Fuji Electric ZKM-2 Specifications

IN-SITU

ZIRCONIA OXYGEN ANALYZER

<HART communication>

DATA SHEET

This oxygen analyzer is used to continuously measure
oxygen concentration in combustion exhaust gas of industrial
boilers or furnaces, and is ideally suited for combustion man­agement and control.
The analyzer system is comprised of the detector and con­verter coupled together as a complete system. Detector set­ting configuration includes the detector flow guide tube and
detector sensor. The flow guide tube is inserted directly into
the gas and directs gas to the sensor for measurement. The
converter (ZKM) is comprised of the signal processor, input/
output and communications, display and system controls.
The converter provided with an unconventional sensor­diagnostic function ensures long-term stable detecting opera­tion.

FEATURES

1. No need for gas sampling devices

Since the sensor unit is directly inserted into a flue, gas-

sampling devices such as gas aspirator and dehumidifier
are not required, which ensures fast response.

2. Easy maintenance

The sensor in a unit structure mounted to the detector can

be replaced easily. Since the detector and the flow guide
tube are installed separately, you can easily replace the fil­ter at the tip of the detector and can maintain the detector
and the flow guide tube separately according to the degree
of corrosion.

3. High reliability ensured by the sensor diagnostic func­tion

To check the degree of sensor depletion due to gas com-

ponents in the target gas, the converter is equipped with
the sensor diagnostic function, so that you know when to
replace the sensor.

4. Improved safety

The converter cuts off the power supply for the detector

when detecting a burnout of thermocouple for heater
control. The converter also cuts off the power supply at
emergency, in response to an external contact input. These
functions along with the key lock function are equipped as
standard to ensure improved safety.

5. Simple operation

A user can operate the converter or make various settings

on an interactive basis. Display language is available in
English, Japanese, or Chinese.

6. HART communication is available as an option

The HART communication enables remote control.

*HART

®

is a registered trademark of the HART Communi-

cation Foundation.

ZFK8, ZKM-2, ZTA

General-use detector

(ZFK8)

<IP66>

Converter (ZKMA)

High-temperature detector

(ZTA)

<IP67>

Converter (ZKMB)

SPECIFICATIONS

General Specifications

Measuring object: Oxygen in noncombustible gas
Measuring method:

Directly insert type zirconia system
Measuring range: 0 to 2 ··· 50 vol% O
(in 1 vol% O2 steps)

Repeatability: Within ±0.5%FS
Linearity: Within ±2%FS
Response time: Within 4 to 7 sec, for 90% (from calibra-

tion gas inlet)

Warmup time: More than 10 min
Analog output: 4 to 20mA DC (allowable load resistance

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

Digital input (option): RS-485 or HART communication
Power supply: Rated voltage;

100 to 120V AC (operating voltage 90
to 132V AC)
200 to 240V AC (operating voltage
190 to 264V AC)

Rated frequency; 50/60Hz
Power consumption:
During warm-up 255VA
During operation 70VA

When the power supply voltage
is 100 or 220 V AC

2

EDSX3-151a

Date

Apr. 25, 2016

ZFK8, ZKM-2, ZTA

Detector Specifications (ZFK)

Measured gas temperature:

Flow guide tube system; −10 to +600ºC

(for general-use, corrosive gas)

Ejector system; −10 to +1500ºC (for

high-temperature gas)

−10 to +800ºC (for general-use)

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

Ejector (general-use):

Probe for guiding measured gas to

detector
Flange; JIS10K 65A RF
Insertion length; 0.5, 0.75, 1, 1.5m (ac-

cording to customer's specification)
Ejector air inlet flow rate:
5 to 10 L/min
Ejector exhaust gas processing:
Into furnace, returned to flue

Ejector heater temperature drop alarm output:

Alarm output when below 100

ºC Me-

chanical thermostat
N.O. (1a) contact, 200V AC, 2A

Operating temperature:

