ZIRCONIA OXYGEN DETECTOR SERVICE MANUAL
Contents
1. APPENDIX TABLE 2 ZFK 3 4 7 Zirconia oxygen Analyzer Detector Output characteristic internal sensor 960 OUTPUT mV 960 OUTPUT mV 0 01 168 57 7 0 24 21 0 02 153 3 8 0 21 27 0 03 144 36 9 0 18 67 0 04 138 02 10 0 16 35 0 05 133 1 11 0 14 25 0 1 117 83 12 0 12 33 0 2 102 56 13 0 10 57 0 3 93 62 14 0 8 93 0 4 87 28 15 0 7 41 0 5 82 36 16 0 5 99 0 6 78 35 17 0 4 66 0 7 74 95 18 0 3 40 0 8 72 01 19 0 221 0 9 69 41 20 0 1 08 1 0 67 09 20 6 0 4238 2 0 51 82 21 0 0 3 0 42 88 22 0 1 025 4 0 36 54 23 0 2 005 5 0 31 62 24 0 2 943 6 0 27 61 25 0 3 84 E OUTPUT mV 50 74 log 21 0596 Fuji Electric Co Ltd 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 fujielectric com products instruments2. Service Manual Lu gt Of x RU 2 og Or CC Lu NO MANUAL TYPE ZFK 3 4 7 TN5A0281a E Fuji Electric Co Ltd CONTENTS 1 PREFACE m 2 MEASUREMENT PRINCIPLE etiem tmr vetet to fete PIS TME N eee 3 1 Zero Air Adjustment Aude hited Be Se ntl edn Ween 3 2 See tee ene dt e reU dr derer ue krets 4 TROUBLE CHECK SHEET iere n e Rh It rao doe ede DK DU RR CM RU PER DER D REPAR nce APPENDIX Wiring Deg EN sved AE Output characteristic 1 1 PREFACE This service manual explains repair and adjustment procedure of the Zirconia oxygen detector ZFK 3 4 7 as a single unit This manual is intended for use with the instruction manual INZ TN4ZFK3 2 MEASUREMENT PRINCIPLE ia ili i i ic i igh Insulatin When yttria stabilized zirconia ceramic is heated to high Heater Insulating Casing temperature only the oxygen ion becomes a movable solid Filter electrolyte In a zirconia element the both sides of which are fitted Air Pi with a platinum electrode the electrode reactions in the followi
3. Item 1 Remove the 2 screws fixing the sensor case from the bottom of the main unit and remove the sensor 3 Remove the 3 M4 screws fixing the sensor c 4 case from the top 5 Assemble a new sensor in reverse order of disassembly 3 Replacement of the printed board ZFK 3 4 1 2 Follow the procedure in Item 1 3 printed board 4 calibrate zero span 4 Replacement of the temperature controller 1 2 Follow the procedure in Item 1 Remove the 8 wires connected to the terminal block of the printed board and 3 screws fixing the Assemble a new printed board in reverse order of disassembly Perform energization and running to 3 Remove the 2 screws from the top of the temperature controller and the socket from the backside and pull out the controller forward 4 Assemble a new temperature controller in reverse order of disassembly 5 Replacement of the constant voltage power supply ZFK 3 4 1 2 Follow the procedure in Item 1 3 Remove the 5 wires and the 2 side fixing screws connected to the upper terminal block of the constant voltage power supply g and remove the constant voltage power supply 4 Assemble a new constant voltage power supply in reverse order of disassembly Fig 3 5 kb Printed board ZFK 3 4 Solid relay ZFK 7 f controller g Constant voltage power supply ZFK 3 4 Not mounted on ZFK 7 Internal diagram of the ox
4. zero gas for 2 to 3 minutes adjust the indication to 0 1mV by VRZ on the printed board ZFK 3 4 For ZFK7 make sure that the indication is within 3mV No adjustment 3 2 Span Adjustment 1 Feed the span gas 1 to 2 at the specified flow rate 2 After the indication is stabilized adjust it by VRS ZFK 3 4 Find the adjustment value using the following expression E Output V 0 3812 x log 21 Px Px Calibration gas concentration Example In case of 1 1 E 0 3812 x log 21 1 1 0 488 Make an adjustment with the VRs control so that 0 488 is obtained Span VR Zero VR VRS VRZ Vg PUE E 5 ws 5 Q 12 6 8 2 2 Ov e 1 Dee PM ee 28838 ONNNN 3 L a d tc CT 5 Hm Fig 2 Printed board mounting diagram ZFK 3 4 For ZFK7 make sure that the indication is within 50 to 70mV when the gas with concentration of I to 2 O N gt is flowed Refer to Appendix Table 2 No adjustment 4 TROUBLE CHECK SHEET Phenomena Cause Checking methods normal value Protective measures Slow response Sensor element Change over between zero and span Replace deterioration gas and check if 60 seconds or longer is needed for 90 response Sample gas is not supplied or output is abnormal Sensor outlet is clogged with crystallized sulfate Visually check for clogging of the outlet of the gas introduction case Remove t
