AUTOMOTIVE EMISSION ANALYZER Multiplex
Contents
1. 8 4 1 4 Sensor signal check head amplifier output sees 9 4 1 5 Check for oxygen sensor signal eee ene 9 4 1 6 Check and adjustment for power supply of main PC board 9 2 ADJUSTMENT mr 10 51 Zero point adjustment d seam Eb PG ARMS 10 2 2 Span poInbcheek acero eene rur te e ER erp uet deer Ugo tu eb YAR B 10 3 9 Zero span 6al bratlon sie eroe 10 5 4 Adjustment of pressure sensor voltage essent 11 6 PARAMETER MODE LULU a A a Pa esse aaa daa yaymas 12 61 Overviewcof each mode ies ee as aaa os bees ecd tet aluet yan 12 6 2 How to set parameter mode rrt ertet ete d Ge Edge 12 6 3 Description of each mode series FREE SEER SEGE SEER BG Ee DEE EE DOE Ge eg sod Fe GARS SE Be be GEGEE eie 13 65d DATACLEAR inni ace ree Baba alay nda 13 6 3 2 JAPANESE ENGLISH indication ee ee ee ee ee ee ee se ee se ese ee ee ee ee ee ee ee 14 6 33 COMPONENT RANGE SED iis nies ies tete ee be ee ek R cri hier kase bi 15 634 PRETER SE E3 iare here sl gegee cei be ee ene n ed Gee be ep eed ees 16 635 Zero OFESET setting nre ree ree et R S 17 6 3 6 LINEARIZER table ee ee emen 18 INZ TN512524 E ii 6 3 7 INTERFERENCE COMPENS2. VR1 24V adjustment TP6 INZ TN512524 E A 5 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
3. Incorrect handling of the unit may lead to death or serious injury to the operator N WARNING eee Incorrect handling of the unit may cause a risk of death or serious injury to the operator N CAUTION Incorrect handling of the unit may lead to injury to the operator or damage to the unit INZ TN512524 E 1 1 PURPOSE OF USE This instrument is a multiplex analyzer capable of measuring 4 components in automotive emission carbon monoxide CO hydrocarbon HC carbon dioxide CO and oxygen O 2 ITEMS ON DANGER AND WARNING 2 1 General safety precautions D Before operating this instrument read and understand the contents of this manual 2 Do not allow any person to use this instrument unless she he is familiarized with the operation 3 Preparation for operation inspection and maintenance must be performed as mentioned in this manual 2 INZ TN512524 E 2 2 Operating precautions Failure to observe any of the follovving precautions could result not only in damage to the instrument but in personal injury or death Be sure to read the following items and use the instrument correctly N DANGER The span gas cotained in a can is harmful Do not spray it to human body t may lead to a risk of death or serious injury N WARNING Be careful with electric shocks e Turn OFF the power before performing wiring work to prevent risk of death or serious i
4. m Service Manual AUTOMOTIVE EMISSION ANALYZER 60 H6 C0 0 Multiplex Analyzer Measuring Instrument TYPE ZKE De M Fuji Electric Co Ltd INZ TN512524d E CONTENTS INTKODUCLION LL 0 aaz yaaa daa Dada a 1 l PULPOSBUEUSEL LLL A Ra 2 2 ITEMS ON DANGER 2 2 1 General Safety precautions iet EER ten i eere s e re uve qoo kde t va ke 2 2 2 Operatimig precautions cie AGE Ee EE se De y a a 3 3 DESCRIPTION OF OPERATING PARTS AND CHECK ITEMS 4 3 1 Sampling System EE EFE Na ee rud 4 EE EE 4 3 1 2 4 3 2 Measuring dei EE EAE 5 3 2 SR b s b OE HE ER EA N 5 3 2 2 Troubleshooting eere EK oek eg Ter s Y sig ee pe se Ge 6 3 3 Electric system and PC board SE REGEER RS GEGEE RE EE GR ss EG Ek RR sek ba ns 7 3 9 6 ii KERR iio EE N EE ES 7 3 3 2 Troubleshooting ns m T 4 VOLTAGE CHECK e AT OE EE N 8 4 l Voltasecheck of parts eee e etsi TEE ays 8 41 1 Check for power supply voltage of amplifier PC board 8 4 1 2 Check for motor driven signal seen emen 8 4 1 3 Check for pump driven signal with pump driven
5. oldind e ER peu UMEIG BUMIM JO 40102 peu usa MOJSA SUM yorig mecoom Leer INZ TN512524 E 22 E m O SNO OLNO 8 7 080 Gauld andino eds ec c BEL BAJEA piousjos AS UNO YNO dung o d ENS Od Jeyijduiv TERS duind 9a Aiddns 1eyidure pe H OIN ooJnos 1461 Od Jeyidue peay eouelsisoJ 10 99 p Aes 1u os loni i JO198UU09 Sune d ki HH V L dq aI Jamod SuluoHAS apis apis eounosiuDi 40014 105495 AY UO y UO au o Buxy v o pejeuuo p p uuog A jun 1 y os Aiddns 1204 A 2 9 2 Piping diagram Drain separator Membrane fi ter Measured gas Pressure AA MH sensor L Men Tube with i different dia Solenoid 4 Solenoid type double absorber Calibration gas inlet i Sampling cell Oe sensor Sampling gas outlet Drain outlet Soft transparent vinyl tube 4 8 42 8 Polyurethane tube 9 5 5 Toaron tube 69295 Toaron tube 7 4 Hose band 8 Hose band 4 3 Hose band INZ TN512524 E 7 9 3 Layout of amplifier PC board check pins and controls VR1 HC
