IN-SITU ZIRCONIA OXYGEN ANALYZER ZSB DATA SHEET This oxygen analyzer is used to continuously measure oxygen concentration in combustion exhaust gas of industrial boilers or furnaces, and is ideally suited for combustion moni-toring and control. The analyzer consists of a flow guide tube with a detector, which is directly inserted into a flue, etc. to introduce the gas to be analyzed, a transducer, which performs control, signal processing, display, input to and output from outside, and communication, and an auto calibration/blow unit. The detector of a unit sensor structure facilitates on-site maintenance. The transducer provided with an unconventional sensor diagnostic function and sensor renewal function ensures long-term stable detecting operation. FEATURES 1.No need for gas sampling devices Since the sensor unit is directly inserted into a flue, etc., gas-sampling devices such as gas aspirator and dehumidifier are not required, which ensures high response speed. 2.Easy maintenance The sensor in a unit structure mounted to the detector can be replaced easily. Since the detector and the flow guide tube are installed separately, the filter at the tip of the detector can be replaced easily, and detector and the flow guide tube can be maintained separately depending on the degree of formation of rust, for example. 3.High reliability ensured by the sensor diagnostic and sensor renewal functions Depending on the components in the gas to be measured, the sensor electrode may degrade. The transducer diagnoses the degree of degradation of the sensor and renews it electrically, thus ensuring high reliability and long-term stable measurement. 4.Improved safety Detecting a break of the thermocouple for heater control installed at the sensor, power supply to the detector is stopped. Furthermore, external contact input stops power supply to the detector in an emergency. Those functions along with the key lock function are equipped as standard to ensure improved safety. 5.Simple operation The transducer can be operated and various settings can be made using an interactive system, and display language is available in English, Japanese, and Chinese. SPECIFICATIONS General Measuring object: Oxygen in noncombustible gas Measuring method: Directly insert type zirconia system Measuring range: Repeatability: 0 to 2 ···Setting range at option 2 in 50 vol% O2 (in 1 vol% O2 steps) Within ±0.5%FS Linearity: Within ±2%FS Response time: Within 4 to 7 sec, for 90% (from calibration gas inlet) More than 10 min. Warmup time: Analog output: Power supply: 4 to 20mA DC (allowable load resistance 500Ω or less) or 0 to 1V DC (output resistance more 100Ω or more) Rated voltage; 100 to 120V AC (operating voltage 90 to 132V AC) Rated frequency; 50/60Hz EDS3-124c Date Apr 1, 2011 ZSB Power consumption: Material: Maximum 240VA (Detector: approx. 200VA, Converter: approx. 40VA) Normal 70VA (Detector: approx. 50VA, Converter: approx. 20VA) Steel plates (main frame) Mass: Approx. 1.6kg Finish color: Silver and SUS metallic color Calibration gas flow: 1.5 to 2 L/min Blowdown air inlet pressure: 200 to 300kPa Outer dimensions (H x W x D): Mass: Finish color: Wall-mounting type: 700 X 400 X 180mm Self-standing type: 1500 X 530 X 550mm Wall-mounting type: Approx. 27 kg (excluding cable, detector and standard gas) Self-standing type: Approx. 