Technical Model ZR22G, ZR402G

Information Direct in-situ

Separate Type Zirconia Oxygen Analyzers
TI 11M12A01-03E (Hardware Edition)

Contents
1. Overview................................................................................................... 2
2. Measurement Principle of Zirconia Oxygen Analyzers....................... 3
3. System Configuration............................................................................. 5
3.1 System Configuration Using a General-purpose Detector...........................5
3.2 System Configuration Using a High-temperature Detector..........................7
4. ZR22G Detector Construction and Features........................................ 9
4.1 General-purpose Detector Construction.......................................................10
4.2 High-temperature Detector Construction......................................................11
4.3 Pressure Compensation Method....................................................................12
5. ZR402G Converter Functions and Features.......................................13
5.1 Human Machine Interface (HMI).....................................................................13
5.1.1 Basic Panel and Touch Panel Switch............................................................... 13
5.1.2 Display Configuration (for Oxygen Analyzer)................................................... 15
5.1.3 Trend Graph Display........................................................................................ 16
5.1.4 Detailed-data Display....................................................................................... 17
5.1.5 Execution/Setup Display.................................................................................. 21
5.2 Output Functions.............................................................................................24
5.2.1 Current Output.................................................................................................. 24
5.2.2 Contact Output................................................................................................. 25
5.3 Oxygen Concentration Alarms.......................................................................27
5.3.1 Alarm Output Actions........................................................................................ 27
5.3.2 Setting Alarms.................................................................................................. 28
6. Calibration..............................................................................................29
6.1 Calibration Overview.......................................................................................29
6.2 Calibration Gas.................................................................................................29
6.3 Two-point Calibration.......................................................................................30
6.4 One-point Calibration.......................................................................................30
6.5 Calibration Modes............................................................................................31
6.6 Setting the Calibration Time............................................................................31
7. Blow Back Function..............................................................................32
7.1 Blow Back Modes.............................................................................................32
7.2 Blow Back Operations.....................................................................................32
8. Directions for Use..................................................................................33
8.1 Effect of Coexisting Combustible Gases......................................................33
8.2 Effect of Humidity in Reference Gas (Air)......................................................33
8.3 Precautions When Shutting Down a Furnace or Boiler...............................33
8.4 Dry Gas Base and Wet Gas Base...................................................................34
8.5 In Case Equipment is Turned On and Off Frequently..................................34
Revision History.............................................................................................35

Yokogawa Electric Corporation TI 11M12A01-03E

2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan 1st Edition: Dec. 2010 (YK)
Tel.: 81-422-52-5617 Fax.: 81-422-52-6792
 1. Overview

1. Overview
Oxygen concentration is widely measured for the sake of conserving energy, preventing air
pollution, controlling quality, and so forth.
There are many types of oxygen analyzers which use various principles of measurement.
Zirconia oxygen analyzers, which can measure the oxygen concentration in high-temperature
gases directly, are optimal for combustion management and control, etc. in combustion
equipment and are used in many industries such as iron- and steelmaking, electric power, oil and
petrochemicals, chemicals, ceramic, paper and pulp, and textiles.
The ZR22G/ZR402G Separate Type Zirconia Oxygen Analyzers have the following features:
• A general-purpose detector can directly measure gas of up to 700ºC. Moreover, when
combined with the high-temperature probe adapter, it can measure gas of up to 1400ºC.
• For the Zirconia cell, which is a key component of zirconia oxygen analyzers, a zirconia
element and platinum electrodes are molecularly bonded by a method developed by
Yokogawa. Therefore, the zirconia sensor can deliver consistent measurements for a long
period without the electrode being peeled off.
• The heater assembly used to heat up the zirconia cell is constructed so that it can be
replaced in the field. Even if a wire in the heater breaks, the heater can be easily replaced in
the field.
• The converter features a large liquid-crystal display that is easy to see and read.
• A high-resolution graphic display is available, and trend graph display of up to 150 min is
possible.
• A touch panel is used for operations, allowing information to be easily read out and set up.
• Operations are performed interactively with the operation display, so the Instruction Manual
is not needed in daily operations.
• During calibration, the sensor (cell) response time, internal resistance value, zero calibration
factor, span collection factor, etc. are checked and the data are evaluated comprehensively.
This allows the remaining life of the cell to be predicted.
• Two current outputs (4 – 20 mA) and four SPDT relay contact outputs are available.
Measurement data, alarms, errors, etc. can be output.

This technical information document (TI 11M12A01-03E) is intended to help users understand
and make the best use of these features of the ZR22G/ZR402G Separate Type Zirconia Oxygen
Analyzers.
For descriptions of typical applications, see the following application edition of this technical
information document:
ZR22G, ZR402G Separate Type Zirconia Oxygen Analyzers (Application Edition) (TI
11M12A01-01E)

TI 11M12A01-03E 2010.12.3-00
 2. Measurement Principle of Zirconia Oxygen Analyzers 

2. Measurement Principle of Zirconia

Oxygen Analyzers
A solid electrolyte such as zirconia can conduct oxygen ions at high temperature.
As shown in Figure 2.1, when a zirconia element with platinum electrodes bonded to both sides
of it is heated up in contact with gases having different partial-oxygen pressures on either side,
the element acts as a concentration cell. In other words, the electrode in contact with the gas with
a higher partial-oxygen pressure acts as a negative electrode. As the gas comes in contact with
the zirconia element in this negative electrode, oxygen molecules in the gas acquire electrons
and become oxygen ions. Moving in the zirconia element, they eventually arrive at the positive
electrode on the opposite side. There, the electrons are released and the ions return to oxygen
molecules by the following process:
Negative electrode: O2 + 4e → 2O2-
Positive electrode: 2O2- → O2 + 4e
By this reaction, an electromotive force is generated between the two electrodes governed by
Nernst’s equation:

RT PX
E=- ln ···················· (1)
nF PA
where, R: Gas constant
n: 4
F: Faraday’s constant
T: Absolute temperature
Px:  xygen concentration in a gas (measurement gas) in contact with the
O
positive electrode (%)
PA: Oxygen concentration in a gas (reference air) in contact with the negative
electrode (%)
Because the sensor (zirconia element) of the ZR22G Detector is heated up to 750ºC, equation (1)
becomes:

PX
E = -50.74 log ······················ (2)
PA

Reference air
PA
Electrode(negative)

Zirconia element

Electrode (positive)
PX
Measurement gas
F0201.ai

Figure 2.1 Schematic diagram of measurement principle

TI 11M12A01-03E 2010.12.3-00
 2. Measurement Principle of Zirconia Oxygen Analyzers

Figure 2.2 shows the principle construction of the ZR22G Detector.

