Fuji Electric ZFK8 Series User manual

Instruction Manual
THE DIRECT INSERTION TYPE
ZIRCONIA OXYGEN
ANALYZER DETECTOR
TYPE:  ZFK8
INZ-TN5ZFK8d-E
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Thank you very much for your kind purchase of Fuji’s zirconia oxygen analyzer detector (Type ZFK 8).
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provements of the product.
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IRULWDQ\ZD\
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actually.
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refer to any time as requirfed.
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PREFACE
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Related instruction manuals
Direct insertion type zirconia oxygen analyzer converter (Type : ZKM).................................,1=71=.0(
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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
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out previous notice
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Prior to operating this detector, read this “Safety precautions” carefully for correct use.
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SAFETY PRECAUTIONS
DANGER
IIWKLVDSSDUDWXVLVDEXVHGDGDQJHURXVFRQGLWLRQFRXOGFRPHDERXWDQGLWLVVXS-
posed to die or get a serious injury.
CAUTION
,IWKHDSSDUDWXVLVDEXVHGDGDQJHURXVFRQGLWLRQFRXOGDULVHDQGLWLVVXSSRVHGWRJHW
medium injury or a minor injury and a physical damage is supposed to occur.
PROHIBITION
7KLVLQGLFDWHVDSURKLELWLRQDFWZKLFKPXVWQRWGR
Precautions in installing and wiring
DANGER
: 7KLVSURGXFWLVQRWDQH[SORVLRQSURRIW\SH'RQ¶WXVHLWLQDQH[SORVLYHJDV
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occur.
CAUTION
: ,QVWDOOWKLVSURGXFWLQDSODFHFRPSDWLEOHZLWKWKHFRQGLWLRQVVHWIRUWKLQ³LQ-
VWUXFWLRQPDQXDO´7KHXVHDWDSODFHQRWFRQIRUPLQJWRWKHLQVWDOODWLRQFRQGL-
WLRQVPD\UHVXOWLQDQHOHFWULFVKRFND¿UHDQGPDOIXQFWLRQ
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PRVWFDUHZLWKEORZRXWIURPWKHIXUQDFH7KHUHLVDULVNRIEXUQLQMXU\
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ZLUHFKLSVLQWRWKHSURGXFW2WKHUZLVHD¿UHIDLOXUHRUPDOIXQFWLRQPD\UHVXOW
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SRZHUVRXUFHGLIIHUHQWIURPWKHUDWLQJPLJKWFDXVHD¿UH
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results in getting an electric shock as the case may be.
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WHULDOZKLFKLVQRWEHDUDEOHWRWKHUDWLQJLVHPSOR\HGLWPLJKWFDXVHD¿UH
PROHIBITION
: 1HYHUGRWKHZRUNDWDSODFHZKHUHWKHSURGXFWJHWVZHWZLWKZDWHUVXFKDVWKH
rain.
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failure.
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Precautions in operation, stop, maintenance and check
DANGER
: ,QFDVHZKHUHFRPEXVWLEOHJDVLVFRQWDLQHGLQWKHPHDVXUHGJDVFKHFNWKHJDV
FRPSRVLWLRQDQGVSHFL¿FDWLRQVFDUHIXOO\EHIRUHXVLQJ2WKHUZLVHWKHRULJLQDO
SHUIRUPDQFHLVQRWGLVSOD\HGDQGWKHUHLVDIHDURIH[SORVLRQ
CAUTION
: 'RWKHZRUNLQDFRQGLWLRQZKHUHWKHPDLQSRZHUKDVEHHQWXUQHGRII,IWKH
ZRUNLVGRQHZKLOHFXUUHQWLVÀRZLQJWKHUHLVDIHDURIJHWWLQJDQHOHFWULFVKRFN
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DQGWKHVXUIDFHWHPSHUDWXUHLVDOVRYHU\KLJK6RQHYHUWRXFKWKHGHWHFWRUE\
bare hand.
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GRZQIXOO\
There is a fear of getting a burn.
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ZLVHWKHRULJLQDOSHUIRUPDQFHLVQRWIXOO\GLVSOD\HGDQGDDFFLGHQWRUIDLOXUH
may result.
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PROHIBITION
: 1HYHUGRWKHZRUNDWDSODFHZKHUHUDLQZDWHUVSODVHVWKHSURGXFWGLUHFWO\
 $IDLOXUHWRREVHUYHWKLVLQVWUXFWLRQPD\UHVXOWLQJHWWLQJDQHOHFWULFVKRFNRU
failure.
Other precaution
CAUTION
: )RUDIDLOXUHZKLFKFDQQRWEHMXGJHGHYHQLIUHIHUULQJWRWKHLQVWUXFWLRQPDQXDO
be sure to ask the nearest dealer or Fuji adjustment serviceman for repair. If
GLVDVVHPEOHGFDUHOHVVO\DQDFFLGHQWRULQMXU\FRXOGUHVXOW
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CONTENTS
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6. Maintenance and Check ......................................................................................................... 
