Michell Instruments XZR400A1, XZR400A2, XZR-400-WM, XZR-400-RM, XZR-400-BM User Manual
...
XZR400 Series
Oxygen Analyzers
User’s Manual
97472 Issue 3
August 2018
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© 2018 Michell Instruments
This document is the property of Michell Instruments Ltd. and may not be copied or
otherwise reproduced, communicated in any way to third parties, nor stored in any Data
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XZR400 Series User’s Manual
iv 97472 Issue 3, August 2018
Contents
Safety .............................................................................................................................. viii
Electrical Safety ......................................................................................................... viii
Pressure Safety .......................................................................................................... viii
Temperature Safety .................................................................................................... viii
Toxic Materials ........................................................................................................... viii
Repair and Maintenance ............................................................................................. viii
Calibration ................................................................................................................. viii
Safety Conformity ...................................................................................................... viii
Abbreviations ......................................................................................................................ix
Warnings ............................................................................................................................ x
1 INTRODUCTION ................................................................................................1
1.1 Operating Principle .......................................................................................... 2
1.2 The MSRS Technology...................................................................................... 3
2 INSTALLATION ..................................................................................................6
2.1 Unpacking the Analyzer ................................................................................... 6
2.2 Preparation ..................................................................................................... 6
2.3 Dimensions - XZR400A1 ................................................................................... 7
2.3.1 Installing the XZR400A1 .............................................................................. 7
2.4 Dimensions - XZR400A2 ................................................................................... 8
2.4.1 Installing the XZR400A2 .............................................................................. 9
2.5 Dimensions - XZR400A3 ................................................................................. 10
2.6 Dimensions - XZR400A4 ................................................................................. 10
2.7 Operating Requirements ................................................................................ 11
2.7.1 Environmental Requirements ..................................................................... 11
2.7.2 Electrical Requirements ............................................................................. 11
2.7.3 Gas Requirements .................................................................................... 11
2.7.4 Sampling System ...................................................................................... 11
2.8 Connections to the XZR400A1 ........................................................................ 12
2.8.1 Front Panel .............................................................................................. 12
2.8.2 Back Panel ............................................................................................... 12
2.8.3 Gas Inlet, Outlet and Bypass Gas Connections ............................................ 13
2.8.4 Electrical Terminal Block ............................................................................ 14
2.8.5 D-Sub DE9 plug ....................................................................................... 14
2.8.6 Pluggable 8 pins electrical connector ......................................................... 14
2.8.7 Sample Path ............................................................................................ 15
2.8.7.1 Signal Processing Path ........................................................................... 17
2.9 Connections to the XZR400A2 ........................................................................ 18
2.9.1 Gas Sample Inlet and Outlet Fittings .......................................................... 19
2.9.2 Electrical Terminal Block ............................................................................ 20
2.9.3 D-Sub DE9 plug ....................................................................................... 20
2.9.4 D-Sub DA15 plug ...................................................................................... 21
2.9.5 Sample Path ............................................................................................ 21
2.9.6 Signal Processing Path .............................................................................. 22
2.9.7 Alarm Outputs .......................................................................................... 22
2.10 Connections to the XZR400A3 ........................................................................ 23
2.10.1 Front Panel .............................................................................................. 23
2.10.2 Side Panel ................................................................................................ 24
2.10.3 Electrical Terminal Block ............................................................................ 25
2.11 Connections to the XZR400A4-Transportable .................................................... 26
2.11.1 Electrical Terminal Block ............................................................................ 27
2.11.2 D-Sub DE9 Type Plug ................................................................................ 27
XZR400 Series User’s Manual
Michell Instruments v
2.12 Mains Power Supply - XZR400A1, XZR400A3 & XZR400A4 ................................ 28
2.12.1 Analog Outputs Connections ..................................................................... 29
2.12.2 Alarm Output Connections ........................................................................ 30
2.13 Gas Connection ............................................................................................. 31
3 OPERATION ...................................................................................................32
3.1 General Operational Information ..................................................................... 32
3.2 Powering-up the System ............................................................................... 33
