Zirconia Oxygen

Analyzer

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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Introduction – Typical Combustion
FUEL RICH （Flue gas condition in the firebox） AIR RICH

(Insufficient Air) Efficiency Extended Life (Excess Air)

• Reduce fuel • Reduce coking
consumption • Prevent formation
- Explosion risk
CO • Increase
throughput
of hotspots - Energy loss
• Tube life - Affect heater life cycle
- Unburned fuel

Emissions Safety
• Reduce Pollutants: • API-556
NOx, CO • Prevent risk of unstable
combustion
• Reduce greenhouse
gases: CO2 • Prevent unnecessary trips
• Detect leakage of fuel
shut-off valve
O2

Stoichiometric air demand

Optimal Excess Oxygen level

% EXCESS AIR
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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1. Yokogawa O2 Analyzer Line-up
OX400

Zirconia

Yokogawa
Para-
O2 magnetic
Analyzer

Laser

TDLS8000
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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2. Selection Flow Chart (1)

Oxygen Analyzer

Application

Semiconductor etc. Combustion control

“ppm” measurement or Process control etc.

OX400

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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2. Selection Flow Chart (2)

Combustion control or Process control etc.

Flammable gas NO
Next page
included?

No ignition source YES

Direct in-situ Sampling

Explosion-proof YES
Required? MG8E
NO

TDLS8000

MG8G
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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2. Selection Flow Chart (3)

ZR Series

Averaging
Measurement? NO

YES

Line averaging Multi point averaging

TDLS8000
AV550G+ZR22
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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AGENDA

1. Zirconia Products Outline

Yokogawa Zirconia O2 analyzer
ZR22G/S
ZR202G/S
ZR402G
AV550G

2. Zirconia Sensor Principle & Structure

3. MS Code

4. Other Equipment

5. Summary

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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1. Zirconia Products Outline

Yokogawa Zirconia O2 Analyzer

Long history, since 1970’s
Reliable zirconia sensor
Application; Power plant, steel, chemical, etc.

ZR22G

ZR202G
ZR402G AV550G

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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1. Zirconia Products Outline

Yokogawa Zirconia O2 Analyzer

Long history, since 1970’s
Reliable zirconia sensor

Current
3rd Generation models(2000s)
(1990s) (ZR series)
Multifunction (ZA8C)
2nd Generation
(1980s)
1st Generation Microprocessor-based
(1970s) (ZO21C)
Analog Type (ZO6C)
Same design sensor
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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1. Zirconia Products Outline

ZR22G/S Detector (1)

 Proven zirconia sensor
 Long Life, Fast response
 Field replaceable design
 Sensor, Heater
 Ex-proof available (ATEX, FM, CSA, IEC)
 Zone1, Div.1

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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1. Zirconia Products Outline

ZR22G/S Detector (2)

ZR22G/S Specification Description
Measurement range 0-5~0-100 %O2
Repeatability ±1%FS 0-5%O2～0-25%O2 range

Linearity ±0.5%FS 0-5%O2～0-25%O2 range

Response time <5 sec 90% response

Sample gas temp. 0~700℃ (1400℃) (ZO21P-H is required)

Pressure compensation type
Sample gas pressure -5～+250kPa ZR22S; -5～5kPa
(No press. Comp.)

Ambient temp. -20～+150℃

Pressure compensation type
Enclosure NEMA4X or Ex-proof type

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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1. Zirconia Products Outline

ZR402G Converter (1)

 LCD touch screen operation
 HART communication & configuration
 Auto calibration
 Sensor diagnostics with cell life
 Just as “Guide”
 NEMA4X enclosure
 No Explosion-proof model

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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1. Zirconia Products Outline

ZR402G Converter (2)

ZR402G Specification Description
Display range 0.00～100%O2
Display size 320 by 240 dot With touchscreen

Analog output 4-20mA 2-points

Relay output 3+1 (for fail-safe)
Contact input 2 For calibration etc.

Digital communication HART

Ambient temp. -20～55℃
Enclosure NEMA4X
Safety EN, CSA, UL

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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1. Zirconia Products Outline

ZR202G/S Integral type (1)

 Local display, Infra-red “push-button” operation
 HART communication & configuration
 Automatic calibration unit can be attached
 Reduces wiring costs
 Ex-proof available (ATEX, FM, CSA, IEC).
 Zone1, Div.1

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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1. Zirconia Products Outline

ZR202G/S Integral type (1)

ZR202G/S Specification Description
Analog output 4-20mA 1-point
Relay output 1+1 (for fail-safe)
Contact input 2 For calibration etc.

