Service Manual - Fuji Electric
Contents
1. using a wire which cannot endure the ratings a fire may occur Caution on use e When handling the standard gas such as calibration gas read the D AN G e R instruction manual of the standard gas carefully and use the gas correctly e Avoid continuous operation with the casing drawn out Otherwise the C A UTI ON casing may fall to cause an injury e During operation avoid opening the casing and touching the internal parts Otherwise you may suffer a burn or shock hazard IV TN512955 E Caution on maintenance and check e Before working such as restrictor replacement with the casing open be sure to turn off power supply and perform air and N gas purging of not A D AN G E R only the analyzer inside but also the sample gas line and reference gas line In addition carefully prevent oil and grease from adhering to the restrictor filter packing etc Otherwise poisoning fire or explosion may be caused due to gas leakage etc Before working take off a wrist watch finger ring or the like metallic accessories And never touch the instrument with a wet hand Otherwise you will have a shock hazard If the fuse is blown eliminate the cause and then replace it with the one of the same capacity and type as before Otherwise shock hazard or fault may be caused e Ifthe cause of any fault cannot be determined despite reference to the instruction manual be sure to contact your dealer or Fuji Electric s technician in2. Photo 4 6 Removal of display printed circuit board Screw TN512955 E 9 CHECK FOR SIGNALS 9 1 9 3 TN512955 E Check of voltage across printed circuit board Check of power supply voltage CPU board J6 GND J5 45V wrens 5 0 0 3V A D board J13 GND ss J11 15V 150 0 5V J13 GND rss J12 15V 15 0 0 5V J13 GND ss J14 12V 12 0 0 5V J13 GND se J15 5V 5 0 0 5V Output board CNE ICpw Vss FENL T0 IV Fea 5 0 0 3V CNS 2pin VG CNS5 1 H15V vee 15 0 0 5V CN5 2 pin VG CN5 a 3 15V On 15 0 0 5 Check of magnet driven pulse Check the pulse between terminals at the lower part of the sensor using an oscilloscope i 12 Sor15Hz 3 Pulse cycles depend on power frequencies At power frequency of 50Hz 12 5 0 5Hz At power frequency of 60Hz 15 0 0 5 Hz Check and adjustment of synchronous rectification waveforms Synchronous rectification waveforms should be checked 1f they vary widely Check points Use an oscilloscope to check waveforms between pin 4 of AC amplifier board Q7 and A D board J13 Note that the tester should be directly applied to the IC pin since pin 4 of the AC amplifier board Q7 is not provided with a check terminal Be careful not to short between adjacent pins Observe and check the waveforms according to waveform examples Not good OV Perform the following procedure when synchronous rectification waveforms are widely different from the go
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4. er E EE de ee ee eee ee 16 TN512955 E CAUTION ON SAFETY First of all read this Caution on safety carefully and then use the analyzer in the correct way e The cautionary descriptions listed here contain important information about safety so they should always be observed Those safety precautions are ranked in 2 levels DANGER and CAUTION A D AN G E R Wrong handling may cause a dangerous situation in which there is a risk of death or heavy injury Wrong handling may invite a dangerous situation in which there is a N C AUTI O N possibility of medium level trouble or slight injury or only physical damage is predictable Caution on installation and transport of gas analyzer N D AN G E This unit is not explosion proof type Do not use it in a place with explosive gases to prevent explosion fire or other serious accidents This unit should be installed in a place which conforms to the conditions noted in the instruction manual Otherwise it may cause electric shocks fire or malfunction of the unit During installation work care should be taken to keep the unit free from entry of cable chips or other foreign objects Otherwise it may cause fire trouble or malfunction of the unit N C AUTION For lifting the gas analyzer be sure to wear protective gloves Bare hands may invite an injury Before transport fix the casing so that it will not open Otherwise the casing may be separated and fall to cause an injury Th
