5E-MAC6710

Automatic Proximate Analyzer

Service Manual

KY2.789.120AS

Changsha Kaiyuan Instruments Co., LTD.

1. Instructions
1.1. Safety Precautions

The Service Manual introduces the installation and diagnostics of this instrument.
Maintenance personnel should read and fully understand this manual and follow all the
precautions and warnings in this Manual. CKIC assumes no responsibility for any
accident or damage caused by failure, or use in disregard of instructions in this Manual.

Maintenance personnel shall have professional technical training by CKIC and have the
skill to complete the relevant operations under the guidance of the Manual.

1.1.1 Safety of Electricity

• Ensure the equipment is well grounded. Do use grounding plug and socket. Do NOT
change the original standard power cord.

• The thunder and lightning may cause a risk on you. Do not operate this equipment
during thunderstorm and it must be disconnect from facility power and external
internet wire.

• Do NOT operate the equipment together with high-power electrical equipment by

one power socket, lest it may result in unstable voltage.

• Do NOT plug out any component or cord before power-off.

• Regularly check the power cord and power plug and make sure they are in a good
condition and pressed by other components.

1
1.1.2 Safety of Gas Supply

• When the gas required (O2, N2, He, CO2, mixed gas of CO and CO2) is high
pressure gas, contacts with flammable and explosive materials are not allowed in
operations, otherwise there may be fire or violent explosion.

• When using the high-pressure gas cylinder, the gas source must be kept away from
heat and open flames. Operations must be strictly in accordance with the safety
procedures of high-pressure cylinders to ensure there is no gas leakage to avoid
the explosion, personal poisoning, suffocation and other dangerous occurrences.

2
1.2. Caution Symbols

The following symbols may be found on CKIC equipment or their components. These
symbols indicate the use of specific safety guidelines. Operator and service personal
must follow these instructions for personal safely and to prevent damage to the
equipment.

This symbol indicates a caution.

(Specific instructions are referred to the
manual)

This symbol indicates a risk of electric

shock. Please do not touch. If needed,
refer to the specific instructions and
operate in compliance with this Manual.

This symbol indicates a high temperature

surface. Do not touch it with hand. If
needed, refer to the specific instructions
and operate in compliance with this
Manual.

This symbol indicates a risk of squeezing

hands when the instrument is working. If
needed, refer to the specific instructions
and operate in compliance with this
Manual.

3
1.3. Package
After receiving instrument, please check the packing and items in your package. For any
damage or lack of components, please contact forwarder and CKIC to confirm
responsibility. The packing list for MAC6710 is as follows.
Note: All components listed below are subject to change without prior notice.
Please refer to the packing list received with instrument.

4
 Standard Configuration List

No. ERP No. Description SPEC QTY Unit Note

1)Standard Configuration

1 401147 Lenovo Computer RS232, 19'' 1 PCS Optional

LASERJET PRO
2 402003 Laser Printer 1 PCS Optional
P1106
3 110911 5E-MAC6710 5E-MAC6710 1 Set
2)Main Accessories

4 3011205008 Three-Core Power Socket 20A 1 PCS

5 3050103008 Oxygen Regulator 190X-80 2 PCS

6 3150300123 Hose Connector(Φ4mm) 53N10A(JU2005) 1 PCS

7 213014148 PU Gas Tube(Blue) Φ8×5 12 Meter

8 3090500017 PU Gas Tube(White) Φ6×4 8 Meter
9 3040201006 Annular Gas Tube MAGD2-005 1 PCS
10 3150300022 Hose Connector ￠80 2 PCS
11 3150300016 Hose ￠80（4m/PCS） 1 PCS
12 3111300030 Clamp φ80～100 2 PCS
13 3040500097 Electronic Balance WKE204 1 PCS
14 3040101005 Balance Arm 1 PCS
15 212028011 Balance Arm Base 1 PCS
16 3090600015 Shield Cover of Balance 1 PCS
In the
17 3130401339 Balance Pan 1 PCS balance
package
18 226014002 Radiating Components 1 PCS
19 3040101004 Ceramic Rotating Shaft 1 PCS
20 3040101058 Positioning Pillar 2 PCS
21 3040101001 Ash Rotary Tray φ302 1 PCS
Serial Port Wire with
22 3030400006 2 PCS
Magnetic Ring
23 3030400001 Three-Core Power Wire 10A 1 PCS
Three-core Aviation Power
24 227000020 20A 1 PCS
Line
5
25 226014001 Pump Components 1 PCS

26 2016120064 Threaded Joint APC8-02 2 PCS

Power Adapter Cable of

27 1 PCS
Upper Furnace Lid
Power Adapter Cable of
28 1 PCS
Pump
3)Consumptive Material
29 3040101042 Ash Crucible MAGD2-001 25 PCS
30 3011206038 Fuse φ5×20, 3.15A 5 PCS
31 3040101037 Crucible Lid MAGD2-F001 25 PCS
Standard Coal Sample
32 15<Vd<20 1 Bottle
(GBW)
Standard Coal Sample
33 20<Vd<25 1 Bottle
(GBW)
Standard Coal Sample
34 25<Vd<30 1 Bottle
(GBW)
35 3040202007 Glass Spoon KY/QT022 5 PCS
36 3011405005 Mouse Pad CKIC 1 PCS
37 409001 Cover Cloth 145×150cm 1 PCS
38 50304002 Canvas Gloves 1 Pair
4) Tools
39 50208030 Hexagonal Spanner 2.5 1 PCS
40 50208031 Hexagonal Spanner 3 1 PCS
41 50208032 Hexagonal Spanner 4 1 PCS
42 50208033 Hexagonal Spanner 5 1 PCS
43 50203006 Screwdriver (-) 6×100 1 PCS
44 50203016 Screwdriver (+) 6×100 1 PCS
45 3040302004 Crucible Tongs 46cm 1 PCS
46 50208003 Adjustable Spanner 300×36 1 PCS
47 3011205006 Junction Box GN105(3-3) 10A 1 PCS
5) Documents
Real Time Data Analysis
48 3120200005 Management Software For 5E-CDIS 1 Set
Coal Quality V1.0
49 406001 Enclosed Document Applicable to all PCS

6
 instruments of
CKIC
50 403193 Instruction Manual 5E-MAC6710 PCS
51 Software 5E-MAC

7
2. Introduction
2.1. Application

5E-MAC6710 Automatic Proximate Analyzer is manufactured by CKIC.

