Fuji Electric ZKM User manual

Instruction Manual
INZ-TN1ZKMe-E
ZIRCONIA OXYGEN
ANALYZER CONVERTER
Type: ZKM

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INZ-TN1ZKM-E
PREFACE
We are grateful for your purchase of Fuji Direct Insertion Type Zirconia Oxygen Analyzer Converter (ZKM).
First read this instruction manual carefully until an adequate understanding is acquired, and
then proceed to installation, operation and maintenance of the converter. Improper handling
may result in accidents or injury.
The specifications of this converter will be changed without prior notice for further product
improvement.
Modification of this converter is strictly prohibited unless a written approval is obtained
from the manufacturer. Fuji will not bear any responsibility for a trouble caused by such a
modification.
This instruction manual shall be stored by the person who actually uses the converter.
After reading through the manual, be sure to keep it near at hand for future reference.
This product falls within category 9 (Monitoring and control instruments including indus-
trial monitoring and control instruments) of Annex 1 of EU RoHS directive (2011/65/EU).
Please do not use it for consumer use.
This instruction manual should be delivered to the end user without fail.
Manufacturer: Fuji Electric Co., Ltd.
Type: Described in the nameplate put on the main body
Date of manufacture: Described in the nameplate put on the main body
Product nationality: Japan
Related instruction manual
Direct insertion type zirconia oxygen analyzer detector (Type: ZFK8)··············INZ-TN5ZFK8-E
Fuji Electric Co., Ltd. 2008
Notice Issued in October 2008
Revised in December 2008
Revised in May 2009
Revised in July 2009
Revised in April 2011
Revised in September 2013
It is prohibited to transfer part or all of this manual without Fuji
Electric’s permission in written format.
Description in this manual is subject to change without prior no-
tice.

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SAFETY PRECAUTIONS
First of all, read this “SAFETY PRECAUTIONS” carefully, and then use in the correct way.
Installation, transportation, wiring, use, maintenance of this product shall be carried out by suitably trained
personnel.
First-time users should operate the instrument under the supervision of a fully competent person in the
operation.
Be sure to observe the instructions shown below, because they describe important information on safety.
Those safety precautions are ranked in 3 levels, “DANGER”, “CAUTION” and “PROHIBITION”.
DANGER
If operation is incorrect, a dangerous situation may occur, resulting in
death or serious injuries.
CAUTION
If handled wrongly, a dangerous situation may occur, and medium trou-
ble or slight injury may be caused and only property damage may be
caused.
PROHIBITION
Items which must not be done are noted.
The items noted under “
CAUTION
” may also result in serious trouble depending on circumstances.
All the items are important and must be fully observed.
Caution on installation and transportation
DANGER
This unit is not explosion-proof type. Do not use it in an atmosphere
of explosive gases. Otherwise serious accidents such as explosion or
fire may result.
CAUTION
This unit should be installed in a place which conforms to the condi-
tions noted in the instruction manual. Otherwise, it may cause electric
shocks, fire, failure or malfunction of the unit.
During installation work, care should be taken to keep the unit free
from entry of cable chips or other foreign objects. Otherwise, it may
cause fire, failure or malfunction of the unit.
For installation, observe the rule on it given in the instruction manual
and select a place where the weight of converter can be endured. In-
stallation at an unsuited place may cause turnover or fall and there is a
risk of injury.
Be sure to wear gloves when handling the unit.
Bare hands may invite an injury.
Before transport, fix the door so that it will not open. Otherwise, the
door may be separated and fall to cause an injury.

