Service Manual - Fuji Electric
Contents
1. quauodwioo 18 Jopajap Bunnsou ty N 2 gounos y6n gt 49019 eondo Joy MS H3NOd Josuas 70 O NSA3 S gt K o Y Sls F E ee ON pleog aidu C ON pseog Ja aWy N D p pieog uleyy N ON peog Ia pay piesi Jd UBU A qo JE Nop Heno uae utes enof ENO een y 031 EE 9NO S V pa iE eno ZNO eer D ino L LNO F itunes Z 409907 Wun Aiddns samog m 2 308901 LR E oo ZL E N al L LI ZINS m NO E E EINO 9 Mm 400 eondo 104 a El 6NO OLNO fee i ldnu lur oloud 8NO a gg S301va1 LINO ui 2 49019 ondo 10 lt Ej 9NO Je dn 19 U 0 0Ud pueog 13410 Di2. 12 3 Mother printed circuit board mother board oooooonoccnoccnocanonanonnnonnnonnnnanonan oran cono conos 13 4 I O terminal printed circuit board I O terminal board 13 8 Liquid crystal display LCD asa 13 9 Powersupplyyy u u a u b u kulaka uqa a a aaa 13 10 Membrane Ke ye aaa ML dast IA a ahua S esi ii asa 14 Y FACTORY MODE ss ds LS ss ss Sau ants 15 1 How to go to factory mode n maanani mimi 15 2 Contents and setting of each item n nuan 16 1 Zero ofi una nn aan a idas 16 2y AS Dida a su lt SSS IAEA de tat aan kan kunu 17 3 Other parametefSu a pasan is aaa ms 18 A 20 5 Tntialdata cron na is 21 6 Calcula A Car Vada Riva R das a sd as 22 4 ERROR JUDGEMENT CRITERIA FOR ERROR CODES 23 1 Countermeasures against trouble na ss 24 5 TROUBLESHOOTING AND DATA COLLECTION 24 2 Data sampling at trouble ww ai 25 3 Troubleshooting of detectors aaaa ss 26 1 Trouble Judgment yau eating ak A aga od is 26 Di ATV aa sac vies hd a S Ag AS K WAA 26 APPENDIX 1 MEASURING PRINCIPLE DIAGRAM A 1 APPENDIX 2 SOFT FLOW DIAGRAM a A 2
3. tester that flows a current of 2 mA or more If used the detection element may be damaged Sensitivity deterioration due to sealed gas leak Calibration error fluctuation in indication and poor stability of analyzer s measured value After making sure the light source is normal and the cell is clean check moisture sensitivity For the method of fault judgment and sensitivity check refer to 5 3 Troubleshooting of detectors in 5 TROUBLESHOOTING AND DATA COLLECTION Replace detector INZ TN514722 E e Replacement Turn off power supply to the analyzer remove the bolts which fix the detector and remove the detector Mount a new detector and tighten the bolts The type of detector varies with the gas component to be measured So before mounting check the symbol marked on the detector label e Adjustment after replacement Optical balance adjustment moisture interference adjustment and zero span calibration G e e s o e a e R1 2 OOO R3 4 000 R 2000 Al Detector type 6 Built in O sensor e Recommended period of replacement 10 years Error mode Phenomenon Check Measures Replacement Breakage of O sensor Zero is read on the O meter and the reading remains unchanged even for the span gas Confirmation of O input voltage Measure the voltage between check terminals TP4 and SC on the main PC board using a digital voltmeter and make sure the volt
4. LO z P15 pa 2 SO VG1 YA ly 0 ly O Vcc 3 3V VR4 GND1 l ey TP10 GND2 CN2 E G Ye 5 TK369163R0 Japan CN1 CN5 A 3 Amplifier PC board TP2 TP4 TP3 Dy2 DV1 TP sms ES TPA lo O y WA SEB On N15 Os SG A 4 E TK365874R1 Japan INZ TN514722 E Fuji Electric Systems Co Ltd Head Office Gate City Ohsaki East Tower 11 2 Osaki 1 chome Shinagawa ku Tokyo 141 0032 Japan http www fesys co jp eng Instrumentation Div International Sales Dept No 1 Fuji machi Hino city Tokyo 191 8502 Japan Phone 81 42 585 6201 6202 Fax 81 42 585 6187 http www fic net jp eng
5. 1 39olq reondo 10 A 81 49ZVO1 yun Ajddns JSAOd z y901q eondo 10 A 8 49ZVG1 D Y yun A ddns iemo Bubu Juetueinsestu pue s ueuodu 02 SEB jo Jagwnu ay yM SILIBA S1019819p jo JEgunU ay yoo q eondo puogas ay aney JOU s op yolym Jez jeue y 0 pajunoul jou ale Z ON pseog Jen dure pue z Yoojg peondo 10 payloads sed ay ejon J uno 7 eng 19414 SION Jap INZ TN514722 E e Piping diagram t 000 O gt sensor Toaron 06 03 OUI bb dl Toaron 06 03 Infrared light source side Sample cell 1st optical block Yellow capillary L 20mm Papes INLET Ho N CH1 CH2 Yell
6. FC Instruction Manual INFRARED GAS ANALYZER TYPE ZKJ 3 iii ui ai iii i EN Fuji Electric Systems Co Ltd INZ TN514722 E PREFACE This service manual describes the infrared gas analyzer Type ZKJ This service manual is intended for use with the instruction manual to help you in understanding maintenance and inspection for the infrared gas analyzer ZKJ However the basic operation of the analyzer is not covered in this manual This manual provides information about the parameter settings in the factory mode adjustment and precautions for parts replacement and troubleshooting for the infrared gas analyzer ZKJ which are not covered in the instruction manual This service manual gives you useful hints to take immediate remedy for after sales service e First read the instruction manual and service manual carefully until an adequate understanding is acquired and then proceed to installation operation and maintenance of the gas analyzer Wrong handling may cause an accident or injury e The specifications of this analyzer will be changed without prior notice for further product improvement e Modification of this gas analyzer is strictly prohibited unless a written approval is obtained from the manufacturer Fuji Electric will not bear any responsibility for a trouble caused by such a modification Manufacturer Fuji Electric Instrumentation Co Ltd Type Described in Fuji Electric s company nameplate on main
