YOKOGAWA ZR202S User manual

User’s
Manual Model ZR202S
Integrated type Explosion-proof
Zirconia Oxygen Analyzer
IM 11M13A01-04E
IM 11M13A01-04E
6th Edition

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IM 11M13A01-04E
<Introduction>
Introduction
Thank you for purchasing the ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer.
Please read the following respective documents before installing and using the ZR202S Integrated
type Explosion-proof Zirconia Oxygen Analyzer.
The related documents are as follows.
General Specications
Contents Document number Note
Model ZR22S and ZR202S
Explosion-proof Direct In Situ Zirconia Oxygen Analyzer GS 11M13A01-01E
* the “E” in the document number is the language code.
User’s Manual
Contents Document number Note
Model ZR202S
Integrated type Explosion-proof Zirconia Oxygen Analyzer IM 11M13A01-04E (This manual)
Model ZR22A, ZR202A
Heater Assembly IM 11M12A01-21E
Model EXAxt ZR Series
HART Protocol IM 11M12A01-51E
* the “E” or “EN” 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 Explosion-proof Zirconia Oxygen Analyzer has been developed for
combustion control in various industrial processes. There are several version of this analyzer so you
can select one that matches your application.
Optional accessories are also available to improve measurement accuracy and automate calibration.
An optimal control system can be realized by adding appropriate options.
This instruction manual describes almost all of the equipment related to the EXAxt ZR.
You may skip any section(s) regarding equipment which is not included in your system.
Regarding the HART Communication Protocol, refer to IM 11M12A01-51E.
IM11M12A01-51E has been published as “Model EXAxt ZR series HART protocol”.
Regarding Separate type Explosion-proof Zirconia Oxygen Analyzer, refer to IM 11M13A01-02E.
< 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. >
Media No.IM 11M13A01-04E 6th Edition :June 2017 (YK)
All Rights Reserved Copyright © 2005, Yokogawa Electric Corporation

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<Introduction>
Models and descriptions in this manual are listed below.
Model Product Name Description in this manual
Specication Installation Operation Maintenance CMPL
ZR202S Integrated type Explosion-proof
Zirconia Oxygen Analyzer
ZO21R-L Probe Protector
ZA8F Flow Setting Unit
(for manual calibration use)
— Automatic Calibration Unit
—Calibration Gas Unit Case (Part No.
E7044KF)
—Check Valve
(Part No. K9292DN, K9292DS)
ZO21S Standard Gas Unit
CMPL: Customer Maintenance Parts List
This manual consists of twelve chapters. Please refer to the reference chapters for installation,
operation and maintenance.
Table and Contents
Chapter Outline Relates to
Installation Operation
Maintenance
1. Overview Equipment models and system conguration examples
2. Specications Standard specication, model code (or part number),
dimension drawing for each equipment
3. Installation Installation method for each equipment
4. Piping Examples of piping in two standard system
congurations
5. Wiring Wiring procedures such as “Power supply wiring”,
“Output signal wiring” or others
6. Components Major parts and functions are described
7. Startup Basic procedure to start operation of EXAxt ZR.
Chapter 7 enables you to operate the equipment
immediately.
8. Detailed Data
Setting
Details of key operations and displays
9. Calibration Describes the calibration procedure required in the
course of operation
10. Other
Functions
Other functions described
11. Inspection and
Maintenance
How to conduct maintenance of EXAxt ZR and
procedures for replacement of deteriorated parts
12. Troubleshooting This chapter describes measures to be taken when an
abnormal condition occurs
CMPL (parts list) User replaceable parts list
: Read and completely understand before operating the equipment.
: Read before operating the equipment, and refer to it whenever necessary.
: Recommended to read at least once.

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<Introduction>
ATEX Documentation
This is only applicable to the countries in the European Union.
GB
DK
I
E
NL
SF
P
F
D
S
LT
LV
PL
EST
SLO
H
BG
RO
M
CZ
SK
GR

