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

6
2.2.3 Mounting method of high dust-use flow 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 flow as shown below.
Gas flow
Gas flow
Fitted with high dust cover
Gas outlet
Gas flow
Gas outlet
Gas flow
For high dust
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 fixing 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
M4-Mounting screw
Heat insulating cover
(according to designation)
M4-Screw ring M4-tapped hole
(for fixing heat insulating cover)
+
Inserting
angle
Up
Down

7
3.1 Piping of calibration gas
As the piping material, use a teflon-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 teflon 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.
3.2 Piping of reference gas inlet
If the atmosphere around the terminal box is significantly 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.
• 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.”
3.3 Piping for blow down air
Connect the blow air inlet (4 locations) of blowdown-fitted flow 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 teflon tube. And, use L-shape joint or union without bending the pipe wherever possible and keep
the piping length as short as possible.
2 Reference gas inlet
1 Packing
3. PIPING
(3) Frount ferrule
(2) Nut
(4) Back ferrule
ø6mm or ø1/4inch teflon
tube for piping
Main body
(calibration gas inlet)
(1) Coupling
CAUTIONS
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.
Joint for calibration gas:
If you order the joints for reference gas additionally, remove the hexago-
nal plugs and attach the joints for reference gas (two locations) as shown
in the figure on the right.
Attachment of joints for reference gas:

8
3.4 Piping drawing
Flow guide tube
Gas temperature.
600ºC max.
Gas temperature.
600ºC max.
Gas temperature.
600ºC max.
AC power
supply
Blue Yellow Red
White
White
Black
(Option)
AC power
supply
Sample gas outlet
Sample gas outlet
Flow guide tube
for high particulate
Flow guide for high
particulate with cover
ø6mm or ø1/4 inch tube
for calibration gas
(not supplied)
*2 Ref. air
to Detector
Flowmeter
Flowmeter
Valve
MEASURE
ZERO
SPAN
(0.2 to 0.5L/min)
(not supplied)
Reduction valve
(ZBD6)
Reduction valve
(ZBD6)
Standrad gas
for zero point (ZBM)
Reduction valve
(unnecessary when
supply air pressure
is 50 to 100kPa)
*1 Air supply
*1
Span gas (ZBM)
O2 input
Thermocouple
input
Analog output
4 to 20mA DC
or 0 to 1V DC
Fault
contact
output
FAULT BLOW
Blow
contact
output
Calibrating
gas contact
output
Heater
HEATER
RS232C
or
RS485
(option)
Thermocouple
for combustion
control Contact input
Alarm
contact
output
Maintenance
contact
output
Calibrating gas
contact output
Note: *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.
Flow guide tube system (with valve)
Rc1/4
(upper side blow port should be selected)
Blow-down, 200 to 300kPa
15ASGP
tube equivalent
or ø10/ø8 PTFE
pipe or copper pipe
(not supplied)
15ASGP
tube equivalent
or ø10/ø8 PTFE
pipe or copper pipe
(not supplied)
Solenoid valve
(not supplied)
Reduction valve
(unnecessary when supply air pressure is
200 to 300kPa)
Supply air
Rainproof cover
Detector
(ZFK8)
Converter (ZKM)
Rainproof flexible
conduit.
(Max. 20m)
*3
*4
12 3
1
2
3
45
6
PE
1
15
234567891011121314
16 17 18 19 20 21 22 23 24 25 28
26 27
＋−＋−
＋−
＋−
O2 TC1
AO
TC2 DI1 DI2 DI3 DICOM
ALARM MAINTE
NSV AC COM L
or
ZV
ZERO
GAS
SPAN
GAS
TM-1
TM-2
*2
Ref. air