7. 3 S 4 Check the amplifier PC board Refer to amplifier printed circuit board in this manual 5 If this trouble has occurred on the zirconia O meter check the sensor output voltage 6 If ERROR No 7 has occurred carry out span calibration forcibly and check the result gt If ERROR No 6 occurs return to above 3 Error occurs in automatic calibration ERROR No 9 has occurred Depending on whether the error has occurred in zero calibration or span calibration the relevant measure described above should be taken 4 Drift 1 Check that specified flow rate of measured gas is supplied to the analyzer main unit gt Locate a gas leaked portion and remedy 2 s Check that the cell window O ring detector window and cell inside are not contaminated Clean the cell and window Replace parts 5 Readings are high or low too much 1 Check for influence by moisture interference Carry out moisture interference adjustment 2 x Check if the concentration of interference component in measured gas is too high Moisture should be below 2 C saturation Check for other interference components Ask the user what components are contained in measured gas 6 Readings are not increased 1 Check that specified flow rate of measured gases are supplied to the analyzer main unit Locate a gas leaked portion and remedy 2 Check that zero and span calibration can be performed If possible check for sampling sy
8. El Preamplifier Permanent magnet Y Photo diode Emitting diode Signal Display process calculation Output INZ TN514722 E SOFT FLOW DIAGRAM APPENDIX 2 yurod Buipjoy ndino ue sajesipui ysi sv SION uoljesuedwoo JEL9AUOO jeus uolezue u r 4 414 12461A an indu Josues ainjejadwa ainjejadweajo JOSUS9S eunjeiedus anjea uogejnojeo snosue uejsu On uogeopul VWoz 0 y JO OG ALO1O uonesuaduloo anJeA uoejnojeo nyes dw uoeJqijeo J9OH9AUOO UOHES PU sno uelue su ON uo ezue ur1 uedg lulod ouez Joyy rev6id an Ieu6 S yndul 10 99 8q yu 020 y JO AA EE satu anjen uogejnojeo obeJane uopejnojeo Jejew O aBesane HuoN ON Buon UOISI AUO0 O VWoz O y JO OG AL01 0 uoljeiques uoleo1put aunjesadwia uoeuqujeo juaujsnipe Jajlenuoo eubis ueds julod ouaz sayy ey la 9SJO amy duliol lp odu09 anjea uopejnojeo isos snosue uejsu e eel ON uoljesuedwoo VWOZ O y JO OG ALO 0 Loy eo pu a9uaJa ayu uoljesuesdwoo ainyesodwia uonedqileo ju unsn pe u u Auoo ueds iod oz 9 llel5iq eSJO aN euBis indu JOJ9919P UIEIN uonesuedwoo Uone uonedqie9 eunyejedtuey uol zue ur yulod ueds julod 0127 julod 0107 uolesuedwoo oSu J llul uauoduloy seb yes 104 Jusuoduo9 AE paJe Jjul INZ TN514722 E A 2 APPENDIX 3 PRINTED CIRCUIT BOARD DIAGRAM Main PC board INZ TN514722 E
9. 0 5 lt span calibration coefficient lt 16 Zirconia oxygen 12000 lt A D conversion value in Span calibration lt 16000 Error 7 An amount of span This error occurs in the following condition calibration is over 50 50 of FS lt Span calibration concentration set value current of full scale display Error 8 Measured values fluctuate If A D conversion value fluctuates beyond each range specified below to much during zero and in calibration an error occurs span calibration Infrared component paramagnetic oxygen meter A D input value 100 Zirconia oxygen Oxygen concentration after mV conversion 0 2 mV Error9 Calibration is abnormal Error corresponding to No 4 to No 7 occurs during auto calibration during auto calibration Error 10 Output cable connection is Error occurs if no response is made from the output IC Improper Main portions to be checked during error Error No Main portions to be checked Error 1 Sector motor rotation mother and amplifier printed circuit board synchronization signal rectangular waves between GND and MPD3 on main printed circuit board 8 33 Hz 5 Vp p Emons See service manual 5 1 No zero calibration can be performed Error 5 Eons See service manual 5 1 No span calibration can be performed Error 7 Error 8 a y gt Error 9 See service manual 5 1 Zero calibration and span calibration can not be performed Contact portions of main printed circuit board and mo
10. APPENDIX 3 PRINTED CIRCUIT BOARD DIAGRAM A 3 ii INZ TN514722 E CAUTION ON SAFETY First of all read this Caution on safety carefully and then use the analyzer in the correct way e The cautionary descriptions listed here contain important information about safety so they should always be observed Those safety precautions are ranked in 2 levels DANGER and CAUTION K gt DANGER Wrong handling may cause a dangerous situation in which there is a risk of death or heavy injury N CAUTION Wrong handling may invite a dangerous situation in which there is a possibility of medium level trouble or slight injury or only physical damage Is predictable Caution on installation and transport of gas analyzer lt gt DANGER e This unit is not explosion proof type Do not use it in a place with explosive gases to prevent explosion fire or other serious accidents N CAUTION e This product must be installed in a place that meets the conditions specified in the instruction manual Use of the analyzer in a place that does not meet the above conditions may result in electric shocks fire or malfunction e During installation work attention should be paid not to allow entrance of wire fragments or other foreign matter into the product Otherwise a fire trouble or malfunction may be caused e When the gas analyzer needs to be lifted be sure
11. electric AN CAUTION shocks may be caused e When the fuse is blown detect its cause and use a new fuse of the same type and capacity as those of the old one to prevent electric shocks or other trouble Others e Ifthe cause of any fault cannot be determined despite reference to the instruction manual be sure to contact your dealer or Fuji Electric s technician in charge of adjustment If the instrument is disassembled carelessly you may have a shock hazard or injury AN C AUTIO N e Don t use replacement parts which are not specified by Fuji Electric Use of such parts will not only degrade performance but also result in an accident or trouble e The old parts after replacement due to maintenance etc must be disposed of as incombustible waste INZ TN514722 E V 1 STRUCTURE OF ANALYZER AND NAMES OF PARTS 1 Analyzer main unit gt 2 2 8 EIRIS o s 5 _ S5 5 92 228 ls gt S o HIL 3 2 3 2 8 t a 5 8 5 2 Ss 2 5 IG S S 5 ES 2125 ay ja S Z sa pone cee ie a A INZ TN514722 E Parts No Part name Parts No Part name 1 Decorative sheet with built in keys 8 Gas inlet outlet fittings 2 LCD panel 9 Main P C B 3 Fuse holder 10 Mother P C B 4 Glass tube fuse 11 Amplifier P C B 5 6 7 Switching power supply 13 Built in paramagnetic O
