O2 Learning Handbook

Zirconia Crystal Clear

TI 11M00A20-01E
Table of Contents
1. Introduction..................................................................................................................................................................................................................4

2. Theory...........................................................................................................................................................................................................................4
2.1 Why Measure O2?.....................................................................................................................................................................................5
2.2 Oxygen Measurement Principle and Theory.........................................................................................................................................6
2.3 Humidity Measurement Principle and Theory.......................................................................................................................................8
2.4 Units of Measure.......................................................................................................................................................................................8
2.4.1 Absolute Humidity.................................................................................................................................................................8
2.4.2 Relative Humidity..................................................................................................................................................................8
2.4.3 Dew Point...............................................................................................................................................................................9
2.4.4 Mixing Ratio...........................................................................................................................................................................9
2.4.5 Other Units.............................................................................................................................................................................9
2.4.6 Accuracy of the Humidity Analyzer.....................................................................................................................................9
2.5 Comparison and Advantage over Competitive O2 Principles..............................................................................................................9
2.5.1 Paramagnetic.........................................................................................................................................................................9
2.5.2 Electrochemical......................................................................................................................................................................10
2.5.3 Optical: Tunable Diode Laser Spectroscopy.......................................................................................................................10

3. Yokogawa Products and Features.............................................................................................................................................................................12

3.1 Zirconia Oxygen Detector, Model ZR22..................................................................................................................................................12
3.2 Construction and Features of a Zirconia Cell.........................................................................................................................................12
3.3 Zirconia Oxygen Pressure Compensation, Model ZR22G-P.................................................................................................................12
3.4 Zirconia Oxygen High Temperature Adapter.........................................................................................................................................13
3.5 Calibration Equipment..............................................................................................................................................................................14
3.6 Filters and Accessories..............................................................................................................................................................................16
3.7 Probe Protectors and Probe Supports....................................................................................................................................................17
3.8 Zirconia Oxygen Single Unit Analyzer, Model ZR402G.........................................................................................................................18
3.9 Zirconia Oxygen Multi Unit Averaging Analyzer, Model AV550G........................................................................................................18
3.10 Integral Type Zirconia Oxygen Detector and Analyzer, Model ZR202..............................................................................................19
3.11 Zirconia Oxygen Low Concentration Analyzer, Model OX400...........................................................................................................19
3.12 Limiting Current Type Oxygen Analyzer...............................................................................................................................................20
3.12.1 Model OX100........................................................................................................................................................................20
3.12.2 Model OX102........................................................................................................................................................................20

4. Application Notes.........................................................................................................................................................................................................23
4.1 Boiler...........................................................................................................................................................................................................26
4.1.1 Package boiler........................................................................................................................................................................26
4.1.2 Power generation boiler (Heavy oil, Gas)...........................................................................................................................27
4.1.3 Pulverized coal boiler............................................................................................................................................................28
4.1.4 Black liquor recovery boiler..................................................................................................................................................29
4.2 Iron and Steel Furnaces............................................................................................................................................................................30
4.2.1 Iron & steel heating furnace................................................................................................................................................30
4.2.2 Hot blast stove (blast furnace facility)................................................................................................................................31
4.2.3 Coke oven facility...................................................................................................................................................................32
4.2.4 Soaking pit..............................................................................................................................................................................33
4.3 Ceramic, Brick, Glass & Cement Furnaces/ Kilns)..................................................................................................................................34
4.3.1 Rotary type lime kiln..............................................................................................................................................................34
4.3.2 Cement kiln (cyclone outlet gas).........................................................................................................................................35
4.4 Petroleum Refining and Petrochemical Fired Heaters.........................................................................................................................36
4.4.1 Naphtha cracking furnace....................................................................................................................................................37
4.4.2 Petroleum refinery process fired heater example............................................................................................................38
4.5 Garbage Incinerator..................................................................................................................................................................................39
4.6 Non-Combustion Applications.................................................................................................................................................................40
4.6.1 Oxygen enrichment facility..................................................................................................................................................40
4.6.2 Power generation boiler wind box......................................................................................................................................41
4.6.3 Aeration tank..........................................................................................................................................................................42
4.7 Difficult Measurement Applications........................................................................................................................................................43
4.7.1 Glass melting furnace (in-furnace gas)..............................................................................................................................43
4.7.2 Calcination furnace...............................................................................................................................................................44
4.7.3 Facilities with reducing gas atmospheres..........................................................................................................................44

5. Installation Guide........................................................................................................................................................................................................44
5.1 What is in an Installation Loop................................................................................................................................................................44
5.2 Zirconia Probe Installation.......................................................................................................................................................................44
5.2.1 Location..................................................................................................................................................................................44
5.2.2 Probe Insertion Hole.............................................................................................................................................................44
5.2.3 Installation of the Detector..................................................................................................................................................45
5.3 Installation of Accessories and Parts......................................................................................................................................................45

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 5.3.1 Filters.......................................................................................................................................................................................45
5.3.2 Check Valve (Option Code “/CV”.........................................................................................................................................46
5.3.3 Probe Protector.....................................................................................................................................................................46
5.3.4 Calibration Units....................................................................................................................................................................47
5.4 Installation of the High Temp Tee (ZO21P/ZR22P)................................................................................................................................47
5.4.1 Probe Insertion Hole.............................................................................................................................................................47
5.4.2 Probe Adapter........................................................................................................................................................................47
5.5 Installation of the Analyzer (ZR402G/AV550G)......................................................................................................................................48
5.6 Installation of the Integral Zirconia Oxygen Analyzer (ZR202*).........................................................................................................48
5.7 Installation of the OX400..........................................................................................................................................................................48
5.8 Installation of the OX100/ OX102............................................................................................................................................................49
5.8.1 Installation of the Sensor.....................................................................................................................................................49
5.8.2 Installation of the Sampling Unit (K9424GA).....................................................................................................................49

6. Selection Guide............................................................................................................................................................................................................49
6.1 Oxygen analyzer selection flow chart.....................................................................................................................................................49
6.2 System configuration................................................................................................................................................................................52
6.2.1 ZR402G/ZR22 Direct In Situ Zirconia Oxygen.....................................................................................................................52
6.2.2 Selection According to Use...................................................................................................................................................53
6.2.3 Examples of System Component Selection Based on Sample Gas Conditions.............................................................57
6.3 Compatibility between old and existing models...................................................................................................................................60

7. Basic Steps for Maintenance and Trouble Shooting...............................................................................................................................................60

7.1 Maintenance for ZR22 and ZR202...........................................................................................................................................................60
7.1.1 Cleaning the Calibration Gas Tube......................................................................................................................................60
7.1.2 Replacing the Sensor Assembly...........................................................................................................................................60
7.1.3 Replacing the Heater Assembly...........................................................................................................................................60
7.1.4 Replacement of Dust Filter...................................................................................................................................................60
7.1.5 Replacement of the Fly Ash Filter........................................................................................................................................61
7.1.6 Replacement of O-ring..........................................................................................................................................................61
7.2 Calibration..................................................................................................................................................................................................61
7.2.1 Best Practices for Calibration...............................................................................................................................................62
7.2.2 Calibration of the Humidity Analyzer..................................................................................................................................62
7.3 Trouble Shooting.......................................................................................................................................................................................62
7.3.1 Error and Alarm.....................................................................................................................................................................62
7.3.2 Basic Zirconia Probe Check..................................................................................................................................................63
7.3.3 Testing O2 Cell.......................................................................................................................................................................64
7.3.4 My detector is reading a high O2 level...............................................................................................................................64
7.3.5 My detector is reading a low O2 leve..................................................................................................................................65
7.3.6 Other Abnormal Values........................................................................................................................................................65
7.3.7 Experiencing Erratic Reading...............................................................................................................................................65
7.3.8 Probe Temperature low and not warming up...................................................................................................................65
7.3.9 Probe Temperature Too High..............................................................................................................................................66
7.3.10 High Impedance Reading (Zirconia cell & contact resistance & lead resistance).......................................................66
7.3.11 Short Sensor Life.................................................................................................................................................................66
7.3.12 Short Heater Life..................................................................................................................................................................66
7.3.13 Automatic Calibration Panel, Model AC8..........................................................................................................................66

8. Zirconia Analyzer – Question & Answers..................................................................................................................................................................67

8.1 Application.................................................................................................................................................................................................67
8.2 Installation.................................................................................................................................................................................................69
8.3 Maintenance..............................................................................................................................................................................................69
8.4 Accessories.................................................................................................................................................................................................73
8.5 Models........................................................................................................................................................................................................73

9. Lock Out Specifications...............................................................................................................................................................................................73

9.1 Oxygen Analyzer System Specification for a Single Channel Analyzer and Detector Requirements.............................................73
9.2 Oxygen Analyzer System Specification for an Integrated type Oxygen Analyzer and Detector Requirements...........................75
9.3 Oxygen Analyzer System Specification for Multi-Channel Averaging Oxygen Analyzer and Detector Requirements................76

10. Customer Application Data Sheet............................................................................................................................................................................79

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1. Introduction the moisture content; a type of humidity measurement
that is more commonly referred to as Absolute
Successful industrial product sales requires strong Humidity. It is important to note that moisture content
technical and application knowledge of the equipment in anything other than air, i.e. combustion exhaust gas,
involved as well as a comprehensive understating of cannot be measured.
the market ‘s competitive elements, such as features,
benefits and pricing. This handbook has been designed However, no matter the desired measurement some
as an ongoing sales tool, which will be updated common difficulties that you will face are:
and amended on a regular basis to help keep the sales
force abreast of new market developments based • A variety of established competitors
on process/application improvement as well as new • Conservative end-users who are reluctant to switch
product developments. from one supplier to another
• A growing number of government regulations
Oxygen concentration measurements are used in a
variety of applications including, energy conservation, 2. Theory
pollution reduction and process quality control and
accomplished using several different measurement Plant boilers are closed vessels in which water under
principals. Even Governmental regulations to control pressure is transformed into steam by the application
CO2 and NOx emissions, affect even small municipal, of heat. In the boiler furnace, the chemical energy in
private and commercial utility boilers and furnaces as the fuel is converted into heat, and it is the function of
they must be controlled or at least tested on a regular the boiler to transfer this heat to the water it contains
basis. However, Zirconia-based Oxygen Analyzers are in the most efficient manner possible. Most often the
most commonly used for combustion control, burner boiler is designed to generate high quality steam for
optimization and to increase the efficiency of boilers use throughout the plant. The fuel that is used for
and industrial heaters to achieve fuel conservation. heating the boiler may either be: Gaseous such as
Major end-users are found in the following industrial natural gas, cokes-oven gas/ blast furnace gas; Liquid,
fields: such as heavy/light fuel oil, jet oil, liquefied petroleum
gas, gasoline, nafta or chemical waste; or Solid such as
• Electrical Power Generation wood/bark, coal, brown coal, or peat.
• Chemical and Petrochemical
• Iron and Steel Manufacturing Perfect combustion occurs when the correct amounts
• Petroleum Refinery of fuel and oxygen are combined so that both are
• Pulp & Paper totally consumed, with no combustibles or uncombined
• Textiles oxygen remaining in the resulting flue gas. Under ideal
conditions, combustion-reaction obeys the following
There are still countries where extractive oxygen stoichiometric reaction equation:
analyzer systems are in use for combustion control
CxHy + aC + bCO + (x + ¼y + a + ½b) O2 → (a + b + x) CO2 + ½yH2O + ΔHeat
(paramagnetic, TDLS, thermo-magnetic, polarographic,
electrochemical, fuel-cell). These offer an excellent
However, fuel may contain impurities and additives to
sales opportunity since the advantages and benefits of
improve viscosity, therefore ideal combustion can only
zirconia analyzers over extractive methods are easily
be achieved if all of the following requirements are met
demonstrated. The following are some of the benefits
simultaneously:
and features of the Yokogawa Zirconia
Oxygen Analyzers:
• Consistent fuel composition at all times
• Pure oxygen in used instead of simple plant air
• Compact design for flexible low-cost installation
• Complete molecular mixing of oxygen and fuel, at the
• Long-life sensor
same temperature and pressure
• Reduced maintenance and calibration using
• Unlimited reaction time and zone
self-diagnostics
• Constant in-outlet conditions (pressure, temperature,
• Excellent price/ performance correlation
flow, composition) are maintained
• Consistent boiler/furnace load
Yokogawa’s Zirconia Oxygen analyzer can also be used
to measure humidity in specific applications. This is a
In practice, none of the above requirements are
benefit because most humidity analyzers are normally
completely achieved due to the physical restrictions
designed for ambient temperatures and not suitable
in burner design, use of (economical) ambient air
for the high temperatures that we find in bakery
rather than expensive pure oxygen, and aging of boiler
ovens, Pizza ovens, Paper driers or Plywood driers.
equipment.
The zirconia high temperature analyzer is designed to
measure oxygen concentrations in the air and calculate

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 When there is insufficient air for combustion
control, the fuel is not completely consumed and
gives off smoke. This is a sign of energy loss and
undesirable emissions. If left unchecked the buildup
of combustibles will lead to a safety hazard. On the
other hand, if excess air for combustion is supplied, the
unused air is overheated and emitted from the stack,
causing a heat loss. This increases the emissions of
NOx and SO2, which cause air pollution. In order to
achieve complete combustion there must be a balance
or air-fuel ratio where the boiler is operating as close to
zero “excess air” as possible.

Figure 2.2 Efficiency Graph

“Air-fuel ratio” or “Excess air” refers to the amount

of air theoretically required to achieve complete
combustion of the fuel supplied to the furnace of the
boiler. The “air-fuel ratio” or “excess air” is used to
achieve the highest efficiency for a system based on
each different fuel source. “Excess air” can be obtained
by measuring the oxygen concentration in the exhaust
Figure 2.1 Example of Environment
gas and calculated by:

n = (1 / (21-Oxygen concentration)) x 21

2.1 Why Measure O2? Data is available that shows the various fuel sources
and an indication of their typical value for excess air;
Either the measurement of oxygen or carbon monoxide shown in the table below are just a few of the common
can be used to determine the level of excess air. fuel sources:
However, measuring CO alone will not define which
type of an environment, fuel rich or air rich, a burner
is operating in. Therefore combustion control needs to Fuel Excess of Air (%)
be based on accurate and dependable Oxygen analysis. Coke oven gas 5-10
To ensure complete combustion chamber are supplied
Natural Gas 5-10
with excess air to increase the amount of oxygen
and the probability of combustion of all fuel. The Coal, pulverized 15-20
combustion efficient will increase with increased excess Coal, stoker 20-30
air, until the heat loss in the excess air is larger than
the heat provided by more efficient combustion. Oil (No. 2 and No. 6) 10-20

Under actual operating conditions some amount

of excess air is always necessary to bring the
combustibles level close to zero. The challenge is
to minimize these effects by achieving completed
combustion with the lowest excess air levels possible. It
is important to accurately measure and control oxygen
analysis because:

• Insufficient air is a waste of fuel which is a waste of

money. As a rule of thumb each 10% excess O2 is
equivalent to a 1% in wasted fuel.

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 basic measurement principles and
the advantages/disadvantages for
paramagnetic, electrochemical and
optical measurement types.

There are two different types of

Zirconia measurement systems; the
amperometric which is used in
Yokogawa products such as the OX100
and OX102, and the most common type
is what is known as potentiometric.
This type is used in Yokogawa products
such as the ZR series and the OX400.

Figure 2.5 shows a schematic of

the amperometric system. An
amperometric sensor consists of a
Figure 2.3 Fuel Consumption as a function of Oxygen Concentration
zirconia cell that has a high voltage being applied
across the two platinum electrodes. Oxygen then flows
thru the diffusion hole and comes into contact with the
cathode of the heated zirconia element. As the Oxygen
interacts with the cathode a current is generated.
The measured current is proportional to the diffusion
rate from the sample gas to the cathode. This output
current is linear to the oxygen concentration.

Figure 2.4 % Excess air Vs. Oxygen Concentration

• To minimize heat loss since the more excess-air

used, the more heat required to warm it prior to
combustion resulting is wasted heat contained in the Figure 2.5 Amperometric measurement principle
waste gas carried to the stack.
• Optimizing fuel consumption by maintaining Advantages to this type of system are this it is capable
complete combustion. of measuring trace oxygen concentration from ppm
• Minimizing power consumption by ancillary devices to percentage level, and calibration is required only on
(air blowers; damper positioners). the span side (air). The disadvantages are that if the
• Reduction of air pollution since a surplus of excess sample gas contains a flammable gas, a measurement
air at high temperatures allows for the formation of error occurs, and presence of dust causes clogging
SO2, SO3 and NOx from the fuel impurities and air- of the gas diffusion holes on the cathode side; a filter
nitrogen. must be installed in a preceding stage.