Voltmeter
E

Zirconia element Probe

Measurement
gas
Reference gas

Electrodes
F0202.ai

Figure 2.2 Principle construction of the ZR22G Detector

When air is used as a reference gas on the negative electrode side, the relationship between the
oxygen concentration of the measurement gas and the electromotive force of the sensor (= cell)
is as shown in Figure 2.3.
The relationship between the oxygen concentration and the electromotive force of the cell in
Figure 2.3 is only theoretical. Usually, in practice, a sensor shows a slight deviation from the
theoretical value; this deviation is corrected by conducting calibration using calibration gas. For
details of calibration, see chapter 6, “Calibration.”

120

100
0.51 % O2, 81.92 mV (Zero origin of calibration)
80
Sensor (cell) voltage (mV)

60

40

20
21.0 % O2, 0 mV
(Span origin of calibration)
0

-20

-40
0.1 0.5 1 5 10 21.0 50 100
Oxygen concentration (vol% O2) F0203.ai

Figure 2.3 Oxygen concentration in measurement gas vs. sensor (cell) voltage (on the basis of 21.0%
O2)

TI 11M12A01-03E 2010.12.3-00
 3. System Configuration 

3. System Configuration
The system configuration of zirconia oxygen analyzers is divided into two main types, those using
either a general-purpose detector (measurement gas temperature of 700ºC and below) or those
using a high-temperature detector (measurement gas temperature of 1400ºC and below).
Moreover, each of these types is further divided into three subtypes, giving six types in total.

Table 3.1 Types of System Configuration

System Type No. Detector Calibration Method Remarks
L1 Simple type The standard gas unit is used.
General-
L2 purpose General type (manual) Instrumentation air and zero gas
type cylinder are used.
L3 General type (automatic)
H1 Simple type The standard gas unit is used.
High-
H2 temperature General type (manual) Instrumentation air and zero gas
type cylinder are used.
H3 General type (automatic)

There are two methods of feeding in reference air: one is to feed in air near the detector by
natural convection and the other is to use instrument air. The method of using air near the
instrument is simple but there is a problem as described below, so instrument air should be used
if it is available.
In case of using natural convection: M easurement may be affected by the humidity in the
air that is fed in. A large variation in humidity causes a
measurement error, so care is required.
In case of using instrument air: A ir that has been dehumidified at a dew point temperature
of −20ºC or less and from which oil mist and dust have been
removed should be used.

3.1 System Configuration Using a General-

purpose Detector
(1) Type: L1 (simple measurement type)
This is the simplest system consisting of a detector and a converter. This system can be
implemented for monitoring oxygen concentration in the combustion gases of a package boiler.
No piping is required for the reference gas (air) which is fed in at the installation site. The handy
ZO21S standard gas unit is used for calibration.
Model ZR402G Converter
Model ZR22G Detector EXA ZR402G

Signal
Stop valve (6-core shield cable) 100 to
240 V AC
Heater (2-core) Contact input
Analog output, contact output
Model ZO21S standard gas unit

Calibration gas

F0301.ai

Figure 3.1 System configuration diagram for type L1

TI 11M12A01-03E 2010.12.3-00
 3. System Configuration

(2) Type: L2 (without automatic calibration)

This system is for monitoring and controlling oxygen concentration in the combustion gases of
a large-size boiler or heating furnace. Clean (dry) air (21% O2) is used as the reference gas and
the span gas for calibration. Zero gas is fed in from a cylinder during calibration. The gas flow is
controlled by the ZA8F flow setting unit (for manual valve operation).

Model ZR402G Converter

Model ZR22G Detector EXA ZR402G

Signal
Stop valve (6-core shield cable) 100 to
or 240 V AC
check valve Heater (2-core) Contact input
Analog output, contact output
Model ZA8F flow setting unit
Flowmeter Needle valve
Reference gas Air set

Instrument air
Calibration gas Span gas

Reducing
Zero gas cylinder
valve
F0302.ai

Figure 3.2 System configuration diagram for type L2

(3) Type: L3 (with automatic calibration)

This system represents typical applications in large boilers and heating furnaces, where there 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.
This system uses the ZR40H autocalibration 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.

Model ZR402G Converter

Model ZR22G Detector EXA ZR402G

Signal
Check valve (6-core shield cable)
100 to 240 V AC
Heater (2-core) Contact input
Analog output, contact output
Flowmeter Needle
valve
Reference gas Air set
Calibration gas
Instrument air
Solenoid
valve

Reducing
Model ZR40H automatic
valve
calibration unit
Zero gas cylinder
F0303.ai

Figure 3.3 System configuration diagram for type L3

TI 11M12A01-03E 2010.12.3-00
 3. System Configuration 

3.2 System Configuration Using a High-

temperature Detector
(1) Type: H1 (simple measurement type)
This is the simplest system configuration for high-temperature applications and is used for a
package boiler, etc.
For the reference air, air near the installation site is fed in. Calibration is done manually and zero
gas and span gas (air) are introduced to the detector via the ZO21S standard gas unit.

Pressure gauge assembly

Supply air Model ZR402G Converter
(150 kPa) Model ZR22G-015
high-temperature detector EXA ZR402G

Needle valve

Signal
Ejector assembly
Stop (6-core shield cable)
100 to
Model ZO21P-H valve 240 V AC
high-temperature Heater (2-core) Contact input
probe adapter Analog output,
Model ZO21S standard gas unit contact output

Calibration gas
Measurement gas
F0304.ai

Figure 3.4 System configuration diagram for type H1

(2) Type: H2 (without automatic calibration)

This system is for controlling and measuring oxygen concentration with high accuracy in a large
boiler or heating furnace.
The reference gas uses instrument air. Calibration is done manually, and zero gas (from a
cylinder) and span gas (instrument air) are fed via the ZA8F flow setting unit.

Pressure gauge assembly

Supply air Model ZR402G Converter
(150 kPa) Model ZR22G-015
high-temperature detector EXA ZR402G

Needle valve

Ejector assembly Signal

Check (6-core shield cable) 100 to
Model ZO21P-H valve 240 V AC
high-temperature or Heater (2-core) Contact input
probe adapter Stop Analog output,
valve Model ZA8F flow setting unit contact output
Flowmeter Needle valve
Reference gas Air set

Measurement gas Instrument air

Calibration gas Span gas

Reducing
Zero gas
valve
cylinder
F0305.ai

Figure 3.5 System configuration diagram for type H2

TI 11M12A01-03E 2010.12.3-00
 3. System Configuration

(3) Type: H3 (with automatic calibration)

This system is for controlling and measuring oxygen concentration with high accuracy in a large
boiler or heating furnace.
The reference gas uses instrument air. Calibration is performed by operating the automatic
calibration unit based on commands from the converter.

