Instruction Manual

ZIRCONIA OXYGEN
ANALYZER CONVERTER

TYPE: ZRY

OXYGEN ANALYZER
Vol% O2

INZ-TN1ZRYa-E
PREFACE

We are grateful for your purchase of Fuji Electric’s Zirconia Oxygen Analyzer Converter (ZRY).

• First read this instruction manual carefully until an adequate understanding is acquired, and then
proceed to installation, operation and maintenance of the analyzer converter. Wrong handling may
cause an accident or injury.
• The specifications of this analyzer converter will be changed without prior notice for further prod-
uct improvement.
• Modification of this analyzer converter is strictly prohibited unless a written approval is obtained
from the manufacturer. Fuji Electric 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 analyzer converter.
• After reading the manual, be sure to store it at a place easier to access.
• This instruction manual should be delivered to the end user without fail.

Manufacturer: Fuji Electric Co., Ltd.

Type: Described in Fuji Electric’s company nameplate on main frame
Date of manufacture: Described in Fuji Electric’s company nameplate on main frame
Product nationality: Japan

© Fuji Electric Co., Ltd. 1998

Request
Issued in June, 1998
• It is prohibited to transfer part or all of this manual without Fuji Electric’s Rev. 1st edition April, 2000
permission in written format.
• Description in this manual will be changed without prior notice for fur-
ther improvement.

i
CAUTION ON SAFETY

First of all, read this “Caution on safety” carefully, and then use the analyzer in the correct way.

• The cautionary descriptions listed here contain important information about safety, so they should always be
observed. Those safety precautions are ranked 2 levels; DANGER and CAUTION.

Wrong handling may cause a dangerous situation, in which there is a

DANGER risk of death or heavy injury.

Wrong handling may invite a dangerous situation, in which there is a

CAUTION possibility of medium-level trouble or slight injury or only physical
damage is predictable.

• Even an undesirable action described in “ CAUTION ” may lead to a grave result depending on situation.
Be sure to observe DANGER and CAUTION because they are both important for ensuring safety.

Caution on installation and transport of gas analyzer

• This unit is not explosion-proof type. Do not use it in a place with

DANGER explosive gases to prevent explosion, fire or other serious accidents.

• This unit should be installed in a place which conforms to the condi-

tions noted in the instruction manual. Otherwise, it may cause elec-
tric shocks, fire 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, trouble 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 gas analyzer can be endured.
Installation at an unsuited place may cause turnover or fall and there

CAUTION is a risk of injury.

• For lifting the gas analyzer, be sure to wear protective gloves. Bare
hands may invite an injury.
• Before transport, fix the casing so that it will not open. Otherwise, the
casing may be separated and fall to cause an injury.
• The gas analyzer is heavy. It should be transported carefully by two or
more persons if manually required. Otherwise, body may be damaged
or injured.

Caution on piping

• If leaked gas contains oxygen at a high concentration, there is a risk of

fire.
DANGER • Connect pipes correctly referring to the instruction manual. Wrong
piping may cause gas leakage.

ii
 Caution on wiring
• The unit must be earthed as specified. Otherwise, it may cause elec-
tric shocks, malfunction, etc.
• Be sure to use a power supply of correct rating. Connection of power
CAUTION supply of incorrect rating may cause fire.
• Wiring work must be performed with the main power set to OFF to
prevent electric shocks.
• Use wiring materials that match the rating of the unit. Use of wiring
materials out of rating may cause fire.

Caution on use
• During operation, avoid opening the casing and touching the internal
parts. Otherwise, you may suffer a burn or shock hazard.
• Avoid touching the detector with bare hand during operation. Other-
CAUTION wise, you may suffer a burn because the detector may have reached a
high temperature (about 800°C).
• During operation, avoid removing and placing the detector on or near
a combustible material. Otherwise, fire may occur.

Caution on maintenance and check

• 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.
CAUTION • 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 a shock hazard.
• If the fuse is blown, eliminate the cause, and then replace it with the
one of the same capacity and type as before. Otherwise, shock hazard
or fault may be caused.

Others

• If the cause of any fault cannot be determined despite reference to the

instruction manual, be sure to contact your dealer or Fuji Electric’s
technician in charge of adjustment. If the instrument is disassembled
carelessly, you may have a shock hazard or injury.
CAUTION • 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 fault may be caused.
• Replacement parts such as a maintenance part should be disposed of
as incombustibles.

iii
CONTENTS

PREFACE ................................................................................................................................................ i
CAUTION ON SAFETY ....................................................................................................................... ii
CONTENTS .......................................................................................................................................... iv
1. GENERAL DESCRIPTION ........................................................................................................... 1
1.1 Direct insertion type zirconia oxygen analyzer ................................................................................... 1
1.2 Confirmation of delivered components ............................................................................................... 1
1.3 Confirmation of type of delivered components................................................................................... 1