48 kg (excluding cable, detector and standard gas) Munsell 5Y7/1, semi-gloss Mounting method: Wall-mounting or self-standing Detector (ZFK8) Measured gas temperature: Flow guide tube system; −20 to +600ºC (for general-use, corrosive gas) Measured gas pressure: −3 to +3kPa Flow guide tube: • With or without blowdown nozzle Flange; JIS5K 65A FF Insertion length; 0.3, 0.5, 0.75, 1m • For high particulate gas (with blowdown nozzle) With or without cover Flange; JIS5K 80A FF Insertion length; 0.3, 0.5, 0.75, 1m Operating temperature: −10 to +60ºC for Primary detecting element −5 to +100ºC for detector 125ºC or less at detector flange surface with power applied Storage temperature: −20 to +70ºC Structure: Dust/rain-proof structure (IEC IP66 equivalent, except the filter part at the tip) Use a heat insulation cover in cold climates (as specified) Filter: Alumina (filtering accuracy 50µm) and quartz paper Main materials of gas-contacting parts: Zirconia, SCS14 (SUS316 equivalent), platinum, SUS304 Calibration gas inlet: φ6mm tube join Reference air inlet: φ6mm tube join Detector mounting: Horizontal plane ±45º, ambient air should be clean. Outer dimensions (L × max. dia.): 210mm × 100mm 2 Converter (ZKM3) 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 •Instrument anomalies Note1) •Alarm Note2) •Zero calibration gas valve •Span calibration gas valve •Under blowdown Note3) Note1) The following Instrument errors (1) Thermocouples break (2) Sensor break (3) Temperature fault (4) Calibration fault (5) Zero/span fault (6) Output error the contact ON Note2) Alarm selects just one as mentioned below (1) High (2) Low (3) H/L (4) HH (5) LL, it turns ON while operating. Note3) Under blow down, it is available in case of option, and it turns ON while operating. Contact input signal: (1)Contact specification; 3 points (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: Calibration gas: (a) Manual calibration with key operation (b) Auto. calibration (option) Calibration cycle; 00 day 00 hour to 99 days 23 hours (c) All calibration • Settable range 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 dust with compressed air that has deposited in the flow guide tube. Blowdown can be performed only for a predetermined time and at prede-termined 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 manual/ auto calibration, blowdown, sensor recovery proc-essing, warm-up, PID auto tuning, and while maintenance mode setting is "available". The hold function can also be released. Communication function: RS232C (MODBUS) standard specification RS485 (MODBUS) (option) Combustion efficiency display: When you select this display, "rich mode display" will be simultaneously displayed. 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 +55ºC Operating humidity: 95% RH or less, non condensing Storage temperature: −30 to +70ºC Storage humidity: 95% RH or less, non condensing Outer dimensions (H × W × D): 182 × 163.5 × 70.6mm Mass: Approx. 2kg (excluding cable and detector) (IP66) Mounting method: Mounted flush on panel 3 ZSB CODE SYMBOLS 1 2 3 4 5 6 7 8 2 - Z S B 9 10 11 12 13 14 15 Description Converter mounting (4th digit) Wall-mounting type (with indication window) Self-stand type (with indication window) 4th digit 1 2 Sensor, Power supply, Cal. Gas inlet (5th digit) For general use without protection cover, 100/115 V AC, 50/60 Hz and inlet for φ6 mm tube For general use with protection cover, 100/115 V AC, 50/60 Hz and inlet for φ6 mm tube * Protection cover should be selected when ambient temperature is -10°C or lower. 