YOKOGAWA ZR22P User Manual
User’s
Manual
Model ZR22P
High Temperature Adapter
IM 11M12A01-01E-A
IM 11M12A01-01E-A
1st Edition
ZR22P High Temperature Adapter
INTRODUCTIONI. ......................................................................................................... 4
OVERVIEWII. ..................................................................................................................4
SPECIFICATIONSIII. ........................................................................................................ 5
INSTALLATIONIV. ............................................................................................................ 7
4.1 Installation ..........................................................................................................................................7
4.1.1 Location ..........................................................................................................................................7
4.1.2 Adapter Insertion Point ...................................................................................................................7
4.1.3 Adapter Insertion and Process Flange Preparation ........................................................................7
4.2 Mounting the ZR22G Detector to the ZR22P High Temperature Adapter .........................................8
4.2.1 Installation Location ........................................................................................................................8
4.3 Usage of the ZR22P High Temperature Probe Adapter ....................................................................9
PIPINGV. ....................................................................................................................... 11
5.1 Piping to the High Temperature Probe Adapter ...............................................................................11
5.2 Mounting the Auxiliary Eductor ........................................................................................................11
5.3 Piping Parts for the ZR22P ..............................................................................................................12
EDUCTOR OPTIONSVI. ................................................................................................ 13
6.1 Air Eductor, Pre-Attached with Regulator and Gauge (/BE Option) .................................................13
6.1.2 Air Source .....................................................................................................................................13
6.2 Air Eductor, Exhaust Return (/ER Option) ........................................................................................14
6.3 Separate Air Eductor, NOT Pre-Attached (/SE Option) ...................................................................15
Automatic Blowback Option (/AV)VII. .......................................................................... 16
7.1 Principle of Operation ......................................................................................................................16
7.2 Piping to the split adapter ................................................................................................................16
7.2.1 Block Valve with Actuator ...................................................................................................16
7.2.2 Blowback Air ......................................................................................................................16
7.3 Wiring to the ZR402G for Blowback ................................................................................................16
7.3.1 Adapter Tee Blowback Control ...........................................................................................16
7.3.2 Operation of the ZR22P Control .........................................................................................17
7.3.3 Blowback Timing Sequence ...............................................................................................17
Maintenance and Trouble ShootingVIII. ........................................................................19
8.1 Maintenance ....................................................................................................................................19
8.2 Trouble Shooting ..............................................................................................................................19
8.3 Maintenance for Air Eductor Return ................................................................................................21
APPENDIX A, Dimensional Drawings ........................................................................23
APPENDIX B, Wiring Diagrams .................................................................................27
APPENDIX C, Spare Parts ........................................................................................ 31
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ZR22P High Temperature Adapter
INTRODUCTION1.
The purpose of the ZR22P High Temperature Adapter is to accommodate the ZR22 series of Zirconia Oxygen
Detectors for use in process gas temperatures that exceed 700ºC (1292 ºF). The adapter is also used in high
temperature applications that are subject to frequent plugging or clogging, such as lime kilns, or fuels with high
particulate loading.
OVERVIEW2.
The ZR22P High Temperature Adapter uses air pressure to draw a sample away from the process and cool
the process sample to a temperature below 700C. This allows the Zirconia oxygen detector to operate
safely away from the high temperatures that would otherwise damage the probe, heater and cell assembly.
The ZR22P Probe can be designed to accommodate the varying needs of the process sample. For negative
process pressures, the High Temperature Adapter can be tted with an air eductor to draw the sample from
the primary process and bring it to the ZR22G detector.
Several models of the ZR22P are available for different applications and environments. For ordering
information and part numbers, please refer to the Oxygen Selection Guide.
IM 11M12A01-01E-A
ZR22P High Temperature Probe Adapter
ZR22P SPECIFICATIONS3.
The ZR22P is available in several variations, with multiple options. Additionally, this high temperature oxygen
probe adapter can be customized to meet the customer’s needs. There are three types of material, depending
upon sample temperature, which can be used for the transport tube. Additionally, there are varying transport
lengths available:
Construction: Rainproof, non explosion-proof construction.
Installation: Flange mounted
Installation Flange:
ANSI Class, 150#, 4 inch RF ange, SUS304 1.
ZR22G probe side, JIS 5K32A, FF ange 2.
Insertion Length: 0.3 meter (11.8 in) to 3.0 meter (9.84 ft), or no transport tube (-NNN).
Sample gas temperature: 700°C (1292°F) to 1871°C (3400°F).
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Material in contact with the process gases:
Silicon Carbide (SiC), for temperatures up to 1427°C (2600°F)1.
