Fuji Electric ZFK8 Operating Manual

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Page 1

Instruction Manual

THE DIRECT INSERTION TYPE

ZIRCONIA OXYGEN

ANALYZER DETECTOR

TYPE: ZFK8

INZ-TN5ZFK8c-E

Page 2

PREFACE

Thank you very much for your kind purchase of Fuji’s zirconia oxygen analyzer detector (Type ZFK 8).

• Read this instruction manual carefully to get a thorough understanding of how this zirconia oxygen analyzer works prior to installing, operating and maintaining the zirconia oxygen analyzer.

If abused, unnecessary troubles or failure could occur.

• The speciﬁ cation of this zircoia oxygen analyzer may be subject to change without previous notice for improvements of the product.

• Under no circumstances should this zirconia oxygen analyzer be modiﬁ ed without permission.

If any trouble should occur because of having been modiﬁ ed without permission, we won’t be responsible

for it anyway.

• This instruction manual should be kept in custody by a person who operates the zirconia oxygen analyzer actually.

• After reading this manual, it should always be kept in a place which allows the person who operates it to refer to any time as requirfed.

• A due consideration should be given so that this instruction manual is delivered to a ﬁ nal user certainly.

Manufacturer : Fuji Electric Co., Ltd.

Type : Described in the nameplate put on the main body

Date of manufacture : Described in the nameplate put on the main body

Product nationality : Japan

Related instruction manuals

Direct insertion type zirconia oxygen analyzer converter (Type : ZKM) .................................INZ-TN1ZKM

Direct insertion type zirconia oxygen analyzer-use ejector (Type : ZTA) ................................ INZ-TN1ZTA

Fuji Electric Co., Ltd. 2008



NOTE

• It is prohibited to transfer a part or all of the contents of this manual without permission.

• The contents of this manual may be subject to change in future with-

Issued in Aug , 2008 Rev.1st edition Oct , 2008 Rev.2st edition Apr , 2009 Rev.3rd edition Apr , 2011

out previous notice

Page 3

SAFETY PRECAUTIONS

Prior to operating this detector, read this “Safety precautions” carefully for correct use.

• In the precautions shown here, important contents on safety are included. So, be sure to observe them. The safety precautions have been ranked into “DANGER” and “CAUTION”.

f this apparatus is abused, a dangerous condition could come about and it is

DANGER

supposed to die or get a serious injury.

CAUTION

PROHIBITION:

DANGER

CAUTION

• When this product is mounted on a furnace which is under operation, take

• In the case of the wiring work, be careful not to drop foreign matters including

• Connect a power source compatible with the speciﬁ ed rating. Connection of

• Before doing the wriring work, be sure to turn off the main power. Otherwise,

• Use proper wiring materials according to the rating of apparatus. If a wiring

If the apparatus is abused, a dangerous condition could arise and it is supposed to get medium injury or a minor injury and a physical damage is supposed to occur.

This indicates a prohibition (act which must not do).

Precautions in installing and wiring

• This product is not an explosion-proof type. Don’t use it in an explosive gas atmosphere. Otherwise, irreparable troubles including explosion or a ﬁ re

could occur.

• Install this product in a place compatible with the conditions set forth in

“instruction manual”. The use at a place not conforming to the installation conditions may result in an electric shock, a ﬁ re and malfunction.

utmost care with blow-out from the furnace. There is a risk of burn injury.

wire chips into the product. Otherwise, a ﬁ re, failure or malfunction may result.

power source different from the rating might cause a ﬁ re.

it results in getting an electric shock as the case may be.

material which is not bearable to the rating is employed, it might cause a ﬁ re.

• Never do the work at a place where the product gets wet with water, such as

PROHIBITION:

A failure to observe this instruction may result in getting an electric shock or

the rain.

failure.

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Precautions in operation, stop, maintenance and check

DANGER:

CAUTION:

• The operating temperature of the detector (tip of ceramic heater) is about 800

Otherwise, there is a fear of getting a burn.

• Before cleaninhg the ﬂ ow guide tube, turn off the main power and cool the

There is a fear of getting a burn.

• Don’t use any other renewal part than those designated by the maker. Other-

• Dispose of the renewal parts such as the maintenance parts as an incombus-

PROHIBITION:

A failure to observe this instruction may result in getting an electric shock or

• In case where combustible gas is contained in the measured gas, check the gas

composition and speciﬁ cations carefully before using. Otherwise, the original performance is not displayed, and there is a fear of explosion.

• Do the work in a condition where the main power has been turned off. If the

work is done while current is ﬂ owing, there is a fear of getting an electric shock.

°C and the surface temperature is also very high. So, never touch the detector by bare hand.

tube down fully.

wise, the original performance is not fully displayed and a accident or failure may result.

tible.

• Never do the work at a place where rain water splases the product directly.

failure.

CAUTION:

Other precaution

• For a failure which cannot be judged even if referring to the instruction manual,

be sure to ask the nearest dealer or Fuji adjustment serviceman for repair. If disassembled carelessly, an accident or injury could result.

iii

Page 5

PREFACE ......................................................................................................................................... i

SAFETY PRECAUTIONS .............................................................................................................. ii

1. Introduction .............................................................................................................................. 1

1.1 General description of zirconia oxygen analyzer ........................................................................1

1.2 Device conﬁ guration of direct insertion type oxygen analyzer ...................................................1

1.3 Description of each component ...................................................................................................2

1.4 Check of type ...............................................................................................................................2

1.5 Check of delivered articles ..........................................................................................................2

2. Mounting .................................................................................................................................. 3

2.1 Mounting location .......................................................................................................................3

2.2 Mounting method ........................................................................................................................3

3. Piping ....................................................................................................................................... 7

3.1 Piping of calibration gas ..............................................................................................................7

3.2 Piping of reference gas inlet ........................................................................................................7

3.3 Piping for blow down air .............................................................................................................7

3.4 Piping drawing ............................................................................................................................8

4. Wiring ..................................................................................................................................... 12

4.1 Before wiring .............................................................................................................................13

4.2 Wiring to each terminal .............................................................................................................13

4.3 Mounting of conduit ..................................................................................................................14

5. Operation and Stop ................................................................................................................. 15

5.1 Start of operation .......................................................................................................................15

5.2 Stop of operation .......................................................................................................................15

6. Maintenance and Check ......................................................................................................... 16

6.1 Check .........................................................................................................................................16

6.2 Maintenance ..............................................................................................................................17

6.3 Standard output of detector .......................................................................................................19

6.4 Arrangement ..............................................................................................................................20

7. Troubleshooting ...................................................................................................................... 21

8. Appendix ................................................................................................................................ 22

8.1 Speciﬁ cation ..............................................................................................................................22

8.2 Designation of type (code table) ...............................................................................................24

8.3 Device composition ..................................................................................................................25

8.4 Outline diagram (unit: mm) .......................................................................................................26

Page 6

1. INTRODUCTION

1.1 General description of zirconia oxygen analyzer

This zirconia oxygen analyzer makes use of the oxygen ion conductivity of solid electrolytes composed mainly of zirconia (ZrO2) at high temperatures.

If electrodes of platinum or the like are attached to both faces of a solid electrolyte and the faces are on the conditions of different oxygen partial pressures, an electrochemical reaction causes an electromotive force between both the electrodes. This phenomenon is called concentration cell action.

Microscopically, it is assumed that electrochemical reactions occur at the interface (three-phase interface) among a solid electrolyte, electrode and oxygen.

High-oxygen partial pressure side: O2 + 4e– → 2O2– (ionization)

Low-oxygen partial pressure side: 2O2– → O2 + 4e– (molecularization)

An electromotive force (E) generated is expressed as follows with Nernst’s equation:

High-oxygen partial pressure side P

Solid electrolyte

Electrode

Low-oxygen partial pressure side P

Zirconia

Oxygen molecule

Platinum

Ionization

Molecularization

Tree-phase interface: a part where electrochemical reactions occur.

