Instruction Manual

ZIRCONIA OXYGEN
ANALYZER CONVERTER
(SINGLE-CHANNEL TYPE)

TYPE: ZRM

INZ-TN1ZRMa-E
 PREFACE
We are grateful for your purchase of Fuji Electric’s Zirconia Oxygen Analyzer Converter (ZRM).

• 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 product 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 con-
verter.
• 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 Instrumentation 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 Systems Co., Ltd. 1993

Request
Issued in Nov., 1993
• It is prohibited to transfer part or all of this manual without Rev. 1st edition Sep., 1997
Fuji Electric’s permission in written format.
• Description in this manual will be changed without prior
notice for further 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

DANGER there is a risk of death or heavy injury.

Wrong handling may invite a dangerous situation, in which

CAUTION there is a 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

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

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

the conditions noted in the instruction manual. Otherwise, it
may cause electric 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 instruc-
CAUTION tion manual and select a place where the weight of gas ana-
lyzer can be endured.
Installation at an unsuited place may cause turnover or fall
and there 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. Oth-
erwise, the casing may be separated and fall to cause an in-
jury.
• 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.
• For installation and maintenance accessible by qualified per-
sonnel only.

ii
 Caution on piping

DANGER
• If leaked gas contains oxygen at a high concentration, there is a risk of fire.
• Connect pipes correctly referring to the instruction manual. Wrong piping may cause gas leak-
age.

Caution on wiring

CAUTION
• The unit must be earthed as specified. Otherwise, it may cause electric shocks, malfunction, etc.
• Be sure to use a power supply of correct rating. Connection of power 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.
• The supply voltage category of this instrument is II. Relay contact is category I.
• Analog output and digital input of this instrument are Safe Separated (SELV) circuit.
• Establish an external over-current protection device (e.g. circuit-breaker) with a rating of no
more than 5A as per the general product specification.
• Connect correctly wiring L (live)/N (neutral) to the power supply terminal.
• Enforce construction of protective earth wiring by all means.
• Install correctly according to regulation of each country, as not being External Disconnection
Device for this instrument.

Caution on use

CAUTION
• 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. Otherwise, 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.

iii
 Caution on maintenance and check

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. Otherwise, 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

CAUTION
• 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.
• Do not use a replacement part other than specified by the instrument maker. Otherwise, ad-
equate performance will not be provided. Besides, an accident or fault may be caused.
• Replacement parts such as a maintenance part should be disposed of as incombustibles.

iv
 CONTENTS

PREFACE ................................................................................................................................................ i

CAUTION ON SAFETY ....................................................................................................................... ii

1. GENERAL DESCRIPTION ........................................................................................................ 1-1

1.1 Direct insertion type zirconia oxygen analyzer.................................................................. 1-1
1.2 Confirmation of delivered components.............................................................................. 1-1
1.3 Confirmation of type of delivered components ................................................................. 1-2

2. NAME AND FUNCTION OF EACH PART .............................................................................. 2-1

2.1 Name and function of converter part ................................................................................. 2-1
2.2 Name and function of display and control panel ............................................................... 2-2

3. INSTALLATION ......................................................................................................................... 3-1

3.1 Location for installation ..................................................................................................... 3-1
3.2 Installaion ........................................................................................................................... 3-2
3.3 Outline dimensions of converter ........................................................................................ 3-3

4. WIRING AND PIPING ............................................................................................................... 4-1

4.1 Before wiring ..................................................................................................................... 4-1
4.2 Wiring to each teminal ....................................................................................................... 4-2
4.3 Wiring and piping diagram ................................................................................................ 4-3
4.4 Handling of standard gas (An article on separate order) ................................................... 4-4

5. PREPARATION FOR OPERATION .......................................................................................... 5-1

6. OPERATION START AND SHUTDOWN ................................................................................ 6-1

6.1 Starting ............................................................................................................................... 6-1
6.2 Shutdown ........................................................................................................................... 6-1
6.3 Measurement during operation .......................................................................................... 6-2
6.4 Confirmation of alarm condition........................................................................................ 6-3
6.5 Oxygen detector standard output voltage........................................................................... 6-4

7. CALIBRATION ........................................................................................................................... 7-1

7.1 Preparation ......................................................................................................................... 7-1
7.2 Manual calibration ............................................................................................................. 7-2
7.3 Automatic calibration ......................................................................................................... 7-3
7.4 Automatic calibration with remote start............................................................................. 7-5

v
8. BLOWDOWN .............................................................................................................................. 8-1
8.1 Preparation for blowdown .................................................................................................. 8-1
8.2 Manual blowdown.............................................................................................................. 8-2
8.3 Automatic blowdown ......................................................................................................... 8-3

9. MAINTENANCE AND CHECK ................................................................................................ 9-1

9.1 Check ................................................................................................................................. 9-1
9.2 Fuse replacement................................................................................................................ 9-3
9.3 Troubleshooting ................................................................................................................. 9-4

10. SETTING AND OPERATING OF PARAMETER ................................................................... 10-1

10.1 Procedure for setting analog output range ....................................................................... 10-3
10.2 Procedure for setting moving average time ..................................................................... 10-3
10.3 Procedure for setting span calibration gas concentration ................................................. 10-4
10.4 Procedure for setting zero calibration gas concentration ................................................. 10-4
10.5 Procedure for setting automatic calibration interval ........................................................ 10-5
10.6 Procedure for setting waiting time before measurement ................................................. 10-5
10.7 Procedure for setting blowdown interval ......................................................................... 10-6
10.8 Procedure for setting blowdown time .............................................................................. 10-6
10.9 Procedure for setting oxygen gas concentration high-alarm value .................................. 10-7
10.10 Procedure for setting oxygen gas concentration low-alarm value ................................... 10-7
10.11 Procedure for selecting contact output function .............................................................. 10-8
10.12 Selection of output hold functions ................................................................................... 10-9
10.13 Procedure for setting password ........................................................................................ 10-9

11. HOW TO CHANGE THE SETTING OF CONVERTER ZRM

DEPENDING ON DETECTOR TYPE .................................... 11-1

12. SPECIFICATION ...................................................................................................................... 12-1

vi
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 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 detec-
tor (type ZFK) and single-channel converter (type ZRM).
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 short-
age of parts.

List of components and accessories

Converter
Accessories of converter
• Power fuse (0.5A)-------------------------- 2
• Heater fuse (3A) --------------------------- 2
• Metal fittings (option) --------------------- 1 set

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 specifications of the detector.
Because it may result in damage to the detector.
2
100/115V AC for ZFK 13-0
5
2
200/220V AC for ZFK 33-0
5

1-1
1.3 Confirmation of type of delivered components
Check model name on main nameplate in order to confirm the delivered components meet your
specifications.
(1) Type of converter (Code symbols)

1 2 3 4 5 6 7 8 9 Digit

Z R M 1 1 Description

1 Configuration

Output signal
B 4 to 20mA DC
E 0 to 1V DC

Optional function
Y No optional function
A Communication function
B Combustion efficiency display function
C Both of communication and combustion efficiency display function

Power
1 90 to 220V AC 50/60Hz

Mounting method
1 Mounting on panel surface
2 Mounting on pipe

1-2
 (2) Type of detector (Code symbols)

1 2 3 4 5 6 7 8 9 Digit

Z F K 3 0 Description

Application
2 For general use
5 Anti-corrosive (for waste incineration plant)

Rainproof cover
Y Without
A With

Flow guide tube

Y Without
A With (300mm)
B With (500mm)
C With (750mm)
D With (1000mm)
U With (300mm)
V With (500mm) Anti-corrosive
W With (750mm)
X With (1000mm)
J With (300mm)
K With (500mm)
L With (750mm)
With blow down nozzle
M With (1000mm)
N With (1500mm)
P With (2000mm)

Power supply
1 100V/115V AC 50/60Hz
3 200V/220V AC 50/60Hz

Specification
0 Standard

Detector for replacement

Application Type Application Type

General use Anti-corrosive
100/115V AC Power ZFK2YY13-0 100/115V AC Power ZFK5YY13-0
General use Anti-corrosive
200/220V AC Power ZFK2YY33-0 200/220V AC Power ZFK5YY33-0

1-3
 (3) Type of exclusive cable connecting converter to detector (Code symbols)

1 2 3 4 5 6 7 8 9 Digit

Z R Z 1 Description

Specification
M For ZRM

Type
R For thermocouple R
K For thermocouple K

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 (detector ZFK side)
2 Both ends

(4) Type of ejector (Code symbols) (Option)

1 2 3 4 5 6 7 8 Digit

Z T A 1 1 Description

Temperature of measured gas

1 For high temperature (max. 1590℃)
2 For general use (max. 800℃)

Insertion length (mm)

B 500
C 750
D 1000
E 1500

Power supply
1 100V/115V AC 50/60Hz
3 200V/220V AC 50/60Hz

1-4
2. NAME AND FUNCTION OF EACH PART

2.1 Name and function of converter part

OXYGEN ANALYZER

ZRM
BLOW DOWN
CALIBRATION
ALARM
vol %

2
SET

1
3

8 6 7

No. Name Function

① Converter fixing screw Knob with screw for opening or closing the cover.
② Operation panel fixing screw Screw for fixing the operation panel to the case.
③ Fuse (0.5A) Fuse for the power supply of the converter.
④ Fuse (0.3A) Fuse for the heater for O2 detector.
⑤ Power switch For power ON and OFF.
⑥ Terminal block Connect cables from external equipments.
⑦ Cable inlet Use to insert external cable (with rubber bushing).
⑧ Cable gland Cable inlet to insert the exclusive cable for the
detector.

