Fuji Electric ZPA User manual

Service Manual
INZ-TN5A1191a-E
INFRARED GAS
ANALYZER
TYPE: ZPA, ZPB, ZPG

TN5A1191-E i
This service manual describes the infrared gas analyzer (Type: ZPA, ZPB, ZPG).
This service manual is intended for use with the instruction manual to help you in understanding maintenance and
inspection for the infrared gas analyzer (ZPA, ZPB, ZPG). However, the basic operation of the analyzer is not covered
in this manual.
This manual provides information about the parameter settings in the factory mode, adjustment and precautions for
parts replacement, and troubleshooting for the infrared gas analyzer (ZPA, ZPB, ZPG) which are not covered in the
instruction manual.
This service manual gives you useful hints to take immediate remedy for after-sales service.
xFirst read the instruction manual and 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.
xThe specifications of this analyzer will be changed without prior notice for further product improvement.
xModification 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.
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
xIt is prohibited to transfer part or all of this manual without Fuji
Electric's permission in written format.
xDescription in this manual will be changed without prior notice
for further improvement.
Request
©Fuji Electric Co., Ltd. 2013
Issued in June, 2013
Rev. 1st edition October, 2013

ii TN5A1191-E
PREFACE.............................................................................................................................................i
CONTENTS ........................................................................................................................................ii
CAUTION ON SAFETY ...................................................................................................................iv
1. STRUCTURE OF ANALYZER AND NAMES OF PARTS......................................................1
(1) Analyzer main unit (External/internal) .............................................................................................. 1
(2) Optical unit......................................................................................................................................... 3
(3) Connection of parts ............................................................................................................................ 6
1) Wiring diagram (ZPA)..................................................................................................................... 6
2) Wiring diagram (ZPB)..................................................................................................................... 7
3) Wiring diagram (ZPG)..................................................................................................................... 8
4) Internal piping diagram (ZPA)......................................................................................................... 9
5) Internal piping diagram (ZPB)....................................................................................................... 10
6) Internal piping diagram (ZPG) ...................................................................................................... 11
2. MAINTENANCE AND INSPECTION, AND REPAIR AND ADJUSTMENT AT REPLACEMENT
OF MEASURING UNITS ..............................................................................................................12
(1) Light source...................................................................................................................................... 12
(2) Sector motor and sector.................................................................................................................... 12
(3) Cell, cell window and O-ring........................................................................................................... 13
(4) Detector unit (except for O2sensor)................................................................................................. 13
(5) Built-in O2sensor (paramagnetic type)............................................................................................ 14
(6) Built-in O2sensor (galvanic cell type)............................................................................................. 15
(7) Printed circuit board (see printed board diagram at the back of the manual)................................... 15
1) Main board..................................................................................................................................... 15
2) AIO board...................................................................................................................................... 15
3) Main power board.......................................................................................................................... 16
4) Light Source power board ............................................................................................................. 16
(8) Liquid crystal display (LCD) ........................................................................................................... 16
(9) Power supply.................................................................................................................................... 17
(10) Operation Parts................................................................................................................................. 18
(11) Solenoid valve.................................................................................................................................. 19
3. FACTORY MODE.....................................................................................................................20
(1) How to go to factory mode............................................................................................................... 20
(2) Setting change items ........................................................................................................................ 21
1) Zero limit....................................................................................................................................... 21
2) Range limit .................................................................................................................................... 22
3) Calibration coefficient................................................................................................................... 23
(3) Setting value reference items ........................................................................................................... 24
1) A/D data......................................................................................................................................... 24
4. ERROR JUDGEMENT CRITERIA FOR ERROR CODES .....................................................25
5. TROUBLESHOOTING AND DATA COLLECTION .............................................................27
(1) Countermeasures against trouble ..................................................................................................... 27
1) Zero calibration can not be performed...........................................................................................27
2) Span calibration can not be performed.......................................................................................... 27
3) Drift ............................................................................................................................................... 27
CONTENTS