When it is used to analyze the moisture, ash, volatile matter and fixed carbon in coal, it
conforms to the following standards:

GB /T483-2007 General Provisions of Coal Analysis Method;

GB/T 212-2008 Proximate Analysis of Coal;
DL/ 1030-2006 Proximate Analysis of Coal- Automatic Instrument Method
MT/T 1087-2008 Proximate Analysis of Coal-Instrument Method
ASTM D7582-2012 Standard Test Methods for Proximate Analysis of Coal and
Coke by Macro Thermogravimetric Analysis1

When it is used to analyze the moisture, ash, volatile matter and fixed carbon in coke, it

conforms to the following standards:

GB/T 2001-1991 Proximate Analysis of Coke

When it is used to analyze the combustibles in ash slag, it conforms to the

following standards:
When it is used to analyze the moisture, ash, volatile matter in coal forged petroleum
coke, it conforms to the following standards:

YS / T 587 "Carbon anode with calcined petroleum coke detection method"

When it is used to analyze the ignition loss of cements, it conforms to the following
standards:

GB/T 176 ”Method for chemical analysis of cement”

When it is used to analyze the ignition loss of iron core, it conforms to the following
standards:
8
GB/T 6730.68-2009 ”Iron ores - Determination of ignition loss -gravimetric method”

• Limestone moisture, Ga(OH)2, GaCO3 and GaSO4

2.2. 2.2 Principle---Thermogravimetry

Equipped with infrared heating equipment and electronic balance to weigh the sample
during heating under special atmosphere, specified temperature and specified time to
calculate the moisture, ash and volatile etc. of the sample.

5E-MAC6710 can be calibrated by furnace temperature calibration or standard coal

calibration as described below:

• Calibration of Furnace Temperature :

Furnace Temperature Calibration adopts high level standard thermocouple in

the furnace chamber. After the temperature reaches the set temperatures
stably for 20 minutes, input the temperature error into the software to keep the
temperature measured temperature and standard thermocouple temperature
consistent.

• Calibration of standard coal: when the reference material is used for analysis,
the analysis results should be within the uncertainty of the reference material.

2.3. Technical Parameters

• Auto Sample Weighing

• 19 samples per batch;
• Furnace temp. control: Room temp.~10000 ℃, Precision±5℃
• Power Supply: 220VAC/50Hz
• Maximum power: 4.5kW

2.4. Structure Diagram

The instrument consists of one analyzer, one PC and one printer. (See figure 2-1)

9
 Analyzer
Monitor

Furnace SCM

RS232

Balance Gearing

PC

Mouse
Printer
Keyboard

Figure 2-1

10
 2.5. General Structure
2.5.1. Inner Structure (see figure 2-2)

Crucible
Furnace
Carousel
Positioning Pillar
Rotating Shaft
Ventilation Ring

Balance Arm

Y-type Connector
Gas Cylinder

Rotating Mechanism
Balance Thermocouple

Figure 2-2 General Structure

Function:
1 Crucible Load the sample.
2 Carousel Hold the crucibles.
3 Balance Arm Support the crucible during the weighing.
4 Furnace Heat the sample.
5 Balance High precision: 0.0001 g.
Support the carousel and connect the carousel and rotating
6 Ceramic Shaft
mechanism.
7 Positioning Pillar Connect the carousel and ceramic shaft.
8 Thermocouple Collect the internal temperature of high temperature furnace.
Rotating
9 Rotate mechanism for carousel.
Mechanism
10 Gas Cylinder Automatically open and close the furnace lid.
11 Ventilation Ring Connect the gas uniformly to the furnace.

11
 2.5.2 Front Panel (Figure 2-3)

Flowmeter

Lid OPEN/CLOSE

Rotary Button Upper Furnace Heating

Monitor Lower Furnace Heating

Confirm Button Power (ON/OFF)

Y-Type Connector
Gas Cylinder

Rotary Mechanism
Balance Thermocouple

Figure 2-3

Function:

1 Rotating Button Rotate the crucible position.

2 Monitor Display the balance value.

Confirm the sample weighing and start next sample
3 Confirming Button
weighing.
4 Flowmeter Display the nitrogen or oxygen flow.
Upper Furnace Heating
5 Indicate if the upper furnace is heating or not.
Indicator
Lower Furnace Heating
6 Indicate if the lower furnace is heating or not.
Indicator
Open and close the furnace lid.In this process, there
7 Lid Opening/Closing Button will be sound to prompt the operator to keep distance
from the moving area for safety.
8 Power Supply Control the power supply for circuit components.

12
 2.5.3 Rear Panel
Smoke Exhausting Fan

Cooling Fan

Upper Furnace Power Inpu

Heating Switch

Upper Furnace Power Outpu

N2 Inlet
Gas Cylinder Inlet
O2/Compressed Gas Inlet

Circuit Power Supply

RS232 Serial Port
Heating Power Supply
Pump Power Supply

Figure 2-4

Function:
Discharge the smoke and dust generated in the
1 Smoke Exhausting Fan
analysis.
Upper Furnace Power Input power supply for the heating parts of upper
2
Input furnace.
3 Cooling Fan Cool down the instrument.
4 Heating Switch Control the power of heating parts.
Upper Furnace Power Output power supply for the heating parts of upper
5
Output furnace.
Connect compress gas , whose gas pressure is
6 Gas Cylinder Inlet 0.2~0.3MPa.The gas pressure can be adjusted to
control the speed of opening and closing furnace lid.
Input power supply for circuit boards and other
7 Circuit Power Supply
components.
8 Heating Power Supply Input power supply for heating furnace.
Connect the O2/Compress Gas to offer gas for the
9 O2/Compressed Gas Inlet
analysis.
13
10 N2 Inlet Connect N2 to offer gas for the analysis.
Connect the RS232 Serial Port to the PC Port with
11 RS232 Serial Port
the serial cable.
12 Pump Power Supply Input power supply for the pump components.