2-1
2.2 Name and function of display and control panel
4

OXYGEN ANALYZER ZRM

1 BLOW DOWN
2 CALIBRATION
3 ALARM
vol % 6

9
SET

5 8

No. Name Function

① Blowdown lamp Lights when being set at “Auto blowdown”, and
flickers under blowdown operation.
② Calibration lamp Lights when being set at “Auto calibration”, and
flickers under calibration operation.
③ Alarm lamp Lights when “Upper limit/Lower limit” or “Fault”
occurred.
④ Oxygen concentration Displays oxygen gas concentration.
display
⑤ Display Displays measuring range, contents of setting, etc.,
and also displays abnormal conditions.
⑥ Up key
⑦
⑧
⑨
Down key
Cursol key
Set key
} Refer to each operation procedure flow in chapter
6 to 10.

2-2
3. INSTALLATION

CAUTION
• Installation 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) For installation in restricted areas (i. e. enclose with a fence) only, accessible by qualified
persons only.

(2) Space for routine inspection and wiring available.

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

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

(5) Non-corrosive atmospheric environment.

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

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

• The supply voltage category of this instrument is II. Relay contact is category I.
• Analog output and digital input of this instrument are Safe Separated (SELV) circuit.
• Establish an external over-current protection device(e.g. circuit-breaker) with a rating of no more
than 5A as per the general product specification.
• Connect correctly wiring L(live)/N(neutral) to the power supply terminal.
• Enforce construction of protective earth wiring by all means.
• Install correctly according to regulation of each country, as not being External Disconnection
Device for this instrument.
• For installation and maintenance accessible by qualified personnel only.

3-1
3.2 Installation
3.2.1 Panel mounting

Mounting dimension (unit ; mm) Mounting method

4-M5
No. Name Piece
195
1 Converter 1
2 Pan head screw 4
50

M5 × 10
(attached to the
converter)

1 2
Panel face

3.2.2 Pipe mounting

Mounting method

No. Name Piece

1 Converter 1
2 Pan head screw M5 × 10 4
3 Ling 4
4 Mounting plate for pipe 1
5 Band for pipe 2
1 2 3 4 5 6 6 Hexagonal screw nut M5 4

Attached to the converter when

specified the pipe mounting

3-2
3.3 Outline dimensions of converter
3.3.1 Panel mounting
204 88.6
193 18
6

220

200
50

194 Cable grand 35

9

55 28 37 4-φ23 cable inlet

176

3.3.2 Pipe mounting

204
193
6
50

2B-pipe for
mounting
(φ60.5±0.5A)
194 Cable grand

3-3
4. WIRING AND PIPING

CAUTION
• 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

① For installation and maintenance accessible by qualified personnel only.
② Install correctly according to regulation of each country, as not being External Disconnection
Device for this instrument.
③ Establish an external over-current protection device (e.g. circuit-breaker) with a rating of no
more than 5A as per general product specification.
④ The over voltage category of this instruments is II. But the parts of output terminals is category
I.
⑤ Analog output and digital input of this instrument are Safe Separated (SELV) circuit.
⑥ Make sure that the power voltage for the converter conforms to that for the detector (ZFK2 or 5)
to be connected.
⑦ For power supply use 600V vinyl insulation wire with AWG18 (34/0.18) or equivalent in
quality.
⑧ Provide adequate protection of the exclusive cable (6 cores in total), which connects the detector
to converter, using wire protection tube, etc.
Separate these cables from the power cable (noise prevention).
⑨ Keep the wire for output signals as far as possible (more than 30cm) from the power line and
heavy current lines to prevent induced noise. Use a shielding cable as much as possible and
ground the shields as the same point.

Caution :Connection of wiring to the external terminals, exclusive use of ring crimp lugs
with proper insulating sleeve.

⑩ Connect correctly wiring L (live)/N (neutral) to the power supply terminal.

⑪ Enforce construction of protective earth wiring by all means.

4-1
4.2 Wiring to each teminal

(Note 1)
9 10
OXYGEN ANALYZER
Closed during calibration
ZRM
or blowdown of detector.
BLOW DOWN (Note 2)
CALIBRATION
ALARM 11 12
vol %
Closed during blowdown
of detector.
SET (Note 3)
22 23
Closed during zero calibration.
24 23
Closed during span calibration.

Contact capacity (all relays) :

1 2 3 4 5 6 7 8 9 10 11 12 13 14 250V AC 2A (resistance load)
15 16 17 18 19 20 21 22 23 24 25 26 27 28

(Note 4)
18 Automatic calibration
19 start in close

PE Automatic calibration
20 disable in close
External terminal block

SELV Primary

1 2 3 4 5 6 7 8 9 10 11 12 13 14
+ - + - + - + -
Analog Auxiliary Detector Thermo- Contacts Contacts To heater
output input input couple for main- for blow for detector
input of tenance (Note 2)
detector (Note 1)

15 16 17 18 19 20 21 22 23 24 25 26 27 28
DxA DxB FG DI1 DI2 COM Not ZV COM SV N L
used
Transmission Digital Contacts for Signal Frame Power supply
outputs for input valves for ground ground
RS-485 (Note 4) calibration
gas (Note 3)

PE
• Wiring screws on the terminal block are M3 screws.
• Connection of wiring to the external terminals, exclusive use of ring crimp lugs with proper
insulating sleeve.
SELV Primary

Reinforced insulation must be maintained over safe separation on

termination of wires/crimps.

Min. 3A

4-2
4.3 Wiring and piping diagram
(1) With flow guide tube
4-core exclusive Converter
cable for thermo- AOUT AUXIN ZrSIG T.C. MAINT BLOW HEATER
couple R 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Flow guide 6
Blue
tube Detector Yellow
5
Red
3
White
4
Black
1
White
2
Blowdown Calibra-
ZFK inlet tion gas ZERO/SPAN
1 inlet 2-core RS485 DI VALVE SG FG POWER PE
6 3 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1R/min exclusive
PE cable
5 4
2
Flow rater
0.2 to 2R/min

AC power supply

Solenoid valve Standard gas

Pressure
for zero gas reducing O2/N2 (ZBM)
valve for
standard Pressure reducing valve
gas
Instrumentation air
Solenoid valve or standard gas (ZBM)
for span gas
Pressure reducing valve
Instrumentation air
Solenoid valve
for blowdown

(2) With ejector

4-core exclusive Converter
cable for thermo- AOUT AUXIN ZrSIG T.C. MAINT BLOW HEATER
couple R 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Ejector Blue
6
Detector 5
Yellow
Red
3
White
4
Black
1
White
2
1 2 4 5 Calibra-
tion gas ZERO/SPAN
2-core RS485 DI VALVE SG FG POWER PE
1R/min
exclusive 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Alarm of cable
temperature
down of heater Flow rater
0.2 to 2R/min
ZFK
1 AC power supply
6 3
PE Solenoid Pressure Standard gas
5 4
valve for reducing O2/N2 (ZBM)
2 zero gas valve for
standard
Pressure reducing valve
gas
Instrumentation air
Solenoid valve or standard gas (ZBM)
for span gas
Pressure reducing valve
For blowdown
Instrumen-
Solenoid valve tation air Pipe materials
for blowdown Polyethylene tube φ6/φ4
Flow rater
Teflon tube φ6/φ4
For ejector 5 to 10R/min Copper pipe φ8/φ6
15ASGP equivalent tube

4-3
4.4 Handling of standard gas (An article on separate order)
(1) Handling
① Make sure the handle is closed on the high pressure gas container, then detach the cap nut.
② Attach the high pressure gas container using the cap nut with packing of the pressure reducing
valve.
③ Make sure the secondary pressure adjusting valve is turned fully counterclockwise (pressure not
applied) and the outlet needle is turned fully clockwise (closed), then open the handle.
④ Turn the secondary pressure adjusting valve clockwise and set to the normal value of 20 to 30
kPa {0.204 to 0.306kgf/cm2}, then open the outlet needle slowly to allow the gas to flow.