3.3 Warm-Up Period ............................................................................................ 34
3.4 Main Screen .................................................................................................. 36
3.5 Control Parameters Display ............................................................................ 37
3.5.1 Confi guration ........................................................................................... 38
3.5.2 Changing the Access Code ........................................................................ 39
3.6 The Main (Expert) Menu ................................................................................ 41
3.6.1 Analog 1 .................................................................................................. 42
3.6.2 Alarms ..................................................................................................... 43
3.6.3 Auto Adjustment (Optional) ....................................................................... 45
3.6.4 System .................................................................................................... 49
3.6.5 Total Pressure Correction (Optional)........................................................... 51
3.6.6 COMM ..................................................................................................... 52
3.6.6.1 RS232 .................................................................................................. 52
3.6.6.2 RS485 .................................................................................................. 52
3.6.7 Flow ........................................................................................................ 53
4 CALIBRATION ..................................................................................................54
4.1 Defi nitions .................................................................................................... 55
4.1.1 ADJUSTMENT / Calibration Screen Pages 3.2, 3.2.1, 3.2.2 & 3.2.3 ............... 56
4.1.2 Diagnosis of the MSRS Sensor Status - Screen pages 3.2.4 to 3.2.7 ............. 59
5 MAINTENANCE ................................................................................................62
5.1 Troubleshooting Guide / Failure Analysis ......................................................... 62
Tables
Table 1 XZR400 Series MSRS Assembly .....................................................................5
Table 2 RS232 Commands ..................................................................................... 75
XZR400 Series User’s Manual
vi 97472 Issue 3, August 2018
Figures
Figure 1 Zirconia Sensor Operating Principle ..............................................................3
Figure 2 MSRS Sensor..............................................................................................4
Figure 3 MSRS Dimensions .......................................................................................4
Figure 4 MSRS Wiring ..............................................................................................4
Figure 5 XZR400 Series MSRS Assembly ....................................................................5
Figure 6 Dimensions - XZR400A1 ..............................................................................7
Figure 7 Dimensions - XZR400A2 ..............................................................................8
Figure 8 Dimensions - XZR400A2 with External Pump Option ......................................9
Figure 9 Dimensions - XZR400A3 ............................................................................10
Figure 10 Dimensions - XZR400A4 ............................................................................10
Figure 11 Front Panel XZR400A1 ..............................................................................12
Figure 12 Back Panel XZR400A1 ...............................................................................12
Figure 13 Gas Circuit Diagram for Rack Version .........................................................13
Figure 14 Gas Circuit Diagram for Rack & Pump Version .............................................13
Figure 15 Electrical Terminal Block XZR400A1 ............................................................14
Figure 16 Sample Path XZR400A1 .............................................................................15
Figure 17 Sample Path with Pump Fitted XZR400A1 ...................................................16
Figure 18 Connections XZR400A2 .............................................................................18
Figure 19 Gas Circuit Diagram for XZR400A2 .............................................................19
Figure 20 Electrical Terminal Block XZR400A2 ............................................................20
Figure 21 XZR400A2 Sample Path .............................................................................21
Figure 22 Connections Front Panel - XZR400A3 .........................................................23
Figure 23 Connections Side Panel - XZR400A3 ...........................................................24
Figure 24 Electrical Terminal Block XZR400A3 ............................................................25
Figure 25 Connections Front Panel - XZR400A4 .........................................................26
Figure 26 Electrical Terminal Block XZR400A4 ............................................................27
Figure 27 D-Sub DE9 Plug - XZR400A4 ..................................................................... 27
Figure 28 Power Input Socket ..................................................................................28
Figure 29 Start-up Screen ........................................................................................34
Figure 30 Oven Temperature Screen .........................................................................34
Figure 31 Sample Flow Adjustment ...........................................................................35
Figure 32 Main Screen .............................................................................................36
Figure 33 Control Parameters Screen ........................................................................ 37
Figure 34 Main Menu Access Screen .........................................................................38
Figure 35 Main Menu Screen ....................................................................................38
Figure 36 Main Menu Screen ....................................................................................41
Figure 37 Analog Output Screen ...............................................................................42
Figure 38 Alarm Screen (Main) .................................................................................43
Figure 39 Alarm Screen (Alarm 1) .............................................................................44
Figure 40 Auto Adjustment Screen ...........................................................................45
Figure 41 Pressure Correction Screen .......................................................................51
