Service Manual - Fuji Electric
Contents
1. Pin Symbol Voltage Pin Symbol Voltage 1 V3 15V 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 VI 5V 8 VI 5V LDA10F 419 Lent 13 m ACIL b CN2 FG A Output i o Output El 00 Name plate FA Pin Symbol Voltage 1 y 2 3 V SV 4 V 5V TN513433 E 11 9 e Error mode e Phenomena e Check e Measures Membrane key Key contacts are worn It prevents the switch from being operated Check for the contacts with main printed circuit board Replace the membrane key e Precautions on replacement Replacement To the main printed circuit board is connected the cable connector CN1 from the key Since a stopper is provided on the CN1 connector do not pull the flexible cable forcedly Poor contact may result in the key When removing the stopper slide it lightly toward you by holding both sides of CN1 with fingers flexible cable fully into the depth and attach the stopper When attaching the stopper insert the The flexible cable should be installed with its contact surface facing toward the printed circuit board 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 replace it with a new one Remove the pow2. Fo Service Manual INFRARED GAS ANALYZER TYPE ZRJ 5 HA UN NN A Fuji Electric Co Ltd INZ TN513433a E PREFACE This service manual describes the infrared gas analyzer Type ZRJ 5 This service manual is intended for use with the instruction manual to help you in understanding maintenance and inspection for the infrared gas analyzer ZRJ 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 ZRJ 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 Delivered Items Quantity Remark Analyzer main unit Power ca
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4. instruments
5. 2 MAINTENANCE AND INSPECTION AND REPAIR AND ADJUSTMENT AT REPLACEMENT OF MEASURING UNITS 1 Light source e Recommended period of replacement 5 years 2 1 Error mode Phenomena Check 2 Error mode Phenomena Check Measures Replacement Short circuit in and disconnection from the light Scale out indication of analyzer Error 1 occurs Turn OFF the power of the analyzer and remove the Sealed gas in light source leaks Fluctuated Indication If the analyzer output is drifted due to ambient lt Motor unit for light source gt source electrically heated wire power cable connected to the light source Pull out connectors CN6 and CN7 on the motherboard Measure resistance between 2 pin terminals at the light source and the resistance value must be 37Q 20 Ifresistance values are infinite the light source may be broken As the resistance value is decreased the indication will be drifted in the minus direction Measure the resistance between terminals with cables disconnected conditions around the analyzer and other units are normal except for the light source sealed gas may leak If the light source is found defective replace the light source motor unit 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 Adjustment after replacement Adjust amp gain
6. ENT 24 1 Method for span calibration by standard gas with the same composition as plant gas 24 2 Method for span calibration by check 5 25 APPENDIX 1 MEASURING PRINCIPLE A 1 APPENDIX 2 SOFT FLOW DIAGRAM ad A 2 APPENDIX 3 PRINTED CIRCUIT BOARD A 3 ii TN513433 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 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 D D AN G E R Wrong handling may cause a dangerous situation in which there is a risk of death or heavy injury Wrong handling may invite a dangerous situation in which there is a N CAUTIO N possibility of medium level trouble or slight injury or only physical damage is predictable S PROHIBITION Items which must not be done are noted Caution on installation and transport of gas analyzer D D AN G E R e This unit is not explosion proof type Do not use it in a place with explosive gases to prevent explosion fire or other serious accidents e For installation observe the rule on it giv
7. Perform a voltage check of the main printed circuit board in addition to the above Sensor signal check Flow zero gas and check to assure that a digital voltmeter indicates 1 8 V to 2 6 V between TP2 and SC If specified voltage cannot be obtained regulate the voltage by using a VR1 Adjustment after replacement Perform the following procedures in sequence after replacement Failure to follow the sequence may result in damage to the detector O Sensor voltage regulation Turn ON the power with the detector signal cable CN11 disconnected Use VR2 and adjust the voltage to be within 0 1 V of the 1st component detector display voltage between SC and DV1 Adjustment of amplifier circuit Turn OFF the main unit once Connect the detector signal cable and turn ON the power again Wait for about 30 minutes until the instrument is warmed up Then supply zero gas Adjust the VR1 so that a voltmeter indicates 2 0 0 2V between TP2 and SC Perform zero point and span point calibration by supplying the specified standard gas Perform an output adjustment See factory mode 9 Output adjustment 2 Amplifier printed circuit board see Appendix 3 Used when measuring components are 2 or more excluding Oz e Check Voltage check regulation Check terminal Regulation VR Regulation voltage GND DV1 VR2 2nd component detector voltage 0 1 V GND DV2 VR4 3rd component detector voltage 0 1 V Sensor signal ch
