User’s Manual Model ZR22P High Temperature Adapter IM 11M12A01-01E-A IM 11M12A01-01E-A 1st Edition
ZR22P High Temperature Adapter I. INTRODUCTION.......................................................................................................... 4 II. OVERVIEW................................................................................................................... 4 III. SPECIFICATIONS........................................................................................................ 5 IV. INSTALLATION. ...........................................................................
ZR22P High Temperature Adapter 1. INTRODUCTION 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. 2.
ZR22P High Temperature Probe Adapter 3. ZR22P SPECIFICATIONS 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.
Model ZR22P High Temperature Probe Adapter Tee Configuration -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.
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: 1. Easy and safe access to the adapter and detector for maintenance. 2. Ambient temperature of not more than 150ºC (302ºF), and the detector terminal box should not be affected by radiant heat. 3. A clean environment without corrosive gases.
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 flange surface to prevent gas leakage. The gasket material should be selected depending on the characteristics of the measured process sample gas.
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. 1. It is recommended that the detector be mounted vertically. If it is necessary to mount the detector horizontally, ensure that the probe tip is placed no higher that the probe base. Figure 4.2. 2.
b. c. d. e. 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. Ensure that the temperature of the probe adapter does not fall below the dew point of the gas in winter conditions.
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.
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 5.3 Piping Parts for the ZR22P Detector Piping Location Calibration Gas Inlet High Temperature Detector Reference gas inlet Parts Notes Check valve Recommended by Yokogawa: (M1234VV-A).
6. Eductor Options The Eductor option(s) are used to draw the sample through the high temperature adapter when the process pressure is negative. 6.1 Air Eductor, Pre-Attached with Regulator and Gauge (/BE Option).* *This option cannot be used with the /HT or /AV options. Note: The /BE option is a pre-attached, pre-heated instrument air connection. This eductor option pre-heats the instrument air via convective heat from the adapter.
6.2 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. The process gases are then piped back into the process through the adapter flange. See Figure 6.2. The air supply to the eductor is fed through a 1/8” NPT internal connection.
Figure 6.3 M1132KA Stainless Steel Air Eductor 6.3 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. Figure 6.
7. Automatic Blowback Option (/AV) 7.1 Principle of Operation This option should be chosen when there is a probability of process particles clogging the sampling system. The design consists of an automatic blowback valve and solenoid that is activated by the ZR402G Single Channel Oxygen Analyzer or the AV550G Multi-Channel Oxygen Averaging Unit. The actuator uses a 4-way, 2 position single solenoid valve with a double acting air actuator.
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. A Type J thermocouple is included to maintain the temperature of the adapter at approximately 600°F. The solenoid valves that control the overall blowback system are also prewired.
Chart 7.
Maintenance and Trouble Shooting 8.1 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.
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. Remove power from the analyzer and adapter tee. 3. Turn off air supply to the eductor. 4. Remove the probe from the adapter. 5.
8.3 Maintenance for Air Eductor Return The following maintenance instructions are for the eductor return option only. The eductor and/or the return piping may plug from time to time. The following is recommended for disassembling the eductor and the return piping: 1. 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. 2. Remove the insulation (if applicable) from the eductor return piping. 3.
APPENDIX A Dimensional Drawings IM 11M12A01-01E-A
ZR22P-H-A-100-C*U/SE Note: Transport tube insertion lengths can vary upon customer requirements between 0.0m to 3.
ZR22P-H-A-100-C*U/ER Note: Transport tube insertion lengths can vary upon customer requirements between 0.0m to 3.
ZR22P-H-A-150-C*U/BE Note: Transport tube insertion lengths can vary upon customer requirements between 0.0m to 3.
APPENDIX B Wiring Diagrams IM 11M12A01-01E-A
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APPENDIX C Spare Parts IM 11M12A01-01E-A
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: Exhaust Capacity: Sensitivity: 1” WC Effect of Supply Pressure Variation: Maximum Supply Pressure: Air Consumption: Output Range: Port size: Materials: Weight: 20 SCFM (33.6m/hr) at 100 psig supply – 20psig at outlet 0.1 SCFM (0.17m/hr – downstream pressure 5 psig above setpoint Less than 0.
Weight: 0.5 lbs (0.2 kg) Air Eductor, M1132KA Vacuum Force: 7.6” Hg Vacuum Flow: 2 to 5 SCFM Air Consumption: 1.
Thinband Heater, M1233LN (Eductor /ER option ONLY) Power Supply: Consumption: Leads: 120 VAC 100 Watts 36” Type L high temp leads (2 3/8” Diameter to 2 ½”wide) Thinband Heater, M1133EC Power Supply: Consumption: Leads: IM 11M12A01-01E-A 120 VAC 400W 36” Type L high temp leads (2 ” Diameter to 2 ½”wide)
