INFRARED GAS ANALYZER
Contents
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3. FC Service Manual INFRARED GAS ANALYZER TYPE ZRE Fere I o ie o o Fuji Electric Co Ltd INZ TN5A0354a E PREFACE This service manual describes the infrared gas analyzer Type ZRE This service manual is intended for use with the instruction manual to help you in understanding maintenance and inspection for the infrared gas analyzer ZRE However the basic operation of the analyzer is not covered in this manual This manual provides information about the parameter settings in the factory mode adjustment and precautions for parts replacement and troubleshooting for the infrared gas analyzer ZRE which are not covered in the instruction manual This service manual gives you useful hints to take immediate remedy for after sales service e First read the instruction manual and service manual carefully until an adequate understanding is acquired and then proceed to installation operation and maintenance of the gas analyzer Wrong handling may cause an accident or injury e The specifications of this analyzer will be changed without prior notice for further product improvement e Modification of this gas analyzer is strictly prohibited unless a written approval is obtained from the manufacturer Fuji Electric will not bear any responsibility for a trouble caused by such a modification Manufacturer Fuji Electric Co Ltd Type Described in Fuji Electric s company nameplate on main frame Date
4. 1 Set CO concentration to span calibration concentration set value 2 Perform span calibration by using the operation key TN5A0354 E 21 2 Output Method for span calibration by check gas The method for span calibration by use of check gas give in 2 is explained based on the example Since span calibration has an error of calibration curve preset a calibration indication on the calibration curve graph attached to this analyzer for indirect calibration 1 The following calibration curve graph is attached to the test results for the product In graph the calibration curve by the scale gas that is similar to plant gas and determines scales of this analyzer and the calibration curve by the check gas that is adjusted by the scale gas gas of simple composition of N balance gas to facilitate the analyzer check are drawn Calibration curve by 1 0V scale gas 22 composition of plant 9 lt gases pi LILLLAM 0 8 7 M m LX Tu d us Calibration curve by Z check gas 74 N2 balance gas 0 6 Z When supplying m 0 5 7 instruments adjusted 0 4 Vi 2d composition 0 0 0 1 02 03 04 05 06 07 08 09 1 CO2 Measuring gas concentration 0 89 CO gt Calibration curve graph attached to the product 2 When using 0 95 CO and remainder N check gas as calibration gas 0 9596 In graph a point of 0 95 on X axis should be stretched upward draw a line toward Y axis from the cross p
5. 2 Setting change items 1 Zero limit e Function Switches measured concentration values below zero to either display or no display mode e Operation method Changes the setting in Factory mode 12 Others and Zero limit Factory mode initial screen The cursor is in 12 Set values are inverted by pressing the En key 7 Mode Select an item thers when the cursor is aligned with the Zero limit 29 th key ZERO limit Switch between ON and OFF by the A or e ey hans indt Establish the setting contents by pressing the A0 No Language If you don t want to establish the contents press the Es ZERO gas 77 Protocol key Var ied Range DIO No e Setting contents Factory Mode OFF does not display and output values below zero Others ON displays and outputs values below zero ZERO limit e Initial value OFF default Disappear MM limit Language ZERO gas Cylinder Protocol MO Varied Range ON DIO No 0 This mode is used at the time of adjustment in order to check a display If the minus display Zero limit is set to Appear be sure to return the lock to OFF after adjustment TN5A0354 E 13 2 Range limit e Function Measured concentration values used for O correction or moving average computation can be switched to either with limiter upper limit 110 F S or without limiter the g
6. DANGER CAUTION and PROHIBITION D D AN G E R Wrong handling may cause a dangerous situation in which there is a risk of death or heavy injury Wrong handling may invite a dangerous situation in which there is a N C AUTION possibility of medium level trouble or slight injury or only physical damage is predictable SN PROHIBITION Items which must not be done are noted Caution on installation and transport of gas analyzer D DAN G E R e This unit is not explosion proof type Do not use it in a place with explosive gases to prevent explosion fire or other serious accidents e For installation observe the rule on it given in the instruction manual and select a place where the weight of gas analyzer can be endured Installation at an unsuited place may cause turnover or fall and there is a risk of injury e For lifting the gas analyzer be sure to wear protective gloves N C AUTION Bare hands may invite an injury e Before transport fix the casing so that it will not open Otherwise the casing may be separated and fall to cause an injury e During installation work care should be taken to keep the unit free from cable chips or other foreign objects Otherwise it may cause fire trouble or malfunction of the unit V TN5A0354 E Caution on piping In piping the following precautions should be observed Wrong piping may cause gas leakage If the leak
