Service Manual - Fuji Electric
Contents
1. 8 6 Built in O sensor galvanic cell nn sassa 8 7 Printed circuit board see printed board diagram at the back of the manual 9 1 Mamgboarg A seandveedgntedudbenndessabendddasoaudvtesdaenucessnendeenteanddeedabalabeaadtesdens 9 DY ATO Do EE 9 S Liquid erystal display LED tit ea o eaaa 9 9 Power Up a iio 10 10 Operation Partit tea dees ebb nad de Can R y m A y d 11 do ACTORA MODE m ao 12 1 Howto goto factory Mode iii iii 12 2 Setting ELL EE 13 RW e ye A as 13 2 Range A SOLOS 14 3 Calibration coefficientu n e 15 3 Setting value reference items n n nunus 16 1 AAD A A gala aaa 16 4 ERROR JUDGEMENT CRITERIA FOR ERROR CODES a 17 5 TROUBLESHOOTING AND DATA COLLECTION 19 1 Countermeasures against trouble n annassa 19 1 Zero calibration can not be performed nasus 19 2 Span calibration can not be performed ccoo nono nono asas 19 O 19 4 Readings are high or low too much 19 5 Readi gs are notancreased vns dsd 19 2 Data sampling at troubles ii is 20 6 ADJUSTMENT IN HEAT TREATMENT FURN2. R1 and R2 represent range and 2 Factory Mode Zero calibration coefficient is displayed on the left side of coefficient screen and span calibration coefficient is displayed on the Chi R right side NOx R2 Ch2 1 502 Ri Ch3 R 002 R2 Ch4 R Co R2 Cho 02 How to change numeric value Select a desired item using the A and Y keys Factory Mode coefficient Press the Gi key to enter the screen of the item hl Ri selected NOx R2 Ch2 Ri 502 R2 Move the cursor in front of the value to be changed using Ch3 R the O or key and then press the Gi key and a Re the value is highlighted CO R2 Change the numeric value and move the digits using the 7 E a or key Establish the setting contents by pressing the Gi key If you don t want to establish the contents press the so key TN5A0354 E 15 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 key on the Factory Mode initial screen Factory mode initial screen Ch1 input Temperature 16 Ground 1227 U value sensor 4 1 Ch2 input Temperature 17 Gitter 1 2 value sensor 5 D ES value value Factory Mode A D Data Ch5 input Gitter 3 1 Gitter 4 2 value sensor 1 Tem
3. Fo Service Manual INFRARED GAS ANALYZER TYPE ZRE ESSE v A A A N n Fuji Electric Co Ltd INZ TN5A0354c 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
4. 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 c upper end of the fixing plate as in the right figure b Flow the gas in the same manner in 3 to read the count value of each gas Respectively replace the read values of Zero with Zb and Moisture with Hb Calculate the Zero point Zx count value as following x 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 4 light source il il Rear expansion AH chamber Detector 101 Mass flow Motor Measurement cell sensor Chopper y Preamplifier block Indication Signal processing Output Principle Diagram of Magnetic Force Ty
5. El mid 5 gt gt ep 2 nin E o nin 2213 2 2313 la S o S op ol E Elolo TLE o RIAS FEE ami e z o lo 2 Am no q a TN5A0354 E 3 Connection of parts 1 Wiring diagram d onauBewesed 10 Gd Il 15 s euolldo Josuas O US 0964441 2688 ed i o1ueAeD ad oyeubeueseg MOJA Ala 4 Pod H umolg uoneoyioads y o Buipioooe HUM Gy ES 10 0 00 ulp 9 pig 10 i t s gt ng e uoneono ds ay o Buipioooe lu uoduioo pug JO j98
6. 61641 0000000000 126 1267992860 Or 2909990009 SIE 200 oF 200 n SE02IN2311 82620231 ennon Z LZLBNZAL prog 85 Frai y n edeg kor HE os 6666600600 SIND PEQUENA yun foy ao 0 Zlino 1867992860 oran ia O INO 0 18 1 1 204 olq 240 1867992860 0000000000 suo Bu1p10998 speoq TN5A0354 E 2 Internal piping diagram and optical layout r Sample gas outlet 1 Sampling gas inlet 1 Purge inlet 150 Sample gas outlet 2 i Pe Sample gas inlet 2 Rear face Built in ae a Optical unit 2 i Oz analyzer e zz Flovv checker 1 Front face Correspondence of measurable components and Optical units Measurable components Single component NO SO CO2 CO CH4 Optical unit 1 Each measurable component Optical unit 2 None Double component CO2 CO COCO None Double component NO CO NO SO2 NO NO CO 502 Three component NO SO2 CO NO SO2 CO Four component NO SO2 CO2 CO TN5A0354 E S02 002 2 MAINTENANCE AND INSPECTION