2. NAME AND FUNCTION OF EACH PART ................................................................................. 2

2.1 Name and function of converter part................................................................................................... 2
2.2 Name and function of display and control panel................................................................................. 2

3. INSTALLATION ............................................................................................................................ 3
3.1 Location for installation ...................................................................................................................... 3
3.2 Installation ........................................................................................................................................... 3

4. WIRING AND PIPING .................................................................................................................. 4

4.1 Before wiring ...................................................................................................................................... 4
4.2 Wiring to each teminal ........................................................................................................................ 4
4.3 Wiring and piping diagram ................................................................................................................. 5

5. PREPARATION FOR OPERATION ............................................................................................. 6

6. OPERATION AND STOP ............................................................................................................. 6
6.1 Starting ................................................................................................................................................ 6
6.2 Shutdown ............................................................................................................................................. 6
6.3 Key operation flow diagram (outline) ................................................................................................. 7
6.4 Check on alarm data ............................................................................................................................ 8
6.5 Oxygen detector standard output ........................................................................................................ 8

7. SETTING OF CALIBRATION GAS CONCENTRATION .......................................................... 9

7.1 How to set span calibration gas concentration .................................................................................... 9
7.2 How to set zero calibration gas concentration .................................................................................... 9

8. CALIBRATION ............................................................................................................................ 10
8.1 Preparation ........................................................................................................................................ 10
8.2 Manual calibration ............................................................................................................................ 10

9. RANGE SELECTION .................................................................................................................. 11

10. ADJUSTMENT ............................................................................................................................. 12
10.1 Zirconia input signal adjustment ....................................................................................................... 12
10.2 Temperature input adjustment ........................................................................................................... 13
10.3 Current output adjustment ................................................................................................................. 14
10.4 Setting of detector control temperature ............................................................................................. 15
10.5 Selection of alarm contact output ...................................................................................................... 16

11. MAINTENANCE AND CHECK ................................................................................................. 17

11.1 Check ................................................................................................................................................. 17
11.2 Fuse replacement ............................................................................................................................... 17
11.3 Troubleshooting ................................................................................................................................ 18

12. APPENDIX ................................................................................................................................... 19

12.1 Specification ...................................................................................................................................... 19
12.2 Designation of type (PILC code table) .............................................................................................. 20
12.3 Outline diagram (unit:mm) ............................................................................................................... 22

iv
1. GENERAL DESCRIPTION

This instruction manual describes the installation, operation and maintenance of the single-channel type
converter, so read through it before using the converter. For the sensor, flow guide tube used with the con-
verter, 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 ZRY).
It is used to measure oxygen concentration in waste gas during combustion for controlling gas combustion.

1.2 Confirmation of delivered components

Inspect the external appearance and number of accessories to confirm there is no damage or shortage of parts.

List of components and accessories

Converter
Accessories of converter
• Power fuse (0.5A) ------------------------------ 1
• Heater fuse (3A) -------------------------------- 1

CAUTION
Power voltage for the converter must conform to that for the detector (ZFK2 or 5)
to be connected. Don’t use any power voltage different from the power specifica-
tions of the detector.
Because it may result in damage to the sensor.

100/115V AC for ZFK 2 14-0

5
200/220V AC, or 230V AC for ZFK 2 3 4-0
5 5

1.3 Confirmation of type of delivered components

Check model name on specification nameplate to confirm that the delivered components are as described in
Item 12.2 Designation of type (PILC code table).

-1-
2. NAME AND FUNCTION OF EACH PART

2.1 Name and function of converter part

OXYGEN ANALYZER

Vol% O2

FUSE AC250V
3.15A T 500mA T

HEATER POWER

No. Name Function

Cover fixing screw (4 places) Screw for opening or closing the cover.
Operation panel fixing screw (3 places) Screw for fixing the operation panel to the case.
Fuse (0.5A) Fuse for the power supply of the converter.
Fuse (3A) Fuse for the heater for O2 sensor.
Terminal block Connect cables from external equipments.
Cable inlet Use to insert external cable.
Cable gland Cable inlet to insert the exclusive cable for the sensor.

2.2 Name and function of display and control panel

1

OXYGEN ANALYZER

Vol% O2

ZERO SPAN CAL. ESC

+ - ENT SET

FUSE AC250V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 3.15A T 500mA T
+ - + - + - N L
T.C Zr.SIG A.OUT ALARM HEATER FG POWER HEATER POWER

2 3 4 5

No. Name Function

Oxygen concentration Displays oxygen gas concentration.
display

}
ZERO key
SPAN key Refer to each operation procedure flow in chapter 6 to
CAL key 10.
ESC key

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3. INSTALLATION

CAUTION
• Install the analyzer safely and securely so that it will not fall.

3.1 Location for installation

The location for installation should meet the following conditions.

(1) Space for routine inspection and wiring available.

(2) Vibration, dust, dirt and humidity are minimal.

(3) No direct influence of radiation from heating furnace or the like (converter).

