FujiFilm ZPA Service Manual Download | Manualshive

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Summary of Contents for ZPA

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Page 2: ... and then proceed to installation operation and maintenance of the gas analyzer Wrong handling may cause an accident or injury x The specifications of this analyzer will be changed without prior notice for further product improvement x Modification of this gas analyzer is strictly prohibited unless a written approval is obtained from the manufacturer Fuji Electric will not bear any responsibility ...

Page 3: ...anic type 15 2 7 PCB 15 1 Main board 15 2 AIO board 16 3 Main power supply board 16 4 Light source power supply board 16 2 8 LCD 16 2 9 Switched mode power supply SMPS 17 2 10 Operation keys 18 2 11 Solenoid valve 19 2 12 Filter 19 3 FACTORY MODE 20 3 1 How to go to factory mode 20 3 2 Zero limit 21 3 3 Range limit 22 3 4 Calibration coefficient 23 3 5 A D conversion value 24 4 ERROR CRITERIA 25 5...

Page 4: ...2 DATA FLOW DIAGRAM 33 APPENDIX 3 PCB COMPONENT LAYOUT 34 Main board 34 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 ...

Page 5: ...plosion proof type Do not use it in a place with explosive gases to prevent explosion fire or other serious accidents CAUTION x For installation observe the rule 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 x For lifting the gas analyzer be sure to wear p...

Page 6: ... not be applied to the analyzer Otherwise any pipe in the analyzer may be disconnected to cause gas leakage x 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 Wiring CAUTION x Wiring work must be performed with the main power set to OFF to prevent electric shocks x Enforce construct...

Page 7: ...s analyzer during operation If you touch something inside you may get burned or electrical shock PROHIBITION x Do not allow metal finger or others to touch the input output terminals in the analyzer Otherwise shock hazard or injury may occur x Do not smoke nor use a flame near the gas analyzer Otherwise a fire may be caused x Do not allow water to go into the gas analyzer Otherwise hazard shock or...

Page 8: ... technician in charge of adjustment If the analyzer is disassembled carelessly you may have a shock hazard or injury x Do not use a replacement part other than specified by the analyzer maker Otherwise adequate performance will not be provided Besides an accident or fault may be caused x Replacement parts such as a maintenance part should be disposed of as incombustibles ...

Page 9: ...A1191 E 1 1 1 Analyzer 27 2 1 6 18 5 11 22 17 17 35 35 16 29 29 29 36 36 16 22 4 14 28 26 9 34 7 21 19 20 12 10 10 10 13 6 3 8 A A B D D B C C E E F G F G 9 34 10 10 10 32 25 33 31 23 24 15 30 1 STRUCTURE ...

Page 10: ...inlet 14 Key board 15 LCD 16 Triple gas port unit 17 Dust cap 18 Flow checker ass y none 19 Galvanic cell type O2 sensor unit 20 Galvanic cell type O2 sensor socket 21 Galvanic cell type O2 sensor plate 22 Ferrite core 23 Filling seal 24 Specification name plate 25 SSW board none 26 AO board 27 Main board 28 AIO board 29 DIO board 30 Commu board 31 Main power board 32 Power supply 1 33 Power suppl...

Page 11: ...TN5A1191 E 3 1 2 Optical unit ...

Page 12: ...Part name 1 Light source unit 8 Cell fixing block 2 LS power board 9 Block cell ass y 3 Pipe cell ass y 10 Window ass y 4 Window ass y 11 Block cell 5 O ring 12 Gas filter 6 Pipe cell 13 Filter 7 Cell mounting 14 Detector unit 15 Base plate ...

Page 13: ...3 2 1 Twisted pair cable Power supply 1 ZWS50BAF 24 R79254N21 CN1 4 3 2 1 8 V1 Main power board TQ500854C1 7 6 5 4 3 2 1 G1 G2 V2 G3 2 1 CN3 2 1 CN2 Light source board 1 TQ500855 C1 6W 1 2 CN1 Light source 1 TQ500855 C1 6W 1 2 CN1 DIO board 1 TQ501059C1 3 7 6 5 4 2 1 CN1 3 2 5 6 1 7 3 7 6 5 4 2 1 3 7 6 5 4 2 1 CN2 3 7 6 5 4 2 1 CN1 3 7 6 5 4 2 1 3 7 6 5 4 2 1 CN2 5 FG Cable TQ500863C2 Cable TQ5008...