310 Stainless Steel, for temperatures up to 1082°C (1980°F)2.
Alumina Ceramic, for temperatures up to 1871°C (3400°F)3.
Zirconia/Platinum cell4.
SUS 304 (ange)5.
The actual weight of the ZR22P High Temperature Adapter will vary with material selection, installed options and
transport tube length.
IM 11M12A01-01E-A
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Model Notes
ZR22P High Temperature Probe Adapter
Tee Conguration
-H Basic Design (Side Eductor Port)
-T Basic Design (Bottom Port)
-S Split Design (For Blowback)
Transport Tube Material
-A Silicon Carbide (SIC). Up to 2600°F / 1427°C
-B 310 S Stainless Steel. Up to 1980°F / 1082°C
-C Alumina Ceramic. Up to 3400°F / 1871°C
-N No Transport Tube
Insertion Length
-033 0.3 meter (11. 8”)
-050 0.5 meter (18”)
-100 1.0 meter (3’ 3”)
-150 1.5 meter (4’ 11”)
-300
3.0 meter (9’ 10”) Requires Probe Support or
Protector
-NNN No Transport Tube
Flange Connection
-C*U ANSI 4.0 inch, 150# FF Flange
Option: Heater System
/HT Aux heater system (to 600°F). Incl. controller & heater
Option: Blowback Valve
/AV Automatic valve (Only with ZR22P-S)
Option: Eductor
/BE
/ER
Heated air eductor pre-attached with regulator & gauge
Cannot be used with /HT, /AV of -F.
Air ejector with return exhaust pre-attached with
regulator & gauge.
/SE Separate air ejector, regulator (NOT pre-attached)
/SCT Stainless Steel tag plate
IM 11M12A01-01E-A
4. Installation
4.1 Installation
4.1.1 Location
The following should be taken into consideration when installing the High Temperature Adapter and
Oxygen Detector:
Easy and safe access to the adapter and detector for maintenance.1.
Ambient temperature of not more than 150ºC (302ºF), and the detector terminal box should not be 2.
affected by radiant heat.
A clean environment without corrosive gases.3.
CAUTION
A natural convection type detector (model ZR22G), which uses ambient air as a reference gas, requires
that the ambient air concentration be constant. Clean, dry instrument air is recommended for quality
and accurate measurement.
4. No or extremely low vibration.
5. The measurement gas satises the specications described in Chapter 2 of the ZR22G Instruction
Manual, IM 11M12A01-02E.
6. No measured gas pressure uctuations
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4.1.2 Adapter Insertion Point
When preparing the insertion point, the following should be taken into consideration:
CAUTION
If the detector is mounted horizontally, the calibration and reference gas inlets on the ZR22G Probe •
should face downwards
The sensor (Zirconia cell) at the probe tip may be damaged due to thermal shock if water drops are •
allowed to accumulate on it, as it is always at high temperature.
When using an adapter with an eductor return, ensure that the gasket material does not interfere with the •
eductor return port on the adapter ange.
4.1.3 Adapter Insertion and Process Flange Preparation
When forming the adapter insertion hole, the following should be taken into consideration:
Ensure that the insertion point has an equal ange type (ANSI 4.0 inch, 150# FF Flange), with proper 1.
bolt hole spacing and diameter.
The distance between the process wall and the process ange should be 100mm (4.0 inches) or 2.
more, as shown in Figure 4.1.
Attach the transport tube (if provided) to the ange base of the adapter prior to installing the ZR22P.3.
CAUTION
The weight of the adapter and probe combined can weigh up to 100 lbs. It is recommended that •
the ZR22P adapter be installed WITHOUT the ZR22G detector to avoid damaging the entire unit.
Use caution when lifting and positioning the adapter and probe into place. Utilize lifting devices, •
and or a two person lift when available.
IM 11M12A01-01E-A
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Figure 4.1
4.2 Installation of the Detector (Model ZR22G-015-Q)
Note: Ceramic (Zirconia) is used in the sensor (cell) portion of the detector probe. Care should be
taken to not drop the detector during installation. The same applies to the High Temperature Adapter
transport tube.
A gasket should be used on the ange surface to prevent gas leakage. The gasket material should be
selected depending on the characteristics of the measured process sample gas. It should be heat and
corrosion resistant to the sample temperatures and gases present. These parts are to be supplied by
the user, and are described in Table 4.1.