−10 to +60ºC for Primary detecting ele-

ment

−5 to +100ºC for ejector section
125ºC or less at detector flange surface

with power applied

Storage temperature:

Sensing element: −20 to +70ºC
Ejector: −10 to +100ºC
Structure: Dust/rain-proof structure(IEC IP66

equivalent)
Filter: Alumina(filtering accuracy 50µm) and

quartz paper

Main materials of gas-contacting parts:

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

SUS316, SUS304
Calibration gas inlet:
f6mm tube join, f1/4-inch tube join, or

ball valbe (as specified)
Reference air inlet (option):
f6mm tube join or f1/4-inch tube join (as

specified)
Detector mounting:
Horizontal plane ±45º, ambient sur-

rounding air should be clean.
Outer dimensions: (L × max. dia.) 210mm × 100mm (de-

tector)
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

Calibration gas flow:

1.5 to 2 L/min
Blowdown air inlet pressure:

2

200 to 300kPa {2 to 3 kgf/cm

}

Converter specification (ZKM)

Concentration value indication:

Digital indication in 4 digits

Contact output signal:

(1) Contact specification; 6 points, 1a 250V AC/3A or 30V DC/3A
(2) Contact function;

• Under maintenance

• Under blowdown

Note3)

• Span calibration gas valve

• Zero calibration gas valve

• Instrument anomalies

• Alarm

• Range identification output

Note2)

Note1)

Note4)

Note1) The following Instrument errors (1) Thermocou-

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

Note3) Under blow down is available in case of option,

and it turns ON while operating.

Note4) It turns ON during range selection, and turns OFF

when the range 1 is selected.

Contact input signal:

(1) Contact specification; 3points (the following option)
ON; 0V (10mA or less), OFF; 5V
(2) Contact function;

• External hold

• Calculation reset

• 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

(c) All calibration
Calibration gas: • Available range settings
Zero gas; 0.010 to 25.00% O
Span gas: 0.010 to 50.00% O

2

2

• Recommended calibration gas concen­tration

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

2

2

(oxygen concentration in the air)

Blowdown: A function for blowing out with com-

(option)

pressed air dust that has deposited in
the flow 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 minute 00 second

to 0 minutes 999
seconds

2

Output signal hold:
Output signal is held during calibra-

tion, processing diagnosis of sensor,
warm-up, PID auto tuning, under set
up maintenance mode "available" and
blowdown. The hold function can also
be released.

Valve and Flow meter (option):

Selects zero or span gas during manual
zero or span calibration. Mounted on the
side of the converter.

Communication function:

HART communication (option)
RS485 (MODBUS) (option)
Combustion efficiency display (option):
This function calculates and displays

combustion efficiency from oxygen con­centration and measured gas tempera­ture.

Thermocouple (R) or thermocouple (K)

is required for temperature measure-

ment.
Range: 0 to 1000°C, Accuracy: ±5°C.
On the version with combustion effi-

ciency display, an alarm function of "rich

mode" indication is also available.

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
Enclosure: Dust-proof, rainproof

(corresponding to IP66 or IP67 of IEC)
* when the specified cable gland is at-

tached.

Material: Aluminum case
Outer dimensions (H x W x D):

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

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

detector)

IP67: Approx. 4.5kg (excluding cable and

detector)

Cable:Approx. 4kg/m (with rainproof

flexible conduit)

Finish color: Case: Silver

Cover: Munsell 6PB 3.5/10.5 (blue)

Mounting method: Mounted flush on panel or on pipe

Electrical Safety:
Overvoltage category
; II power supply input
; I relay interfaces
(IEC1010-1)
External overcurrent protective device
; 10A
Equipment interfaces are safety
separated (SELV)

EC Directive Compliance

The product conforms to the requirements of the Low Volt­age Directive 2006/95/EC and EMC directive 89/336/EEC
(as amended by Directive 92/31/EEC), both as amended by
Direc-tive 93/68/EEC.
It conforms to following standards for product safety and
electromagnetic compatibility:

