YOKOGAWA EXAxt ZR402G User manual

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

i
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
uIntroduction
Thank you for purchasing the ZR202G Integrated type Oxygen/Humidity Analyzer.
Please read the following respective documents before installing and using the ZR202G
Integrated type 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 ZR202G
Integrated type Oxygen/Humidity Analyzer IM 11M12A01-04E (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 Integrated type Zirconia Oxygen/Humidity Analyzer is usually the Oxygen
Analyzer, but it is to the High Temperature Humidity Analyzer when the option code “/HS (Set for
Humidity Analyzer)” is selected.
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 Integrated type Zirconia Oxygen/Humidity Analyzer has been developed for
combustion control in various industrial processes. There are several version of this analyzer so
you can select one that matches your application.
Optional accessories are also available to improve measurement accuracy and automate
calibration. An optimal control system can be realized by adding appropriate options.
This instruction manual describes almost all of the equipment related to the EXAxt ZR. You may
skip any section(s) regarding equipment which is not included in your system.
Regarding the HART Communication Protocol, refer to IM 11M12A01-51E.
IM 11M12A01-51E has been published as ‘’Model EXAxt ZR series HART protocol’’.
Regarding Separate type Zirconia Oxygen Analyzer, refer to IM 11M12A01-02E.
<Before using the equipment, please read any descriptions in this manual related to the
equipment and system that you have, on appropriate use and operation of the EXAxt ZR.>
No. IM 11M12A01-04E 11th Edition : Jul. 2017 (YK)
All Rights Reserved Copyright © 2000, Yokogawa Electric Corporation

ii
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
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
ZR202G Integrated type Oxygen
Analyzer ○○○○○
ZO21R Probe protector ○ ○
ZH21B Dust protector (only for Humidity
analyzer) ○ ○
ZA8F Flow setting unit (for manual
calibration use) ○○○
ZR20H Automatic Calibration unit ○ ○ ○ ○
-Case Assembly for calibration
gas cylinder (Part No. E7044KF) ○ ○
-Check valve (Part No.
K9292DN, K9292DS) ○ ○
-Dust 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 BCB
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 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.

iii
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
n For the safe use of this equipment
WARNING
Be sure not to accidentally drop it. Handle safely to avoid injury.
Connect the power supply cord only after conrming that the supply voltage matches the rating of
this equipment. In addition, conrm that the power is switched off when connecting power supply.
Some 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 probe is made of ceramic (zirconia element). Do not drop the
equipment or subject it to pressure stress.
• Do NOT allow the sensor (probe tip) to make contact with anything when installing the
analyzer.
• Avoid any water dropping directly on the probe (sensor) of the analyzer when installing it.
• Check the calibration gas piping before introducing the calibration gas to ensure that there
is no leakage of the gas. If there is any leakage of the gas, the moisture drawn from the
sample gas may damage the sensor.
• The probe (especially at the tip) becomes very hot. Be sure to handle it with gloves.
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.

iv
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
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.

v
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
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 different 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 different. 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.

vi
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
n Special descriptions in this manual
This manual indicates operation keys, displays and drawings on the product as follows:
l Operation keys, displays on the panel
Enclosed in [ ]. (Ex. “MODE” key)
(Ex. message display → “BASE”)
(Ex. data display → “102” lit, “102” ashing)
l Drawing for ashing
Indicated by gray characters (Flashing) (lit)
l Displays on the LCD display panel
9
8
7
6
5
4
3
2
1
0
W
V
U
T
S
R
Q
P
O
N
M
L
K
J
I
H
G
F
E
D
C
B
A
Alphanumerics Alphanumerics AlphanumericsLED Display LED Display LED Display
Z
Y

vii
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
u CE marking products
n Authorised Representative in EEA
The Authorised 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.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.

