ref.INZ-TN513328-E
Contents
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3. Zero is read on the O meter and the reading remains unchanged even for the span gas Confirmation of O input voltage Measure the voltage between check terminals TP4 and SC on the main PC board using a digital voltmeter and make sure the voltage is about 0 V for zero gas and 0 5 to 1 V for span gas If the voltage does not change between the zero and span gases the O sensor is damaged Replacement of sensor Turn OFF the analyzer main unit Unplug the O sensor connector Then remove the screws which fasten the O sensor mounting plate to the main frame and separate the O sensor together with the mounting plate The O sensor is fixed by screws from the rear side of the mounting plate So remove the screws to detach the O sensor A new sensor is mountable by reversing the above procedure Adjustment after replacement Zero and span calibration 10 INZ TN513328 E 7 Printed circuit board see printed circuit diagram at the back of the manual 1 Main printed circuit board main board Note The main board is set according to the specifications of each analyzer When placing an order for a replacement PC board notify the serial number of your analyzer in advance so that the new board will have suitable parameters in it e Check Check of circuit voltage Check terminal Adjusting VR Regulated voltage Contents GND1 Vec 5 0 2V Digital 5 V VG1 P15 15 0 5V A
4. 2 Error mode Phenomena Check e Measures 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 e Adjustment after clean and replacement Check of optical balance adjust if significantly deviated and calibration of zero span points and response 5 Detector except for O2 sensor e Recommended period of replacement 5 years 1 Error mode Phenomena Check 2 Error mode Phenomena Check e Measures Detector Damage to mass flow detector ge Scale out indication of analyzer calibration error GND 52 77 PC board TT l Turn OFF the power of the analyzer and disconnect the connector connected from detector to board x F Measure each resistance between GND and S1 on the 7 P PC board of detector and between GND and S2 The 90000000 measure values must be between 250 and 600 If wit red the resistance value is be
5. F UI Service Manual SBUSECriele INFRARED GAS ANALYZER TYPE ZKJ 2 EE Fuji Electric Co Ltd INZ TN513328 E PREFACE This service manual describes the infrared gas analyzer Type ZKJ This service manual is intended for use with the instruction manual to help you in understanding maintenance and inspection for the infrared gas analyzer ZKJ 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 ZKJ 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 Instruments Co Ltd Type Described in Fuji Electric s company nameplate on main frame Date of manufa
6. 0000 128 16128 1 0000 a Lea cmo 128 16128 1 0000 39 Factory Mode Calibration INZ TN513328 E 6 Calculation Factory mode initial screen e Function Displays a screen in which the values The cursor is in 17 under the internal calculation of analyzer can be checked for each gas component e Operation As described below Factory Mode Select component Calculation Select an item by the and Y keys Press the En key for entry into each indication screen D NOx DOZ COZ Co Select a gas component by the 4 and keys Oe Press the En key for entry into the calculation check screen When further pressing the EN key change of the 3 1 1 Eso values will stop The previous status can be restored so Factory Mode ZERO Zero gas by pressing the key Calculation SPAN Span gas NOx ENT Freeze Contents of indication In selection of infrared component Y X Main Y Compo X Y A D conversion input values X Yl After offset X Y2 Scale conversion X Y3 Filter X Y4 Zero calibration for each of Main and Compo X Y5 Span temperature compensation X6 Interference compensation X7 Zero temperature compensation X8 Zero calibration X9 Span calibration X10 Linearization In selection of paramagnetic or external oxygen meter In selection of zirconia oxygen meter X
7. Fixes the calibration value at zero point to 0 ON Makes the calibration value at zero point variable Initial value OFF INZ TN513328 E 21 e Error 10 judgment Function It is settable whether to judge an error Error 10 which occurs if the connection to the input output terminal is abnormal Operation ON OFF selection as in the above item Contents of setting ON Selects Error 10 judgment OFF Avoids Error 10 judgment Initial value ON e Range link calibration coefficient Function The calibration coefficient to be used for calibration can be checked and initialized when range linked calibration is set in user mode calibration setting and calibration range action Operation Operation and screen are described below Press the Eso key for entry into the coefficient check and clearing screen Factory Mode Select an tem Others Under ZERO Disappear FERO val OFF Error1D Check ON B SPAN coefficient ZERO gas Cylinder MODBUS Disable Select a gas component by the and keys EN 1 1 Eso Pressing the En key clears the factor to 1 0000 Factory Mode Select initialized Pressing the 50 key returns display to the Others component previous screen e Zero gas action Function The gas to be used for zero calibration is selectable between cylinder gas and atmospheric air In calibration the calibration contact according to your selection is operated Operation While the indication o
8. Joy 54 1J ldnului oloud 9 2 1617 pieoq 1 ulolN o E 1a190 q Ie9ndo 10 81 46 0 EI yun Ajddns samog 2 I I 1 6 pue sjuauoduoo 566 Jaquunu v YIM S HEA SJ019818p yo Jequinu ayy yooq jeondo puo2 s au JOU s op ydym Jaz jeue ay 104 ae Z ON peoq 31108 pue z yoojq 3109 104 3111205 syed sy z yoolq Ie9ndo 1o A 81 IS2VG1 yun Ajddns samog e SION Japjoy asny INZ TN513328 E 20 Piping diagram OOO Oz sensor Infrared light source side Toaron 06 03 th u i Sample cell 1st optical block Yellow capillary L 20mm 1 Toaron 66 63 N NET y CH1 CH2 Yellow capillary L 10mm Toaron 69 05 L 35 OUTLET He U INLET CH3 CH4 Toaron 09 05 OUTLET 1 N Teflon 06 04 co Sample cell 2nd optical block Infrared light source side 0 indicates a ho