2.2 Oxygen Measurement Principle and Figure 2.6 shows the basic potentiometric method
Theory which uses a solid electrolyte such as zirconia with
platinum electrodes attached that when heated the
The most common oxygen measurement methods are; device acts as an oxygen concentration cell.
Zirconia type systems, Paramagnetic, Electrochemical,
and optical type systems. Each of these measurement
methods has advantages and disadvantages,
therefore it is important to select the appropriate
method for each application. Section 2.5 explains the

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 is equilibrium between Oxygen molecules and ions.
The relationship between the voltage generated and
the O2 partial pressure is logarithmic. The Oxygen
molecules react in the following manner:

Figure 2.6 Potentiometric measurement principle

Basically a concentration gradient of Oxygen ions is Figure 2.8 Schematic

established within the Zirconia lattice which produces

a voltage potential between the platinum electrodes Negative electrode (Higher oxygen partial pressure
according to the NERNST equation: side) O2 + 4e → 2O2-
Positive electrode (Lower oxygen partial pressure
E = - RT/nF ln PX/PA side) 2O2- → O2 + 4e

Where, R: Gas Constant When plant air is used as the reference gas, the
N: 4 theoretical relationship between the oxygen
F: Faraday’s constant concentration of the measurement gas and the
T: Absolute temperature electromotive force of the zirconia sensor (= cell) is as
PX: Oxygen concentration in a gas shown in Figure 2.9. In practice, sensors will exhibit
(measurement gas) in contact with the slight deviations from the theoretical value but this
positive electrode (%) deviation is corrected when the sensor is calibrated.
PA: Oxygen concentration in a gas (reference air)
in contact with the negative electrode (%)

The Zirconia becomes conductive only at high

temperatures: above 600°C. Yokogawa uses a heater
that controls the temperature of the Zirconia to 750˚C.
At that temperature the equation becomes:

E = E0 - 50.74 logpx/pa , which equals E = −50.74 log(O2/21)

when instrument air is used as reference gas and when
pressure is equal on both sides.
Figure 2.9 Schematic diagram of principle construction of the ZR22 Detector

It is important to note that the sensor (zirconia

element) is heated to 750°C during measurements.
If the process gas contains combustible gases such
as carbon monoxide, hydrogen, and methane, these
gases burn at the detector and consume oxygen,
causing the oxygen concentration measured to be
less than the actual value. Therefore, zirconia oxygen
analyzers should be used only when the effect of
coexisting combustible gases can be ignored or when
their effect on oxygen concentration can be corrected.
Figure 2.7 Oxygen partial pressure vs. Zirconia cell mV output (on basis of 21.0% O2) Generally, exhaust gases after combustion that are
emitted from combustion equipment such as boilers
If the Oxygen concentration on both sides of the and industrial furnaces have been completely burned;
Zirconia is equal then the ions move randomly through therefor the volume of combustible gases is very small
the crystal and no voltage is generated. However, if the in comparison with oxygen and their influence can be
concentration is different on both sides, then the ignored.
ions move to the low concentration side because there

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Advantages versus conventional (extractive) methods Figure 2.10 shows graphically, if the Oxygen
are: concentration is y mol%, then the Air concentration is
• Intrinsic fast response (within 5 seconds) due to no (100/21) * y mol%. For ideal gases the mol fraction is
sampling system. the same as the volumetric fraction, so 1 mol%= 1 vol%
• In-situ measurement; direct insertion into the
sample. The composition of dry air is:
• Absence of moving parts. 78.084% Nitrogen, 20.946% Oxygen, 0.033%
Carbondioxyde, 0.934% Argon In round figures: 21%
Potential disadvantages are: Oxygen, 78% Nitrogen and 1% other gases.
• Cell Fragility: May crack when exposed to thermal
shocks or sever mechanical agitation which The moisture content of the gas is 100 % minus the Air
could generate false high output that may create concentration in vol%
hazardous situations.
• Cell output is dependent on differential O2 pressure In other words: Moisture content: x is 100- y*(100/21)
at the electrodes; requiring well defined reference
gas. Cell output is also temperature dependent, Graphical: x/100= y/21
especially at low O2 levels.
• High operating temperature (600-1000°C) poses 2.4 Units of Measure
safety concerns as being a potential ignition source
for combustible in the sample. 2.4.1 Absolute Humidity

2.3 Humidity Measurement Principle and The absolute humidity is expressed as vol% H2O in gas,
Theory which is the primary unit displayed in the Zirconia
high temperature analyzer.
The Zirconia analyzer is designed to measure Oxygen
at high temperatures. Humidity analyzers are normally 2.4.2 Relative Humidity
designed for ambient temperature and not suitable for
the high temperatures that we find in bakery ovens, In ambient air conditions one uses normally rH as
Pizza ovens, Paper driers or Plywood driers. unit for humidity measurement. This is the relative
humidity and it is the percentage of the maximum
If the Humidity measurement is needed in pure Air- humidity at this temperature where the moisture will
Water gas mixtures, then the Oxygen analysis is not condense. The Zirconia high temperature humidity
suitable to measure the Water content of the gas. analyzer can also display relative humidity, but only
when a temperature input is given to the analyzer by
This is the basic principle behind the Yokogawa High means of a mA input of a temperature transmitter.
Temperature Humidity analyzers. In the following graph you see at what moisture
concentration condensation occurs as function of the
temperature.

For example at 30°C condensation occurs when

the absolute humidity is 3 vol%. When the absolute
humidity at 30°C is 2 vol%, then the relative humidity:
rH= 2/3= 67%.

Figure 2.10

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 2.4.4 Mixing Ratio

The Zirconia Humidity analyzers have the possibility to

choose Mixing Ratio as unit of measurement. This is
the ratio: kg water/kg dry air. This unit of measurement
is widely used for humidity control of driers. When the
moisture concentration is x vol%, we can calculate the
mixing ratio out of this value:

The molecular weight of water is 18 and the molecular

weight of dry air is 28.8. Therefore; Y mol....

Y mol H2O= 18*x g/l water

(100-x)mol Air = 28.8*(100-x) g/l air

So the mixing ratio of a gas with x vol% water is

18/28.8*x/(100-x) or 0.622*x/(100-x)

2.4.5 Other Units

Figure 2.11

There are many other humidity units that are not

For applications of the Zirconia High Temperature
supported by the Yokogawa Humidity analyzers. They
Humidity analyzer the following chart is more useful.
can simply be calculated from the vol% H2O primary
unit of measurement. Please consult Internet for the
conversion factor. A complete set is found as HumiCalc
on www.thunderscientific.com

2.4.6 Accuracy of the Humidity Analyzer

The Humidity analyzer is measuring Oxygen, so the

accuracy for the humidity readings is determined by
the accuracy of the Oxygen analyzer.

The range of 0- 100 vol% H2O corresponds to a range of

21- 0 vol% O2. The repeatability of this analyzer
is 0.5% FS= 0.1 vol% or 0.5 vol% H2O.

The range of 0- 25 vol% H2O corresponds to a range of

15.75 – 21 vol% Oxygen. The repeatability of this range
is the same: 0.5 vol% H2O, which is now 2% FS.
Figure 2.12

2.4.3 Dew Point These accuracy specifications are valid for process
pressures of +/- 0.5 kPag or +/-5 mbarg and when dry
This unit is normally used to express the quality of instrument air is used as reference gas.
Instrument Air. For those applications the Zirconia
analyzer is not suitable, because the moisture content 2.5 Comparison and Advantage over
of instrument air is too low. In paper driers this may be Competitive O2 Principles
an important parameter: it shows at what temperature
condensation will occur. 2.5.1 Paramagnetic

The dew point is also shown in the charts shown above. This utilizes the fact that Oxygen is a paramagnetic gas
The charts are only valid for standard barometric which distinguishes oxygen from other gases because
pressure: “sea level”. it is attracted into a strong magnetic field. Basically
when a gas sample is introduce to the instrument the
oxygen will be drawn into the magnetic field resulting
in a change in the flow rate. The flowrate change
is proportional to the oxygen concentration of the

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sample gas. Paramagnetic analyzers may be used for
measurement of oxygen at any level between 0-100%.

Figure 2.13 Paramagnetic Measurement Principle

Advantages:

• Capable of measuring flammable gas mixtures that

cannot be measured by a zirconia oxygen detector
with its heated cell.
• A paramagnetic system offers the fastest response
time and is more resistant to vibration or shock.
Figure 2.14 Electrochemical measurement principle
Disadvantages:
Advantages:
• Some other gases, such as N2O, CO2, or NO2, are also
paramagnetic and their presence in the gas stream
• The detecting system can be made compact; this
can cause a false reading.
measurement system is available in portable or
• Because of the sample system the response time is
transportable form.
slow, sometimes up to 30 seconds or more.
• Relatively inexpensive in comparison with oxygen
• Require accurate temperature conditioning of
analyzers of other measurement systems.
detector and sample.
• Accurate flow and pressure control of the sample and
Disadvantages:
auxiliary gas is needed.
• This method is also sensitive to fluctuations of
• The cell life is limited. The sensor contains an internal
ambient conditions, vibration and mechanical
electrolyte solution and evaporation of the water out
agitations, variations in background gases and
of the cell makes the sensor nonfunctional. Typical
detector drift.
lifetime is 6- 24 months.
• The electrochemical cells are sensitive to
2.5.2 Electrochemical
temperature, although the effect is relatively small.
Changing the temperature from +20 to –20°C will
Electrochemical sensors, also known as fuel cells,
result in approximately a 10% loss of output signal.
measure percent or trace (ppm) levels of oxygen
in a gas or gas mixture. Sensor consists of anode,
2.5.3 Optical: Tunable Diode Laser Spectroscopy
membrane, a semi-solid electrolyte and a cathode. The
oxygen will pass through the membrane/diaphragm in
Tunable Diode Laser Spectroscopy (or TDLS)
direct proportion to the partial pressure of the oxygen
measurements are based on absorption spectroscopy.
outside of the sensor. Oxygen enters the sensor and
The TruePeak Analyzer is a TDLS system and operates
is reduced when it comes in contact with the cathode
by measuring the amount of laser light that is
while the anode is oxidized in the following reactions:
absorbed (lost) as it travels through the gas being
measured. In the simplest form a TDL analyzer consists
Cathode: O2 + 2H2O + 2e- → 4OH- (Reduction)
of a laser that produces infrared light, optical lenses to
Anode: 2Pb + 4OH- → 2PbO + 4e- + 2H2O (Oxidation)
focus the laser light through the gas to be measured
and then on to a detector, the detector, and electronics
These two reactions produce a small current that is
that control the laser and translate the detector signal
proportional to the amount of oxygen concentration
into a signal representing the gas concentration.
reacting.

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 Gas molecules absorb light at specific colors, called Advantages:
absorption lines. This absorption follows Beers law.
• Capable of measuring a number of near infrared
TDLS Analyzers are effectively infrared analyzers which absorbing gases in difficult process applications.
obey the Beer-Lambert Law. • Capability of measuring at very high temperature,
high pressures and under difficult conditions
I = I0 •e -E•G•L (corrosive, aggressive, high particulate service).
• Most applications are measured in-situ, reducing
where I is the radiation intensity after absorption, installation and maintenance costs.
I0 is the initial radiation intensity,
E is the extinction coefficient, Disadvantages:
G is the gas concentration,
and L is the path length of the measurement area. • The installation of the flange is necessary for both
sides of the process.

It is important to select the appropriate

Figure 2.15 Optical measurement principle
measurement method for the application. The
below table is to be used as a quick reference only.

Potentiometric ZR
Application Potentiometric OX400
Product Series

Package boilers A* X

Combustion control A X

Incinerator combustion control A X

Lime or Cement kiln combustion control A* X

Safety control (explosion prevention) at various plants X X

Oxygen concentration control of gas containing a flammable gas X X

Low-oxygen concentration X A

Oxygen deficiency prevention and Atmospheric control X A

Oxygen concetration control of glove boxes X A

Naptha cracking furnaces X X

N2 and air purity control for air separators X A

Continuous measurement of flow gases during food packaging X B

Oxygen concentration control of N2 reflow furnaces X A

Humidity in Paper Driers A X

Humidifiers A X

Rating: A = Recommended, B= Applicable, X= Not Applicable

*Depending on the product selection

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3. Yokogawa Product and Features 3.2 Construction and Features of a Zirconia
Cell
A typical system configuration can be divided into
three main types; those using a separate detector and Zirconia cell construction should meet the following
analyzer; those using an integral detector and analyzer; basic requirements:
and those designed for bench top purposes. Not all
products mention below are offered globally, please • Constructed of an inert composition
consult your local office for area product offerings. • Highly selective conductance for pure oxygen-ions
• Stable with temperature and time
3.1 Zirconia Oxygen Detector, Model ZR22 • Non-permeable
• Resistant to thermal shocks and mechanical
Developed from the field proven ZO21D zirconia agitations for normal industrial processes
detector technology, the EXAxt ZR22 in-situ type
zirconia detector provides dependable and accurate The cell’s platinum element is molecularly bonded to
continuous monitoring of oxygen concentration in the zirconia by a proprietary method developed by
combustion utilizing its zirconia cell (E7042UD). The Yokogawa, which eliminates the risk of the platinum
ZR22 is offered in two different versions depending separating from the zirconia and the measurement
on the area classification; model ZR22G for general failing. The platinum electrodes also have a special
purpose and model ZR22S for explosion proof for coating to protect them from deterioration caused by
hazardous applications. It is available in lengths from SO2 or NOX contained in the measurement gas. These
0.15 meter to 5 meters. The ZR22G and ZR22S can features ensure the detector will perform reliably and
measure the gas of a temperature up to 700°C directly. have longer life.
For gas temperatures higher than 700°C, the high
temperature adapter can be used to measure up to
1400°C. For more information please see section 3.4.

The new detector’s modular design incorporates

a rebuildable heater and thermocouple assembly,
the industry standard Yokogawa zirconia cell, and
removable reference and calibration lines to create an
oxygen measurement product designed for simple, Figure 3.2 Yokogawa Zirconia Cell

quick and low-cost field maintenance.

3.3 Zirconia Oxygen Pressure
Compensation, Model ZR22G----P

The Zirconia cell is heated to 750°C and exposed to the

process gas on one side and a reference gas (normally
clean, dry air) with a known O2 concentration on the
other side. If there is a difference in O2 concentration
between the process gas and reference gas, the cell will
generate a voltage (mV). The bigger the difference, the
bigger the voltage generated. The analyzer measures
Figure 3.1 ZR22 Series Detector
this voltage then calculates the O2 concentration.

The ZR22 offers the following features: The “force” that causes this voltage is actually the
difference in partial pressure of oxygen between the
• The platinum element of the Zirconia cell is process gas and reference gas. Partial pressure can be
molecularly bonded to the zirconia material to defined as the mole fraction (% concentration) times
eliminate the platinum from peeling off and the total absolute pressure.
increasing cell life.
• The zirconia cell can be easily replaced by removing For Example: Air at atmospheric pressure (101.4 kPa
four bolts. The filter attached at the front of the absolute pressure) has an oxygen concentration of
sensor is a large wire-mesh that prevents dust 20.9%. The partial pressure of oxygen in air is 20.9% of
particles from entering the sensor. 101.4 kPa which is 21.19 kPa.
• The heater assembly is designed for replacement in
the field if desired. Flue gas at atmospheric pressure may have an oxygen
concentration of 3%. The partial pressure of oxygen in
the flue gas would be 3% of 101.4 kPa which is 3.04 kPa.

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 If the reference gas and process gas are at the same
total pressure, the only thing that will contribute to the
oxygen partial pressure differential is the concentration
of oxygen on the process side.

Standard Zirconia probes are designed to vent the

reference gas to atmosphere, which pretty much
assures the reference gas is very close to atmospheric
pressure (101.4 kPa absolute, 0 kPa gauge). Most of
the applications where Zirconia probes are used to
measure oxygen are low pressure applications (<4.98
kPa gauge). This means the total pressure of the
process gas and reference gas are close, so errors in
the measurement are minimal.

It is in higher process pressure applications (>4.98 Figure 3.4 Illustration of Pressure Compensation Method

kPa gauge) that the errors in the measurement can

become substantial with non-compensated Zirconia Considerations
probes. The increase in process pressure increases
the partial pressure of oxygen, even though the % To maintain an accurate measurement, the Pressure
concentration of oxygen remains the same. Remember Compensated detectors should be considered if the
that the analyzer assumes that the only thing that process pressure is greater than 4.98 kPa, and varies
increases the partial pressure of oxygen is an increase widely.
in % concentration.
Ensure that your process can withstand having 0.8
Pressure compensated probes are designed to LPM of air introduced into it, and that the air can be
equilibrate the reference gas pressure with the process easily dissipated downstream (no sleeves, protectors
gas pressure. To accomplish this, the reference gas or supports that will trap the reference air). Some
is exhausted into the process at a low flow rate of 0.8 applications cannot be “contaminated” with reference
LPM. When the total reference gas pressure equals air. For these applications, one solution is to use a
the total process pressure, the only thing that will standard (non-compensated) probe, and calibrate the
contribute to the oxygen partial pressure differential probe in-situ at process pressure. This will “calibrate
is the concentration of oxygen in the process. This out” the pressure induced error, but will decrease
system also allows the process pressure to vary, as the the usable life span of the cell (cells have a zero point
reference gas pressure will float with the changes as correction up to 30%).
long as it is flowing.
3.4 Zirconia Oxygen High Temperature
Adapter
The purpose of the High Temperature Adapter (ZO21P
or ZR22P) is to accommodate the ZR22 series of
Zirconia Oxygen Detectors for use in process gas
temperatures that exceed 700°C (1292°F).

The High Temperature Probe Adapter uses either

existing process pressure, or vacuum pressure to
draw a sample away from the process and cool it to
a temperature below 700°C. This allows the Zirconia
detector to operate away from the high temperatures
where the cell/detector is not designed to work.

Several models of the High Temperature Adapter are

Figure 3.3 Illustration of Standard (un-compensated probe)
available for different applications and environments,
and can be selected to accommodate the varying needs
of these process samples. When building a model code
a few questions need to be considered:

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What is the required process flange connection size? 3.5 Calibration Equipment
• What is the temperature of the process? For calibration needs, Yokogawa offers a variety of
The High Temperature Probe Adapter system can products from portable calibration units, integrated
accommodate process temperatures of 700°C calibration units, to manual and automatic calibration
(1292°F) to 1871°C (3400°F), when using alumia panels. Not all products mention below are offered
ceramic transport tube. The adapter itself is made globally, please consult your local office for area
of 316 Stainless Steel, but he transport tube (in-situ product offerings.
portion) utilizes different materials based on the
temperature ranges of the process gases. Please • The Standard Gas Unit (ZO21S) is a portable unit
note that the alumina ceramic is not offered globally, for calibration gas supply consisting of span gas (air)
and you should consult your local office for area pump, zero gas cylinder with sealed inlet, flow rate
product offerings. checker and flow rate needle valve.
• What is the process pressure?
If the process has a positive pressure the sample gas
will naturally be forced up to the oxygen probe. When
there is a negative process pressure, the sample
will need to be drawn to the oxygen probe. The
High Temperature Probe Adapter can be fitted with
and air educator (ejector), which creates a vacuum
to draw the sample to the probe. Depending upon
environmental regulations, the customer may wish to
vent the sample gases to atmosphere, or return the Figure 3.6 ZO21S

sample back into the process. The Eductor (ejector)

Return option, pipes the sample gases back through • The Portable Calibration Gas Kit (M1233SR) is a
the adapter flange into the process. portable unit for calibration that comes with a 105L
• Is there a high amount of particulate? zero gas cylinder (1% O2 with a balance of N2) and a
Many processes contain large amounts dust and 105L span gas cylinder (21% O2 with a balance of N2).
particulates (i.e. lime kilns), and these particulates • The Flow Setting Unit (ZA8F) consists of a flow
can clog the oxygen sampling system. The High Temp meter and flow control valve to control flow rates of
Adapter can be provided with an Automatic Blowback calibration gas and reference gas when instrument
system to keep the sampling system open. It is air is provided
controlled via the ZR402G Converter or the AV550G
Averaging system. A 4-way, 2 position single solenoid
valve with a double acting air actuator is used to
isolate the detector during blowback operation.
• Where does the sample gas go?
Occasionally, the ambient conditions outside of the
process may lead to a condensation build up within
the educator (ejector). The high temp adapter can be
provided with a heating option that uses conductive
and convective heat from the process gasses to heat
the instrument air prior to reaching the educator
(ejector). The process gasses are then vented to
atmosphere, instead of being piped back into the
process.

