Servomex SERVO PRO 14440D1 User manual

Part Number: 01440002D
Revision: 5
Language: UK English
Service Manual
SERVOPRO 1440D1
Light Industrial Gas Analyser
EMISSIONS ANALYSERS

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01440D1
Light Industrial Gas Analyser
Service Manual
Ref.: 01440/002D/5
Order as part No. 01440002D

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Table of Contents
01440D Light Industrial Gas Analyser Service Manual. i
1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Scope of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
2 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Test Equipment and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2 Sample condition requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3 Servicing the Oxygen Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3.1 Replacement of the 1158 Transducer . . . . . . . . . . . . . . . . . . 2.3
2.3.2 Replacement of the measuring Cell . . . . . . . . . . . . . . . . . . . 2.4
2.3.3 Adjusting the Transducer Gain . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.4 Replacing the Thermal Fuse Assembly and/or Heater Disc . 2.6
2.4 Servicing the Infrared Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.4.1 Removal of the Infrared Transducer . . . . . . . . . . . . . . . . . . . 2.7
2.5 Checking the Analogue Outputs and Display. . . . . . . . . . . . . . . . . . . . 2.8
2.5.1 Checking the Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.5.2 Checking the Span . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6 Replacing the Flow Sensor (01800925) . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.7 Replacing the Power Supply Unit (PSU) . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.8 Replacing the Relay/Output PCB (01420906) . . . . . . . . . . . . . . . . . . . 2.11
2.9 Replacing the Main Control PCB (01420915). . . . . . . . . . . . . . . . . . . . 2.11
2.10 Replacing the Front User Interface PCB (01420904) . . . . . . . . . . . . . . 2.12
2.11 Replacing the Led Front Panel display (2553-7332). . . . . . . . . . . . . . . 2.13
2.12 Replacing the infra-red Interface PCB (01415930). . . . . . . . . . . . . . . . 2.13
2.13 Replacing the Internal Pump (S1420940). . . . . . . . . . . . . . . . . . . . . . . 2.14
2.14 Replacement Plumbing Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
2.14.1 01440D1FTX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
2.14.2 01440D1STD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
3 SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1 Drawings Incluced in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

Table of Contents
01440D Light Industrial Gas Analyser Service Manual.ii

List of Tables
01440D Light Industrial Gas Analyser Service Manual. iii
Table 2.1 Requirements for Sample Conditions. . . . . . . . . . . . . . . . . . . . . . . 2.2
Table 2.2 SW3 Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Table 3.1 Spares for Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Table 3.2 Spares for General Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Table 3.3 Spares Infrared Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Table 3.4 Spare for Oxygen Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

List of Tables
01440D Light Industrial Gas Analyser Service Manual.iv

List of Figures
01440D Light Industrial Gas Analyser Service Manual. v
Figure 2.1 Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Figure 2.2 Transducer Pot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Figure 2.3 Range Changes and Alarm Function Setting . . . . . . . . . . . . . . . . 2.11
Figure 2.4 Component Layout, Front Panel PCB (01420904B) . . . . . . . . . . 2.13
Figure 2.5 01440D1FTX Plumbing Schematic . . . . . . . . . . . . . . . . . . . . . . . 2.14
Figure 2.6 01440D1STD Plumbing Schematic . . . . . . . . . . . . . . . . . . . . . . . 2.15
Figure 2.7 Interconnecting Wiring - 01440D1STD Oxygen Analyser . . . . . . 2.16
Figure 2.8 Interconnecting Wiring - 01440D1STD Carbon Dioxide Analyser 2.17
Figure 2.9 Interconnecting Wiring - 01440D1FTX Infra-Red Analyser . . . . . 2.18
Figure 2.10 Interconnecting Wiring - 01440D1FTX Oxygen Analyser. . . . . . . 2.19
Figure 2.11 Circuit Diagram, Front Panel PCB 01420904B . . . . . . . . . . . . . . 2.20
Figure 2.12 Circuit Diagram, Front Panel PCB 01420904B . . . . . . . . . . . . . . 2.21
Figure 2.13 Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

