Michell Instruments XZR500ST Page 19 User Manual Download

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XZR500 User’s Manual

Michell Instruments

INSTALLATION

2. Place the outer probe (c) with the

ange gasket (b) according to the

drawing in

Figure 8. The gas inlet hole should face the process

ow.



Process flow

Gas inlet
hole





Process flow

Gas inlet
hole



Figure 10

Flange Gasket Orientation

Mount the probe head (e) with the

ange gasket (d) on to the tubular

counter-

ange (a). Secure the tubular counter

ange,

ange for outer

tube and

ange of the probe head together by secure nuts onto four bolts

on the counter

ange.

e. Probe head

d. Gasket for flange

b. Gasket for flange

a. Tubular

counter flange



Figure 11

Tubular Counter Flange Position

Summary of Contents for XZR500ST

Page 1: ...XZR500ST Oxygen Analyzer User s Manual 97137 Issue 8 April 2017...

Page 2: ...s information when contacting Michell Instruments for service purposes Analyzer Code Serial Number Invoice Date Location of Instrument Tag No Analyzer Code Serial Number Invoice Date Location of Instr...

Page 3: ...td and may not be copied or otherwise reproduced communicated in any way to third parties nor stored in any Data Processing System without the express written authorization of Michell Instruments Ltd...

Page 4: ...it 13 2 4 2 1 Connection to the Mains 14 2 4 2 2 Connection of the 0 4 20 Output 14 2 4 2 3 Connection of the Alarms 14 2 4 3 Connection of the Cable to the Sensor Head 14 3 OPERATION 16 3 1 Outputs 1...

Page 5: ...R500 MSRS Mounting Diagram 35 Figure 17 XZR500 Top View 36 Figure 18 XZR500 Side View 36 Figure 19 XZR500 Sensor Head Probe General Dimensions 50 Figure 20 Position of the Probe 52 Figure 21 Installat...

Page 6: ...55 Appendix G Mounting Options 59 G 1 Tubular Counter Flange and Insulators 59 G 2 Mounting Plate Dimensions 60 Appendix H Second 4 20 mA Output 62 Appendix I Automatic Calibration Optional 64 Append...

Page 7: ...ng pressure to be applied to the instrument The specified safe working pressure for all versions of this instrument is 10 bar Temperature Some parts of the analyzer can be at a very high temperature D...

Page 8: ...er s ppm parts per million T Temperature V Volt W Watts Warnings The following general warnings listed below are applicable to this instrument They are repeated in the text in the appropriate location...

Page 9: ...nd measurement we have developed a highly advanced and miniaturized oxygen sensor the MSRS This innovative sensor is at the heart of the XZR500 analyzer A key strength of the MSRS is that it has a bui...

Page 10: ...ium status of an internal metal oxide to provide a reference Therefore this built in metallic reference sensor does not require any reference gas The MSRS is a very small cylinder 3mm in diameter and...

Page 11: ...r tube 25 2 and the inner tube 23 During this process the gases contact the sensor through diffusion They then flow into the inner tube and to the flue via the bevelled edge The tubes are fitted so th...

Page 12: ...Unit provides the Human Machine Interface HMI for the XZR500 analyzer It is housed in a metal case with a screen and three touch buttons to allow access to menus Inside there is a motherboard a micro...

Page 13: ...Used to change the value Access key to the Calibration menu Value down key Used to change the value Access key to the Set up menu Table 1 Control Keys The analog output signal can be set in 0 20 mA or...

Page 14: ...n of the alarms high or low and hysteresis level the fail safe value output value sent by the electronics in case of general failure language English French or Italian the output analog signal the ass...

Page 15: ...wer requirements 230 or 115 V 15 10 50 60 Hz Operating ambient temperature and moisture Temperature from 0 to 55 C Relative moisture from 5 to 90 non condensing Maximum temperature of the sample gases...

Page 16: ...as ejector system with heating see Appendix F Rear insulation 1 3 3 Options Self calibration 115 V 60 Hz power supply RS232 interface see Appendix B 1 Transmits all data straight from to a computer te...