5th digit A B Sensor cable + calibration gas tube (6th digit) None 6 m cable (without conduit) + 6 m Teflon tube (φ6/φ4) 10 m cable (without conduit) + 10 m Teflon tube (φ6/φ4) 15 m cable (without conduit) + 15 m Teflon tube (φ6/φ4) 20 m cable (without conduit) + 20 m Teflon tube (φ6/φ4) 6 m cable (with conduit) + 6 m Teflon tube (φ6/φ4) 10 m cable (with conduit) + 10 m Teflon tube (φ6/φ4) 15 m cable (with conduit) + 15 m Teflon tube (φ6/φ4) 20 m cable (with conduit) + 20 m Teflon tube (φ6/φ4) 6 m cable (4-core cable only. Heater cable should be prepared by customer.) + 6 m Teflon tube (φ6/φ4) 10 m cable (4-core cable only. Heater cable should be prepared by customer.) + 10 m Teflon tube (φ6/φ4) 15 m cable (4-core cable only. Heater cable should be prepared by customer.) + 15 m Teflon tube (φ6/φ4) 20 m cable (4-core cable only. Heater cable should be prepared by customer.) + 20 m Teflon tube (φ6/φ4) * When exclusive-special conduit and heater cable are not used, the following conduit should be used. Conduit with outer diameter φ23 and inner diameter φ16 as specified in JIS C8411 For preparing two heater cables, their rating should be 3 A or more. 6th digit Y A B C D E F G H J K L M Calibration gas unit (7th digit) Automatic calibration unit + zero gas + filter regulator Automatic calibration unit + zero gas + air standard gas Manual calibration unit + zero gas + filter regulator Manual calibration unit + zero gas + air standard gas 7th digit 1 2 3 4 9th, 10th, 11th digits 0 5 5 5 5 5 5 5 5 6 6 6 6 Z Y A A A A B B B B D D D D Z 0 3 5 7 1 3 5 7 1 3 5 7 1 Z 12th digit B E 13th digit J E C 14th digit 1 2 15th digit Y 1 4 Flow guide tube (9th, 10th and 11th digit) (Flange) (Application) None None SUS304 For general use SUS304 For general use SUS304 For general use SUS304 For general use SUS316 For corrosive SUS316 For corrosive SUS316 For corrosive SUS316 For corrosive SUS316 Without high particulate cover SUS316 Without high particulate cover SUS316 Without high particulate cover SUS316 Without high particulate cover Others Others Output signal (12th digit) 4 to 20mA DC 0 to 1V DC Language (13th digit) Japanese English Chinese Communication functions (14th digit) RS232 RS485 Reference gas (15th digit) None φ6mm tube joint (Length) None 300mm 500mm 750mm 1000mm 300mm 500mm 750mm 1000mm 300mm 500mm 750mm 1000mm Others (Note) With blow-back unit With blow-back unit With blow-back unit With blow-back unit DEVICE CONFIGURATION The device to be combined differs according to the conditions of the gas to be measured. Please select the flow guide tube, referring to the table shown below. Measured gas Application Temperature Boiler, refuse incinerator, sludge incinerator, 600ºC or less etc. Gas Flow 5 to 20m/s Device configuration Dust Type at 4th to 7th digits Note Flow guide tube at 9th to 11th digits Less than 0.2g/Nm3 For boiler. Fuel; gas, oil ZSB 2– 5A Less than 1g/Nm3 When moisture content in measured gas is low. ZSB 2– 5B Less than 25g/Nm3 When moisture content in measured gas is low. With blow-down ZSB 2– 6D Note (1) Dust volume is approximate value. (2) Reference air port specification should be selected when standard gas concentration changes. (3) For optional specifications, contact the manufacturer separately. SCOPE OF DELIVERY 1)Standard delivery 1 set x zirconia oxygen analyzer 1 set x instruction manual 1 set x standard accessories ·1 x O-ring (for detector) ·1 x ceramic filter (for detector) ·2 each x fuse (3.15 A, 0. 5 A) ·1 set x inlet (for standard gas connection) ·1 x polyethylene tube (for standard gas connection) ·1 x Toaron tube (for standard gas connection) ·1 set x flow guide tube accessories (bolt, nut, spring washer x 4 pieces each) 2)Items to be prepared separately ·Replacement detector ·Spare (detector) Spares for 1-year operation 1 x O-ring 2 x ceramic filter 1 x Filter frame Spares for 2-year operation 2 x O-ring 4 x ceramic filter 2 x Filter frame CAUTIONS ·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 (+300ºC or higher), the flange should be separated from the furnace wall in order to bring the detector flange surface temperature below the specified value (+125ºC). The