7. and No 20 Gitter 4 2 only 10 000 lt No 17 to 20 lt 59 999 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 checked by the counter indication when the Factory mode screen is displayed 35 000 lt No 15 lt 55 000 Error 4 Zero calibration is not Infrared component within the allowable range 0 5 lt zero calibration coefficient lt 5 Other than infrared component 2 000 lt zero calibration coefficient lt 12 000 Error 5 A amount of zero This error occurs in the following condition calibration is over 50 50 of FS lt 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 type O built in galvanic cell type O built in paramagnetic Oz 0 5 lt span calibration coefficient lt 16 Zirconia O 6 000 lt span calibration coefficient lt 32 000 Error 7 An amount of span This error occurs in the following condition calibration is over 50 50 of FS lt of full scale Span calibration concentration set value current display Error 8 Measured values fluctuate Check if measu
8. the end of work Piping Wiring Screws etc 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 analyzer 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 Ki Z ER 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 board 12 Power supply terminal block 27 Main board 13 Power supply 28 AIO board 14 Key unit 29 DIO board 15 LCD 30 USB board TN5A0354 E 2 Optical unit o 8 Gi 2 8 m gt 212 en E E 5 E EIS E JS S x PS 5 8 S ll i BR s S Gil oO Om z og z 2 x siniz n s Aa o 8 Gi S
9. 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 20 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 Phenomena Fluctuated Indication Check 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 e 2 Measures If the light source is found defective replace the light source motor unit Measure the resistance between terminals with cables disconnected 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 Perform zero and span calibration 2 Sector motor and sector ot e Recommended period of re
10. 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 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 No in any case so that zero point will not be affected lt Example gt 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 gt directly scale gas 2 Check gas 0 9 to 1 CO Perform span calibration remainder is N indirectly A small amount of ga
11. 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 Perform zero and span calibration and check response time for each component 4 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 Precautions on replacement 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 contaminati
12. nameplate on main frame Date 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 1st edition April 2011 Rev 2nd edition June 2013 e It is prohibited to transfer part or all of this manual without Fuji Rev 3rd edition October 2013 Electric s permission in written format e Description in this manual will be changed without prior notice for further improvement TN5A0354 E i CONTENTS PREFACE a A ses Aaa he pig Sa anatase ta aos i CONTENTS ise qas Ga ae Aca eee A A EARLE 11 CAUTION ON SABE EE iv 1 STRUCTURE OF ANALYZER AND NAMES OF BARTIR 1 1 Analyzer main unit External internal ccc cccecseeseceteceseeeseceecseeeeseeeeseceaeeeseeeseecsaeessecnseenseeeaeens 1 2 Optical Ud a ad Es 3 5 Connech nio PS A ds 4 1 Wiring AA ii A A AA A a E 4 2 Internal piping diagram and optical layout nn sasana 5 2 MAINTENANCE AND INSPECTION AND REPAIR AND ADJUSTMENT AT REPLACEMENT OF MEASURING UN noo 6 BEER Oe 6 2 Sector motor anid sector s a uu a ida 6 3 Cell cell window and O Tring n cnn cnn non oran r ran nara nora nora ron rra rra ran rra neos 7 4 Detector unit except for O 7 5 Built in O sensor
13. the power and check the voltage at the connector If no voltage is applied to it replace e Measures Replace the power supply e Replacement Turn OFF the analyzer power Disconnect the cable from the Main board and replace it with a new one e Check after replacement Check the power supply voltage on the Main board LDA60F 2 Name plate Sa Pin Symbol 1 Voltage 1 Vi 15V 2 G2 Ground 15V 3 G2 Ground 15V 4 V2 15V 5 Gl Ground 15V 6 Gl Ground 15V 7 vil 5V 8 vi 5V 10 TN5A0354 E 10 Operation Parts e Error mode e Phenomena e Check Allocation of Connector Switch Connector pin No Wear on switching Faulty operation Be sure to tum 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 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 Assembl