14
3. Installation

3.1. Environmental Requirements

A. The instrument should be installed in a ventilated room to prevent the human body
from being affected by the released gas;
B. The instrument should be installed in a stable status without shaking to avoid the
effect on precise balance;
C. Heat resources are not allowed.
D. Ambient temperature should around 5 ℃～ ℃ （ ～ ）
40 ; Humidity should be 20 85 %RH.
E. The analyzer shall be put on a solid table, which should have a height of 60cm ～
70cm.

3.2. Power Supply

1. The power supply of analyzer and computer should be 220VAC/50Hz/10A.
2. The furnace power of moisture and ash analysis should be 220VAC/50Hz/25A.
3. The furnace power of volatile analysis should be 220VAC/50Hz/25A.

3.3. Water and gas requirements

1. According to the requirements of the analysis sample, oxygen (99.99%) and
nitrogen (99.99%) can be configured with an air pressure of 0.2MPa. Operator can
also choose to configure the compressed air pump to meet the gas supply
requirements.
2. There is no requirement on the water source.

3.4. Computer Installation

3.4.1. Host configuration
The computer system of 5E-MAC6710 includes Windows 98/NT/XP/2000/2003/WIN
7/WIN 8/WIN 10 with an RS232.

3.4.2. Software Installation

Insert the disk into the CD driver, enter “5E-MAC” program, double click the “Setup.exe”,
and then click Next to complete the installation.

15
 （Figure 3-1）
Click Next to pop up the dialog box as figure 3-2.

Figure 3-2

16
Click Next to pop up the dialog box as figure 3-3

Figure 3-3

Click Finish. If the operating system has not installed the Data Access, double click the
“setup.exe” in the “Data Component Installation Disk”. Click Next according to the
prompt to finish the installation. Click Restart to restart the computer.

3.4.3. Function and Settings

Main Interface

The main interface includes Title Bar, menu Bar, Manufacturer Bar, and Status Bar as
the figure below:

17
 Figure 3-4
1. Title Bar——Display the software title. In this dialog box, the title is 5E
Automatic Proximate Analysis System.
2. Menu Bar——Menu bar includes Settings, Start analysis, Function, View,
Data Management, Help. When the contents under the menu is gray, the
menu is not valid temporarily;
3. Tool Bar——Tool bar includes System Settings, Start Analysis, Data Query,
Calculation, Exit.
4. Status Bar——Display the parameters and working status.

18
 [Settings(S)] Menu

\\\\\\

Figure 3-5

System Settings (O)

After entering [System Settings], it will display the dialog box as shown in Figure 3-6.

1. Moisture analysis includes normal method and quick method. The operator
can select the method according to needs.
2. Ash analysis includes normal method and quick method. The operator can
select the method according to needs.
3. The sample weighing method of ash and moisture includes continuous and
separate weighing. The operator can select the method according to needs.
4. The print method includes default and Excel. The operator can select the
method according to needs.
5. Analysis Settings/Print Report : not print, proximate analysis result, etc. The
operator can select the mode according to needs.
6. Analysis Settings/Numbering Method : Auto/manual. The operator can select
the method according to needs.
7. Mad% Default: When the moisture test value is negative, the display and
reference conversion are used.
8. Analysis content: include coal / coke / ash, measured ash combustible,
measured calcined petroleum coke, measured loss of cement, iron ore loss,
and measured biomass fuel.The operator can select moisture analysis , ash
analysis or volatile analysis according to needs.
9. Temperature Calibration: include moisture calibration, ash calibration, furnace
calibration of volatile matter, and oven calibration of volatile matter.
10. The atmosphere setting of "moisture analysis" includes: "compression pump"
19
 and "nitrogen bottle". The parameters should be set according to the gas
source configuration.
11. The residue weighing of moisture and ash are used to set the precision and
weighing interval.
12. Instrument Model is used to set the model of instrument.
13. Temperature control and time control is used to set the temperatures, time,
and heating rate.

Figure 3-6

[COMM Setting] Menu

It is used to select the balance type and serial port through which a computer
communicates with the analyzer. The serial port includes Com1/ Com2/ Com3/ Com4.
The balance type includes BS224S (Sartorius)/ WKE204(METTLER)/ ATX224

20
(SHIMADZU)/ CP214(OHAUS).

Figure 3-7

[Transmit Settings]
Click transmit settings to pop up the dialog box.

This menu is used to set the upload serial port, files to be transmitted, etc.

Figure 3-8
21
Database Password Settings (K)

It is used to set the password to access the database.

Figure 3-9

Report Settings(R)
Click Settings-Report Settings to pop up the interface as figure 3-10.
Report settings is mainly used to set the items to be printed. Meanwhile , the report
title, instrument model, standards and so on can also be modified.

22
 Figure 3-10

Print (P)
Print is used to print the results(It can be selected by mouse).
Click Print to pop out the following dialog box.

23
 Figure 3-11

Print Preview(V)

Print is used to preview the results to be printed.

Click Print Preview(V) to pop up the following dialog box.

Figure 3-12

24
 User Settings
Click User Settings to set the information of users.

Exit (X)

Click the Exit menu to pop up the dialog box. Click [Yes] to exit from the program
immediately.

Start Analysis(E)

Figure 3-13

Click the [Start Analysis(E)] menu to enter the sample adding interface.
Input the crucible location, sample amount, sample name, operator name, etc.
Note: 19 samples only per batch. Click Next to enter the analysis interface. In the
analysis interface, operator can weigh the empty crucible, weigh the sample, analysis, or
stop the analysis according to needs.

25
 Figure 3-14

Figure 3-15

[Function(F)] Menu

26
 Figure 3-16

[Hardware Debugging(F)] Menu

Click Function-hardware debugging. The interface will appear.

The debugging function of the program helps debug the analyzer and test whether
hardware works normally. The hardware debugging window includes Carousel “Move
Up”, “Move Down”, “Rotate”, “Stop”, Nitrogen control”, “Test Heating Control”, “Fan
Control”, etc.

27
 Figure 3-17

Online Aging
Click Function-Online Aging.
This function used to test the status of valve, carousel, etc.

