Service Manual MV1000/MV2000 SM MV1000-01E Yokogawa Electric Corporation 1st Edition
Important Notice to the User • This manual contains information for servicing YOKOGAWA’s MV1000 and MV2000. Check the serial number to confirm that this is the correct service manual for the instrument to be serviced. Do not use the wrong manual. • Before any maintenance and servicing, read all safety precautions carefully. • Only properly trained personnel may carry out the maintenance and servicing described in this service manual.
Trademark Revisions ii • vigilantplant and MVAdvanced are registered trademarks or trademarks of Yokogawa Electric Corporation. • Adobe and Acrobat are registered trademarks or trademarks of Adobe Systems Incorporated. • Company and product names that appear in this manual are registered trademarks or trademarks of their respective holders. • The company and product names used in this manual are not accompanied by the registered trademark or trademark symbols (® and ™).
Introduction This manual contains information for servicing YOKOGAWA’s MV1000 and MV2000. WARNING This service manual is to be used by properly trained personnel only. To avoid personal injury, do not perform any servicing unless you are qualified to do so. Refer to the safety precautions prior to performing any servicing. Even if servicing is carried out according to this service manual, or by qualified personnel, YOKOGAWA assumes no responsibility for any result occurring from that servicing.
• Do Not Operate in an Explosive Atmosphere Do not operate the instrument in the presence of flammable liquids or vapors. Operation in such an environment constitutes a safety hazard. Prolonged use in a highly dense corrosive gas (H2S, SOx, etc.) will cause a malfunction. • Do Not Remove Covers The cover should be removed by YOKOGAWA’s qualified personnel only. Opening the cover is dangerous, because some areas inside the instrument have high voltages.
Overview of This Manual This manual is meant to be used by qualified personnel only. Make sure to read the safety precautions at the beginning of this manual as well as the warnings and cautions contained in the chapters relevant to any servicing you may be carrying out. This manual contains the following chapters. Chapter 1 Principles of Operation Describes the principles of operation of the instrument. Chapter 2 Troubleshooting Lists problems that can occur and gives corrective actions.
Contents Important Notice to the User...............................................................................................................i Trademark.......................................................................................................................................... ii Revisions........................................................................................................................................... ii Introduction...............................................
Contents Chapter 6 Chapter 7 1 Customer Maintenance Parts List 6.1 6.2 Customer Maintenance Parts List (MV1000)........................................................................ 6-1 Customer Maintenance Parts List (MV2000)........................................................................ 6-9 2 Replacing Parts 7.1 7.2 Introduction........................................................................................................................... 7-1 Replaceable Parts.............
Chapter 1 Principles of Operation 1.1 Principles of Operation 1 Principles of Operation The following explains the principles of operation of the MV.
1.1 Principles of Operation Saving Data Display/Keys Calculation Alarms Other Functions The capacity of the internal memory is either 80 MB (standard memory) or 200 MB (expansion memory). The CF card can be used as an external memory medium. The MV uses an LCD display. You can control the MV with key operations. You can calculate the difference between two measurement inputs, perform linear scaling, square roots, calibration correction, and other computations.
Chapter 2 Troubleshooting 2.1 Failure Analysis Flow Chart 1 When a failure occurs, refer to the flow chart below for corrective actions. 2 Troubleshooting Doesn’t function at all (nothing is displayed) 3 Is the power switch* ON? Does the switch operate normally? NO Turn the switch ON correctly. 4 YES Is the power supply wired correctly? NO 5 Wire it correctly.
2.1 Failure Analysis Flow Chart Keys do not operate correctly Is the key lock set? YES Release the key lock setting. NO See No. 4 of the checklist. If there is a problem with a display screen or other function Have measures against external noise been taken? NO YES See No. 2, 3, 7, 9, and 10 of the checklist in section 2.2. • Keep measurement input, communication, and other wires and cables away from noise sources. • Be sure to ground all instruments.
2.