Pressure gauge assembly

Supply air Model ZR402G Converter
(150 kPa) Model ZR22G-015
high-temperature detector EXA ZR402G

Needle
valve

Ejector assembly Signal

Check (6-core shield cable)
valve 100 to 240 V AC
Model ZO21P-H Contact input
high-temperature Heater (2-core)
Analog output,
probe adapter Flowmeter Needle contact output
valve
Reference gas Air set
Calibration gas
Instrument air
Measurement gas Solenoid
valve

Reducing
Model ZR40H Zero gas cylinder
valve
automatic calibration unit

F0306.ai

Figure 3.6 System configuration diagram for type H3

TI 11M12A01-03E 2010.12.3-00
 4. ZR22G Detector Construction and Features 

4. ZR22G Detector Construction and

Features
The ZR22G Zirconia Oxygen Analyzer Detector can measure gas of up to 700ºC directly.
If gas with temperatures higher than 700ºC needs to be measured, the high-temperature probe
adapter can be used to measure gas of up to 1400ºC.
The ZR22G Detector has the following features:
• The zirconia element and platinum electrodes are molecularly bonded by a method
developed by Yokogawa, which eliminates the risk of peeling.
Thanks to a special coating, the platinum electrodes are also protected from deterioration
caused by the measurement gas and are not affected by SO2 or NOX contained in the
measurement gas. This allows the detector to perform consistently for a long period.
• Because the zirconia cell uses a leadless electrode construction thanks to full-peripheral
contact using nichrome wire coil, there is no risk of wire breakage and the cell can be easily
replaced.
• The heater assembly used to heat up the zirconia element is constructed so that it can be
replaced in the field. Even if a wire in the heater breaks, the heater assembly can be easily
replaced.

Full-peripheral contact is provided here

using nichrome wire coil.

Platinum electrode using Yokogawa’s

molecular bonding technique F0401.ai

Figure 4.1 Appearance of the zirconia sensor

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10 4. ZR22G Detector Construction and Features

4.1 General-purpose Detector Construction

Figure 4.2 shows the part names and functions of the general-purpose detector.
The sensor (zirconia cell) can be easily replaced by simply removing four bolts. The filter attached
at the front of the sensor is a large-mesh wire net that prevents large dust particles from entering
the sensor.

Terminal box
JIS C 0920 splash-proof type equivalent to IP44D or
JIS C 0920 waterproof type equivalent to NEMA 4X/IP66
(Achieved when the cable entry is completely sealed
with a cable gland in the recirculation pressure
compensated version)

Flange
Used to mount the detector.
Probe Selectable from JIS, ANSI
This part is inserted in the furnace. or DIN standard models
Length is selectable from
0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0 m,
3.6, 4.2, 4.8 and 5.4 m
Dust filter mounting screw
Calibration gas
pipe opening
Contact
Metal O-ring

Pipe support U-shaped pipe

Bolt Probe

Screw
Sensor (cell)
Filter

Washer F0402.ai

Figure 4.2 Part names and functions of general-purpose detector (standard type)

TI 11M12A01-03E 2010.12.3-00
 4. ZR22G Detector Construction and Features 11

4.2 High-temperature Detector Construction

Figure 4.3 shows the part names and functions of the high-temperature detector.
The detector construction is the same as that of the general-purpose detector noted above, but
the flange size is different. For the high-temperature probe adapter, two types of probe materials
are provided: SUS310S and silicon carbide (SiC). The SUS310S probe adapter is used to
measure gases at up to 800ºC, while the silicon carbide (SiC) probe adapter is for gases up to
1400ºC.

Sample gas outlet

When a negative
measurement gas
Separate Type
pressure is used, connect
High-temperature Detector
the auxiliary ejector
(ZR22G-015)
assembly.
When the temperature of the
When the measurement
measurement gas is between
gas is high-temperature
700 and 1400ºC, mount the
and high-pressure and
detector with a ZO21P-H probe
does not fall below 700ºC,
adapter. The construction is
connect a throttle valve
the same as that of the
(e.g. a needle valve).
general-purpose detector
(except the flange size).
The probe length is 15 cm.
Flange
Selectable from JIS, ANSI or
DIN standard models High-temperature Probe Adapter
(ZO21P-H)
The probe is made of either SUS 310S or
silicon carbide (SiC).
The probe length is either 1.0 m or 1.5 m.
When using an SiC probe, mount it
vertically downward.

F0403.ai

Figure 4.3 Part names and functions of the high-temperature detector

TI 11M12A01-03E 2010.12.3-00
12 4. ZR22G Detector Construction and Features

4.3 Pressure Compensation Method

If the in-furnace pressure is high or there are variations in the in-furnace pressure, the pressure
balance between the inside of the furnace and the reference air is lost, making it difficult to
measure the oxygen concentration accurately.
In this case, the detector’s pressure compensation function can be used to return the reference
air to the furnace to maintain the pressure balance between the inside of the furnace and the
reference air side. This enables reliable measurements to be made.
This function allows in-furnace pressures of up to 250 kPa to be measured.

Furnace inside

Zirconia cell Reference air

Calibration
gas pipe

Heater
Calibration gas inlet
Reference air pipe
Reference air inlet

F0404.ai

Figure 4.4 Pressure compensation method

TI 11M12A01-03E 2010.12.3-00
 5. ZR402G Converter Functions and Features 13

5. ZR402G Converter Functions and

Features
5.1 Human Machine Interface (HMI)
• Equipped with a back-lit large display unit that is easy to see and read.
• High-resolution graphic display. Up to 150 minutes of trend graph can be displayed.
• The touch panel allows information to be easily read and set up.
• Interactive operations along with operation display, eliminating the need for an Instruction
Manual.

5.1.1 Basic Panel and Touch Panel Switch

Tag name
display area
Switch display area
Primary value

Alarm and error

Secondary value
display area
Tertiary value
F0501.ai

Figure 5.1 Basic panel display

l Basic panel display

Tag name display area: Displays the set tag name.
Primary to tertiary display items: Displays the selected item in large letters (see Table 5.1).
Secondary and tertiary display items: Display the selected items in small letters (see Table 5.1).
Switch display area:  isplays switches and functions selected according to
D
the panel display (see Figure 5.2).
Alarm and error display area: D isplays an error if an alarm or error occurs. If you
touch this area, the details of the error or alarm are then
displayed.

Table 5.1 Display Items

Primary Secondary &
Item Display
value tertiary values
Oxygen
  Oxygen concentration during measurement
concentration
Air ratio  Current computed air ratio
Moisture
 Moisture quantity (%H2O) in the exhaust gas
quantity
Oxygen concentration with the equipment set for oxygen
Output 1 item  
analyzer (See *1 below.)
Oxygen concentration with the equipment set for oxygen
Output 2 item  
analyzer (See *1 below.)
Current
 Current value output from analog output 1
output 1
Current
 Current value output from analog output 2
output 2
*1: If an analog output smoothing constant is set, the oxygen concentration display then includes these settings.

