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Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers

Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers

Product catalog summary

Overview
This document provides detailed specifications and operational guidelines for the Yokogawa ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers. These devices are designed for measuring oxygen concentration and humidity in combustion gases and industrial processes, featuring both separate and integrated probe and converter configurations.

Features

Replaceable built-in heater assembly for reduced maintenance costs.
Long-life, high-reliability Zirconia sensor.
Three-reference gas supply methods: natural air convection, instrument air, and pressure compensated.
Separate type converter with LCD touchscreen for ease of operation.
Integrated type reduces wiring, piping, and installation costs.
Remote maintenance via digital communications (HART).

System Configurations
Separate Type: Utilizes instrument air for reference gas and allows for automatic calibration. Suitable for large boilers and industrial furnaces.
Integrated Type: Combines probe and converter, suitable for similar applications with a temperature limit of -20 to 55°C.

Applications

Oxygen concentration monitoring in large, medium, and small boilers.
Humidity monitoring in drying furnaces and humidifiers.

Specifications

Measurement Range: 0.01 to 100 vol% O2.
Output Signal: 4 to 20 mA DC.
Repeatability: ±0.5% to ±1% depending on the range.
Response Time: 90% response within 5 seconds.
Sample Gas Temperature: 0 to 700°C, with options for higher temperatures.
Sample Gas Pressure: -5 to +250 kPa, with pressure compensation options.

Components

ZR22G and ZR202G Detectors.
ZR402G Converter.
Various accessories for calibration and protection.

Procedures
The analyzer operates with an LCD touchscreen and provides output signals of 4 to 20 mA DC. It supports automatic, semi-automatic, and manual calibration modes, requiring the ZR40H Automatic Calibration Unit for automatic processes. Calibration settings include span and zero gas concentration, with intervals up to 255 days. The analyzer also features a blowback function and maintenance functions for data settings and checks.

Standards and Safety
The equipment conforms to safety standards EN 61010-1, CSA C22.2 No.61010-1, and UL 61010-1, as well as EMC standards EN 61326 Class A and EN55011 Class A Group 1. It is marked for Korea Electromagnetic Conformity. The power supply voltage ranges from 85 to 264 V AC, with a frequency range of 45 to 66 Hz.

Recommendations
For installations where the probe insertion length exceeds 2.5 meters, vertical downward mounting within ±5° is recommended, along with the use of a probe protector. The document advises using dehumidified air with a dew point of -20°C or less for the reference gas system to ensure optimal performance.

Key Data
The document provides detailed weight specifications for various probe lengths, ranging from 6 kg to 23 kg depending on the insertion length and standard used (JIS or ANSI). It also specifies ambient and storage temperature ranges, ambient humidity, and installation altitude limits.

Installation and Construction

Mounting: Flange mounting with specific angles depending on probe length. Probe materials include SUS316 stainless steel and Inconel for high-temperature applications.
Construction: Non-explosion proof with replaceable heater and thermocouple. Conforms to various safety and EMC standards.

Options and Accessories

High Temperature Probe Adapter: For measuring O2 in gases exceeding 700°C, with specific material and pressure requirements.
Ejector Assembly: Used when sample gas pressure is negative, includes needle valve and pressure gauge assembly.
Probe Protector: Recommended for high-velocity gas flows.

Functions

Display: LCD display for oxygen concentration, moisture quantity, and other parameters. Displays alarms and errors.
Maintenance: Allows for data setting updates and calibration checks. Supports interactive operation with optical switches.

Specifications and Components
The document outlines various components and specifications for detectors and analyzers used in industrial settings, particularly focusing on protecting equipment from dust and high temperatures. Key components include dust filters, dust guard protectors, and dust protectors for high-temperature humidity analyzers. Materials used are primarily stainless steel (SUS316, SUS304) and silicon carbide (SiC).

Installation and Usage
Installation details specify the use of bolts, nuts, and washers for mounting detectors and probes. Specific models like the ZO21R-L-200-□*B are recommended for probe insertion lengths of 2.5 meters or more. The document also provides guidelines for using dust filters and protectors to prevent damage from dust particles and corrosive components.

Calibration and Maintenance
The document describes units like the ZO21S Standard Gas Unit and ZA8F Flow Setting Unit, which are used for calibration and flow control. Automatic calibration units (ZR40H and ZR20H) are detailed for both separate and integrated types, emphasizing dust-proof and rainproof construction. Maintenance involves using stop valves and check valves to manage gas flow and prevent contamination.

Technical Specifications
Technical details include insertion lengths, flange types, material specifications, and weight for various components. Power supply requirements, ambient temperature, and humidity conditions are specified for optimal operation. The document also includes model and code information for different configurations and options.

Recommendations and Best Practices
Recommendations include using specific materials and configurations for high-temperature environments and ensuring proper installation to prevent equipment wear. The document advises on selecting appropriate options for specific applications, such as using Inconel bolts for high-temperature use and ensuring constant reference gas supply.

