YOKOGAWA ZR202S User manual

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

i
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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IM 11M13A01-04E
<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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IM 11M13A01-04E
<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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IM 11M13A01-04E
<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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IM 11M13A01-04E
<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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IM 11M13A01-04E
<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.

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IM 11M13A01-04E
<Introduction>
uAfter-Sales Warranty
lDo not modify the product.
lYokogawa warrants the product for the period stated in the pre-purchase quotation.
Yokogawa shall conduct dened warranty service based on its standard.
lDuring the warranty period, for repair under warranty carry or send the product to the
local sales representative or service ofce. Yokogawa will replace or repair any damaged
parts and return the product to you.
• Before returning a product for repair under warranty, provide us with the model name and serial
number and a description of the problem. Any diagrams or data explaining the problem would
also be appreciated.
• If we replace the product with a new one, we won’t provide you with a repair report.
lIn the following cases, customer will be charged repair fee regardless of warranty period.
• Failure of components which are out of scope of warranty stated in instruction manual.
• Failure caused by usage of software, hardware or auxiliary equipment, which Yokogawa did not
supply.
• Failure due to improper or insufcient maintenance by user.
• Failure due to modication, misuse or outside-of-specications operation which Yokogawa
does not authorize.
• Failure due to power supply (voltage, frequency) being outside specications or abnormal.
• Failure caused by any usage out of scope of recommended usage.
• Any damage from re, earthquake, storms and oods, lightning, disturbances, riots, warfare,
radiation and other natural changes.
lYokogawa does not warrant conformance with the specic application at the user site.
Yokogawa will not bear direct/indirect responsibility for damage due to a specic applica-
tion.
lYokogawa will not bear responsibility when the user congures the product into systems
or resells the product.
l Maintenance service and supplying repair parts will be covered for ve years after the
production ends. For repair for this product, please contact the nearest sales ofce de-
scribed in this instruction manual.

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<Introduction>

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IM 11M13A01-04E
<CONTENTS>
Model ZR202S
Integrated type Explosion-proof Zirconia Oxygen Analyzer
CONTENTS
IM 11M13A01-04E 6th Edition
Introduction ..............................................................................................................i
u CE marking products..................................................................................ix
uAfter-Sales Warranty....................................................................................x
1. Overview.................................................................................................... 1-1
1.1 < EXAxt ZR > System Conguration............................................................... 1-1
1.1.1 System 1 ............................................................................................ 1-1
1.1.2 System 2 ............................................................................................ 1-2
1.2 < EXAxt ZR > System Components ................................................................ 1-2
1.2.1 System Components ......................................................................... 1-2
1.2.2 Oxygen Analyzer and Installation ...................................................... 1-2
2. Specications ........................................................................................... 2-1
2.1 General Specications ..................................................................................... 2-1
2.1.1 Standard Specications..................................................................... 2-1
2.1.2 ZR202S Integrated type Explosion-proof Zirconia Oxygen Analyzer 2-4
2.1.3 ZO21R Probe Protector................................................................... 2-11
2.2 ZA8F Flow Setting Unit................................................................................... 2-12
2.3 ZO21S Standard Gas Unit .............................................................................. 2-14
2.4 Other Equipment............................................................................................. 2-15
2.4.1 Stop Valve (L9852CB, G7016XH) ................................................... 2-15
2.4.2 Check Valve (K9292DN, K9292DS)................................................2-15
2.4.3 Air Set...............................................................................................2-16
2.4.4 Pressure Reducing Valve for Gas Cylinder (G7013XF, G7014XF).2-17
2.4.5 ZR202A Heater Assembly ...............................................................2-17
3. Installation................................................................................................. 3-1
3.1 Installation of ZR202S Zirconia Oxygen Analyzer......................................... 3-1
3.1.1 Installation Location ........................................................................... 3-1
3.1.2 ATEX Flameproof Type...................................................................... 3-2
3.1.3 FM Explosion-proof Type................................................................... 3-3
3.1.4 CSA Explosion-proof Type................................................................. 3-4
3.1.5 IECEx Flameproof Type..................................................................... 3-5
3.1.6 Probe (Detector) Insertion Hole......................................................... 3-7
3.1.7 Installation of the Probe (Detector) .................................................... 3-7
3.1.8 Installation of the Probe Protector (ZO21R) ...................................... 3-8

