Fuji Electric ZFKE Operating Manual

Instruction Manual

THE DIRECT INSERTION TYPE

ZIRCONIA OXYGEN

ANALYZER DETECTOR

TYPE: ZFKE

INZ-TN5ZFKE-E

PREFACE

Thank you very much for your kind purchase of Fuji’s explosion-proof zirconia oxygen analyzer detector (Type ZFKE).

• 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 Instrumentation 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 explosion-proof zirconia oxygen analyzer detector (Type : ZKME) ...... INZ-TN1ZKME-E

Fuji Electric Systems Co., Ltd. 2009

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 without previous notice

Issued in May, 2009

SAFETY PRECAUTIONS

Prior to operating the 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”.

DANGER

CAUTION

: I

If the apparatus is abused, a dangerous condition could arise and it is supposed to

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

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

supposed to die or get a serious injury.

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

• Although this is explosion-proof type, do not use it in the place where explosive gases always exist (zone 0) to prevent explosion, ﬁ re or otherserious

accidents.

• 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 a 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 getsw wet with rain directly.

PROHIBITION:

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

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 incombustible

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 an accident or failure may result.

article.

• 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 dissasembled 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 Description of ﬂ ameproof ..........................................................................................................1

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

1.4 Description of each component ...................................................................................................2

1.5 Check of type ...............................................................................................................................2

1.6 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 .............................................................................................................................12

4.2 How to open the cover ...............................................................................................................13

4.3 Wiring to each terminal .............................................................................................................13

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 ......................................................................................................... 22

8. Appendix ................................................................................................................................ 23

8.1 Speciﬁ cation ..............................................................................................................................23

8.2 Designation of type (code table) ...............................................................................................25

8.3 DEVICE CONFIGURATION .................................................................................................27

8.4 OUTLINE DIAGRAM (Unit:mm) .........................................................................................28

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

Three-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 Description of ﬂ ameproof

Flameproof is the unit that has passed the test conducted by the public institution as an ﬂ ameproof-structured instrument. A test certiﬁ cate and a name plate including necessary speciﬁ cations for the purpose of explosion-proof are attached to such an accepted unit. Conﬁ rm them and use the unit according to those contents. On the name plate for instrument of ﬂ ameproof, the 17th digit of type code, either with N for China or T for Japan, is stated. The certiﬁ cation mark by public institution is also attached.

1.3 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

ConverterDetector

Flow of gas

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

1.4 Description of each component

CAUTIONS

• The operating temperature of detector (tip of 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. Especially when a ﬁ lter at the end of the detector is replaced, take utmost care.

(1) ZFKE

Furnance environment (Gas to be measured)

Filter cap

Measured gas

Ceramic heater

Joint for calibration gas

Packing

Heat insulating material

Thermo sticker

Calibration gas inlet

Air environment (Reference gas)

Terminal box

Terminal box lid

Hexagon plug or reference gas inlet * According to designation of type

Dedicated cable gland

Wiring hole

Caution in handling

• Since the detector is made of porcelain of zirconia, there is a case where it breaks due to drop or impact. So, be sufﬁ ciently careful.

• The detector is unusable for a plant in which water droplets might run down inside a sampling pipe.

• There is no need to remove M5-hexagon set screw of the terminal box unless otherwise a reference gas inlet is used. Don’t loosen the screw without thought since a waterprooﬁ ng effect becomes zero.

1.5 Check of type

The name of type has been put in the speciﬁ cation name-plate. Make sure it is as ordered.

Refer to Item 8.2 “Desingation of type”.

1.6 Check of delivered articles

Make sure the following articles have been delivered without lack.

No. Description

Detector 1 unit Conﬁ rmed in Item 1.3

Instruction manual (this manual) 1 copy INZ-TN5ZFKE-E

3 Packing

Mounting screw, plain & spring washer (M5) Accessories 6 pcs each See Item 2.2.1.

Thermo sticker Speciﬁ cation goods 1 sh. See Item 2.2.1.

5 6 Filter cap 7 Spring 8 Hexagonal wrench

Flow guide tube Speciﬁ cation goods As ordered See Item 6.2.2 and 2.2.3.

Reference gas inlet Speciﬁ cation goods As ordered See Item 3.2.

Classiﬁ cation Q'ty Remark

Accessories 1 sheet See Item 2.2.1.

Speciﬁ cation goods 1 piece See Item 6.2.2

Accessories 1 piece See Item 2.2.1

2. MOUNTING

2.1 Mounting location

DANGER

• Although this is explosion-proof type, do not use it in a place where explosive gases always exist (zone

0) to prevent explosion, ﬁ re or other serious accidents.

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 (acceleration: 2 m/s2, frequency: within 5 to 100 Hz), dust and hu-

midity (equivalent to IP65 or less)

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 downward. A failure of the detector may result.

Flow guide tube

Gas flow

Packing (accessory)

Mounting screw (accessory)

Detector flange

+45°

-45°

Detector

Wiring hole

Down

Thermo sticker

Detector

Down Down

Fixing screw for cover (use an attached hexagonal wrench)

1 Attach the packing (accessory, Viton P36) to the detector ﬂ ange. Subsequently, attach the detector to

the ﬂ ange of the ﬂ ow guide tube 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 work of the detector completed, 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 owing 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 means 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 companion 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)

Companion 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 Companion 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 companion ﬂ ange.

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

dust is under 0.2g/Nm

• 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

＋

Inserting angle

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

3 When amount of dust is over 0.2g/Nm

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

Down

−

Inserting angle

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

(Desingation of type : When 10th digits are D, E, F, G, J, K)

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

Fitted with high dust cover

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°.

Gas outlet

Gas flow

Inserting angle

Down

3. PIPING

3.1 Piping of calibration gas

As the piping material, use a teﬂ on-made ø6 mm or ø1/4 inch tube.

• From the coupling attached to the detector, remove 2 nut, 3 front ferrule and 4 back ferrule, put them through the ø6 mm or ø1/4 inch teﬂ on tube for piping, and then attach it to

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.

3.2 Piping of reference gas inlet

Main body (calibration gas inlet port)

1 Coupling

5 adapters

3 Frount ferrule

4 Back ferrule

2 Nut

ø6 mm or ø1/4 inch teflon tube for piping

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 : 20.6 vol%), 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 to 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

3.3 Piping for blow down air

1 Packing

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 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.

+ 25 hidden pages

Fuji Electric ZFKE Operating Manual

PREFACE

SAFETY PRECAUTIONS

CONTENTS

1. INTRODUCTION

1.1 General description of zirconia oxygen analyzer

1.4 Description of each component

1.5 Check of type

1.6 Check of delivered articles

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