Catalog excerpts

Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers-1

General Specications Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers Overview This analyzer consists basically of a probe and a converter that are used as both a Zirconia Oxygen Analyzer and High Temperature Humidity Analyzer. The probe is of direct insertion type, and the converter uses a digital display. Two types of analyzers are available: separate type and integrated type. As its name implies, the integrated type combines probe and converter. Separate and integrated type Zirconia oxygen analyzers need not use a sampling device, and allow direct installation of the probe in the wall of a ue or furnace to measure the concentration of oxygen in the stack gas. The converter displays the cell temperature and cell emf in addition to the oxygen concentration. This analyzer is most suitable for monitoring the oxygen concentration of combustion gases in large or small boilers, various industrial furnace and combustion devices, or for the control of low-oxygen combustion. Separate type and integrated type Zirconia High Temperature Humidity Analyzers are used to measure the humidity of hot gases continuously in driers which use an electrical heater or hot gas as the heat source. They can also be used in a variety of manufacturing applications in humidiers, as well as in driers, for humidity measurement and control. They can help improve productivity in these application elds. Features: • The built-in heater assembly of the probe can be replaced on site, reducing maintenance costs. • The probe uses a long-life, high-reliability Zirconia sensor. • The probe uses three-reference gas supply methods (natural air convection, instrument air, and pressure compensated) in its applications. • The separate type converter incorporates a LCD touchscreen for ease of operation. • This converter can be used as an oxygen analyzer as well as a high temperature humidity analyzer. • The integrated type integrates both probe and converter, to reduce wiring, piping, and installation costs. This type of unit uses an optical switch for ease of operation at the site. • Remote maintenance using digital communications (HART) reduces maintenance costs. *1 *1: HART is a registered trademark of HART Communication Foundation 4 to 20 mA DC signal line with superimposed HART AC signal Relaying terminals Ao+ + Control room Terminal board Receiving instrumen load resistance: 250 Ω to 550 Ω HART Communicator Model 275 HART Communicator Model 275 HART Communicator Model 275 Yokogawa Electric Corporation 2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan Tel.: 81-422-52-5617 Fax.: 81-422-52-6792 GS 11M12A01-01E ©Copyright June 2000 12th Edition Dec. 2012

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Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers-2

Basic System Conguration System conguration - Separate type System configuration Example 1 of Separate type Analyzer Automatic calibration system uses instrument air for reference gas. For the calibration gas, a standard gas cylinder may be used for more accurate calibration. Applications: Oxygen concentration monitoring and control in large boilers (for private power generation and for business use) and in heating furnaces, and the like. Humidity monitoring and control in drying furnaces and humidifiers. ZR22G Separate type Zirconia Oxygen/High Temperature Humidity Analyzer, Detector *2 *1 Signal...

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Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers-3

Basic System Conguration System conguration — Separate type System configuration Example 2 of Integrated type Analyzer System configuration Example 2 of Separate type Analyzer Instrument air is used as the reference gas. A standard gas cylinder can be used for the calibration gas for more accurate calibration. Application example: Oxygen concentration monitoring and control in large boilers (for private power generation and for business use) and in heating furnaces. Humidity monitoring and control in drying furnaces and humidifiers. ZR22G Separate type Zirconia Oxygen/High Temperature Humidity...

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Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers-4

System Components Separate type Integrated type Model ZR22G Separate type Zirconia Oxygen / High Temperature Humidity Analyzers,Detector Model ZR402G Separate type Zirconia Oxygen / High Temperature Humidity Analyzer, Converter(*1) Model ZR202G Integrated type Zirconia Oxygen / High Temperature Humidity Analyzers Model ZO21P High Temperature Probe Adapter for separate type Zirconia Oxygen Analyzer E7046EC, E7046EN Auxiliary Ejector Assembly for High Temperature Probe of separate type Oxygen Analyzer Model ZO21R Probe Protector for Zirconia Oxygen Analyzers K9471UA Dust Filter for Oxygen Analyzer...

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Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers-5

■STANDARD SPECIFICATIONS (Oxygen Analyzer) Example of Application Separate and integrated type Zirconia Oxygen Analyzers • Large, medium and small boilers (boilers for power generation: heavy oil, gas or coal) • Various industrial furnaces (renery process/iron manufacture heating furnace, coal kiln, and black liquid recovery boilers) For other applications, contact Yokogawa Electric Corporation. • May not be applicable corrosive gas such as ammonia, chlorine is present-check wit YOKOGAWA. General Specications Oxygen Analyzer Measurement Object: Oxygen concentration in combustion exhaust gas and...

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Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers-6

<> <> When the probe insertion length is 2.5 m or more, mount vertically downward (within ±5°) and use a probe protector. Weight: Insertion length of 0.4 m: approx. 6 kg (JIS 5K 65) / approx. 11 kg (ANSI 150 4) Insertion length of 1.0 m: approx. 8 kg (JIS 5K 65) / approx. 13 kg (ANSI 150 4) Insertion length of 1.5 m: approx. 10 kg (JIS 5K 65) / approx. 15 kg (ANSI 150 4) Insertion length of 2.0 m: approx. 12 kg (JIS 5K 65) / approx. 17 kg (ANSI 150 4) Insertion length of 3.0 m: approx. 15 kg (JIS 5K 65) / approx. 20 kg (ANSI 150 4) Insertion length of 3.6 m: approx. 17 kg (JIS 5K 65) / approx....

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Model ZR22G, ZR402G, and ZR202G Direct In Situ Zirconia Oxygen Analyzers and High Temperature Humidity Analyzers-7

<> <> Password Functions: Enter your password to operate the analyzer excepting data display. Individual passwords can be set for maintenance and setup. Display and setting content: Measuring Related Items: Oxygen concentration (vol% O2), output current value (mA), air ratio, moisture quantity (in hot gases) (vol% H2O) Display Items: Cell temperature (°C), thermocouple reference junction temperature (°C), maximum/minimum/average oxygen concentration (vol% O2), cell e.m.f. (mV), cell internal resistance (Ω), cell condition (in four grades), heater on-time rate (%), calibration record (ten times),...

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.

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