Blank Page

Toc-1
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
Model ZR202G
Integrated type
Oxygen/Humidity Analyzer
CONTENTS
IM 11M12A01-04E 11th Edition
uIntroduction....................................................................................................i
u Safety Precautions ......................................................................................iv
u CE marking products.................................................................................vii
1. Overview.................................................................................................... 1-1
1.1 < EXAxt ZR > System Conguration............................................................... 1-1
1.1.1 System 1 ............................................................................................ 1-1
1.1.2 System 2 ............................................................................................ 1-2
1.1.3 System 3 ............................................................................................ 1-3
1.2 < EXAxt ZR > System Components ................................................................ 1-4
1.2.1 System Components ......................................................................... 1-4
1.2.2 Oxygen/Humidity Analyzer and Accessories..................................... 1-4
2. Specications ........................................................................................... 2-1
2.1 General Specications ..................................................................................... 2-1
2.1.1 Standard Specications..................................................................... 2-1
2.1.2 ZR202G Integrated type Zirconia Oxygen Analyzer.......................... 2-2
2.1.3 ZO21R Probe Protector ..................................................................... 2-9
2.1.4 ZH21B Dust Protector...................................................................... 2-10
2.2 ZA8F Flow Setting Unit and ZR20H Automatic Calibration Unit................ 2-11
2.2.1 ZA8F Flow Setting Unit .................................................................... 2-11
2.2.2 ZR20H Automatic Calibration Unit................................................... 2-14
2.3 ZO21S Standard Gas Unit .............................................................................. 2-16
2.4 Other Equipment............................................................................................. 2-17
2.4.1 Dust Filter for Oxygen Analyzer (part no. K9471UA)....................... 2-17
2.4.2 Dust Guard Protector (K9471UC).................................................... 2-17
2.4.3 Stop Valve (part no. L9852CB or G7016XH)................................... 2-18
2.4.4 Check Valve (part no. K9292DN or K9292DS)................................ 2-18
2.4.5 Air Set............................................................................................... 2-19
2.4.6 Zero Gas Cylinder (part no. G7001ZC) ........................................... 2-20
2.4.7 Pressure Regulator (G7013XF or G7014XF) for Gas Cylinder....... 2-21
2.4.8 Case Assembly (E7044KF) for Calibration gas Cylinder................. 2-21
2.4.9 ZR202A Heater Assembly ............................................................... 2-22
3. Installation................................................................................................. 3-1
3.1 Installation of ZR202G Zirconia Oxygen/Humidity Analyzer ....................... 3-1

Toc-2
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
3.1.1 Probe Insertion Hole .......................................................................... 3-1
3.1.2 Installation of the Probe ..................................................................... 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 ZA8F Flow Setting Unit ............................................................ 3-5
3.3 Installation of ZR20H Automatic Calibration Unit ......................................... 3-6
3.4 Installation of the Case Assembly (E7044KF) for Calibration Gas Cylinder3-7
3.5 Insulation Resistance Test............................................................................... 3-8
4. Piping......................................................................................................... 4-1
4.1 Piping for System 1........................................................................................... 4-1
4.1.1 Piping Parts for System 1 .................................................................. 4-2
4.1.2 Piping for the Calibration Gas ............................................................ 4-2
4.1.3 Piping for the Reference Gas............................................................. 4-2
4.2 Piping for System 2........................................................................................... 4-2
4.2.1 Piping Parts for System 2 .................................................................. 4-3
4.2.2 Piping for the Calibration Gas ............................................................ 4-3
4.2.3 Piping for the Reference Gas............................................................. 4-4
4.3 Piping for System 3........................................................................................... 4-4
4.4 Piping for the Oxygen Analyzer with Pressure Compensation................... 4-6
4.4.1 Piping Parts for Oxygen Analyzer with Pressure Compensation ...... 4-8
4.4.2 Piping for the Calibration Gas ............................................................ 4-8
4.4.3 Piping for the Reference Gas............................................................. 4-8
5. Wiring......................................................................................................... 5-1
5.1 General............................................................................................................... 5-1
5.1.1 Terminals for the External Wiring....................................................... 5-2
5.1.2 Wiring ................................................................................................. 5-2
5.1.3 Mounting of Cable Gland ................................................................... 5-3
5.2 Wiring for Analog Output ................................................................................. 5-3
5.2.1 Cable Specications .......................................................................... 5-4
5.2.2 Wiring Procedure ............................................................................... 5-4
5.3 Wiring Power and Ground Terminals ............................................................. 5-4
5.3.1 Wiring for Power Line......................................................................... 5-4
5.3.2 Wiring for Ground Terminals .............................................................. 5-5
5.4 Wiring for Contact Output................................................................................ 5-5
5.4.1 Cable Specications .......................................................................... 5-5
5.4.2 Wiring Procedure ............................................................................... 5-5
5.5 Wiring for Contact Input................................................................................... 5-5
5.5.1 Cable Specications .......................................................................... 5-6
5.5.2 Wiring Procedure ............................................................................... 5-6
6. Components ............................................................................................. 6-1
6.1 ZR202G Zirconia Oxygen/Humisity Analyzer ................................................ 6-1

