Fuji Electric ZFK8 Operating Manual

Instruction Manual

THE DIRECT INSERTION TYPE

ZIRCONIA OXYGEN

ANALYZER DETECTOR

TYPE: ZFK8

INZ-TN5ZFK8c-E

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

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.

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

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

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

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

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.

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”.

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

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)

+ 24 hidden pages

Fuji Electric ZFK8 Operating 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