9. both mode again INZ TN513328 E 29 APPENDIX 1 Infrared ray type NO SO CO2 CO and CH4 MEASURING PRINCIPLE DIAGRAM Motor Distribution cell also used as interference files 67 Reference cell Detector Rotary sector 1 I 2 Sector synchronization nfrared light source Sample cell signal single light source Sample gas inlet Sample gas outlet Gain changeover AC voltage amplification ENERO Ozmeter Option A D M RAM CPU ROM Indication R l External input contact output D A block Operation key Indication Output 0to1VDC or 4 to 20 mA DC Paramagnetic type O Permanent Mirror magnet 1 Gas inlet gt Measuring Magnetic field cell Gas outlet Preamplifier Permanent magnet Y Photo diode Emitting diode 1 Signal Display process calculation Output INZ TN513328 E SOFT FLOW DIAGRAM APPENDIX 2 yulod 601 0 1 0100 ue 5515310 1 5515 1 SION anjea uoejnojeo 09102151 O v Vuuoz o y JO Od Alo 0 012210 1 anjen uolyejnojeo obejane BuO ON Vuuoc o y JO Alo 0 uoneolpui 2 uonejnojeo 5 02
10. 50 mV and press the Gi key in about 10 seconds The cursor will move to 100mV Range 7 With the cursor placed on 100mV Range apply 100 mV and press the E key in about 10 seconds The cursor will move to 250mV Range 8 With the cursor placed to 250mV Range apply 250 mV and press the Gei key in about 10 seconds The cursor will return to 50mV Range 9 Press the Eso key and adjustment is completed After adjustment has been completed check that the indication value is within the range of 0 2 mV with respect to the input value when 0 50 and 150 mV is applied to the O input terminal according to 1 Sensor Input Value in the Maintenance mode If the indication is beyond the range repeat steps 1 to 9 Factory Made z Adi Select an item Selection of 02 Zirconia B Input Adj Factory Mode Input mV te Terminal The 1 2 Adjustment 8820 Zero 100m Range ZP Range Adj Span 50 Range elt 100 l V Range V Range Factory Mode Input Om to Terminal The 1 2 Ad ustment Zero B 100m Range 200m Range Adj Span 50m Range 100m4 Range 2901 Range 18 INZ TN513328 E 2 Output adjustment e Function Adjust the zero point and span point The cursor is im i of the analog output to 4 to 20 mA or 0 to 1 V e Operation The Analog Output Adjustment screen is as shown in right
11. Other parameters e Selection of minus indication Factory mode initial screen The cursor is in 13 Function Minus side indication below zero of measured concentration values can be selected or avoided Operation Minus indication selecting screen is shown at right Invert indication of the setting item by the key Factory Mode Select an item Others B Under ZERO Disappear FERO val OFF Error1D Check ON SPAN coefficient ZERO gas Cylinder MODBUS Disable Select Disappear Appear by a and keys En 1 1 Es Press the EN key for determining your setting or deca Factory Mode The value under zero the Eso key for avoiding it Others is disappeared Contents of setting Yes Indicates and outputs the minus side Under ZERO Avoids indication and output of the minus 27 Check ON SC SPAN coefficient ZERO gas Cylinder Initial value Disappear MODBUS Disable This mode is used for checking the indication in adjustment When Appear is set for Minus Indication prior to adjustment be sure to set Disappear after adjustment e Calibration concentration zero variable Function Turn ON this setting when calibration to a value other than 0 is desired in zero calibration and a calibration concentration at zero point will become settable Operation Invert the relevant setting as in the selection of minus indication and select ON or OFF as desired Contents of setting OFF
12. Phenomena Check 2 Error mode Phenomena Check 3 Error mode Phenomenon Check e Measures e Replacement Short circuit in and disconnection from the light source electrically heated wire Scale out indication of analyzer Turn OFF the power of the analyzer and remove the power cable connected to the light source Unplug the CN8 and CN9 connectors on the mother board Make sure a voltage of 19 8 0 5 V is output between pins and 2 of CN8 or CN9 on the mother board Measure the resistance between the terminals of the connector having 2 pins on the light source side The measured value is normally 20 Q 2 Q When the resistance value is infinite cabling is discontinuous As the resistance value decreases the span narrows sensitivity is degraded Sealed gas in light source leaks Fluctuated indication Infrared light source Resistance between these terminals To mother board CNS or CN9 If the analyzer output is drifted due to ambient conditions around the analyzer and other units are normal except for the light source sealed gas may leak Separation of light source fixing spring balance cannot be adjusted Remove the light source unit and check it visually Analyzer s indication of measured value is unstable or surpasses the scale and optical If the light source is found defective replace the light source unit Unplug connectors CNS for 1st opt
13. caution is ignored body damage or injury may be caused INZ TN513328 E Caution on piping lt gt DANGER In piping the following precautions should be observed Wrong piping may cause gas leakage If the leaking 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 e Exhaust should be led outdoors so that it will not remain in the locker and installation room e 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 e 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 N CAUTION e The specified grounding construction is a requisite Negligence of grounding may cause electric shocks or malfunction e Be sure to use a power supply of correct rating Connection of power supply of incorrect rating may cause fire e Wiring work must be performed with the main power set to OFF to prevent electric shocks e Wires should be the proper one meeting the ratings of this instrument If using a wire which cannot endure