Figure 3.7 ZA8F Flow setting unit

Figure 3.5 High Temperature Probe Adapter

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 • The Automatic Calibration Unit (ZR40H) should be The AC1 includes individual span, zero and block
used when automatic calibration is required for the solenoids with manual overrides for easy setup of
separate type or integrated type and instrument air flow rates. It also contains a 1 amp fuse with an LED
is provided. indicator to signal a power surge. The user has a
choice of copper or stainless steel tubing in addition
to NEMA 4 or NEMA 4X enclosures. The AC1 provides
excellent regulation control of reference air and
calibration gas flow rates.

Figure 3.8. ZR40H Auto Calibration unit

• The Manual Calibration Panel (MC1) is for a single

oxygen probe. It provides regulation of the reference
air and calibration gas while allowing the operator to
Figure 3.10 Automatic Calibration Panel
select zero or span gas for calibration. Separate flow
meters are used to set calibration gas flow rates and
The model AC4 automatically calibrates up to four
reference air.
oxygen detectors while the model AC8 can calibrate a
maximum of eight.

• The Integrated Automatic Calibration Unit

(IAC24) is an ultra-compact device that mounts
directly onto the ZR22G or ZR202G zirconia detector,
recommended for indoor installations only. It has
no user adjustable parts, is only 4 inches wide and
used for single detectors. The unique mounting
configuration is designed to minimize installation
time. Just connect the calibration and reference
gases, set the correct pressure, and the device and
analyzer do the rest.

Figure 3.9 Manual Calibration Panel

• The Automatic Calibration Panel (AC1/AC4/AC8)

is used either with the ZR402 or AV550 converter
and allows the user the luxury of setting flow rates
and timing sequences. There are three types of
automatic calibration units with 1-, 4- and 8- channel
capacities for automatic execution of calibration
using solenoid(s). Each allows for independent
adjustment of flow rates for all reference air and
calibration gases with standard manual overrides for
each channel.
Figure 11. IAC24

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• The Check Valve prevents water vapor in the process • Filter Material: Hastelloy X
from diffusing down the calibration line where it • Base Material: 316 SS
may condense and cause the cell to crack. A check • Max. O.D.: 6.35cm (2.5in)
valve should be used on all natural gas and positive • Max Operating temp: 700°C (1292°F)
pressure applications and any time a calibration line • Pore size: 10 micron
is installed with long periods (>3 months) of time
between calibrations. • The Hastelloy X Sintered Filter (M1200DB-06) is a
sintered filter that addresses blockage and coating
problems experienced by tough applications that are
more stagnate.

Figure 3.14 M1200DB-06 Filter Design

Figure 3.12 Check Valve Design

• The Dust and Oil Filter (E7042UQ) attaches to the

3.6 Filters and Accessories end of the ZR22 Oxygen Probe, and is used for oil
fired applications as well as black liquor recovery
Many industries use a variety of fuel sources to fire
systems. The Filter utilizes a Silicon Carbide (SiC) filter
their processes, including natural gas, coal, oil, trash
disc enclosed in a 316SUS cylinder. Once installed the
and waste (also known as biomass). Coal and biomass
filter will have the same outside diameter as the ZR22
fuels release a significant amount of carbon particulate
Oxygen Probe (as shown).
when burned, known as fly ash. This fly-ash can clog
the Zirconia cell, resulting in slow or no response to
changes in the oxygen concentration. Depending on
your region Yokogawa offers various filters to assist in
the prevention of clogging.

• The Self Cleaning Fly-Ash Filter (M1234SE-A) is

a sintered filter that incorporates an aerodynamic
shield that deflects the particles, and prevents fly-ash
build up from clogging the ZR22 Oxygen Probe. This
filter should be used whenever coal or biomass is the
primary fuel source.

Figure 3.15 E7042UQ Filter Design

The Dust Filter (K9471UA) is used to protect the cell

from corrosive dust components or high velocity dust
in recovery boilers and cement kiln. Sample gas flow
rate must be 1m/sec or more to replace gas inside
zirconia sensor.

Figure 3.13 M1234SE-A Filter Design

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 • The Eductors (Ejector) are used in high temperature
installations where negative pressure is present.
Using instrument air, the eductor (ejector) draws
a sample through the adapter tee for quick
measurement without mechanical assistance.
Different models are available in the different
regions.

Note: Positive pressure requires the use of a needle valve to restrict

the flow of sample gas.

Figure 3.16 K9471UA Filter Design

• The Dust Guard Protector (K9471UC) is

recommended when sample the gas is likely to flow
directly into the cell due to the detectors position in
the stack where flammable dust or water drops may
go into the cell.

Figure 3.19 One example of an eductor (ejector) Design

3.7 Probe Protectors and Probe Supports

Probe protector (ZO21R or ZR22R) is used when the

sample gas flow velocity is approx. 10m/sec (33ft/
sec) or more and dust particles may be present that
can wear away the detector, such as a pulverized
coal boiler or fluidized bed furnace (or burner). The
Figure 3.17 K9174UC Filter Design probe protector is a stainless steel tube attached to a
flange that provides full length protection for the ZR22
• The Dust Protector (ZH21B) is used for high oxygen probe. A probe protector should also be used
temperature humidity applications such as paper when a probe insertion length is 2.5 m or more and in
dryers. This protector is designed to protect the horizontal installation.
probe output from dust agitation (i.e., to prevent
combustible materials from entering the probe cell)
where humidity measurements are made under
dusty environments.

Figure 3.20 ZO21R/ZR22R Design

Probe support (ZR22V) is not available in all regions,

but it is used for natural gas applications where there is
no particulate but is used to provide addition structural
support for probe over 3 meters in length when
installed in horizontal orientation.

Figure 3.18 ZH21B Filter Design

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 • Can measure either oxygen concentration or
humidity with a single analyzer
• Highly reliable measurements with trend-data graphs
• Contact input allows calibration activation, range
change and detector performance validation

3.9 Zirconia Oxygen Multi Unit Averaging

Analyzer, Model AV550G

The O2mation, model AV550, averaging oxygen

analyzer was designed with a focus on practical
performance. Yokogawa has refined its expertise in
the combustion oxygen business into this new and
creative product. It is packed with features designed
Figure 3.21 ZR22V Design to minimize plant down time and technical support for
the oxygen measurement.
3.8 Zirconia Oxygen Single Unit Analyzer,
Model ZR402G Its intuitive color touch screen operation, powerful
new process diagnostic tools and creative hardware
The EXAxt Zircon Oxygen Analyzer (Model ZR402G) is design makes power boiler oxygen trim automation
used to monitor and control the oxygen concentration simple, predictable and reliable. The trend graph
in combustion gases, in boilers and industrial furnaces, helps diagnose problems and view individual detector
for wide application in industries which consume performance over time. Maintenance and inspection
considerable energy—such as steel, electric power, oil are simplified by a modular hardware design. The
and petrochemical, ceramics, paper and pulp, food, Hot Swap feature allows changing channel modules
or textiles, as well as incinerators and medium/small without powering off the analyzer. Each channel card
boilers. It can help conserve energy in these industries. is fitted with spacious, and accessible, self-trapping
terminal strips that make wiring and maintenance fast
and easy.

Figure 3.22 Model ZR402G Figure 3.23 Model AV550 Averaging Converter

The ZR402G offers the following features: The AV550G offers the following features:

• Liquid-crystal touch panel display provides easy • Full Color Liquid-crystal touch panel display
operation • Back-lit LCD allows viewing even in the darkness
• Back-lit LCD allows viewing even in the darkness • Handles input of up to 8 oxygen detectors
• Interactive model displays instructions to follow, • Interactive model displays instructions to follow,
including those for: settings, oxygen concentration including those for: settings, oxygen concentration
trends, and calibration operations trends, and calibration operations
• Error codes and details of errors can be checked in • Error codes and details of errors can be checked in
the field without the need to refer to the appropriate the field without the need to refer to the appropriate
instruction manual instruction manual
• Digital communications features are provided • Multiple display modes shows average, single or all
as standard – this enables the analyzer to be detector gas concentrations
maintenance-serviced remotely • Redundant channel systems using multiple CPUs

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 • Can measure either oxygen concentration or • The sensor (zirconia cell) can be easily replaced
humidity with a single analyzer by simply removing four bolts. The filter attached
• Highly reliable measurements with trend-data graphs at the front of the sensor is a large-mesh wire net
• “Hot swap” of channel cards so the analyzer remains that prevents large dust particles from entering the
on line during maintenance sensor.
• Eight 4-20mA outputs for individual detectors • The heater assembly used to heat up the zirconia cell
• Three 4-20mA outputs for average oxygen is constructed so that it can be replaced in the field.
concentration outputs Even if a wire in the heater breaks, the heater can be
• Failed, in calibration, or alarming, detectors are easily replaced in the field.
automatically excluded from average calculations • Can cut wiring, piping and installation costs
• Automatic or manual type calibration methods • Can be operated in the field without opening the
• 24V or 120VAC auto-calibration power option cover using an infrared switch
• Contact input allows calibration activation, range • Can measure either oxygen concentration or
change and detector performance validation humidity with a single analyzer
• Intuitive “common language” operation • Remote maintenance using digital communication
• Housing temperature alarm to notify user of over reduces maintenance cost
temperature conditions on the electronics
3.11 Zirconia Oxygen Low Concentration
3.10 Integral Type Zirconia Oxygen Analyzer, Model OX400
Detector and Analyzer, Model ZR202
The OX400 is an accurate and reliable low-
The EXAxt ZR Integrated type Zirconia Oxygen Analyzer concentration zirconia oxygen analyzer capable of
(ZR202) integrates both probe and converter into measuring O2 concentrations, from 0-10 ppm up to
one installed instrument. There is model ZR202G for 0-100 vol% O2. This is the latest oxygen analyzer from
general purpose and model ZR202S for explosion Yokogawa, and its development was based on the
proof for hazardous applications. The analyzer does company’s long experience and strong track record
not need a sampling device, and it allows for direct with this technology.
installation of the probe in the wall of a flue or furnace
to measure the concentration of oxygen in the stack A proprietary new thin-film deposition technology was
gas of the temperature up to 700°C. The probe uses a used in the zirconia sensor that creates a molecular
high-reliability Zirconia sensor (E7042UD) and a heater bond between the zirconia element and the platinum
assembly that can be replaced on site. layer. This prevents separation, enables a reduction in
sensor size and ensures a high-speed response and
The analyzer is equipped with three infrared switches, long life.
which enable the user to operate the equipment
without opening the cover on site. Analyzer calibration The OX400 can be used to control and monitor
can also be fully automated and the automatic various semiconductor applications, and to control
calibration unit is provided. Choose the equipment environment, air leakage into inert gas, and other
which best suits your needs so that an optimal processes.
combustion control system can be obtained.

Figure 3.24 ZR202 Series Integral Detector and Analyzer

The ZR202 offers the following features:

Figure 3.25 Low Concentration Oxygen Analyzer

• For the Zirconia cell, which is a key component

of zirconia oxygen analyzers, a zirconia element The OX400 offers the following features:
and platinum electrodes are molecularly bonded
by a method developed by Yokogawa. Therefore, • Long life and high-speed response thanks to the use
the zirconia sensor can deliver consistent of Yokogawa’s proprietary new thin-film deposition
measurements for a long period without the technology, the sensor has three times the lifespan
electrode being peeled off. of those used in our earlier products.

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• A cylindrical sensor design facilitates the replacement 3.12.2 Model OX102
of measurement gases, thereby helping to assure a
high-speed response. The OX102 Oxygen Analyzer measures oxygen
• Either pump or aspirator sampling can be selected, concentration from ppm to percent levels in a single
depending on the application analyzer and is ideal for ppm-level measurements
• Built-in functions and a variety of self-diagnosis in applications such as nitrogen reflow furnaces and
functions semiconductor plants.
• Comes with multi selector, auto range, partial range,
and pump on/off functions The zirconia oxygen sensor uses a method that is
• A variety of self-diagnosis functions are provided based on the limiting current principle and is compact,
that detect malfunctions such as heater temperature yet has high-performance. The sensor is designed for
error, temperature sensor burnout, and sensor installation by direct insertion.
resistance value error.
• The sensor can be replaced on-site. When a sample gas contains organic solvent at a few
• Compact and lightweight for easy installation. ppm to percent level in applications such as nitrogen
reflow furnaces, an optional sampling unit is required.
3.12 Limiting Current Type Oxygen
Analyzer

3.12.1 Model OX100

The OX100 Oxygen Analyzer measures oxygen

concentration from ppm to percent levels and is ideal
for ppm-level measurements in such applications as
nitrogen reflow furnaces and semiconductor plants.
The zirconia oxygen sensor is based on the limiting
current principle and is compact, yet provides high-
performance. The sensor is designed for installation by
direct insertion. Where a sample gas contains organic
solvent at a few ppm to percent level in applications Figure 3.27 Low Concentration Oxygen Analyzer

such as nitrogen reflow furnaces, an optional sampling

unit is required. The OX102 offers the following features:

• A single instrument capable of measuring 100 ppm to

25% oxygen
• Simple one touch calibration
• Self-diagnostics assure high reliability
• “One touch” sensor replacement
• Compact size

It is important to select the appropriate product for

the application. The below tables are to be used as a
quick reference of the different products available and
their specifications. Table 2 is also included to assist
Figure 3.26 Low Concentration Oxygen Analyzer
when you will select an OX400 over an OX100/OX102.

The OX100 offers the following features:

• A single instrument capable of measuring 1000ppm

to 25% oxygen
• Simple one touch calibration
• Self-diagnostics assure high reliability
• “One touch” sensor replacement
• Compact size

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 Table 1: Quick Reference Model Specifications

Measuring System Zirconia

Model ZR22*, ZR402G ZR202* ZR22*, AV550G OX400 OX100/OX102

0-1000 ppm O2/

Min. Measuring Range 0-5 Vol% O2 0-5 Vol% O2 0-5 Vol% O2 0-10 ppm O2
0-100 ppm O2

Max. Measuring Range 0-100 vol% O2 0-100 vol% O2 0-100 vol% O2 0-100 vol% O2 0-25 vol% O2

Settable arbitrarily within the range Fixed 2 ranges/

Measuring Range Setting Auto/Man.
(in vol% O2 units) 0-100 ppm O2

Partial Range Available Available Available Available Not Available

4-20 mA DC and 4-20 mA DC or 1-5

4-20 mA DC
Output Signal 4-20 mA DC HART 4-20 mA DC HART 0-1, 5, 10 V DC/
8 points Fieldbus
V DC (selectable) 4-20 mA DC

Sample Gas Temperature 0-1400°C 0-700°C 0-1400°C 0-50°C 0-70°C

Sample Gas Pressure -5-250 kPa -5-250 kPa -5-250 kPa 0-300 Pa 1013±40 hPa Abs

10 sec or less (1%

Response Time (90%) (When gas
O2 or more) 30 sec
is introduced from the detector 5 sec or less 5 sec or less 5 sec or less
or less (less than
inlet)
1% O2)

Warm-up time 20 min 20 min 20 min 20 min or less

Non-Explosion Non-Explosion
Explosion proof Construction Option Available Option Available Option Available
proof protected proof protected

Stationary/
Application Form Stationary Stationary Stationary Stationary
Transportable

Separately Installed Sample May be required depending on

Not Required Not Required Not Required
System applications

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Table 2: When to quote OX400 instead of OX100/OX102
Measuring System Zirconia Limiting Current

Model OX400 OX100/OX102

Min. measuring range 0 – 10 ppm O2 0 – 1000 ppm O2/0 – 100 ppm O2

Measuring range setting Auto/Man. Fixed to 2 ranges/0 – 100 ppm O2

Partial range Available Not Available

4 – 20 mA DC and 0-1, 5, 10 V DC 4 – 20 mA DC or 1 – 5 V DC/4 –

Output signal
(selectable) 20 mA DC

Sample gas temperature 0 – 50°C 0 – 70°C

Sample gas pressure 0 – 300 Pa 1013±40 hPa Abs

Response time (90%) (When gas is introduced 10 sec or less (1% O2 or more)
from the detector inlet) 30 sec or less (less than 1% O2)

Warm-up time 20 mins or less 3 mins

Oxygen concentration control of N2 reflow

A B/A
furnaces

Atmospheric control of
semiconductor manufacturing A B/A
equipment

N2 and air purity control for air

A B/A
separators

Oxygen deficiency prevention X A

Oxygen concentration control of

glove boxes for research and A B/A
development and parts machining

Oxygen concentration control of

experimental clean rooms for
B A
environment, fermentation,
biochemistry, etc.

Continuous measurement of flow

B A
gases during food packaging

Rating: A=Recommended, B=Applicable, X=Not Applicable

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 4. Application Notes
This section takes up typical application examples
for the zirconia oxygen analyzer. These individual
applications are structured as follows.

Application examples: Overview of individual devices,

and sample points.

Sample gas condition examples: Examples of sample

gas conditions, and block diagrams and type numbers
for zirconia oxygen analyzer systems to be used under
those conditions.