28
 Figure 3-18

Volatile Analysis Calibration by Normal Method

Click Function/Volatile Analysis Calibration by Normal Method to pop up the calibration

interface. This function is used to calibrate the classical equation of volatile curve.

29
 图 3-19
Ash Analysis Calibration by Normal Method

Click Function/Ash Analysis Calibration by Normal Method to pop up the calibration

interface. This function is used to calibrate the classical equation of ash curve.

Figure 3-20
30
Volatile Analysis Calibration by Quick Method

Click Function/Volatile Analysis Calibration by Quick Method to pop up the calibration

interface. This function is used to calibrate the quick equation of volatile curve.

图 3-21

Ash Analysis Calibration by Quick Method

Click Function/Ash Analysis Calibration by Quick Method to pop up the calibration

interface. This function is used to calibrate the quick equation of ash curve.

31
 Figure 3-22
Furnace Temp. Calibration(L)

Click Function-furnace calibration to pop up the furnace temperature interface.

Furnace Temp. Calibration(L) is used to set the target furnace temperature of moisture,
ash, and volatile matter, and calibrate temperature of thermocouple and compensation
temperature in the cooling end.

Figure 3-23

Compact and repair databases (Y)

It is used to compact and repair the databases.
Burn the Crucibles for Volatile Analysis(N)

32
It is used to burn and clean the crucibles.

Data Transmit Port(D)

Click "Function---Data Transmit Port" to upload the test data through the serial port.

Import Setting Information(I)

Click "Features--- Import Settings Information" to import system parameters from a file.

Export Setting Information(Q)

Click "Features---Export Settings Information" to export system parameters to a file.

View (V)

It is used to display or hide the Status Bar, Tool bar and Statistic Window

Figure 3-24

Data Manager(M)

33
 Figure 3-25

The query condition window is selected according to the conditions of the test, the data
backup and data import. The query results are shown as the figure below. The query
result can be printed or previewed directly or generate the report form and export data.

Figure 3-26

Figure 3-27

Help(H)”

34
 Figure 3-28

Press F1 key to view the on-line help, the detailed operation instructions, and click on
“About” sub-menu to view the version and copyright information.

3.5. Circuit Connection

1. Connect the host power supply to 220V / 50Hz / 10A power outlet, and the computer
power supply should share the same power supply.
2. Connect the furnace power supply to the 220V / 50Hz / 25A power outlet.

Note:
The power supply of the heating part should be 25A.
In the debugging process, when the power supply and heating power supply
disconnect, the circuit breaker should be kept off.

3. Connect the host RS232 serial port to the computer's RS232 serial port.

3.6. Removal of temporary fastening device

Temporary fastening device is used to temporarily tighten some parts to prevent bumps
from causing damages to parts.

3.6.1. Removal of the fixed seat

Please pay attention to the warning signs on the parts before lifting the rotating
mechanism and operate according to the figure below. Remove the fixed seat first and
then carry out the debugging.

35
 Figure 3-29

3.6.2. Removal of the fastening screws.

Take out the pump components from the box first. Please pay attention to the signs and
labels on the parts, and remove the fastening screws in the bottom according to the
figure below to return the four rubber pads to the natural status.

36
 Figure 3-30

3.7. Balance Installation

Remove the balance arm and balance bracket (Figure 3-31), then open the left cover of
the analyzer, and put the balance in the analyzer—the three grounding bolts of the
balance should be inserted into the three holes for locking the balance bolts properly,
then install the balance pan bracket, balance pan to the balance in turn, then insert the
balance power wire and signal wire into the power interface and data interface
correspondingly. The position where balance locates can be regulated by adjusting the
height of three lock bolts inside the analyzer, and level of the balance can be adjusted by
the four grounding bolts of the analyzer.

37
 Balance Arm

Shielding Cover

Fastening Screw

Balance Arm Base

Shielding Ring

Adjusting Screw

Fastening Screw
Flat Gasket
Nut
Supporting Board

Pillar

Figure 3-31

3.8. Installation of air pump and gas circuit

A. In the power-off state, use the equipped air pump power cable to connect the
five-core aviation socket.
B. Use the gas tube to connect the air pump with main air inlet of the host.
C. semicircle ceramic plates are placed flat at the bottom of the hearth with a rotating
shaft hole as the center.

38
D. The glass vent pipe is long legs downward and is inserted into the furnace body,
and the long legs are inserted into the reserved hole beside the thermocouple until
the glass air tight ring pipe is placed flat on the ceramic plate at the bottom of the
furnace body
E. Connect the glass vent pipe to the blue gas tube with a hose.

3.9. Installation and Commissioning of Carousel

Positioning Pole

Carousel

Shaft
Pressure Block
Index Plate
Pressure Plate

Lifting Block Light Sensor

Lifting Pointer Light Sensor Block

Limit Block of Slide Rail Installing Block

Bearing

Connecting Shaft
Gear Motor

Rotating Motor
Camshaft

Lifting Light Sensor Light Sensor

Bearing Slide Rail Lifting
Base Plate
Fixed Base

Figure 3-32

39
3.10 Balance Arm
3.10.1 Installation
Put the balance base on balance pan and cover it with shield. Insert balance arm into the
hole on base. Do not press balance beam with force. Then tighten fastening screw on
balance base(Refer to figure 3-31).

3.10.2 Adjustment of the Balance Position

To view the balance arm to ensure it is in the center of hole (if touch the furnace) firstly,
and if balance arm is not in the center, the balance beam must be adjusted to be in the
center and not to touch the furnace by adjusting the two front grounding bolts.

Then run the analysis program, and open “Hardware Debugging” under “Function”, and
turn on “Carousel Reset” , then put crucible in the Hole 0 of the carousel, then click on
“Carousel Down” to view if the crucibles have been propped up completely (the crucible
can not touch the carousel) and if the balance readings is stable, if not please adjust the
height and central position of the balance beam. The height of the balance arm can be
adjusted by changing the balance height or the depth of balance beam inserted into the
balance pedestal. If the balance arm is not upright to the carousel, it also can be
adjusted by turning the balance pedestal.