Toc-3
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
6.2 ZA8F Flow Setting Unit, ZR20H Automatic Calibration Unit ........................ 6-2
7. Startup ....................................................................................................... 7-1
7.1 Checking Piping and Wiring Connections..................................................... 7-1
7.2 Valve Setup ........................................................................................................ 7-1
7.3 Supplying Power to Converter ........................................................................ 7-2
7.4 Operation of Infrared Switch ........................................................................... 7-2
7.4.1 Display and Switches......................................................................... 7-2
7.4.2 Display Conguration......................................................................... 7-4
7.4.3 Entering Parameter Code Selection Display..................................... 7-5
7.4.4 Selecting Parameter Codes............................................................... 7-6
7.4.5 Changing Set Values ......................................................................... 7-6
7.5 Conrmation of Equipment Type Setting....................................................... 7-8
7.6 Selection of Measurement Gas ....................................................................... 7-9
7.7 Output Range Setting....................................................................................... 7-9
7.7.1 Oxygen Analyzer -Minimum Current (4 mA) and Maximum Current (20
mA) Settings....................................................................................... 7-9
7.7.2 Output Range Setting ...................................................................... 7-11
7.7.3 Humidity Analyzer -Minimum Current (4 mA) and Maximum Current (20
mA) Settings..................................................................................... 7-11
7.8 Setting Display Item........................................................................................ 7-12
7.8.1 Oxygen Analyzer - Setting Display Item .......................................... 7-12
7.8.2 Humidity Analyzer - Setting Display Item......................................... 7-13
7.9 Checking Current Loop.................................................................................. 7-13
7.10 Checking Contact I/O...................................................................................... 7-14
7.10.1 Contact Output Check ..................................................................... 7-14
7.10.2 Checking Calibration Contact Output .............................................. 7-15
7.10.3 Checking Input Contacts.................................................................. 7-16
7.11 Calibration ....................................................................................................... 7-16
7.11.1 Calibration Setup ............................................................................. 7-16
7.11.2 Manual Calibration........................................................................... 7-19
8. Detailed Data Setting ............................................................................... 8-1
8.1 Current Output Setting..................................................................................... 8-1
8.1.1 Oxygen Analyzer_Current Output Setting ......................................... 8-1
8.1.2 Oxygen Analyzer_Analog Output Setting.......................................... 8-1
8.1.3 Setting Minimum Oxygen Concentration (at 4 mA) and Maximum Oxygen
Concentration (at 20 mA)................................................................... 8-2
8.1.4 Minimum and Maximum Settings Corresponding to 4 mA and 20 mA8-2
8.1.5 Input Ranges...................................................................................... 8-2
8.1.6 Entering Output Damping Constants................................................. 8-5
8.1.7 Selection of Output Mode .................................................................. 8-5
8.1.8 Default Values.................................................................................... 8-5
8.2 Output Hold Setting .......................................................................................... 8-5
8.2.1 Denition of Equipment Status .......................................................... 8-6

