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Fuji Electric ZKMA, Instruction Manual

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Summary of Contents for ZKMA

Page 1: ......

Page 2: ...eading through the manual be sure to keep it near at hand for future reference This product falls within category 9 Monitoring and control instruments including indus trial monitoring and control inst...

Page 3: ...ases Otherwise serious accidents such as explosion or fire may result CAUTION This unit should be installed in a place which conforms to the condi tions noted in the instruction manual Otherwise it ma...

Page 4: ...removing the detector from the flue for maintenance and check make sure the furnace is stopped Otherwise you may suffer a burn Before working take off a wrist watch finger ring or the like metallic ac...

Page 5: ...fter the completion of repair 4 2 Scope of warranty 1 If any failure or malfunction attributable to Fuji Electric occurs in the period of warranty we shall pro vide the product after repairing or repl...

Page 6: ...ensure the service life it is important to perform planned maintenance of the product including limited life parts and consuma ble parts 7 Maintenance plan Maintenance can be divided into preventive...

Page 7: ...the temperature rises by 10 C Arrhenius law Replacement Estimate the lifetime of capacitor according to your operating environment and have the capacitor replaced or overhauled at appropriate time at...

Page 8: ...tor 10 4 2 2 Cable gland and input and output lines 11 4 2 3 Allocation of the terminal block 12 4 3 Wiring and piping diagram 13 4 4 Handling of standard gas An article on separate order 17 5 OPERATI...

Page 9: ...time setting of automatic calibration option 57 10 2 4 Performing all calibration option 58 10 2 5 Performing a manual span calibration 59 10 2 6 Performing a manual zero calibration 60 10 2 7 Calibra...

Page 10: ...tting of measurement recovery time maintenance hold 91 10 5 13 Hold treatment setting error hold 92 10 5 14 Hold value setting error hold 93 10 5 15 Setting of hold setting value error hold 94 10 5 16...

Page 11: ...ation 1 When you specified RS485 communication or HART communication Language Japanse English or Chinese as specified 5 Mounting bracket 1 set For panel mount version M8 sems screw stainless steel 4 p...

Page 12: ...nverter type ZKM The analyzer intended for the measurement of oxygen concentration in exhaust gas is used for combustion control Caution Power voltage for the converter must conform to that for the de...

Page 13: ...2 INZ TN2ZKMA E 2 OPERATING PARTS AND THEIR FUNCTIONS 2 1 Outline Drawing 1 ZKMA 2 ZKMB...

Page 14: ...centration value and setting values LED Lights during power supply ESC key Used to return to the previous screen or exit the setting Digit key Used to change the setting values Up key ENT key Used to...

Page 15: ...uit and the power circuit are installed Communication board RS485 communication board or HART communication board is installed Fuse Protects the CPU board and the I O board from over current Terminal...

Page 16: ...ire failure or malfunction 3 1 Installation site Install the converter in a place that satisfies the following conditions 1 Space for periodic inspection and wiring work is available 2 Vibration dust...

Page 17: ...ion 72 4 M8 250 No Name Quantity 1 Converter 1 2 Sems screw M8 12 4 Code Standard tightening torque M8 12 5 N m 3 2 2 Pipe mounting ZKMA Installation No Name Quantity 1 Converter 1 2 Hexagon nut M8 4...

Page 18: ...onverter 1 2 Sems screw M8 12 4 Code Standard tightening torque M8 12 5 N m 3 2 4 Pipe mounting ZKMB Installation Pipe for mounting 5 6 1 2 3 4 5 2 3 4 No Name Quantity 1 Converter 1 2 Hexagon nut M8...

Page 19: ...itch or a circuit breaker to the power supply of the transmitter Use the external switch or the circuit breaker that is rated to 5A and compliant with IEC947 1 or IEC947 3 We recommend installing the...

Page 20: ...th are caulked separately double caulking Connect the ground wire to the following M4 screw round terminal of the main ground wire tooth lock washer casing 3 Provide adequate protection of the exclusi...

Page 21: ...thermocouple input with the cable gland so that its sheath is 10 mm or less When attaching the nut turn it by hand until it does not move and then tighten it with a spanner by about 1 4 turn Note 2 Wi...