Pressure reducing valve

(ZBD6)

Handle Secondary
Cap nut
pressure meter
Primary pressure
meter

Cap nut
Packing

Secondary pressure
adjusting valve
Outlet needle
High pressure
gas container

(2) Piping
① The gas outlet of the pressure reducing valve is of Rc 1/4 (PT1/4 internal thread). Prepare a joint
and tube (φ 6/ φ 4 teflon tube, etc.).
(3) Caution
① Fasten securely, so there is no gas leakage from the pressure reducing valve connection nor from
threaded part of the joint.
② Store high pressure gas containers in a place protected from direct sunlight and rain.
③ After use, be sure to close the handle.

4-4
5. PREPARATION FOR OPERATION
Preparation can be performed after installation or on the bench.
Note) For using the detector ZFK5, setting of detector temperature needs to be changed from 800 to
750℃. So refer to “11. How to change the setting of converter ZRM depending on detector
type.”

① Wiring check (Refer to 4.2, 4.3)

h

② Confirmation of the power supply specifications (Confirm the specifications of the main power
supply and voltage.)
h

③ Piping check (Refer to 4.3)

h

④ Power ON
Open the front cover of the converter and turn ON the power switch located in the lower right
corner.
↓

Fuji Electric The message shown left appears on the LCD screen.
Oxygen Analyzer

MEASURE After about 3 seconds a message denoting

0 to 25.0 vol%O2 “Measurement mode” appears on the
LCD screen and LEDs are lit as shown
left.

⑤ Warmup (After 15 minutes from power ON, accurate measurement data may be obtained.)
h

⑥ Parameter setting and key operation procedures

Parameter settings at shipment (initialization) are tabulated on page 5-3 and key operation
procedures are described in a flow diagram on page 5-4.
Refer to chapter 10 for changing parameters.
h

5-1
⑦ Calibration
At the first operation, perform manual calibration after warmup using a calibration gas.
Refer to chapter 7 for calibration procedures.
h

⑧ Automatic calibration
Automatic calibration may be performed at specified time intervals.
Refer to 7.3 for automatic calibration settings.
h

⑨ Blowdown
A flow guide tube blowdown feature prevents the flow guide tube from clogging due to dust in
the gas stream.
Refer to chapter 8 for operation procedures
h
Operation

5-2
 Parameter settings at shipment (initialization)
Parameter Displayed message Range Initial value of parameter Reference page
Output range 2.0 to 50.0 %O2 in 25.0 %O2 10-4
OUTPUT RANGE
0.5% steps
25.0%O2

Moving average AVERAGING TIME 0 to 300 sec. in 1 sec. 2 sec. 10-4

interval 002 SEC step

Calibration gas 8.000 to 23.000%O2 20.600 %O2 10-5

SPAN GAS SET
concentration (span in 0.001%O2 steps
20.600 %O2
gas)
Calibration gas ZERO GAS SET 0.010 to 50.000%O2 01.010 %O2 10-5
concentration (zero 01.010 %O2 in 0.001%O2 steps
gas)
Cycle interval for 00 day 00 hour 00 day 00 hour 10-6
AUTO CAL. CYCLE
automatic calibration to 90 day 60 hour
00 DAY 00 H

Waiting time for MEAS. WAIT TIME 0 to 300 sec. in 1 sec. 10 sec. 10-6
measurement 000 SEC steps

Cycle interval for 00 hour 00 min. 00 hour 00 min. 10-7

AUTO BLOW CYCLE
automatic blowdown to 99 hour 60 min.
00 H 00 MIN

Blowdown time BLOW DOWN TIME 0 min. 00 sec. 0 min. 30 sec. 10-7
0 MIN 30 SEC to 9 min. 60 sec.

High oxygen concen- HIGH ALARM 0.10 to 55.00 %O2 55.00 %O2 10-8
tration alarm 55.00 %O 2

Low oxygen concen- LOW ALARM 0.01 to 55.00 %O2 0.01 %O2 10-8
tration alarm 00.01 %O2

Output hold OUTPUT HOLD YES or NO NO 10-10

<NO> (Not hold)

Selection of contact D.Out Select DO.1 to DO.4 DO.1 BLOW DOWN 10-9
outputs DO.1 MAINTENANCE (Terminal No. 11 - 12 )
BLOW DOWN
MAINTENANCE DO.2 MAINTENANCE
ZERO VALVE (Terminal No. 9 - 10 )
SPAN VALVE
HIGH ALARM DO.3 ZERO VALVE
LOW ALARM (Terminal No. 22 - 23 )
H/L ALARM
FAULT DO.4 SPAN VALVE
NONE (Terminal No. 24 - 23 )
Password 0000 to 9999 0000 10-10
PASSWORD SET
0000

5-3
 Key operation flow diagram (outline)

MEASURE MODE MEASURE HOLD : SET key

MAINTE MODE 0 to 25.0 vo1%O2
: key
CELL R
EXIT MEAS. MODE
1000.0mV 800℃ : key

ALARM 1234s ALARM 2345s

High alarm Low alarm

CLEAR ALARM AND CLEAR ALARM AND

FAULT NO FAULT NO

MEASURE MODE MANUAL CAL MANUAL CAL SPAN

MAINTE MODE AUTO CAL

MANUAL CAL AUTO CALIBRATION

EXIT MAINTE MODE
AUTO CAL < EXECUTE? N >

MANUAL BLOW DOWN MANUAL BLOW DOWN

AUTO BLOW DOWN < START? N >

MANUAL BLOW DOWN AUTO BLOW DOWN

AUTO BLOW DOWN < EXECUTE? N >

SET MODE INPUT PASSWORD OUTPUT RANGE OUTPUT RANGE

0000 AVERAGEING TIME 25.0%O2

OUTPUT RANGE AVERAGEING TIME

AVERAGEING TIME 002 SEC

SPAN GAS SET SPAN GAS SET

ZERO GAS SET 20.600 %O2

SPAN GAS SET ZERO GAS SET

ZERO GAS SET 02.600 %O2

AUTO CAL. CYCLE AUTO CAL. CYCLE

MEAS. WAIT TIME 00 DAY 01 H

AUTO CAL. CYCLE MEAS. WAIT TIME

MEAS. WAIT TIME 0 000 SEC

AUTO BLOW CYCLE AUTO BLOW CYCLE

BLOW DOWN TIME 00 H 00 MIN

AUTO BLOW CYCLE BLOW DOWN TIME

BLOW DOWN TIME 0 MIN 00 SEC

HIGH ALARM HIGH ALARM

LOW ALARM 55.00 %O2

HIGH ALARM LOW ALARM

LOW ALARM 00.01 %O2

OUTPUT HOLD OUTPUT HOLD

D. OUT Select < YES >

OUTPUT HOLD D. OUT Select

D. OUT Select DO. 1 BLOW DOWN

Station No.
Comm. Select

* Selectable with
Station No.
Comm. Select * option function

PASSWORD SET PASSWORD SET PASSWORD SET

EXIT SET MODE EXIT SET MODE 0000

5-4
6. OPERATION START AND SHUTDOWN

6.1 Starting
After correct wiring and piping has been completed, turn the power switch in the converter ON,
and measuring operation will begin.
Note : 15 min. of warmup time is necessary after power ON.
Caution of before starting
① Furnace operation should only be started after 15 min. or more of warmup time has elapsed.
② When a detector is to be installed in a furnace already in operation, take care to blow out
harmful gas from the furnace and then install the fully warmed up detector quickly.

6.2 Shutdown

(1) When a process (furnace etc.) is to be shutdown for a short time i.e. a week or so
It is strongly recommended to keep the detector in operation to avoid possible deterioration
of platinum electrodes in the detector and destruction of the wet sensor element (depending
on the condition in furnace and/or ambient conditions) due to power ON-OFF.
In case of the detector with an ejector (option), shutdown the air source.