6. No Is pressure sensor See Page11 voltage normal Yes Adiust pressure sensor voltage s air tightness OK See Manual Y Replace pressure sensor Take a step of parts in trouble INZ TN512524 E 8 4 PROBE IN alarm in trouble Contents of trouble PROBE IN indication lamp di ROBE IN indication lamp keeps on lighting or does not light J keeps on lighting PROBE IN indication lamp does not light 8 5 Other trouble a Contents of touble Fuse is burn out by the power ON Wiring or shorted or parts are in trouble 2 Gas will leak even if calibration gas is supplied INZ TN512524 E Poor air tightness of sampling system No See manual Is air tightness OK Repair parts in trouble Adjust voltage of CO2 and HC meters Do CO2 meter and HC meter read normal voltage See Page 10 CO2 meter reading 4vol or less HC meter reading of 20volppm or less Replace sensor unit Perform zero calibration Reasons for replacement Remark PCB is See Page 10 other Detach the PCB voltage supply connector Amplifier CN7 and check faulty parts of the primary and secondary sides See Instruction Manual Perform airtightness check of each part 31 ATTACHED DRAWINGS 9 9 1
7. see instruction manual Y Clean cell and window Is connector attached properly Yes Is each unit voltage proper s the resistance value of light source proper Yes Replace PC board No Take a remedy of faulty part See Page 10 Check and adjust No Replace the light source Y Perform zero and span calibrations again 29 8 2 Fluctuations in indication value Contents of trouble Concentration indication is suddenly scale over Fluctuations are sharpened 8 3 Contents of trouble Filter replacement indication lamp keeps lighting Filter replacement indication lamp does not light 30 Measuring indications are suddenly changed Yes Check again by flowing measuring gas See Instruction Manual Is indication normal by flowing zero gas s motor driven No signal normal See Page 8 Repair amplifier and main PCB s motor revolution normal See Page 8 Yes Replace motor Repair amplifier and main PCB It seems that optical system is in trouble See chapter 4 to check for voltage in each unit Filter replacement alarm in trouble ee replacement indication la mp keeps on lighting or does not
8. 10 PE F 620 Ico 1999 05 08 15 00 P P E F EF 0500 INZ TN512524 E 6 3 11 Check of sensor signals The indication just after the A D conver 1999 05 08 15 00 PARAMETER MODE sion of each sensor CO HC CO2 02 1 DATA CLEAR 2 JAPANESE ENGLISH temperature pressure can be read It a COMEONENL HENGE SET helps you in analyzing trouble 6 LINERIZER 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION D Press the key on the PARAM 9 MINUS 10 PE F ETER screen The pump is driven to qel switch to this mode 2 Move the cursor to select any of analog input components you want to read by B CO Variables pressing the key and then press HC Variables CO Variabl the key Oz Variables 3 To retum to the PARAMETER 2 pl I amp omponent value screen press the s key co 0 10vol Description of analog input AinP No COUNT Sensor 3 11 and 15 are not used 0 Value just after A D conversion CO Co o Temp 13 CO HC O2 variables X COUNT X8 to X15 are not used 0 Value just after A D conversion Value after offset Value after zero temperature compensation Value after zero calibration 4 Value after interference compensation Value after span temperature compensation 6 Value after span calibration Value after linearization INZ TN51252
9. of 2 component 3 component and 4 component by pressing the key Press the SET key The cursor moves to HC RANGE 4 Select 10000volppm or 14000volppm by the D key and press the key 1999 05 08 15 00 PARAMETER MODE 1 DATA CLEAR 2 JAPANESE ENGLISH Bl 3 COMPONENT RANGE SET 4 PRINTER SET 5 OFFSET 6 LINERIZER 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION 9 MINUS 10 PE F DI 50 1999 05 08 15 00 COMPONENT RANGE SET COMPONENT 2 3 4 HC RANGE 10000 14000 NO OF COMPONENTS 2 2 component display CO HC igs ae 3 component display CO HC CO 4 4 component display HC RANGE 10000 10000volppm meter in full scale 14000 14000volppm meter in full scale 620 160 1999 05 08 15 00 COMPONENT RANGE SET COMPONENT 2 3 4 HC RANGE 110000 14000 GD 8 The display will return to the PARAMETER screen INZ TN512524 E 15 6 3 4 PRINTER SET This mode is used vvhen selecting any printer other than recom mended printer D Point the cursor to 4 PRINTER SET by pressing the key 2 Press the key to switch the screen to this mode 3 Select any of baud rates 9600 4800 and 2400 by pressing the and press the e key The cursor will move to the BIT selection 4 Select either 8 or 7 by the key and press
10. the key again The cursor moves to the PARITY selection 5 Select any of None Even and Odd from PARITY and press the Ge key The cursor will disappear 6 Pressing the key will return to the PARAMETER screen Pressing the key will return to the PARITY screen BAUD RATE 9600 4800 2400 BIT s T PARITY None Odd Even 16 1999 05 08 15 00 PARAMETER MODE 1 DATA CLEAR 2 JAPANESE ENGLISH 3 COMPONENT RANGE SET 4 PRINTER SET 5 OFFSET 6 LINERIZER 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION 9 MINUS 10 PE F n 620 ke 1999 05 08 15 00 PRINTER SET BAUDRATE 9600 4800 2400 BIT 8 7 PARITY NONE ODD ENEN 620 Iso 1999 05 08 15 00 PRINTER SET BAUDRATE 9600 4800 2400 PARITY NONE ODD ENEN 620 ke 1999 05 08 15 00 PRINTER SET BAUDRATE 9600 4800 2400 BIT 8 7 PARITY NONE ODD ENEN 620 50 1999 05 08 15 00 PRINTER SET BAUDRATE 9600 4800 2400 BIT 8 7 PARITY NONE ODD ENEN BIT 7 INZ TN512524 E 6 3 5 Zero OFFSET setting This mode is used to offset zero electrically vvhen replacing the main or amplifier PC board D Point the cursor pl to 5 OFFSET by pressing the key 2 Press the key to switch the screen to this mode 3 Use an adjuster on the amplifier PC board to adjust analog values of components