8. Sector motor rotation light source motherboard and detector signal on amplifier printed circuit board Rectangular waves between GND and MPD3 on main printed circuit board 10Hz 5Vp p Error 3 Ainp No 15 of A D data in factory mode Voltage between SC TP5 on main printed circuit board Error 4 See service manual 5 1 No zero calibration can be performed Error 5 See service manual 5 1 No zero calibration can be performed Error 6 See service manual 5 1 No span calibration can be performed Error 7 See service manual 5 1 No span calibration can be performed Error 8 Error 9 See service manual 5 1 Zero calibration and span calibration can not be performed Error 10 Contact portions of main printed circuit board and motherboard printed circuit board plug in connector Contact portions of mother printed circuit board and output printed circuit board cable 513433 21 5 TROUBLESHOOTING AND DATA COLLECTION 1 Countermeasures against trouble 1 3 4 5 No zero calibration can be performed Check that a specified amount of zero gas is supplied to the analyzer main unit Locate a gas leaked portion and remedy Check if detector signal is as specified based on result of detector signal checked on motherboard printed circuit board and amplifier printed circuit board gt Adjust detector signals Ifa check cannot be made on signals check the detector Record voltage when zero ga
9. The cursor is in 12 zero Under ZERO Switching between Appear and Disappear by the A or Error1 Check O key ZERO gas MODEUS Establish the setting contents by pressing the End key Error Check Interference adj If you don t want to establish the contents press the so key Setting contents Disappear does not display and output values below zero Appear displays and outputs values below zero Under ZERO 10 Check Initial value Disappear default Disappear ZERO gas M DBUS Error Check Interference adj This mode is used at the time of adjustment in order to check a display If the minus display disappear under Zero is set to Appear be sure to return the lock to Disappear after adjustment 18 513433 5 Coefficient Function Displays zero offset and calibration coefficient Operation The coefficient initial screen is as shown at right Select any item by using the 2 or key Press the En key and each display screen appears In case of offset selection In case of selection of Offset Display contents Displayed for each CH Offset Offsets detector or O meter Calibration coefficient In case of calibration coefficient Display contents Displayed in range of each CH Zero mn Zero calibration coefficient Span ess Span calibration coefficient 513433 Factory mode initial screen The cursor is in 14 Factory Mode coeffi
10. and perform zero point and span point calibration Sector motor and sector Recommended period of replacement 5 years 1 Error mode Phenomena Check 2 Error mode Phenomena Check Measures Replacement Motor rotation stop Scale out indication of analyzer Error 1 occurs With the analyzer power ON check that the shaft is Unstable rotation or stop of a sector Scale out indication of analyzer With the analyzer power ON check if unusual noise If the sector motor is found defective replace the Light source motor unit as viewed from cell side normally rotating as viewed from the motor Error 1 occurs Indication is fluctuated is generated from the motor due to metal contact If no noise is heard remove the light source motor unit Turn ON the power of the analyzer and check the rotation of motor shaft and sector Motor shaft Check sector rotation from here light source motor unit 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 Adjustment after replacement Adjust amp gain and perform zero point and span point calibration 513433 3 Cell cell window and O ring e Service life Usable unless contaminated or corroded e Recommended period of replacement 2 years with O ring e 1 Error mode Contamination of cell mi
11. at treatment furnace has much gas of such composition it is considering as the adjustment for heat treatment furnaces In order to perform exact measurement there are two methods in span calibration Composition of the standard gas for span calibration used for each method and its method are explained using an example For the standard gas for zero calibration use dry N in any case so that zero point will not be affected 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 Ho 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 gas like 0 2 CH with little effect on span calibration may be excluded from the standard gas 1 Method for span calibration by standard gas with the same composition as plant gas When using the standard gas with the same composition as plant gases given in 1 calibration can be performed without correction as an error in calibration curve does not occur 1 Set CO concentration to spa
