YOKOGAWA ZR22G, ZR402G split zirconia oxygen/humidity analyzer

YOKOGAWA ZR22G, ZR402G split zirconia oxygen/humidity analyzer

Core parameters and components of the product

（1） Core components and functions

ZR22G detector:

Type: Universal type (sample temperature range 0-700 ℃), High temperature type (0.15m probe, paired with ZO21P adapter, sample temperature range 0-1400 ℃)

Probe length: 0.15-5.4m (excluding 0.15m for humidity analyzer), material: SUS316 (universal type), SiC/SUS310S (high temperature type)

Protection level: equivalent IP44D (universal type), IP66 (pressure compensation type, when cable is sealed)

ZR402G converter:

Display: 320 × 240 dot LCD touch screen, supporting numerical values, trend charts, and fault display

Power supply: 100-240V AC (50/60Hz), maximum power consumption of 300W

Communication: Supports HART protocol (refer to IM 11M12A01-51E document)

Auxiliary equipment:

ZO21R probe protector: suitable for scenarios with gas velocity ≥ 10m/s, anti dust wear

ZH21A dust protector: only for use with humidity analyzers, to prevent combustible dust from entering

ZA8F flow setting unit: for manual calibration, controlling the flow rate of calibration gas/reference gas

ZR40H automatic calibration unit: automatically switches calibration gas, supports timed calibration

（2） Key measurement parameters

Measurement type, measurement range, accuracy, related indicators, response time

Oxygen concentration 0.01-100 vol% O ₂ repeatability ± 0.5% -1% (range), linearity ± 1% -3% (range) 90% response ≤ 5 seconds

Humidity (volume fraction) 0-100 vol% H ₂ O repeatability ± 1 vol% H ₂ O (sample gas pressure ≤ 2kPa)-

Humidity (mixing ratio) 0-1.000 kg/kg --

Core operating procedures

（1） Installation and wiring

Installation requirements:

Environment: Detector ambient temperature -20-150 ℃, converter -20-55 ℃, no corrosive gases, no vibration

Probe installation: For lengths ≤ 2m, it can be installed horizontally to vertically. For lengths ≥ 2.5m, it needs to be installed vertically (± 5 °). High temperature SiC probes need to be installed vertically

Flange specifications: Supports JIS, ANSI, DIN and other standards, and needs to be matched with equipment models

Wiring specifications:

Cable: 6-core shielded cable for detector signal (two-way resistance ≤ 10 Ω), 2-core cable for heater, temperature resistance ≥ 80 ℃

Grounding: Protective grounding resistance ≤ 100 Ω, shielding layer connected to converter FG terminal

Partition wiring: separate signal cables from power/heater cables to avoid interference

（2） Calibration process

Calibration preparation:

Gas requirements: Zero gas (0.95-1.0 vol% O ₂+N ₂), span gas (dry and clean air, dew point ≤ -20 ℃)

Flow setting: Calibrate air flow rate of 600 ± 60 ml/min, reference air flow rate of 800-1000 ml/min

Calibration mode selection:

Manual calibration: Gas valve is manually controlled through ZO21S/ZA8F unit, suitable for system 1/2

Semi automatic calibration: Start with touch panel or touch input, complete calibration according to preset time

Automatic calibration: System 3 dedicated, automatically executed at set intervals (up to 255 days)

Core steps:

Span calibration: Introduce span gas and confirm calibration after the value stabilizes

Zero calibration: Introduce zero gas and complete calibration in the same way

After calibration: Close the calibration gas valve and wait for the output to stabilize (default 10 minutes)

（3） Key points for safe operation

Power safety: Confirm that the power supply voltage matches the rated value of the equipment (100-240V AC), and disconnect the power before wiring

High temperature protection: The working temperature of the detector probe reaches 750 ℃, and gloves should be worn during maintenance to avoid direct contact

Gas safety: Calibration gas/sample gas may be toxic, ventilation or protective mask should be worn during maintenance, and pipelines should be checked for leaks

Sensor protection: The sensor is made of ceramic material to avoid impact and pressure, and direct contact with water droplets is prohibited

Maintenance and troubleshooting

（1） Regular maintenance

Daily maintenance: Clean and calibrate the gas pipeline (anti clogging), check the filter (K9471UA dust filter)

