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Stenhoj SGA 400 Service Manual

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SERVICE MANUAL
SGA 400
© Stenhöj Sverige AB V0.2

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  • Page 1 SERVICE MANUAL SGA 400 © Stenhöj Sverige AB V0.2...

  • Page 2: Table Of Contents

    Replacing the display board ..............................10 Replacing micro bench in SGA 400 ............................11 Difference of installing the IR bench in old version of SGA 400 and in new version ............13 Cleaning procedure for IR bench 7911 ..........................14 Replacing OLD pump................................
  • Page 3 ERROR BENCH TEMP RAIL 54 ............................52 ERROR 55 - BENCH PRESS RAIL ............................52 ERROR BENCH REF RAIL 56 ............................52 ERROR 64 - BENCH O2 RAIL ..............................52 ERROR 99 - BENCH COMMUNICATION ..........................52 ERROR SMOKE COMMUNICATION 119 ..........................

  • Page 4: Introduction

    1. INTRODUCTION The service manual is meant to be used as a helpful tool when performing maintenance, service and repairs of the SGA 400 gas analyzer. This manual is purposed for internal use only and the contents may not be copied or reproduced, fully or partially, without permission in writing from Stenhöj Sverige AB.

  • Page 5: Parts Description

    PARTS DESCRIPTION FRONT PANEL...

  • Page 6: Rear Panel

    REAR PANEL Oxygen sensor 25. Gas & Water Outlet Sensor 26. Calibration gas inlet Fine filter 27. Connection to smoke meter (opacimeter SGA 100) Water separator outlet 28. Power supply connector Sample gas inlet 29. Serial no label...

  • Page 7: Right Side Panel

    RIGHT SIDE PANEL Bluetooth- antenna (optional) Accessories connector Accessories connector CAN connector RS232 connector USB connector Prepares Blue Tooth parity...

  • Page 8: Removing The Top Of Sga 400

    REMOVING THE TOP OF SGA 400 To release the cover of the analyzer all six screws marked in the picture below must be removed.

  • Page 9: Sga 400 Wiring

    SGA 400 WIRING...

  • Page 10: Sga 400 Sampling System

    SGA 400 SAMPLING SYS TEM...

  • Page 11: Maintenace

    Water system from the inside. MAINTENACE REPLACING THE DISPLA Y BOARD 1. Release the top cover of the analyzer and place the cover on a desk where the front is facing the desk surface. 2. Release the six nuts marked red in the picture above 3.

  • Page 12: Replacing Micro Bench In Sga 400

    4. Release the flat cable by gently pulling the six pin- connector out from the connector J3 on the display board. 5. Reassemble with new board in reverse order. REPLACING MICRO BENC H IN SGA 400...
  • Page 13 Remove the six screws and release the cover of the analyzer. Release the five screws shown on the picture above.

  • Page 14: Difference Of Installing The Ir Bench In Old Version Of Sga 400 And In New Version

    30 min before calibrating with gas. Letting the analyzer run in measuring mode is necessary to achieve stabilization in the micro bench before gas calibration. DIFFERENCE OF INSTALLING THE IR BENCH IN OLD VERSION OF SGA 400 AND IN NEW VERSION Old version SGA 400.

  • Page 15: Cleaning Procedure For Ir Bench 7911

    CLEANING PROCEDURE F OR IR BENCH 7911 The cleaning procedure for a 7911 IR bench is a short and simple moment which will insure that no substances or dust are inside the optics of the bench sabotaging the sampling. Tools needed: •...
  • Page 16 Connect the hoses between the bench and the syringe as the image below shows. Place a small weight at the end of the hose that goes into the beaker in order to keep this end from springing out of the beaker and spilling liquid. Make sure the weight you use is clean.

  • Page 17: Replacing Old Pump

    • Finally reconnect the tubing between the “T” and the pressure transducer. REPLACING OLD PUMP Disconnect the power lead and any other lead to the analyzer. Remove the four screws on the bottom of the chassis that secure the pump unit inside the analyzer. Before disconnecting the hoses to the pump unit you may want to mark each end of the hoses if that would make it more easy for you to remember how to connect them back later.