TN5A1191-E iii
4) Readings are high or low too much................................................................................................27
5) Readings are not increased.............................................................................................................27
(2) Data sampling at trouble...................................................................................................................28
6. ADJUSTMENT IN HEAT TREATMENT FURNACE.............................................................29
(1) Method for span calibration by standard gas with the same composition as plant gas.....................29
(2) Method for span calibration by check gas ........................................................................................30
7. Moisture interference adjustment (NO, SO2only)......................................................................31
APPENDIX 1. MEASURING PRINCIPLE DIAGRAM ............................................................ A-1
APPENDIX 2. SOFT FLOW DIAGRAM ................................................................................... A-2
APPENDIX 3. PRINTED BOARD DIAGRAM.......................................................................... A-3
Main board............................................................................................................................................. A-3
AIO board.............................................................................................................................................. A-4
Amplifier board ..................................................................................................................................... A-4
Main power board.................................................................................................................................. A-5
Light Source power board ..................................................................................................................... A-5

iv TN5A1191-E
First of all, read this “Caution on safety” carefully, and then use the analyzer in the correct way.
xThe cautionary descriptions listed here contain important information about safety, so they should always
be observed. Those safety precautions are ranked in 3 levels, “DANGER”, “CAUTION” and
“PROHIBITION”.
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.
PROHIBITION
Items which must not be done are noted.
Caution on installation and transport of gas analyzer
DANGER
xThis 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
xFor installation, observe the rule on it given in the instruction manual
and select a place where the weight of gas analyzer can be endured.
Installation at an unsuited place may cause turnover or fall and there is a
risk of injury.
xFor lifting the gas analyzer, be sure to wear protective gloves.
Bare hands may invite an injury.
xBefore transport, fix the casing so that it will not open. Otherwise, the
casing may be separated and fall to cause an injury.
xDuring installation work, care should be taken to keep the unit free from
cable chips or other foreign objects. Otherwise, it may cause fire, trouble
or malfunction of the unit.
CAUTION ON SAFETY

TN5A1191-E v
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.
xConnect pipes correctly referring to the instruction manual.
xExhaust should be led outdoors so that it will not remain in the locker
and installation room.
xExhaust 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.
xFor 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
xWiring work must be performed with the main power set to OFF to
prevent electric shocks.
xEnforce construction of class-3 grounding wire by all means.
If the specified grounding construction is neglected, a shock hazard or
fault may be caused.
xWires should be the proper one meeting the ratings of this analyzer. If
using a wire which cannot endure the ratings, a fire may occur.
xBe sure to use a power supply of correct rating. Connection of power
supply of incorrect rating may cause fire.
Caution on use
DANGER
xFor correct handling of calibration gas or other reference gases, carefully
read their instruction manuals beforehand. Otherwise, carbon monoxide
or other hazardous gases may cause an intoxication particularly.
CAUTION
xBefore leaving unused for a long time or restarting after left at such a
status for an extended length of time, follow the directions of each
instruction manual because they are different from normal starting or
shutdown. Otherwise, the performance may be poor and accidents or
injuries may be caused.
xDo not operate the analyzer for a long time with its door left open.
Otherwise, dust, foreign matter, etc. may stick on internal walls, thereby
causing faults.

vi TN5A1191-E
Caution on use
PROHIBITION
xDo not allow metal, finger or others to touch the input/output terminals
in the analyzer. Otherwise, shock hazard or injury may occur.
xDo not smoke nor use a flame near the gas analyzer. Otherwise, a fire
may be caused.
xDo not allow water to go into the gas analyzer. Otherwise, hazard shock
or fire in the analyzer may be caused.
Caution on maintenance and check
DANGER
xWhen doors are open during maintenance or inspection, be sure to purge
sufficiently the inside of the gas analyzer as well as the measuring gas
line with nitrogen or air, in order to prevent poisoning, fire or explosion
due to gas leak.
CAUTION
Be sure to observe the following for safe operation avoiding the shock
hazard and injury.
xRemove the watch and other metallic objects before work.
xDo not touch the analyzer with wet-handed.
xIf 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.
xDo not use a replacement part other than specified by the analyzer
maker. Otherwise, adequate performance will not be provided. Besides,
an accident or fault may be caused.
xReplacement parts such as a maintenance part should be disposed of as
incombustibles.
Others
CAUTION
xIf 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 analyzer is disassembled
carelessly, you may have a shock hazard or injury.