5. occurs the instrument will be stopped without calibration Countermeasures Perform span point calibration manually If a span calibration error does not occur with manual span calibration there is nothing wrong with the instrument Check the settings for gas flow time in the span calibration and sampling system that is different between manual calibration and automatic calibration If the MANUAL SPAN CAL ERR code 1s displayed in the manual calibration check if calibration gas range settings and calibration concentration settings are proper Caution If the range setting has changed or when a gas cylinder for span calibration that is widely different from previous concentration value has been replaced an error may occur in an initial calibration but it there is nothing wrong with the instrument Perform span point calibration forcedly in the manual span calibration TN512955 E 11 Err3 Input over error INPUT OVER ERR This code is displayed when the sensor signal is large Countermeasures This error relates to reference gas sample gas and range settings First check 1f the range settings are proper Check if the reference gas is properly selected within the range to be set Starting from 0 N gas is selected From 21 air gas is selected and from 100 O is selected If the reference gas is correctly selected check 1f there is possibility that any of the sample gases exceeds the range oxygen is included too much If the sam
6. replacement restrictor replacement or internal piping replacement has been completed be sure to perform an airtightness test and flow check for reference gas according to preparation for operation in the instruction manual Turn ON the power while supplying the reference gas to warm up the instrument After replacement of a printed circuit board sensor or switching power supply has been performed carry out the signal check as described in Section 5 After that perform zero calibration and span calibration and flow sample gas Caution For protection of the sensor be sure to flow reference gas first and then sample gas How to pull out inner case Be sure to purge the cylinders and give protection to the sensor according to How to stop analyzer given in section 2 1 Turn the knurled screw on the front panel counterclockwise as shown in Photo 2 1 and pull out the inner case by holding the handles with hands refer to Photo 2 2 In the inner case the sensor printed circuit boards and switching power supply are arranged The sensor in the inner case is connected to the gas inlet of the outer case by Teflon tube The printed circuit boards in the inner case are wired to output printed circuit boards of the outer case by cables So be careful when pulling out the inner case to avoid confusing the piping or wiring Photo 2 1 Description of knurled screw Knurled screw Loosen the 2 knurled screws as shown in the Photo by turni
7. Fo Service Manual PARAMAGNETIC OXYGEN ANALYZER TYPE ZAJ D tes Fuji Electric Co Ltd TN512955b E PREFACE e This service manual contains information required for service engineers to perform maintenance and check of the paramagnetic oxygen analyzer Since this manual does not provide basic description such as operating principle and key operation you are requested to use this service manual together with related instruction manual e First read the instruction manual and the service manual carefully until an adequate understanding is acquired and then proceed to installation operation and maintenance of the gas analyzer Wrong handling may cause an accident or injury e The specifications of this analyzer will be changed without prior notice for further product improvement e Modification of this gas analyzer is strictly prohibited unless a written approval is obtained from the manufacturer Fuji Electric will not bear any responsibility for a trouble caused by such a modification Delivered items me LE o Restrictor Hu Spare Packing 2 Spare erare Peking 4 Spare orresiricion et a N CO I e CN ee Wrench 2 For reference gas joint Manufacturer Fuji Electric Co Ltd Type Described in Fuji Electric s company nameplate on main frame Date of manufacture Described in Fuji Electric s company nameplate on main frame Product nationality Japan Fuji Electric Co Ltd 2001 Issued in Sep 2001
8. Request Rev 1st edition April 2011 Rev 2nd edition April 2013 e It is prohibited to transfer part or all of this manual without Fuji Electric s permission in written format e Description in this manual will be changed without prior notice for further improvement TN512955 E CONTENTS PRETA CE a one 1 CONTENTS SR TEN 11 CAUTONONS ARRET SR lan de do Ca toc 111 Ls NAME OFEACH PAD ida l Ze BEFORE MAIN TEN N Els ia 2 2 1 TOW 10 SLOP allay ZEN assis acacia ens asta nce ee ss 2 2220 HOW TO OP Crate ana ZE ates ht ele es ected nn 2 2 93 HOWTO POU OU CASC osc eo a es a eh os 2 De NDIOSTIMENTR basis 4 3 1 LCD contrast adjustment Display 1 LCD at the top front oooococccccccnnnnnnnnnnnns 3 3 2 Output adjustment 4 to 20mA 0 to IV 5 4 REPCACEMENTOF PAR S sas 6 Al Replacement Of restrictor al 6 4 2 Replacement of switching power SUpply nono o nono nono nnnnnnnos 6 43 Replacement Of SAS AA AAA 7 4 4 Replacement OCdis play cenit tias 8 3 CHECK FORSIGNA ES di 9 5 1 Check of voltage across printed circuit board 9 5 2 CHECK OF MASEL diven pulse nunsiraiis iie aena A E AEE 9 5 3 Check and adjustment of synchronous rectification waveforms cc00ceeeeeeeeeees 9 6 Countermeasures against trouble sis dans NN A se 11 Gal Error cod and COMME EMCAs UTE ia 11 6225 MOUDIESMOOLING seee 13 Te Maenan CS DaN i ac 14 A E E E cones a eee ona ae 15 DDR RoE enn er eR Oe den