12. ble Fuse 250V AC 7 0 5A delay type Instruction Manual Test result Manufacturer Fuji Electric Co Ltd Type Described in Fuji Electric s company nameplate on main frame Date of manufacture Described in Fuji Electric s company nameplate on main frame Product nationality Japan OFufi Electric Co Ltd 2006 Issued in June 2006 Request Rev Ist edition April 2011 It 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 TN513433 E CONTENTS PREFACE A A A a 1 CONTENTS a SAE 11 CAUTION ON SAFETY wi ia A 111 1 STRUCTURE OF ANALYZER AND NAMES OF 5 22 1 1 Analyzer main O a 1 2 Measuring clean a A LAR A R 3 5 A AAA 4 2 MAINTENANCE AND INSPECTION AND REPAIR AND ADJUSTMENT AT REPLACEMENT OF MEASURING UNITS cal ii LaS 6 O St SOURCE ts ld AAA A ta che acon Hiei eens 6 2 Sector motor and Secta aa ds 6 3 Cell coll window and ONT iieiaeie aies R R is 7 4 Detector except Tor Us icono cairo dla aida ikisambaa 7 5 B ilt in O det dad dice 8 6 Printed circuit board see printed circuit diagram at the back of the manual 9 1 Mother printed circ
13. check Adjust if output is offset See factory mode output adjustment 7 Liquid crystal display LCD e Service life of parts 5 years e Error mode Deterioration e Phenomena LCD is not displayed or the display is dim or flickers e Check Check LCD drive voltage on the main board See Check for printed circuit board Adjust contrast main board VR3 Check connection to the main board e Countermeasures against error Replace LCD 10 TN513433 E e Replacement Turn OFF the power Disconnect the connector from the main printed circuit board and replace it with a new one e Adjustment after replacement Check the drive voltage and adjust the contrast See Adjustment after replacement of main PC board 8 Power supply e Recommended period of replacement 5 years e Error mode Power down e Phenomena No display and no output e Check Check if short circuit occurs Disconnect the secondary SW power connector Turn ON the power and check the voltage at the connector Ifno voltage is applied to it replace e Measures Replace the S W power supply e Replacement Turn OFF the instrument power Disconnect the connector from the motherboard and replace it with a new one e Check after replacement Check the power supply voltage on the main printed circuit board LDC30F 2 LDC60F 2 Name plate Name plate
14. cient O Offset Calibration oy To Factory Mode ent offset 20448 20448 In case of selection of Calibration coefficient Factory Mode Calibration 0001 01 00 i SOQppm l 0000 01 0000 0 2000ppm 01 0000 01 0 10 14 000 00 ii O 25vol 000 00 100 tl 19 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 Detector signals generated due to motor chopping are converted signal is faulty into rectangular waves and rectangular waves are monitored If waves are not generated or irregular an error occurs 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 44288 Ainp No 15 x 46336 Error 4 Zero calibration is not Infrared component within the allowable range 0 7 lt zero calibration coefficient x 4 0 Paramagnetic oxygen 3000 lt zero calibration coefficient lt 3000 Zirconia oxygen 5mV lt input voltage lt 5 mV Error 5 A amount of zero This error occurs in the following con
15. dition 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 5 lt span calibration coefficient lt 6 Paramagnetic oxygen 0 5 lt span calibration coefficient lt 10 Zirconia oxygen 10 mV lt input voltage lt 10 mV 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 measured values fluctuate excessively during calibration to much during zero and Infrared component paramagnetic oxygen span calibration If measured values are not stabilized in 60 seconds a change of more than 100 counts is continued Zirconia oxygen If measured values are not stabilized in 60 seconds a change of input voltage is continued by more than 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 20 513433 Main portions to be checked during error Error No Main portions to be checked Error 1