Digital communication HART

Ambient temp. -20～55℃
Pressure compensation type
Enclosure NEMA4X or Ex-proof type

Safety EN, CSA, UL

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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1. Zirconia Products Outline

AV550G Averaging Converter

 Multi channel oxygen analyzer
 8 individual detector outputs and 3 average
outputs
 Large, Color display
 Automatic calibration
 Foundation Fieldbus available

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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1. Zirconia Products Outline

AV550G Detector Features (2)

AV550G Specification Description
Display range 0.00～100%O2
Display size 5.7”, 320 by 240 dot With touchscreen
3-average
Analog output 4-20mA 8-individual

Relay output 4+1 (for fail-safe) + 8-individual output

Contact input 2 For calibration etc.

Digital communication Foundation Fieldbus

Ambient temp. -5～50℃
Enclosure Indoor type
Safety EN, CSA, UL

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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AGENDA

1. Zirconia Products Outline

2. Zirconia Sensor Principle & Structure
Principle of Zirconia O2 Analyzer
Principle of Humidity Analyzer
Detector Structure

3. MS Code

4. Other Equipment

5. Summary

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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2. Zirconia Sensor Principle & Structure

Principle of Zirconia O2 Analyzer (1)

 Sensor structure and principle
E Electromotive force
－ ＋ 750℃
℃
Ｏ２
Ｏ2--
Reference air
Ｏ2--

Ｏ２
Sample gas

Zirconia Cell Molecularly Bonded Platinum

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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2. Zirconia Sensor Principle & Structure

PX
PA
E; Electromotive force [V]
R; Gas Constant (8.31 J/mol ºK)
T; Absolute Temperature [ºK] ( ºK = 273.15 + ºC )
n; Electrons (= 4)
F; Faraday’s Constant ( 9.64 × 104 coulomb/mol )
Px ; Partial Pressure of O2 on Sample Side of Cell
PA; Partial Pressure of O2 on Reference Side of Cell

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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2. Zirconia Sensor Principle & Structure
Principle of Zirconia O2 Analyzer (2)

100

67mV
75
EMF [mV]

50

25
20.95%

0
0.2 1.0 10 100
O2 [%]
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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2. Zirconia Sensor Principle & Structure
Principle of Humidity Analyzers

H 2O X
Water 79%
H2O Air
100 % N2
100 %
Nitrogen

O2 21%
Y Oxygen

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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2. Zirconia Sensor Principle & Structure
Detector Structure
Contact spring Heater TC (type-K)
Cell output
Cell

Terminal

U-shape pipe

Calibration gas pipe Reference gas pipe Gas connection port

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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AGENDA

1. Zirconia Products Outline

2. Zirconia Sensor Principle & Structure

3. MS Code
Probe length
Wetted Material
Reference Air
Option

4. Other Equipment

5. Summary

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code

ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description
① Probe Length Insertion probe length
② Wetted Material Cal gas pipe material can be selected
③ Flange ANSI, DIN, JIS, 14 type available
④ Reference Air 3 types, which is appropriate?
⑤ Gas Thread Gas port thread, NPT(ANSI) or R(ISO)
⑥ Connection box Thread Cable entry thread, NPT or G or M or Pg
⑦ Instruction Manual English or Japanese
⑧ Spare (Always “-A”)
⑨ Options Valve, Filter, Tag etc.

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code

ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description
① Probe Length Insertion probe length
② Wetted Material Cal gas pipe material can be selected
③ Flange ANSI, DIN, JIS, 14 type available
④ Reference Air 3 types, which is appropriate?
⑤ Gas Thread Gas port thread, NPT(ANSI) or R(ISO)
⑥ Connection box Thread Cable entry thread, NPT or G or M or Pg
⑦ Instruction Manual English or Japanese
⑧ Spare (Always “-A”)
⑨ Options Valve, Filter, Tag etc.

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code
① Probe length
MS code Length Note
for high temp. (with ZO21P)
-015 0.15m
Flange “-Q” is required
-040 0.4m
・・・

・・・

-200 2.0m
-250 2.5m
-300 3.0m
-360 3.6m
In horizontal installation,
ZO21R Probe protector is
-420 4.2m
required
-480 4.8m
-540 5.4m
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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3. MS-code
ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description
① Probe Length Insertion probe length
② Wetted Material Cal gas pipe material can be selected
③ Flange ANSI, DIN, JIS, 14 type available
④ Reference Air 3 types, which is appropriate?
⑤ Gas Thread Gas port thread, NPT(ANSI) or R(ISO)
⑥ Connection box Thread Cable entry thread, NPT or G or M or Pg
⑦ Instruction Manual English or Japanese
⑧ Spare (Always “-A”)
⑨ Options Valve, Filter, Tag etc.