Toc-4
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
8.2.2 Preference Order of Output Hold Value............................................. 8-7
8.2.3 Output Hold Setting............................................................................ 8-7
8.2.4 Default Values.................................................................................... 8-7
8.3 Setting Alarms................................................................................................... 8-8
8.3.1 Alarm Values...................................................................................... 8-8
8.3.2 Alarm Output Actions ......................................................................... 8-8
8.3.3 Alarm Setting...................................................................................... 8-9
8.3.4 Default Values.................................................................................. 8-10
8.4 Output Contact Setup..................................................................................... 8-10
8.4.1 Output Contact................................................................................. 8-10
8.4.2 Setting Output Contact .................................................................... 8-11
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 Input Contact ....................................................................... 8-13
8.5.3 Default Values.................................................................................. 8-13
8.6 Other Settings ................................................................................................. 8-13
8.6.1 Setting the Date-and-Time............................................................... 8-13
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 ................................................................................ 8-20
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
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 ........................................................................ 9-6
9.2.3 Zero gas Concentration ..................................................................... 9-7
9.2.4 Span gas Concentration .................................................................... 9-7
9.2.5 Calibration Time ................................................................................. 9-7
9.3 Calibration ......................................................................................................... 9-9
9.3.1 Manual Calibration............................................................................. 9-9
9.3.2 Semi-automatic Calibration ............................................................... 9-9
9.3.3 Automatic Calibration....................................................................... 9-10
10. Other Functions...................................................................................... 10-1
10.1 Detailed Display .............................................................................................. 10-1

Toc-5
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
10.1.1 Oxygen Concentration..................................................................... 10-2
10.1.2 Humidity ........................................................................................... 10-2
10.1.3 Mixing Ratio ..................................................................................... 10-2
10.1.4 Relative Humidity ............................................................................. 10-2
10.1.5 Dew Point......................................................................................... 10-2
10.1.6 Air Ratio............................................................................................ 10-3
10.1.7 Cell Temperature.............................................................................. 10-3
10.1.8 Process Gas Temperature............................................................... 10-3
10.1.9 C. J. Temperature............................................................................. 10-3
10.1.10 Amount of Water Vapor in Exhaust Gas .......................................... 10-3
10.1.11 Cell Voltage ...................................................................................... 10-4
10.1.12 Thermocouple Voltage..................................................................... 10-4
10.1.13 Cold Junction Voltage ...................................................................... 10-4
10.1.14 Current Output ................................................................................. 10-4
10.1.15 Response Time................................................................................ 10-4
10.1.16 Cell’s Internal Resistance ................................................................ 10-5
10.1.17 Robustness of a Cell........................................................................ 10-5
10.1.18 Heater On-Time Ratio...................................................................... 10-5
10.1.19
Oxygen Concentration (with time constant), Humidity (with time constant), and
Mixing Ratio (with time constant) ............................................................. 10-6
10.1.20 Maximum Oxygen Concentration, Humidity, and Mixing Ratio ...... 10-6
10.1.21 Minimum Oxygen Concentration, Humidity, and Mixing Ratio ........ 10-6
10.1.22 Average Oxygen Concentration, Humidity, and Mixing Ratio ......... 10-6
10.1.23 Span and Zero Correction Ratios .................................................... 10-6
10.1.24 History of Calibration Time............................................................... 10-7
10.1.25 Time ................................................................................................. 10-7
10.1.26 Software Revision............................................................................ 10-7
10.2 Operational Data Initialization ...................................................................... 10-7
10.3 Initialization Procedure .................................................................................. 10-8
10.4 Reset................................................................................................................. 10-8
10.5 Handling of the ZO21S Standard Gas Unit................................................. 10-21
10.5.1 Standard Gas Unit Component Identication................................ 10-21
10.5.2 Installing Gas Cylinders ................................................................. 10-21
10.5.3 Calibration Gas Flow...................................................................... 10-22
10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit................... 10-23
10.6.1 Preparation Before Calibration ...................................................... 10-24
10.6.2 Operating the Span Gas Flow Setting Valve ................................. 10-24
10.6.3 Operating the Zero Gas Flow Setting Valve .................................. 10-24
10.6.4 Treatment After Calibration............................................................ 10-24
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