11. to 0 1V0 1V or less when the zero gas N is supplied See Page 10 Note 1 Option O meter reads the counter indication if pro vided Note 2 Zero gas is permitted in the air if the O meter is not provided Note 3 The CO meter is used for internal compensation even when the 2 component mode is selected This mode also is effective 1999 05 08 15 00 PARAMETER MODE 1 DATA CLEAR 2 JAPANESE ENGLISH 3 Oz RANGE SET 4 PRINTER SET NO 15 5 OFFSET 6 LINERIZER 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION 9 MINUS 10 P E F 1999 05 08 15 00 OFFSET Digital counter value YES NO CO HC CO2 Oz VVhen the 4 component GED YES lcs display mode is selected the Oe meter is displayed 1999 05 08 15 00 OFFSET YES NO co 0 HC 0 CO2 0 O2 0 4 Select YES or NO from the OFFSET screen and press the amp key NO The OFFSET screen will return to the PARAMETER screen with out executing OFFSET YES It executes OFFSET 5 Press the YES button again and the cursor will disappear The component counter indicates a value near 0 6 Pressing the key returns to the PARAMETER screen INZ TN512524 E 17 6 3 6 LINEARIZER table generation 18 This mode is used vvhen replacing the PC board and sensor unit ente
12. when sucking air If not replace it Procedures 1 Detach the connector inserted into the amplifier PC board CNS 2 Turn the oxygen sensor counterclockwise to remove from the mount ing board 3 Wind a seal tape on the replacement oxygen sensor and screw in clockwise Oxygen sensor INZ TN512524 E 27 7 9 LCD fluorescent tube Reason for replacement The fluorescent tube is a consumable Replacement should be per formed every 10 000 hours 1 Remove F P C cable from the main PC board CN4 2 Remove 4 tapping screws which secure the front panel 3 The rear cover of the LCD panel is secured by claws at 5 positions 4 Remove the rear cover by using a driver 5 Lift both ends of the connecting lines for replacement 6 For assembly reverse the replacement procedure Procedures Connection line Rear cover claw LCD 7 Fixing screvv 4 taping screvv nverter PC board 28 INZ TN512524 E 8 TROUBLESHOOTING CHART 8 1 Improper zero calibration Contents of errors D After calibration the Component Display lamp flickers CO 9 004 H een CO 0 05A 1999 10 01 12 00 ML N 2 Display is under bar or over bar 1999 10 01 12 00 GO volppm 0 05 INZ TN512524 E Zero calibration does not return to 0 Does zero gas flow Yes No stains in optical system Flow zero gas
13. 4 E 23 7 UNIT REPLACEMENT 7 1 Infrared ray light source unit Reason for replacement Disconnected or deteriorated infrared ray light source leak of sealing gas cracked window improper readings due to contamination Check 1 Visually check that the window is not dirty or the sealing pipe is not damaged 2 Detach the connector and check the winding resistance values of the light source The resistance values should be 3 90 30 Procedures 1 Detach the connector inserted into the repeating connector 2 Remove 2 M4 screws which fix to the optical system base plate 3 Remove the cell unit from the light source holder 4 For assembly after repair or replacement reverse the above proce dure Cell unit 7 Light source unit 2 M4 screw Optical system base plate 7 2 Sensor unit Reason for replacement Fluctuating indication due to damaged sensor dirty and scratched B P F and damaged motor Check 1 Perform a visual check of window and B P F for stain or scratch 2 Check that the sector rotates in a fixed cycle 3 Check that the sensor signal is normal See Page 9 Procedures 1 Detach the connector that is attached to the sensor unit 2 Remove 2 M4 screws which secure to the optical system base plate 3 Remove the cell unit from the light source holder 4 For assembly after repair or replacement reverse the above proce dures after repair or replacement Cell unit Sensor unit ptical
14. A 1 9 1 1 Wiring diagram Manufacture before March 2004 A 1 9 1 2 Wiring diagram Manufacture after April 2004 222 A 2 92 Pipimg lui AE OE N A 3 9 3 Layout of amplifier PC board check pins and controls s A 4 9 4 Layout of main PC board check pins and controls 2222 A 5 INZ TN512524 E INTRODUCTION You are now the owner of the automotive emission carbon monoxide hydrocarbon carbon dioxide oxygen multiplex analyzer measuring instrument Before using the instrument be sure to read and understand the contents of this manual The precautions and operating instructions should be observed to ensure the full performance of the unit and to prevent unexpected trouble such as electric shocks accidents resulting in injury or death due to absorption of harmful gases Manufacturer Fuji Electric Instrumentation Co Ltd Type Described in nameplate on main frame Date of manufacture Described in nameplate on main frame Product nationality Japan N WARNING This instruction manual shows the following warning symbols on danger warning and cau 2 tion and their descriptions which are very important to ensure safe operation of the unit Before using the unit be sure to read and understand the description of the symbols to prevent accidents resulting in injury or death or damage to the unit AN DANGER