16. e Into each parameter screen Maintenance Mode screen press the Eso key TN513433 E 13 2 Setting 1 Oz adjustment Function Necessary adjustment is carried out for each oxygen sensor Operation The setting screen where adjustment is performed is as follows Selection of O sensor No change will be required for the O sensor because it is factory set for best performance before shipment When Paramagnetic and External O are selected O offset is displayed in the setting item When Zirconia is selected Zirconia adjustment screen is displayed in the setting item Move the cursor to any adjustment item by using the up arrow key or down arrow key and press the En key Then the adjustment screen appears In case of O offset adjustment O offset adjustment allows you to store electrical offset required for measurement by using a paramagnetic sensor and external O meter Operation When performing offset adjustment by the built in O sensor disconnect the motherboard CN8 connector and input 0 V or short circuit at the input terminal Add 0 mV short to the O input With the cursor placed next to Input Adj O offset adjustment the O Offset screen is displayed by pressing the En key Press the End key on the offset screen and the message appears prompting you to verify that you want to offset the O sensor After conf
17. eck Supply zero gas and check to assure that a voltmeter indicates 1 8 V to 2 6 V between TP2 and SG1 for 2nd component TP6 and SG2 for 3rd component If specified voltage cannot be obtained regulate the voltage by using a VR1 for 2nd component VR3 for 3rd component e Adjustment after replacement Perform the following procedures in sequence after replacement Failure to follow the sequence may result in damage to the detector O Sensor voltage regulation Turn ON the power with the detector signal cable CN1 CN2 disconnected Use VR2 VR4 and adjust the voltage to be 0 1 V of the 2nd 3rd component detector display voltage between GND and DV1 GND and DV2 TN513433 E 9 Adjustment of amplifier circuit Turn OFF the main unit once Connect the detector signal cable and then turn ON the power again Wait for about 30 minutes until the instrument is warmed up Then supply zero gas Adjust the VR1 VR3 so that a voltmeter indicate 2 0 0 2V between TP2 and SG1 TP6 and SG2 VR3 TP6 and SG2 are for the 3 component Perform zero point and span point calibration by supplying the specified standard gas 3 Main printed circuit board see Appendix 3 Note The main board is set according to the specifications of each analyzer When ordering notify instrument serial number So the main P C B has suitable parameter in it e Check Voltage check Check terminal Adjusting VR Reg
18. en 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 A N CAUTION 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 TN513433 E ili Caution on piping 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 Otherwise any pipe in the analyzer may be disconnected to cause gas leakage For piping use a pipe and a pressure reducing valve to which oil and grease are not adhering If such a mat
19. er switch and install it in the reverse procedure as removal key cable to the connector of the main print circuit board e Check after replacement Check key in operation 10 Amplifier gain and adjustment of detector voltage See 6 Printed circuit board 1 mother printed circuit board and 2 amplifier printed circuit board After replacing measuring parts adjust the amplifier gain After replacing a detector perform a voltage adjustment of the detector For check terminals and controls see Table as given below Strip off membrane key and adhesives are wiped off completely Then Connect the No adjustment is required for the O meter Detector voltage Amplifier gain Portions to be Portions to be Control Controls checked 7 checked m Mother printed circuit Mother printed circuit Mother printed circuit Mother printed circuit i board board board board component SC DVI VR2 SC TP2 VRI 2nd Amplifier printed Amplifier printed Amplifier printed Amplifier printed circuit board circuit board circuit board circuit board component GND DV1 VR2 SGI TP2 VRI 31d Amplifier printed Amplifier printed Amplifier printed Amplifier printed a circuit board circuit board circuit board circuit board component GND DV2 VR4 SG2 TP6 VR 3 Adjust the detector voltage to voltage 0 1 V specified on the detector label 2 0V 0 2V when supply zero gas Adjust the amplifier gain
20. erial 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 instrument 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 lt gt 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 etc may stick on internal walls thereby causing faults 513433 Caution on use KS PROHIBITION Do not allow metal finger or others to touc
21. etector voltage on the 00000000 printed circuit board and plug the RA 000 connector into the detector Do R 000 not insert the connector before VEOOO CO L voltage regulation or the element may be damaged Type of detector Adjustment of amp gain and zero span point Sensor voltage calibration 9 Built in O detector e Error mode e Phenomena e Check e Measures e Replacement Damage to O detector detector indication is at 0 and O detector will not even respond to span gas Check of O input voltage Apply a digital voltage meter between the check terminal TP4 and SC on the main printed circuit board and check that it 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 Replace detector Turn OFF the analyzer main unit Since the detector case is common to the OV line be careful when installing it avoid contacting the analyzer main unit case and O detector case Generally an insulation mounting plate is supplied e Adjustment after replacement Zero and span calibration 513433 6 Printed circuit board see printed circuit diagram at the back of the manual 1 Mother printed circuit board see Appendix 3 e Check Voltage check regulation Check terminal Regulation VR Regulation voltage SC DV1 VR2 1st component detector voltage 0 1 V