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1.1 General description of zirconia oxygen analyzer
This zirconia oxygen analyzer makes use of the oxygen ion conductivity of solid electrolytes composed
PDLQO\RI]LUFRQLD=U2) 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
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EHWZHHQERWKWKHHOHFWURGHV7KLVSKHQRPHQRQLVFDOOHGFRQFHQWUDWLRQFHOODFWLRQ
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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)
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electrically.
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1.3 Description of each component
 =).
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
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1.5 Check of delivered articles
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1R Description &ODVVL¿FDWLRQ Q'ty 5HPDUN
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Thermo sticker $FFHVVRULHV VK 6HH,WHP
6&HUDPLF¿OWHU $FFHVVRULHV VK 6HH,WHP
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Caution in handling
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zero.
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(VSHFLDOO\ZKHQDFHUDPLF¿OWHUDWWKHHQGRIWKHGHWHFWRULVUHSODFHGWDNHXWPRVWFDUH
CAUTION
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2.1 Mounting location
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or incorrect operation.
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and appliances bringing about electromagnetic induction trouble and electrostatic induction trouble)
nearby the detector.
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2.2 Mounting method
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EORZRXWIURPWKHIXUQDFHRWKHUZLVHWKHUHLVDIHDURIJHWWLQJDEXUQ
2. MOUNTING
CAUTION
DANGER
CAUTION
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2.2.1 Mounting method of detector
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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°
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<How to check>
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thermo sticker
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 0RXQWLQJPHWKRGRIÀRZJXLGHWXEH
(Designation of type: When 9th to 11th digits are 5A , 5B and 5C)
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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
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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
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XQGHUJ1P
(Desingation of type: When 9th to 11th digits are 5A )
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LVXQGHUJ1P
(Designation of type: When 9th to 11th digits are 5A )
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(Designation of type: When 9th to 11th digits are 5B and 5C )
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+
Inserting
angle
–
Inserting
angle
Up
Down
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6
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(Desingation of type : When 9th to 11th digits are 6Dand 6E)
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Gas flow
Gas flow
Fitted with high dust cover
Gas outlet
Gas flow
Gas outlet
Gas flow
For high dust
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2.2.4 Mounting of heat insulating cover
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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
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a spanner after it cannot be turned any more by hand.
3.2 Piping of reference gas inlet
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body.
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installation method of piping.
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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
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Joint for calibration gas:
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CAUTION
All manuals and user guides at all-guides.com