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INZ-TN1ZKM-E
Cautions on wiring
CAUTION
Be sure to turn off all the power before performing wiring. Otherwise
electric shock may result.
Be sure to perform class D grounding work.
Otherwise, electric shock or failure may result.
Select a proper wiring material that satisfies the ratings of the instru-
ment. Otherwise, electric shock or fire may result.
Connect power source of correct rating. Connection of a power source
of incorrect rating may lead to a risk of fire.
Cautions on use
DANGER
If unusual smell or sound has been produced, immediately stop the
instrument. Any discharge produced may cause a fire.
CAUTION
Leaving the converter unused for a long time or restarting it after dis-
use requires procedures different from normal operation or suspension
procedures. Be sure to follow the instructions in each instruction man-
ual. Otherwise, intended performance may not be achieved, or acci-
dents or injury may result.
Do not operate the converter for a long time with its door left open.
Otherwise, dust, foreign matter, etc. may stick on internal walls, there-
by causing failure.
PROHIBITION
Do not touch the input/output terminals with metal or finger. Other-
wise, failure, electric shock or injury may result.
Caution on maintenance and inspection
CAUTION
Before maintenance and check, be sure to turn off the main power
supply and wait until the detector is cooled adequately. Otherwise,
you may suffer a burn.
Before removing the detector from the flue for maintenance and
check, make sure the furnace is stopped. Otherwise, you may suffer a
burn.
Before working, take off a wrist watch, finger ring or the like metallic
accessories. And never touch the instrument with a wet hand. Other-
wise, you will have electric shocks.
If the fuse is blown, eliminate the cause, and then replace it with the
one of the same capacity and type as before. Otherwise, it may cause
electric shocks or failure.
Others
CAUTION
If the cause of a failure cannot be identified by referring to the instruc-
tion manual, be sure to contact your dealer or Fuji’s technician in
charge of adjustment. Disassembling the instrument carelessly may
result in electric shock or injury.
Do not use a replacement part other than specified by the instrument
maker. Otherwise, adequate performance will not be provided. Be-
sides, an accident or failure may be caused.
Replacement parts such as a maintenance part should be disposed of
as incombustibles.

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INZ-TN1ZKM-E
Contents
PREFACE ..........................................................................................................................................................i
SAFETY PRECAUTIONS............................................................................................................................. ii
CHECKING OF CONTENTS OF THE PACKAGE................................................................................ viii
STORAGE CONDITIONS.......................................................................................................................... viii
1. GENERAL....................................................................................................................................................1
1.1 Direct insertion type zirconia oxygen analyzer ........................................................................................1
2. OPERATING PARTS AND THEIR FUNCTIONS...................................................................................2
2.1 External appearance..................................................................................................................................2
2.1.1 Outline Drawing.................................................................................................................................2
2.1.2 Terminal block....................................................................................................................................3
2.2 OPERATING PARTS AND THEIR FUNCTIONS..................................................................................4
2.2.1 External appearance ...........................................................................................................................4
2.2.2 Internal constitution ...........................................................................................................................5
2.3 Description on display/operation panel ....................................................................................................6
3. INSTALLATION..........................................................................................................................................7
3.1 Installation site..........................................................................................................................................7
3.2 How to install the converter......................................................................................................................8
3.2.1 Mounting on panel surface (ZKM1).................................................................................................8
3.2.2 Pipe mounting (ZKM1)......................................................................................................................8
3.2.3 Mounting on panel surface (ZKM2).................................................................................................9
3.2.4 Pipe mounting (ZKM2)....................................................................................................................9
4. WIRINGAND PIPING..............................................................................................................................10
4.1 Before wiring..........................................................................................................................................10
4.2 Wiring to terminals .................................................................................................................................11
4.2.1 O2sensor input / Input method of O2sensor thermocouple .............................................................11
4.2.2 Cable gland and input and output lines ............................................................................................11
4.2.3 Allocation of the terminal block.......................................................................................................12
4.3 Wiring and piping diagram .....................................................................................................................13
4.4 Handling of standard gas (An article on separate order) ........................................................................17
5. OPERATION..............................................................................................................................................18
5.1 Preparation for operation ........................................................................................................................18
5.2 Key operation flow diagram (outline) ....................................................................................................19
5.3 Initial parameter value table ...................................................................................................................23
5.3.1 Parameters related to measurement..................................................................................................23
5.3.2 Parameters related to calibration......................................................................................................23
5.3.3 Parameters related to blowdown (displayed if the option is provided)............................................24
5.3.4 Parameters related to maintenance...................................................................................................24
5.3.5 Other parameters ..............................................................................................................................25
6. OPERATION START AND STOP ..........................................................................................................27
6.1 Operation start ........................................................................................................................................27
6.2 Operation stop.........................................................................................................................................27
6.3 Actions during operation.........................................................................................................................28
6.4 Check the contents of display .................................................................................................................29
6.4.1 Check of state information ...............................................................................................................29
6.4.2 Checking the error information........................................................................................................30