TN5A1191-E 1
(1) Analyzer main unit (External/internal)
27
2
1
6
18
5
11
22
17
17
35
35
16
29
29
29
36
36
16
22
4
14
28
26
9
34
7
21
19
20
12
10
10
10
13
6
3
8
A
A
B
D
D
B
C
C
E
E
F
G
F
G
9
34
10
10
10
32
25
33
31
23
24
15
30
1. STRUCTURE OF ANALYZER AND NAMES OF PARTS

2 TN5A1191-E
Mount or not
Part No. Part name ZPA ZPB ZPG
1 Case ass’y
2 Base
3 Front panel ass’y
4 Solenoid Valve (SV) ass’y none
5 Power supply mounting plate
6 Handle
7 Paramagnetic type O2sensor unit
8 Power switch
9 Pipe fuse
10 Fuse holder
11 Noise filter
12 Power inlet terminal
13 Power inlet
14 Key board
15 LCD
16 Triple gas port unit
17 Dust cap
18 Flow checker ass’y none
19 Galvanic cell type O2sensor unit
20 Galvanic cell type O2sensor socket
21 Galvanic cell type O2sensor plate
22 Ferrite core
23 Filling seal
24 Specification name plate
25 SSW board none
26 AO board
27 Main board
28 AIO board
29 DIO board
30 Commu board
31 Main power board
32 Power supply 1
33 Power supply 2 none
34 Power inlet (terminal) mounting plate
35 Filling plate none none
36 Hexagnal spacer

TN5A1191-E 3
(2) Optical unit
12
14
11
10
5
1
15
9
2
13
12
14
1
15
4
7
8
7
8
4
5
5
6
3
2

4 TN5A1191-E
13
14
14
4
7
8
7
8
4
5
5
6
11
10
5
1
15
9
3
12
2
13
12
14
13
12
14
1
15
4
7
8
7
8
4
5
5
6
3
2

TN5A1191-E 5
12
13
14
12
14
11
10
5
1
15
9
2
Part No. Part name Part No. Part name
1 Light source unit 8 Cell fixing block
2 LS power board 9 Block cell ass’y
3 Pipe cell ass’y 10 Window ass’y
4 Window ass’y 11 Block cell
5 O ring 12 Gas filter
6 Pipe cell 13 Filter
7 Cell mounting 14 Detector unit
15 Base plate