Table 4.1 Oxygen Measurement

Industry Application Benefits Model Remarks Location Reference

Power Excess Air Boilers Ref section b

(Natural gas, of BOILER
furnace oil application in
fuelled) TI
Boilers (Coal 11M12A01-­01E
Fuelled)

Power Oxygen Improves Detector: ZR22G Temperature: 300 to Economizer AN

concentration combustion Probe protector: ZO21R/ 400°C outlet 10M01P01-
in exhaust efficiency ZR22R Flow rate: ≤ 30 m/s 03E
gases from Converter: ZR402G Pressure: ±1.5 kPa
pulverized Manual calibration unit: Dust concentration:
coal power ZA8F/MC1 approx. 15 g/Nm
boilers Calibration gas unit 3 or less
Pressure regulator for gas
cylinder: A probe protector
• P/N G7013XF (inlet W22, should be attached
outlet Rc1/4) or P/N to the probe for
G7014XF (inlet W22, outlet protection against Ref section c
1/4NPT)/M1132ZX wear or damage. The of BOILER
• Case assembly for probe protector application in
calibration gas cylinder: should be mounted TI
P/N E7044KF with the notch of the 11M12A01-­01E
Note: the calibration gas probe head pointing
cylinder must be purchased downstream in the
locally gas flow

Power Oxygen Increases Detector: ZR22G Temperature: 150 to Boiler & AN

concentration Combustion Converter: ZR402G 300°C Economizer 10M01P01-­02E
in package efficiency Manual calibration unit: Flow velocity: 15 m/s outlet Ref section a
Boiler Flue gas ZA8F/MC1 Options max. of BOILER
Dust guard protector: P/N Pressure: ±0.5 kPa application in
K9471UC/M1234SE-A Dust: 1 g/Nm3 max. TI 11M12A01-­
01E

Refinery Excess Air Fired Heaters, Ref section a

Incinerators, & b of
Fluidized P.etroleum
Catalytic Refining &
crackers Petrochemical
regeneration, Fired Heaters
Cracking application in
Furnaces TI 11M12A01-­
01E

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Iron & Steel Air leak Efficiency Detector: ZR22G/C/CV Large dust & High Wind box, AN 10M01F01-
detection improvement Probe protector: ZO21R/ Humidity Process Boiler 01E
in sintering ZR22R
furnaces Quality Converter: ZR402G Check for probe
improvement Automatic calibration unit: protector orientation
Oxygen of sintered ore ZR40H/AC1/IAC24 against the gas flow
measurement
in Boilers

Iron & Steel Monitoring Maintains high Detector: ZR22G-015-S-Q-…/ Temperature: 900 to Furnace AN
of oxygen product quality CV 1400°C reheat, heat, 10M01F01-
concentrations by monitoring High temperature probe Pressure: 30 to 50 kPa and soak 03E
in steel mill oxygen in steel adapter Dust: Trace zones Ref section a of
reheating mill reheating ZO21P/ZR22P Fuel: Gas Iron & Steel
furnaces furnaces Auxiliary ejector for high Mills application
temperature use When the probe is in
Ensures stable P/N E7046E/M1132KE installed horizontally, TI 11M12A01-
continuous Converter: ZR402G bracings must 01E
measurement Manual calibration unit: be provided for
of oxygen ZA8F/MC1 mechanical support.
concentrations Calibration gas unit
Pressure regulator for gas
Reduces cylinder:
operating costs • P/N G7013XF (inlet W22,
outlet Rc1/4) or P/N
G7014XF (inlet W22, outlet
1/4NPT)/M1132ZX
• Case assembly for
calibration gas cylinder:
P/N E7044KF
Note: the calibration gas
cylinder must be purchased
locally

Iron & Steel Oxygen Improves Detector: ZR22G-015-S-Q-…/ Temperature: 20 to Duct AN

concentration combustion CV/Z 350°C 10M01F01-
in Hot Blast efficiency Z: Glove box option 02E
Stoves Converter: ZR402G Pressure: 3.5 to 10
Manual calibration unit: kPa
ZA8F/MC1
Calibration gas unit Dust: 50 mg/Nm3
Pressure regulator for gas
cylinder: Fuel: Gas
P/N G7013XF (inlet W22,
outlet Rc1/4) or P/N G7014XF
(inlet W22, outlet 1/4NPT)/
M1132ZX
Case assembly for calibration
gas cylinder: P/N E7044KF
Note: the calibration gas
cylinder must be purchased
locally

Pulp & Paper Excess Air/ Detector: ZR22G/CV Temperature : Black Liquor Ref section
Air Demand Probe protector: ZO21R/ 150 to 500°C Recovery d of BOILER
ZR22R Boilers application in
Converter: ZR402G TI 11M12A01-
Manual calibration unit: 01E
ZA8F/MC1
Calibration gas unit
Pressure regulator for gas
cylinder:
P/N G7013XF (inlet W22,
outlet Rc1/4) or P/N G7014XF
(inlet W22, outlet 1/4NPT)/
M1132ZX
Case assembly for calibration
gas cylinder: P/N E7044KF
Note: the calibration gas
cylinder must be purchased
locally

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 Cement Indication of Rotating Ref section a
Calcining rate, Cement Kiln, & b of
Nox Flue gas exit Ceramic,
production, from the Kiln Brick, Glass &
Increases Kiln application
product quality in TI 11M12A01-
01E

Electrical & Humidity Ensures Detector: ZR22G/SV Temperature: Inside the AN 10M01N01-
Electronics measurement product Converter: ZR402G/HS 200 to 400°C steam 01E
in Tantalum quality & yield Portable calibration unit: pyrolysis
Capacitor improvement, ZO21S/M1233SR Pressure: furnace
Pyrolysis stable 10 to 20 Pa
Furnaces continuous
humidity Humidity:
measurements 25 to 80 vol% H2O
in high
temperature
environment,
Reduces
operating costs

Pulp & Paper Humidity Increases dryer Detector: ZR22G Temperature: 50 to In the Hood AN 10M01J01-
measurement heat energy Dust protector: 120°C or the exhaust 01E
for paper dryer efficiency, ZH21/M12345E-A duct of the
control ensures high Converter: ZR402G Pressure: Negative Hood
paper quality Manual calibration unit: Dust: Trace amounts
& reduces ZA8F/Z Z: with dehumidifier (paper dust), clean
operating costs (when needed) /MC1 dry air should be
Pressure regulator for gas used for reference
cylinder: air, dust protector to
P/N G7013XF (inlet W22, be used to prevent
outlet Rc1/4) or P/N G7014XF ignition due to paper
(inlet W22, outlet 1/4NPT)/ dust
M1132ZX
Case assembly for calibration
gas cylinder:
P/N E7044KF

Note: the calibration gas

cylinder must be purchased
locally

Chemical Humidity Ensures Detector: ZR22G/SV Sample gas Steamer AN 10M01E01-

measurement stable product component: 01E
in dyeing & quality, stable Converter: ZR402G Steam: 90 to 100%;
discharge continuous air: remaining
process humidity Portable Calibration unit:
measurements ZO21S/M12335R Temperature:
in high 70 to 110°C
temperature
environment, Pressure: 10 to 30 kPa
Reduces
operating costs

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4.1 Boiler

4.1.1 Package boiler

This is the most common application. Although the

system is generally used for combustion monitoring,
there are also cases in which it will be used for VVVF
or other such combustion control schemes.

Sample point Sample type Detector Objective

Boiler furnace outlet or

L1, (L2) D1, (D2) Combustion monitoring
economizer outlet

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 4.1.2 Power generation boiler (Heavy oil, Gas)

This is a large-scale facility in which use for combustion

control is more common than for combustion
monitoring.

In cogeneration, the majority of cases involve

measurement at a single point. In electric power
companies, measurements are performed at multiple
points in a single flue.

Sample point Sample type Detector Objective

Boiler furnace outlet or Combustion monitoring

L2, L3 D1, (D2)
economizer outlet O2 control

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4.1.3 Pulverized coal boiler

These are almost always large facilities such as power

generation boilers; the zirconia oxygen analyzer is used
for combustion monitoring and combustion control.
Since the exhaust gas entrains a rather large amount
of ash dust, a detector with dust protector will be used.

Sample point Sample type Detector Objective

Economizer outlet
L2, L3 (detector with probe Combustion monitoring
(economizer, feedwater D4
protector) O2 control
afterheater)

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 4.1.4 Black liquor recovery boiler

The spent liquor in a pulp production process is

commonly referred to as “black liquor”. The sodium
carbonate and sulfate components in this black
liquor are recovered by burning it and using the heat
to generate steam. The oxygen analyzer is used to
monitor or control the combustion in the combustion
facility (boiler). Since the exhaust gas includes large
amounts of dust (hydrated sodium sulfate) and water
vapor, a detector with filter is selected.

Sample point Sample type Detector Objective

Economizer outlet
(economizer, feedwater L2, L3 (detector with filter) D3, (D4) Combustion monitoring
preheater)

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4.2 Iron and Steel Furnaces

4.2.1 Iron & steel heating furnace

These furnaces are for the heating of steel slabs,

and generally the measured gas is at a high
temperature of 1000°C or above. The oxygen
concentration is controlled to a low level to prevent
oxidation of the slabs. These are also some cases in
which there is some amount of CO in the gas, and in
which magnetic oxygen analyzers or infrared type CO
analyzers are used.

Sample point Sample type Detector Objective

Preheat zone, heating zone,

H2, H3 D5 Combustion monitoring
soaking zone

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 4.2.2 Hot blast stove (blast furnace facility)

The hot blast stove is a facility used to heat the air used
in a blast furnace to provide the high temperature hot
air blast.

The air is heated by combustion of the gas generated

from the coke ovens. The zirconia oxygen analyzer is
used to control or monitor this combustion.

Sample point Sample type Detector Objective

L2, L3
(If pressure is high, a pressure Combustion monitoring
Duct D1
compensated detector is O2 control
selected.)

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4.2.3 Coke oven facility

This facility is used to produce the coke used in the

blast furnace.

The zirconia oxygen analyzer is used to monitor the

exhaust gas from the heater combustion used for
destructive distillation of the coal.

Sample point Sample type Detector Objective

Flue L2, L3 D1, (D2) Combustion monitoring

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 4.2.4 Soaking pit

The soaking pit is a type of furnace used to maintain

the ingots at a constant temperature. Oxygen
concentration is controlled at a low level to suppress
ingot surface oxidation.

Sample point Sample type Detector Objective

Ahead of recuperator H2, (H3) D5 Combustion monitoring

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4.3 Ceramic, Brick, Glass & Cement
Furnaces/Kilns

4.3.1 Rotary type lime kiln

The zirconia oxygen analyzer is used for combustion

monitoring to conserve energy.

Careful attention to detector mounting position and

orientation is required due to the presence of large
amounts of abrasive particulates and intrusion air.

Sample point Sample type Detector Objective

L2, L3 D4
Kiln end Combustion monitoring
(H2, H3) (D3, D5, D6)

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 4.3.2 Cement kiln (cyclone outlet gas)

Cement production consumes approximately 100 liters

or more of fuel (heavy oil) per ton of cement. Thus,
combustion management by means of zirconia oxygen
analyzers has become a critical element.

There are cases in which O2, CO, and CO2

measurements are performed using a sampling system
at the kiln outlet.

Sample point Sample type Detector Objective

Cyclone outlet L2, L3 D4, (D3) Combustion monitoring

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4.4 Petroleum Refining and Petrochemical
Fired Headers

In petroleum refining and petrochemical plants fired

heaters are so numerous that you could almost say
that there is one in almost every process. Also, since
a site consists not of just a single petroleum refining
process but rather of ten or more processes, this
means that you have that many fired heaters, too
(located at the arrows in the diagram above).

In addition to the fired heaters, there will also be a

number of boilers. Thus combustion monitoring (or
control) is a vital element.

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 4.4.1 Naphtha cracking furnace

This is the first process in a petrochemical facility,

in which the Naphtha supplied from the petroleum
refinery is heated and cracked to produce a variety
of products. There will be not just one but rather
anywhere from six to twelve fired heaters, each with its
own stack.

Analyzer installation locations Sample point System type Detector Objective

L2, L3
H2, H3 D1, D2 Combustion
▬► Fired heaters Stack or convection
Explosion-proof type external D5, D6 monitoring
terminal box may also be selected

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4.4.2 Petroleum refinery process fired heater
example

There are two possible locations for the sample

point in fired heaters for petroleum refining and
petrochemicals: in the stack, or in the vicinity of the
furnace outlet (convection zone).

Sample point System type Detector Remark

Stack L2, L3 D1, D2

Explosion-proof type with terminal box
Furnace outlet may also be selected.
H2, H3 D5, D6
(convection zone)

Analyzer installation locations Sample point Temperature

1 ▬► Approx. 300 to 500oC

Stack Convection
2 ▬► Approx. 600 to 900oC

Wind Box

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 4.5 Garbage Incinerator

This is a facility to handle by incineration the

combustible waste generally contained in municipal
garbage.

The exhaust gas of the incinerator outlet contains large

quantities of dust and corrosive gases, and a large
water vapor component.

Yokogawa should be consulted concerning the

installation of the unit.

Sample point System type Detector Objective

H2, H3
Note: depending on the
Incinerator outlet
conditions at the sample D5 Combustion monitoring
(gas cooler outlet)
point, a sampling type
system may be required.

Scrubber outlet
L2, L3 D1, (D3) Combustion monitoring
(or stack)

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4.6 Non-Combustion Applications

4.6.1 Oxygen enrichment facility

Although in most combustion systems air is used

as-is, there are cases such as in blast furnaces in steel
plants where the air will be enriched with oxygen gas
to raise efficiency. When this is done, oxygen analyzers
are used to monitor the oxygen generation unit (air
separator, etc.), and/ or to check the condition of the
mixing with the air in later process stages. In these
cases, the oxygen analyzer will be measuring values
higher than the concentration of oxygen in the air
(approximately 21%).

Sample point System type Detector Objective

Oxygen supply line

H3 (Note 1) Note 2 Operational monitoring
Oxygen compressor outlet

Air-oxygen mixing line H3 (Note 1) Note 2 Operational monitoring

Note 1: Measurement will be done using a sampling system, since all the points are at high pressure.
Note 2: The high-temperature detector should be used.

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 4.6.2 Power generation boiler wind box

In large boilers such as those for power generation,

part of the combustion exhaust gas is recycled to the
combustion intake, and the oxygen concentration in
the recycled gas is monitored so that it does not drop
too low.

The analyzer range will be a partial range that includes

the atmospheric oxygen concentration, such as
15 to 22% O2.

Sample point System type Detector Objective

Wind box L2, L3 D1 (Note) O2 control alarm

Note: The ZO21DW (terminal box explosion-proof type detector; pressure compensated type) or the ZR22G (pressure compensated type) will be
used. These are many cases in which the AV550G averaging converter will be used.

Wind Box

wind box

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4.6.3 Aeration tank

In one type of sludge processing, oxygen gas is

introduced into the processing tanks to maintain the
dissolved oxygen concentration in the sludge liquid
at a proper level. Efficiency is checked by measuring
the oxygen concentration in the exhaust gas from the
processing tank.

Sample point System type Detector Objective

Exhaust line L2, L3 D1 Efficiency monitoring and alarm

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 4.7 Difficult Measurement Applications On the other hand when we come to measurement of
the gas inside the furnace, continuous measurement
4.7.1 Glass melting furnace (in-furnace gas) with a direct in situ zirconia oxygen analyzer (high-
temperature system) is either extremely difficult
Oxygen concentration in glass melting furnace stacks or impossible due to the dust and fumes from the
can be measured with no problems the same as in components of the glass. However, since continuous
other general combustion exhaust gas applications. measurements are being performed in some cases by
the method shown in the diagram, we offer this for
Glass melting furnace (stack): Temperature 0 to 600°C your reference.
System block diagram type No: L2, L3

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4.7.2 Calcination furnace 5.1 What is in an Installation Loop
Exhaust gas oxygen concentration measurement for
fluidized-bed calcination furnaces, sulfur combustion
furnaces and other such furnaces which burn sulfur-
containing materials or elemental sulfur presents
sample conditions such as the following, so direct in
situ type zirconia oxygen analyzers cannot be used for
measurement.

Corrosive gas in exhaust gas: SO2 7 to 18%

Note: The Yokogawa direct in situ type zirconia oxygen analyzers

are fully capable of measurement in exhaust gases containing SO2
concentrations up to 5000 ppm.
Fig 5.1 Illustrates an example of a complete loop interface

4.7.3 Facilities with reducing gas atmospheres

5.2 Zirconia Probe Installation
The term “reducing gases” refers to those gases
which react with metal oxides to reduce them either Proper Installation of the ZR22* needs the following:
to metal or to oxides of a lower degree of oxidation.
These gases are composed of a reducing component, • Calibration/reference gas lines should be mounted in
of which H2 is the primary example, and an inert gas a downward position to avoid moisture buildup.
component such as N2. • Calibration/Reference lines should be non-permeable
(avoid copper and some plastics, they will allow
These reducing gases are used for purposes such moisture to permeate through the line)
as protecting metal surfaces from oxidation or • Calibration gas max flow rate is 600 cc/min
decarbonization during heat treatment, or to improve • Reference gas max flow rate is 800 cc/min
certain properties. If an attempt is made to use a direct • Do not mount the probe with the tip higher than the
in situ type zirconia oxygen analyzer in such a metal probe base.
treatment furnace, the combustible gas (reducing gas) • Signal and heater cables should be installed in
and oxygen in the sample gas will incite a combustion separate conduits.
reaction like that shown below in the high-temperature • Extra Cable length should be added and coiled to
cell section (generally above 600°C), causing a negative allow ample ability for removal.
measurement error, so that measurement is generally • Shields on the signal and heater cables should be
impossible under these conditions landed on 1 end only.
• Make sure all wire lugs are tight
2CO+O2 →2CO2 • Do not splice cables. One continuous cable is
2H2+O2 →2H2O recommended.
CH4+2O2 →CO2+2H2O • Avoid grounding out the heater wires. It can damage
the electronics.
5. Installation Guide 5.2.1 Location
* This is to be used as a supplement to the Instruction The following should be taken into consideration when
Manual. For more detail information, please refer installing the detector:
Instruction Manual.*
• If there are process pressure fluctuations then the
Improper installation of the detector may cause press comp version of the zirconia probe may be
inaccurate measurement or damage in short-term needed.
service. • Before removal allow the probe to cool down
naturally to avoid thermal shock. Do not pour water
• Easy access for inspection and maintenance on the probe to speed up the process
• Ambient temperature does not exceed 150°C, and the
terminal box is not exposed to radiantheat 5.2.2 Probe Insertion Hole
• A clean environment free from corrosive gases
• Minimum vibration When preparing the probe insertion hole, the following
should be taken into consideration.

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 • Do not mount the probe with the tip higher than the 5.2.3.1 Good and Bad Example Guide
probe base
• If the probe length is 2.5 meters or more the detector Typical good/bad installation examples are shown
should be mounted vertically (no more than a 5 below for your reference
degree tilt)
• The detector probe should be mounted at right
angles to the measurement gas flow or the probe tip
should point downstream
• Documentation shows the image below indicating the
appropriate hole for each assembly type. However, this
does not take into consideration all of the products
offered globally and it is recommended that the
hole always be a minimum of 65 mm. This allows for
installation of all filter types on the first installation or
after initial installation if one needs to be added later.

