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1、Instruction Manual Fuji Electric Co.,Ltd.INZ-TN4ZFK2-E THE DIRECT INSERTION TYPE ZIRCONIA OXYGEN ANALYZER DETECTORTYPE: ZFK2 ZFK5 i Thank you very much for your kind purchase of Fujis zirconia oxygen analyzer detector (Type ZFK 2,5). Read this instruction manual carefully to get a thorough understan
2、ding 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 improvements of
3、the product. Under no circumstances should this zirconia oxygen analyzer be modified without permission. If any trouble shoudl occur because of having been modified without permission, we wont be responsible for it anyway. This instruction manual should be kept in custody by a person who operates th
4、e 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 NOTE It i
5、s 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 without previous notice Fuji Electric Co., Ltd., 1997 Issued in July, 1997 Related instruction manuals Single channel: Zirconia oxygen analyzer con
6、verter (Type : ZRM)INZ-TN1ZRM Multi-channel: Zirconia oxygen analyzer converter (Type : ZRN) .INZ-TN1ZRM Direct insertion type zirconia oxygen analyzer-use ejector (Type : ZTA).INZ-TN1ZTA Manufacturer:Fuji Electric Co., Ltd. Type:Described in the nameplate put on the main body Date of manufacture:De
7、scribed in the nameplate put on the main body Product nationality:Japan ii 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 abo
8、ut medium injury or a minor injury and a physical damage is supposed to occur. PROHIBITION:This indicates a prohibition (act which must not do). Precautions used in mounting and wiring DANGER: This product is not made with an explosion-proof specifications. Dont use it in an explosive gas atmosphere
9、. 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 incorre
10、ct operation. When this product is mounted on a furnace which is under operation, take utmost care with blow-out from the furnace. It might get a burn. 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 malfunct
11、ion 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 w
12、iring 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 rain water splashes the product directly. A failure to observe this instruction may result in getting an
13、electric shock or failure. Prior to operating this analyzer, 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 PR
14、ECAUTIONS iii Precautions used 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
15、. 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 and the surface temperature is also very high. So
16、, 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. Dont use any other renewal part than those designated by the maker. Other- wise, the o
17、riginal performance is not fully displayed and a trouble or failure may result. Dispose of the renewal parts such as the maintenance parts as an incombusible article. PROHIBITION: Never do the work at a place where rain water splases the product directly. A failure to observe this instruction may re
18、sult 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 dissasembled without a thought for the outcome, an accident or inju
19、ry could result. iv CONTENTS PREFACE.i SAFETY PRECAUTIONS .ii 1.INTRODUCTION 1 1.1General description of zirconia oxygen analyzer. 1 1.2Description of each component 1 1.3Check of type . 2 1.4Check of delivered articles. 2 2.MOUNTING. 2 2.1Mounting location 2 2.2Mounting method. 2 2.3Mounting of hea
20、t insulating cover . 5 3.PIPING 6 3.1Piping of calibration gas 6 3.2Piping for blow down air . 6 3.3Piping of reference gas inlet. 6 3.4Piping drawing . 7 4.WIRING 7 4.1Before wiring . 8 4.2Wiring to each terminal 8 4.3Mounting of conduct tube 8 5.OPERATION AND STOP . 9 5.1Start of operation 9 5.2St
21、op of operation 9 6.MAINTENANCE AND CHECK . 10 6.1Check . 10 6.2Maintenance . 11 6.3Standard output of detector 12 6.4Arrangement 13 7.TROUBLE-SHOOTING 14 8.APPENDIX. 15 8.1Specification 15 8.2Designation of type (PILC code table) 17 8.3Composition of apparatus 19 8.4Dimensions 20 1 1.1General descr
22、iption of zirconia oxygen analyzer This zirconia oxygen analyzer makes use of conductivity that a solid electolyte composed mainly of zirconia (ZrO2) allows only oxyzen ion to pass through at high temperature. This is an oxygen sensor which mea- sures an electromotive force produced by difference in
23、 oxygen concentration between gas to be measured and reference air based on the principle of oxygen concentration cell. It is possible to measure the oxygen concentraion with high accuracy by combining with a multi-channel converter (Type: ZRN) to which maximum 9 detectors can be connected or a sing
24、le-channel converter (Type : ZRM). 1.2Description of each component The operating temperature of detector (tip of ceramic heater) is about 800C and the surface tem- perature is also very high. So, never touch it by bare hand. Otherwise, there is a fear of getting a burn. Especially when a ceramic fi
25、lter at the end of the detector is replaced, take utmost care. (1) ZFK2 Ceramic filter O-ring Quartz filter Ceramic heater Heat insulating material Joint for calibration gas Cable gland Terminal box Terminal box lid Filter frame M5-hexagon set screw (or reference gas inlet) * According to designatio