9. SC key several times to change it to the Measurement mode In this case don t press the ENT key Otherwise the adjustment contents would change and disable adjustment e Factory adjustment mode Press the MODE key several times on the Measurement screen and the User Adjustment screen appears Press the ZERO key 5 times on the User Adjustment screen and the Factory Adjustment mode will be selected This mode contains 4 to 20mA output 0 to 1V output coil pulse manual gain synchronous pulse zero memory span memory magnet reset and peak code input Be careful not to get in items other than 4 to 20mA output and 0 to 1V output In 4 to 20mA output and 0 to 1V output be sure to press the ENT key to save the change that is adjusted by A or W key After adjustments press the ESC key to escape to the Measurement mode MEAS MODE H ON R OFF L OFF A OFF ESC il Press the MODE key several times to get in the Adjustment mode ADJUST MODE gt MOVE AVE ACLOCK ESC Press the ZERO key 5 times Factory Mode 0 1V Move 4 20mA or 0 1V up one line by A or W key Press the A4 20mA Y Sync period gt key to enter the Output Adjustment screen v 0 1V OUT OV viv Select either OV zero or 1V Adjust the output by A or V span and press the gt key key while reading the digital voltmeter and press the ENT key 0 1V OUT OV Press AW key E ET Adjustment of 4 to 20mA should be performed i
10. charge of adjustment If the instrument is disassembled carelessly you may have a shock hazard or injury Do not use a replacement part other than specified by the instrument maker Otherwise adequate performance will not be provided Besides an accident or fault may be caused Replacement parts such as a maintenance part should be disposed of as incombustibles TN512955 E V 1 NAME OF EACH PART 1 Handle 2 Knurled screw 3 Power switch 4 Display and operation panel Reference gas inlet 7 Purge gas inlet 6 Sample gas outlet 5 Sample gas inlet 2 Power terminal 9 VO signal terminal 1 1 Screw for FG 0 I O signal terminal 2 13 RS 232C connector option option Rear TN512896 E 2 BEFORE MAINTENANCE 2 1 How to stop analyzer If sample gas includes flammable corrosive and toxic gases purge the inner case by supplying a safe gas such as N2 or air from the cylinder and then pull it out To stop the gas supply zero gas for a few minutes for protection of the sensor First stop the sample gas and then stop supplying the reference gas in 10 minutes Turn OFF the power and disconnect the power cable except for LCD contrast adjustment given in Section 3 1 output adjustment in 3 2 and signal check in 5 How to operate analyzer After sensor
11. dress Byte data data Zero and span calibration E00C6 8 8 4 Word coefficients Temperature table table E011A 12 C 3 Log A temperature compensation EOODA 36 24 Long table Zero temperature compensation tabl E034E 124C 3 Long able ma T 100 gain E00C5 1 1 Length of data is expressed in bytes Figures in parenthesis are expressed in hexadecimal TN512955 E 15 Appendix Appendix 1 Piping diagram Rear panel of analyzer k e A INLET am OUTLET gt O Gas outlet SUBGAS nn e Reference gas inlet Name of product Applicable length Piping diameter opse f Nylon tube About 0 5 m 16 TN512955 E eww ew ee ewe ee ng ee ee ee eee ee ee mony i 9NO Z pueoq ndno i ee we e e ee ee ee ee e n e e Ja due S OV p1eog Nd 4 IAI ono no O _ JOQ Sol o gt O O la Josuas re eer tee te ree JEUSE JO SIWEY aa LA 391 907 TT E IN 9 AR de Le E 2 ZNO IND EA N 2 X Y gt el o eee x yooq euwe zouben 4 3 J0 Va L 4 Japjoy LS LS ae SS O gt iN 3 UOIIMS asny 1911 yoo q a La A E 119 A ddns SSION IBUIUUS lt E TNO INO J MOd JOMOd Buum UsAUp jouben tactic es 17 TN512955 E 18 Appendix 3 1 CPU printed board JO J6 PC3 PC2 PCI A 0 J TN512955 E Appendix 3 2 A D printed circuit board nn i CNIS e eae Sy Shi yO 4 2 c29 0 017 sO co Fam org B i sO T