6 TN5A1191-E
(3) Connection of parts
1) Wiring diagram (ZPA)
Orange
Earth
（UF2028BZ-7997-3P-CT）
NL
Twistedpaircable
E
12
34
Fuseholder＆Fuse
Twistedpaircable
Yellow Red Black Brown
White
Blue
Wirecolor
（TQ500972）
Amplifierboard
34
CN16
Motor1
5
CN1
6
Cable
（Withmotor）
2 3 4CN5 1
CN9
+15V GND2 -15V GND2 +5V GND1 GND1 +5V
（TQ501056C1）
Mainboard
（R77501N3）
Powerswitch
（Secondarysied）
（Primaryside）
（TQ500870P1）
CN2
52
34
CN1
3
1
19 18
20 19 18
FFCcable
123
（TQ500909P1）
21
Displayunit
（TQ500910P1）
79
10
8456 123
379
10
865421
Keyboard
（TQ500974C1）
321
（TQ500973C1）
Commuboard
Motor2
5
6
Cable
（Withmotor）
2 3
4
CN6
1
CN1
12
CN8
19 20
12
19 20
（TQ501057）
AIOboard
CN2
4
DIOboard2
（TQ501059C1）
DIOboard3
（TQ501059C1）
123
（Galvaniccelltype）
O
2
20
Cable
（TQ500862C1）
Cable
（TQ500911C1）
Cable
（TQ500863C2）
CN1
CN1 CN1
12
910
1
2
9
10
12
910
12
910
1
2
9
10
1
2
9
10
1
2
9
10
12
910
（TQ500869C2）
Flatcable
（TQ500869C2）
Flatcable
（TQ500869C2）
Flatcable
CN12 CN13
CN14 CN15
Flatcable
（TQ500865C1）
1234
CN16
12
12
CN3
ToMainboardCN16
（TQ501056C1）
Cable
（TQ500864C1）
Cable
（TQ500859C1）
CN2
CN3 CN7
CN2
CN1
12
CN10
2 1
Green
3 4 2 1 6 7 8 5
（TQ400893C1） （TQ500918C1）
O
（Paramagnetictype）
2
0-1V
GND
POWERSUPPLY（+）
POWERSUPPLY（-）
Ferritecore（GRFC-5）
NL
E
Powerinlet＆Inletsideholder
（R77419N8／CM-42）
1
1a
2
2a
CN1
N
3
1
L
ACINPUT
CN2 4
321
Twistedpaircable
Powersupply1
ZWS50BAF-24
（R79254N21）
CN1 4321
8
V1
Mainpowerboard
（TQ500854C1）
7654321
G1 G2V2 G3
2
1
CN3
2
1
CN2
Lightsourceboard1
TQ500855
C1=6W
1 2
CN1
Lightsource1
TQ500855
C1=6W
1 2
CN1
DIOboard1
（TQ501059C1）
37654 21
CN1
3 2 5 6 1 7
37654 21 37654 21
CN2
37654 21
CN1
37654 21 37654 21
CN2
5
FG
Cable
（TQ500863C2）
Cable
（TQ500863C1）
Ferritecore（GRFC-5）
（Toearth）
（TQ500868C1）
（JWA2110-0063FC）
（TQ500869C2）
Flatcable
Twistedpaircable
（TQ500866C1）
Twistedpaircable
（TQ500866C1）
（R79181N13） （R79181N13）
（R77419N4／CM-11(C245)）
（R75867N24／F-400-01B2） （R75796N17／0213-002MXP(2A)）
（CablefromNoisefilter）
（TQ500931P103／Brown）
（TQ501195P2orP12）
（Blue）
（CablefromNoisefilter／Brown）
Cable
（TQ500861C2）
Cable
（TQ500861C1）
（TQ500931P101,Green／Yellow）
（TQ501195P1orP11）
Cable
（TQ500867C1）
Powersupplycordrockholder（R77419N9／CM-42A）
Cable（withLCD）
1
2
CN2
Lightsource2
1
2
CN2
Twistedpaircable
（TQ500866C2）
Twistedpaircable
（TQ500866C2）
Lightsourceboard2
Cable（TQ400907C1）
CN4
（Tobasecellspacer）
（TQ500972）
Amplifierboard
（TQ500972）
Amplifierboard
（TQ500972）
Amplifierboard
CN1
CN1
CN2
for1st
component
for2nd
component
for3rd
component
for4th
component
Powersupply
terminal
block （O2sensoroptional,selectgalvaniccell
typeorparamagnetictype）
（Selectfor3rd&4thcomponent,
accordingtothespecification）
（SelectDIO1,2,3
boards,accordingto
thespecifications）
（Selectfor2ndcomponent
accordingtothespecification）
External
O2
Noise
filter
（TQ500930P16／RSEL-2002W）
or
（R79155N56／MR-2021）

