Instruction Manual

THE DIRECT INSERTION TYPE

ZIRCONIA OXYGEN
ANALYZER DETECTOR
TYPE: ZFK8

INZ-TN5ZFK8b-E

PREFACE
Thank you very much for your kind purchase of Fujis zirconia oxygen analyzer detector (Type ZFK 8).
Read this instruction manual carefully to get a thorough understanding of how this zirconia oxygen analyzer
works prior to installing, operating and maintaining the zirconia oxygen analyzer.
If abused, unnecessary troubles or failure could occur.
The specification of this zircoia oxygen analyzer may be subject to change without previous notice for improvements of the product.
Under no circumstances should this zirconia oxygen analyzer be modified without permission.
If any trouble should occur because of having been modified without permission, we wont be responsible
for it anyway.
This instruction manual should be kept in custody by a person who operates the zirconia oxygen analyzer
actually.
After reading this manual, it should always be kept in a place which allows the person who operates it to
refer to any time as requirfed.
A due consideration should be given so that this instruction manual is delivered to a final user certainly.

Manufacturer
Type
Date of manufacture
Product nationality

: Fuji Electric Instrumentation Co., Ltd.

: Described in the nameplate put on the main body
: Described in the nameplate put on the main body
: Japan

Related instruction manuals

Direct insertion type zirconia oxygen analyzer converter (Type : ZKM) ................................. INZ-TN1ZKM
Direct insertion type zirconia oxygen analyzer-use ejector (Type : ZTA) ................................ INZ-TN1ZTA

NOTE
It is prohibited to transfer a part or all of the contents of this manual
without permission.
The contents of this manual may be subject to change in future without previous notice

Fuji Electric Systems Co., Ltd. 2008

Issued in Aug , 2008
Rev.1st edition Oct , 2008
Rev.2st edition Apr , 2009

SAFETY PRECAUTIONS
Prior to operating this detector, read this Safety precautions carefully for correct use.
In the precautions shown here, important contents on safety are included. So, be sure to observe them. The safety
precautions have been ranked into DANGER and CAUTION.

DANGER:

If this apparatus is abused, a dangerous condition could come about and it is

supposed to die or get a serious injury.

CAUTION:

If the apparatus is abused, a dangerous condition could arise and it is supposed to

get medium injury or a minor injury and a physical damage is supposed to occur.

PROHIBITION: This indicates a prohibition (act which must not do).

Precautions in installing and wiring

DANGER:

This product is not an explosion-proof type. Dont use it in an explosive gas

atmosphere. Otherwise, irreparable troubles including explosion or a fire
could occur.

CAUTION:

Install this product in a place compatible with the conditions set forth in
instruction manual. The use at a place not conforming to the installation
conditions may result in an electric shock, a fire and malfunction.
When this product is mounted on a furnace which is under operation, take
utmost care with blow-out from the furnace. There is a risk of burn injury.
In the case of the wiring work, be careful not to drop foreign matters including
wire chips into the product. Otherwise, a fire, failure or malfunction may
result.
Connect a power source compatible with the specified rating. Connection of
power source different from the rating might cause a fire.
Before doing the wriring work, be sure to turn off the main power. Otherwise,
it results in getting an electric shock as the case may be.
Use proper wiring materials according to the rating of apparatus. If a wiring
material which is not bearable to the rating is employed, it might cause a fire.

PROHIBITION: Never do the work at a place where the product gets wet with water, such as
the rain.
A failure to observe this instruction may result in getting an electric shock or
failure.

ii

Precautions in operation, stop, maintenance and check

DANGER:

In case where combustible gas is contained in the measured gas, check the gas
composition and specifications carefully before using. Otherwise, the original
performance is not displayed, and there is a fear of explosion.

CAUTION:

Do the work in a condition where the main power has been turned off. If the
work is done while current is flowing, there is a fear of getting an electric
shock.
The operating temperature of the detector (tip of ceramic heater) is about 800
C and the surface temperature is also very high. So, never touch the detector
by bare hand.
Otherwise, there is a fear of getting a burn.
Before cleaninhg the flow guide tube, turn off the main power and cool the
tube down fully.
There is a fear of getting a burn.
Dont use any other renewal part than those designated by the maker. Otherwise, the original performance is not fully displayed and a accident or failure
may result.
Dispose of the renewal parts such as the maintenance parts as an incombustible.

PROHIBITION:

Never do the work at a place where rain water splases the product directly.
A failure to observe this instruction may result in getting an electric shock or
failure.

Other precaution
CAUTION:

For a failure which cannot be judged even if referring to the instruction manual,
be sure to ask the nearest dealer or Fuji adjustment serviceman for repair. If
disassembled carelessly, an accident or injury could result.

iii

CONTENTS
PREFACE ......................................................................................................................................... i
SAFETY PRECAUTIONS .............................................................................................................. ii
1.

Introduction .............................................................................................................................. 1
1.1
1.2
1.3
1.4
1.5

2.

Mounting .................................................................................................................................. 3
2.1
2.2

3.

8.

Start of operation .......................................................................................................................15

Stop of operation .......................................................................................................................15

Maintenance and Check ......................................................................................................... 16

6.1
6.2
6.3
6.4

7.

Before wiring .............................................................................................................................13

Wiring to each terminal .............................................................................................................13
Mounting of conduit ..................................................................................................................14

Operation and Stop ................................................................................................................. 15

5.1
5.2

6.

Piping of calibration gas ..............................................................................................................7

Piping of reference gas inlet ........................................................................................................7
Piping for blow down air .............................................................................................................7
Piping drawing ............................................................................................................................8

Wiring ..................................................................................................................................... 12
4.1
4.2
4.3

5.

Mounting location .......................................................................................................................3

Mounting method ........................................................................................................................3

Piping ....................................................................................................................................... 7
3.1
3.2
3.3
3.4

4.

General description of zirconia oxygen analyzer ........................................................................1

Device conguration of direct insertion type oxygen analyzer ...................................................1
Description of each component ...................................................................................................2
Check of type...............................................................................................................................2
Check of delivered articles ..........................................................................................................2

Check .........................................................................................................................................16
Maintenance ..............................................................................................................................17
Standard output of detector .......................................................................................................19
Arrangement ..............................................................................................................................20

Troubleshooting...................................................................................................................... 21
Appendix ................................................................................................................................ 22
8.1
8.2
8.3
8.4

Specication ..............................................................................................................................22
Designation of type (code table) ...............................................................................................24
Device composition ..................................................................................................................25
Outline diagram (unit: mm) .......................................................................................................26

iv

1.

INTRODUCTION

1.1

General description of zirconia oxygen analyzer

This zirconia oxygen analyzer makes use of the oxygen ion conductivity of solid electrolytes composed
mainly of zirconia (ZrO2) at high temperatures.
If electrodes of platinum or the like are attached to both faces of a solid electrolyte and the faces are on the
conditions of different oxygen partial pressures, an electrochemical reaction causes an electromotive force
between both the electrodes. This phenomenon is called concentration cell action.
Microscopically, it is assumed that electrochemical reactions occur at the interface (three-phase interface)
among a solid electrolyte, electrode and oxygen.
High-oxygen partial pressure side: O2 + 4e 2O2 (ionization)
Low-oxygen partial pressure side: 2O2
O2 + 4e (molecularization)
An electromotive force (E) generated is expressed as follows with Nernsts equation:

High-oxygen partial
pressure side PH
O2

Nernsts equation

Solid electrolyte
Ionization

E=

2-2OO
Electrode

O2

RT
4F

PH(O2)
1n

PL(O2)

Molecularization Electromotive
force
E
: Electromotive force
PH(O2) : Oxygen partial pressure of a
reference gas (atmosphere)
PL(O2) : Oxygen partial pressure of a
measured gas
R
: Gas constant 8.3144[Jm ol-1K-1]
T
: Absolute temperature[K]
F
: Faraday constant 9.649104[cmol-1]

Low-oxygen partial
pressure side PL
Tree-phase interface:
a part where electrochemical
reactions occur.
Zirconia
Platinum
Oxygen molecule

1.2

Device conguration of direct insertion type oxygen analyzer

The direct insertion type zirconia oxygen analyzer consists of the detector with a sensor unit, the ow guide
tube that is directly inserted to the stack or the like in order to supply a gas to the detector, and the converter
that performs sensor control, signal processing, output/display, and external transmission. The detector and
converter are connected with a cable.
Stack
Detector

Flow guide tube

Converter

Cable
(sensor output line, thermocouple output line,
heater power wire)

Flow of gas

Replacement of the existing detector ZFK2 with the detector ZFK8:

In principle, the detector ZFK8 is compatible with the existing detectors ZFK2 and ZFK5 structurally and
electrically.
However, the M4 screws for the terminal block of the detector were changed to the M3 screws. If using
the existing cable, change the M4 terminal for cable end treatment on the detector side to the M3 terminal.
The detectors ZFK8, ZFK2 and ZFK5 can be connected to the converters ZRY, ZRM or ZKM.
The ow guide tube can be connected to the existing products.

1.3

Description of each component

CAUTIONS

The operating temperature of detector (tip of ceramic heater) is about 800C and the surface temperature is also very high. So, never touch it by bare hand. Otherwise, there is a fear of getting a burn.
Especially when a ceramic lter at the end of the detector is replaced, take utmost care.
(1) ZFK2
Furnace environment
(Gas to be measured)
Ceramic filter

Air environment
(Reference gas)
O-ring

Thermo sticker
Terminal box

Filter frame
Measured gas

Terminal box lid

Quartz filter
Ceramic heater

Heat insulating
material

Joint for calibration gas

Calibration
gas inlet

Hexagon plug or reference gas inlet

* According to designation of type
Cable gland
Wiring hole

Caution in handling

Since the detector is made of porcelain of zirconia, there is a case where it breaks due to drop or
impact. So, be sufficiently careful.
The detector is unusable for a plant in which water droplets might run down inside a sampling pipe.
There is no need to remove M5-hexagon set screw of the terminal box unless otherwise a reference
gas inlet is used. Dont loosen the screw without thought since a waterproofing effect becomes zero.

1.4

Check of type
The name of type has been put in the specication name-plate. Make sure it is as ordered.
Refer to Item 8.2 Desingation of type.

1.5

Check of delivered articles

Make sure the following articles have been delivered without lack.
No.

1
2
3
4
5
6
7
8
9

Description
Detector
Instruction manual (this manual)
O-ring
Mounting screw, plain & spring washer (M5)
Thermo sticker
Ceramic filter
Flow guide tube
Heat insulating cover
Reference gas inlet

Classification

Q'ty
1 unit
1 copy

Accessories
Accessories
Accessories
Accessories
Specification goods
Specification goods
Specification goods

1 pc.
6 pcs each
1 sh.
1 sh.
As ordered
As ordered
As ordered

Remark
Confirmed in Item 1.3
INZ-TN5ZFK8-E
See Item 2.2.1.
See Item 2.2.1.
See Item 2.2.1.
See Item 6.2.3.
See Item 2.2.2 and 2.2.3.
See Item 2.2.4
See Item 3.2.

2.

MOUNTING

2.1

Mounting location

DANGER

This product has no explosion-proof specification. Dont use the product in an explosive gas
environment. If used, a serious trouble such as a fire or explosion might occur.

Install this product at a place compatible with the following conditions. The use of it at a place not
conforming the installation conditions specified in this manual could cause an electric shock, a fire
or incorrect operation.