9
Flow guide tube
Gas temperature.
600ºC max.
Gas temperature.
600ºC max.
Gas temperature.
600ºC max.
AC power
supply
Blue Yellow Red
White
White
Black
AC power
supply
AC power
supply
Sample gas outlet
Sample gas outlet
Flow guide tube
for high particulate
Flow guide for high
particulate with cover
ø6mm or ø1/4 inch tube
for calibration gas
(not supplied)
*2 Ref. air
to Detector
Flowmeter
(ZBD4)
(1 to 1.5L/min)
(0.2 to 0.5L/min)
(not supplied)
Joint
Solenoid valve
(not supplied)
Reduction valve
(ZBD6)
Standrad gas
for zero point (ZBM)
Reduction valve
(unnecessary when supply air pressure is 50 to 100kPa)
*1 Air supply
*1
Standard gas for
span point (ZBM)
Span point
Reduction vale
(ZBD6)
Solenoid valve
(not supplied)
O2 input
Thermocouple
input
Analog output
4 to 20mA DC
or 0 to 1V DC
Fault
contact
output
FAULT BLOW
Blow
contact
output
Calibrating
gas contact
output
Heater
HEATER
RS232C
or
RS485
(option)
Thermocouple
for combustion
control Contact input
Alarm
contact
output
Maintenance
contact
output
Calibrating gas
contact output
Note: *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.
Flow guide tube system
Rc1/4
(upper side blow port should be selected)
Blow-down, 200 to 300kPa
15ASGP
tube equivalent
or ø10/ø8 PTFE
pipe or copper pipe
(not supplied)
15ASGP
tube equivalent
or ø10/ø8 PTFE
pipe or copper pipe
(not supplied)
Solenoid valve
(not supplied)
Reduction valve
(unnecessary when supply air pressure is
200 to 300kPa)
Supply air
Rainproof cover
Detector
(ZFK8)
Converter (ZKM)
Rainproof flexible
conduit.
(Max. 20m)
*3
*4
12 3
1
2
3
45
6
PE
1
15
234567891011121314
16 17 18 19 20 21 22 23 24 25 28
26 27
＋−＋−
＋−
＋−
O2 TC1
AO
TC2 DI1 DI2 DI3 DICOM
ALARM MAINTE
NSV AC COM L
or
ZV
ZERO
GAS
SPAN
GAS
TM-1
TM-2
*2
Ref. air

10
Gas temperature.
1500ºC max.
Ejector (ZTA) Ejector (5 to 10L/min)
Copper pipe ø6/ø4mm
(not supplied)
Copper pipe ø10/ø6mm
(not supplied)
Copper pipe
ø10/ø8mm
(not supplied)
Flowmeter
(ZBD)
Rainproof flexible
conduit.
(Max. 20m)
RS232C
or
RS485
(optein)
TM-2
Detector (ZFK8)
AC power
supply
Power supply
Heater temperature drop
Alarm
Joint
Supply air
Solenoid valve
(not supplied)
AC power
supply
ø6mm or ø1/4 inch tube
for calibration gas
(not supplied)
Reduction valve
(unnecessary when supply air pressure
is 200 to 300kPa )
White
White
Bule
Black
Red
Yellow
*3
*4
TM-1
Ejector system (with valve)
AC power
supply
O2 input
Thermocouple
input
Analog output
4 to 20mA DC
or 0 to 1V DC
Fault
contact
output
FAULT BLOW
Blow
contact
output
Calibrating
gas contact
output
Heater
HEATER
Thermocouple
for combustion
control Contact input
Alarm
contact
output
Maintenance
contact
output
Calibrating gas
contact output
(Option)
*2 Ref. air
to Detector
Flowmeter
Flowmeter
Valve
MEASURE
ZERO
SPAN
(0.2 to 0.5L/min)
(not supplied)
Reduction valve
(ZBD6)
Reduction valve
(ZBD6)
Standrad gas
for zero point (ZBM)
Reduction valve
(unnecessary when
supply air pressure
is 50 to 100kPa)
*1 Air supply
*1
Span gas (ZBM)
Note: *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.
1
2
4
5
12 3
1
2
3
45
6
PE
1
15
2 3 4 5 6 7 8 9 10 11 12 13 14
16 17 18 19 20 21 22 23 24 25 28
26 27
＋−＋−
＋−
＋−
O2 TC1
AO
TC2 DI1 DI2 DI3 DICOM
ALARM MAINTE
NSV AC COM L
or
ZV
ZERO
GAS
SPAN
GAS