7. 6 PARIA LNO bo e 20206 ene EO S Z N E ENYN 9217 212 ZNO o Hoz PJeoq pno ROSE Z ov LI o LO Pajuud Oly SNO JAS gt ZNO T r LZerS 928601 8NO S 9 ejqeo ed INO ONO Gummy Burgoueig l m 9005 9 LAL9ZLINZAL ML yoyms 1 MOd 5 2 F 2 309901 P26L02A1 5 pus C er be JN Aiddns smog 020 0251 T a 9 9 S9 pe6r NO ENQ ZNO eiqeo 66666 126 ders 9g mi MEA ldu 128YS928601 INS 000 0000 00000 8105 ele 02 1842311 SIGNAL seee A lli Teman pJeoq pejuud eiqe2 LOEZ64INZ9 eie 5 qqe O44 parent i 200 m a1qey d Es EAU ZNO ZEPS 28601 jeuieix3 teen 000 Es bee 3 6TS928861 00990000009 eie NO OE ZNO 6 1 820 1 e oz lqeEo LZL8INZL pJeoq no H 8262INZ311 206156 1 1 eu 9LNO pueog paund asn ereonvxD yun eydsiq m l ee O p luud ureyy OL yun fey n F SIM 162 12679928601 LO yg 101 INO qoru 7 02 1929 9igeo pJeoq noo pejuud 6010 spyeoq jnouro pejuud Old PU 2010 LOIG 9919S TN5A0354 E 2 Internal piping diagram and optical layout r Sample gas outlet 1 Sampling gas inlet 1 Purge inlet uni Sample gas outlet 2 i
8. E Sample gas inlet 2 eS y Rear face 1 Optical block 2 a Light source unit No 3 No 2 No 4 Fa 4 No 1 Built in 9 Oz analyzer Optical block 1 a m Flovv checker 2 Flow checker 1 Front face Correspondence of measured components and measuring units Measurable components Single component NO SO CO2 CO CH4 Measuring element 1 Each measurable component Measuring element 2 None Double component COs CO CO2 CO None Double component NO CO NO SO2 NO NO CO 502 Three component NO SOs CO NO SO2 CO Four component NO SO2 CO2 CO TN5A0354 E SO CO 2 MAINTENANCE AND INSPECTION AND REPAIR AND ADJUSTMENT AT REPLACEMENT OF MEASURING UNITS 1 Light source e Recommended period of replacement 5 years lt Motor unit for light source gt e 1 Error mode Error mode 1 Short circuit in and disconnection from the light source electrically heated wire Phenomena Scale out indication of analyzer Error 1 occurs Check Turn OFF the power of the analyzer and remove the power cable connected to the light source Measure resistance between 2 pin terminals at the light source and the resistance value must be 370 220 If resistance values are infinite the light source may be broken As the resistance value is decreased the indication will be drifted in the minus direction Error mode 2 Sealed gas in light source leaks Phenom
9. be supplied Since measurement in a heat treatment furnace has much gas of such composition it is considering as the adjustment for heat treatment furnaces In order to perform exact measurement there are two methods in span calibration Composition of the standard gas for span calibration used for each method and its method are explained using an example For the standard gas for zero calibration use dry N in any case so that zero point will not be affected Example Assume that a 0 1 CO meter of the infrared ray gas analyzer measures CO contained in plant gases When plant gases are composed of 0 5 CO 23 CO 30 H 0 2 CH and 46 3 Nb either of the following is used as the span calibration standard gas Standard gas type Composition of standard gas Method for span adjustment 1 Standard gas with the same 0 9 to 1 CO Perform span calibration composition as plant gases 23 CO 30 H remainder is N directly scale gas 2 Check gas 0 9 to 1 CO Perform span calibration remainder is N indirectly A small amount of gas like 0 2 CH with little effect on span calibration may be excluded from the standard gas 1 Method for span calibration by standard gas with the same composition as plant gas When using the standard gas with the same composition as plant gases given in 1 calibration can be performed without correction as an error in calibration curve does not occur
10. board 12 Power supply terminal block 27 Main print board 13 Power supply 28 AIO print board 14 Key unit 29 DIO print board 15 LCD 30 USB print board TN5A0354 E 2 Measuring element y i di S o Part No Part name Part No Part name 1 Light source unit 8 Cell fixing block 2 Base plate 9 Block cell ass y 3 Pipe cell ass y 10 Window ass y 4 Window ass y 11 O ring 5 O ring 12 Gas filter 6 Pipe cell 13 Filter 7 Cell mounting 14 Detector unit TN5A0354 E 3 Connection of parts 1 Wiring diagram ad oneuBeurejed 10 ad il o1uenjeb joejes jeuondo Josuas zO 5 O96ZWZYL 2E88HYAL NO A s3 d jeooiueAeo d oneubeueseg
11. P10 CH3 Analog output selection Amplifier board CNI To main board TP1 After AC amplifier amplified 0 8V 35000 counts to 1 25V 55000 counts DV1 Detector voltage SC TP1 Ground GND DVI Ground JP1 Resistance mounting for gain adjustment JP2 Resistance mounting for gain adjustment A 4 TN5A0354 E 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 instruments