CAUTIONS

Mount the detector by selecting the places shwon below:

1 Place where there is a space which allows doing daily check and wiring work
2 Place where there is little vibration, dust and humidity
3 Place where peripheral air environment is non-corrosive.
4 Place where there are no electric appliances producing noise trouble (For example : motor, transformer
and appliances bringing about electromagnetic induction trouble and electrostatic induction trouble)
nearby the detector.
5 Place where ambient temperatue and humidity are -10 to +60C and less than 95%RH .

2.2

Mounting method

CAUTIONS

When mounting the detector on a furnace which is under operation, take utmost care about the
blowout from the furnace; otherwise, there is a fear of getting a burn.

2.2.1

Mounting method of detector

Caution in mounting

Up

Up

Never mount the detector with the tip turned upward or

downward. A failure of the detector may result.

Flow guide tube

or ejector (ZTA)

Down

Mounting screw, plain washer,

spring washer (accessory) - 3 locations

Detector

Up

Down Down

thermo sticker

+45
-45
O-ring (accessory)

Detector

Gas flow
Detector flange

2
3
4

Wiring hole

Attach the O-ring (accessory, Viton P36) to the groove of the detector. Subsequently, attach the detector to the ange of the ow guide tube or ejector (type: ZTA) by xing the mounting screws (accessory,
M5) and the at and spring washers (accessories) to the three locations (at the opposing corners of six
mounting holes) (recommended tightening torque: 3.5 N m).
Attach the detector so that it is within the range of 45 to the horizontal plane.
Attach the detector so that the wiring hole is located at the bottom.
Set the temperature of the detector ange to 125C or less regardless of the measured gas temperature.

<How to check>
Complete the mounting, piping and wiring of the detector, make sure the color of thermo sticker 125 put
on the detector ange is not changing to red in the exhaust gas measuring condition (while current is owing to the detector and the plant is under running). (Usually, the color of thermo sticker is light pink.)
If the color has changed to red, it measns that the temperature of detector ange has been over 125C. So,
take the following steps:
(a) Change the existing flange packing to a thicker one.
(b) Use a longer mating flange.
(c) Mount the flow guide tube according to Item 2.2.2.
By taking the above steps, minimize heat transfer from the gas duct wall and lower the temperature.
The thermo sticker does not return to its originatl condition once it discolors. So, after taking the steps, reput a thermo sticker available as an accessory on the detector ange and make certain that it does not turn
red. (For the part No. for additional procurement of the thermo sticker, refer to Item 6.4.

2.2.2

Mounting method of ow guide tube

(Designation of type: When 9th to 11th digits are 5A, 5B and 5C)

The ange of ow tube has mounting holes at 8 locations. These holes are available for regulating an inow into the ow guide and mounting the tube correctly in the owing direction of gas and it is enough if
mounted at 4 locations.
(1) Direction of tongue and Partition plate of ow guide tube
1 When exhaust gas temperature is under 200C and gas owing velocity is low
As illustrated below, set the partition plate inside the ow guide tube at a right angle to the gas ow and
mount the tube so that the tongue turns to an upstream direction relative to the gas ow.
Packing (not included
in scope of supply)

Furnace wall
Partition plate
Tongue

Arrow mark of
flow guide tube
Gas flow

min.60mm
Mating flange (not included
in scope of supply)

15 (JIS5K-65A)

When exhaust gas temperature is 200C or higher and gas flowing velocity is fast
As illustrated below, till the partition plate inside the flow guide tube 45 to the gas flow and mount the
tube so that the tongue turns to a down-steam direction relative to gas flow.
Gas flow
Furnace wall

Packing (not included

in scope of supply)
15 (JIS5K-65A)

Gas flow

Tongue
Partition plate

Arrow mark of
flow guide tube

min.150mm

Arrow mark of flow guide tube

Mating flange (not included

in scope of supply)

(2) Inserting angle of ow guide tube

According to the temperature of exhaust gas and the amount of dust, the inserting angle of the ow guide
tube differs. With reference to the following conditions, install a mating ange.
1 When exhaust gas temperarture is under 200C and amount of dust is
under 0.2g/Nm3
Up

(Desingation of type: When 9th to 11th digits are 5A )

Inserting angle: within a range of -45 to +45
When exhaust gas temperature is 200C or higher and amount of dust
is under 0.2g/Nm3
(Designation of type: When 9th to 11th digits are 5A)
Inserting angle: within a range of -20 to +20
When amount of dust is over 0.2g/Nm3
(Designation of type: When 9th to 11th digits are 5B and 5C)
Inserting angle: within a range of 0 to +45

+
Inserting
angle

Down

Inserting
angle

2.2.3

Mounting method of high dust-use ow guide tube

(Desingation of type : When 9th to 11th digits are 6D and 6E)
Mount the tube so that the gas outlet turns downward relative to the gas ow as shown below.
Fitted with high dust cover

For high dust

Gas outlet

Gas outlet

Gas flow

Gas flow

Gas flow

Gas flow

Up
+
Inserting
angle

Be careful not to block the gas outlet by the furnace wall or pipe and
keep the periphery of the outlet widely.
Set the inserting angle within a range of 0 to +45.
2.2.4

Down

Mounting of heat insulating cover

For using at a cold distric, use a heat insulating cover (For the part No. for additional procurement of the heat
insulating cover, refer to Item 6.4).
Put M4-mounting screw of the heat insulating cover into M4-heat insulating cover xing tapped hole of
the teminal box with M4-screw ring put between the tapped hole and screw.
Do not use a heat insulating cover in the place where the temperature is high.
Terminal box

Heat insulating cover

(according to designation)

M4-Mounting screw
M4-Screw ring

M4-tapped hole
(for fixing heat insulating cover)

3.

PIPING

3.1

Piping of calibration gas

As the piping material, use a teon-made 6mm or 1/4inch tube.
From the coupling attached to the detector, remove (2) nut,
(3) front ferrule and (4) back ferrule, put them through to the
6mm or 1/4inch teon tube for piping, and then attach it
to (1) coupling.
For mounting (2) nut, tighten by making about 2 turns with
a spanner after it cannot be turned any more by hand.

Main body
(calibration gas inlet)
(1) Coupling

(3) Frount ferrule

Joint for calibration gas:

The joint for calibration gas is a special joint with a built-in check valve.
If a malfunction occurs, order the joint for calibration gas and attach it.

(4) Back ferrule

(2) Nut

6mm or 1/4inch teflon

tube for piping

3.2

Piping of reference gas inlet

If the atmosphere around the terminal box is signicantly dirty or the humidity of the location is extremely
high, install piping for reference gas.
If the 13th digit of the type is A or B, the piping for reference gas is delivered together with the detector
body.

CAUTIONS

When used at an ordinary place (oxygen concentration : 20.6vol%), the reference gas is unnecessary.
So, dont remove a hexagonal plug of the mounting port of reference gas inlet unnecessarily since a
waterproofness becomes poor.
Refer to the previous section 3.1 Piping of calibration gas for the
installation method of piping.
Set one of the two reference gas ports as inlet and the other as outlet.
Install piping so that dust or water does not enter the outlet.

Attachment of joints for reference gas:

If you order the joints for reference gas additionally, remove the hexagonal plugs and attach the joints for reference gas (two locations) as shown
in the gure on the right.

3.3

1 Packing
2 Reference gas inlet

Piping for blow down air

Connect the blow air inlet (4 locations) of blowdown-tted ow guide tube by detaching a plug of the upperside blow port (1 location) so that drain does not accumulate.
For the blow piping, use a copper tube equivalent to 15A SGP or larger (tube having larger inside diameter)
or 10/8 teon tube. And, use L-shape joint or union without bending the pipe wherever possible and keep
the piping length as short as possible.

3.4

Piping drawing

Flow guide tube system (with valve)

Rc1/4
(upper side blow port should be selected)
Blow-down, 200 to 300kPa

Reduction valve
(unnecessary when supply air pressure is
200 to 300kPa)

Solenoid valve
(not supplied)

Supply air

15ASGP
tube equivalent
or 10/8 PTFE
pipe or copper pipe
(not supplied)

15ASGP
tube equivalent
or 10/8 PTFE
pipe or copper pipe
(not supplied)

Rainproof cover

Flow guide tube

Detector
(ZFK8)
AC power
supply
Gas temperature.
600C max.

5
Sample gas outlet

Yellow

Red

*2
Ref. air
Blue

Rainproof flexible
conduit.
(Max. 20m)

White
Black
White

Gas temperature.
600C max.
Flow guide tube
for high particulate

Sample gas outlet

Converter (ZKM)

1
Gas temperature.
600C max.
Flow guide for high
particulate with cover

O2

TC1

O2 input

Thermocouple
input

*4
6mm or 1/4 inch tube
for calibration gas
(not supplied)

6
AO

10

BLOW

11

12

13

TM-1

14

ZERO
GAS
Calibrating

HEATER
Blow
Fault
Heater
contact gas contact
contact
output
output
output
Alarm
Maintenance
contact
Calibrating gas
contact
output
contact output
output

Contact input

ALARM

TC2

DI1

DI2

DI3 DICOM

15

17

18

19

16

ZV

FAULT

Analog output
4 to 20mA DC
or 0 to 1V DC
Thermocouple
for combustion
control

or

20

SPAN
GAS

MAINTE
COM

21

22

23

24

25

SV

26

AC power
supply

PE

*3

N AC L

27

28

1
2

RS232C
or
RS485
(option)

TM-2

3
(Option)
Flowmeter

Valve

Reduction valve
(ZBD6)

MEASURE
ZERO

Standrad gas
for zero point (ZBM)

SPAN
Reduction valve
(ZBD6)

*1
Span gas (ZBM)

Flowmeter
*2 Ref. air

*1 Air supply
to Detector
(0.2 to 0.5L/min)
(not supplied)

Reduction valve
(unnecessary when
supply air pressure
is 50 to 100kPa)

Note: *1 Standard gas or instrumentation air

can be used in place of span gas.
*2 Instrument quality air or bottled air is
available as reference air instead of
ambient air.
*3 Protective earth.
*4 Connect the shield of a exclusive cable
with the ground terminal in the converter.

Flow guide tube system

Rc1/4
(upper side blow port should be selected)
Blow-down, 200 to 300kPa

Solenoid valve
(not supplied)

Reduction valve
(unnecessary when supply air pressure is
200 to 300kPa)
Supply air

15ASGP
tube equivalent
or 10/8 PTFE
pipe or copper pipe
(not supplied)

15ASGP
tube equivalent
or 10/8 PTFE
pipe or copper pipe
(not supplied)

Rainproof cover

Flow guide tube

Detector
(ZFK8)
AC power
supply
Gas temperature.
600C max.