12. e gas analyzer is heavy It should be transported carefully by two or more persons if manually required Otherwise body may be damaged or injured TN512955 E 111 Caution on piping In piping the following precautions should be observed Wrong piping may cause gas leakage If the leaking gas contains a toxic component there is a risk of serious accident being induced Also if combustible gas is contained there is a danger of explosion fire or the like occurring e Connect pipes correctly referring to the instruction manual A D AN G E B e Exhaust should be led outdoors so that it will not remain in the locker and installation room Exhaust from the analyzer should be relieved in the atmospheric air in order that an unnecessary pressure will not be applied to the analyzer Otherwise any pipe in the analyzer may be disconnected to cause gas leakage For piping use a pipe and a pressure reducing valve to which oil and grease are not adhering If such a material is adhering a fire or the like accident may be caused Caution on wiring e The unit must be earthed as specified Otherwise it may cause electric shocks malfunction etc e Be sure to use a power supply of correct rating Connection of power A supply of incorrect rating may cause fire CA UTI O N e Wiring work must be performed with the main power set to OFF to prevent electric shocks e Wires should be the proper one meeting the ratings of this instrument If
13. effective range is INPUT UNDERERR Value is flowing abnormal Err5 OUTPUT DEVICE ERR Output printed Check if the connector of output printed circuit board is circuit board is unplugged abnormal Replace the output printed circuit board Contact the nearest Fuji representative e Errl Auto zero calibration error AUTO ZERO CAL ERR This code is displayed if zero calibration values as measured in the automatic calibration fluctuate 20 larger than previous calibration value If an error occurs the instrument will be stopped without calibration Countermeasures Perform zero point calibration manually If an error does not occur with manual zero calibration there is nothing wrong with the instrument Check the settings for gas flowing time in the automatic calibration and the sampling system that is different between manual calibration and automatic calibration If the MANUAL ZERO CAL ERR code appears in the manual calibration check calibration gas range settings and calibration concentration settings Caution If the range settings have changed an error may be displayed in an initial calibration But this is not anerror Perform zero point calibration forcedly in the manual zero calibration e Err2 Auto span calibration error AUTO SPAN CAL ERR This code is displayed if span calibration value as measured in the automatic calibration fluctuates 20 larger than previous calibration value If an error
14. hile holding the sensor by hand and remove the sensor and mounting board from the instrument Unscrew 4 screws fastening the mounting board so that the sensor can be separated from the mounting board When mounting a new sensor reverse the removal procedure Before connecting the sensor signal cable adjust voltage with VR1 until voltage specified on the replacement sensor 1s obtained from between CN 2 pins 1 and 4 on the A D printed circuit board After sensor voltage adjustment has been completed connect the sensor signal cable and check the sensors against the operation check list Photo 4 2 Sensor piping Pipe Pipe Photo 4 3 Photo 4 4 Inner case as viewed from upper part Inner case as viewed from lower part Sensor signal cable Magnet driving Thermistor cable TN512955 E T Replacement of display unit First turn OFF the instrument power switch Pull out the AC power cable Draw the inner case from the instrument as described in section 2 3 Unscrew 6 screws from the side panel 2 screws from the lower part of the inner case and remove the front frame from the inner case Note that the soldered AC power cable cannot completely be removed from the instrument Unscrew 6 screws fastening the display printed circuit board from the rear of the frame Replace the display printed circuit board After replacement measure contrast of LCD according to section 3 1 Photo 4 5 Removal of front frame Screw LR SS Screw
