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Service Manual - Fuji Electric

1. Sel Il lee eee eeel GII l IS sf 4 Power terminal ka 0 COMP1 1st component input output terminal Rear panel O COMP2 2nd component input output terminal 3 AUTO CAL input output terminal option 42 Os input output terminal option Part name Description D Grip Used to pull out the interior base 2 Knurled knob Used to fasten the instrument and case 3 Power switch Turn ON to supply power to the internal components excluding the pump After 3 or 4 seconds the LED indicator lights up 4 Indication operation panel Indicates gas concentration measuring range etc and contains keys neces sary for routine operation and settings Refer to section 4 for operating method 5 Sample gas inlet Connect gas to be measured here Sample gas outlet Connect pipe for discharging measured gas here D Reference gas inlet Connect reference gas here in case of differential flow system Reference gas outlet Connect pipe here for discharging reference gas 9 Purge gas inlet Connect pipe for purge gas here 0 COMPI 1st component input output terminal Used for 1st component of standard type and sample switching type or flow differential type D COMP2 2nd component
2. Output Zero span Digital conversion value terminal indication Variable from 0 to 2000 No in hexadecimal notation Comparison between each component and output terminal No For the contents of each output see section 3 3 2 to 3 3 5 Figure in parentheses denotes the output terminal No of the one component or one compo nent O analyzer of flow differential type sample switching type Output terminal No COMP1 COMP2 O2 AUTO CAL ET off d H 060 060 OO ER OS Oo Oo GO OO OO OO M E OO 9r Ye OW O e Note When option function is not provided the digital conversion value is displayed as 0000 at zero point and 1000 at span point 27 4 3 3 Mode 17 lamp test Press the Press the ENT In this mode each LED lamp is tested key and all LED lamps will light FUNC key and the indication will be changed over to mode 18 Eh 0 90 90 a Se Y e d Y N e Se KS 7 N 28 4 3 4 Mode 18 reset This mode is used when the parameter mode is reset to the user mode Press Oe ENT
3. CN2 to CNS Red a Power supply voltage approx 18V DC i AN Red E White 3 Input signal EE v Brown 4 X X O GND Shield 5 Ground shield wire Fig 7 1 Replacement The douser interference compensation detector light adjusting plate and detector can be taken out simultaneously by removing the detector mounting bolts 2 pcs See Fig 7 3 After replacement is finished make the optical zero adjustment in accordance with section 6 3 7 3 Motor unit Fault Rotation error Check 1 Check if the motor shaft is turning with the power supply turned ON 2 Turn OFF the power supply and remove the sector cover M4 X 4 pcs and then make sure that the sector does not touch any other parts If faulty make repair Sector cover mountings screws M4 X 4 pcs Sector cover terminal block Sector cover on e AT Sector Motor mounting Screws M4 X2 pcs Sector cover Set Infrared light source unit Moter Fig 7 2 Replacement 1 Disconnect the motor terminals from the sector cover terminal block 2 Remove the motor mounting screws M4 X 2 pcs and replace the motor After replacement is finished check the optical zero in accordance with section 6 3 If deviated greatly make adjustment 42 7 4 Distributing cell unit Fault Leak of seal gas Check Check the gas seal pipes and window for damage scratches or contamination Replacement 1 Detach the cover
4. 39 6 Check the input signal waveform at each point by the synchroscope For the check terminals use the individual terminals on the main printed circuit board 2 The peak to peak value of the signal voltage changes depending upon the measured compo nent and range First component Second component CP7 SC CP10 SC CP9 SC CP12 SC Ts Be Bs Su ege St E Bo Y L Y Zero EB TX ER L ag ers 05 HE 2852 25 gt HE E E ocE LEES AozZE 120msec o o o Y G Same level as in zero gas Y0 Same level as in zero gas Span L Er between CP10 and SC L T between CP12 and SC E eg S o o o o y a y H20 me Z Same level as in H2O Ste G Same level as in H20 2C S n between CP7 and SC SE i pi between CP9 and SC saturation T xs 40 7 7 1 7 2 REPAIR If the analyzer does not operate normally the following causes are assumed so proceed with check ing according to the individual items When making repair never give shocks to the gas seal pipes 2 pipes provided at lower part of the detector nor exert an unreasonable force to them Infrared light source unit Fault Disconnection or deterioration of the infrared light source or leak of seal gas Check 1 Check if the infrared supply voltage is 20 0 2V DC between 1 and on the sector cover terminal block If not check the power supply voltage on the main printed circuit board see
5. NJ LO CO I 00 A 24 WW BASS10 8 VCC GND Appended figure 4 10000 uF 7 pov 4 Wiring fiagram full option product 6 Junction terminal Power switch 23 3 Dgo ii Transformer Wiring color is shown at right A 25 Green Blue Red White Brown Black Orange Yellow Two core shielded cable One core shielded cable Appended figure 4 Wiring fiagram full option product AUTO CAL 02 2nd component 1st component Output printed Output printed Output printed Output printed board assembly board assembly board assembly board assembly CO CO 2 Converter CN9 22 Main printed baord 2 assembly 1212 eooOoowxoosov 2 B SOMmvVaAMAWN Flat cable 26P a S ea Ex 8 Sensor Main1 Compt ba ES e E gioi En Iu Nj Rs REC S 1 o 4 O02 2 4321 a 8 A O 3 CN9 CN8 22 E A 4 EE in TT a S Junction printed borad assembly O 6 CNS 154 HO 7 AB 8 TxD 12 1 0 9 PAS 10 CNS RxD o 0 Sor Main printed board 1 assembly a ta GC RS232C 1 ERIS 9 2 CN4 gt l S Dal om 1 i E Flatcable 4 4 ena ti 5 Se A1 2 9 0 A 95 CN6 Bi 2 9 10 B 1919 Fl
6. 2 If more than one error have occured errors are indicated sequentially by pressing the ENT key starting with the error code having the lowest numbered one When the ENT key is pressed again after all error codes are indicated the error indication is cleared but the errors appear again so far as they remain 3 If an error code is indicated first check the power source and gas piping for abnormal ity 4 If error occurs the FAULT contact output is contactive 5 An error code may be indicated due to disturbance noise or one shot noise Locate the cause and apply the appropriate remedy in accordance with the error code table section 9 2 Error codes list This analyzer is provided with self diagnosis function and an error code is displayed if an abnor mality occurs in the instrument Carry out the following remedies when an error code appears Whenan error code appears first check for an abnormality in the power supply or gas piping Theanalyzer will not operate correctly unless the cause of the error is removed But the error indication remains as it is as a history until the ENT key is pressed 51 Error codes and countermeasures Error code Contents of error code State of analyzer Cause Check and countermeasure E 0 Trouble with digital circuit memory re
7. D1 D3 A0 LS138 TD62785P 1 1 1 1 2 2 3 3 4 6 4 ER RESET RL 0138 CLK An BUD 29 GND IRQ 0 nro RL3 2 AO RL4 5 CS RL5 6 LES BB RD L7 B WR SHIFT 36 ve CTL STB 37 DBO SLO 32 111 1 DBi SL1 33 2 2 DB2 SL2 34 313 3 DB3 SL3 35 414 4 DB4 OUT AO 27 5 5 DB5 OUTA1 26 6 6 DB6 OUTA2 25 7 DB7 OUTA3 24 8 OUT BO 31 9 OUTB1 30 10 OUTB2 29 11 OUT B3 28 12 GEIER Q7 BASS7 8 1 p n es 02117 214 a SS 5 59 14 5 E 6 CII DAG 33 1 87 2 615 6 A 13 7 Bud VCC GND A 23 1 6 1 6 2 1 rlr Ke 1 a COM b COM a COM b COM HDSP 7801 10 HDSP 7801 9 10 PLOT o oUo DO FINN LOLON 00 HDSP 7801 a COM HDSP 7801 10 6 568 9 sian bal o 2000 DO COLO sr eu eon CO t LO CO P 00 10 9 fe LO GL 9D158 ele co o co co 55 GET ZS GER 38 ass 0 B8 asg aq d ol S 1 o cao d c 0o0O90 OO ua 000 00 HL ua oo DO 9 s O O e LO I1 S iLO Mm NOFIN Omo LO Jo c0 lula to co r joo Indication printed circuit board circuit diagram HDSP 7801 HDSP 7801 21 21 BASS8_ 8 BASS9 8 GL 9D156 GL 9D156 COLO sr eu eon COI LOCO P 00 HDSP 7801 HDSP 7801 GL 9D156 b COM GL 9D156 O colto str ICON TN ojo Jn 00 Appended figure 3 c LO KO P 0
8. 5 Sub indication Indicates measuring range error code various setpoints etc Range changeover key Used when changing the range High range is set when pressing and low range is set when pressing O D Function indicator lamp Relevant lamp lights up when following functions are set MEAS Lights up in measuring status CAL SET ALM SET HOLD Flashes in hold setting mode or lights steadily while hold function is activated Flashes in calibration concentration setting mode Flashes in alarm setting mode RMT RANGE Flashes in remote range setting mode or lights steadily while remote range function is activated AUTO CAL Flashes in auto calibration setting mode or lights steadily While auto calibration function is activated Function key Setting mode is changed at each press of this key Refer to section 4 9 Component selector key Set component is changed for each setting mode or span calibration 40 Digit shift key Shift is made from highest toward lowest digit at each press of this key P Numeric input key Selected digit is incremented at each press of this key 42 ENT key By pressing this key after setting the set contents are memorized and become valid 43 Zero calibration key Used for zero point calibration Lamp flashes in zero calibration mode 4 Span calibration key Used for span calibration Lamp flashes in span calibration
9. Be careful not to apply unreasonable force when cleaning Cell assembling tool Use the exclusive cells lt e assembling tool furnished u Retaining ring O ring retainer PA I Outer O ring r Inner O ring Infrared ray transmitting window Sample gas outlet Sample gas inlet Reference cell section Bolt hole for bolt which fastens together distribu tion cell and detector Sample cell section Sample cell structure for cells with length of 32 16 8 4 2mm The sample cell and reference cell are integral Sample cell structure block cell 36 6 3 Optical zero adjustment method optical balance method When the sample cell is reassembled after having been removed for cleaning or the like this adjustment should be carried out before use Following is the adjustment procedure 1 First carry out electrical zero adjustment With the power turned off detach the connectors CN2 and 3 for 1st component and CN4 and 5 for 2nd component leading from the detector which are connected with the main PCB 2 Next turn on the power and calibrate the zero point using ZERO and CAL keys 2 Turn off power connect the connectors CN2 and 3 1st component and CN4 and 5 2nd component and turn on power again Supply dry nitrogen from the sample gas inlet and wait until the indication stabilizes 3 Set up the optic