22. h or low too much Check that a large quantity of interference components moisture and CO3 is not contained in sampling gas Check the components contained in measured gases Ask the user what components are contained in measured gas Readings are not increased Check that specified amount of measured gases are supplied to the analyzer main unit Locate a gas leaked portion and remedy Check that zero and span calibration can be performed gt If possible check for sampling gas related to measured gas and take remedies If not possible check the item 1 and 2 22 513433 2 Data sampling at trouble When trouble occurs be sure to sample the following data In the case of the trouble in connection with the characteristic please sample data please surely sample data to a factory at the time of an inquiry Supply the gas given in Table and sample the measured value of measurement screen sensor input values in maintenance mode Supply gas Gas concentration Span calibration Measurement display Sensor input value in composition concentration set maintenance mode value Zero gas Range Range 2 Span gas Range Range 2 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 calibratio
23. h the input output terminals in the instrument Otherwise shock hazard or injury may occur Do not smoke nor use a flame near the gas analyzer Otherwise a fire may be caused Do not allow water to go into the gas analyzer Otherwise hazard shock or fire in the instrument may be caused Caution on maintenance and check lt gt DANGER When doors are open during maintenance or inspection be sure to purge sufficiently the inside of the gas analyzer as well as the measuring gas line with nitrogen or air in order to prevent poisoning fire or explosion due to gas leak N CAUTION Be sure to observe the following for safe operation avoiding the shock hazard and injury Remove the watch and other metallic objects before work Do not touch the instrument wet handed If the fuse is blown eliminate the cause and then replace it with the one of the same capacity and type as before Otherwise shock hazard or fault may be caused Do not use a replacement part other than specified by the instrument maker Otherwise adequate performance will not be provided Besides an accident or fault may be caused Replacement parts such as a maintenance part should be disposed of as incombustibles Others N CAUTION If the cause of any fault cannot be determined despite reference to the instruction manual be sure to contact your dealer or Fuji Electric s technician in charge of adjustment If the instrumen
24. irming that the O input is completed press the 220 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 Factory mode initial screen The cursor is in 7 Q Selection of 02 Paramagnetic Input Adj Selection of 02 Paramagnet ic D Input Adj Factory Mode Input Om to Terminal 02 Adj TN2 Adj Adjustment 1 O 2offset 14 513433 In case of zirconia adjustment When measuring the O concentration the data can be stored for converting A D counter values into voltage Factory Mode Select an tem 02 Adj values e Operation Zirconia adjustment screen that appears Selection of Z Zirconia shown in right R Input Adj Connect a standard voltage generator to the input terminal of ZRJ and perform zirconia adjustment while applying each voltage mimic input to the terminal O TO O Apply 0 mV to the O input terminal O With the cursor placed next to Adj Zero press the ca JIBU to Terminal npu En key to move the cursor to a position next to Adjustment 100mV Range DAdj Zero 100mY Range Press the En key after about 10 seconds have passed 260 Range 50my Range 100mY Range 250m Range the voltage value is saved and the curs
25. lovvs a current of 2 mA or more to be supplied vvhen measuring resistance othervvise the element can be damaged e 2 Error mode Sensitivity deterioration due to sealed gas leak Phenomena Calibration error and fluctuation in indication Check Check indication value at zero point Check the indication value for each component on the Sensor Input Value screen in the Maintenance mode Ifthe light source is in normal condition and the cell is free of contamination the counter value indicates 38000 to 42000 when zero gas is supplied If the counter value is below the range sensitivity can be degraded e Measures Replace detector TN513433 E 7 5 e Replacement e When a cell is a block cell remove the light source motor unit The light source motor unit and block cell are screwed to the detector Unscrew the detector and then the light source motor unit and block cell can be separated from the detector After that unscrew the block cell side the block cell can be separated from the detector Install a new detector in reverse procedure of removal 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 Adjustment after replacement Voltage regulation of detector Regulate the detector voltage to the voltage specified on the label Note Adjust the d