15. n the same procedure as in 0 to 1V TN512955 E 5 4 REPLACEMENT OF PARTS 4 1 Replacement of restrictor Stop the analyzer as described in section 2 1 How to stop analyzer Then pull out the inner case The restrictor for reference gas line should be replaced when it is clogged if gas flow is reduced to less than 5 mL Be careful when handling the restrictor to prevent it from being clogging with foreign matter since the restrictor diameter is very small Never touch the restrictor directly If the restrictor is dropped or touched in error rinse it with acetone for about 10 seconds and mount it after drying After restrictor replacement apply soapy water to the connections of the pipe and joint and check for a gas leak After confirming that there is no sign of a gas leak check the gas flow to the restrictor 5 to 20 mL Photo 4 1 Replacement of restrictor Illustration of disassembly Do not turn this wrench Restrictor Packing Cap screw Pipe 4 2 Replacement of switching power supply The switching power supply is classified into two types for magnet driving and for circuit use As shown in the Photo 2 3 SW power supply 1 is used for magnet driving and SW power supply 2 for circuit use To replace the switching power supply perform how to stop analyzer given in section 2 1 Turn OFF this instrument power switch and disconnect the AC power cable Then pull the inner case out of the inst
16. ng them counterclockwise with a driver or fingers TN512955 E Photo 2 2 Inner case drawn Pull the handles toward you by holding them with hands A stopper provided on the outer case prevents the inner case from being removed fully Photo 2 3 Components inside the inner case SW power supply 1 for magnet driving SW power supply 2 for circuit driving Sensor A D printed circuit board CPU printed circuit board Display printed circuit board TN512955 E 3 3 ADJUSTMENT 3 1 LCD contrast adjustment Display 1 LCD at the top front The LCD of the concentration display is not provided with a means of performing contrast adjustment The LCD contrast adjustment is performed by means of the VR of the display printed circuit board When the VR is turned clockwise by a precision driver display characters turn dark and when it is turned counterclockwise they turn light Adjust the contrast to make it easy for the users to see the display Photo 3 1 Contrast adjustment Contrast adjustment VR 4 TN512955 E 3 2 Output adjustment 4 to 20mA 0 to 1V To perform output adjustment connect a digital voltmeter to the output terminal and set the measurement screen in the Factory Adjustment mode Caution Perform the output adjustment within the range of 4 to 2mA and 0 to 1V on the Adjustment screen If other adjustment screen appears and you are at a loss what to do on the screen press the E
17. nge settings have changed an error may be displayed in an initial calibration But this is not an error Perform zero point calibration forcedly in the manual zero calibration e Manual span calibration error MANUAL SPAN CAL ERR 12 When span calibration has been performed in the manual mode via key operation this code appears when calibrated values fluctuate 20 larger than previous calibrated ones Countermeasures Check that the range and calibration concentration settings are proper Check the sampling system and calibration gas Caution If the range settings have changed an error may be displayed in an initial calibration But this is not an error Perform span point calibration forcedly in the manual span calibration TN512955 E 6 2 Troubleshooting Indication fluctuates large Is ambient vibra Take anti vibration tion large countermeasure YES Include buffer tank in exhaust line NO YES YES Reduce pressure By stopping measured gas Is it reduced a F or reference Is cap screw YES Tighten cap NO gas joint By stopping measured gas nt and reference gas loose Beer f Perform air tightness otero BrO check about o reference gas line Reduce noise Replace PC board To external a terminal ads NO Check power supply line NO Is ambient noise large Does measure ment gas pressure fluctuate NO YE Is power supply s
18. od example Caution e Failure to adjust synchronous rectification waveforms may result in inaccurate measurement e If you go into a wrong Adjustment Item screen of the Factory mode be sure to press the ESC key and then retry from the first step On the different Adjustment Item screen don t press the ENT key or the gt key or accurate measurement cannot be performed and poor measurement results will be obtained MEAS MODE H ON R OFF L OFF A OFF N MODE Press the key several times to change to the Adjustment mode ADJUST MODE gt MOVE AVE A CLOCK N ZERO Press the key 5 times In the Factory mode that is displayed move Synchronous Pulse one line up by using A or W key Press the gt key to go into the Synchronous Pulse Phase adjustment screen Sync phase Press AW key ENT While observing the synchronous rectification waveforms with an oscilloscope adjust them by using A or W key Establish waveforms with the ENT key If you want to stop halfway press the ESC key Factory Mode Sync phase A Amp gain W Zero save Al Y 10 TN512955 E 6 Countermeasures against trouble 6 1 Error code and countermeasures Errl AUTO ZERO CAL ERR Calibration Confirm the set zero or span calibration Err2 AUTOSPANCALERR Value ismore value than 20 FS font diseno Confirm the gas concentration in gas previous value cylinder Confirm the range INPUT OVER ERR Sensor input e Check if gas outside