14. the ratings a fire may occur Caution on use o DANGER e When handling standard gas such as calibration gas read the instruction manual for the standard gas for correct handling AN CAUTION e Avoid continuous operation with the casing drawn out Otherwise the casing may fall to cause injury e During operation never touch the inside with the casing open because there is a danger of burns or electric shocks INZ TN513328 E Caution on maintenance and check e Before accessing the inside of analyzer with the casing open for capillary replacement or the like purpose be sure to turn off power supply and purge not only the analyzer inside but also the measuring gas D D AN G E R line and auxiliary gas line adequately with the air or N gas Also carefully prevent oil etc from sticking to the capillary filter packing and the like parts This is required for preventing poisoning fire and explosion due to gas leak etc e Before starting the work take off metallic parts such as wrist watch and ring and never touch the device with wet hands Otherwise electric AN CAUTION shocks may be caused e When the fuse is blown detect its cause and use a new fuse of the same type and capacity as those of the old one to prevent electric shocks or other trouble Others e Ifthe cause of any fault cannot be determined despite reference to the instruction manual be sure to contact yo
15. you want to offset the O sensor 4 After confirming that the O input is completed press the 3 key to save the offset values Each gain is automatically exchanged to save the offset values About 15 seconds will be required for saving When Go is selected the Now offsetting message appears After offset the screen returns to the one shown in right INZ TN513328 E 17 In case of zirconia adjustment When measuring the concentration the data can be stored for converting A D counter values into voltage values Operation Zirconia adjustment screen is shown at right For this adjustment disconnect the cable from the O sensor to input terminal of ZKJ connect a reference voltage generator to the input terminal and perform zirconia adjustment while applying each voltage simulative input to the terminal 1 Apply 0 mV to the O input terminal 2 With the cursor placed next to Adj Zero press the EN key to move the cursor to a position next to 100mV Range 3 Press the En key after about 10 seconds have passed the voltage value is saved and the cursor moves to the 250mV Range 4 Press the En key in about 10 seconds the voltage value is saved and the cursor returns to 100mV Range 5 Press the Eso key and escape from Adj Zero 6 Move the cursor to Adj Span and press the 3 key The cursor move to 50mV Range Enter
16. 10215 ON Vuuoc O y JO Od Alo 0 uoneolpul uoneolpul D BA uonep n oleo 010275 11 VW 0201 y JO Od ALO 2 2 Duo uolejnojeo UOISJ AUO9 O uoneuq leo julod 656 uone q leo x UohneEzuB UT Juiod 7 uollesu du io5 OL J l AU05 5 uonezue ur Jet 06 an Indu Josues 105495 uolesu duio5 70 2220 uoezueaur uede 4 72 q l 6 a v EES ndul 10 99 2q ls lis Jajau O uone q leo 52 030050108 Joao 65 uedS qulod oJez 406 a y 6 odwoy yu rol o uonesuedwoo 6 21901 uollesu du io5 uonesuedwoo ju unsn pe 2 1100 0197 ueds uod 0 6 2 66 19SHO a y jeubis yndul 10 99 Pp 11 uonesuedwoo 29493 919 U uauoduloy 566 yes 104 juauodulos Ap INZ TN513328 E A 2 APPENDIX 3 PRINTED CIRCUIT BOARD DIAGRAM Main PC board INZ TN513328 E LO Z P15 sO gt O VG1 e Vcc 3 3V TP10 GNDA GND1 I VR4
17. 2 3 5 6 7 9 12 13 14 15 16 and 17 can be viewed Select digits by the key Change numerical values by using A or Y key After password entry has been completed press the En key and the Factory Mode initial screen appears How to select setting item from Factory Mode screen Factory Mode Ton On the Factory Mode screen that appears point the cursor to the item you want by using the a or key PILC Code 10 Output Adj CH No 11 Memory 5 CH Data 12 8 0 Data Zero ffset 13 thers Gain idi 14 Phase 44 Linearization 15 00 Comp Temperature 16 Coefficient 02 Add 17 Calculation Output SW To return from each setting screen to the initial screen press the 50 E 1 1 VVhen escaping from the Factory Mode screen to the Into each parameter screen To get access to each setting screen press the EN key 1 2 9 4 9 0 T 8 9 INZ TN513328 E 15 2 Setting 1 Oz adjustment Factory mode initial screen e Function Paramagnetic External or The cursor is in 8 Zirconia sensor is selectable Necessary adjustment can be carried En 1 1 Eso out for each oxygen measurement e Operation The setting screen where O Mode select an item adjustment is performed is as follows B Selection of 02 Paramagnetic Input Adj Selection of O sensor Match the cursor with Selection of O and press the 3 key Indication of this set
18. A D conversion input value X A D conversion input value XI After offset XI mV conversion value X2 Scale conversion X3 Filter X4 Zero point temperature compensation A3 Zero calibration X6 Span temperature compensation X7 Span calibration X8 Linearization Action When pressing the zero key the zero valve turns on and it turns off when pressing the key again When pressing the span key the span valve turns on and it turns off when pressing the key again INZ TN513328 E 25 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 Motor rotation detector signal is faulty Detector signals generated due to motor chopping are converted into rectangular waves and rectangular waves are monitored If waves are not generated or irregular an error occurs A D conversion value count can be checked on the A D data indication screen in the factory mode 59000 lt Ainp No 12 13 14 15 lt 61000 Error 4 2 calibration is not If the following ranges are not met in zero calibration an error occurs within the allowable range Infrared component 5000 lt A D conversion value in zero calibration lt 25000 Paramagnetic oxygen 3000 lt zero calibration coefficient lt 3000 Zirconia oxygen Zero calibratio