15. ATION table generation 19 6 3 8 TEMPERATURE COMPENSATION table generation 20 639 MINUS imdicatioti seed oek ie ee rrr rrr Errant seek ag Ee ee eb ke 21 6310 PE EE EE EE LE 22 6 3 11 Check of sensor sipghials ue eet s b tree be xt etd 23 UNIT RBPLACENMIENT ceris a Rada a a euro Aye veta su EE Ru deed eed 24 7 1 Infrared ray light source unit 24 ME oe s ice tei N EE EE EE E 24 13 OO RE NE RE N EO EE IE 25 7 4 Switching power source unit see see ee Se ee ee Ge RA eee AR E ek 25 5 Pump RR EE RE EE ER ESEE EEEE 26 TO Solenoid Valve tt uino nee netter ERE EGER lasts 26 TA 27 7 8 27 7 9 LCDiluorescenttube d y d 28 TROUBLESHOOTING CHART 29 8 1 Improper z ro calibration 29 8 2 Fluctuations in indication value esee 30 8 3 Filter replacement alarm in trouble D EE EE 30 84 PROBE IN alarm in trou ble issues ss iese ss Gees ertet Here 31 85 Se RR EE EE EE N 31 ATTACHED DRAWINGS esse en Des Ge R a A 1 9 1 Witing dia ram Uu e EERE
16. Note Press your hand tightly against the port Otherwise airtightness may be impaired 4 Using VRS adjust the voltage across TP5 SC to 2 200V 0 1V Cover the port with the palm of your hand INZ TN512524 E 11 6 PARAMETER MODE To repair this instrument the following data may have to be changed 6 1 Overview of each mode Mode No Name Contents 1 DATA CLEAR Initializes internal data present parameter mode 2 JAPANESE ENGLISH Switches Japanese to English or vice versa indication 3 COMPONENT RANGE SET Sets the number of display components and HC range 4 PRINTER SET Sets when a printer other than recommended one is connected 5 OFFSET Sets hardware offset values 6 LINEARIZER table generation Converts non linear output into linear output 7 INTERFERENCE Compensates for mutual interference COMPENSATION table generation 8 TEMPERATURE Compensates for influence of ambient temperature COMPENSATION table generation 9 MINUS indication Sets with without of a minus indicator 10 P E F entry Sets propane ratio coefficients at the time of HC span calibration Alive signal values of each sensor Reads signals from sensors of CO HC CO O temperature pressure 6 2 How to set parameter mode D Select 8 PARAMETER SET from the Menu screen 2 Press the key to set this mode and the screen will be switched to this PARAMETER SET screen 3 Using the digi
17. Press the key to switch the screen to this mode 3 Select either zero or span TEMPERATURE TABLE by the key Note TEMPERATURE TABLE is a collection of temperature sensor data No change must be made for routine work 4 Press the key to select any component you want to change by using the key 5 Press the key again to change the Y axis data by the key After setting press the key to save the data Pressing the key returns to the PARAMETER screen X axis Temperature value no change can be made Y axis Amount of compensation change can be made 1999 05 08 15 00 PARAMETER MODE 1 DATA CLEAR 2 JAPANESE ENGLISH 3 COMPONENT RANGE SET 4 PRINTER SET 5 OFFSET 6 LINERIZER 7 INTERFERENCE COMPENSATION m 8 TEMPERATURE COMPENSATION 9 MINUS 10 PE F 6201 ED PARAMETER MODE TEMP COMP TEMPERATURE TABLE 1 ZERO TEMPERATURE TABLE SPAN TEMPERATURE TABLE 620 1590 PARAMETER MODE TEMP COMP ZERO COMP B CO HC CO2 O2 cep 159 PARAMETER MODE CO TEMP COMP ZERO COMP X Y x Y 1 L 4 2 5 INZ TN512524 E 6 3 9 MINUS indication This mode is used to set the indication belovv zero to 0 D Point the cursor pito 9 MINUS by pressing the key 2 Press the key to switch the screen to this mode 3 Select ON or OFF to indicate the MINUS indication by pres
18. W 9 1 1 W iagram d iring Manufacture before March 2004 iagram d iring y us ENO YS928601 Kay 19eus HUM s ng SBUEIO a g ped NO A NUM eg A 1 5 0 5 A PA Ploualos NOS AHFZOZEAND feysAuo pinbr NOll K s aiding x yoe z peu umesg DuLlA JO 40102 c dat ue4 avanos OOI 1osues lay uo au uo Buxy u o Dur y o p lp uuoo pepeuuoo o pseoq Od UEN m L med dund 5q pinbr1 YNO IZEYS928 INO r pisa 2005 1461 jellie beer __ eouelsisel Aes jueoseJon 4 V 40 10 p ejnyejeduie 10j9euuoo HE Li apis apis Jamod ButuoiiMS Aiddns samod jun 1 y os INZ TN512524 E 9 1 2 VViring diagram Manufacture after April 2004 Kex 1eeus END Ve Y9928601 O dd Kay 19949 HUM s ng o SBUEIO a g pseoq Od UIEN sayy NO 7 e res pinbr1 JeyeAuj O d AHFZOZEAND q es A pinbri dam 014 NO A s
