Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for FujiFilm ZPA
Summary of Contents for FujiFilm ZPA
- Page 2 This service manual is intended for use with the instruction manual to help you in understanding maintenance and inspection for the infrared gas analyzer (ZPA, ZPB, ZPG). However, the basic operation of the analyzer is not covered in this manual.
-
Page 3: Table Of Contents
1. STRUCTURE ..........................1 1.1 Analyzer* ............................1 1.2 Optical unit ............................3 1.3 Wiring diagram ..........................5 1) ZPA ..............................5 2) ZPB ..............................6 3) ZPG ..............................7 1.4 Internal piping diagram ........................8 1) ZPA ..............................8 2) ZPB .............................. - Page 4 AIO board ............................35 Amplifier board ........................... 35 Main power board ..........................36 Light source power board* ........................36 Those marked with asterisk are the items of which detail is not common among ZPA, ZPB, and ZPG. Other items are common. TN5A1191-E...
-
Page 5: Safety Instructions
SAFETY INSTRUCTIONS First of all, read this “Caution on safety” 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 in 3 levels, “DANGER”, “CAUTION” and “PROHIBITION”... - Page 6 Piping 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.
- Page 7 Operation For correct handling of calibration gas or other reference gases, carefully DANGER read their instruction manuals beforehand. Otherwise, carbon monoxide or other hazardous gases may cause an intoxication particularly. Before leaving unused for a long time or restarting after left at such a status for an extended length of time, follow the directions of each instruction manual because they are different from normal starting or shutdown.
- Page 8 Others If the cause of any fault cannot be determined despite reference to the instruction manual, be sure to contact your dealer or Fuji Electric’s technician in charge of adjustment. If the analyzer is disassembled AUTION carelessly, you may have a shock hazard or injury. Do not use a replacement part other than specified by the analyzer maker.
-
Page 9: Structure
1. STRUCTURE 1.1 Analyzer TN5A1191-E... - Page 10 Mount or not Part No. Part name Case ass’y Base Front panel ass’y Solenoid Valve (SV) ass’y none Power supply mounting plate Handle Paramagnetic type O sensor unit Power switch Pipe fuse Fuse holder Noise filter Power inlet terminal Power inlet Key board Triple gas port unit Dust cap...
-
Page 11: Optical Unit
1.2 Optical unit TN5A1191-E... - Page 12 Part No. Part name Part No. Part name Light source unit Cell fixing block LS power board Block cell ass’y Pipe cell ass’y Window ass’y Window ass’y Block cell O ring Gas filter Pipe cell Filter Cell mounting Detector unit Base plate TN5A1191-E...
-
Page 13: Wiring Diagram
1.3 Wiring diagram 1) ZPA TN5A1191-E... -
Page 14: Zpb
2) ZPB TN5A1191-E... -
Page 15: Zpg
3) ZPG TN5A1191-E... -
Page 16: Internal Piping Diagram
1.4 Internal piping diagram 1) ZPA Optical unit 2 (IR Unit 2) Optical unit 1 (IR Unit 1) Built-in sensor INLET1 OUTLET1 Sampling gas outlet Sampling cell Note) Sampling gas inlet 2 cells may be used by combination of measuring component. -
Page 17: Zpb
2) ZPB Optical unit 2 (IR Unit 2) Optical unit 1 (IR Unit 1) (Left) (Right) Built-in sensor Sampling cell REFERENCE INLET1 OUTLET1 Note) 2 cells may be used Sampling gas inlet Sampling gas and by combination of reference gas outlet measuring Reference gas inlet component. -
Page 18: Zpg
3) ZPG Sampling cell Optical unit 1 (IR Unit 1) (Left) (Right) Built-in sensor REFERENCE INLET1 OUTLET1 Sampling gas inlet Sampling gas outlet and reference gas outlet Reference gas inlet Gas components measured by each optical unit No. of gases to be Gases to be measured Optical unit 1... -
Page 19: Maintenance And Inspection
2. MAINTENANCE AND INSPECTION 2.1 Light source unit Recommended replacement cycle: ZPA and ZPB : 5 years : 2 years Possible errors caused by the deterioration of this part: a) Short circuit or disconnection of the hot wires of the light source... -
Page 20: Sector Motor And Sector
2.2 Sector motor and sector Recommended replacement cycle: Light source motor unit ZPA and ZPB : 5 years as viewed from cell side : 2 years Possible errors caused by the deterioration of this part: a) Stop of motor rotation Symptoms: Error 1, display of dashes (----) Check: Turn on the analyzer, and check that the motor shaft rotates. -