Page 14: ...6 TN5A1191 E 2 ZPB ...

Page 15: ...TN5A1191 E 7 3 ZPG ...

Page 16: ...NLET1 OUTLET1 Sampling gas outlet Sampling gas inlet Built in O2 sensor Gas components measured by each optical unit No of gases to be measured Gases to be measured Optical unit 1 Optical unit 2 1 NO SO2 CO2 CO or CH4 One of the left None 2 CO2 and CO CO2 and CO None 2 NO and CO NO CO 2 NO and SO2 NO SO2 3 NO SO2 and CO NO SO2 and CO 4 NO SO2 CO2 and CO NO and CO SO2 and CO2 ...

Page 17: ...TLET1 FL1 Left FL2 Right Sampling gas and reference gas outlet Built in O2 sensor SV1 NO IN NC SV2 NO IN NC Gas components measured by each optical unit No of gases to be measured Gases to be measured Optical unit 1 Optical unit 2 1 NO SO2 CO2 or CO One of the left None 2 CO2 and CO CO2 and CO None 2 NO and CO NO CO 2 NO and SO2 NO SO2 3 NO SO2 and CO NO SO2 and CO 4 NO SO2 CO2 and CO NO SO2 CO2 a...

Page 18: ...t INLET1 REFERENCE OUTLET1 FL1 Left FL2 Right Sampling gas outlet and reference gas outlet Built in O2 sensor SV1 NO IN NC SV2 NO IN NC Gas components measured by each optical unit No of gases to be measured Gases to be measured Optical unit 1 Optical unit 2 1 NO SO2 CO2 or CO One of the left None ...

Page 19: ...g CO2 analyzer 6 2 0 3 If the resistance is infinite the wires are damaged Note that if the resistance is smaller than the above criteria the reading drifts towards minus direction b Filler gas leakage from the light source unit Symptom Unstable indication Check If regardless there is no abnormality in any parts other than the light source the measured value output greatly fluctuates or drifts aff...

Page 20: ...ero calibration and span calibration 2 3 Cell cell window and O ring z Lifespan and recommended replacement period Cell and cell window can be used for years unless they are seriously contaminated or corroded O ring should be replaced every two years z Possible troubles occur on this part a Contamination of cell and or cell window Symptoms display of dashes drift calibration error Check Disassembl...

Page 21: ...connect the connector on the detector unit 3 Measure the resistance J1 J4 and the resistance J2 J3 of the amp board on the detector unit The resistances shall be between 57 ohm and 63 ohm If the resistance is greater than the above range it means the sensor element is damaged Do not use an ohmmeter through which an electric current of 2 mA or greater passes The element may be damaged c Detector vo...

Page 22: ...e values meet the requirements shown in the Table on the previous page Voltage between the terminals DV1 and GND on the AMP board Count value while flowing the zero gas Resistance J1 J4 and the resistance J2 J3 of the amp board 2 Carry out the zero calibration and the span calibration 2 5 Built in O2 sensor magnetic type z Possible troubles occur on this part Damage of the O2 sensor Symptoms the r...

Page 23: ...spheric pressure 1013 hPa Theoretically estimated replacement cycle of the galvanic O2 sensor KE 25 used in this gas analyzer is 450 000 vol h Based on this estimate if you continuously measure the oxygen of 25 vol the replacement cycle should be 450 000 vol h 25 vol 24 h day 365 days year 2 05 year 2 7 PCB Refer to Appendix 3 PCB component layout 1 Main board z Voltage check Check terminal Check ...