TI 11M12A01-03E 2010.12.3-00
14 5. ZR402G Converter Functions and Features

l Touch Panel Switch

The ZR402G uses a touch panel that can be operated by just touching the switch display. The
switches displayed in this area and their functions vary depending on the panel display, allowing
all switch operations. Figure 5.2 shows the types of switches and their functions.

Home key: Enter key:

Returns to the Execution/Setup Used to confirm the input value or
Enter
display. a selected item.
Setup key:
Reject key:
Used to enter the Execution/Setup
Moves back to the previous display.
display.
Cursor key: Detailed-data key:
Moves the cursor down. Displays the analog input value.
Cursor:
Graph display key: Points the cursor at the currently
Displays a trend graph. selected item.

Alarm: Error:
Displayed if an alarm occurs. Displayed if an error occurs.
F0502.ai

Figure 5.2 Switch names and their functions

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 5. ZR402G Converter Functions and Features 15

5.1.2 Display Configuration (for Oxygen Analyzer)

Figure 5.3 shows the display configuration. A password can be used to protect the displays
positioned below the Execution/Setup display.

[Basic panel display]

[Detailed-data display] [Execution/Setup [Trend Graph display]

display]

[Password Entry display]

Calibration execution Blow back execution Reset panel display Maintenance Commissioning
panel display (Setup) display
Display setup mA-output setup
Returns to the Returns to the Returns to the
Display item mA-output1
Execution/Setup Execution/Setup Execution/Setup
Trend graph mA-output2
display. display. display.
Auto return time Output held
Language Alarm setup
Calibration setup Hysteresis
Mode Contact delay
Points Setpoints
Zero- and Span-gas Contact setup
conc. Input contacts
Timing Output contacts
Blow back setup Others
mA-output loop check Clock
Contact check Averaging
Fuel setup
Passwords
Defaults
Returns to the Returns to the
Execution/Setup Execution/Setup
display. display.

F0503.ai

Figure 5.3 Display configuration

TI 11M12A01-03E 2010.12.3-00
16 5. ZR402G Converter Functions and Features

5.1.3 Trend Graph Display

When the key is pressed in the basic panel display, the graph display showing measured
values on the time axis appears. This display is useful for viewing the trend of measured values
or checking the stability of the reading by observing trend data of the oxygen concentration during
automatic calibration.

Figure 5.4 Trend Graph display

l Display of the Trend Graph Display

Time axis (user selectable, 1 to 150 min)
Measured value axis (user selectable)
Tag number (user settable)
Currently measured value

l Sampling Period
This graph allows the plotting of 60 data items on one graduation on the time axis. So, if you set
a ten-second sampling period, one graduation corresponds to 600 seconds (Figure 5.5).
The allowable sampling periods range from 1 to 30 seconds. If you set a one-second sampling
period, the axis of the abscissas then corresponds to five minutes. If you set it to 30 seconds, the
axis of the abscissas then corresponds to 150 minutes.
25.0 % O2 10 min/div.

Upper limit set Time per graduation,

calculated by the set
sampling period

Lower limit set

0.0 % O2 12.3 % O2

60 data items
Currently measured value

Sampling period F0505.ai

Figure 5.5 Sampling period

TI 11M12A01-03E 2010.12.3-00
 5. ZR402G Converter Functions and Features 17
l Measured Value Axis
Set the upper and lower limits of measured values on the y-axis of the graph. The allowable
settings for both upper-limit and lower-limit values range from 0 to 100% O2.

5.1.4 Detailed-data Display

The Detailed-data display is used to display the detailed operation data.
There are ten panel displays for viewing detailed data. The following briefly describe the
operational data displayed on the detailed-data display.

F0506.ai

Figure 5.6 Detailed-data display

(1) Span-gas and Zero-gas Correction Ratios

These are used to check for degradation of the sensor (cell). If the correction ratio is beyond the
limits as shown in Figure 5.7, the sensor should no longer be used. These ratios are calculated
as shown below.

81.92 Zero origin

ez
Cell electromotive force, mV

Calibration curve
before correction
Previous
zero-gas data B A
Corrected
e1 calibration curve
(Theoretical
es calibration curve)
C
0 Span origin
21.0 p1 0.51
Span-gas concentration
Oxygen concentration (vol% O2)

Zero-point correction factor = (B/A) x 100 (%) Correctable range: 100 ± 30%
Span correction factor = (C/A) x 100 (%) Correctable range: 0 ± 18%
F0507.ai

Figure 5.7 Calculation of a two-point calibration curve and correction factors using zero and span gases

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18 5. ZR402G Converter Functions and Features

(2) Response Time

The cell’s response time is obtained in the procedure shown in Figure 5.8. If only either a zero-
point or span calibration has been carried out, the response time will not be measured just as it
will not be measured in manual calibration.
The response time is obtained after the corrected calibration curve has been found. The response
time is calculated, starting at the point corresponding to 10% of the analog output up to the point
at 90% of the analog output span. That is, this response time is a 10 to 90% response.

Five minutes maximum

Response time

mA

100%
90%

10% of analog
output span
Time
Start calibration Calibration
complete
F0508.ai

Figure 5.8 Functional drawing of response time

(3) Robustness of a Cell

The robustness of a cell is an index for predicting the remaining life of a sensor and is expressed
as one of four time periods during which the cell may still be used:
(1) more than one year
(2) more than six months
(3) more than three months
(4) less than one month
The above four time periods are tentative and used only for preventive maintenance, not for
warranty of the performance.
This cell’s robustness can be found by a comprehensive evaluation of data involving the cell’s
response time and internal resistance and zero gas and span gas ratios.

(4) Cell Temperature

This indicates the cell (sensor) temperature, usually 750ºC, obtainable from the “thermoelectromotive
force” and “cold junction temperature” described below.

(5) C. J. Temperature
This indicates the detector terminal box temperature, which compensates for the cold junction
temperature for a thermocouple measuring the cell temperature. When the ZR22G Detector is
used, the maximum C. J. temperature will be 150ºC. If the terminal box temperature exceeds this,
take measures, for example, so that the terminal box is not exposed to radiation to reduce that
temperature.
The maximum C. J. temperature varies depending on the type of detector.

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 5. ZR402G Converter Functions and Features 19
(6) Cell Voltage
The cell (sensor) voltage will be an index to determine the amount of degradation of the
sensor. The cell voltage corresponds to the oxygen concentration currently being measured.
If the indicated voltage approximates the ideal value (corresponding to the measured oxygen
concentration), the sensor will be assumed to be normal.
The ideal value of the cell voltage (E), when the oxygen concentration measurement temperature
is controlled at 750°C., may be expressed mathematically by:
E = -50.74 log (Px/PA) [mV]

where, Px: Oxygen concentration in the measured gas

PA: Oxygen concentration in the reference gas, (21% O2)
Table 5.2 shows oxygen concentration versus cell voltage.