26、n of type Calibration gas inlet Wiring hole Air environment (Reference gas) Furnace environment (Gas to be measured) Thermo sticker Measured gas (2) ZFK5 O-ring Quartz filter Ceramic heater Heat insulating material Joint for calibration gas Cable gland Terminal box Terminal box lid Filter frame M5-h
27、exagon set screw (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 Ceramic filter Since the detector is made of porcelain of zirconia, there is a case where
28、 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. Dontt loosen the scre
29、w without thought since a waterproofing effect becomes zero. 1.INTRODUCTION CAUTIONS Caution in handling 2 1.3Check 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”. 1.4Check of delivered articles Make sure the
30、 following articles have been delivered without lack. Remark Confirmed in Item 1.3 INZ-TN4ZFK2 See Item 2.2.1. See Item 2.2.1. See Item 2.2.1. See Item 6.2.3. See Item 2.2.2 and 2.2.3. See Item 2.3. See Item 3.1. See Item 3.3. Qty 1 unit 1 copy 1 pc. 6 pcs each 1 sh. 1 sh. (*) (*) 1 pc. (*) Descript
31、ion Detector Instruction manual (this manual) O-ring (Viton P36) Mounting screw, plain otherwise, there is a fear of getting a burn. 2.MOUNTING DANGER CAUTIONS CAUTIONS 3 2.2.1Mounting method of detector Never mount the detector with the tip turned upward or downward. A failure of the detector may r
32、esult. O-ring (accessory) Mounting screw, plain washer, spring washer (accessory) - 3 locations Flow guide tube or ejector (ZTA) Gas flow Detector flangeWiring hole Detector +45 -45 Fitting O-ring (accessory) into a groove of the detector flange, use a plain washer and spring washer (both of which a
33、re an accessory) for the mounting screw and mount on the flange of flow guide tube or ejector (ZTA) at 3 locations (any desired 3 locations in 6 mounting holes). Install so that the detector becomes a range of 45 relative to a horizontal plane. Mount so that the wiring hole of detector comes to down
34、side. Keep the temperature of detector flange below 125C, regardless of exhaust gas temperature. With the mounting, piping and wiring work of the detector completed, make sure the color of thermo sticker 125 put on the detector flange is not changing to red in the exhaust gas measuring condition (wh
35、ile current is flowing 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 125C. So, take the following steps: (a) Change the existing flange packing to
36、 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 taki
37、ng 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”. Up UpUp Down Down DownDetector Caution in mounting 4 2.2.2Mounting method of fl
38、ow guide tube (Designation of type: When 9th to 11th digits are 5AI I, 5BI I and 5CI I) The flange of flow tube has mounting holes at 8 locations. These holes are available for regulating an inflow into the flow guide and mounting the tube correctly in the flowing direction of gas and it is enough i
39、f mounted at 4 locations. (1) Direction of tongue and position plate of flow guide tube When exhaust gas temperature is under 200C 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
40、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 15 (JIS5K-65A) Arrow mark of flow guide tube Furnace wall When exhaust gas temperature is 200C or higher
41、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 fl
42、ow guide tube Tongue Partition plate Packing (not included in scope of supply) Arrow mark of flow guide tube 15 (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 dif
43、fers. With reference to the following conditions, install a mating flange. When exhaust gas temperarture is under 200C and amount of dust is under 0.2g/Nm3 (Desingation of type: When 9th to 11th digits are 5A I I) Inserting angle: within a range of -45 to +45 When exhaust gas temperature is 200C or
44、higher and amount of dust is under 0.2g/Nm3 (Designation of type: When 9th to 11th digits are 5AI I) Inserting angle: within a range of -20 to +20 When amount of dust is over 0.2g/Nm3 (Designation of type: When 9th to 11th digits are 5BI I and 5CI I) Inserting angle: within a range of 0 to +20 + - I
45、nserting angle Inserting angle Up Down 5 2.2.3Mounting method of high dust-use flow guide tube (Desingation of type : When 9th to 11th digits are 6DI I and 6EI I) 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 cov
46、er 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 45. 2.3Mounting of heat insulating cover For using at a cold distric, use a heat insulati
47、ng 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. Terminal box M4-
48、Mounting screw Heat insulating cover (according to designation) M4-Screw ring M4-tapped hole (for fixing heat insulating cover) + - Inserting angle Inserting angle Up Down 6 3.1Piping of calibration gas As the piping material, use a teflon-made 6/4 tube. (1) ZFK2 Removing nut and milli-sleeve from j
49、oint kept put on the detetor, connect to 6/4 teflon tube for piping and fit inner which is the accessrory of the joint to the joint in a condition where the inner has been held between joint and teflon tube. For mounting nut , tighten by making about 2 turns with a spanner after it cannot be turned any more by hand. (2) ZFK5 Removing nut at piping side and milli-sleeve at piping side from the joint kept put on the detector, connect to 6/4 teflon tube for pi