Fuji Electric ZFK8 Series User manual

INZ-TN5ZFK8b-E
Instruction Manual
THE DIRECT INSERTION TYPE
ZIRCONIA OXYGEN
ANALYZER DETECTOR
TYPE: ZFK8

i
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 specification of this zircoia oxygen analyzer may be subject to change without previous notice for im-
provements of the product.
• Under no circumstances should this zirconia oxygen analyzer be modified without permission.
If any trouble should occur because of having been modified 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 final user certainly.
PREFACE
©Fuji Electric Systems Co., Ltd. 2008
Issued in Aug , 2008
Rev.1st edition Oct , 2008
Rev.2st edition Apr , 2009
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
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
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-
out previous notice

ii
Precautions in installing and wiring
DANGER:• This product is not an explosion-proof type. Don’t use it in an explosive gas
atmosphere. Otherwise, irreparable troubles including explosion or a fire
could occur.
CAUTION:• 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 fire and malfunction.
• When this product is mounted on a furnace which is under operation, take
utmost care with blow-out from the furnace. There is a risk of burn injury.
• In the case of the wiring work, be careful not to drop foreign matters including
wire chips into the product. Otherwise, a fire, failure or malfunction may
result.
• Connect a power source compatible with the specified rating. Connection of
power source different from the rating might cause a fire.
• Before doing the wriring work, be sure to turn off the main power. Otherwise,
it results in getting an electric shock as the case may be.
• Use proper wiring materials according to the rating of apparatus. If a wiring
material which is not bearable to the rating is employed, it might cause a fire.
PROHIBITION:
• Never do the work at a place where the product gets wet with water, such as
the rain.
A failure to observe this instruction may result in getting an electric shock or
failure.
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”.
SAFETY PRECAUTIONS
DANGER:If this apparatus is abused, a dangerous condition could come about and it is
supposed to die or get a serious injury.
CAUTION: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.
PROHIBITION:
This indicates a prohibition (act which must not do).

iii
Precautions in operation, stop, maintenance and check
DANGER: • In case where combustible gas is contained in the measured gas, check the gas
composition and specifications carefully before using. Otherwise, the original
performance is not displayed, and there is a fear of explosion.
CAUTION: • Do the work in a condition where the main power has been turned off. If the
work is done while current is flowing, there is a fear of getting an electric
shock.
• The operating temperature of the detector (tip of ceramic heater) is about 800
°C and the surface temperature is also very high. So, never touch the detector
by bare hand.
Otherwise, there is a fear of getting a burn.
• Before cleaninhg the flow guide tube, turn off the main power and cool the
tube down fully.
There is a fear of getting a burn.
• Don’t use any other renewal part than those designated by the maker. Other-
wise, the original performance is not fully displayed and a accident or failure
may result.
• Dispose of the renewal parts such as the maintenance parts as an incombus-
tible.
PROHIBITION: • Never do the work at a place where rain water splases the product directly.
A failure to observe this instruction may result in getting an electric shock or
failure.
Other precaution
CAUTION: • 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.

iv
CONTENTS
PREFACE ......................................................................................................................................... i
SAFETY PRECAUTIONS .............................................................................................................. ii
1. Introduction .............................................................................................................................. 1
1.1 General description of zirconia oxygen analyzer ........................................................................1
1.2 Device configuration 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 Specification ..............................................................................................................................22
8.2 Designation of type (code table) ...............................................................................................24
8.3 Device composition ..................................................................................................................25
8.4 Outline diagram (unit: mm).......................................................................................................26

1
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:
1.2 Device configuration of direct insertion type oxygen analyzer
The direct insertion type zirconia oxygen analyzer consists of the detector with a sensor unit, the flow 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.
1. INTRODUCTION
High-oxygen partial
pressure side PH
Low-oxygen partial
pressure side PL
Solid electrolyte
O2
O2
Electrode
O2-
Ionization
Molecularization
Electromotive
force
Nernst’s equation
RT PH(O2)
PL(O2)
E= 1n
4F
E: Electromotive force
PH(O2): Oxygen partial pressure of a
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]
Oxygen molecule
Zirconia
Platinum
Tree-phase interface:
a part where electrochemical
reactions occur.
O2-
ConverterDetector
Flow guide tube
Flow of gas
Stack
Cable
(sensor output line, thermocouple output line,
heater power wire)
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 flow guide tube can be connected to the existing products.
Replacement of the existing detector ZFK2 with the detector ZFK8:

