User`s Manual Model ZR22P High Temperature Adapter
Contents
1. de vs 14 6 3 Separate Air Eductor NOT Pre Attached SE 15 Automatic Blowback Option 16 TUUM 16 GAFON Othe spit 16 L2 16 Tide BIOWDACK All 16 7 3 Wiring to the ZR402G for BIOWDACK 16 Lo Adapter Tee Blowback 16 1 9 2 Operation of the 2 22 ee 17 23 3 BIOWDack Timing SEQUENCE ieee 17 Maintenance and Trouble 19 Foret bri a 19 8 2 Trouble SNOOUMG T DU 19 6 3 Maintenance for Air Eductor 21 APPENDIX A Dimensional 5 23 APPENDIX S ime De etatem 27 APPENDIX Sp ale 31 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 700 C 1292 F2. 5 or ZO21P 5 AV WIRING SCHEMATIC 7794020 RELAY 4 TEAMINALS 29 amp 30 ZABC RELAY 3 TERMINALS 14 amp 15 AG F 1 GROUND HOT RU DCS OR OTHER CONTROL ZROOP S or ZO21P 8 CONTROL ENCLOSURE 254020 or mec PULSE PUSH TO ACTUATE RELAY F 4 Y 434506708 18 5 O Ri 15 14 7AA02 ZABC BLOWBACK PULSE LED BL AIR ON n p 51 VALVE CLOSED 4 3 T 0 a e BLOWBACK AIR VALVE Yi NORMALLY CLOSED v NG _ LED EXTRACTOR AIR OR WATER OFF 52 VALVE NOT OPEN fy 12 EXTRACTOR OR WATER VALVE Lary v NORMALLY OPEN OPEN WHEN VALVE 15 FULLY OPEN BLACK CAP TAN OFF DELAY TRI OFF DELAY TIMER 28402 or ZABC PULSE 15 SEC m 2 WacINPUT 2 LED BLOCKING VALVE CLOSED ru H 2 2 Oo i BLOCKING VALVE B INITIATE 1 V mH NORMALLY OPEN MON Pot PRESSURE SWITCH c NO CLOSED IF PRESSURE gt 7 PSI 2 m e NC IM 11M12A01 01E A 31 APPENDIX C Spare Parts IM 11M12A01 01E A 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 2 10 24 UNC TINS HOLES 1 4 EXH ALIS PORT 143 0 aet i b rf 1 4 NPT gt 63 5 Flow Capacity 20 SCFM 33 6m hr at 100 psig supply
3. 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 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 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 fitted 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 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 Installation Flange mounted Installation Flan
4. User s Manual EAS Model ZR22P High Temperature Adapter IM 11M12A01 01E A vigilant YOKOGAWA M MT2401 01E A 1st Edition VII VIII ZR22P High Temperature Adapter INTRODUCTION E Eus SS EYE YES n VENE Vasa 4 OVERVIEW c M 4 SPECIFICATION d EE VU LU CREE REC eR ER 5 INSTALLATION aa 7 4 Ws SUA OW 7 LOCO ren 7 4 1 2 Adapter ee re 7 4 1 3 Adapter Insertion and Process Flange Preparation 7 4 2 Mounting the 28223 Detector to the ZR22P High Temperature Adapter 8 mM acie All OW 8 4 3 Usage of the ZR22P High Temperature Probe 9 PIPING 11 5 1 Piping to the High Temperature Probe 11 5 2 MOUNTING 14 11 5 9 PIPING Parts for ING ZR22P arenie PR 12 EDUCTOR OPTIONS 13 6 1 Air Eductor Pre Attached with Regulator and Gauge BE 13 ene ne 13 6 2 Air Eductor Exhaust Return ER 2
5. 20psig at outlet Exhaust Capacity 0 1 SCFM 0 17m hr downstream pressure 5 psig above setpoint Sensitivity 1 WC Effect of Supply Pressure Variation Less than 0 2 psig for 25 psi change Maximum Supply Pressure 250 psig Air Consumption Less than 6 SCFM Output Range 0 to 60 psi Port size 4 Materials Body Die cast aluminum alloy Diaphragm Nitrile elastomer and nylon fabric Trim Brass zinc plates steel acetyl Weight 4 0 16 1 8 kg Pressure Gauge M1132ME i 73 11 Q Gauge Size 2 50mm Measuring Range to 60 psi Connection 4 IM 11M12A01 01E A Weight 33 0 5 16 0 2 kg Air Eductor M1132KA AIR SUPPLY INLET 1 8 FNPT EXE VACUUM OUTLET O gt INLET 1 4 MNPT 1 4 MNPT 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 4 MNPT Exhaust 74 MNPT Material 316 SS Weight 6oz 1709 117 gt H Version Vacuum Level Vacuum Flow Capability in Closed System in an Open System Compressed Air Usage Produces vacuum flow rates up to 7 6 scfm and a vacuum levels up to 25 47 a p 24 13 E 20 10 5 Model Number IDII0HSS TDI90HSS TD260HSS 5 16 2 5 Diameter 0 647 316 147 Ba 6 Vacuum Level Hg 24 8 25 0 25 4 a 5 Vacuum Flow scm 23 4 2 16 8 4
6. the time delay the block valve will open and the air eductor solenoid will open AN NOTE Blowback should only be performed as needed as extreme blowback frequency will cause a long stabilization time for reading to return to normal levels after blowback IM 11M12A01 01E A IM 11M12A01 01E A Blowback Air Pulse approximately every 10 sec Stop Eductor 6 Start Eductor Close Block Valve 5 Open Block Valve ZR402G Contact Input Initiates blowback C4 time interval ZR402G Time Delay or Pressure Switch Chart 7 1 Blowback Timing Sequence 19 Maintenance and Trouble Shooting 8 1 8 2 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 Dust found sticking to the probe itself should be blown off using low pressure compressed air or use a soft cloth with distilled water For maintenance inspection and cleaning of the ZR22G Oxygen Detector please refer to instruction manual IM 11M12A01 02E Chapter 11 Should any dust or particulate remains after the initial cleaning attempt to remo
