YOKOGAWA EXAxt ZR22G Manual

Technical
Information
ZR22G, ZR402G
Direct In Situ
Zirconia Oxygen Analyzer
(Applications Volume)
TI 11M12A01-01E
TI 11M12A01-01E
©Copyright Feb. 2004 (KP)
4th Edition Mar. 2017 (YK)
Yokogawa Electric Corporation
2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan
Tel.: [phone] Fax.: [phone]

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TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation
ZR22G, ZR402G
Direct In Situ Zirconia Oxygen Analyzer
(Applications Volume)
Mar. 14, 2017-00
CONTENTS
TI 11M12A01-01E 4th Edition
1. Overview.................................................................................................... 1-1
2. Installation Guide ..................................................................................... 2-1
2.1 Selecting an Installation Site ........................................................................... 2-1
3. SystemCongurations............................................................................ 3-1
3.1 ZR402G Direct In Situ Zirconia Oxygen Analyzer System Block Diagrams3-1
3.2 Selection According to Use ............................................................................. 3-2
3.3 Examples of System Component Selection
Based on Sample Gas Conditions .................................................................. 3-6
4. Applications.............................................................................................. 4-1
4.1 Boiler .................................................................................................................. 4-1
(1) Package boiler ................................................................................... 4-1
(2) Power generation boiler (Heavy oil, Gas).......................................... 4-2
(3) Pulverized coal boiler........................................................................ 4-3
(4) Black liquor recovery boiler................................................................ 4-4
4.2 Iron and Steel Furnaces ................................................................................... 4-5
(1) Iron & steel heating furnace ............................................................... 4-5
(2) Hot blast stove (blast furnace facility) ................................................ 4-6
(3) Coke oven facility............................................................................... 4-7
(4) Soaking pit ......................................................................................... 4-8
4.3
Ceramic, Brick, Glass & Cement Furnaces/Kilns) ..................................................... 4-9
(1) Rotary type lime kiln........................................................................... 4-9
(2) Cement kiln (cyclone outlet gas)...................................................... 4-10
4.4 PetroleumReningandPetrochemicalFiredHeaters ............................... 4-11
(1) Naphtha cracking furnace................................................................ 4-12
(2) Petroleumreneryprocessredheaterexample............................ 4-13
4.5 Garbage Incinerator........................................................................................ 4-14
4.6 Non-Combustion Applications...................................................................... 4-15
(1) Oxygen enrichment facility............................................................... 4-15
(2) Power generation boiler window box............................................... 4-16
(3) Aeration tank.................................................................................... 4-17
4.7 DifcultMeasurementApplications ............................................................. 4-18
(1) Calcination furnace .......................................................................... 4-18
(2) Facilities with reducing gas atmospheres........................................ 4-18

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TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
Revision Information ...............................................................................................i

<1. Overview> 1-1
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
1. Overview
The EXAxt Zircon Oxygen Analyzer (Model ZR402G) is used to monitor and control the oxygen
concentration in combustion gases, in boilers and industrial furnaces, for wide application
in industries which consume considerable energy—such as steel, electric power, oil and
petrochemical, ceramics, pulp and paper, food, or textiles, as well as incinerators and medium/
small boilers. It can help conserve energy in these industries. The ZR402G also contributes
to preservation of the earth’s environment in preventing global warming and air pollution by
controlling complete combustion to reduce CO2SOx and NOx.
The ZR22G 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ueandcanmeasurethe
gases directly. For use in combustion gases at temperatures up to 1400°C, choose the general-
use 0.15m long detector, which is combined with ZO21P-H, the high-temperature probe adapter.
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 ZR402G converter is equipped with various standard functions such as measurement and
calculation as well as maintenance functions including self-test. Analyzer calibration can also be
fully automated— and ZR40H, an automatic calibration unit, is available. Choose the detector
version which best suits your needs so that an optimal combustion control system can be
obtained.
Use this TI as a system selection guide and application note.

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<2. Installation Guide> 2-1
TI 11M12A01-01E Mar. 14, 2017-00All Right Reserved Copyright © 2004, Yokogawa Electric Corporation
2. Installation Guide
2.1 Selecting an Installation Site
Improper installation of the detector may cause inaccurate measurement or damage in short-
term service.
(1) Easy access for inspection and maintenance.
(2) Ambient temperature does not exceed 150°C, and the terminal box is not exposed to
radiant heat.
(3) A clean environment free from corrosive gases.
(4) Minimum vibration.
Typical good/bad installation examples are shown below for your reference.
Bad Example Good Example
Duct Gas Flow
(Oriented obliquely against
the gas flow)
(Installed on a bend in the duct)
(Mounted above the horizontal)
(Subjected to condensation)
Probe Protector
Dust Guard Protector
F0201.ai
(A corrosive gas or flammable gas
is contained in the atmosphere)
Instrument air
(As reference gas)

