YOKOGAWA EXAxt ZR22G Instruction Manual

Tech Note: Unreleased Date: October 22, 2013
Standard ZR22G Heater and Cell Replacement
Necessary Parts to Order
ZR22A-###-A-A (Heater str t assembly with tool (M1234HD-A) provided)
B1011ER (O-Ring for piping connector)
B1013ER (O-Ring for piping connector to reference gas cap)
B1013ER (O-Ring for piping connector to calibration gas cap)
B1014ER (O-Ring for reference gas cap)
B1014ER (O-Ring for calibration gas cap)
E7042UD (If replacing the zirconia cell as well; otherwise only the K9470BJ metal
o-ring, the E7042BS contacting spring, and E7042AY filter screen are needed)
High-temperat re grease
Tools Needed
#2 Philips-head screwdriver
Pick set or tweezers (having both is optimal)
8mm socket
Torq e wrench
10mm combination wrench or an appropriately sized crescent wrench
Allen wrench
4.5mm pin spanner (if sing the type one oil and gas d st filter)
Verify the heater is off and has sufficient time to cool before attemptin this
procedure. Use Appendices A and B as a reference for this uide.
Zirconia Cell Removal
Remove (1) by twisting it co nter-clockwise if yo have type the type one filter; if
yo have type two keep reading.
Remove the fo r bolts (2) and washers (3) on the heated end of the probe by
t rning them co nter-clockwise with an 8mm socket wrench. Remove the
contactor plate (4), calibration j-t be (5) and filter screen (6) from the tip of the
probe. Remove the zirconia cell (6) by twisting it clockwise while sim ltaneo sly
gently p lling it away from the tip of the probe. The metal o-ring (7) sho ld fall
o t with the cell removed. Yo sho ld not re- se this o-ring, otherwise the cell

Tech Note: Unreleased Date: October 22, 2013
may become damaged. Once the cell is removed, the n t (8) which holds the
heater in place becomes visible.
Heater Strut Removal
Open the terminal cover on the head of the probe by loosening the set screw
sing an allen wrench and then t rn the cover co nter-clockwise. Remove the
positive cell wire and both thermoco ple wires from the top terminal block (26)
sing a Philips-head screwdriver to loosen the screws (31). The top terminal block
can now be removed by loosening the screws (28) in the pper-left and lower-
right corners, being caref l not to lose the spacers (29) between the screws and
terminal block. The two heater wires may now be removed sing the Philips-
head screwdriver. Next, loosen the two screws (15) that hold the bolt cover (12)
to the air connector block (13) and slide the cover back toward the flange. This
will expose the fo r sets of bolts (10) and washers (11) which hold the terminal
box to the air connector and probe. Remove (10) by t rning them co nter-
clockwise, taking care not to let the terminal box (16) fall. Gently slide the
terminal box away from the probe witho t damaging the wiring. Loosen screw
(19) to detach the air connector (13) from the heater str t (23). Flip the probe
over and sing special service tool M1234HD-A, insert the tool’s raised end into
the notches in the n t (8). Remove the n t by sticking a tool s ch as a
screwdriver in the hole at the other end of the service tool and t rn it co nter-
clockwise. Once the n t is removed the heat str t (23) can be removed from
the probe’s t be (24). The heater str t sho ld be removed with care to not
damage the calibration line. Remove the contactor spring (9), which is located
in the groove near the back of where the heater n t was, with a pick or pair of
tweezers. Now is a good time to label wiring if it is deemed necessary.
Air Connector Servicin
Remove the transl cent o-ring (14) from the air connector and discard it. Loosen
the screw (25) holding the plate (17) to the air connector (13) by t rning it
co nter-clockwise. Once the plate is removed the air caps (20) can be
removed. Use a pick to remove o-ring (21) from the reference and calibration
air caps (20). The other o-rings (22) are in the connector holes that the air caps
were in. These can also be removed with a pick or by p shing them o t from the
back. Discard all old o-rings. Install an o-ring (22) in the groove in each air cap
hole, ens ring it is seated at the bottom of the hole. Then install an o-ring (21) on