7. to accumulate on it as it is always at high temperature e When using an adapter with an eductor return ensure that the gasket material does not interfere with the eductor return port on the adapter flange Adapter Insertion and Process Flange Preparation When forming the adapter insertion hole the following should be taken into consideration 1 Ensure that the insertion point has an equal flange type ANSI 4 0 inch 150 FF Flange with proper bolt hole spacing and diameter 2 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 e The weight of the adapter and probe combined can weigh up to 100 Ibs It is recommended that the ZH22P adapter be installed WITHOUT the ZR22G detector to avoid damaging the entire unit e 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 Bounds of the probe insertion hole location Flange matches 100 mm the detector size horizontal vertical 100 mm Figure 4 1 4 2 Installation of the Detector Model ZR22G 015 Q Note Ceramic Zirconia is used the sensor cell portion of the detector probe Care should be taken to not drop the detector during installation The same applies t
8. 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 Reducing nipple R1 2 R1 4 or R1 2 1 4NTP Needle valve Figure 5 2 Mounting the needle valve for restricting exhaust flow IM 11M12A01 01E A In cases where condensation is likely to occur when the sample gas 1 cooled protect the probe adapter with an insulating material as illustrated in Figure 5 3 Ensure that adequate space 1 left for probe and air line maintenance Cover flange Sample gas outlet Adapter for high temperature probe Detector Insulating material Probe A Figure 5 3 Preventing condensation 5 3 Piping Parts for the ZR22P Detector ms Pars Notes O Location Recommended by Yokogawa M1234VV A Available through Yokogawa Nipple Re 1 4 or inch NPT Calibration Gas Inlet Zero Gas Cylinder Recommended by Yokogawa M1132KD Regulator and M1132ME Gauge Available through Yokogawa Gas Pressure Regulator High Temperature Reference Joint for tube 1 4 or inch NPT General parts Detector gas inlet connection Recommended by Yokogawa M1132KA Stainless Steel Eductor M1234WR A Teflon Eductor for high Sample particle applications Gas outlet Auxiliary Eductor inch Reducing nipple R or General parts to inch NPT Parts are used when requir
9. 190 Air Consumption scm 42 14 13 4 Weight oz 9 9 110 iiid 0 40 60 80 0 40 60 80 0 40 60 80 Air Supply Pressure psig Air Supply Pressure psig Air Supply Pressure psig 110 55 12 rrozsonss 3 5 2 75 2 0 3 IM 11M12A01 01E A 34 Thinband Heater M1233LN Eductor ER option ONLY Power Supply 120 VAC Consumption 100 Watts Leads 36 Type L high temp leads 2 3 g Diameter to 2 2 wide Thinband Heater M1133EC VW 2 24 44 Power Supply 120 VAC Consumption 400W Leads 36 Type L high temp leads 2 Diameter to 2 2 wide IM 11M12A01 01E A
10. LOL IM 11M12A01 01E A Fan SLAY doa TEAMS H 5 50 ZR22P S or ZO21P S HT AV WIRING SCHEMATIC WE SE ER OPTIONS F 2 45A i La 5 10 15 t Lal Te Di 7 8 TEMPERATE ALM I 12 ALM a 13 1 1 TT i i 1 Tin EF Ad ITI DC E CTS DORT eT Dis uo e i 1 3 ash Di Ta Di Desin 5 dc dern LED DL LITE 224 C88 IFI fs Coie al LEO ETRE TBR Fi d 1 4 1 4 mad Ux PLL wx 1 LED HEATER DH TAMAR T morum mum 2 a i if a a ik al TCE CLTC T DA HEATER BIELAY THERMOCOUPLE TYPE J RED maps me m n 2 n i ra B 12 LETS HEATER i id HTH N EEN H 1 LIS ATOR T C HTA 1 EE 1 4 imos LED a amp IMITATE PEI CAL FATH E LoS k AD AS 1 PLAY HILATIDN 3 HEATER F UE DN Dol TRI Ti WALT IHR Lv 29 ZR22P
11. Port 52 lt INLET 1 4 MNPT 1 4 MNPT 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 74 FNPT connection 163 0 6 40 1 61 A F 41 0 A F 64 0 2 50 3 47 5 1 5M Figure 6 4 Separate Eductor Option SE IM 11M12A01 01E A 16 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 The automated valve closes when blowback is initiated thereby isolating the detector during blowback operations The actuator is electrically controlled by a solenoid which is pre wired from the factory A NOTE This option requires a ZR22P S split design flange NOTE The AV option is NOT suitable for Hazardous Area Classification 7 2 7 2 1 7 2 2 7 3 Piping to the split adapter Block Valve with Actuator The actuator requires 80 psi 60psi minimum of cle