Mounting Flange Specication Accessory Name Quantity Note
ZR22G-015 Probe
JIS 5K32A Flange
ZR22P Adapter to Process
ANSI 4.0 inch 150# FF Flange
*Specications for gasket material(s) vary, and are dependent upon process application. A local pipetting
distributor can assist with proper selection of gasket materials
*Gasket 1
Bolt (M12 x 50) 4
Nut (M12) 4
Washer (M12) 8
*Gasket 1
Bolt (M16x 60) 8
Nut(M16) 8
Washer (M16) 16
Table 4.1
Heat and Corrosion Resistant
Heat and Corrosion Resistant
4.2.1 Installation Location
The ZR22G-015-Q model detector is used with the ZR22P High Temperature Probe Adapter, when
sample gas temperatures exceed 700ºC (1292ºF). Additionally, this detector can be utilized where
maintenance space is limited.
IM 11M12A01-01E-A
The installation requirements of the ZR22G Zirconia Oxygen Detector should be consistent with
the procedures outline in Section 4.1. Further installation instructions can be found in the ZR22G
Instruction manual IM 11M12A01-02E, Chapter 3.
It is recommended that the detector be mounted vertically. If it is necessary to mount the 1.
detector horizontally, ensure that the probe tip is placed no higher that the probe base. Figure
4.2.
When installing the high temperature probe adapter, be sure to insert a gasket between the 2.
anges to prevent gas leakage, Table 4.1. When the process pressure is negative, ensure that
there is no leakage of air into the process.
When mounting the detector in a position other than vertical, the cable inlet should face 3.
downward.
When installing the detector in a low ambient temperature location, such as in cool open air, 4.
cover the probe adapter including the eductor with a heat insulator (e.g. ceramic wool) to keep
the assembly warm. This will help to prevent condensation from entering the eductor and probe.
9
Figure 4.2
4.3 Usage of the ZR22P High Temperature Probe Adapter
During analysis, the surface temperature of the probe adapter should be within the range from the
dew point of the measured gas to prevent eductor clogging, gasket deterioration and bolt scoring.
Where the dew point of the measured gas is not known, keep within the range of 200ºC to 300ºC
(392ºF to 592ºF).
The temperature shall be measured at the probe in the probe adapter and the surface of the blind
ange at the opposite side.
When the surface temperature is not within the above specied range, the following measures can
be taken to change the temperature:
(1) When the surface temperature exceeds 300ºC (572ºF):
When the process pressure is negative, lower the pressure setting to reduce induction a.
of the sample gas. Refer to section 6.1 of this manual for setting of induction ow. When
IM 11M12A01-01E-A
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the induction ow is reduced, ensure that the eductor inducts air when the process
pressure uctuates.
When the process pressure is positive, close the needle valve for the sample gas outlet b.
to reduce exhaust gas ow. Refer to section 5.1 for piping instructions.
When the probe adapter is surrounded by a heat insulator, remove the insulation. Ensure c.
that the temperature of the probe adapter does not fall below the dew point of the gas in
winter conditions.
To prevent temperature rises due to radiant heat, insert a heat insulator between the d.
process wall and the probe adapter.
To prevent temperature rises from thermal conduction, place the mounting ange as far e.
from the process wall as possible (4” min).
(2) When the surface temperature is less than 200ºC (392ºF):
When the process pressure is negative, raise the eductor air pressure to increase a.
induction ow of the measurement gas. Refer to section 6.1 of this manual for setting of
induction ow. Excessive dust may accumulate, and the eductor may clog if induction
ow increases.
When the process pressure is positive, open the needle valve for the sample gas outlet b.
to increase the gas ow.
Warm the probe adapter. Refer to Appendix A for instructions relating to the /HT Heated c.
Air Eductor Option. Ensure that the temperature does not drop below freezing point.
When the surface is still less than 200ºC (392ºF) or below the dew point of the measured d.
gas regardless if the above measure have been taken, warm the adapter with an
external; heat source such as steam.
IM 11M12A01-01E-A
5. Piping
5.1 Piping to the High Temperature Probe Adapter
The measured gas should be at a temperature below 700°C (1292°F) before reaching the •
detector sensor. If the gas is under negative pressure, it should be fed to the detector by suction.
If the measured gas is under negative pressure, connect the auxiliary eductor as illustrated in •
Figure 5.1. Mount the pressure gauge as close as possible to the auxiliary eductor. However, if
the ambient temperature is too high, mount the gauge in a location with an ambient temperature
below 40ºC (104 ºF).
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Figure 5.1 Mounting the Auxiliary Eductor
5.2 Mounting the Auxiliary Eductor
If the temperature of the sample gas exceeds the specied value and its pressure exceeds 0.49
kPa, the sample gas temperature may not fall below 700°C (1292°F) at the detector. In such a case,
connect a needle valve through a nipple to the probe adapter sample gas exhaust, so that the
sample gas exhaust volume is restricted. For additional eductor options, refer to chapter 6 of this
manual.
Figure 5.2 Mounting the needle valve for restricting exhaust ow
IM 11M12A01-01E-A
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