12. sensor INZ TN514722 E 2 Measuring element For combination of 1 optical block with one sample cell Parts Parts Parts No Part name No Part name No Part name 1 Sector motor 10 Cell window for pipe cell 18 O ring 2 for block cell 2 Motor mounting plate 11 Reference cell 19 Cell window for block cell 3 Sector 12 Sample cell 20 Block cell 5 Infrared light source 13 Trimmer assembly 21 Measurement detector 6 Light source unit cover 14 Cell pushing 23 Light control plate 7 Photo interrupter 15 Window pushing 24 Interference compensation detector 8 Distribution cell 16 O ring 1 for block cell 25 Light shielding plate 9 O ring for pipe cell 17 Washer INZ TN514722 E For combination of 1 optical block with 2 sample cells INZ TN514722 E 3 Connection of parts e Connection diagram 79019 eondo 104 JOJO N E Lay901q endo 104 JOJO N z 490 q eondo 104 J9ALIP JOJO so a ap uonesusdwoo auejapaju uauoduoo puz 1olo lep Bulinsaw quouoduioo puz 1004p uollesueduuoo L 390lq Bondo 104 J9ALIP 10 0 N z yoo g jeondo Jo aly ounos JUBA zouesayiaqut juauodwoo 15
13. coefficient CHI Range 1 Range 2 e Sampling system diagram If sampling system diagram is prepared report the diagram number If sampling system diagram is not prepared report the sketch For other troubles sample various data about necessary setting items INZ TN514722 E 25 3 Troubleshooting of detectors 1 Trouble judgment a Check that the sampling line is not abnormal and that the dehumidifying line filter status and sample gas properties do not have a problem b Check that other units and functions of the analyzer are not abnormal Make sure the light source sample cell and synchronization signal circuit do not have a problem c Examine each correlation with the ambient temperature and plant operating conditions such as gas and heat radiation 2 A D data a Calculate sensitivity against steam from the A D data reliable bubbler and electronic cooler Check the A D data of each detector on the optical balance screen when flowing each gas listed in the following table For generation of 2 C wet zero gas use a Measurement detector Main Interference compensation detector Compo Dry zero gas Zm Zc Dry span gas Sm Sc 2 C wet zero gas Wm Wc Span gas concentration P ppm Steam sensitivity H P X Wm Zmy Sm Zm ppm concentration of measured component e SO meter e NO meter When H gt 70 ppm SO equivalent the detector may be faul
14. occurs Disconnect the secondary SW power connector Turn ON the power and check the voltage at the connector If no voltage is applied to it replace e Measures Replace the S W power supply e Replacement Turn OFF the instrument power Disconnect the connector from the motherboard and replace it with a new one e Check after replacement Check the power supply voltage on the main printed circuit board 13 LDC30F 2 LDC60F 2 Name plate Name plate 7 Ba m B gt CN2 CNT Output L s2 BE FE f s r i AC N vi p hci s tal Pin Symbol Voltage Pin Symbol Voltage 1 V3 15V i N PE 2 G2 2 G2 3 G2 3 G2 4 V2 15V 4 V2 15V 5 Gl 5 gi 6 Ta 6 VI 5V 7 VI 5V 8 VI 5V LDA10F Es Pin Symbol Voltage i LA qe 1 CN1 V ACIL ACIN CN2 2 V FG Output El 3 V 5V ee Nee 4 V 5V Name plate Pin Symbol Voltage O cnt 1 to 3 _v IB Output L 4t06 V 19 8V Input L Output 3 Name plate Output voltage variable resistor 10 Membrane key Error mode Phenomena Check Measures Replacement Check after r Key contacts are worn It prevents the switch from being operated Check for the contacts with main printed circuit board Repla
15. oxygen conversion value or average conversion value at 110 of the range ON Measurement value of up to 110 of the range can be used for calculation OFF Values up to the measurement limit can be used Initial value ON e Calibration concentration zero variable Set it to ON to select a value other than 0 in zero calibration The setting of zero calibration concentration can thus be varied ON Values other than 0 can be selected as zero calibration concentration OFF Zero calibration concentration is fixed to 0 Initial value OFF INZ TN514722 E e Error 10 check e ZERO gas e MODBUS e Range variable Selection can be made from checking and not checking errors that may occur when connection of I O terminal is erroneous ON Performs Error10 check OFF Does not perform Error10 check Initial value ON Gas in cylinder or air can be selected as zero gas Cylinder Cylinder gas N2 air cylinder is used Air Airis used Note that the operation of the solenoid valve for calibration varies depending on the setting Selection can be made from using and not using communication function via MODBUS protocol ON MODBUS communication is used OFF MODBUS communication is not used The range modification function in maintenance mode can be enabled disabled ON The range modification function in maintenance mode is enabled OFF The range modification function in maintenanc