  • Page 18: Replacing Of Parts In Pump

    Assemble the new pump in reverse order. REPLACING OF PARTS I N PUMP Use a screw driver with six edge- bit of 2,5 mm or an Allen key to unscrew the four screws that hold the pump head to the pump chamber.
  • Page 19 Use a 2 mm Allen key to unscrew the diaphragm of the pump.
  • Page 20 Note! When mounting the new diaphragm into the pump make sure that the small disc above the diaphragm is turned upwards where its notch fits the edges of the screw. Image showing the pump head with the rubber packing attached and the pump chamber to the right.

  • Page 21: Replacing The Mpu- Board

    Image showing the pump head with the rubber packing off. Note! The demonstration above shows the disassembly and the parts of the gas pump. The dismantling and the parts of the water pump are identical to the gas pumps. REPLACING THE MPU - BOARD Tools needed: Phillips screwdriver/electric screwdriver 2 pcs...
  • Page 22 Remove the four screws of the right side plate by using a Phillips screwdriver or an electrical screwdriver and use a 5,5 mm wrench or a pair of pliers to hold steady the nuts on the other side of the plate.
  • Page 23 Note! The nut located behind the MPU- board and closest to the bottom of the chassis might be hard to reach with a wrench or with normal size- pliers. You may use longer pliers to reach it or a long screwdriver to put between the nut and the metal plate witch supports the MPU- board, and in this way keep the nut steady while unscrewing its screw on the other side.
  • Page 24 Image showing the MPU- board together with the right side plate. Unscrew the two screws from the RS232- connector on the right side plate.
  • Page 25 After unscrewing the two screws the right side plate is easy removed from the MPU- board. Use a pair of pliers or a 5,5 mm wrench to hold the nuts while unscrewing the screws with a Phillips screwdriver.

  • Page 26: Replacing The Solenoid

    Image showing the MPU- board removed from all plates and ready for replacing. Mount the new board in reverse order. REPLACING THE SOLENOID Disconnect the power lead and any other lead to the analyzer. Remove the two screws on the bottom of the chassis that secure the magnet solenoid inside the analyzer.
  • Page 27 Before continuing with the exchanging of the magnet solenoid the carbon filter should be released. Release the two wired power cable in J3 connector on the power board.
  • Page 28 Use a pair of pliers to cut the ends of the hoses that are connected to the metal fittings. Always use pliers to cut the used ends of the hoses and never attempt to reuse the end of a hose if it has been connected to a fitting once.

  • Page 29: Cleaning Of The Solenoid

    If a hose is removed from a fitting without cutting the used end of the hose and you try to reuse the same end of the hose you will probably detect leakage very shortly. A used end of a hose has formed its own shape and will no longer dense for being refitted to a rippled fitting again, not even to the ordinary fitting it once was connected to.
  • Page 30 4. Use alcohol and cotton swabs to clean all the parts that were affected with liquids or dirt. 5. Insure that all parts are free from dirt and that they are dry before reassembling the solenoid. Use sealing tape on the threads of the bolts when refitting the parts to the solenoid. This will reduce the future risk of leakage.
  • Page 31 The fitting marked in the image below is connected to the upper fitting of the solenoid but the piston inside the solenoids rod is blocking the air flow in to this inlet. When the solenoid is not activated this circuit is closed and a vacuum should be able to be pumped up without blocking the upper fitting.

  • Page 32: Replacing The Carbon Filter

    REPLACING THE CARBON FILTER Remove the two screws on the bottom of the chassis that secure the magnet solenoid inside the analyzer. If needed, use a flat screw driver to release the carbon filter from the hose. Refit the new filter and mount back the magnet solenoid in reverse order. REPLACING THE BUILT IN PRINTER Release the top cover of the analyzer and place it on a desk where the front is facing the desk surface.

