FujiFilm ZPA User manual

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
Rev. 2nd edition July, 2018

ii TN5A1191-E
PREFACE............................................................................................................................................. i
TABLE OF CONTENTS ....................................................................................................................ii
SAFETY INSTRUCTIONS ............................................................................................................... iv
1. STRUCTURE............................................................................................................................... 1
1.1 Analyzer* ........................................................................................................................................... 1
1.2 Optical unit......................................................................................................................................... 3
1.3 Wiring diagram .................................................................................................................................. 5
1) ZPA.................................................................................................................................................. 5
2) ZPB.................................................................................................................................................. 6
3) ZPG.................................................................................................................................................. 7
1.4 Internal piping diagram ...................................................................................................................... 8
1) ZPA.................................................................................................................................................. 8
2) ZPB.................................................................................................................................................. 9
3) ZPG................................................................................................................................................ 10
2. MAINTENANCE AND INSPECTION..................................................................................... 11
2.1 Light source unit* ............................................................................................................................ 11
2.2 Sector motor and sector.................................................................................................................... 12
2.3 Cell, cell window, and O-ring .......................................................................................................... 12
2.4 Detector unit (excluding O2sensor)* ............................................................................................... 13
2.5 Built-in O2sensor (magnetic type)................................................................................................... 14
2.6 Built-in O2sensor (galvanic type) .................................................................................................... 15
2.7 PCB .................................................................................................................................................. 15
1) Main board..................................................................................................................................... 15
2) AIO board ...................................................................................................................................... 16
3) Main power supply board .............................................................................................................. 16
4) Light source power supply board .................................................................................................. 16
2.8 LCD.................................................................................................................................................. 16
2.9 Switched-mode power supply (SMPS) ............................................................................................ 17
2.10 Operation keys ................................................................................................................................. 18
2.11 Solenoid valve* ................................................................................................................................ 19
2.12 Filter ................................................................................................................................................. 19
3. FACTORY MODE..................................................................................................................... 20
3.1 How to go to factory mode............................................................................................................... 20
3.2 Zero limit.......................................................................................................................................... 21
3.3 Range limit ....................................................................................................................................... 22
3.4 Calibration coefficient...................................................................................................................... 23
3.5 A/D conversion value*..................................................................................................................... 24
4. ERROR CRITERIA* ................................................................................................................. 25
5. TROUBLESHOOTING ............................................................................................................. 27
6. ADJUSTMENT FOR HEAT TREATMENT FURNACES ...................................................... 29
6.1 Method for span calibration by standard gas with the same composition as plant gas .................... 29
6.2 Method for span calibration by check gas........................................................................................ 30
7. MOISTURE INTERFERENCE ADJUSTMENT* .................................................................... 31
CONTENTS

TN5A1191-E iii
APPENDIX 1. MEASURING PRINCIPLE DIAGRAM ...............................................................32
APPENDIX 2. DATA FLOW DIAGRAM .....................................................................................33
APPENDIX 3. PCB COMPONENT LAYOUT..............................................................................34
Main board ..........................................................................................................................................34
AIO board............................................................................................................................................35
Amplifier board ...................................................................................................................................35
Main power board................................................................................................................................36
Light source power board*..................................................................................................................36
Those marked with asterisk are the items of which detail is not common among ZPA, ZPB, and ZPG.
Other items are common.

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.
Installation and Transport
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 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.
xAs the analyzer is heavy, the carry of the gas analyzer should be done by
at least two person to avoid pain or injury.
SAFETY INSTRUCTIONS

TN5A1191-E v
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.
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.

vi TN5A1191-E
Operation
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.
xStop the gas analyzer while the analyzer is slid out from the rack.
Otherwise, the gas analyzer may drop and cause injury.
xDo not open the cover of the gas analyzer during operation. If you touch
something inside, you may get burned or electrical shock.
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.
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.

TN5A1191-E vii
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.
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.