16. printed circuit board Do not unplug or plug the connector from or into the board with the analyzer power ON or the electronic parts and indication block may be damaged Before replacement be sure to turn OFF the analyzer The cable connector CN5 from the membrane key is connected to the main printed circuit board Since a stopper is provided on the CN5 connector the flexible cable should not be pulled forcibly Forcible pulling may result in poor contact For disconnecting the flexible cable slide the stopper lightly toward you by holding both sides of CN5 with fingers And for reconnecting the flexible cable insert it fully down to the bottom and attach the stopper The flexible cable should be inserted with its contact face directed toward the printed circuit board e Adjustment after replacement The above mentioned voltage check adjustment and contrast adjustment VR4 Contrast should be adjusted so as to be easy to see indications at the height of your eyes In factory mode zero offset adjustment output adjustment Moisture interference adjustment and zero span calibration INZ TN514722 E 11 2 Amplifier printed circuit board amplifier board One board provided for each optical block the following check items are for one board e Check Check of circuit voltage Check terminal Regulated voltage Contents a SG P15 15 0 5V 15 V power supply b SG N15 15 0 5V 15 V power supply N15 DV1 17 5 0
17. 5V lst component detector power supply used in common for Main and Compo 2nd component detector power supply used in common for Main and Compo e SG TP5 2 5 0 1V Reference voltage for A D conversion d N15 DV2 17 5 0 5V Check of signal processing block Unplug all connectors of the cables from the detector Display the screen for 11 A D Data in Factory Mode In the A D Data screen numbers 0 to 3 stand for signals from the amplifier board for the 1st optical block and numbers 4 to 7 stand for signals from the amplifier board for the 2nd optical block Check if the count value in each number lies within a range of 15000 1000 Detector signal check check by flowing the following gases nek Under zero gas flow Under span gas Under 2 C wet zero gas terminal flow SG TPI PSR 1 0 to 2 0Vp p TP1 and TP2 at almost SG TP2 _ the same magnitude ST TP3 1 0 to 2 0Vp 8 33 Hz 0 2 Vp p maz in AC R k and KOR j SG TP4 signal width e same magnitude TP2 and TP4 signals are 0 V when the lower end of measuring range is 0 to 10 or more e Precautions on check The amplifier board is connected to the mother board by connector If the connector is not plugged in adequately the above check may not bring about a normal result Before check make sure the connector is plugged in correctly e Precautions on replacement A cable from the detector is c
18. TN514722 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 Motor rotation detector Detector signals generated due to motor chopping are converted into signal is faulty rectangular waves and rectangular waves are monitored If waves are not generated or irregular an error occurs A D conversion value count can be checked on the A D data indication screen in the factory mode 59000 lt Ainp No 12 13 14 15 lt 61000 Error4 Zero calibration is not If the following ranges are not met in zero calibration an error occurs within the allowable range Infrared component 5000 lt A D conversion value in zero calibration lt 25000 Paramagnetic oxygen 8000 lt A D conversion value in zero calibration lt 14000 Zirconia oxygen 10000 lt A D conversion value in zero calibration lt 13000 Error 5 An amount of zero This error occurs in the following condition calibration is over 50 50 of FS lt Zero calibration concentration set value current of full scale display Error6 Span calibration is not When span calibration coefficient is not within the following range within the allowable range error occurs Infrared component 0 05 lt span calibration coefficient lt 10 0 Paramagnetic oxygen
19. a e Function Used to memorize the interference coefficient and the span and the The cursor is in 16 sensitivity to moisture of each detector at the time of delivery The x J T Eso change from the factory mode setting can thus be checked Factory Mode Initial Data e Operation The factory mode initial screen is shown at right Select the value to be changed using the P sPAN H2O keys and press the x key to highlight the value 3 selected Change the value using the keys move the cursor to the next digit to be changed When change is completed press the x key to confirm the change and press the Eso key not to confirm the change Factory Mode Initial Data Setting contents Infrared component only can be set per Ch M represents Main while C represents SPAN H2O I 2930 025 Compensation of the detector CP Sets the correction coefficient of lt Maintenance gt lt 5 Moisture interference adjustment gt at the time of delivery SPAN Span sensitivity in the minimum range at the time of delivery H2O Sensitivity to moisture in the minimum range at the time of delivery Values for SPAN and H2O represent the range of the count INZ TN514722 E 21 6 Calculation e Function Displays the result of calculation for each component e Contents Displays infrared component an
20. age is about 0 V for zero gas and 0 5 to 1 V for span gas If the voltage does not change between the zero and span gases the O sensor is damaged Replacement of O sensor Turn OFF the analyzer main unit Unplug the O sensor connector Then remove the screws which fasten the O sensor mounting plate to the main frame and separate the O gt sensor together with the mounting plate The O sensor is fixed by screws from the rear side of the mounting plate So remove the screws to detach the O sensor A new sensor is mountable by reversing the above procedure Adjustment after replacement Zero and span calibration 10 INZ TN514722 E 7 Printed circuit board see printed circuit diagram at the back of the manual 1 Main printed circuit board main board Note The main board is set according to the specifications of each analyzer When placing an order for a replacement PC board notify the serial number of your analyzer in advance so that the new board will have suitable parameters in it e Check Check of circuit voltage Check terminal Adjusting VR Regulated voltage Contents GNDI Vcc 5 2V Digital 5 V VG1 P15 15 0 5V Analog 15 V VG1 N15 15 0 5V Analog 15 V GND1 3 3V 3 3 0 1V Digital 3 3 V GND2 TP10 VR4 About 26 V LCD drive voltage contrast adjustment e Precautions on replacement The cable connector CN2 from LCD is connected to the main