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6.4.3 Checking the alarm information...................................................................................................... 30
6.5 Oxygen detector standard output voltage............................................................................................... 31
7. CALIBRATION......................................................................................................................................... 32
7.1 Preparation ............................................................................................................................................. 32
7.2 Manual calibration ................................................................................................................................. 33
7.3 Auto calibration (option)........................................................................................................................ 35
7.4 Remote calibration ................................................................................................................................. 37
7.5 All calibration (option)........................................................................................................................... 39
8. BLOWDOWN (OPTION)......................................................................................................................... 40
8.1 Preparation for blowdown...................................................................................................................... 40
8.2 Manual blowdown.................................................................................................................................. 40
8.3 Automatic blowdown ............................................................................................................................. 41
8.4 Remote blowdown ................................................................................................................................. 43
9. MAINTENANCE AND CHECK.............................................................................................................. 45
9.1 Checking ................................................................................................................................................ 45
9.2 Consumable parts................................................................................................................................... 45
9.3 Spare parts.............................................................................................................................................. 45
9.4 Replacement of fuse............................................................................................................................... 46
9.5 Troubleshooting ..................................................................................................................................... 47
10. SETTINGAND OPERATING OF PARAMETER............................................................................... 49
10.1 Measured menu.................................................................................................................................... 49
10.1.1 Display range setting screen.......................................................................................................... 49
10.1.2 Decimal point position setting screen............................................................................................ 50
10.1.3 Full scale setting screen................................................................................................................. 51
10.1.4 Setting screen for calculation time of maximum and minimum values appears ........................... 52
10.2 Calibration menu.................................................................................................................................. 53
10.2.1 Automatic calibration setting (option)........................................................................................... 53
10.2.2 Date and time for starting automatic calibration (option) ............................................................. 54
10.2.3 Cycle time setting of automatic calibration (option).....................................................................55
10.2.4 Performing all calibration (option)................................................................................................ 56
10.2.5 Performing a manual span calibration........................................................................................... 57
10.2.6 Performing a manual zero calibration ........................................................................................... 58
10.2.7 Calibration gas setting ................................................................................................................... 59
10.2.8 Calibration waiting setting (option)............................................................................................... 60
10.2.9 Calibration error clear ................................................................................................................... 61
10.2.10 Operation setting screen of calibration range.............................................................................. 62
10.3 Blowdown menu (option) .................................................................................................................... 63
10.3.1 Automatic blowdown setting......................................................................................................... 63
10.3.2 Date and time setting of automatic blowdown ..............................................................................64
10.3.3 Automatic blowdown cycle setting ............................................................................................... 65
10.3.4 Procedure for setting blowdown time............................................................................................ 66
10.3.5 Perfoming manual blowdown........................................................................................................ 67
10.4 Maintenance menu ............................................................................................................................... 68
10.4.1 Error log display............................................................................................................................ 68
10.4.2 Clearing error logs......................................................................................................................... 70
10.4.3 Alarm log display .......................................................................................................................... 71
10.4.4 Clearing alarm logs ....................................................................................................................... 72
10.4.5 Operation log display .................................................................................................................... 73
10.4.6 Clearing operation logs ................................................................................................................. 75
10.4.7 Sensor check setting for calibration (option)................................................................................. 76
10.4.8 Sensor recovery setting for calibration (option)............................................................................ 77
10.4.9 Performing a manual sensor check................................................................................................ 78
10.4.10 Performing manual sensor recovery............................................................................................ 79
10.4.11 Cell internal resistance display .................................................................................................... 80