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<CONTENTS>
3.2 Installation of ZA8F Flow Setting Unit ............................................................ 3-8
3.2.1 Installation Location ........................................................................... 3-8
3.2.2 Mounting of ZA8F Flow Setting Unit.................................................. 3-9
3.3 Insulation Resistance Test............................................................................. 3-10
4. Piping......................................................................................................... 4-1
4.1 Piping for System 1........................................................................................... 4-2
4.1.1 Piping Parts for System 1 .................................................................. 4-2
4.1.2 Piping for the Calibration Gas Inlet .................................................... 4-3
4.1.3 Piping for the Reference Gas Inlet..................................................... 4-3
4.1.4 Piping for the Reference Gas Outlet.................................................. 4-3
4.2 Piping for System 2........................................................................................... 4-4
5. Wiring......................................................................................................... 5-1
5.1 General............................................................................................................... 5-1
5.1.1 Terminals for the External Wiring....................................................... 5-2
5.1.2 Wiring................................................................................................. 5-3
5.1.3 Mounting of Cable Gland ................................................................... 5-3
5.2 Wiring for Analog Output ................................................................................. 5-4
5.2.1 Cable Specications .......................................................................... 5-4
5.2.2 Wiring Procedure ............................................................................... 5-4
5.3 Wiring Power and Ground Terminals ............................................................. 5-5
5.3.1 Wiring for Power Line......................................................................... 5-5
5.3.2 Wiring for Ground Terminals .............................................................. 5-5
5.4 Wiring for Contact Output................................................................................ 5-6
5.4.1 Cable Specications .......................................................................... 5-6
5.4.2 Wiring Procedure ............................................................................... 5-6
5.5 Wiring for Contact Input................................................................................... 5-6
5.5.1 Cable Specications .......................................................................... 5-6
5.5.2 Wiring Procedure ............................................................................... 5-7
6. Components ............................................................................................. 6-1
6.1 ZR202S Zirconia Oxygen Analyzer ................................................................. 6-1
6.2 ZA8F Flow Setting Unit, Automatic Calibration Unit..................................... 6-2
7. Startup ....................................................................................................... 7-1
7.1 Checking Piping and Wiring Connections..................................................... 7-2
7.2 Valve Setup ........................................................................................................ 7-2
7.3 Supplying Power to Analyzer .......................................................................... 7-2
7.4 Operation of Infrared Switch ........................................................................... 7-3
7.4.1 Display and Switches......................................................................... 7-3
7.4.2 Display Conguration......................................................................... 7-4
7.4.3 Entering Parameter Code Selection Display..................................... 7-5
7.4.4 Selecting Parameter Codes............................................................... 7-6
7.4.5 Changing Set Values ......................................................................... 7-7

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<CONTENTS>
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
7.8 Checking Current Loop.................................................................................. 7-11
7.9 Checking Contact I/O...................................................................................... 7-11
7.9.1 Checking Contact Output.................................................................7-12
7.9.2 Checking Calibration Contact Output ..............................................7-13
7.9.3 Checking Contact Input ...................................................................7-14
7.10 Calibration ....................................................................................................... 7-15
7.10.1 Calibration Setup .............................................................................7-15
7.10.2 Manual Calibration...........................................................................7-17
8. Detailed Data Setting ............................................................................... 8-1
8.1 Setting Display Item.......................................................................................... 8-1
8.2 Current Output Setting..................................................................................... 8-1
8.2.1 Setting Minimum Oxygen Concentration ( at 4 mA) and Maximum Oxygen
Concentration ( at 20 mA).................................................................. 8-2
8.2.2 Entering Output Damping Constants................................................. 8-2
8.2.3 Selection of Output Mode .................................................................. 8-2
8.2.4 Default Values.................................................................................... 8-2
8.3 Output Hold Setting .......................................................................................... 8-3
8.3.1 Denition of Equipment Status .......................................................... 8-3
8.3.2 Preference Order of Output Hold Value............................................. 8-5
8.3.3 Output Hold Setting............................................................................ 8-5
8.3.4 Default Values.................................................................................... 8-5
8.4 Oxygen Concentration Alarms Setting........................................................... 8-6
8.4.1 Setting the Alarm Values.................................................................... 8-6
8.4.2 Alarm Output Actions ......................................................................... 8-6
8.4.3 Alarm Setting......................................................................................8-7
8.4.4 Default Values.................................................................................... 8-8
8.5 Contact Output Setting..................................................................................... 8-8
8.5.1 Contact Output................................................................................... 8-8
8.5.2 Setting Contact Output.......................................................................8-9
8.5.3 Default Values..................................................................................8-10
8.6 Contact Input Setting...................................................................................... 8-11
8.6.1 Setting Contact Input ....................................................................... 8-11
8.6.2 Default Values.................................................................................. 8-11
8.7 Other Settings ................................................................................................. 8-12
8.7.1 Setting the Date-and-Time............................................................... 8-12
8.7.2 Setting Periods over which Average Values are Calculated and Periods
over which Maximum and Minimum Values Are Monitored............. 8-13
8.7.3 Setting Fuels .................................................................................... 8-14
8.7.4 Setting Purging ................................................................................8-18