14. with the power ON or electronic parts may be damaged Before replacement be sure to turn OFF the analyzer e Adjustment after replacement After replacement check for the voltage shown above Perform contrast adjustment while viewing the LCD Determine an easy to see height and adjust contrast Menu mode gt Parameter gt contrast Refer to the instruction manual for details of operating method Press the switch to check that all keys are normally operated 2 AIO board see Appendix 3 e Adjustment after replacement Output check Adjust if output is offset Refer to the instruction manual for details of operating method 8 Liquid crystal display LCD e Service life of parts 30 000 hours Lighting continuously e Error mode Deterioration e Phenomena LCD is not displayed or the display is dim or flickers e Check Adjust contrast remove or plug the connector Check connection to the main board e Countermeasures against error Replace LCD 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 9 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
15. 9S 1 abuelo Juauoduo9 t 9000 Q000 jusuodtuoo 40102 up 10 g9 PE Leer Leer go pug 10 mooo CELNA AN 9INO enoloo 2264241 INO oc SEI oo 902012 896 1 PEOLWLYL QA 00 ai 2892024 D So oudug pueoq J9ynduy yoolq euw S i A m fiddns SEO ia0eds pi aseq 01 jusuoduos jueuoduoo 9 04 Si yey Peig OO a SE 15110 3102 8111194 NS NOJO O Fun SINTO O EE OO NO Q O oo APIR 99 wennt ajgeo ed pueog s n D s L Z eps Eel IA i 1001 enot SH i Rell z ul ls s bag 201 ue s s SIoN jeondo paseaju e eondo ee Y reiege eae CS asn49 Jepjoy gen 9 04 unos 16 0 LZLBINZAL Hed pueog uen 0418 WZAL 1059662311 ed paysimy preog Old 20 x ASH d INO opp sed palsim IND 5 4040 LES inant E 201 69L8 NZAL CONS Ov as 120 eno Y ASIF We Sen ater 1269992861 p soq oly 8No sh 460 IN LAND Bunu l LS2 NAM 99900000000 aqe 9 Me 9 Ld L9Z LINA UOJIMS 1 MOd E H 2 409001 LA llo rasa 8 ne a Addins samog amo 9 9 oo oo ZNO ENO 0 lqeo 0000000000 26 VZ6Y992860 iz y 18679928610 gt gt OOO 009090900000 000090 20 E Kean 5966 4 1 019349 OLLSWZ4L Da Del fe Tell 14912311 8100 z pieog Old one pa geo Dey Dele zl 1 H AUI 4 Y x Leen Yeon REN
16. ACE eee 21 1 Method for span calibration by standard gas with the same composition as plant gas 21 2 Method for span calibration by check ease 22 7 Moisture interference adjustment NO SO only cono conocio co a 23 TN5A0354 E APPENDIX 1 MEASURING PRINCIPLE DIAGRAM 00 nu A 1 APPENDIX 2 SOFT FLOW DIAGRAM uu u n sana una ama NR uQ Sus A 2 APPENDIX 3 PRINTED BOARD DIAGRAM a A 3 Mam Doma ripio A 3 ATO board ti A Ya b ya d si A 4 Amiplifier e A A S d A 4 TN5A0354 E 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 DANGER CAUTION and PROHIBITION N 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 N DAN G E R e This unit is not exp
17. Val composition 0 e 0 0 1 02 03 04 05 06 07 08 0 9 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 9596COz In graph a point of 0 95 on X axis should be stretched to upward draw a line toward Y axis from the cross point 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 7 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 2 3 4 5 6 7 8 9 To start adjustment set the light control plate at the we Light control plate same height 10 to 15mm upper than c upper end of c Fixi the fixing plate as in the right figure a 1 E Enter Maintenance mode 1 Sensor Input lt Fixing plate Flow zero gas and gas contained water of 2 C N2 NO SOz detector
18. c may stick on internal walls thereby causing faults TN5A0354 E Caution on use S PROHIBITION Do not allow metal finger or others to touch the input output terminals in the analyzer 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 analyzer may be caused Caution on maintenance and check N 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 work Do not touch the analyzer with 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 analyzer 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 Please be sure to check about the gas analyzer being in a safe state after
19. e 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 6 To Factory Mode by using the or Maintenance Select operating item Mode key on the Maintenance Mode screen and enter the EN key Then the password input screen appears Sensor Input Value Error Log Cal Log Output Adj Other Parameter To Factory Mode Enter the password To select setting items set 4 0 4 3 4 Option 5 Pressure 12 Others 14 Coefficient are settable with Input Password 4048 4 0 4 3 Items 1 2 3 6 7 8 9 11 13 and 15 can be viewed Select digits by the O key Change numerical values by using A or Y key After password entry has been completed press the Gi key and the Factory Mode initial screen appears J How to select setting item from Factory Mode screen Factory Mode Select operating item On the Factory Mode screen that appears point the cursor to the item you want by using the A or key To get 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 access to each setting screen press