Page 17: ...the tubing situated between the stack and the probe head should be very well insulated or even heated If necessary Michell Instruments can manufacture a complete insulating cover for the outside part...

Page 18: ...s simple to set up Follow the instructions below 1 Weld the tubular counter flange a onto the stack Follow the orientation shown below to ensure that the probe head is set in a vertical position Slope...

Page 19: ...le Process flow Gas inlet hole Figure 10 Flange Gasket Orientation 3 Mount the probe head e with the flange gasket d on to the tubular counter flange a Secure the tubular counter flange flange for out...

Page 20: ...d edge see Figure 12 Process flow f Inner tube c Outer tube Bevelled edge Gas inlet hole Figure 12 Inner Tube Orientation 5 Place the locking ring h with the locking ring gasket g the rear nut i and t...

Page 21: ...fications The wires should be stripped to 8mm at each end There is a ground wire at one end of the supplied cable This end should be connected to the Control Unit 2 4 2 Connection of the Cable supplie...

Page 22: ...s used and terminated appropriately Follow the Table 4 wiring diagram pins 34 and 35 Connect the braid to the copper bar near the cable gland 2 4 2 3 Connection of the Alarms We suggest that shielded...

Page 23: ...using the end with 6 wires according to the Figure 14 wiring diagram Ref TC TC M F F Blue ___________ White ___________ Green ___________ Red ___________ Brown ___________ Brown ___________ Blue White...

Page 24: ...selectable to be either 0 20 mA or 4 20 mA The range is selectable between 0 and 25 3 1 2 Alarms The system has 3 alarm contacts 1 general failure alarm warning of furnace under temperature 20 C below...

Page 25: ...warm up the display shows The measured temperature value alternates with the message Low alarm during one second in every two seconds When the temperature is within 30 C of the required temperature af...

Page 26: ...r key cycles displayed parameters Minus key to enter the set up mode Plus key to enter the calibration mode 3 3 1 Visualization Menu The visualization menu displays the following parameters O2 concent...

Page 27: ...meter Oven temperature Your selection Visu Cal Set 5 Press and hold the Enter key to re enter the main selection menu Ambient temperature xx x C 6 Press the Enter key from the main selection menu to s...

Page 28: ...Press the Enter key from the main selection menu to show the fifth parameter Absolute pressure O2 Concentration xx xx 11 Repeating the process again will return to the default displayed parameter O2 c...

Page 29: ...trigger point for Alarm 2 Hysteresis 1 00 of the measurement range Sets relay hysteresis Fail safe value 0 00 of the output scale Sets the fault alarm If released the output signal switches to the sel...

Page 30: ...d Consequences All the parameters change to the default value The analyzer is no longer calibrated DO NOT change the value from 0 00 without consulting the factory Restoring to standard configuration...

Page 31: ...point and press the Enter key to confirm the selection and move to the next parameter NOTE If the alarm is set as Low alarm this page will display Low Alarm 1 accordingly NOTE This set point value is...

Page 32: ...Press the Enter key to confirm the selection The Access code page will appear 3 3 2 2 Access code 0 20 advanced settings Access code 0 20 At the Access code page use the and keys to enter the 0 20 co...

Page 33: ...ge the value without consulting the factory Press the Enter key to move to the next parameter High Adjust High adjust 2 00 This page shows the High adjust function that allows the user to adjust the r...

Page 34: ...e Press the Enter key to confirm the selection and move to the next parameter NOTE This value is in For example 0 01 equals 0 01 O2 Measurement range upper limit Rec range up 10 00 This page shows the...

Page 35: ...Enter key to move to the next parameter Offset pressure Offset pressure 8 00 This page displays the offset pressure The value is factory pre set and may vary for individual analyzers CAUTION Do not c...

Page 36: ...00 and press the Enter key to skip this procedure and go back to the default display If cell cleaning is required press the and keys to adjust the value to 0 10 and press the Enter key to start the pr...