Page 21: Detector Unit (Excluding O Sensor)
35,000 and 80,000 (ZPA) or between 350,000 and 800,000 (ZPB and ZPG). If the count is lower than 30,000 (ZPA) or 300,000 (ZPB and ZPG), the sensitivity of the analyzer may be degraded. -
Page 22: Built-In O Sensor (Magnetic Type)
Replacement Notes The AMP board is populated with components necessary for each detector. When you order the detector unit for replacement, therefore, inform a) the serial number of the gas analyzer, b) the serial number of the detector, and c) the detector type. Turn off the analyzer before replacing the detector unit. -
Page 23: Built-In O Sensor (Galvanic Type)
2.6 Built-in O sensor (galvanic type) Recommended replacement cycle: 2 years Possible troubles occur on this part: Sensor deterioration Symptoms: span drift or unstable readings Check: Disconnect the cable from CN16 on the main board. Connect a digital voltmeter on the both ends of the connector of the O sensor side. -
Page 24: Aio Board
Check: voltage Check terminal Check voltage Contents VIN-GND1 common for +24.0±1.0 V (Input voltage) ZPA, ZPB and ZPG +15.0±0.5 V for ZPA and ZPB VOUT-GND2 (Output voltage) +9.0±0.5 V for ZPG After replacement: Carry out the voltage check as shown above. -
Page 25: Switched-Mode Power Supply (Smps)
Turn off the analyzer before replacement. Disconnect the cables from the main board and the power switch, and replace the power supply. After replacement: Check the power supply voltage on the main board. ZWS50BAF-24 (common for ZPA, ZPB & ZPG) LFA10F-12 (only for ZPB & ZPG) Voltage +12 V... -
Page 26: Operation Keys
2.10 Operation keys Possible troubles occur on this part: Abrasion of the switches Symptoms: no response to key operation Check: 1. Turn OFF the power. 2. Disconnect the cables. 3. Measure the resistance of the connector of the key that does not work. 4. -
Page 27: Solenoid Valve
2.11 Solenoid valve Recommended replacement cycle: 3 years Symptoms: short-circuit or disconnection due to the solenoid coil burn out, or wear of the core Replacement: Turn off the analyzer before replacing the sensor. Disconnect the wires and tubes. Replace the solenoid valve. -
Page 28: Factory Mode
3. FACTORY MODE 3.1 How to go to factory mode Point the cursor to “6. To Factory Mode” by using the Maintenance Select operating item Mode key on the Maintenance Mode screen and press the key. Then, the password input screen appears. 1. Sensor Input Value 2. Error Log 3. Cal. Log... -
Page 29: Zero Limit
3.2 Zero limit You can switch whether or not to show the values below zero of the measured value. OFF: Values below zero are not displayed ON: Values below zero are displayed The default setting is “OFF”. If you turn “ON” the zero limit to check the indication during analyzer adjustment, do not forget to turn it “OFF”... -
Page 30: Range Limit
3.3 Range limit You can switch on and off of the limiter applied on the measured value used for O correction and for calculating the moving average. ON: indication and output of the measured value is limited up to 110% of FS OFF: the measured value is indicated and transmitted up to limit of the display. -
Page 31: Calibration Coefficient
3.4 Calibration coefficient This menu allows you to change the coefficient for zero calibration and for span calibration. Factory mode > 14. Coefficient Factory mode initial screen The cursor is in 14. - “R1 and R2” means the range 1 and the range 2 respectively. -
Page 32: A/D Conversion Value
Check that the A/D values during dry zero gas flow fall under the following range. No. 0 (Infrared ray component 1) 35,000 to 80,000 (ZPA) or 350,000 to 800,000 (ZPB & ZPG) No. 1 (Infrared ray component 2) 35,000 to 80,000 (ZPA) or 350,000 to 800,000 (ZPB & ZPG) No. -
Page 33: Error Criteria
When the A/D conversion value of the reference voltage is out of faulty. the following range, the analyzer emits the error 3. 35,000 No. 15 80,000 (ZPA) or 350,000 No. 15 800,000 (ZPB and ZPG) Error 4 Zero calibration is not Infrared component: 0.5 zero calibration coefficient 5... - Page 34 Points to be checked upon errors Error No. Points to be checked page Error No. 1 Sector rotation, light source, and detector signal on amplifier board — Error No. 2 • Factory mode > 11. A/D data > No. 17 to No. 20 •...