3.11 Hardware Debugging

Note: hardware debugging is the debugging interface provided by software to adjust
the parts to fit in.
A. COMM Settings
Turn on the power switch on the front panel of the instrument. Open the MAC software
installed on the host, select the "Settings" item in the menu bar, select the
"communication Settings", and pop up the window below.

40
 Figure 3-33

Connect the serial port to the computer with serial wire.

Choose the balance type according to the installed balance, and use MKE204
balance by default.

Manufacturer Balance Type Selected Balance Model

Sartorius ，
BS224 XX88 （ ）
BS224S Sartorius
METTLER MKE204 MKE204（METTLER）

Click the "OK" button to save the parameter to the DSP motherboard.

B. Instrument Model Settings

Click Settings and select System Settings to pop up the interface as below:

41
 Figure 3-34
Select 5E-MAC6710 and click OK.

C. Hardware Debugging Interface

Select Function-Hardware Debugging in the menu bar to pop up the dialog box as
the figure below:

42
 Figure 3-35

When the COMM is normal, the current temperature should be displayed.

D. Carousel

Set up the debug interface, turn "1 hole" at the bottom, click "start to rotate" button,
the turntable should rise to high position, then turn 1 hole, and stop the movement.
At this point the turntable stays at the high position.
Click Down , the carousel will drop to the low position and stop moving.
Click UP, the carousel will rise to the high position and stop moving.
If the carousel continuously makes ascending and descending movements, the
upper optical slot or the lower optical slot beside the carousel lifting mechanism can
be detected to be effectively shaded by the shutter plate moving up and down with
the carousel.
If the high level optical slot is not shaded, the fixed high or low positions of optical
slots can be adjusted to the shaded position.

43
 If the low level optical slot is not shaded, the overall height of the bracket can rise to
the position that can be shaded.

If there is no guarantee that the upper optical slot can be shaded and the lower
optical slot can be shaded when descending, the relative position of the upper and
lower slots on the bracket shall be shortened.When the carousel rises, the shade
stops at the upper optical slot, and when the carousel drops, the shade stops at the
lower optical slot.
Note: If you do not rotate a hole first, but directly push the Down button, the carousel
has no drop action, it may be the reason that the positioning optical slot is
blocked,or carousel is not aligned with crucible hole, or hardware protection
prohibits the carousel descending.

E. Adjustment of Reset Slot and Counter Slot

a) Power off the instrument, disconnect the Addin Pair of stepper motor, and
power on the instrument. Rotate the dial by hand, and turn the dial through the
groove of the optical slot. Keep it in the middle position. If not, adjust the counting
slot holder. Similarly, the single needle reset indicator on the dial shall be kept in the
middle position through the groove position of the reset optical slot. If not, adjust the
reset optical slot, and the fixed seat or the reset pointer.

Figure 3-36

b) The counter slot is on and the reset slot is off. The reset optical slot is shaded
by the reset pointer, the counter is full of the grooves. In this case, the counter slot is
effective, the reset slot is valid.

44
 Figure 3-37

c) Both the counter slot and reset slot are off.The reset optical slot is shaded by
the reset pointer, while the counter slot is shaded by the dial. The current state is In
this case, the counter slot is invalid, and the reset slot is valid.

Figure 3-38

d) The counter slot is off, and the reset slot is on; The reset slot is not shaded by
reset pointer, while the counter slot is shaded by dial. In this case, both the counter
slot and reset slot are invalid.

45
 Figure 3-39

e) Both the counter slot and reset slot are on; the reset slot is not shaded by the
reset pointer, and the counter slot gets through the dial grooves; In this case, the
counter slot is valid, while the reset slot is invalid.

Figure 3-40

Note:The most important thing to emphasize in the above procedure is that when
reset slot is shaded by the reset pointer, the process of counter slot is not allowed
to be destroyed. If this occurs, the relative position between the reset slot and the
counter slot shall be adjusted until the requirements are met.

46
F. Carousel Reset Debugging

Power on the instrument, click rotate reset button, the carousel should rise to the upper
position and start rotation until it reaches the reset position. At this moment , the carousel
stays at the upper position.

G. Sample Weighing Rod Debugging

Check whether the rod passes through the center of the hole at the bottom of the
furnace. If the rod is deflected, adjust the horizontal adjustment screw of the balance
base or the balance itself, and make sure that the sample rod is vertical through the
center of the hole at the bottom of the furnace.

A crucible is placed on the carousel, a moisture/ash crucible is placed on the

moisture/ash part, and a volatile crucible is placed on the volatile part of the carousel.
Check the distance of the sample bar tray from the bottom of the crucible. Keep the
distance of 2mm as well. Fasten the sample rod fixing screw. Click on the "Carousel
Rotation" button, let the carousel rotate for 1 round, check the bottom of the crucible.

Click the "Reset" button, after the carousel reset is completed, press "Down"". When the
carousel drops to a low position, it stops motion. Check the distance between the top
crucible and the crucible hole to make sure there is no contact and sufficient safety
redundancy. Turn the 1 crucible in turn and repeat the above check. In case of contact
danger, adjust the balance level adjustment screw to ensure that the top of the crucible
is not contacted with the hole wall of the crucible.

H. Analog weighing debugging

Click "Start the instrument will automatically complete the following actions:

A) automatic reset.

B) automatic weighing 1 crucible one time, and read the weight of the crucible shown
in the blank column on the right.

Observe the weighing process, check the weight of the crucible weight data, if any,
re-check the debugging processes of carousel lift, carousel reset and turn, optical slot
and optical slot reset , weighing rod and balance components until the analog weighing
is normal.

47
I. Fan, solenoid valve debugging

Click the "Fan On / Off" button to confirm the fan operation.

Click the "Oxygen valve on / off" button to confirm the operation of the oxygen
solenoid valve.
Click the "nitrogen valve on / off" button to confirm the operation of the nitrogen
solenoid valve.

J. Gas Circuit Debugging

Figure 3-41

The ventilation circuit is shown as above.

