YOKOGAWA ZO21DW User manual

User’s
Manual In-Situ Type Zirconia Oxygen
Analyzer
Model ZO21DW
Detector
IM 11M03A02-00E
IM 11M03A02-00E
3rd Edition

<INTRODUCTION> i
IM 11M03A02-00E
INTRODUCTION
The zirconia oxygen analyzer is used for monitoring and controlling the combustion conditions of
processes in all elds which require combustion control. This zirconia oxygen analyzer features
the direct measurement of the oxygen concentration in a furnace by inserting the detector into the
furnace. However, for accurate measurement, it is preferable that there be no pressure di󰀨erence
between the measuring gas in contact with the sensor anode and the reference gas supplied on
the cathode side.
The Model ZO21DW zirconia oxygen detector is constructed in such a way that the reference
gas outlet is open to the inside of the furnace. Hence, the measured gas and reference gas
pressures can be kept at about the same level, making high accuracy measurements possible.
This instruction manual describes all the handling and operations of the Model ZO21DW Zirconia
Oxygen Detector, including installation, wiring, running, inspection, maintenance, etc. Read it
thoroughly before handling the detector in order to get a full demonstration of its performance.
For handling the converters associated with this detector, see the corresponding instruction
manual.
Before using the instruments, read any descriptions related to your instruments and system to
ensure the best performance.
User’s manual of instrument related to the ZO21DW is as follows:
Model Title Manual No.
ZR402G Separate Type Zirconia Oxygen Analyzer IM 11M12A01-02E
Media No. IM 11M03A02-00E 3rd Edition : Aug. 2018 (YK)
All Rights Reserved Copyright © 2009, Yokogawa Electric Corporation

<INTRODUCTION>
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IM 11M03A02-00E
For the safe use of this equipment
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
measured gas may damage the sensor.
• The detector (especially at the tip) becomes very hot. Be sure to handle it with gloves.
WARNING
The product is very heavy. 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.
nAbout 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 e󰀨ort 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 o󰀩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 a󰀨ect 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.

<INTRODUCTION> iii
IM 11M03A02-00E
l 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.
lThe 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.

<INTRODUCTION>
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After-sales Warranty
nDo not modify the product.
nDuring the warranty period, for repair under warranty carry or send the
producttothelocalsalesrepresentativeorserviceo󰀩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.
l If we replace the product with a new one, we won’t provide you with a repair report.
l Yokogawa warrants the product for the period stated in the pre-purchase quotation
Yokogawa shall conduct dened warranty service based on its standard. When the
customer site is located outside of the service area, a fee for dispatching the maintenance
engineer will be charged to the customer.
nIn 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
Electric did not supply.
• Failure due to improper or insu󰀩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.
n Yokogawa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application.
n YokogawaElectricwillnotbearresponsibilitywhentheuserconguresthe
product into systems or resells the product.
n 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o󰀩cedescribedinthisinstructionmanual.

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IM 11M03A02-00E
<CONTENTS>
Model ZO21DW
Detector
In-Situ Type Zirconia Oxygen Analyzer
CONTENTS
IM 11M03A02-00E 3rd Edition
INTRODUCTION .......................................................................................................i
For the safe use of this equipment.............................................................ii
After-sales Warranty ...................................................................................iv
1. SPECIFICATIONS ..................................................................................... 1-1
1.1 StandardSpecications................................................................................... 1-1
1.2 Model and Codes .............................................................................................. 1-2
1.3 External Dimensions ........................................................................................ 1-3
2. INSTALLATION ......................................................................................... 2-1
2.1 Installation Site.................................................................................................. 2-1
2.2 ProbeInsertionHole......................................................................................... 2-1
2.3 Detector Installation ......................................................................................... 2-2
3. PIPING........................................................................................................ 3-1
3.1 PipingforSystem1........................................................................................... 3-1
3.1.1 Parts Required for Piping in System 1 ...............................................3-2
3.1.2 Connection to the Calibration Gas Inlet ............................................. 3-2
3.1.3 Piping for the Reference Gas Inlet ..................................................... 3-3
3.2 PipingforSystem2........................................................................................... 3-4
3.2.1 Piping Parts for System 2 ..................................................................3-4
3.2.2 Piping for the Calibration Gas ............................................................ 3-5
3.2.3 Piping for the Reference Gas............................................................. 3-6
3.2.4 Valve Operation of Reference Gas Outlet ......................................... 3-6
3.3 PipingforSystem3.......................................................................................... 3-6
4. WIRING ...................................................................................................... 4-1
4.1 General............................................................................................................... 4-1
4.1.1 Cable Specication ............................................................................ 4-1
4.1.2 Wiring Procedure ............................................................................... 4-2
4.2 Wiring for Detector Output............................................................................... 4-3
4.2.1 Connection to the Detector ................................................................4-3
4.3 WiringforPowertoDetectorHeater............................................................... 4-4
4.3.1 Connection to Detector ......................................................................4-4
4.4 PowerandGroundingWiring.......................................................................... 4-5
4.4.1 Power Wiring ...................................................................................... 4-5
4.4.2 Grounding Wiring ............................................................................... 4-5

