Single Channel Oxygen Analyzer System ZR22/ZR402

The Single Channel Zirconia Oxygen Analyzer System delivers accurate O2 and humidity measurements utilizing Yokogawa’s zirconia oxygen analyzers for combustion monitoring and control, helping industries achieve lowered CO2, SOx, and NOx emissions. The oxygen analyzer system provides minimized downtime and simplified maintenance with advanced diagnostics, an intuitive design and technician training.

System

The Zirconia Oxygen Analyzer System includes the ZR402G converter and ZR22 detector and is capable of measuring oxygen concentration or humidity in non-combustion applications with a single analyzer. Its LCD touch screen provides easy operation, and digital communications are standard, allowing for remote configuration and troubleshooting.

ZR402G Converter

The ZR402G converter is equipped with an LCD touch screen featuring an intuitive operating system with a variety of display modes and error codes with built-in error details. Other standard functions include measurement, calculation, and self-test maintenance functions to enable easier operation and troubleshooting.

ZR22G/ZR22S Detector

The ZR22G separate-type detector is an in-situ probe that uses a high-reliability zirconia sensor. The zirconia cell and heater assembly can be replaced in the field, reducing maintenance costs. The ZR22S separate-type detector for explosion-proof applications is also available and offers the following explosion-proof certifications:

  • ATEX
  • FM
  • CSA

Features

Accurate Maintenance Scheduling with Advanced Diagnostics

Predictive diagnostics from the analyzer simplify troubleshooting and provide technicians with the necessary data to create a minimal calibration schedule.

Reduced Downtime with a Robust Cell Design

The probe's cell is designed with a large measurement surface area, making it less susceptible to contaminants, which allows for longer periods between cell replacements and calibrations.  

 

Increased Measurement Availability with an Intuitive Design

The probe uses a long-life, high-reliability zirconia sensor and has an intuitive design that enables easy troubleshooting and repair in the field, minimizing downtime and reducing costs since technicians only need to replace the needed parts.

Increased Process Uptime with Customized Training Resources

Yokogawa’s knowledgeable representatives and support technicians provide operation and repair training for all Yokogawa products both in the factory and in the field. Training ranges from basic operation to advanced troubleshooting, helping you achieve more efficient operations and simplified maintenance.

Measurement object Oxygen concentration in combustion exhaust gas and mixed gas
Measurement system Zirconium oxide sensor
Measurement range 0.01 to 100 vol% O2
Output signal 4 to 20 mA DC, two points (ZR402G) (maximum load resistance 550Ω)
Setting range Any 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 temperature 0 to 700℃ (Probe only)
700 to 1871℃ (with 0.15m probe with JIS 5K 32 FF flange and ZR22P High Temperature Probe Adapter)
Probe length 0.15, 0.4, 0.7, 1.0, 1.5, 2.0, 2.5, 3.0, 3.6, 4.2, 4.8, 5.4 m
Contact output Four points (one is fail-safe, normally open)
Contact input Two points
Calibration Method; 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 Temperature Probe (ZR22G): -20 to 150℃
Converter (ZR402G): -20 to 55℃)
Reference Gas System

Instrument Air (preferred): 50 kPa (200 kPa with check valve) + the pressure inside the furnace; Approx. 1 Nl/min consumption

Natural convection

Power supply 85 to 264 V AC; 45 to 66 Hz
Measurement object Oxygen concentration in combustion exhaust gas and mixed gas
Measurement system Zirconium oxide sensor
Explosion-proof Approval ZR22S-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 range 0.01 to 100 vol% O2
Output signal 4 to 20 mA DC, two points (ZR402G) (maximum load resistance 550Ω)
Setting range Any 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 temperature 0 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 length 0.15, 0.4, 0.7, 1.0, 1.5, 2.0 m
Contact output Four points (one is fail-safe, normally open)
Contact input Two points
Calibration Method; 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 System Instrument Air: 50 kPa + the pressure inside the furnace; Approx. 1Nl/min consumption
Wiring Connection ATEX; 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 supply 85 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)
Overview:

To detect air leaks, an oxygen analyzer is used. The ZR22/ZR402 Direct In-Situ Zirconia Oxygen Analyzer has been well received due to its good response speed, stability, and maintainability.

Industries:
Overview:

Drying is an important part of the papermaking process that evaporates the remaining water in the wet paper web. This is performed with a dryer, and the humidity control in this dryer is essential to maintaining high paper quality (e.g., strength, paper surface) and high heat energy efficiency.

Industries:
Overview:

There are various methods for continuous fabric dyeing as well as dye fixing. When dye is directly applied, steaming (heat treatment) is required. At present the pad-steam method is widely used for continuous dyeing. To ensure stable product quality, the humidity in the steamer is kept at a constant level. 

Overview:

Humidity control is important to maintain product quality and improve yield. The ZR402G/HS Direct In Situ Zirconia High Temperature Humidity Analyzer is easy to maintain as it requires no sampling system.

Overview:

To technology in iron & steel industry is continuously improved to obtain the best possible performance. The improved plant performance gives rise to the higher quality improvement and lower cost, and simultaneously environmental friendly plant operation.

Industries:
Overview:

A furnace for heating slabs needs to be operated under low oxygen conditions at high temperatures of 1000°C and above to prevent oxidation of the steel. The measurement of oxygen concentrations in the furnace is essential in this process.

Industries:
Overview:

In a pulverized coal-fired boiler of a large power plant, an oxygen analyzer is essential for combustion control. A pulverized coal-fired boiler is an industrial or utility boiler that generates thermal energy by burning pulverized coal (also known as powdered coal or coal dust).

Industries:
Overview:

In a hot blast stove, the by-product gas produced in a coke oven is burned to preheat the air blast for the blast furnace. To improve the combustion efficiency and conserve energy in a hot blast stove, it is essential to be able to control combustion by measuring and adjusting the oxygen concentration in the exhaust gases.

Industries:
Overview:

A package boiler operates more efficiently if the oxygen concentration in the flue gas is reduced. Optimizing air intake for boiler operation requires continuous measurement of the oxygen concentration in the flue gas.

Industries:
Application Note
Overview:

Tantalum Capacitors are electrolytic capacitors that use a material called tantalum for the electrodes. Large values of capacitance similar to aluminum electrolytic capacitors can be obtained.

Industries:
Instruction Manuals
General Specifications
Software
Technical Information
Certificates
Drawings
Forms

How-tos

    Overview:

    Replacing a ZR22A heater strut on a ZR22G zirconia oxygen probe. While we strive to provide the most safe and accurate information possible, we are not responsible for any loss or damages resulting from attempting to replicate the acts conducted in this video. Furthermore, we shall not be held liable for use or misuse of information contained in this video.

    Overview:

    Replacing the zirconium oxide cell on a Yokogawa ZR series probe with the E7042UD cell kit. Note that the removal of the heater nut with the special service tool is not required, but makes the contact spring easier to see and remove/install. While we strive to provide the most safe and accurate information possible, we are not responsible for any loss or damages resulting from attempting to replicate the acts conducted in this video. Furthermore, we shall not be held liable for use or misuse of information contained in this video.

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