Normally, the compressed air supplied with the pump is fed from the oxygen inlet and
provides the function of blast during the moisture test, providing sufficient air combustion
during the ash test. When using the air pump to provide air supply, the manual two-way

48
valve 3 open, manual two-way valve 5 off, the pump out of the compressed air is not
through the instrument panel flow meter directly into the bottom of the furnace bore
circular tube. Click the "Oxygen valve open" button, the pump starts to work. According
to the flow meter on the pump, adjust the ventilation volume of the largest 10 ~ 15L / min,
then the instrument panel flow meter without flow display.
If the customer requests nitrogen and oxygen to do the experiment, the external supply
of gas were received to the nitrogen and oxygen inlet, manual two-way valve 3 off,
manual two-way valve 5 open, nitrogen and oxygen are required through the instrument
panel flow meter , Into the circular vent tube. The pressure gauge on the external
cylinder should be adjusted to 0.2MP. Click the "Oxygen Valve Open" button to adjust
the throttle valve 7, the flowmeter on the panel shows the flow rate of 4L / min, click the
"oxygen valve off" button. Click the "nitrogen valve open" button, adjust the throttle valve
7, the panel flow meter shows the flow rate of 4L / min, click the "nitrogen valve off"
button. Note that oxygen and nitrogen can not be opened at the same time.

K. Cylinder Gas Debugging

Figure 3-42
49
As shown above, the ventilation throttle can control the opening speed of the furnace
cover and adjust the exhaust throttle to control the closing speed of the furnace lid.

L. Heating Furnace Debugging

The heating circuit is as follows ：

Figure 3-43
50
Turn on the furnace and the red indicator of the two solid state relays on the base plate is
bright. Turn off the furnace and the red indicator of 2 solid state relay will be off. In this
case, the heating circuit works normally. If abnormal, check if the connections of solid
state relays, solid state relay, DSP board, control panel and switch power supply that
provides 4-channel output are normal.
Connect the power supply to the main engine with 220V/25A power, turn off the circuit
breaker behind the closed instrument and close the lid.
Turn on the furnace again, the 2 heating indicator on the instrument panel should be
bright. Turn off the furnace and the two lights on the panel are out. If abnormal, check the
heating power relay 1 and the heating power relay 2, the proximity switch of the door, the
metal indicator panel,and the indicator.

51
4. Operation
4.1. Test operation
1) Click 【Start Test】 menu to enter the test data input interface, as shown in Figure
4-1. The interface dialog box includes "data input" and "position input"; "data input "Box
includes " sample number "," sample name "," laboratory "and other input box.

Figure 4-1
2) "Position input"
Click the green circle on the circular dial under "Position input", and a red dot appears in
the center of the small circle to indicate that position is selected. Click the green circle
again and the red dot disappears to indicate that the location is unchecked. Click the
"Select All" button, all the center of the circle will appear a red dot, that select all the
location, this button to switch to "undo all selected", click "Undo Select" button, all red
dot disappears, that canceled All selected location, the button to switch to "all selected".
Green small circle on behalf of the instrument turntable cruise, No. 0 hole to correct the
crucible position, you must put the calibration crucible, can not be placed in the sample,
52
otherwise the measurement results.
3) "Data Input"
Under "Data Input", enter the corresponding "Sample No.", "Sample Name",
"Laboratory". (If you select "Auto Number" in [System Settings], you only need to enter
the corresponding "Sample Name" / "Laboratory"; enter the "Test Name" / "Laboratory"
drop-down box Name "/" laboratory technician "system automatically save. Enter all the
sample information, click 【Next】 button, enter the test work interface, as shown in
Figure 4-36.
4) "Query Modification"
If you enter the wrong sample information, you can "query changes" to find the wrong
location, you can correct. (Must be modified before clicking the [Next] button). Of course,
you can also modify the test interface number, sample name,operators, CO2%, Mad% (if
this experiment does not include moisture analysis).
5) "Sample name" and "laboratory technician" drop-down box maintenance
Time, the "sample name" / "laboratory" drop-down box there are many no longer needed
data, then you can clear the drop-down box information, click the "management
drop-down box" below the [sample name] and [ Laboratory technician], according to the
prompts to complete the operation.

Figure 4-2
6) Analysis Interface is the main interface of this program. In top half of interface the
53
analyzing or weighing crucible number (expressed in red dot) is in the left upper side.
The Temp.-Mass curve is in the bottom half part. In the bottom half of the interface, data
form and real time information, total sample number, error hint (if there is error), current
actual temp. of stove, balance reading and analysis time will be displayed.

7) Weigh Empty Crucible with Lid for X Analysis

Click [Weigh Empty Crucible with Lid for X Analysis] to weigh the empty crucible
with lid. But before weighing, the empty crucible must be put in order from No. 0 to
the last one for analysis with lids. If clicked the Weigh Empty Crucible with X button,
and it has been under weighing, but if you don’t want to start weighing the empty
crucible X with lids again, at that time there are two selections available: One is to
select “No” when the system hints put sample or not after weighing empty crucible X
with lid. The other one is to press “Stop X Analysis” during weighing empty crucible
X with lid, and the system will hint if stop the current analysis or not, select “No” ,
there will be a hint “restart weighing it or not”, then press “Yes”, it will be OK. If the
following items are required to be analyzed, input corresponding value before
clicking the [Weigh Empty Crucible with Lid for X Analysis] button.

If the ash residue is to be analyzed, the CO2 content in CO2% will be entered before
clicking on “Weigh Empty Crucible with Lid”, and if moisture analysis is included
(only ash), the corresponding moisture content must be entered in Mar%. And the
system will prompt you to confirm.

Input the values of SO3d and Sd for the VMdmmf.

Input the values of MMad, CO2adBurnt for the Vdmmf .

If it is the first time to test the items above, for the convenience of inputting
corresponding value, adjust the title name, sequence. and width.

8) Weigh Moisture and Ash Sample

After having automatically weighed vacant crucibles, the program will prompt you to
put samples in (prompt music will be heard). Click the [OK] button of the pop-up
54
 dialog box. When the Carousel resets and stops rotating (the Carousel stops at the
location of #0 crucible), press the red “Rotate” button on the front panel of the
analyzer to rotate the Carousel and put samples into crucibles in turn. After that,
click the [Weigh Moisture and Ash Samples] button. Then, the program
automatically weighs samples

(Note: #0 crucible is used for correction only. No sample can be put into it! ).

