YOKOGAWA ZR802S User manual

User’s
Manual ZR802S
Explosion-proof Zirconia
Oxygen Analyzer, Converter
IM 11M13G01-02EN
IM 11M13G01-02EN
1st Edition

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IM 11M13G01-02E
<Introduction>
uIntroduction
Thank you for purchasing the ZR802S Explosion-proof Zirconia Oxygen Analyzer, Converter.
Please read the following respective documents before installing and using the ZR802S
Explosion-proof Zirconia Oxygen Analyzer, Converter.
The related documents are as follows.
General Specications
Contents Document number Note
ZR802S, and ZR202S
Explosion-proof Zirconia Oxygen Analyzer, Converter GS 11M13G01-01EN Online manual
* the “EN” in the document number is the language code.
User’s Manual
Contents Document number Note
ZR802S
Explosion-proof Zirconia Oxygen Analyzer, Converter IM 11M13G01-02EN Printed manual (This manual)
ZR802S
Explosion-proof Zirconia Oxygen Analyzer, Converter
Start-up and Safety Precautions
IM 11M13G01-01EN Online manual
* the “EN” in the document number is the language code.
Technical Information
Contents Document number Note
ZR802G and ZR802S
Zirconia Oxygen/Humidity Analyzer, Converter HART
Communication
TI 11M12G01-61EN Online manual
ZR802G and ZR802S
Zirconia Oxygen/Humidity Analyzer, Converter MODBUS
Communication
TI 11M12G01-62EN Online manual
* the “EN” in the document number is the language code.
For latest User’s Manual, download it from our website or scan QR code.
http://www.yokogawa.com/an/zr802/download/
An exclusive User’s Manual might be attached to the products whose su󰀩x codes or option
codes contain the code “Z” (made to customers' specications). Please read it along with this
manual.
The Explosion-proof Zirconia Oxygen Analyzer, Converter has been developed for combustion
control in various industrial processes. This analyzer basically consists of a detector and a
converter. You can select between several versions, based upon your application.
Optional accessories are also available to improve measurement accuracy and automate
calibration. An optimal control system can be realized by adding appropriate options.
This instruction manual refers to almost all of the equipment related to the ZR.
You may skip any section(s) on the equipment which is not included in your system.
Media No. IM 11M13G01-02E 1st Edition : Mar. 2023 (YK)
All Rights Reserved Copyright © 2023, Yokogawa Electric Corporation

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<Introduction>
This user’s manual describes the way of installation, operation, maintenance, and others about
Zirconia Oxygen Analyzer. Please note that some part of this manual may mention the products
or system that you don’t use.
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
ZR22S General-purpose detector 
ZR22S High temperature detector (0.15 m)
ZR802S Zirconia Oxygen Analyzer    
ZO21R Probe protector for ZR22S 
ZO21P High temperature probe
adapter 
ZA8F Flow setting unit
(for manual calibration use)   
-Auxiliary ejector assembly for
high temperature use
(Part No. E7046EC, 7046EN)
-Calibration gas unit case
(Part No. E7044KF)
-Check valve (Part No.9292DN,
K9292DS )
 
CMPL : Customer Maintenance Parts List
This manual consists of twelve chapters. Please refer to the reference chapters for installation,
operation and maintenance.
Table of Contents
Chapter Outline Relates to
Installation Operation Maintenance
1. Overview Equipment models and system
conguration examples B C B
2. Specications
Standard specication, model code (or part
number), dimension drawing for each equipment
A B B
3. Installation Installation method for each equipment A C
4. Wiring Wiring procedures such as “Power supply
wiring”, “output signal wiring” or others A C
5. Components and
Their Functions
Major parts and function are described in
this manual C B B
6. Startup
Basic procedure to start operation of
Zirconia Oxygen Analyzer, Converter.
Chapter 7 enables you to operate the
equipment immediately.
A C
7. Detailed Data
Setting Details of key operations and displays B C
8. Calibration Describes the calibration procedure
required in the course of operation. B C
9. Other Functions Other functions described B A
10. Inspection and
Maintenance
How to conduct maintenance of Zirconia
Oxygen Analyzer, Converter and procedures for
replacement of deteriorated parts
B A
11. Troubleshooting This chapter describes measures to be
taken when an abnormal condition occurs. C B
CMPL (parts list) User replaceable parts list C A
A: Read and completely understand before operating the equipment.
B: Read before operating the equipment, and refer to it whenever necessary.
C: Recommended to read it at least once.

