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<8.  Troubleshooting>

8-1

IM 12J05D02-01E

8. Troubleshooting

This chapter describes the countermeasures for failures, classifying the cases into three 

categories: dissolvedoxygen converter failure, detection of failure with the self-diagnosis function, 

and abnormal measured values. The causes for abnormal measured values are not limited to 

equipment failures. If an abnormal phenomenon occurs, first check the following items:

•  Is the property of the measuring solution different from normal ?
•  Is the dissolvedoxygen sensor properly installed?

8.1 

Measures in the case of converter operation 

failure

8.1.1 

No dissolved-oxygen converter operation

If the converter does not operate even when the power is supplied, one cause may be a blown 

fuse inside the converter.
Examine the fuse by turning off the power supply (see Subsection 3.3.1 on page 3.5).
If the fuse is blown, replace it with a new one. If fuses frequently blow and the cause is not clear, 

request an inspection by Yokogawa.
If the fuse is normal, examine the wiring system.

8.1.2 

Operation key or display failure

If the operation keys do not operate smoothly or the display fails (e.g., a missing character 

segment), repair of the printed circuit board (digital board) (replacement with a new one) is 

required.
After the printed circuit board is replaced, operation checks and parameter settings are 

necessary.
Contact Yokogawa and request board-replacement work.

8.2 

Measures in the case of failure (Error) 

detection

If a failure is detected through the self-diagnosis of the DO402G dissolved oxygen converter, 

the FAIL contact is closed. The FAIL lamp on the operation panel lights up and an error number 

appears in the data display.

NOTE

If an error is detected during configuration, the FAIL contact signal is output immediately but the 

error number is displayed after that action or operation is completed.

When a FAIL contact signal is output, take measures according to Table 8.1.

9th Edition: Aug. 05, 2015-00

Содержание EXA DO402G

Страница 1: ...User s Manual Model DO402G Dissolved Oxygen Converter Style S3 IM 12J05D02 01E IM 12J05D02 01E 9th Edition...

Страница 2: ...t use an abrasive or solvent in cleaning the instrument Yokogawa is not responsible for damage to the instrument poor performance of the instrument or losses resulting from such if the problems are ca...

Страница 3: ...take to avoid such risks CAUTION This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument hardware or software from being damaged or a...

Страница 4: ...s manual may have different display positions or character types e g the upper lower case Also note that some of the images contained in this user s manual are display examples n Warranty and service...

Страница 5: ...of failure Process environmental conditions that may be related to the failure of the device A statement whether warranty or nonwarranty service is requested Complete shipping and billing instruction...

Страница 6: ...1 General 2 1 2 2 Operating specifications 2 4 2 3 Model and suffix codes 2 5 3 Installation and Wiring 3 1 3 1 Installation and dimensions 3 1 3 1 1 Installation site 3 1 3 1 2 Mounting methods 3 1 3...

Страница 7: ...de 5 5 5 2 1 Setpoints 5 6 5 2 2 Range 5 8 5 2 3 Hold 5 10 5 2 4 Wash 5 12 5 2 5 Service 5 13 5 3 Notes for guidance in the use of service coded settings 5 14 5 3 1 Parameter specific functions 5 14 5...

Страница 8: ...intenance to be implemented on occasion 7 1 7 2 Periodic maintenance for the EXA DO402G converter 7 2 7 3 Fuse Replacement 7 2 8 Troubleshooting 8 1 8 1 Measures in the case of converter operation fai...

Страница 9: ...Blank Page...

Страница 10: ...hat it was not damaged during shipment If damage is found retain the original packing materials including the outer box and then immediately notify the carrier and the relevant Yokogawa sales office M...

Страница 11: ...unting Selecting a proper installation site will permit ease of operation Sensors should normally be mounted close to the converter in order to ensure easy calibration and peak performance If the unit...

Страница 12: ...Chloride concentration compensation can be programmed Automatic temperature compensation Built in barometric air pressure compensation Hold function enables fixed output signal during maintenance Two...

Страница 13: ...and indicating which keys are to be pressed in the display l Automatic air calibration Calibration for a dissolved oxygen instrument is performed by simple air calibration please refer to 6 3 1 sectio...

Страница 14: ...lt in air pressure sensor automatically compensates for barometric influences between 900 to 1100 mbar 90 to 110 kPa l Sensor diagnostics The DO sensor is checked for low impedance between the silver...