Toc-6
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
11.1.2 Replacing the Sensor Assembly...................................................... 11-2
11.1.3 Replacement of the Heater Assembly ............................................. 11-4
11.1.4 Replacement of Dust Filter .............................................................. 11-6
11.1.5 Replacement of O-ring..................................................................... 11-6
11.1.6 Stopping and Re-starting Operation................................................ 11-7
11.2 Inspection and Maintenance of the Converter ............................................ 11-7
11.3 Replacement of Flowmeter for ZR20H Automatic Calibration Unit .......... 11-9
12. Troubleshooting ..................................................................................... 12-1
12.1 Displays and Measures to Take When Errors Occur .................................. 12-1
12.1.1 What is an Error? ............................................................................. 12-1
12.1.2 Measures to Take When an Error Occurs ....................................... 12-2
12.2 Displays and Measures to Take When Alarms are Generated................... 12-4
12.2.1 What is an Alarm? ............................................................................ 12-4
12.2.2 Measures Taken When Alarms are Generated ............................... 12-4
12.3 Measures When Measured Value Shows an Error...................................... 12-8
12.3.1
Measured Value Higher (Lower for Humidity Analyzer) Than True Value .. 12-8
12.3.2
Measured Value Lower (Higher for Humidity Analyzer) Than True Value .. 12-9
12.3.3 Measurements Sometimes Show Abnormal Values ..................... 12-10
Customer Maintenance Parts List......................................CMPL 11M12A01-04E
Customer Maintenance Parts List......................................CMPL 11M12A01-12E
Customer Maintenance Parts List..........................................CMPL 11M3D1-01E
Revision Information ...............................................................................................i

<1. Overview> 1-1
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
1. Overview
The EXAxt ZR Integrated type Zirconia 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, pulp and paper, food, or textiles, as well as incinerators and
medium/small boilers. It can help conserve energy in these industries. The EXAxt ZR also
contributes to preservation of the earth’s environment in preventing global warming and air
pollution by controlling complete combustion to reduce CO2, SOx and NOx.
The EXAxt ZR Integrated type Zirconia Oxygen/Humidity Analyzer integrates both probe and
converter. The analyzers need not use a sampling device, and allow direct installation of the
probe in the wall of a ue or furnace to measure the concentration of oxygen in the stack gas of
the temperature up to 700°C.
The EXAxt ZR Integrated-type Zirconia High-temperature Humidity Analyzer integrates
the detector and the converter in one unit. This analyzer can measure humidity of hot air
continuously, so can be used to measure humidity of air in driers which are heated by steam or
electricity. It can also be used in a variety of manufacturing applications with humidiers, as well
as with driers, for humidity measurement and control. It can help improve productivity in these
application elds.
The probe uses a high-reliability Zirconia sensor and a heater assembly that can be replaced on
site.
The analyzer is equipped with three infrared switches, which enable the user to operate the
equipment without opening the cover on site. Analyzer calibration can also be fully automated
and the automatic calibration unit is provided. Choose the equipment which best suits your needs
so that an optimal combustion control system can be obtained.
Some examples of typical system conguration are illustrated below:
1.1 < EXAxt ZR > System Conguration
The system conguration should be determined by the conditions; e.g. whether the 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 an integrated type analyzer. This system can be
implemented for monitoring oxygen concentration in the combustion gases 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 ZO21S
standard gas unit is used for calibration.
Zero gas from this unit and span gas (air) is sent to the probe through a tube which is connected
during calibration.

<1. Overview> 1-2
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
~
ZR202G Integrated type
Zirconia Oxygen/Humidity Analyzer
ZO21S Standard gas unit
Stop valve
Calibration gas
F1.1E.ai
~
100 to 240 V AC
100/110/115
200/220/240 V AC
Contact input
Analog output, contact output
Digital output (HART)
Figure1.1 Example of System 1
NOTE
• As this system uses ambient air for the reference gas, measuring accuracy will be affected
by the installation location.
• A stop valve should be connected to the calibration gas inlet of the equipment. The valve
should be fully closed unless calibration is in progress.
1.1.2 System 2
This system is for monitoring and controlling oxygen concentration in the combustion gases of
a large-size boiler or heating furnace. Instrument air (clean and dry air of oxygen concentration
21%) is used as the reference gas and the span gas for calibration. Zero gas is fed from a
cylinder during calibration.
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.
The gas ow is controlled by the ZA8F ow setting unit (for manual valve operation).
~
ZR202G Integrated type
Zirconia Oxygen/Humidity Analyzer
F1.2E.ai
ZA8F flow setting unit
Reference gas
Calibration gas
Needle
valve
Flowmeter
Instrument air
Air Set
Calibration
gas pressure
regulator
Zero gas cylinder
Calibration gas unit case
Stop valve
or
Check valve
Span gas(Same as Zero gas calibration)
100 to 240 V AC
Contact input
Analog output, contact output
Digital output (HART)
Figure1.2 Example of System 2