flow guide tube should be attached in the direction in which the gas flow to the detector decreases. ·If much dust is contained in the gas, the flow guide tube should be connected obliquely from the top. This tube should also be connected in the direction where gas flow into the detector section is reduced. ·In application to refuse incineration, automatic blow-down of the flow guide tube should be avoided (in order to protect the tube from corrosion due to drain formation). Blow-down should be carried out manually when indication change becomes small during stop of the incinerator. 5 ZSB CONFIGURATION 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 φ10/φ8mm Teflon pipe or steel pipe (not supplied) Heat insulation cover Flow guide tube 15ASGP tube equivalent or φ10/φ8mm Teflon pipe or steel pipe (not supplied) Detector (ZFK8) Gas temperature. 600ºC max. 6 1 3 5 Ref. air 2 4 White Black White Yellow Blue Rainproof flexible conduit. (Max. 20m) Red Gas outlet Gas temperature. 600ºC max. Flow guide tube for high particulate Cable gland Gas outlet T1 Converter (ZKM) R1 1 2 + O2 – Gas temperature. 600ºC max. 3 4 + TC1 – O2 input Flow guide tube for high particulate with cover Thermocouple input 6 AO 7 Thermocouple for combustion control 10 11 12 13 TM-1 14 ZERO GAS Fault contact output Blow HEATER contact Calibrating output gas contact output Alarm Maintenance contact Calibrating gas contact output contact output output Contact input ALARM + TC2 – DI1 DI2 DI3 DICOM 15 17 18 19 16 9 ZV Analog output 4 to 20mA DC or 0 to 1V DC *1 8 – or 20 SPAN GAS MAINTE COM 21 22 23 24 25 SV 26 AC power supply N AC L 27 28 1 φ6mm Teflon tube for calibration gas (not supplied) 5 + 2 TM-2 3 Converter Auto breaker R T E 1 2 3 4 Maintenance signal during calibration/maintenance 6 5 7 8 9 10 11 T1 12 R1 Earth 3 AC power supply *1 Use a screw for mounting of converter main unit TGS 2 When auto calibration is selected (1.5L/min) Zero Solenoid valve Joint Pressure regulator Zero O2/N2 Flowmeter Solenoid valve (0.2L/min) Standard gas for zero point Span Reference air Flowmeter Container box Span Supply air Reduction valve (mounted on the main unit) 6 Pressure regulator Air or O2/N2 Standard gas for span point When air standard gas is selected OUTLINE DIAGRAM (Unit : mm) Self-standing type: ZSB2 400 180 100 External connection terminal (converter) {490} {350} Instrumentation air inlet (for blow-back) Rc1/2 G1/2 700 Rc1/2 Instrumentation air outlet (for blow-back) Regulator + solenoid valve (selectable by code symbol) Anchor plan, anchor bolts (option) M12×160×50 1500 External connection terminal (power supply) Rc1/4 Instrumentation air outlet (for span calibration gas) Filter regulator (selectable by code symbol) 760 Rc1/4 Instrumentation air inlet (for span calibration gas) 4-φ15 30 490 530 350 550 Front view (Front) Cable gland exclusive for detector Right side view EXTERNAL CONNECTION DIAGRAM (POWER SUPPLY) 1 2 3 R T E 4 Power Ground supply 5 6 7 8 9 10 11 12 Maintenance signal Calibration status/ maintenance status Inlet (for φ6 mm tube) (Rear) Cable gland A15A (Box bottom view) 7 ZSB Wall-mounting type: ZSB2 Instrumentation air inlet (for blow-back) Rc1/2 400 255 180 300 External connection terminal (converter) G1/2 700 Rc1/2 Rc1/4 Instrumentation air outlet (for span calibration gas) Filter regulator (selectable by code symbol) Rc1/4 Instrumentation air inlet (for span calibration gas) Right side view Front view (Front) 500 Instrumentation air outlet (for blow-back) Regulator + solenoid valve (selectable by code symbol) External connection terminal (power supply) Rear view Cable gland exclusive for detector EXTERNAL CONNECTION DIAGRAM (POWER SUPPLY) 1 2 3 R T E 4 Inlet (for φ6 mm tube) (Rear) Cable gland A15A (Box bottom view) 8 4-φ15 Power Ground supply 5 6 7 8 9 Maintenance signal Calibration status/ maintenance status 10 11 12 Converter: ZKM3 163.5 10 70.6 143.5 Oxygen Analyzer OXYGEN TRANSM ITTER Made in Japan 50/60Hz 60VA Fuji Electric Co.,Ltd. TYPE OUTPUT DC POWER AC SER. NO. MFD 172 ESC ENTER POWER 注 意 182 MODE POWER 変換器へ供給する電源電圧は、接続される 検出器の電源電圧に合わせてください。 