19. ple gas is beyond the range change the range e Err4 Input under error INPUT UNDER ERR This code is displayed when the sensor signal is larger in the negative direction Countermeasures This error relates to reference gas sample gas and range settings Check for the range settings Check if the reference gas is properly selected within the range to be set Starting from 0 N gas 1s selected From 21 air gas is selected and from 100 O is selected If it is properly selected check if some gas among the sample gases is included as set in the range or if even a small quantity of oxygen is contained in the reference gas for example If the sample gas 1s not included as set in the range change the reference gas and range e Err5 Output device error OUTPUT DEVICE ERR This code is displayed when a response is not received from an output printed circuit board Countermeasures Check the cable between the CPU printed board and output printed board Check if there is poor contact between the connector and receptacle or if the cable is disconnected e Manual zero calibration error MANUAL ZERO CAL ERR When zero calibration has been performed in the manual mode via key operation this code appears when calibrated values fluctuate 20 larger than previous calibrated values Countermeasures Check that the range and calibration concentration settings are proper Check the sampling system and calibration gas Caution If the ra
20. rument as described in section 2 3 and remove the mounting board on which the switching power supply is mounted by loosening 2 screws from the top Disconnect the primary and secondary connectors Remove 4 screws and insulation washers fastening the mounting board and switching power supply to remove the switching power supply from the mounting board When mounting a new switching power supply reverse the removal procedure Be sure to attach insulation screw washers required for mounting the new switching power supply on the mounting board For replacement of switching power supply 1 check the magnet driving pulse section 5 2 and for switching power supply 2 check voltage for the printed circuit board as shown in section 5 1 6 TN512955 E 4 3 Replacement of sensor Caution Since accuracy cannot be guaranteed when sensors are replaced at the site sensors must be factory adjusted at replacement First be sure to turn OFF the power switch to the instrument Disconnect the AC power cable Supply a zero gas and then pull out the inner case from the instrument and detach cap nuts for pipes D and which are connected to the sensor as shown in Photo 4 2 Next remove the SUS pipe for the reference gas in the same procedure as when the restrictor has been replaced Remove thermistor soldered cable magnet driving cable screwed to the sensor lower part and sensor signal cable connector Unscrew 3 screws from the mounting board w
21. upplied YES Is fuse burn YES Replace fuse Check measure ment gas line Span adjustment NO Check reference cannot be made Needle valve gas supply source for reduce DS E valve NO Open needle valve fully YES To ref Replace restrictor RA and filter gas line Fee Zero adjustment Is air YES Purge reference cannot be made contained gas line NO TN512955 E 13 7 Maintenance parts 14 Recommended Name Man Drawing No Remarks replacement cycle Recommended replacement cycle for maintenance parts 1s at least 2 years parts every 2 years Maintenance parts including No 1 to No 4 used near the reference gas should be replaced every 2 years However if there is no problem with reference gas flow a constant flow of 5 to 20 mL is maintained or indication does not fluctuate there is no need to replace them Prepare maintenance TN512955 E 8 Others If transmission function RS232C 1s available as an option the following parameters can be viewed by a dedicated tool Zero and span calibration coefficients A D counted value at calibration Temperature table Temperature table for temperature compensation Span temperature compensation table Temperature compensation table for span point Zero temperature compensation table Temperature compensation table for zero point 2 gain 2 O2 gain 100 gain 100 O gain Length of data Number of Type of Name First ad
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