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<Introduction>
Precautions in Handling Explosion-proof Zirconia Oxygen Analyzer
The explosion-proof zirconia oxygen analyzer (Model ZR202S) are designed as explosion-proof
instruments.
When using either of these instruments in an explosion-susceptible hazardous area, note the
following and observe the given precautions:
Use only the supplied, the explosion-proof zirconia oxygen analyzer (Model ZR202S) and
accessories, or any explosion-proof certication may be invalidated.
For the details, refer to the system congurations in the manual.
CAUTION
Only trained persons use this instrument in industrial locations.
Explosion-proof Approval followings:
ZR202S-A (ATEX); Ex db IIB+H2T2 Gb, Ex tb IIIC T300°C Db
ZR202S-B (FM); Class I, Division 1, Groups B, C and D, Class II/III, Division 1,
Groups E, F and G, T2
ZR202S-C (CSA); Class I, Division 1, Groups B, C and D, Class II/III, Division 1,
Groups E, F and G, T2
ZR202S-D (IECEx); Ex db IIB+H2T2 Gb, Ex tb IIIC T300°C Db
For the safe use of this equipment
WARNING
EXAxt ZR is very heavy. Be sure not to accidentally drop it. Handle safely to avoid injury.
Connect the power supply cord only after conrming that the supply voltage matches the rating of this
equipment. In addition, conrm that the power is switched off when connecting power supply.
Some process gas is dangerous to people. When removing this equipment from the process line for
maintenance or other reasons, protect yourself from potential poisoning by using a protective mask or
ventilating the area well
CAUTION
Requirements for explosion-proof use:
The ambient temperature is in the range of -20 to +55ºC. The surface temperature of the ZR202S is
not over the temperature class T2 (300ºC)*
* The surface temperature of the amplier box does not exceed 70ºC.
Oxygen concentration of sample/reference /calibration gas shall not exceed that found in normal air,
typically 21 vol%.

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<Introduction>
NOTE
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.
(1) About This Manual
• This manual should be passed on to the end user.
• The contents of this manual are subject to change without prior notice.
• The contents of this manual shall not be reproduced or copied, in part or in whole, without
permission.
•This manual explains the functions contained in this product, but does not warrant that those will
suit the particular purpose of the user.
•Every effort has been made to ensure accuracy in the preparation of this manual. However,
should any errors or omissions come to the attention of the user, please contact the nearest
Yokogawa Electric representative or sales ofce.
•This manual does not cover the special specications. This manual may not be changed on any
change of specication, construction and parts when the change does not affect the functions or
performance of the product.
•If the product is used in a manner not specied in this manual, the safety of this product may be
impaired.
NOTE
This instrument is tested and certied as explosion-proof type. Please note that the construction of the
instrument, installation, external wiring, maintenance or repair is strictly restricted, and non-observa-
tion or negligence of this restriction would result in dangerous condition.
(2) Safety and Modication Precautions
•Follow the safety precautions in this manual when using the product to ensure protection and
safety of personnel, product and system containing the product.

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<Introduction>
(3) The following safety symbols are used on the product as well as in this manual.
WARNING
This symbol indicates that the operator must follow the instructions laid out in this manual in order to
avoid the risk of personnel injury electric shock, or fatalities. The manual describes what special care
the operator must exercise to avoid such risks.
CAUTION
This symbol indicates that the operator must refer to the instructions in this manual in order to prevent
the instrument (hardware) or software from being damaged, or a system failure from occurring.
NOTE
This symbol draws attention to information essential for understanding the operation and functions.
Protective Ground Terminal
Function Ground Terminal (Do not use this terminal as the protective
ground terminal.)
Alternating current

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

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<Introduction>
NOTICE
l Specication check
When the instrument arrives, unpack the package with care and check that the instrument has not
been damaged during transportation. In addition, please check that the specication matches the
order, and required accessories are not missing. Specications can be checked by the model codes
on the nameplate. Refer to Chapter 2 Specications for the list of model codes.
lDetails on operation parameters
When the EXAxt ZR Integrated type Explosion-proof Zirconia Oxygen Analyzer arrives at the user
site, it will operate based on the operation parameters (initial data) set before shipping from the
factory.
Ensure that the initial data is suitable for the operation conditions before conducting analysis. Where
necessary, set the instrument parameters for appropriate operation.
For details of setting data, refer to chapters 7 to 10.
When user changes the operation parameter, it is recommended to note down the changed setting
data.
lProduct Disposal:
The instrument should be disposed of in accordance with local and national legislation/regulations.
 Trademark Acknowledgments
• All other company and product names mentioned in this user’s manual are trademarks or regis-
tered 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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<Introduction>
u CE marking products
Authorized Representative in EEA
The Authorized Representative for this product in EEA is Yokogawa Europe B.V. (Euroweg 2, 3825
HD Amersfoort, The Netherlands).
 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.
Users
This product is designed to be used by a person with specialized knowledge.
lHow to dispose the batteries:
This is an explanation about the new EU Battery Directive (DIRECTIVE 2006/66/EC). This directive is
only valid in the EU.
Batteries are included in this product. Batteries incorporated into this product cannot be removed by
yourself. Dispose them together with this product.
When you dispose this product in the EU, contact your local Yokogawa Europe B.V.ofce. Do not
dispose them as domestic household waste.
Battery type: Manganese dioxide lithium battery
Notice:
The symbol (see above) means they shall be sorted out and collected as ordained in ANNEX II in
DIRECTIVE 2006/66/EC.