1
5

3
2

*2
Ref. air

Sample gas outlet

Blue

Yellow

Red

Rainproof flexible
conduit.
(Max. 20m)

White
Black
White

Gas temperature.
600C max.
Flow guide tube
for high particulate

Sample gas outlet

Converter (ZKM)

1
Gas temperature.
600C max.
Flow guide for high
particulate with cover

O2

TC1

O2 input

Thermocouple
input

6
AO

Thermocouple
for combustion
control

6mm or 1/4 inch tube

for calibration gas
(not supplied)

Fault
contact
output
Alarm
contact
output

Contact input

ALARM

TC2

DI1

DI2

DI3 DICOM

15

17

18

19

16

10

11

12

13

TM-1

14

ZV

FAULT

Analog output
4 to 20mA DC
or 0 to 1V DC

*4

or

20

ZERO

BLOW

GAS
Blow Calibrating
contact gas contact
output
output

Maintenance
contact
output

Calibrating gas
contact output

22

23

AC power
supply

SPAN
GAS

MAINTE
COM

21

HEATER
Heater

24

25

PE

*3

N AC L

SV

26

27

28

1
2

RS232C
or
RS485
(option)

TM-2

3
AC power
supply
Solenoid valve
(not supplied)

Joint

Reduction valve
(ZBD6)

Standrad gas
for zero point (ZBM)

Flowmeter
(ZBD4)
(1 to 1.5L/min)

Reduction valve
(unnecessary when supply air pressure is 50 to 100kPa)

*2 Ref. air

*1 Air supply

to Detector

(0.2 to 0.5L/min)
(not supplied)

Solenoid valve
(not supplied)

Reduction vale
(ZBD6)

Span point

Note: *1 Standard gas or instrumentation air can be used in place of span gas.
*2 Instrument quality air or bottled air is available as reference air instead
of ambient air.
*3 Protective earth.
*4 Connect the shield of a exclusive cable with the ground terminal in
the converter.

*1
Standard gas for
span point (ZBM)

Ejector system (with valve)

Ejector (ZTA)

Flowmeter
(ZBD)

Ejector (5 to 10L/min)

Reduction valve
(unnecessary when supply air pressure
is 200 to 300kPa )
Joint
Supply air

1
2
4
5

Gas temperature.
1500C max.

Power supply

Copper pipe 6/4mm

(not supplied)

Heater temperature drop

Alarm

Solenoid valve
(not supplied)

Copper pipe
10/8mm
(not supplied)

Copper pipe 10/6mm

(not supplied)

Detector (ZFK8)
6

1
5

AC power
supply

3
2

4
White

Rainproof flexible
conduit.
(Max. 20m)

Black
White
Bule

Yellow

Red

O2

O2 input

TC1

6
AO

Thermocouple
input

Thermocouple
for combustion
control

6mm or 1/4 inch tube

for calibration gas
(not supplied)

10

11

12

13

TM-1

14

FAULT

BLOW

ZERO
GAS
Calibrating

HEATER
Blow
Fault
Heater
contact gas contact
contact
output
output
output
Alarm
Maintenance
contact
Calibrating gas
contact
output
contact output
output

Contact input

ALARM

TC2

DI1

DI2

DI3 DICOM

15

17

18

19

16

ZV

Analog output
4 to 20mA DC
or 0 to 1V DC

*4

or

20

SPAN
GAS

MAINTE
COM

21

22

23

24

25

SV

26

AC power
supply

*3
PE

N AC L

27

28

1
2

RS232C
or
RS485
(optein)

TM-2

3
(Option)
Flowmeter

Valve

AC power
supply

Reduction valve
(ZBD6)

MEASURE
ZERO

Standrad gas
for zero point (ZBM)

SPAN
Reduction valve
(ZBD6)
Note: *1 Standard gas or instrumentation air
Flowmeter
can be used in place of span gas.
*2 Instrument quality air or bottled air is
*2 Ref. air
available as reference air instead of
ambient air.
to Detector
*3 Protective earth.
*4 Connect the shield of a exclusive cable
(0.2 to 0.5L/min)
with the ground terminal in the converter.
(not supplied)

*1
Span gas (ZBM)
*1 Air supply
Reduction valve
(unnecessary when
supply air pressure
is 50 to 100kPa)

10

Ejector system
Ejector (ZTA)

Flowmeter
(ZBD)

Ejector (5 to 10L/min)

Reduction valve
(unnecessary when supply air pressure
is 200 to 300kPa )
Joint
Supply air

1
2
4
5

Gas temperature.
1500C max.

Power supply

Copper pipe 6/4mm

(not supplied)

Heater temperature drop

Alarm

Solenoid valve
(not supplied)

Copper pipe
10/8mm
(not supplied)

Copper pipe 10/6mm

(not supplied)

Detector (ZFK8)
6

1
5

AC power
supply

3
2

4
White

Rainproof flexible
conduit.
(Max. 20m)

Black
White
Bule

Yellow

Red

O2

O2 input

TC1

6
AO

Thermocouple
input

Thermocouple
for combustion
control

6mm or 1/4 inch tube

for calibration gas
(not supplied)

10

11

12

13

TM-1

14

BLOW

ZERO
GAS
Calibrating

HEATER
Blow
Fault
Heater
contact gas contact
contact
output
output
output
Alarm
Maintenance
contact
Calibrating gas
contact
output
contact output
output

Contact input

ALARM

TC2

DI1

DI2

DI3 DICOM

15

17

18

19

16

ZV

FAULT

Analog output
4 to 20mA DC
or 0 to 1V DC

*4

or

20

SPAN
GAS

MAINTE
COM

21

23

22

24

25

AC power
supply

*3
PE

N AC L

SV

26

27

28

1
2

RS232C
or
RS485
(optein)

TM-2

3
AC power
supply
(1 to 1.5L/min)
Joint

Solenoid valve
(not supplied)

Reduction
vale (ZBD6)

Standrad gas
for zero point (ZBM)
Flowmeter
(ZBD4)
Reduction valve (unnecessary when
supply air pressure is 50 to 100kPa)

*2 Ref. air
to Detector

*1 Air supply
Solenoid valve
(not supplied)

(0.2 to 0.5L/min)
(not supplied)
Note: *1 Standard gas or instrumentation air can be used in place of span gas.
*2 Instrument quality air or bottled air is available as reference air instead
of ambient air.
*3 Protective earth.
*4 Connect the shield of a exclusive cable with the ground terminal in
the converter.

11

Reduction
vale (ZBD6)

Span gas
*1 Standard gas for
span point (ZBM)

4.

WIRING
CAUTIONS

In the case of the wiring work, be careful not to drop foreign matters including wire chips inside the
product. Otherwise, this might cause a fire, failure or malfunction.
Connect a power source compatible with the rating. Connection of a power source not conforming
to the rating may cause a fire.
Before proceeding with the wiring work, be sure to turn off the main power supply. Otherwise, there
is a fear of getting an electric shock.
As the wiring material, use a proper one conforming to the rating of apparatus. The use of a wiring
material which is not bearable to the rating could cause a fire.

PROHIBITION

Under no circumstances be the work at a place where the product gets wet with water, such as the
rain. Otherwise, an electric shock or failure may result.

12

4.1

Before wiring
Put a cable (6 cores in all) connected between detector and converter into a piping tube for protecting the
cable. Also, put the cables for R thermocouple and element output away from the power cable to take a
noise preventive step.
When an exclusive cable is not used, use the following wire rods:
For heater (2 pcs.) ...............3A or more in rating
For R thermocouple ............Specied in JIS C1610-1995 (equivalent to RCA-2-G-0.75mm2-S2).
Recommended wire rod (at 20 C)
Element output
compensation conductor
0.75

For heater
Composition

Nominal sectional area (mm2)

Number of composed element wires/
diameter of element wire (mm)
Outside dia. (mm)
Thickness of vinyl insulating material (mm)
Thickness of vinyl sheath (mm)
Max. conductor resistance per unit length (:km)
Test voltage (V)
Insulation resistance per unit length (M:km)
Rating (A)

30/0.18
1.1

1.14
0.6

1.0
24.4
1000
5
7

1.5

1500
40

For wiring of the detector, be sure to use a solderless terminal (for M3).
Recommended solderless terminal ............ Solderless terminal prescribed in JIS C 2805 (Nominal designation: R1.25-3)

4.2

Wiring to each terminal

CAUTIONS

Be careful not to mix up the wiring for thermocouple (four-core, white) and the wiring for heater
(two-core, white).
(1) Black

2 core
wire

Exclusive cable
for converter

Heater power
100 to 120VAC 50/60Hz
or 200 to 240VAC 50/60Hz
(1) Black
(2) White

(6) Blue
(3) Red
S+ H
6
1

5
S-

Thermo couple (R-type)

(3) Red
(4) White
4 core
wire

grounding terminal screw: M4

T+
3

2
T-

(4) White
(5) Yellow

Sensor output
(5) Yellow
(6) Blue

Screw for wiring connections: M3

13

(2) White

Connect the protective grounding to one of the two terminals in the gure below. (Class D (Class 3)
grounding, grounding resistance: 100 or less)

T+

Note
3

made in japan

TK4J4664R0

S+ H
6
1

S-

T-

Grounding
terminal

Use the cable more than 0.75mm2 for main ground (earth) line.
For solderless terminal , doubly caulk the core and the sheath
separately.
The core should be poked from 0.5 to 1.0 mm.
The core should be so as not to
be seen or not to be come apart.

Grounding
terminal

The crimping (vary by tools)

should clearly be in the
normal place.

Wireng of protective grounding terminal

Attach the solderless terminals to

the grounding terminals with them
between the tooth lock washer and
screw with washer .
(recommended tightening torque:
1.8 Nm)

No space required between

the insulating material and
the wire.

Use

type of solderless terminal .

Screw with washer M4

Tooth lock
washer
Double caulking

4.3

Mounting of conduit
Remove (2) packing holder nut,(3) packing and (4) bushing from M coupling of the main body.
Fit the (2) packing holder nut and (3) packing onto the conduit and t the end face of conduit into a groove
of the (4) bushing.
Insert the (4) bushing tted to the conduit into (1) M coupling of the main body and tighten with the (3)
packing and (2) packing holder nut for xing.
(2) Packing holder nut

Packing at main body side

(2) Packing holder nut

(4) Bushing
Conduit

(4) Bushing

(3) Packing

(3) Packing

Conduit

(1) Main body M coupling

14

(1) Main body M coupling

5.

OPERATION AND STOP

DANGER

5.1

In case where combustible gas is contained in the measured gas, make sure of the gas composition
and specifications carefully before using this product. Otherwise, the original performance is not
displayed and there is a fear of explosion.

Start of operation
If the power switch of the converter is turned on after completion of wiring and piping work, the detector
starts its operation.
After warm-up at least 10 minutes, start the operation of the furnace.
After zero calibration and span calibration have nished, get to work on the measurement.
For the method of calibration, refer to each instruction manual of converters (ZKM, ZRM and ZRY).
When the converters (ZKM, ZRM and ZRY) are not used, run the zero and span calibration gases and
calibrate by converting the output in a stabilized state into oxygen concentration according to the standard
output table of converter in Item. 6.3.
If using the reference gas, supply it before the calibration. (ow rate: 0.2 to 0.5L/min)

5.2

Stop of operation
If the power is turned on in in a state of dew condensation, it leads to the failure of detector. Stop the operation following the procedures described below.
(1) In case of short-term shutdown (about 1 week) of furnace
Keep the power supply of the detector (converter) turned ON. This can prevent the detector from
getting dewed.
Also, note that if ON-OFF is repeated in a condition where the detector has dewed (according to the
furnace and ambient conditions), the detector might fail.
When the ejector (ZTA) is in use, stop the air supply to the ejector.
(2) In case of long-term shutdown of furnace
Turn off the power of the detector (converter) after the peripheral air of the detector inside the furnace
(especially, temperature and humidity) has become an air environment. Or, turn off the power after
taking the detector out of the furnace and leaving it as it is for 15 minutes or more.
When the ejector (ZTA) is in use, stop the air supply to the ejector.