List of Figures
01440D Light Industrial Gas Analyser Service Manual.vi

01440D Light Industrial Gas Analyser Service Manual. 1.1
1 INTRODUCTION
1.1 Scope of this Manual
This manual covers the servicing of the Servomex 1440D series of gas analysers.
This range of analysers can measure up to two gases, based on one of two
measurement principles; a Servomex Single Beam Single Wavelength (SBSW)
infrared transducer and a Servomex paramagnetic oxygen transducer.
• Refer to the QuickStart Manual or the Technical Data Sheet for the latest
technical specification.
• Addresses for technical assistance and spares are given on the rear cover.
• For information on installation and operation, please refer to the QuickStart
Manual, reference part number 01440003D
• This manual includes WARNINGS, CAUTIONS and NOTES, which provide
information relating to the following:
About this Manual
Ref.: 01440/002D/5
Order as part no.: 01440002D
WARNINGS
• Hazards which could result in personal injury or death.
CAUTIONS
• Hazards which could result in equipment or property damages.
NOTES
• Alert the user to pertinent facts and conditions.

01440D Light Industrial Gas Analyser Service Manual.1.2
WARNING
• The electrical power used in this equipment is at a voltage high enough
to endanger life. Trained personnel should only perform servicing.
Service training is available from Servomex.
• Before carrying out servicing or repair the equipment should be
disconnected from the electrical power supply. Tests must be made to
ensure that disconnection is complete. Note that the relay contacts
may be supplied from a separate source of electrical power.
• It may be necessary to fault find with the electrical power connected.
Where this is necessary extreme caution should be exercised.
• The analyser may contain toxic, corrosive, flammable or asphyxiant
gases. Flush the analyser pipe work with clean dry air before
commencing work.

01440D Light Industrial Gas Analyser Service Manual. 2.1
2REPAIR
2.1 Test Equipment and Tools
The following test equipment and tools should be available to personnel responsible
for maintenance and calibration of the analyser.
• Volt/ohm/milli-amp meter of high input impedance, resolution 0.1mV.
• Flat blade screwdriver, 6mm width.
• Soldering iron 25W.
• De-solder braid or vacuum de-soldering tool.
• Potentiometer trimming tool.
• 2.5mm AF Allen Key
• 3mm AF Allen Key
• Open-ended wrench, width across flats 0.45 in (7/16in) British 3/16 nominal,
non-magnetic.
• Manometer, with a range exceeding 500mm Wg and a bore not exceeding
5mm.
• Calibration gases:
• Clean dry nitrogen with an oxygen concentration of less than 0.1% O2.
• 01440D1STD and 01440D1FTX: Clean dry air, nominal concentration 20.9 O2
(for oxygen analysers) or a certified calibration gas with a suitable CO2content
(for Carbon Dioxide analyser).
• 01440D1FTX only: A certified calibration gas with a suitable CO or CH4
content (for Infra-red analysers).

01440D Light Industrial Gas Analyser Service Manual.2.2
2.2 Sample condition requirements
Table 2.1 Requirements for Sample Conditions
Dew Point At least 5°C below ambient temperature.
Temperature Nominally at ambient temperature.
Inlet / Outlet
connections
Note: do not
restrict analyser
vent
01440D1STD
6.4mm (1/4”) OD tube.
01440D1STD +
BPR
01440D1FTX 3.2mm (1/8”) OD tube.
Inlet pressure
01440D1STD 1 to 10psig (7 to 70kPag).
01440D1STD +
BPR 17 to 20psia (120 to 140kPaa).
01440D1FTX Typically 0.3kPag (30mmWG) at 200ml/
min.
Flow Rate
01440D1STD 1 to 6l/min.
01440D1STD +
BPR 1 to 2l/min.
01440D1FTX USER LIMITED to 250ml/min. MAXIMUM.
Particulates
01440D1STD <3µm (micro meters), an internal,
replaceable, 0.6µm filter is fitted as
standard.
01440D1STD +
BPR
01440D1FTX The user must fit an external filter of
0.6µm.
Condition
01440D1STD Must not be flammable, toxic or corrosive,
as well as being clean and oil free.
01440D1STD +
BPR
01440D1FTX Must not be corrosive, as well as being
clean and oil free.