10. FS Instruction Manual NON DISPERSION TYPE INFRARED GAS ANALYZER TYPE ZRF SCH Fuji Electric Systems Co Ltd INZ TN510237 E PREFACE Congratulations on your purchase of Fuji Electric s Infrared Gas Analyzer Type ZRF This service manual provides descriptions on the maintenance inspection repair and adjustment proce dures of the non dispersion type infrared gas analyzer ZRF It is recommended to refer to the related instruction manual and parts list when reading this service manual Before using be sure to read the related instruction manual carefully to ensure correct mainte nance inspection and repair of the infrared gas analyzer Note that incorrect handling may lead to trouble or personal injury The specifications of this infrared gas analyzer are subject to change for improvement without prior notice Do not attempt to modify the infrared gas analyzer without permission Fuji Electric is not responsible for any trouble caused by modification without permission Manufacturer Fuyi Electric Instrumentation 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 Fuji Electric Systems Co Ltd 1997 NOTICE Issued in Dec 1997 e It is strictly prohibited to transfer part or all of this service manual without Fuji Electric s permission Descri
11. Note The calculted value in the parenthesis is four max CAL ENT 19 4 2 3 Optical balance adjustment When the sample cell is reassembled after having been detached for cleaning or the like this optical zero adjustment should be performed before use When this mode is assumed the input signal from the measurement detector is displayed on the main indicator while the input signal from the interference compensating detector is displayed on the sub indicator The numerics vary in a range of 999 to 3200 This adjustment is made so that the readings on both indicators approach zero Refer to section 6 3 Optical zero adjustment method for details With the i D C indication flashing press the CAL key and the input signal from the measurement detector will appear on the main indicator while the input signal from the interference compensating detector will appear on the sub indicator Press the CAL key after the optical balance adjustment N cautions A mistake in this adjustment will cause problems in measurement 20 4 2 4 Interference compensation coefficient setting This is used for adjusting the interfere
12. Span set value input A ENT CAL gt 1 EA COMP gt O analyzer zero set value input Each component span set value input Hold setting range FUNC Remote range setting mode NN gt come gt ca A Upper lower limit alarms Upper limit lower limit alarm set value input gt gt Hysteresis set value input value setting mode gt A Hold ON OFF setting Perform in each range Ce in each range ENT gt A Remote range ON OFF setting FUNC Key lock setting mode FUNC ON OFF setting FUNC FUNG 2JLAJLENT wl L2 JL LENT feunc gt JLA LENT Truc Automatic calibration Kg Current time setting p gt Calibration start time gt Calibration period setting setting mode setting FUNG gt A ENT FUNC c ENT FUNC gt A ENT Automatic calibration lt Gas flow mode setting ll Gas flow time setting gt A Key lock ON OFF setting CAL Maintenance mode S
13. 17 Lamp test Refer to 4 3 3 18 Reset Refer to 4 3 4 19 to 21 Refer to TD524500 22 Error function ON OFF changeover in adjustment Refer to 4 3 5 CAUTIONS Never perform this operation Do not turn ON the power while pressing the and y keys as the parameter mode is completely cleared This instrument is provided with a function of all clearing the parameter mode If the fol lowing operation is made the Q21 E7PROM on the main printed circuit board 1 must be replaced When the power supply is started up while pressing the keys the following display appears f uood The program corresponding to this function the version name printed on Q19 and Q20 on the main printed circuit board TK7F0633 TK4F0479 In case of without option mean value or 1H C el For standard type Incase of option mean value 4H TK7C8148 A For sample switching In case of without option mean value or 1H TK7D8333 Incase of option mean value 4H The all clear function is deleted in the programs after the above mentioned programs 23 2 How to set the parameter setting mode The parameter mode consists of an adjustment mode 1 and adjustment mode 2 The operating method for the adjustment mode 2 mode 6 14 17 18 22 is described in this manual For the adjustment mode 1 see the TD524500 This mode can be set from any position of the user mode by pressing the foll
14. 2 pieces on the L front panel and pull out the analyzer Knurled 7 V knob interior by means of the grips i Nf k P Knurled knob Power switch General maintenance and inspection are to be performed under the conditions shown above If it becomes necessary to com pletely remove the main unit lift up the front of it and pull it out toward you At this time it should be noted that the piping and wiring are exposed at the same time 2 Loosen the cap nuts fixing the gas inlet pipe and remove the internal gas inlet pipe 3 Remove two detector Note Be careful since the distribution and block cells are fixed together with the detector 4 Using the furnished cell assembly tool turn the retaining ring leftward and detach it from the cell Infrared ray transmitting window Refer to the next page Inner O ring Outer O ring O ring retainer Retaining ring Q p 35 5 For cleaning the infrared ray transmitting window and cell interior first remove heavy con tamination with a soft brush or the like then wipe lightly with a soft cloth Be especially careful when cleaning the window since it is easily scratched CAUTION If the infrared ray transmitting window is only lightly contaminated it can be cleaned by wiping lightly with the soft cloth to which chrome oxide powder is added But if heavily contaminated then the window must be replaced
15. 37 6 4 Interference compensation adjusting method AA 38 6 5 Power source voltage admstment esee ener nre 39 T REPAIR 41 WA nfrared light TES 41 T2 Detector GE 41 KS Ge rei ie EE 42 TA Distributing Cell Ult ti nario 43 GES Call A seat 43 7 6 Prnted cucuit board Unit TT 44 17 Parts to be adjusted after parts replacement for the parts see the parts list Vilna Ia 45 TROUBLESHOOTING EE 46 8 1 Incase the indication does not light sese seene 46 8 2 Incase the indication does not change 47 8 3 Incase the indication does not stabilized sss 48 8 4 Incase the response is slow sese 49 8 5 dnecaseadrftis large 5e ie Pe s Coelo re eio ie tt tih o Ro deeds 50 ERROR CODES AND REMEDIES eecht EENEG 51 9 1 Error codes and r medies cuco io e a a ete eet eret 51 02 Error codes list T mee de eere et cete eta 51 Appended figure 1 Main printed circuit board 1 circuit diagram sss sss sese sees eee A 1 Appended figure 2 Main printed circuit board 2 circuit diagram ce eee sees A 9 Appended figure 3 Indication printed circuit board circuit diagram sss sss esse esse sees ee eee A 21 Appended figure 4 Wiring diagram full option product sss sees sees eee A 25 Appended figure 5 Main printed circuit board 1 layout 00 eee sees eee A 27 Appended figure 6 Main printed circuit board 2 layout esee A 28 Appended figure 7 Indication printed circuit board layout sese e
16. R96 R94 CP9 MAIN2 __ _ __ 1K 47K 2 gt Q29 1 C47 5 C46 R95 Rot tu RE Q29 in tu 1K 47K x S 82K eT R92 Cc Li leu X C48 SC SC 0 1u SC DB lt 7 0 gt SC COMP2 CP12 220K COMP2 CG21 P12 CG22 POS ae T E C623 o e 3 S 8r 81 RI BD S S le 37 E 25 470 Le N12 A 13 Appended figure 2 Main printed circuit board 2 circuit diagram P05 E gt 25 gt mi sl L glo ST OT ST OT Vss C54 0 22u 2 pe 1 q RAS 2 3 451C 4 7K 10 4510 D5 d 7 CNTM21 3 RAS 4 Q20 18953 a LL E 4 7K Z i 5 RA5 a 1 b Vss 47K 12 Laso D6 13 d 12 CNTM22 7 RAS g Q20 1 18953 eo L1 4 7K 2 Vss VF1 VF2 VF1 VF2 Vec glo o e als OT AT T ST V 82K ij R80 1 C55 f E een 0 22u 83K 4 2 0027 4 451C CNTC21 Em m CNTC22 7 7 RAG g Q27 1 18953 L1 4 7K 3 x x Vss 16 Q21 fie Q19 16 Q26 451C 451C 451C 4052 4052 4051 4051 11 11 i 7 ep prp E 7 N12 l Main printed circuit board 2 circuit diagram Appended figure 2 TMP VF1 C 22K R232 PRESS 02 Top o 3 R236 P05 ii Vcc es CP1 7414 7414 12 11 D 10 Q22 COILP SLCT
17. YES Repair NO Is power source voltage normal NO Adjust power supply voltage See section 6 5 YES YES Is noise put on power line Eliminate noise NO s indication stabilized by purging instrument interior YES Purge instrument interior NO Are wire or connectors NO connected properly Repair YES NO Is infrared light source normal Replace infrared light source See section 7 1 YES NO Is detector normal Replace detector See section 7 2 YES NO Are motor and sector unit normal Replace motor and sector unit See section 7 3 YES Overhaul is necessary 48 8 4 In case the response is slow Note 1 If an error code Section 9 2 Response is slow is indicated see the error code table Is response time set properly Check and change set value See section 4 2 1 Is flow rate of sample gas Set flow rate to specified value See section 3 2 2 Is a large capacity vessel YES Such as tank inserted on the cource Such remedy as bypass is necessary of external piping Is there looseness or comming off in internal piping Repair Is absorbent gas mixed with measured
18. Can parameter mode be set Can all LEDs be lighted in parameter mode 17 Replace main PCB1 See section 4 3 5 YES Reset to measurement mode Execute soft reset in mode18 46 8 2 In case the indication does not change Note 1 If an error code is indicated see the error code table Section 9 2 Note 2 Connect CN2 3 only in the one component analyzer Connect CN2 3 4 5 only in the two component analyzer Indication is unchanged E NO S S Fee gt Set flow rate to specified value See section 3 2 2 i Is there looseness or YES E Repair comming off in internal piping Are sensor input signal connector CN2 3 4 5 of main PCB2 connected No Connect connector NO Is infrared light source normal gt Replace infrared light source See section 7 1 N Is detector normal s Replace detector See section 7 2 Is voltage of PCB normal See section 6 5 Adjust power source voltage 47 8 3 In case the indication does not stabilized Note 1 If an error code is indicated see the error code table Section 9 2 Indication is not stabilized Is instrument subjected to YES vibration from outside Take anti vabration measure NO Is there comming off or looseness in internal piping