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

Turn OFF the power switch of the instrument after gas in the furnace has been replaced
completely by ambient air.

6-1
6.3 Measurement during operation
While the instrument is operating, the following displays can be changed.
• Measurement mode display
• Data display of output voltage and temperature of the detector
• Alarm display
• Alarm clear display
Note : If no key is operated for more than 10 min. during operation, the instrument returns to
“Measurement mode display” automatically.
Key operation

Measurement mode MEASURE HOLD When setting outputs to “HOLD”,

display 0 to 25.0 vol %O2 “HOLD” is displayed.

The output voltage and temperature of the

Detector output CELL R connected detector. (Refer to the tables of
data display 30mV 800℃
detector standard output.)
R stands for a type of thermocouple.
Alarm display ALARM 1S
TEMP. HIGH

Numerals at upper right on the screen

show the time in second when alarm (or
Alarm clear display CLEAR ALARM AND fault) occured.
FAULT NO

Note) When no keys are used for more

End of EXIT MEAS MODE than 10 minutes during operation,
measurement mode the image “Measurement mode
display” appears automatically.

Caution
In case detector voltage rises beyond 200 mV (corresponding to 0.0023% O2) during measurement,
“RICH MODE” is displayed and the concentration indicating LED indicates detector output volt-
age.

6-2
6.4 Confirmation of alarm condition
Alarm lamp “ALARM” on the operation panel is lit red when an alarm (or a fault) has been oc-
curred. Operate the alarm display screen as shown below to investigate the alarm condition.

SET
ALARM 1234s ALARM 1234s FAULT 2345s
High alarm High alarm Tmp
SET

Alarm display screen in Confirmation screen of ……… When two or more alarms are
the measurement mode condition occured, confirm each alarm
condition by operating the △ or
▽ key.

1) Within 7 minutes after turning on power supply, alarm (or fault) is disabled.
2) Up to 16 alarms (or faults) are stored in memory in the order of the time of occurrence. The
data stored in memory are cleared by the following operation.

SET SET
CLEAR ALARM AND CLEAR ALARM AND CLEAR ALARM AND
FAULT NO FAULT NO FAULT YES

Alarm condition display by LC display

Display message Alarm condition
TEMP. FAULT ! The temperature of the detector element is without 750 to 850℃
(or 700 to 800℃)
CALIB. FAULT ! Calibration was not successful. (The indication is not stable yet at the time of
7 minutes later than the time when the valve for calibration gas has been
opened.)
Zero Cal Fault Zero point calibration was not successful.
(No calibration 2 minutes after the start of calibration.)
Span Cal Fault Span point calibration was not successful.
(No calibration 2 minutes after the start of calibration.)
High alarm O2 gas concentration is higher than the set value.
Low alarm O2 gas concentration is lower than the set value.
CELL FAULT ! Output voltage of the detector is higher than 1.2V.

6-3
6.5 Oxygen detector standard output voltage

O2 Output O2 Output O2 Output

concentra- voltage concentra- voltage concentra- voltage
tion (%) (mV) tion (%) (mV) tion (%) (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

6-4
7. CALIBRATION

In order to maintain good accuracy, proper calibration using calibration gas is necessary.
The following 3 methods of calibration are provided.
• Manual calibration (Refer to 7.2)
• Automatic calibration (Refer to 7.3)
• Automatic calibration with remote start (Refer to 7.4)

7.1 Preparation
• Wiring/piping check
Wiring and piping work should be made correctly referring to Item. 4.3. At this time, 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 1.5 ±0.5r/min.
• Setting of calibration gas concentration
Referring to Chapter 10 “Setting”, set the oxygen concentration in standard gas cylinder to be
used.
• Contact output check
Referring to Chapter 10 “Setting”, check to make sure that the contact functions of the external
terminals block are allocated for ZERO VALVE and SPAN VALVE.

7-1
 7.2 Manual calibration
Description
• Span/zero is calibrated once by key operation.
• Calibration must be made in the order of span and zero.
• At the start of calibration, the CALIBRATION lamp on the operation panel begins to blink,
indicating that calibration operation is under way. The lamp is always ON during auto-
calibration.
• For calibration, allow calibration gas to flow into the detector. When the detector output
signals is stabilized, calibrating operation is started to comprete the processing.
• When the converter is set in output signal hold mode during calibration, the output signal is
held at a value prior to calibration. The holding time is extended to the time designated for
the next measurement even after the completion of calibration.

Operation Performing span calibration

Key operation Description Displayed message(LCD)
① Display the message shown at right refer-
ring to the key operation flow diagram. MANUAL CAL.
AUTO CAL.

② SET Press SET key, then the message at right

appears. For zero calibration, select MANUAL CAL. SPAN
△ ▽
“ZERO” message with △ or ▽ key.

③ SET Press SET key, display the screen for

starting calibration. Select Y with △ or MANUAL CAL. SPAN
△ or ▽ <START ? N>
▽ key.
By pressing the SET key, calibration is
④ SET MANUAL CAL. SPAN
started. Open the main plug of the standard
gas cylinder to allow the calibration gas to <START ? Y>
flow into the detector. When the signal is
stabilized, calibrating operation is started to
complete the calibration. At the comple-
tion, close the main plug of the gas cylin-
der.
Note) When the wiring and piping of the
standard gas and solenoid valve
have been finished, the flow of gas
is controlled by the solenoid valve.

How to interrupt

(1) Before calibration start

MANUAL CAL. SPAN Press the SET key to start interrupt the calibration operation during the
<START ? Y> message at left is displayed.

(2) During calibration operation

MANUAL CAL. SPAN The message as shown left during calibration operation. Select N with
<START ? N> △ or ▽ key and press SET key to interrupt the calibration operation.

7-2
7.3 Automatic calibration
Description
• Calibration is performed at time intervals set in advance.
• The solenoid valve is driven by contact signal from the terminal block to feed the standard gas
for automatic calibration with span gas and zero gas.
• At the start of automatic calibration, the lamp “CALIBRATION” on the operation panel is ON.
This lamp blinks during calibration.
• When the converter is set in output signal hold mode during calibration, the output signal is held
at a value prior to calibration. The holding time is extended to the time designated for the next
measurement even after the completion of calibration.
• For automatic calibration, it is necessary to set automatic calibration cycle (Item 10.5), calibra-
tion gas concentration (Item 10.3) and contact output (Item 10.11)

Calibration Automatic calibraiton

starting time interval

Span
calibration
Zero
calibration
Calibration gas
valve (span)
Calibration gas
valve (zero)
Analog output
signal
Hold Hold prolong Hold Hold
prolong

Operation Start automatic calibration after 5 hours and 30 minutes.

Key operation Description Displayed message
(LCD)
① *Check to make sure that “Calibration
MANUAL CAL.
inhibition contact input” is “Open”.
AUTO CAL.
(No.19 and 20 terminals)

Display the message shown at right refer-

ring to the key operation flow diagram
(outline).

② SET Press SET key twice, then the message

AUTO CALIBRATION
shown at right appears.
<EXECUTE ? N>

③ △ ▽ Select Y by pressing △ or ▽ key.

AUTO CALIBRATION
<EXECUTE ? Y>

④ SET Press SET key, then the message shown at

START DELAY TIME
right appears.
00h 00min

7-3
 Operation Start automatic calibration after 5 hours and 30 minutes.
Key operation Description Displayed message
(LCD)
⑤ > △ ▽ Set the time required for the first calibra-
tion using the keys > , △ and ▽ . START DELAY TIME
05h 30min

⑥ SET By pressing the SET key, the lamp

“CALIBRATION” on the operation panel
is ON and, at the same time, the automatic MANUAL CAL.
calibration timer start operating. At this AUTO CAL.
time, the data shown at right is displayed
by the liquid crystal element. The first
calibration is started 5 hours and 30 min-
utes later.

How to interrupt

(1) Before calibration start

AUTO CALIBRATION At the operation step ③ , select N with △ or ▽ key and press SET
<EXECUTE ? N> key on the screen shown at left, then interrupt the calibration.

(2) During calibration operation

AUTO CALIBRATION At the operation step ② , select CANCEL with △ or ▽ key after pressing
<CANCEL ? Y> SET key once, and press SET key, then the automatic calibration opera-
tion is canceled.