Table 5.2 Oxygen Concentration Vs. Cell Voltage, (cell temperature: 750°C)
%O2 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
mV 117.83 102.56 93.62 87.28 82.36 78.35 74.95 72.01 69.41

%O2 1 2 3 4 5 6 7 8 9
mV 67.09 51.82 42.88 36.54 31.62 27.61 24.21 21.27 18.67

%O2 10 21.0 30 40 50 60 70 80 90
mV 16.35 0 -7.86 -14.2 -19.2 -23.1 -26.5 -29.5 -32.1

%O2 100
mV -34.4

(7) Thermocouple Voltage

The cell (sensor) temperature is measured with a Type K (chromel-alumel) thermocouple. The
thermocouple cold junction is located in the detector terminal box. The cell temperature and the
thermocouple voltage (including the voltage corresponding to the cold junction temperature) are
displayed.

(8) Cold Junction Resistance (C. J. Voltage)

The ZR22G Detector measures the cold junction temperature using an RTD (Pt 1000).

(9) Cell’s Internal Resistance

A new cell (sensor) indicates its internal resistance of 200Ω maximum. As the cell degrades, so
will the cell’s internal resistance increase. The degradation of the cell cannot be found only by
changes in cell’s internal resistance, however. Those changes in the cell’s internal resistance will
be a hint to knowing the sensor is degrading. The updated values obtained during the calibration
are displayed.

(10) Software Revision

The revision (number) of the software installed in the ZR402G Converter is displayed.

(11) Maximum Oxygen Concentration

The maximum oxygen concentration and the time of its occurrence during the period specified
in the Averaging display are displayed. If the setup period elapses, the maximum oxygen
concentration that has been displayed so far will be cleared and a new maximum oxygen
concentration will be displayed. If the setup period of time is changed, the current maximum
oxygen concentration will be displayed.

TI 11M12A01-03E 2010.12.3-00
20 5. ZR402G Converter Functions and Features

(12) Minimum Oxygen Concentration

The minimum oxygen concentration and the time of its occurrence during the period specified
in the Averaging display are displayed. If the setup period elapses, the minimum oxygen
concentration that has been displayed so far will be cleared and a new minimum oxygen
concentration will be displayed. If the setup period of time is changed, the current minimum
oxygen concentration will be displayed.

(13) Average Oxygen Concentration

The average oxygen concentration during the periods over which average values are calculated
that is specified in the Averaging display is displayed. If the setup period elapses, the average
oxygen concentration that has been displayed so far will be cleared and a new average oxygen
concentration will be displayed. If the setup period of time is changed, the current average
oxygen concentration will be displayed.

(14) Heater On-Time Ratio

The probe sensor is heated to and maintained at 750ºC. When the measured gas temperature is
high, the amount of heater ON-time decreases.

(15) Time
The current date and time are displayed. These are backed up by the built-in batteries after the
power is switched off, so no adjustment is required.

(16) History of Calibration Time

The calibration-conducted dates and times, and span-gas and zero-gas ratios for the past ten
calibrations are stored in memory.

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 5. ZR402G Converter Functions and Features 21

5.1.5 Execution/Setup Display

This display is used to calibrate or maintain the equipment or perform basic setup. There are
three execution displays and two data setup displays (five displays in total). Their operations can
be protected by a password.

l Basic Panel Display

This display shows the general measurement status.
When the key is pressed, the following display appears.

F0509.ai

Figure 5.9 Basic panel display

l Execution/Setup Display
Select the required item from among the items displayed.
For example, if you wish to make setup, select Setup using the ▼ key and press the [Enter] key.

F0510.ai

Figure 5.10 Execution/Setup display

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22 5. ZR402G Converter Functions and Features

(1) Execution display

l Calibration Execution Display
This is the execution display for calibration, and is used to perform manual or semi-automatic
calibration.

F0511.ai

Figure 5.11 Calibration execution display

l Blow back Execution Display

This display is used to execute blow back.

F0512.ai

Figure 5.12 Blow back execution display

l Reset display
If an error occurs, you can reset the equipment from this display in the following cases:
(1) Error 1 – if the cell voltage is incorrect
(2) Error 2 – if a temperature alarm occurs
(3) Error 3 – if the A/D converter is defective
(4) Error 4 – if an EEPROM write error occurs

F0513.ai

Figure 5.13 Reset display

TI 11M12A01-03E 2010.12.3-00
 5. ZR402G Converter Functions and Features 23
(2) Setup display

l Maintenance Display
This display is used to set data for equipment maintenance or make a loop check, etc.

F0514.ai

Figure 5.14 Maintenance display

l Commissioning (Setup) Display

This display is used to set up the operation data such as current outputs or alarms.

F0515.ai

Figure 5.15 Commissioning (Setup) display

TI 11M12A01-03E 2010.12.3-00
24 5. ZR402G Converter Functions and Features

5.2 Output Functions

5.2.1 Current Output
The ZR402G Zirconia Oxygen Analyzer Converter has two 4 – 20 mA DC current outputs. The
output range of measured value (oxygen concentration) can be arbitrarily set from 0 to 5 in a
range of 0 to 100 vol% O2. A partial range can also be set (the ratio between the maximum and
minimum values should be 1.3 or more).
Setting is made by selecting “mA-output setup” in the Commissioning (Setup) display shown in
Figure 5.15 and then choosing “mA-output 1” or “mA-output 2” in the mA-output setup display.

F0516.ai F0517.ai

Figure 5.16 mA-output setup display Figure 5.17 mA-output 1 range display

The following output functions can also be set up.

l Setting Output Smoothing Constants

If a measured value which is adversely affected by rapid changes in the oxygen concentration of
the measurement gas is used as the basis for control, frequent on-off actions of the output may
result. To avoid this, the converter allows output smoothing constants to be set from 0 to 255
seconds, using the mA-output 1 range display shown in Figure 5.17.

l Output Hold Setting

The “output hold” functions hold an analog output signal at the measured value just before
occurrence or a preset value during the equipment’s warm-up time or calibration or if an error
arises. Outputs 1 and 2 cannot be set individually.
Table 5.3 shows the relationship between individual equipment states and the analog outputs that
can be retained.

Table 5.3 Individual Equipment States and the Analog Outputs That Can Be Retained
Equipment state
During Under Under calibration On error
Output hold warm-up maintenance During blow back occurrence
values available
4 mA 
20 mA 
Without hold feature   
Retains output from just before
  
occurrence
Set value (2.4 to 21.6 mA)    
: The output hold functions are available.

