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IM 12J6B3-E-H

Maintenance 7-1

7. MAINTENANCE

It is important for maintaining the measurement accuracy of the EXA DO series of wire dissolved-oxygen
metering system to perform inspection and maintenance at fixed intervals. It also serves to prevent
problems from arising.
This chapter describes daily inspection and maintenance for the purpose of maintaining system
performance.

7-1. Overall dissolved-oxygen metering system

Tables 7-1 and 7-2 show the inspection and maintenance items for equipment composing 4-wire dissolved-
oxygen metering system. The procedure of inspection and maintenance for the dissolved-oxygen converter
is described in Section 7-2. For inspection and maintenance of the sensors and holders, see each
instruction manual respectively.

7-1-1. Inspection and maintenance to be implemented periodically

Table 7-1 shows the items which are recommended to be inspected and maintained periodically.

Table 7-1. Items for periodic inspection and maintenance of 4-wire dissolved-oxygen metering

system

7-1-2. Inspection and maintenance to be implemented on occasion

Occasionally implement the maintenance that is not directly related to measurement functions and
maintenance associated with errors.

Table 7-2. Items for occasional inspection and maintenance of 4-wire dissolved-oxygen metering

Instrument or apparatus

Item

Recommended Interval

All equipment

a. Calibration

a. 1 to 2 months

Dissolved-oxygen sensor

a. Cleaning of membrane

a. 1 to 2 months

b. Polishing of silver electrode

b. 6 to 8 months

surface and replacement of electrolyte

c. Replacement of membrane assembly

c. 6 to 8 months

Dissolved-oxygen converter

a. Inspection of temperature indication

a. 6 months

(error check)

b. Replacement of fuse

b. 1 to 2 years

Float holder

a. Sweeping of winch mechanism

a. (depends on installation

environment)

Immersion holder

a. Inspection of sensor holding O-ring

a. 6 months

b. Sweeping of cleaner nozzle

b. 1 to 2 months

c. Inspection for leakage from the solenoid

c. 6 months

valve for cleaning utility

Faulty phenomenon

System content of inspection

Error E2 occurrence

Check whether the dissolved-oxygen sensor membrane is
contaminated or not.
Check whether the nozzle is clogged or not.

Error E3 occurrence

Polish the silver electrode surface of the dissolved-oxygen sensor
and replace the electrolyte.

It is difficult to see the inside

Wipe off the dirt on the transparent window using tissue paper or

of the converter through the

the like. (Use detergent for hard-to-clean dirt.)

window

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Содержание EXA DO402G

Страница 1: ...Instruction Manual Model DO402G Converter for Dissolved Oxygen IM 12J6B3 E H 5th Edition YOKOGAWA...

Страница 2: ......

Страница 3: ...3 3 3 AC power 3 5 3 3 4 DC power 3 5 3 3 5 Grounding the housing 3 5 3 3 6 Switching on the instrument 3 5 3 3 7 Changing the supply voltage 3 6 3 4 Wiring the contact signals 3 6 3 4 1 General prec...

Страница 4: ...libration method 6 4 6 3 1 Preparation 6 4 6 3 2 Calibration operation water calibration method 6 4 6 3 3 Procedure for water calibration 6 5 6 4 Calibration procedure using manual calibration method...

Страница 5: ...and service Yokogawa products and parts are guaranteed free from defects in workmanship and material under normal use and service for a period of typically 12 months from the date of shipment from th...

Страница 6: ...IM 12J6B3 E H...

Страница 7: ...materials including the outer box and then immediately notify the carrier and the relevant Yokogawa sales office Make sure the model number on the textplate affixed to the top of the display board of...

Страница 8: ...ion and peak performance If the unit must be mounted remotely from the sensors WF10 extension cable can be used up to a maximum of 50 metres 150 feet with a BA10 junction box The EXA is delivered with...

Страница 9: ...range settings selection of output signals and alarm functions Analog output with adjustable damping time Password protection for each programming level Built in wash timer with remote start possibil...

Страница 10: ...ed The chloride concentration value is set manually via the service level The EXA D0402 takes account of the effects of salinity and temperature simultaneously The advantage of this construction is th...

Страница 11: ...disabled burn low 3 5 high 22 on mA1 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 MA...

Страница 12: ...model 32 sensors with 12 19 and 25 mm shaft These sensors are available in many different configurations The sensor is a polarographic sensor and therefore settings of service code 01 has to be change...