Page 24: ...oltage Check terminal Check voltage Contents VIN GND1 Input voltage 24 0 1 0 V common for ZPA ZPB and ZPG VOUT GND2 Output voltage 15 0 0 5 V for ZPA and ZPB 9 0 0 5 V for ZPG z After replacement Carry out the voltage check as shown above 2 8 LCD z Service life 30 000 hours when continuously used z Possible troubles occur on this part Display deterioration backlight failure Symptoms black screen d...

Page 25: ...nals Turn on the analyzer and measure the voltages on each terminal If the voltage does not meet the rated value shown in the table below the power supply is failed z Replacement Turn off the analyzer before replacement Disconnect the cables from the main board and the power switch and replace the power supply z After replacement Check the power supply voltage on the main board ZWS50BAF 24 common ...

Page 26: ...on If the switch is normal the connection is made by pressing the switch and broken by releasing the switch z Replacement 1 Detach the main board and the main board mounting plate from the base of the front panel 2 Remove two screws on the key board 3 Replace the key board 4 Set up the parts 5 Connect the cables z After replacement Check that all the keys work properly Allocation of Connector Conn...

Page 27: ...nt Carry out zero calibration and span calibration IN NC NO NO IN NC 2 12 Filter When you replace the solenoid valve be sure to replace the filter as well z Recommended replacement cycle 3 years Symptom filter get clogged and gas won t pass through z Replacement 1 Turn off the analyzer before replacement 2 Remove the hose clamp and then pull out the hose from the filter 3 Put the hose through the ...

Page 28: ... the ENT key The Factory Mode initial screen appears The items you can edit are 4 Option 5 Pressure 12 Others 14 Coefficient 16 Sample Switch All the other items can only be viewed ENT CEVQT QFG 5GNGEV QRGTCVKPI KVGO 2 QFG J 0Q J CVC 1RVKQP 2TGUUWTG KPGCTK CVKQP GOQT EEGUU CVC 1VJGTU PVGTHGTGPEG QGHHKEKGPV CNEWNCVKQP 5CORNG 5YKVEJ 6GORGTCVWTG 1WVRWV 59 1 59 Point the cursor to the item you want to...

Page 29: ...to turn it OFF after adjustment Factory mode 12 Other parameters Zero limit Factory mode initial screen The cursor is in 12 ENT ESC Point the cursor to Zero limit and press the ENT key The setpoint ON or OFF is inverted ENT ESC By using the or key switch between ON and OFF and press the ENT key If you want to cancel the change press the ESC key before pressing the ENT key CEVQT QFG 1VJGTU 6JG XCNW...

Page 30: ...he display z The default setting is ON Factory mode 12 Other parameters Range limit Factory mode initial screen The cursor is in 12 ENT ESC Point the cursor to Range limit and press the ENT key The setpoint ON or OFF is inverted ENT ESC By using the or key switch between ON and OFF and press the ENT key If you want to cancel the change press the ESC key before pressing the ENT key CEVQT QFG 1VJGTU...

Page 31: ...NT ESC R1 and R2 means the range 1 and the range 2 respectively The third column from left shows the zero calibration coefficient and the fourth shows the span coefficient ENT ESC Select the component and range you want edit and press the ENT key Use the and key to change the value and the key to select the digit and press the ENT key If you want to cancel the change press the ESC key before press...

Page 32: ...sor 2 14 Pressure 7 Temperature sensor 3 15 Reference voltage Factory mode initial screen The cursor is in 11 ENT ESC 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 2 Infrared ray component 3 35 000 t...

Page 33: ...alibration is over 50 of full scale This error occurs in the following condition 50 of FS Zero calibration concentration set value current display Error 6 Span calibration is not within the allowable range When span calibration coefficient is not within the following range error occurs Infrared component 0 1 d span calibration coefficient d 10 External O2 built in galvanic cell type O2 built in pa...

Page 34: ...board and the main board 24 Error No 3 Factory mode 11 A D data No 15 the voltage between TPVH1 TPVS1 on the main board 24 Error No 4 5 TROUBLESHOOTING Zero calibration error 27 Error No 5 Error No 6 5 TROUBLESHOOTING Span calibration error 27 Error No 7 Error No 8 5 TROUBLESHOOTING Zero calibration error and Span calibration error 27 Error No 9 Error No 10 Connection between DIO boards Connection...