15

6.

MAINTENANCE AND CHECK

CAUTIONS

Do the work in a condition where the main power supply has been turned off.
If the work is done while current is flowing, there is a fear of getting an electric shock.
The operation temperature of the detector (tip of the ceramic heater) is about 800C and the surface
temperature is also very high. So, never touch it by bare hand. Otherwise, there is a fear of getting a
burn.
Before proceeding with the cleaning of the flow guide tube, turn off the main power and cool the tube
down fully and then, do the work. Otherwise, there is a fear of getting a burn.
Dont use other renewal parts than those designated by the maker. Otherwise, the original performance
is not displayed fully and an accident or failure could come about.
Dispose of the renewal parts including the maintenance parts as an incombustible.

PROHIBITION

6.1

Under no circumstances the work at a place where the product gets wet with water, such as the rain.
Otherwise, an electric shock or failure may result.

Check
Perform the check periodically for using the product always in good condition. Especially, perform the
checks shown in table below. Moreover, perform the periodic check at a time of checking the furnace or
every 6 months.

Daily check

Check items
Execution of zero & span calibration

Check for looseness of cable gland.

Periodic check

Check of residue in calibration gas cylinder

Check of blowdown (when blowdown
nozzle is fitted)
Check for leak from packing fitted between
flow guide tube and mating flange and
O-ring of detector.
Removing detector, check for clogging of
ceramic filter of detector.
Check by disconnecting for clogging or
corrosion of flow guide tube.
Check by removing for clogging or corrosion of sampling probe of ejector (ZTA).
Check by removing if air outlet port of
ejector (ZTA) is left stopped up.

Details of checking work

When the converters (ZKM, ZRM and ZRY) are in use: With reference to the instruction manuals of the converters (ZKM, ZRM and
ZRY), check once a week as a rough standard. (calibration gas flow
rate : 1.5 to 2.0L/min)
When the converters (ZKM, ZRM and ZRY) are not used: Running
the zero and span calibration gases, make calibration once a week
as a rough standard by converting the output in a stabilized state
into oxygen concentration according to the standard output table of
converter in Item 6.3.
Retighten the cable gland or if the packing is found deteriorated,
replace.
Check it by a primary pressure gauge.
Referring to each instruction manual of the converters (ZKM, ZRM
and ZRY), check at 200 to 300kPa.
If either of the packing and O-ring or both of them are found deteriorated, replace with new O-ring (refer to the part No. for procurement
in Item 6.4) and replace the packing (not included in scope of supply).
When it is necessary to replace the ceramic filter, refer to Item 6.2.2.
Check following the procedure in Item 6.2.3.
Check following the procedure in Item 6.2.4.
Clean the air outlet port of the thermal insulation part of furnace wall.

16

6.2

Maintenance
The replacing intervals of sensor unit, ceramic lter and O-ring, and the maintenance periods of ow guide
tube and sampling probe differ depending on the working conditions including the components of measured
gas and the amount of dust.
The replacing intervals in a general conditions are shown below. Determine the replacing intervals in the
individual working condition with a period till a rst replacement after delivery and operation as a rough
standard.
Sensor unit ................................................ Yearly
Ceramic lter............................................ At 6 month interval
Flow guide tube ........................................ At 3 to 4 year interval
ZTA sampling probe ................................. At 3 to 4 year interval
O-ring ....................................................... Yearly

6.2.1

Replacement of Sensor unit

Caution about the replacement of the sensor unit:

Check that the sensor unit complies with the specifications of the power supply you use.
Avoid replacing the sensor unit while the current is applied.
The temperature of the detector becomes high. Replace the sensor unit after the temperature is reduced sufficiently.

(1) Turn off the power for the detector. (Set the switch of the converter or the main power supply to OFF.)
(2) Check that the surface temperature of the detector is reduced sufciently.
(3) Remove the terminal box cover and then remove the terminal block cover in the terminal box (M3 screw,
two locations).
(4) Remove the six wires connected the terminal block of the sensor unit (M3 screws, six locations).
(5) Remove the screw with washer (M3 screws, four locations) fastening the sensor unit .
(6) Remove the sensor unit and o-ring from the detector.
(7) Attach the supplied O-ring of the replacement sensor unit to the groove for the O-ring at the detector.
(8) Attach the replacement sensor unit to the detector.
(Attach the sensor unit so that the rotational direction is as shown in the gure below.)
(9) Fasten the sensor unit with the supplied screw with washer (M3 screws, four locations).
(recommended tightening torque: 0.7 Nm)
(10) Connect six wires to the terminal block of the sensor unit and attach the terminal block cover.
(11) Attach the terminal box cover.
Groove for the O-ring

O-ring

Sensor unit
(1) Black
(6) Blue
(3) Red
S+ H
6
1

2 core
wire
Exclusive cable
for converter
4 core
wire

Heater power
100 to 120V AC 50/60Hz
or 200 to 240V AC 50/60Hz
(1) Black
(2) White

TK4J4664R0

Detector

made in japan

Pan head screw with washers

(4 pieces)

T+

5
S-

2
T-

(4) White
(5) Yellow

Thermo couple (R-type)

(3) Red
(4) White
Sensor output
(5) Yellow
(6) Blue

17

Grounding wire
screw: M4

Screw for wiring connections: M3

(2) White

6.2.2

Replacement of ceramic lter

(1) After turning OFF the power of the detector, lower the surface
Reflector
temperature of the tip (at the ceramic lter side) by cooling down
fully with the air.
(2) After having been cooled down fully, remove the lter frame
from the detector, take the ceramic lter and reector off the lter
frame.
(3) Set a new ceramic lter and reector in the lter frame and t the
frame to the detector and then, tighten till the ceramic lter does
Ceramic filter
not move any longer. (Be careful then not to fail to set the reecFilter frame
tor in place. For the part No. for additional procurement of the
reector, refer to Item. 6.4).
6.2.3

Maintenance of ow guide tube

After removing the ow guide tube from the furnace wall and then, from the detector, cool the tube down
fully in the air.
Remove dust sticking to the outside of the ow guide tube by water-washing with the use of a scrubbing
brush.
Remove dust sticking to the inside of the ow guide tube by using a metallic rod or screwdriver.
(Clean so that tube is through at least about 3/4 part of the whole interior.)
For the ow guide tube for high dust, remove together dust sticking around the gas outlet.

6.2.4

Maintenance of sampling probe

After removing the ejector (ZTA) from the furnace wall and then, the sampling probe from the ejector,
cool the probe down fully in the air.
Remove dust sticking to the outside of the ow guide tube by using a scrubbing brush.

CAUTIONS

The high temperature-use sampling probe (made of SIC) of the ejector (ZTA) is liable to break. So,
be careful not to cool abruptly by water (quenching) or apply undue force to the probe in the dust
removing work.
Remove dust sticking to the inside of the ow guide tube by using a metallic rod or screwdriver.
(Clean so that the tube is through at least about 3/4 part of the whole interior.)

18

6.3

Standard output of detector

For the output voltage of the detector, refer to the standard output table below.
Standard output table (Reference)

Oxygen
concentration
(Vol%)
0.01
0.05
0.1
0.5
1.0
1.2
1.4
1.5
1.6
1.8
2.0
2.2
2.4
2.5
2.6
2.8
3.0

Detector output
(Unit: mV)
168.15
132.68
117.41
81.94
66.67
62.65
59.25
57.73
56.31
53.71
51.39
49.29
47.37
46.47
45.61
43.98
42.46

Oxygen
concentration
(Vol%)
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
11.0
12.0
13.0

Detector output
(Unit: mV)
39.06
36.12
33.52
31.20
29.10
27.18
25.42
23.79
22.26
20.84
19.51
18.25
17.06
15.92
13.82
11.91
10.14

19

Oxygen
concentration
(Vol%)
14.0
15.0
16.0
17.0
18.0
19.0
20.0
20.6
21.0
22.0
23.0
24.0
25.0
30.0
35.0
40.0
45.0
50.0

Detector output
(Unit: mV)
8.51
6.99
5.57
4.23
2.97
1.78
0.65
0.00
-0.43
-1.45
-2.43
-3.37
-4.27
-8.29
-11.68
-14.62
-17.22
-19.54

6.4
No.

Arrangement
Description

Classification

Ceramic filter

Consumable

Part No. for procurement

(Procured type)
*ZZPZFK5-TK750201P1

Detector O-ring (P38)

Consumable

*ZZPZFK5-8552836

Viton

Sensor unit for replacement

Spare parts

According to designation of type in

Item. 8.2

screw with washer (M38):

4 pcs.
O-ring (S22.4, Viton) : 1 pc.

According to part No. for procurement

of flow guide shown in table below
*ZZPZFK5-TK7N6820C1

Flow guide tube

Spare parts

Calibration gas inlet

(for I6mm tube)
Calibration gas inlet
(for 1/4 inch tube)
Thermo sticker

Reference gas inlet

(for I6mm tube)

Additionally
procurement part
Additionally
procurement part
Additionally
procurement part
Additionally
procurement part

Reference gas inlet

(for 1/4 inch tube)

Additionally
*ZZPZFK5-TK7K1652P10
procurement part

6
7

10 Reflector
11 Heat insulating cover

Remark

*ZZPZFK5-TK7N6820C2
*ZZPZFK5-TK746983P1
*ZZPZFK5-TK7K1652P9

Gasket included.
(2 pieces are required for the
standard gas inlet/outlet.)
Gasket included.
(2 pieces are required for the
standard gas inlet/outlet.)

Additionally
*ZZPZFK5-TK7H6762P1
procurement part
Additionally
*ZZPZFK5-TK4E5339C1
procurement part

Part No. for procurement of ow guide

Type designation digits
Procurement DWG. No.
9
10
11
5
A
3
*ZZP-TK464430C1
5
A
5
*ZZP-TK464430C2
5
A
7
*ZZP-TK464430C3
5
A
1
*ZZP-TK464430C4
5
B
3
*ZZP-TK4B5999C1
5
B
5
*ZZP-TK4B5999C2
5
B
7
*ZZP-TK4B5999C3
5
B
1
*ZZP-TK4B5999C4
5
C
3
*ZZP-TK4A3274C1
5
C
5
*ZZP-TK4A3274C2
5
C
7
*ZZP-TK4A3274C3
5
C
1
*ZZP-TK4A3274C4
6
D
8
*ZZP-TK7H8487C3
6
E
8
*ZZP-TK7H8487C3
*ZZP-TK7H8489C2

Classification

Inserting length

For general use

For general use
For general use
For general use
Corrosive gas
Corrosive gas
Corrosive gas
Corrosive gas
Fitted with blowdown nozzle
Fitted with blowdown nozzle
Fitted with blowdown nozzle
Fitted with blowdown nozzle
High dust flow guide tube
Fitted with high dust flow guide tube cover

300mm
500mm
750mm
1000mm
300mm
500mm
750mm
1000mm
300mm
500mm
750mm
1000mm
800mm
800mm

20

7.

TROUBLESHOOTING
CAUTIONS

If a failure should occur which cannot be judged even if referring to the operation manual, be sure to
ask the nearest dealer or Fuji adjustment serviceman for repair. If disassembled carelessly, there is a
fare of an accident or injury.

Troubles
Indication is fixed.
Indication response
is slow.