Electromotive force

Nernst’s equation

E : Electromotive force P

reference gas (atmosphere) PL(O2) : Oxygen partial pressure of a measured gas

R : Gas constant 8.3144[J･mol-1･K-1] T : Absolute temperature[K] F : Faraday constant 9.649×104[c･mol-1]

H(O2

L(O2

E= 1n

H(O2

RT 4F

) : Oxygen partial pressure of a

)

1.2 Device conﬁ guration of direct insertion type oxygen analyzer

The direct insertion type zirconia oxygen analyzer consists of the detector with a sensor unit, the ﬂ ow guide tube that is directly inserted to the stack or the like in order to supply a gas to the detector, and the converter that performs sensor control, signal processing, output/display, and external transmission. The detector and converter are connected with a cable.

Stack

Flow guide tube

Flow of gas

Cable (sensor output line, thermocouple output line, heater power wire)

Replacement of the existing detector ZFK2 with the detector ZFK8:

In principle, the detector ZFK8 is compatible with the existing detectors ZFK2 and ZFK5 structurally and electrically.

However, the M4 screws for the terminal block of the detector were changed to the M3 screws. If using the existing cable, change the M4 terminal for cable end treatment on the detector side to the M3 terminal.

The detectors ZFK8, ZFK2 and ZFK5 can be connected to the converters ZRY, ZRM or ZKM.

The ﬂ ow guide tube can be connected to the existing products.

ConverterDetector

Page 7

Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan http://www.fujielectric.com Phone: 81-3-5435-7280, 7281 Fax: 81-3-5435-7425 http://www.fujielectric.com/products/instruments/

International Sales Div Sales Group

Page 8

2. MOUNTING

2.1 Mounting location

DANGER

• This product has no explosion-proof speciﬁ cation. Don’t use the product in an explosive gas environment. If used, a serious trouble such as a ﬁ re or explosion might occur.

CAUTIONS

• Install this product at a place compatible with the following conditions. The use of it at a place not conforming the installation conditions speciﬁ ed in this manual could cause an electric shock, a ﬁ re or incorrect operation.

Mount the detector by selecting the places shwon below:

1 Place where there is a space which allows doing daily check and wiring work

2 Place where there is little vibration, dust and humidity

3 Place where peripheral air environment is non-corrosive.

4 Place where there are no electric appliances producing noise trouble (For example : motor, transformer

and appliances bringing about electromagnetic induction trouble and electrostatic induction trouble) nearby the detector.

5 Place where ambient temperatue and humidity are -10 to +60°C and less than 95%RH .

2.2 Mounting method

CAUTIONS

• When mounting the detector on a furnace which is under operation, take utmost care about the blowout from the furnace; otherwise, there is a fear of getting a burn.

Page 9

2.2.1 Mounting method of detector

Caution in mounting

Up Up

• Never mount the detector with the tip turned upward or

Flow guide tube or ejector (ZTA)

Gas flow

downward. A failure of the detector may result.

Mounting screw, plain washer, spring washer (accessory) - 3 locations

O-ring (accessory)

Detector flange

Detector

Wiring hole

+45°

-45°

Down

Detector

Down Down

thermo sticker

1 Attach the O-ring (accessory, Viton P36) to the groove of the detector. Subsequently, attach the detec-

tor to the ﬂ ange of the ﬂ ow guide tube or ejector (type: ZTA) by ﬁ xing the mounting screws (accessory, M5) and the ﬂ at and spring washers (accessories) to the three locations (at the opposing corners of six mounting holes) (recommended tightening torque: 3.5 N · m).

2 Attach the detector so that it is within the range of ±45° to the horizontal plane.

3 Attach the detector so that the wiring hole is located at the bottom.

4 Set the temperature of the detector ﬂ ange to 125°C or less regardless of the measured gas temperature.

• Complete the mounting, piping and wiring of the detector, make sure the color of thermo sticker 125 put on the detector ﬂ ange is not changing to red in the exhaust gas measuring condition (while current is ﬂ ow- ing to the detector and the plant is under running). (Usually, the color of thermo sticker is light pink.)

• If the color has changed to red, it measns that the temperature of detector ﬂ ange has been over 125°C. So, take the following steps:

(a) Change the existing ﬂ ange packing to a thicker one.

(b) Use a longer mating ﬂ ange.

By taking the above steps, minimize heat transfer from the gas duct wall and lower the temperature.

The thermo sticker does not return to its originatl condition once it discolors. So, after taking the steps, reput a thermo sticker available as an accessory on the detector ﬂ ange and make certain that it does not turn red. (For the part No. for additional procurement of the thermo sticker, refer to Item “6.4”.

Page 10

2.2.2 Mounting method of ﬂ ow guide tube

■

(Designation of type: When 9th to 11th digits are 5A

The ﬂ ange of ﬂ ow tube has mounting holes at 8 locations. These holes are available for regulating an in- ﬂ ow into the ﬂ ow guide and mounting the tube correctly in the ﬂ owing direction of gas and it is enough if

mounted at 4 locations.

(1) Direction of tongue and Partition plate of ﬂ ow guide tube

1 When exhaust gas temperature is under 200°C and gas ﬂ owing velocity is low

As illustrated below, set the partition plate inside the ﬂ ow guide tube at a right angle to the gas ﬂ ow and

mount the tube so that the tongue turns to an upstream direction relative to the gas ﬂ ow.

■

, 5B

and 5C

■

)

■

Packing (not included in scope of supply)

Mating flange (not included in scope of supply)

Arrow mark of flow guide tube

ø15 (JIS5K-65A)

Partition plate

Tongue

Gas flow

Furnace wall

min.60mm

2 When exhaust gas temperature is 200°C or higher and gas ﬂ owing velocity is fast

As illustrated below, till the partition plate inside the ﬂ ow guide tube 45° to the gas ﬂ ow and mount the

tube so that the tongue turns to a down-steam direction relative to gas ﬂ ow.

Gas flow

Tongue

Partition plate

Arrow mark of flow guide tube

Furnace wall

min.150mm

Packing (not included in scope of supply)

ø15 (JIS5K-65A)

Arrow mark of

flow guide tube Mating flange (not included in scope of supply)

(2) Inserting angle of ﬂ ow guide tube

According to the temperature of exhaust gas and the amount of dust, the inserting angle of the ﬂ ow guide tube differs. With reference to the following conditions, install a mating ﬂ ange.

1 When exhaust gas temperarture is under 200°C and amount of dust is

under 0.2g/Nm

(Desingation of type: When 9th to 11th digits are 5A

)

■

• Inserting angle: within a range of -45 to +45°

2 When exhaust gas temperature is 200°C or higher and amount of dust

is under 0.2g/Nm

(Designation of type: When 9th to 11th digits are 5A

• Inserting angle: within a range of -20 to +20°

3 When amount of dust is over 0.2g/Nm

(Designation of type: When 9th to 11th digits are 5B

)

■

Down

and 5C

■

)

■

• Inserting angle: within a range of 0 to +45°

Inserting angle

–

Inserting angle

Page 11

2.2.3 Mounting method of high dust-use ﬂ ow guide tube

(Desingation of type : When 9th to 11th digits are 6D and 6E)

Mount the tube so that the gas outlet turns downward relative to the gas ﬂ ow as shown below.

For high dust

Gas outlet

Gas flow

Be careful not to block the gas outlet by the furnace wall or pipe and keep the periphery of the outlet widely.

Set the inserting angle within a range of 0 to +45°.

2.2.4 Mounting of heat insulating cover

For using at a cold distric, use a heat insulating cover (For the part No. for additional procurement of the heat insulating cover, refer to Item “6.4”).

• Put M4-mounting screw of the heat insulating cover into M4-heat insulating cover ﬁ xing tapped hole of the teminal box with M4-screw ring put between the tapped hole and screw.

• Do not use a heat insulating cover in the place where the temperature is high.

Terminal box

Fitted with high dust cover

Gas flow

Heat insulating cover (according to designation)

Gas outlet

Gas flow

Down

Inserting angle

M4-Mounting screw

M4-Screw ring

M4-tapped hole (for fixing heat insulating cover)

Page 12

3. PIPING

3.1 Piping of calibration gas

As the piping material, use a teﬂ on-made ø6mm or ø1/4inch tube.