Fig 5.2 illustrates an example of the probe insertion hole

5.2.3 Installation of the Detector

The following should be taken into consideration when

mounting the general-use detector:

• The cell (sensor) at the tip if the detector is made

of ceramic (zirconia); Do not drop the detector, as
impact will damage it.
• A gasket should be used between the flanges to
prevent gas leakage. The gasket material should
be heatproof and corrosive-proof, suited to the
characteristics of the measured gas
5.3 Installation of the Accessories and Parts
General-use:
5.3.1 Filters
• Make sure that the cell mounting screws (four) at the
probe tip are not loose. If a dust filter is used, make 5.3.1.1 Dust Filter (Part No. K9471UA)
sure it is properly attached to the detector.
• Where the detector is mounted horizontally, the • The dust filter is used to protect the Zirconia sensor
calibration gas inlet and the reference gas inlet from corrosive dust or a high concentration of dust
should face downward. such as in utility boilers and concrete kilns. If a filter is
used in combustion systems other than these, it may
have adverse effects such as response delay. These
combustion conditions should be examined carefully
before using a filter.
• The dust filter requires gas flow 01-1 m/sec. or faster
at the front surface of the filter (K9471UA)

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**Mount the dust filter assembly by putting it on the end *NOTE: When using the M1234SE-A Self Cleaning Fly-Ash Filter in
conjunction with the ZR22R Probe Protector, repeat the steps above,
of the detector and screw the assembly clockwise. Put a
but invert the M1234SE-A shield away from the direction of flow.
hook pin wrench (K9471UX), 52 to 55 in diameter, into the
hole on the assembly to fasten or remove it. Apply a heat-
• Tighten the clamp screw until the filter cannot be
resistant coating to the threads on the detector. When
moved by hand. The filter will be fully tightened
remounting Filter assembly after having once removed it
before the space between clamp block is completely
from the detector and reapply the heat-resistant coating
closed. THE SCREW SHOULD NOT BE TIGHTENED
BEYOND THIS POINT. Over tightening the assembly
5.3.1.2 Dust Filter (option Code “/F1”)
can damage the detector and filter.
This option is also part of the model code 01 ZR22
detector. This is a Carborundum/SUS316 filter of 30
microns used to protect the cell from corrosive dust
components or high velocity dust. This component is
must except for gas fired boilers.

5.3.1.3 Fly Ash Filter (Part No. M1234SE-A)

5.3.2 Check Valve (Option Code “/CV”)
• Slide the closed end of the filter shield over the end
of the probe approximately 9 inches. This option is part of the model code of ZR22*
detector. This Check valve should be connected at the
“Calibration In” port of the Probe head. This check
valve is nothing but a non, return valve & it ensures
that the calibration gas flows from Calibration Unit
to probe head only and there is no reverse flow from
probe head to Calibration Unit. The check valve can
be used when using either automatic calibration or
• Slide the filter element over the detector and into manual calibration.
the space between the detector and the shield
approximately 8 inches. This may be a snug fit, and If this Check valve is not installed at the probe head
might require a firm push; however, the filter should there may be back flow of process gas to Calibration
not be forced onto the detector. Unit and this process gas which consists of moisture
will get condensed in calibration gas line while coming
in contact with ambient temperature. Due to this,
during next calibration cycle this moisture will be
carried to zirconia cell. As the zirconia cell is always
heated up to 750°C, the moment moisture hits the
cell it will give thermal shock & the cell will break
immediately.

To avoid this, it is a must to select option code /CV

• Slide the end of the shield over the filter while selecting the model code. While commissioning
the analyzer, Check Valve must be installed at the
probe head before it is inserted in the stack.

Please note that a Stop valve is also available however,

it can only be used when manual calibration is being
used.

• Align the shield so it protects the filter element from 5.3.3 Probe Protector
direct gas flow. The shield should cover the filter, and
be flush with the closed end of the filter, as shown: This is essentially an SS316 sleeve connected with
SS304 flange to the Analyzer Probe. This is illustrated in
the Fig. 5.3 drawing. As the name suggests, this is used
to protect the probe from erosion. As there is a higher
velocity flow of flue gases thru’ the stack, it will cause
erosion to the probe if it is installed in the stack without
Probe Protector. Probe Protector is a consumable item
& it should be inspected at regular intervals so as to

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 check its health and if found some signs of erosion, it
should be replaced immediately. By replacing Probe
Protector which is a low value item, we are able to
safeguard our Analyzer Probe which is much costlier to
replace.

Figure 5.3 Probe Protector (Z021R/ZR22R)

5.3.4 Calibration Units

Calibration Unit (Either Manual or Automatic)

allows calibration gases to pass thru’ the cell during
calibration. It also regulates & filters the Instrument
grade air before it is flowing thru’ the Reference side of
Figure 5.4 High temperature mounting
the cell.

This is essential because if plant instrument air 5.4.2 Probe Adapter

contains the moisture, it will again give thermal shock
to the cell & will break the cell. To overcome this During analysis, the surface temperature of the probe
problem, it is advisable to use Calibration Unit. adapter should be within the range from more than
the dew point of the sample gas and 300°C or less to
The zero gas normally used has an oxygen prevent ejector clogging, gasket deterioration or bolt
concentration of 0.95 to 1.0 vol%O2 with a balance of scoring.
nitrogen gas (N2). The span gas widely used is clean air
(at a dew-point temperature below -20 deg C and free Where the dew point of the sample gas is not known,
of oily mist or dust, as in instrument air). keep within the range of more than 200°C to less than
300°C.
5.4 Installation of the High Temp Tee The temperature shall be measured at the probe in the
(ZO21P/ZR22P) probe adapter and the surface of the blind flange at
the opposite side.
5.4.1 Probe Insertion Hole
When the surface temperature is not within the above
A high temperature detector consists of a ZR22G-015 range, the following measures can be taken to change
Detector and ZO21P High Temperature Probe Adapter the temperature.
(Z021P/ZR22P). When forming the probe insertion hole,
the following should be taken into consideration: When the surface temperature exceeds 300°C

• If the probe is made of silicon carbide (SiC), the probe • When the furnace pressure is negative, lower the
hole should be formed so that the probe is mounted pressure setting to reduce induction flow of the
vertically (within ± 5° tilt). sample gas.
• In the case where the probe is made of stainless steel • Ejector Assembly for High Temperature, for the
and the probe adapter is to be mounted horizontally, setting of induction flow. When you reduce induction
the probe hole should be formed so that the probe flow, ensure that the ejector inducts air when the
tip is not higher than the probe base. furnace pressure fluctuates.

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• When the furnace pressure is positive, close the • A wall or construction should be strong enough to
needle valve for the sample gas outlet to reduce the support the weight of the converter
exhaust gas flow. • Signal and heater cables should be installed in
• Ensure that the temperature of the probe adapter separate conduits.
does not fall below the dew point of the gas in winter. • Shields on all cables should be landed on 1 end only.
• To prevent temperature rises due to radiant heat, • Make sure all wire lugs are tight.
insert heat insulator between the wall of the furnace • Do not splice cables. One continuous cable is
and the probe adapter. recommended.
• To prevent temperature rises from thermal • Avoid grounding out the heater wires. It can damage
conduction, place the mounting flange as far from the electronics.
the wall of the furnace as possible.
The following guidelines below should be taken into
When the surface temperature is less than 200°C or consideration when installation the
below the dew point of the sample gas AV550G:

• When the furnace pressure is negative, raise the The averaging converter is designed for indoor
pressure setting to increase induction flow of the installation and should be installed in the instrument
sample gas. If there is much dust in the gas, the ejector panel in a control room. For outdoor installation, the
may become clogged as induction flow increases. averaging converter should be installed in an outdoor
• When the furnace pressure is positive, open the instrument panel protected from direct sunlight and
needle valve of the sample gas outlet to increase the the weather. The outdoor site location should be
gas flow. equipped with a cooling system for controlling the
• Warm the probe adapter. internal temperature, if necessary. Also, the outdoor
• When the surface temperature is still less than 200°C case should be installed in a location that keeps the
or below the dew point of the sample gas, even if the case free from corrosive gases or dust.
above measures have been taken, warm the probe
adapter using a heat source such as steam. * For more detail information about the analyzer
installation refer to the appropriate Instruction Manuals.

5.6 Installation of the Integral Zirconia

Oxygen Analyzer (ZR202*)

It is the same as installation of ZR22G. However the

ambient temperature of the ZR202G Integrated type
Zirconia Oxygen analyzer should be between - 20°C
and 55°C.
Figure 5.5 Drawing of Ejector, P/N M1234XE
5.7 Installation of the OX400
5.5 Installation of the Analyzer (ZR402G/
Be sure to observe the following precautions when
AV550G)
connecting the gas pipe to the OX400:
Proper Installation Site of the Converter needs the
• The connections for both the gas inlet and outlet
following:
are Rc1/4 or 1/4NPT. Use the specified thread and
securely connect the gas pipe so that no leakage will
• Allows the operator to easily access/use for
occur.
inspection and maintenance.
• When screwing in the pipe, be sure to hold the inlet
• Do not mount the convertor in direct sun light.
hexagonal part in place with a wrench or the like. Not
• An ambient temperature of not more than 55°C and
doing so and using a strong force when screwing
the temperature variation should be small: the daily
in the pipe may cause the thread on the OX400 to
temperature range within 15°C is recommended.
rotate, resulting in damage to the internal pipe.
• Humidity is moderate (40 to 75% RH) and no
• With respect to piping, use a metal pipe. Use of
condensation may occur.
materials such as plastic, vinyl, rubber, and the like
• No corrosive gases are present.
may result in inaccurate measurements due to the
• No dust exists.
transmission of oxygen from the air and absorption
• There is minimal vibration.
onto the inside surface of the pipe. Particularly
• The converter should be near the detectors: the
with respect to silicon tube, be careful because
two-way resistance between detector and converter
due to its large oxygen transmission rate, accurate
should not exceed 10Ω.

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 measurements cannot be performed in the low 5.8.2 Installation of the Sampling unit (K9424GA)
concentration range.
• Be careful of leakage from the pipe because it may The sampling unit is a desktop type and should be
cause measurement errors. Particularly in the low installed on a stand near the sampling point.
concentration range, take great care because even Note the following when installing the unit. The unit
though the pressure inside the pipe is positive, should be installed in places where:
oxygen may flow from the air due to diffusion,
resulting in a large error. • Ambient temperature is in the range of 0 to 40°C and
• Fluctuations of back pressure at the pipe outlet temperature fluctuations are minimal.
may cause measurement errors, so always keep the • Mechanical vibration is negligible.
pressure at the atmosphere pressure level as much • Adequate space for inspection and maintenance,
as possible during operation. such as replacing filter element, is secured.
• The unit should be securely mounted on a stand to
prevent it falling.
• No exposure to rain or water is allowed.

The sampling unit incorporates a suction pump, which

requires power supply of 100-240VAC.; The pumps and
activated charcoal filter used in this equipment have
limited life, and periodic maintenance or replacement
will be required. Install this equipment in an accessible
location to facilitate maintenance.

Maintenance conditions vary depending on the gas

conditions. Replacement intervals for the filter and
activated charcoal should be determined in accordance
with the operating conditions.

• Used eight hours a day, pump life will be

approximately one year.
*NOTE: If no suction device [-N] is specified, the aspirator is removed • Filter life is about 50 hours. (if measured gas contains
from this diagram. Refer to sec. 6.4 in IM when using aspirator. isopropyl alcohol of concentration 500 ppm, and flow
is 500 ml/min.)
5.8 Installation of the OX100/ OX102
6. Selection Guide
5.8.1 Installation of the Sensor

Use the nipple provided as an accessory, mount it

6.1 Oxygen analyzer selection flow chart
horizontally and secure it so that it cannot vibrate.
The Oxygen Product Selection Guide is designed to
assist you in the selection of the appropriate oxygen
• When tightening, for cap use torque of 1 to 1.5 Nm,
analyzer system for your application. To make the most
and for other items use torque of 2 to 2.5 Nm.
appropriate selection, you will need to know a few
• Sensor cable should be within 30 cm of sensor
things about your application such as temperature,
housing, and angle of bend (see figure below) should
pressure, flow-rate, and area rating. If you should find
not be greater than 60°.
that your application requires equipment beyond what
• When mounting sensor through a 17 mm hole,
is shown here, please fill out the application data sheet
mounting plate should be no greater than 4 mm
at the back of this document and forward to your local
thick.
Yokogawa representative.

To use this guide, begin with the Oxygen Analyzer

selection and follow the flow charts to build your model
codes as you answer “yes” or “no” questions.

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 ZR series

TDLS8000

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 TDLS8000

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6.2 System configuration

This section includes two types of system selection

guides for direct in situ zirconia oxygen analyzers.
The reader should refer first the examples of system
selection by application, and then examine the system
block diagram and component device overviews.

6.2.1 ZR402G/ZR22 Direct In Situ Zirconia Oxygen

1) System Selection Examples, by Application

General-purpose detector (0 - 700°C) High-temperature detector (700 - 1400°C)

Application
System types Detector System types Detector

Boiler (fuel oil, gas) L1, L2, L3 D1, (D2) H2, H3

Boiler (pulverized coal,

Common L2, L3 D4 H2, H3
fluidized bed)

Boiler (bark, wood scrap) L2, L3 D3, (D1) H2, H3

Heating furnaces &

L2, L3 H2, H3 D5
soaking pits

Hot blast stove L2, L3 D1 H2, H3

Iron & steel
Coke ovens & annealing
L2, L3 D1, (D2) H2, H3 D6, (D7)
furnaces

Sintering furnace L2, L3 D1, (D4) H2, H3

Non-ferrous Heating, sintering &

L2, L3 D1, (D4) H2, H3 D5, (D6)
metals melting furnaces

Coal kilns (rotart &

L2, L3 D4, (D3) H2, H3 (D5, D6)
vertical)

Cement kilns (cyclone

L2, L3 D4, (D3) H2, H3
outlet)
Ceramic, brick,
glass & cement Glass melting furnaces
L2, L3 H2, H3 D5, (D6)
manufacture (inside furnace)

Glass melting furnaces

L2, L3 H2, H3 D5, (D6)
(flue)

Ceramic firing furnaces L2, L3 H2, H3 D5, (D6)

Petroleum/ Fired heaters & cracking

L2, L3 D1, (D2) H2, H3 D5, (D6)
Petrochemical furnaces

Black liquor recovery

Pulp & paper L2, L3 D3, (D4) H2, H3
boilers

Electrical generating
L2, L3 D1 H2, H3
boilers (window box)

Garbage & sludge

Other L2, L3 D1, D3 H2, H3 D5
incinerators

Oxygen enrichment
L2, L3 H2, H3 D7*
equipment

The meanings of these codes are explained on the pages that follow.

Note 1: Sampling system is required due to the high pressure.

The symbol such as L1 and D1 used in “the Types of System Configuration and Detector” are only applicable in this Technical Information
document for quick reference. They do not appear in other literatures including the bulletin, general specifications, or user’s manual.

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 2) System Block Diagram Types

System Type

Simple Type General Type

System Type No. Detector Remarks
Manual Automatic
—
Calibration Calibration

L1 General-purpose o x x using ZO21S standard gas unit

L2 General-purpose x o x using instrument air & zero gas cylinder

L3 General-purpose x x o using instrument air & zero gas cylinder

H1 High-temperature o x x using standard gas unit

H2 High-temperature x o x using instrument air & zero gas cylinder

H3 High-temperature x x o using instrument air & zero gas cylinder

O: Yes, X: None

6.2.2 Selection According to Use

Available model accessary table

Accessary Model Code

High temperature probe adapter ZO21P-H or ZR22P

Auto calibration unit ZR40H or IAC24/AC1

Please check the general specification which model is availabale in your area.

(1) Type: L1 (simple measurement system)

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 6.2.3 Examples of System Component Selection Based on Sample Gas Conditions

(1) Detector and Accessories

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 (2) Converter and accessories (flow setting unit, calibration gas, etc.)

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6.3 Compatibility between Old and Existing Models

Existing Model Old Model

Converter
ZR402G ZA8C, HA400, AV8C
Detector

Existing Model ZR22G Compatible Compatible with modifications (Note)

Old Model Z021D Compatible Compatible

Note: Compatibility can be achieved by replacing the ROM and mounting a cold junction temperature compensation board. It is recommended
that this modification be requested to our service station. Applicable ROMs and temperature compensation boards will be available on
December 1, 2000 for order entry and on January 26, 2001 for shipment. See the table below for ROM part numbers. The part number of a ROM
extraction tool is K9471JT, and the part numbers of cold junction temperature compensation boards are K9471JA for the ZA8C and HA400 and
K9471JB for the AV8C.

Language
Japanese English German French
Model

ZA8C K9290LF K9290KF K9290MF K9290MG

HA400 (kg) K9293HT K9293HU K9293HW K9293HV

HA400 (%) K9293HP K9293HQ K9293HS K9293HR

AV8C K9296CN K9296CN K9296CN K9296CN

7. Basic Steps for Maintenance and If the sensor becomes no longer operable (for
example, due to breakage), investigate the cause and
Trouble Shooting remedy the problem as much as possible to prevent
recurrence.
7.1 Maintenance for ZR22 and ZR202
Please note that is it important that the contact and the
7.1.1 Cleaning the Calibration Gas Tube metal o-ring are replaced each time the cell is replaced
to ensure proper sealing.
The calibration gas, supplied through the calibration
gas inlet of the terminal box into the detector, flows • Clean contact spring groove & probe flange.
through the tube and comes out at the tip of the probe. • Insert new contact spring
The tube might become clogged with dust from the • Place Metal o-ring on/between cell and flange
sample gas. If you become aware of clogging, such • Insert J-tube into filter retainer.
as when a higher pressure is required to achieve a • Install filter onto J-tube (between cell and retainer)
specified flow rate, clean the calibration gas tube. • Install washers on cell bolts.
• Install cell, retainer, and filter assembly into probe
flange.
• Finger tighten all 4 cell bolts
• Tighten all 4 bolts in a criss-cross pattern to 52 in. lbs.
(1/8 turn at a time)

Figure 7.1 Cleaning the Calibration Gas Tube

7.1.2 Replacing the Sensor Assembly

The performance of the sensor (cell) deteriorates as its

surface becomes soiled during operation.
Therefore, you have to replace the sensor when its life
expectancy expires, for example, when it can no
longer satisfy a zero correction ratio of 100 ± 30% or a
span correction ratio of 0 ± 18%. In addition, the
sensor assembly is to be replaced if it becomes
damaged and can no longer operate during Figure 7.2 Exploded View of Sensor Assembly

measurement.