Page 37: ...nties of the calibration gas when calculating the overall analyzer uncertainty Any uncertainty of the oxygen content of the calibration gas may introduce considerable error in the calibration of the a...

Page 38: ...next page Inject gas and then go to Test gas value under Set up menu Access code 0 12 to adjust it Please refer to details in Section 3 3 2 1 Press the Enter key to move to the next page Inject gas Ye...

Page 39: ...th a control gas Assure that the control gas has a different oxygen concentration from the gas used for calibration e g 2 if the calibration gas was at 8 The Calibration kit with both gases is availab...

Page 40: ...real live measurement of the purge process gas This procedure cleans all the calibration gas in the analyzer It takes about 3 minutes At the end of the purge the 4 20 mA output will be released Adjus...

Page 41: ...s but it can be stopped after 1 minute by pressing the key No effect No effect Purge sequence lasts 3 minutes but it can be stopped after 1 minute by pressing the key Your selection Visu Cal Set Injec...

Page 42: ...kwards and forwards the tip disk on the inner tube will sweep the inside of the outer tube Clean the inner tube with a long metal brush or abrasive cloth It should then be cleaned with hot water and a...

Page 43: ...Disconnect the sealing head Figure 4 3 Remove the MSRS Figure 4 5 Clean the sealing head if necessary Re insert the clean sealing head the new MSRS Ref 204 011 and new o rings Ref 108 006 see Figures...

Page 44: ...XZR500 User s Manual 36 97137 Issue 8 April 2017 MAINTENANCE Figure 17 XZR500 Top View Figure 18 XZR500 Side View...

Page 45: ...late Remove the furnace Place the new furnace you may have to enlarge the holes in the corner plate to allow the furnace wire s terminals to pass Replace the stop washers Replace the corner plate Brin...

Page 46: ...ller card 4 Remove the faulty microcontroller card 5 Fit the new microcontroller card 6 Connect the flat cable to the new card 7 Plug the analyzer to the mains and switch the power on 8 Restore the st...

Page 47: ...er card see Section 4 4 Furnace temperature Low alarm Value 2 The message Low alarm alternates every 2 seconds with the value of the temperature measured It will appear when the furnace temperature is...

Page 48: ...T Figure 7 or check that the test gas value in Access Code 0 12 is the same as the actual calibration gas value refer to Section 3 3 2 1 Faulty MSRS this must be replaced TC wire break General alarm 4...

Page 49: ...ce for flue MSRS sensor XZR500 SMP Spare MSRS sensor XZR500 209002 Complete Gasket Kit XZR500 KD Keyboard display with cable XZR500 205010 Earthing braid for XZR500 XZR500 201002 XZR500 Control Unit X...

Page 50: ...XZR500 User s Manual 42 97137 Issue 8 April 2017 APPENDIX A Appendix A Technical Specifications...

Page 51: ...l output Output Load Over 1000 Self diagnostics Included in readout Output Ranges Freely configured between 0 01 to 25 Alarms 2 alarms user adjustable 10W 1 fault alarm Display Resolution 0 1 in stand...

Page 52: ...XZR500 User s Manual 44 97137 Issue 8 April 2017 APPENDIX B Appendix B Configuration for the RS232 Port Optional...

Page 53: ...ort Optional RS232 interface features are Speed 9600 bauds No parity 8 bits 1 stop The wiring cable should be equipped with 2 DB9 female plugs and connected as follows pin 2 pin 2 pin 3 pin 3 pin 5 pi...

Page 54: ...es the alarms RECEIPT _ETA Display of calibration gas value XX XX E_ETA_X XX Sets calibration gas value X XX _STP Display of furnace temperature set point XXX XX E_STP_XXX XX Sets furnace temperature...

Page 55: ...XZR500 User s Manual Michell Instruments 47 APPENDIX C Appendix C Calculation of CO2...