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INZ-TN1ZKM-E
10.4.12 Maintenance mode setting...........................................................................................................81
10.4.13 Password setting...........................................................................................................................82
10.4.14 PID auto tuning ............................................................................................................................83
10.5 Parameter menu ....................................................................................................................................84
10.5.1 Current date and time setting .........................................................................................................84
10.5.2 Contact input setting ......................................................................................................................85
10.5.3 Selection of alarm contact output...................................................................................................86
10.5.4 High limit setting of oxygen concentration....................................................................................87
10.5.5 Lower limit setting of oxygen concentration .................................................................................88
10.5.6 HH limit setting of oxygen concentration......................................................................................89
10.5.7 LL limit setting of oxygen concentration .......................................................................................90
10.5.8 Hysteresis Setting...........................................................................................................................91
10.5.9 Hold treatment setting (maintenance hold) ...................................................................................93
10.5.10 Hold value setting (maintenance hold)........................................................................................94
10.5.11 Setting of hold setting value (maintenance hold) ........................................................................95
10.5.12 Setting of measurement recovery time (maintenance hold)........................................................96
10.5.13 Hold treatment setting (error hold)..............................................................................................97
10.5.14 Hold value setting (error hold).....................................................................................................98
10.5.15 Setting of hold setting value (error hold) ....................................................................................99
10.5.16 Setting of key lock .....................................................................................................................100
10.5.17 LCD brightness adjustment........................................................................................................101
10.5.18 Setting of automatic OFF time ...................................................................................................102
10.5.19 Station number setting................................................................................................................103
10.5.20 Adjustment screen for analog output 0% ...................................................................................104
10.5.21 Adjustment screen for analog output 100% ...............................................................................105
10.5.22 Fuel coefficient setting (option) .................................................................................................106
10.6 Factory menu ......................................................................................................................................107
10.6.1 Password setting screen................................................................................................................107
11. HOW TO CHANGE THE SETTING...................................................................................................108
11.1 How to change the setting of converter ZKM depending on detector type ........................................108
12. SPECIFICATIONS................................................................................................................................109
12.1 Specifications......................................................................................................................................109
12.2 Code symbols......................................................................................................................................111

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CHECKING OF CONTENTS OF THE PACKAGE
Check that all of the following are contained in the delivered package.
(1) Zirconia Oxygen Analyzer Converter main unit 1 unit
(2) Accessories 1 set (Refer to the table below.)
Table 1 Standard accessories
No. Item Quantity Remarks
1 Tube type fuse (250 V T 0.5 A) 2 For main unit (F1)
2 Tube type fuse (250 V T 2.5 A) 2 For heater (F2)
3 Instruction manual 1
The “Japanese,” “English” or “Chinese”
manual is attached.
(As specified)
4 Communication Manual 1
The instruction manual of “MODBUS” is
attached.
(As specified)
5 Mounting bracket 1 set
The “panel attachment bracket” and “pipe
attachment bracket” are attached.
(As specified)
STORAGE CONDITIONS
Store the unit in a location that meets the following conditions:
(1) Vibration, dust, dirt, and humidity are minimal.
(2) A place not subjected to radiated heat from a heating furnace, etc.
(3) The atmosphere is non-corrosive.
(4) A place where ambient temperature and humidity are –30 to +70°C (non condensing) and 95% RH or
less.

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INZ-TN1ZKM-E
1. GENERAL
This manual describes the installation, operation, and the maintenance of the zirconia oxygen analyzer con-
verter. Read it carefully before using the converter. For the detector, flow guide tube and ejector used with
the converter, refer to relevant instruction manuals.
1.1 Direct insertion type zirconia oxygen analyzer
The direct insertion type zirconia oxygen analyzer consists of a direct insertion type zirconia detector (type
ZFK) and converter (type ZKM).
The analyzer intended for the measurement of oxygen concentration in exhaust gas is used for combustion
control.
Caution
Power voltage for the converter must conform to that for the detector to be connected. Don’t use any
power voltage different from the power specifications of the detector. Otherwise it may result in damage
to the detector.
100/120V AC50/60Hz for ZFK8R1
200/240V AC50/60Hz for ZFK8R3
Operating environment
1) Operating temperature: -20 to 55°C
2) Operating humidity: 95%RH or less, non condensing
3) Power voltage: 100 to 120V AC 50/60Hz or 200 to 240V AC 50/60Hz
4) Pollution degree: 2
5) Installation category: II