  • Page 33: Replacing The Power Board

    Release the plastic fastenings by pushing them upwards with your finger and then pushing them outside the printer with a screwdriver. Install the new printer in reverse order. REPLACING THE POWER BOARD The power board should be of revision E if no later is released. Tools needed: Wrench or a bit of 5,5 mm combined with screwdriver 1 pc...
  • Page 34 Power to printer Power inlet from external power supply In order to facilitate the work you should release the top cover of the analyzer and place it aside. Note how the leads to the power board are connected before releasing them. However, the board’s connections are named with the function to where they supply the voltage as well.

  • Page 35: Battery Rpm/Oiltemp-Kit Installation

    6. Fit the new board in reverse order. Note! You may find it easier to refit some of the leads to the power board before rather than after having assembled the board and tightened it with the nuts. BATTERY RPM/OILTEMP-KIT INSTALLATION...
  • Page 36 Remove the top cover of the analyzer and the left panel of the chassis body. Assemble the circuit board with the metal plate and place the plastic distances between the metal plate and the board.
  • Page 37 In order to connect the circuit board with the power board and with the MPU board the power- and the data lead should be connected as the arrows shows. Blue arrows show the cable S131 for data connection and pink arrows show cable S144 for power connection. SGA 400 with Battery RPM/OILTemp option seen from outside.

  • Page 39: Installing Of Inductive Rpm/Oiltemp Option

    INSTALLING OF INDUCTIVE RPM/OILTEMP OPTION Parts needed: Phillips screwdriver 1 pc Wrench 5,5 mm 1 pc Inductive RPM/OILTemp kit 1 pc Remove the top cover of the gas analyzer. Release the side plate as the picture below shows. Use a Phillips screw driver or an electric screwdriver to loosen the screws while holding the nuts on the other side of the plate with a wrench or pliers.
  • Page 40 1. Plate released 2. The Inductive RPM/OILTemp- kit. Fit the board of the Inductive kit to the RPM- metal plate. The two plastic rings should first be threaded through the connectors of the board, than the metal plate is passed through the connectors in the same manner as the rings, and finally the plate is fastened to the board with the two nuts.
  • Page 41 Fit the RPM- metal plate on the body of the analyzer by fastening it with the same screws that used to fasten the old metal plate. Now you will connect the cables from the RPM- board to the power board and to the MPU- board. The power cable should be connected between the larger connector of the RPM- board and J12 on the power board and (blue arrows).

  • Page 42: Installing Nox Option

    The s/w of the analyzer is usually programmed from production to detect the h/w of any new RPM/OILTemp option. No further s/w- installation is necessary. INSTALLING NOX OPTION Article no of NOx kit for SGA 400 is 528424. 1. List of needed parts: Article...
  • Page 43 Use a screwdriver to remove the plastic plug covering the NOx location on the rear panel. Remove also the four screws that secure the water separating system off the rear panel wall. Picture showing what the ordinary hose connection inside an SGA 400 looks like. Remove the hose from the outlet fitting as the picture shows.
  • Page 44 Assemble the loosen hose to the fitting to the right as the picture shows. Assemble a 10 cm long hose between the next fitting of the NOx- cell holder and the outlet fitting. Release the four screws on the rear panel that hold the water separating system and pull slightly the system inside the analyzer.

  • Page 45: Leak Check In Sga 400

    The isolation works as protection against fast shifting temperatures. 9.Connect the cable’s other end to the NOx connector on the micro bench (red arrow). 10.Reassemble the SGA 400 and start the analyzer with power. 11. Calibrate the NOx sensor with calibration gas (see user’s manual for instructions).
  • Page 46 If not you can start a leak check manually through program P-1 in the program menu. The plastic filter cups in the SGA 400 are also examples of what could cause leaks in SGA 400. A proper suggestion to seal them is to put some silicon pasta around both the cup edges before mounting them back to the water module.
  • Page 47 Leak checking the pumps If no crack was found on the water trap house it’s time to remove the top cover of the analyzer and to search for the leak inside. Remove the hose from the in suction of the water pump (red arrow in the picture above) and use your vacuum pump to pump up a vacuum and check if the vacuum drops.
  • Page 48 Do the same procedure with the gas pump. The gas pump is named “PK1”. The in suction- fitting is marked also here with arrow in. Leak checking the solenoid: Remove the hose that goes from top fitting of the magnet solenoid to the water trap (red arrow in the picture below) and stick the vacuum pump connector to that end of the hose.