To set the output hold function, select “Set presets” on the mA-output setup display. This causes
the display shown in Figure 5.18 to appear.

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 5. ZR402G Converter Functions and Features 25
From this display, select the desired item. Figure 5.19 shows an example of selecting
“Maintenance.” Then the desired output status can be selected.

F0518.ai F0519.ai

Figure 5.18 mA-output presets display Figure 5.19 Example of mA-output presets

5.2.2 Contact Output

There are four contact outputs.
For contact outputs 1 to 3, you can select either normally energized or normally de-energized.
Setting items can also be selected. Table 5.4 shows a list of setting items.
Contact output 4 is normally energized and the setting item is also fixed to “Error.”
The setting items and contact actions of contact outputs 1 to 3 are handled as follows: Press the
Setup key in the basic panel display to display the Execution/Setup display shown in Figure 5.10
and select “Setup.” Then select “Contact setup” in the Commissioning (Setup) display shown
in Figure 5.15. The Contact setup display shown in Figure 5.20 appears. In this display, select
“Contact output 1” to “Contact output 3” to set up individual items.

F0520.ai F0521.ai

Figure 5.20 Contact setup display Figure 5.21 Output contact 1 display

F0522.ai

Figure 5.22 Example display of setting Contact 1 Others

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26 5. ZR402G Converter Functions and Features

Table 5.4 Contact Output Settings

Item to be selected Description
If "high-high alarm ON" is selected, contact output occurs when the high-high-limit
High-high-limit alarm alarm is issued. To do this, it is required, in alarm setup, that the high-high alarm be
set on beforehand.
If "high alarm ON" is selected, contact output occurs when the high-limit alarm is
High-limit alarm provided. To do this, it is required, in alarm setup, that the high-limit alarm be set on
beforehand.
Alarm and Error Settings

If "low alarm ON" is selected, contact output occurs when the low-limit alarm is
Low-limit alarm provided. To do this, it is required, in alarm setup, that the low-limit alarm be set on
beforehand.
If "low-low alarm ON" is selected, contact output occurs when the low-low-limit alarm
Low-low-limit alarm is issued. To do this, it is required, in alarm setup, that the low-low alarm be set on
beforehand.
If calibration coefficient alarm is ON (enabled), then when a zero- calibration
Calibration coefficient alarm coefficient alarm (alarm 6) or span calibration coefficient alarm (alarm 7) occurs then
calibration coefficient alarm contact output occurs.
Startup power stabilization If set ON then contact output occurs when startup power stabilization timeout alarm
timeout alarm (alarm 8) occurs.
Error If "Error ON" is selected, contact output occurs when an error results.
If "Warm-up ON" is selected, contact output occurs during warm-up.
Warm-up
For the definition of warm-up.
If "Range Change ON" is selected, contact output occurs ("answer-back signal to
a range change signal") while a range change signal is applied to a contact input.
Output range change
To do this, it is required, in input contact setup, that the range change be selected
beforehand.
If "Calibration ON" is selected, contact output occurs during calibration.
Calibration
For the definition of "During calibration,".
If "Maintenance ON" is selected, contact output occurs during maintenance.
Other settings

Maintenance
For the definition of "During maintenance,".
If "Blow back ON" is selected, contact output occurs during blow back.
Blow back
For the definition of "During blow back,".
High-limit temperature
Not supported by the oxygen analyzer.
alarm
If "Cal. gas press. low ON" is selected, contact output occurs ("answer-back signal to
a calibration-gas low-pressure signal")when a calibration-gas low-pressure signal is
Calibration gas press. low
applied to the contact input. To do this, it is required, in input contact setup, that "Cal.
gas press. Low" be selected beforehand.
If "Process upset" is selected, contact output occurs ("answer-back signal to a
process upset signal) when the process upset signal is applied to the contact input.
Process upset
To do this, it is required, in input contact setup, that "process upset" be selected
beforehand.
Note: To provide an alarm with an output contact, be sure to make an alarm setting.
When using contact output as an answer-back signal for an input contact, be sure to make an input contact.

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 5. ZR402G Converter Functions and Features 27

5.3 Oxygen Concentration Alarms

The analyzer enables four alarms — high-high, high, low, and low-low alarms — to be set for the
oxygen concentration.
The setting range is 0 to 100% O2 for any alarm.

5.3.1 Alarm Output Actions

If the measured values of the oxygen concentration fluctuate between normal (steady state)
values and the alarm setting, alarm-outputs may be frequently issued and canceled. To avoid
this, set an alarm delay and hysteresis for alarm canceling under the alarm output conditions.
When a delay time is set, an alarm will not be issued so quickly even if the measured value differs
from the steady-state and enters the alarm setpoint range. If the measured value remains within
the alarm setpoint range for a certain period of time (the preset delay time), an alarm will be
issued. On the other hand, there will be a similar delay each time the measured value returns to
the steady state from the alarm setpoint range (canceling the alarm status).
If hysteresis is set, alarms will be canceled when the measured value is less than or greater than
the preset hysteresis values.
If both the delay time and hysteresis are set, an alarm will be issued if the measured value is in
the alarm setpoint range and the delay time has elapsed. For the alarm to be reset (canceled),
the measured value must be beyond the preset hysteresis value and the preset delay time must
have elapsed. These alarm output actions are shown in Figure 5.23.

Alarm range
A B C D

7.5%
High-limit Hysteresis:
alarm setpoint 2.0%
5.5%
Oxygen
concentration
Delay time: 5 sec Delay time: 5 sec Delay time: 5 sec
Alarm output
ON
OFF F0523.ai

Figure 5.23 Alarm output action

In the example in Figure 5.23, the high-limit alarm point is set to 7.5% O2, the delay time is set to
five seconds, and hysteresis is set to 2% O2. Alarm output actions in each section in the figure
above are as follows:
Section “A”: A
 lthough the oxygen concentration exceeds the high-limit alarm setpoint, it falls
below the high-limit alarm setpoint before the preset delay time of five seconds
elapses. So, no alarm is issued.
Section “B”: T
 he oxygen concentration exceeds the high-limit alarm setpoint and the delay
time elapses during that measurement. So, an alarm is issued.
Section “C”: A
 lthough the oxygen concentration falls below the hysteresis set value, the value
rises again and exceeds the hysteresis set value before the preset delay time
elapses. So, the alarm is not canceled.
Section “D”: T
 he oxygen concentration falls below the hysteresis set value and the preset
delay time elapses, so the alarm is canceled.