2.2 Troubleshooting Checklist The table below describes the most common types of failures and their corrective actions. Action Replace Adjust Check No.
2.2 Troubleshooting Checklist 1 Action Replace Adjust Check No.
Chapter 3 3.1 Testing Acceptance Test 1 This section describes the procedure to perform the acceptance test. 2 1. Read the preface to the user’s manual, “Checking the Contents of the Package” and verify that you have all of the contents. 2. Make sure to understand the operating procedures as described in the user’s 3 3. Check each function using the user’s manual. Testing manual. 4. Read and implement section 3.2, “Self Diagnostic Test.” 4 5. Read and implement section 3.3, “Performance Test.
3.2 Self Diagnostic Test The MV is provided with complete self diagnostic functions to enhance reliability in measurement and serviceability. When you turn ON the power, the MV will automatically execute the following types of diagnoses alternately and display the results. After these tests are completed, the recorder is ready for use. 1. Main program (Flash ROM) test 2. Main RAM write/read test 3. A/D and A/D EEPROM test 4. Memory acquisition test (write test from Flash) 5.
3.3 Performance Test 1 Read the warning and cautions below before beginning tests. 2 Test Environment Item Ambient temperature Relative humidity Atmospheric pressure Power supply frequency Power supply waveform DC power supply ripple Vibration Position Interference*1 Electrical field Magnetic field Atmospheric pollutants Other external effects*2 *1 Interference refers to common mode noise, series mode noise, power supply noise, and other phenomena in the signal line.
3.4 Test Procedures Insulation Resistance ● Test Procedures Perform a measurement with an insulation resistance meter and check whether the results satisfy the reference values. Perform the measurement with the power switch turned ON.
3.4 Test Procedures 1 MV2000 Functional ground terminal Power inlet Power supply screw terminals 3 Protective ground terminal 2 Testing 4 5 Withstand Voltage ● Test Procedures Perform the test with a withstanding voltage tester, and check whether the results satisfy the reference values. Perform the measurement with the power switch turned ON.
3.4 Test Procedures Measurement Accuracy ● Overview The measurement accuracy is tested using two different* integral times. * But only one integral time is used when using the MV2000 with the /MC1 option. The measurement accuracy test is performed in one of the following ways. • One representative channel for each A/D converter is tested, and the channel-tochannel error between the representative channel and other channels is tested (see next page).
3.4 Test Procedures 1 Reference Value (Integral Time: 20 ms (50 Hz)/16.7 ms (60 Hz)) Range 20 mV 60 mV 200 mV 6V 20 V 50 V Pt100 TC-T TC-K Cu10 (GE) Pt50 +20.000 mV 0.000 mV –20.000 mV +60.00 mV 0.00 mV –60.00 mV +200.00 mV 0.00 mV –200.00 mV +2.0000 V 0.0000 V –2.0000 V +6.000 V 0.000 V –6.000 V +20.000 V 0.000 V –20.000 V +50.00 V 0.00 V –50.00 V –200°C: 18.52 Ω 0°C: 100.00 Ω 600°C: 313.71 Ω 0°C: 0.000 mV 0°C: 0.000 mV –200°C: 1.326 Ω 0°C: 9.036 Ω 300°C: 20.601 Ω –200°C: 8.57 Ω 0°C: 50.
3.4 Test Procedures Reference Junction Compensation Accuracy ● Test Procedures Measure 0°C on all channels, and check that the display is within the reference values below. Set all channels to thermocouple type T. Reference value: ±0.5°C Calibrated thermocouple wires 0°C standard temperature device (Model: ZC114 from Coper Electronics Co., Ltd. or equivalent) +/A –/B Input terminal block • Use a calibrated thermocouple, and wires of 0.5 diameter or less without terminal tips.