(4) Non-corrosive atmospheric environment.

(5) No electric machinery nearby, which may cause noise trouble (such as motor, transformer) or produce
electromagnetic and electrostatic induction.

(6) Ambient temperature within -10 to +50 and ambient humidity less than 90%RH (converter).

3.2 Installation
3.2.1 Panel mounting

Mounting dimension (unit ; mm) Mounting method

No. Name Piece

1 Converter 1
2 Pan head screw
M8 4
Excluded from the (
(scope of supply
Panel face

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4. WIRING AND PIPING

CAUTIONS
• Wiring work must be carried out with all power supplies turned off.
Otherwise, you may suffer electric shock.

• The analyzer should be grounded without fail (Class 3 grounding).

4.1 Before wiring

Power supply voltage to the converter should match with that of the sensor (Type ZFK2 or 5).
For wiring to the power supply, use 600V vinyl insulation power cable (JISC3307) of 1.25mm2
or equivalent.
For the wiring of thermocouple, be sure to use a compensating wire.
Exclusive cable (6 cores in total) between the sensor and converter should be installed in a cable
conduit for protection. It should be separated from power cable for prevention of noise.
For use of the exclusive cable, see Item 12.2 Designation of type.
Output signal cable should be separated more than 30cm away from power line to prevent effect
of induction noise. Shielded cables should be used and grounded at one point with M4 screw
with toothed washer.
Note) When connecting cables to external terminal block, recommended insulation sleeve solderless
terminals should be used (for M4 screw).

4.2 Wiring to each teminal

OXYGEN ANALYZER

Vol% O2

FUSE AC250V
3.15A T 500mA T

HEATER POWER

External terminal block

1 2 3 4 5 6 7 8 9 10 11 12 13 14
N L

THERMO- ZIRCONIA DC4 20mA ALARM DETECTOR POWER

COUPLE SIGNAL ANALOG CONTACT HEATER SUPPLY
SIGNAL OUTPUT OUTPUT POWER
SIGNAL SUPPLY

-4-
4.3 Wiring and piping diagram
With flow guide tube

Flow guide 4-core exclusive Converter

tube cable
Sensor

Red
Calibra-
AC power supply
tion gas White
inlet
1R/min Blue

Yellow

Black

White

2-core
exclusive cable
Standard gas
Manual operated Pressure reducing
Flow rater O2/N2 (ZBM)
valve for zero gas valve for standard
0.2 to 2R/min gas
Pressure reducing valve
Instrumentation air
Manual operated or standard gas (ZBM)
valve for span gas

-5-
5. PREPARATION FOR OPERATION

Preparation can be performed after installation or on the bench.

Wiring check (Refer to 4.2, 4.3)
h
Confirmation of the power supply specifications (Confirm the specifications of the main power supply
and voltage.)
h
Piping check (Refer to 4.3)
h
Power ON
• Turn ON the power
• LED lighted.
• The analyzer is set in measurement display mode after warm-up (15 minutes).
h
Warmup (After 15 minutes from power ON, accurate measurement data may be obtained.)
h
Standard gas (composition gas) concentration setting
For the standard gas concentration to be used, see Chapter 7.
h
Calibration
At the first operation, perform manual calibration after warmup using a calibration gas.
Refer to chapter 8 for calibration procedures.
h
Operation

6. OPERATION AND STOP

6.1 Starting
After correct wiring and piping has been completed, turn the converter power ON, and measuring opera-
tion will start.
Note : 15 minutes is required for warming-up after power ON.
Caution before starting operation
Furnace operation should be started after 15 minutes. or more of warmup time has elapsed.
When a sensor is to be installed in a furnace during operation, take care to blow out harmful
gas from the furnace and then install the fully warmed up sensor quickly.

6.2 Shutdown

(1) When a process (furnace etc.) is to be shutdown for a short time (about one week)
The sensor should be operated continuously to avoid possible deterioration of platinum electrodes
and destruction of its element by repeating power ON-OFF operation in a wet condition (depending
on the condition in furnace and/or ambient conditions)

(2) When a process (furnace etc.) is to be shutdown for a long time

Turn OFF the analyzer after gas in the furnace has been replaced completely by ambient air.

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6.3 Key operation flow diagram (outline)

Zero calibration (Item 8.2)

ZERO
All of 3 digits blink

Span calibration (Item 8.2)

SPAN
All of 3 digits blink

Calibration gas concentration setting zero (Item 7.2)

ZERO ESC
1st digit blinks

Calibration gas concentration setting span (Item 7.1)

SPAN ESC
1st digit blinks

Zirconia input signal

ENT ESC ENT ZERO adjustment zero (Item 10.1)
Keep key on for 5 sec. Decimal point in Decimal point in 2nd digit blinks
1st digit blinks 2nd digit blinks
Zirconia input signal
SPAN adjustment span (Item 10.1)
3rd digit blinks

Temperature input adjustment zero (Item 10.2)

ZERO

2nd digit blinks in 700 display.