Figure 42 Comm Screen ..........................................................................................52
Figure 43 Flow Correction Screen .............................................................................53
Figure 44 Calibration Procedure with XZR400A1 ........................................................54
Figure 45 Screen Page 3.2 ....................................................................................... 56
Figure 46 Screen Page 3.2.1 ....................................................................................56
Figure 47 Screen Page 3.2.2 ....................................................................................57
Figure 48 Screen Page 3.2.3 ....................................................................................58
Figure 49 Screen Page 3.2.8 ....................................................................................58
Figure 50 Screen Page 3.2.4 ....................................................................................59
Figure 51 Screen Page 3.2.5 ....................................................................................59
Figure 52 Screen Page 3-2-6 ....................................................................................60
Figure 53 Screen Page 3-2-7 ....................................................................................60
Figure 54 Pressure Correction Screen .......................................................................79
XZR400 Series User’s Manual
Michell Instruments vii
Appendices
Appendix A Technical Specifi cations .............................................................................. 67
Appendix B Modbus (RTU) over RS485 ......................................................................... 70
B.1 Port Confi guration ........................................................................ 70
B.2 Hardware Confi guration ............................................................... 70
B.3 RS485 Register Map .....................................................................71
Appendix C RS232 Serial Output .................................................................................. 74
C.1 Port Confi guration ........................................................................ 74
C.2 Hardware Confi guration ............................................................... 74
C.3 RS232 Command List ................................................................... 75
Appendix D Extended Operating Range - (Optional) ...................................................... 77
Appendix E Process Pressure Correction - (Optional) ....................................................79
E.1 Process Pressure Correction Input Connections .............................. 79
Appendix F Flow Fault Contact - (Optional) ................................................................... 81
F.1 Flow Fault Output Connections ..................................................... 81
Appendix G Commutable Scale (Auto-Ranging) .............................................................83
Appendix H Optional moisture sensor ...........................................................................85
Appendix I Quality, Recycling & Warranty Information ...................................................88
Appendix J Analyzer Return Document & Decontamination Declaration ..........................90
Figure 55 Main Page ................................................................................................85
Figure 56 Control Parameters Page ...........................................................................85
Figure 57 Main Menu ............................................................................................... 85
Figure 58 DP Sensor Page ........................................................................................86
XZR400 Series User’s Manual
viii 97472 Issue 3, August 2018
Safety
The manufacturer has designed this equipment to be safe when operated using the procedures
detailed in this manual. The user must not use this equipment for any other purpose than that
stated. Do not apply values greater than the maximum value stated.
This manual contains operating and safety instructions, which must be followed to ensure the safe
operation and to maintain the equipment in a safe condition. The safety instructions are either
warnings or cautions issued to protect the user and the equipment from injury or damage. Use
qualifi ed personnel and good engineering practice for all procedures in this manual.
Electrical Safety
The instrument is designed to be completely safe when used with options and accessories
supplied by the manufacturer for use with the instrument. The input power supply voltage is 90
to 264 V A C, 47/63 Hz. Refer to labels on instrument or calibration certifi cate.
Pressure Safety
DO NOT permit pressures exceeding 2 barg (29 psig) to be applied to the instrument. This maximum
pressure applies to all versions of the instrument.
Temperature Safety
During operation some parts of the instrument can be at very high temperatures.
Toxic Materials
The use of hazardous materials in the construction of this instrument has been minimized. During
normal operation it is not possible for the user to come into contact with any hazardous substance
which might be employed in the construction of the instrument. Care should, however, be exercised
during maintenance and the disposal of certain parts. Long exposure or breathing of the calibration
gases may be dangerous.
Repair and Maintenance
The instrument must be maintained either by the manufacturer or an accredited service agent. Refer
to www.michell.com for details of Michell Instruments’ worldwide offi ces contact information.
Calibration
The recommended calibration (or verifi cation) interval for the analyzer is 1 to 3 months depending
on the location and application in which the instrument is used.
Safety Conformity
This product carries the CE mark and meets the requirements of relevant European safety directives.
XZR400 Series User’s Manual
Michell Instruments ix
Abbreviations
The following abbreviations are used in this manual:
AC alternating current
A Ampere
barg pressure unit (=100 kP or 0.987 atm) gauge
°C degrees Celsius
°F degrees Fahrenheit
l/h liters per hour
l/min liters per minute
mA milliampere
min minute
ppm parts per million
psig pound(s) per square inch (gauge)
RS232 Modbus RTU serial data transmission standard
RS485 Modbus RTU serial data transmission standard
T temperature
V Volts
XZR400 Series User’s Manual
x 97472 Issue 3, August 2018
Warnings
The following general warnings listed below are applicable to this instrument. They are
repeated in the text in the appropriate locations.
Where this hazard warning symbol appears in the following
sections, it is used to indicate areas where potentially hazardous
operations need to be carried out.
Where this symbol appears in the following sections it is used to
indicate areas of potential risk of electrical shock.
Where this hot surface warning appears in the
following sections it is used to indicate areas where
the surface may potentially be dangerously hot.