19. EAROM 6 SCK RAM 013 IOCS 7414 9 B Srk Q13 Vss A 3 Appended figure 1 101 lt 7 0 gt 102 lt 7 0 gt 103 lt 7 0 gt RM11 RM12 RM13 RM21 RM22 RM23 RM31 START Vcc f A 4 TD62381 Main printed circuit board 1 circuit diagram Vcc T a L1 10 Vcc 1 RA8 47K T arb 18 958 7 6 54 3 2 12 Ok R ap l 14 Q4p 1 5 asp 1 l amp Op 17 Q70 is ggptt_t 10 030 1 RAS 47K E UI idu ando 9 4T3T2 2 5 ab LLLLLE 3153 Q3b 16 s sis eis el 4 g Q4 b 15 III 5 14 Ib Q5p 6 13 7 16 06p 5 8 17 i care 9 18 Q8p GND VCC 031 1 RA4 47K TD62381 JI HU H 18 9 212 12 Q2p bebe HHEH 14 Q4p 1 D Vo i l amp Op 7 ap m 18 E 10 V SSR ID11 ID12 ID13 ALMH1 ALML1 S SSR RSV FLT ID21 1D22 1D23 ALMH2 ALML2 1D31 ALMH3 ALML3 TUNE ZERO SPAN1 SPAM2 SPAM3 CALERR 02ZERO S S V V S V INTO CLK1 CLKO Appended figure 1 Main printed circuit board 1 circuit diagram R5 VcclN C4 T Jr D2 DCPO05 o O o E 2 d 2801815 C151 T R4 s lp VecCT L3 E EE 100 4 Q2 K S SE Sns TA 03 cL uy Vss Vss P20IN SIB01 02 0 27 D1 DCP20 si C151 T R3 7 2 gt Ge S gt P20CT gt 5 P A gis 100 4 o K WI ola Sme Sms Se nx BTs 04 SU 2 A SC i l o 2 EA e
20. FRD5 1EB A02 eo SC PC2 P05 ES VET R212 Y P12 820K oe H 2 038 ZD4 29k T4 451C DACH T LA 28B679 Q39 4 15 o 3 RD2 2E 11 TD62381P Eo 4510 fe N12 s c 104 gl 5 VOS Sees SC PC4 P12 P20 4 P05 4510 be VF1 5 11 N12 E am 510K 3 DAG KE 2 E 2SB679 Q3 x Pog TD62381P E B co A05 C st R110 820K ol R126 El S H 201 22K AJ 10 nT 288679 al 4510 RD2 2E me ell ee A05 CO e 37 R154 EJ P20 510K el 820K 15 4 SI 31131088 200 22K Ti Oe REP 1 C _ 288679 1 sl 4510 RD2 2E eg EE zD9 amp e 107 ee RD5 1EB Le 5 A07 it VO7 99 PC7 Appended figure 2 CNT CN2 Gn A J N CM I 1 P20 o A J lM lA 330 R252 Vcc AD 06 AD 04 AD 02 AD 00 DB 6 DB 4 DB 2 DB 0 ORD INTR CLKO Vss N12 P12 P20 MAIN1 MAIN1 SC SHILD MAIN2 MAIN2 SC SHILD Main printed circuit board 2 circuit diagram CNT IOCS AD 07 AD 05 AD 03 AD 01 DB 7 DB 5 DB 3 DB 1 IOWR SCLK MCLK RESET SC P20 P20 COMP1 COMP1 SC SHILD LZ P20 m COMP2 COMP2 SC m SHILD o A J lM lA Appended figure 2 Main printed circuit board 2 circuit diagram CN9 CN6 1 COILP A01 2 COILN PC1 A02 PC2 TE P05 s 2 PRESS 3 sc PC3 A04 PC4 CNS A05 PC5 A06 PC6 A07 PC7 CN10 1 10201 ie 2 PC1 SC 3 10202 1 PC3 A 20 Appended figure 3 I
21. an additional function of zero display by masking the minus sign In this mode the masking function is cleared by setting 1 30 5 INSPECTION lt gt DANGER When doors are open during maintenance or inspection for adjusting the optical system etc 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 leaks N cautions Before working take off a wrist watch finger ring or the like metallic accessories And never touch the instrument with a wet hand Otherwise you will have a shock hazard 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 31 Perform the daily check and routine check in accordance with the following checking table Checking portion Checking Table Symptom Cause Remedy Portions to be checked everyday Recorder indication Abnormal increase or decrease of indicated value 1 Dust is contained in sample cell 2 Air is absorbed on the coarse of sampling piping 1 Clea
22. input output terminal Input output terminal for 2nd component of two component analyzer 2 O input output terminal option Input output terminal for O analyzer 43 AUTO CAL input output terminal option Input output terminal for auto calibration function 4 Power terminals Supply power to the analyzer 2 2 Name and description of components on indication operation panel D Day indication 6 Sub indication Range changeover key 8 Unit indication lamp Main indication D Component indication SU Tuim SA i A m MO WE FR A AS O O O O 2 O O Function indicator lamp MEAS CALSET ALMSET RMT RANGE AUTO CA SPORE Calibration start key Span calibration key 3 Zero calibration key 2 ENT key Function key 8 Component selector key Digit shift key Numeric input key Three components of NO SO2 and Oz are indicated in this figure Part name Description D Component indication Indicates kind of gas measured 2 Main indication Indicates measured concentration Also indicates various setpoints for alarm function auto calibration function option etc 3 Unit indication lamp Indicates unit of measured gas concentration D Day indication Indicates current day or day of starting by means of bar in auto calibration option setting mode Indication SU MO TU WE TH FR SA Day Sun Mon Tue Wed Thu Fri Sat
23. key and DE will be indicated Press the ENT key again and the parameter mode will be reset to the measurement mode user mode When no reset is executed press the FUNCIkey and the indication will be changed over to the mode 22 29 4 3 5 Mode 22 ON OFF error function This mode is used to reset the error restriction during adjustment However E Mito E j cannot be reset Li The data set in this mode becomes error ON with function provided without fail when the power supply is turned OFF Press the ENT key and the indication is changed ENT over to E p h Press the SPAN key to select or ry qo IT and are changed over to each other alternately every time the SPAN key is pressed Press the ENT key and the data will be stored Press the FUNC key and the indication will be changed over to the mode 6 ENT S The error function is provided qo l The error function is reset CAUTIONS Programs after 96 01 31 after program history No TK7F0479G and TK7F0633G have
24. or injured During installation work care should be taken to keep the unit free from entry of cable chips or other foreign objects Other wise it may cause fire trouble or malfunction of the unit Caution on piping On 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 explo sion fire or the like occurring Connect pipes correctly referring to the instruction manual Exhaust gas should be led outdoors so that it will not remain in the sampling device and indoors 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 dis connected to cause gas leakage For piping use a pipe and a pressure reducing valve to which oil and grease are not adhering If such a material is adhering a fire or the like accident may be caused Caution on wiring NA CAUTION Wiring is allowed only when all power supplies are turned off This is required for preventing a shock hazard Enforce construction of class 3 grounding wire by all means If the specified grounding construction is neglected a shock regard or fault may be caused Wires should be the proper one meeting the ratings of this instru ment If using a
25. should be dis posed of as incombustibles Others A 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 instrument is disassembled carelessly you may have a shock hazard or injury 1v CONTENTS PREFACE a tatu E bdo apu aM ls de eso LEE 1 SAFETY PRECAUTPION 20 a A A E 11 I OPERATION PRINCIPE E e den eee Ae a 1 1 1 Standard type ener etie een ee deoa e e ssl ri 1 1 2 Sample switching type snes npe gi iie i atado pr Ege 2 2 NAME AND DESCRIPTION OF EACH COMPONENT A 4 2 1 Name and description of each component on case 00 ee eee ee eee eee eee 4 2 20 Name and description of components on indication operation panel sees 6 Se PIPINGAND WIRING cesta tos ooa ig testa cte taches bit toni 8 ak Piping method eegene seid easiest dte bep ddr rende 8 SEET el EE 9 2 3 W ring Method cem te ii HERE Repo Ee pL eco eee in ro EE 11 4 OPERATION OF INDICATION OPERATION PANEL eere 17 LM ER Be EE 17 4 2 Maintenance Mode iii lc tae dap pte eed ie 18 43 SParameterunput Set e eee Pere ede eerte dre 23 5 INSPECTION nianses t er tat See Eeer dE 31 O MAINTENANCE once ee A A EA 33 6 1 How to clean sample cell pipe cell ee sese 33 6 2 How to clean sample cell block cet 35 6 3 Optical zero adjustment method optical balance method
26. wire which cannot endure the ratings a fire may Occur Use power source that matches the rating of the unit Use of power source out of rating may cause fire Caution on use lt gt DANGER When handling the standard gas such as calibration gas read the instruction manual of the standard gas carefully and use the gas correctly AN CAUTION Avoid continuous operation with the casing drawn out During operation avoid opening the casing and touching the internal parts Otherwise you may suffer a burn or shock haz ard iii Caution on maintenance and check o DANGER When doors are open during maintenance or inspection for adjusting the optical system etc 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 explo sion due to gas leaks A CAUTION Before working take off a wrist watch finger ring or the like metallic accessories And never touch the instrument with a wet hand Otherwise you will have a shock hazard 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 instru ment maker Otherwise adequate performance will not be provided Besides an accident or fault may be caused Replacement parts such as a maintenance part
27. 02 4 E 219 5 Am Th JF L Le L ces jp 049 R286 a9 UE DTE T TS ers C48 OT STE am AF AE Gea Rd JF 5 R196 c91 sx RM x B26 iL c7 R93 Con R09 amp JF R234 R200 4810 OS E 28 28 C87 C90 l R205 _ BTT C20 dk He ce ec g amp dk F R204 C84 t O gt c12 O ce Q13 C47 G C59 q 8 c9 Cu a 3 dk R17 C76 R18 A a 4dr R66 C57 R86 H 3 3 EE 87 euo duce SE S R21 O R22 R42 ORs i R67 Om R85 R89 Onso E O 3 5 S wo oi Ed eene fl 2 GRO TOR mo DEES aee soe e o CO PORE errs eee y EG D DE RE DD GI 9 L Q10 9 S Q26 FR o Ce L 8 C4 8 ES EE T as R87 en R2 z S in R E RIO R103 R14 R10 Ri2 R40 R38 R62 R60 R64 E R83 025 vo 024 045 Q17 8 R111 C18 R107 R179 R117 EK R112 dk Ce a R113 Q39 R174 big Q30 rer EZ S O R10 3 R135 6 F y R10 L R39 JF Ca R41 JF Can C56 R84 F Ce o R224 Q O R1 Q R13 CO R63 CH R82 Q O O8 R222 C22 C6 C23 C7 C40 E C55 Es ru R228 c73 C78 7 C754 C72 L e H H dk H H H qF H y Geng ORI m G R226 O R121 a Q A R227 R157 RT R R214 R223 R136 3 TE HA2 9 JE RA3 C53 RA5 TE R158 R128 2 2l HH BO R218 R137 8 e 8 8 S R221 SE g E 2 D R115 R163 pan R171 casa C66 Q40 a42 9 R217 C52 D2 cas JE C10 D5 C93 1 ZD9 C107 4 ZDb14Q38 JL C106 Js ZD8 R219 ES pe RAS R109 R172 R170 R178 D3 bt Er D9 C94 C95 C79 LI gt E TI bi ps men G51 R225 Di D4 D6 d R181 d A etc R122 a g o eo el R134 Ges CS 2 2 8 Be 6 Q8 mea S T F JL R229 C67 JI it R154 E R138
28. 4 a TZD6 5 E C70 C43 Q22 C25 mrs dh ewer Fc R188 S SS euo Jr ctos 4H C105 JE R1877 C102 R193 co p 28g C103 E y e T qs 9 5 1 less LU 28511 86211 88811 8 a Fa s Pg O cc cc cc tc cc cc coo coo ao S Zob DC O D IL cz JL Ga F F T7 Q14 Q8 C65 C2 Ti Te M T 5 J25 J16 CO D BI C g Qn 8 Ce KA ECO EC OOO OOO 4d OO L E O J1 J3 J2 J4J6J5 J7 J9 J8 J10J12 J11 J13 J15 J14 J32J20J19 J18 J33 gt J24J23 J22 J27 Jet 317 H A 28 B10A10 t board layout ircui ted c ion prin Indicat Appended figure 7 E E TK201122R3 C8 JL RA6 MADE IN JAPAN LED9 610 LED10 6 10 6 LED12 tpe ur 5 1 LED11 5 1 LED13 cade DEPIS LED16 1 101 101 101 10 C LD12 Lal C LD13 5 65 6 1 LED 5 1 LED2 5 1 LEps LED6 SE LED8 E a T 5 65 65 65 6 LED21 LED22 LED23 LED24 C12 RAS d RAS 6 10 LED3 6 10 LED4 6 1 LED17 5 1 LED18 5 1 LED19 5 1 LED20 5 a S S D r el o LD2 LD3 e DE JE is A 29 Output printed circuit board layout Appended figure 8 B1 A1 R 1K351727R1 Japan OO 0202 G E L1 E 10 TR3 20 PC6 PC5 PC4 PC7 A 30 Fuji Electric Systems Co Ltd Head Office Gate City Ohsaki East Tower 11 2 Osa