21. be separated by removing four screws from the motor mounting plate Fasten a replacement motor to the mounting plate and mount the motor by reversing the demounting procedure For mounting the motor rotate the sector manually before fixing the motor cover and make sure the sector does not come in contact with the light source base light source photo interrupter wires etc frictional sound must not be emitted Finally fix the light source unit cover e Adjustment after replacement Check of optical balance adjust if significantly deviated and calibration of zero span points 3 Reference cell e Recommended period of replacement 5 years Error mode Leakage of gas filled in cell Phenomenon Analyzer s measured value is unstable in particular stability against change in ambient temperature is degraded e Measures Replacement of reference cell e Replacement Remove the reference cell and mount a new one e Adjustment after replacement Optical balance adjustment moisture interference adjustment and zero span calibration 8 INZ TN514722 E 4 Cell cell window and O ring e Service life Usable unless contaminated or corroded e Recommended period of replacement 2 years with O ring 1 Error mode Phenomena Check 2 Error mode Phenomena Check e Measures Contamination of cell mixture of foreign matter and contamination of cell window Scale out indication drift and calibration error occurred t
22. ce the membrane key Turn OFF the power Disconnect the connector from the main print circuit board Remove soldered portion of the power switch and remove the power switch from the main instrument Strip off membrane key and adhesives are wiped off completely Then replace it with a new one Remove the power switch and install it in the reverse procedure as removal Connect the key cable to the connector of the main print circuit board eplacement Check key in operation 14 INZ TN514722 E 3 FACTORY MODE 1 How to go to factory mode Maintenance Select operating item Mode Point the cursor to 8 To Factory Mode by using the or key on the Maintenance Mode screen and enter the Sensor Input Value Error Log Gal Log Optical Adjustment Interference Compensation Adj Output Adjustment Other Parameter To Factory Mode Enter the password To select setting items set 4 0 4 3 4 Zero offset Adj 10 Output Adj 12 Others and Input Password 4048 15 Coefficient are settable with 4043 Items 1 2 3 5 6 7 8 9 11 13 14 16 and 17 can be viewed Select digits by the key Change numerical values by using or key x key Then the password input screen appears ha After password entry has been completed press the D key and the Factory Mode initial screen appears Yo Factory Mode Select an tem How to select s
23. d results of calculation by oxygen analyzer etc Display contents when infrared component is selected X Main Y Component X Y A D conversion input value X Y1 After offset X Y2 Scale conversion X Y3 Filter X Y4 Zero calibration for each of Main and Compensation X Y5 Span temperature correction X6 Interference correction X7 Zero temperature correction X8 Zero calibration X9 Span calibration X10 Linearize X11 Interference correction when an analyzer other than zirconia O2 analyzer is selected X A D conversion input value X1 After offset X2 Scale conversion X3 Filter X4 Zero point temperature correction X5 Zero calibration X6 Span temperature correction X7 Span calibration X8 Linearize when a zirconia O2 analyzer is selected X A D conversion input value X1 After offset X2 Filter X3 Input conversion Zero span calibration X4 Linearize Factory mode initial screen The cursor is in 17 Factory Mode select component Calculation E NOx DOZ CO2 Factory Mode ZERO Zero gas Calculation SPAM Span gas NOx ENT Freeze Operation Press the key and the contact for zero solenoid valve is set to ON Press it again and it is set to OFF Press the key and the contact for solenoid valve of the channel displayed is set to ON Press it again to set it to OFF Press the x key to stop the value 22 INZ
24. e mode is disabled Initial value ON INZ TN514722 E 19 20 4 Coefficient check e Function Used to display and change calibration coefficient e Operation The initial screen for coefficient check is shown at right Select a desired item using the 4 and keys Press the x key to enter the screen of the item selected e Zero selection Displayed per Ch R1 Zero Subtraction of range 1 From left Main Compensation After M C R2 Zero Subtraction of range 2 Meaning is the same is above e Span selection Displayed per Ch R1 and R2 represent span calibration coefficient for range 1 and 2 respectively The value at right 1 0000 is not used at RI Move the cursor in front of the value to be changed using the A P keys and then press the x key and the value is highlighted Change the value using the keys and move to the next digit to be changed When the change is completed press the x key to confirm the change Press the Eso key not to confirm the change Factory mode initial screen The cursor is in 15 Factory Mode coefficient T zero Span Factory Mode Coefficient Zero In case of selection of span Factory Mode Coefficient Span Chi NOx Ch IR 02 R Chs IR CO2 IR Ch 4 IR CO Ch IR Oz INZ TN514722 E 5 Initial Dat