XZR400 Series User’s Manual
Michell Instruments 1
INTRODUCTION
1 INTRODUCTION
The XZR400 Series Trace Oxygen Analyzer is designed to measure oxygen as an inpurity
in nitrogen, carbon dioxide, argon, helium or other inert gases. Analysis is both quick
and stable, utilizing our metallic sealed reference sensor (MSRS), with no requirement
for reference air.
There are 4 versions of the XZR400 analyzer. All are trace oxygen analyzers designed to
measure oxygen content in gas, between 0.01 ppm and 25% O2 (250,000 ppm).
Michell Instruments can supply the analyzer so that it is suitable for use with enriched
oxygen samples, including pure oxygen which may accidentally be introduced to the
sample. This cleaning service must be ordered at the time of purchase as special
components are required.
Extended operating ranges of 0 to 30% or 0 to 50% O2 can be supplied but will require
the analyzer to be cleaned for oxygen service.
Typical applications include:
Gas purity
Inerting or blanketing specifi c atmospheres
Combustion pre-mixing analysis
Respiratory or medical gas mixtures
Heat treatment
Four models of the XZR400 Series Oxygen Analyzer are available:
• A rack-mount model XZR400A1 (XZR-400-RM)
• A wall-mount model XZR400A2 (XZR-400-WM)
• A bench-mount model XZR400A3 (XZR-400-BM)
• A transportable model XZR400A4 (XZR-400-TP)
NOTE: The rack-mount version can be supplied with a built-in Easidew
sensor for measuring moisture in the range -100 to +20 °C
Sample gases at pressures up to a maximum of 2 barg (29 psig) can be accepted.
XZR400 Series User’s Manual
2 97472 Issue 3, August 2018
INTRODUCTION
The XZR400 Series includes the following front panel mounted items:
• Liquid crystal touchscreen display
• Flow adjustment valve
• Bypass control valve
1.1 Operating Principle
The analyzer operates on the zirconium oxide (zirconia) principle.
A sample of the gas to be measured is connected to the inlet port of the analyzer. The
sample gas fl ows through stainless steel pipework into the oven where the zirconia
oxygen sensor is located.
The sample fl ow should be set to between 1 and 3 l/hr using the electronic fl owmeter,
and sample and bypass needle valves on the front of the unit.
The sample gas circulates in the oven, which is heated to temperatures above 600°C,
necessary for the zirconia oxygen sensor to operate properly.
The Michell Metallic Sealed Reference Sensor (MSRS) generates a signal that is
proportional to the logarithm of the ratio of the oxygen partial pressure in the sample
to the oxygen partial pressure contained on the sealed reference side of the MSRS.
The analyzer provides the O2 concentration on the screen and via the 4-20 mA output
(optional on XZR400A3).
The optional Easidew Transmitter utilizes ceramic impeadance technology and further
details can be found on our website.
XZR400 Series User’s Manual
Michell Instruments 3
INTRODUCTION
1.2 The MSRS Technology
The zirconium oxide sensors are often referred to as the ‘high temperature’
electrochemical sensors. The principle is based on the Nernst principle [W. H. Nernst
(1864-1941)]. Zirconium oxide sensors use a solid state electrolyte and are stabilized
with yttrium oxide. The zirconium oxide probe is plated on opposing sides with platinum
which serves as the sensor electrodes. For a zirconium oxide sensor to operate properly,
it must be heated to approximately 600°C. At this temperature, on a molecular basis,
the zirconia lattice becomes porous, allowing the movement of oxygen ions from a
higher concentration of oxygen to a lower one, based on the partial pressure of oxygen.
The movement of oxygen ions across the zirconium oxide produces a voltage between
the two electrodes, the magnitude of which is based on the oxygen partial pressure
differential created by the reference and sample gas.
(T)
Zirconia
P
P
ref.
P
P
meas.
E
Figure 1
Zirconia Sensor Operating Principle
Within the oven the zirconium oxide MSRS is maintained at a temperature of 634°C.
The MSRS generates a signal that is proportional to the natural logarithm of the partial
pressure of oxygen p (O2).
E =
RT
4F
p (O
2
ref)
p (O
2
meas)
ln
With a known reference electrode and a constant temperature it is possible to defi ne
the partial pressure of oxygen using the Nernst-equation (see above).
The conductivity of zirconium oxide increases exponentially with temperature. The oxide
ion conductivity is optimized at temperatures above 600°C.
The MSRS technology allows the design of miniaturized zirconium oxide-based oxygen
sensors. The low mass and volume of the MSRS sensors have a positive effect on the
response time, which is one of the best available on the market.