TN5A1191-E 1
1.1 Analyzer
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

2 TN5A1191-E
Part No. Part name Mount or not
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
1.2 Optical unit

4 TN5A1191-E
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

TN5A1191-E 5
1.3 Wiring diagram
1) 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）

6 TN5A1191-E
2) ZPB

TN5A1191-E 7
3) ZPG

8 TN5A1191-E
1.4 Internal piping diagram
1) 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
Gas components measured by each optical unit
No. of gases
to be
measured
Gases to be measured Optical unit 1 Optical unit 2
1 NO, SO2, CO2, CO, or CH4One of the left None
2 CO2and CO CO2and CO None
2 NO and CO NO CO
2 NO and SO2NO SO2
3 NO, SO2, and CO NO SO2and CO
4 NO, SO2, CO2, and CO NO and CO SO2and CO2

TN5A1191-E 9
2) 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
IN NC
SV2
NO
IN NC
Gas components measured by each optical unit
No. of gases
to be
measured
Gases to be measured Optical unit 1 Optical unit 2
1 NO, SO2, CO2, or CO One of the left None
2 CO2and CO CO2and CO None
2 NO and CO NO CO
2 NO and SO2NO SO2
3 NO, SO2, and CO NO SO2and CO
4 NO, SO2, CO2, and CO NO SO2
,
CO2
,
and CO

10 TN5A1191-E
3) 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
IN NC
SV2
NO
IN NC
Gas components measured by each optical unit
No. of gases
to be
measured
Gases to be measured Optical unit 1 Optical unit 2
1 NO, SO2, CO2, or CO One of the left None

TN5A1191-E 11
2.1 Light source unit
zRecommended replacement cycle:
ZPA and ZPB : 5 years
ZPG : 2 years
zPossible errors caused by the deterioration of this part:
a) Short circuit or disconnection of the hot wires of the light source
unit
Symptom: Error 1, display of dashes (----)
Check:
1. Turn off the analyzer.
2. Disconnect the power cables from of the light source unit.
3. Measure the resistance between two-pin terminals of the light
source unit.
If the resistance meets the following requirements, the light
source unit is normal.
ZPA, ZPB,
ZPG (CO2analyzer only) 36.5±2 
ZPG (excluding CO2analyzer) 6.2±0.3 
If the resistance is infinite, the wires are damaged.
Note that if the resistance is smaller than the above criteria, the reading drifts towards minus direction.
b) Filler gas leakage from the light source unit
Symptom: Unstable indication
Check: If, regardless there is no abnormality in any parts other than the light source, the measured value
output greatly fluctuates or drifts affected by the ambient air, it may be caused by the leakage of the
filler gas of the light source.
zReplacement
1. Disconnect a) the wires from two-pin terminals and b) the motor connector.
2. Remove two screws used to join the light source unit and the base plate.
3. Replace the light source unit.
4. Carry out zero calibration and span calibration.
2. MAINTENANCE AND INSPECTION

12 TN5A1191-E
2.2 Sector motor and sector
zRecommended replacement cycle:
ZPA and ZPB : 5 years
ZPG : 2 years
zPossible errors caused by the deterioration of this part:
a) Stop of motor rotation
Symptoms: Error 1, display of dashes (----)
Check: Turn on the analyzer, and check that the motor shaft rotates.
b) Unstable rotation
Symptoms: Error 1, reading fluctuation, or display of dashes (----)
Check: Turn on the analyzer, and check that you hear no abnormal
noise from the motor, for example, metallic rubbing noise or
rattling noise. If there is no abnormal noise, remove the light
source unit from the base plate, and turn on the analyzer to
directly check that the motor shaft and the sector rotate.
zReplacement
1. Disconnect a) the wires from two-pin terminals and b) the motor connector.
2. Remove two screws used to join the light source unit and the base plate.
3. Replace the light source unit.
4. Carry out zero calibration and span calibration.
2.3 Cell, cell window, and O-ring
zLifespan and recommended replacement period:
Cell and cell window can be used for years unless they are seriously contaminated or corroded. O-ring
should be replaced every two years.
zPossible troubles occur on this part:
a) Contamination of cell and/or cell window
Symptoms: display of dashes (----), drift, calibration error
Check: Disassemble the cell, and check the contamination inside the cell.
b) Break of the cell window
Symptoms: the reading won’t change, slow response, calibration error, reading fluctuation
Check: visually check the cell window.
zRemedies:
Cell: clean the cell. Refer to the instruction manual on how to clean the cell. If the deposits are not removed
or the cell is heavily corroded, replace the cell.
Cell window: clean the window. If the window is heavily contaminated or broken, replace it.
zReplacement:
Refer to the instruction manual. After cleaning, carry out zero and span calibration, and check the response
speed.
Light source motor unit
as viewed from cell side
Motor shaft
Check sector rotation
from here.