26. mA Adjust so that error is minimized 20mA Within 20mA 0 05 mA Adjust so that error is minimized 16 TN513433 E 3 A D data Function Measures the counter readings immediately after A D conversion Operation To measure the counter readings press the En key on the Factory Mode initial screen Factory mode initial screen ol Te Ainp Ainp Type Type The cursor is in 11 No No Infrared ray 0 8 Temperature component 2 Infrared ra Infrared ra 1 4 9 d Factory Mode component 3 component 1 A D Data 2 10 3 11 4 12 Oxygen input 5 13 6 14 Reference 7 15 voltage When supplying zero gas dry No 9 Infrared ray component 1 38000 to 42000 No 0 Infrared ray component 2 38000 to 42000 No 1 Infrared ray component 3 38000 to 42000 No 12 Oxygen input 18000 to 22000 No 8 Temperature 15000 to 25000 If A D data are within the range there is no problem If infrared ray composition 2 infrared ray composition 3 and oxygen do not exist ignore Nos 0 1 and 12 513433 17 4 Disappear under Zero Function Switches measured concentration values below zero to either display or no display mode Operation The Disappear under zero screen is as shown in right Set values are inverted by pressing the 20 Factory mode initial screen when the cursor is aligned with the disappear under
27. n 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 TN513433 E 25 APPENDIX 1 MEASURING PRINCIPLE DIAGRAM Infrared ray type SO CO2 CO and CH4 Gas inlet Infrared ray light source 1 a Motor C Measuring cell hopper Display Signal process calculation unit Paramagnetic type O Permanent Mirror magnet Gas inlet Magnetic field Gas outlet Permanent magnet Emitting diode Output Gas outlet Front expansion room Rear expansion room Detector Mass flow sensor Preamplifier Preamplifier 513433 SOFT FLOW DIAGRAM APPENDIX 2 anjea snosue uejsul ALO 9d Aejdsig D BA YU UV AOUI abesany AL O 9d Aejdsig anjea snosue ue sul AL O 9d Aejdsig JUlOd aJeo pu uonenojeo uoneln le O v abesany uonenojeo Hew ysu asy 30N Josues JaeAuos GAY zue ur1 12 610 uoyesuaduloo Josuas Aejdsig anjea snosue ue sul AL 0 9d uonein leo UO SA AUO ZO uonemn le
28. n calibration concentration set value 2 Perform span calibration by using the operation key 24 TN513433 E 2 Method for span calibration by check gas The method for span calibration by use of check gas give in 2 is explained based on the example Since span calibration has an error of calibration curve preset a calibration indication on the calibration curve graph attached to this analyzer for indirect calibration 1 The following calibration curve graph is attached to the test results for the product In graph the calibration curve by the scale gas that is similar to plant gas and determines scales of this analyzer and the calibration curve by the check gas that is adjusted by the scale gas gas of simple composition of N balance gas to facilitate the analyzer check are drawn Calibration curve by scale gas composition of plant gases Calibration curve by check gas N2 balance gas When supplying check gases to instruments adjusted Output by the scale gas composition Measuring gas concentration 0 8995 2 Calibration curve graph attached to the product 2 When using 0 95 CO and remainder N check gas as calibration gas In graph a point of 0 95 on X axis should be stretched to upward draw a line toward Y axis from the 0 95 C0 2 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 ca
29. n concentration set values together with span calibration concentration set value Check each coefficient by Coefficient in the factory mode Coefficient Component Offset value Range value Zero coefficient Span coefficient CHI Range 1 Range 2 CH2 Range 1 Range 2 CH3 Range 1 Range 2 e Sampling system diagram If sampling system diagram is prepared report the diagram If sampling system diagram is not prepared report the sketch For other troubles sample various data about necessary setting items TN513433 E 23 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 N such as argon Ar are contained including the measuring components it is known that the calibration curve output performance to gas concentration of gas analyzers will be affected pressure broadening In such a case analyzer is adjusted with gases similar to plant gas compositions in manufacturing adjustment by scale gas After this adjustment the analyzer is checked the calibration curve with N balance gas calibration curve by check gas Graphs with these calibration curves drawn are attached to products to be supplied Since measurement in a he