TN5A1191-E 7
2) Wiring diagram (ZPB)
NL
E
21
43
Twistedpaircable
34
CN16
5
CN1
6 2 3 4CN5 1
CN9
+15V GND2 -15V GND2 +5V GND1 GND1 +5V
（TQ501056C1）
Mainboard
（R77501N3）
Powerswitch
CN2
52
34
CN1
3
1
19 18
20 19 18
123
（TQ500909P1）
21
（TQ500910P1）
79
10
6548123
379
10
865421
Keyboard
（TQ500974C1）
321
（TQ500973C1）
5
6
2 3
4
CN6
1
CN1
12
CN8
19 20
12
19 20
（TQ501057）
AIOboard
CN2
4
123
O
2
20
Cable
（TQ500862C1）
Cable
（TQ500911C1）
Cable
（TQ500863C2）
CN1
CN1 CN1
12
910
1
2
9
10
12
910
12
910
1
2
9
10
1
2
9
10
1
2
9
10
（TQ500869C2）
Flatcable
（TQ500869C2）
Flatcable
（TQ500869C2）
Flatcable
CN12 CN13
CN14 CN15
Flatcable
（TQ500865C1）
12 34
CN16
12
12
CN3
（TQ501056C1）
Cable
（TQ500864C1）
Cable
（TQ500859C1）
CN2
CN3 CN7
CN2
CN1
12
CN10
2 1
3 4 2 1 6 7 8 5
O
2
0-1V
GND
POWERSUPPLY（+）
POWERSUPPLY（-）
NL
E
1
1a
2
2a
CN1
N
3
1
L
ACINPUT
CN2 4
321
Powersupply1
ZWS50BAF-24
（R79254N21）
CN1 4321
8
V1
Mainpowerboard
（TQ500854C1）
7654321
3G2V2G1G
2
1
CN3
2
1
CN2
37654 21
CN1
3 2 5 6 1 7
37654 21 37654 21
CN2
37654 21
CN1
37654 21 37654 21
CN2
2 1
CN3
2 1
CN2
CN1
（TQ500975C1）
SSWboard
CN1
N
1
L
ACINPUT
Powersupply2
LFA10F-12
（R79277N33）
Cable（selectNoDIOoptions）
（TQ500863C1）
FG
1 2
1
2
3
1245673
CN4 CN2
3 5
5
FG
SV1 SV2
DC12V
GND
DC12V
GND
withSV（SolenoidValve）1
withSV（SolenoidValve）2
Cable
（TQ500863C1）
Cable
（TQ500863C2）
Cable
（TQ500863C1）
Cable（TQ500978C1）
Ferritecore（GRFC-5）
Twistedpaircable
（TQ400915C1）
（JWA2110-0063FC）
（TQ500869C2）
Flatcable
Twistedpaircable
（TQ500866C1）
Twistedpaircable
（TQ500866C1）
）1C709004QT（elbaC
（R79181N13） （R79181N13）
（CablefromNoisefilter）
（TQ500930P103／Brown）
（TQ501195P2,orP12）
（Blue）
（CablefromNoisefilter／Brown）
（TQ500930P101,Green／Yellow）
（TQ501195P1,orP11）
（TQ400893C1） （TQ500918C1）
Cable
（TQ500861C2）
Cable
（TQ500861C1）
Cable
（TQ500867C1）
TQ500855
C1=6W
1 2
CN1
TQ500855
C1=6W
1 2
CN1
1
2
CN2
1
2
CN2
（TQ500866C2）
（TQ500866C2）
12
910
Fuseholder＆Fuse
（R75867N24／F-400-01B2） （R75796N17／0213-002MXP(2A)）
DIOboard2
（TQ501059C1）
DIOboard3
（TQ501059C1）
DIOboard1
（TQ501059C1）
CN4
Lightsourceboard1 Lightsourceboard2
Lightsource1 Lightsource2
Twistedpaircable
Twistedpaircable
Powerinlet＆Inletsideholder
（R77419N8／CM-42） （R77419N4／CM-11(C245)）
straptnemhcatta／）A24-MC／9N91477R（redlohkcordrocylppusrewoP
（UF2028BZ-7997-3P-CT）
（TQ500870P1）
Earth
（Tobasecellspacer）
Twistedpaircable
（Secondarysied）
（Primaryside）
Ferritecore（GRFC-5）
（Toearth）
（TQ500972）
Amplifierboard
（TQ500972）
Amplifierboard
（TQ500972）
Amplifierboard
（TQ500972）
Amplifierboard
Motor2
Cable
（Withmotor）
Motor1
Cable
（Withmotor）
Orange
Yellow Red Black Brown
White Blue
Wirecolor
Green
ToMainboardCN16
Commuboard
Displayunit
Cable（withLCD）
FFCcable
（Galvaniccelltype）
（Paramagnetictype）
CN1
CN1
CN2
Powersupply
terminal block
Noise
filter
for1st
component
for2nd
component
for3rd
component
for4th
component
（Selectfor3rd&4thcomponent,
accordingtothespecification）
（SelectDIO1,2,3
boards,accordingto
thespecifications）
to
Powersupply
1
External
O2
for
Reference
gas
for
Sample gas
to
Powersupply
2
（Selectfor2ndcomponent
accordingtothespecification）
（O2sensoroptional,selectgalvaniccell
typeorparamagnetictype）
（TQ500930P16／RSEL-2002W）
or
（R79155N56／MR-2021）