12. T AIR EJECTOR WITH RETURN EXHAUST 0 93 23 9 MS 8 IT T oju 248 0 140 01 10 _ 027 0 C E 01 30 1 er 033 0 REGULATOR 8 919 1 20 75 HOLES 9190 5 97 50 BOLT CIRCLE 23 8 0 94 THK FLANGE 4 ANSI 150 RAISED FACE FLANGE NOTES 1 APPROX WEIGHT 24 3 LBS 11 2 REGULATOR ADJUSTABLE UPTO 60 SHOULD BE CONNECTED TO CLEAN DRY INSTRUMENT AIR 3 4 FNPT 7 50 BOTTOM VIEW 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 26 1 4 FNPT HEATED EJECTOR ASSEMBLY 4 016 0 20 63 HOLES ON A 090 0 03 54 BOLT CIRCLE 2 PLACES RE amp gi 5 04 50 9 7 0 38 THK FLANGE 01 30 M 033 0 REGULATOR E 8 91 9 1 90 75 HOLES 2190 5 27 50 BOLT CIRCLE 23 8 0 94 THK FLANGE amp 4 ANSI 150 mes RAISED FACE FLANGE em aq 3 NOTES 1 APPROX WEIGHT 24 3 LBS 11 Kg 2 REGULATOR ADJUSTABLE UPTO 60PSI SHOULD BE CONNECTED TO CLEAN DRY 3 4 FNPT INSTRUMENT AIR 7 60 193 0 BOTTOM VIEW 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 27 APPENDIX Wiring Diagrams IM 11M12A01 01E A 28
13. an dry instrument air Attach 4 stainless steel tubing to the FNPT fitting of the blowback solenoid The tubing between the solenoid and actuator is prefabricated at the factory The block valve is controlled by a single solenoid where the valve closes when the solenoid is energized and opens when deenergized Blowback Air The blowback air solenoid uses between 60 psi and 80 psi of clean dry instrument air Attach stainless steel tubing to the 14 FNPT fitting of the blowback solenoid which is mounted at the ZR22P adapter Wiring to the ZR402G for blowback NOTE Run separate conduit for heater and signal wiring NOTE For additional information regarding set up procedures for the ZR40G blowback 7 3 1 IM 11M12A01 01E A sequence refer to the ZR402G Instruction Manual IM11M12A01 02E Chap10 2 e Heater output 14AWG 1 twisted pair 2 conductor with shield terminated at the converter Signal output 16 AWG 3 twisted pair 6 conductors with the shield terminated at the converter e Less that 10 ohms total loop resistance For additional wiring details refer to the wiring diagrams in Appendix 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 7 3 2 17 Two 2 band heaters pre attached and pre wired to a heater control
14. ched with regulator amp gauge Cannot be used with HT AV of F Air ejector with return exhaust pre attached with regulator amp gauge Separate air ejector regulator NOT pre attached SCT Stainless Steel tag plate 4 Installation 4 1 Installation 4 1 1 CAUTION A CAUTION A CAUTION 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 Ambient temperature of not more than 150 C 302 F and the detector terminal box should not be affected by radiant heat A clean environment without corrosive gases 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 Noor extremely low vibration 5 The measurement gas satisfies the specifications described in Chapter 2 of the ZR22G Instruction Manual IM 11M12A01 02E 6 No measured gas pressure fluctuations Adapter Insertion Point When preparing the insertion point the following should be taken into consideration e Ifthe detector is mounted horizontally the calibration and reference gas inlets on the ZR22G Probe should face downwards e The sensor Zirconia cell at the probe tip may be damaged due to thermal shock if water drops are allowed
15. d not exceed the recommended air supply of 20 psig f Note The BE Eductor Option cannot be used with the HT or AV Options IM 11M12A01 01E A 14 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 Plumbing to the eductor is customer supplied Clean dry instrument air should be used for this application at a pressure no greater than 20 psi The components that make the eductor return include the air eductor regulator and gauge however the regulator and gauge are remote from the unit 4 816 0 00 63 ON 290 0 23 54 BOLT CIRCLE 2 PLACES m ojs AIR M 5 SUPPLY 2 Y eg e ois EXHAUST 1 AIR EJECTOR 2 e 9114 3 WITH RETURN EXHAUST i 04 50 0 93 9 i i 91 90 dT 248 0 01 10 _ 027 0 Z 21 30 e c 033 0 Figure 6 2 Eductor Return ER Option IM 11M12A01 01E A 15 AIR SUPPLY INLET 1 8 FNPT OUTLET gt