Regular replacement: Sensor components (according to the calibration coefficient, zero gas calibration proportional to 100 ± 30% and span gas calibration proportional to 0 ± 18% are normal), metal O-rings (must be replaced when replacing sensors), heater units (when resistance is abnormal)

Cycle: It is recommended to conduct regular inspections at intervals not exceeding those specified in the equipment manual, and the calibration cycle should be adjusted according to the usage scenario

（2） Common faults and their solutions

Key points for troubleshooting fault types, fault codes/phenomena

Cell voltage fault Error 1: Check the CELL ± wiring, whether the sensor is damaged, and the internal wiring of the detector

Heater temperature fault Error 2: Check the heater resistance (≤ 90 Ω), thermocouple wiring, and cold end temperature (-25-155 ℃)

Zero calibration coefficient alarm Alarm 6 confirms that the zero gas concentration is consistent with the set value, the gas flow rate is normal, and the sensor is not contaminated

High measurement value (oxygen analyzer) - check whether the reference gas humidity is stable, whether the calibration gas leaks, and whether the sample gas pressure is abnormal

Other key information

Product disposal: Local/national environmental regulations must be followed, and batteries must be classified and recycled (EU/UK region)

Spare parts list: Key spare parts include sensor components (E7042UD/ZR01A01), fuses (A1113EF, 3.15A), and metal O-rings (K9470BJ)

Key issues

Question 1: What are the core differences between the three system configurations of ZR22G and ZR402G analyzers? What scenarios are they applicable to?

Answer: The core difference lies in the calibration method and auxiliary equipment configuration, which are applicable in the following scenarios:

System 1: Only includes detector+converter+ZO21S standard gas unit, without fixed calibration gas pipeline, requiring manual connection of calibration gas, suitable for simple humidity monitoring scenarios such as small boiler oxygen concentration monitoring and food production;

System 2: Add ZA8F flow setting unit, zero gas cylinder, pressure reducing valve, reference gas is instrument air, support manual precise calibration, suitable for scenarios such as large boilers and heating furnaces that require regular manual calibration;

System 3: Replace with ZR40H automatic calibration unit, support timed automatic calibration, including combustible gas detection contact input (cutting off heater power), suitable for scenarios such as large industrial furnaces that require long-term stable operation and reduce manual intervention.

Question 2: How to determine if the sensor (zirconia cell) needs to be replaced? What are the key points to pay attention to when replacing?

answer:

Replacement criteria: ① The calibrated zero gas calibration ratio exceeds 100 ± 30% or the span gas calibration ratio exceeds 0 ± 18%; ② In the detailed data display, the cell internal resistance significantly increased (new sensor ≤ 200 Ω, reaching 3-10k Ω after aging); ③ Cell robustness shows' life<1 month '; ④ The sensor has cracks, corrosion, or impact damage.

Replacement precautions: ① Operate after the detector has completely cooled down to avoid high-temperature burns; ② The metal O-ring (K9470BJ) and contact (E7042BS) must be replaced and old parts cannot be reused; ③ When installing the sensor, the four fixing bolts should be tightened evenly (with a torque of about 5.9 N · m) to avoid uneven force damage; ④ After replacement, the calibration process needs to be re executed to ensure measurement accuracy.

Question 3: What is the highest priority troubleshooting step when the device displays Error 2 (heater temperature fault)? What are the corresponding criteria for judgment?

Answer: The steps and criteria for priority screening are as follows:

Firstly, check the polarity of the thermocouple wiring: confirm that the detector TC+is connected to the converter TC+, and TC - is connected to TC -. If connected incorrectly, it will directly cause abnormal temperature detection, which is the most common cause;

Measure heater resistance: Disconnect the HTR terminal of the detector and measure the resistance value. The normal value should be ≤ 90 Ω. If the resistance value is too high, the heater will be disconnected and the heater unit needs to be replaced;

Check thermocouple resistance: After the detector cools down to a temperature difference of ≤ 50 ℃ from the environment, measure the TC ± terminal resistance. Normally, it should be ≤ 5 Ω. If it is>5 Ω, the thermocouple will break and the heater unit needs to be replaced;

Check the cold end temperature: Check the C.J. temperature through detailed data display. The normal temperature should be between -25-155 ℃. If it exceeds, check the cold end sensor or wiring.