19. components Phenomena Probable cause Remedies Infrared ray light Readings remains unchanged Disconnected e Measure winding source unit light source resistance value windings within 3 90 30 Readings are not stable due to lack of Dirty window e Clean sensitivity Improper accuracy linearity of CO2 Sealing gas Replace light source unit meter released Cell unit Readings are not stabilized due to Dirty sampling e Clean lack of sensitivity and zero cell calibration or span calibration is not carried out Readings are not stabilized due to Deteriorated Replace leak of sampling gas O ring Cell holder Readings are not stabilized due to Dirty window e Clean lack of sensitivity and zero calibration or span calibration is not carried out Sensor unit Readings are not stabilized Dirty band pass Clean filter BPF Readings are not stabilized Deteriorated or e Replace damaged sensor head amplifier Readings remains unchanged Improper motor Check for motor signal revolutions See Page 8 Readings remains unchanged Sector revolution Reinsert sector Temperature is not compensated Disconnected properly temperature compensation resistance Oxygen sensor Oxygen meter readings are improper Check oxygen Disconnect the oxygen sensor along for sensor connector and check voltage the voltage Zero gas N 0 to ImV Span gas corresponding to 21 27mV 8mV 6 INZ TN512524 E 3 3 Ele
20. ctric system and PC board 3 3 1 Outline The electric system is used to operate the double suction pump motor fan and each PC board electrically The PC board incorporates the first stage IC s of AC amplifier circuits of CO HC and CO in the head amplifier sensor unit The amplifier PC board incorporates analog circuit pump driven circuit solenoid valve driven circuit and motor driven circuit for CO HC and CO and O CPU and memory IC are mounted on the main printed board Since the electrical system uses switch ing power for power supply it is compact and lightweight This section provides the troubleshooting which helps you to determine if each part is properly functioning 3 3 2 Troubleshooting Name of components Phenomena Probable cause Remedies Power cord Electricity is not supplied to each unit Replace Tube fuse Electricity is not supplied to each unit Replace Fuse holder Electricity is not supplied to each unit Damaged or Replace improper contact Power switch Electricity is not supplied to each unit Improper contact Replace Switching power Electricity is not supplied to amplifier Faulty circuit Replace printed board Head amplifier See Pages 8 and 9 See Pages 8 and 9 Main printed board See Page 9 See Page 9 EEN Amplifier printed board See Pages 8 and 9 See Pages 8 and Sy 9 INZ TN512524 E 7 4 VOLTAGE CHECK 4 1 Voltage check of parts 4 1 1 Check for power supply vol
21. he reference voltage Ref gain Note 3 No gain adjustment is required for the oxygen sensor Components Setting voltage Points to be checked Adjuster Ref 2 000V DC 0 05V Across TP4 SC VR4 CO 0 100V DC 0 1 V Across TP2 SC VR2 HC 0 100V DC 0 1 V Across TP1 SC VRI CO 0 200V DC 0 1 V Across TP3 SC VR3 Span point check After zero point adfustment flovv supplied eylinder gas through the calibration gas inlet to check for span point voltage Note 1 Check for the span point when the pump is securely stopped Components Setting voltage Points to be checked Span gas Ref 2 000V DC 0 5V Across TP4 SC CO 0 600V to 1 100 V DC Across TP2 SC 3 0 to 3 5vol CO HC 0 600V to 1 100 V DC Across TP1 SC 3600 to 4000 volppm C H CO 1 400V to 1 900 V DC Across TP3 SC 18 0 to 20 0 vol CO 5 3 Zero span calibration 10 Carry out zero span calibration by pressing the front key For calibration procedure refer to Instruction Manual INZ TN512524 E 5 4 Adiustment of pressure sensor voltage D Drive the pump by pressing key to suck in air through the drain port in about 15 sec 2 Attach a voltmeter across TPS SC of the amplifier PC board Using VR6 adjust the voltage to 0 000V 0 1V zero point adjustment for pressure sensor 3 Cover the drain separator port with the palm of your hand so that airtightness can be maintained
22. ing Procedures power supply unit 4 For assembly after replacement reverse the above procedure Pump unit 2 tapping screw Fixing claw 7 6 Solenoid valve unit Reason for replacement Error in reading is found due to leak Switching of zero gas and sampling gas is improper Check 1 Apply pressure of less than 20kPa to A port of the solenoid valve to check for leak Note Gas inlets A and Flow path direction Non conductive A OB are provided at Conductive DE the main unit 1 Remove 4 tapping screws from the membrane filter mounting board 2 Remove the solenoid valve that is secured to the mounting board unit by 2 M3 screws 3 For assembly after replacement reverse the above replacement Procedures procedure 26 INZ TN512524 E 7 7 PC board unit Reason for replacement It is damaged due to shorted power supply Check Check for voltage and waveform at each part For details see Page 8 to 10 Procedures 1 Detach the connector connected to each unit 2 Remove 2 tapping screws that secure the PC board 3 The amplifier is fixed to the main PC board by a single fixture 1 4 For assembly after replacement reverse the above procedure 7 8 Oxygen sensor unit Reason for replacement This sensor unit is a consumable Replacement should be performed every year Check Measure the voltage at both ends of the sensor connector Voltage should be more than 10mV
