L9852CB, G7016XH Stop Valve for Calibration gas line A(A) B B
K9292DN,K9292DS Check Valve for Calibration gas line (A) A B B
G7003XF/K9473XK, G7004XF/K9473XG Air Set A A B B
G7001ZC Zero gas Cylinder A A B B
G7013XF, G7014XF Pressure Reducing Valve for Gas Cylinder A A B B
E7044KF Case Assembly for Calibration gas Cylinder A A B B
Model ZR22A Heater Assembly (Spare Parts for Model ZR22G) B B B B B
A: Items required for the above system example
B: To be selected depending on each application. For details, refer to corresponding chapter.
(A): Select either
1.2.2 Detectors and Accessories
Detector
(ZR22G)
Detector
(ZR22G)
Detector(ZR22G)
Probe Protector
(ZO21R)
Gas Flow
F06.ai
+
Sample gas temperature 0 to 700°C Sample gas temperature 700 to 1400˚C
Mounting
Insertion
length General use Probe
High temperature detector
Application Application
Horizontal
to
vertical
Horizontal
to
vertical
Horizontal
to
vertical
Vertical
Vertical
0.15
to
2 m
0.15
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
Black liquid
recovery boiler
Cement
Kiln
Sample inlet
Sample
outlet
Sample inlet
High temperature
detector
Heating
furnace
Temperature:
Probe material: SUS310S 800˚C
Probe material: SiC 1400˚C
Mounting: Vertical downwards
Insertion length: 1.0 m, 1.5 m
When duct pressure is atmospheric
or negative, attach air ejector.
High temperature auxiliary ejector
assembly (E7046EC, E7046EN)
Pressure gauge
Needle
valve
Blow
Absorption
structure
Inlet
Ejector
Probe adapter
for high
temperature use
ZO21P-H
Dust filter for
Oxygen Analyzer
(K9471UA)
Dust guard
protector
(K9471UC)
or
Dust protector
(ZH21B)
Detector
(only ZR22G
-040)
Humidity analyzer use

  <2.Specications> 2-1
IM 11M12A01-02E 16th Edition : Mar. 19, 2020-00
2. Specications
This chapter describes the specications for the following:
ZR22G General use separate type detector (See Section 2.2.1)
ZO21R Probe protector (See Section 2.2.2)
ZH21B Dust protector (See Section 2.2.3)
ZR22G (0.15 m) High temperature separate type detector (See Section 2.3.1)
ZO21P Adapter for High temperature probe (See Section 2.3.2)
ZR402G Separate type converter (See Section 2.4)
ZA8F Flow setting unit (See Section 2.5.1)
ZR40H Automatic calibration unit (See Section 2.5.2)
ZO21S Standard gas unit (See Section 2.6)
2.1 General Specications
n 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)
The sampling gases containing a corrosive gas such as ammonia or
chlorine may be applicable to our oxygen gas analyzer. In this case,
contact with YOKOGAWA and its agency.
(In case of Humidity Analyzer, Water vapor (in vol%) in mixed gases (air
and water vapor))
Measurement System: Zirconia system
Measurement Range: 0.01 to 100 vol%O2
(In case of Humidity Analyzer, 0 to 100 vol% H2O or 0 to 1.000 kg/kg)
Output Signal: 4 to 20 mA DC (maximum load resistance 550 Ω)
Setting Range: Any setting in the range of 0 to 5 through 0 to 100 vol%O2(in 1 vol%O2),
or partial range
In case of Humidity Analyzer,
Moisture quantity; 0 to 25 through 0 to 100 vol% H2O (in 1 vol%
H2O), or partial range.
Mixture ratio; 0 to 0.2 through 0 to 1.000 kg/kg (in 0.001 kg/kg), or
partial range.
Digital Communication (HART): 250 to 550 Ω, depending on number of eld devices connected
to the loop (multi-drop mode).
Note: HART is a registered trademark of the HART Communication Foundation.
Display Range: Oxygen concentration; 0 to 100 vol%O2
In case of Humidity Analyzer,
Moisture quantity; 0 to 100 vol% H2O, Mixture ratio; 0 to 1 kg/kg, Relative
humidity; 0 to 100% RH (Note), Dew point; -40 to 370°C (Note)
Note: These values are a󰀨ected by temperature and absolute pressure, So accurate temperature and
pressure values must be inputted to the converter.
Warm-up Time: Approx. 20 min.
These characteristics are calculated by oxygen concentration measured in air which include
water vapor.