<2. Installation Guide> 2-2
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
Installation Site of the Converter (in case of ZR402G)
1. Allows the operator to easily read the display and operate the keys.
2. Easy access for inspection and maintenance.
3. Ambient temperature does not exceed 55°C, and temperature variations are minimal.
4. Humidity is moderate (40 to 75% RH) and no corrosive gases are present.
5. Minimum vibration.
6. Near to the detector.
7. Not exposed to direct sun light.
Instrument air is used as the reference gas
EXAZR402G
~
ZR402G Converter
Check valve
or Stop valve
ZA8F Flow Setting Unit
ZR22G Detector
100 to
240 V AC
Air Set
Instrument air
Calibration gas
Reference gas
Flowmeter Needle
valve
Zero gas cylinder
Span gas
Contact input
Analog output, contact output
(Digital output HART)
Signal
(6-core shield cable)
Heater (2-core)
F0202.ai
1) Install the stop valve or check valve securely so that the gas does not leak.
2) Use the ZA8F flow setting unit and zero gas cylinder.
3) Use a shielded cable for the signal line.
Regulator
Ambient air is used as the reference gas
EXAZR402G
F0203.ai
~
~
ZR22G Detector
1) Install the stop valve securely so that the gas does not leak.
2) Use the ZO21S standard gas unit.
3) Use a shielded cable for the signal line.
ZR402G Converter
Stop valve
Calibration gas
ZO21S Standard gas unit
100 to
240 V AC
Contact input
Analog output, contact output
(Digital output HART)
Signal
(6-core shield cable)
Heater (2-core)

  <3.SystemCongurations> 3-1
TI 11M12A01-01E Mar. 14, 2017-00All Right Reserved Copyright © 2004, Yokogawa Electric Corporation
3. SystemCongurations
This section includes two types of system selection guides for direct in situ zirconia
oxygenanalyzers.Thereadershouldreferrsttheexamplesofsystemselection
by application, and then examine the system block diagram and component device
overviews.
3.1 ZR402G Direct In Situ Zirconia Oxygen
Analyzer System Block Diagrams
(1) System Selection Examples, by Application
Application
General-purpose detector
(0 to 700°C)
High-temperaturedetector
(700 to 1400°C)
System types Detector System types Detector
Common Boiler (fuel oil, gas) L1, L2, L3 D1, (D2) H2, H3
Boiler
(pulverizedcoal,uidized
bed)
L2, L3 D4 H2, H3
Boiler (bark, wood scrap) L2, L3 D3, (D1) H2, H3
Iron & steel Heating furnaces & soaking pits L2, L3 H2, H3 D5
Hot blast stove L2, L3 D1 H2, H3
Coke ovens & annealing
furnaces L2, L3 D1, (D2) H2, H3 D6, (D7)
Sintering furnace L2, L3 D1, (D4) H2, H3
Non-ferrous
metals
Heating, sintering & melting
furnaces L2, L3 D1, (D4) H2, H3 D5, (D6)
Ceramic,
brick,
glass &
cement
manufacture
Coal kilns (rotary & vertical) L2, L3 D4, (D3) H2, H3 (D5, D6)
Cement kilns (cyclone outlet) L2, L3 D4, (D3) H2, H3
Ceramicringfurnaces L2, L3 H2, H3 D5, (D6)
Petroleum/
Petrochemical
Fired heaters & cracking
furnaces L2, L3 D1, (D2) H2, H3 D5, (D6)
Pulp & paper Black liquor recovery boilers L2, L3 D3, (D4) H2, H3
Other Electrical generating boilers
(window box) L2, L3 D1 H2, H3
Garbage & sludge incinerators L2, L3 D1, D3 H2, H3 D5
Oxygen enrichment equipment L2, L3 H2, H3 D7*1
The meanings of these codes are explained on the pages that follow.
Note 1: Sampling system is required due to the high pressure.
The symbols such as L1 and D1, representing system types or detectors in the table above
and others in this manual, are only applicable in this Technical Information document for quick
reference.Theydonotappearinotherliteraturesincludingthebulletin,generalspecications,or
user’s manual.

  <3.SystemCongurations> 3-2
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
(2) System Block Diagram Types
Ο:Yes,: None
System
type No. Detector
System type
Remarks
Simple
type General type
—
Manual
Calibration
Automatic
Calibration
L1 General-purpose Ο  using ZO21S standard gas unit
L2 General-purpose Οusing instrument air & zero gas cylinder
L3 General-purpose   Οusing instrument air & zero gas cylinder
H1 High-temperature Ο  using standard gas unit
H2 High-temperature Οusing instrument air & zero gas cylinder
H3 High-temperature   Οusing instrument air & zero gas cylinder
3.2 Selection According to Use
Examples of selection according to use System type No.
For monitoring (package boilers, etc.) L1 / H1
For high precision measurement for control purposes, etc. L2 / H2
For automatic calibration options L3 / H3
(1) Type: L1 (simple measurement system)
EXAZR402G
F0301.ai
~
~
<1> ZR22G Detector <2> ZR402G Converter
Stop valve
Calibration gas
<3> ZO21S Standard gas unit
100 to
240 V AC
Contact input
Analog output, contact output
(Digital output HART)
Signal*1
(6-core shield cable)
Heater (2-core)
*1: Shield cable; Use shielded signal cables, and connect the shield to the FG terminal of the converter.