Страница 13: ...re DO PI control table burn up 22 mA or burn down 0 or 3 5 mA to signal failure E Temperature compensation 0 50 C Sensor types Pt100 or Pt1000 RTD 2k2 NTC PB36 Yokogawa compatible 22 k NTC Ingold comp...

Страница 14: ...ature Contact output is also available to signal Hold Active Control function On Off PI pulsed Proportional duty cycle control with integral term PI frequency Proportional frequency control with integ...

Страница 15: ...ble terminals for up to 2 5 mm2 finished wires Protection weather resistant to IP65 and NEMA 4X standards Mounting Pipe wall or panel using optional hardware H Data protection Non volatile memory for...

Страница 16: ...IM 12J6B3 E H...

Страница 17: ...severe weather conditions Maintenance procedures are possible avoiding corrosive environments The ambient temperature and humidity of the installation environment must be within the limits of the inst...

Страница 18: ...Wall and pipe mounting diagram Figure 3 4 Internal view of EXA wiring compartment OPTION U Universal pipe wall mounting kit pipe mounting vertical wall mounting pipe mounting horizontal 80 3 15 2x 6...

Страница 19: ...ack for these cables 6 Replace the screen shield plate over the lower terminals Always replace the screen plate over the power and contact outputs for safety and to avoid interference 7 Connect the an...

Страница 20: ...se The fuse rating is dependent on the supply to the instrument The 250 VAC fuses should be of the time lag type conforming to IEC127 Fuse ratings are 230 VAC 50 mA 100 VAC 100 mA 115 VAC 100 mA 24 VD...

Страница 21: ...e rear of the housing using a braided wire cable See figure 3 8 3 3 6 Switching on the instrument After all connections are made and checked the power can be switched on from the power supply Make sur...

Страница 22: ...he contact in and output signals and shielded multi core cable for the analog signals 3 4 2 Contact outputs The EXA unit s four contact outputs can be wired to suit your own custom requirements Figure...

Страница 23: ...re compensator has two wires with the markings T1 T2 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 t...

Страница 24: ...pensator cathode and anode to terminals 11 12 17 and 18 in this sequence Connect the cable shield when provided to terminal 14 Figure 3 9 Cable gland assembly with tagplate 3 9 Tag plate mounting When...

Страница 25: ...gives access to the service menu See table 4 1 LEVEL 3 Service For more advanced configuration selections press the button marked then press NO repeatedly until you reach SERVICE Now push the YES but...

Страница 26: ...e required number ENT When the required value has been set using the keys press ENT to confirm the data entry Please note that the EXA 402 does not register any change of data until the ENT key is pre...

Страница 27: ...dditional steps are introduced to the configuration and programming operations Maintenance Press MODE key The display shows 000 and PASS Enter a 3 digit passcode as set in Service Code 52 to obtain ac...

Страница 28: ...iciency Cell current slope Press YES to fix the selected second line of display YES YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO DISPLAY DISPLAY DISPLAY DISPLAY DISPLAY DISPLAY DISPLAY DISP...

Страница 29: ...At this stage the user will be prompted for pass code where this has been previously set up in service code 52 in chapter 5 Air calibration See calibration section 6 H20 calibration See calibration s...

Страница 30: ...The HOLD feature must first be activated in the commissioning mode section 5 YES NO MEASURE SETPOINTS RANGE SET HOLD SERVICE MEASURE NO MODE YES ENT S1 S2 WASH S3 FAIL S4 YOKOGAWA MODE WASH CONTACTS M...

Страница 31: ...MEASURE NO MODE YES ENT S1 S2 WASH S3 FAIL S4 YOKOGAWA MODE WASH CONTACTS MARKINGS WITHIN ENCLOSURE NOTE Relay S3 must first be set for WASH in service code 42 Manual wash start stop is enabled with...

Страница 32: ...3 and 4 when 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...

Страница 33: ...s it may be 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...

Страница 34: ...5 2 1 Setpoints 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 DISP...

Страница 35: ...hown for setpoint 1 YES NO YES NO YES NO NO NO NO Process Alarms on S 3 and S 4 are only available when enabled in Service Codes 40 49 Analogue control setpoint is only available when enabled in Servi...

Страница 36: ...ng 5 2 2 Range 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 DISPL...

Страница 37: ...by Service Code 31 ENT ENT Choose 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 ENT...

Страница 38: ...NO YES NO 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 HOL...

Страница 39: ...2J6B3 E H Parameter setting 5 11 YES NO ENT HOLD HOLD HOLD HOLD HOLD ENT HOLD ENT ENT ENT HOLD values set return to commissioning menu ENT ENT Set HOLD fixed value for mA2 YES Set HOLD fixed value for...