7-4
7.4 Automatic calibration with remote start
Automatic calibration is started by the contact input of external terminal block. Set the calibration
cycle referring to Chapter 10.
For remote calibration, wiring and piping work should be performed for the standard gas cylinder
and solenoid valve as explained in Chapter 4. Then, set the contact output for ZERO VALVE and
SPAN VALVE.
① Check that the calibration disable contact input is open.
(No. 19 and 20 terminals)
② Close the calibration start contact input for more than 1 second.
(No. 18 and 20 terminals)
③ The first automatic calibration is now started and, at the same time, the lamp “CALIBRATION”
on the operation panel turns ON. This lamp goes off at the completion of automatic calibration.
DI1 DI2 COM

18 19 20

Automatic
calibration
start

Automatic calibration disable

The external terminal block No. 18, 19 and 20 are used for contact input. By closing No. 18-19,
automatic calibration is started and, by closing No. 19-20, it is disabled.
As in the case of automatic calibration with key operation in Item 7.3, calibration cycle and contact
output should be selected. Also, the piping and wiring for the standard gas cylinder and solenoid
valve should be completed.

7-5
8. BLOWDOWN

In order to prevent the flow guide tube from being clogged with dust contained in gas being mea-
sured, dust desposits in the flow guide tube is removed by blowing compressed air such as instru-
mentation air, etc. When utilizing this blowdown fuction, a flow guide tube with blowdown nozzle
is required. There are the following 2 different methods for blowdown.
• Manual blowdown
• Automatic blowdown (cyclic operation)

8.1 Preparation for blowdown

• Wiring/piping check
Perform wiring and piping correctly referring to Item.4.3. Since high pressure is applied to the
piping, be sure to use blind-nut type joints at connections. Special care should be take with
regard to air-tightness.
• Setting of blowdown time
Referring to Chapter 10 “Setting”, set blowdown time.
• Contact output check
Referring to Chapter 10 “Setting”, check to make sure that the contact functions of the external
terminals block are allocated for BLOWDOWN.

8-1
8.2 Manual blowdown
Description
• Using key operation, perform blowdown only once.
• Using contact signal from the terminal block, drive the solenoid valve on the outside. Then,
remove dust by blowing compressed air such as instrumentation air, etc. into the flow guide
tube.
• At the start of blowdown, the “BLOWDOWN” lamp on the operation panel begins to brink,
indicating that blowdown operation is under way. In the case of automatic blowdown, this lamp
keeps lighting.
• When output signal is set in hold mode during blowdown operation, it is held at a value prior to
the start of blowdown operation. The holding time is extended to the time designated for the
next measurement even after the completion of blowdown operation.

Operation Performing manual blowdown

Key operation Description Displayed message
(LCD)
① Display the message shown at right refer-
MANUAL BLOW DOWN
ring to the key operation flow diagram.
AUTO BLOW DOWN

② SET Press SET key, then the message at right

appears. MANUAL BLOW DOWN
<START? N>

③ △ ▽ Select Y with △ or ▽ key.

MANUAL BLOW DOWN
<START? Y>

④ SET Press the SET key. The blowdown

MANUAL BLOW DOWN
contact of the external terminal block is
AUTO BLOW DOWN
closed to start blowdown operation. When
preset blowdown time is expired, the
blowdown contact is closed and the
blowdown operation is completed.

How to interrupt

(1) Before blowdown

MANUAL BLOW DOWN Press the SET key to interrupt the blowdown operation during the
<START ? N> message at left is displayed.

(2) During blowdown

MANUAL BLOW DOWN The message as shown left during blowdown operation.
<START ? Y> Select N with △ or ▽ key and press SET key to interrupt the
blowdown operation.

8-2
8.3 Automatic blowdown
Description
• Blowdown operation is performed at time intervals set in advance.
• Using contact signal from the terminal block, drive the solenoid valve and remove dust by
blowing instrumentation air, etc. into the flow guide tube with blowdown nozzle.
• At the start of automatic blowdown, the lamp “BLOWDOWN” on the operation panel is ON.
This lamp blinks during blowdown operation.
• During blowdown operation, when output signal is set in hold mode, it is held at the value prior
to the start of blowdown operation.
• To perform automatic blowdown, automatic blowdown cycle (Item 10.7) and blowdown time
(Item 10.8) should be set in advance.
Automatic Automatic
blowdown blowdown
starting time interval

Blowdown
Closed Closed
contact

Analog output
signal Hold Hold Hold Hold
prolong prolong

Operation Start automatic blowdown after 1 hours and 20 minutes.

Key operation Description Displayed message
(LCD)
① Display the message shown at right refer-
ring to the key operation flow diagram MANUAL BLOW DOWN
(outline). AUTO BLOW DOWN

② SET Press SET key twice, then the message AUTO BLOW DOWN
show at right appears. <EXECUTE ? N>

③ △ ▽ Select Y by pressing △ or ▽ key. AUTO BLOW DOWN

<EXECUTE ? Y>
④ SET Press SET key, then the message show at
START DELAY TIME
right appears.
00h 00min

⑤ > △ ▽ Set the time required for the first START DELAY TIME
blowdown operation using the keys > , △ 01h 20min
and ▽ .
⑥ SET By pressing the SET key, the lamp
“BLOWDOWN” on the operation panel is MANUAL BLOW DOWN
ON and, at the same time, the blowdown AUTO BLOW DOWN
timer start operating. At this time, the data
shown at right is displayed by the LCD.
The first blowdown is started 1 hours and
20 minutes later.

8-3
How to interrupt
(1) Before automatic blowdown start
At the operation step ③ , select N with △ or ▽ key and press SET
AUTO BLOW DOWN key on the screen shown at left, then interrupt the blowdown operation.
<EXECUTE ? Y>

(2) During automatic blowdown operation

At the operation step ② , CANCEL with △ or ▽ key after pressing SET
AUTO BLOW DOWN key once, and press SET key, then the automatic blowdown operation is
<CANCEL ? Y> canceled.

8-4
9. MAINTENANCE AND CHECK

9.1 Check
In order to keep the instrumentation operating in good condition, perform the following periodical
maintenance and check.
Perform maintenance and check once every year or 2, or at time of furnace check.

Items for check Recommended interval, method of checking, remedy

for abnormalities, etc.
Zero, span calibration Calibrate once every week
(Refer to Chapter 7 “Calibration”)
Deterioration of If deteriorated, replace with new ones.
Daily packings and O-rings
check Check for loose cable Retighten or replace the packing.
ground
Check the remain Check the amount using primary pressure.
pressure in the cali-
bration gas cylinder
Clogging or corrosion Remove the flow guide tube from the furnace wall,
of flow guide tubes remove the detector and wash the flow guide tube with
water.
Yearly Clogging or corrosion Remove the ejector from the furnace wall, disassemble
check of ejector type sam- the prove and wash it with water.
pling prove
Clogging of air outlet Remove the ejector from the furnace wall and clean the
of ejectors air outlet located in the heat insulation layer of the
furnace wall.

9-1
List of parts for periodical change (consumption articles)

No. Name Period of change Code to order

Ceramic filter 2 to 6 months *ZZPZFK3-A090
1 (dependig on dust content in
process gas
2 O-ring for detector Once a year *ZZPZFK3-A100

List of spare parts

No. Name Code to order
3 Detector ZFK □ YY □ 3
4 Ceramic filter *ZZPZFK3-A090
5 Flow guide tube *ZZPZFK3-A01 □

Expendable item
The contrast of LCD (liquid crystal display) indicator becomes deteriorated after using for about 7
years.
In such a case, the indicator needs to be replaced with a new one.
For replacement, contact our service station.

9-2
9.2 Fuse replacement
When a fuse blows, turn off the power switch, and replace the fuse after investigating the cause and
making any necessary repairs.
Open the front cover of the converter. Two fuses are located at lower right. The upper fuse is for
protection of the converter circuit and the lower one is for protection of the heater. Take care that
these fuses are different each other in the rated current.
For replacement, use a vessel style (flat-blade) screwdriver or coin. Push down the cap on the fuse
holder and rotate about 1/4 turn counterclockwise (90°) 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 (90°) clockwise until it is fitted to the fuse holder.