Страница 15: ...1 mA2 code 32 Password protection disabled for mains comm serv level code 52 Autoreturn return to measure in 10 minutes enable or disable code 50 Add functions in MAINT disabled wash start setpoint ad...

Страница 16: ...Select service code 01 S TYPE and set it to 1 polarographic sensor then press the ENT key Select 1 CELL2 9 and set the nominal output to 60 nA Next select service code 10 T SENS and set it to 3 22 kNT...

Страница 17: ...y mode and to enter that value in service code 01 The temperature compensator is a NTC resistance and that can be chosen by entry of 3 in code 10 The wiring of the sensor is different as well The red...

Страница 18: ...minimum 10 maximum 300 Temperature minimum 25 C 77 F maximum 50 C 122 F l Output Signals Two isolated outputs of 0 4 20 mA DC with common negative Maximum load 600 Ohm Auxiliary output can be chosen f...

Страница 19: ...Hold Active Contact S1 to S3 Contact S4 Status LED NO NC LED NO NC Alarm FAIL OFF On Closed Open On Open Closed Alarm FAIL OFF Off Open Closed Off Closed Open Power OFF Off Open Closed Off Open Closed...

Страница 20: ...ote 2 Note 1 This instrument is a Class A product and it is designed for use in the industrial environment Please use this instrument in the industrial environment only A A Note 2 Installation categor...

Страница 21: ...teristics The following tolerance is added to above performance mA output tolerance 0 02 mA of 0 4 20 mA Digital display tolerance 1 digit l Response time 0 90 10 s l Ambient operating temperature 10...

Страница 22: ...d Oxygen Converter Type 1 General Power Supply Voltage 1 2 5 115 V 15 AC 50 60 Hz 2 230 V 15 AC 50 60 Hz 100 V 15 AC 50 60 Hz Language E J English Japanese Options U PM H3 H4 SCT AFTG ANSI X1 Pipe wal...

Страница 23: ...Blank Page...

Страница 24: ...solved oxygen sensor the allowable maximum cable length is 10 m Select an installation site where Mechanical vibrations and shocks are negligible No relay power switches are in the direct environment...

Страница 25: ...t S3 and S4 E Contact output S1 and S2 F Power supply Adaptor for conduit work option code AFTG ANSI Unit mm inch Approx 55 Adaptor G 1 2 female AFTG 1 2 NPT female ANSI 49 7 24 8 66 3 15 3 15 1 93 2...

Страница 26: ...m dia 3 holes Nominal 50A O D 60 5mm mounting pipe F14 1 ai Example of bracket used for pipe mounting Example of bracket used for wall mounting 7 40 6 85 1 97 5 31 0 51 8 82 7 87 1 38 0 59 2 76 3 94 0...

Страница 27: ...ote External wiring connection terminal size is for 2 mm pin Protective grounding 100 or less 1 2 3 31 32 33 41 42 43 51 52 53 71 72 73 C NC NO C NC NO C NC NO C NC NO G SCREEN SCREEN 17 Jumper Shield...

Страница 28: ...for insulating 6 In the case of use of contact input refer to item 3 3 2 1 1 5 6 3 3 2 White Green Green Yellow Clear Red 3 4 DOX10 Power supply unit 3 3 Power supply Brown Blue BROWN BLUE Figure 3 5...

Страница 29: ...back for these cables 6 Replace the screen shield plate over the lower terminals WARNING Always replace the screen plate over the power and contact outputs for safety and to avoid interference 7 Conn...

Страница 30: ...de the power cables through the gland closest to the power supply terminals Use 2 5 mm2 14 AWG wires to connect to the terminals We recommend that the cables be terminated with pin terminals see figur...

Страница 31: ...de diameter between 6 12 mm 0 24 0 47 in 1 Use D or E for cable gland of DO70G power cable when both DO70G and contact input are used Figure 3 7 Glands to be used for cabling WARNING When connecting a...

Страница 32: ...be at least 1 25 mm2 The overall cable diameter should be between 6 12 mm 0 24 0 47 in 3 3 4 Grounding the housing WARNING Protective grounding must be made to prevent electric shock To protect the in...

Страница 33: ...er before wiring 3 4 1 General precautions The contact output signals consist of voltage free relay contacts for switching electrical appliances SPDT They can also be used as digital outputs to signal...