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<CONTENTS>
5. NAMEANDFUNCTIONOFCOMPONENTS........................................... 5-1
6. OPERATION .............................................................................................. 6-1
6.1 Start-Up .............................................................................................................. 6-1
6.1.1 Inspection of Piping and Wiring Conditions ....................................... 6-1
6.1.2 Checking of Set Valves ...................................................................... 6-1
6.1.3 Supplying Heater Power .................................................................... 6-1
6.1.4 Calibration .......................................................................................... 6-1
6.2 Stationary Operation ........................................................................................ 6-2
6.2.1 Checking Operating Conditions ......................................................... 6-2
6.2.2 Stopping and Restarting Operations ................................................. 6-2
7. INSPECTIONANDMAINTENANCE ........................................................ 7-1
7.1 Inspection and Maintenance of the Detector................................................. 7-2
7.1.1 Cleaning the Calibration Gas Tube .................................................... 7-2
7.1.2 Replacing the Sensor Assembly ........................................................ 7-3
7.1.3 Stopping and Re-starting Operation .................................................. 7-6
CustomerMaintenancePartsList........................................ CMPL11M06B02-01
Revision Information ...............................................................................................i

<1. SPECIFICATIONS> 1-1
IM 11M03A02-00E
1. SPECIFICATIONS
In this chapter, the specications of the ZO21DW detector is described.
1.1 StandardSpecications
The probe, as a whole, is not explosion-protected (Calibration gas inlet, reference gas outlet) and
only its terminal box section is explosion-protected.
Sample Gas Temperature:
0 to 600°C
SampleGasPressure:
-20 to +20 kPa
Insertion Length:
0.4, 1.0, 1.5, 2.0, 3.0 m
Ambient Temperature:
-10 to +70°C (terminal box temperature)
Reference-air Flow Rate:
800 ml/min. (Use instrument air. Reference gas is discharged into the furnace.)
Material in Contact with Gas:
SUS316, Zirconia, SUS304 (JIS) or ASTM grade 304 (ange)
Installation:
Flange mounting
Probe mounting angle; Between the horizontal and vertically down positions
Note: Probe protector (ZO21R-L-150-∗B/R, GS11M12A01-01E) is
required when insertion length is 3 m and horizontal installation.
Joint; Rc1/8
Flange; JIS 10K-100-FF, ANSI Class 150-4-RF, and DIN PN10 DN100-4
Construction:
The terminal box of ZO21DW ameploof specication
TIIS ameploof type certication
Protection Concept: d2G4
Weight:
With insertion length of 0.4 m, approx. 6.5 kg; 1.0 m, approx. 10.0 kg; 1.5 m, approx. 13.0 kg;
2.0 m, approx. 17.0 kg; 3.0 m, approx. 20.0 kg

<1. SPECIFICATIONS>
1-2
IM 11M03A02-00E
1.2 Model and Codes
Model Su󰀩xcode Option code Description
ZO21DW -L · · · · · · · · · · Probe with ameproof terminal box
Insertion length -040 · · · · · · · · · · 0.4 m
-100 · · · · · · · · · · 1.0 m
-150 · · · · · · · · · · 1.5 m
-200 · · · · · · · · · · 2.0 m
-300 · · · · · · · · · · 3.0 m
Flange joint connection -J · · · · · · · · · · JIS 10K-100-FF
-A · · · · · · · · · · ANSI Class 150-4-RF
-E · · · · · · · · · · DIN PN10 DN100-4
Style code *A · · · · · · · · · · Style A
Options /CV With check valve
/SV With stop valve
/G Cable glands (2 pieces) (Note1)
Note1: Cable gland [/G] must be specied when installed in hazardous area.
Name PartNo. Description
CABLE GLAND G7272YE Matal Fittings with resisting pressure. O. D.ø11 to ø13

<1. SPECIFICATIONS> 1-3
IM 11M03A02-00E
1.3 External Dimensions
Unit : mm
L ( *) 315
± 5
Flange
∅
42.7
Reference gas inlet
Rc1/8
C
( *) L = 400, 1000, 1500, 2000, 3000 (mm)
Reference gas return
Approx. 210
2-G3/4 Wiring hole
∅
150
Terminal box
t
Calibration gas inlet
Rc1/8
∅
B
∅
A
F1.1E.ai
48
ModelandSu󰀩x
codes
Length
L
(mm)
Flange
Flange A B C t Weight
(kg)
ZO21DW-L-040-J*A 400
JIS 10K-100-FF
( or equivalent ) 210 175 8 - ø19 18
Approx. 6.5
ZO21DW-L-100-J*A 1000 Approx. 10
ZO21DW-L-150-J*A 1500 Approx. 13
ZO21DW-L-200-J*A 2000 Approx. 17
ZO21DW-L-300-J*A 3000 Approx. 20
ZO21DW-L-040-A*A 400
ANSI CLASS 150-4-
RF
( or equivalent )
228.6 190.5 8 - ø19 24
Approx. 6.5
ZO21DW-L-100-A*A 1000 Approx. 10
ZO21DW-L-150-A*A 1500 Approx. 13
ZO21DW-L-200-A*A 2000 Approx. 17
ZO21DW-L-300-A*A 3000 Approx. 20
ZO21DW-L-040-E*A 400
DIN PN10-DN100-4
( or equivalent ) 220 180 8 -ø18 20
Approx. 6.5
ZO21DW-L-100-E*A 1000 Approx. 10
ZO21DW-L-150-E*A 1500 Approx. 13
ZO21DW-L-200-E*A 2000 Approx. 17
ZO21DW-L-300-E*A 3000 Approx. 20