Fuse unit specifications

Size : 5.2mm Ø × 20mm
For converter Capacity : 500mA 250V AC
circuit 0.5A
ex. IEC T type

For heater
3A

Fuse unit specifications

Size : 5.2mm Ø × 20mm
Capacity : 3A 250V AC
ex. IEC T type

9-3
9.3 Troubleshooting

Symptoms Probable causes Checking methods Remedy

No display Converter fuse Check the fuse and supply voltage Replace fuse
blown out specification. Check power supply
voltage
Indication Filter and/or flow Visual check of filter and flow guide Clean or replace
does not guide tube clogged tube for contamination or clogging. filter
change or Check for loosen and gas leaks at piping Tighten pipe connec-
slow connections and mounting place of tions
response detector.
Detector element Change over between zero and span gas Replace detector
deterioration and check if 5 minutes or longer is element
needed for 90% response.
Decrease in flow Check response to process gas after Increase process gas
velocity of exhaust shutting down calibration gas. flow into the flow
gas Move the direction (mounting position) guide tube
of “arrow” of the flow guide slightly.
Tempera- Break of wiring Ohmic check of wiring Replace
ture alarm
continues Wrong wiring Wiring check Correct wiring
for more
than 20 Lower power supply Check of supply voltage specification Check supply
min. after voltage voltage
power Break of thermo- Ohmic check Replace detector
switched couples element
ON Blown heater fuse Ohmic check of fuse Replace fuse
Break in detector Check heater resistance Replace detector
heater 50 to 55Ω for 115V, 200 to 250Ω for element
220V (Excluding wiring resistance)
Automatic Difference between Check the set value for calibration gas Set proper value
calibration calibration gas concentration. (Refer to 10.3 and
is not concentration and its 10.4)
possible setting
Wrong paratmeters Check automatic calibration intervals. Set proper param-
setting eters
Contact input for Check that the line between the termi- Correct wiring
“Auto calibration nals ⑲ and ⑳ is not shorted.
disable” is closed.

9-4
Symptoms Probable causes Checking methods Remedy
Zero and/or Difference between Check the set value for calibration gas Set correct values
span alarm calibration gas concentration.
concentration and its
setting or Check piping Correct piping
misconnection
between zero and
span gas
Indication Loose flange and its Check for gas leaks in detector and Tighten mounting
too high or surroundings mounting part of flow guide tube flange. screws
too low Replace O-ring
Deteriorated Check for leaks from the outside. Seal
O-rings
Detector malfunction Check for gas leaks at calibration gas Tighten connectors
inlet.
Check detector element voltage (mV) for Replace detector
higher or lower than other detector when element
flowing zero gas
Abnormal detector Refer to check items for detector tem- Replace detector
element temperature perature alarm described above. (P.9-4) element
Indication difference Oxygen concentration is higher in dry Normal
between dry and wet base.
base measurement

9-5
10. SETTING AND OPERATING OF PARAMETER

(1) Setting parameters and flow diagram of parameter setting procedures

A flow diagram below shows how to enter the parameter set mode, how to select the parameter to be
set and how to exit from the parameter set mode.

＞△＜
SET MODE < SET > INPUT PASSWORD < SET > OUTPUT RANGE Analog output range
0000 AVERAGING TIME setting
＜▽＞ ＞△＜
OUTPUT RANGE Moving average
AVERAGING TIME interval setting
＜▽＞ ＞△＜
SPAN GAS SET Span caliberation gas
ZERO GAS SET concentration setting
＜▽＞ ＞△＜
SPAN GAS SET Zero caliberation gas
ZERO GAS SET concentration setting
＜▽＞ ＞△＜
AUTO CAL. CYCLE Automatic calibration
MEAS. WAIT TIME interval setting
＜▽＞ ＞△＜
AUTO CAL. CYCLE Waiting time before
MEAS. WAIT TIME measurement
＜▽＞ ＞△＜
AUTO BLOW CYCLE Automatic blowdown
BLOW DOWN TIME interval setting
＜▽＞ ＞△＜
AUTO BLOW CYCLE Blowdown time setting
BLOW DOWN TIME
＜▽＞ ＞△＜
HIGH ALARM High alarm value
LOW ALARM setting
＜▽＞ ＞△＜
HIGH ALARM Low alarm value
LOW ALARM setting
＜▽＞ ＞△＜
OUTPUT HOLD Output holding
D. Out select function selecting
＜▽＞ ＞△＜
OUTPUT HOLD Contact output
D. Out select function setting
＜▽＞ ＞△＜
STATION No. Station No. setting
Comm Select
＜▽＞ ＞△＜
STATION No. Communication
Comm Select function selecting *
＜▽＞ ＞△＜
PASSWORD SET Password setting
EXIT SET MODE
＜▽＞ ＞△＜
PASSWORD SET (Depress < SET > key to exit
EXIT SET MODE the parameter set mode.)
＜▽＞

* cation
Settable only when option communi-
function is provided.

10-1
(2) How to enter “Set mode”
Prior to entering “Set mode”, the correct password must be input.
Note : Refer to 10.13 for password setting procedure.
(The password is set as 0000 at shipment.)

Example : Entering the password 1234

Operation (In case the password 1234.)
Key operation Description Displayed message
① △ or ▽ or Press keys (repeatedly if necessary) to
SET display the Mode selection screen as shown MEASURE MODE
at right. MAINTE. MODE

② △ or ▽ Press key to move the cursor to “SET

SET MODE
MODE” shown at right.

③ SET Press SET key to display the password

INPUT PASSWORD
input screen.
0000

④ △ Set “1” as shown at right. INPUT PASSWORD

1000
⑤ > △ Move the cursor to the next digit and set
"2” by pressing △ key. INPUT PASSWORD
1200

⑥ > △ Move the cursor to the 3rd digit and set "3”
by pressing △ key. INPUT PASSWORD
1230

⑦ > △ Move the cursor to the 4th digit and set "4”
INPUT PASSWORD
by pressing △ key.
1234

⑧ SET Press SET key, then the mode turns to the

“SET MODE”. OUTPUT RANGE
AVERAGING TIME

Password
Note : If a wrong password is used, operation returns to the “Mode selection” state ( ② in the
above table).
If the operator forgets the correct password, use 6284 to enter the “Set mode”.

(3) Setting range of each item

Setting range for some items have been determined. If an input outside the setting range is used, a
message “Error ! Try again” blinks 3 times.
In such a case, input a correct value once again after the display back to the original.

10-2
10.1 Procedure for setting analog output range
Description
• In this mode, the full scale values are set for analog outputs.
• Available setting range is 2.0 to 50.0%O2, 0.5%O2 step.
• The 3rd digit (the right of decimal point) is set to 0 or 5.

Operation Setting analog output range 0 to 27.5% (when it was set to 0 to 5.0% prior
(example) to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. OUTPUT RANGE
AVERAGING TIME

② SET Press the SET key. OUTPUT RANGE

05.0%O2

③ △ ▽ > Set to 27.5 by pressing the △ , ▽ and > OUTPUT RANGE

keys. 27.5%O2

OUTPUT RANGE
④ SET Press the SET key.
AVERAGING TIME

10.2 Procedure for setting moving average time

Description
• The moving average time of measured value is set. When 0 is set, it becomes instantaneous value.
• Average setting range is 0 to 300 sec.
• This method is used to delay output signal response.

Operation Setting moving average time to 15 sec. (when it was set to 2 sec. prior to
(example) setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. OUTPUT RANGE
AVERAGING TIME

② SET Press the SET key. AVERAGING TIME

002 SEC

③ △ ▽ > Set to 15 by pressing the △ , ▽ and > AVERAGING TIME

keys. 015 SEC

OUTPUT RANGE
④ SET Press the SET key.
AVERAGING TIME

10-3
10.3 Procedure for setting span calibration gas concentration
Description
• Span calibration gas concentration is set. Normally, the air (atmospheric) is used for setting.
• When using the air, 20.6%O2 is set.
• Available setting range is 9.000 to 23.000%O2.

Operation Setting span calibration gas concentration to 20.600%O2

(example) (when it was set to 21.000%O2 prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. SPAN GAS SET
ZERO GAS SET

② SET Press the SET key. SPAN GAS SET

21.000 %O2

③ △ ▽ > Set to 20.600 by pressing the △ , ▽ and SPAN GAS SET

> keys. 20.600 %O2

SPAN GAS SET

④ SET Press the SET key.
ZERO GAS SET

10.4 Procedure for setting zero calibration gas concentration

Description
• Zero calibration gas concentration is set. Set to the value shown on calibration gas cylinder.
• Gas of less than 2.0%O2 should be used as zero gas.
• Available setting range is 0.010 to 50.000%O2.

