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Single Channel Oxygen Analyzer System ZR22/ZR402

Yokogawa’s zirconia oxygen analyzers are used for combustion monitoring and control in a wide variety of applications and help industries to make considerable achievements in energy saving. The applications range from energy-consuming industries, such as iron and steel, electric power, oil and petrochemical, ceramics, pulp and paper, food, and textiles, to various combustion facilities, such as incinerators and small- and medium sized boilers. Combustion monitoring and control using the analyzer also contribute to a lowering of CO2, SOx, and NOx emissions by allowing for more complete combustion, thus preventing global warming and air pollution.

Yokogawa Oxygen Analyzers
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Single Channel Oxygen Analyzer System ZR22/ZR402

 

Models: ZR22G, ZR22S, ZR402G, ZR22P, ZR22R, ZR22V, AC1, MC1, M1233SR, IAC-24, WZ-H, M1234SE-A, M1200DB-06

Yokogawa’s zirconia oxygen analyzers are used for combustion monitoring and control in a wide variety of applications and help industries to make considerable achievements in energy saving. The applications range from energy-consuming industries, such as iron and steel, electric power, oil and petrochemical, ceramics, pulp and paper, food, and textiles, to various combustion facilities, such as incinerators and small- and medium sized boilers. Combustion monitoring and control using the analyzer also contribute to a lowering of CO2, SOx, and NOx emissions by allowing for more complete combustion, thus preventing global warming and air pollution.

The ZR402G converter is equipped with an LCD touch screen which has various setting displays, a calibration display, oxygen concentration trend display, with easier operation and improvement of display functions. The converter is equipped with various standard functions such as measurement and calculation as well as maintenance functions including self-test. The ZR22G separate-type detector uses a high-reliability zirconia sensor, and its heater assembly can be replaced on site. The detector is mounted, for example, on the wall of a flue and can measure the gases directly. The ZR22S separate-type detector for explosion-proof applications is also available.

 

  • The separate type converter ZR402G incorporates a LCD touchscreen for ease of operation.
  • The built-in heater assembly of the probe can be replaced on site, reducing maintenance costs (ZR22G only).
  • The probe uses a long-life, high-reliability, field replacable Zirconia sensor.
  • Remote maintenance using digital communications (HART) reduces maintenance costs.

Note: HART is a registered trademark of HART Communication Foundation.

 

Measurement objectOxygen concentration in combustion exhaust gas and mixed gas
Measurement systemZirconium oxide sensor
Measurement range0.01 to 100 vol% O2
Output signal4 to 20 mA DC, two points (ZR402G) (maximum load resistance 550Ω)
Setting rangeAny setting in the range of 0 – 5 vol%O2 to 0 – 100 vol%O2 (in 1 vol% O2), or partial range
Digital communication (HART)250 to 550Ω, depending on number of field devices connected to the loop (multi-drop mode)
Sample gas pressure-5 to +250 kPa (Pressure compensation option necessary over +5 kPa)
Sample gas temperature0 to 700℃ (Probe only)
700 to 1871℃ (with 0.15m probe with JIS 5K 32 FF flange and ZR22P High Temperature Probe Adapter)
Probe length0.15, 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0, 3.6, 4.2, 4.8, 5.4 m
Contact outputFour points (one is fail-safe, normally open)
Contact inputTwo points
CalibrationMethod; zero/span calibration
Calibration mode; automatic, semi-automatic and manual (with an LCD touchscreen)
Construction of detector (ZR22G)Heater and thermocouple replaceable construction.
Non-explosion-proof. Equivalent to NEMA4X/IP66
Construction of converter (ZR402G)Non-explosion-proof, outdoor installation, equivalent to NEMA4X/IP66
Ambient TemperatureProbe (ZR22G): -20 to 150℃
Converter (ZR402G): -20 to 55℃)
Reference Gas SystemInstrument Air (preferred): 50 kPa (200 kPa with check valve) + the pressure inside the furnace; Approx. 1 Nl/min consumption

Natural convection

Power supply85 to 264 V AC; 45 to 66 Hz

 