• From the coupling attached to the detector, remove (2) nut, (3) front ferrule and (4) back ferrule, put them through to the ø6mm or ø1/4inch teﬂ on tube for piping, and then attach it to (1) coupling.

• For mounting (2) nut, tighten by making about 2 turns with a spanner after it cannot be turned any more by hand.

Joint for calibration gas:

The joint for calibration gas is a special joint with a built-in check valve.

If a malfunction occurs, order the joint for calibration gas and attach it.

Main body (calibration gas inlet)

(1) Coupling

(3) Frount ferrule

(4) Back ferrule

(2) Nut

ø6mm or ø1/4inch teflon tube for piping

3.2 Piping of reference gas inlet

If the atmosphere around the terminal box is signiﬁ cantly dirty or the humidity of the location is extremely high, install piping for reference gas.

If the 13th digit of the type is “A” or “B,” the piping for reference gas is delivered together with the detector body.

CAUTIONS

• When used at an ordinary place (oxygen concentration : 20.6vol%), the reference gas is unnecessary. So, don’t remove a hexagonal plug of the mounting port of reference gas inlet unnecessarily since a waterproofness becomes poor.

Refer to the previous section “3.1 Piping of calibration gas” for the installation method of piping.

Set one of the two reference gas ports as “inlet” and the other as “outlet.”

Install piping so that dust or water does not enter the “outlet.”

Attachment of joints for reference gas:

If you order the joints for reference gas additionally, remove the hexagonal plugs and attach the joints for reference gas (two locations) as shown in the ﬁ gure on the right.

2 Reference gas inlet

1 Packing

3.3 Piping for blow down air

Connect the blow air inlet (4 locations) of blowdown-ﬁ tted ﬂ ow guide tube by detaching a plug of the upper- side blow port (1 location) so that drain does not accumulate.

For the blow piping, use a copper tube equivalent to 15A SGP or larger (tube having larger inside diameter) or ø10/ø8 teﬂ on tube. And, use L-shape joint or union without bending the pipe wherever possible and keep the piping length as short as possible.

Page 13

3.4 Piping drawing

Flow guide tube system (with valve)

Rc1/4 (upper side blow port should be selected) Blow-down, 200 to 300kPa

Solenoid valve (not supplied)

Reduction valve (unnecessary when supply air pressure is 200 to 300kPa)

Supply air

Flow guide tube

Gas temperature. 600ºC max.

Sample gas outlet

Gas temperature. 600ºC max.

Flow guide tube for high particulate

Sample gas outlet

*2 Ref. air

Blue

Rainproof cover

123

Yellow

Detector

(ZFK8)

Red

White Black White

15ASGP tube equivalent or ø10/ø8 PTFE pipe or copper pipe (not supplied)

AC power supply

Rainproof flexible conduit. (Max. 20m)

15ASGP tube equivalent or ø10/ø8 PTFE pipe or copper pipe (not supplied)

Converter (ZKM)

Gas temperature. 600ºC max.

Flow guide for high particulate with cover

ø6mm or ø1/4 inch tube for calibration gas (not supplied)

RS232C

RS485

(option)

(Option)

*2 Ref. air

to Detector

115234567891011121314

＋

O2 input

−

Thermocouple for combustion control

＋

TC2

＋

TC1

Thermocouple

input

−

＋

−

4 to 20mA DC

Contact input

DI1

Analog output

or 0 to 1V DC

DI2 DI3

18 19

−

FAULT BLOW

Fault

contact

output

ALARM

DICOM

Alarm

contact

output

21 22

Blow

contact

output

Maintenance

contact

output

MAINTE

23 24

GAS

Calibrating

gas contact

output

ZERO

Calibrating gas

contact output

COM

25 28

12 3

TM-2

Flowmeter

Valve

MEASURE

Reduction valve (ZBD6)

ZERO

Standrad gas for zero point (ZBM)

*1 Span gas (ZBM)

Note:

Flowmeter

SPAN

Reduction valve (ZBD6)

*1 Air supply

Reduction valve

(0.2 to 0.5L/min)

(not supplied)

(unnecessary when supply air pressure is 50 to 100kPa)

TM-1

HEATER

Heater

AC power

SPAN

supply

GAS

NSV

26 27

*1 Standard gas or instrumentation air can be used in place of span gas. *2 Instrument quality air or bottled air is available as reference air instead of ambient air. *3 Protective earth. *4 Connect the shield of a exclusive cable with the ground terminal in the converter.

Page 14

Flow guide tube system

Rc1/4 (upper side blow port should be selected) Blow-down, 200 to 300kPa

Solenoid valve (not supplied)

Reduction valve (unnecessary when supply air pressure is 200 to 300kPa)

Supply air

Flow guide tube

Gas temperature. 600ºC max.

Sample gas outlet

Gas temperature. 600ºC max.

Flow guide tube for high particulate

Sample gas outlet

*2 Ref. air

Blue

Yellow

Rainproof cover

Detector

(ZFK8)

123

Red

White Black White

15ASGP tube equivalent or ø10/ø8 PTFE pipe or copper pipe (not supplied)

AC power supply

Rainproof flexible conduit. (Max. 20m)

15ASGP tube equivalent or ø10/ø8 PTFE pipe or copper pipe (not supplied)

Converter (ZKM)

Gas temperature. 600ºC max.

Flow guide for high particulate with cover

＋

O2 input

115234567891011121314

ø6mm or ø1/4 inch tube for calibration gas (not supplied)

12 3

RS232C

RS485

(option)

TM-2

Flowmeter (ZBD4) (1 to 1.5L/min)

*2 Ref. air

to Detector

(0.2 to 0.5L/min)

(not supplied)

*1 Standard gas or instrumentation air can be used in place of span gas.

Note:

*2 Instrument quality air or bottled air is available as reference air instead of ambient air. *3 Protective earth. *4 Connect the shield of a exclusive cable with the ground terminal in the converter.

＋

−

Thermocouple

Thermocouple for combustion control

＋

−

TC2

TC1

input

−

Contact input

DI1

Joint

＋

−

Analog output

4 to 20mA DC

or 0 to 1V DC

DI2 DI3

18 19

Solenoid valve (not supplied)

FAULT BLOW

Fault

contact

output

Alarm

contact

output

ALARM

DICOM

21 22

Reduction valve (ZBD6)

ZERO

GAS

Calibrating

Blow

gas contact

contact

output

Maintenance

contact

output

MAINTE

23 24

Standrad gas for zero point (ZBM)

Reduction valve (unnecessary when supply air pressure is 50 to 100kPa)

HEATER

Heater

Calibrating gas contact output

COM

25 28

SPAN

GAS

26 27

AC power supply

NSV

AC power supply

*1 Air supply

TM-1

Reduction vale (ZBD6)

Span point

*1 Standard gas for span point (ZBM)

Page 15

Ejector system (with valve)

Ejector (ZTA)

Gas temperature. 1500ºC max.

Detector (ZFK8)

123

Black

Yellow

Bule

Red

Flowmeter

Ejector (5 to 10L/min)

Power supply

1 2

Heater temperature drop

4 5

Alarm

Copper pipe ø10/ø8mm (not supplied)

White

(ZBD)

Copper pipe ø6/ø4mm (not supplied)

Solenoid valve (not supplied)

AC power supply

Rainproof flexible conduit. (Max. 20m)

Reduction valve (unnecessary when supply air pressure is 200 to 300kPa )

Joint

Copper pipe ø10/ø6mm (not supplied)

Supply air

ø6mm or ø1/4 inch tube for calibration gas (not supplied)

RS232C

RS485

(optein)

*1 Standard gas or instrumentation air

Note:

can be used in place of span gas. *2 Instrument quality air or bottled air is available as reference air instead of ambient air. *3 Protective earth. *4 Connect the shield of a exclusive cable with the ground terminal in the converter.