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code
② Wetted Material
Description
MS-code
Main Material Calibration gas pipe
-S Stainless steel Stainless steel
Inconel
-C Stainless steel
(Prevent corrosion, e.g. HCL)

Calibration gas pipe

Condensation
.

| Document Number| October 22, 2019 |

Cal gas inlet
© Yokogawa Electric Corporation
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3. MS-code

ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description
① Probe Length Insertion probe length
② Wetted Material Cal gas pipe material can be selected
③ Flange ANSI, DIN, JIS, 14 type available
④ Reference Air 3 types, which is appropriate?
⑤ Gas Thread Gas port thread, NPT(ANSI) or R(ISO)
⑥ Connection box Thread Cable entry thread, NPT or G or M or Pg
⑦ Instruction Manual English or Japanese
⑧ Spare (Always “-A”)
⑨ Options Valve, Filter, Tag etc.

| Document Number| October 22, 2019 |

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3. MS-code
④ Reference air type
“-C” Natural convection “-E” Instrument Air “-P” Pressure Comp.

Wide gap Small hole Sealing enclosure

Enclosure; IP44 Enclosure; IP44 Enclosure;IP66/NEMA4X
| Document Number| October 22, 2019 |
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3. MS-code

Natural convection type “-C”

 Instrument air is not required
 Measurement is not stable due to humidity
 Instrument air can be connected
 Replacement of ZO21D (Recommend)

Gap

Plug
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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3. MS-code
Instrument air type “-E”
 “Rain proof type”
 Better enclosure protection than natural
convection type
 Can not use as natural convection type

Small hole (Outlet)

Reference air inlet

| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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3. MS-code
Pressure compensation type “-P”
 Sample gas pressure; MAX.250 kPa
 IP66/NEMA4X enclosure
 No fluctuation by sample gas pressure
 Ref. air pressure setting; Inside probe >
Furnace
Return pipe Sealing wall

To furnace

Reference air inlet

| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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3. MS-code
ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description
① Probe Length Insertion probe length
② Wetted Material Cal gas pipe material can be selected
③ Flange ANSI, DIN, JIS, 14 type available
④ Reference Air 3 types, which is appropriate?
⑤ Gas Thread Gas port thread, NPT(ANSI) or R(ISO)
⑥ Connection box Thread Cable entry thread, NPT or G or M or Pg
⑦ Instruction Manual English or Japanese
⑧ Spare (Always “-A”)
⑨ Options Valve, Filter, Tag etc.

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code

⑨ Option
Option code Description
/C Inconel bolt and U-shape pipe
/CV Check valve
/SV Stop valve (Needle valve)
/F1 Dust filter
/F2 Dust guard filter
/PT Printed tag plate (Label)
/SCT Stainless steel tag plate

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code

⑨ Option (1)
Option code Description
/C Inconel bolts and U-shape pipe
 Sample gas temperature ≧ 600℃
 Prevent bolts and U-shape pipe seizing

Bolts for fixing

U-shape pipe
the cell (4 pics)

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code
⑨ Option (2) “/SV” or “/CV”
Option Description
code Part name Usage
/SV Stop valve Manual calibration
/CV Check valve Automatic calibration

Stop valve Check valve

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code
Check valve “/CV”
 Enable to conduct Automatic-calibration
 Body; Stainless steel, Piston; FPM
 Supply pressure range; 150〜350kPa
 Setting; Sample gas pressure + 150kPa
 Max. Sample gas pressure; 200kPa

Piston Body

IN OUT

Check valve

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code

⑨ Option (3) “/F1” or “/F2”

Option Description
code Part name Application
Concrete kiln
/F1 Dust filter Recovery boiler etc.
General purpose
/F2 Dust guard protector Dust; 1g/Nm3～
SiC filter Flow

Dust filter Dust guard protector

| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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3. MS-code
⑨ Option (3) “/F1” or “/F2”
Option code
Advantage Disadvantage
Name

/F1 - Corrosive dust -Slow response

- Flammable dust -Clogged
Dust filter (ZO21R prevent it from being clogged)

/F2 - Fast response - Corrosive dust

Dust guard - Unlikely to be clogged - Flammable dust
protector

F1; Needs careful selection

F2; Recommend
Fly Ash filter – coal & Biomass fuel
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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3. MS-code

ZR402G-①-②-③-④/⑤
ZR402G Description
① Converter thread Cable entry thread
② Display Display language
English, German, French, Chinese, Japanese
③ Instruction Manual English, Chinese, Japanese
④ Spare (Always “-A”)
⑤ Option Humidity setting, Hood, Tag, Namur* NE43
* Namur ;
German standard for actuator components

Hood

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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3. MS-code

ZR202G-①-②-③-④-⑤-⑥-⑦-⑧-⑨/⑩
ZR202G Description
① Probe Length Insertion probe length
② Wetted Material Cal gas pipe material can be selected
③ Flange ANSI, DIN, JIS, 14 type available
④ Auto calibration Back pack type Auto calibration unit
⑤ Reference Air 3 types, which is appropriate?
⑥ Gas Thread Gas port thread, NPT(ANSI) or R(ISO)
⑦ Connection box Thread Cable entry thread, NPT or G or M or Pg
⑧ Instruction Manual English or Japanese
⑨ Spare (Always “-A”)
Options Valve, Filter, Tag, Namur NE43 etc.
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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AGENDA