If you have pressed down the [Weigh Moisture and Ash Samples] button, the
system has begun to weigh moisture and ash samples, but needs to do it again. In
this case, you also have two choices: After the system has weighed moisture and
ash samples, it will give a prompt of whether to begin analysis and you should select
[No]; at any time before the system has weighed moisture and ash samples, click
the [Stop Moisture and Ash Analysis] button. The system gives a prompt of whether
to terminate the current test and you should select [No]. The system gives another
prompt of whether to weigh moisture and ash samples again and you should select
[YES]. Do not turn on the fan before weighing moisture and ash samples lest the
weighing should be affected.

9) Start X Analysis

After automatic weighing of empty crucible, it will give indicating sound

automatically to add samples. Click “OK” button. When carousel resets and stops
rotating, press “Rotate” button on instrument to start rotating carousel. Load
samples into crucibles in order. After sample loading, click “Weight X Sample
Weight”, it will automatically weigh sample mass (No. 0 crucible is for calibration
only, do not load samples).

10) Stop X Analysis

If click on “Stop X Analysis” button during analysis, the system will hint if pause the
analysis, if you click on “OK” button, the system w ill hint if exit, if click on “OK’
again, then it will exit from the analysis.

55
11) Prompts and Operation Skills during the Test

a) Input Moisture and CO2 Data

If the current test does not determine moisture or CO2, you must manually input
numeric values in the grids of Mad% and CO2%. That is, click the column where you
want to input data and do not input data until the vertical line cursor flashes. You
may move upward or downward by pressing ↑ or ↓ on the keyboard. At this time,
you may press Enter and input data in this column.

b) You may press and hold a heading (for example, date) in a form with the left key of
the mouse. When the red mark “▲” appears, drag the heading leftward or rightward
to the place you want and then loosen the left key. The heading automatically
moves to the place and rearrangement is made possible. If there are 3 dots behind
some data, it indicates that this column is not wide enough and you only need to put
the mouse between the heading of this column and that of next column. When “ ”
appears, press and hold the left key of the mouse and do not loosen it until there is
a proper width. In this way, all content will display.

c) During a test, you may set the number of columns displayed in a form. That is, move
the cursor onto the form and right click to select a corresponding item to be
modified.

d) Modify Heading Name, Order and Width

1) Modify the heading of a form: Many data items, such as No., sample name and
sample mass, are defined. Some users need to change them, for example, to
change a sample name into a coal sample code; some want to adjust order;
some need three items while others need four. For the sake of users, they may
select whatever field they need to display or modify a field name or data display
font. Operating procedures: adjust the order of fields: set the field to be
displayed. Note: One field is one column in a form. First, right click the
heading of a form (The heading is the first line of the form. It is invariably grey).
The interface will pop up. Click the [Set Column of Form] menu to enter the
56
interface (Figure 4-30).

The program defines altogether 39 fields (some irrelevant fields are not listed).
In Figure 4-31, the fields in the left white square will not displayed in a form
while those in the right will. If you want to add a field in the left square to the
right side, you may double click the field. Or you may select the field (turn into
blue) and then click the [Add->] button. In this way, you may add the field to the
end of the right square. Likewise, you may remove a field in the left square in
the same way. If you want to adjust the order of the fields in the right square,
you may select them (turn into blue) and click the [Up] or [Down] button. Then,
you may click the [OK] button to save your setting. When you enter next time,
you will see them in the set order. Needless to say, when you click the [OK]
button, the program will immediately update its display as adjusted. If you click
[Cancel], your modification will not be validated.

Figure 4-3

57
 Figure 4-4
（2）Adjust the width of the field, modify the field name. Similarly, click Figure 4-3 in the
[set table header] menu, you can enter the interface as shown in Figure 4-5. After
entering this interface you can only see the fields that appear in the table. If you want to
modify the field name or width of a field or the position of the header in the column, you
can select it first (click the field with the left mouse button) Field, so that the right side of
the change in the label of the text box will appear in your selected field name, the field
name to modify the desired field name, you can also modify the width, modify the
position in the title, that is, alignment, modify
After all the titles and then click the "OK" button, it will save the changes just, and
immediately update the table shows the next time you enter the changes just as
effective.

Figure 4-5

（3）Modify the display font of the data in the table. Similarly, click Figure 4-37 in the [set

the font] menu, you can enter the interface as shown in Figure 4-6. Into this interface, it

should be noted that some Western fonts do not choose, because some Western fonts

do not support Chinese, will show garbled, and the color settings are invalid. Changes to
58
the font will affect all of the same table in the program, but the field name, field width and

order changes will only affect the current table, and will not affect the other parts of the

table. For example, in the results of the query to modify the font for the fifth, then all other

forms of data fonts are five, but if the results in the query only need to show the number

and Vad%, modified only the results of the query shows the two Field, and the number of

fields in the test form does not change. However, the tables in the general query and the

advanced query interface are the same table.

Figure 4-6

(4) Modify the title of the report for the system. (excluding the template) as shown in

figure 4-7.

Figure 4-7
The "company" dialog box may enter the device's name, and the input will automatically
be added to the header of the printed result. The "department" dialog box can enter the
department that uses the instrument.

59
4. Routine Maintenance
Routine maintenance has a very positive effect on the normal use of the equipment.

4.1. Crucible|
The crucible is made of ceramic material. It is advisable to remove the residue

when the furnace has been cooled to ambient temperature. Put the crucible into

the muffle furnace under the temperature of 850 ℃ for 15 minutes. Take out the
crucible from the furnace, clean it, and put it back to the carousel for next use.

4.2. Thermocouple
Thermocouple is a consumable with a service life of around 12 months. It must be

K-type Thermocouple manufactured by CKIC when the thermocouple is

necessary to be replaced. Other Thermocouples are not allowed, because it may

cause temperature control failure and furnace damage.

4.3. Abnormal Power Failure

During the analysis , there is abnormal power failure occasionally. When the

abnormal power failure occurs, please do not turn the carousel with your hands.

When it gets the power on, check the instrument, and be sure that the carousel is

in the initial position before your operation.