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28 6. Calibration

5.3.2 Setting Alarms

To set alarm setpoints, hysteresis, and delay time, do the following.
Press the Setup key in the basic panel display to show the Execution/Setup display in Figure
5.10 and then select “Setup”. Then select “Alarm setup” in the Commissioning (Setup) display in
Figure 5.15 to show the Alarm setup display in Figure 5.24.
In this display, select the required item and make the respective settings.

F0524.ai F0525.ai

Figure 5.24 Alarm setup display Figure 5.25 Oxygen alarms display

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 6. Calibration 29

6. Calibration
6.1 Calibration Overview
The sensor (cell) electromotive force of the zirconia oxygen analyzer is governed by Nernst’s
equation (see chapter 2, “Measurement Principle of Zirconia Oxygen Analyzers”).
When the sensor is heated up to 750ºC and air is used as the reference gas, the relationship
between the oxygen concentration of the measurement gas and the electromotive force of the
sensor (cell) is as shown in Figure 6.1. However, this relationship is only theoretical. In practice,
the sensor (cell) usually shows a slight deviation from the theoretical value. Moreover, the sensor
deteriorates over time, causing the electromotive force to change.
Therefore, it is necessary to calibrate using calibration gas to correct the deviation from the
theoretical value.

120

100
0.51 % O2, 81.92 mV (Zero origin of calibration)
80
Sensor (cell) voltage (mV)

60

40

20
21.0 % O2, 0 mV
(Span origin of calibration)
0

-20

-40
0.1 0.5 1 5 10 21.0 50 100
Oxygen concentration (vol% O2) F0203.ai

Figure 6.1 Relationship between oxygen concentration in measurement gas and cell’s electromotive
force (on the basis of 21.0% O2)

6.2 Calibration Gas

A gas with a known oxygen concentration is used for calibration. Normal calibration is performed
using two different gases: a “zero gas” of low oxygen concentration and a span gas of high
oxygen concentration (two-point calibration).
In some cases, only one of the gases needs to be used for calibration. However, even if only one
of the gases is normally used, calibration using both gases should be done at least once.
The following gases are normally used for zero gas and span gas.
• Zero gas: Oxygen concentration of 0.95 to 1.0 vol% O2 with a balance of nitrogen gas (N2)
• Span gas: C
 lean air (at a dew-point temperature below −20ºC and free of oily mist or dust
as in instrument air)
Note: Nitrogen gas (N2) with an oxygen concentration of 0% cannot be used as zero gas.
This is because, as described in the chapter on the measurement principle, the zirconia oxygen analyzer detects, as
electromotive force (E), changes in the partial oxygen pressure (PX) on the measurement side with respect to the partial oxygen
pressure (PA) on the reference side.
Because this electromotive force (E) is logarithmically proportional to PX/PA, if PX is 0%, the electromotive force becomes infinite,
disabling calibration. In general, gas of 1% O2 is used for calibration with zero gas.

TI 11M12A01-03E 2010.12.3-00
30 6. Calibration

6.3 Two-point Calibration

Figure 6.2 shows a two-point calibration using two gases: zero and span gases. Cell
electromotive forces for a span gas with an oxygen concentration p1 and a zero gas with an
oxygen concentration p2 are measured while determining the calibration curve passing between
these two points. The oxygen concentration of the measurement gas is determined from this
calibration curve.
In addition, the calibration curve corrected by calibration is compared with the theoretical
calibration curve for determining the zero-point correction ratio represented by B/A x 100 (%) on
the basis of A, B and C shown in Figure 6.2 and a span correction ratio of C/A x 100 (%). If the
zero-point correction ratio exceeds the range of 100 ± 30 % or the span correction ratio becomes
larger than 0 ± 18 %, calibration of the sensor becomes impossible.

81.92 Zero origin

ez
Cell electromotive force, mV

e2
Calibration curve
before correction

B A
Corrected
e1 calibration curve
(Theoretical
calibration curve)
es
C
0 Span origin
21.0 p1 p2 0.51
(Span-gas concentration) (Zero-gas concentration)
Oxygen concentration (vol% O2)
Zero-point correction factor = (B/A) × 100 (%) Correctable range: 100 ± 30%
Span correction factor = (C/A) × 100 (%) Correctable range: 0 ±18%
F0602.ai

Figure 6.2 Calculation of a Two-point Calibration Curve and Correction Factors using Zero and Span
Gases

6.4 One-point Calibration

Figure 6.3 shows a one-point calibration using only a span gas. In this case, only the cell
electromotive force for a span gas with oxygen concentration p1 is measured. The cell
electromotive force for the zero gas is carried over from a previous measurement to obtain the
calibration curve. The principle of calibration using only a span gas also applies to the one-point
calibration method using a zero gas only.
The methods of obtaining the span correction ratio and zero-point correction ratio are the same
as those of two-point calibration.

81.92 Zero origin

ez
Cell electromotive force, mV

Calibration curve
before correction
Previous
zero-gas data B A
Corrected
e1 calibration curve
(Theoretical
es calibration curve)
C
0 Span origin
21.0 p1 0.51
Span-gas concentration
Oxygen concentration (vol% O2)

Zero-point correction factor = (B/A) x 100 (%) Correctable range: 100 ± 30%
Span correction factor = (C/A) x 100 (%) Correctable range: 0 ± 18%
F0507.ai
Figure 6.3 Calculation of a One-point Calibration Curve and Correction Factors using a Span Gas

TI 11M12A01-03E 2010.12.3-00
 6. Calibration 31

6.5 Calibration Modes

Zirconia oxygen analyzers employ the following three operation modes for calibration.
• Manual calibration:  llows zero and span calibrations, or either one manually in turn.
A
• Semi-automatic calibration: Lets calibration start with the touch panel or a contact input, and
undergoes a series of calibration operations following preset
calibration periods and stabilization time.
• Automatic calibration: Performs calibration automatically following preset calibration
periods.

6.6 Setting the Calibration Time

(1) For manual calibration
First set the output stabilization time. This indicates the time required from the end of calibration
to entering a measurement again. This time, after calibration, the measurement gas enters the
sensor to set the time until the output returns to normal. The output remains held after completing
the calibration operation until the output stabilization time elapses. The calibration time set ranges
from 00 minutes, 00 seconds to 60 minutes, 59 seconds.

(2) For semi-automatic calibration

Set the output stabilization time and calibration time. The calibration time is the time required from
starting the flow of the calibration gas to reading out the measured value. The set calibration time
is zero and span calibrations.
The calibration time set ranges from 00 minutes, 00 seconds to 60 minutes, 59 seconds.
Figure 6.4 shows the relationship between the calibration time and output stabilization time.