25. etting item from Factory Mode screen On the Factory Mode screen that appears point the cursor to the item you want by using the P or key 2 1 PILC Code 10 Memory Access 2 CH No 11 970 Data To get access to each setting screen press the x key 3 CH Data 12 Others 4 Zero Offset 15 Phase Adj 5 Gain Adj 14 Interference B Linearization 15 Coefficient T Temperature 16 Initial Data 8 Output SW 17 Calculation 9 DIO SW To return from each setting screen to the initial screen Es J U Es press the Eso key Into each parameter screen When escaping from the Factory Mode screen to the Maintenance Mode screen press the Eso key INZ TN514722 E 15 2 Contents and setting of each item 1 Zero offset e Function Stores the offset value of the A D converter e Operation The offset adjustment screen is shown at right Be sure to remove the cable of the detector from the amplifier board before making the adjustment Select a component to be adjusted using the and keys Press the x key to confirm the selection Press the x key again and the offset value is stored Press the Eso key to exit without making the adjustment Factory mode initial screen The cursor is in 4 Parameter Select CH No Response Time Chi NOx 15234 16025 Ch BO2 1600 16134 Ch3 CO2 15921 15682 Ch4 CO 15999 16062 EChS Oz 10012 11234 12345 ALL Ch Select ALL Ch and adjust
26. frame Date of manufacture Described in Fuji Electric s company nameplate on main frame Product nationality Japan Fuji Electric Systems Co Ltd 2006 Issued in July 2006 Request e 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 INZ TN514722 E i CONTENTS PREEBACE Saa AA MA ye au vam T eit i CAUTION CON SAFETY s tekst Lau nu Tunktagasskask k Maud akas anawika iii 1 STRUCTURE OF ANALYZER AND NAMES OF PARTS 1 1 AZ Ud a aa 1 2 Meastrin el Mt id A ie Aia 3 3 Connection of paria dia Sanu Sa aa 5 2 MAINTENANCE AND INSPECTION AND REPAIR AND ADJUSTMENT AT REPLACEMENT OF MEASURING UNITS 7 A DEE aa 7 2 Sector Motor and Sec un da A debe uya E 8 3 U Reterencescella u y saa sa 8 4 Cell cell window and O ring n rn nnnan anar sa s a 9 5 Detector except for O sensor la sasar 9 6 Built in O Sensor oo eee ecccesseessecseceseceseceseceeeseeseneseneceseeeseeeseecsaecsaecedeceaeenseeseeeseeeseneeses 10 7 Printed circuit Board uu ica akamkazia 11 1 Main printed circuit board main board a 11 2 Amplifier printed circuit board amplifier board
27. from the light source Scale out indication of analyzer Turn OFF the power of the analyzer and remove the electrically heated wire power cable connected to the light source Unplug the CN8 and CN9 connectors on the mother board Make sure a voltage of 19 8 0 5 V is output between pins 1 and 2 of CN8 or CN9 on the mother board Resistance between Measure the resistance between the terminals of the these terminals connector having 2 pins on the light source side To mother board The measured value is normally 20 O 2 O CN8 or CN9 When the resistance value is infinite cabling is discontinuous As the resistance value decreases the span narrows sensitivity is degraded Sealed gas in light source leaks Fluctuated indication If the analyzer output is drifted due to ambient conditions around the analyzer and other units are normal except for the light source sealed gas may leak Separation of light source fixing spring Analyzer s indication of measured value is unstable or surpasses the scale and optical balance cannot be adjusted Remove the light source unit and check it visually If the light source is found defective replace the light source unit Unplug connectors CNS for 1st optical block and CN9 for 2nd optical block on the mother board Open the light source unit cover remove the two screws which fasten the light source and replace the light source unit with a no
28. ment can be made simultaneously for the Chs except for Oy Before adjusting the O offset value be sure to remove the connector of the built in O sensor and then short circuit O2_IN between 1 2 of TN2 on the external terminal bock or input OV The stored offset value appears on the screen 16 INZ TN514722 E 2 A D data e Function Measures the counter readings immediately after A D conversion Factory mode initial screen The cursor is in 11 e Operation To measure the counter readings press the x key on the Factory Mode initial screen Factory Mode A D Data Ainp T Ainp T No 3ps No aS Opica 3 5 Ainp NO Count Ainp NO Count 1 1 Main ee ee Optical block 1 9 Temperature 1 1 Compo 2 Optical block 10 _ 1 2 Main 3 Opticalblock 7 14241 15 59855 1 2 Compo 4 Optical block 12 Optical block 1 2 1 Main motor pulse 5 Optical block 13 Optical block 1 2 1 Compo motor pulse 6 Optical block 14 Optical block 2 2 2 Main motor pulse 7 Optical block 15 Optical block 2 2 2 Compo motor pulse When supplying zero gas dry No 0 to 7 infrared component No problem within 10000 to 22000 However ignore the values where no detector is available No 8 oxygen sensor input No problem within 10000 to 18000 However if an oxygen meter is not provided ignore this input No problem within 5000 t
29. o 18000 No problem within 58000 to 61000 If the 2nd optical block is not provided ignore Nos 14 and 15 No 9 temperature sensor input No 12 to 15 INZ TN514722 E 17 3 Other parameters e Function e Operation Used to set the following Factory mode initial screen The Other parameters screen is The cursor is in 12 shown at right Select the setting contents using the 2 and keys y T Press the x key and the setting is highlighted ea Mode Select an item B ZERO limit FF Range limit FF ZERO val FF Errorl Check N ZERO gas ylinder MODEUS FF Varied Range N Switch the setting using the and Y keys Press the x key to confirm the setting x J T x Eso Press the Eso key not to confirm the setting K Mode Select an item thers ZERO limit DFF Range limit OFF ZERO val OFF Errorl Check ON ZERO gas Cylinder MODBUS OFF Varied Range On Setting contents e Zero limit e Range limit The fractional value can be displayed or omitted ON Select ON not to display the fractional value OFF Select OFF to display the fractional value Initial value ON Select OFF to check the fractional portion of the displayed value when making adjustment Be sure to set it back to ON when checking work is completed Selection can be made from limiting or not limiting the instantaneous concentration value to be used for calculation of