Страница 40: ...NO NO NO NO 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 EN...

Страница 41: ...ICE MEASURE 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 Nomina...

Страница 42: ...aphic sensor with the nominal cell current to be user defined General Note Dissolved oxygen sensors fall into two categories galvanic and polarographic Yokogawa offer both types Settings for Yokogawa...

Страница 43: ...fined 9 3 75 A I CELL Sensor output 50 nA 0 0 Polarographic User defined 9 50 nA 02 CHECK Sensor check Zero check disabled 0 0 1 0 Zero check enabled 1 0 5 A Slope check disabled 0 min 40 Slope check...

Страница 44: ...emperature display Code 12 T ADJ Adjust offset in temperature measurement when the sensor is at a stable known value Code 13 T MAN Enable and set manual temperature compensation The maximum and minimu...

Страница 45: ...mp Comp Pt100 RTD 0 Pt1000 RTD 1 1 PB36 2k2 NTC DO30 2 22k NTC SM31 3 11 T UNIT Temp units Celsius 0 0 Fahrenheit 1 12 T ADJ Temp adjust Adjustment 7 5 C or 13 5 F 13 T MAN Manual TC Automatic tempera...

Страница 46: ...eater time and or a smaller step gives mg l greater stability before a calibration can be accepted Use caution however to avoid very long calibration times Code 21 0 CAL Not normally necessary zero ca...

Страница 47: ...ge range 0 50 mg l 0 05 mg l or 0 300 21 0 CAL Zero cal Zero calibration disabled 0 0 Zero Calibration enabled 1 22 ZERO Zero entry Zero range galvanic 0 nA Check 0 5 A No check 19 99 A Zero range pol...

Страница 48: ...elect burn out signalling of diagnosed failures Code 33 RGmA2 Set proportional band for PI control on mA2 Code 34 tImA2 Set integral time for PI control on mA2 Code 35 36 TABL1 Set up output lineariza...

Страница 49: ...acting PI control 0 0 Direct acting PI control 1 32 BURN Burn out No burn out function on mA1 0 0 0 Burn low on fail on mA1 1 Burn high on fail on mA1 2 No burn out function on mA2 0 Burn low on fail...

Страница 50: ...activity in progress so the measurement is not live For S3 There is the extra possibility to set up for a wash controller For S4 There is the extra possibility to set up for FAIL indication Digit Y s...

Страница 51: ...value 0 Proportional duty cycle 1 Proportional pulse frequency 2 Activation by temperature 3 PI control inactive 0 PI control active 1 42 S 3 Contact S3 Contact 3 inactive 0 4 0 0 Low alarm configura...

Страница 52: ...tart working Code 45 RANGE Proportional range is the value above or below the setpoint that generates full output in proportional control PER The time period of the overall pulse control cycle one ON...

Страница 53: ...300 0 1 mg l T HYST Temp hyst Temperature hysteresis 0 5 C 0 10 F 0 5 C 45 RANGE Prop control Proportional range 0 50 mg l 5 0 mg l PER Duty cycle Period Duty cycle 5 100 s 10 0 s FREQ Frequency Frequ...

Страница 54: ...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 Soft fail gives a flashing FAIL...

Страница 55: ...ane failure Soft fail 0 Membrane failure Hard fail 1 1 Hard Err 07 Temperature sensor open Soft fail 0 Temperature sensor open Hard fail 1 1 Hard Err 08 Temp sensor shorted Soft fail 0 Temp sensor sho...

Страница 56: ...ck calendar for the logbook is set for current date and time as reference MINUT SECND YEAR MONTH DAY Code 62 ERASE Erase logbook function to clear the recorded data for a fresh start This may be desir...

Страница 57: ...OMM Communication Set communication Off 0 0 1 Off Set communication On 1 Communication write enable 0 write Communication write protect 1 protect SET Baud rate parity Baud rate 1200 0 3 1 2400 1 4800...

Страница 58: ...d to check the QIC factory generated test certificate To use this test feature it is necessary to have the detail provided only in the QIS Quality Inspection Standard or the Service manual NOTE attemp...

Страница 59: ...IM 12J6B3 E H Parameter setting 5 31 Code Display Function Function detail X Y Z Default values Test and setup mode 80 TEST Test and setup Built in test functions as detailed in QIS and Service Manual...

Страница 60: ...IM 12J6B3 E H...

Страница 61: ...the traditional way to calibrate dissolved oxygen analyzers in laboratory environment Accurate results can be obtained if the calibration is performed carefully The water calibration may include a zer...