29. 7 A0 M 18 cLk2 cS b 20 M q os 16 GAT2 RD b 17 OUT2 WR Q34 8253 Cam CLKO GATO DAC1 RD VS LS jN Q D OUTO 15 D4 14 13 18 DAC2 16 17 CLK1 GAT1 D5 D6 LL e uo for LE loo o lo ejo 9 8 7 6 5 4 3 2 OUT1 D7 A0 Al CLK2 CS GAT2 RD Y ojo o DB lt 7 0 gt AD lt 15 00 gt Vss DAC5 DAC6 CLKO DACC DAC7 Vcc OUT2 WB 2 Q33 CRST CS1 CS2 Vss A 10 Appended figure 2 Main printed circuit board 2 circuit diagram CP7 MAIN1 C9 d tu MAIN1 oll CLI SC DB 7 0 SC COMP1 CP10 C11 tu COMP1 x SI SC CG11 0612 __ CDI S 5 470 Le A 11 Appended figure 2 Main printed circuit board 2 circuit diagram P05 s 3 E 3 8T 8r 5T B Vss 1 CNTM11 Q4 18953 Sils Vss 451C D2 T4 N t CNTM12 Q4 19953 e SI Vss Vcc oO o Vss i CNTC11 Q11 15K Vss 451C D3 y CNTC12 Qt 14 18953 10 Vss Appended figure 2 Main printed circuit board 2 circuit diagram C62 Quy 93 T L
30. ART 02ZERO Vss Appended figure 1 CN2 Ai Vcc A2 DB 0 A3 DB 1 A4 DB 2 AS DB 3 A6 DB 4 A7 DB 5 A8 DB 6 A9 DSP3 A10 Ves B1 Vcc B2 RESET B3 DB 7 B4 IORD BS IOWR B6 CLK1 B7 AD 00 B8 DSP1 B9 DSP2 B10 Vss CN5 1 TXD 2 RXD 3 Vss CNS 1 S SSR 2 V SSR Main printed circuit board 1 circuit diagram CN8 1 10201 2 PC1 3 10202 4 PC3 CN7 1 ACAIN 2 AC1COM 3 4 AC2IN 5 AC2COM CN9 sav V SN CN3 1 Vcc 2 VecCT 3 DCP05 4 Vss 5 P20 6 P20CT 7 DCP20 8 SC 9 ACN12 10 ACCOM A 8 Appended figure 2 Main printed circuit board 2 circuit diagram 7402 7414 IOWR oe iS S s od amp CRST E 74107 Q22 134 3 ADJCOM 1 CNTT 1 GCNTT VCNT CNTM11 CNTM12 CNTC11 CNTC12 CNTM21 CNTM22 SCKA CNTC21 SCKB CNTC22 RESET S GCNTM1 4 GCNTCI 5 9 1 GCNTM2 13 ii 1 Sj xr GCNTC2 lt o 0 RESET Q14 O CP3 CP6 CP5 CP8 A 9 Appended figure 2 Main printed circuit board 2 circuit diagram SCKB Vcc CLKO DACC CLKS CNTT i RA9 1 15K UI 9 8 7 DAC3 1 DAC4 1 8253 DO CLKO DI GATO D2 OUTO D3 D4 D5 D6 D7 D
31. COILN A 15 Appended figure 2 Main printed circuit board 2 circuit diagram 13 14 i 11 1 3 Q49 D12 4 13 CNTT 451C 18953 VF2 o 4 7K Ee Ka 15K Vss CP18 CP17 Vss Q Q P20 P05 Sas cle wile ile As VF2 8 87 8S 87 EL 2 SCKA 3 uis LB SCKB Do RESET ER Loe SCLK 10K Q22 a SCLK 8 8 Vss Vss A 16 Appended figure 2 Main printed circuit board 2 circuit diagram 10201 Vcc RVI Vss D ES 2SB679 Q31 DAC aT a A TD62381P E RV1 e 2 6004 PC1 Q43 4 R1 10201 7 C151 SY EIA 451c Lann Q40 3 3K i d RD5 1EB 4 BRE ues N ex PC1 SU Get RD5 1EB ih ZD12 SC 4 GO S 10202 aes P20 E e 2 gt 6004 Q41 4 R2 Vcc Blo ZE 6004 6004 4PS2041 8 Ds 7 sE 5 Q31 Q41 Q41 oo DAC3 2 So AB 3 16 PC1 oS TD62381P S 102024 PC3 P05 6004 Q47 DO T T ili SC el N12 A 17 Main printed circuit board 2 circuit diagram Appended figure 2 o E 510K a 2 T5 E r 25B679 S C151 RD2 2E J32 J33 ZD8 amp
32. Enforce construction of class 3 grounding wire by all means If the specified grounding construction is neglected a shock regard 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 Use power source that matches the rating of the unit Use of power source out of rating may cause fire The external terminals are provided on the rear of the instrument Carry out wiring to each terminal according to the figure Terminal screws are M3 but power terminals are MA Use shielded wires for the output signals to suppress the influence of external noise Ca P Si ES UE SI S Jj Power terminals see 3 3 1 Auto CAL input output terminal see 3 3 5 Oe input output terminal option see 3 3 4 COMP2 2nd component input output terminal see 3 3 3 COMP1 1st component input output terminal see 3 3 2 11 3 3 1 Power terminals The power terminals are arranged as shown in the figure Connect the specified power supply to the terminals and connect a grounding wire to the ground terminal The grounding should be made securely Use solderless terminals for M4 for connection to the terminals Avoid installing this analyzer near an electrical appa ratus which produces power source noise Such as high frequency furnac
33. Error code appears at the sub indication in the case of a single component analyzer and at the 2nd component sub indication in the case of multi component analyzer When multiple errors have occurred the error codes appear successively starting from the lowest numbered one upon pressing ENT key After displaying all the error codes press ENT key again and the error display disappears but they will reappear if the fault is not removed Turn ON the power supply When the analyzer operates correctly it is considered normal When an error occurs the FAULT contact output is conductive 52 Appended figure 1 Vcc 12 289KHz SI 6171819 1 RA6 Main printed circuit board 1 circuit diagram 64180R1P6 C39 22p 2 Vss Vcc SCK q gt aper Geh ek 11 9 6 SCK gt ab Vss TOUT CP4 O Vcc ATBITO po Q24 CP5 Vcc Vcc 1 RAS 15K Hi 270256 CINE A Q2 A2 Q3 01 12 15 16 17 18 19 fo en A eo RAM A 1 Appended figure 1 Main printed circuit board 1 circuit diagram CP6 Vcc RESET vd RESET WDTR 5 EE sl 3 RN1002 7414 E SanL RESET 15953 x 10K Q13 Vss T3 Vss Vss 4 4 A Vcc AT oO ex Tse SN751701P a zx VCC VCC Vcb__ 32 768KH
34. L keys 3 Set up the interference compensation setting mode as in section 4 3 1 Ker Gi t P will appear in the upper two digits of the main indicator on the front panel while a total of 5 numerals will appear in the ad On lower digit of the main indicator plus the amp four digits of the sub indicator lce 011010 0 A Q A negative sign appears in the second lowest digit of the main indicator 4 Feed interference gas saturated H O at LL D 0 C or 2 C as illustrated When the Sp OP 8 Sof suco 9 indication is stabilized press COMP key LESS and select the component to be adjusted a ENT then adjust it until the indicated value becomes almost O within 2 of the full scale using gt key and key 5 After the adjustment is finished press ENT key to record the data in memory gt Na Measured gas inlet 0or2C saturated H20 Es Water Bubbler Cold water or electronic cooler 38 6 5 Power source voltage adjustment The check and adjustment variable resistor are shown in the following figure Top view CN3 VR1 CNS VR ps CP1 Se N Ys COCO CLO VR1 VR2 Qr Main printed ci
35. ad write impossible Not operated until trouble is removed Malfunction due to noise Digital circuit is Turn ON the power supply When the analyzer operates correctly it is considered normal E 1 Trouble with digital defective Replace the main printed circuit ws board circuit output ic read write impossible E 3 Synchronizing signal Both the Improper adjustment of Adjust synchronizing signal on has stopped indicated value synchronizing signal main printed circuit board 2 and output value Improper rotation of CP1 CS VR1 have stopped motor and chopper Check motor and chopper for LED stops Synchronizing signal proper rotation flickering at each process circuit is Check connector for proper setting defective connection nstantaneous power Replace main printed circuit failure board 2 E 4 Zero point calibration Measurement is Improper zero gas Check gas components and dew is out of the calibra possible but zero Unbalance of optical points tion range calibration is system Check sampling system E 6 Integrated drift of impossible N GE system parts are Check the inside of cell for Ee efective ee em 50 FS of each SE e balance of optica measurement range Replace light source E 8 One time zero point Replace sensor calibration exceeds 50 FS of measure ment range E 5 Span point calibration Measurement is Improper setting of Check calibration se
36. al zero adjustment mode as in section 4 2 3 The following indications will appear on the main and sub indicators of the analyzer front panel Main indicator Sub indicator Input signal Input signal from measurement from interference detector compensating detector 4 Operate the optical zero adjusting knob so that the numeric value on the main indica Optical zero tor approaches zero adjusting knob 5 Operate the dimmer plate so that the numeric value on the sub indicator ap proaches zero Dimmer plate 6 Repeat steps 4 and 5 to bring the numeric values on the main and sub indicators as close to N cautions A mistake in this adjustment will cause problems in measurement zero as possible 37 6 4 Interference compensation adjusting method Since this adjustment requires highly trained technique please contact Fuji 1f 1t becomes necessary Adjust the interference compensation if the effect of interference is large more than 2 FS of full scale Dry N2 0 5 min 1 After warming up the instrument supply dry N at a rate of 0 5 minute from the sample gas inlet one With the flow differential system supply dry nitrogen continually to the reference E SS ae QS ae lolol amp cell 2 After indication is stabilized carry out zero calibration using the ZERO and CA
37. ard type The wiring method is as follows Instantaneous value output signal 0to 1V DC or 4 to 20mA DC Lo Moving average value 3 output signal 0 to 1V DC or o Range identification d contact output option 4 to 20mA DC option Upper limit alarm SS contact output 5 option Lower limit alarm S output Xe Remote range option input option 13 COMP1 COMP 2 input output terminal block lt Instantaneous value output gt Instantaneous value of 0 to 1V DC or 4 to 20mA DC is outputted lt Moving average output gt option Specified 1 or 4hours moving average value of 0 to 1V DC or 4 to 20mA DC is outputted lt Upper limit alarm contact output gt option When signal exceeds upper limit terminals 5 and turn from ON to OFF and and turn from OFF to ON 1c contact 250V AC 2A resistive load lt Lower limit alarm contact output gt option When signal is below lower limit terminals 8 and 9 turn from ON to OFF and and 40 turn from OFF to ON 1c contact 250V AC 2A resistive load lt Range identification contact output gt option Terminals 43 and 4 are conductive when 1st range is selected 43 and 4 are open when 2nd range 1s selected la contact 250V AC 2A resistive load lt Remote range input gt option Ist range is selected when 5V DC is inputted to terminals 1 and 20 2nd range is selected when there is no input to terminals 49 and Ex