EN61010-1 : 2010, EN62311: 2008

Safety requirements for electrical
equipment for measurement, control and

laboratory ese.
“Installation Category II”
“Pollution Degree 2”
“Altitude up to 2187 yard (2,000 m)”
EN61326-1 : 2006, EN61326-2-3: 2006
EN61000-3-2 : 2006, A1: 2009, A2: 2009
EN61000-3-3 : 2008

Electrical equipment for measurment,

control and laboratory use. EMS

requirements.

ZFK, ZKM

3

ZFK8, ZKM-2, ZTA

CODE SYMBOLS

(Detector) (Converter)

4 5 6 7 8 9 10 11 12 13 14 15 16

ZFK 8 R 5 - -

Digit Descrip tion Note Code

6 Calibration g as

inlet

7 Power supply 100 to 120 V A C 50/6 0 Hz 1

8 Revision No. 5

9 Flow guide tube

10 fla nge applic ation length

11 no tub e 0Y0

SUS3 04 general use 300 mm 5A3

SUS3 04 general use 500 mm 5A5

SUS3 04 general us e 750 mm 5A7

SUS3 04 general us e 1000 mm 5A1

SUS316 for corros ive gas 300 mm 5B3

SUS316 for corros ive gas 500 mm 5B5

SUS316 for corros ive gas 750 mm 5B7

SUS316 for corros ive gas 1000 mm 5B1

SUS316 with blowd own nozzle 3 00 mm 5C3

SUS317 with blowd own nozzle 5 00 mm 5C5

SUS318 with blowd own nozzle 75 0 mm 5C7

SUS319 with blowd own nozzle 10 00 mm 5C1

SUS316 for high par ticulate 30 0 mm 6D3

SUS317 for high par ticulate 50 0 mm 6D5

SUS318 for high par ticulate 750 mm 6D7

SUS319 for high par ticulate 100 0 mm 6D1

SUS316 for high par ticulate with cover 3 00 mm 6E3

SUS317 for high par ticulate with cover 5 00 mm 6E5

SUS318 for high par ticulate with cover 75 0 mm 6E7

SUS319 for high par ticulate with cover 10 00 mm 6E1

Others ZZZ

12

Heat- retaining

cover

13 Refer ence gas

inlet

14 Filt er spec Standar d 1

15 Inst ruction manual

languag e

16

Specifi cation

namepla te

For ø 6mm tub e (SUS) 1

For ø 1/4 i nch tube (S US) 2

With bal l valve 3

200 to 24 0 V AC 50/6 0 Hz 3

Withou t Y

With A

None Y

For ø 6 mm tube ( SUS) A

For ø 1/4 i nch tube (S US) B

Japanes e J

English E

Chinese C

Standar d (100 to 120 V AC 50 /60 Hz) 1

Standar d (200 to 24 0 V AC 50/6 0 Hz) 2

ZKM 2 - 1 - Y R

Digit Descrip tion Note Code

4 Enclosure IP6 6 A

5 Analog output

signal

6 Communicatio n

functio n

7 Mounting bracket No ne Y

8 Revision No. 2

9 Optional funct ions None Y

10 La nguage Japanes e J

11 Sele ctor valve/

flowmeter

12 — — 1

13 Ca ble gland Withou t Y

14 — — Y

15 — — R

16 Th ermocoupl e

for combus tion

efficie ncy display

*Thermo couple is to be prepare d separately.