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<Introduction>
nPrecautions in Handling Explosion-proof Zirconia Oxygen Analyzer,
Converter
The Explosion-proof Zirconia Oxygen Analyzer, Converter (ZR802S) 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, Converter (ZR802S) 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.
nFor the safe use of this equipment
WARNING
Handle it with care. Be sure not to accidentally drop it.
Handle safely to avoid injury.
Connect the power supply cord only after conrming that the supply voltage matches the rating of
this equipment. In addition, conrm that the power is switched o󰀨 when connecting power supply.
Some 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
Oxygen concentration of sample/reference /calibration gas shall not exceed that found in normal
air, typically 21 vol%.
CAUTION
The cell (sensor) at the tip of the detector is made of ceramic (zirconia element). Do not drop the
detector or subject it to pressure stress.
• Do NOT allow the sensor (probe tip) to make contact with anything when installing the
detector.
• Avoid any water dropping directly on the probe (sensor) of the detector when installing it.
• Check the calibration gas piping before introducing the calibration gas to ensure that there
is no leakage of the gas. If there is any leakage of the gas, the moisture drawn from the
sample gas may damage the sensor.
• The detector (especially at the tip) becomes very hot. Be sure to handle it with gloves.

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<Introduction>
CAUTION
This instrument is tested and certicated as explosion-proof type. Please note that the
construction of the instrument, installation, external wiring, maintenance or repair is strictly
restricted, and non-observation or negligence of this restriction would result in dangerous
condition.
nNOTICE
l Specication check
When the instrument arrives, unpack the package with care and check that the instrument has
not been damaged during transportation. In addition, please check that the specication matches
the order, and required accessories are not missing. Specications can be checked by the model
codes on the nameplate. Refer to Chapter 2 Specications for the list of model codes.
lDetails on operation parameters
When the Separate type Oxygen Analyzer arrives at the user site, it will operate based on
the operation parameters (initial data) set before shipping from the factory.
Ensure that the initial data is suitable for the operation conditions before conducting
analysis. Where necessary, set the instrument parameters for appropriate operation.
For details of setting data, refer to chapters 7 to 10.
When user changes the operation parameter, it is recommended to note down the changed
setting data.

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<Introduction>
uSafety Precautions
nNotes 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.
nDrawing Conventions
Some drawings may be partially emphasized, simplied, or omitted, for the convenience of
description.
Some screen images depicted in the user’s manual may have di󰀨erent display positions or
character types (e.g., the upper / lower case). Also note that some of the images contained in this
user’s manual are display examples.
n Trademark Notices
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.
nProduct Disposal
The instrument should be disposed of in accordance with local and national legislation/
regulations.
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.

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<Introduction>
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.
nWarning 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.
nAll rights reserved
The copyright of the programs and online manuals contained in the software media shall remain
with YOKOGAWA.
You are allowed to print the required pages of the online manuals for the purposes of using and/
or operating the product. However, you are not allowed to print or reproduce the entire document.
Except as stated above, no part of the online manual may be reproduced, either in electronic
or written form, registered, recorded, transferred, sold, or distributed (in any manner including
without limitation, in the forms of paper documents, electronic media, lms, or transmission
via the network). Any in-action and/or silence by YOKOGAWA with regard to any breach of the
above shall not be taken as any waiver of its rights whatsoever and YOKOGAWA reserves all its
rights until expressly waived by written notication and no other occasions.
n Trademark Acknowledgments
• All other company and product names mentioned in this user’s manual are trademarks or
registered trademarks of their respective companies.
• We do not use TM or ® mark to indicate those trademarks or registered trademarks in this
user’s manual.