Temperature input adjustment span (Item 10.2)

SPAN

3rd digit blinks in 800 display.

Current output adjustment zero (Item 10.3)

ENT ZERO ESC
Keep key on for 5 sec. 000 is displayed.

Current output adjustment span (Item 10.3)

SPAN ESC
100 is displayed.

Alarm data display (Item 6.4)

ESC Detector ESC
Keep key on for 3 sec. temperature Keep key on
display for 3 sec.

CAL error clear (calibration error only)

Note) How to cancel operation

Press the ESC key during setting to cancel operation midway, returning to measurement display.

-7-
6.4 Check on alarm data
When a fault (error) warning output appears at the converter alarm contact output terminals (No. 7 and No.
8), the alarm data can be checked by the following operation.
Measurement
display
Alarm data display
ESC ESC
Keep key on for 3 sec. Keep key on for 3 sec.

CAL error clear (calibration error only)

After checking the alarm data, press the CAL key and the alarm of zero/span calibration error will be
cleared.
Alarm data

The 3rd digit ; 50°C (or more) higher than the detector control temperature
Temperature error
; 50°C (or less) lower than the detector control temperature
The 2nd digit ; Difference of more than 5%O2 between zero calibration gas
Zero calibration error concentration and zero calibration set value
Blank ; Normal
The 1st digit ; Difference of more than 5%O2 between span calibration gas
Span calibration error concentration and span calibration set value
Blank ; Normal

Conditions of converter alarm contact output (between No.7 and No.8 terminals)

The 5th digit of

converter code Power OFF Power ON, Power ON,
symbols normal alarm

B Open Open Closed

C Open Closed Open

6.5 Oxygen detector standard output

O2 concentration Output value O2 concentration Output value O2 concentration Output value
% mV % mV % mV

0.01 168.15 5.0 31.20 25.0 -4.266

0.1 117.41 10.0 15.93 30.0 -8.284
0.5 81.94 15.0 6.991 40.0 -14.623
1.0 66.67 20.0 0.651 50.0 -19.54
1.5 57.73 20.6 0
2.0 51.39 21.0 -0.4238

-8-
7. SETTING OF CALIBRATION GAS CONCENTRATION

While setting zero/span calibration concentration, press the ZERO key once, then the number of the digit
increases by one digit, and press the SPAN key, then the number of the digit decreases by one digit. Setting
digit is moved to the right by one by pressing the ENT key. However, if the ENT is pressed while setting the
3rd digit, calibration concentration setting will be ended.
Note) Pressing the ESC key allows the setting to be canceled midway.

7.1 How to set span calibration gas concentration

Description
• Set span calibration gas concentration. Use air generally.
• For air, set 20.6% O2.
• The settable range is from 10.0 to 29.9% O2.

Operation How to set the span calibration gas concentration to 21.0% O2.
Order
(It is generally set to 20.9% O2 before shipment).
Key operation Description Displayed message
SPAN + ESC Press the SPAN key and ESC key simulta-
neously, then the lamp begins to blink (the
number in the 1st digit blinks).

ENT , ZERO Press the ENT key to blink the 2nd digit. Press
the ZERO key to change “0” to “1”.

ENT , ZERO Press the ENT key to blink the 3rd digit. Press
the ZERO key (increase) to change “9” to “0”.
Press the ENT key, then the display set to 21.0
ENT returns to measurement display status.
Measurement diaplay
To cancel the setting, press the ESC key.

7.2 How to set zero calibration gas concentration

Description
• Set zero calibration gas concentration. Set the value specified on the gas cylinder.
• For zero gas, Use O2 gas of 1.01% or less.
• The settable range is from 0.00 to 99.9% O2.

Operation How to set the zero calibration gas concentration to 1.00% O2.
Order
(It is generally set to 1.01% O2 before shipment).
Key operation Description Displayed message
ZERO + ESC Press the ZERO key and ESC key simulta-
neously, then the lamp begins to blink (the
number in the 1st digit blinks).

ENT , ENT , Press the ENT key twice to blink 3rd digit.
SPAN Press the SPAN key (decrease) to change “1” to
“0”.

ENT Press the ENT key, then the display that is set
to 1.00 returns to measurement display status.
Measurement diaplay

To cancel the setting, press the ESC key.

-9-
8. CALIBRATION

In order to maintain good accuracy, proper calibration using calibration gas is necessary.
Perform manual operation (Refer to 8.2).

8.1 Preparation
• Wiring/piping check
Wiring and piping work should be made correctly referring to Item. 4.3. The main plug of standard gas
should be left open. Since high pressure is present at piping connections, use blind-nut type joints and
take special care with regard to air-tightness. Calibration gas flow should be 1 to 1.5r/min.
• Setting of calibration gas concentration
Referring to Chapter 7 “Setting of calibration gas concentration”, set the oxygen concentration in standard
gas cylinder to be used.