Page 22: ...11 INZ TN2ZKMA E 4 2 2 Cable gland and input and output lines 1 ZKMA 2 ZKMB...

Page 23: ...12 INZ TN2ZKMA E 4 2 3 Allocation of the terminal block...

Page 24: ...13 INZ TN2ZKMA E 4 3 Wiring and piping diagram 4 3 1 1 Flow guide tube system...

Page 25: ...14 INZ TN2ZKMA E 4 3 1 2 Flow guide tube system with valve...

Page 26: ...15 INZ TN2ZKMA E 4 3 1 3 Ejector system...

Page 27: ...16 INZ TN2ZKMA E 4 3 1 4 Ejector system with valve...

Page 28: ...ckwise and set to the normal value of 20 to 30 kPa then open the outlet needle slowly to allow the gas to flow Handle Secondary pressure meter Fow rater Primary pressure meter Secondary pressure adjus...

Page 29: ...emperature control does not complete within 10 minutes the analyzer stops warm up to start operation however for 7 minutes after the warm up stoped the analyzer cannot detect the error of the heater t...

Page 30: ...be performed at specified time intervals Refer to 7 3 for automatic calibration settings 9 Blowdown option A flow guide tube blowdown feature prevents the flow guide tube from clogging due to dust in...

Page 31: ...20 INZ TN2ZKMA E 5 2 Key operation flow diagram outline...

Page 32: ...21 INZ TN2ZKMA E...

Page 33: ...22 INZ TN2ZKMA E...

Page 34: ...23 INZ TN2ZKMA E...

Page 35: ...ration function Displayed if the option is provided AUTO CALIBRATION YES NO YES or NO Invalid Auto calibration function Invalid 10 2 1 Date and time for starting automatic calibration Displayed if the...

Page 36: ...ic blowdown START DATE 99 01 01 00 00 Date and time in the fu ture in the calendar 99 01 01 00 00 10 3 2 Automatic blowdown cycle time AUTO BLOW CYCLE 24h 00m 00h 00m to 99h 59m m 00 to 59 24h 00m 10...

Page 37: ...tion Range 1 Range 2 LOW ALARM 00 020 vol 0 001 to 55 000 vol in 0 001 vol steps 00 020 vol 10 5 5 Upper 2 limit of oxygen concentration Range 1 Range 2 H HIGH ALARM 55 000 vol 0 001 to 55 000 vol in...

Page 38: ...T TIME 010 s 0 to 300 sec in 1 sec steps 10 sec 10 5 12 Key lock function KEY LOCK YES NO YES or NO No Key lock func tion is invalid 10 5 16 Automatic OFF time BACKLIGHT TIME 10 m 0 to 99 in 1 minute...

Page 39: ...table depending on the ambient temperature power supply voltage and other conditions In such a case especially when you first use the analyzer perform PID auto tuning after the stop of warm up Refer t...

Page 40: ...29 INZ TN2ZKMA E 6 3 Actions during operation While the instrument is operating the following displays can be changed...

Page 41: ...calibration S Span calibration Displayed together with CAL or RIC during span calibration Z Zero calibration Displayed together with CAL or RIC during zero calibration SCK Sensor check Displayed duri...

Page 42: ...concentration error Appears when the oxygen concentration exceeds any of specified HH High Lower LL limit values Refer to 10 5 4 to 10 5 8 H High limit error Appears together with ALM L Lower limit e...

Page 43: ...concentration Output value mV O2 concentration Output value mV O2 concentration Output value mV 0 01 176 38 5 0 32 73 25 0 4 475 0 1 123 15 10 0 16 71 30 0 8 689 0 5 85 95 15 0 7 333 40 0 15 34 1 0 6...

Page 44: ...ing correctly referring to Item 4 3 At this time the main valve of standard gas should be left open Since high pressure is present at piping connections use cap nut joints and take special care with r...

Page 45: ...CALIBRATION MENU MANUAL SPAN CAL 2 Press the key to perform manual span calibration If supplying calibration gas manually without the auto calibration function The operator shall open the span gas va...

Page 46: ...ration value and cell electromotive force are displayed Wait until the oxygen concentration is stabilized MANUAL ZERO CAL 2 01 053 9 mV 10 Press the key to determine the zero calibration factor During...