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<CONTENTS>
9. Calibration................................................................................................. 9-1
9.1 Calibration Briefs .............................................................................................. 9-1
9.1.1 Principle of Measurement.................................................................. 9-1
9.1.2 Calibration Gas .................................................................................. 9-2
9.1.3 Compensation.................................................................................... 9-3
9.1.4 Characteristic Data from a Sensor Measured During Calibration ..... 9-4
9.2 Calibration Procedures .................................................................................... 9-5
9.2.1 Calibration Setting.............................................................................. 9-5
9.2.2 Calibration.......................................................................................... 9-8
10. Other Functions...................................................................................... 10-1
10.1 Detailed Display .............................................................................................. 10-1
10.1.1 Air Ratio............................................................................................10-3
10.1.2 Cell Temperature.............................................................................. 10-3
10.1.3 C. J. Temperature.............................................................................10-3
10.1.4 Amount of Water Vapor in Exhaust Gas .......................................... 10-3
10.1.5 Cell Voltage......................................................................................10-4
10.1.6 Thermocouple Voltage..................................................................... 10-4
10.1.7 Cold Junction Voltage ......................................................................10-4
10.1.8 Current Output ................................................................................. 10-4
10.1.9 Response Time................................................................................10-5
10.1.10 Cell’s Internal Resistance ...............................................................10-5
10.1.11 Robustness of a Cell....................................................................... 10-5
10.1.12 Heater On-Time Ratio.....................................................................10-6
10.1.13 Oxygen Concentration (with time constant)....................................10-6
10.1.14 Maximum Oxygen Concentration ................................................... 10-6
10.1.15 Minimum Oxygen Concentration ....................................................10-6
10.1.16 Average Oxygen Concentration...................................................... 10-6
10.1.17 Span and Zero Correction Ratios ................................................... 10-6
10.1.18 History of Calibration Time..............................................................10-7
10.1.19 Time.................................................................................................10-7
10.1.20 Software Revision...........................................................................10-7
10.2 Operational Data Initialization ...................................................................... 10-8
10.3 Initialization Procedure .................................................................................. 10-9
10.4 Reset............................................................................................................... 10-10
10.5 Handling of the ZO21S Standard Gas Unit................................................. 10-17
10.5.1 Standard Gas Unit Component Identication................................10-17
10.5.2 Installing Gas Cylinders .................................................................10-18
10.5.3 Calibration Gas Flow......................................................................10-18
10.6 Methods of Operating Valves in the ZA8F Flow Setting Unit................... 10-21
10.6.1 Preparation Before Calibration ......................................................10-21
10.6.2 Operating the Span Gas Flow Setting Valve .................................10-21
10.6.3 Operating the Zero Gas Flow Setting Valve ..................................10-21

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<CONTENTS>
10.6.4 Treatment After Calibration ............................................................10-21
11. Inspection and Maintenance................................................................. 11-1
11.1 Inspection and Maintenance of the Detector............................................... 11-2
11.1.1 Cleaning the Calibration Gas Tube.................................................. 11-2
11.1.2 Replacing the Sensor Assembly...................................................... 11-2
11.1.3 Replacement of the Heater Assembly ............................................. 11-5
11.1.4 Replacement of Flame Arrestor Assembly ...................................... 11-7
11.1.5 Replacement of O-ring..................................................................... 11-8
11.1.6 Stopping and Re-starting Operation................................................ 11-8
11.2 Inspection and Maintenance of the Analyzer............................................... 11-9
11.3 Replacement of Flowmeter for Automatic Calibration Unit .................... 11-11
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 Measures When Measured Value Shows an Error ...................................... 12-9
12.3.1 Measured Value Higher Than True Value........................................ 12-9
12.3.2 Measured Value Lower Than True Value ......................................12-10
12.3.3 Measurements Sometimes Show Abnormal Values .....................12-10
Customer Maintenance Parts List......................................CMPL 11M13A01-04E
Customer Maintenance Parts List..........................................CMPL 11M3D1-01E
Revision Information ...............................................................................................i