30. or moves to the 250mV Range Press the En key in about 10 seconds the voltage value is saved and the cursor returns to 100mv Range O Press the Eso key and escape from Adj Zero E J T E Move th to Adj Span the E key Factory Mode Input to Terminal The cursor move to S0mV Range Enter 50 mV 02 Input TN2 1 2 Adjustment and press the En key in about 10 seconds The Adi Zero 9 100m Range cursor will move to 100mV Range O With the cursor placed on 100mV Range apply 100 250mV Range mV and press the En key in about 10 seconds The Adj Span 50m Range cursor will move to 250mV Range 100mY Range With the cursor placed to 250mV Range apply 250 mV and press the En key in about 10 seconds The 250mV Range cursor will return to 50mV Range O 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 O to O TN513433 E 15 2 Output adjustment e Function Adjust the zero point and span point of the analog output to 4 to 20 mA or to 1 V Factory mode initial screen e Operation The Analog O
31. s is supplied and check the detector voltage Check the A D data against the display see Factory mode and A D data Check voltage at the main printed circuit board Check the switching power supply Record the A D data when zero gas is supplied No span calibration can be performed Check that span gas concentration and span concentration settings are the same Check that specified amount of span gas is supplied to the analyzer main unit gt 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 No zero calibration can be performed Check if detector signal is as specified based on result of detector signal checked on motherboard printed circuit board and amplifier printed circuit board gt Record voltage when span gas is supplied to compare with the voltage when zero gas is supplied Check the detector and detector voltage Check the A D data against the display see Factory mode and A D data Check voltage at the main printed circuit board Check the switching power supply Record the A D data when span gas is supplied Drift Check that specified amount of measured gas 1s supplied to the analyzer main unit Locate a gas leaked portion and remedy Check that the cell window O ring detector window and cell inside are not contaminated gt Clean the cell and window Replace parts Readings are hig
32. t is disassembled carelessly you may have a shock hazard or injury 513433 1 STRUCTURE OF ANALYZER AND NAMES OF PARTS 1 Analyzer main unit Parts No Part name 1 Cover 2 4 6 Screw 3 Rail 5 Terminal ass y 7 Terminal cable 8 Power supply cable TN513433 E 1 Parts No Part name Parts No Part name 1 Membrane key 9 Purge gas inlet fittings 2 LCD unit 10 Main P C B 3 Fuse holder 11 Mother P C B 4 Fuse 12 Amplifier P C B 6 Power supply 13 O sensor 7 Power supply 8 Gas inlet outlet fittings 513433 2 Measuring element Parts Parts Part name Part name Part name No No No 4 Base board 16 Cover 29 Pipe cell 5 IR source unit 20 Detector unit 30 Window for pipe cell 7 Block cell 25 Support 31 O ring for pipe cell 8 Window for block cell 26 Pushing 9 O ring for block cell 28 Filter 513433 3 Connection of parts e Connection diagram JEU day q d 18401 405433 FO LOM SUI AMEE A N au gwa deploy 513433 e Piping diagram 5 1 50 Big H BOL y LULL AJB des 001 1 58 6649 801 0 2 71 x udun Oy 23 ajdwes r 000 011 1 Saa 401201 TES Ade pde 0 2 71 xs Josuas 20 513433
33. to 12 513433 3 FACTORY MODE 1 How to go to factory mode Point the cursor to 5 To Factory Mode by using the A Maintenance Select operating tem ode or key on the Maintenance Mode screen and enter the En key Then the password input screen appears Sensor Input Value Error Log 02 ref Value 12402 Password Setting To Factory Mode Enter the password To select setting items set 4043 7 O adjustment 9 Output adjustment 12 Disappear under Zero are settable with 4043 Items 1 2 3 5 6 7 8 9 11 12 13 and 14 can be viewed Select digits by the O key Change numerical values by using 2 or o key Input Password 4048 After password entry has been completed press the En key and the Factory Mode initial screen appears e How to select setting item from Factory Mode screen On the Factory Mode screen that appears point the cursor to Factory Mode Select an item the item you want by using the O or key To get access to each setting screen press the En key PILG Cod Code CH No CH Data 9 Output Adj 1 1 Zero Offset 1 1 1 1 0 Memory Access 1 4 0 Data 2 Others Linearization 3 CO Comp Temperature 4 02 Adj 5 Output SW Coefficient Disp Element To return from each setting screen to the initial screen press the Esc key y T E When escaping from the Factory Mode screen to th