Calibration start
(contact or switch input)

Span calibration
Calibration time
(span-gas valve open)

Zero-point calibration
Calibration time
(zero-gas valve open)

Analog output status

Stabilization
time

Analog output remains held

(when output remains held) F0604.ai

Figure 6.4 Calibration and output stabilization time settings

(3) For automatic calibration

In addition to the above output stabilization time and calibration time, set the interval, start date,
and start time. Interval means the calibration interval, ranging from 000 days, 00 hours to 255
days, 23 hours. Set the first calibration day, and the start-calibration time, respectively.

TI 11M12A01-03E 2010.12.3-00
32 7. Blow Back Function

7. Blow Back Function

The probe easily becomes clogged if the sample gas contains too much dust such as in a
recovery boiler or cement kiln. The blow back function is used to remove such dust with air
pressure.

7.1 Blow Back Modes

The zirconia oxygen analyzer offers the following two blow back modes:

l Semi-automatic blow back

In this mode, touch panel operations or contact input signals will start and perform blow back
operations according to a preset blow back time and output stabilization time.

l Automatic blow back

Performs blow back operations automatically according to a preset interval, blow back time, and
output stabilization time.

7.2 Blow Back Operations

Figure 7.1 shows a timing chart for the operation of blow back. To execute blow back with a
contact input, use a contact input with an ON-time period of 1 to 11 seconds. Once blow back
starts, a contact output opens and closes at 10 second intervals during the preset blow back time.
After the blow back time elapses, the analog output remains held at the preset status until the
hold time elapses. As the hold (output stabilization) time, set the time until the measured gas is
returned to the sensor and the output returns to the normal operating conditions, after completing
blow back operations.

ON-time period of 1 to 11 seconds for the contact input

Blow back start

(with contact input or
touch panel operation)
Blow back time
ON ON ON
(for 10 (for 10 (for 10
Contact output
seconds) seconds) seconds)
(blow back switch) OFF
(for 10 seconds) Hold time

Analog output remains held

Analog output (with HOLD feature specified)
F0701.ai

Figure 7.1 Operation of blow back

• Blow back time: Can be set from 00 min, 00 sec to 60 min, 59 sec.
• Hold time (output stabilization time): Can be set from 00 min, 00 sec to 60 min, 59 sec.

TI 11M12A01-03E 2010.12.3-00
 8. Directions for Use 33

8. Directions for Use

To achieve accurate measurements with a zirconia oxygen analyzer, the following must be
considered.

8.1 Effect of Coexisting Combustible Gases

The sensor (zirconia element) is heated to 750ºC during measurements. If the process gas
contains combustible gases such as carbon monoxide, hydrogen, and methane, these gases
burn in the detector and consume oxygen, causing the oxygen concentration measured by the
oxygen analyzer to be smaller than the actual value. Therefore, zirconia oxygen analyzers should
be used only when the effect of coexisting combustible gases can be ignored or when their effect
on oxygen concentration can be corrected.
Generally, exhaust gases after combustion that are emitted from combustion equipment such as
boilers and industrial furnaces have been completely burned; the volume of combustible gases
such as carbon monoxide is very small in comparison with oxygen, and so their influence can
be ignored. However, if the excess air ratio is extremely small or if combustion is non-uniform,
causing carbon monoxide to be produced, care is required.

8.2 Effect of Humidity in Reference Gas (Air)

Zirconia oxygen analyzers use a gas whose oxygen concentration is known and always
consistent, as the reference gas.
In general, air is used as the reference gas. The oxygen concentration of dry air is constant at
20.95%; however, air generally contains water vapor, in which case the oxygen concentration
varies with temperature and humidity.
In zirconia oxygen analyzers, a measurement error is caused if the temperature or humidity of the
reference gas (air) varies significantly between calibration and measurement. When instrument
air is used as the reference gas, this error can be ignored, but if it cannot be used, care is
required.

8.3 Precautions When Shutting Down a Furnace

or Boiler
When operating an instrument such as boiler or industrial furnace is stopped with the zirconia
oxygen analyzer operation, moisture can condensate on the sensor portion and dusts may stick
to it.
If operation is restarted in this condition, the sensor which is heated up to 750°C firmly fix the
dusts on itself. Consequently, the dusts can make the sensor performance very lower. If a large
amount of water is condensed, the sensor can be broken and never reuseful.
To prevent the above nonconformity, take the following action when stopping operation.
(1) If possible, keep on supplying the power to converter and flowing reference air to the sensor.
If impossible to do the above, remove the detector.
(2) If unavoidably impossible to supply the power and removing the detector, keep on following
air at 600ml/min into the calibration gas pipe.

TI 11M12A01-03E 2010.12.3-00
34 8. Directions for Use

8.4 Dry Gas Base and Wet Gas Base

Exhaust gas emitted by combustion of fuel contains water vapor generated by the burning of
hydrogen in the fuel.
When directly measuring gases in a flue with a zirconia oxygen analyzer, exhaust gas containing
moisture is measured. Values measured under these conditions are called “values based on a
wet gas.”
In contrast, for oxygen analyzers that sample and measure exhaust gases, the sample gas
temperature is lowered to normal temperature in the process of being introduced into the
analyzer and moisture that would condense into water is also removed from the sample gas.
Values measured after removing the moisture in this way are called “values based on a dry gas.”
While a value based on a dry gas regards the total gas composition available after moisture
removal as 100%, a value based on a wet gas assumes that the gas composition including water
vapor is 100%. Therefore, the results differ between both measurement types even when the
oxygen concentration of the same exhaust gas is measured (see Figure 8.1).
This difference between the measurement types is largest when gas containing much hydrogen
is burned (since much water vapor is generated). Special care is required when the output (based
on a wet gas) of the zirconia oxygen analyzer is calculated in combination with other analytical
values measured based on a dry gas (for example, CO or NOx concentration measured using an
infrared gas analyzer).
Note: Our model ZR402G Zirconia Oxygen Analyzer Converter incorporates a “dry gas-based” calculation function; it can output dry
gas-based values.

100%
Moisture content
Moisture content that has been
removed
100%
CO2 CO2
8.6% 10.3%
O2 2.6% O2 3.1%
Ar 0.9% Ar 1.0%

N2 N2
71.2% 85.5%

Wet gas-based value Dry gas-based value F0801.ai

Figure 8.1 Values based on a wet gas or dry gas

8.5 In Case Equipment is Turned On and Off

Frequently
To avoid temperature changes around the sensor, it is recommended that (rather than turning it
on and off) power be continuously supplied to the Oxygen Analyzer if it is used in an application
where it is used periodically.
It is also recommended to flow a span gas (instrument air) beforehand.

TI 11M12A01-03E 2010.12.3-00
 35

Revision History
Manual Title: Model ZR22G, ZR402G
Direct In-site Separate type Zirconia Oxygen Analyzers
(Hardware Edition)
Manual Number: TI 11M12A01-03E

December 2010/1st Edition

Newly published

TI 11M12A01-03E 2010.12.3-00