Страница 34: ...diameter is 6 to 12 mm Tighten the cables to 0 5 N m torque 3 4 3 Contact input Voltage free contact do not apply voltage Wash start or input remote range change either choice It is necessary to use s...

Страница 35: ...2 and or 11 12 and must be connected to terminal 11 and 12 The measuring electrode the cathode is marked with IE and or 13 and must be connected to terminal 13 The reference electrode the anode is mar...

Страница 36: ...h Wirning galvanic Sensor Figure 3 12 Wiring galvanic sensor 3 7 Wiring other galvanic sensors Consult the users manual for the color identification of the sensor cable and connect temperature compens...

Страница 37: ...olor of the wiring of the sensor cable supports the indication of each terminal Color of sensor cable White Green Green Yellow Clear Red Brown Blue DO402G 11 12 14 17 18 DOX10 F0312 ai Digital Communi...

Страница 38: ...ensor cable and DO402G terminals are shown in the following table Connections of the sensor cable and DOX10 terminals are shown in the following table DO70G Wiring color Red Clear Green Yellow Green W...

Страница 39: ...e the jumper cable for future use if may be needed when a galvanic sensor is used F0314 ai Digital Communications 12 13 15 16 63 66 65 62 61 95 94 93 92 91 SCREEN mA2 mA1 SCREEN TL TL 17 11 CONT mA OU...

Страница 40: ...lso gives access to the service menu See table 4 1 l LEVEL 3 Service For more advanced configuration selections press the button marked then press NO repeatedly until you reach SERV Now push the YES b...

Страница 41: ...he Measuring mode press twice when hold is activated YES NO keys These are used to select choices from the menu YES is used to accept a menu selection NO is used to reject a selection or to move ahead...

Страница 42: ...eps are introduced to the configuration and programming operations l Maintenance Press MODE key The display shows 000 and PASS Enter a 3 digit passcode as set in Service Code 52 to obtain access to th...

Страница 43: ...ss temperature Barometric pressure Software release number Slope Cell current Wash start in maintenance mode when enabled in service code 51 Display Access Saturation Current output 1 Manual temp when...

Страница 44: ...tion 6 Display DISP See operation section 4 Setpoint SETP Select and adjust setpoint when enabled in service menu section 5 service code 51 See section 5 4 for adjustment procedure Wash WASH Manually...

Страница 45: ...HOLD Note The HOLD feature must first be activated in the commissioning mode section 5 2 3 Refer to note of section 5 2 3 Hold also YES NO MEASURE SETPOINTS RANGE SET HOLD SERVICE MEASURE NO MODE YES...

Страница 46: ...tion 5 2 4 for automatic cycle timing setup Manual temperature adjustgment menu is added to the maintenance mode Manual temperature adjustgment is only visible if the manual temperature in service cod...

Страница 47: ...en enabled in service codes 42 and 43 Setpoint analogue control output mA2 when enabled in code 31 Note To enable adjustment of setpoints in maintenance mode Service Code 51 must be set to ON Setpoint...

Страница 48: ...desirable to select 0 5 mg L range for example and maybe 0 25 C temperature range Service codes 30 to 39 can be used to choose other output parameters on mA output 2 HOLD The EXA converter has the abi...

Страница 49: ...oints ENT ENT ENT ENT ENT ENT ENT ENT repeated keystrokes YES NO NO NO NO NO NO NO YES NO YES NO YES YES NO YES NO YES NO YES NO YES NO SETPOINTS RANGE SET HOLD SERVICE MEASURE H2O CAL DISPLAY HOLD MO...

Страница 50: ...point 1 YES NO YES NO YES NO NO NO NO Process Alarms on S3 and S4 are only available when enabled in Service Codes 40 to 49 Analogue control setpoint is only available when enabled in Service Code 31...

Страница 51: ...nge YES NO YES NO NO NO NO NO NO YES YES NO YES ENT YES NO See facing page ENT ENT ENT ENT ENT ENT ENT ENT YES NO YES NO YES NO YES NO SETPOINTS RANGE SET HOLD SERVICE MEASURE H2O CAL DISPLAY HOLD MOD...

Страница 52: ...Range to adjust then set begin scale 0 and end scale 100 of the mA output signal using the and ENT keys Selection of mA output 0 20 4 20 mA is in Service Code 30 Note Range 2 does not appear when PI c...

