Yokogawa News

Yokogawa Adds ZR802S Explosion-proof Converter to OpreX Analyzers Lineup

Features sensor self-assessment and data logging functions that significantly reduce operating costs.

Yokogawa Adds ZR802S Explosion-proof Converter to OpreX Analyzers Lineup

The new ZR802S converter and the ZR22S detector (foreground)

Yokogawa Electric Corporation has announces that it has developed the ZR802S explosion-proof converter and will be releasing it for sale as part of its OpreX Analyzers lineup in all markets on December 12. The ZR802S converter supports the IECEx, FM, ATEX, CSA, China Ex, Korea Ex, India Ex, and Taiwan Ex explosion-proof standards.

It is intended for use with the ZR22S explosion-proof zirconia oxygen detector, an existing Yokogawa product with a highly durable zirconia sensor that is highly dust resistant and easy to install and replace. Together, the ZR802S converter and the ZR22S detector comprise a complete oxygen analyzer system.

Development Background
Plant operators need to increase operational efficiency by improving uptime and introducing labor-saving measures, and thus are looking to decrease the likelihood of instrument failures that can lead to plant stoppages or a deterioration in product quality, and to eliminate the need to perform on-site inspections of instruments.

As such, Yokogawa has sought with its zirconia oxygen concentration analyzers to introduce remote monitoring and other capabilities that reduce the time and effort required for maintenance operations and increase uptime. The ZR802S converter features a self-assessment function that provides early detection of deterioration in a zirconia oxygen detector, a data logging function that records essential maintenance information, and support for a number of key communication protocols. It is expected that these innovations will help to significantly reduce OPEX.

1. Automatic transmission of sensor resistance value at regular intervals, enabling replacement timing to be determined without on-site inspection
Up to now, assessment of sensor deterioration by checking the sensor resistance value has normally been carried out whenever maintenance personnel went on site to perform calibration. As this work is usually performed on a scheduled basis at intervals of a month or more, it has not always been possible to spot problems in time, leading to sudden sensor breakdowns and decreased uptime.

With its self-assessment function, the ZR802S converter is able to regularly measure the resistance value of the sensor in the ZR22S detector and send this data over a wired connection to the plant’s control system. Once an operator receives notification of a higher resistance value, which is an indication of deterioration in the sensor, maintenance personnel can take immediate action to correct the problem and prevent an instrument failure, thereby sustaining plant uptime.

2. Data logging function that helps to reduce maintenance time and downtime in the event of a fault
The ZR802S converter can log up to 40 days of measurements, alarm on/off history, and sensor resistance trend graphs, among other data. As well as being able to directly display logs on the LCD screen, it is also possible to export the data using an SD card. In the event of a fault, it can determine whether it is due to the analyzer system or the distributed control system (DCS) by looking into differences with the data from the host device. This helps reduce maintenance time and the downtime required to find a solution.

3. Industry-first communication protocol support, meeting a range of needs and enabling cloud-based management
The ZR802S converter is the only product in the zirconia oxygen analyzer market that supports all three of the following communication protocols: HART7 for analog output, and Modbus TCP and Modbus RTU for digital communications. It also complies with the NAMUR NE43 guideline for the issuance of signals to indicate a sensor fault and the NAMUR NE107 guideline for on-site instrument self-assessment functions.

Using the ZR802S converter’s communication functions, cloud-based management is also possible, and this not only increases convenience in terms of data analysis and other such activities, it also enables operation with the minimum number of staff, making it suitable for a range of uses by customers in a variety of industries.

4. Support for multiple languages and provision of operational support
In addition to Japanese and English, the device LCD can also be set to display information in French, German, Chinese, and Portuguese. Russian will be added in the near future. Furthermore, information on what steps should be taken in response to specific alarms can now be displayed on the LCD screen, enabling even less knowledgeable and experienced personnel to perform necessary maintenance.

Major Target Markets
Oil refining, petrochemicals, chemicals, electric power, steel


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