12. ads about 0 V with zero gas and 0 5V to 1V with span gas If no change in voltage is made with zero and span gases detector can be damaged Replace detector Tum OFF the analyzer main unit Since the O detector case is common to the 0V line be careful when installing it avoid contacting the analyzer main unit case and O detector case Generally an insulation mounting plate is supplied e Adjustment after replacement Zero and span calibration GND Main board CN16 No 2 Main board CN16 No 1 TN5A0354 E 6 Printed circuit board see printed circuit diagram at the back of the manual 1 Main board see Appendix 3 e Check Voltage check Check terminal Check voltage Contents TPVCI TPGI 5 10 3 V Digital 5 V TP15 TPG1 15 40 5 V Analog 15 V TPN15 TPGI 15 0 5 V Analog 15 V TPVHI TPGI 3 3 10 2 V Digital 3 3 V TPVL1 TPGI 1 25 40 1V e Precautions on replacement e The main board is set according to the specifications of each analyzer When ordering notify instrument serial number So the main P C B has suitable parameter in it e Do not remove or plug the connector from or into the board with the power ON or electronic parts may be damaged Before replacement be sure to turn OFF the instrument e Adjustment after replacement After replacement check for the voltage shown above Perform contrast adjustment while viewing the LCD Determine an easy to see heig
13. and replace it with a new one e Check after replacement Check the power supply voltage on the main printed circuit board LDA60F 2 Name plate Pin Symbol Voltage 1 V3 15V 2 G2 3 G2 4 V2 15V 5 Gl 6 Gl y VI T5V 8 VI 5V 10 TN5A0354 E 9 Operation Parts e Error mode e Phenomena e Check Allocation of Connector Connector pin Wear on switching Faulty operation Be sure to turn OFF the main unit power supply before inspecting 1 Remove the cable 2 Measure the resistance for connector pin No of switch that does not function with a tester see Allocation of Connector Table 3 Press the switch that does not function to check the continuity Normally it is conductive when pressing the switch and opens when releasing the switch E uh E Switch e Measures e Replacement No 10 pin Cable Replace the operation unit Remove the main board and the main board mounting plate Remove the nut spring washer washer at 4 corners of the operation unit You can now remove the operation unit and replace it with a new one Assemble all the parts in reverse order of disassembly Finally insert the cable into the connector e Check after replacement Check that all keys function TN5A0354 E 11 3 FACTORY MODE 1 How to go to factory mode Point the cursor to 5 To Factory M
14. ature Reference 7 15 sensor 3 voltage Count 65444 56779 66982 85663 6855 44939 44756 44869 C O71 m Co PO O When supplying zero gas dry No 0 Infrared ray component 1 35000 to 55000 No Infrared ray component 2 35000 to 55000 No 2 Infrared ray component 3 35000 to 55000 No 3 Infrared ray component 4 35000 to 55000 No 4 Oxygen input 18000 to 22000 If A D data are within the range there is no problem If infrared ray composition 2 3 4 and oxygen do not exist ignore No 1 2 3 and 4 TN5A0354 E 15 2 Calibration coefficient Function Displays calibration coefficient Operation The coefficient initial screen is as shown at right Factory mode initial screen The cursor is in 14 RI and R2 represent span calibration coefficient for range Factory Mode 1 and 2 coefficient Zero calibration coefficient is displayed on the left side of Chi R screen and span calibration coefficient is displayed on the NOx R2 Ch2 RI S02 R2 Ch3 R 002 R2 Ch4 R co R2 Ch5 02 right side How to change numeric value Select a desired item using the A and Y keys Factory Mode coefficient Press the En key to enter the screen of the item Chi RI selected NOx R2 Ch2 Ri S02 R2 Move the cursor in front of the value to
15. be changed using Ch3 R the A or o key and then press the Ex key and am m the value is highlighted co R2 Change the numeric value and move the digits using the 9 a or NA key Establish the setting contents by pressing the En key If you don t want to establish the contents press the s key 16 TN5A0354 E 4 ERROR JUDGEMENT CRITERIA FOR ERROR CODES This section covers the error judgement criteria for error codes For the contents of errors refer to Instruction Manual Error No Contents Criteria Error 1 Light source and data are Detector signals generated due to motor chopping are converted faulty into rectangular waves and rectangular waves are monitored If waves are not generated or irregular an error occurs Error 2 Monitor gitter resistance When the gitter resistance voltage is outside the following range voltage after A D conversion error occurs A D conversion value count can be checked on the A D Data of the Factory mode Monitoring can be performed for No 17 Detector 1 1 No 18 Detector 1 2 No 19 Detector 2 1 and No 20 Detector 2 1 only 3000 x No 17 to 20 x 59999 Error 3 A D conversion signal is Monitor A D conversion reference voltage main printed circuit faulty board When the reference voltage is outside the following range after A D conversion error occurs A D conversion values counter values can be che