Measurement objectOxygen concentration in combustion exhaust gas and mixed gas
Measurement systemZirconium oxide sensor
Explosion-proof ApprovalZR22S-A (ATEX); EEx d IIB + H2,
ZR22S-B (FM); Class I, Division1, Groups B, C and D
ZR22S-C (CSA); Class I, Division1, Groups B, C and D
ZR22S-D (IECEx); Ex d IIB + H2, T2
Measurement range0.01 to 100 vol% O2
Output signal4 to 20 mA DC, two points (ZR402G) (maximum load resistance 550Ω)
Setting rangeAny setting in the range of 0 – 5 vol%O2 to 0 – 100 vol%O2 (in 1 vol% O2), or partial range
Digital communication (HART)250 to 550Ω, depending on number of field devices connected to the loop (multi-drop mode)
Sample gas pressure±5kPa
For 0.15m probe, -0.5 to +5 kPa.
No pressure fluctuation in the furnace should be allowed
Sample gas temperature0 to 700℃
700 to 1871℃ (with 0.15m probe with JIS 5K 32 FF flange and ZR22P High Temperature Probe Adapter (certain options only))
Probe length0.15, 0.4, 0.7, 1.0, 1.5, 2.0 m
Contact outputFour points (one is fail-safe, normally open)
Contact inputTwo points
CalibrationMethod; zero/span calibration
Calibration mode; automatic, semi-automatic and manual (with an LCD touchscreen)
Construction of detector (ZR22S)Heater and thermocouple replaceable construction, equivalent to NEMA4X/IP66
Construction of converter (ZR402G)Non-explosion-proof, outdoor installation, equivalent to NEMA4X/IP66
Ambient Temperature-20 to +60℃ (-20 to +150℃ on the terminal box surface) (ZR22S)
-20 to +55℃ (ZR402G)
Reference Gas SystemInstrument Air: 50 kPa + the pressure inside the furnace; Approx. 1Nl/min consumption
Wiring ConnectionATEX; M20 by 1.5 mm or 1/2 NPT select one type (4 pieces)
FM; 1/2 NPT (4 pieces)
CSA; 1/2 NPT (4 pieces)
IECEx; M20 by 1.5 mm or 1/2 NPT select one type (4 pieces)
Power supply85 to 264 V AC; 45 to 66 Hz

 

Repeatability±0.5% Maximum value of set range
Linearity±1% Maximum value of set range
Drift±2% Maximum value of set range/month
Response time (T90)90% response within 5 sec (60 sec for explosion-proof ZR22S)

 

M1233SR Portable Calibration Kit

This portable calibration kit is designed for applications where there is no permanently mounted calibration solution and can be used with any ZR probe. It consists of two 103 L calibration gas bottles (1% O2, balance N2 for zero and 21% O2, balance N2 for span), two 0.5 L/min flow regulators, ten feet of tygon tubing, and one 1/4″ NPT to 1/8″ barb fitting, all contained in a hard carrying case with a shoulder strap.

MC1 Manual Calibration Panel

The MC1 can be used to calibrate the sensor and monitor reference air delivery for any ZR probe. The panel allows easy operator adjustment of calibration and reference gas flow rates, as well as manual switching between zero and span calibration gases. The panel requires standard clean, dry, instrument air for reference air and span calibration gas, and also requires zero calibration gas.

AC1 Automatic Calibration Unit

This automatic calibration unit can be used to calibrate the sensor and monitor reference air delivery for any ZR probe attached to the ZR402G analyzer. Calibration is simplified by allowing the whole calibration procedure to be done from the analyzer’s interface (or remotely) in semi-automatic mode, or by setting a timed automatic calibration in the ZR402G. The solenoid valves also have manual overrides for troubleshooting or performing a manual calibration if desired. The unit requires standard clean, dry, instrument air for reference air and span calibration gas, and also requires zero calibration gas.

IAC-24 Compact Automatic Calibration Unit

This automatic calibration unit is directly mounted to the ZR22G probe’s reference and calibration ports. Calibration is simplified by allowing the whole calibration procedure to be done from the analyzer’s interface (or remotely) in semi-automatic mode, or by setting a timed automatic calibration in the ZR402G. This unit does not have manual overrides and must be used in indoor applicaitons only. The unit requires standard clean, dry, instrument air for reference air and span calibration gas, and also requires zero calibration gas.

 

 

M1234SE-A (Self-Cleaning) and M1200DB-06 (Standard) Fly-Ash Filters

The accumulation of fly-ash on the zirconia cell affects its ability to measure oxygen concentration.
Fly-ash and its constituents can reduce the life of the zirconia cell and affect the cells response time
to changes in gas concentration. Yokogawa’s large surface area sintered metal filters are designed
to keep particulate and ash off the measurement cell.

E7042UQ Oil/Gas Dust Filter

This filter is used to protect the cell from corrosive dust components in natural gas or oil-fired applications.

 

WZ-H Heater and Signal Cabling

Two cables are needed to connect a ZR22 to an AV550G or ZR402G. One heater cable set is necessary to send power from the analyzer to the heater assembly on the probe, and one signal cable set is used to provide the analyzer with information about the probe’s cell voltage, thermocouple reading, and remote junction temperature for compensation. We recommend running these cables in separate conduit to avoid heater wires having an affect on the signal wire readings.

 

 

Yokogawa ZR402G Product Manual

 

Manual & Datasheet

#FileDescriptionDate addedAdded byFile sizeDownloads
1 pdf ZR22G ZR402G ZR22G ZR402G
10/09/2017 15:45Miss Long629 KB318
2 pdf Yokogawa Oxygen Analyzer Module ZR22G-ZR402G Drawings Yokogawa Oxygen Analyzer Module ZR22G/ZR402G Drawings
12/16/2017 14:53Miss Long781 KB166

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