XZR400 Series User’s Manual
4 97472 Issue 3, August 2018
INTRODUCTION
Figure 2
MSRS Sensor
Conventional zirconium oxide sensors require an air reference on one side of the sensor
with the sample on the other. This provides a known constant on one side. The Michell
MSRS does not require an air reference but instead utilizes a metal, and its oxide,
sealed in the zirconium sheath. This allows the sensor operation to be irrespective of
the ambient air quality and negates the requirement for a ‘zero’ calibration gas.
Figure 3
MSRS Dimensions
Temperature is a major component in the Nernst equation and can affect the accuracy
of some sensors. Placing the thermocouple in contact with the small sensor body helps
provide a very accurate temperature measurement. The complete design offers high
accuracy and repeatability.
02 Meas.
0
2
Ref. S Thermocouple
Figure 4
MSRS Wiring
XZR400 Series User’s Manual
Michell Instruments 5
INTRODUCTION
Figure 5
shows the MSRS and its S thermocouple installed in a 4-hole aluminum tube.
This confi guration has the part number XZR400-SMP. Any reference to the MSRS sensor
refers to this complete assembly which is considered solid state and non user-serviceable.
4
567
1
2
3
Figure 5
XZR400 Series MSRS Assembly
Item Description Wiring
1 MSRS
2 S-type thermocouple
3 4-hole alumina tube
4 Stainless steel connector
5O
2
reference wire blue wire
6 Common (O
2
meas. & - TC) white wire
7 Positive thermocouple (+TC) orange wire
Table 1 XZR400 Series MSRS Assembly
XZR400 Series User’s Manual
6 97472 Issue 3, August 2018
INSTALLATION
2 INSTALLATION
It is essential that the installation of the electrical and gas
supplies to this analyzer be undertaken by qualifi ed personnel.
2.1 Unpacking the Analyzer
Open the box and unpack carefully as follows. Save all the packing materials for the
purpose of returning the instrument for any warranty claims.
1. Remove the accessories (if ordered with the analyzer). If no accessories
have been ordered the box should contain the following items:
• XZR400 Series Oxygen Analyzer
• Power cable (except XZR400A2 model)
• User’s Manual
• Test result sheet
2. Remove the documentation and packing material.
3. Remove the analyzer and power cable.
2.2 Preparation
Carefully read the following guidelines before installing the analyzer. If you are not sure
about the installation conditions and other important factors please contact a Michell
Instruments’ Application Engineer or a Michell Instruments’ representative prior to the
installation.
The following list will help you to identify the recommended preparation steps:
• The analyzer should be installed at ambient temperatures between 0 and
+55°C (32 to +131°F).
• The location of the installation should allow access to the display.
• The location of the installation should not expose the analyzer to any
vibration.
• The cables should not be exposed to extreme temperatures and mechanical
strain.
XZR400 Series User’s Manual
Michell Instruments 7
INSTALLATION
2.3 Dimensions - XZR400A1
483mm
(
19”
)
362mm + 50mm for cable clearance
(14.25” + 1.96”)
3U
132mm
(5.2”)
XZR-400-RM
OXYGEN ANALYZER
Handles protrude
40mm (1.6”)
FLOW
ADJUSTMENT
BYPASS
Figure 6
Dimensions - XZR400A1
2.3.1 Installing the XZR400A1
Choose your installation site carefully following the recommendations above. Once
installed into the rack, there should be at least 2U clearance spaces from other equipment
above and below the instrument.
To install, follow the steps below:
1. If necessary, remove any covers from the rack cabinet to gain access to
the rear and side.
2. Slide the instrument into the rack and support its weight while the four
fi xing screws are inserted.
3. Ensure that the front panel of the instrument is fl ush and square with the
front of the rack and tighten the fi xing screws.
XZR400 Series User’s Manual
8 97472 Issue 3, August 2018
INSTALLATION
2.4 Dimensions - XZR400A2
274mm
(10.79”)
260mm
(10.24”)
220mm
(8.66”)
180mm
(7.09”)
152mm
(5.98”)
109mm
(4.29”)
172mm
(6.77”)
110mm
(4.33”)
30mm
(1.18“)
30mm
(1.18”)
30mm
(1.18”)
201mm
(7.91”)
236mm
(9.29”)
305mm
(12.01”
42mm
30mm
FLOW
ADJUSTMENT
BYPASS
CONTROL
GAS IN
GAS OUT
(1.18”)
(1.65”)
Figure 7
Dimensions - XZR400A2
XZR400 Series User’s Manual
Michell Instruments 9
INSTALLATION
274mm
(10.79”)
260mm
(10.24”)
220mm
(8.66”)
180mm
(7.09”)
152mm
(5.98”)
201mm
(7.91”)
20mm
(.79”)
60mm
(2.4”)
490mm
(19.29”)
305mm
(12.01”)
370mm
(14.57”)
390mm
(15.35”)
FLOW
ADJUSTMENT
BYPASS
CONTROL
470mm
(18.50”)
305mm
(12”)
53mm
(2.09”)
6mm (0.24”) tube
Analyzer power supply
Particulate
filter
Gas Inlet
6mm
4 x Ø 8.4
230 V AC
50 Hz
470mm
(18.50”)
Figure 8
Dimensions - XZR400A2 with External Pump Option
2.4.1 Installing the XZR400A2
Choose your installation site carefully following the recommendations above.