Note 2) On the version with combustion efficiency display, an alarm function of "rich mode" indication is

4 5 6 7 8 9 10 11 12 13 14 15 16

IP67 B

4 to 20 mA DC B

0 to 1 V DC E

None Y

RS- 485 2

HART 3

Mounting o n panel surface 1

Pipe moun ting 2

Combus tion efficie ncy display Note 2 1

Blowdown 2

Auto calib ration 3

Combus tion efficie ncy display + Bl owdown Note 2 4

Combus tion efficie ncy display + Au to calibration Note 2 5

Blowdown + A uto calibration 6

Combus tion efficie ncy display + Bl owdown + Auto

calibra tion

English E

Chinese C

None Y

With val ve (For ø6 mm t ube) 1

With val ve + flowmeter ( For ø6 mm tube ) 2

With val ve (For ø1/ 4 inch tube) 3

With val ve + flowmeter ( For ø1/4 inch t ube) 4

With A

None Y

Type R thermo couple R

Type K thermo couple K

also available.

Note 2 7

4 5 6 7 8

ZTA 1 1

Digit Descrip tion Note Code

4 Measured gas

temperatu re

5 — — 1

6 Insertion len gth

[mm]

7 Power supply

voltage

8 Revision No. — 1

(Replacement Detector element)

Power supply Code symbols

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

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

For high tem perature (+150 0°C max.) 1

General u se (+80 0°C max.) 2

500 B

750 C

1000 D

1500 E

100V/ 115 V AC 50 /60 Hz 1

200V /220 V AC 50 /60Hz 3

230 V AC 5 0/60 Hz 5

(Dedicated cable)(Ejector)

4 5 6 7 8 9

ZRZ K R 1 -

Digit Descrip tion Note Code

Connec table

4

device

5 Type R t hermocoup le R

6 Length

7 N one 6 m YA

8 Revision No. — 1

9 Cable end

treatment

Note 1) F or connection between detector and converter, use a rainproof flexible conduit.

ZKM K

Rainproof fl exible conduit

None 10 m YB

None 15 m YC

None 20 m YD

None 30 m YE

None 40 m YF

None 50 m YG

None 60 m YH

None 70 m YJ

None 80 m YK

None 90 m YL

None 100 m YM

6 m 6 m Note 1 AA

10 m 10 m Note 1 BB

Note 1

15 m 15 m Note 1 CC

20 m 25 m Note 1 DD

None 0

One side ( detector side) 1

Both sides 2

Cable

4

SCOPE OF DELIVERY

Detector ( ZFK) Detector main unit 1

Converter (ZKM ) Converter main unit 1

Ejector ( ZTA) Ejector main unit 1

Dedicated cable
(ZRZ)

Viton O ring 1
Mounting screw (M5 x 16 ) 6
Thermal sticker 1
Ceramic filter 1
Instruction manual 1
Flow guide tube (as specified ) 1
Heat-retaining cover (as specified) 1
Reference gas inlet port ( as specified) 2

Fuse (2.5A) 2
Ferrite core 1
Instruction manual 1
Metal

fittings

Insertion tube 1
Packing 1
M16 nut and washer ( stainless steel) 4

Cable ( of the specified length) 1

Items to be prepared separately:

(1) Standard gas for calibration
Type ZBM
Type ZBM

NSH4-01 (up to 5% O2 range)

NSJ4-01 (over 5% O2 range)
(2) Pressure regulator for standard gas (type ZBD61003)
(3) Flowmeter
Type; ZBD42203, 0.2 to 2L/min (for calibrating gas)
Type; ZBD42403, 1 to 10L/min (for ejector)

Description Q'ty

<For panel mounting >
M8 sems screw (stainless steel) 4
<For pipe mounting >
U bolt (stainless steel) 2
M8 nut and washer (stainless

steel)
Suppor t (stainless steel) 2

CAUTIONS

• If combustible gas (CO, H2 etc.) exists in the measured
gas, error will occur due to burning at the sensor section.
The inclusion of corrosive gas (Si vapor, alkaline metal, P,
Pb etc.) will shorten the life of the sensor.

• When the measured gas temperature is high (+300°C
or higher), the flange should be separated from the
furnace wall in order to bring the detector flange surface
temperature below the specified value +125°C). The flow
guide should be attached in the direction in which the gas
flow to the detector decreases.