19. Es 1 1 Es Select any of the output terminals OUT 1 to 12 to be Factory Mode Ad adjusted by using the A or key and connect a Output Adj ZE digital multi meter to the output terminal st VTP T and SPAN aI Correspondence of the OUT number to output terminal OUT 1 to 12 corresponds to CH1 to CH12 Set value is inverted by pressing the Ex key Use the A or key and adjust the indication so Factory Mode just OUTPUT that the digital multi meter reads 4 mA or 0 V for Output Adj and SPAN zero point adjustment and 20 mA or 1 V in case of ZERO SPAN 01900 12500 span point adjustment The indication can be increased or decreased by using the a or key If the values are larger than expected change the upper significant digit by using the Adjustment is established by pressing EN key If you don t want to establish adjustment press the Eso key e Contents of setting values The output number OUT 1 to 12 corresponds to CH1 to CH12 The set values are converted into the digital values to transfer to the D A converter Adjustment value Voltage output OV Within 0V 0 002 V Adjust so that error is minimized 1 Within 1 V 0 002 V Adjust so that error is minimized Current output 4mA Within 4mA 0 05 mA Adjust so that error is minimized 20 mA Within 20mA 0 05 mA Adjust so
20. Ka n 5 2 a a len M vi 8 INZ TN513328 E 2 Measuring element For combination of 1 optical block with one sample cell 7 Part name 7 Part name 7 Part name 1 Sector motor 10 Cell window for pipe cell 18 O ring 2 for block cell 2 Motor mounting plate 11 Reference cell 19 Cell window for block cell 3 7 12 Sample cell 20 Block cell 5 _ Infrared light source 13 Trimmer assembly 21 Measurement detector 6 Light source unit cover 14 Cell pushing 23 Light control plate 7 Photo interrupter 15 Window pushing 24 lnterference compensation detector 8 Distribution cell 16 1O ring 1 for block cell 25 Light shielding plate 9 O ring for pipe cell 17 67 INZ TN513328 E For combination of 1 optical block with 2 sample cells screw N 4 INZ TN513328 E Z yoolq Ieondo 104 yoolq eondo 104 JOJO N 2 Yoolq jeondo 104 JOALIP 4010 N yoolq eondo 104 JOJO 3 Connection of parts e Connection diagram
21. concentration of interference component in measured gas is too high Moisture should be below 2 C saturation Check for other interference components Ask the user what components are contained in measured gas 6 Readings are not increased 1 Check that specified flow rate of measured gases are supplied to the analyzer main unit Locate a gas leaked portion and remedy 2 Check that zero and span calibration can be performed If possible check for sampling system related to measured gas and take remedies If not possible check the item 1 and 2 INZ TN513328 E 27 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 On the measured component that caused a trouble supply the gas given in the following table and write down the measured value of measurement screen and Sensor Input Value in Maintenance Mode Measurement Component Range 1 Range 2 component and range Calibration Measurement Sensor input value in Sensor input value in Supply gas concentration set display value maintenance mode maintenance mode value Main Compo Range 1 Zero gas Range 2 Range 1 Spa
22. cture Described in Fuji Electric s company nameplate on main frame Product nationality Japan OFuji Electric Instrument Co Ltd 2002 Issued in January 2002 Request 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 INZ TN513328 E CONTENTS PREFACE A ini a a I BC RR KREE 1 HENRIETTE MI 1 STRUCTURE OF ANALYZER AND NAMES OF PARTS 1 15 Analyzer main NN 1 2 Measuring glement a uuu Su S RLS 3 3 Connection of E 5 2 MAINTENANCE AND INSPECTION AND REPAIR AND ADJUSTMENTAT REPLACEMENT OF MEASURING UNITS 7 ERR BE EE 1 2 Sector Motor and sect it ad 8 3 Reference celli A aq A A A 8 4 Cell cell window and OTni ita aerea ais 9 5 Detector except for SENSOL 7 9 6 Built O Sensor a ee 10 7 Printed circuit board 11 1 Main printed circuit board main board asss 11 2 Amplifier printed circuit board amplifier board 5222 12 3 Mother printed circuit board mother board s l sil 13 4 VO terminal pri
23. e observed Those safety precautions are ranked in 2 levels DANGER and CAUTION CL DANGER Wrong handling may cause a dangerous situation in which there is a risk of death or heavy injury N CAUTION Wrong handling may invite a dangerous situation in which there is a possibility of medium level trouble or slight injury or only physical damage is predictable Caution on installation and transport of gas analyzer lt gt DANGER 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 N CAUTION e This product must be installed in a place that meets the conditions specified in the instruction manual Use of the analyzer in a place that does not meet the above conditions may result in electric shocks fire or malfunction e During installation work attention should be paid not to allow entrance of wire fragments or other foreign matter into the product Otherwise a fire trouble or malfunction may be caused e When the gas analyzer needs to be lifted be sure to put on protective gloves Don t hold the analyzer with bare hands to prevent injury Before transporting the analyzer fix its casing so as not to open If the casing is separated and falls injury may be caused e The gas analyzer is heavy For carrying the analyzer manually have at least two persons conduct it with utmost care If this