01440D Light Industrial Gas Analyser Service Manual. 2.3
2.3 Servicing the Oxygen Transducer
2.3.1 Replacement of the 1158 Transducer
1. Carefully remove the foam cover from the transducer and disconnect
the 16-way ribbon cable from the transducer, the sample connections
to the cell and the heater and thermal fuse wires from TB2 on front
the panel PCB.
2. Loosen the 4 off M4 nuts retaining the bracket that the transducer is
located on. Slide the whole assembly to one side and lift out from the
analyser.
With 01440D1FTX versions, when the assembly is free, unsolder the
Yellow and Black wires from the transducer cell connections. Move
the sleeves on the Pink and Grey wires and unsolder them from the
yellow and black wires from the transducer PCB.
3. Unscrew the transducer from the bracket by the 3 off screws located
on the underside of the bracket, then remove the remaining insulation
and the 3 off M4 pillars.
4. Remove the thermal fuse and heating element, from the underside of
the transducer, being careful not to damage it.
5. Installation is the reverse of the removal process. Ensure thermal
fuse and heater are correctly reconnected. For wiring see Figure 2.7
(or 2.10 for FTX version).
With 01440D1FTX versions, the Yellow and Black wires to the cell on
the new transducer must be unsoldered and then resoldered to the
Pink and Grey wires from the Protection PCB (connect Yellow to Pink
and Black to Grey). Replace the sleeves and fit a cable tie to secure
them.
The Yellow and Black wires from the Protection PCB must be
soldered to the transducer cell connections (Yellow to the connection
marked with yellow spot).
WARNING
• The opening of covers or removal of parts, except those to which
access can be gained by hand, may expose electrical terminals.
Ensure power is disconnected before working on the analyser.
NOTE
• Due to the strong magnetic field, which exists around the transducer, it
is advisable to remove wristwatches if worn when servicing the oxygen
transducer.

01440D Light Industrial Gas Analyser Service Manual.2.4
6. The pipe from the outlet of the flow sensor, if fitted, goes to the upper
gas connector on the cell.
7. Ensure pipework is leak tight. See Section 2.13.1 or 2.13.2.
8. Calibrate the analyser and check both the analogue output and
display reading. See Section 2.5.
2.3.2 Replacement of the measuring Cell
1. Remove the Transducer as described in section 2.3.1.
2. Unsolder the yellow and black wires from the measuring cell and with
an Allen key loosen the cell locking clamp screw. Grip the cell by the
sides and pull the cell out of the magnet frame. (note that the magnet
will exert a very strong holding force on the cell)
3. The replacement cell must be fitted the correct way up with the yellow
spot connection at the top. With the cell fully home tighten the cell
locking clamp screw and re-solder the wires to the cell with the yellow
wire to the connection marked with the yellow spot.
4. Refit the transducer, using the ‘O’ rings supplied with the new cell, the
reverse of section 2.3.1, but do not refit the foam cover at this stage.
Figure 2.1 Cell Replacement
MAGNET FRAME
MEASURING CELL
LOCKING DEVICE
MEASURING CELL
YELLOW SPOT

01440D Light Industrial Gas Analyser Service Manual. 2.5
5. Connect a nitrogen supply to the analyser, flow or pressure rates as
per section 2.2.
6. Ensure the electrical safety of all parts and power-up the analyser.
SETTING THE ZERO (follows on from cell change procedure)
7. Set the ZERO on the front panel to mid point (5 turns from either
end).
8. Adjust the ZERO pot on the top of the transducer, so that the display
reads 0 ±2% O2.
9. Set the ZERO on the front panel so that the display reads 0 ±0.1%
O2.
SETTING THE SPAN (follows on from setting the zero)
10. Adjust the FINE SPAN pot on the top of the transducer fully
clockwise. The potentiometer will ‘click’ when it reaches the end.
11. Adjust the SPAN on the front panel fully clockwise.
12. Connect an air supply to the analyser, flow or pressure rates as per
section 2.2.
13. Adjust the COARSE SPAN pot on the top of the transducer, so that
the front panel displays a nominal 120% of air, approximately 25.1%
O2.
14. Adjust the SPAN on the front panel fully counter clockwise.
15. Adjust the FINE SPAN pot on the top of the transducer, so that the
display reads 93% of air, approximately 19.5% O2.
16. Refit the foam cover from transducer of the transducer and allow the
analyser to stabilise.
17. Adjust the SPAN on the front panel so that the display reads 20.9 ±
0.1% O2.