Tech Note: Unreleased Date: October 22, 2013
each air cap’s lower groove (20). Insert the caps (20) into the air connector (13),
do not p sh them in all of the way. P sh the caps in j st so far that the bottoms
of the top grooves are fl sh with the s rro nding s rface. Slide the plate (17) into
place between the grooves in the caps and tighten the screw (25) that
connects the plate to the air connector by twisting it clockwise. Make s re the
screw (19) and its holder (18) are sec red to the plate before proceeding.
Heater Strut and Air Connector Installation
It is easiest to place replace the contact spring (9) at this step by sing tweezers
or a pick to place it in the inner-most groove at the top of the heater. Slide the
heater str t (23) into the probe t bing (24), g iding the calibration t be thro gh
the hole in the tip of the heater and holes on the str t. Be caref l not to twist or
force the heater str t into the probe or damage to the calibration t bing may
occ r. Once the heater is f lly inserted, flip the heater over, add high-
temperat re anti-seize grease to the contactor n t (8) and install it in the tip of
the probe by twisting special service tool M1234HD-A clockwise sing a
screwdriver in its end to tighten it (technically, this sho ld be torq ed to 106 inch-
po nds, b t this is not too critical, j st make s re it is sn g). Now, flip the probe
back over and feed the wires of the probe thro gh the large air connector (13)
opening. The side with the two small holes sho ld be going down on the probe
where the calibration t bes will seat themselves into the air connector. Tighten
the plate screw (19) f lly by t rning it clockwise into the hole at the end of the
heater str t ntil the air connector (13) cannot move. Replace the o-ring (14) on
the top of the air connector’s s rface. Make s re to replace the sleeve (12) if it
was removed with its notched side facing the air connector. The j nction box
(16) may now be fitted to the top of the air connector (13), caref lly feeding the
probe wires thro gh the j nction box. Reattach the fo r sets of bolts (10) and
washers (11) thro gh the small probe flange to connect the j nction box (16)
and air connector (13) to the probe. Slide the bolt cover (12) back p the probe
with the c to t portion on the air connector’s port holes and sec re it by t rning
the two screws (15) clockwise into the air connector. Replace the heater wires
on the lower terminal block (27) sing screws (31) at terminals seven and eight
(no need to pay attention to polarity). The pper terminal block (26) may now
be re-installed sing screws (28) with spacers (29) in the pper-left and lower-
right corners. Ens re that the (-) CELL wire at terminal two is bridged to the
pper-left screw, also ens re that the RJC (30) body is gro nded at the lower-
right screw. Using screws (31), attach the (+) CELL wire on the terminal one on
the pper terminal block (26), attach the sheathed (+) TC wire at terminal three,

Tech Note: Unreleased Date: October 22, 2013
and attach the bare (-) TC wire at terminal fo r. Sec re the terminal box cover
by screwing it on clockwise and tighten the set screw with an allen wrench.
Zirconia Cell Installation
Place the metal o-ring (7) on groove at the base of the zirconia cell (6) and
gently p sh the cell into the tip of the probe while t rning the cell clockwise at
the base. Hook the calibration j-t be (5) into the contactor plate (4), the long
end of the j-t be sho ld be in the center of the contactor plate. Feed the filter
(32) over the long end of the j-t be on the bottom end of the contactor plate
(4). Take the assembly consisting of (4), (5) and (32) and place it on the tip of the
probe, the long j-t be end sho ld go in the center of the zirconia cell and the
short end sho ld go in oval hole in the base plate of the zirconia cell. If sing the
type two oil and gas d st filter (1), go ahead and screw it on the tip of the probe
clockwise. Next, se fo r sets of bolts (2) and n ts (3) to sec re the cell to the tip
of the probe, t rning them 1/8
th
of a t rn at a time, ntil 52 inch-po nds of
torq e are applied. If sing a type one oil and gas d st filter (1), it may now be
screwed on the tip of the probe and set in place sing a pin spanner.

Tech Note: Unreleased Date: October 22, 2013
Appendix A
Number MS Code Description
1
1
K9471UA Oil and gas d st filter. Only screws on the tip of the probe.
1
2
E7042UQ YCA version of oil and gas d st filter. Screws and bolts on to
the probe.
2 M1234DK Hastelloy O
2
cell bolt.
3 M1200DF Washer for M1234DK.
4 E7042BR Contact plate.
5 K9470BM Calibration t be (J-T be)
6 E7042BB Zirconia cell.
7 K9470BJ Metal o-ring.
8 K9470BA Heater assembly n t.
9 E7042BS Contactor spring.
10 Y9640NU Bolt to join the terminal box to the air connector assembly
and probe.
11 Y9600SU Washer for Y9640NU.
12 K9470BE Terminal box bolt cover.
13 K9470AN Air connector assembly.
14 B1011ER Air connector assembly o-ring.
15 Y9408LU Screw to hold K9470BE to K9470AN.
16 K9470BS Terminal box. (Cap is K9477AP)
17 K9470AL Plate to hold down caps in K9470AN.
18 Y9101XB O-ring to keep Y9430LU from falling off of the plate.
19 Y9430LU Screw to sec re plate to the heater str t.
20 K9470AS Air cap.
21 B1014ER O-ring to fit on the air caps.
22 B1013ER O-ring for the air connector holes.
23 ZR22A Heater str t assembly.
24
25 Y9408LU Screw to sec re plate to the air connector.
26 K9472YD Upper terminal block.
27 K9472YC Lower terminal block.
28 Y9730YA Spacer for Y9318JU.
29 Y9318JU Terminal block to terminal box screw.
30 K9470BG Pt1000 RTD for meas ring cold j nction temperat re.
31 Y9406JU Terminal block screw.
32 E7042AY Meshed filter.

Tech Note: Unreleased Date: October 22, 2013
Appendix B