20. erwise 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 N CAUTION Wiring work must be performed with the main power set to OFF to prevent electric shocks Enforce construction of class 3 grounding wire by all means If the specified grounding construction is neglected a shock hazard or fault may be caused Wires should be the proper one meeting the ratings of this analyzer If using a wire which cannot endure the ratings a fire may occur Be sure to use a power supply of correct rating Connection of power supply of incorrect rating may cause fire Caution on use N DANGER For correct handling of calibration gas or other reference gases carefully read their instruction manuals beforehand Otherwise carbon monoxide or other hazardous gases may cause an intoxication particularly N CAUTION 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 shutdown Otherwise the performance may be poor and accidents or injuries may be caused Do not operate the analyzer for a long time with its door left open Otherwise dust foreign matter et
21. h9 to 12 Analog output selection JP1 Voltage output selection 1 2 Nonstandard 0 5V or more JP10 2 3 Standard 0 1V or less Ch3 Analog output selection JP11 Ch4 Analog output selection Amplifier board CN1 To Main board TP1 After AC amplified 0 8V 35 000 counts to 1 25V 55 000 counts Detector voltage SC TP1 Ground GND DVI Ground JP1 Resistance mounting for gain adjustment JP2 Resistance mounting for gain adjustment A 4 TN5A0354 E FO 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
22. losion 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 N 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 Connect pipes correctly referring to the instruction manual Exhaust 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 Oth
23. on the counter value indicates 35 000 to 55 000 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 board on the detector The measure values must be between 250 and 60Q If the resistance value is fluctuated beyond the specified range the detector element may be damaged Note Do not use measurement analyzer that allows a current of 2mA or more to be supplied when measuring resistance otherwise the element can be damaged Detector voltage control failure Label Calibration error and fluctuation in indication 00000000 Check amplifier board and measure voltage between DV1 000000 GND of the terminal It is normal if the value is within 0 4 of the voltage V 000 CO L specified on the label Voltage of each detector When ordering notify analyzer serial number detector serial number and the detector type ex NO H So the Amplifier board has suitable gain in it The Amplifier board is set according to the specificaions TN5A0354 E 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 un
24. pe Measurement O Mirror Permanent magnet Gas inlet gt i i Measurement m cell Magnetic field i Z Gas outlet vv Y Y AT Preamplifier Permanent gt gt magnet Light emitting diode Photodiode Signal processing ndication and calculation block Output 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 plou y Buunp peddojs si uonejndwoy dutod Sejeo pul y Hew ASUSIS Y 1 30N TN5A0354 E Josuas 1216 q y snosuejuejsul Vor ON AL O uo esuadwos O oq Josuas Aelds q Aeyds q s 5 YU U AOUI D BA abeJoay uongejnojeo UONEINIEI ON AL O AL 0 9d 9d uolniqile5 uonejnojeo uolyenjony julod uedg jeubis ndui Aejdsia 0 5 ZO uoneiqueg zue ul1 lutod 0197 1914 Joao ON JO O 61 2 2 snosuejuejsu UODEIDOIE O y AL O 14010 od uolesqied 1 uolyesuedwoo uonesu dulo uonen onil uopeJqueo uopequeo umeu duu IguBi
25. perature 14 Pressure sensor 2 Temperature Reference 7 15 sensor 3 voltage When supplying zero gas dry Count 65444 56779 66982 85663 6855 44939 44756 44869 T F co PO O O No 0 Infrared ray component 1 35 000 to 55 000 No Infrared ray component 2 35 000 to 55 000 No 2 Infrared ray component 3 35 000 to 55 000 No 3 Infrared ray component 4 35 000 to 55 000 No 4 O sensor input 18 000 to 22 000 If A D counts are within the range there is no problem If infrared ray composition 2 3 4 and O sensor do not exist ignore No 1 2 3 and 4 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 Gitter 1 2 No 18 Gitter 2 2 No 19 Gitter 3 2