Probable causes
Clogging of ceramic filter
of detector and flow guide
tube interior
Leak from joint and airtightness of mounted part.
Deterioration of detector

Decrease of exhaust gas

flowing velocity

Temperature alarm
continues coming on
despite 20 minutes
having elapsed after
turning on power.

Disconnection of cable
Error in wiring
Low supply voltage
Disconnection of thermocouple
Blow out of fuse of converters (ZKM, ZRM and
ZRY)
Disconnection of detector
heater

Indication is too high

or too low.

Looseness of flange
mounted part or defects
of O-ring or packing (not
included in scope of supply).

Deterioration of detector

Abnormality of detector
temperature
Change of ambient air
oxygen concentration of a
terminal box or very high
humidity

Check procedures (normal values)

Check visually for fouling of ceramic filter of detector and clogging of flow guide tube interior
with dust.
Check for looseness of each joint
and airtightness of mounted part.
Check by changing zero calibration gas over to span calibration
gas and vice versa if it takes
more than 5 minutes for 90%
response.
Check exhaust gas responding
time after stop of calibration gas
supply.
Check continuity.
Check wiring.
Check if supply power is as
specified.
Check continuity.
Check if resistance across terminals No. 3 and No. 4 is 2 to 3:.
Check continuity of fuse.

Check heater resistance as follows (exclusive of wiring resistance):

For 100V : 50 to 55:
For 200V : 240 to 260:
Check airtightness of detection
unit, flow guide tube and flange
mounted part.

Check for leak in from periphery.

Check airtightness of calibration
gas supply port.
Check at a time of running zero
and span calibration gases if
detector output (mV) is higher
or lower than others. (Refer to
Table in Item 6.3).
Check indicated temperature of
converter.
Check ambient air oxygen concentration of a terminal box is
20.6vol%.

21

Remedies
Clean or exchange ceramic filter, if need be.

Retighten and replace

joint(s), if need be.
Replace detector.

Increase amount of
exhaust gas inside flow
guide tube to be taken in.
Clean flow guide tube.
Replace cable.
Wire correctly.
Supply correct power.
Replace detector.

Exchange fuse(s).
(Refer to each instruction
manual of conver-ters
ZKM, ZRM and ZRY).
Replace detector.

Retighten mounting
screw.
Exchange O-ring.
Exchange packing
(not included in scope of
supply
Shield
Retighten calibration
gas joint.
Replace detector.

Use reference gas inlet.

8.

APPENDIX

8.1

Specication

8.1.1

General

Measuring object:

Main materials of gas-contacting parts:

Detector; Zirconia,SCS14, SUS316, platinum
Flow guide tube; SUS304 or SUS316
Ejector (general use); SUS316, SUS304
Ejector; (for high temperature) SiC, SUS316,
SUS304

Oxygen in noncombustible gas

Measuring method: Direct insertion type zirconia system

Measuring range:

0 to 2 arbitrary 2 ranges are settable at

50vol%O2 (in 1 vol% O2 steps)

Repeatability:

Within 0.5%FS

Linearity:

Within 2%FS

Response time:

Within 4 to 7 sec, for 90% (from calibration

gas inlet)

Warmup time:

More than 10 min

Analog output:

4 to 20mA DC (allowable load resistance

500 or less) or 0 to 1V DC (output resistance
100 or more)

Power supply:

Rated voltage;
100 to 120V AC (operating voltage 90 to
132V AC)
200 to 240V AC (operating voltage 190 to
264V AC)
Rated frequency; 50/60Hz

Calibration gas inlet:

Inlet for 6mm tube or 1/4inch tube (as
specied)
Reference gas inlet (option):
Inlet for 6mm tube or 1/4inch tube (as
specied)
Detector mounting: Horizontal plane 45, ambient air should be
clean.
Outer dimensions: (L max. dia.) 210mm 100mm
Mass (approx.) {weight}:
Detector; 1.6kg
Ejector; 15kg (insertion length 1m)
Flow guide tube (general-use, 1m); 5kg
Ejector air inlet ow rate:
5 to 10 L/min

Power consumption: Maximum 240VA (Detector: approx. 200VA,

Converter: approx. 40VA)
Normal 70VA (Detector: approx. 50VA,
Converter: approx. 20VA)

8.1.2

Calibration gas ow:

1.5 to 2 L/min
Blowdown air inlet pressure:
200 to 300kPa
Ejector exhaust gas processing:
Returned to inside the furnace or ue

Oxygen detector (ZFK8) and ejector (ZTA)

Measured gas temperature:

Flow guide tube system; 20 to +600C
(for general-use, corrosive gas)
Ejector system; 20 to +1500C
(for high-temperature gas)
20 to +800C (for general-use)

Heater temperature drop alarm output (ejector):

Alarm output when below 100 C
Mechanical thermostat
1a contact AC 200V 2A

8.1.3

Measured gas pressure:

3 to +3kPa
Flow guide tube:

With or without blow-down nozzle

Flange; JIS5K 65A FF
(JIS5K-80AFF for high particulate gas)
Insertion length; 0.3, 0.5, 0.75, 1m
(0.8m for high particulate gas)

Contact output signal:

(1) Contact specication; 6 points, 1a 250V AC/3A or 30V DC/3A
(2) Contact function;
Under maintenance
Under blowdown Note3)
Span calibrating gas
Zero calibration gas

Ejector (general-use):
Probe for guiding measured gas to detector
Flange; JIS10K 65A RF
Insertion length; 0.5, 0.75, 1, 1.5m
(according to customer's specication)

Instrument anomalies Note1)

Alarm Note2)
Note1) The following Instrument errors (1) Thermocouples
break (2) Sensor break (3) Temperature fault (4) Calibration fault (5) Zero/span adjustment fault (6) Output
error turn the contact-ON

Operating temperature:
20 to +60C for detector
5 to +100C for ejector section
125C or less at detector ange surface with
power applied

Note2) Alarm selects just one as mentioned below (1) High (2)
Low (3) High and Lower (4) High-high (5) Low-low, it
turns ON while operating.
Note3) It is enable during blowdown when an option is specied, and it turns ON while operating.

Storage temperature:
Detector: 30 to +70C
Ejector: 10 to +100C

Contact input signal:

Dust/rain-proof structure (IEC IP66 equivalent)

(1) Contact specication; 3points (the following option)

However, except a lter on edge:

Heat insulating cover is required in cold
climates (as specied)
Filter:

Converter specication (ZKM)

Concentration value indication:

Digital indication in 4 digits

For high particulate (with blowdown nozzle):

With/without cover
Flange; JIS5K 80AFF
Insertion length; 0.8. (standard)

Structure:

Silver and SUS metallic color

Finish color:

ON; 0V (10mA or less), OFF; 5V

(2) Contact function;
External hold

Alumina(ltering accuracy 50m) and quartz

paper

Calculation reset

22

 Heater OFF

Finish color:

Blow down (option)

Inhibition of calibration

Large case (IP67):

Case: Munsell 6PB 3.5/10.5 (blue)
Cover: Silver

Calibration start
Range change
Calibration method:
(a) Manual calibration with key operation
(b) Auto. calibration (option)
Calibration cycle; 00 day 00 hour to 99
days 23 hours

Mounting method: Panel mounting or pipe mounting

(c) All calibration

Calibration gas: Range settings

Zero gas; 0.010 to 25.00% O2

Span gas: 0.010 to 50.00% O2
Recommended calibration gas concentration

Zero gas; 0.25 to 2.0% O2

Span gas; 20.6 to 21.0% O2
(oxygen concentration in the air)
Blowdown :
(option)

A function for blowing out dust with compressed air that has deposited in the ow
guide tube. Blowdown can be performed for
a predetermined time and at predetermined
intervals.
Blowdown cycle; 00 hour 00 minute to 99
hours 59 minutes

Output hold:

Output can be held during manual calibration,

auto calibration, blowdown, sensor recovery
process, warm-up. And the hold release function can be available.

Cock(option):

Selects zero or span gas during manual zero or

span calibration. Mounted on the side of the
converter.

Blowdown time;

0 seconds to 999 seconds

Communication function:
RS232C (MODBUS) standard specication
RS485 (MODBUS)(option)
Combustion efciency display (option):
When you select this display, "rich mode
display" will be an simultaneous display.
This function calculates and displays combustion efciency from oxygen concentration and
measured gas temperature.
Thermocouple (R) is required for temperature
measurement.
Operating temperature:
20 to +55C
Operating humidity:
95% RH or less, non condensing
Storage temperature:
30 to +70C
Storage humidity:

95% RH or less, non condensing

Construction:

Dust-proof, rainproof construction

(corresponding to IP66 or IP67 of IEC)

Material:

Aluminume case

Outer dimensions (H x W x D):

170 X 159 X 70mm (IP66)
220 X 230 X 95mm (IP67)
Mass {weight}:

Small case (IP66):

Case: Silver
Cover: Pantone Cool Gray IC-F

IP66: Approx. 2kg (excluding cable and

detector)
IP67: Approx. 4.5kg (excluding cable and
detector)

23

8.2

Designation of type (code table)

8.2.1

Detector

1 2 3 4 5 6 7 8

Z F K 8 R

8.2.2

9 10 11 12 13

5 -

Replacement sensor unit

14 15 16

Power supply

Code symbols

100 to 120V AC

ZFK8YY15-0Y0YY-0YY

200 to 240V AC

ZFK8YY35-0Y0YY-0YY

Description

- 1

Cal. gas inlet

For I6mm tube (SUS)
For I1/4 inch tube (SUS)
Ball valve

1
2
3

8.2.3

Power supply
100 to 120VAC 50/60Hz
200 to 240VAC 50/60Hz

1
3

1 2 3 4 5 6 7 8

Z T A

Flow guide tube

flange application
length
None
SUS304 general use
300mm
SUS304 general use
500mm
SUS304 general use
750mm
SUS304 general use
1000mm
SUS316 for corrosive gas
300mm
SUS316 for corrosive gas
500mm
SUS316 for corrosive gas
750mm
SUS316 for corrosive gas
1000mm
SUS316 with blow-down nozzle 300mm
SUS316 with blow-down nozzle 500mm
SUS316 with blow-down nozzle 750mm
SUS316 with blow-down nozzle 1000mm
SUS316 for high particulate
800mm
SUS316 for high particulate with 800mm
cover
Others
Others
Others
Note) Standard flange size is JIS5K-65A FF,
but flange size for high particulate is
JIS5K-80A FF

0Y 0
5A3
5A5
5A7
5A1
5B3
5B5
5B7
5B1
5C3
5C5
5C7
5C1
6D8
6E8
ZZZ

Heat insulating cover

Without
With

Y
A

Reference gas inlet

Non
For I6mm tube (SUS)
For I1/4 inch tube (SUS)

Y
A
B

Filter spec.
Standard

Instruction manual language

Japanese
English
Chinese

J
E
C
1
2

Ejector

Specification name plate

Standard (100 to 120V AC 50/60Hz)
Standard (200 to 240V AC 50/60Hz)

24

Description
Measured gas temperature
For high temperatures (+1500C max.)
General-use (+800C max.)