5. he clogging Replace with a gas introduction case mist provided with gas outlet pot Output is unstable ZFK 3 4 Check if the connector is Repair Disconnection of connector or poor contact disconnected or move the connector part to check for the indication change Disturbance noise Check if output is hunting Eliminate noise Sensor element deterioration Flow zero span gas continuously for 10 minutes or so and observe the indication status Replace the sensor element Output is not deflected or remains the same Fuse is blown out or Check the fuse and the supply Replace the fuse or power is not voltage specification check the power supply supplied ZFK 3 4 Check if the connector is Repair Disconnection of connector or poor contact disconnected or move the connector part to check for the indication change Sensor is defective Change over between zero and span gas and check for the indication change Remove one end of the sensor terminal block 3 4 and check for continuity The range should be within 2 to 3 Q Replace the sensor element Solid relay is defective When 24V DC is applied to the outer end 7 8 check if AC power between 1 2 on the sensor element is turned on or off Check with a tester Replace the printed board or the solid relay Printed board is defective Change over between zero and span gas a
6. nd check if the voltage value between the sensor outer end 5 6 indicates as shown below Air 3mV or lower 1 to 2 7 5 50 to 70mV Replace the printed board or the solid relay or sensor element ZFK 3 4 Constant voltage power supply is Check if the CN2 of the constant voltage power supply indicates 12 0 1V Replace the constant voltage power supply defective Temperature Check if the temperature indication is Replace the temperature controller is constant in a range of 800 5 C controller defective Output swings Measuring range is Flow measured gas after zero span Review the over exceeded calibration specifications 5 REPAIR 1 Replacement of the sensor element 1 device is operating install an oxygen meter by bypass piping Leave the device for about 30 minutes till it cools down 2 Remove the case cover a 3 4 Change the measuring gas line to the Air atmosphere and then turn off the power switch When the Remove the 6 wires connected to the sensor terminal block b and the 3 M4 screws fixing the sensor Pull out the sensor d from the sensor case e and assemble the new sensor in reverse order of disassembly After wiring is checked perform energization and running to calibrate zero span When replacing the sensor element also replace the packing with a new one 2 Replacement of the sensor case 1 2 Follow the procedure in
7. ng expressions occur for the oxygen concentrations P and P5 P gt P sm Electrode of P side O2 4e gt 20 negative electrode es T Electrode Zirconia element Electrode of P5 side 20 gt 4e positive electrode Fig 1 Detector structure That is the oxygen ion moves from the side where oxygen concentration is higher to side where it is lower This energy for moving the ion generates the electric force E indicated in the following expression P 05 in V 4F P O gt Coefficient 50 74 is the value when the 182 o 50 74 log P 02 mV at 800 C zircornia element is 750 C The sensor unit becomes 750 C with 800 C temperature E Electric force control Oz Comparative Air oxygen concentration P5 O2 Oxygen concentration in the measured gas R Gas constant 8 3144 J moC K T Absolute temperature F Faraday constant 9 649 x 10 c mot Therefore unknown oxygen concentration O5 can be calculated from the electric force E 3 ADJUSTMENT 3 1 Zero Air Adjustment 1 Remove the 3 screws fixing the case cover 2 Feed the zero gas Dry Air through the sample gas inlet on the lower side of the main unit at the specified flow rate 0 5L min 3 After the voltage indication between the external terminals block 4 and 5 the terminal block on the front panel 7P is stabilized feed
8. ygen analyzer APPENDIX Wiring Diagram RT ZFK3 4 ar I Power supply OQ F 3A 7 M 85 to AC 85 to 265V AC Temperature 11 10 7 controller Approx 8mV 800 C Sensor mV 85 to 265V AC Oz Sensor O O O O AC 12V 0 IE zi TL 1816 100 to 115V AC voltage IN or power DC POWER ei ZFK 200 to 220V AC supply SUPPLY CN3 Amp P C B 22 6 7 RH 518 als C Temperature alarm Output When the setting value 800 C is exceeded Main power Temperature by 20 C supply alarm Output ZFK7 I 200 to 240V AC for CE compatible types __ Power supply O2 Sensor 100 to 115V AC ZFK or 200 to 220V AC Temperature alarm Output APPENDIX TABLE 1 ZFK 3 4 Zirconia oxygen Analyzer Output characteristic table ZFK 3 4 output 9605 OUTPUT mV 9605 OUTPUT mV 0 05 1000 12 0 92 7 0 1 885 3 13 0 794 0 5 618 8 14 0 67 1 1 0 504 0 15 0 55 7 2 0 389 3 16 0 45 0 3 0 3222 17 0 35 0 4 0 274 5 18 0 25 5 5 0 237 6 19 0 16 6 6 0 2074 20 0 8 8 7 0 181 9 21 0 0 0 8 0 159 8 22 0 7 7 9 0 140 3 23 0 15 1 10 0 122 8 24 0 22 1 11 0 107 1 25 0 28 9 E OUTPUT V 0 3812 log 21 02
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