16. bration and response Detector unit except for O sensor e Recommended period of replacement 5 years Detector e 1 Error mode Error mode 1 Phenomena Check Error mode 2 Phenomena Check Error mode 3 Phenomena Check e 2 Measures Calibration error and fluctuation in indication Check indication value at zero point Scale out indication of analyzer Error 1 occurs Turn OFF the power of the analyzer and disconnect the Replace detector Sensitivity deterioration due to sealed gas leak Check the indication value for each component on the Sensor Input Value screen in the Maintenance mode If the light source is in normal condition and the cell is free of contamination the counter value indicates 35000 to 55000 when zero gas is supplied If the counter value is below the range sensitivity can be degraded Damage to mass flow detector connector connected from the detector to PC board Measure resistance between J1 J4 and J2 J3 of the amplifier printed circuit board on the detector The measure values must be between 25Q and 600 If the resistance value is fluctuated beyond the specified range the detector element may be damaged Note Do not use measurement instrument that allows a current of 2 mA or more to be supplied when measuring resistance otherwise the element can be damaged Detector voltage control failure Ravel Calibration error and fluctua
17. cked by the counter indication when the Factory mode screen is displayed 35000 x No 15 x 45000 Error 4 Zero calibration is not Infrared component within the allowable range 0 5 lt zero calibration coefficient lt 5 Other than infrared component 2000 lt zero calibration coefficient lt 12000 Error 5 A amount of zero This error occurs in the following condition calibration 1s over 5096 5096 of FS of full scale Zero calibration concentration set value current display Error 6 Span calibration is not When span calibration coefficient is not within the following range within the allowable range error occurs Infrared component 0 1 lt span calibration coefficient lt 10 External input galvanic cell type built in paramagnetic 0 5 span calibration coefficient lt 16 Zirconia oxygen 6000 lt span calibration coefficient x 32000 Error 7 An amount of span This error occurs in the following condition calibration 1s over 5096 5096 of FS of full scale Span calibration concentration set value current display Error 8 Measured values fluctuate Check if measured values fluctuate excessively during calibration to much during zero and Infrared component paramagnetic oxygen span calibration If measured values are not stabilized 1n 60 seconds change of more than 100 counts 1s continued Zirconia oxygen If measured values are not stabilized in 60 seconds change of input voltage is continued by more than 100 E
18. e a gas leaked portion and remedy Check if detector signal is as specified see Detector unit Check the detector 1 Record voltage when zero gas is supplied Amplifier board TP1 2 Check the detector voltage Amplifier board DV1 Check the A D data against the display see Factory mode and A D data Check voltage at the main board Check the switching power supply voltage Record the A D data when Zero gas is supplied No span calibration can be performed Check that span gas concentration and span concentration settings are the same Check that specified amount of span gas is supplied to the analyzer main unit Locate a gas leaked portion and remedy Check that zero calibration can be properly performed If zero calibration can not be performed repeat the procedure 1 No zero calibration can be performed Check if detector signal is as specified see Detector unit Record voltage when span gas 1s supplied to compare with the voltage when zero gas 1s supplied Check the A D data against the display see Factory mode and A D data Check voltage at the main board Check the switching power supply Record the A D data when span gas is supplied Drift Check that specified amount of measured gas is supplied to the analyzer main unit Locate a gas leaked portion and remedy Check that the cell window O ring detector window and cell inside are not contaminated gt Clean the cell and windo
19. eck sector rotation light source motor unit e 3 Replacement To replace the motor unit remove the cable between 2 pin terminals and motor connector Loosen 2 screws that fasten the light source motor unit to the optical base plate e 4 Adjustment after replacement Adjust amp gain and perform zero point and span point calibration 6 TN5A0354 E 3 4 Cell cell window and O ring e Service life Usable unless contamination or corrosion is excessive e Recommended period of replacement 2 years with O ring e 1 Error mode Error mode 1 Phenomena Check Error mode 2 Phenomena Check e 2 Measures e 3 Replacement Contamination of cell mixture of foreign matter and contamination of cell window Scale out indication drift and calibration error occurred to analyzer Disassemble the cell to assure that the inside is clean Crack in cell window No change in indication slow response calibration error and indication fluctuation Perform a visual check of the cell window Cell Clean the inside of the cell refer to the instruction manual for details Replace If the inside is exposed to excessive contamination or corrosion Cell window Clean the cell window Replace if the inside is exposed to excessive contamination For replacement refer to the instruction manual e 4 Adjustment after clean and replacement Adjust amp gain and check zero point and span point cali