AC power supply

NSV

TM-1

1152 3 4 5 6 7 8 9 10 11 12 13 14

＋

O2 input

−

Thermocouple for combustion control

＋

TC2

＋

TC1

Thermocouple

input

−

＋

−

Analog output

4 to 20mA DC

or 0 to 1V DC

Contact input

DI1

DI2 DI3

18 19

−

FAULT BLOW

Fault

contact

output

ALARM

DICOM

Alarm

contact

output

21 22

Blow

contact

output

Maintenance

contact

output

MAINTE

23 24

GAS

Calibrating

gas contact

output

ZERO

Calibrating gas

contact output

COM

25 28

HEATER

Heater

SPAN

GAS

26 27

12 3

(Option)

Flowmeter

TM-2

Val ve

MEASURE

Reduction valve (ZBD6)

AC power supply

ZERO

Standrad gas for zero point (ZBM)

*1 Span gas (ZBM)

*1 Air supply

*2 Ref. air

to Detector

Flowmeter

(0.2 to 0.5L/min)

(not supplied)

SPAN

Reduction valve (ZBD6)

Reduction valve (unnecessary when supply air pressure is 50 to 100kPa)

Page 16

Ejector system

Gas temperature. 1500ºC max.

Ejector (ZTA)

Detector (ZFK8)

Bule

123

Black

Yellow

Red

Flowmeter

Ejector (5 to 10L/min)

Power supply

1 2

Heater temperature drop

4 5

Alarm

Copper pipe ø10/ø8mm (not supplied)

White

(ZBD)

Copper pipe ø6/ø4mm (not supplied)

Solenoid valve (not supplied)

AC power supply

Rainproof flexible conduit. (Max. 20m)

Reduction valve (unnecessary when supply air pressure is 200 to 300kPa )

Joint

Copper pipe ø10/ø6mm (not supplied)

Supply air

115234567891011121314

＋

−

O2 input

Thermocouple for combustion

ø6mm or ø1/4 inch tube for calibration gas (not supplied)

control

＋

TC2

12 3

RS232C

RS485

(optein)

TM-2

(1 to 1.5L/min)

Flowmeter

(ZBD4)

*2 Ref. air

to Detector

(0.2 to 0.5L/min)

(not supplied)

*1 Standard gas or instrumentation air can be used in place of span gas.

Note:

＋

−

TC1

Thermocouple

input

−

DI1

Joint

＋

Analog output

4 to 20mA DC

or 0 to 1V DC

Contact input

DI2 DI3

18 19

Solenoid valve (not supplied)

−

FAULT BLOW

Fault

contact

output

ALARM

DICOM

Blow

contact

output

Alarm

contact

output

21 22

Reduction vale (ZBD6)

ZERO

GAS

Calibrating

gas contact

output

Maintenance

contact

output

MAINTE

23 24

Standrad gas for zero point (ZBM)

Reduction valve (unnecessary when supply air pressure is 50 to 100kPa)

HEATER

Heater

Calibrating gas

contact output

SPAN

GAS

26 27

NSV

COM

25 28

*1 Air supply

Reduction vale (ZBD6)

Span gas

*1 Standard gas for span point (ZBM)

AC power supply

TM-1

AC power supply

Page 17

4. WIRING

CAUTIONS

• In the case of the wiring work, be careful not to drop foreign matters including wire chips inside the product. Otherwise, this might cause a ﬁ re, failure or malfunction.

• Connect a power source compatible with the rating. Connection of a power source not conforming to the rating may cause a ﬁ re.

• Before proceeding with the wiring work, be sure to turn off the main power supply. Otherwise, there is a fear of getting an electric shock.

• As the wiring material, use a proper one conforming to the rating of apparatus. The use of a wiring material which is not bearable to the rating could cause a ﬁ re.

PROHIBITION

• Under no circumstances be the work at a place where the product gets wet with water, such as the rain. Otherwise, an electric shock or failure may result.

Page 18

4.1 Before wiring

Put a cable (6 cores in all) connected between detector and converter into a piping tube for protecting the cable. Also, put the cables for R thermocouple and element output away from the power cable to take a noise preventive step.

When an exclusive cable is not used, use the following wire rods:

• For heater (2 pcs.) ...............3A or more in rating

• For R thermocouple ............Speciﬁ ed in JIS C1610-1995 (equivalent to RCA-2-G-0.75mm2-S2).

• Recommended wire rod (at 20 ºC)

For heater

Element output

compensation conductor Nominal sectional area (mm2) 0.75 Number of composed element wires/

diameter of element wire (mm)

30/0.18

Outside dia. (mm) 1.1 1.14 Thickness of vinyl insulating material (mm) 0.6

Composition

Thickness of vinyl sheath (mm) 1.0 1.5

Max. conductor resistance per unit length (Ω/km) 24.4 — Test voltage (V) 1000 1500 Insulation resistance per unit length (MΩ•km) 5 40 Rating (A) 7 —

For wiring of the detector, be sure to use a solderless terminal (for M3).

•

Recommended solderless terminal ............ Solderless terminal prescribed in JIS C 2805 (Nominal designation: R1.25-3)

4.2 Wiring to each terminal

CAUTIONS

• Be careful not to mix up the wiring for thermocouple (four-core, white) and the wiring for heater (two-core, white).

(1) Black

(3) Red

T+HS+

grounding terminal screw: M4

2 core wire

Heater power 100 to 120VAC 50/60Hz or 200 to 240VAC 50/60Hz

(1) Black (2) White

(6) Blue

Exclusive cable for converter

4 core wire

Thermo couple (R-type) (3) Red

(4) White

Sensor output (5) Yellow

(6) Blue

T-

S-

(5) Yellow

Screw for wiring connections: M3

(4) White

(2) White

Page 19

Connect the protective grounding to one of the two terminals in the ﬁ gure below. (Class D (Class 3)

grounding, grounding resistance: 100Ω or less)

T+HS+

madeinjapan

Grounding

Grounding terminal

terminal

Wireng of protective grounding terminal

TK4J4664R0

T-

S-

Attach the solderless terminals to the grounding terminals with them between the tooth lock washer and screw with washer .

( recommended tightening torque:

1.8 N·m)

Screw with washer M4

Tooth lock washer

Grounding

Grounding terminal

terminal

Note

• Use the cable more than 0.75mm2 for main ground (earth) line.

• For solderless terminal , doubly caulk the core and the sheath separately.

The core should be poked from 0.5 to 1.0 mm.

The core should be so as not to be seen or not to be come apart.

The crimping (vary by tools) should clearly be in the normal place.

No space required between the insulating material and the wire.

• Use “ ” type of solderless terminal .

Double caulking

4.3 Mounting of conduit

• Remove (2) packing holder nut,(3) packing and (4) bushing from M coupling of the main body.

• Fit the (2) packing holder nut and (3) packing onto the conduit and ﬁ t the end face of conduit into a groove of the (4) bushing.

• Insert the (4) bushing ﬁ tted to the conduit into (1) M coupling of the main body and tighten with the (3) packing and (2) packing holder nut for ﬁ xing.

(2) Packing holder nut

Conduit

(3) Packing

(1) Main body M coupling

Packing at main body side

(4) Bushing

(2) Packing holder nut (4) Bushing

(3) Packing

Conduit

(1) Main body M coupling

Page 20

5. OPERATION AND STOP

DANGER

• In case where combustible gas is contained in the measured gas, make sure of the gas composition and speciﬁ cations carefully before using this product. Otherwise, the original performance is not displayed and there is a fear of explosion.

5.1 Start of operation

• If the power switch of the converter is turned on after completion of wiring and piping work, the detector starts its operation.

• After warm-up at least 10 minutes, start the operation of the furnace.

• After zero calibration and span calibration have ﬁ nished, get to work on the measurement.

• For the method of calibration, refer to each instruction manual of converters (ZKM, ZRM and ZRY).

• When the converters (ZKM, ZRM and ZRY) are not used, run the zero and span calibration gases and calibrate by converting the output in a stabilized state into oxygen concentration according to the standard output table of converter in Item. “6.3”. If using the reference gas, supply it before the calibration. (ﬂ ow rate: 0.2 to 0.5L/min)

5.2 Stop of operation

If the power is turned on in in a state of dew condensation, it leads to the failure of detector. Stop the operation following the procedures described below.