Page 35: ...ro calibration error above Detector check 1 Record the voltage TP1 SC of the AMP board during the span gas flow 2 Check the count values sensor input value in the maintenance mode during the span gas flow p 13 z Drift Check that specified amount of gas is supplied to the analyzer If the gas amount is deficient check the piping for leaks and repair them Check that the cell window O ring detector wi...

Page 36: ...ange leave the cells for the Range 2 blank If troubles occur in multiple components take a record for each component If troubles occur in the O2 analyzer add a column for the zero calibration concentration set value that corresponds to the span calibration concentration set value Coefficient in the factory mode Channel No Component Range value Zero coefficient Span coefficient Ch1 Range 1 Range 2 ...

Page 37: ...n calibration used for each method and its method are explained using an example For the standard gas for zero calibration use dry N2 in any case so that zero point will not be affected Example Assume that a 0 1 CO2 meter of the infrared ray gas analyzer measures CO2 contained in plant gases When plant gases are composed of 0 5 CO2 23 CO 30 H2 0 2 CH4 and 46 3 N2 either of the following is used as...

Page 38: ...tion gas In graph a point of 0 95 on X axis should be stretched to upward draw a line toward Y axis from the cross point with the check gas calibration curve From the cross point with calibration curve on the scale gas composition 0 89 or equivalent values can be obtained 3 Set this point 0 89 to the span calibration concentration of the calibration concentration set value 4 Supply 0 95 check gas ...

Page 39: ...plate at the same height 1 to 6mm lower than c upper end of the fixing plate as in the right figure b 5 Flow the gas in the same manner in 3 to read the count value of each gas Respectively replace the read values of Zero with Zb and Moisture with Hb 6 Calculate the Zero point Zx count value as following Zx Zb Ha Za Hb Zb Za Hb Ha 7 Move the light control plate up and down while flowing zero gas a...

Page 40: ... Chopper Gas outlet Gas inlet Principle Diagram of Magnetic Force Type Measurement O2 Output Indication Signal processing and calculation block Preamplifier Gas outlet Gas inlet Measurement cell Mirror Magnetic field Photodiode Permanent magnet Permanent magnet Light emitting diode Principle Diagram of Galvanic cell Type Measurement O2 Thermistor Electrolyte Diaphragm Positive electrode Negative e...

Page 41: ...TN5A1191 E 33 APPENDIX 2 DATA FLOW DIAGRAM ...

Page 42: ... type O2 1 2 3 4 5 6 CN14 Optical unit 2 1 CN12 Optical unit 1 1 CN15 Optical unit 2 2 CN13 Optical unit 1 2 CN16 O2 sensor input TP3 AD integral waveform LED2 CPU operation check Red blinking normal LED4 Power supply check Green lighting normal CN4 Program boot CN1 LCD signal CN7 To Commu board CN3 Key switch signal TP4 3 3V Backup battery TPVH1 3 3V Digital TPVL1 1 25V Digital TPVS1 0V Digital g...

Page 43: ...hort circuit between 1 2 Current output Short circuit between 2 3 Voltage output JP10 Ch3 Analog output selection Additional AO board 1 JP1 to 4 Ch5 to 8 Analog output selection Ch5 Ch6 Ch7 Ch8 JP1 to 4 Ch9 to 12 Analog output selection Ch9 Ch10 Ch11 Ch12 DV1 Detector voltage JP1 Resistance mounting for gain adjustment JP2 Resistance mounting for gain adjustment SC TP1 Ground GND DV1 Ground TP1 Af...

Page 44: ...er supply 1 VCC Digital CN4 to Main board CN2 to LS power board 1 CN3 to LS power board 2 VSS Digital ground VOUT output voltage GND2 output ground GND1 input ground for ZPG for ZPA and ZPB CN2 to Main power board CN1 to Light Source VIN input voltage GND Analog ground 15V Analog ...

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