Fuji Electric ZKJ Series - Dual Beam Infrared Gas Analyzer Maintenance Manual (English) User's Guide
Summary
This comprehensive service manual provides expert support for the Infrared Gas Analyzer (ZKJ), designed for skilled technicians performing maintenance and after-sales service. It goes beyond basic operation, covering detailed instructions on component replacement, adjusting various core parts like detector modules and circuit boards, factory mode parameter settings, and advanced troubleshooting techniques. Essential reading for ensuring precise calibration and reliable performance of your gas analyzer unit.
Page 1 Text Content
Service Manual
INFRARED GAS ANALYZER
TYPE: ZKJ-3
INZ-TN514722a-E
Page Summary Contents For Fuji Electric ZKJ Series - Dual Beam Infrared Gas Analyzer Maintenance Manual (English) User's Guide
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Service Manual INFRARED GAS ANALYZER TYPE: ZKJ-3 INZ-TN514722a-E
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PREFACE This service manual describes the infrared gas analyzer (Type: ZKJ). This service manual is intended for use with the instruction manual to help you in understanding maintenance and inspection...
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CONTENTS PREFACE ..........................................................................................................................i CAUTION ON SAFETY.............................................
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CAUTION ON SAFETY 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 saf...
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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 ...
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Caution on maintenance and check • Before accessing the inside of analyzer with the casing open for capillary replacement or the like purpose, be sure to turn off power supply and purge not only the a...
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1. STRUCTURE OF ANALYZER AND NAMES OF PARTS (1) Analyzer main unit Parts No. Part name 1 Top cover 2, 4 Mounting screw 3 Slide rail 5 Input/output terminal 6 Input/output cable 7 Power supply cable IN...
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Parts No. Part name Parts No. Part name 1 Decorative sheet (with built-in keys) 8 Gas inlet/outlet fittings 2 LCD panel 9 Main P.C.B 3 Fuse holder 10 Mother P.C.B 4 Glass-tube fuse 11 Amplifier P.C.B ...
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(2) Measuring element For combination of 1 optical block with one sample cell Parts Part name No. Part name Parts No. Part name Parts No. 1 Sector motor 10 Cell window (for pipe cell) 18 O-ring 2 (for...
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For combination of 1 optical block with 2 sample cells screw 4 INZ-TN514722-E
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(3) Connection of parts In le • Connection diagram us ho ld er ot e) he ar ts pe ci fie fo op tic al lo ck nd pl ifi er oa rd o. re ot ou nt ed th an al yz er hi ch oe no t h av th se co nd pt ic al l...
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• Piping diagram O2 sensor Infrared light source side Toaron φ6/φ3 Sample cell (1st optical block) Yellow capillary L=20mm Toaron φ6/φ3 Teflon φ6/φ4 INLET CH2 Yellow capillary L=10mm(Toaron φ9/φ5 L=35...
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2. MAINTENANCE AND INSPECTION, AND REPAIR AND TENANCE AND INSPECTION, A D REPAIR AND ADJUSTMENT AT REPLACEMENT OF MEASURING UNITS STMENT AT REPLACEM NT OF MEASURING U ITS (1) Light source • Recommende...
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(2) Sector motor and sector • Recommended period of replacement : 2 years (Sector motor) 1) Error mode : Motor rotation stop Phenomena : Analyzer’s measured value surpasses the scale or indicated valu...
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(4) Cell, cell window and O-ring • Service life : Usable unless contaminated or corroded. • Recommended period of replacement : 2 years with O-ring 1) Error mode : Contamination of cell, mixture of fo...
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• Replacement : Turn off power supply to the analyzer, remove the bolts which fix the detector and remove the detector. Mount a new detector and tighten the bolts. The type of detector varies with the...
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(7) Printed circuit board (see printed circuit diagram at the back of the manual) 1) Main printed circuit board (main board) Note) The main board is set according to the specifications of each analyze...
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2) Amplifier printed circuit board (amplifier board) One board provided for each optical block (the following check items are for one board) • Check : Check of circuit voltage Check terminal Regulated...
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3) Mother printed circuit board (mother board) • Adjustment after replacement: Output adjustment (Refer to “ Output Adj.” in Maintenance Mode.) 4) I/O terminal printed circuit board (I/O terminal boar...