8 TN5A1191-E
3) Wiring diagram (ZPG)
NL
E
21
43
34
CN16
5
CN1
6 2 3 4CN5 1
CN9
+15V GND2 -15V GND2 +5V GND1 GND1 +5V
（TQ501056C1）
（R77501N3）
Powerswitch
（TQ500870P1）
CN2
52
34
CN1
3
1
19 18
20 19 18
123
（TQ500909P1）
21
（TQ500910P1）
79
10
6548123
379
10
865421
（TQ500974C1）
321
（TQ500973C1）
CN1
12
CN8
19 20
12
19 20
（TQ501057）
AIOboard
CN2
4
123
O
2
20
（TQ500862C1）
（TQ500911C1）
1
2
9
10
12
910
1
2
9
10
（TQ500869C2）
CN12 CN13
Flatcable
（TQ500865C1）
12 34
CN16
12
12
CN3
（TQ501056C1）
（TQ500864C1）
（TQ500859C1）
CN2
CN3 CN7
CN2
CN1
12
CN10
2 1
3 4 2 1 6 7 8 5
O
2
0-1V
GND
POWERSUPPLY（+）
POWERSUPPLY（-）
NL
E
（R77419N8／CM-42）
1
1a
2
2a
CN1
N
3
1
L
ACINPUT
CN2 4
321
ZWS50BAF-24
（R79254N21）
CN1 4321
8
V1
（TQ500854C1）
7654321
3G2V2G1G
2
1
CN3
2
1
CN2
37654 21
CN1
3 2 5 6 1 7
37654 21 37654 21
CN2
37654 21
2 1
CN3
2 1
CN2
CN1
（TQ500975C1）
CN1
N
1L
ACINPUT
LFA10F-12
（R79277N33）
（TQ500863C1）
FG
1 2
1
2
3
1245673
CN4 CN2
3 5
5
FG
SV1 SV2
DC12V
GND
DC12V
GND
（TQ500863C1）
Cable
（TQ500863C2）
Cable
（TQ500863C1）
Cable（TQ500978C1）
Ferritecore（GRFC-5）
（TQ400915C1）
（JWA2110-0063FC）
Twistedpaircable
（TQ500866C1）
）1C709004QT（elbaC
（R79181N13） （R79181N13）
（R77419N4／CM-11(C245)）
（CablefromNoisefilter）
（TQ500931P103／Brown）
（TQ501195P2）
（Blue）
（CablefromNoisefilter／Brown）
（R351171R25YM）
（TQ400893C1） （TQ500918C1）
（TQ500861C2）
（TQ500861C1）
（TQ500867C1）
TQ500855
C1=6W C2=12W
1 2
CN1
1
2
CN2
（TQ500866C2）
1
2
9
10
1
2
9
10
CN14 CN15
DIOboard2
（TQ501059C1）
DIOboard1
（TQ501059C1）
CN4
（UF2028BZ-7997-3P-CT）
Powerinlet＆Inletsideholder
straptnemhcatta／）A24-MC／9N91477R（redlohkcordrocylppusrewoP
Earth
Twistedpaircable
Ferritecore（GRFC-5）
（Toearth）
（TQ500931P101,Green／Yellow）
（Tobasecellspacer）
（Secondarysied）
（Primaryside）
Fuseholder＆Fuse
（R75867N24／F-400-01B2） （R75796N17／0213-002MXP(2A)）
Twistedpaircable
Twistedpaircable
Powersupply1
Mainpowerboard
Cable
Lightsourceboard1
Lightsource1
Twistedpaircable
（TQ500972）
Amplifierboard
Flatcable
Motor1
Cable
（Withmotor）
Mainboard
Displayunit
Cable（withLCD）
FFCcable
Keyboard
Cable
Cable
Commuboard
CN1
SSWboard
withSV（SolenoidValve）1
withSV（SolenoidValve）2
ToMainboardCN16
Powersupply2
Cable
Cable
Cable（selectNoDIOoptions）
Cable
Cable
Cable
（Galvaniccelltype）
（Paramagnetictype）
Orange
Yellow Red Black Brown
White Blue
Wirecolor
Green
CN1
CN2
Powersupply
terminal
block
Noise
filter
to
Powersupply
2
for1st
component
for
Reference
gas
for
Sample gas
（SelectDIO1,2
boards,accordingto thespecifications）
to
Powersupply
1
External
O2
（O2sensoroptional,selectgalvaniccell
typeorparamagnetictype）
（TQ500930P16／RSEL-2002W）
or
（R79155N56／MR-2021）