8.2 Manual calibration

Caution before operation
• Span/zero is calibrated once.
• Calibration should be performed in the order of span and zero.
• For calibration, allow calibration gas to flow into the sensor. When the sensor output signal is stabilized,
key operation is performed to complete the processing.

Operation Performing span calibration.

Order
Key operation Description Displayed message
Open the stop valve to flow span gas.

Measurement diaplay
SPAN Press SPAN , then the message at right ap-
pears. All of 3 digits blink.

(All of 3 digits blink)

ENT When display is stabilized, press ENT key and
span calibration is completed.
Measurement diaplay
Close the stop valve.
To cancel span calibration, press the ESC key.

Operation Performing zero calibration.

Order
Key operation Description Displayed message
Open the stop valve to flow zero gas.

Measurement diaplay
ZERO Press ZERO , then the message at right
appears. All of 3 digits blink.
(All of 3 digits blink)
ENT When display is stabilized, press ENT key and
zero calibration is completed.
Measurement diaplay
Close the stop valve.
To cancel span calibration, press the ESC key.

-10-
9. RANGE SELECTION

Open the door by removing 4 screws (M5).

Remove 3 mounting screws (M3) fastening the operation panel. Remove the operation panel.
Set the range selection switch at the near of the operation panel at range position.

Operation panel

J1 : 0 to 10%range

J2 : 0 to 5%range

J3 : 0 to 25%range
Set before delivery

-11-
10. ADJUSTMENT

10.1 Zirconia input signal adjustment

Description
• This is used to adjust zero/span input of zirconia sensor signal.
• This adjustment should be made when required accuracy cannot be obtained after calibration.
In general, do not perform the above operation because it is based on the factory adjustment mode.

(1) How to adjust zero input

Operation (example) How to adjust zero input
Order
Key operation Description Displayed message
Apply a voltage of 0±0.01mV to external
terminals of 3(+) and 4( ).
ENT + ESC Hold down the ENT key and ESC key
simultaneously for more than 5 seconds, then
the decimal point in the 1st digit begins to
blink.
ENT Press the ENT key, then the decimal point in
the 2nd digit begins to blink.
ZERO Press the ZERO key to blink the number in the
2nd digit.
ENT After confirming that voltage is applied to the
terminals, press the ENT key, and then zero
input adjustment can be performed.

To cancel adjustment, press the ESC key.

(2) How to adjust span input

Operation (example) How to adjust span input
Order
Key operation Description Displayed message
Apply a voltage of 50±0.01mV to external
terminals of 3(+) and 4( ).
ENT + ESC Hold down the ENT key and ESC key
simultaneously for more than 5 seconds, then
the decimal point in the 1st digit begins to
blink.
ENT Press the ENT key, then the decimal point in
the 2nd digit begins to blink.
SPAN Press the SPAN key to blink the number in the
3rd digit.
ENT After confirming that voltage is applied to the
terminals, press the ENT key, and then span
input adjustment can be performed.

To cancel adjustment, press the ESC key.

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10.2 Temperature input adjustment
Description
• This is used to adjust zero/span adjustment of the thermocouple.
In general, do not perform the above operation because it is based on the factory adjustment mode.

(1) How to perform zero adjustment of thermocouple input

Operation (example) How to perform zero adjustment of thermocouple input
Order
Key operation Description Displayed message
Apply a voltage confirming to 700 to external
terminals, 1(+) and 2(-).

ENT + ESC Hold down the ENT key and ESC key simulta-
neously for more than 5 seconds, then the decimal
point in the 1st digit begins to blink.
ZERO Press the ZERO key, 2nd digit blinks in 700 display.
After confirming that voltage is applied to the termi-
ENT nals, press the ENT key, and then zero adjustment can
be performed.

To cancel adjustment, press the ESC key.

(2) How to perform span adjustment of thermocouple input

Operation (example) How to perform span adjustment of thermocouple input
Order
Key operation Description Displayed message
Apply a voltage confirming to 800 to external
terminals, 1(+) and 2(-).
ENT + ESC Hold down the ENT key and ESC key simulta-
neously for more than 5 seconds, then the decimal
point in the 1st digit begins to blink.

SPAN Press the SPAN key, 3rd digit blinks in 800 display.
After confirming that voltage is applied to the termi-
ENT nals, press the ENT key, and then span adjustment
can be performed.

To cancel adjustment, press the ESC key.

-13-
10.3 Current output adjustment
Description
• This adjustment should be made when
required accuracy can not be obtained after
calibration.
This is adjusted prior to delivery, so no Ammeter
250Ω
further adjustment is required for normal
operation.
• Adjust current by connecting an ammeter
and a load resistor of 250Ω to external
terminals 5(+) and 6( ).