30. o analyzer Disassemble the cell to assure that the inside is clean Crack in cell window No change in indication slow response calibration error and indication fluctuation Perform a visual check of the cell window Cell Clean the inside of the cell refer to the instruction manual for details Replace If the inside is exposed to excessive contamination or corrosion Cell window Clean the cell window Replace if the inside is exposed to excessive contamination e Adjustment after clean and replacement Check of optical balance adjust if significantly deviated and calibration of zero span points and response 5 Detector except for O sensor e Recommended period of replacement 5 years 1 Error mode Phenomena Check 2 Error mode Phenomena Check e Measures Detector Damage to mass flow detector Scale out indication of analyzer calibration error occurs Turn OFF the power of the analyzer and disconnect the PG board connector connected from the detector to PC board Measure each resistance between GND and S1 on the PC board of detector and between GND and S2 The measure values must be between 25Q and 600 If red Lared the resistance value is beyond the specified range the c omg white detector element may be damaged r Note For resistance measurement avoid using a measuring device such as analog To amplifier board
31. onnected to the amplifier board If the connector is unplugged or plugged in with the analyzer power ON the detector may be damaged Before replacement be sure to turn off the power supply e Adjustment after replacement Verification of the contents of the above checks adjustment as per 4 Zero Offset in Factory Mode and zero span calibration 12 INZ TN514722 E 8 9 INZ TN514722 E 3 Mother printed circuit board mother board e Adjustment after replacement Output adjustment Refer to Output Adj in Maintenance Mode 4 1 O terminal printed circuit board I O terminal board e Adjustment after replacement Output check Adjust if output is offset Refer to 10 Output Adj in Factory Mode Liquid crystal display LCD Service life of parts 5 years Error mode Deterioration Phenomena LCD is not displayed or the display is dim or flickers Check Check LCD drive voltage on the main board See Check for printed circuit board Check connection to the main board Countermeasures against error Replace LCD 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 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
32. ow capillary L 10mm Toaron 49 45 L 35 OUTLET Ho INLET V CH3 CH4 Toaron 9 95 OUTLET He a po Sample cell 2nd optical block Infrared light source side 0 indicates a hose band For pipe joint use Toaron 09 06 we Block cell 2nd optical block This is a piping diagram of the analyzer without a purging line When the O2 meter and the second optical block are not provided pipes must be connected by bypassing them 000 Oz sensor Infrared light source side E T 6 93 ji E caron 46 4 Sample cell 1st optical block E Hout if i Toaron 06 63 Yellow capillary L 20mm iP M Teflon 06 04 W NfToaron 09 05 INLET 0 An XX Toaron 69 05 LAA capillary L 10mm Toaron 99 5 L 35 OUTLET H8 Toaron 9 05 PURGE Sample cell 2nd optical block w Infrared light source side 3 F 0 indicates a hose band T For pipe joint use Toaron f9 f6 Block cell 2nd optical block This is a piping diagram of the analyzer with a purging port When the O meter and the second optical block are not provided pipes must be connected by bypassing them INZ TN514722 E 2 MAINTENANCE AND INSPECTION AND REPAIR AND ADJUSTMENT AT REPLACEMENT OF MEASURING UNITS 1 Light source e Recommended period of replacement 5 years Infrared light source 1 Error mode Phenomena Check 2 Error mode Phenomena Check 3 Error mode Phenomenon Check e Measures e Replacement Short circuit in and disconnection
33. rmal one e Adjustment after replacement Optical balance adjustment and zero span calibration INZ TN514722 E 2 Sector motor and sector e Recommended period of replacement 2 years Sector motor 1 Error mode Motor rotation stop Phenomena Analyzer s measured value surpasses the scale or indicated value does not change and ERROR 1 occurs Check With the analyzer powered on remove the light source cover and make sure the sector is rotating 2 Error mode Unstable rotation or stop of a sector Phenomena Scale out indication of analyzer Error 1 occurs Indication is fluctuated Check With the analyzer power ON check if unusual noise is generated from the motor due to metal contact Sound at a constant high frequency is not abnormal If no noise is heard remove the light source unit cover Turn ON the power of the analyzer and check the rotation of motor shaft and sector e Measures If the sector motor is defective it must be replaced with a new one e Replacement Detach the light source unit cover Unplug the connector which is connected from the motor to the motor driver and pull the cable out of the cubicle through the grommet hole Remove four screws M4 from the motor mounting plate which is fastened to the base of light source unit and the motor and sector can be pulledout The sector can be separated by removing the sector setscrew which fastens the sector to the motor shaft and then the motor can
34. stem related to measured gas and take remedies gt If not possible check the item 1 and 2 24 INZ TN514722 E 2 Data sampling at trouble When trouble occurs be sure to sample the following data In the case of the trouble in connection with the characteristic please sample data please surely sample data to a factory at the time of an Inquiry Supply the gas given in Table and sample the measured value of measurement screen sensor input values in maintenance mode On the measured component that caused a trouble supply the gas given in the following table and write down the measured value of measurement screen and Sensor Input Value in Maintenance Mode Measurement Component Range 1 Range 2 component and range Calibration Measurement Sensor input value in Sensor input value in Supply gas concentration set display value maintenance mode maintenance mode value Main Compo Range 1 Zero gas Range 2 Range 1 Span gas Range 2 2 C wet Range 1 zero gas Range 2 Range 1 Sample gas Range 2 If there is no Range 2 the part of a Range 2 is entry needlessness If trouble occurs to other components sample data for each component e Iftrouble occurs on the O meter there is no sensor input value for Compo Check each coefficient by Coefficient in the factory mode Channel No Offset Moisture interference Zero coefficient Span