38. are changed over to each other by a solenoid valve every 50 seconds using the solenoid valve drive signal sent from the main printed circuit board The sample cell and reference cell are provided with infrared ray transmitting windows at both ends The sample gases are exposed to the infrared rays which are transmitted through these windows and absorb the infrared rays according to the measurement component The sample gas through the CO CO converter does not absorb the infrared ray of the wave length peculiar to the carbon monoxide while the sample gas containing the carbon monoxide put in the sample cell absorbs the infrared ray The infrared rays transmitted through these two cells are incident upon the reference side detector vessel and sample side detector vessel respectively The pressure of the detector vessel on the larger light quantity side the side of the sample gas through the CO CO converter becomes higher than that of the other detector vessel Therefore the gas flows from the reference side to the sample side at the moment of making the infrared ray incident upon the detector vessels but 1t flows re versely at the moment of interrupting the infrared rays This flow is converted into an AC voltage by the mass flow sensor This AC voltage is subjected to A D conversion and digital processing Trimmer Reference cell Distribution cell interference filter Reference c Wa gas gas outlet Interference compensating dete
39. at cable 20P i AB i 1010 i CN1 Indication printed E q board assembly AB A 26 Main printed circuit board 1 layout Appended figure 5 CP1 CP3 CP5 CP7 0000 L QOO T 2 12 1 CP2 CP4 CP6 CN6 CN9 nA OREA 87 e o Q R12 C20 REC5 o Q11 i ST nm Ocso JE a aI Q4 i Q c48 4k c49 Jk O R7 Q5 m TK342832R3 Japan A 27 t board 2 layout ircui in printed ci Ma Appended figure 6 CNG 3 CN7 1 4 CN8 1 CP19 VRI VR2 CP2 CP4 CP6 CP8 CPI O CP20 R206 OO R251 O R208 CP3 CP5 CP7 CP R252 R253 R209 OO x l SI 9 R198 050 i R148 160 7 nar VE Ras pag oh Les om D CM og RaM mg mG J I Or 2 R50 id L JL JL TI R20 R199 JE R25_ 4 R44 R46 Blei tot tt R92 R94 R100 R197 R2
40. ce cell Interference compensating detector Infrared light source single light source Motor AC voltage Sample cell amplifier Rotary sector one point chopper Sample Sample gas inlet gas outlet PATAS a O2 meer S RAM CPU ROM o External input contact output D A Indicator A L A PM Alarm output ons Heaton Range identifi peraung SS cation signal Calibration output Each mean O2 value Output Remote range input correction ta 1V or External hold input value 4 to 20mA DC Option Option Operation principle diagram standard type 1 2 Sample switching type The following description is given on the infrared carbon monoxide analyzer However this ana lyzer makes the similar action in case of other components The sample switching type infrared analyzer is based on a basic operation principle that the carbon monoxide has a unique infrared ray absorption spectrum The monoxide is measured by a flow route changeover and flow differential system with the sample gas through a carbon monoxide carbon dioxide converter set to zero gas One of the sample gases processed by the pre processor gets in the sample cell of the analyzer while the other is converted into a gas containing no carbon monoxide through the CO CO converter and 1t is put in the reference cell The flow routes of these gases
41. ctor s O O e O e Infrared light source single light source 00 O gt 0 Qe sE AC voltage Motor Sample cell amplifier Sample Sample d li gas inlet gas outlet Gain changeover Sector synch signal A D dl RAM CPU ROM Indication Alarm output Range identifi Mean Output Operating key cation signal value Oto1Vor output 4 to 20mA DC Rotary sector one point chopper 1 External input contact output D A Indicator Calibration output option Remote range input External hold input a Option Operation principle diagram sample switching type Flow Solenoid checker valve Filter v CO CO2 Sv2 e converter CO sample gas Q DAL O SV3 SV1 ZRF3 Sampling system block diagram for ZRF3 2 NAME AND DESCRIPTION OF EACH COMPONENT 2 1 Name and description of each component on case ZAE INFRARED GAS ANALYZER D Grip Knurled knob 9 Power switch Indication operation panel Front panel D Reference gas inlet Reference gas outlet Sample gas outlet Purge gas inlet 5 Sample gas inlet Note and 8 are used for differential flow system only COMP1 COMP2 O2 AUTOCAL
42. cuit board Adjustment and setting are not necessary Output part printed circuit board Adjustment and setting are not necessary for 1st component Output part printed circuit board Adjustment and setting are not necessary for 2nd component Output part printed circuit board Adjustment and setting are not necessary for O Output part printed circuit board Adjustment and setting are not necessary for AUTO CAL Flowmeter filter unit Check for proper sealing CO CO converter Check for proper sealing Note If the optical system unit is detached during replacement of any parts other than the above check the optical system balance after reattaching it 45 B TROUBLESHOOTING 8 1 In case the indication does not light Indication does not light Is power NO source supplied Y Supply power source Is power switch turn ON NO YES Is fuse blown Trun ON switch disconnection YES YES caused by poor contact Repair or short circuit Are connectors Insert connectors inserted tight into CN2 and CN3 of main Decouple connector from CN3 of main PCB and set fuse Is each part S us Source voltage of PCB ge adjusted See section 6 5 Is fuse blown PCB fault Fault in primary side power line parts Replace or repair
43. e electric welder etc If use of the analyzer near such an apparatus is unavoidable then keep the power lines separate to avoid noise If noise from a relay solenoid valve or the like enters the power source then attach a varistor or a spark killer to the noise source as shown in the figure Note that attaching the varistor or spark killer away from the noise source will be ineffective When the noise generating source is located nearby Grounding wire SS Power supply LI Source m ZRF power supply Varister or spark killer Close connection Noise generating Source 12 3 3 2 COMP 1 1st component input output terminal This output terminal is used with the standard single component type sample switching type or flow differential type The wiring method is as follows Instantaneous value output signal CD O 0 to 1V DC or 4 to 20mA DC Eg Moving average value 3 output signal 0 to 1V DC or Ee a T 4 to 20mA DC option Upper limit alarm contact output option Range identification contact output option Fault External hold input option Lower limit alarm contact output R Remote range changeover signal input option CAA A option 5 3 3 3 COMP2 2nd component input output terminal This output terminal is for the 2nd component of the stand
44. e sure to press ENT key If another key is pressed without pressing ENT key the numerical value which has been set is not registered 3 After ENT key is pressed oC display lamp lights up 18 4 2 1 Response time setting Press CAL key while oC display lamp is flickering and will be displayed At this time the sub display lamp flickers Press COMDP key to select desired setting component Next set the response time of the electric system Numerical value 1 to 199 O 1 to 49 is set from the top digit displayed by the flicker of sub display lamp 90 response time electric system 0 22 x 1 to 199 sec Numerical value increases by pressing key Digits are selected by pressing gt key After setting the response time press ENT key ENT 4 2 2 O conversion reference value setting With the 9 C indication flashing press the CAL key and 2 will be indicated The sub indication now flashes Set a reference value 0 to 19 O Press the key and the numeric will be incremented Press ENT key after setting a reference value O converted concentration Note 21 Set value x NO concentration 2 O concentration
45. ee section 4 2 X Changes depending upon whether option is provided 17 4 2 Maintenance mode To set the maintenance mode perform the following operation in the key lock mode The maintenance mode refers to setting and adjustment in the following five modes Response time setting mode O conversion reference value setting mode option Optical balance adjustment mode Interference compensation coefficient setting mode Indication and clearing of drift amount integrated value a N oe O e NO L H m a E E ZTAN VY l CAL l e RR ENS NO C j 5 ENT m M Response l PA time setting mode ENT O conversion CAL reference value setting mode Optical balance CAL adjustment mode Interference CAL compensator coefficient setting mode ENT Clearing of drift amount integrated value Measurement mode Cautions on operation 1 When O display conversion function is not provided O conversion reference value setting mode is not available By pressing CAL key in the response time setting mode the display is changed for op tional balance adjustment 2 When any setting is finished b
46. et is at atmospheric pressure Sample gas Flow meter Span calibration gas 3 2 Sampling 3 2 1 Sample gas condition 1 Remove all dust included in sample gas by means of a filter Use a filter capable of eliminating dust particles of 0 31 at the final stage 2 The dew point of sample gas must be lower than the ambient temperature to prevent accumula tion of drain inside the analyzer If water vapor is included in the sample gas then feed the gas through a dehumidifier to lower the dew point to around 0 C 3 If SO mist is included in sample gas then use a mist filter cooler etc to exclude the mist The same applies if other kinds of mist are included 4 Note that if strongly corrosive gas such as CL F or HC is included in sample gas in a large amount it will shorten the service life of the analyzer 5 The sample gas temperature should range from 0 to 50 C Be careful not to introduce a high temperature gas directly into the analyzer 3 2 2 Sample gas flow rate The sample gas flow rate should be as follows Provide a flowmeter as shown in the preceding diagram to measure the flow rate Standard type 0 5 0 25 minute Sample switching type 1 1 0 1 4 minute sample gas reference gas Flow differential type 0 5 0 5 0 25 minute sample gas reference gas 3 2 3 3 2 4 3 2 5 Preparation of standard gas Prepare standard ga