1
2

Insertion length [mm]

500
750
1000
1500

B
C
D
E
1
3
5

Power supply
100V/115V AC 50/60Hz
200V/220V AC 50/60Hz
230VAC 50/60Hz

8.2.4

Converter
(2) Exclusive cable for converter

(1) ZKM
1 2 3 4 5 6 7 8

Z KM

1 2 3 4 5 6 7 8

9 10 11 12

1 -

Z R Z KR

Description

Structure
Small case (IP66)
Large case (IP67)
Bench type

1
2
3

1
2

Optional Functions
None
Combustion efficiency display function Note4)
Blowdown
Auto calibration
Combustion efficiency display
+ Blowdown Note4)
Combustion efficiency display
+ Auto calibration Note4)
Blowdown + Auto calibration
Combustion efficiency display + Blowdown
+ Auto calibration Note4)

Y
1
2
3
4
5
6
7

0
1
2

Y
1
2

Cable length
6m
10m
15m
20m
30m
40m
50m
60m
70m
80m
90m
100m
6m
10m
15m
20m

Terminal treatment
None
One side (detector side)
Both sides

Note5) For connection between detector and

converter, the conduit to be used should
be rainproof flexible type.

Display language
Japanese
English
Chinese

J
E
C

Conduit length
None
None
None
None
None
None
None
None
None
None
None
None
6m
10m
Note5
15m
20m

YA
YB
YC
YD
YE
YF
YG
YH
YJ
YK
YL
YM
AA
BB
CC
DD

Mounting bracket
None (Specify "None" when the bench
type is selected)
Mounting on panel surface
Pipe mounting

Types
For R thermocouple

Communication function
RS-232C
RS-485

1
2

Description
Connectable devices
For ZKM

Output signal
4 to 20mA DC
0 to 1V DC
Other

B
E
Z

1 -

Option
Option
With valve (Specify "None" when the bench
type or the auto calibration is selected)
With valve + flowmeter

Note4) When you select this display, rich mode

will be a simultaneous display.

8.3

Device composition

The device to be combined differ according to the conditions of the gas to be measured. Select the devices to be
combined with reference to the following table.
Application Temperature Gas Flow

Measured gas
DUST

Protection
cover

Note
Fuel; gas, oil
Fuel: coal
with blow down
Included low moisture
Included low moisture
with blow down
Included low moisture
with blow down
Included high moisture
with blow down
When a measurement gas has
a low water content with blow
down
When a measurement gas has
a low water content with blow
down

General-use 600C or
(boiler)
less

5 to 20m/s Less than 0.2g/Nm3

Less than 10g/Nm3

For
600C or
corrosive
less
gas (refuse
incinerator)
Sludge

5 to 20m/s Less than 1g/Nm3

Less than 10g/Nm3

Less than 25g/Nm3

no

Less than 25g/Nm

yes

1m/s or
less

Less than 1g/Nm3

1m/s or
less

Less than 1g/Nm3

incinerator
General-use 800C or
(furnace)
less
1500C or
less

Device conguration
Detector type
Converter Ejector
type
type
ZFK8R
ZFK8R

5-5A
5-5C

ZKM
ZKM

ZFK8R
ZFK8R

5-5B
5-5C

ZKM
ZKM

ZFK8R

5-6D

ZKM

ZFK8R

5-6E

ZKM

ZFK8R

5-0Y0

ZKM

ZTA2

ZFK8R

5-0Y0

ZKM

ZTA1

Note (1) Dust volume is approximate value.

(2) Instrument quality air or bottled air is available as Reference gas by selecting detector with Reference
gas inlet.

25

8.4

Outline diagram (unit: mm)

(1) Detector (ZFK8)
Approx.132
80

Approx.62

Approx.130

67
5
6-6

Heat insulating cover

(as specified)

Terminal box

60

Filter

85

Thermocouple

1
3
2
4
Black / White/ red / White/

Approx.30
Ref. gas inlet (as specified)
SUS316,for 6/4 tube
Or 1/4 inch tube

Heater

Element output

125.5

26

79

EXTERNAL CONNECTION DIAGRAM

2-core wire

Ground-wire
Screw: M4

Calibration gas inlet

(as specified)
SUS316,for 6/4 tube
Or 1/4inch tube

5
6
yellow / blue

4-core wire

Exclusive cable

Exclutive
Cable gland

(2) Replacement sensor unit

(132.7)
3.5

20

(17.5)

(88.4)

4-3.5(For detector mounting)

T+

5
S-

45

TK4J4664R0

made in japan

40

S+ H
6
1

45

35

2
T-

(3) Flow guide tube (for general use)

155
Approx. L

12

Approx. 20

130
67

34

Gas inlet

20

ZFK8R

Gas outlet

6-M5
detector
mounting side
815
MTG. holes

Oxygen detector

26

Code 11th

L (m)

0.3

MASS
2.7
Approx.(kg)

5-5A3
5
7
1

0.5 0.75 1.0

3.3

4.1

4.8

L=
(as specified)

(4) Flow guide tube (For corrosive gas)

155
12

Approx. 40

Approx. L

130

3
67

67

60.5

Gas inlet

ZFK8R

6-M5
detector side

Gas outlet

Code 11th

L (m)

0.3

MASS
3.3
Approx.(kg)

5-5B3
5
7
1
5

0.5 0.75 1.0

4.5

6.1

7.6

L=
(as specified)

8-15
MTG. holes

Oxygen detector

(5) Flow guide tube (with blow down nozzle)

155

Approx. L

18

Approx. 20

130
67

60.5

67

Gas inlet
6-M5
detector
mounting
side

ZFK8R

5-5C3
5
7
1

Gas outlet

Oxygen detector

Blow down air inlet

4-Rc1/4
with plug

27

Code 11th

L (m)

0.3

Mass
3.0
Approx.(kg)
815
MTG. holes

0.5 0.75 1.0

3.8

4.8

5.7

L=
(as specified)

18
0

4-Rc1/4 with plug

1
45

(6) Flow guide tube (for high particulate)

Blow down air inlet

8 - 19
MTG. hole

When mounting, select

one of blow inlets on
the upper side
(for prevention of drain)

67

29

.5

Flange: JIS 5K80A FF

ZFK MTG. position

185

Packing

ZFK8R

Gas outlet

Approx. L

5-6D3
5
7
1

50

'longate
hole

30
Code 11th

L (m)

0.3

Mass
4.5
Approx.(kg)

Gas flow
Tube (50A SCH40)

28

0.5 0.75 1.0

5.6

7.0

8.3

L=
(as specified)

45
1

4-Rc1/4 with plug

18
0

(7) Flow guide tube (for high particulate with cover)

Blow down air inlet

When mounting, select
one of blow inlets on
the upper side
8 - 19
MTG. holes (for prevention of drain)

67
2
9

.5

Flange: JIS 5K80A FF

(175)

ZFK MTG. position

Packing

(Approx. L)

Approx. L+10

ZFK8R

5-6E3
5
7
1

30
Code 11th

L (m)

0.3

Mass
7.1
Approx.(kg)

Gas flow

Protection tube (65A SCH40)

50

'longate
hole
Gas outlet

(38)

29

L=
9.0 11.4 13.6 (as specified)

*Height of an adaptive mating flange is approx. 150mm.

(Do not block the gas outlet)

Tube (50A SCH40)

0.5 0.75 1.0

International Sales Div.1

Sales Group
Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome,
Shinagawa-ku, Tokyo 141-0032, Japan
http://www.fesys.co.jp/eng
Phone: 81-3-5435-7280, 7281 Fax: 81-3-5435-7425
http://www.fic-net.jp/eng

IN-SITU

ZIRCONIA OXYGEN ANALYZER

DATA SHEET
This oxygen analyzer is used to continuously measure
oxygen concentration in combustible exhaust gas of industrial
boilers or furnaces, and is ideally suited for combustion management and control.
The analyzer system is comprised of the detector and converter coupled together as a complete system. Detector setting configuration includes the detector flow tube and detector sensor. The flow tube is inserted directly into the gas and
directs gas to the sensor for measurement. The converter
(ZKM) is comprised of the signal processor, input/output and
communications, display and system controls.
The converter is equipped with advanced functionality
such as performing the sensor diagnostics and sensor recovery function, so the detector can be used within long term
stability.

ZFK8, ZKM, ZTA

General-use detector
(ZFK8)

High-temperature detector
(ZTA)

FEATURES
1. Gas sampling device is unnecessary
For quick response, insert the detector directly into the
flue Gas sampling functions such as a gas aspirator and a
dehumidifier are not required.
2. Easy maintenance
The sensor equipped with the detector, has unit construction, it is easy to replace.
By separating the detector and the flow guide tube, filter
replacement is easy.
3. More reliable than sensor diagnosis, sensor recoverable function
Depending on the concentration of the measurement gas,
the power of the sensor might deteriorate. The equipment
includes sensor recovery function electronically, checking
the deterioration status of the sensor depletion.
Therefore, it has high reliability and long-lasting stability.
4. Safe and secure
System detects thermocouple break for heater control on
the sensor side. Safety functions of isolating power supply to the detector or isoralting power via external contact
input are also.
5. Easy operation
The operation and setting for the converter can be performed interactively, and available as English, Japanese or
Chinese for language display.

<IP66>
Converter (ZKM1)

<IP67>
Converter (ZKM2)

SPECIFICATIONS
General Specifications
Measuring object: Oxygen in noncombustible gas
Measuring method:
Directly insert type zirconia system
Measuring range: 0 to 2 setting range at option 2 in 50
vol% O2
(in 1 vol% O2 steps)
Repeatability:
Within 0.5%FS
Linearity:
Within 2%FS
Response time:
Within 4 to 7 sec, for 90% (from calibration gas inlet)
Warmup time:
More than 10 min
Analog output:
4 to 20mA DC (allowable load resistance
less than 500:) or 0 to 1V DC (output
resistance more than 100:)
Power supply:
Rated voltage;
100 to 120V AC (operating voltage 90
to 132V AC)
200 to 240V AC (operating voltage
190 to 264V AC)
Rated frequency; 50/60Hz
Power consumption:
Maximum 240VA (Detector: approx.
200VA, Converter: approx. 40VA)
Normal 70VA (Detector: approx. 50VA,
Converter: approx. 20VA)