35. therboard printed circuit board plug in Error 10 connector Contact portions of mother printed circuit board and output printed circuit board cable INZ TN514722 E 23 5 TROUBLESHOOTING AND DATA COLLECTION 1 Countermeasures against trouble 1 No zero calibration can be performed ERROR No 4 5 or 8 has occurred 1 Check that a specified flow rate of zero gas is supplied to the analyzer main unit gt Locate a gas leaked portion and remedy 2 Check optical balance Refer to optical balance adjustment in instruction manual Adjust optical balance 3 Check the A D data against the display Refer to Sensor Input Value in Maintenance Mode 4 If this trouble has occurred on the zirconia O measurement check the sensor output voltage 5 If ERROR No 5 has occurred carry out zero calibration forcibly and check the result gt If ERROR No 4 occurs return to above 2 No span calibration can be performed ERROR No 6 7 or 8 has occurred 1 Check that specified flow rate of span gas is supplied to the analyzer main unit Locate a gas leaked portion and remedy 2 N Check that zero calibration can be properly performed If zero calibration cannot be performed repeat the procedure in No zero calibration can be performed described above Check the A D data against the display Refer to Sensor Input Value in Maintenance Mode Check for change from when flowing the zero gas
36. to put on protective gloves Don t hold the analyzer with bare hands to prevent injury e Before transporting the analyzer fix its casing so as not to open If the casing is separated and falls injury may be caused e The gas analyzer is heavy For carrying the analyzer manually have at least two persons conduct it with utmost care If this caution is ignored body damage or injury may be caused INZ TN514722 E Caution on piping lt gt DANGER In piping the following precautions should be observed Wrong piping may cause gas leakage If the leaking gas contains a toxic component there is a risk of serious accident being induced Also if combustible gas is contained there is a danger of explosion fire or the like occurring e Connect pipes correctly referring to the instruction manual e Exhaust should be led outdoors so that it will not remain in the locker and installation room e Exhaust from the analyzer should be relieved in the atmospheric air in order that an unnecessary pressure will not be applied to the analyzer Otherwise any pipe in the analyzer may be disconnected to cause gas leakage e For piping use a pipe and a pressure reducing valve to which oil and grease are not adhering If such a material is adhering a fire or the like accident may be caused Caution on wiring N CAUTION e The specified grounding construction is a requisite Negligence of grounding may cause elec
37. tric shocks or malfunction e Be sure to use a power supply of correct rating Connection of power supply of incorrect rating may cause fire e Wiring work must be performed with the main power set to OFF to prevent electric shocks e Wires should be the proper one meeting the ratings of this instrument If using a wire which cannot endure the ratings a fire may occur Caution on use K gt DANGER e When handling standard gas such as calibration gas read the instruction manual for the standard gas for correct handling N CAUTION e Avoid continuous operation with the casing drawn out Otherwise the casing may fall to cause injury e During operation never touch the inside with the casing open because there is a danger of burns or electric shocks INZ TN514722 E Caution on maintenance and check e Before accessing the inside of analyzer with the casing open for capillary replacement or the like purpose be sure to turn off power supply and purge not only the analyzer inside but also the measuring gas D DAN G E R line and auxiliary gas line adequately with the air or N gas Also carefully prevent oil etc from sticking to the capillary filter packing and the like parts This is required for preventing poisoning fire and explosion due to gas leak etc e Before starting the work take off metallic parts such as wrist watch and ring and never touch the device with wet hands Otherwise
38. ty When H gt 180 ppm NO equivalent the detector may be faulty Span A D data This data varies with range ratio It is therefore unreliable to judge whether the detector is normal or not according to this data alone If steam sensitivity is abnormal in 1 compare the span A D data with that at shipment from the factory and judge the detector also using the result in 1 26 INZ TN514722 E APPENDIX 1 MEASURING PRINCIPLE DIAGRAM Infrared ray type NO SO CO2 CO and CH Motor Distribution cell also used as Trimmer interference filter Reference cell Detector Rotary sector O o o e o e 0 O 0 s e o e o U Lr J ul Sector synchronization Infrared light source Sample cell signal single light source Sample gas inlet Sample gas outlet lt Gain changeover AC voltage amplification es ee Oani l r ASS os ES Option A D a RAM CPU ROM Sea AAA Indication External input contact output D A block kori attie A Operation key Indication O Output Oto 1VDC or 4 to 20 mA DC Paramagnetic type O Permanent Mirror magne Gas inlet gt _ Measuring Magnetic field cell Gas outlet
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