<1. Overview> 1-3
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
1.1.3 System 3
This example, System 3, represents typical applications in large boilers and heating furnaces,
where is a need to monitor and control oxygen concentration. The reference gas and calibration-
time span gas are (clean, dry) instrument air. Zero gas is supplied from a gas cylinder.
System 3 uses the ZR20H automatic calibration unit, with auto-switching of the calibration gas.
A “combustible gas detected” contact input turns off power to the heater. There’s also contact
output from the converter that can be used to operate a purge gas valve to supply air to the
sensor.
~100 to 240 V AC
Automatic calibration unit
Reference gas
Calibration gas (Zero)
Contact input
Analog output, contact output
Digital output (HART)
Air Set
Instrument air
Calibration gas unit case
Calibration
gas pressure
regulator
Zero gas cylinder
ZR202G Integrated type Zirconia Oxygen/Humidity Analyzer
with automatic calibration unit (ZR202G-□-□-□-A-□-□-□-□-A)
F1.3E.ai
Span gas
ZR20H
*3
Note:
The installation temperature limits range for integrated type analyzer is -20 to 55°C.
*2
*1
*1 Shield cable:
Use shielded signal cables, and connect the shields to the FG terminal of the converter.
*2 Select the desired probe from the Probe Conguration table on page 1-4.
*3 When a zirconia oxygen analyzer is used, 100% N2gas cannot be used as the zero gas.
Use approx. 1 vol% O2gas (N2-based).
Figure1.3 Example of System 3

<1. Overview> 1-4
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
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 ZR202G Integrated type Zirconia Oxygen Analyzers A A A A A
Model ZO21R Probe Protector for Zirconia Oxygen Analyzers 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 ZR20H Automatic Calibration Unit for Integrated type 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) 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 ZR202A Heater Assembly (Spare Parts for ZR202G) 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 Oxygen/Humidity Analyzer and Accessories
F1.4E.ai
Detector
(ZR202G)
Detector(ZR202G)
Probe Protector
(ZO21R)
Dust Filter
(K9471UA)
or
Dust Guard
Protector
(K9471UC)
+
Sample gas temperature 0 to 700°C
Mounting Insertion length General-use Probe Application
Horizontal
to
vertical
Horizontal
to
vertical
Horizontal
to
vertical
Vertical
Vertical
0.4
to
2 m
0.4
to
2 m
2.5 m
or more
3 m
or less
2.5 m
or more
• Boiler
• Heating furnace
• For pulverized coal boiler with gas flow velocity
10 m/sec or more
• Cement Kiln
• Black liquid recovery boiler
• Cement Kiln
Gas Flow
Sample inlet
Dust protector
(ZH21B)
ZR202G
Only
ZR22G-040
Humidity analyzer use

  <2.Specications> 2-1
IM 11M12A01-04E 11th Edition : Jul. 19, 2017-00
2. Specications
This chapter describes the specications for the following:
ZR202G General-use Integrated type Zirconia Oxygen Analyzer (See Section 2.1.2)
ZO21R-L Probe protector (See Section 2.1.3)
ZH21B Dust protector (See Section 2.1.4)
ZA8F Flow setting unit (See Section 2.2.1)
ZR20H Automatic calibration unit (See Section 2.2.2)
ZO21S Standard gas unit (See Section 2.3)
K9471UA Dust Filter for Oxygen Analyzer (See Section 2.4)
2.1 General Specications
2.1.1 Standard Specications
Measured Object: Oxygen concentration in combustion exhaust gas and mixed gas
(excluding inammable gases). May not be applicable corrosive gas
such as ammonia, chlorine is present-check with YOKOGAWA.)
(In case of Humidity Analyzer, Water vapor (in vol%) in mixed gases (air
and water vapor))
Measured 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 affected 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.
Repeatability: (Excluding the case where the reference gas is by natural convection)
±0.5% Maximum value of set range; less than 0 to 25 vol%O2range
±1% Maximum value of set range; 0 to 25 vol%O2or more and up
to 0 to 100 vol%O2range
In case of Humidity Analyzer, ± 1 vol% H2O; (Sample gas pressure 2
kPa or less)