(1) In case of short-term shutdown (about 1 week) of furnace

• Keep the power supply of the detector (converter) turned “ON”. This can prevent the detector from getting dewed.

Also, note that if “ON-OFF” is repeated in a condition where the detector has dewed (according to the

furnace and ambient conditions), the detector might fail.

• When the ejector (ZTA) is in use, stop the air supply to the ejector.

(2) In case of long-term shutdown of furnace

• Turn off the power of the detector (converter) after the peripheral air of the detector inside the furnace (especially, temperature and humidity) has become an air environment. Or, turn off the power after taking the detector out of the furnace and leaving it as it is for 15 minutes or more.

• When the ejector (ZTA) is in use, stop the air supply to the ejector.

Page 21

6. MAINTENANCE AND CHECK

CAUTIONS

• Do the work in a condition where the main power supply has been turned off.

If the work is done while current is ﬂ owing, there is a fear of getting an electric shock.

• The operation temperature of the detector (tip of the ceramic heater) is about 800°C and the surface temperature is also very high. So, never touch it by bare hand. Otherwise, there is a fear of getting a burn.

• Before proceeding with the cleaning of the ﬂ ow guide tube, turn off the main power and cool the tube down fully and then, do the work. Otherwise, there is a fear of getting a burn.

• Don’t use other renewal parts than those designated by the maker. Otherwise, the original performance is not displayed fully and an accident or failure could come about.

• Dispose of the renewal parts including the maintenance parts as an incombustible.

PROHIBITION

• Under no circumstances the work at a place where the product gets wet with water, such as the rain. Otherwise, an electric shock or failure may result.

6.1 Check

Perform the check periodically for using the product always in good condition. Especially, perform the checks shown in table below. Moreover, perform the periodic check at a time of checking the furnace or every 6 months.

Check items Details of checking work

Execution of zero & span calibration • When the converters (ZKM, ZRM and ZRY) are in use: With refer-

Check for looseness of cable gland. Retighten the cable gland or if the packing is found deteriorated,

Check of residue in calibration gas cylinder Check it by a primary pressure gauge. Check of blowdown (when blowdown

nozzle is ﬁ tted) Check for leak from packing ﬁ tted between

ﬂ ow guide tube and mating ﬂ ange and O-ring of detector.

Removing detector, check for clogging of ceramic ﬁ lter of detector.

Check by disconnecting for clogging or corrosion of ﬂ ow guide tube.

Check by removing for clogging or corrosion of sampling probe of ejector (ZTA).

Check by removing if air outlet port of ejector (ZTA) is left stopped up.

Periodic check Daily check

ence to the instruction manuals of the converters (ZKM, ZRM and ZRY), check once a week as a rough standard. (calibration gas ﬂ ow rate : 1.5 to 2.0L/min)

• When the converters (ZKM, ZRM and ZRY) are not used: Running the zero and span calibration gases, make calibration once a week as a rough standard by converting the output in a stabilized state into oxygen concentration according to the standard output table of converter in Item “6.3”.

replace.

Referring to each instruction manual of the converters (ZKM, ZRM and ZRY), check at 200 to 300kPa.

If either of the packing and O-ring or both of them are found deteriorated, replace with new O-ring (refer to the part No. for procurement in Item “6.4”) and replace the packing (not included in scope of supply).

When it is necessary to replace the ceramic ﬁ lter, refer to Item “6.2.2”.

Check following the procedure in Item “6.2.3”.

Check following the procedure in Item “6.2.4”.

Clean the air outlet port of the thermal insulation part of furnace wall.

Page 22

6.2 Maintenance

The replacing intervals of sensor unit, ceramic ﬁ lter and O-ring, and the maintenance periods of ﬂ ow guide tube and sampling probe differ depending on the working conditions including the components of measured gas and the amount of dust.

The replacing intervals in a general conditions are shown below. Determine the replacing intervals in the individual working condition with a period till a ﬁ rst replacement after delivery and operation as a rough standard.

• Sensor unit ................................................ Yearly

• Ceramic ﬁ lter ............................................ At 6 month interval

• Flow guide tube ........................................ At 3 to 4 year interval

• ZTA sampling probe ................................. At 3 to 4 year interval

• O-ring ....................................................... Yearly

6.2.1 Replacement of Sensor unit

Caution about the replacement of the sensor unit:

• Check that the sensor unit complies with the speciﬁ cations of the power supply you use.

• Avoid replacing the sensor unit while the current is applied.

• The temperature of the detector becomes high. Replace the sensor unit after the temperature is reduced sufﬁ ciently.

(1) Turn off the power for the detector. (Set the switch of the converter or the main power supply to “OFF”.)

(2) Check that the surface temperature of the detector is reduced sufﬁ ciently.

(3) Remove the terminal box cover and then remove the terminal block cover in the terminal box (M3 screw,

two locations).

(4) Remove the six wires connected the terminal block of the sensor unit (M3 screws, six locations).

(5) Remove the screw with washer (M3 screws, four locations) fastening the sensor unit .

(6) Remove the sensor unit and o-ring from the detector.

(7) Attach the supplied O-ring of the replacement sensor unit to the groove for the O-ring at the detector.

(8) Attach the replacement sensor unit to the detector.

(Attach the sensor unit so that the rotational direction is as shown in the ﬁ gure below.)

(9) Fasten the sensor unit with the supplied screw with washer (M3 screws, four locations).

(recommended tightening torque: 0.7 N·m)

(10) Connect six wires to the terminal block of the sensor unit and attach the terminal block cover.

(11) Attach the terminal box cover.

Groove for the O-ring

Detector

Exclusive cable for converter

O-ring

2 core wire

4 core wire

Sensor unit

Pan head screw with washers (4 pieces)

Heater power 100 to 120V AC 50/60Hz or 200 to 240V AC 50/60Hz (1) Black (2) White

Thermo couple (R-type) (3) Red

(4) White

Sensor output (5) Yellow (6) Blue

(6) Blue

T+HS+

made in japan

T-

S-

(5) Yellow

Screw for wiring connections: M3

(1) Black

(3) Red

Grounding wire screw: M4

TK4J4664R0

(4) White

(2) White

Page 23

6.2.2 Replacement of ceramic ﬁ lter

(1) After turning “OFF” the power of the detector, lower the surface

temperature of the tip (at the ceramic ﬁ lter side) by cooling down fully with the air.

(2) After having been cooled down fully, remove the ﬁ lter frame

from the detector, take the ceramic ﬁ lter and reﬂ ector off the ﬁ lter frame.

(3) Set a new ceramic ﬁ lter and reﬂ ector in the ﬁ lter frame and ﬁ t the

frame to the detector and then, tighten till the ceramic ﬁ lter does not move any longer. (Be careful then not to fail to set the reﬂ ec- tor in place. For the part No. for additional procurement of the reﬂ ector, refer to Item. “6.4”).

6.2.3 Maintenance of ﬂ ow guide tube

• After removing the ﬂ ow guide tube from the furnace wall and then, from the detector, cool the tube down fully in the air.

• Remove dust sticking to the outside of the ﬂ ow guide tube by water-washing with the use of a scrubbing brush.

• Remove dust sticking to the inside of the ﬂ ow guide tube by using a metallic rod or screwdriver.

(Clean so that tube is through at least about 3/4 part of the whole interior.)

• For the ﬂ ow guide tube for high dust, remove together dust sticking around the gas outlet.

Reflector

Ceramic filter

Filter frame

6.2.4 Maintenance of sampling probe

• After removing the ejector (ZTA) from the furnace wall and then, the sampling probe from the ejector, cool the probe down fully in the air.

• Remove dust sticking to the outside of the ﬂ ow guide tube by using a scrubbing brush.

CAUTIONS

• The high temperature-use sampling probe (made of SIC) of the ejector (ZTA) is liable to break. So, be careful not to cool abruptly by water (quenching) or apply undue force to the probe in the dust removing work.

• Remove dust sticking to the inside of the ﬂ ow guide tube by using a metallic rod or screwdriver.

(Clean so that the tube is through at least about 3/4 part of the whole interior.)