47. gas Make check using cylinder gas Is absorbent material used for connection piping Replace connection piping Optical system unit or the like is assumed to be deteriorated Carry out overhaul 49 8 5 In case a drift is large Note 1 If an error code is indicated see the error code table Section 9 2 Drift is large Clean cell or window Check dust removing and dehumidify ing functions of sampling system Is window of light source detector in cell contaminated YES Is airtight in sampling normal Repair airtight failure part Is detector normal Replace detector See section 7 2 Is infrared light source normal Replace infrared light source unit See section 7 1 YES Is each power supply normal Adjust power supply voltage See section 6 5 Analyzer is normal Use analyzer as it is after making zero and span calibration 50 9 9 1 9 2 ERROR CODES AND REMEDIES Error codes and remedies If the instrument has caused an error an error code is indicated When an error code is indicated apply the following remedies 1 An error code is indicated on the sub indicator in case of the one component analyzer or on the sub indicator of the second component in case of the multi component analyzer
48. h parameter as required 7 6 2 Main printed circuit board 2 Fault Power supply voltage sync signal input signal or output signal error Check 1 Check and adjust each of the power supply voltage sync signal and input signal in accordance with section 7 5 2 Check and adjust the output signal in the parameter mode 14 section 4 3 2 Replacement The main printed circuit board 2 can be replaced by decoupling each connector and removing the PCB mounting screws M3 X 2 pcs After replacement is finished make adjustment in the parameter mode 14 section 4 3 2 7 6 3 Indication printed circuit board Fault Lighting failure of each LED or 7 segment LED Check Light on all LEDs in the parameter mode 17 section 4 3 3 Replacement 1 Remove the connector between the main printed circuit board 1 and the indication printed circuit board then remove the screws M4 X 6 pcs on side and M3 X 2 pcs on bottom holding the front panel The front panel is now removed Be careful with the wiring of the power switch connected to the panel 2 Remove the screws M3 X 8 pcs holding the display print panel for re placement 7 6 4 Output printed circuit board COMP1 COMP2 O AUTO CAL Fault Relay contact fault Check Check the relay operation while turning ON OFF the relay contacts by setting an alarm or the like Replacement Remove the mounting screws M3 X 2 pcs of the terminal block on the rear surface of the main u
49. iven in this chapter At the same time check the sampling devices particularly the filter to prevent the cell interior from being contaminated by dust mist or the like How to clean sample cell pipe cell This unit is strictly adjusted prior to delivery from the factory and special care should be taken when handling it 1 To purge the sample cell turn off the power switch and stop the flow of sample gas and flow zero gas for a few minutes Loosen the knurled knobs 2 pieces on the front panel and pull out the analyzer interior by means of the grips General maintenance and inspection are to be performed under the conditions shown above If it becomes necessary to com pletely remove the main unit lift up the front of it and pull it out toward you At this time it should be noted that the piping and wiring are exposed at the same time 2 Loosen the cap nuts fixing the gas inlet pipe and detach the internal gas inlet pipe 3 Remove the screws from the left and right cell retaining places n the case of the sample switching type remove both the sample and reference cells With the standard type remove only the sample cell o Knurled kno Screw Cell L Reference y retainin Vla cell M Cell plate Ig OLE retaining WA late We X A p ES JLA Cap nut fixing gas inlet pipe Cap nut fixing gas inlet pipe Sample cell 4 For cleaning the infrared ray tran
50. ki 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
51. m x Be zi CC 1 ACN12 3 le omg ACCOM Bs Ka ES S e UU ST ER lu A 5 Appended figure 1 Main printed circuit board 1 circuit diagram Ve Vcc 10201 gt N 3N LE ST ESTIS TS Vss ACTIN us AC1COM 3 U n2 o 158232 n2 PCI 7812 Bon o IN OUT S P12 Q9 G 10202 2 3 N sL 42 3 2 sc a L gt L8 OTS OTS acon UR d 5 8 a A SC AC2COM wo 159232 H L alz e g TT 0 CH O To o e G on l GND TIN OUTO N12 A 6 CNT A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 CN4 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 Appended figure 1 Vcc RM11 RM12 RM13 ID11 ID12 ID13 ALMH1 ALML1 FLT Vss RSV Vcc RM31 1D31 ALMH3 ALML3 Vss Main printed circuit board 1 circuit diagram A 7 CN1 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 CN4 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 IOCS AD 07 AD 05 AD 03 AD 01 DB 7 DB 5 DB 2 DB 1 IOWR SCLK MCLK RESET SC P20 Vcc RM21 RM22 RM23 ID21 ID22 ID23 ALMH2 ALML2 Vss Vcc TUNE ZERO SPAN1 SPAN2 SPAN3 CALERR ST
52. mode 5 Calibration start key Start key for manual calibration Zero is calibrated by pressing ZERO and CAL keys CAL lamp lights steadily during calibration Span is calibrated by pressing SPAN and CAL keys CAL lamp lights steadily during calibration 3 PIPING AND WIRING lt gt DANGER On 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 in duced Also if combustible gas is contained there is a danger of explosion fire or the like occur ring Also if combustible gas is contained there is a danger of explosion fire or the like occur ring 3 1 Piping method Connect pipes correctly referring to the instruction manual Exhaust gas should be led outdoors so that it will not remain in the sampling device and indoors Exhaust from the analyzer should be relieved in the atmospheric air in order that an unnec essary 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 adher ing If such a material is adhering a fire or the like accident may be caused 1 Piping procedure Connect pipes to the gas inlets and outlets located at the rear top of the analyzer Use anticorr
53. n sample cell and at the same time check sampling device particularly gas filter 2 Find out leak from sampling line and repair it Flow rate of sample gas Including flow rate of purge gas when internal purge is per formed Deviated from standard flow rate of 0 5 0 25 min Adjust by needle valve of flow rater Check monitor filter menbrane filter Greatly contami nated Damage to primary filter etc 1 Replace primary filter 2 Replace filter Portions to be checked weekly Zero point of analyzer Deviation of zero point Zero point adjustment Span point of analyzer Deviation of standard point Span adjustment Replacement of monitor filter membrane filter Irrespective of symptom Replace filter Portions to be checked every three months Cleaning of sample cell Irrespective of symptom Clean sample cell Use furnished sample cell cleaning cloth for cleaning Portions to be checked yearly Analyzer Irrespective of symptom Overhaul Output of analyzer After overhaul 32 Instrument error test 6 6 1 MAINTENANCE If dust or water drips get in the measurement cell its interior is contaminated and a drift may occur Since an error code is indicated if measurement or calibration is disabled check if the measurement cell is contaminated When its is contaminated clean it in the procedure g
54. nce compensation when there is much interference In this mode adjust so that an indicated value is within 2 of gas concentration of full scale while flowing interference gas 0 C or 2 C saturated H O Refer to section 6 4 Interference compensation adjusting method for details With the 1 7 indication flashing press the CAL key p will be indicated Main display lamp r p flickers and The compensation coefficient is the lower two digit on the main indicator and a value within 32768 to 32768 on the sub indicator The lower 2nd digit of main display is negative symbol Press the COMP key to select the desired component Set the compensation coefficient Press the key and the numeric will be incremented Press the gt key and the numeric will be decremented Press ENT key after setting the compensation coeffi cient cr 9 Note In case the sub indication is a one the device operates reversely N CAUTIONS A mistake in this adjustment will cause problems in measurement 21 4 2 5 Indication and clearing of integrated drift value When the L 0 indication flashing press the CAL key and indicate the zero point drift amount on the main indicator and the span poi
55. ndication printed circuit board circuit diagram 38 39 1 1 2 2 5 3 6 4 7 5 S 36 20 SW8 085 uu 34 4 3 C vo3 35 i 6 02 27 i Zoch Y4li 2 9 4528 vllt S RIE 5 om YT 7 LS138 8 1 15 A YO 2 14 5 B Yi 0 Gi 4 5 OG2A G2B GND GND Q13 CS1 AO WR D7D5D3D1 RESET TD62083AP 1 8 Vcc GND A 21 Appended figure 3 Indication printed circuit board circuit diagram TDG2788p 1 01 ah UA HA Al E E 7918 0015 2 ao Vie Q4 BASS4 8 1 GL 9D156 HDSP 7801 t7 3 8 10 1 3 4 o 10l9 18 LD1 8 116 1 7 H3 An LD3 GL3HD43 6 SR YY GL3HD43 B H1 LD5 GL3HD43 AUN CHEN LD7 V GL3HD43 2 GL3HD43 An LD9 8 T An LD11 GL3HD43 6 i T An LD13 GL3HD43 4 5 GL3HD43 6 7 8 BASS5 8 1 Vcc e 9 9 10 C4 C5 C6 Q4 Toiy Gell Toiy Dit 10 10 9 GND A 22 Appended figure 3 VCC pe 1 RA2 47K Indication printed circuit board circuit diagram BASS6 12 1 RESET RD 0 CLK Dei D7 WR D5 CS1 DO D2 D4 CSO
56. nit and the terminal block and output printed circuit board will be able to be replaced together Decouple the connectors and replace the output printed circuit board 44 7 7 Parts to be adjusted after parts replacement for the parts see the parts list Replacement parts Contents of adjustment and setting After balance adjustment of the optical system make Infrared light source zero and span calibrations and interference correction coefficient setting After balance adjustment of the optical system make Distributing cell zero and span calibrations and interference correction coefficient setting Motor unit After balance adjustment of the optical system make zero and span calibrations After balance adjustment of the optical system make Cell unit zero and span calibrations interference correction coefficient setting and air tight check After balance adjustment of the optical system make Detector unit zero and span calibrations interference correction coefficient setting and air tight check Each parameter mode is set at shipment from the factory Main printed circuit board 1 Check the output signal and adjust it in the parameter mode 14 if the output value deviates Also make zero and span calibrations Check the output signal and adjust it in the parameter Main printed circuit board 1 mode 14 if the output value deviates Also make zero and span calibrations Indication printed cir