Page 56: ...rned CO2 K2 20 9 O2 20 9 where K2 is absolute max CO2 Set K2 factor in Access code 0 20 pressing the and keys i e for coal capture 18 39 Consult Michell for K2 value When not otherwise specified CO2 f...

Page 57: ...XZR500 User s Manual Michell Instruments 49 APPENDIX D Appendix D XZR500 Sensor Head and Probe General Dimensions...

Page 58: ...Figure 19 XZR500 Sensor Head Probe General Dimensions Probe Version Outer Tube Dimensions Outer Diameter x Wall Thickness Inner Tube Dimensions Outer Diameter x Wall Thickness Stainless Steel 33 4 x...

Page 59: ...XZR500 User s Manual Michell Instruments 51 APPENDIX E Appendix E Back Flushing System Optional...

Page 60: ...he probe in place of the sealing screw a cable standard length 6 meters for connecting the electro valve A hose for compressed air standard length 6 meters For positioning the probe tubes see the draw...

Page 61: ...electro valve open for a longer time it is better to increase the frequency of cleaning If the electro valve stays open too long the flow of cold air would cool the inside of the probe and this might...

Page 62: ...XZR500 User s Manual 54 97137 Issue 8 April 2017 APPENDIX F Appendix F Heated Flue Gas Ejection System Optional...

Page 63: ...iagram of the installation follows The system comprises An XZR500 Sensor Head without inner probe tube An air ejector with adjustable flow placed at the sensor rear side It is heated and insulated An...

Page 64: ...adjust the set point at 200 C press the SET key and scroll with the scroll keys Cancellation of the alarms Press the SET key during 2 seconds Get to LCY enter code 1000 Press the SET key during 2 sec...

Page 65: ...d be used if the dust is minimal In the case of the ejector being completely clogged up it should be washed with hot water We advise that you have a complete ejector ref 205 021 as a spare In order to...

Page 66: ...XZR500 User s Manual 58 97137 Issue 8 April 2017 APPENDIX G Appendix G Mounting Options...

Page 67: ...g g g g g g g h h h h Figure 23 XZR500 Flange and Back Flange Optional g g h h h h h h h h h h h h h h g g g g A A 175mm 185mm 85 2 A MADE OF TWO HALF SHELLS ALUMINUM PROTECTIVE COVER ISOXAL 8 10 CLO...

Page 68: ...XZR500 User s Manual 60 97137 Issue 8 April 2017 APPENDIX G G 2 Mounting Plate Dimensions 45 45 M8 x4 at 90 55 40 100cm 39 3 100cm 39 3 4cm 1 6 30cm 11 8 Figure 25 Mounting Plate Dimensions...

Page 69: ...XZR500 User s Manual Michell Instruments 61 APPENDIX H Appendix H Second 4 20mA Output...

Page 70: ...utput is galvanic isolated 500 V Wiring of the 2nd 4 20 mA output on the connector on the electronic card is as follows terminal 27 4 20 mA terminal 28 4 20 mA h 27 28 Connector Connector 29 38 39 50...

Page 71: ...XZR500 User s Manual Michell Instruments 63 APPENDIX I Appendix I Automatic Calibration Optional...

Page 72: ...sequence This assumes that the calibration gas is connected permanently and the cal gas value is properly configured in the electronics The sequence can be initiated by either using the keys at on the...

Page 73: ...XZR500 User s Manual Michell Instruments 65 APPENDIX J Appendix J Quality Recycling Warranty Information...

Page 74: ...ctives Full information can be found on our website at www michell com compliance This page contains information on the following directives ATEX Directive Calibration Facilities Conflict Minerals FCC...

Page 75: ...XZR500 User s Manual Michell Instruments 67 APPENDIX K Appendix K Return Document Decontamination Declaration...

Page 76: ...micals YES NO Radioactive substances YES NO Other hazards YES NO Please provide details of any hazardous materials used with this equipment as indicated above use continuation sheet if necessary Your...

Page 77: ......

Page 78: ...http www michell com...

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