FUSE T 0.5A HEATER CAUTION FUSE T 2.5A Power supply must be selected the same voltage of detector. POWER ON OFF + O2 − + TC1 − + AO − FAULT BLOW ZV HEATER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ALARM MAINAC COM SV + TC2 − DI1 DI2 DI3 DIN L TENANCE COM 4-φ4.5 MTG. holes External terminal (TM1) O2 sensor input O2 sensor thermocouple input Exclusive cable Analog output 4-20mA DC or 0-1V DC 1 + O2 2 3 − + 4 TC1 − 5 + AO 6 Fault contact output contact capacity 250V AC/3A 30V DC/3A 7 8 9 + 15 TC2 11 12 13 14 ZV FAULT BLOW ALARM Ground terminal M4 10 − or O2 sensor heater power output Blow contact output 250V AC/3A 30V DC/3A − DI1 DI2 DI3 DICOM 16 17 18 19 22 Alarm contact output 250V AC/3A 30V DC/3A Thermocouple input type R Contact input (combustion control) Short circuit : on (Current 5mA) Open : off (Voltage 5V) HEATER SPAN GAS MAINTE 21 20 ZERO GAS 23 COM 24 25 Maintenance contact output 250V AC/3A 30V DC/3A SV 26 Calibrating gas contact output contact capacity 250V AC/3A 30V DC/3A N 27 AC L 28 AC Power supply input (100 to 240V AC) COMMUNICATION TERMINAL (TM2) /INSERTION TERMINAL Terminal number 1 2 3 Remarks RS232C TXD RXD GND Standard RS485 TRX+ TRX– GND Option 9 ZSB Detector: ZFK8 Approx.132 φ 80 Approx.62 Approx.130 φ 67 5 6-φ 6 Temp.Proof cover (To order) Terminal box φ 85 Heater 125.5 φ 26 φ 79 EXTERNAL CONNECTION DIAGRAM Approx.30 ° 60 Filter Thermocouple 1 3 2 4 Black / White/ red / White/ 2-core wire Ground-wire Screw: M4 Calibration gas inlet Ref. Air inlet (to order) (To order) SUS316,for φ 6/φ 4 tube SUS316,for φ 6/φ 4 tube Exclusive Cable gland Sensor unit (ZFK8YY) (132.7) 20 (?17.5) 3.5 4-φ 3.5(Mount for detector) 5 S- H 2 4 T- 45° TK4J4664R0 3 made in japan 40 T+ S+ H 6 1 45° φ 35 10 5 6 yellow / blue 4-core wire Exclusive-special cable Replacement Detector element (88.4) Element output Flow guide tube (for general-use) φ155 Approx. L 12 Approx. 20 φ130 φ67 φ34 Gas inlet 20 ZSB 6-M5 detector side Gas outlet Code 11th 3 L (m) 0.3 Oxygen detector MASS 2.7 Approx (kg) 5 7 1 0.5 0.75 1.0 3.3 2-5A 3 5 7 1 4.1 4.8 Z 8-φ15 MTG. holes L= (to order) Flow guide tube (for corrosive gas) φ155 12 Approx. 40 Approx. L φ130 3 φ67 φ60.5 φ67 Gas inlet ZSB 6-M5 detctor side Gas outlet Oxygen detector 2-5B 3 5 7 1 Code 11th 3 L (m) 0.3 MASS 3.3 Approx (kg) 5 7 1 0.5 0.75 1.0 4.5 6.1 7.6 Z L= (to order) 8-φ15 MTG. holes 11 ZSB 45 φ1 4-Rc 1/4 with plug φ180 Flow guide tube (for high particulate) Blow down air inlet At installation, select upper blow port at one position (as a measure for drain). 8-φ19 MTG. hole φ67 φ29 .5 Code 11th 3 L (m) 0.3 MASS 4.5 Approx (kg) Flange: JIS 5K80A FF 5 7 1 0.5 0.75 1.0 5.6 7.0 8.3 Z L= (to order) ZSB MTG. position Gas outlet Approx. L 185 Packing ZSB 50 Oblong hole 2-6D 3 5 7 1 30 Gas flow Applicable companion flange height about 160 mm (Closing gas outlet should be avoided.) Tube (50A SCH40) Caution on Safety *Before using this product, be sure to read its instruction manual in advance. International Sales Div Sales Group Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan http://www.fujielectric.com Phone: 81-3-5435-7280, 7281 Fax: 81-3-5435-7425 http://www.fjielectric.com/products/instruments/ Information in this catalog is subject to change without notice. Printed in Japan