YOKOGAWA ZR22P User Manual
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YOKOGAWA ZR22P User Manual

YOKOGAWA ZR22P User Manual

High temperature adapter
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User's
Manual
Model ZR22P
High Temperature Adapter
IM 11M12A01-01E-A
IM 11M12A01-01E-A
1st Edition

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Summary of Contents for YOKOGAWA ZR22P

  • Page 1 User’s Manual Model ZR22P High Temperature Adapter IM 11M12A01-01E-A IM 11M12A01-01E-A 1st Edition...

  • Page 3: Table Of Contents

    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 PIPING ........................

  • Page 4: Introduction

    OVERVIEW 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.

  • Page 5: Specifications

    310 Stainless Steel, for temperatures up to 1082°C (1980°F) Alumina Ceramic, for temperatures up to 1871°C (3400°F) Zirconia/Platinum cell SUS 304 (flange) The actual weight of the ZR22P High Temperature Adapter will vary with material selection, installed options and transport tube length. IM 11M12A01-01E-A...
  • Page 6 ANSI 4.0 inch, 150# FF Flange Option: Heater System Aux heater system (to 600°F). Incl. controller & heater Option: Blowback Valve Automatic valve (Only with ZR22P-S) Option: Eductor Heated air eductor pre-attached with regulator & gauge Cannot be used with /HT, /AV of -F.

  • Page 7: Installation

    The distance between the process wall and the process flange should be 100mm (4.0 inches) or more, as shown in Figure 4.1. Attach the transport tube (if provided) to the flange base of the adapter prior to installing the ZR22P. CAUTION •...

  • Page 8: Mounting The Zr22G Detector To The Zr22P High Temperature Adapter

    Table 4.1 Installation Location 4.2.1 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...

  • Page 9: Usage Of The Zr22P High Temperature Probe Adapter

    This will help to prevent condensation from entering the eductor and probe. Figure 4.2 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.
  • Page 10 the induction flow is reduced, ensure that the eductor inducts air when the process pressure fluctuates. When the process pressure is positive, close the needle valve for the sample gas outlet to reduce exhaust gas flow. Refer to section 5.1 for piping instructions. When the probe adapter is surrounded by a heat insulator, remove the insulation.

  • Page 11: Piping

    Piping 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. •...

  • Page 12: Piping Parts For The Zr22P

    In cases where condensation is likely to occur when the sample gas is cooled, protect the probe adapter with an insulating material as illustrated in Figure 5.3. Ensure that adequate space is left for probe and air line maintenance. Figure 5.3 Preventing condensation Piping Parts for the ZR22P Piping Detector Parts...

  • Page 13: Eductor Options

    A general purpose air regulator should be used to adjust the flow of instrument air entering the eductor. The Yokogawa model M1132KD Pressure Regulator is recommended for use with this application. Refer to Table 5.1 for applicable tubing and connections.

  • Page 14: Air Eductor, Exhaust Return (/Er Option)

    Air Eductor, Exhaust Return (/ER Option).* *This option cannot be used with the /HT option. Note: The /ER option has pre-attached instrument air piped to the adapter to draw the sample up to the probe. The eductor creates a vacuum, which draws the sample through the transport tube and past the ZR22G Probe.

  • Page 15: Separate Air Eductor, Not Pre-Attached (/Se Option)

    Figure 6.3 M1132KA Stainless Steel Air Eductor Separate Air Eductor, Not Attached, (/SE Option) The Separate Eductor option is a standard High Temperature Adapter that allows the customer to supply their own air source and eductor. The High temperature adapter is threaded for ¼” FNPT connection.

  • Page 16: Automatic Blowback Option (/Av)

    7.3.1 Adapter Tee Blowback Control The user provides power supply input to the ZR22P. The Cable should meet all NEC codes for 115 VAC, 10A supply. The user also provides a 14 AWG, 2 conductor cable from the ZR402G to the ZR22P.

  • Page 17: Operation Of The Zr22P Control

    Two (2) band heaters are pre-attached and pre-wired to a heater controller, mounted in a NEMA 4X enclosure at the ZR22P adapter. The temperature controller is factory set for a high alarm set point of 700°F. If this alarm set point is exceeded, the controller will shut off the power to the heaters.
  • Page 18 Chart 7.1 Blowback Timing Sequence IM 11M12A01-01E-A...

  • Page 19: Maintenance And Trouble Shooting

    Maintenance and Trouble Shooting Maintenance The High Temperature Adapter is structured so that the gas to be measured is directed the detector with the high temperature probe adapter. Therefore, if the probe or the sample gas outlet clogs, a precise measurement is no longer possible, as the gas flow is significantly reduced. If a high temperature adapter/detector combination is used, it must be inspected periodically and cleaned if any part of the assembly becomes clogged with dust or particulates.
  • Page 20 Problem 2: Oxygen reading is abnormally low during normal operation. Possible cause(s): The transport tube may be clogged and the eductor is drawing a vacuum. NOTE: Cell damage may occur from excessive vacuum pressures. Solution: 1. Verify that air flow to the eductor is adequate to draw a sample. (Max. 20 psi) 2.

  • Page 21: Maintenance For Air Eductor Return

    The following is recommended for disassembling the eductor and the return piping: Remove power from the ZR22P control box by opening the fuse switch located on the terminal box, inside of the control box at the adapter tee.

  • Page 23: Appendix A Dimensional Drawings

    APPENDIX A Dimensional Drawings IM 11M12A01-01E-A...
  • Page 24 ZR22P-H-A-100-C*U/SE Note: Transport tube insertion lengths can vary upon customer requirements between 0.0m to 3.0m IM 11M12A01-01E-A...
  • Page 25 ZR22P-H-A-100-C*U/ER Note: Transport tube insertion lengths can vary upon customer requirements between 0.0m to 3.0m IM 11M12A01-01E-A...
  • Page 26 ZR22P-H-A-150-C*U/BE Note: Transport tube insertion lengths can vary upon customer requirements between 0.0m to 3.0m IM 11M12A01-01E-A...

  • Page 27: Appendix B Wiring Diagrams

    APPENDIX B Wiring Diagrams IM 11M12A01-01E-A...
  • Page 28 IM 11M12A01-01E-A...
  • Page 29 IM 11M12A01-01E-A...

  • Page 31: Appendix C Spare Parts

    APPENDIX C Spare Parts IM 11M12A01-01E-A...
  • Page 32 Pressure Regulator, M1132KD This general purpose regulator is used to adjust the pressure of the instrument air entering the air eductor on the ZR22P. Flow Capacity: 20 SCFM (33.6m/hr) at 100 psig supply – 20psig at outlet Exhaust Capacity: 0.1 SCFM (0.17m/hr – downstream pressure 5 psig above setpoint Sensitivity: 1”...
  • Page 33 Weight: 0.5 lbs (0.2 kg) Air Eductor, M1132KA Vacuum Force: 7.6” Hg Vacuum Flow: 2 to 5 SCFM Air Consumption: 1.7 SCFM Recommended Air Supply: Up to 20 psi Connections: Air Supply: 1/8” FNPT Vacuum: ¼” MNPT Exhaust: ¼” MNPT Material: 316 SS Weight:...
  • Page 34 Thinband Heater, M1233LN (Eductor /ER option ONLY) Power Supply: 120 VAC Consumption: 100 Watts Leads: 36” Type L high temp leads (2 ” Diameter to 2 ½”wide) Thinband Heater, M1133EC Power Supply: 120 VAC Consumption: 400W Leads: 36” Type L high temp leads (2 ” Diameter to 2 ½”wide) IM 11M12A01-01E-A...

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