26. placement 5 years 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 Motor shaft no noise is heard remove the light source motor unit Turn ON the power of the analyzer and check the Check sector rotation rotation of motor shaft and sector from here e 2 Measures If the sector motor is found defective replace the light source motor unit 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 Perform zero and span calibration 6 TN5A0354 E 3 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
27. plug in connector Contact portions of DIO board and AIO board cable 18 TN5A0354 E 5 TROUBLESHOOTING AND DATA COLLECTION 1 Countermeasures against trouble 1 3 4 5 Zero calibration can not be performed Check that a specified amount of zero gas is supplied to the analyzer main unit Locate a gas leaked portion and remedy Check if detector signal is as specified see Detector unit gt Check the voltage of detector 1 Record voltage when zero gas is supplied Amplifier board TP1 SC 2 Check the detector voltage Amplifier board DV1 GND Check the A D data against the display see Factory mode and A D data Check voltage at the Main board Check the power supply voltage Record the A D data when zero gas is supplied Span calibration can not be performed Check that span gas concentration and span concentration value 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 gt If zero calibration can not be performed repeat the procedure 1 Zero calibration can not be performed Check if detector signal is as specified see Detector unit gt gt Record voltage when span gas is supplied to compare with the voltage when zero gas is supplied Check the A D data against the display see Factory mode and A D data Check vol
28. red values fluctuate excessively during calibration to much during zero and Infrared component built in paramagnetic type O span calibration If measured values are not stabilized in 60 seconds change of more than 100 counts is continued Built in galvanic cell type O Zirconia O If measured values are not stabilized in 60 seconds change of input voltage is continued by more than 100mV Error 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 16 Comnecting part between detector amplifier board and Main board cable connector Error 3 No 15 of A D data in factory mode Voltage between TPVH1 TPVS1 on main printed circuit board Error 4 See service manual 5 1 Zero calibration can not be performed Error 5 Error 6 See service manual 5 1 Span calibration can not 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 DIO boards
29. s display Zero limit is set to Appear be sure to return the setting 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 graph 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 Ex key and the setting value is highlighted Others Switch between ON and OFF by the A or key ZERO limit and establish the setting contents by pressing the Gi Range limit AO No key Language ZERO gas Cylinder Protocol MO Varied Range ON DIO No e Setting contents Factory Mode Range limit is usable ON Displays and outputs values up to 11096F S Others OFF Displays and outputs values up to the graph is within the panel ZERO limit OFF Range limit pu AO No 12 e Initial value ON Language ENG ZERO gas Cylinder Protocol MO Varied Range ON DIO No 0 14 TN5A0354 E 3 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
30. s 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 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 gt balance gas to facilitate the analyzer check are drawn Y A DM Calibration curve by I scale gas AA composition of plant 9 gases Se BERS 0 8 ES OCH T 111 AA Calibration curve by Z check gas P N2 balance gas 0 6 Z When supplying ALI 2 0 5 7 analyzer adjusted by 0 4 A
31. s yndul Aeyds q UODEIOIE ezuesum yulod ueds yulod ueds julod 0 7 julod 0 97 Jeu jewbiq seyeauoo q y Joes X ttt HO juauodulo9 Aes paJeJJu anjea jndul Josuas A 2 APPENDIX 3 PRINTED BOARD DIAGRAM Main board JP3 O analyzer gain switchover External zirconia type Oz built in galvanic cell type Oz Built in paramagnetic type Oz External input type Oz TPVHI 3 3v Digital TP3 AD integral waveform TP4 3 3V Backup battery TPVL1 1 25V Digital TPVSI ov Digital ground Common with TPG1 TPVCI sv Digital CN16 oF ut i un m ar R z gee O sensor input l CPU operation check Red blinking normal m a Power supply check Green lighting normal TPGI ov Analog ground Common with TPVS1 CN8 To AIO board CN2 LCD back light TP2 Motor pulse Power supply input Optical unit 1 motor Optical unit 2 motor TN5A0354 E A 3 AIO board JP8 Additional AO board 1 Additional AO board 2 Ch1 Analog output selection Short circuit between 1 2 Current output CN10 External O sensor input IN Short circuit between 2 3 Voltage output CN3 JP9 Ch2 Analog output selection CN1 To Main board CN2 JP1 to 4 To DIO board C