01440D Light Industrial Gas Analyser Service Manual.2.6
2.3.3 Adjusting the Transducer Gain
It may be necessary to adjust the Span of the transducer if the altitude of use
is greater than about 1200m (4000ft) above sea level.
1. Carefully remove foam cover from transducer.
2. Adjust the FINE SPAN pot on the top of the transducer fully
clockwise. The potentiometer will ‘click’ when it reaches the end.
3. Adjust the SPAN on the front panel fully clockwise.
4. Connect an air supply to the analyser, flow or pressure rates as per
section 2.2.
5. Adjust the COARSE SPAN pot on the top of the transducer, so that
the front panel displays a nominal 120% of air, approximately 25.1%
O2.
6. Refit the foam cover of the transducer and allow the analyser to
stabilise.
7. Adjust the SPAN on the front panel so that the display reads 20.9 ±
0.1% O2.
2.3.4 Replacing the Thermal Fuse Assembly and/or Heater Disc
1. Remove the Transducer as described in section 2.3.1.
2. If replacing the heater disc, remove the protective backing from the
new heater disc and press firmly onto the base of the transducer.
Ensure transducer base is clean.
3. Refit transducer as described in section 2.3.1. Refit the foam cover
of the transducer.
4. After replacing the thermal fuse assembly or heater disc, the
transducer temperature should be re-checked. Connect a voltmeter
to pins 7 and 8 (0V) on SK5. When the instrument has warmed up,
adjust RV1 on control PCB 1420/915 so that the reading is 323
±3mV.

01440D Light Industrial Gas Analyser Service Manual. 2.7
2.4 Servicing the Infrared Transducer
The Infrared transducer in the analyser is non-field serviceable. In the unlikely event
of failure, the transducer should be removed by following the procedure below and
returned to Servomex for repair or replacement.
A list of the IR transducers available is given in Section 3.4.
2.4.1 Removal of the Infrared Transducer
1. Remove the two M4 nut holding down the interface assembly
01415930.
2. Carefully ease the interface assembly (01415930) from the pin
connectors on the transducer PCB.
3. Disconnect the transducer pipes from the sampling system.
4. Loosen the 4 off M4 nuts retaining the bracket that the transducer is
located on. Slide the whole assembly to one side and lift out from the
analyser.
5. When the assembly is free, unscrew the transducer from the bracket
by the 3 off screws located on the underside of the bracket.
6. For the longer “off board” sensors only: slacken the two fixing screws,
which retain the Infrared bench to the side mounting plate. Utilise the
slot on the front fixing to remove the bench without completely
undoing the fasteners.
7. Remove the transducer PCB by squeezing the catches on the 4 off
PCB mounting supports, and gently pulling the board off the mounts.
8. Installation of the new transducer is the reverse of the above
procedure.
WARNING
• The opening of covers or removal of parts, except those to which
access can be gained by hand, may expose electrical terminals.
Ensure power is disconnected before working on the analyser.

01440D Light Industrial Gas Analyser Service Manual.2.8
9. Transducer pots must be wound fully clockwise, reference Figure 2.2.
2.5 Checking the Analogue Outputs and Display.
Ensure that the analyser has warmed up for at least 1 hour before calibration.
For oxygen units set range to the lowest O2concentration (usually range 2).
2.5.1 Checking the Zero
1. Connect a DVM across pins 8(-ve) and 15(+ve) on SK5.
2. With nitrogen connected to the inlet at the correct pressure and flow
(see section 2.1), the DVM should read 0.0000V ±0.0001V.
3. If not then adjust zero control behind flip down door on front panel.
(For oxygen units if zero is not achievable then the coarse zero will
need adjustment. See section 2.3.2. Setting the zero)
4. The instrument display should read ‘zero’% ±1 least significant digit.
Figure 2.2 Transducer Pot Adjustment
NOTE
• Calibration gas accuracy must be taken into consideration when
setting the zero and span. The figures in the following steps assume
pure N2and either air (for oxygen) or 100% FULL SCALE (Infra-red
transducers) span gas.
SET SPAN AND ZERO
FULLY CLOCKWISE