20. ena Fluctuated Indication Check If the analyzer output is drifted due to ambient Measure the resistance conditions around the analyzer and other units are between terminals with cables normal except for the light source sealed gas may disconnected leak e 2 Measures If the light source is found defective replace the light source motor unit e 3 Replacement To replace the motor unit remove the cable between 2 pin terminals and motor connector Loosen 2 screws that fasten the light source motor unit to the optical base plate e 4 Adjustment after replacement Adjust amp gain and perform zero point and span point calibration 2 Sector motor and sector Light source motor unit e Recommended period of replacement 5 years as viewed from cell side e 1 Error mode Error mode 1 Motor rotation stop Phenomena Scale out indication of analyzer Error 1 occurs Check With the analyzer power ON check that the shaft is normally rotating as viewed from the motor Error mode 2 Unstable rotation of a sector Phenomena Scale out indication of analyzer Error 1 occurs Indication is fluctuated Check With the analyzer power ON check if unusual noise is generated from the motor due to metal contact If no noise is heard remove the light source motor unit Turn ON the power of the analyzer and check the rotation of motor shaft and sector e 2 Measures If the sector motor is found defective replace the from here Ch
21. f trouble occurs to O sensor sample zero calibration concentration set values together with span calibration concentration set value Check each coefficient by Coefficient in the factory mode Coefficient Component Range value Zero coefficient Span coefficient CHI Range 1 Range 2 CH2 Range 1 Range 2 CH3 Range 1 Range 2 e Sampling system diagram If sampling system diagram is prepared report the diagram If sampling system diagram is not prepared report the sketch For other troubles sample various data about necessary setting items 20 TN5A0354 E 6 ADJUSTMENT IN HEAT TREATMENT FURNACE What is the adjustment in heat treatment furnaces If in plant gases to be measured actually a large amount of other lower molecular weigh gases than nitrogen N2 such as hydrogen H or a large amount of other higher molecular weight gases than nitrogen N2 such as argon Ar are contained including the measuring components it is known that the calibration curve output performance to gas concentration of gas analyzers will be affected pressure broadening In such a case analyzer is adjusted with gases similar to plant gas compositions in manufacturing adjustment by scale gas After this adjustment the analyzer is checked the calibration curve with N balance gas calibration curve by check gas Graphs with these calibration curves drawn are attached to products to
22. ht and adjust contrast Menu mode Parameter contrast Refer to the instruction manual for details of operating method Press the switch to check that all keys are normally operated 2 AIO terminal board Refer to AlO board in Appendix 3 PRINTED BOARD DIAGRAM on the page A 3 e Adjustment after replacement Output check Adjust if output is offset Refer to the instruction manual for details of operating method 7 Liquid crystal display LCD e Service life of parts 5 years e Error mode Deterioration e Phenomena e Check Countermeasures against error Replace LCD LCD is not displayed or the display is dim or flickers Adjust contrast remove or plug the connector Check connection to the main board e Replacement Turn OFF the power Disconnect the connector and replace it with a new one e Adjustment after replacement Adjust the contrast refer to the instruction manual for details of operating method TN5A0354 E 9 8 Power supply e Recommended period of replacement 5 years e Error mode Power down e Phenomena No display and no output e Check Check if short circuit occurs Disconnect the secondary SW power connector Turn ON the power and check the voltage at the connector If no voltage is applied to it replace e Measures Replace the S W power supply e Replacement Turn OFF the instrument power Disconnect the connector from the motherboard
23. ing gas contains a toxic component there is a risk of serious accident being induced Also if combustible gas is contained there is a danger of explosion fire or the like occurring e Connect pipes correctly referring to the instruction manual D D AN G E R e Fxhaust should be led outdoors so that it will not remain in the locker and installation room Exhaust from the analyzer should be relieved in the atmospheric air in order that an unnecessary pressure will not be applied to the analyzer Otherwise any pipe in the analyzer may be disconnected to cause gas leakage For piping use a pipe and a pressure reducing valve to which oil and grease are not adhering If such a material is adhering a fire or the like accident may be caused Caution on wiring e Wiring work must be performed with the main power set to OFF to prevent electric shocks e Enforce construction of class 3 grounding wire by all means If the specified grounding construction is neglected a shock hazard or N CAUTIO N fault may be caused e VVires should be the proper one meeting the ratings of this instrument If using a wire which cannot endure the ratings a fire may occur e Besure to use a power supply of correct rating Connection of power supply of incorrect rating may cause fire Caution on use e For correct handling of calibration gas or other reference gases carefully gt D AN G E R read their instruction manuals bef