16. e at the opposite side When the surface temperature is not within the above specified range the following measures can be taken to change the temperature 1 When the surface temperature exceeds 300 C 572 F a When the process pressure is negative lower the pressure setting to reduce induction of the sample gas Refer to section 6 1 of this manual for setting of induction flow When IM 11M12A01 01E A 10 IM 11M12A01 01E A 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 To prevent temperature rises due to radiant heat insert a heat insulator between the process wall and the probe adapter To prevent temperature rises from thermal conduction place the mounting flange as far from the process wall as possible 4 min 2 When the surface temperature is less than 200 C 392 F a When the process pressure is negative raise the eductor air pressure to increase induction flow of the measurement gas Refer to section 6 1 of this manual for setting of induction flow Excessive dust may accumulate and the eductor may c
17. ed General parts can be purchased on the open market Table 5 1 IM 11M12A01 01E A 13 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 pre attached pre heated instrument air connection This eductor option pre heats the instrument air via convective heat from the adapter As contact heat from the process gases heat the adapter the convective heat raises the temperature of the instrument air The purpose for heating the instrument air is to prevent condensation build up from clogging the eductor Refer to Figure 6 1 The process gases are then vented to atmosphere instead of being piped back into the process Additional dimensions can be found in Appendix B 1 4 HEATED EJECTOR ASSEMB 2 3 ees L t SL gt t I 1 Figure 6 1 ZR22P BE 6 1 2 Clean dry instrument air should be used to prevent condensation and allows for a more accurate measurement 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 Note Flow to the eductor shoul
18. ge 1 ANSI Class 150 4 inch RF flange SUS304 2 28223 probe side JIS 5K32A FF flange 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 8400 F Material in contact with the process gases Silicon Carbide SiC for temperatures up to 1427 C 2600 F 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 WP D IE The actual weight of the ZR22P High Temperature Adapter will vary with material selection installed options and transport tube length IM 11M12A01 01E A IM 11M12A01 01E A Model Notes ZR22P High Temperature Probe Adapter Tee Configuration H Basic Design Side Eductor Port T Basic Design Bottom Port S oplit Design For Blowback Transport Tube Material Silicon Carbide SIC Up to 2600 F 1427 C gt 310 S Stainless Steel Up to 1980 F 1082 C O Alumina Ceramic Up to 3400 F 1871 C N No Transport Tube Insertion Length 3 0 meter 9 10 Requires Probe Support or 300 Protector NNN No Transport Tube Flange Connection C U ANSI 4 0 inch 150 FF Flange Option Heater System IHT Aux heater system to 600 F Incl controller amp heater Option Blowback Valve AV Automatic valve Only with ZR22P S Option Eductor Heated air eductor pre atta
19. ir cycle 1 finished and all the pressure has returned to less than 0 7 psi the blocking valve will open and the eductor valve will open See the sequence of events in chart 7 1 NOTE When Relay 3 is activated Heaters 1 and 2 are disabled Relay 3 latches ON until 115V 7 3 3 power is cycled OFF Blowback Timing Sequence Event 1 Blowback is initiated with the contact closure from the ZR402G Closure is at least 1 second Event 2 Block Valve is closed Event 3 Air Eductor is closed by the block A limit switch The Air eductor cannot close unless event 2 has occurred Event 4 Blowback solenoid is pulsed at 10 second intervals as received from the ZR402G contact output Although the actual pulse from the ZR402G occurs 2 seconds after the contact closure the air flow for blowback is briefly delayed until Events 2 and 3 have occurred Event 5 Block valve opens after delay timer of 15 seconds lapses and the pressure switch indicates that the residual pressure blowback is normal less than 0 7 psi Event 6 The air eductor is opened so that air flows through the eductor Sampling of the process returns to normal The duration of the blowback pulse is determined by the Calibration Time programmed at the ZR402G in menu C4 The block valve will remain closed because of the relay timer which is shipped with a preset time delay of 15 seconds The timer is not adjustable At the end of the blowback time as set in the C4 menu and