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 tube for high
particulate with cover
I6mm or I1/4 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)
Standard 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
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 I10/I8 PTFE
pipe or copper pipe
(not supplied)
15ASGP
tube equivalent
or I10/I8 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
LSV AC COM N
or
ZV
ZERO
GAS
SPAN
GAS
TM-1
TM-2
*2
Ref. air
All manuals and user guides at all-guides.com


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 tube for high
particulate with cover
I6mm or I1/4 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)
Standard 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 valve
(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
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 I10/I8 PTFE
pipe or copper pipe
(not supplied)
15ASGP
tube equivalent
or I10/I8 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
LSV AC COM N
or
ZV
ZERO
GAS
SPAN
GAS
TM-1
TM-2
*2
Ref. air
All manuals and user guides at all-guides.com


Gas temperature.
1500ºC max.
Ejector (ZTA) Ejector (5 to 10L/min)
Copper pipe I6/I4mm
(not supplied)
Copper pipe I10/I6mm
(not supplied)
Copper pipe
I10/I8mm
(not supplied)
Flowmeter
(ZBD)
Rainproof flexible
conduit.
(Max. 20m)
RS485
(option) TM-2
Detector (ZFK8)
AC power
supply
Power supply
Heater temperature drop
Alarm
Joint
Supply air
Solenoid valve
(not supplied)
AC power
supply
I6mm or I1/4 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)
Standard 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
234567891011121314
16 17 18 19 20 21 22 23 24 25 28
26 27
＋−＋−
＋−
＋−
O2
TC1
AO
TC2 DI1 DI2 DI3 DICOM
ALARM MAINTE
LSV AC COM N
or
ZV
ZERO
GAS
SPAN
GAS
All manuals and user guides at all-guides.com


Gas temperature.
1500ºC max.
Ejector (ZTA) Ejector (5 to 10L/min)
Copper pipe I6/I4mm
(not supplied)
Copper pipe I10/I6mm
(not supplied)
Copper pipe
I10/I8mm
(not supplied)
Flowmeter
(ZBD)
Rainproof flexible
conduit.
(Max. 20m)
RS485
(option) 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
I6mm or I1/4 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
valve (ZBD6)
Reduction
valve (ZBD6)
Span gas
Standard 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
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.
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
LSV AC COM N
or
ZV
ZERO
GAS
SPAN
GAS
All manuals and user guides at all-guides.com
all-guides.com


4. WIRING
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WRWKHUDWLQJPD\FDXVHD¿UH
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is a fear of getting an electric shock.
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CAUTION
PROHIBITION
All manuals and user guides at all-guides.com


)RUZLULQJRIWKHGHWHFWRUEHVXUHWRXVHDVROGHUOHVVWHUPLQDOIRU0

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4.2 Wiring to each terminal
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4.1 Before wiring
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FDEOH$OVRSXWWKHFDEOHVIRU5WKHUPRFRXSOHDQGHOHPHQWRXWSXWDZD\IURPWKHSRZHUFDEOHWRWDNHD
noise preventive step.
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 )RU5WKHUPRFRXSOH ............6SHFL¿HGLQ-,6&HTXLYDOHQWWR5&$*PP6).
 5HFRPPHQGHGZLUHURGDW&
Composition
For heater Element output
compensation conductor
1RPLQDOVHFWLRQDODUHDPP 
1XPEHURIFRPSRVHGHOHPHQWZLUHV
GLDPHWHURIHOHPHQWZLUHPP 
2XWVLGHGLDPP  
Thickness of vinyl insulating material (mm) 
Thickness of vinyl sheath (mm)  
Max. conductor resistance per unit length (:km)  —
7HVWYROWDJH9  
Insulation resistance per unit length (M:NP  
5DWLQJ$  —
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
CAUTION
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
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JURXQGLQJJURXQGLQJUHVLVWDQFHȍRUOHVV
Note
 8VHWKHFDEOHPRUHWKDQPPfor main ground (earth) line.
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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.
8VH³ ´W\SHRIVROGHUOHVVWHUPLQDO
4.3 Mounting of conduit
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RIWKHEXVKLQJ
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SDFNLQJDQGSDFNLQJKROGHUQXWIRU¿[LQJ
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
$WWDFKWKHVROGHUOHVVWHUPLQDOVWR
WKHJURXQGLQJWHUPLQDOVZLWKWKHP
EHWZHHQWKHWRRWKORFNZDVKHUDQG
VFUHZZLWKZDVKHU
(recommended tightening torque:
1ÂP
Screw with washer M4
Tooth lock
washer
Double caulking
All manuals and user guides at all-guides.com


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displayed and there is a fear of explosion.
5.1 Start of operation
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starts its operation.
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calibrate by converting the output in a stabilized state into oxygen concentration according to the standard
RXWSXWWDEOHRIFRQYHUWHULQ,WHP³´
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5.2 Stop of operation
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WLRQIROORZLQJWKHSURFHGXUHVGHVFULEHGEHORZ
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JHWWLQJGHZHG
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WDNLQJWKHGHWHFWRURXWRIWKHIXUQDFHDQGOHDYLQJLWDVLWLVIRUPLQXWHVRUPRUH
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5. OPERATION AND STOP
DANGER
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