2
1.3 Description of each component
(1) ZFK2
Ceramic filter O-ring
Quartz filter
Ceramic heater
Heat insulating
material
Joint for calibration gas Cable gland
Terminal box
Terminal box lid
Hexagon plug or reference gas inlet
* According to designation of type
Calibration
gas inlet Wiring hole
Air environment
(Reference gas)
Furnace environment
(Gas to be measured)
Thermo sticker
Measured gas
Filter frame
1.4 Check of type
The name of type has been put in the specification name-plate. Make sure it is as ordered.
Refer to Item 8.2 “Desingation of type”.
1.5 Check of delivered articles
Make sure the following articles have been delivered without lack.
No. Description Classification Q'ty Remark
1Detector 1 unit Confirmed in Item 1.3
2Instruction manual (this manual) 1 copy INZ-TN5ZFK8-E
3O-ring Accessories 1 pc. See Item 2.2.1.
4Mounting screw, plain & spring washer (M5) Accessories 6 pcs each See Item 2.2.1.
5Thermo sticker Accessories 1 sh. See Item 2.2.1.
6Ceramic filter Accessories 1 sh. See Item 6.2.3.
7Flow guide tube Specification goods As ordered See Item 2.2.2 and 2.2.3.
8Heat insulating cover Specification goods As ordered See Item 2.2.4
9Reference gas inlet Specification goods As ordered See Item 3.2.
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 sufficiently 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 waterproofing effect becomes zero.
CAUTIONS
• The operating temperature of detector (tip of ceramic heater) is about 800°C and the surface temper-
ature is also very high. So, never touch it by bare hand. Otherwise, there is a fear of getting a burn.
Especially when a ceramic filter at the end of the detector is replaced, take utmost care.

3
2.1 Mounting location
• This product has no explosion-proof specification. Don’t use the product in an explosive gas
environment. If used, a serious trouble such as a fire or explosion might occur.
• Install this product at a place compatible with the following conditions. The use of it at a place not
conforming the installation conditions specified in this manual could cause an electric shock, a fire
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
• 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. MOUNTING
DANGER
CAUTIONS
CAUTIONS

4
2.2.1 Mounting method of detector
• Never mount the detector with the tip turned upward or
downward. A failure of the detector may result.
Up Up Up
Down Down Down
Detector
Caution in mounting
O-ring (accessory)
Mounting screw, plain washer,
spring washer (accessory) - 3 locations
Flow guide tube
or ejector (ZTA)
Gas flow
Detector flange Wiring hole
Detector
+45°
-45°
1 Attach the O-ring (accessory, Viton P36) to the groove of the detector. Subsequently, attach the detec-
tor to the flange of the flow guide tube or ejector (type: ZTA) by fixing the mounting screws (accessory,
M5) and the flat 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 flange to 125°C or less regardless of the measured gas temperature.
<How to check>
• Complete the mounting, piping and wiring of the detector, make sure the color of thermo sticker 125 put
on the detector flange is not changing to red in the exhaust gas measuring condition (while current is flow-
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 flange has been over 125°C. So,
take the following steps:
(a) Change the existing flange packing to a thicker one.
(b) Use a longer mating flange.
(c) Mount the flow guide tube according to Item “2.2.2”.
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, re-
put a thermo sticker available as an accessory on the detector flange 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”.
thermo sticker

5
2.2.2 Mounting method of flow guide tube
(Designation of type: When 9th to 11th digits are 5A
■
■, 5B
■
■and 5C
■
■)
The flange of flow tube has mounting holes at 8 locations. These holes are available for regulating an in-
flow into the flow guide and mounting the tube correctly in the flowing direction of gas and it is enough if
mounted at 4 locations.
(1) Direction of tongue and Partition plate of flow guide tube
1 When exhaust gas temperature is under 200°C and gas flowing velocity is low
As illustrated below, set the partition plate inside the flow guide tube at a right angle to the gas flow and
mount the tube so that the tongue turns to an upstream direction relative to the gas flow.
Tongue
Partition plate
Packing (not included
in scope of supply)
Mating flange (not included
in scope of supply)
Gas flow min.60mm
ø15 (JIS5K-65A)
Arrow mark of
flow guide tube
Furnace wall
2 When exhaust gas temperature is 200°C or higher and gas flowing velocity is fast
As illustrated below, till the partition plate inside the flow guide tube 45° to the gas flow and mount the
tube so that the tongue turns to a down-steam direction relative to gas flow.
Mating flange (not included
in scope of supply)
Gas flow
Gas flow
Arrow mark of flow guide tube
Tongue
Partition plate
Packing (not included
in scope of supply)
Arrow mark of
flow guide tube
ø15 (JIS5K-65A)
min.150mm
Furnace wall
(2) Inserting angle of flow guide tube
According to the temperature of exhaust gas and the amount of dust, the inserting angle of the flow guide
tube differs. With reference to the following conditions, install a mating flange.
1 When exhaust gas temperarture is under 200°C and amount of dust is
under 0.2g/Nm3
(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/Nm3
(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/Nm3
(Designation of type: When 9th to 11th digits are 5B
■
■and 5C
■
■)
• Inserting angle: within a range of 0 to +45°
+
Inserting
angle
–
Inserting
angle
Up
Down