20. ler 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 Two separate limit switches are used to control the eductor solenoid and the blowback solenoids The limit switches are mounted in a separate enclosure Eductor Solenoid Normally Open N N O Block Valve Normally Open NO Blowback Air Solenoid Normally Closed NC The end user must provide contact closure to input 1 terminals 13 amp 15 to the ZR402G in order to initiate blowback Operation of the ZR22P Control The ZR22P has a separate electrical control circuit mounted at the adapter tee for blowback control Standard operation of this unit requires connection to the ZR402G Oxygen Analyzer contact output 3 When the ZR402G initiates a blowback sequence after a contact closure to contact input 1 the blocking valve will close the eductor valve will close and the blowback air valve will be pulsed by the ZR402G contact output The pressure switch is preset to 0 7 psi on fall which will prevent the opening of the block valve if there is any pressure trapped in the transport tube due to an unsuccessful blowback When the blowback a
21. log if induction flow increases When the process pressure is positive open the needle valve for the sample gas outlet to increase the gas flow Warm the probe adapter Refer to Appendix A for instructions relating to the HT Heated Air Eductor Option Ensure that the temperature does not drop below freezing point When the surface is still less than 200 C 392 F or below the dew point of the measured gas regardless if the above measure have been taken warm the adapter with an external heat source such as steam 11 5 Piping 5 1 Piping to the High Temperature Probe Adapter e 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 e 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 40 C 104 F Auxiliary ejector for high temperature use Adapter for high temperature probe Figure 5 1 Mounting the Auxiliary Eductor 5 2 Mounting the Auxiliary Eductor If the temperature of the sample gas exceeds the specified 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
22. mended 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 When installing the high temperature probe adapter be sure to insert a gasket between the flanges to prevent gas leakage Table 4 1 When the process pressure 15 negative ensure that there is no leakage of air into the process 3 When mounting the detector in a position other than vertical the cable inlet should face downward 4 When installing the detector in a low ambient temperature location such as in cool open air 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 Wiring connection Mount the probe so that the probe tip is not higher than the probe base When using an SiC probe mount the probe vertically with an allowable tilt of 5 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 Where the dew point of the measured gas is not known keep within the range of 200 C to 300 C 392 F to 592 F The temperature shall be measured at the probe in the probe adapter and the surface of the blind flang
23. ng Check the voltage at terminals 2 and 8 Ensure that the air supply to the eductor has been turned off Remove the air supply from the eductor Loosen the band heaters screws CAUTION DO NOT completely remove the screws from the band heater Additionally it is not necessary to remove the wiring from the heater band Carefully detach the air eductor from the solenoid Note It is not necessary to remove the wiring from the solenoid Remove the fittings that secure the eductor to the piping Slide the band heater off of the eductor IM 11M12A01 01E A 23 APPENDIX A Dimensional Drawings IM 11M12A01 01E A 24 1 4 FNPT 4 816 0 00 63 HOLES 290 0 03 54 BOLT CIRCLE 2 PLACES 6 40 24 50 9 7 0 38 THICK FLANGE 5 1 61 BER 41 0 AJF 3 4 FNPT 5 0FT 1 5 01 30 233 0 REGULATOR 8 519 1 90 75 HOLES ON 2190 5 07 50 BOLT CIRCLE 23 8 0 94 THK FLANGE 4 ANSI 150 RAISED FACE FLANGE NOTES 1 APPROX WEIGHT 24 3 Ibs 11Kgs 2 REGULATOR ADJUSTABLE UPTO 60psi SHOULD BE CONNECTED TO CLEAN DRY INSTRUMENT AIR BOTTOM VIEW 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 25 4 216 0 20 63 HOLES 290 0 03 54 BOLT CIRCLE 2 PLACES 297 0 11 70 Ole AR Pp SUPPLY eu EXHAUS