Страница 53: ...YES NO YES NO YES NO NO NO NO NO NO YES YES NO YES NO YES NO YES NO YES YES NO HOLD active last measured value HOLD deactivated return to commissioning menu YES HOLD SETPOINTS RANGE SET HOLD SERVICE M...

Страница 54: ...HOLD values set return to commissioning menu When using wash and active HOLD for maintenance wash should be OFF in the commissioning mode section 5 2 4 After that wash should be ON again for returnin...

Страница 55: ...NO NO YES YES NOTE The menu item WASH will not appear unless selected in Service Code 42 NO YES NO Wash system timings are set with the and ENT keys in the setpoint menu ENT ENT ENT ENT ENT ENT SETPO...

Страница 56: ...MAN CAL DISPLAY HOLD MODE AIR CAL WASH ENT ENT ENT YES ENT ENT Example Service Code 01 Select Sensor Type for galvanic sensor for polarographic With the ENT keys ENT H2O CAL ENT ENT Nominal cell curr...

Страница 57: ...n is not used the default check therefore set to off When zero check enabled the maximum permissible zero offset should be set as a signal current When slope check enabled the maximum as minimum calib...

Страница 58: ...form salinity compensation simply by setting the salinity compensation to 1 enabled in Code 04 but requires the NaCl concentration For measurement in consideration of the salinity of a sample first ma...

Страница 59: ...The zero point is reset to the default when 0 is set zero calibration disabled even after calibration Code 22 ZERO Zero current values can be entered manually If a zero calibration is made in maintena...

Страница 60: ...CELLset in code 01 SL MAX set in code 02 3 75 A 50 nA 23 29 Not used 5 3 4 mA output settings Code 30 mA Select 0 20 mA or 4 20 mA for each of the mA outputs Code 31 OUTP F Select the parameter to be...

Страница 61: ...abled 0 0 Enabled 1 39 Not used Note To enable wash function set Service Code 38 to 0 Service Code 42 to 4 0 0 and Service Code 51 to 0 1 0 5 3 5 Contact outputs Code 40 S1 S2 Process relays can be se...

Страница 62: ...e frequency 2 Activation by temperature 3 PI control inactive 0 PI control active 1 43 S4 Contact S4 Contact 4 inactive 0 4 00 Low alarm configuration 1 High alarm configuration 2 Active during HOLD 3...

Страница 63: ...Alarm Functions Control output mA Pl control on the 2nd mA output The 2nd mA output can be configured to give a P I proportional and integral control output The setpoint proportional band and integra...

Страница 64: ...dicate a fault or error the FAIL contact will be switched In most cases this will be caused by a malfunction of the measuring loop The FAIL contact is also closed when the power is removed The FAIL co...

Страница 65: ...dy FAIL flag in the display and a continuous contact closure All the other contacts controls are inhibited except HOLD contacts and a Fail signal is transmitted on the outputs when enabled in code 32...

Страница 66: ...Temperature sensor open Hard fail Temp sensor shorted Soft fail Temp sensor shorted Hard fail Cell current abnormal Soft fail Cell current abnormal Hard fail Abnormal measured value Soft fail Abnorma...

Страница 67: ...an result in corruption of the instrument setup and will impair the performance of the unit Code Display Function Function detail X Y Z Default values Communication 60 COMM SET ADDR Communication Baud...

Страница 68: ...ration in particular should be carried out after leaving the sensor operating in air or measurement liquid for about half a day The time for stabilizing the zero point can be reduced by shorting the t...

Страница 69: ...ssage will appear on the display and the procedure is aborted The calculated sensor parameters are compared with preset tolerances and if these conditions are not met Error E2 Zero Error or E3 Slope E...

Страница 70: ...reading Is stable the CAL END message appears Note To start calibration with a zero solution press NO zero calibration must be activated in service code 21 Transfer to zero solution and press YES Whe...

Страница 71: ...a long time to calibrate the DO30G sensor or other galvanic sensors and polarographic sensors with sulfite saturated water Even after CAL END is displayed wait 40 to 50 minutes and then press the YES...

Страница 72: ...for single point adjustment Note To start calibration with a zero solution press NO zero calibration must be activated in service code 21 Transfer to zero solution and press YES When the reading is st...

Страница 73: ...iscrepancies Most important calibration data are Dissolved oxygen concentration at saturation conditions as function of temperature barometric pressure altitude and salinity These data are included in...