57. nt drift amount on the sub indicator for each component Select the range with the amp O keys and the integrated zero JL CAL point and span point drift values will be indicated for that range The indication is a indication of gas concentra tion of full scale When the integrated drift value appears press the FUNC key and the measurement mode will be resumed Range val ENT Zero clearing Carry out zero clearing after cleaning the sample cell When the integrated drift value appears on the indicator press the ENT key and the integrated zero point and span point drift values will be cleared to zero for each component and each range The indicator will then display 22 4 3 Parameter input setting When the detector or main printed circuit board is replaced each characteristic data should be set in this mode Since the instrument may not be normally operated unless each parameter is properly set utmost care should be exercised about this setting For key operations other than this item see the TD524500 1 Role of each mode Mode No Refer to TD524500 Setting of interference compensation coefficient Refer to 4 3 1 Refer to TD524500 14 Zero Span adjustment of external output signal Refer to 4 3 2 15 to 16 Refer to TD524500
58. onent span gas la contact 250V AC 2A resistive load Span gas 3 contact output Contact output for driving solenoid valve for flowing O analyzer span gas la contact 250V AC 2A resistive load lt Auto calibration abnormal contact output gt Contact output when abnormality occurs during auto calibration lt Remote start input gt Input for starting auto calibration via external signal Calibration started by inputting 5V DC be tween terminals 13 and 14 16 4 OPERATION OF INDICATION OPERATION PANEL 4 1 lights HOLD MEAS CAL SET lamp flickers ALM SET lamp flickers lamp flickers RMT RANGE lamp flickers AUTO CAL lamp flickers The key operations permitted on this instrument are roughly classified into three types a user mode for measurement and setting by general user see section 4 1 of the instruction manual a mainte nance mode for setting and adjustment in each maintenance see section 4 2 and a parameter input mode for setting each characteristic value during parts replacement see section 4 3 The individual modes are described below sequentially User mode User mode lamp Measurement mode FUNG Zero span calibtarion value setting mode with O analyzer provided 1 component 2 components analyzer only For details of key operation see the instruction manual cow
59. osive tubes made of Teflon stainless steel polyethylene or the like for connecting the analyzer and sampling system Avoid using rubber or soft vinyl tubes even if there is no worry about corrosion Improper piping material may cause inaccurate indication due to adsorption of gas The pipe connections are Rc1 4 PT1 4 or NPT1 4 internal thread And the pipes should be kept as short as possible to quicken the response A suitable inner diameter is about 4mm Note that dust entering the analyzer may cause a malfunction so be sure to use clean pipes and joints SAMPLE GAS INLET OUTLET PURGE P SO Purge gas inlet Connect purge gas pipe here Reference gas outlet Connect pipe here for discharging reference gas Z 9 amp 9 69 9 69 696960 ARRE V Q S Q S S 69696969 C9 69 G9 z Reference gas inlet Connect reference gas pipe here in case of flow differential system Sample gas outlet Connect pipe here for discharging measured gas Sample gas inlet Connect gas pipe to be measured here 2 Piping diagram Shown next is an example of the configuration for measuring three components When using Zirconia O analyzer Gas analyzer ZRF Sample gas inlet Sample gas outlet Arrange so that sample gas outl
60. owing three keys 0 simultaneously In case of one component analyzer In case of two component analyzer FUNC FUNC d In case of three component analyzer o O e o O Q FUNC t E d AECE EH O D SPAN CAL CD When this mode is set the Mode No d d indication shown to the left 2 Select the mode No to be set using the SPAN or CAL key SPAN key No up CAL Key No down Don t press any key other than the above keys 24 4 3 1 Mode 6 interference correction coefficient setting It this mode the moisture interference correction coefficient can be set every component This is a coefficient by which the component side signal is to be multipled This setting should be done so that the influence of an interference gas may be lessened within the specification when it flow actually This mode is not used in actual adjustment but interference adjustment is made using the maintenance mode mentioned separately and coefficient set there can be read by this mode Desired coefficient 0 5 to 1 8 After the parameter mode is set press he ENT Key and the indica
61. ption in this manual will be changed without prior notice for further improvement SAFETY PRECAUTION First of all read this Safety Precaution carefully and then use the analyzer in the correct way The cautionary descriptions listed here contain important information about safety so they should always be observed Those safety precautions are ranked 2 levels DANGER and CAUTION Warning A Symbol Meaning 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 possibility of medium level trouble or slight injury or only physical damage is predictable This unit is not an explosion proof type Do not use it in a place with explosive gases to prevent explosion fire or other serious accidents For installation observe the rule on it given in the instruction manual and select a place where the weight of gas analyzer can be endured Installation at an unsuited place may cause turnover or fall and there is a risk of injury For lifting the gas analyzer be sure to wear protective gloves Bare hands may invite an injury Before transport fix the casing so that it will not open Other wise the casing may be separated and fall to cause an injury The gas analyzer is heavy It should be transported carefully by two or more persons if manually required Otherwise body may be damaged
62. rcuit board 2 Main printed circuit board 2 Minimo FE 555580515 I LJ circuit board 1 CP1VR1 Upper CP2 4 6 81012141618 SC g I gt Indication printed stage ed circuit board 2 Lower 357911131517 VSS stage Main printed circuit board 1 Wu pq asp CP12 3 4 5 6 7 8 P20 SCVCC VSS 1 Turn ON the power switch 2 Adjust VR1 until the voltage between the check terminals P20 and SC on the main printed circuit board 1 is 20 00 0 05V 3 Adjust VR2 until the voltage between the check terminals VCC and VSS on the main printed circuit board 1 is 5 00 0 05V 4 Adjust VR2 until the voltage between the check terminals CP2 and SC on the main printed circuit board 2 is 5 00 0 05V 5 Connect a synchroscope between the check terminals CP1 and VSS on the main printed circuit board 2 and adjust VR1 until the voltage having the following waveform is obtained If this signal is interrupted E 3 error occurs and the indication do not flicker during various setting operations Note If the following waveform is not obtained the capacity of C30 C31 C100 or C101 should be changed Oscillation Main Between Normal waveform waveform PCB 2 CP1 and VSS VR1 A VR1 lt lt REO EA BV C B C After checking if the waveform is as shown 0 m A B above at A B and C points of VR1 set the 60msec e waveform at the C points middle point Le 120msec gt between A and B of VR1
63. s A and B as shown in Fig 7 3 2 Remove the sector cover B and the distributing cell mounting screws M4 X 2 pcs and replace the distributing cell Since the optical adjusting trimmer is attached to the distributing cell attach this trimmer at the same time After replacement is finished check the optical zero adjustment in accor dance with section 6 3 If the optical zero point deviates greatly make adjustment 7 5 Cell unit Fault Scratches on the window or corrosion of cell inner faces Check Make cleaning in accordance with Chapter 6 Maintenance If the cell unit is corroded severely replace it Block cell Detecting mounting bolt Cell keep fixture KL S O ring lt gt Window Al D ISS i Interference a a compensation detector Light adjust plate Detector 99 amQ Y e Trimmer 8 oW Distributing cell unit Sector cover terminal block Sector cover A Infrared light source unit Fig 7 3 Optical system assembly drawing 43 7 6 Printed circuit board unit 7 6 1 Main printed circuit board 1 Fault Power supply voltage error digital circuit fault Check Check the power supply voltage and adjust it in accordance with section 6 5 Replacement The main printed circuit board 1 can be replaced by decoupling each connector and removing the PCB mounting screws M3 X 2 pcs After replacement is finished make the zero and span calibrations Set eac
64. s esse eee eee A 29 Appended figure 8 Output printed circuit board layout sere A 30 vi 1 OPERATION PRINCIPLE 1 1 Standard type The infrared rays radiated from the infrared light source is divided into two parts by the distributing cell to be incident upon the sample cell and reference cell respectively Interference gas is sealed in the distributing cell to lessen the influence of the interference gas contained in the sample gas The infrared ray is absorbed by the sample gas in the sample cell and the transmitted light quantity is reduced by the absorbed quantity Meanwhile such a gas that does not absorb the infrared ray is sealed in the reference cell so the infrared ray is transmitted without being absorbed The rotary chopper provided between the infrared light source and distributing cell turns on a cycle of approx 9Hz Therefore a larger quantity of infrared ray and a smaller quantity of infrared ray are incident to the detector simultaneously on a cycle of approx 9Hz A Fuji unique mass flow type detector is employed as this detector This detector converts the difference between these light quantities into a resistance variation and generates an AC signal of approx 9Hz Furthermore this detector func tions as an interference compensation detector which lessens the influence of the interference gas contained in the sample gas by a special method Distribution cell interference filter Trimmer Referen
65. s for zero point and span point calibration Zero gas N gas Span gas Gas with concentration of 80 or more of full scale for each component When using a Zirconia O analyzer use air for zero gas Zero gas Air O analyser span gas in measuring method Note Span gas 1 to 2 O O analyser span gas in measuring method Gas with concentration of 80 or more of full scale for other than Zirconia O ana lyzer Note When calibrating the low and high ranges of Zirconia type O analyzer use 9 to 10 O N for the low range and air for the high range Analyzer interior purging Although purging of the analyzer interior is normally unnecessary it should be considered in the following cases 1 When combustible gas is included in the measured gas 2 When corrosive gas is included in the atmosphere at the installation site 3 When the same gas as the measured components is included in the atmosphere at the installa tion site In such cases purge the analyzer interior with instrumentation air or N The flow rate for purging should be about 1 minute And dust or mist should be completely eliminated from the gas for purging Pressure at sample gas outlet Arrange so that the sample gas outlet is at atmospheric pressure 10 3 3 Wiring method N CAUTIONS Wiring is allowed only when all power supplies are turned off This is required for pre venting a shock hazard