24. ircuit between 3 4 Built in paramagnetic type Short circuit between 5 6 External input TPVHI 33v Digital TP3 AD integral waveform TP4 3 3V Backup battery TPVLI 1 25V Digital TPVSI 0v Digital ground TPVC1 5v ON 2 Digital Oxygen input i Optical block 2 1 Optical block 1 1 2 O AUS T oda TPN15 15v f Analog 1 CN4 Program boot 1 CN3 E Key switch signal ke LED4 Power supply check Green blinking normal 1 0v Analog ground Common vvith digital TP2 Motor pulse CNS To AIO board CN2 Screen back light Power supply input Optical block 1 motor Optical block 2 motor TN5A0354 E A 3 Main board JP8 CH 1 Analog output selection Additional AO board 1 Additional AO board 2 Short circuit between 1 2 Current output CN10 External oxygen input IN Short circuit between 2 3 Voltage output CN3 External oxygen input OUT JP9 CN2 To DIO board JP1 to 4 CHS to 8 Analog output selection JP1 to 4 CH9 to 12 Analog output selection JP1 Voltage output selection 1 2 Nonstandard 0 5V or more 2 3 Standard 0 1V or less JP11 CH4 Analog output selection J
25. k Do not touch the instrument wet handed If the fuse is blown eliminate the cause and then replace it with the one of the same capacity and type as before Otherwise shock hazard or fault may be caused Do not use a replacement part other than specified by the instrument maker Otherwise adequate performance will not be provided Besides an accident or fault may be caused Replacement parts such as a maintenance part should be disposed of as incombustibles Others N CAUTION If the cause of any fault cannot be determined despite reference to the instruction manual be sure to contact your dealer or Fuji Electric s technician in charge of adjustment If the instrument is disassembled carelessly you may have a shock hazard or injury vi TN5A0354 E 1 STRUCTURE OF ANALYZER AND NAMES OF PARTS 1 Analyzer main unit External internal TN5A0354 E Part No Part name Part No Part name 1 Case ass y 16 Triple gas port unit 2 Base 17 Gas port unit 3 Front panel ass y 18 Flow checker ass y 4 Angle 19 Galvanic O sensor unit 5 Power supply mounting plate 20 Galvanic O sensor socket 6 Grip 21 Galvanic O sensor plate 7 Magnetic force type O sensor unit 22 Ferrite core 8 Power switch 23 19 inch mounting bracket 9 Pipe fuse 24 Specification name plate 10 Fuse holder 25 ROM historical name plate 11 Noise filter 26 AO
26. nnonnnonnnonn nono noon conocio nn nono nono r rn rr nennen nnns 19 23 Drift sinere O 19 4 Readings are high or low too much ener innen 19 5 Readings are not increased sse ener enne en nne nnnes 19 2 Data sampling at trouble 4 terrere ite cade rre bee cies iege et re e Rie ee ea take ies 20 6 ADJUSTMENT IN HEAT TREATMENT FURNACE 2222 21 1 Method for span calibration by standard gas with the same composition as plant gas 21 2 Method for span calibration by check gas sees enne enne 22 7 Moisture interference adjustment NO SO only essere 23 APPENDIX 1 MEASURING PRINCIPLE DIAGRAM 5 22 222 2 2222 A 1 ii TN5A0354 E APPENDIX 2 SOFT FLOW DIAGRAM AAA AA ree A 2 APPENDIX 3 PRINTED BOARD A 3 ATO board P T A 3 Mainboard etn ene tee dede s asan A 4 Amplifier Board jes d e et lh eee R n te ede A 4 TN5A0354 E ili CAUTION ON SAFETY First of all read this Caution on safety carefully and then use the analyzer in the correct way y y y y e The cautionary descriptions listed here contain important information about safety so they should always be observed Those safety precautions are ranked in 3 levels
27. ode by using the A or A key on the Maintenance Mode screen and enter the En key Then the password input screen appears Enter the password To select setting items set 4 0 4 3 4 Zero Offset 5 Linearization 14 Coefficient are settable with 4 0 4 3 Items 1 2 3 4 5 6 7 8 9 11 12 13 and 15 can be viewed Select digits by the 9 key Change numerical values by using 4 or M key After passvvord entry has been completed press the En key and the Factory Mode initial screen appears e How to select setting item from Factory Mode screen On the Factory Mode screen that appears point the cursor to the item you want by using the 9 A or M key To get access to each setting screen press the En key To return from each setting screen to the initial screen press the Eso key When escaping from the Factory Mode screen to the Maintenance Mode screen press the so key MaintenancelX Select operating item Mode Sensor Input Value Error Log Cal Log Output Adj Other Parameter To Factory Mode t Password 4048 Ge Factory Mode Select operating item PILC Code 10 Memory Access Ch No 11 A D Data Ch Data 12 Others Option 13 Interference Pressure 14 Coefficient Linearization 15 Calculation Temperature Output SW DIO SW 1 2 3 4 5 6 8 9 12 TN5A0354 E
28. of manufacture Described in Fuji Electric s company nameplate on main frame Product nationality Japan OFuji Electric Co Ltd 2008 Issued in February 2008 Request Rev Ist edition April 2011 e t is prohibited to transfer part or all of this manual without Fuji Electric s permission in written format e Description in this manual will be changed without prior notice for further improvement TN5A0354 E i CONTENTS 1 CON TEIN US I A 1 CAUTION ON SAFETY 3 o eere oer AAA ird ela sag A y iv 1 STRUCTURE OF ANALYZER AND NAMES OF 5 1 1 Analyzer main unit External internal ss s s s s s es s s enne enne 1 2 Meas ringelemeht IA ec y n 3 3 Conn ctioniot PS edd Mas tiit Man Lev cde en 4 LEWIS diagram id A A A A A AAA ro epa etuer eq 4 2 Internal piping diagram and optical layout sese enne 5 2 MAINTENANCE AND INSPECTION AND REPAIR AND ADJUSTMENT AT REPLACEMENT OF MEASURING UNITS a decease veces em ee alec des 6 15 ED ERICH ER 6 2 Sector motor arid sector ood e bre decani i e cete b 6 3 Cell cell window and O ring esses eene nnne eere enne nnne 7 4 Detector unit except for sensor