TN5A1191-E 9
4) Internal piping diagram (ZPA)
Optical unit 2 (IR Unit 2)
Optical unit 1
(IR Unit 1)
Sampling cell
Note)
2 cells may be used
by combination of
measuring component.
INLET1
OUTLET1
Sampling gas outlet
Sampling gas inlet
Built-in
O
2 sensor
Correspondence of measuring components and optical units
Measuring components Optical unit 1 Optical unit 2
1-component for NO, SO2, CO2, CO and CH4Each component None
2-components for CO2/CO CO2/CO None
2-components for NO/CO, NO/SO2NO
NO
CO
SO2
3-components for NO/SO2/CO NO SO2/CO
4-components for NO/SO2/CO2/CO NO/CO SO2/CO2

10 TN5A1191-E
5) Internal piping diagram (ZPB)
Optical unit 2 (IR Unit 2) Optical unit 1 (IR Unit 1)
Sampling cell
Sampling gas inlet
Reference gas inlet
Note)
2 cells may be used
by combination of
measuring
component.
INLET1REFERENCE OUTLET1
FL1
(Left)
FL2
(Right)
Sampling gas and
reference gas outlet
Built-in
O
2
sensor
SV1
NO
INNC
SV2
NO
INNC
Correspondence of measuring components and optical units
Measuring components Optical unit 1 Optical unit 2
1-component for NO, SO2, CO2, CO and CH4Each component None
2-components for CO2/CO CO2/CO None
2-components for NO/CO, NO/SO2NO
NO
CO
SO2
3-components for NO/SO2/CO NO SO2/CO
4-components for NO/SO2/CO2/CO NO SO2/CO2/CO

TN5A1191-E 11
6) Internal piping diagram (ZPG)
Sampling cell Optical unit 1 (IR Unit 1)
Sampling gas inlet
Reference gas inlet
INLET1REFERENCE OUTLET1
FL1
(Left)
FL2
(Right)
Sampling gas outlet and
reference gas outlet
Built-in
O
2
sensor
SV1
NO
INNC
SV2
NO
INNC
Correspondence of measuring components and optical units
Measuring components Optical unit 1 Optical unit 2
1-component for NO, SO2, CO2and CO Each component None