  • Page 49: Configuring Sga 400

    CONFIGURING SGA 400 INSTALLING O400 CONFIG LOADER Make sure that the SGA 400 is not connected to the PC Run O400CLsetup.exe Follow instruction until you get to the last page On the last page wait for the “DOS window” to disappear before you press Finish.

  • Page 50: Updating The Sga 400

    Navigate to O400 Config Loader Vx.x.x Press Remove UPDATING THE SGA 400 Turn on the SGA 400 Connect the USB cable to the PC Start O400 Config Loader Click Browse…, navigate to the *.o400c file you have received from SGA and press open or double-click the file.

  • Page 51: Error Codes And Their Descriptions

    Press Download to start configuration If the file contains new software the SGA 400 will restart two times before settings and language is downloaded When everything is done and if everything is successful press next and finally Finish on the last page to end the...

  • Page 52: Error Bench Hardware Fail

    The O2- cell is a battery and wears out over time. A normal life length of a new O2- cell is just above one year. The user can extend the life of the O2- cell by putting the analyzer to pause or switching it of when not in use. The O2- cell should have a voltage of between 7-13 mV when measuring in surrounding air for the cell to work properly.

  • Page 53: Error Bench Co2 Rail

    If input voltage is between 9-30 V DC and if no liquids are detected the bench should be replaced. ERROR BENCH CO2 RAIL • Restart the analyzer with power at last once and with no accessories connected to it. No smoke unit, no remote control, no Bluetooth unit etc.

  • Page 54: Error Smoke Communication 119

    Following explains various errors that may occur in the gas analyzer. Each error is monitored by possible causes and suggestions on solutions. Failure Possible cause Possible solution Accessories connected to - Disconnect all analyzer is faulty. accessories and restart Analyzer doesn’t start SGA 400 with power. with power despite proper connection to power supply.
  • Page 55 Power supply 12 VDC bad. - Replace power supply 12 VDC. Power board in OPUS 400 bad. - Replace power board.
  • Page 56 Shut down both analyzers No communication to The smoke unit is not connected from power and smoke unit OPUS 100. to OPUS 400 or was connected connect/reconnect all the after OPUS 400 was powered cables. Power up first the smoke unit and thereafter the OPUS 400.

  • Page 57: Service And Maintenance

    Measure the same voltage message appears on the again and note if the error displays again. message appears on the displays again. SERVICE AND MAINTENANCE The SGA 400 gas analyzer is very easy to maintain. The basic steps for a proper maintenance are:...
  • Page 58 If your SGA 400 is of older series you probably have the same size of both the water filter and the fine filter, no less important to put them in their correct locations in the water separating module.
  • Page 59 The purpose of the pasta is to make it easier for the user to fasten them but mainly to reduce the risk of leakage between the cups and the water module. A leakage her would affect the leak check. The filters of the water separating module and their article number: 528422...
  • Page 60 Make sure that the new filters sit tight in their location in the water separator module when changing them. Filters that are loose cause deterioration when separating the vapour from the exhausts and that would damage the IR bench, among other things. The fine filter and the water separating filter can be soiled by dirt and particles even if they look clean.

  • Page 61: Spare Part List

    The front panel should be polished regularly to ensure a proper view of the readings on the displays. Service sheet for SGA 400 For a detailed service form of SGA 400 please contact your distributor or Stenhöj Sverige. SPARE PART LIST...
  • Page 62 AC/DC adapter 150W RoHS 40060 Power cable 230 V AC 5 m black 44035 Printer SGA 400 40100 Power and signal cable Thermal printer SGA 400 60182 Pump 12 V DC 44009 Solenoid valve 12 VDC 44091 CHECK VALVE 0,5 PSI RED...

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