Follow the steps below:
1. Identify a clean and fl at surface on a wall or other vertical location e.g.
an instrument panel that is suitable to hold the analyzer.
2. Prepare the mounting site by drilling 4 holes in appropriate locations
corresponding to the dimension and location of the fastening holes at the
back of the analyzer enclosure.
3. Fix the analyzer vertically to the installation surface using suitable screws.
The gas connections and the electrical connections should be on the
bottom.
XZR400 Series User’s Manual
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INSTALLATION
2.5 Dimensions - XZR400A3
220mm
(8.6”)
290mm
(11.4”)
260mm
(10.2”)
203mm
(7.9”)
236mm
(9.3”)
Figure 9
Dimensions - XZR400A3
2.6 Dimensions - XZR400A4
420mm
(16.5”)
450mm
(17.7”)
300mm
(11.8”)
350mm
(13.8”)
Figure 10
Dimensions - XZR400A4
XZR400 Series User’s Manual
Michell Instruments 11
INSTALLATION
2.7 Operating Requirements
2.7.1 Environmental Requirements
The XZR400 Series should be installed in a clean, dust free environment. The
recommended ambient temperature is +20 to +25°C (+68 to +77°F) although the
instrument will operate, within specifi cation, inside the temperature band of 0 to +55°C
(32 to +131°F). It must be installed indoors in a non-condensing atmosphere.
2.7.2 Electrical Requirements
The analyzer requires the following electrical supply:
90 to 264 V AC, 47/63 Hz
There are 2 concentration alarm relays. The output contacts are normally open and
potential free. The relay switching capability is 10 W max (up to 100 V or up to 0.5 A).
2.7.3 Gas Requirements
To ensure that the sample gas is properly conditioned a
sampling system might be required.
Contact Michell Instruments if you wish to order a suitable
sampling system.
The gas must be clean, dry and oil mist free with the pressure up to a maximum of 2
barg (29 psig) and with particle size < 3 m.
The analyzer is not suitable for samples with hydrocarbons
present. These will combust on the cell and consume oxygen
molecules.
2.7.4 Sampling System
Depending upon the application a sampling system may be used to cope with high
pressure samples, samples with contamination or outdoor installations. The sampling
system may include components such as fi lters, pressure gauges, by-pass loops,
calibration inlet, pressure regulators and sample pumps - all installed on a panel, or in
an enclosure.
It is recommended that a stainless steel construction is used for all parts that will be in
contact with the gas.
Please consult Michell Instruments if a sampling system is required. Install the sampling
system as close as possible to the XZR400 Series analyzer to ensure the best possible
measurement results.
NOTE: Michell Instruments can provide a suitable sampling system when
delivering the analyzer. Contact a Michell Instruments’ Application Engineer
for more information.
XZR400 Series User’s Manual
12 97472 Issue 3, August 2018
INSTALLATION
2.8 Connections to the XZR400A1
2.8.1 Front Panel
ABC
Item Description
A Touchscreen LCD
B Flow adjustment needle valve
C Bypass control needle valve
Figure 11
Front Panel XZR400A1
2.8.2 Back Panel
An electrical connection terminal is provided for signal and alarm connections.
Item Description
A Inlet fi tting for gas sample to be analyzed.
B Outlet fi tting for gas sample output bypass.
C Outlet fi tting for gas sample to be analyzed.
D Manufacturer's plate.
E Mains socket (90-132 / 187-264 V AC, 47/63 Hz).
F On/Off button.
G Housing for analyzer's 2 x electrical protection fuses
(250 V AC, 6.3 A)
H Housing for solenoid valve's electrical protection fuses (250 V AC, 3.15 A).
Only fi tted on the rack with automatic setting option.
J Optional connector for the automatic setting option.
K Optional D-sub DE9 male plug (RS232 port).
L Electrical connector.