12 TN5A1191-E
(1) Light source
xRecommended period of replacement : 5 years
x1) Error mode
Error mode (1) : Short circuit in and disconnection from the light
source electrically heated wire.
Phenomena : Scale-out indication of analyzer, Error-1 occurs.
Check : Turn OFF the power of the analyzer and remove the
power cable connected to the light source.
Measure resistance between 2-pin terminals at the
light source, and the resistance value must be 36.5
±2ȍ(for ZPA, ZPB and ZPG-CO2) or 6.2 ±0.3ȍ
(for ZPG-NO,SO2and CO). If resistance values are
infinite, the light source may be broken. As the
resistance value is decreased, the indication will be
drifted in the minus direction.
Error mode (2) : Sealed gas in light source leaks.
Phenomena : Fluctuated Indication
Check : If the analyzer output is drifted due to ambient
conditions around the analyzer and other units are
normal except for the light source, sealed gas may
leak.
x2) Measures : If the light source is found defective, replace the light source motor unit.
x3) Replacement : To replace the motor unit, remove the cable between 2-pin terminals and motor connector.
Loosen 2 screws that fasten the light source motor unit to the optical base plate .
x4) Adjustment after replacement :
Perform zero and span calibration.
(2) Sector motor and sector
xRecommended period of replacement : 5 years
x1) Error mode
Error mode (1) : Motor rotation stop
Phenomena : Scale-out indication of analyzer , Error- 1 occurs.
Check : With the analyzer power ON, check that the shaft is
normally rotating as viewed from the motor.
Error mode (2) : Unstable rotation of a sector
Phenomena : Scale-out indication of analyzer: Error- 1 occurs.
Indication is fluctuated.
Check : With the analyzer power ON, check if unusual noise
is generated from the motor due to metal contact. If
no noise is heard, remove the light source motor unit.
Turn ON the power of the analyzer and check the
rotation of motor shaft and sector
x2) Measures : If the sector motor is found defective, replace the light
source motor unit.
x3) Replacement : To replace the motor unit, remove the cable between 2-pin terminals and motor connector.
Loosen 2 screws that fasten the light source motor unit to the optical base plate.
x4) Adjustment after replacement :
Perform zero and span calibration.
2. MAINTENANCE AND INSPECTION, AND REPAIR AND
ADJUSTMENT AT REPLACEMENT OF MEASURING UNITS
Light source motor unit
as viewed from cell side
Motor shaft
Check sector rotation
from here.
< Light source unit >
Measure the resistance
between terminals with cables
disconnected.

TN5A1191-E 13
(3) Cell, cell window and O-ring
xService life : Usable unless contamination or corrosion is excessive.
xRecommended period of replacement : 2 years with O-ring
x1) Error mode
Error mode (1) : Contamination of cell, mixture of foreign matter, and contamination of cell window
Phenomena : Scale-out indication, drift and calibration error occurred to analyzer
Check : Disassemble the cell to assure that the inside is clean.
Error mode (2) : Crack in cell window
Phenomena : No change in indication, slow response, calibration error, and indication fluctuation
Check : Perform a visual check of the cell window.
x2) Measures : Cell : Clean the inside of the cell (refer to the instruction manual for details).
Replace if the inside is exposed to excessive contamination or corrosion.
Cell window : Clean the cell window. Replace if the inside is exposed to excessive
contamination.
x3) Replacement : For replacement, refer to the instruction manual.
x4) Adjustment after clean and replacement :
Perform zero and span calibration and check response time for each component.
(4) Detector unit (except for O2sensor)
xRecommended period of replacement : 5 years
x1) Error mode
Error mode (1) : Sensitivity deterioration due to sealed gas leak
Phenomena : Calibration error and fluctuation in indication
Check : Check indication value at zero point
Check the indication value for each component on the
“Sensor Input Value” screen in the “Maintenance” mode. If
the light source is in normal condition and the cell is free of
contamination, the counter value indicates 35,000 to 55,000
(ZPA) or 350,000 to 550,000 (ZPB & ZPG) when zero gas is
supplied. If the counter value is below the range, sensitivity
can be degraded.
Error mode (2) : Damage to mass-flow detector.
Phenomena : Scale-out indication of analyzer , Error- 1 occurs.
Check : Turn OFF the power of the analyzer and disconnect the
connector connected from the detector to PC board. Measure
resistance between J1 – J4 and J2 – J3 of the amplifier board
on the detector. The measure values must be between 57:
and 63:. If the resistance value is fluctuated beyond the
specified range, the detector element may be damaged.
Note : Do not use measurement analyzer that allows a current of 2mA or more to be
supplied when measuring resistance, otherwise the element can be damaged.
Error mode (3) : Detector voltage, control failure
Phenomena : Calibration error and fluctuation in indication
Check : Check amplifier board and measure voltage between
DV1–GND of the terminal.
It is normal if the value is fill the voltage range table
below.
Detector
Check terminal Check voltage Detector type(*1)
+6.5±0.05 V CO-L, CO-M (for ZPA&ZPB), CO-F, CO-H
CO2-L, CO2-M, CO2-H
+8.08±0.1 V CH4-L, C H4-M, C H4-H
+12±0.1 V NO-H, CO-M (for ZPG)
DV1-GND
(detector
voltage) +9.05±0.1 V SO2-BH
*1㧦written in the lavel on the Detector.
Label
CO-L
Type