3.4 Test Procedures 1 Pulse Input Function ● Overview This test performed when the /PM1 option is specified. Enter calculation settings, input a pulse signal, and perform the test. 2 ● Test Instruments Instrument Function generator Specifications Accuracy: ±20ppm of setting for 100 Hz 3 Testing ● Setup 1. Press the MENU key, then choose Math channel > Calculation expression 4 (Expression). 2. Enter the following expressions. Press the ESC key to return to the setting menu.
Chapter 4 4.1 Adjustments Before Making Adjustments 1 This chapter explains how to perform adjustments to the MV1000/MV2000. Environment 2 See section 3.3, “Test Environment.” 3 Instrument Operation For operating procedures in setting mode and basic setting mode, see the following manuals.
4.2 Adjusting the A/D Converters ● Overview The number of included A/D converters differs depending on the instrument model. For all of the A/D converters, input a predetermined value for each range and take measurements, then save the calibration values. ● Instruments Used Instrument DC voltage generator Variable resistors Specifications Accuracy: ±0.005% of setting + 1 µV or better Accuracy: 0.01% + 2 mΩ or better ● Calibration Calibrated Channels A/D No.
4.2 Adjusting the A/D Converters 1 ● Calibration Procedure 1. Press the UP arrow key while turning ON the power. The instrument starts up in Calibration Mode, and the A/D No. are displayed. 2. Select the A/D No. to calibrate with a soft key, then press the DISP/ENTER key. MV1000 MV2000 2 3 4 MV1000 Adjustments 3. Press the Cal/Exec #2 soft key. 5 MV2000 6 7 Shows the day the A/D most recently adjusted Inputting a Reference Signal 4.
4.2 Adjusting the A/D Converters 7. Press the End #4 soft key. MV1000 MV2000 Saving Adjusted Values 8. Use the left or right arrow key to choose Yes (save calibration values) or No (do not save), then press the DISP/ENTER key. MV1000 MV2000 9. Repeat steps 2 – 8 to adjust all A/D No. When finished, press the ESC key. Concluding Adjustments 10. Turn OFF the power switch.
SM MV1000-01E CN1 CN11 CN15 CN1 CN2 CN12 CN5 CN6 CN7 CN8 CN1 CN2 ETHERNET USB RS-422 RS-232 POW INP SCREW POW INP INLET CN3 CN4 B8706RL B8706TL B8706SL B8706UL B8706RM B8706TM B8706SM B8706UM W/O OPT.
5-2 CN5 CN30 CN7 CN8 RS-422 RS-232 B8706RL B8706TL B8706SL B8706UL B8706RM B8706TM B8706SM B8706UM W/O OPT. USB RS232 RS422 RS422+USB B8706SN B8706UN RS232+USB B8706RN B8706TN Screw COMM Inlet POW TERM COMM BOARD ASSY CN3 CN4 CN3 POW CABLE B9968MJ CN1 B8806RB DISP CABLE B9968MD A1527UP INV.
Chapter 6 Customer Maintenance Parts List Customer Maintenance Parts List (MV1000) 1 2 ! 6.1 + - AX 24V AM DC 12V 3 4 5 6 Customer Maintenance Parts List POW ER 7 Note: Parts marked with a symbol are Customer Maintenance Parts (CMP). The contents of this CMPL are subject to change without prior notice as a result of continuing improvements to the instrument's performance and functions. Copyright Nov. 2007 (YK). 1st Edition: Nov.
6.1 Customer Maintenance Parts List (MV1000) Complite Set 2 6 13 14 8 9 10 11 VA 24 + 12 C VD 12 5 A M X ! 7 4 3 15 1 16 17 18 2 20 POW ER 21 19 21 Item 1 2 3 4 Part No. B8805BA B8805BG B8706MJ Y9305LB Qty 1 1 1 4 Description Bezel Assembly Cover FFC (0.
6.1 Customer Maintenance Parts List (MV1000) Body Assembly 1 3 1 2 3 5 6 2 4 3 7 4 14 8 15 9 5 10 13 11 6 12 13 16 17 Item Part No.