Operation Setting zero calibration gas concentration to 1.010%O2

(example) (when it was set to 2.000%O2 prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. SPAN GAS SET
ZERO GAS SET

② SET Press the SET key. ZERO GAS SET

02.000 %O2

③ △ ▽ > Set to 1.010 by pressing the △ , ▽ and ZERO GAS SET

> keys. 01.010 %O2

SPAN GAS SET

④ SET Press the SET key.
ZERO GAS SET

10-4
10.5 Procedure for setting automatic calibration interval
Description
• Automatic calibration interval is set. Automatic calibration is not effected when it is set to 00
day and 00 hour.
• Standard calibration cycle is about 7 to 30 days.
• Available setting range is 00 day and 00 hour to 90 days and 60 hours.

Operation Setting automatic calibration interval to 07 days and 12 hours

(example) (when it was set to 00 day 00 hour prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. AUTO CAL. CYCLE
MEAS. WAIT TIME

② SET Press the SET key. AUTO CAL. CYCLE

00 DAY 00 H

③ △ ▽ > Set to 07 DAY 12H by pressing the △ , AUTO CAL. CYCLE

▽ and > keys. 07 DAY 12 H

AUTO CAL. CYCLE

④ SET Press the SET key.
MEAS. WAIT TIME

10.6 Procedure for setting waiting time before measurement

Description
• By setting output hold to ON, analog output is held during calibration and blowndown. But if
measurement is made immediately, correct measurement is not possible because calibration gas
or blowdown air is still present. So, output hold extension time needs to be set.
• Available setting range is 0 to 300 seconds, 60 seconds is standard.
Operation Setting measurement standby time to 30 sec.
(example) (when it was set to 0 sec. prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. AUTO CAL. CYCLE
MEAS. WAIT TIME

② SET Press the SET key. MEAS. WAIT TIME

0000 SEC

③ △ ▽ > Set to 030 by pressing the △ , ▽ and > MEAS. WAIT TIME
keys. 030 SEC

AUTO CAL. CYCLE

④ SET Press the SET key.
MEAS. WAIT TIME

10-5
10.7 Procedure for setting blowdown interval
Description
• Automatic blowdown interval is set. Automatic blowdown is not effected when set to 00 hour
and 00 minute.
• Available setting range is 00 hour 00 minute to 99 hours and 60 minutes.
• It should be set longer than the total of blowdown time (Chapter 10.8) and measurment standby
time (Chapter 10.6).

Operation Setting automatic blowdown interval to 6 hours and 30 minutes

(example) (when it was set to 00 hour and 00 minute)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. AUTO BLOW CYCLE
BLOW DOWN TIME

② SET Press the SET key. AUTO BLOW CYCLE

00 H 00 MIN

③ △ ▽ > Set to 06H 30MIN by pressing the △ , ▽ AUTO BLOW CYCLE

and > keys. 06 H 30 MIN

AUTO BLOW CYCLE

④ SET Press the SET key.
BLOW DOWN TIME

10.8 Procedure for setting blowdown time

Description
• Blowdown time is set.
• Available setting range is 0 minute and 00 second to 9 minutes and 60 seconds.

Operation Setting blowdown time to 1 minute

(example) (when it was set to 30 seconds prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. AUTO BLOW CYCLE
BLOW DOWN TIME

② SET Press the SET key. BLOW DOWN TIME

0 MIN 30 SEC

③ △ ▽ > Set to 01MIN 00 by pressing the △ , ▽ BLOW DOWN TIME

and > keys. 1 MIN 00 SEC

AUTO BLOW CYCLE

④ SET Press the SET key.
BLOW DOWN TIME

10-6
10.9 Procedure for setting oxygen gas concentration high-alarm value
Description
• High-alarm value is set. High-alarm is occurred when measured value is higher than this value.
• Available setting range is 0.10 to 55.00%O2.

Operation Setting high-alarm value to 30.00%O2

(example) (when it was set to 55.00%O2 prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. HIGH ALARM
LOW ALARM

② SET Press the SET key. HIGH ALARM

55.00 %O2

③ △ ▽ > Set to 30.00 by pressing the △ , ▽ and HIGH ALARM

> keys. 30.00 %O2

HIGH ALARM
④ SET Press the SET key.
LOW ALARM

10.10 Procedure for setting oxygen gas concentration low-alarm value

Description
• Low-alarm value is set. Low-alarm is occurred when measured value is lower than this value.
• Available setting range is 0.01 to 55.00%O2.

Operation Setting low-alarm value to 1.00%O2

(example) (when it was set to 0.01%O2 prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. HIGH ALARM
LOW ALARM

② SET Press the SET key. LOW ALARM

00.01 %O2

③ △ ▽ > Set to 01.00 by pressing the △ , ▽ and LOW ALARM

> keys. 01.00 %O2

④ HIGH ALARM
SET Press the SET key.
LOW ALARM

10-7
10.11 Procedure for selecting contact output function
Description
• Function allocated to contact output (DO.1 to DO.4) is selected.
• It is set to the following prior at shipment.
DO.1 BLOWDOWN DO.2 MAINTENANCE
DO.3 ZERO VALVE DO.4 SPAN VALVE
• Contact output corresponding to the terminal No. on the external terminal block are as shown below.
DO.1 ⑪ - ⑫ , DO.2 ⑨ - ⑩ , DO.3 22 - 23, DO.4 24 - 23
• Allocated functions are as shown below.
Blowdown Blowdown solenoid valve contact
MAINTENANCE ON at maintenance operation
(ON during maintenance mode or setting mode operation)
ZERO VALVE Zero gas solenoid valve contact
SPAN VALVE Span gas solenoid valve contact
HIGH ALARM ON at high-alarm
LOW ALARM ON at low-alarm
H/L ALARM ON at high-alarm or low-alarm
FAULT ON at fault
NONE No allocation

Operation Allocation of FAULT function to DO.2

(example) (when it was set to BLOW DOWN prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. OUTPUT HOLD
D. Out Select

② SET Press the SET key. D. Out Select

DO.1 MAINTENANCE

③ △ ▽ Select DO.2 by pressing the △ and ▽ D. Out Select

keys. DO.2 BLOW DOWN
Press the SET key.
D. Out Select
④ SET
DO.2 BLOW DOWN

⑤ △ ▽ Select FAULT by pressing the △ and ▽ keys. D. Out Select

DO.2 FAULT
⑥ SET Press the SET key.
D. Out Select
△ ▽ DO.2 FAULT
⑦ Select EXIT by pressing the △ and ▽ keys.
D. Out Select
⑧ SET Press the SET key. EXIT
Setting has now been completed.
However, for validating the setting, turn off OUTPUT HOLD
the main power supply, and then turn it on. D. Out Select

10-8
10.12 Selection of output hold functions
Description
• When output hold is set to YES, analog output signal is held in the preceding value during
calibration and blowdown operation.
• When calibration at output hold “YES”, the oxygen concentration being displayed is fixed to the
value of calibration gas concentration which has been set in Chapter 10.3 and 10.4.

Operation Setting output hold to YES

(example) (when it was set to NO prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. OUTPUT HOLD
D. Out Select

② SET Press the SET key. OUTPUT HOLD

<NO>

③ △ ▽ Set to YES by pressing the △ and ▽ OUTPUT HOLD

keys. <YES>
④ SET Press the SET key.
OUTPUT HOLD
Note) When output hold is set to YES,
D. Out Select
HOLD is displayed on the measure-
ment mode display.

10.13 Procedure for setting password

Description
• In this mode, the password necessary to enter “SET MODE” is set.

Operation Setting password to 1234

(example) (When it was set to 0000 prior to setting)
Key operation Description Displayed message
(LCD)
① Display the image at right referring to the
outline of key operation. PASSWORD SET
EXIT SET MODE

② SET Press the SET key. PASSWORD SET

0000

③ △ ▽ > Set to 1234 by pressing the △ , ▽ and PASSWORD SET

> keys. 1234

PASSWORD SET
④ SET Press the SET key.
EXIT SET MODE

10-9
11. HOW TO CHANGE THE SETTING OF CONVERTER ZRM
DEPENDING ON DETECTOR TYPE

Described here is the method of changing the setting of converter when the detector to be connected
is other than standard (ZFK2 with R thermocouples).
Detector types which require change of setting and the contents of change:
ZFK5 □□□□ - □ for corrosion resistance
------------------ Change detector temperature to 750℃ (Temp. Control).
ZFK2B □□□□ - □ with K thermocouple
------------------ Change thermocouple type to K (Thermo. Couple).
ZFK2C □□□□ - □ with K thermocouple
------------------ Change thermocouple type to K (Thermo. Couple).