11
Gas temperature.
1500ºC max.
Ejector (ZTA) Ejector (5 to 10L/min)
Flowmeter
(ZBD)
Rainproof flexible
conduit.
(Max. 20m)
RS232C
or
RS485
(optein)
TM-2
Detector (ZFK8)
Solenoid valve
(not supplied)
AC power
supply
Power supply
Heater temperature drop
Alarm
Joint
Supply air
Solenoid valve
(not supplied)
AC power
supply
ø6mm or ø1/4 inch tube
for calibration gas
(not supplied)
Reduction valve
(unnecessary when supply air pressure
is 200 to 300kPa )
White
White
Bule
Black
Red
Yellow
*2 Ref. air
to Detector *1 Air supply
*3
*4
Reduction valve (unnecessary when
supply air pressure is 50 to 100kPa)
TM-1
*1 Standard gas for
span point (ZBM)
(0.2 to 0.5L/min)
(not supplied)
Flowmeter
(ZBD4)
(1 to 1.5L/min)
Solenoid valve
(not supplied)
Reduction
vale (ZBD6)
Reduction
vale (ZBD6)
Span gas
Standrad gas
for zero point (ZBM)
Joint
Ejector system
AC power
supply
O2 input
Thermocouple
input
Analog output
4 to 20mA DC
or 0 to 1V DC
Fault
contact
output
FAULT BLOW
Blow
contact
output
Calibrating
gas contact
output
Heater
HEATER
Thermocouple
for combustion
control Contact input
Alarm
contact
output
Maintenance
contact
output
Calibrating gas
contact output
Note: *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.
Copper pipe ø6/ø4mm
(not supplied)
Copper pipe ø10/ø6mm
(not supplied)
Copper pipe
ø10/ø8mm
(not supplied)
1
2
4
5
12 3
1
2
3
45
6
PE
1
15
234567891011121314
16 17 18 19 20 21 22 23 24 25 28
26 27
＋−＋−
＋−
＋−
O2 TC1
AO
TC2 DI1 DI2 DI3 DICOM
ALARM MAINTE
NSV AC COM L
or
ZV
ZERO
GAS
SPAN
GAS

12
4. WIRING
PROHIBITION
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 fire, failure or malfunction.
• Connect a power source compatible with the rating. Connection of a power source not conforming
to the rating may cause a fire.
• 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 fire.
• 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.

13
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
• Be careful not to mix up the wiring for thermocouple (four-core, white) and the wiring for heater
(two-core, white).
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 ............Specified in JIS C1610-1995 (equivalent to RCA-2-G-0.75mm2-S2).
• Recommended wire rod (at 20 ºC)
Composition
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
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 —
Exclusive cable
for converter
2 core
wire
4 core
wire
Heater power
100 to 120VAC 50/60Hz
or 200 to 240VAC 50/60Hz
Thermo couple (R-type)
(3) Red
(4) White
Sensor output
(5) Yellow
(6) Blue
(1) Black
(2) White
3
1
6
T+
H
S+
4
2
5
T-
H
S-
(1) Black
(2) White
(6) Blue
(3) Red
(5) Yellow
(4) White
Screw for wiring connections: M3
grounding terminal screw: M4
CAUTIONS

14
Connect the protective grounding to one of the two terminals in the figure below. (Class D (Class 3)
grounding, grounding resistance: 100Ωor less)
Note
• Use the cable more than 0.75mm2for 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 .
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 fit the end face of conduit into a groove
of the (4) bushing.
• Insert the (4) bushing fitted to the conduit into (1) M coupling of the main body and tighten with the (3)
packing and (2) packing holder nut for fixing.
Conduit (3) Packing
Packing at main body side
(1) Main body M coupling
Conduit
(2) Packing holder nut (4) Bushing
(3) Packing
(1) Main body M coupling
(2) Packing holder nut
(4) Bushing
3
1
6T+
H
S+
4
2
5
T-
H
S-
madeinjapan
TK4J4664R0
Grounding
terminal
Grounding
terminal
Wireng of protective grounding terminal
3
1
6T+
H
S+
4
2
5
T-
H
S-
madeinjapan
TK4J4664R0
Grounding
terminal
Grounding
terminal
Wireng of protective grounding terminal
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
Double caulking

15
• In case where combustible gas is contained in the measured gas, make sure of the gas composition
and specifications 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 finished, 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. (flow 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 opera-
tion 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.
5. OPERATION AND STOP
DANGER