-
Page 35: Troubleshooting
5. TROUBLESHOOTING Zero calibration error Check that a specified amount of zero gas is supplied to the analyzer. If the gas amount is deficient, check the piping for leaks and repair them. Detector check 1. Check if the voltage DV1 GND of the AMP board are as specified (p.13). 2. - Page 36 Recording the values at error When trouble occurs, be sure to sample the following data. Supply the gas given in Table and sample the measured value of measurement screen, sensor input values in maintenance mode. Supplied gas Gas concentration, Span calibration Measurement display Sensor input value in composition...
-
Page 37: Adjustment For Heat Treatment Furnaces
6. ADJUSTMENT FOR HEAT TREATMENT FURNACES What is the adjustment for heat treatment furnaces? If, in plant gases to be measured, a large amount of other lower-molecular-weigh gases than nitrogen (N ) such as hydrogen (H ), or a large amount of other higher-molecular-weight gases than nitrogen (N ) such as argon (Ar) are contained, it is known that the calibration curve (output performance to gas concentration) of gas analyzers will be affected (pressure broadening). -
Page 38: Method For Span Calibration By Check Gas
6.2 Method for span calibration by check gas The method for span calibration by use of check gas (give in 2) is explained based on the example. (Since span calibration has an error of calibration curve, preset a calibration indication on the calibration curve graph attached to this analyzer for indirect calibration.) The following calibration curve graph is attached to the test results for the product. -
Page 39: Moisture Interference Adjustment
7. MOISTURE INTERFERENCE ADJUSTMENT Moisture interference adjustment is only for NO analyzer and SO analyzer. Purpose : Adjust the light control plate in between the three layer detector so that moisture interference becomes close to zero. Procedure : 1) To start adjustment, set the light control plate at the Light control plate same height (10 to 15mm upper than (c): upper end of Fixing screw... -
Page 40: Appendix 1. Measuring Principle Diagram
APPENDIX 1. MEASURING PRINCIPLE DIAGRAM Principle Diagram of Infrared Type Measurement (NO, SO , CO , CO, CH Front expansion chamber Gas inlet Gas outlet Infrared-ray light source Rear expansion chamber Detector Mass flow Motor Measurement cell sensor Chopper Preamplifier Indication Signal processing block... -
Page 41: Appendix 2. Data Flow Diagram
APPENDIX 2. DATA FLOW DIAGRAM TN5A1191-E... -
Page 42: Appendix 3. Pcb Component Layout
APPENDIX 3. PCB COMPONENT LAYOUT Main board sensor gain switchover) External zirconia type O / built-in galvanic cell type O Built-in paramagnetic type O External input type O TPVH1 (3.3V) (Digital) TPVS1 (0V) TPVL1 (3.3V) (1.25V) (Digital ground) (AD integral waveform) (Backup battery) (Digital) Common with TPG 1... -
Page 43: Aio Board
AIO board Additional AO board 1 Additional AO board 2 (Ch1 Analog output selection) Short circuit between -2 : Current output CN10 (External O sensor input IN) Short circuit between 2-3 : Voltage output (External O sensor input OUT) (Ch2 Analog output selection) (To Main board) To DIO board, SSW board and JP1 to 4... -
Page 44: Main Power Board
Power supply 1 to Main board to LS power board 1 Digital to LS power board 2 (Digital ground) Light source power board for ZPA and ZPB for ZPG to Light Source to Main power board VOUT GND1 GND2...
Need help?
Do you have a question about the ZPA and is the answer not in the manual?
Questions and answers