23. lace Indicating action is slow Check for piping joints Readings are too low due to absorbed air Primary filter holder Readings are too low due to absorbed Damaged Replace holder with probe tightening air Tightening screws Retighten Screws are loose Sampling tube Flow rate is not supplied as specified Clogged Replace tube with connecting cap Indicating action is slow Check for piping joints Readings are too low due to absorbed air Primary filter element Flow rate is not supplied as specified Dirty clogged Replace periodically Indicating action is slow Membrane filter Flow rate is not supplied as specified Replace periodically Indicating action is slow 4 INZ TN512524 E Name of components O ring large small for membrane Primary filter drain separator and packing Drain separator Membrane filter for cover and cylinder Double suction pump Pressure sensor Span gas inlet Internal piping Charcoal filter Phenomena Readings are too low due to absorbed Readings are too low due to absorbed air Readings are too low due to absorbed air Flow rate is not supplied as specified Indicating action is slow Readings are too low due to absorbed air Gases are not suctioned Specified flow rate is not supplied Drain is not exhausted outside Flow rate cannot be monitored No readings of standard gases are not indicated since standard gases are
24. njury due to electric shocks Before using the instrument read and understand the contents of this instruc tion manual Incorrect handing of the instrument may lead to unexpected accidents the operation Do not allow any person to use the instrument unless she he is familiarized with Kb Incorrect handing of the instrument may lead to unexpected accidents INZ TN512524 E 3 DESCRIPTION OF OPERATING PARTS AND CHECK ITEMS 3 1 Sampling system 3 1 1 Outline The sampling system is used to supply a specified amount of automotive emissions to the measur ing unit by removing a trace of dust or drain from gases exhausted through the tail pipe of auto mobiles For an analyzer to measure automotive emissions accurately each unit of the sampling system must meet the following requirements 1 Flow rate monitored by pressure gauge is as specified 2 Air is not sucked into the units which are measuring automotive emissions 3 It is designed not to allow dust or drain to enter the measuring unit If these requirements are not met the instrument may provide different measuring readings from actual concentration of emission gases The following chart will help you locate the probable cause of trouble or perform the routine maintenance and check for the sampling system 3 1 2 Troubleshooting Name of components Phenomena Probable cause Remedies Probe Flow rate is not supplied as specified Clogged e Rep
25. not supplied to the measuring unit Readings are too low due to absorbed air Response speed is too slow to return to zero point 3 2 Measuring unit 3 2 1 Outline Probable cause Damaged or scratched Damaged or scratched Incorrect fitting Damaged Fitting of connect ing cap Clogged Damaged Closing of door Damaged dia phragm Disconnect excit ing coil or burn out Improper sensor Improper circuit Clogged Damaged or improper plugging Excessively clogged Remedies Replace O ring Replace packing Check Replace O ring Check Replace pump Check for pump signal See Page 8 Check for sensor Check for sensor circuit nternal piping Check for connections Check for connections Replace The measuring unit flows cleaned up exhaust gases filtered by the sampling system into the internal sampling cell It optically analyzes CO HC and CO contained in the gases and converts them into electrical signal voltage change Use of solid state sensor and band pass filter makes the measuring unit compact which is composed of infrared ray light source cell sampling cell only and sensor unit In addition an O meter option uses galvanic cells This section covers troubleshooting which aids you in finding out the causes of trouble and taking its remedy when the instrument is in trouble INZ TN512524 E 5 3 2 2 Troubleshooting Name of
26. pe 8 VD 820 io 45V 190 7 s zia 8 655 uo 6 N 12105 za ee 5 a 5 lc ED 2 g af N FS o C LU II 2 D 92100 850 020 8 5 ere 8140 6615 ob Up 8 iz F Down LA 600 8 48 ord Bu 290 550 29 wo 6 99 m KH PCc4 PC9 Pce B PC10 PC18 Note The following parts are not mounted on this PC board PC7 EZ TK366845R1 PC15 2 Peiz V 3 m 2895 OG OO JE JO g T3o3773 H as 2 5 5 7 as b PCB Geo 8 o PC16 PCS PC17 L101 P62 VR2 Q30 TI I R115 R113 Q29 SD2 C57 C53 C55 C48 C50 R91 R34 R117 R119 R120 R53 R98 R59 R60 R61 R63 R64 R70 R19 R21 R22 VR3 R114 C51 C49 CN1 CN2 Check pins N15 P15 TP7 TP8 N12 J1 J3 J7 J8 TE TE1 o amp 1 85 2010 9012 SOLO 4 X13 RIISRII4 6 o 01 030 E Q9 GE 57 1 6 C49 gt t S02 8 SELH A Sep oLa 1010 2 us GND Q2 Q27 211 RTTORTT 48 25 Q E 8 E b a Gi 0010202