EDSX3-137a
Date

Jun. 30, 2008

ZFK8, ZKM, ZTA

Detector Specifications (ZFK)
Measured gas temperature:
Flow guide tube system; 20 to +600C
(for general-use, corrosive gas)
Ejector system; 20 to +1500C (for
high-temperature gas)
20 to +800C (for general-use)
Measured gas pressure:
3 to +3kPa (306 to +306mmH2O)
Flow guide tube: With or without blow-down nozzle
Flange; JIS5K 65A FF
(JIS5K-80AFF for high particulate gas)
Insertion length; 0.3, 0.5, 0.75, 1m
(0.8m for high particulate gas)
Ejector (general-use):
Probe for guiding measured gas to
detector
Flange; JIS10K 65A RF
Insertion length; 0.5, 0.75, 1, 1.5m (according to customer's specification)
Operating temperature:
10 to +60C for Primary detecting element
5 to +100C for ejector section
125C or less at detector flange surface
with power applied
Storage temperature:
Sensing element: 20 to +70C
Ejector: 10 to +100C
Structure:
Dust/rain-proof structure(IEC IP66
equivalent)
Filter:
Alumina(filtering accuracy 50m) and
quartz paper
Main materials of gas-contacting parts:
Detector; Zirconia, SUS316, platinum
Flow guide tube; SUS304 or SUS316
Ejector (general use); SUS316, SUS304
Ejector; (for high temperature) SiC,
SUS316, SUS304
Calibration gas inlet:
I6mm tube join or I1/4-inch tube join (as
specified)
Reference air inlet (option):
I6mm tube join or I1/4-inch tube join (as
specified)
Detector mounting:
Horizontal plane 45, ambient surrounding air should be clean.
Outer dimensions: (L max. dia.) 210mm 100mm (detector)
Mass (approx.) {weight}:
Detector; 1.6kg
Ejector; 15kg (insertion length 1m)
Flow guide tube (general-use, 1m); 5kg
Finish color:
Silver and SUS metallic color
Ejector air inlet flow rate:
5 to 10 L/min
Calibration gas flow:
1.5 to 2 L/min
Blowdown air inlet pressure:
200 to 300kPa {2 to 3 kgf/cm2}
Ejector exhaust gas processing:
Within furnace, returned to flue
Heater temperature drop alarm output (ejector):
Alarm output when below 100 C Me-

chanical thermostat
N.O. (1a) contact, 200V AC, 2A
Converter specification (ZKM)
Concentration value indication:
Digital indication in 4 digits
Contact output signal:
(1) Contact specification; 6 points, 1a 250V AC/3A or 30V DC/3A
(2) Contact function;
Under maintenance
Under blowdown Note3)
Span calibrating gas
Zero calibration gas
Instrument anomalies Note1)
Alarm Note2)
Note1) The following Instrument errors (1) Thermocouples break (2) Sensor break (3) Temperature fault
(4) Calibration fault (5) Zero/span adjustment fault
(6) Output error turn the contact-ON
Note2) Alarm selects just one as mentioned below (1)
High (2) Low (3) Upper and Lower (4) High-high
(5) Low-low, it turns ON while operating.
Note3) Under blow down is available in case of option,
and it turns ON while operating.
Contact input signal:
(1) Contact specification; 3points (the following option)
ON; 0V (10mA or less), OFF; 5V
(2) Contact function;
External hold
Calculation reset
Heater OFF
Blow down (option)
Inhibition of calibration
Calibration start
Range change
Calibration method:
(a) Manual calibration with key operation
(b) Auto. calibration (option)
Calibration cycle; 00 day 00 hour to
99 days 23 hours
(c) All calibration
Calibration gas: Range settings
Zero gas; 0.010 to 25.00% O2
Span gas: 0.010 to 50.00% O2
Recommended calibration gas concentration
Zero gas; 0.25 to 2.0% O2
Span gas; 20.6 to 21.0% O2
(oxygen concentration in the air)
Blowdown:
A function for blowing out with compressed air dust that has deposited in
(option)
the flow guide tube. Blowdown can be
performed for a predetermined time and
at predetermined intervals.
Blowdown cycle; 00 hour 00 minute to
99 hours 59 minutes
Blowdown time; 0 minute 00 second
to 0 minutes 999
seconds
Output signal hold:
Output signal is held during calibration,
processing recoverable sensor, warmup, and blowdown. The hold function
can also be released.

Cock (option):

Selects zero or span gas during manual

zero or span calibration. Mounted on the
side of the converter.
Communication function:
RS232C (MODBUS) standard specification
RS485 (MODBUS) (option)
Combustion efficiency display (option):
When you select this display, "rich mode
display" will be an simultaneous display.
This function calculates and displays
combustion efficiency from oxygen
concentration and measured gas temperature.
Thermocouple (R) is required for temperature measurement.
Operating temperature:
20 to +55C
Operating humidity:
95% RH or less, non condensing
Storage temperature:
30 to +70C
Storage humidity: 95% RH or less, non condensing
Construction:
Dust-proof, rainproof construction
(corresponding to IP66 or IP67 of IEC)
Material:
Aluminum case
Outer dimensions (H x W x D):
170 X 159 X 70mm (IP66)
220 X 230 X 95mm (IP67)
Mass {weight}:
IP66: Approx. 2kg (excluding cable and
detector)
IP67: Approx. 4.5kg (excluding cable and
detector)
Finish color:
IP66: Case: Silver
Cover: Pantone Cool Gray 1C-F
IP67: Munsell 6PB 3.5/10.5 (blue)
Cover: Silver (case)
Mounting method: Mounted flush on panel or on pipe

CODE SYMBOLS
(Detector)
4 5 6 7 8

ZFK 8 R

9 10 11 12 13

5 -

14 15

Description

- 1

Cal. gas inlet

For I6mm tube (SUS)
For I1/4 inch tube (SUS)

1
2

Power supply
100 to 120VAC 50/60Hz
200 to 240VAC 50/60Hz

1
3

Flow guide tube

flange
application
None
SUS304 general use
SUS304 general use
SUS304 general use
SUS304 general use
SUS316 for corrosive gas
SUS316 for corrosive gas
SUS316 for corrosive gas
SUS316 for corrosive gas
SUS316 with blow-down nozzle
SUS316 with blow-down nozzle
SUS316 with blow-down nozzle
SUS316 with blow-down nozzle
SUS316 for high particulate
SUS316 for high particulate with
cover
Others

0Y 0
5A3
5A5
5A7
5A1
5B3
5B5
5B7
5B1
5C3
5C5
5C7
5C1
6D8
6E8
ZZZ

length
300mm
500mm
750mm
1000mm
300mm
500mm
750mm
1000mm
300mm
500mm
750mm
1000mm
800mm
800mm

Protection cover
Without
With

Y
A

Reference air inlet

Non
For I6mm tube (SUS)
For I1/4 inch tube (SUS)

Y
A
B

Filter spec.
Standard

1
J
E
C

Instruction manual language

Japanese
English
Chinese

Electrical Safety:
Overvoltage category
; II power supply input
; I relay interfaces
(IEC1010-1)
External overcurrent protective device
; 10A
Equipment interfaces are safety
separated (SELV)

(Replacement Detector element)

The product conforms to the requirements of the

Electromagnetic compatibility Directive 89/336/EEC
as detailed within the technical construction file
number TZ734575. The applicable standards used to

Power supply

Code symbols

100 to 120V AC

ZFK8YY15-0Y0YY-0Y

200 to 240V AC

ZFK8YY35-0Y0YY-0Y

demonstrate compliance are :

EN 55011 : 1992 CLASSA Conducted and Radiated emissions

EN 50082-1 : 1992

Radiated immunity, ESD and FBT

ZFK, ZKM

ZFK8, ZKM, ZTA

(Converter)

(Ejector)

1 2 3 4 5 6 7 8

Z KM

1 2 3 4 5 6 7 8

9 10 11

Description

1 Construction
IP66
IP67

1
2

Optional Functions
None
Combustion efficiency display function Note4)
Blowdown
Auto calibration
Combustion efficiency indication + Blowdown
Combustion efficiency indication
+ Auto calibration
Blowdown + Auto calibration
Combustion efficiency indication + Blowdown
+ Auto calibration

Y
1
2
3
4
5
6
7

Display language
Japanese
English
Chinese

J
E
C

Y
1
2

Cock (Specify none when the analyzer

has auto calibration function.)
Without
With (IP66 case)
With (IP67 case)

Note4) When you select this display, rich mode

will be a simultaneous display.

(Exclusive-special cable)
1 2 3 4 5 6 7 8

Z R Z KR

Description

1 -

Connectable devices
For ZKM

Types
For R thermocouple

Conduit length
None
None
None
None
None
None
None
None
None
None
None
None
6m
10m
Note5
15m
20m

YA
YB
YC
YD
YE
YF
YG
YH
YJ
YK
YL
YM
AA
BB
CC
DD
0
1
2

Insertion length [mm]

500
750
1000
1500
1
3
5

Mounting bracket
Mounting on panel surface
Pipe mounting

1
2

Measured gas temperature

For high temperatures (+1500C max.)
General-use (+800C max.)
B
C
D
E

Communication function
RS-232C
RS-485

1
2

Description

1
2

Output signal
4 to 20mA DC
0 to 1V DC
Other

B
E
Z

Power supply
100V/115V AC 50/60Hz
200V/220V AC 50/60Hz
230VAC 50/60Hz

SCOPE OF DELIVERY
Detector:

Detector main unit 1, Viton O ring

1, mounting screw (M5mm 16) 6,
thermal sticker 1, flow guide tube (as
specified) 1, ceramic filter 1, rainproof cover (as specified) 1, Instruction
manual 1
Converter:
Converter main unit 1, mounting
bracket set, (as specified) 1
Accessories (AC250V 500mA T fuse
2, AC250V 2.5A T fuse 2),
Instruction manual 1
Ejector:
Ejector main unit 1, insertion tube 1,
M16mm nut, and washer 4, packing
1
Items to be prepared separately:
(1) Standard gas for calibration
Type ZBM NSH4-01 (up to 5% O2 range)
Type ZBM NSJ4-01 (over 5% O2 range)
(2) Reduction valve for standard gas (type ZBD61003)
(3) Flowmeter
Type; ZBD42203, 0.2 to 2L/min (for calibrating gas)
Type; ZBD42403, 1 to 10L/min (for ejector)

CAUTIONS
Cable length
6m
10m
15m
20m
30m
40m
50m
60m
70m
80m
90m
100m
6m
10m
15m
20m

Cable end treatment

None
One side (detector side)
Both sides

Note5) For connection between detector and

converter, the conduit to be used should
be rainproof flexible type.

Z T A

If combustible gas (CO, H2 etc.) exists in the measured

gas, error will occur due to burning at the sensor section.
The inclusion of corrosive gas (Si vapor, alkaline metal, P,
Pb etc.) will shorten the life of the sensor.
When the measured gas temperature is high (+300C
or higher), the flange should be separated from the
furnace wall in order to bring the detector flange surface
temperature below the specified value +125C). The flow
guide should be attached in the direction in which the gas
flow to the detector decreases.
When much dust is included in the gas, the flow guide
tube should be attached at an inclination so that the flow
goes from below to above. And the flow guide should
be attached in the direction in which the gas flow to the
detector decreases.
In the case of a refuse incinerator, automatic blow down
of the flow guide should not be performed (to prevent
corrosion of the flow guide tube due to drainage). Blowdown should be performed manually when change in
the indication has become very little with the furnace
stopped.

CONFIGURATION
Flow guide tube system
Rc1/4
(upper side blow port should be selected)
Blow-down, 200 to 300kPa

Solenoid valve
(not supplied)

Reduction valve
(unnecessary when supply air pressure is
200 to 300kPa
Supply air

15ASGP
tube equivalent
or 10/8 PTFE
pipe or copper pipe
(not supplied)

15ASGP
tube equivalent
or 10/8 PTFE
pipe or copper pipe
(not supplied)

Rainproof cover

Flow guide tube

Detector
(ZFK8)

Gas temperature.
600C max.

3 4

AC power
supply

6
Bule

Black
Red Yellow
White White

Rainproof flexible conduit.

20m max.

Sample gas outlet

Converter (ZKM)

4-core
cable
2-core
cable

Thermocouple
input
O2 input

Gas temperature.
600C max.

Analog
output

Fault contact
output

Calibrating gas
Blow
contact
contact output
output
Heater
NC

10

11

12

13

Flow guide tube

for high particulate
Blue Yellow Red White

Black White

4 to 20mA DC
or
0 to 1V DC

14
(TM1-1)

Sample gas outlet

1
(TM2)

RS232C
or
RS485
(option)

Gas temperature.
600C max.