Page 24

6.3 Standard output of detector

For the output voltage of the detector, refer to the standard output table below.

Standard output table (Reference)

Oxygen

concentration

(Vol%)

0.01 168.15

0.05 132.68

0.1 117.41

0.5 81.94

1.0 66.67

1.2 62.65

1.4 59.25

1.5 57.73

1.6 56.31

1.8 53.71

2.0 51.39

2.2 49.29

2.4 47.37

2.5 46.47

2.6 45.61

2.8 43.98

3.0 42.46

Detector output

(Unit: mV)

concentration

Oxygen

(Vol%)

3.5 39.06

4.0 36.12

4.5 33.52

5.0 31.20

5.5 29.10

6.0 27.18

6.5 25.42

7.0 23.79

7.5 22.26

8.0 20.84

8.5 19.51

9.0 18.25

9.5 17.06

10.0 15.92

11.0 13.82

12.0 11.91

13.0 10.14

Detector output

(Unit: mV)

Oxygen

concentration

(Vol%)

14.0 8.51

15.0 6.99

16.0 5.57

17.0 4.23

18.0 2.97

19.0 1.78

20.0 0.65

20.6 0.00

21.0 -0.43

22.0 -1.45

23.0 -2.43

24.0 -3.37

25.0 -4.27

30.0 -8.29

35.0 -11.68

40.0 -14.62

45.0 -17.22

50.0 -19.54

Detector output

(Unit: mV)

Page 25

6.4 Arrangement

No. Description Classiﬁ cation Part No. for procurement

1 Ceramic ﬁ lter Consumable *ZZPZFK5-TK750201P1

2 Detector O-ring (P38) Consumable *ZZPZFK5-8552836 Viton

3 Sensor unit for replacement Spare parts According to designation of type in

4 Flow guide tube Spare parts According to part No. for procurement

5 Calibration gas inlet

(for

6 Calibration gas inlet

(for 1/4 inch tube)

7 Thermo sticker Additionally

8 Reference gas inlet

(for

9 Reference gas inlet

(for 1/4 inch tube)

10 Reﬂ ector Additionally

11 Heat insulating cover Additionally

6mm

tube)

Additionally procurement part

procurement part Additionally

procurement part

Additionally procurement part

procurement part

Item. “8.2”

of ﬂ ow guide shown in table below *ZZPZFK5-TK7N6820C1

*ZZPZFK5-TK7N6820C2

*ZZPZFK5-TK746983P1

*ZZPZFK5-TK7K1652P9 Gasket included.

*ZZPZFK5-TK7K1652P10 Gasket included.

*ZZPZFK5-TK7H6762P1

*ZZPZFK5-TK4E5339C1

(Procured type)

screw with washer (M3×8): 4 pcs. O-ring (S22.4, Viton) : 1 pc.

(2 pieces are required for the standard gas inlet/outlet.)

Remark

Part No. for procurement of ﬂ ow guide

Type designation digits

9 10 11 5 A 3 *ZZP-TK464430C1 For general use 300mm 5 A 5 *ZZP-TK464430C2 For general use 500mm 5 A 7 *ZZP-TK464430C3 For general use 750mm 5 A 1 *ZZP-TK464430C4 For general use 1000mm 5 B 3 *ZZP-TK4B5999C1 Corrosive gas 300mm 5 B 5 *ZZP-TK4B5999C2 Corrosive gas 500mm 5 B 7 *ZZP-TK4B5999C3 Corrosive gas 750mm 5 B 1 *ZZP-TK4B5999C4 Corrosive gas 1000mm 5 C 3 *ZZP-TK4A3274C1 Fitted with blowdown nozzle 300mm 5 C 5 *ZZP-TK4A3274C2 Fitted with blowdown nozzle 500mm 5 C 7 *ZZP-TK4A3274C3 Fitted with blowdown nozzle 750mm 5 C 1 *ZZP-TK4A3274C4 Fitted with blowdown nozzle 1000mm 6 D 8 *ZZP-TK7H8487C3 High dust ﬂ ow guide tube 800mm 6 E 8 *ZZP-TK7H8487C3

Procurement DWG. No. Classiﬁ cation Inserting length

Fitted with high dust ﬂ ow guide tube cover 800mm

*ZZP-TK7H8489C2

Page 26

7. TROUBLESHOOTING

CAUTIONS

• If a failure should occur which cannot be judged even if referring to the operation manual, be sure to ask the nearest dealer or Fuji adjustment serviceman for repair. If disassembled carelessly, there is a fare of an accident or injury.

Troubles Probable causes Check procedures (normal values) Remedies

• Indication is ﬁ xed.

• Indication response is slow.

• Temperature alarm continues coming on despite 20 minutes having elapsed after turning on power.

• Indication is too high or too low.

• Clogging of ceramic ﬁ lter of detector and ﬂ ow guide tube interior

•

Leak from joint and airtightness of mounted part.

• Deterioration of detector • Check by changing zero calibra-

• Decrease of exhaust gas ﬂ owing velocity

• Disconnection of cable • Check continuity. • Replace cable.

• Error in wiring • Check wiring. • Wire correctly.

• Low supply voltage • Check if supply power is as

• Disconnection of thermocouple

• Blow out of fuse of converters (ZKM, ZRM and ZRY)

• Disconnection of detector heater

• Looseness of ﬂ ange mounted part or defects of O-ring or packing (not included in scope of supply).

• Deterioration of detector • Check airtightness of calibration

• Abnormality of detector temperature

• Change of ambient air oxygen concentration of a terminal box or very high humidity

• Check visually for fouling of ceramic ﬁ lter of detector and clogging of ﬂ ow guide tube interior with dust.

• Check for looseness of each joint and airtightness of mounted part.

tion gas over to span calibration gas and vice versa if it takes more than 5 minutes for 90% response.

• Check exhaust gas responding time after stop of calibration gas supply.

speciﬁ ed.

• Check continuity.

• Check if resistance across terminals No. 3 and No. 4 is 2 to 3Ω.

• Check continuity of fuse. • Exchange fuse(s).

• Check heater resistance as follows (exclusive of wiring resistance): For 100V : 50 to 55Ω For 200V : 240 to 260

• Check airtightness of detection unit, ﬂ ow guide tube and ﬂ ange mounted part.

• Check for leak in from periphery. • Shield

gas supply port.

• Check at a time of running zero and span calibration gases if detector output (mV) is higher or lower than others. (Refer to Table in Item “6.3”).

• Check indicated temperature of converter.

• Check ambient air oxygen concentration of a terminal box is

20.6vol%.

• Clean or exchange ceramic ﬁ lter, if need be.

•

Retighten and replace joint(s), if need be.

• Replace detector.

• Increase amount of exhaust gas inside ﬂ ow guide tube to be taken in.

• Clean ﬂ ow guide tube.

•

Supply correct power.

• Replace detector.

(Refer to each instruction manual of conver-ters ZKM, ZRM and ZRY).

• Replace detector.

• Retighten mounting screw.

• Exchange O-ring.

• Exchange packing (not included in scope of supply

•

Retighten calibration gas joint.

• Replace detector.

• Use reference gas inlet.