Страница 62: ...ce codes 01 20 and or 22 2 Patience improves the accuracy of calibration When the EXA prompts the user that the preset criteria are met by showing CAL END message it only means that the minimum criter...

Страница 63: ...o the normal readout NO YES YES MEASURE MAN CAL DISPLAY HOLD NO MODE YES ENT YOKOGAWA MODE AIR CAL CONTACTS S1 S2 WASH S3 FAIL S4 H2O CAL 12J6B2 22 NO YES 6 2 2 Procedure for Air Calibration Press the...

Страница 64: ...d water The zero oxygen solution contains 20 30 grams of sodium sulfite per liter 6 3 2 Calibration operation water calibration method If both zero and span calibration are used it is better to start...

Страница 65: ...ay returns to the normal readout NO YES NO YES YES NO YES When the reading is stable the CAL END message appears Press YES After briefly displaying WAIT the display returns to the normal readout MEASU...

Страница 66: ...zer The following precautions must be taken into account The sample must be analyzed directly after sampling to avoid change of dissolved oxygen concentration or temperature after sampling The referen...

Страница 67: ...he key When the correct value is displayed press ENT to enter the change YES After briefly displaying WAIT the display returns to the normal readout YES Press YES to return to the measuring mode Singl...

Страница 68: ...oxygen mg l at various temperatures and elevations based on sea level barometric pressure of 760 mm Hg Temp Elevation metres above sea level C 0 300 600 900 1200 1500 1800 0 14 6 14 1 13 6 13 2 12 7...

Страница 69: ...d to measurement functions and maintenance associated with errors Table 7 2 Items for occasional inspection and maintenance of 4 wire dissolved oxygen metering Instrument or apparatus Item Recommended...

Страница 70: ...ing a soft damp cloth or soft tissue To deal with more stubborn stains a neutral detergent may be used NOTE Never used harsh chemicals or solvents In the event that the window becomes heavily stained...

Страница 71: ...issolved 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 suppl...

Страница 72: ...re is high CODE 10 setting CODE 10 setting is not correct Examine the sensor cable connection Sensor cable wiring failure status Temperature sensor has failed If the temperature sensor fails abnormal...

Страница 73: ...again E16 All modes Call for maintenance interval time exceeded Perform maintenance Reset interval E17 RANGE mode Incorrect span Change the maximum or minimum value In the range setting a value which...

Страница 74: ...IM 12J6B3 E H...

Страница 75: ...K1543AA 7 EXA 402 case K1541JJ 8 Fuse box of 10 pieces for 230 VAC 0 050 A T K1543AK Fuse box of 10 pieces for 115 VAC 0 100 A T K1543AL Fuse box of 10 pieces for 24 VDC 1 0 A T K1543AM 9 Cable gland...

Страница 76: ...IM 12J6B3 E H...

Страница 77: ...A2 10 0 mg l 0 0 mg l 50 0 mg l 0 0 ppm 50 0 ppm 0 0 sat 300 sat T1 25 0 C 77 F 0 0 C 30 F 50 C 130 F T2 25 0 C 77 F 0 0 C 30 F 50 C 130 F T3 25 0 C 77 F 0 0 C 30 F 50 C 130 F T4 25 0 C 77 F 0 0 C 30...

Страница 78: ...1 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 0 0 both off 33 RG mA2 5 0 mg l only for PI control 34 tI mA2 100 s...

Страница 79: ...1 hard fail Err 04 1 hard fail Err 07 1 hard fail Err 08 1 hard fail Err 09 1 hard fail Err 12 1 hard fail Err 16 0 soft fail Err 22 0 soft fail SOFT 0 LCD fail 54 E12 150 55 CALL M 0 Off 56 UNIT 0 m...

Страница 80: ...hanges made by software release 1 3 The maximum wash interval was 18 2 hours instead of the specified 36 hours When the slope was manually changed using service code 22 the change had no effect on the...

Страница 81: ...ult Check setup Polarographic outside 100 to 500 nA E10 EEPROM write failure Fault in electronics Try again if unsuccessful contact Yokogawa E12 Abnormal measured value Wrong DO sensor or temperaure C...

Страница 82: ...2113 Tel 61 2 805 0699 Fax 61 2 888 1844 SINGAPORE Yokogawa Engineering Asia Pte Ltd 11 Tampines Street 92 SINGAPORE 528872 Tel 65 783 9537 Fax 65 786 2606 JAPAN Yokogawa Electric Corporation 2 9 32...

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