66. section 6 5 2 Disconnect the light source terminals from the sector cover terminal block and check its resistance value The resistance value should be approx 18Q If this value deviates greatly the light source may be deteriorated or discon nected Replace the light source Replacement 1 Disconnect the light source terminals from the sector cover terminal block and remove the light source unit mounting screws 2pcs then light source will be able to be replaced See Fig 7 3 After replacement is finished make the optical zero adjustment in accor dance with section 6 3 Detector unit Fault Disconnection of the mass flow sensor or leak of detector seal gas Check 1 Confirmation of detector supply voltage Check the voltage between pins CD and of each connector of CN2 to CN5 on the main printed circuit board 2 see Fig 7 1 The normal voltage should be within 18 0 3V 2 Confirmation of disconnection of mass flow sensor Decouple each connector of CN2 to CNS from the main printed circuit board and check the resistance values between pins 2 and Y and be tween pins 9 and 4 see Fig 7 1 The normal value of each resistance should be within 25 to 500 3 Leak of detector seal gas After the confirmation 1 and 2 are finished take out the detector and check the gas seal pipes and window for scratches or contamination etc 41 Each connector
67. smitted window and cell interior first remove heavy contami nation with a soft brush or the like then wipe lightly with a soft cloth Be especially careful when cleaning the window since it is easily scratched 33 5 When cleaning of the sample cell is finished then reassemble the cell in its original position If the zero point has deviated considerably when operating again select a low range and carry out optical zero adjustment see section 6 3 Also the drift integrated value should be cleared see section 4 2 5 CAUTION If the infrared ray transmitting window is only lightly contaminated it can be cleaned by wiping lightly with the soft cloth to which chrome oxide powder is added But if heavily contaminated the window must be replaced Be careful not to apply unreasonable force when cleaning Infrared ray transmitting window Retaining ring Sample gas inlet UI d O ring HE Cell Gas inlet pipe fixing screw Cap nut Sample gas outlet The infrared ray transmitting window and retaining ring are attached with an adhesive Sample cell structure 34 6 2 How to clean sample cell block cell 1 Turn off the power switch stop the flow of sample gas and flow zero gas for a few minutes Loosen the knurled knobs
68. t value and is out of calibration possible but zero calibration set value and cylinder range calibration is cylinder Check sampling system EJ Integrated drift of impossible Unbalance of optical Check the inside of cell for dote du system contamination Se Eso heast N Optical system parts are Adjust the balance of optical t defective system Ment Tange Replace light source E 9 One time span point Replace sensor calibration exceeds 50 FS of measure ment range E 10 Zero calibration is Measurement is Abnormal sampling Check piping connection and impossible due to possible but system improper gas gas flow unstable input calibration is flow Replace sensor impossible Defective sensor Check wiring and connector E 11 Span calibration is Measurement is V EPS vibraton EEN aud impossible due to possible but span Ty P amp unstable input calibration is impossible E 16 O input signal is low Measurement value O sensor is defective Check O sensor output voltage of O analyzer is Input circuit is defective Check wiring and connector E c different from E 23 O input signal is over q ensity E 17 Temperature sensor Measurement error Temperature sensor is Check resistance of TMP 1 on input signal is low due to ambient defective printing circuit board 2 approx E 24 Temperature sensor temperature may e Temperature circuit is 3KQ input signal is over become large defective
69. ternal hold input Input to COMPI terminal option Hold setting component is outputted and held with 5V DC inputted between 7 and Q0 Fault Input to COMPI terminal Contact output when analyzer incurs an abnormality la contact 250V AC 2A resistive load 14 3 3 4 O input output terminals option This is the input output terminal for the standard type O analyzer The wiring method is as follows Instantaneous value output signal 0 to 1V DC or Range identification 4 to 20mA DC contact output option O analyzer input signal Oto 1V DC Remote range input option Upper limit alarm contact output O converted value option output signal 1st e 0 to 1V DC or o 4 to 20mA DC Lower limit alarm contact output O converted value option output signal 2nd component 0 to 1V DC or 4 to 20mA DC O input output terminal block lt Instantaneous value output Instantaneous value of 0 to 1V DC or 4 to 20mA DC is outputted O analyzer input signal gt O analyzer signal of 0 to 1V DC linear is inputted O conversion output O conversion instantaneous value is outputted with preset conversion reference value Upper limit alarm contact output option When upper limit is exceeded terminals 5 and 6 turn from ON to OFF and 16 and 7 turn from OFF to ON 1c contact 250V AC 2A resistive load Lower limit alarm contact output option When signal is belo
70. tion will be changed over Select in component to be set by the COMP key This ENT procedure need not to be taken in case of the one compo nent The indication of the settable component flickers Change the set value of the correction coefficient by the following keys Interference correction coefficient SPAN key The correction coefficient is incremented by 0 001 ZERO SPAN CAL CAL key The correction coefficient is decremented by 0 001 SPAN key ZERO key The correction coefficient is incremented by 0 050 CAL key ZERO key The correction coefficient is decremented by 0 050 Press them simultaneously Press the ENT key and the data will be stored 25 4 3 2 Mode 14 adjustment of output signal In this mode the output signal value can be set and adjusted Press the ENT key and the indication will be changed over Connect a digital voltmeter or ammeter to the terminal block of the output to be adjusted Adjust the output signal value at the zero point by the SPAN key or CAL key SPAN Incremented by 1 each The adjusted value should be within 0 1 of the f
71. ull scale output CAL Decremented by 1 each Press the key to change over the indication Next adjust the output signal value at the span point by the SPAN key or CAL Key The adjusted value should be within 0 1 of the full scale output Press gt key and each output terminal No will be changed over Similarly adjust the zero and span points of each output terminal No SPAN Incremented by 1 each CAL Decremented by 1 each Press the ENT key to stored the data Next press the FUNC key and the indication will be changed over the mode 17 26 The key functions to be used for adjustment are as follows When the SPAN key is pressed the value is incremented by 1 and the output value is also increased When the CAL key is pressed the value is decremented by 1 and the output value is also decreased When the ZERO Kev and SPAN key are pressed simultaneously the output value is increased more speedily When the ZERO Kev and CAL Key are pressed simultaneously the output value is decreased more speedily The contents of the indication are shown below
72. w lower limit terminals 8 and 49 turn from ON to OFF and 9 and Q9 turn from OFF to ON 1c contact 250V AC 2A resistive load Range identification contact output option Terminals D and 42 are conductive when 1st range is selected O and 2 are open when 2nd range 1s selected la contact 250V AC 2A resistive load Remote range input option Ist range is selected when 5V DC is inputted to terminals 3 and 44 2nd range is selected when there is no input to terminals 13 and 4 15 3 3 5 AUTO CAL input output terminal option This is the output terminal for the auto calibration function The wiring method is as follows Auto calibration CA ia contact output Auto calibration abnormal contact output B E NI start input Zero gas contact output Span gas 1 contact output Span gas 2 contact output Span gas 3 contact output AUTO CAL input output terminal block option Contact output during auto calibration Contact between 1 and 2 is ON during auto calibration 1a contact 250V AC 2A resistive load Zero gas contact output Contact output for driving solenoid valve for flowing zero gas la contact 250V AC 2A resistive load Span gas 1 contact output Contact output for driving solenoid valve for flowing 1st component span gas 1a contact 250V AC 2A resistive load Span gas 2 contact output Contact output for driving solenoid valve for flowing 2nd comp
73. z N12 Se Wi TXD RECO RESP XT2 d ix Veb 7 FRESET a SAS Vss Q16 E IORD STA DEA STS IOWR 5 RTC Vss A Vss Vcc Vcc Vss 1 RA5 15K 1 RA2 15K 7 8 9 6 7 8 9 DB lt 7 0 gt SEPPEPBB SPPFRFFRL AD lt 15 00 gt 270256 6264A 2854H 00 10 Qi 0 00 10 ai 0 00 10 quito of 9 A0 01 9 A0 01 9 A0 21 92 8 M Q2 A1 Q2 A1 Q2 A2 o 02 8 o 02 Zu o 03 7 03 7 15 3 03 7 15 3 A3 Q4 A3 Q4 A3 Q4 04 6 04 6 16 4 04 6 16 4 A4 Q5 A4 Q5 A4 Q5 05 Ze 06175 05 5 ot 5 05 Slas aO 06 4 18 6 06 4 06 4 18 6 AB Q7 A6 Q7 A6 Q7 07 3 19 7 07 3 19 7 07 3 19 7 A7 Q8 A7 Q8 A7 Q8 08 25 08 25 08 25 0 Hm 09 zk 09 24 o T 10 21 10 21 i0 21 Vcc 12 2 le la le Is A12 gt r iD 8 NC 9r SF r ST Em AB S 2006 Vss q WE Q21 Vcc Sy Sol I o OT T 37 IOWR IORD EAROM Vss A 2 Appended figure 1 Main printed circuit board 1 circuit diagram DB lt 7 0 gt AD lt 15 00 gt 8255 0 34 4 0 ee kem Bac XD a3 PA2TT g MEE ES Be PA4 39 5 De bAgi38 6 uas Lu o r e G uu GD gt gt om E de CH Zen RIR 6 WR Bil qUS PB3 o5 4 PB4 RESET RESET PBS 22 1 01 8 PB7 du a e A pr PeH H cear a Per H PO4 12 5 IOCS POS n Poo 0 A DSP1 POT DSP2 DSP3 Q23 RTC da IORD 74373 0 2 1Q 1D WR 309 40H IOE l OWR 3 9 l 5D 8 4 i2 lo E Em n o 7432 7Q 8D EAEE 18 2 E Hie aa 1 mE o OE Q28 RSTO RSTI 7414

Service Manual - Fuji Electric

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