34. uit board see Appendix 3 9 2 Amplifier printed circuit board see Appendix 3 Used when measuring components are 2 or more excluding 9 3 Main printed circuit board see Appendix 3 2 10 4 VO terminal printed circuit board I O terminal 2 10 D Liquid erystal display LED Viatri diia dE dan tds 10 8 Powersupply wa a a ia is 11 9 Membrane Kit A id m l 12 10 Amplifier gain and adjustment of detector 12 S ISA A 13 1 H yvto go to factory Ai dd ARADA da Endara 13 2 Oi ai is 14 1 Oz adyustment ci 14 2 Output adjiistrient ia ds 16 BY AMD dada in s s da 17 A Disappear Under Zero ti ii aid 18 D COCTICICT CG 6 6 cece WAA CUR A 19 4 ERROR JUDGEMENT CRITERIA FOR ERROR CODES 2552 20 5 TROUBLESHOOTING AND DATA COLLECTION 2222 22 1 Countermeasures against trouble oooconinccnoconococonoconoconaconnnonnnnononan nono nono nonn ccoo nc corno rra nr narran m ia 22 2 Data sampling at trouble costaren a a a a A 23 6 ADJUSTMENT IN HEAT TREATM
35. ulated voltage Contents GND Vec 5 0 2 V Digital 5 V VG P15 15 20 5 V Analog 15 V VG NI5 15 20 5 V Analog 15 V VG VD 5 0 1 V Analog 5 V VG N12 12 20 3 V Analog 12 V SC TP5 2 5 20 1 V A D conversion reference voltage GND TP6 VR4 Displayed Clearly LCD drive voltage e Precautions on replacement e The cable connector CN2 from LCD is connected to the main printed circuit board Do not remove or plug the connector from or into the board with the power ON or electronic parts may be damaged Before replacement be sure to turn OFF the instrument e The cable connector CN1 from the membrane key is connected to the main printed circuit board Since a stopper is provided on the CN1 connector do not pull the flexible cable forcedly Poor contact to membrane key may result When removing the stopper slide it lightly toward you by holding both sides of CN1 with fingers When attaching the stopper insert the flexible cable fully into the depth and attach the stopper The flexible cable should be installed with its contact surface facing toward the printed circuit board e Adjustment after replacement After replacement perform a voltage check Use VR4 and perform contrast adjustment while viewing the LCD Determine an easy to see height and adjust contrast Press the switch to check that all keys are normally operated 4 VO terminal printed circuit board I O terminal board e Adjustment after replacement Output
36. utput Adjustment screen is The cursor is in 9 as shown in right En J T Es Select any of the output terminals OUT 1 to 8 to be Factory Mode Adjust OUTPUT Output Adj ZERO and SPAN adjusted by using the or A key and connect a digital multi meter to the output terminal SPAN Correspondence of the OUT number to output terminal OUT 1 to 8 corresponds to CHI to CH8 Set value is inverted by pressing the EN key Use the 2 or key and adjust the indication so that the digital multi meter reads 4 mA or 0 V for zero point Factory Mode adjustment and 20 mA or 1 V in case of span point Output Adj adjustment The indication can be increased or decreased by using the 2 or M key If the values are larger than expected change the upper significant digit by using the O key Adjustment is established by pressing the If you don t want to establish adjustment press the Eso key e Contents of setting values The output number OUT 1 to 8 corresponds to CH1 to CH8 The set values are converted into the digital values to transfer to the D A converter e Initial value OUT 1 to 8 At current output Zero 1340 Span 1740 At voltage output Zero 0000 Span 1760 e Adjustment value Voltage output OV Within 0V 0 002 V Adjust so that error is minimized 1V Within 1V 0 002 V Adjust so that error is minimized Current output 4mA Within 4mA 0 05
37. xture of foreign matter and contamination of cell window Phenomena Scale out indication drift and calibration error occurred to analyzer Check Disassemble the cell to assure that the inside is clean e 2 Error mode Crack in cell window Phenomena No change in indication slow response calibration error and indication fluctuation Check Perform a visual check of the cell window e Measures 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 Replacement For replacement refer to the instruction manual e Adjustment after clean and replacement Adjust amp gain and check zero point and span point calibration and response 4 Detector except for O2 sensor Detector e Recommended period of replacement 5 years e 1 Error mode Damage to mass flow detector Phenomena Scale out indication of analyzer Error 1 occurs Check Turn OFF the power of the analyzer and disconnect the connector connected from the detector to PC board Measure resistance between 4 7 and 5 7 of the bridge printed circuit board on the detector The measure values must be between 250 and 600 If the resistance value is fluctuated beyond the specified range the detector element may be damaged Note Do not use measurement instrument that al
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