24. ence adjustment and zero span calibration INZ TN513328 E 11 2 Amplifier printed circuit board amplifier board One board provided for each optical block the following check items are for one board e Check Check of circuit voltage Check terminal Regulated voltage Contents a SG P15 15 0 5V 15 V power supply b SG N15 15 0 5V 15 V power supply N15 DV1 17 540 5V st component detector power supply used in common for Main and Compo 2nd component detector power supply used in common for Main and Compo e SG TP5 2 5 0 1V Reference voltage for A D conversion d N15 DV2 17 540 5V Check of signal processing block Unplug all connectors of the cables from the detector Display the screen for 12 A D Data in Factory Mode In the A D Data screen numbers 0 to 3 stand for signals from the amplifier board for the Ist optical block and numbers 4 to 7 stand for signals from the amplifier board for the 2nd optical block Check if the count value in each number lies within a range of 15000 1000 Detector signal check check by flowing the following gases Under zero gas flow Under span gas Under 2 C wet zero gas terminal flow SG TP1 S N 2 1 1 0 to 2 0Vp p TP1 and TP2 at almost SG TP2 _ the same magnitude ST TP3 1 0 to 2 0Vp 8 33 Hz 0 2 Vp p max in AC 7 and SG TP4 signal width e same magnitude 2 a
25. f the relevant setting is inverted select Cylinder or Air as in the selection of minus indication INZ TN513328 E Contents of setting Initial value e MODBUS Function Operation Cylinder Cylinder air or N gas is used as the gas for zero calibration Air Atmospheric air is used as the gas for zero calibration Cylinder In communication with the serial communication port it is settable whether to use the MODBUS protocol or not Simple selection of Used or Unused status as described above Contents of setting Initial value Disable The MODBUS communication protocol is unused Enable The MODBUS communication protocol is used Disable INZ TN513328 E 23 5 Coefficient e Function Displays zero offset and calibration coefficient e Operation The coefficient initial screen is as shown at right Select any item by using the or key Press the EN key and each display screen appears In case of moisture interference or offset selection Display contents Displayed for each CH Offset Offsets detector or O sensor HO 6 Moisture interference compensation coefficient In case of calibration coefficient e Display contents Displayed in range of each CH Zen Zero calibration coefficient Span Span calibration coefficient 24 el Te Factory Mode Coefficient Ta Offset Calibration l 80 Factory Mode coefficient 128 16128 1
26. ical block and CN9 for 2nd optical block on the mother board Open the light source unit cover remove the two screws which fasten the light source and replace the light source unit with a normal one e Adjustment after replacement Optical balance adjustment and zero span calibration TN512896 E 2 Sector motor and sector e Recommended period of replacement 2 years Sector motor 1 Error mode Motor rotation stop Phenomena Analyzer s measured value surpasses the scale or indicated value does not change and ERROR 1 occurs Check With the analyzer powered on remove the light source cover and make sure the sector is rotating 2 Error mode Unstable rotation or stop 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 Sound at a constant high frequency is not abnormal If no noise is heard remove the light source unit cover Turn ON the power of the analyzer and check the rotation of motor shaft and sector e Measures If the sector motor is defective it must be replaced with a new one e Replacement Detach the light source unit cover Unplug the connector which is connected from the motor to the motor driver and pull the cable out of the cubicle through the grommet hole Remove four screws M4 from the motor mounting plate which is fastened to the ba
27. lace LCD Replacement Turn OFF the power Disconnect the connector from the main printed circuit board and replace it with a new one Adjustment after replacement Check the drive voltage and adjust the contrast Power supply Recommended period of replacement 5 years Error mode Power down Phenomena No display and no output 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 Measures Replace the S W power supply Replacement Turn OFF the instrument power Disconnect the connector from the motherboard and replace it with a new one Check after replacement Check the power supply voltage on the main printed circuit board INZ TN513328 E 13 LDC30F 2 LDC60F 2 Name plate Feii LDC6OF EG input N y lla Output L H Pin Symbol Pin Symbol Voltage 1 V3 1 V3 15V 2 G2 2 G2 3 G2 3 G2 4 V2 15V 4 V2 15V 5 Gl 5 Gl 6 Gl 6 Vi 5V 7 V1 5V 8 V1 5V LDA10F Pin Symbol Voltage 1 LI 5 7 CN1 se CN2 2 SE El 3 V 15 6 HV sv 4 7577 Name plate Pin Symbol Vo
28. ltage O cnt 1 to 3 Vy BER 1 Ge 4061 V 19 8V Name plate Output voltage variable resistor 10 Membrane key e Error mode e Phenomena e Check e Measures e Replacement Key contacts are worn It prevents the switch from being operated Check for the contacts with main printed circuit board Replace the membrane key Turn OFF the power Disconnect the connector from the main print circuit board Remove soldered portion of the power switch and remove the power switch from the main instrument Strip off membrane key and adhesives are wiped off completely Then replace it with a new one Remove the power switch and install it in the reverse procedure as removal Connect the key cable to the connector of the main print circuit board e Check after replacement Check key in operation 14 INZ TN513328 E 3 FACTORY MODE 1 How to go to factory mode Maintenance Select operating item Mode Point the cursor to 8 To Factory Mode by using the A or key on the Maintenance Mode screen and enter the Sensor Input Value Error Log Password Setting Optical Adjustment Interference Compensation Adj 02 ref Value 12402 Station 1 To Factory Mode En key Then the password input screen appears Enter the password To select setting items set 4 0 4 3 8 02 Adj 10 Output Adj and 13 Others are settable with 4043 Items 1