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 7.1.3 Replacing the Heater Assembly closed. THE SCREW SHOULD NOT BE TIGHTENED
BEYOND THIS POINT. Over tightening the assembly
Replace the heater assembly when the heater is can damage the detector and filter.
broken. For more details, please refer IM

7.1.4 Replacement of Dust Filter

Set the dust filter in place using a special pin spanner

(with a pin 4.5 mm in diameter: part no.K9471UX
or equivalent). If a dust filter that has already been
replaced once is used again, apply grease (Never-Seez:
G7067ZA) to the threads of the dust filter.
7.1.6 Replacement of O-ring
7.1.5 Replacement of the Fly Ash Filter
The detector uses three different types of O-rings. (For
a pressure compensating model, two O-rings are used
• Slide the closed end of the filter shield over the end
for individual uses. Two O-rings are used for reference
of the probe approximately 9 inches.
gas sealing and require periodic replacement. For more
details, please refer to the IM.

7.2 Calibration

There are 3 modes of calibration:

• Slide the filter element over the detector and into
the space between the detector and the shield • Manual calibration: You manually step through the
approximately 8 inches. This may be a snug fit, and calibration. This mode allows you to change
might require a firm push; however, the filter should • Semi-auto calibration: This mode is a “one touch”
not be forced onto the detector. calibration mode. In the semi-auto calibration mode
you just start the calibration and it does everything
else. You have to set the calibration, hold times,
calibration gas values previous to using this mode.
• Auto-Calibration: You set the start date, time,
frequency, calibration time, hold times and the
analyzer does calibration on its own.

• Slide the end of the shield over the filter It is important to note that before you can run
automatic calibration or semi-automatic calibration,
you have to configure the calibration setup for the Hold
time and Calibration time in the instruments before
you can run a semi-auto or an auto-cal.

• Hold Time: The time you want the probe to hold

before it releases the current output. (so the
Align the shield so it protects the filter element from calibration gas can clear the probe and be back to
direct gas flow. The shield should cover the filter, and process measurement)
be flush with the closed end of the filter, as shown: • Calibration time: Set this to allow ample time for the
calibration gas to flow from the calibration system to
the probe and stabilize

All of the calibration modes output calibration signals

through the calibration contacts and send the output
thru relay contacts.
*NOTE: When using the M1234SE-A Self Cleaning Fly-Ash Filter in
conjunction with the ZR22R Probe Protector, repeat the steps above,
but invert the M1234SE-A shield away from the direction of flow.

• Tighten the clamp screw until the filter cannot be

moved by hand. The filter will be fully tightened
before the space between clamp block is completely

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7.2.1 Best Practices for Calibration Anytime there is a failure on the AV550 or the ZR402
the units will shut the probe heater down immediately.
When performing a calibration it is important that you: These failures will show an X on the ZR402/AV550
screens.
• Wait minimum 1 hour after powering a probe up to
calibrate. Things that cause a failure:
• Calibration gas flow should never exceed 600 cc/min
(0.6 l/min). • Cell voltage goes outside limits (excessive high or
• Clean/Dry instrument air is used as the typical span low)
gas. • Heater goes below 730°C or above 780°C
• Zero gas should be between .0.1-4% oxygen balance • CPU/Eprom function failure
nitrogen. Do not use mix bottles or 100% nitrogen for • Zero calibration failure
zero calibration. (1% and 2% are the 2 most common • Span calibration failure
used gases)
• Use ZR20-CAL or equivalent gas bottle which includes Please note that when testing your system it is always
regulator and flow control (0.5 l/min) good practice to start with any tests that can be
• Calibration should be performed at operating performed in the analyzer. If the analyzer tests fine
conditions. then check the probe next. If the probe test good then
• When you calibrate the Zirconia outside the furnace, you know the cable is bad and should be replaced.
you need to use only one standard gas and use Also when turning power off to the analyzers it is never
ambient air as second gas. The concentration recommended to use the fuses. Always use either the
depends on humidity and temperature: electronics or a breaker. Using the fuses could cause a
typically 20.5 vol%. short in the instrument.
• If the furnace operates under pressure different from
atmosphere you make an error on reading that is the 7.3.1 Error and Alarm
same as the relative pressure difference.
( -20 mbar = -2% of reading). When the display shown in Figure 7.3 or Figure 7.4
appears, pressing the error indication brings up a
7.2.2 Calibration of the Humidity Analyzer description of the error. The content of errors that are
displayed includes those shown in Table 7.1.
The Humidity analyzer cannot be calibrated with
Humidity standards, but will be calibrated as every
other Zirconia analyzer with a 1% Oxygen in Nitrogen
standard gas and with dry instrument air as second
standard.

7.3 Trouble Shooting

When troubleshooting it is important to know

and understand the following because 90% of the
problems are solved without soldering , adjustment or
initialization.

• Ask the questions

◦◦ Problem description?
◦◦ Serial number, Software revision
◦◦ Known or New problem?
◦◦ Old or New installation?
◦◦ Process conditions ( Pressure, Temperature,
Flow rate, Dust/Solids concentration, Process
composition)
◦◦ Display reading? before and after running defaults Figure 7.3 Display on ZR402G

◦◦ Diagnostic information? before and after running

defaults
• Understand the application
• Understand the installation
• Understand the customers’ expectations Figure 7.4 Display on ZR202

• Analyze the problem or complaint.

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 Table 7.1

Error Code Error Type Occurence Conditions

Error1 Cell voltage failure The cell (sensor) voltage signal input to the converter falls below -50 mV.

Error2 Heater temperature failure The heater temperature does not rise during failure warm-up, or it falls
below 730ºC or exceeds 780ºC after warm-up is completed.
Or this occurs if the TC+, TC- thermocouple terminals are wired to
converter with reverse (wrong) polarity.

Error3 A/D converter failure The A/D converter fails in the internal electrical circuit in the converter.

Error4 Memory failure Data properly are not written into memory in the internal electrical
circuit in the converter.

When an alarm is generated, the alarm indication

blinks in the display to notify of the alarm. Pressing the
alarm indication displays a description of the alarm.

Alarms include those shown in Table7.2. If an alarm

is generated, actions such as turning off the heater
power are not carried out. The alarm is canceled when
the cause of the alarm is removed.
Table 7.2 Types of Alarms and Reasons for Occurrence

Alarm Code Alarm Type Occurrence Conditions

Alarm 1 Oxygen concentration alarm Measured oxygen concentration value exceeds or falls below the
preset alarm limits.

Alarm 6 Span-point calibration coefficient alarm In automatic or semi-automatic calibration, zero correction ratio is
outside the range of 100 ±30%.

Alarm 7 Span-point calibration coefficient alarm Span correction ratio is outside the range of 0±18%

Alarm 8 EMF stabilization timeup alarm In automatic or semi-automatic calibration, cell voltage does not
stabilize after calibration time is up.

Alarm 10 Cold junction temperature alarm Temperature of the cold junction placed in the detector terminal
box falls below -25ºC or exceeds 155ºC.

Alarm 11 Thermocouple voltage alarm Generated when thermocouple voltage exceeds 42.1 mV
(about 1020ºC) or falls below -5 mV (about -170ºC).

Alarm 13 Battery low alarm Internal battery needs replacement.

7.3.2 Basic Zirconia Probe Check the other) checks out like a diode. One direction is
high resistance (typically in the MΩ) then the other
Ohm Meter Checks: direction will be open.
• Typical failure will have resistance both directions or
• Heater : 57-85Ω (typical is 62-67Ω). short.
• Typical failure is Open or shorted
• TC : if the probe is on the bench less than 3Ω, in the 500Vdc Insulation Meter Checks (Aka: Megger/
stack and hot less than 100Ω(it is a type K TC) Insulation Tester):
• Typical failure is open or short to the case.
• Cell negative wire to the case. It should be a direct Be sure there are no wires attached to probe before
short to the case. doing this test. The unit must be disconnected from the
• Failure would be above 5Ω or intermittent/erratic cable and analyzer.
readings.
• TC + to the case. Should be 20M+
Cold junctions: • TC – to the case. Should be 20M+
• Cold Junction + to the case. Should be 20M+
• RTD type (red/black or red/white wire) approx 1100Ω, • Cold Junction – to the case. Should be 20M+
no polarity (2 wire PT1000 RTD) . • Both sides of the heater to the case. Should be 20M+
• Typical failure is Open or shorted.
• Transistor type (silicon mushroom cap with 2 wires
and a metal table to one side, and a single wire to

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Additional Checks: 7.3.4 My detector is reading a high O2 level

• If you have the O2 cell out of the probe you can check • The measuring gas pressure becomes higher:
the Cell+ wire using an ohm meter. Measure between When the process pressure increases the oxygen
the Cell+ terminal and the groove where the contact reading will be higher. Certain steps should be taken
spring is. The reading should be less than 3 ohms. to ensure a proper measurement.
• With the O2 cell out you can also check the Cell+ to ◦◦ Can improvement in facility be made so that
case/ground using a 500 Vdc Megger. The reading pressure change does not occur?
should be 20M+. ◦◦ Can the probe be calibrated at process pressure?
• You can check the Cell- wire inside the probe head, ◦◦ Change the Oxygen Probe to a Pressure
make sure cell- is connected the body of the probe. compensating model
Should be less than 3 ohms (this is testing the short • Moisture content in a reference gas changes
brown-ish wire that runs from the cell- to the case). (increases) greatly:
• If you have the cell out you can pressure test the If ambient air at the detector installation site is used
calibration line. Flip the O2 cell over and put a piece for the reference gas (convection sourced), a large
of rubber between the cell flange and calibration change of moisture in the air may cause an error
line outlet. Then connect a pressure gauge to the in measured oxygen concentration value (vol% O2).
calibration line input, apply a couple PSI to the line, When this is the case, use a gas in which moisture
shut the inlet pressure off, the calibration line should content is constant such as a clean dry instrument air
hold the line pressure for 5-10 minutes easily or a bottled gas source such as a 21% O2 balanced in
Nitrogen.
7.3.3 Testing O2 Cell • Calibration gas (span gas) is mixing into the cell
due to leakage:
The base test procedure for testing an O2 cell is as If the span gas is mixing into the cell due to leakage
follows: as a result of failure of the valve in the calibration
gas tubing system, the measured value shows a
• Turn the power off to the analyzer value higher than normal. Check valves (needle
• Remove the cell + & - wires from the analyzer/ valves, check valves, solenoid valves for automatic
channel card. calibration, etc.) in the calibration gas tubing system
• Place a short between the Cell + & - on the analyzer/ for leakage. For manual valves, check them after
channel card. confirming that they are in fully closed states. In
• Apply power the analyzer. The unit should warm up addition, check the tubing joints for leakage. Plug off
without error. If the unit comes up with a cell failure calibration line at the back of probe. If problem goes
the electronics/ channel card is bad. away find the leak in the calibration system.
• Connect a millivolt meter to the 2 wires you just • The reference gas is mixing into the process gas
removed. and vice versa:
• Apply Zero and/or Span calibration gas (500 cc/Min). Since the difference between oxygen partial
Measure the loose wires at the electronics. pressures on the cell anode and cathode sides
◦◦ Span Gas (instrument Air) should read close to 0mV becomes smaller, the measured value shows a higher
(+/- 5 mV) value. Process gas and/or the reference gas may be
◦◦ Zero Gas Should read as follows: leaking. Visually inspect the cell. If any crack is found,
0.4% O2 – 84 mV’s (75-90 mV’s) replace the cell assembly with a new one.
1% O2 – 67 mV (55-70 mV’s) • Cracked O2 cell:
2% O2 – 52 mV’s (45-55 mV’s) To test run calibration, apply zero gas at 500cc/min
*Please note that the different ranges are given max. See if reading is stable and correct, if not stable or
to accommodate for negative or positive process it is reading high it is likely the cell is cracked. If the cell
pressure* is leaking then you will start to see the O2 level climb.
• If the voltages are not stable or not within those The time before you see this climb depends on the
ranges go to the back of the ZR22G and remove the distance form the gas source, it could take 15-30 min.
Cell + and Cell – wires from the probe. • Damaged calibration line/Manifold:
• Then apply both gases again and measure the Remove O2 cell. Plug end of calibration line (You can
millivolts on the ZR22G terminal Cell + and flip the O2 cell over, place a small piece of rubber in
Cell –. If the signals are correct there but not at the between the cell and flange and install the cell to
electronics, you have a problem with your cable. If plug off the line). Apply a approximately 1 PSI to the
the signals are not correct at the back of the probe calibration line, shut the pressure off and see if it
you most likely have a broken/damaged O2 cell. holds pressure.

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 • If using the High Temp Tee: • Excess moisture in process:
◦◦ The Eductor (Ejector) could be Plugged therefore If excessive moisture is in the process it can come in
needs cleaning or replacement. contact with the O2 probe (750°C) and cause steam
◦◦ The Eductor (Ejector instrument air pressure right at the O2 cell. If you have excessive steam at the
could be set to low. –Verify air pressure is set high O2 cell it will read low, as well as possibly damage the
enough O2 cell.
• If using the High Temp Tee:
7.3.5 My detector is reading a low O2 level ◦◦ The Eductor (Ejector) could be Plugged therefore
needs cleaning or replacement.
• The measuring gas pressure becomes lower. ◦◦ The Eductor (Ejector instrument air pressure
When the process pressure decreases, the oxygen could be set to low. –Verify air pressure is set high
reading will be lower. Certain steps should be taken enough
to ensure a proper measurement.
◦◦ Can improvement in facility be made so that 7.3.6 Other Abnormal Values
pressure change does not occur?
◦◦ Can the probe be calibrated at process pressure? • Noise may be mixing in with the converter from the
◦◦ Change the Oxygen Probe to a Pressure detector output wiring.
compensating model ◦◦ Check whether the equipment is securely
• Moisture content in a reference gas changes grounded.
(decreases) greatly. ◦◦ Check whether or not the signal wiring is laid along
If ambient air at the detector installation site is used heater cables or other power cords.
for the reference gas (convection sourced), a large • The converter may be affected by noise from the
change of moisture in the air may cause an error power supply.
in measured oxygen concentration value (vol% O2). • Check whether or not the converter power is supplied
When this is the case, use a gas in which moisture from the same outlet, switch, or breaker as other
content is constant such as a clean dry instrument air power machines and equipment.
or a bottled gas source such as a 21% O2 balanced in
Nitrogen. 7.3.7 Experiencing Erratic Reading
• Calibration gas (zero gas) is mixed into the cell
due to leakage. • Be sure heater and signal wires are in separate
If the zero gas is mixed into the detector due to conduits.
leakage as a result of failure of the valve provided • Flow zero gas at 300-500 cc/min on probe. If reading
in the calibration gas tubing system, the measured continually drifts up the O2 cell is cracked.
value shows a value lower than normal. Check valves • Perform a calibration
(needle valves, check valves, solenoid valves for ◦◦ If readings are unstable and calibration fails see cell
automatic calibration, etc.) in the calibration gas troubleshooting.
tubing system for leakage. For manual valves, check ◦◦ If unit calibrates correctly the problem is outside of
them after confirming that they are in fully closed the probe.
states. • Possible causes of erratic readings outside the probe:
• Combustible components exist in the measured ◦◦ Excess moisture in high temp tee (or condensing
gas. moisture in process)
Clogging at the cell can occur if residual combustibles ◦◦ Pockets of un-burnt hydrocarbons in process (this
are present (carbon build up). If combustible will cause low spikes)
components exist in the measured gas, they burn in ◦◦ Turbulence in process flow (turbulent pressure)
the cell and thus oxygen concentration decreases.
Remove the probe and clean the cell. Check that 7.3.8 Probe Temperature low and not warming up
there are no combustible components.
• Bad O2 cell: • On an AV550 If the probe fails to warm up turn off
Run calibration. If cell resistance is above 200Ω and reset the channel. On the ZR402G recycle the
replace the cell. power to the analyzer.
• Leak in calibration system (zero gas): • Unwire the Heater, TC, and CJ and perform the ohm
Plug off calibration line at the back of probe. meter check on the Heater, TC, and CJ.
If problem goes away find the leak in the zero
calibration gas side of the calibration system. If you find a failure in one of the above, go to the back
• Excess hydrocarbons: of the probe and check them inside the probe housing.
O2 probes control at 750°C, If the process has If there is not failure in the probe housing, but there
excessive hydrocarbons (un-burnt fuel) they can burn is one at the electronics the problem is in the cable.
on the tip of the probe consuming the oxygen at the Therefore if all the values check out in the probe then
tip of the probe and making the reading go low. you need to check out the electronics.

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• Reconnect the wires from the heater, TC, and CJ. AV550
• Then reset the analyzer/channel, measure the • Be sure that the heater and signal cables are landed
voltage going to the heater. It should be 60-120Vac on the correct card/heater connection. If a pair of
(Voltage is a modulated voltage but can be measured heaters is criss-crossed it can cause this.
as AC) • On an AV550 try swapping a working channel card
• If power is not present check the fuses. On the AV550 with the channel in question. If a different card works
they are on the power unit (just above where the properly it is a bad channel card.
heater wires up). There are 2 fuses per channel. On • Swap probe to a working channel. If it works on a
the ZR402Gthey are on the board. new channel and not on the old channel the power
unit is damaged.

7.3.10 High Impedance Reading (Zirconia cell &

contact resistance & lead resistance)

• Zirconia cell chemically attacked

• Zirconia cell broken
• Contact spring corroded
• Spring groove corroded
• Platinum wire between flange and cell damaged

7.3.11 Short Sensor Life

• Corrosion by flue gas

◦◦ Check for dust in sensor
◦◦ If dust is found, then burning dust corrodes sensor
surface: Platinum peels off
ZR402G ◦◦ Then use probe protector or probe adapter
◦◦ Flyash filter will also improve lifetime.
• Problem can be caused by corrosion of contact
spring and contact groove. Corrective action is to
polish groove and replace spring every time sensor is
replaced.

7.3.12 Short Heater Life

• Heater life is determined by number of start-up’s

rather than service life.
• Use step-down transformer if frequent start-up
cannot be avoided.
AV550G • 230 VAC is more burdening the heater than 100 VAC
by high peak voltages during start-up.
7.3.9 Probe Temperature Too High • If heater life is too short and there is no visible
corrosion, then please report. We may get you free
This is for if your probe starts up and it goes to 780°C replacement.
and shuts down
7.3.13 Automatic Calibration Panel, Model AC8
• Check your wiring. Make sure AC power is not wired
directly to the heater. If your AC8 solenoids all fail to work but work in
• Check to be sure both heater wires are running up to manual mode check the fuses. Also check to be sure
the heater (the heater is a floating ground heater and there is a Jumper from the PS to PS terminals.
should not be grounded anywhere)
• Do the base ohm/megger checks.