Operation (example) How to perform zero adjustment of current output

Order
Key operation Description Displayed message
ENT Hold down the ENT key for more than 5
seconds, then the decimal point in the 3rd digit
begins to blink.
ZERO + ESC Press the ZERO key and ESC key simulta-
neously, and zero adjustment mode (000
display) is displayed.
SPAN or Press the SPAN key (increase) or press SPAN
SPAN + ESC key + ESC key simultaneously (decrease) so
that the ammeter may read 4mA.
ENT When the ammeter reads 4±0.05mA, press the
ENT key. Zero adjustment is performed.

To cancel zero adjustment, press the ESC key.

Operation (example) How to perform span adjustment of current output

Order
Key operation Description Displayed message
ENT Hold down the ENT key for more than 5
seconds, then the decimal point in the 3rd digit
begins to blink.
SPAN + ESC Press the SPAN key and ESC key simulta-
neously, and span adjustment mode (100
display) is displayed.
ZERO or Press the ZERO key (increase) or press ZERO
ZERO + ESC key + ESC key simultaneously (decrease) so
that the ammeter may read 20mA.
ENT When the ammeter reads 20±0.05mA, press the
ENT key. Span adjustment is performed.

To cancel span adjustment, press the ESC key.

-14-
10.4 Setting of detector control temperature
Description
• Setting of control temperature is required according to types of the detector to be connected.
Type of detector and control temperature
ZFK2 (general use type) .... Set to 800°C
ZFK5 (corrosion-proof type) ... Set to 750°C
In general, do not perform the above operation because it is based on the factory adjustment mode.
When the detector needs to be replaced with another type, it becomes necessary to change the set value.

Operation (example) Setting to 750°C (ZFK5)

Order
Key operation Description Displayed message
ENT + ESC Press the ENT key and ESC key at the same
time for more than 5 seconds, and the decimal
point in the lst digit begins to blink.
ZERO When the ZERO key is pressed, the detector is
set in the temperature control mode with the figure
700 displayed and the 2nd digit begins to blink.
SPAN Next, press the SPAN key. The figure “7” in
the 1st digit begins to blink.
ZERO Then, press the ZERO key. The figure “7”
blinking in the 1st digit disappears and the 2nd
digit begins to blink.
ENT Press the ENT key (or ESC key), and the
control temperature is set to 750°C when the
(or ESC )
display returns to the measurement mode. Measurement display

To cancel the above operation, press the ESC key.

* Do not press the ESC key under the condition of .

Operation (example) Setting to 800°C (ZFK2)

Order
Key operation Description Displayed message
ENT + ESC Press the ENT key and ESC key at the same
time for more than 5 seconds, and the decimal
point in the lst digit begins to blink.
SPAN When the SPAN key is pressed, the detector is
set in the temperature control mode with the figure
800 displayed and the 2nd digit begins to blink.
ZERO Next, press the ZERO key. The figure “8” in
the 1st digit begins to blink.
SPAN Then, press the SPAN key. The figure “8”
blinking in the 1st digit disappears and the 3rd
digit begins to blink.
ENT Press the ENT key (or ESC key), and the
control temperature is set to 800°C when the
(or ESC ) Measurement display
display returns to the measurement mode.
To cancel the above operation, press the ESC key.
* Do not press the ESC key under the condition of .

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10.5 Selection of alarm contact output
Description
• Select the converter alarm contact output.
• Select the contact output from the 5th digit of the converter code symbols.
The 5th digit of code symbol:
B.... Normal Open contact is selected.
C.... Normal Close contact is selected.
For details of alarm contact output, refer to Item 6.4 Check on alarm data (Page 8).
In general, do not perform the above operation because it is based on the factory adjustment mode.

Operation (example) Selection of alarm contact output

Order
Key operation Description Displayed message
ENT When the ENT key is pressed for more than 5
seconds, the decimal point in the 3rd digit
begins to blink.
ENT + ESC Press the ENT key and ESC key at the same
time to display the setting of the present contact
Normal Open contact
output.
Normal Open contact
Normal Close contact
ZERO By pressing the ZERO key, and
are selected alternately. Normal Close contact

ENT By pressing the ENT key, the setting is finished

when the display returns to the measurement
Measurement display
mode.
To cancel the above operation, press the ESC key.

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11. MAINTENANCE AND CHECK

11.1 Check
In order to keep the instrumentation operating in good condition, perform the following periodical mainte-
nance and check.
Perform maintenance and check once every year or 2, or at time of furnace check.
Check items Measures
Zero, span calibration Calibrate once every week (Refer to Chapter 8 “Calibration”)
Deterioration of packings If deteriorated, replace with new ones.
Daily and O-rings
check Check for loose cable Retighten or replace the packing.
ground
Check the remain pressure Check the amount using primary pressure.
in the calibration gas
cylinder
Clogging or corrosion of Remove the flow guide tube from the furnace wall, remove the
Peri- flow guide tubes detector and wash the flow guide tube with water.
odical Clogging or corrosion of Remove the ejector from the furnace wall, disassemble the
check ejector type sampling prove prove and wash it with water.
Clogging of air outlet of Remove the ejector from the furnace wall and clean the air
ejectors outlet located in the heat insulation layer of the furnace wall.