Alarm Maintenance Calibrating gas

contact
contact
contact
output
output
output

Contact input

Thermocouple
for combustion
control

Flow guide for high

particulate with cover

(TM1-2)
C

15

16

17

18

20

21

22

23

24

25

*3

26

27

28

PE

AC power
supply

6mm or 4 inch tube

for calibration gas
(not supplied)
Joint

*2 Ref. air

19

Solenoid valve
(not supplied)

Reduction
valve (ZBD6)
Standrad gas
for zero point
(ZBM)

Flowmeter
(ZBD4)
(1 to 1.5L/min)

Reduction valve
(unnecessary when supply air pressure is 50 to 100kPa)

to Detector

*1 Air supply
(0.2 to 0.5L/min)

Solenoid valve
(not supplied)

Reduction vale
(ZBD6)

Span point
*1
Standard gas for
span point (ZBM)

Note: *1 Standard gas or instrumentation air can be used in place of span gas.
*2 Instrument quality air or bottled air is available as reference air instead of ambient air.
*3 Protective earth.

ZFK8, ZKM, ZTA

Ejector system
Ejector (ZTA)

Flowmeter
(ZBD)

Ejector (5 to 10L/min)

Reduction valve
(unnecessary when supply air pressure
is 200 to 300kPa )
Joint
Supply air

1
2
4
5

Gas temperature.
1500C max.

Power supply

Copper pipe I6/I4mm

(not supplied)

Heater temperature drop

Alarm

Solenoid valve
(not supplied)

Copper pipe
I10/I8mm
(not supplied)

Copper pipe I10/I6mm

(not supplied)

Detector (ZFK8)

3 4

Black Red Yellow

White White Bule
Rainproof flexible
conduit.
AC power
supply

4-core
cable
2-core
cable

Converter (ZKM)

Thermocouple Analog
output
input
O2 input

Fault contact
output

Calibrating gas
Blow
contact
contact output
output
Heater
NC

10

11

Blue Yellow Red White 4 to 20mA DC

or
0 to 1V DC

12

13

Black White

14
(TM1-1)

1
(TM2)

RS232C
or
RS485
(optein)

3
Contact input

Thermocouple
for combustion
control

Alarm
contact
output

Maintenance Calibrating gas

contact
contact
output
output
C

15

16

17

18

19

20

21

22

23

24

25

(TM1-)2
*3

26

27

28

PE

I6mm or I4 inch tube

for calibration gas
(not supplied)

(1 to 1.5L/min)
Joint

Solenoid valve
(not supplied)

AC power
supply

Reduction
vale (ZBD6)
Standrad gas
for zero point (ZBM)

Flowmeter
(ZBD4)
Reduction valve (unnecessary when supply air pressure is
50 to 100kPa)

*2 Ref. air

*1 Air supply

to Detector
(0.2 to 0.5L/min)

Solenoid valve
(not supplied)

Reduction
vale (ZBD6)
*1 Standard gas for
span point (ZBM)

Note:

*1 Standard gas or instrumentation air can be used in place of span gas.

*2 Instrument quality air or bottled air is available as reference air instead of ambient air.
*3 Protective earth.

DEVICE CONFIGURATION
The device to be combined differ according to the conditions of the gas to be measured. Select the devices to be combined
with reference to the following table.
Measured gas
Application

Temperature Gas Flow

General-use

600C or

(boiler)

less

For corrosive 600C or

gas (refuse

Device configuration

DUST

Protection Note
cover

5 to 20m/s Less than 0.2g/mm3

Less than 10g/Nm3
5 to 20m/s Less than 1g/Nm3
3

Less than 10g/Nm

less

incinerator)
Less than 25g/Nm3 no
3

Less than 25g/Nm

3

yes

General-use

800C or

Less than Less than 1g/Nm

(boiler)

less
1590C or

1m/s
Less than Less than 1g/Nm3

less

1m/s

Detector type

Converter Ejector
type
type

Fuel; gas, oil

ZFK8R

5- A 5

-1

Fuel: coal

ZFK8R

5- C 5

-1

with blow down

Included low moisture

ZFK8R

5- B 5

-2

Included low moisture

ZFK8R

5- C 5

ZFK8R
with blow down
Included high moisture ZFK8R
with blow down
SUS316 tube
ZFK8R
with blow down
ZFK8R
SIC tube

with blow down

Included low moisture

ZKM
ZKM

-2

ZKM
ZKM

5- D 6

-2

ZKM

5- E 6

-2

ZKM

5-0Y0

-1

ZKM

ZTA1

5-0Y0

-1

ZKM

ZTA2

with blow down

Note (1) Dust volume is approximate value.

(2) Instrument quality air or bottled air is available as reference air by selecting detector with reference air inlet.

ZFK8, ZKM, ZTA

OUTLINE DIAGRAM

(Unit:mm)
Mounting hole
2-9

2.5

Converter (ZKM1)
<IP66>

75

142
72

153

10

2.5

U bolts M8 (option)

170

239

200

Oxgen Analyzer

MODE

ESC

ENTER

POWER

Cock (option)
Rc 1/83
Mounting for 2B pipe
ZKM
Oxgen Analyzer

153

For contact Input/output

Earth terminal (M4)

For output
For sensor (coupling)
For power supply
For communication

Mtg. Plate

Converter (ZKM2)
<IP67>

Mounting hole
4-9
195

72
20

U bolts M8 (option)

ESC

ENTER

POWER

312

220

MODE

Cock (option)
Rc 1/83

Mounting for 2B pipe

14

230

5
1

U bolts M8 (option)
95

5.7

39

For sensor (coupling)

4-G1/2
For power supply
For contact Input/output
For output

For communication

EXTERNAL TERMINAL (TM1)

40

Thermocouple
input

O2 signal
input

Blow output
contact
250V AC/3A COM
25
30V DC/3A

Heater power
output

+ TC1

+ AO

FAULT
BLOW ZV
2
3
4
5
6
7
8
9
10 11
15 16 17 18 19 20 21 22 23 24
+ TC2 DI1 DI2 DI3 DI- ALARM
MAINTENANCE
COM

HEATER
12 13
25 26
COM SV

14
27
N

28
AC
L

SPAN
GAS

Thermocouple
inputtype R

Contact input
250V AC3A
30V DC3A

Alarm
contact output
250V AC/3A
30V DC/3A

Maintenance
output contact
250V AC/3A
30V DC/3A

Calibrating gas
contact output
250V AC/3A
30V DC/3A

40

40

40

COMMUNICATION TERMINAL (TM2)

ZERO
GAS

+ O2
1

Fault
contact output
contact capacity
Analog
250V AC/3A
output
4-20mA DC 30V DC/3A
or 0-1V DC

Power supply
input
100V AC to 120V or
200V AC to 240V

Terminal number Remarks

1
2
3
RS232C TXD RXD GND standard
RS485 TRX+ TRX GND option

Detector (ZFK8)
Approx.132

I 80

Approx.62

Approx.130

I 67
5

6-I 6

Temp.Proof cover
(To order)

Terminal box

I 79

Heater

Element output

Thermocouple

60

125.5

I 26

I 85

EXTERNAL CONNECTION DIAGRAM

1
3
2
4
Black / White/ red / White/

Approx.30

Filter

2-core wire

Ground-wire
Screw: M4

Calibration gas inlet

Ref. Air inlet (to order) (To order)
SUS316,for I 6/I 4 tube SUS316,for I 6/I 4 tube
Or 1/4 inch tube
Or 1/4inch tube

5
6
yellow / blue

4-core wire

Exclusive-special cable

Exclutive
Cable gland

Sensor unit (ZFK8YY)

(132.7)

3.5

20

(?17.5)

(88.4)

4-I 3.5(Mount for detector)

TK4J4664R0
5

S-

T-

45

made in japan

40

T+

S+ H
6
1

45

I 35

Flow guide tube

155
Approx. L

12

Approx. 20

130
67

34

Gas inlet

20

ZFK8R

Gas outlet

Oxygen detector

5-5A3
5
7
1

6-M5
detector side

815
MTG. holes

Cord 11th

L (m)

0.3

0.5

MASS
2.7
Approx.(kg)

3.3

0.75 1.0
4.1

4.8

L=
(to order)

ZFK8, ZKM, ZTA

Flow guide tube (with blow-down nozzle)
155

Approx. L

18

Approx. 20

130
67

60.5

67

Gas inlet
6-M5
detector side

ZFK8R

5-5C3
5
7
1

Gas outlet

Oxygen detector

Cord 11th

L (m)

0.3

Mass
3.0
Approx.(kg)

Blow down air inlet

4-Rc1/4
with plug int.thd.

3.8

4.8

815
MTG. holes

5
14

180

Flow guide tube (for high particulate)

4 - Rc 1/4
with plug int thd.

Blow down air inlet

Select an upper port to
avoid the condensation
in the piping
8 - 19
MTG. hole

67

29.5

Flange: JIS 5K80A FF

ZFK MTG. position

185

Packing

5-6D3
5
7
1

Gas outlet

800

50

ZFK8R

30
Cord 11th

L (m)

0.3

Mass
4.5
Approx.(kg)
Gas flow
Tube (50A SCH40)

10

0.5 0.75 1.0

5.6

7.0

8.3

0.5 0.75 1.0

L=
(to order)

5.7

L=
(to order)

180

14

Flow guide tube (for high particulate with cover)

4 - Rc 1/4
with plug int thd.

Blow down air inlet

8 - 19
MTG. holes

Select an upper port to

avoid the condensation
in the piping

67
29

.5

Flange: JIS 5K80A FF

(175)

ZFK MTG. position

50

Packing

ZFK8R

5-6E3
5
7
1

800

(790)

Gas outlet
30
Cord 11th

L (m)

0.3

Mass
7.1
Approx.(kg)

Gas flow

Protection tube (65A SCH40)

(38)

0.5 0.75 1.0

L=
9.0 11.4 13.6 (to order)

Tube (50A SCH40)

Flow guide tube

155
12

Approx. 40

Approx. L

130

3
67

67

60.5

Gas inlet

ZFK8R

Gas outlet

6-M5
detector side

Cord 11th

L (m)

0.3

MASS
3.3
Approx.(kg)
Oxygen detector

5-5B3
5
7
1
5

0.5 0.75
4.5 6.1

1.0
7.6

L=
(to order)

8- 15
MTG. holes

11

ZFK8, ZKM, ZTA

Ejector (ZTA)
4-M16 bolt

Viewed from P direction

42.7

30
8

170

Gas inlet
217

25

105

190

Approx. L

140
(JIS 10K65ARF)

L [mm] 500 750 1000 1500

40
Detector
(ZFK8)

Ejector air
outlet
(Rc1/4)

35
Blow -down air inlet
(Rc1/4)
Ejector air inlet
(Rc1/4)

40

50

45

Cable gland
(A15C)

EXTERNAL CONNECTION DAIAGRAM

1

AC
power supply
AC100/110V
AC200/220V
AC230V

Heater temp.drop alam

Caution on Safety
*Before using this product, be sure to read its instruction manual in advance.

Sales Div. III, International Sales Group

Global Business Group
Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome,
Shinagawa-ku, Tokyo 141-0032, Japan
http://www.fesys.co.jp/eng
Phone: 81-3-5435-7280, 7281 Fax: 81-3-5435-7425
http://www.fic-net.jp/eng

Information in this catalog is subject to change without notice.

Printed in Japan