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LDC30F-2 LDC60F-2 Name plate Name plate Input(N) Output(L) Pin Symbol Voltage Pin Symbol Voltage 1 V3 –15V 1 V3 –15V LDA10F Pin Symbol Voltage 1 –V 2 –V Output (+) Output (–) Name plate Pin Symbol Vol...
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3. FACTORY MODE (1) How to go to factory mode Point the cursor to “8. To Factory Mode” by using the or key on the Maintenance Mode screen and enter the key. Then, the password input screen appears. En...
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(2) Contents and setting of each item 1) Zero offset Factory mode initial screen The cursor is in 4 • Function : Stores the offset value of the A/D converter. • Operation : The offset adjustment scree...
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2) A/D data • Function : Measures the counter readings Factory mode initial screen immediately after A/D conversion. The cursor is in 11 • Operation : To measure the counter readings, press the key on...
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3) Other parameters • Function : Used to set the following. Factory mode initial screen • Operation : The “Other parameters” screen is The cursor is in 12 shown at right. Select the setting contents u...
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• Error 10 check : Selection can be made from checking and not checking errors that may occur when connection of I/O terminal is erroneous. ON: Performs Error10 check. OFF: Does not perform Error10 ch...
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4) Coefficient check • Function : Used to display and change Factory mode initial screen calibration coefficient. The cursor is in 15 • Operation : The initial screen for coefficient check is shown at...
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5) Initial Data • Function : Used to memorize the interference Factory mode initial screen coefficient, and the span and the The cursor is in 16 sensitivity to moisture of each detector at the time of...
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6) Calculation • Function : Displays the result of calculation Factory mode initial screen for each component. The cursor is in 17 • Contents : Displays infrared component and results of calculation b...
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4. ERROR JUDGEMENT CRITERIA FOR ERROR CODES * This section covers the error judgement criteria for error codes. For the contents of errors, refer to Instruction Manual. Error No. Contents Criteria Err...
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5. TROUBLESHOOTING AND DATA COLLECTION (1) Countermeasures against trouble 1) No zero calibration can be performed (ERROR No. 4, 5 or 8 has occurred.) 1) Check that a specified flow rate of zero gas i...
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(2) Data sampling at trouble When trouble occurs, be sure to sample the following data. In the case of the trouble in connection with the characteristic, please sample data (please surely sample data ...
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(3) Troubleshooting of detectors 1) Trouble judgment a. Check that the sampling line is not abnormal and that the dehumidifying line/filter status and sample gas properties do not have a problem. b. C...
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APPENDIX 1. MEASURING PRINCIPLE DIAGRAM Infrared ray type (NO, SO2, CO2, CO, and CH4) Motor Distribution cell (also used as Trimmer interference filter) Reference cell Detector Rotary sector Sector sy...
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APPENDIX 2. SOFT FLOW DIAGRAM In te rfe re nc In fra re ra co po ne nt (f or ac ga co po ne nt co pe ns at io ai de te ct or pa Ze ro oi nt Ze ro oi nt /D ffs et ig ita l f ilt er Ze ro oi nt pa po in...
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APPENDIX 3. PRINTED CIRCUIT BOARD DIAGRAM Main PC board cc 3. 3V cc 3. 3V TK ap an INZ-TN514722-E A-3
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Amplifier PC board TP3TP4 DV1DV2 TP1 TP2DV1DV2 TP1 TP3TP4 SG N15 TK365874R1 Japan A-4 INZ-TN514722-E
Manual Details
| Brand | Dual |
|---|---|
| Pages | 37 |
| File Size | 878.52 KB |
| Published | May 31, 2026 |
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Frequently Asked Questions
What is required before operating the analyzer?
You must read both the instruction manual and this service manual carefully until you achieve adequate understanding.
Can I modify the gas analyzer myself?
No, modification is strictly prohibited unless written approval is obtained from the manufacturer. Fuji Electric will not be responsible for resulting damage.
How can I perform a zero offset adjustment on the light source?
The manual describes setting the signal sample gas inlet and gain outlet during factory mode procedures.
What signals does the amplifier board use for outputting data?
It supports outputs of 0 to 1 V DC or 4 to 20 mA DC, depending on the detector type.