Page 47: ...tion 10 2 3 Cycle time setting of automatic calibration option 10 2 7 Calibration gas setting 10 2 8 Calibration waiting setting option and 10 5 12 Setting of measurement re covery time maintenance ho...

Page 48: ...ght appears SET AUTO CAL START DATE 10 Press the key to display the screen on the right and press the key The cycle time setting of automatic calibration screen appears SET AUTO CAL AUTO CAL CYCLE 11...

Page 49: ...rbitrarily set the contact inputs 17 18 19 and 20 of the external terminal block see 10 5 2 Contact input setting Piping and wiring for the standard gas cylinder and the solenoid valve shall be instal...

Page 50: ...1 7 Close the contact set to the REMOTE CAL Remote calibration is performed 12 34 Vol How to cancel Press the key to cancel the operation Note Automatic calibration is not performed under the followin...

Page 51: ...during calibration 10 4 5 Performing a manual sen sor check are required Refer to Sections 4 2 and 4 3 for the wiring of solenoid valves Procedure Operation example Executes all calibration Key opera...

Page 52: ...d to air tightness Setting of blowdown time Referring to 10 3 4 Procedure for setting blowdown time set blowdown time 8 2 Manual blowdown Description You can perform blowdown operation once by key ope...

Page 53: ...etting blowdown time are required Blowdown contact Analog output signal Closed Closed Contact output for maintenance Automatic blowdown starting date Automatic blowdown interval Hold Hold prolong Hold...

Page 54: ...and key to set the auto blowdown interval Press the key to set the value AUTO BLOW CYCLE 24h 00m 12 Press the key AUTO BLOW CYCLE 24h 00m 13 The screen on the right appears SET AUTO BLOW AUTO BLOW CYC...

Page 55: ...t the contact inputs 17 to 19 and 20 of the terminal block see 10 5 2 Contact input setting Piping and wiring for the supply air and the solenoid valve shall be installed Description You can perform b...

Page 56: ...ON 6 The screen on the right appears Press the key several times and return to the measurement screen DIGITAL INPUT DI 1 7 Close the contact set to the Blowdown ON Blowdown is performed 12 34 Vol How...

Page 57: ...ne Pay attention to the exposed surface of packing if there are any cracks 9 2 Spare parts No Name Part number Q ty Remarks 1 LCD module assembly ZZPZKM2 TK4K9805C1 1 set Includes LCD 2 I O board ZZPZ...

Page 58: ...ou can see the a fuse on the case To replace the fuse insert a flathead screwdriver or coin into the fuse cap and turn it to the left while pressing it in order to remove the cap and replace the fuse...

Page 59: ...ty Open the cover and you can see the volume knob VR1 on the CPU board Turn the knob with a flathead screwdriver to adjust the contrast ZKMA Open the front cover and the inner cover and you can see th...

Page 60: ...s setting Check the set value for calibration gas concentration Set proper value Re fer to 10 2 7 Wrong parameters setting Check automatic calibration intervals Set proper parame ters The calibration...

Page 61: ...uples Break of sensor Wrong wiring Cable check of wiring Wiring check Replace the defec tive parts Correct wiring Turn on off the power supply Range cannot be switched Range setting is set in the cont...

Page 62: ...mple Setting the display range to Range 1 Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key The display...

Page 63: ...Range 1 Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key MEASURE MENU OUTPUT RANGE 2 Press the key The...

Page 64: ...ing the full scale value to 20 00 Range 1 Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key MEASURE MENU...

Page 65: ...alues to 24 hours Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key The setting screen for calculation t...

Page 66: ...ey AUTO CALIBRATION YES 5 The display returns to the screen on the right SET AUTO CAL AUTO CALIBRATION Note If the time for automatic calibration comes during manual treatments calibration blowdown or...

Page 67: ...escription Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key CALIBRATION MENU SET AUTO CAL 2 Press the key to display the screen o...

Page 68: ...CD 1 Display the screen on the right in accordance with the key op eration summary and press the key CALIBRATION MENU SET AUTO CAL 2 Press the key to display the screen on the right and press the key...