ZR402G
Measure the heater voltage as the probe warms up.
You should see the heater voltage change and attempt
to regulate above 730°C. If the voltage does not
change until it hits 780°C the electronic control circuit is
damaged.

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 8. Zirconia Analyzer – Question & Q4. What happens if sample gas contains corrosive gases
like HCl, SO2, SO3, H2S, Cl2, NH3?
Answers
A4. Generally these gases are to be avoided since these
8.1 Application react with Zirconia element & attack the Platinum
electrode which will lead to erroneous readings, large
Q1. When to select Zirconia principle for measuring zero/ span drift, long response time.
Oxygen?
Our Zirconia sensor has much resistance to the above
A1. Zirconia is the measurement of choice when direct gases compared to our competitors & also have special
measurement without sampling system is used with alumina coated Platinum electrode. We can handle
a high speed of response for process control. The SO2 – 5000 PPM, NO-1000 ppm, HCL 50 PPM. Corrosion
most common application is for combustion control from SO2 will be more severe when the Oxygen
of boilers, heaters or furnaces. Also for the indirect concentration is low. Combustion of low quality fuel (
measurement of moisture in air-water vapour mixtures high Sulphur) will shorten the lifetime of the sensors
in applications where high temperatures and dirty
environment prevent the use of traditional moisture Special care need to be taken for Incinerators as they
analyzers. may have high amount of these unwanted gases! In
these applications often high concentrations of HCl
Q2. When Zirconia Principle cannot be used? are present in the flue gas together with high water
concentrations. This does not only shortens the lifetime
A2. Zirconia uses a sensor at high temperatures and of the sensor, but condensation on the detector
Platinum electrodes. Therefore the Zirconia cannot be surface causes corrosion of the Stainless Steel body.
used in applications where Hydrocarbons are present Application of a corrosion protection like a coating of
or possible. These Hydrocarbons react with Oxygen at Derakane on the detector are a good solution for these
the sensor surface and this causes measuring errors application.
( low readings) and in worst case explosions: The
sensor acts then as an ignition source: for explosions Q5. What happens if sample contains combustible gases
you need Fuel, Oxygen and Ignition. This makes a like Hydrogen, CO or Methane ?
Zirconia analyzer a hazard in any gas fired furnace
or heater during start-up conditions or shut down A5. The oxygen concentration to be measured
conditions, when explosive gas mixtures can occur in decreases! When we look at these examples we can
the furnace or heater. Only when safety devices are roughly calculate the measuring errors when these
used that purge the sensor and shut off the power gases react with Oxygen on the surface of the sensor:
to the heater during these hazardous conditions the
Zirconia analyzer can be used safely. The flame arrester 2 H2 + O2 >> 2 H2O
used in the ZR22S and ZR202S only offer some added 2 CO + O2 >> 2 CO2
safety when the sample gas is within the ambient CH4 + 3O2 >> CO2 + 2 H2O
temperature limits of the product ( max 55 or 60°C)
So when the Oxygen concentration is 3 vol% and the
Q3. Why is CO Analyzer needed for combustion concentration of CO is 1 vol%, then the reading will be
measurement? 3- 0.5*1 = 2.5 %. The error is -0.5 vol%

A3. Every combustion process is performed with an If the concentration of Methane is 1 vol% then the
excess of air. This is necessary because burners are not reading will be 3 – 3*1 = 0 vol% Here the error is -
ideal and cannot operate purely under stoichiometric 3 vol%
conditions. The excess air may not be too high, because
then efficiency of the burner drops and pollution will This is a simplified explanation, because diffusion
result from the formation of Nitrous oxydes. The only rate of the gases is also important and this makes the
method to be sure that the burners operate at optimal measuring errors in presence of Hydrogen much more
condition is to monitor the CO concentration. If the severe.
excess air ratio is too low, CO concentrations will rise.
Q6. Till what sample temperature Zirconia probe can be
Our Laser Analyzer model TDLS8000 can measure CO used ?
very accurately at combustion zone where it is to be
measured A6. Sample temperature can be up to 700°C for normal
configuration of probe. The sensor temperature
is controlled at 750°C, so the sample gas must be
lower. Otherwise an accurate temperature control of

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the sensor is not possible. At high temperatures the
Stainless Steel will also show increased corrosion,
so the normal detector can be used till 600°C where
between 600 and 700°C the use of Inconel mounting
screws is recommended. The ZR22S and ZR202S use
flame arresters of sintered stainless steel so they
should not be used at temperatures above 500 degrees
to avoid blockage of flame arrester by corrosion. When
using Zirconia Oxygen Analyzer, what kind of matters
that require attention (effects of flammable gas) are
there?

The sensor (zirconia element) is heated to 750°C

during measurements. If the process gas contains
combustible gases such as carbon monoxide,
hydrogen, and methane, these gases burn in the Q8. Pressure compensation function
detector and consume oxygen, causing the oxygen
concentration measured by the oxygen analyzer to A8. If the in-furnace pressure is high or there are
be smaller than the actual value. Therefore, zirconia variations in the in-furnace pressure, the pressure
oxygen analyzers should be used only when the effect balance between the inside of the furnace and the
of coexisting combustible gases can be ignored or reference air is lost, making it difficult to measure
when their effect on oxygen concentration can be the oxygen concentration accurately. The Zirconia
corrected. analyzer does not measure the Oxygen concentration,
but the partial pressure of Oxygen. If the pressure on
Generally, exhaust gases after combustion that are both sides of the sensor is equal, then we can simply
emitted from combustion equipment such as boilers calculate the concentration from the output voltage of
and industrial furnaces have been completely burned; the sensor. If the pressure in the furnace is -100 mbarg,
the volume of combustible gases such as carbon then the measurement will read 10 rel% too low, if
monoxide is very small in comparison with oxygen, the analyzer is calibrated when there was no pressure
and so their influence can be ignored. However, if the difference. For example when the analyzer is calibrated
excess air ratio is extremely small or if combustion in the workshop. If the pressure in the process
is non-uniform, causing carbon monoxide to be fluctuates and is causing errors that are unacceptable
produced, care is required. for the user the detector’s pressure compensation
function can be used to return the reference air to the
Q7. How does the humidity in reference gas (air) influence it? furnace to maintain the pressure balance between the
inside of the furnace and the reference air side.
A7. Zirconia oxygen analyzers use a gas whose oxygen This enables reliable measurements to be made.
concentration is known and always consistent, as the This function allows in-furnace pressures of up to
reference gas. 250 kPa to be measured.

In general, air is used as the reference gas. The oxygen

concentration of dry air is constant at 20.95%; however,
air generally contains water vapor, in which case the
oxygen concentration varies with temperature and
humidity. For example at ambient temperature of 40°C
and 100 % relative humidity the Oxygen reference
concentration is only 19 vol%.

In zirconia oxygen analyzers, a measurement error is

caused if the temperature or humidity of the reference
gas (air) varies significantly between calibration
and measurement. If the analyzer is calibrated with
instrument air as reference and installed with ambient
air natural convection configuration the Oxygen
Pressure compensation function
readings will read (21-19)/19 = 10 rel% too low. When
instrument air is used as the reference gas, this
It is very important that a check valve is mounted in
error can be ignored, but if it cannot be used, care is
the pressure return line. Otherwise there is a risk of
required.
blow back, when the reference air supply fails or when

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 there is some leak like improperly sealed cover or cable calibration, the cell expected life time is displayed in
glands: the over pressure will cause the sample gas the display. Points of consideration are cell resistance,
to enter the detector and as result the readings will zero and span ratio and in case of autocal installations:
be wrong ( much too high) and the detector internal response time.
components will be severely attacked by the hot flue
gas. Q4. How to know the cell is no longer functional?

8.2 Installation A4. Cell robustness value after every calibration can
indicate the cell life! The cell response time during
Q1. Where to install the Oxygen probe? calibration also slows down if the cell is deteriorating
provided the calibration gas path etc is taken into
A1. If Oxygen reading is used for Trimming control, account for the response time ! In worst case the sensor
location close to the combustion zone is desirable, but will show E1 error message and this indicates either
the temperature & oxygen concentration distribution that the sensor is broken or that the sensor is corroded
should also be considered. Better to go with customer so badly that the calibration cannot be successfully
recommendation on the location. Important is to install performed.
the Oxygen probe at a location that the dirty fluegas
cannot come in contact with the Zirconia sensor. Probe Q5. Explain the precautions when shutting down a furnace
protectors, probe adapters, filters and generally vertical or boiler.
mounting are possibilities to improve the situation
Make sure that regardless of the selected detector A5. If operation of the zirconia oxygen analyzer
model the access hole for the Oxygen probe is always 65 is stopped during plant shutdown, moisture may
mm diameter or more. condense on the detector’s probe in contact with gas,
causing dust to adhere to it. If operation is restarted
Q2. How far can the converter be located from the in this condition, dust on the sensor will become
detector? firmly adhered and severely affect its performance. In
addition, if condensed water accumulates, the sensor
A2. It depends on the size of the wire the distance to may be broken by heat shock, making the analyzer
be limited to the loop resistance of the wire does not unusable.
exceed 10 ohms. Rule of thumb is if the wire is 2 sq mm
– can go up to 500 meters When stopping the zirconia oxygen analyzer, it is
important to do the following:
8.3 Maintenance
• Keep on supplying power to the zirconia oxygen
Q1. How often Calibration is required? analyzer.
• Purge the sensor by a continuous flow of instrument
A1. Typical interval is 1 to 3 months depending on the air through the calibration pipe.
application, It is recommended to do the calibration • If it is impossible to keep on supplying power to the
every 2 weeks immediately after new installation. analyzer remove the detector from the system.
When this shows that the sensor does not drift in • If the process is shut off and the gas is non corrosive
this application the period can be extended. If the ambient air, then you can keep the detector without
sensor drifts in between these calibration intervals the power and purged with instrument air: both cal gas
installation must be reviewed carefully to improve the and ref gas connection.
performance. Sensors are expensive, so the user needs Note: If the process is running, but the Zirconia analyzer is not kept
to pay attention to a proper installation to get good under power, then condensation on the detector may seriously
performance and low cost of ownership. corrode the detector, even if the cal and ref connections are purged.

Q2. How can I clean the fly ash filter M1234SE-A? Never connect power to the analyzer before the
calibration pipe and sensor are properly purged
A2. They can remove the filter and use water and
vinegar to clean the filter. Allow it to dry completely Q6. Notes for when running and stopping the analyzer
before returning it to the probe. repeatedly on a regular basis

Q3. How long will the Zirconia cell last? A6. From previous question it is clear that frequent
running and stopping of the Zirconia analyzer is
A3. A typical lifetime for a Zirconia sensor is 3 years not good for good performance. Condensation and
depending on the gas composition of the sample corrosion can damage the Oxygen probe. Also frequent
and the quality of the installation. After each 2-point start-up of the heater shortens the lifetime of the

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heater. If unavoidable, then the user should install a The concentration of the Zero gas can be anywhere
step-down transformer if the power supply is 220- 240 between 0.3 and 100 vol% and the concentration of the
Volt-AC. The power supply range of the analyzer is 85 to span gas can be set anywhere between 4.5 and 100%
276 VAC and in this abnormal situation it is best to keep under the condition that the Oxygen concentration
the power supply voltage low. in the span gas is at least 10 times higher than the
Oxygen concentration in the zero gas.
Q7. Overview of the calibration of zirconia oxygen analyzer
Note: An N2 gas of oxygen concentration of 0% can
A7. The electromotive force E (mV) is given by Nernst’s not be used for zero gas. Zirconia is a logarithmic
equation. The following figure shows the relation of measurement and 0% does not exist on a logarithmic
oxygen concentration and sensor (cell) electromotive scale. The “zero gas” must be a standard gas with a
forces, when the zirconia element is heated up to known and stable Oxygen concentration.
750°C.
Q9. What are two-point calibration and one-point
The measurement principles of a zirconia oxygen calibration?
analyzer have been described below. However, the
relationship between oxygen concentration and the A9. There are two calibrations for zirconia oxygen
electromotive force of a cell is only theoretical. Usually, analyzers; two-point calibration using zero and span
in practice, a sensor shows a slight deviation from the gases, and one-point calibration using only a span gas.
theoretical value. This is the reason why calibration
is necessary. To meet this requirement, an analyzer 1. Two-point Calibration:
calibration is conducted so that a calibration curve
is obtained, which corrects the deviation from the The following figure shows a two-point calibration
theoretical cell electromotive force. using two gases: zero and span. Cell electromotive
forces for a span gas with an oxygen concentration
p1 and a zero gas with an oxygen concentration
p2 are measured while determining the calibration
curve passing between these two points. The oxygen
concentration of the measurement gas is determined
from this calibration curve.

In addition, the calibration curve corrected by

calibration is compared with the theoretical calibration
curve for determining the zero-point correction ratio
represented by B/A × 100 (%) on the basis of A, B and
C shown in the bellow figure and a span correction
ratio of C/A × 100 (%). If the zero-point correction ratio
exceeds the range of 100±30 % or the span correction
ratio becomes larger than 0±18 %, calibration of the
sensor becomes impossible.
Oxygen concentration in a Measurement Gas vs Cell Voltage (21% O2 Equivalent)

Q8. What gas is used for calibration?

A8. A gas with a known oxygen concentration is

used for calibration. Normal calibration is performed
using two different gases: a “zero gas” of low oxygen
concentration and a “span gas” of high oxygen
concentration (two-point calibration). In some cases,
only one of the gases needs to be used for calibration.
However, even if only one of the gases is normally
used, calibration using both gases should be done at
least once.

The zero gas normally used has an oxygen

concentration of 0.95 to 1.0 vol%O2 with a balance of
Calculation of a Two-point Calibration Curve and Correction Factors using Zero and
nitrogen gas (N2). The span gas widely used is clean air Span Gases
(at a dew-point temperature below -20°C and free of
oily mist or dust, as in instrument air).

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 2. One-point Calibration: The output remains held after completing the
calibration operation until the output stabilization
The next figure shows a one-point calibration using time elapses. The calibration time set ranges from 00
only a span gas. In this case, only the cell electromotive minutes, 00 seconds to 60 minutes, 59 seconds.
force for a span gas with oxygen concentration p1 is
measured. The cell electromotive force for the zero gas 2. When the calibration mode is in Semi-automatic:
is carried over from a previous measurement to obtain
the calibration curve. In addition to the above output stabilization time
and calibration time, set the interval, set the output
The principle of calibration using only a span gas also stabilization time and calibration time.
applies to the one-point calibration method using a
zero gas only. The calibration time is the time required from starting
the flow of the calibration gas to reading out the
The way of “Zero-point correction Factor” and “Span measured value.
correction Factor” is the same as the case of Two-point
Calibration. The set calibration time is effective in conducting both
zero and span calibrations. The following figure shows
the relationship between the calibration time and
output stabilization time.

Calculation of a One-point Calibration Curve and Correction Factors using a Span Gas

3. When the calibration mode is in Automatic:

Q10. Calibration operation modes and calibration time
setting In addition to the above output stabilization time and
calibration time, set the interval, start date, and start
A10. There are three calibration modes available : time.

• Manual calibration which allows zero and span Interval means the calibration intervals ranging from
calibrations or either one manually in turn; 000 days, 00 hours to 255 days, 23 hours. Set the first
• Semi-automatic calibration which lets calibration calibration day and the start-calibration time to the
start with the touchpanel or a contact input, and start date and start time respectively.
undergoes a series of calibration operations
following preset calibration periods and stabilization Q11. What is preventive maintenance functions of the
time; zirconia oxygen analyzer?
• Automatic calibration which is carried out
automatically following preset calibration periods. A11. There The following information necessary
for routine maintenance can be displayed. This
Calibrations are limited by the following mode information can be used to determine the calibration
selection: period and prepare for the zirconia cell in a timely
manner.
1. When the calibration mode is in Manual:
1. Span-gas and Zero-gas Correction Ratios
First, set the output stabilization time. This indicates
the time required from the end of calibration to These are used to check for degradation of the sensor
entering a measurement again. (cell). If the correction ratio is beyond the Correctable
range, the sensor should no longer be used. These
This time, after calibration, the measurement gas ratios can be found by calculating the data as shown
enters the sensor to set the time until the output below.
returns to normal.

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 This cell’s robustness can be found by a total
evaluation of data involving the response time, the
cell’s internal resistance, and calibration factor.
However, if a zero or span calibration was not made,
the response time cannot be measured. In such a case,
the cell’s robustness is found except for the response
time.

4. Cell voltage

The cell (sensor) voltage will be an index to determine

the amount of degradation of the sensor. The cell
voltage corresponds to the oxygen concentration
currently being measured. If the indicated voltage
Span-gas and Zero-gas Correction Ratios approximates the ideal value (corresponding to the
measured oxygen concentration), the sensor will be
2. Response Time assumed to be normal.

The cell’s response time is obtained in the procedure The ideal value of the cell voltage (E), when the oxygen
shown in below figure. concentration measurement temperature is controlled
at 750°C ., may be expressed mathematically by:
If only either a zero-point or span calibration has been
carried out, the response time will not be measured E = -50.74 log (Px/PA) [mV]
just as it will not be measured in manual calibration.
where, Px: Oxygen concentration in the measured gas
The response time is obtained after the corrected PA: Oxygen concentration in the reference gas,
calibration curve has been found. (21% O2)

The response time is calculated, starting at the point Oxygen Concentration Vs. Cell Voltage
corresponding to 10% of the analog output up to the (cell temperature: 750°C )
point at 90% of the analog output span. That is, this
response time is a 10 to 90% response.

% O2 mV % O2 mV

0.1 117.83 6 27.61

0.2 102.56 7 24.21

0.3 93.62 8 21.27

0.4 87.28 9 18.67

0.5 82.36 10 16.35

0.6 78.35 21 0

0.7 74.95 30 -7.86

Response Time 0.8 72.01 40 -14.2

0.9 69.41 50 -19.2

3. Robustness of a Cell
1 67.09 60 -23.1
The robustness of a cell is an index for predicting the 2 51.82 70 -26.5
remaining life of a sensor and is expressed as one of
3 42.88 80 -29.5
four time periods during which the cell may still be
used: more than a year, more than six months, more 4 36.54 90 -32.1
than three months, less than one month. 5 31.62 100 -34.4

The above four time periods are tentative and only

used for preventive maintenance, not for warranty of
the performance.