11.2 Fuse replacement

When a fuse blows, turn off the power switch, and replace the fuse after investigating the cause.
Open the front cover of the sensor. Two
fuses are located at lower right. The right
fuse is for protection of the sensor circuit
and the left one is for protection of the
heater.
Take care that these fuses are different
each other in the rated current. For sensor circuit
For replacement, use a vessel style (flat- 0.5A
blade) screwdriver or coin.
Push down the cap on the fuse holder and For heater
rotate about 1/4 turn counterclockwise 3.15A
until the cap is removed from the fuse
holder.
Then, replace the fuse with a new one.
Next, push in the cap and rotate about 1/4 turn clockwise until it is fitted to the fuse holder.

Fuse unit specifications (Reference)

Specification
For circuit ø5.2 × 20mm 0.5A JIS C 6575 MF51 250V 0.5A
For heater ø5.2 × 20mm 3A JIS C 6575 MF51 250V 3.15A

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11.3 Troubleshooting
Symptoms Probable causes Checking methods Remedy
No display Converter fuse blown Check the fuse and supply voltage specifica- Replace fuse
out tion. Check power supply
voltage
Indication Filter and/or flow Visual check of filter and flow guide tube for Clean or replace filter
does not guide tube clogged contamination or clogging. Tighten pipe connec-
change or Check for loosen and gas leaks at piping tions
slow re- connections and mounting place of detector.
sponse Sensor element Change over between zero and span gas and Replace sensor element
deterioration check if 5 minutes or longer is needed for
90% response.
Decrease in flow Check response to process gas after shutting Increase process gas
velocity of exhaust gas down calibration gas. flow into the flow
Move the direction (mounting position) of guide tube
“arrow” of the flow guide slightly.
Indication Loose flange and its Check for gas leaks in detector and mount- Tighten mounting
too high or surroundings ing part of flow guide tube flange. screws
too low Replace O-ring
Deteriorated Check for leaks from the outside. Seal
O-rings
Senor malfunction Check for gas leaks at calibration gas inlet. Tighten connectors
Check sensor element voltage (mV) for
higher or lower than other sensor when Replace sensor element
flowing zero gas
Break of wiring Ohmic check of wiring Replace

Wrong wiring Wiring check Correct wiring

Lower power supply Check of supply voltage specification Check supply

voltage voltage
Break of thermo- Ohmic check Replace sensor element
couples
Blown heater fuse Ohmic check of fuse Replace fuse
Break in sensor heater Check heater resistance Replace sensor element
50 to 55Ω for 115V, 200 to 250Ω for 220V
(Excluding wiring resistance)
Indication difference Oxygen concentration is higher in dry base. Normal
between dry and wet
base measurement

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12. APPENDIX

12.1 Specification
(1) General
• Measured gas : Oxygen contained in non-combustible gas
• Measuring method : Direct inserting type zirconia system
• Measuring range : 0 to 5%, 1 to 10% and 1 to 25% (selected by setting pin)
• Oxygen concentration : 4 to 20mA DC (allowable load resistance 500Ω max.)
output signal Input-output isolation, linear characteristic versus oxygen concentration
• Alarm contact output : • Contact specifications; 1 point, 1a, 250V AC, 2A
• Contact function; Fault (error)
Alarm contact Close/Open is as specified.
• Self-diagnosis function : Detector temperature error, zero calibration error, span calibration error
• Repeatability : ±1% FS
• Linearity : ±2% FS
• Response speed : Within 7 sec for 90% response (from calibration gas inlet)
• Power supply : 100/115, 200/220 or 230V AC 50/60Hz
• Power consumption : 15VA + 50VA in normal operation
15VA + 200VA at startup
• Warmup-time : 15 minutes approx.
• Cable : Maximum length between sensor and converter 100m (To be ordered separately)
(2) Oxygen detector (type ZFK2, 5)
• Measuring instrument : General use ZFK2
For corrosive gas ZFK5
• Measured gas temperature : -20 to 600°C for flow guide tube type (for general use, corrosive gas)
• Measured gas pressure : -3 to +3kPa {-300 to +300mmH2O}
• Flow guide tube : Without blow-down nozzle
Flange : JIS-5K 65A FF
Insertion length (according to specification) : 0.3, 0.5, 0.75, 1.0m
• Ambient temperature : -20 to 60°C (for cable section)
125°C or less at the sensor flange surface with power ON
• Structure : Dust/rain-proof structure (IEC standard IP55)
• Filter : Alumina (filtration accuracy 50µ) and quartz paper
• Material of gas-contacting : General use detector : Zirconia, SUS316, SUS304, platinum
parts For corrosive gas detector : Zirconia, titanium, platinum, SUS316 (flow guide tube)
• Detector mounting : Horizontal ±45°, surrounding air should be clean.
• Outline dimensions : (L × max. dia.) 210 × 100mm (sensor)
• Mass : Sensor, approx. 1.6kg
Flow guide tube of 1m (general use type), approx. 5kg
• Finish color : Silver and SUS metalic color
(3) Oxygen converter (type ZRY)
• Display : 3-digit LED
• Calibration method : Manual calibration with calibration key
• Calibration gas : • Setting range for zero gas; 0.01 to 9.99% O2
span gas; 10.0 to 29.9% O2
• Recommended concentration of calibration gas :
zero gas; 0.25 to 2.0% O2
span gas; 20.6 to 21.0% O2 (air)
• Structure : Dust/rain-proof structure (IEC standard IP65)
Use a block cap of G1/2 for useless wiring port.
To prevent water leak, use cable gland for other wiring ports.
to prevent water leak.
• Mounting method : Mounting on panel surface
• Finish color : Munsell 6PB35/10.5, Silver
• Outline dimensions (H × W × D) : 230 × 220 × 95mm
• Mass : Approx. 4.5kg
• Ambient temperature : -10 to 50°C
• Ambient humidity : 90%RH or less
• Power source : 90 to 230V AC 50/60Hz