29. oint with the check gas calibration curve From the cross point with calibration curve on the scale gas composition 0 89 or equivalent values can be obtained 3 Set this point 0 89 to the span calibration concentration of the calibration concentration set value 4 Supply 0 95 check gas to perform span calibration Then the concentration value is corrected to 0 89 Measurement suited to actual plants can be performed by this error correction of calibration curve 22 TN5A0354 E T Moisture interference adjustment NO SO only Purpose Procedure Adjust the light control plate in between the three layer detector so that moisture interference becomes close to zero 1 Q 3 4 5 6 7 8 9 To start adjustment set the light control plate at the mi Light control plate same height 10 to 15mm upper than b upper end of Fixi the fixing plate as in the right figure a m e MUR Enter Maintenance mode 1 Sensor Input Fixing plate Flow zero gas and gas contained water of 2 C N2 NO 502 detector balance to read the count value of each gas Respectively replace the read values in NO SO component of Zero with Za and Moisture with Ha Set the light control plate at the same height 1 to 6mm lower than b upper end of the fixing plate as in the right figure c Flow the gas in the same manner in 3 to read the count value of each gas Respectively replace
30. orehand Otherwise carbon monoxide or other hazardous gases may cause an intoxication particularly e Before leaving unused for a long time or restarting after left at such a status for an extended length of time follow the directions of each instruction manual because they are different from normal starting or N C AUTI ON Anido Otherwise the performance may be poor and accidents or injuries may be caused e Do not operate the analyzer for a long time with its door left open Otherwise dust foreign matter etc may stick on internal walls thereby causing faults TN5A0354 E V Caution on use S PROHIBITION Do not allow metal finger or others to touch the input output terminals in the instrument Otherwise shock hazard or injury may occur Do not smoke nor use a flame near the gas analyzer Otherwise a fire may be caused Do not allow water to go into the gas analyzer Otherwise hazard shock or fire in the instrument may be caused Caution on maintenance and check lt gt DANGER When doors are open during maintenance or inspection be sure to purge sufficiently the inside of the gas analyzer as well as the measuring gas line with nitrogen or air in order to prevent poisoning fire or explosion due to gas leak N CAUTION Be sure to observe the following for safe operation avoiding the shock hazard and injury Remove the watch and other metallic objects before wor
31. raph within the panel e Operation method Changes the setting in Factory mode 12 Others and Zero limit Factory mode initial screen The cursor is in 12 When the cursor is in front of the Range limit press the Factory Mode Select an item Others Ex key and the setting value is highlighted Switch between ON and OFF by the A or Y key ZERO limit and establish the setting contents by pressing the Ex Range limit AO No key Language ZERO gas Cylinder Protocol Varied Range DIO No e Setting contents Factory Mode ON Calculates up to 11096F S Others OFF Calculates up to the graph is within the panel ZERO limit ijs Range limit e Initial value ON AO No Language ZERO gas Cylinder Protocol MO Varied Range ON DIO No 0 14 TN5A0354 E 3 Setting value reference items 1 A D data e Function Measures the counter readings immediately after A D conversion e Operation To measure the counter readings press the EN key on the Factory Mode initial screen Factory mode initial screen Chi input Temperature 6 Crd The cursor is in 12 value sensor 4 j Ch2 input Temperature 17 Gitter 1 2 value sensor 5 Es Ch3 input Gitter 1 1 Gitter 2 2 value Ch4 input Gitter 2 1 Gitter 3 2 value Factory Mode A D Data Ch5 input Gitter 3 1 Gitter 4 2 value sensor 1 sensor 2 Temper
32. rror 9 Calibration is abnormal Error corresponding to No 4 to No 8 occurs during auto calibration during auto calibration Error 10 Output cable connection is Error occurs if no response is made from the digital output IC improper TN5A0354 E 17 Main portions to be checked during error Error No Main portions to be checked Error 1 Sector rotation light source and detector signal on amplifier printed circuit board Error 2 See service manual No 17 to 20 in 1 A D data on the page 15 Connecting part between detector amplifier board and main printed circuit board cable connector Error 3 No 15 of A D data in factory mode Voltage between TPVH1 TPG on main printed circuit board Error 4 See service manual 5 1 No zero calibration can be performed Error 5 Error 6 See service manual 5 1 No span calibration can be performed Error 7 Error 8 See service manual 5 1 Zero calibration and span calibration can not be performed Error 9 Error 10 Contact portions between digital output printed circuit boards plug in connector Contact portions of digital output printed circuit board and AID board cable 18 TN5A0354 E 5 TROUBLESHOOTING AND DATA COLLECTION 1 Countermeasures against trouble 1 3 4 5 No zero calibration can be performed Check that a specified amount of zero gas is supplied to the analyzer main unit gt Locat