1. Zirconia Products Outline

2. Zirconia Sensor Principle & Structure

3. MS Code

4. Other Equipment
Calibration Equipment (ZO21S, ZA8F, ZR40H)
Detector Equipment (ZO21P-H, ZO21R-L)

5. Summary

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment

1. Calibration equipment
Description
Model
Product name Usage

ZO21S Standard gas unit Manual calibration

ZA8F Flow setting unit Manual calibration

ZR40H Auto calibration unit Automatic calibration

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment

Description
Model
Product name Usage
Manual calibration
ZO21S Standard gas unit
(with ambient air & zero gas)

Air pump
Flow-
supplying
checker
ambient air

Valve Zero gas

cylinder
(6-pack)
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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4. Other Equipment
System configuration using ZO21S
Exception; Pressure compensation type

ZO21S

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment

Description
Model
Product name Usage
Manual calibration
ZA8F Flow setting unit
(with instrument air & zero-gas)

 Poll mount or wall mount

 Rainproof
 Max. pressure; 300kPa
 Sample gas pressure; MAX.250kPa
 With check valve; MAX.150kPa

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment

System configuration using ZA8F

ZA8F

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment
Description
Model
Product name Usage
Automatic calibration
ZR40H Auto calibration unit
(with instrument air & zero-gas)

 Available only ZR402G

 Poll mount or wall mount
 IP67/NEMA4X (except flow meter)
 Max. pressure; 690kPa
 Sample gas pressure; MAX.250kPa
 With check valve; MAX.200kPa

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment
System configuration using ZR40H

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment

1. Detector equipment
Description
Model
Product name Usage
High temperature sample gas
ZO21P-H Probe adapter
(700～1400℃)
- Brace for long probe
ZO21R-L Probe protector - Protector from abrasion of heavy dust
- Protect dust filter from clogging

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment

Description
Model
Product name Usage
High temperature sample gas
ZO21P-H Probe adapter
700～1400℃

Ejector ZR22G
(Option) Length; -015
Flange; -Q

Probe
ZO21P-H
Sample gas Flow

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment
ZO21P-H-①-②-③-④/⑤
Description
ZO21P-H
code Specification usage
① Probe material -A Stainless steel (SUS310S) ～800℃
～1400℃
-B SiC
(Vertical only)
② Probe length - 0.5～1.0, 1.5m －
③ Flange - ANSI, DIN, JIS, JPI －
④ style code *B － －
⑤ Option Ejector /EJ1 Rc1/4 (ISO) Negative
Pressure
⑤ Option Ejector /EJ2 1/4NPT (ANSI) (-0.5～0 kPa)
Tag plate /SCT Stainless steel tag plate －
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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4. Other Equipment
Ejector or valve
Sample gas pressure
～+0.05 kPa
-0.5～ ～+5 kPa
+0.05～ 5 kPa ～
Ejector P.G Valve
Reducer/Connector
Air

Valve

e.g.) + L9852CB (Rc1/4) or

Option; “EJ1 or EJ2”
Option; None G7016XH (1/4NPT)
(including P.G, valve)
+ Reducer
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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4. Other Equipment
Probe materials
Sample gas temperature
～800 ℃ ～1000 ℃ ～1400 ℃

Vertical SUS310S SUS310S SiC

installation ZO21P-H-B-… ZO21P-H-B-… ZO21P-H-A-…

Inconel600
Horizontal SUS310S
installation
ZO21P-H-Z-… N/A
ZO21P-H-B-…
Z; Tokuchu

Probe

Probe
Vertical Horizontal

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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4. Other Equipment
Description
Model Product
Usage
name
- Brace for long probe (>2.0m)
- Protector from abrasion of heavy dust
ZO21R-L Probe protector
(Flow rate >10m/s2)
- Protect dust filter from clogging

Dust Flow

Gravity

Brace Protect
| Document Number| October 22, 2019 |
© Yokogawa Electric Corporation
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AGENDA

1. Zirconia Products Outline

2. Zirconia Sensor Principle & Structure

3. MS Code

4. Other Equipment

5. Summary

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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5. Summary

Calibration equipment selection

～5
-5～ ～ 150 ～200 ～250
Sample gas pressure
kPa kPa kPa kPa
Needle valve N/A N/A N/A
ZO21S
Manual-cal Check valve N/A N/A N/A N/A

Needle valve N/A

ZA8F
Manual-cal Check valve N/A

ZR40H Needle valve

Auto-cal unit
(For ZR402G) Check valve N/A

ZR20H
Auto-cal unit －
(for ZR202G)

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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Thank you

| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
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