Page 27

8. APPENDIX

8.1 Speciﬁ cation

8.1.1 General

• Measuring object: Oxygen in noncombustible gas

• Measuring method: Direct insertion type zirconia system

• Measuring range: 0 to 2 ··· arbitrary 2 ranges are settable at

50vol%O2

• Repeatability: Within ±0.5%FS

• Linearity: Within ±2%FS

• Response time: Within 4 to 7 sec, for 90% (from calibration

gas inlet)

• Warmup time: More than 10 min

• Analog output: 4 to 20mA DC (allowable load resistance

500Ω or less) or 0 to 1V DC (output resistance 100Ω or more)

• Power supply: Rated voltage;

• Power consumption: Maximum 240VA (Detector: approx. 200VA,

Converter: approx. 40VA) Normal 70VA (Detector: approx. 50VA, Converter: approx. 20VA)

8.1.2 Oxygen detector (ZFK8) and ejector (ZTA

• Measured gas temperature:

Flow guide tube system; −20 to +600ºC

Ejector system; −20 to +1500ºC

−20 to +800ºC

• Measured gas pressure:

−3 to +3kPa

• Flow guide tube: With or without blow-down nozzle Flange; JIS5K 65A FF (JIS5K-80AFF for high particulate gas) Insertion length; 0.3, 0.5, 0.75, 1m (0.8m for high particulate gas)

• For high particulate (with blowdown nozzle):

With/without cover Flange Insertion length

• Ejector (general-use):

Probe for guiding measured gas to detector Flange; JIS10K 65A RF Insertion length; 0.5, 0.75, 1, 1.5m (according to customer's speciﬁ cation)

• Operating temperature:

−20 to +60ºC for detector

−5 to +100ºC for ejector section

125ºC or less at detector ﬂ ange surface with power applied

• Storage temperature:

Detector: −30 to +70ºC Ejector: −10 to +100ºC

• Structure: Dust/rain-proof structure (IEC IP66 equivalent)

• However, except a ﬁ lter on edge:

Heat insulating cover is required in cold climates (as speciﬁ ed)

• Filter: Alumina(ﬁ ltering accuracy 50μm) and quartz paper

(in 1 vol% O2 steps)

100 to 120V AC (operating voltage 90 to 132V AC) 200 to 240V AC (operating voltage 190 to 264V AC) Rated frequency; 50/60Hz

(for general-use, corrosive gas)

(for high-temperature gas)

(for general-use)

;

JIS5K 80AFF

;

0.8. (standard)

• Main materials of gas-contacting parts:

Detector; Zirconia,SCS14, SUS316, platinum Flow guide tube; SUS304 or SUS316 Ejector (general use); SUS316, SUS304 Ejector; (for high temperature) SiC, SUS316, SUS304

• Calibration gas inlet:

Inlet for ø6mm tube or ø1/4inch tube (as speciﬁ ed)

• Reference gas inlet (option):

Inlet for ø6mm tube or ø1/4inch tube (as speciﬁ ed)

• Detector mounting: Horizontal plane ±45º, ambient air should be clean.

• Outer dimensions: (L × max. dia.) 210mm × 100mm

• Mass (approx.) {weight}:

Detector; 1.6kg Ejector; 15kg (insertion length 1m) Flow guide tube (general-use, 1m); 5kg

• Finish color: Silver and SUS metallic color

• Ejector air inlet ﬂ ow rate:

5 to 10 L/min

• Calibration gas ﬂ ow:

1.5 to 2 L/min

• Blowdown air inlet pressure:

200 to 300kPa

• Ejector exhaust gas processing:

)

• Heater temperature drop alarm output (ejector):

Returned to inside the furnace or ﬂ ue

Alarm output when below 100 ºC Mechanical thermostat 1a contact AC 200V 2A

8.1.3 Converter speciﬁ cation (ZKM)

• Concentration value indication: Digital indication in 4 digits

• Contact output signal:

(1) Contact speciﬁ cation; 6 points, 1a 250V AC/3A or 30V DC/3A

(2) Contact function;

• Under maintenance

• Under blowdown Note3)

• Span calibrating gas

• Zero calibration gas

• Instrument anomalies Note1)

• Alarm Note2)

Note1) The following Instrument errors (1) Thermocouples

break (2) Sensor break (3) Temperature fault (4) Calibration fault (5) Zero/span adjustment fault (6) Output error turn the contact-ON

Note2) Alarm selects just one as mentioned below (1) High (2)

Low (3) High and Lower (4) High-high (5) Low-low, it turns ON while operating.

Note3) It is enable during blowdown when an option is speci-

ﬁ ed, and it turns ON while operating.

• Contact input signal:

(1) Contact speciﬁ cation; 3points (the following option)

ON; 0V (10mA or less), OFF; 5V

(2) Contact function;

• External hold

• Calculation reset

Page 28

• Heater OFF

• Blow down (option)

• Inhibition of calibration

• Calibration start

• Range change

• Calibration method:

(a) Manual calibration with key operation (b) Auto. calibration (option) Calibration cycle; 00 day 00 hour to 99

days 23 hours

•

Calibration gas: • Range settings

Zero gas; 0.010 to 25.00% O Span gas: 0.010 to 50.00% O

• Recommended calibration gas concentration

Zero gas; 0.25 to 2.0% O Span gas; 20.6 to 21.0% O

(oxygen concentration in the air)

• Blowdown : A function for blowing out dust with com-

(option)

pressed air that has deposited in the ﬂ ow guide tube. Blowdown can be performed for a predetermined time and at predetermined intervals. Blowdown cycle; 00 hour 00 minute to 99

hours 59 minutes

Blowdown time; 0 seconds to 999 seconds

• Output hold: Output can be held during manual calibration, auto calibration, blowdown, sensor recovery process, warm-up. And the hold release function can be available.

• Cock(option): Selects zero or span gas during manual zero or span calibration. Mounted on the side of the converter.

• Communication function:

RS232C (MODBUS) standard speciﬁ cation RS485 (MODBUS)(option)

• Combustion efﬁ ciency display (option):

When you select this display, "rich mode display" will be an simultaneous display. This function calculates and displays combustion efﬁ ciency from oxygen concentration and measured gas temperature. Thermocouple (R) is required for temperature measurement.

• Operating temperature:

−20 to +55ºC

• Operating humidity:

95% RH or less, non condensing

• Storage temperature:

−30 to +70ºC

• Storage humidity: 95% RH or less, non condensing

• Construction: Dust-proof, rainproof construction

(corresponding to IP66 or IP67 of IEC)

• Material: Aluminume case

• Outer dimensions (H x W x D):

170 X 159 X 70mm (IP66) 220 X 230 X 95mm (IP67)

• Mass {weight}: IP66: Approx. 2kg (excluding cable and detector)

IP67: Approx. 4.5kg (excluding cable and

detector)

• Finish color: Small case (IP66): Case: Silver Cover: Pantone Cool Gray IC-F

Large case (IP67):

Case: Munsell 6PB 3.5/10.5 (blue) Cover: Silver

• Mounting method: Panel mounting or pipe mounting

Page 29

8.2 Designation of type (code table)

8.2.1 Detector

14 15 169101112134123 5678

51R8- -ZFK

1 2 3

1 3

0 Y 0 5 A 3 5 A 5 5 A 7 5 A 1 5 B 3 5 B 5 5 B 7 5 B 1 5 C 3 5 C 5 5 C 7 5 C 1 6 D 8 6 E 8

Z Z Z

Y A

Y A B

Cal. gas inlet

For φ6mm tube (SUS) For φ1/4 inch tube (SUS) Ball valve

Power supply

100 to 120VAC 50/60Hz 200 to 240VAC 50/60Hz

Flow guide tube

flange application length None SUS304 general use 300mm SUS304 general use 500mm SUS304 general use 750mm SUS304 general use 1000mm SUS316 for corrosive gas 300mm SUS316 for corrosive gas 500mm SUS316 for corrosive gas 750mm SUS316 for corrosive gas 1000mm SUS316 with blow-down nozzle 300mm SUS316 with blow-down nozzle 500mm SUS316 with blow-down nozzle 750mm SUS316 with blow-down nozzle 1000mm SUS316 for high particulate 800mm SUS316 for high particulate with 800mm cover Others Others Others Note) Standard flange size is JIS5K-65A FF, but flange size for high particulate is JIS5K-80A FF

Heat insulating cover

Without With

Reference gas inlet

Non For φ6mm tube (SUS) For φ1/4 inch tube (SUS)

Filter spec.

Standard

Instruction manual language

Japanese

English

Chinese

Specification name plate

Standard (100 to 120V AC 50/60Hz)

Standard (200 to 240V AC 50/60Hz)

Description

8.2.2 Replacement sensor unit

Power supply Code symbols

100 to 120V AC ZFK8YY15-0Y0YY-0YY

200 to 240V AC ZFK8YY35-0Y0YY-0YY

8.2.3 Ejector

21 345678

11ATZ

Measured gas temperature

1 2

B C D

For high temperatures (+1500°C max.) General-use (+800°C max.)