Figure 12
Back Panel XZR400A1
XZR400 Series User’s Manual
Michell Instruments 13
INSTALLATION
2.8.3 Gas Inlet, Outlet and Bypass Gas Connections
The fl uidic system comprises 2 fl ow control valves (sensor fl ow and by-pass fl ow), an
electronic fl ow meter and a sensor. The gas connections are stainless steel Swagelok
1/8" quick connecting couplers, which guarantee a perfect seal and easy removal.
The evacuation of the analyzed sample must be carried out at
atmospheric pressure, otherwise the total pressure adjustment
option is required.
The measurement of hazardous gas samples require the
analyzer's outlet to be outside the analysis area and must be in
accordance with local regulations.
Sensor flow
adjustment
Sensor
Electronic
flow meter
Gas outlet
bypass
sample
Analyzed
gas
outlet
Bypass flow
adjustment
Inlet for gas
to be
analyzed
Figure 13
Gas Circuit Diagram for Rack Version
Sensor flow
adjustment
Sensor
Pump
Electronic
flow meter
NO
Solenoid
valve
NC
Solenoid
valve
Gas outlet
bypass
sample
Analyzed
gas
outlet
Bypass flow
adjustment
Inlet for gas
to be
analyzed
Figure 14
Gas Circuit Diagram for Rack & Pump Version
XZR400 Series User’s Manual
14 97472 Issue 3, August 2018
INSTALLATION
2.8.4 Electrical Terminal Block
1 2 3 4 5 6 7 8 9 10111213141516
Item Function
1 (+) 4-20 mA Output No 1. Measurement proportional to the chosen O
2
scale.
2 0 V from the 4-20 mA Output No 1 & 2.
3 (+) 4-20 mA Output No. 2. Measurement proportional to the chosen 0
2
scale.
4-5 General fault alarm dry contact (250 V AC, 2 A or 30 V DC, 2 A on resistive load.
6-7 Alarm No. 1 dry contact terminal (250 V AC, 2 A or 30 V DC, 2 A resistive load).
Function mode (positive, normal) and hysteresis can be confi gured by setting the
parameters.
8-9 Alarm No. 2 dry contact terminal (250 V AC, 2A or 30 V DC, 2A resistive load).
Function mode (positive, normal) and hysteresis can be confi gured by setting the
parameters.
10-11 Dry contact terminal for fl ow alarm option (250 V AC, 2 A or 30 V DC, 2 A on
resistive load).
12 (+) 4-20 mA input. Option process pressure correction input.
13 (0V) 4-20 mA input. Option process pressure correction input.
14 RS485 Data +/A.
15 RS485 Data -/B.
16 RS485 0 V.
Figure 15
Electrical Terminal Block XZR400A1
2.8.5 D-Sub DE9 plug
This optional D-Sub DE9 type male plug (9 pin) is used to connect an RS232 port.
2.8.6 Pluggable 8 pins electrical connector
This optional connector allows the connection of terminals for automatic analyzer
calibration.
XZR400 Series User’s Manual
Michell Instruments 15
INSTALLATION
2.8.7 Sample Path
The MSRS sensor is placed inside an oven in which the gases to be analyzed are
circulated. The oven consists of a gas inlet head and a outlet plate. 3 Viton O-rings
ensure the sealing of this device (2 for the inlet and 1 for the outlet).
The internal sample path consists of:
• 2 fl ow control valves: sensor fl ow and by-pass fl ow
• 1 sealing head
• 1 outlet plate
• 1 oven tube
• 1 electronic fl ow meter
• 1 MSRS sensor
• 3 Swagelok 6mm stainless steel bulkhead unions (1 gas inlet and 2
gas outlets) - on the rear panel
XZR400A1
Sensor flow adjustment valve
O2 sensor
By-pass flow adjustment valve
Barometric pressure sensor
Ɨ” bulkhead union Ɨ” bulkhead unionƗ” bulkhead union
Sampling gas inlet
Electronic flowmeter 0-12 l/h
Sampling gas outletSampling gas outlet
Figure 16
Sample Path XZR400A1
XZR400 Series User’s Manual
16 97472 Issue 3, August 2018
INSTALLATION
XZR400A1 WITH INTERNAL PUMP:
• 3 Swagelok 6mm stainless steel bulkhead unions (1 gas inlet and 2
gas outlets) - on the rear panel
• 1 sampling pump (3 l/min)
• 2 electrovalves
XZR400A1
Sensor flow adjustment valve
O2 sensor
By-pass flow adjustment valve
Barometric pressure sensor
Ɨ” bulkhead union Ɨ” bulkhead unionƗ” bulkhead union
Sampling gas inlet
Electronic flowmeter 0-12 l/h
Sampling gas outletSampling gas outlet
P
N.O. Solenoid valve
N.C. Solenoid valve
Sampling pump
Figure 17
Sample Path with Pump Fitted XZR400A1
XZR400 Series User’s Manual
Michell Instruments 17
INSTALLATION
2.8.7.1 Signal Processing Path
The values of oxygen concentration and fl ow passing through the sensor are displayed
continuously.
