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XZR500 User’s Manual

97137 Issue 8, April 2017

MAINTENANCE

4.4

Replacement of the XZR500 Microcontroller Card

While the power is on, note down the values of all the parameters (see

Section 3.3.2). All settings and parameters will be lost when the faulty

microcontroller card is changed.

Turn off the power and disconnect the lead from the mains.

3. Disconnect

the

at cable from the microcontroller card.

Remove the faulty microcontroller card.

Fit the new microcontroller card.

6. Connect

the

at cable to the new card.

Plug the analyzer to the mains and switch the power on.

Restore the standard con

guration (see Section 3.3.2).

Re-set the parameter values you noted down.

10. Wait for few hours before adjusting the analyzer with test gas (see Section

3.3.3).

4.5

Replacement of Fuses

Replace the fuses according to the following chart:

Power Supply

F1 fuse (right)

F2 fuse (left)

230V

T 160 mA

T 1 A

115V

T 400 mA

T 2 A

Table 7

Fuse Replacement

T xxx mA means that a kick fuse must be used.

Содержание XZR500ST

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 77: ......

Страница 78: ...http www michell com...

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