• When much dust is included in the gas, the flow guide
tube should be attached at an inclination so that the flow
goes from below to above. And the flow guide tube
should be attached in the direction in which the gas flow
to the detector decreases.

• In the case of a refuse incinerator, automatic blow down

4

of the flow guide should not be performed (to prevent
corrosion of the flow guide tube due to drainage). Blow­down should be performed manually when change in
the indication has become very little with the furnace
stopped.

DEVICE CONFIGURATION

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 configuration

Application Temperature Gas Flow DUST Heat-

General-use

(boiler)

For corrosive

gas (refuse

incinerator)

General-use

(boiler)

Note (1) Dust volume is approximate value.

(2) Instrument quality air or bottled air is available as reference air by selecting detector with reference air inlet.

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

Less than 25g/Nm

Less than

1m/s
Less than

1m/s

Less than 1g/Nm

Less than 1g/Nm

retaining
cover

3

—

3

—

3

—

3

—

3

no

3

yes

3

—

3

— SIC tube

Note Detector type Converter

Fuel; gas, oil

Fuel: coal

with blow down
Included low moisture

Included low moisture

with blow down
Included low moisture

with blow down
Included high moisture

with blow down
SUS316 tube

with blow down

ZFK8R

ZFK8R

ZFK8R

ZFK8R

ZFK8R

ZFK8R

ZFK8R

ZFK8R 5-0Y0 -1

with blow down

5

5- A -1

5

5- C -1

5

5- B -2

5

5- C -2

6

5- D -2

6

5- E -2

5- 0Y0 -1

type

ZKM —
ZKM —

ZKM —
ZKM —

ZKM —

ZKM —

ZKM ZTA2

ZKM ZTA1

Ejector
type

5

ZFK8, ZKM-2, ZTA

Flow guide tube system (with valve)

CONFIGURATION

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

Flow guide tube

Gas temperature.
600ºC max.

*2
Ref. air

Sample gas outlet

Gas temperature.
600ºC max.

Flow guide tube
for high particulate

Blue

Heat-retaining cover

123

6

Red

Yellow

Detector

(ZFK8)

45

White
Black
White

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

AC power
supply

Rainproof flexible
conduit.
(Max. 20m)

Solenoid valve
(not supplied)

Pressure regulator
(unnecessary when supply air pressure is
200 to 300kPa)

Supply air

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

Sample gas outlet

Gas temperature.
600ºC max.

Flow guide tube for high
particulate with cover

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

RS485

(option)

(Option)

*2 Ref. air

to Detector

1152 3 4 5 6 7 8 9 10 11 1 2 13 14

−

O2

Thermocouple
for combustion
control

＋

TC2

＋

TC1

Thermocouple

input

−

＋

O2 input

*4

16

＋

−

Analog output

4 to 20mA DC

or 0 to 1V DC

Contact input

DI1

17

AO

or

DI2 DI3

18 19

−

FAULT BLOW

Fault

contact

output

ALAR M MA INTE

DICO M

20

Alarm

contact

output

21 22

Blow

contact
output

Maintenance

contact

output

23 24

ZV

 GAS

Calibrating

gas contact

output

ZERO

1 2 3

TM-2

Flowmeter

Valve

MEASURE

Pressure regulator
(ZBD6)

ZERO

Standard gas
for zero point (ZBM)

*1
Span gas (ZBM)

Flowmeter

SPAN

Pressure regulator
(ZBD6)

*1 Air supply

Pressure regulator

(0.2 to 0.5L/min)

(not supplied)

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

Converter (ZKM)

TM-1

HEATER

Calibrating gas

contact output

COM

25 28

Note:

AC power

SPAN

supply

GAS

AC

LSV

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.
*5 HART communication (option) uses a
4-20mA analog output terminal.

PE

N

*3

6