29. n concentration after mV conversion 5 mV Error 5 amount of zero This error occurs in the following condition calibration is over 50 50 of FS lt Zero calibration concentration set value current of full scale 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 05 lt span calibration coefficient lt 5 Paramagnetic oxygen 0 5 lt span calibration coefficient lt 16 Zirconia oxygen Span calibration concentration after mV conversion 10 mV Error 7 An amount of span This error occurs in the following condition calibration is over 50 50 of FS lt Span calibration concentration set value current of full scale display Error 8 Measured values fluctuate If A D conversion value fluctuates beyond each range specified below to much during zero and in calibration an error occurs span calibration Infrared component paramagnetic oxygen meter A D input value 100 Zirconia oxygen Oxygen concentration after mV conversion 0 2 mV Error 9 Calibration is abnormal Error corresponding to No 4 to No 7 occurs during auto calibration during auto calibration Error 10 Output cable connection is Error occurs if no response is made from the output IC improper Main portions to be checked during error Error No Main portions to be checked Error 1 Sector motor rota
30. n gas Range 2 2 C wet Range 1 zero gas Range 2 Range 1 Sample gas Range 2 If there is no Range 2 the part of a Range 2 is entry needlessness If trouble occurs to other components sample data for each component If trouble occurs on the meter there is no sensor input value for Compo Check each coefficient by Coefficient in the factory mode Channel No Offset Moisture interference Zero coefficient Span coefficient CHI Range 1 Range 2 e Sampling system diagram If sampling system diagram is prepared report the diagram number If sampling system diagram is not prepared report the sketch For other troubles sample various data about necessary setting items 28 INZ TN513328 E 3 Troubleshooting of detectors 1 Trouble judgment a Check that the sampling line is not abnormal and that the dehumidifying line filter status and sample gas properties do not have a problem b Check that other units and functions of the analyzer are not abnormal Make sure the light source sample cell and synchronization signal circuit do not have a problem c Examine each correlation with the ambient temperature and plant operating conditions such as gas and heat radiation 2 A D data a Calculate sensitivity against steam from the A D data reliable bubbler and electronic cooler Check the A D data of each detector on the optical balance screen when flowi
31. nalog 15 V VGI N15 15 0 5V Analog 15 V GND1 3 3V 3 3 0 1 V Digital 3 3 V GND2 TP10 VR4 About 26 V LCD drive voltage contrast adjustment e Precautions on replacement cable connector CN2 from LCD is connected to the main printed circuit board Do not unplug or plug the connector from or into the board with the analyzer power ON or the electronic parts and indication block may be damaged Before replacement be sure to turn OFF the analyzer cable connector CN5 from the membrane key is connected to the main printed circuit board Since a stopper is provided on the CNS connector the flexible cable should not be pulled forcibly Forcible pulling may result in poor contact For disconnecting the flexible cable slide the stopper lightly toward you by holding both sides of CNS with fingers And for reconnecting the flexible cable insert it fully down to the bottom and attach the stopper The flexible cable should be inserted with its contact face directed toward the printed circuit board e Adjustment after replacement The above mentioned voltage check adjustment and contrast adjustment VR4 Contrast should be adjusted so as to be easy to see indications at the height of your eyes In factory mode zero offset adjustment zirconia adjustment when equipped with zirconia O meter and output adjustment For adjustments in factory mode refer to factory mode in this manual Moisture interfer
32. nd TP4 signals are 0 V when the lower end of measuring range is 0 to 10 or more Precautions on check The amplifier board is connected to the mother board by connector If the connector is not plugged in adequately the above check may not bring about a normal result Before check make sure the connector is plugged in correctly Precautions on replacement A cable from the detector is connected to the amplifier board If the connector is unplugged or plugged in with the analyzer power ON the detector may be damaged Before replacement be sure to turn off the power supply Adjustment after replacement Verification of the contents of the above checks adjustment as per 4 Zero Offset in Factory Mode and zero span calibration 12 INZ TN513328 E 3 Mother printed circuit board mother board Adjustment after replacement Output adjustment Refer to 10 Output Adj in Factory Mode 4 1 O terminal printed circuit board I O terminal board 8 9 e Adjustment after replacement Output check Adjust if output is offset Refer to 10 Output Adj in Factory Mode Liquid crystal display LCD Service life of parts 5 years Error mode Deterioration Phenomena LCD is not displayed or the display is dim or flickers Check Check LCD drive voltage on the main board See Check for printed circuit board Check connection to the main board Countermeasures against error Rep