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12.2 Designation of type (PILC code table)
(1) Type of converter 1 2 3 4 5 6 7 8 9 10 11 12
ZRY 1 1 1 - 1 RE 0 Description
Alarm contact output, measurement output
B “Close” at alarm, 4 to 20mA DC
C “Open” at alarm, 4 to 20mA DC

Option
Y Without selector cock
D With selector cock

Thermocouple specification
R Thermocouple R
Specification
0 Standard

(2) Type of detector

1 2 3 4 5 6 7 8 9 10 11 12 13 14 Digits

ZFK R 4- - Description
Application
2 General use
5 For corrosive gas (refuse incinerator)
Calibration gas inlet
1 Polyproprene joint for ø6 tube
2 Brass joint for ø1/4 in. tube
Power supply
1 100/115V AC 50/60Hz
3 200/220V AC 50/60Hz
5 230V AC 50/60Hz (CE-marking approved)
Flow guide tube
Flange material Type Length
0Y0 None
5A3 SUS304 General use 300mm
5A5 SUS304 General use 500mm
5A7 SUS304 General use 750mm
5A1 SUS304 General use 1000mm
5B3 SUS316 For corrosive gas 300mm
5B5 SUS316 For corrosive gas 500mm
5B7 SUS316 For corrosive gas 750mm
5B1 SUS316 For corrosive gas 1000mm
ZZZ Others
NOTE) As for the flange dimension, JIS 5K-65A FF is standard.
Protection cover
Y Without
A With
Reference air inlet
Y None
A Rc 1/8
B NPT 1/8
None-standard spec.
Z Other none-standard items

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(3) Type of exclusive cable connecting converter to sensor
1 2 3 4 5 6 7 8 9 Digit
Z R Z 1 Description
Specification
P For ZRY

Type
R For thermocouple R

Flexible conduit length Cable length

Y A Without 6m
Y B Without 10m
Y C Without 15m
Y D Without 20m
Y E Without 30m
Y F Without 40m
Y G Without 50m
Y H Without 60m
Y J Without 70m
Y K Without 80m
Y L Without 90m
Y M Without 100m
A A 6m 6m
B B 10m 10m
C C 15m 15m
D D 20m 20m
Max. flexible conduit length 20m
Max. cable length 100m

Termination
0 Without
1 One end (sensor ZFK side)
2 Both ends

(4) Type of replacement sensor

1 2 3 4 5 6 7 8 9 10 11 12 13 Digits

ZFK R 4 - 0 Y0 YY Description
Application
2 General use
5 For corrosive gas (refer to incinerater)
Calibration gas inlet
1 Polyproprene joint for ø6 tube
2 Brass joint for ø1/4 in. tube
Power supply
1 100/115V AC 50/60Hz
3 200/220V AC 50/60Hz
5 230V AC 50/60Hz (CE-marking approved)

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12.3 Outline diagram (unit:mm)
2-
ø 9

20
72 195

220
Selector cock
312

Provided when "D" is

specified in 6th digit
of PILC code.
Not provided when "Y".

14 230
3.2 95
5
ø1
Cable gland
For ø23.5/ø15.8 tube
39

5-G1/2
40 40 40 40
Connection diagram
1 2 3 4 5 6 7 8 9 10 11 12 13 14
N L
Thermo- Zirconia Analog Alarm Detector Power
couple signal output contact heater supply
signal output power
signal supply

Conditions of converter alarm contact output

(between No.7 and No.8 terminals)
The 5th digit of Power ON, Power ON,
converter code Power OFF normal alarm
symbols
B Open Open Closed
C Open Closed Open

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