FE ZAJ Manuel utilisateur

Service Manual

TN512955b-E

PARAMAGNETIC OXYGEN

ANALYZER

TYPE: ZAJ

TN512955-E i

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.

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.

The specifications of this analyzer will be changed without prior notice for further product improvement.

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.

Name Q'ty Remarks

Analyzer main frame 1 

Filter 2 Spare

Restrictor 1 Spare

Packing 2 Spare (filter area)

Packing 4 Spare (for restrictor)

Fuse 2 2A

Instruction manual 1 

Test report 1 

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

PREFACE

It is prohibited to transfer part or all of this manual without Fuji

Electric’s permission in written format.

Description in this manual will be changed without prior notice

for further improvement.

Request

©Fuji Electric Co., Ltd. 2001

Issued in Sep., 2001

Rev. 1st edition April, 2011

Rev. 2nd edition April, 2013

Delivered items

ii TN512955-E

PREFACE ..........................................................................................................................i

CONTENTS ......................................................................................................................ii

CAUTION ON SAFETY .................................................................................................iii

1. NAME OF EACH PART...........................................................................................1

2. BEFORE MAINTENANCE ......................................................................................2

2-1. How to stop analyzer................................................................................................... 2

2-2. How to operate analyzer.............................................................................................. 2

2-3. How to pull out inner case........................................................................................... 2

3. ADJUSTMENT..........................................................................................................4

3-1. LCD contrast adjustment (Display 1: LCD at the top-front)....................................... 3

3-2. Output adjustment (4 to 20mA, 0 to 1V)..................................................................... 5

4. REPLACEMENT OF PARTS ...................................................................................6

4-1. Replacement of restrictor ............................................................................................ 6

4-2. Replacement of switching power supply..................................................................... 6

4-3. Replacement of sensor................................................................................................. 7

4-4. Replacement of display ............................................................................................... 8

5. CHECK FOR SIGNALS............................................................................................9

5-1. Check of voltage across printed circuit board ............................................................. 9

5-2. Check of magnet driven pulse ..................................................................................... 9

5-3. Check and adjustment of synchronous rectification waveforms ................................. 9

6. Countermeasures against trouble .............................................................................11

6-1. Error code and countermeasures ............................................................................... 11

6-2. Troubleshooting......................................................................................................... 13

7. Maintenance parts .................................................................................................... 14

8. Others .......................................................................................................................15

Appendix .........................................................................................................................16

CONTENTS

TN512955-E iii

First of all, read this “Caution on safety” carefully, and then use the analyzer in the correct way.

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.

DANGER

Wrong handling may cause a dangerous situation, in which there is a risk of

death or heavy injury.

CAUTION

Wrong handling may invite a dangerous situation, in which there is a

possibility of medium-level trouble or slight injury or only physical damage

is predictable.

Caution on installation and transport of gas analyzer

DANGER

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.

CAUTION

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.

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.

The gas analyzer is heavy. It should be transported carefully by two or

more persons if manually required. Otherwise, body may be damaged or

injured.

CAUTION ON SAFETY

iv TN512955-E

Caution on piping

DANGER

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.

Connect pipes correctly referring to the instruction manual.

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

CAUTION

The unit must be earthed as specified. Otherwise, it may cause electric

shocks, malfunction, etc.

Be sure to use a power supply of correct rating. Connection of power

supply of incorrect rating may cause fire.

Wiring work must be performed with the main power set to OFF to

prevent electric shocks.

Wires should be the proper one meeting the ratings of this instrument. If

using a wire which cannot endure the ratings, a fire may occur.

Caution on use

DANGER

When handling the standard gas such as calibration gas, read the

instruction manual of the standard gas carefully and use the gas

correctly.

CAUTION

Avoid continuous operation with the casing drawn out. Otherwise, the

casing may fall to cause an injury.

During operation, avoid opening the casing and touching the internal

parts. Otherwise, you may suffer a burn or shock hazard.

TN512955-E v

Caution on maintenance and check

DANGER

Before working such as restrictor replacement with the casing open, be

sure to turn off power supply, and perform air and N2gas purging of not

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.

CAUTION

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.

Others

CAUTION

If the cause of any fault cannot be determined despite reference to the

instruction manual, be sure to contact your dealer or Fuji Electric's

technician in 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.

TN512896-E 1

RANG

vol%

ESC

MODE

ENT

ZERO SPAN

OXYGEN GAS ANALYZER

POWER

OFF

1 Handle

2 Knurled screw

3 Power switch

4 Display and operation panel

8 Reference gas inlet

7 Purge gas inlet

6 Sample gas outlet

5 Sample gas inlet

9 I/O signal terminal 1

1 Handle

2 Knurled screw

Front

Rear

11 Screw for FG

10 I/O signal terminal 2

(option)

12 Power terminal

13 RS-232C connector

(option)

1. NAME OF EACH PART

2 TN512955-E

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.

2-2. How to operate analyzer

After sensor 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.

2-3. 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

Loosen the 2 knurled screws as shown in the

Photo by turning them counterclockwise with

a driver or fingers.

BEFORE MAINTENANCE

Knurled screw

TN512955-E 3

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)

Sensor

Fuse

SW power supply (2)

(for circuit driving)

A/D printed

circuit board

CPU printed

boa

Display printed

circuit board

4 TN512955-E

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

3. ADJUSTMENT

Contrast

adjustment VR

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