33. ng each gas listed in the following table For generation of 2 C wet zero gas use a Measurement detector Main Interference compensation detector Compo Dry zero gas Zm Zc Dry span gas Sm Sc 2 C wet zero gas Wm Wc Span gas concentration P ppm Steam sensitivity H P X Wm Zmy Sm Zm ppm concentration of measured component e SO meter e NO meter When H gt 70 ppm SO equivalent the detector may be faulty When H gt 180 ppm NO equivalent the detector may be faulty Span A D data This data varies with range ratio It is therefore unreliable to judge whether the detector is normal or not according to this data alone If steam sensitivity is abnormal in 1 compare the span A D data with that at shipment from the factory and judge the detector also using the result in 1 4 Range linked calibration When this analyzer has 2 measuring ranges range linked calibration is settable in setting of calibration range Refer to the instruction manual The range linked calibration function works normally on condition that each range is calibrated correctly This is because the range linked calibration is carried out so that compensation amount is always the same between the ranges If a significant indication error occurs between the ranges set calibration range in each range current and carry out zero span calibration in each range Then set calibration range to the
34. nted circuit board I O terminal board 5222 2222 13 8 Liquid crystal display LCD 13 KEE ITT 13 MINT A 14 D EN 15 1 How to go to factory mode 15 A ay nas Spain A dA NN 16 1 Oz adi stment NN 16 2 QOutputradjustmentu y u l A a 19 20 4 Other parameters eene EEN 21 S Coeffieientu pu Ee EE 24 ECH e EE 25 4 ERROR JUDGEMENT CRITERIA FOR ERROR CODES 26 5 TROUBLESHOOTING AND DATA COLLECTION 27 1 Countermeasures against 10109 27 2 Data sampling at troubles is A AA 28 3 Troubleshooting of detectors n 29 1 Trouble judgment oe aan eege 29 DADO ata usa a ea aya BY ASYA kasku 29 4 Range linked 29 APPENDIX 1 MEASURING PRINCIPLE DIAGRAM A 1 APPENDIX 2 SOFT FLOW DIAGRAM a A 2 APPENDIX 3 PRINTED CIRCUIT BOARD PRAGRAM A 3 INZ TN513328 E CAUTION ON SAFETY First of all read this Caution on safety carefully and then use the analyzer in the correct way e The cautionary descriptions listed here contain important information about safety so they should always b
35. rmed ERROR No 6 7 or 8 has occurred 1 Check that specified flow rate of span gas is supplied to the analyzer main unit Locate a gas leaked portion and remedy 2 Check that zero calibration can be properly performed If zero calibration cannot be performed repeat the procedure in No zero calibration can be performed described above 3 Check the A D data against the display Refer to Sensor Input Value in Maintenance Mode Check for change from when flowing the zero gas 4 Check the amplifier PC board Refer to amplifier printed circuit board in this manual 5 If this trouble has occurred on the zirconia O meter check the sensor output voltage 6 If ERROR No 7 has occurred carry out span calibration forcibly and check the result gt If ERROR No 6 occurs return to above 3 Error occurs in automatic calibration ERROR No 9 has occurred Depending on whether the error has occurred in zero calibration or span calibration the relevant measure described above should be taken 4 Drift 1 Check that specified flow rate of measured gas is supplied to the analyzer main unit Locate a gas leaked portion and remedy 2 Check that the cell window O ring detector window and cell inside are not contaminated Clean the cell and window Replace parts 5 Readings are high or low too much 1 Check for influence by moisture interference Carry out moisture interference adjustment 2 Check if the
36. se band For pipe joint use Toaron 09 06 Block cell 2nd optical block This is a piping diagram of the analyzer without a purging line When the Oz meter and the second optical block are not provided pipes must be connected by bypassing them 000 O sensor P _ source side Toaron 06 03 ili d Toaron 6 03 1 Yellow capillary L 20mm Si 09 05 Pa Sample cell 1st optical block Teflon 06 04 INLET 40 dra 5 k Vall capillary L 10mm Toaron 09 5 L 35 OUTLET 0 Toaron 9 05 PURGE H Sample cell 2nd optical block nfrared light source side LD 0 indicates a hose band For pipe joint use Toaron f9 f6 Block cell 2nd optical block This is a piping diagram of the analyzer with a purging port When the Oz meter and the second optical block are not provided pipes must be connected by bypassing them INZ TN513328 E 2 MAINTENANCE AND INSPECTION AND REPAIR AND ADJUSTMENT AT REPLACEMENT OF MEASURING UNITS 1 Light source e Recommended period of replacement 5 years 1 Error mode
37. se of light source unit and the motor and sector can be pulled out The sector can be separated by removing the sector setscrew which fastens the sector to the motor shaft and then the motor can be separated by removing four screws from the motor mounting plate Fasten a replacement motor to the mounting plate and mount the motor by reversing the demounting procedure For mounting the motor rotate the sector manually before fixing the motor cover and make sure the sector does not come in contact with the light source base light source photo interrupter wires etc frictional sound must not be emitted Finally fix the light source unit cover e Adjustment after replacement Check of optical balance adjust if significantly deviated and calibration of zero span points 3 Reference cell e Recommended period of replacement 5 years Error mode Leakage of gas filled in cell Phenomenon Analyzer s measured value is unstable in particular stability against change in ambient temperature is degraded e Measures Replacement of reference cell e Replacement Remove the reference cell and mount a new one e Adjustment after replacement Optical balance adjustment moisture interference adjustment and zero span calibration 8 INZ TN513328 E 4 Cell cell window and O ring e Service life Usable unless contaminated or corroded e Recommended period of replacement 2 years with O ring 1 Error mode Phenomena Check