32. screw 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 e 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 After replacement check next three subjects 1 check the voltage DV1 GND on Amplifier board shown above 2 check the counter value indicates shown above with zero gas supply 3 check resistance J1 J4 J2 J3 on Amplifier board shown above And perform zero and span calibration 5 Built in O sensor paramagnetic e Error mode Damage to O detector e Phenomena O detector indication is at O and O detector will GND Main board CN16 No 2 not even respond to span gas e Check 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 1t reads 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 O detector can be damaged e Measures Replace O detector e Replacement Turn OFF the analyzer main unit Since the O detector case is common to the 0V line be careful
33. sition 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 e Ifthere 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 If 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 Chl 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 drawing number 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
34. tage at the Main board Check the power supply Record the A D data when span gas is supplied Drift Check that specified amount of sampling gas is supplied to the analyzer main unit gt 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 window Replace parts Readings are high or low too much Check that a large quantity of interference components moisture and CO is not contained in sampling gas Check the components contained in sampling gases Ask the user what components are contained in sampling gas Readings are not increased Check that specified amount of sampling 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 sampling 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 compo
35. the SODA To return from each setting screen to the initial screen press the Esc key En Na Eso When escaping from the Factory Mode screen to the 2 Into each parameter screen Ree M sec pri 12 TN5A0354 E 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 Ex key 7 Mode Select an item thers when the cursor is aligned with the Zero limit itch ON OFF th key ZERO limit Switch between ON and OFF by the A or key hange linir Establish the setting contents by pressing the Gi key AO No Language f If you don t want to establish the contents press the Es ZERO gas Cylinder Protocol key Varied Range DIO No e Setting contents Factory Mode The value under zero is Others disappeared OFF does not display and output values below zero ON displays and outputs values below zero ZERO limit Range limit AO No Language ZERO gas Cylinder Protocol MO Varied Range ON DIO No 0 e Initial value OFF default Disappear This mode is used at the time of adjustment in order to check a display If the minu
36. when installing it avoid contacting the analyzer main unit case and O detector case Main board CN16 No 1 Generally an insulation mounting plate is supplied e Adjustment after replacement Perform zero and span calibration 6 Built in O sensor galvanic cell type e Recommended period of replacement 2 years e Error mode Sensor deterioration e Phenomena Span drift and fluctuation in indication by sensitivity deterioration e Check Same as Built in O sensor paramagnetic type Refer to 5 Check shown above e Measures Same as Built in O sensor paramagnetic type e Replacement Turn OFF the analyzer main unit Disconnect the connector piping and replace it with a new one e Adjustment after replacement Perform zero and span calibration 8 TN5A0354 E 7 Printed circuit board see printed board diagram at the back of the manual 1 Main board see Appendix 3 e Check Voltage check Check terminal Check voltage Contents TPVC1 TPVS1 5 40 3 V Digital 5 V TP15 TPG1 15 40 5 V Analog 15 V TPN15 TPG1 15 0 5 V Analog 15 V 1 51 43 3 60 2 V Digital 3 3 V TPVLI TPVSI 1 25 0 1 V Digital 1 25V e Precautions on replacement e The main board is set according to the specifications of each analyzer When ordering notify analyzer 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
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