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<1.Overview> 1-1
IM 11M13A01-04E
1. Overview
The EXAxt ZR Integrated type Explosion-proof Zirconia Oxygen Analyzer is used to monitor and
control the oxygen concentration in combustion gases, in boilers and industrial furnaces, for wide
application in industries which consume considerable energy-such as steel, electric power, oil and
petrochemical, ceramics, 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 Explosion-proof Zirconia Oxygen Analyzer integrates both probe
and converter. The analyzers need not use a sampling device, and allow direct installation of the
probe in the wall of a flue or furnace to measure the concentration of oxygen in the stack gas of the
temperature up to 700°C.
The probe uses a high-reliability Zirconia sensor and a heater assembly that can be replaced on site.
The analyzer is equipped with three infrared switches, which enable the user to operate the equipment
without opening the cover on site. Analyzer calibration can also be fully automated and the automatic
calibration unit is provided. Choose the equipment which best suits your needs so that an optimal
combustion control system can be obtained.
Some examples of typical system conguration are illustrated below:
1.1 < EXAxt ZR > System Conguration
The system configuration should be determined by the conditions; e.g. whether the calibration is to
be automated, and whether flammable gas is present and requires safety precautions. The system
conguration can be classied into two basic patterns as follows:
1.1.1 System 1
This system is for monitoring and controlling oxygen concentration in the combustion gases of a
large-size boiler or heating furnace. Instrument air (clean and dry air of oxygen concentration 21%)
is used as the reference gas and the span gas for calibration. Zero gas is fed from a cylinder during
calibration. The gas ow is controlled by the ZA8F ow setting unit (for manual valve operation).
~
ZR202S Integrated type Explosion-proof
Zirconia Oxygen Analyzer
F1-1E.ai
ZA8F
Flow Setting Unit
Reference gas
Calibration gas
Needle
valve
Flowmeter
Instrument air
Air Set
Pressure
reducing
valve
*2
Zero gas
cylinder
Stop valve
or
Check valve
Span gas
Hazardous Area
Non-hazardous Area
Calibration gas
unit case
100 to 240 V AC
Contact input
Analog output, contact output
Digital output (HART)
*1
Figure 1.1 Example of System 1
Note:
The installation temperature limits range for integrated type analyzer is -20 to 55°C.
*1 Shield cable:
Use shielded signal cables, and connect the shields to the FG terminal of the analyzer.
*2 When a zirconia oxygen analyzer is used, 100%N2gas cannot be used as the zero gas.
Use approx. 1 vol%O2gas (N2-based).

<1. Overview>
1-2
IM 11M13A01-04E
1.1.2 System 2
This example, System 2, represents typical applications in large boilers and heating furnaces, where
is a need to monitor and control oxygen concentration. Instrument air (clean, dry) is used as the
reference gas and span gas for calibration. Zero gas is supplied from a gas cylinder.
System 2 uses the 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 analyzer
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
Pressure
reducing
valve Zero gas cylinder
ZR202S Integrated type Explosion-proof
Zirconia Oxygen Analyzer
F1-2E.ai
Span gas
*2
Non-hazardous Area
Hazardous Area
*1
Figure 1.2 Example of System 2
1.2 < EXAxt ZR > System Components
1.2.1 System Components
System Components
ZR202S Integrated type Zirconia Oxygen Analyzers
ZO21R Probe Protector for Zirconia Oxygen Analyzers
ZO21S Standard Gas Unit
Automatic Calibration Unit for integrated type Analyzer
L9852CB, G7016XH Stop Valve for Calibration gas line
K9292DN,K9292DS Check Valve for Calibration gas line
G7003XF/K9473XK, G7004XF/K9473XG Air Set
G7013XF, G7014XF Pressure Reducing Valve for Gas Cylinder
Integrated type
System configuration
Example 1 Example 2
T1-1.ai
: Items required for the above system example
: To be selected depending on each application. For details, refer to corresponding chapter.
: Select either
ZR202A Heater Assembly (Spare Parts for ZR202S)
( )
( )
( )
1.2.2 Oxygen Analyzer and Installation
Sample gas temperature 0 to 700ºC
Mounting Insertion length General-use Probe Application
Horizontal
to
vertical
0.4 to 2 m
Integrated type Analyzer
(ZR202S)
Boiler, Heating furnace