38. that error is minimized INZ TN513328 E 19 3 A D data e Function Measures the counter readings Factory mode initial screen immediately after A D conversion The cursor is in 12 e Operation To measure the counter readings press the key on Factory Mode initial screen EN 1 1 9 Ainp T No ype No ype Factory Mode D Data 0 Optical block 8 o E xygen in 1 1 Main Optical block Aine WO Count hinp WO Count 1 Temperature 3913 8 20001 1 11651 9 19900 h E 2 15544 10 11163 1 2 Main 19978 11 11161 Optical block 3 11 0 1 2 Compo 4 Optical block 12 Optical block 1 2 1 Main motor pulse 5 Optical block 13 Optical block 1 2 1 Compo motor pulse 6 Optical block 14 Optical block 2 2 2 Main motor pulse 7 Optical block 15 Optical block 2 2 2 Compo motor pulse When supplying zero gas dry No 0 to 7 infrared component No problem within 10000 to 22000 However ignore the values where no detector is available No 8 oxygen sensor input No problem within 10000 to 18000 However if an oxygen meter is not provided ignore this input No 9 temperature sensor input No problem within 5000 to 18000 No 12 to 15 No problem within 58000 to 61000 If the 2nd optical block is not provided ignore Nos 14 and 15 INZ TN513328 E 4
39. ting item will be Inverted Setting item can be changed by pressing and keys and its selection can be determined by the 3 key Selection of 02 When Paramagnetic and External O gt are selected Input Adj O offset is displayed in the setting item When Zirconia is selected Zirconia adjustment screen is displayed in the setting item After Selection of O offset adjustment or zirconia adjustment can be carried out 16 INZ TN513328 E In case of O offset adjustment O offset adjustment allows you to store electrical Factory Mode Select an item offset required for measurement by using a 02 Adj paramagnetic sensor and external O meter Note For using the built in O sensor unplug the selection of 02 Paramagnetic B Input Adj O sensor connector before adjustment Unless unplugged the O sensor may become faulty e Operation The O offset adjustment screen is shown at the right For this adjustment input 0 V to or shot circuit the O gt input terminal of ZKJ 2 1 Add 0 mV short to the O input 1 1 2 With the cursor placed next to Input Adj offset Factory Mode Input Om to Terminal 02 TN 1 2 adjustment the O Offset screen is displayed by pressing EN key Adjustment 3 Press the 3 key on the O offset screen and the D O 2offset Ge message appears prompting you to verify that
40. tion mother and amplifier printed circuit board synchronization signal rectangular waves between GND and MPD3 on main printed circuit board 8 33 Hz 5 Vp p Holl See service manual 5 1 No zero calibration can be performed Error 5 See service manual 5 1 No span calibration can be performed Error 7 Error 8 5 Error 9 See service manual 5 1 Zero calibration and span calibration can not be performed Contact portions of main printed circuit board and motherboard printed circuit board plug in Error 10 connector Contact portions of mother printed circuit board and output printed circuit board cable 26 INZ TN513328 E 5 IROUBLESHOOTING AND DATA COLLECTION 1 Countermeasures against trouble 1 No zero calibration can be performed ERROR No 4 5 or 8 has occurred 1 Check that a specified flow rate of zero gas is supplied to the analyzer main unit Locate a gas leaked portion and remedy 2 Check optical balance Refer to optical balance adjustment in instruction manual Adjust optical balance 3 Check the A D data against the display Refer to Sensor Input Value in Maintenance Mode 4 If this trouble has occurred on the zirconia O measurement check the sensor output voltage 5 If ERROR No 5 has occurred carry out zero calibration forcibly and check the result gt If ERROR No 4 occurs return to above 2 No span calibration can be perfo
41. ur dealer or Fuji Electric s technician in charge of adjustment If the instrument is disassembled carelessly you may have a shock hazard or injury AN C AUTIO N e Don t use replacement parts which are not specified by Fuji Electric Use of such parts will not only degrade performance but also result in an accident or trouble e The old parts after replacement due to maintenance etc must be disposed of as incombustible waste INZ TN513328 E V 1 STRUCTURE OF ANALYZER AND NAMES OF PARTS 1 Analyzer main unit gt e 2 818 9151561 11912 8 2 Silo SIS llo 2182 elal 2 7 2 52 21519 12 5 218 2 x z K ior Ay INZ TN513328 E LA LEAL CU Al N g o 9 En E l N E m E alle 2 43 15 01 2 15 amp 5 8 2 a 8 EIS alala gx Milis ub a 8 0 B m 2 gil li Aa gt un gt 2 E a 812 2 KEN 21581 1212 2 282222 O galio lolz oO 10212 5 a el P 2 2
42. yond the specified range the detector element may be damaged 1 Note For resistance measurement avoid To amplifier board using a measuring device such as analog tester that flows a current of 2 mA or more If used the detection element may be damaged Sensitivity deterioration due to sealed gas leak Calibration error fluctuation in indication and poor stability of analyzer s measured value After making sure the light source is normal and the cell is clean check moisture sensitivity For the method of fault judgment and sensitivity check refer to 5 3 Troubleshooting of detectors in 5 TROUBLESHOOTING AND DATA COLLECTION Replace detector INZ TN513328 E e Replacement Turn off power supply to the analyzer remove the bolts which fix the detector and remove the detector Mount a new detector and tighten the bolts The type of detector varies with the gas component to be measured So before mounting check the symbol marked on the detector label e Adjustment after replacement Optical balance adjustment moisture interference adjustment and zero span calibration OOOO 1 2 R3 4 000 Rx 000 Al Detector type 6 Built in O sensor e Recommended period of replacement 10 years Error mode Phenomenon Check Measures Replacement Breakage of O sensor
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