Page 69: ...n Displayed message LCD 1 Display the screen on the right in accordance with the key operation summary and press the key the all calibra tion performing screen appears CALIBRATION MENU ALL CALIBRATION...

Page 70: ...rator shall open the span gas valve manually and adjust the flow rate to 1 5 0 5 L min If your detector has the auto calibration function you can acti vate the external solenoid valve using the contac...

Page 71: ...The operator shall open the zero gas valve manually and adjust the flow rate to 1 5 0 5 L min If your detector has the auto calibration function you can acti vate the external solenoid valve using th...

Page 72: ...gas concentrations Range 1 Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key CALIBRATION MENU CAL GAS RA...

Page 73: ...tion to 20 seconds Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key operation summary and press the key CALIBRATION MENU CAL WAIT TIME 2 The...

Page 74: ...rmal contact output Error log information is not cleared Procedure Operation example Clearing a calibration error Key operation Description Displayed message LCD 1 Display the screen on the right in a...

Page 75: ...ange Performs calibration of the range that is currently displayed Procedure Operation example Setting the calibration range to range interlock Key operation Description Displayed message LCD 1 Displa...

Page 76: ...WN 3 Use the key to select the auto blowdown valid YES Press the key to set the value BLOW DOWN YES NO 4 Press the key BLOW DOWN YES 5 The display returns to the screen on the right SET AUTO BLOW BLOW...

Page 77: ...y operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key BLOW DOWN MENU SET AUTO BLOW 2 Press the key The date an...

Page 78: ...ordance with the key op eration summary and press the key BLOW DOWN MENU SET AUTO BLOW 2 Press the key to display the screen on the right and press the key The auto blowdown cycle setting screen appea...

Page 79: ...summary and press the key BLOW DOWN MENU SET AUTO BLOW 2 Press the key to display the screen on the right and press the key The procedure for setting blowdown time screen appears SET AUTO BLOW BLOW DO...

Page 80: ...operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key the manual blowdown performing screen appears BLOW DOWN ME...

Page 81: ...tion is overwritten by a new one Procedure Operation example Displaying an error log on the screen Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with...

Page 82: ...e exceeds the specified range 800 C 70 C Span gas Error The concentration of the calibration span gas being supplied is not stable In a discrimination treatment of stability the error of 0 2 or more c...

Page 83: ...mmary and press the key MAINTE MENU ERROR LOG 2 Use the key to select the error log clear screen ERROR LOG DISP CLEAR 3 Press the key to clearing error logs However it has not been deleted yet CLEAR E...

Page 84: ...in accordance with the key op eration summary and press the key MAINTE MENU ALARM LOG 2 Use the key to select the alarm log display screen ALARM LOG DISP CLEAR 3 Press the key the latest alarm log ap...

Page 85: ...nd press the key MAINTE MENU ALARM LOG 2 Use the key to select the alarm log clear screen ALARM LOG DISP CLEAR 3 Press the key to perform clearing alarm logs However it has not been deleted yet CLEAR...

Page 86: ...nd press the key the manual sensor check performing screen appears MAINTE MENU SENSOR CHECK 2 Supplying atmospheric air or air from cylinder manually 1 5 0 5 L min SENSOR CHECK START 3 Press the key t...

Page 87: ...lay the screen on the right in accordance with the key op eration summary and press the key the maintenance mode setting screen appears MAINTE MENU MAINTENANCE MODE 2 Use the key to select the mainten...

Page 88: ...The factory set password is 0000 An authorized person should manage the set password for remembrance sake Settable value 4 digits from 0 to 9 Procedure Operation example Setting to change from old pas...

Page 89: ...eatment setting maintenance hold You cannot use PID auto tuning with auto calibration or automatic blowdown at the same time Procedure Operation example Execute PID auto tuning from the screen Key ope...

Page 90: ...edure Operation example Setting the current date and time to 13 00 2015 02 25 Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration su...

Page 91: ...imum calculations of O2 by contact input Switch OFF to ON to perform calibration 8 OUTPUT RANGE Switches the range by contact input OFF ON Range 1 Range 2 Note The functions other than NONE cannot be...