24. o 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 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 Specification Accessory Name Quantity we 1 Gasket WEE NEN ZR22G 015 Probe Bolt M12 x 50 A Heat and Corrosion Resistant JIS 5K32A Flange Nut M12 4 Gasket 1 ZR22P Adapter to Process Bolt M16x 60 Heat and Corrosion Resistant Washer M12 NEE NE ANSI 4 0 inch 150 FF Flange Nut M16 Washer M16 for gasket material s vary and are dependent upon process application A local pipefitting distributor can assist with proper selection of gasket materials Table 4 1 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 700 C 1292 F Additionally this detector can be utilized where maintenance space is limited IM 11M12A01 01E A 4 3 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 1 It is recom
25. og has been removed replace the gasket and blind flange 7 Return system to normal operation IM 11M12A01 01E A 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 Remove power from the analyzer and adapter tee 3 Turn off air supply to the eductor 4 Remove the probe from the adapter 5 Visually inspect the cell assembly area of the ZR22G probe for dust particulate clogging the cell screen Remove the blind flange and gasket Ensure that the transport tube is not clogged If no clog exists turn on air supply to the eductor to verify a sample is being drawn 8 Place all components ensuring replacement of the gasket 9 Confirm reference air flow rate to the ZR22G probe is 0 8 LPM 10 Return to normal operation NOTE If the problem persists unburned hydrocarbons be present Additional cleaning and disassembly of the ZR22G probe may be required Problem 3 Oxygen reading is abnormally high Possible causes s e Possible leaks within the system e Eductor may be clogged e Blowback solenoid in constant on position Solutions 1 Ensure the gaskets are properly installed 2 Ensure that the probe calibration gas fit
26. tings are air tight If the calibration gas port is not being used it must be tightly sealed as to not allow air into the probe 3 Remove eductor and check for clogging If the eductor is found to be clogged clean or replace the eductor 4 Ensure that the blowback solenoid programming is correct in the ZR402G G2 menu Problem 4 Blowback solenoid remains ON Solution 1 Confirm proper programming at the ZR402G or AV550G for contact output 3 G2 menu Problem 5 Air eductor is clogged Solution 1 Clean or replace the eductor M1132KA NOTE If a constant high amount of dust or particulate is present a Teflon eductor is available Part IM 11M12A01 01E A Number M1234WR A Problem 6 Block valve does not close Possible causes s 1 Confirm that at least at least 60 psi of air 80psi recommended is attached to the solenoid for the actuator 2 Verify proper wiring 8 3 21 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 Or OVS 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 Remove the insulation if applicable from the eductor return piping Confirm that power has been shut off before proceedi
27. ve the contaminant with a metal rod or metallic brush A removable port blank off plate is located at the top of the high temperature adapter for cleaning the internal portion of the high temperature adapter and the transport tube area If dust or heavy particulate is found in the eductor assembly remove the eductor and blow out the contaminant with low pressure compressed air or rinse with distilled water N CAUTION DO NOT use water to clean any parts of the High Temperature Adapter or ZR22G Oxygen Detector that are used in Lime Kiln operations Troubleshooting Problem 1 Block valve remains closed after blowback cycle is ended and a pressure build up has occurred Possible cause s The pressure switch attached to the blowback inlet has given a contact to the system to keep the valve closed in order to protect the probe from damage To remove a pressure build up 1 Turn off air supply to the eductor 2 Slowly loosen the fitting at the blowback inlet connection to allow the pressure to bleed off CAUTION Process gases may be extremely hot Use caution when loosening the fitting on the blowback connection 3 Remove power from the ZR402G or AV550G blowback circuitry 4 Tighten the fitting at the blowback inlet so that a leak does not occur A leak will cause a high reading during normal operations 5 Remove the blind flange and gasket and manually clean out the transport tube as listed in section 8 1above 6 Once the cl
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