27. r Note If you have purchased sensor units for maintenance supplied data is requested to D Point the cursor pj to 6 LINEARIZER by pressing the key 2 Press the c key to switch the screen to this mode 3 Move the cursor to any component you want to change by using the key 3 4 Press the key to select the crossover you want to change by the key 5 Press the amp key again to change each crossover data by the key 6 Press the 2 key to save the data The cursor will appear 7 Press the key to return to the PARAMETER screen No of crossover points is 16 1 to 16 X axis indicates output values or equivalent Y axis indicates values of concentration or equivalent 1999 05 08 15 00 6 LINERIZER PARAMETER MODE 1 DATA CLEAR 2 JAPANESE ENGLISH 3 COMPONENT RANGE SET 4 PRINTER SET 5 OFFSET 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION 9 MINUS 10 P E F DI ED PARAMETER MODE LINERIZER TABLE e 15 co HC CO PARAMETER MODE LINEARIZER TABLE X Y X Y 9 oo o o1 1 EI 9 d PARAMETER MODE LINEARIZER TABLE Y X Y X 0000 9 SNS e INZ TN512524 E 6 3 7 INTERFERENCE COMPENSATION table generation This mode is used when replacing the PC board or sensor Note If
28. rd Lo is CNI 4 SC check pin Woy he 1240ms 29 CO Across amplifier PC board 0 5 te CNI 6 SC check pin 24oms 2 Ref Across amplifier PC board E sein CNI 2 SC check pin x l240ms 2 4 1 5 Check for oxygen sensor signal Remove CN8 from the PC board Across the ends of the PC board attach a voltmeter to check the voltage Note No power supply is required for the battery powered oxygen sensor Item Points to be checked Voltage check Zero gas N 0to ImV DC O Both terminals of sensor connector Span gas Air 27E8mV DC 4 1 6 Check and adjustment for power supply of main PC board Attach a voltmeter across the check terminals of the main PC board to check that the readings are within the standard range supply voltage Item Points to be checked Setting voltage Adjuster Power supply voltage Across VD VG 5 000V DC 0 2V Check only Indication power Across TP6 GND 24 000V DC 0 2V VRI INZ TN512524 E 5 5 1 5 2 ADJUSTMENT Zero point adjustment Attach a voltmeter to the check terminals of an amplifier PC board Drive the pump by pressing key to suck clean air Using zero point adjuster the voltage should be adjusted as given below when the pump is in suction Note 1 Carry out warm up operation for more than 30 minutes and then perform zero point adjustment while the pump sucks in clean air Note 2 Perform zero point adjustment by t
29. sing the key and press the ge key ON indicates a value below zero OFF sets a value below zero to 0 4 The display returns to the PARAMETER screen INZ TN512524 E 1999 05 08 15 00 PARAMETER MODE 1 DATA CLEAR 2 JAPANESE ENGLISH 3 COMPONENT RANGE SET 4 PRINTER SET 5 OFFSET 6 LINERIZER 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION 15 9 MINUS 10 PE F GED Ke 1999 05 08 15 00 MINUS ON OFF 21 6 3 10 P E F This mode is used to set the range vvhen replacing the PC board and sensor unit enter Note If you have purchased sensor units for maintenance supplied data is requested to D Point the cursor bil to 10 P E F by pressing the key OD 2 Press the key to svvitch the screen to this mode 3 Select the digit you vvant to change by using the key O and set by the key 1 The setting range is from 0 300 to 0 700 VVhen entering 0 000 the converted value be comes X 1 000 or equivalent If a value is entered beyond the range the setting becomes invalid 4 Press the 2 key to save the data then the display returns to the PARAMETER screen 1999 05 08 15 00 B PARAMETER MODE 1 DATA CLEAR 2 JAPANESE ENGLISH 3 COMPONENT RANGE SET 4 PRINTER SET 5 OFFSET 6 LINERIZER 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION 9 MINUS
30. system base plate 2 M4 screw 24 INZ TN512524 E 7 3 Cell unit Reason for replacement Improper air tightness due to deteriorated O ring Check Procedure Poor sensitivity due to contaminated inner surface of the cell 1 Check that O ring is free of crack or scratch 2 Wipe the cell interior with a soft cloth Remove the infrared ray light source unit in Item 7 1 and sensor unit in Item 7 2 and then remove the cell unit T A Switching power source unit Reason for replacement Indication lamp is not lit due to improper power supply voltage Check Procedure INZ TN512524 E Check for power supply voltage of each unit See Page 8 9 1 Detach the primary and secondary connectors of switching power supply 2 Remove claw that secures the case using a driver and the switching power supply unit 3 For assembly after replacement reverse the above replacement procedures Secondary connector Fixing claw Switching power supply Primary connector 25 7 5 Pump unit Reason for replacement Response is improper due to deteriorated diaphragm Check Attach a flowmeter to the drain port to check for the total flow rate drain and sampling port If the total flow is below 3 min replace the pump unit 1 Detach the connector inserted into the amplifier PC board CN3 2 Remove 2 tapping screws securing to the case 3 Remove a claw that secures the case using a driver and the switch