4.4. Gas Cylinder

If oxygen and nitrogen are needed for 5E-MAC6710, it is necessary to regularly

check the value of gas cylinder. Generally speaking , 0.2MPa is normal. If the

value is lower than 0.2MPa, the gas cylinder should be replaced.

60
5. Professional Maintenance and Troubleshooting
This chapter focuses on the analysis of some common fault phenomena, fault

analysis and troubleshooting in the process of instrument operations.

5.1. Carousel Dislocation

1) In the weighing process, when the weighing results of one crucible or more
are not consistent with the empty crucible weighing results, the calculation will be
abnormal.
2) When weighing a certain crucible, the balance will be tared and weighed
normally, while the carousel does not descend for weighing. The counter slot signal
displayed is not in the crucible position.

Troubleshooting ：
1) Check whether the CP - end of the stepper motor drive is strung into a 500 ~ 1K
ohm resistor.
2) Check the reset slot and counter slot. Refer to the chapter 3.13.4 Adjustment
of reset slot and counter slot.
Check the instrument according to procedures and meet the demand as mentioned
above, then the dislocation can be solved.

5.2. Lifting and Rotating Mechanism Failure

A. The lifting and rotating mechanism does not do the lifting movement:

1) Check whether the lifting optical slot is damaged or not.

2) Check whether the motor is damaged or not.
3) Check whether the fastening screw of lifting shaft is loose or not.
4) Check whether the control panel is jammed or not for the deformation of the
lifting shaft.
5) Check whether the control panel is damaged or not.

Troubleshooting:
1) Replace the optical slot
2) Replace the lift motor
3) Fasten the screws
4) Adjust the lifting shaft
5) Replace the control panel
61
B. Lifting and rotating mechanism falls automatically during the test:

1) Check whether the lifting motor is a motor with a damper disc (the rear of the
motor has a metal disk as a damper disc ).
2) Check whether the lifting motor is damaged or not.

Troubleshooting:
The lifting motor must be replaced in all the above phenomena.

C. The lifting and rotating mechanism has abnormal sound in the lifting process:
1) Check whether the deformation of the shaft and plastic friction cause
abnormal sound.
2) Check whether the lifting shaft fastening screws are loose and produce
abnormal sound.
3) Check whether there is excessive noise in the lifting rail or the ball in the slider.
4) Check whether the noise is caused by lifting motor.

Troubleshooting:
1) Adjust the gap between the carousel shaft and the plastic or replace the
carousel shaft.
2) Fasten the screw
3) Add lubricating oil or replace the new guide block after cleaning.
4) Replace lifting motor

D. The lifting mechanism rotates continuously during rotation

1) Check whether the optical slots in the disc position are damaged.
2) Check whether the optical slots in the disc position are loose.
3) Check whether the control panel is damaged or not.

Troubleshooting:
1) Replace the optical slot.
2) Connect all the wire
3) Replace the control panel.

62
5.3. Balance Failure

2) It can not be weighed in the simulating weighing.

3) During the test, when a crucible is to be weighed, the carousel does not
descent to weigh the crucible.

Troubleshooting:
1) Check whether the balance is properly installed. Refer to Chapter 3.7, "Balance
Installation".
2) Check whether the balance beam is properly installed. Refer to Chapter 3.13.8,
"Adjustment of Balance Beam".
3) Check whether the communication Settings are correct. Refer to Chapter 3.13.1,
"COMM Settings".

5.4. Temperature Detection Failure

1) Cannot read the temperature

2) Abnormal temperature display
3) Abnormal Over-temp Alarm

Troubleshooting:
1) Check the communication serial port between the PC and the DSP board.
2) Check whether the power supply on the DSP board is normal.

63
 Figure 6-1

Check if the DSP board is working properly.

For the 4 LED lights on the DSP panel: LED1 works properly with 1.8V voltage ; LED2
works properly with 3.3V voltage ; LED3 is flashing; LED4 is flashing
slowly.Mainboard is working properly. If the LED light is abnormal, replace the main
board.

Check if the thermocouple wiring is correct. The red line is connected to the positive pole
of the thermocouple, and the black wire is connected to the negative pole of the
thermocouple.

When the over-temperature alarms, the temperature does not reach the alarm
temperature yet.

64
 Figure 6-2

The TP1 voltage is detected by a multimeter, and the adjustable resistance R30 is
adjusted so that the voltage of the TP1 is stabilized at about 2.64V. This can set high
temperature furnace overheating alarm temperature.

The TP2 voltage is detected by a multimeter, and the adjustable resistance R32 is
adjusted so that the voltage of the TP2 is stabilized at about 0.51V. Thus, the
temperature of the constant temperature furnace and the temperature of the alarm can
be set.

5.5. Power Failure

Fault
1) the DSP board has no operating voltage, +5V/+12V/-12V/+15V;
2) the control panel has no working voltage, +5V/+12V;
3) stepper motor driver has no working voltage, +27V
4) No heating reaction

Troubleshooting:
1) check whether the main power fuse is in good condition;
65
2) check the power output of the switch;
3) check the power connector;
4) check whether there is a line of short-term, such as balance, power cord is under the
balance of the stent, broken and so on;
5) check whether the heating circuit breaker is closed;
6) check whether the heating relay SFD-112DM is pulled in. As shown in the figure, the
DC control terminal has power on the 5V voltage, while the AC 220V between the 2 feet
is still 220V, the relay is bad, replaced.

Figure 6-3

5.6. Circuit Board Failure

Fault:
1) the lifting motor of the carousel has no instruction to move up and down, or do not
move with the instruction;

2) the sample rod motor has no instruction to move up and down, or do not move with
the instruction;

3) the insulation board motor has no instruction to open and close,or do not move with
the instruction;

4) solenoid valve has no instruction to pull off, or do not move with the instruction;

Troubleshooting:

1) check mechanical failure;

66
2) replace the control panel;

3) check the power failure;

67
 Furnace Lid
Gas
Gas Cylinder
Cylinder

68
Inlet
Y-Tee Gas Inlet Throttle Valve Compressed Gas
P
A
R
附录 A 气路图

Gas Outlet
Throttle Valve
Outlet
汽缸气路图
通气气路图

69
Appendix B Wiring Diagram
Wiring Diagram 1

70
71
Wiring Diagram 2

72
73