Страница 74: ...LD NO MODE YES ENT MODE AIR CAL CONTACTS S1 S2 WASH S3 FAIL S4 H2O CAL NO YES NO After briefly displaying WAIT the display returns to the normal readout Press YES to return to the measuring mode Singl...

Страница 75: ...0432 0 0421 0 0407 0 0400 0 0389 0 0352 0 0371 Table 6 2 Solubility of oxygen mg L at various temperatures and elevations based on sea level barometric pressure of 760 mmHg Temp C Elevation metres abo...

Страница 76: ...barometric pressure of 760 mmHg Temp C Solubility Seawater mg L Fresh water mg L 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 11 97 11 36 10 82 10 29 9 84 9 43 9 05 8 69 8 37 8 06 7 77 7 48 7 21 6 93 6...

Страница 77: ...Blank Page...

Страница 78: ...ent of sensor cap a 1 to 2 months b 6 to 8 months c 6 to 8 months d 6 to 12 months Dissolved oxygen converter a Inspection of temperature indication error check b Replacement of fuse a 6 months b 1 to...

Страница 79: ...is reassembled in order to maintain the housing s weatherproof integrity against water and water vapor The DO measurement uses small signal currents and may otherwise be prone to problems caused by e...

Страница 80: ...he fuse turn off power to the instrument at the external breaker 2 Remove the instrument cover and the high voltage shield plate 3 Remove the cover from the fuse holder by pulling out by hand 4 Remove...

Страница 81: ...Blank Page...

Страница 82: ...th a new one If fuses frequently blow and the cause is not clear request an inspection by Yokogawa If the fuse is normal examine the wiring system 8 1 2 Operation key or display failure If the operati...

Страница 83: ...failure Replace membrane Check for wet O rings in the membrane assembly or wet sealing face Wipe off wet areas and dry out E7 All modes Measured temperature failure too high It exceeds 50 0 C 122 0 F...

Страница 84: ...sat has been set Change the maximum or minimum value in the range so that a span more than the permissible value is obtained E18 CODE 35 36 Table values make no sense Reprogram E19 At data entry Conf...

Страница 85: ...Blank Page...

Страница 86: ...9 Spare Parts 9 1 IM 12J05D02 01E 9 Spare Parts See Customer Maintenance Parts List 9th Edition Aug 05 2015 00...

Страница 87: ...Blank Page...

Страница 88: ...300 sat T1 25 0 C 77 F 0 0 C 32 F 50 C 122 F T2 25 0 C 77 F 0 0 C 32 F 50 C 122 F T3 25 0 C 77 F 0 0 C 32 F 50 C 122 F T4 25 0 C 77 F 0 0 C 32 F 50 C 122 F 10 2 Range Variable Default Lower limit Uppe...

Страница 89: ...Off Calibration parameter functions 20 T SEC 60 sec mg L 0 05 mg L 21 0 CAL 0 Off 22 ZERO 0 A nA SLOPE 3 75 50 A nA mA outputs 30 mA 1 1 both 4 20mA 31 OUTP F 0 2 DO Temp D R 0 Reverse control 32 BURN...

Страница 90: ...brane thickness set Repeat carefully Check code 01 E4 Membrane failure Perforated membrane Replace and recalibrate E7 Temperature too high 50 C 122 F Process temperature too high Wrong sensor programm...

Страница 91: ...user Reprogram E18 Table values make no sense Wrong data programmed Reprogram E19 Programmed values outside acceptable limits Incorrect configuration by user Reprogram E20 All programmed data lost Fau...

Страница 92: ...sing K9672DA 1 Polyuretane baked finish K9672DB 1 Epoxy baked finish 8 K9663MM 1 Cable Gland Assembly 9 Fuse Time Lag Fuse A1105EF 1 For 100 V AC Power 0 200 A T A1105EF 1 For 115 V AC Power 0 200 A T...

Страница 93: ...XL A 1 U Bolt Assembly 4 K9171SY 1 Plate 5 K9171SX 1 Bracket 6 K9171ST 1 Mounting Set PM 7 Y9520LU 2 Screw 8 K9171SW 2 Bracket 9 Y9608KU 4 Screw 10 Sun Protection Cover K9664CA 1 Cabon steel H3 K9664C...

Страница 94: ...ety and EMC conforming standards description for EMC revised Page 4 4 Figure of Section 4 4 Display functions default modified Page 5 16 Explanation of the code 21 modified Page 5 25 Some revision of...

Страница 95: ...Blank Page...

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