31. t select key and value increment key enter the password Type 6361 in the password box 4 Press the ge key to display the PARAMETER MODE screen 12 1999 05 08 15 00 PARAMETER SET PASS WORD 0000 Cursor 106 1999 05 08 15 00 PARAMETER SET PASS WORD 63611 1999 05 08 15 00 PARAMETER MODE Bl 1 DATA CLEAR 2 JAPANESE ENGLISH 3 COMPONENT RANGE SET 4 PRINTER SET 5 OFFSET 6 LINERIZER 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION 9 MINUS 10 P E F INZ TN512524 E 6 3 Description of each mode 6 3 1 DATA CLEAR Note Don t use this mode since it is used to clear internal data If it must be used keep records of information associated vvith all parameters 1999 05 08 15 00 D Point the cursor bil to 1 DATA CLEAR by pressing EE MEER GEE 1 1 DATA CLEAR 2 JAPANESE ENGLISH the key 3 COMPONENT RANGE SET 4 PRINTER SET R A 5 OFFSET 2 Press the key to switch the screen to this mode 6 LINERIZER 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION 9 MINUS 3 Select YES or NO by the key and press the ge 10 PEF key again qel 50 1999 05 08 15 00 DATA CLEAR No The parameter screen will return without executing DATA CLEAR YES Nol Yes A message appears prompting you to verify that you vvant to execute Data Clear F
32. tage of amplifier PC board Attach a voltmeter across the check terminals of an amplifier PC board to check that the readings are vvithin the standard range Item Points to be checked Voltage check Power supply voltage 1 Across Vcc and GND 5 000V DC 0 15V Power supply voltage Across P12 and SC 12 000V DC 0 5V Power supply voltage Across N12 and SC 12 000V DC 0 5V 4 1 2 Check for motor driven signal Attach an oscilloscope to the connector of the amplifier PC board to check for waveform Item Points to be checked Waveform check Motor driven signal Across CN2 D 2 n be terminals Yo 20ms 1 4 1 3 Check for pump driven signal with pump driven Attach an oscilloscope to the connector of an amplifier PC board Press key to check for waveforms when the pump is driven Item Points to be checked Waveform check Across CN3 D 2 terminals Pump driving signal 24Vt 5 i 20ms 1 8 INZ TN512524 E 4 1 4 Sensor signal check Head amplifier output Attach an oscilloscope to the connector of an amplifier PC board Check for waveforms of each component by flowing zero gas air Item component Points to be checked Voltage check CO Across amplifier PC board M CNI 5 SC check pin LA Bosvessos a4oms 292 HC Across amplifier PC boa
33. ue G l NES 1999 05 08 15 00 DATA CLEAR OK Press the amp key NO Press the g key OK 4 Whether pressing the YES or NO button or not this screen will return to the PARAMETER screen INZ TN512524 E 13 6 3 2 JAPANESE ENGLISH indication This mode is used to switch the indication of the MENU and PARAMETER screen to Japanese or English D Point the cursor pl to 2 JAPANESE ENGLISH by pressing the key 2 Press the key to switch the screen to this mode 3 Select TAPANESE or ENGLISH by pressing the key and press the key again JAPANESE Japanese indication mode ENGLISH English indication mode 4 The display will return to the PARAMETER MODE screen 14 1999 05 08 15 00 1 DATA CLEAR 4 PRINTER SET 5 OFFSET 6 LINERIZER 9 MINUS 10 R E F PARAMETER MODE m 2 JAPANESE ENGLISH 3 COMPONENT RANGE SET 7 INTERFERENCE COMPENSATION 8 TEMPERATURE COMPENSATION Gepi Ico 1999 05 08 15 00 JAPANESE JAPANESE ENGLISH ENGLISH ED INZ TN512524 E 6 3 3 COMPONENT RANGE SET This mode is used to set the number of display components and to select the range value of the HC meter D Point the cursor P to 3 COMPONENT RANGE SET by pressing the key 2 Press the to switch the screen to this mode 3 Select any
34. you have purchased sensor units for maintenance supplied data is requested to enter D Point the cursor to 7 INTERFERENCE COMPEN 1999 05 08 15 00 i PARAMETER MODE SATION by pressing the key 2 JAPANESE ENGLISH 3 COMPONENT RANGE SET 4 PRINTER SET 2 Press the e key to switch the screen to this mode 5 OFFSET gt 6 LINERIZER BI 7 INTERFERENCE COMPENSATION 3 Move the cursor to any datat you want to change by E TEMPERATURE GOMPENSATION 10 P E F using the key G l 4 Press the key to select the crossover you want to PARAMETER MODE INTERFERENCE change by the key 161 CO COz 5 Press the e key again to change each crossover data by 2 CO HC 8 HC CO the key d 6 Press the key to save the data The cursor will appear 620 50 PARAMETER MODE INTERFERENCE 7 Pressing the key returns to the PARAMETER screen CO HC CO2 CO CO2 CO e PARAMETER MODE INTERFERENCE CO HC CO CO CO2 CO H00 01 INZ TN512524 E 19 6 3 8 TEMPERATURE COMPENSATION table generation 20 This mode is used when replacing the PC board and sensor unit Note If you have purchased sensor units for maintenance supplied data is requested to enter D Point the cursor pito S TEMPERATURE COMPENSA TION by pressing the 2
35. zero adjustment VR2 CO zero adjustment VR3 CO zero adjustment VR4 CN1 CO HC CO Ref signal input VR2 VR3 Ref adjustment VR5 Pressure span adjustment VR6 Pressure zero adjustment SC Analog GND GND VCC 5V N12 12V P12 12V VR4 VR6 CN2 Motor driven signal output C37 i amp e n e n n Lo n R75 L1 LI CN8 O signal input INZ TN512524 E CNS3 Pump driven signal output 9 4 Layout of main PC board check pins and controls VG GND s EO l HZ ENO ss 2 2 20 Bo ueder ul a
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