Caution
A wrong operation may alter the factory-adjustment value to disable measurement. Therefore,
carry out operations while observing the cautionary instructions.

11-1
<Procedure for transition to factory adjustment mode>
Move on to the screen for terminating the SET mode.

PASSWORD SET By pressing the ＞ key 5 times or more under

EXIT SET MODE display of this screen, the factory adjustment
mode can be called.
Use ▽ key for
advance to next Factory adjustment mode start here.
screen.
Use △ key for return to previous screen.
Zr INPUT Adj
TC Input Adj

Zr Input Adj
TC Input Adj
Under these screens, avoid pressing SET key.
If SET key is pressed in error, turn off power supply
and turn it on. Then retry operation.
Analog Out Adj
Sub Input Adj

For R thermocouple For K thermocouple

Analog Out Adj
Sub Input Adj Thermo Couple Thermo Couple
R-type K-type

Press Select by △ ▽ key.

SET key.
Thermo Couple Determine by SET key.
Temp. Control

Press For ZFK2 For ZFK5

SET key.
Thermo Couple Temp. Control Temp. Control
Temp. Control 800℃ for ZFK2 750℃ for ZFK5
Select by △ ▽ key.

A. Out Select Determine by SET key.

Sub Input Select

Under these screens, avoid pressing SET key.

If SET key is pressed in error, turn off power supply
A. Out Select
Sub Input Select and turn it on. Then retry operation.

EXIT ADJ. MODE Press SET key. SET MODE

Exit from factory adjustment

mode is now made.

11-2
12. SPECIFICATION

General
• Measuring gas : Oxygen in non-combustible gas
• Measuring method : Direct inserting type zirconia method
• Measuring range : 0 to 2 …… 50vol%O2 (selectable in 0.5% O2 steps)
• Oxygen concentration : DC4 to 20mA (allowable load resistance 500Ω max.)
output signal 0 to 1V DC (output resistance 100Ω max.)
Input-output isolation, linear characteristic versus oxygen concentration
• Repeatability : ±0.5% FS
• Linearity : ±2% FS
• Response speed : Within 7 sec for 90% response (from calibration gas inlet)
• Power supply : 100, 150 or 220V AC, 50/60Hz
• Power consumption : 15VA + 50VA in normal operation
15VA + 200VA at startup
• Warmup-time : 15 minutes approx.
• Cable : Maximum length between detector and converter 100m (To be ordered
separately)

Oxygen detector (type ZFK2, 5), Ejector (type ZTA)

• Measuring instrument : General purpose ZFK2
Anti-corrosive type ZFK5
• Measured gas temperature : -20 to 1590℃
-20 to 600℃ for flow guide tube type
(general purpose type, anticorrosive type)
-20 to 800℃ or 1590℃ for ejector type
• Measured gas pressure : -3 to +3kPa {-300 to +300mmH2O}
• Flow guide tube : Two types available, the one without blowdown nozzle and the one with
blowdown nozzle
Flange : JIS 5K 65A RF
Insertion length (according to specifications):
0.3, 0.5, 0.75, 1.0m (without blowdown nozzle)
0.3, 0.5, 0.75, 1.0, 1.5, 2.0m (with blowdown nozzle)
• Ejector (for general purpose) : Probe for introducing measured gas into detector
Flange : JIS 10K 65A RF
Insertion length (according to specifications):
0.5, 0.75, 1.0, 1.5m
• Ambient temperature : -20 to 60℃ for cable section
-5 to 100℃ for ejector
125℃ max. for detector flange surface with power ON
• Structure : Drip-proof (with rainproof cover)
• Filter : Alumina (filtration accuracy 50µ) and quartz paper
• Material of gas-contacting : General purpose detector : Zirconia, SUS316, SUS304, platinum
parts Anti-corrosive detector : Zirconia, titanium, platinum, SUS316
(flow guide tube)
Ejector : SIC, SUS316, SUS304
• Detector mounting : Horizontal ±45°, surrounding air should be clean.

12-1
• Outline dimensions : (L × max. dia.) 210 × 100m (detector)
• Mass : Detector, approx. 1.6kg
Ejector, approx. 1.5kg (insertion length 1m)
Flow guide tube of 1m (general purpose type), approx. 5kg
• Finish color : Munsell N9.5 (silver) and SUS metalic color
• Ejector air input : 5 to 10r/min.
• Blow down air input : 200 to 300kPa {2 to 3kgf/cm2}
• Ejector exhaust gas processing :
Returned to furnace or flue
• Heater temperature drop alarm output (ejector type) :
Alarm output when below 100℃, mechanical type thermostat, 1 make
contact of 200V AC, 2A

Oxygen converter (type ZRM)

• Display : 3-digit LED, 16 digit × 2 lines LCD and 3 lamps
• Output signal hold : Output signal hold during calibration and blowdown is possible
• Contact output : 4 points, contact specification: 1 make contact of 250V AC 2A
Selectable for each contact following functions
During maintenance*
H/L alarm
High alarm
Low alarm
For solenoid valve:
For zero gas*
For span gas*
For blowdown*
Note; Items marked by * are set at shipment.
• Contact input : No-voltage contact, ON at 1kΩ or less
1 for automatic calibration start
1 for automatic calibration inhibition
• Transmission function : RS-485 interface
(Optional) Transmission system : half duplex, bit serial
Synchronous system : start-stop synchronous
Singing system : binary, data length :
8 bit parity : odd/even/non stop bit: 1 or 2 bits
Transmission speed : 1,200 to 19,200BPS
Transmission distance : 500m max.
• Calibration method : a. One-touch calibration with calibration key
b. Automatic calibration (standard)
Calibration interval ; 00 day 00 hour to 90 days 60 hours
• Calibration gas : • Setting range for zero gas; 0.010 to 50.000% O2
span gas; 8.000 to 23.000% O2
• Recommended concentration of calibration gas :
zero gas; 0.25 to 2.0% O2
span gas; 20.6 to 21.0% O2 (air)

12-2
• Detector blowdown : Standard
Blowdown interval; 00 hour 00 minute to 99 hours 60 minutes.
Blowdown time; 0 minute 00 second to 9 minutes 60 seconds.
• Structure : Dust-proof and rain proof type (avoid direct sunlight)
• Mounting method : Mounting on panel surface, or pipe stand (as specified)
• Finish color : Munsell 5Y8/1
• Outline dimensions (H × W × D) : 220 × 193 × 89mm
• Mass : Approx. 3.5kg
• Ambient temperature : -10 to 50℃
• Ambient humidity : 90%RH or less
• Power source : 90 to 230V AC 50/60Hz

Note • The supply voltage category of this instrument is II. Relay contact is category I.
• Analog output and digital input of this instrument are Safe Separated (SELV) circuit.

12-3
Configuration of devices
The configuration of devices differs according to the conditions of the gas to be measured.
Select a suitable combination using the following table for reference.

Measured gas Component devices

Tempera- Applica- Dust Gas flow Detector Converter Ejector Sole- Flow- Flow-
ture tion type type type noid meter meter
valve ZBD422 ZBD424
600℃ General Little With ZFK2□A to D ZRM − − ○ −
or less purpose Much With ZFK2□J to P ZRM − ○** ○ −
Little Without ZFK2□Y ZRM ZTA2 − ○ ○
Much Without ZFK2□Y ZRM ZTA2 ○** ○ ○
Anti- Little With ZFK5□U to X ZRM − − ○ −
corrosive
(for waste
incine- Much* With ZFK5□J to P ZRM − ○** ○ −
rator)
800℃ General With
or less purpose Little ZFK2□Y ZRM ZTA2 − ○ ○
Without
General With
purpose Much ZFK2□Y ZRM ZTA2 ○** ○ ○
Without
1590℃ General With
or less purpose Little ZFK2□Y ZRM ZTA1 − ○ ○
Without
General With
purpose Much ZFK2□Y ZRM ZTA1 ○** ○ ○
Without

Note (*) : Automatic blow down is prohibited (to protect flow guide tube from corrosion).
Note (**) : For blowdown

12-4
Head Office
Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome,
Shinagawa-ku, Tokyo 141-0032, Japan
http://www.fesys.co.jp/eng
Instrumentation Div.
International Sales Dept.
No.1, Fuji-machi, Hino-city, Tokyo 191-8502, Japan
Phone: 81-42-585-6201, 6202 Fax: 81-42-585-6187
http://www.fic-net.jp/eng