33. the read values of Zero with Zb and Moisture with Hb Calculate the Zero point Zx count value 1f possible as following Zx E x Ha Za x m Zb Za Hb Ha Move the light control plate up and down while flowing zero gas and adjust its position so that the value becomes equal to Zx calculated in 6 When the position of the panel is set fasten it with fixing screw After Zero Span calibration flow water of 2 C and check that a deviation is within 1 FS After confirmation in 8 perform paint lock of the fixing screw of the light control panel TN5A0354 E 23 APPENDIX 1 MEASURING PRINCIPLE DIAGRAM Principle Diagram of Infrared Type Measurement NO SO CO2 CO CH4 Front expansion chamber Gas inlet Gas outlet Infrared ray 1 A light source n il il l Rear expansion E chamber Detector Geo Mass flow Motor KO Measurement cell sensor 1 Preamplifier Output Signal processing block Principle Diagram of Magnetic Force Type Measurement O Mirror Permanent magnet Gas inlet gt Measurement cell Magnetic field 5 T T y Gas outlet E Preamplifier Permanent magnet Light emitting diode Photodiode Signal processing 2 and calculation block Ou
34. tion in indication OOOOOOOO Check amplifier board and measure voltage betvveen DV1 GND of the terminal 000000 It is normal if the value is within 0 4 of the voltage V 000 CO L specified on the label Voltage TN5A0354 E 5 e 3 Replacement e When a cell is a block cell remove the light source motor unit The light source motor unit and block cell are screwed to the detector Unscrew the detector and then the light source motor unit and block cell can be separated from the detector After that unscrew the block cell side the block cell can be separated from the detector Install a new detector in reverse procedure of removal Caution Mount the detector in parallel with the cell window and the block cell so as not to cause poor sealing When a cell is a pipe cell the detector is screwed to the rear of the optical base plate First remove the base plate and then unscrew the detector Install a new detector in reverse procedure of removal e 4 Adjustment after replacement Zero and span calibration Built in Oz detector paramagnetic e Error mode e Phenomena e Check e Measures e Replacement Damage to O detector O detector indication is at O and O detector will not even respond to span gas Check of O input voltage Remove the O sensor cable CN16 on the main board and apply a digital voltage meter between the connector 1 2 and then check that it re
35. tput Principle Diagram of Galvanic cell Type Measurement O Resistor Thermistor Electrolyte Negative electrode Diaphragm Positive electrode TN5A0354 E A 1 SOFT FLOW DIAGRAM APPENDIX 2 pjou y Sulinp peddois si uoieyndwog JUIOd Ss ye lpul y BM ASUSIS 1 lON TN5A0354 E Josues enje JeuBig 4 H AUO q v snoeugjuejsu uone naje OV AL O uonesueduioo eunjeJeduie O od Josues Aeyds q Aeyds q o gt jueuleAouJ enjeA oDeJoAvy uone no e O V snosuejuejsuy UOne n E O v AL O AL 0 9d 9d uoneJqieo uone nojeo uogenony 1104 ueds euBis 3ndui fe dsiq eDeJoAy 20 uone q leo ezueeur juod ouaz 2161 qv 10989A J9 9UI ZO 61 2 snoeuegjuejsu uonejno e O v AL O 14210 od uonesq leo 1 uonesueduJoo uonesuedujoo uonenjonj uoneJqueo uoneJqueo eJnjeJeduje euis yndul Aeyds q uoneEiq leo 9zueaur yulod ueds yulod ueds julod oJez julod oJez q l jeybig H AUO q v Jopajeg ZAEAX IX Hx ttt jueuoduJoo ei paeJeJju anjea 1011 Josuas A 2 APPENDIX 3 PRINTED BOARD DIAGRAM AIO board JP3 O analyzer gain switchover Short circuit between 1 2 External zirconia built in galvanic cell type Short c
36. w Replace parts Readings are high or low too much Check that a large quantity of interference components moisture and CO2 is not contained in sampling gas Check the components contained in measured gases Ask the user what components are contained in measured gas Readings are not increased Check that specified amount of measured gases are supplied to the analyzer main unit Locate a gas leaked portion and remedy Check that zero and span calibration can be performed If possible check for sampling gas related to measured gas and take remedies If not possible check the item 1 and 2 TN5A0354 E 19 2 Data sampling at trouble When trouble occurs be sure to sample the following data In the case of the trouble in connection with the characteristic please sample data please surely sample data to a factory at the time of an inquiry Supply the gas given in Table and sample the measured value of measurement screen sensor input values in maintenance mode Supply gas Gas concentration Span calibration Measurement display Sensor input value in composition concentration set maintenance mode value Zero gas Range Range 2 Span gas Range Range 2 2 C Wet gas Sample gas Range 1 Range 2 If there is no Range 2 the part of a Range 2 is entry needlessness e If trouble occurs to other components sample data for each component e I
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