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 5. Cell’s Internal Resistance • ZR22S/ZR202S Explosionproof Zirconia Oxygen
Analyzer
A new cell (sensor) indicates its internal resistance of • AV550G Zirconia Oxygen Averaging Converter
200 Ω maximum. As the cell degrades, so will the cell’s • OX400 Low Concentration Zirconia Oxygen Analyzer
internal resistance increase.
1. ZR202G Direct In-Situ Zirconia Oxygen Analyzer
The degradation of the cell cannot be found only by (Integrated type)
changes in cell’s internal resistance, however. Those
changes in the cell’s internal resistance will be a hint to The integrated type zirconia oxygen analyzer combines
knowing the sensor is degrading. The updated values probe and converter. The wiring cost and the
obtained during the calibration are displayed. installation fee can be decreased compared with the
separate type by the integrated one. The converter can
Q12. After replacement of sensor, what are the tasks that be operated in the field using an optical switch without
is necessary? opening the cover. On the other hand, there are some
restrictions such as the sample gas temperature (700°C
A12. There After replacement of sensor, carry out or less) and functions.
surely Two-point Calibration using zero and span
gases. 2. ZR22S/ZR202S Explosionproof Zirconia Oxygen
Analyzer
Note that calibration should usually be performed in the
measurement state (in the operation state of the furnace when the
analyzer is installed near the furnace).
Two types are available explosionproof direct in situ
zirconia oxygen analyzer. The ZR22S/ZR402G is a
separate type which consists of a ZR22S explosionproof
8.4 Accessories probe and a ZR402G non-explosionproof converter.
The ZR202S is an integrated type which combines a
Q1. Can we use Nitrogen as Zero Gas? probe and a converter. Separate and integrated type
Zirconia oxygen analyzers do not need a sampling
A1. Since N2 gas grade available may contain traces of device, and allow direct installation of the probe in the
Oxygen, the cell voltage becomes unstable & high. wall of a flue or furnace to measure the concentration
So we cannot use only Nitrogen as Zero gas. of oxygen in the stack gas. The converter displays
the cell temperature and cell emf in addition to the
Q2. When to use probe filter? oxygen concentration. This analyzer is most suitable for
monitoring combustion and controlling the low-oxygen
A2. It is used mostly for coal fired Boilers & applications combustion of various industrial furnaces in explosive
where dust/ fly ash is present. Keep in mind the atmosphere at petroleum refinery, petrochemical
presence of filters will increase the response time plant, and natural gas plant.

8.5 Models 3. AV550G Zirconia Oxygen Averaging Converter

Q1. What if the sample temperature is higher than the The AV550G Averaging Converter can accept inputs
recommended temperature? from up to 8 zirconia oxygen detectors ZR22G.
With large boilers used in the utility industry, the
A1. Use the High temperature version configuration oxygen concentration varies in different zones
where an adapter is added to the normal configuration across the flue. In order to obtain the most reliable
with SS/ SiC options for the probe, Up to 1400°C oxygen data, the most common method used is the
sample temperature can be measured with the high arithmetical averaging of several measuring points
temperature option. using an external averaging unit. The model AV550G
Averaging Converter not only averages the signals but
Q2. What types of Zirconia Oxygen Analyzers exist, and fully controls all of the individual detectors thereby
how are they selected? eliminating the need for costly,redundant hardware or
DCS programming.
A2. Yokogawa offers the following zirconia oxygen
analyzers. Select an appropriate one according to your
application and usage.
• ZR22G/ZR402G Direct In-Situ Zirconia Oxygen
Analyzer(Separate type)
• ZR202G Direct In-Situ Zirconia Oxygen Analyzer
(Integrated type)

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9. Lock Out Specifications concentration, alarm and error notification, and 4 to 20
mA output, and menu icons.
9.1 Oxygen Analyzer System Specification Diagnostics: The analyzer system shall be able to
for a Single Channel Analyzer and Detector diagnose the following items: Span correction, zero
Requirements correction, calibration history, response time, Zr cell
robustness, Zr cell resistance, heater on time ratio,
Oxygen Analyzer/Converter mA loop check, contact I/O check, alarm and error
indications, abnormal cell, abnormal cell temperature,
Human Machine Interface: Shall be performed via an defective digital circuits.
LCD touchscreen display, with monochromatic display
and 320 by 240 dot resolution. Maximum Cable Distance: The analyzer maximum
distance between the detector and converter can be up
Trend Graph function: The analyzer shall provide a to 300 m, when the conductor two-way resistance must
trend graph function. be 10 Ω or less (when a 1.25 mm2 cable or equivalent
is used), or 500 m, when the conductor two-way
Oxygen concentration value: The analyzer system resistance must be 10 Ω or less (when a 2 mm2 cable or
shall be able to measure 0.01 to 100% volume oxygen equivalent is used).

Output signal: The analyzer system shall have two a Alarms: The analyzer shall have a user configurable
user configurable 4 to 20 mA output signals (programmable) alarm, to feature High, High-High, and
Low, Low-Low, and oxygen concentration alarms.
Contact output signal: The analyzer shall have four
points, of which, one is “fail-safe” or normally open • The Analyzer shall meet or exceed the following
Contact input signal: The analyzer shall have two Power and Safety requirements:
points, voltage free contacts. The input contact feature ◦◦ The analyzer shall have a universal power supply
shall have the ability for remote range change from ◦◦ Power Supply Voltage: Ratings; 100 to 240 VAC, with
either a remote contact point or automatic control an acceptable range of 85 to 264 VAC
on a DCS. For eg., in combustion control applications, ◦◦ Power Supply Frequency: 50 to 60 Hz, with an
initially the customer will use the default (non- acceptable range of 45 to 66 Hz
changeable) range from 0 to 25 %. Later when the ◦◦ Power Consumption: Max. 300 W, approximately
process to be measured (flue gas) starts, the range 100W for normal conditions
required to be changed to 0 to 10% for eg,. in thermal ◦◦ Safety:
power plants. 1. EN 61010-1: 1993
2. CSA C22.2, No. 61010-1 certified
Automatic Calibration Output: The calibration output 3. UL 3111-1 certified
shall have two output contact points dedicated for an ◦◦ EMC: EN 61326: 1998
auto-calibration unit
• Installation requirements:
Contact capacity: Off-state leakage current shall be ◦◦ The analyzer shall have an ambient operating
3mA or less temperature range of: -20ºC to 55ºC (-4ºF to 131ºF)
◦◦ The analyzer shall have installation location
Digital Communication: The analyzer system shall be requirement: Indoor/Outdoor, panel or pipe mount
HART® communications compatible ◦◦ Ambient Humidity: The analyzer shall be able to
withstand ambient humidity conditions of 0 to 95%
Repeatability: The analyzer shall have a repeatability Relative Humidity
factor of ± 0.5% maximum value of set range is 0 up to
25% O2. • Construction:
◦◦ The analyzer shall conform to NEMA 4X or
Linearity: The analyzer shall have a linearity Equivalent weather resistant and corrosion
measurement of ± 1% maximum value of set range resistance standards.
(Excluding calibration gas tolerances) is 0 up to 25% O2. ◦◦ The finish on the analyzer shall be a Polyurethane,
corrosion resistant coating
Response time: The analyzer system shall have a
response time of 90% of span within 5 seconds Zirconia Oxygen Detector

Display: The analyzer shall be able to simultaneous Measurement system: The analyzer system shall
display three different measurement parameters. utilize a molecularly bonded Zirconia/Platinum sensor
Items to be displayed shall consist of Oxygen

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 Sample gas temperature: The detector shall be Automatic Calibration Output: The calibration output
capable of taking in situ oxygen gas measurements shall have two output contact points dedicated for
with process operating temperatures of 0 to 700°C an auto-calibration unit. An optional integrated auto-
(32°F to 1292°F), up to 1871°C (3400°F) with a high calibration unit shall be made available.
temperature adapter
Digital Communication: The analyzer system shall be
Sample gas pressure: The detector shall be capable of HART® communications compatible
taking in situ oxygen gas measurements with process
pressures in the range of -0.725 psi to 36 psi. Repeatability: The analyzer shall have a repeatability
factor of ± 0.5% maximum value of set the range is
Probe construction: The oxygen probe shall be 0 up to 25% O2.
constructed of the following materials:
• Wetted probe material (In situ): SUS 316, Zirconia/ Linearity: The analyzer shall have a linearity
Platinum cell, Hastelloy B (Inconel 600, 601) measurement of ± 1% maximum value of set range
• Flange material: SUS 304 (Excluding calibration gas tolerances) is 0 up to 25% O2.
• The probe shall utilize a Type K thermocouple for cell
temperature indication Response time: The analyzer system shall have a
• Terminal Box: Aluminum alloy, with a Polyurethane, response time of 90% of span within 5 seconds.
corrosion resistant coating
• The detector shall be available in custom lengths up Display: Items to be displayed shall consist of Oxygen
to 5.4 meters concentration percentage, and alarm/error notification.

Calibration system requirements: Diagnostics: The analyzer system shall be able to

• The system calibration shall not require a snubber or diagnose the following items: Abnormal cell, abnormal
diffuser. cell temperature (low/high), abnormal calibration, A/D
• Calibration gases flow rates: The Zero gas flow rate converter abnormalities, and abnormal digital circuit.
shall be 0.6 LPM or less, and the Reference gas flow
rate shall be 0.8 LPM or less Alarms: The analyzer shall have a user configurable
• Reference air system: The detector shall be able to (programmable) alarm, to feature High, High-High, and
operate utilizing natural convection, instrument air or Low, Low-Low, and oxygen concentration alarms.
pressure compensated reference air • Power Requirements:
• Zero calibration gas: shall consist of 1% oxygen ◦◦ Power Supply Voltage: Ratings; 100 to 240 VAC,
balanced in nitrogen with an acceptable range of 85 to 264 VAC
◦◦ Power Supply Frequency: 50 to 60 Hz, with an
**Based on the following guide lines, specifications and acceptable range of 45 to 66 Hz
requirements, the model analyzer and detector chosen for this
application shall be the Yokogawa ZR402G Single Channel Oxygen
◦◦ Power Consumption: Max. 300 W, approximately
Analyzer, and the ZR22G Zirconia Oxygen Detector.** 100W for normal conditions

9.2 Oxygen Analyzer System Specification • Safety and Electrical conforming standards:
◦◦ Safety:
for an Integrated type Oxygen Analyzer Conforms to EN 61010-1: 1993
and Detector Requirements Conforms to CSA C22.2, No. 61010-1 certified
Conforms to UL 3111-1 certified
Measurement system: The measurement system shall EMC: Conforms to EN 61326: 1998
utilize a molecularly bonded Zirconia/Platinum
Oxygen cell with an integrated electronic analyzer. • Installation Requirements:
◦◦ Sample gas temperature: The analyzer/detector
Human Machine Interface: Shall be performed via a shall be able to withstand sample gas temperatures
monochromatic 6 digit LCD display and three optical of 0 to 0 to 700°C (32°F to 1292°F), up to 1871°C
switches (3400°F) with a high temperature adapter.
◦◦ Ambient Temperature: The analyzer shall have an
Oxygen concentration value: The analyzer system ambient operating temperature range of: -20°C to
shall be able to measure 0.01 to 100% volume oxygen 55°C (-4°F to 131°F)
◦◦ Location: The analyzer shall have installation
Output signal: The analyzer system shall have a user location requirement: Indoor/Outdoor, panel or
configurable 4 to 20 mA output signal. pipe mount Ambient Humidity: The analyzer shall
be able to withstand ambient humidity conditions
Contact output signal: The analyzer shall have two of 0 to 95% Relative Humidity
points, of which, one is “fail-safe” or normally open.

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 ◦◦ Sample gas pressure: The detector shall be calibration record, internal temperature rise alarm
capable of taking in situ oxygen gas measurements record, cell e.m.f. (mV), thermocouple e.m.f. (mV),
with process pressures in the range of -0.725 psi to cold junction resistance (Ω), cell temperature (°C ),
36 psi. cold junction temperature (°C ), span correction factor
• Construction: (%), zero correction factor (%), cell response time
The analyzer/detector shall be constructed for use in (seconds), cell condition, cell internal resistance (Ω),
indoor or outdoor installation, and conform to NEMA next calibration estimate (year/month/day), heater on
4X or equivalent weather and corrosion resistance time rate (%), time (year/month/day, hour/minute),
standards. software revision.

The oxygen probe shall be constructed of, or consist Status message: The averaging unit shall indicate
of, the following materials: alarm and error codes for individual probes.

◦◦ Wetted probe material (In situ): SUS 316, Zirconia/ Validation Function: The averaging unit shall be able
Platinum cell, Hastelloy B (Inconel 600, 601) to permit control room activation of the midpoint gas
◦◦ Flange material: SUS 304 concentration validation.
◦◦ Type K thermocouple
◦◦ Terminal Box: Aluminum alloy, Non-explosion Hot swap function: The averaging unit shall allow the
proof, NEMA 4X equivalent with a Polyurethane, user to change individual channel cards without having
corrosion resistant coating to power the unit down.
◦◦ The heater and thermocouple shall be replaceable.
◦◦ The detector shall be available in custom lengths Calibration: The averaging unit shall be able to
up to 3.0 meters perform manual, semi-automatic and automatic
calibration of all eight probes.
• Calibration system requirements:
◦◦ The system calibration shall not require a snubber Diagnostics: The averaging unit shall be able to
or diffuser. diagnose the following items of each probe: span
◦◦ Calibration gases flow rates: The Zero gas flow rate correction, zero correction, calibration history,
shall be 0.6 LPM or less, and the Reference gas flow response time, Zr cell robustness, Zr cell resistance,
rate shall be 0.8 LPM or less. heater on time ratio, mA loop check, contact I/O check,
◦◦ Reference air system: The detector shall be able alarm and error indications, abnormal cell, abnormal
to operate utilizing instrument air or pressure cell temperature, defective digital circuits.
compensated reference air.
◦◦ Zero calibration gas: shall consist of 1% oxygen Communications: The averaging unit shall be HART®
balanced in nitrogen. or Foundation Fieldbus® compatible, to include the
ability to upgrade to Foundation Fieldbus®
**Based on the following guide lines, specifications and
requirements, the model analyzer and detector chosen for this
application shall be the Yokogawa ZR202G Integrated Oxygen
• Signals:
Analyzer/ Zirconia Oxygen Detector.** Output signal: The analyzer shall have (3) 4 to 20
mA outputs representing averaged O2 values as well
9.3 Oxygen Analyzer System Specification as (8) 4-20mA outputs representing individual probe
readings.
for Multi-Channel Averaging Oxygen
Analyzer and Detector Requirements Contact Output Signal: The averaging unit shall
have five contact output signal points, of which, four
Human Machine Interface: Shall be performed via a are user selectable.
5.7 inch, color LCD touchscreen display.
Contact Input: The averaging unit shall have two
Quantity of Detectors: The averaging unit shall be points, voltage free contacts. The input contact
able to display 1 to 8 oxygen detectors, expandable feature shall have the ability for remote range
from 1 to 8 probes change from either a remote contact point or
automatic control on a DCS. For eg., in combustion
Graph display: The averaging unit shall be able to control applications, initially the customer will use the
display trend analysis and cascade graphs for all eight default (nonchangeable range from 0 to 25 %. Later
probes. when the process to be measured (flue gas) starts,
the range required to be changed to 0 to 10% for eg,.
Data display: The averaging unit shall be able to in thermal power plants.
display the following data items: maximum/minimum/
average oxygen concentration (volume % O2),

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 Contact capacity: Off-state leakage current, 3mA or ◦◦ Calibration gases flow rates: The Zero gas flow rate
less shall be 0.6 LPM or less, and the Reference gas flow
rate shall be 0.8 LPM or less
• Power Requirements: The averaging unit shall have ◦◦ Reference air system: The detector shall be able to
the following power requirements operate utilizing natural convection, instrument air
◦◦ Power Supply Voltage: Ratings; 100/115 VAC, 230 or pressure compensated reference air
VAC, ◦◦ Zero calibration gas: shall consist of 1% oxygen
◦◦ Power Supply Frequency: 50Hz ± 5% to 60Hz ± 5%, balanced in nitrogen
◦◦ Power Consumption: Max 1kw
Max 1.8 for warm-up **Based on the following guide lines, specifications and
requirements, the model analyzer and detector chosen for this
application shall be the Yokogawa AV550GG Multi- Channel Oxygen
• The Averaging Unit shall meet or exceed the Analyzer, and the ZR22G Zirconia Oxygen Detectors. **
following Power and Safety requirements:
◦◦ Safety:
Conforms to EN 61010-1: 2001
Conforms to CSA C22.2, No. 61010-1 certified
Conforms to UL 61010B-1 certified

• EMC:
◦◦ EN 61326, 2002
◦◦ AS/NZS CISPER 11

Construction: The finish on the averaging unit shall

be a Polyurethane corrosion resistant coating. The
averaging unit shall have an option available for a
NEMA 4 enclosure.

Zirconia Oxygen Detector

Measurement system: The analyzer system shall

utilize a molecularly bonded Zirconia/Platinum sensor

Sample gas temperature: The detector shall be

capable of taking in situ oxygen gas measurements
withprocess operating temperatures of 0 to 700ºC
(32ºF to 1292ºF), up to 1871ºC (3400ºF) with a high
temperature adapter

Sample gas pressure: The detector shall be capable of

taking in situ oxygen gas measurements with process
pressures in the range of -0.725 psi to 36 psi.

• Probe construction: The oxygen probe shall be

constructed of the following materials:
◦◦ Wetted probe material (In situ): SUS 316, Zirconia/
Platinum cell, Hastelloy B (Inconel 600, 601)
◦◦ Flange material: SUS 304
◦◦ The probe shall utilize a Type K thermocouple for
cell temperature indication
◦◦ Terminal Box: Aluminum alloy, with a Polyurethane,
corrosion resistant coating
◦◦ The detector shall be available in custom lengths
up to 5.4 meters

• Calibration system requirements:

◦◦ The system calibration shall not require a snubber
or diffuser.

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Yokogawa Electric Corporation Yokogawa Corporation of America Yokogawa Europe B.V. Yokogawa Engineering Asia PTE. LTD
12530 W. Airport Blvd.,
World Headquarters Euroweg 2, 3825 HD 5 Bedok South Road, Singapore 469270,
9-32, Nakacho 2-chome, Sugar Land, TX 77478 Amersfoort, The Netherlands Singapore
Musashino-shi, Tokyo 180-8750 USA
yokogawa.com/eu yokogawa.com/sg
Japan yokogawa.com/us
yokogawa.com/an

The contents of this document are subject to change without prior notice. All rights reserved. Copyright © 2017 Yokogawa Corporation of America.
[Ed:01] Printed in USA TI 11M00A20-01E

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