Insertion length [mm]

500 750 1000 150 0

Power supply

100V/115V AC 50/60Hz

200V/220V AC 50/60Hz

230VAC 50/60Hz

Description

Page 30

8.2.4 Converter

(1) ZKM

910111221 345678

-11MKZ

1 2 3

B E Z

1 2

Y 1 2 3 4

6 7

E C

Description

Structure

Small case (IP66) Large case (IP67) Bench type

Output signal

4 to 20mA DC 0 to 1V DC Other

Communication function

RS-232C RS-485

Mounting bracket

None (Specify "None" when the bench type is selected)

Mounting on panel surface Pipe mounting

Optional Functions

None Combustion efficiency display function Note4) Blowdown Auto calibration Combustion efficiency display

+ Blowdown Note4) Combustion efficiency display

+ Auto calibration Note4) Blowdown + Auto calibration Combustion efficiency display + Blowdown

+ Auto calibration Note4)

Display language

Japanese

English Chinese

Option

With valve (Specify "None" when the bench type or the auto calibration is selected)

With valve + flowmeter

Note4) When you select this display, rich mode

will be a simultaneous display.

(2) Exclusive cable for converter

921 345678

-1KRZRZ

YA YB YC YD YE YF YG YH YJ YK YL

AA BB CC

Connectable devices

For ZKM

Types

For R thermocouple

Conduit length Cable length

None 6m None 10m None 15m None 20m None 30m None 40m None 50m None 60m None 70m None 80m None 90m None 100m 6m 6m 10m 10m

Note5

15m 15m 20m 20m

Terminal treatment

None

One side (detector side)

Both sides

Note5) For connection between detector and

converter, the conduit to be used should be rainproof flexible type.

Description

8.3 Device composition

The device to be combined differ according to the conditions of the gas to be measured. Select the devices to be

combined with reference to the following table.

Measured gas Device conﬁ guration

Application Temperature Gas Flow DUST Protection

cover

General-use

(boiler)

For

corrosive

gas (refuse

incinerator)

Sludge

incinerator

General-use

(furnace)

600ºC or

less

600ºC or

less

800ºC or

less

1500ºC or

less

5 to 20m/s Less than 0.2g/Nm

Less than 10g/Nm

5 to 20m/s Less than 1g/Nm

Less than 10g/Nm

Less than 25g/Nm

1m/s or

Less than 1g/Nm

less

1m/s or

Less than 1g/Nm

less

— Fuel; gas, oil ZFK8R 5-5A ZKM —

— Fuel: coal

with blow down — Included low moisture ZFK8R 5-5B ZKM — — Included low moisture

with blow down no Included low moisture

with blow down

yes Included high moisture

with blow down — When a measurement gas has

a low water content with blow

down — When a measurement gas has

a low water content with blow

down

Note (1) Dust volume is approximate value. (2) Instrument quality air or bottled air is available as Reference gas by selecting detector with Reference

gas inlet.

Note Detector type Converter

type

ZFK8R 5-5C ZKM —

ZFK8R 5-6D ZKM —

ZFK8R 5-6E ZKM —

ZFK8R 5-0Y0 ZKM ZTA2

ZFK8R 5-0Y0 ZKM ZTA1

Ejector

type

Page 31

8.4 Outline diagram (unit: mm)

(1) Detector (ZFK8)

ø80

ø67

6-ø6

Approx.62

Heat insulating cover

(as specified)

Approx.132

Approx.130

Terminal box

EXTERNAL CONNECTION DIAGRAM

60°

Ref. gas inlet (as specified) SUS316,for Or 1/4 inch tube

(2) Replacement sensor unit

(ø17.5)

ø26

Filter

Approx.30

Calibration gas inlet

ø6/ø4 tube

(as specified) SUS316,for Or 1/4inch tube

(132.7)

(88.4) 3.5

ø6/ø4 tube

Ground-wire Screw: M4

Exclutive Cable gland

ø35

ø79

Heater Thermocouple

ø85

125.5

Black / White/ red / White/ yellow / blue

2-core wire 4-core wire

Exclusive cable

4-ø3.5(For detector mounting)

T+

S+

made in japan

S-

TK4J4664R0

T-

45 6

45°

Element output

(3) Flow guide tube (for general use)

Oxygen detector

Approx. L

ø34

Gas inlet

Gas outlet

Approx. 20

6-M5 detector mounting side

ø155

ø130

ø67

8–15 MTG. holes

Z F K 8 R 5 - 5 A 3

Code 11th

L (m)

MASS

Approx.(kg)

0.3

2.7

0.5

0.75

4.1

3.3

5 7 1

1.0

4.8

L= (as specified)

Page 32

(4) Flow guide tube (For corrosive gas)

Oxygen detector

(5) Flow guide tube (with blow down nozzle)

ø155

ø130

ø67

ø155

ø130

ø67

8-ø15 MTG. holes

Z F K 8 R 5 - 5 B 3

Code 11th

L (m)

MASS

Approx.(kg)

0.3

3.3

0.5

4.5

0.75

6.1

1.0

7.6

5 7 1

L= (as specified)

Gas outlet

Approx. 40

Approx. 20

6-M5 detector side

Approx. L

Gas inlet

ø67

ø60.5

Approx. L

Oxygen detector

ø67

ø60.5

Gas inlet

Gas outlet

6-M5 detector mounting side

Blow down air inlet

4-Rc1/4 with plug

8–15 MTG. holes

Z F K 8 R 5 - 5 C 3

0.3

3.0

0.5 0.75 1.0

3.8

Code 11th

L (m)

Mass Approx.(kg)

4.8

5.7

5 7 1

L= (as specified)

Page 33

(6) Flow guide tube (for high particulate)

4-Rc1/4 with plug

ø180

145

Flange: JIS 5K80A FF

ZFK MTG. position

Packing

Gas outlet

Gas flow

Tube (50A SCH40)

ø67

ø29.5

Approx. L

8 - ø19 MTG. hole

185

Blow down air inlet

When mounting, select one of blow inlets on the upper side (for prevention of drain)

'longate

hole

Z F K 8 R 5 - 6 D

Code 11th

L (m)

Mass Approx.(kg)

0.3

4.5

3 5 7 1

0.5 0.75 1.0

5.6

8.3

7.0

L= (as specified)

Page 34

(7) Flow guide tube (for high particulate with cover)

4-Rc1/4 with plug

ø180

ø145

Blow down air inlet

8 - ø19 MTG. holes

ø67

29.5

Flange: JIS 5K80A FF

ZFK MTG. position

When mounting, select one of blow inlets on the upper side (for prevention of drain)

Packing

Gas flow

Protection tube (65A SCH40)

Gas outlet

(38)

Tube (50A SCH40)

Approx. L+10

(Approx. L)

(175)

'longate

hole

*Height of an adaptive mating flange is approx. 150mm. (Do not block the gas outlet)

Z F K 8 R 5 - 6 E

Code 11th

L (m)

Mass

Approx.(kg)

0.3

7.1

3 5 7 1

0.5 0.75 1.0

9.0

13.6

11. 4

L= (as specified)

Page 35

International Sales Div Sales Group

Fuji Electric ZFK8 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PREFACE

SAFETY PRECAUTIONS

CONTENTS

1. INTRODUCTION

1.1 General description of zirconia oxygen analyzer

2. MOUNTING

2.1 Mounting location

2.2 Mounting method

3. PIPING

3.1 Piping of calibration gas

3.2 Piping of reference gas inlet

3.3 Piping for blow down air

3.4 Piping drawing

4. WIRING

4.1 Before wiring

4.2 Wiring to each terminal

4.3 Mounting of conduit

5. OPERATION AND STOP

5.1 Start of operation

5.2 Stop of operation

6. MAINTENANCE AND CHECK

6.1 Check

6.2 Maintenance

6.3 Standard output of detector

6.4 Arrangement

7. TROUBLESHOOTING

8. APPENDIX

8.2 Designation of type (code table)

8.3 Device composition

8.4 Outline diagram (unit: mm)