Page 92: ...hen an LL limit alarm occurs 6 H L ALARM Alarm contact output is performed when an high or lower limit alarm occurs 7 HH LL ALARM Alarm contact output is performed when an HH or LL limit alarm occurs...

Page 93: ...the key op eration summary and press the key PARAMETER MENU OXYGEN ALARM 1 2 Use the key to select the oxygen concentration high limit value setting screen and press the key OXYGEN ALARM 1 HIGH ALARM...

Page 94: ...ith the key op eration summary and press the key PARAMETER MENU OXYGEN ALARM 1 2 Use the key to select the oxygen concentration lower limit value setting screen and press the key OXYGEN ALARM 1 LOW AL...

Page 95: ...y op eration summary and press the key PARAMETER MENU OXYGEN ALARM 1 2 Use the key to select the oxygen concentration HH limit value setting screen and press the key OXYGEN ALARM 1 H HIGH ALARM 3 Use...

Page 96: ...the key op eration summary and press the key PARAMETER MENU OXYGEN ALARM 1 2 Use the key to select the oxygen concentration LL limit value setting screen and press the key OXYGEN ALARM 1 L LOW ALARM...

Page 97: ...ysteresis for alarm condition of oxygen concentration to 20 Range 1 Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and...

Page 98: ...r alarm check set the percentage of the range compared to the full scale as hysteresis width see the figure below This is common among HH limit value High limit value Lower limit value and LL limit va...

Page 99: ...Operation example Setting the analog output hold function to valid Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and...

Page 100: ...tting value Held at the value set as the 10 5 11 Setting of hold setting val ue maintenance hold Procedure Operation example Setting the output value of analog output hold to 0 Key operation Descripti...

Page 101: ...ntenance hold Settable range 0 to 100 Procedure Operation example Setting the output value of analog output hold to 000 Key operation Description Displayed message LCD 1 Display the screen on the righ...

Page 102: ...ription Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key PARAMETER MENU AO HOLD MAINTE 2 Press the key to display the screen on t...

Page 103: ...n Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key PARAMETER MENU AO HOLD ERROR 2 Press the key The analog output hol...

Page 104: ...ng value Held at the value set as the 10 5 15 Setting of hold setting val ue error hold Procedure Operation example Setting the output value of analog output hold to 0 Key operation Description Displa...

Page 105: ...and 100 is to the full scale value 20 mA 1 V Settable range 0 to 100 Procedure Operation example Setting the output value of analog output hold to 000 Key operation Description Displayed message LCD...

Page 106: ...see the screen transition and set values Procedure Operation example Setting the key lock to valid Password is assumed to be 0123 Key operation Description Displayed message LCD 1 Display the screen...

Page 107: ...acklight is not turned off Settable range 0 to 99 min Procedure Operation example Setting the time for automatically turning off the backlight to 10 minutes Key operation Description Displayed message...

Page 108: ...Setting the station number to 01 Key operation Description Displayed message LCD 1 Display the screen on the right in accordance with the key op eration summary and press the key PARAMETER MENU STATI...

Page 109: ...ith the key op eration summary and press the key PARAMETER MENU A OUT ADJUST 3 Press the key The analog output 0 adjustment screen appears A OUT ADJUST ANALOG OUT 0 4 Adjust the analog output with the...

Page 110: ...RAMETER MENU A OUT ADJUST 3 Press the key The analog output adjustment screen appears A OUT ADJUST ANALOG OUT 0 4 Press the key Press the key The analog output 100 adjustment screen appears A OUT ADJU...

Page 111: ...combustion efficiency Using the following formula calculate the combustion efficiency E Combustion efficiency E 100 Fuel coefficient k Temperature of flue gases K Standard oxygen concentration value v...

Page 112: ...en Description You can input the password for authorization authentication in this screen in order to execute the fac tory setting menu Customers cannot execute the factory setting menu This password...

Page 113: ...102 INZ TN2ZKMA E 11 SPECIFICATIONS 11 1 Specifications...

Page 114: ...103 INZ TN2ZKMA E...

Page 115: ...104 INZ TN2ZKMA E 11 2 Code symbols Converter...

Page 116: ...105 INZ TN2ZKMA E Detector...

Page 117: ...106 INZ TN2ZKMA E Ejector Exclusive cable...

Page 118: ......

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