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6.1 Customer Maintenance Parts List (MV1000) Rear Assembly (2/3) 5 1 Model MV1004 MV1006 MV1008 MV1012 MV1024 Qty 2 Item Part No.
6.1 Customer Maintenance Parts List (MV1000) Rear Assembly (3/3) 6 Terminal Assembly-2 MODEL CODE MS CODE MS CODE (OPTION) PART No.
6.1 Customer Maintenance Parts List (MV1000) 7 Standard Accessories (1/2) 1 2 8 1 3 4 9 2 10 5 6 3 Customer Maintenance Parts List 11 12 7 4 13 5 6 14 15 16 18 17 7 Nov.
6.1 Customer Maintenance Parts List (MV1000) Standard Accessories (2/2) 8 Item 1 2 3 4 5 6 Part No.
6.2 Customer Maintenance Parts List (MV2000) 1 2 3 4 5 6 Customer Maintenance Parts List 7 Note: Parts marked with a symbol are Customer Maintenance Parts (CMP). The contents of this CMPL are subject to change without prior notice as a result of continuing improvements to the instrument's performance and functions. Copyright Nov. 2007 (YK). 1st Edition: Nov.
6.2 Customer Maintenance Parts List (MV2000) Complite Set 2 5 13 14 6 7 8 9 10 X A 3 C A AM V 0V 40 z 9 0-2 0H 10 0/6 5 4 1 11 12 15 16 4 2 17 19 Item 1 Description Bezel Assembly (For English) (select) Bezel Assembly (For Japanese) Cover Body Assembly (see page 3) Screw 2 3 4 Part No.
6.2 Customer Maintenance Parts List (MV2000) 3 Body Assembly (1/3) 1 2 1 3 2 4 3 5 6 6 Customer Maintenance Parts List 7 8 7 4 5 Item 1 2 3 4 5 6 7 8 Part No.
6.
6.2 Customer Maintenance Parts List (MV2000) 5 Body Assembly (3/3) Item 1 2 Model MV2008 MV2010 MV2020 MV2030 MV2040 MV2048 Qty 2 3 4 5 Part No.
6.2 Customer Maintenance Parts List (MV2000) Terminal Assembly (1/3) 6 2 1 4 5 3 10 Ba se -T US B SE RIA L(R S-2 32 ) ! 13 10 7 11 6 12 8 14 9 Item 1 2 3 4 5 Part No.
6.2 Customer Maintenance Parts List (MV2000) 7 Terminal Assembly (2/3) 1 2 CODE (OPTION) PowerMS Terminal SELECT AND NOT /C2, /C3 PART NO.
6.2 Customer Maintenance Parts List (MV2000) Terminal Assembly (3/3) 8 OPTION TERMINAL 1 MS CORD (OPTION) AND PART NO.
6.2 Customer Maintenance Parts List (MV2000) 9 Standard Accessories (1/2) 1 2 8 1 3 4 9 2 10 5 6 3 Customer Maintenance Parts List 11 12 7 4 13 5 6 14 15 18 16 19 17 7 Nov.
6.2 Customer Maintenance Parts List (MV2000) Standard Accessories (2/2) 10 Item 1 2 3 4 5 6 Part No.
Chapter 7 7.1 Replacing Parts Introduction 1 This section describes replacing parts necessary for maintenance and repair. Replaceable Parts 2 When it becomes necessary to replace parts, it is recommended to replace entire assemblies rather than specific parts within assemblies. If you plan on replacing parts yourself, please refer to the Customer Maintenance Parts List (CMPL) in chapter 6 for a list of parts supplied by Yokogawa. Parts not on this list are not available through Yokogawa.
7.2 Recommended Replacement Periods for Worn Parts To preserve the reliability of the MV and to use the MV in a good condition for an extended time, it is recommended that periodic replacements be made on parts. The replacement parts may change to accommodate preventive maintenance over extended time. Be sure to check with your nearest YOKOGAWA dealer. The following table shows the recommended replacement period for expendable parts.