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<Introduction>
n ZR802Sʼs fonts
lAdobe-Helvetica
SO10646-1 extension by Markus Kuhn , 2001-03-20 Copyright 1984-1989, 1994 Adobe Systems
Incorporated. Copyright 1988, 1994 Digital Equipment Corporation. Adobe is a trademark of
Adobe Systems Incorporated which may be registered in certain jurisdictions. Permission to use
these trademarks is hereby granted only in association with the images described in this le.
Permission to use, copy, modify, distribute and sell this software and its documentation for any
purpose and without fee is hereby granted, provided that the above copyright notices appear in
all copies and that both those copyright notices and this permission notice appear in supporting
documentation, and that the names of Adobe Systems and Digital Equipment Corporation not be
used in advertising or publicity pertaining to distribution of the software without specic, written
prior permission. Adobe Systems and Digital Equipment Corporation make no representations
about the suitability of this software for any purpose. It is provided "as is" without express or
implied warranty.
nPrecautions for the product
WARNING
Installation and wiring
The ZR802G should only be used with equipment that meets the relevant IEC, American or
Canadian standards.
Yokogawa accepts no responsibility for the misuse of this unit.
Don’t install instruments in the hazardous area.
Do not use an abrasive or organic solvent in cleaning the instrument.
Electrostatic discharge
The ZR802G contains devices that can be damaged by electrostatic discharge. When servicing
this equipment, please observe proper procedures to prevent such damage. Replacement
components should be shipped in conductive packaging. Repair work should be done at
grounded workstations using grounded soldering irons and wrist straps to avoid electrostatic
discharge.
CAUTION
The Instrument is packed carefully with shock absorbing materials, nevertheless, the instrument
may be damaged or broken if subjected to strong shock, such as if the instrument is dropped.
Handle with care.
This instrument is a Class A product, and it is designed for use in the industrial environment.
Please use this instrument in the industrial environment only.
The HART communication may be inuenced by strong electromagnetic eld.
In this case another trial of the HART communication and/or operation with ZR802G touch
screen can be carried out.

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<Introduction>
nOther precautions
• Operations of this equipment are performed by touch screen.
Press the appropriate part of the Display screen to expand the screen, and the calibration
operation and setup change can be performed easily. Pay attention to erroneous operation.
nWarning 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.
nNotes 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.
nDrawing Conventions
Some drawings may be partially emphasized, simplied, or omitted, for the convenience of
description.
Some screen images depicted in the user’s manual may have di󰀨erent display positions or
character types (e.g., the upper / lower case). Also note that some of the images contained in this
user’s manual are display examples.
nProduct Disposal:
The instrument should be disposed of in accordance with local and national legislation/regulations.

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<Introduction>
u CE/UKCA marking products
nAuthorized Representative in the EEA and the Importer into the EU/
EEA Market
The Authorized Representative for this product in the EEA and the importer for this product into
the EU/EEA market via Yokogawa sale channel is:
Yokogawa Europe B.V.
Euroweg 2, 3825 HD Amersfoort, The Netherlands
n Importer for This Product into the Great Britain Market
In relation to UKCA marking, the importer for this product into the Great Britain market via the
YOKOGAWA sales channel is:
Yokogawa United Kingdom Limited
Stuart Road Manor Park Runcorn, WA7 1TR, United Kingdom
n Identication Tag
This manual and the identication tag attached on packing box are essential parts of the product.
Keep them together in a safe place for future reference.
nUsers
This product is designed to be used by a person with specialized knowledge.
nHow to dispose Batteries and Waste batteries:
(Only valid in the EU for EU Battery Directive/Regulation and in the UK for UK Battery
Regulation)
Batteries are included in this product. This marking indicates they shall be sorted out and
collected as ordained in the EU battery Directive/Regulation and UK battery Regulation.
When you need to replace batteries, contact your local Yokogawa o󰀩ce in the EEA and/or UK
respectively.
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.
nInformation of the WEEE Directive
This product is purposely designed to be used in a large scale xed installations only and,
therefore, is out of scope of the WEEE Directive. The WEEE Directive does not apply.
This product should be disposed in accordance with local and national legislation/regulations.
The WEEE Directive is only valid in the EU and UK.