On specifi c screen pages the following control parameters are displayed:
• Oven temperature
• Ambient temperature (corresponding to the thermocouple junction
temperature)
• O
2
concentration
• MSRS sensor voltage
• Barometric pressure (standard) or process pressure (optional)
• Flow passing through the sensor
Analog Outputs:
• 2 x 4-20 mA analog outputs proportional to user-defi ned scales. The
wiring connector is on the rear side
Standard Alarms:
• General fault alarm
• 2 concentration alarms with user-confi gurable high/low thresholds and
hysteresis
Optional Alarm:
• An optional fl ow alarm is available
XZR400 Series User’s Manual
18 97472 Issue 3, August 2018
INSTALLATION
2.9 Connections to the XZR400A2
The connections are shown below.
A
B
C
D
E
F
G
H
Item Description
A Graphic touch screen - displays measurement and menus.
B Multi-turn knurled knob for fi ne adjustment of the gas fl ow.
C Multi-turn knurled knob for basic adjustment of the gas fl ow (bypass).
D Removable plate for access to electrical terminal block and mains fuse.
E Three cable glands are provided for the electrical connections.
F Optional D-Sub DE9 male plug (RS485 or RS232 port).
G Inlet fi tting for the gas sample to be analyzed (for 6mm tube).
H Outlet fi tting for the analyzed gas sample (for 6mm tube).
Figure 18
Connections XZR400A2
XZR400 Series User’s Manual
Michell Instruments 19
INSTALLATION
2.9.1 Gas Sample Inlet and Outlet Fittings
The gas path consists of 2 fl ow control valves (sensor fl ow and by-pass fl ow), a sensor
and an electronic fl owmeter. For the gas inlet and the outlet connections, Swagelok
stainless steel 6mm bulkhead unions are used, which guarantees perfect sealing and
easy removal.
The evacuation of the analyzed sample must be carried out at
atmospheric pressure, otherwise the total pressure adjustment
option is required.
The measurement of hazardous gas samples require the
analyzer's outlet to be outside the analysis area and must be in
accordance with local regulations.
Sensor flow
adjustment
Bypass flow
adjustment
Inlet for gas
to be
analyzed
Analyzed
gas
outlet
Sensor
Electronic
flow meter
Figure 19
Gas Circuit Diagram for XZR400A2
XZR400 Series User’s Manual
20 97472 Issue 3, August 2018
INSTALLATION
2.9.2 Electrical Terminal Block
The terminal block is located by removing the front panel cover.
1 2 3 4 5 6 7 8 9 10111213141516
Item Function
1 Connection to the MSRS cell; system reserved (TC+ – orange).
2 Connection to the MSRS cell; system reserved (common – white).
3 Connection to the MSRS cell; system reserved (reference – blue).
4 Oven connection, system reserved.
5 Oven connection, system reserved (see paragraph 15.2).
6 (+) 4-20 mA output measurement proportional to the chosen O
2
scale. A second
4-20 mA output is available as an option.
7 4-20 mA (0 V).
8-9 Optional. Dry contact alarm for fl ow rate setting (250 V AC, 30 V DC or 2 A, 2 A
resistive load). Direction of action.
10-11 Threshold alarm No. 1 dry contact terminal (250 V AC , 2 A or 30 V DC, 2 A on
resistive load). Function mode (positive, normal) and hysteresis can be confi gured
by setting the parameters.
12 Threshold alarm No. 1 dry contact terminal (250 V AC , 2 A or 30 V DC, 2 A on
resistive load). Function mode (positive, normal) and hysteresis can be confi gured
by setting the parameters.
13 Shared contact for alarms No.1 and No. 2.
14 Threshold alarm No. 2 dry contact terminal (250 VAC , 5A or 30 VDC, 5A on
resistive load). Function mode (positive, normal) and hysteresis can be confi gured
by setting the parameters.
15 Mains supply phase.
16 Mains supply neutral.
The equipment is protected by a T2 A - 250 V AC timed fuse (5 x 20 mm) located near
the terminal block
Figure 20
Electrical Terminal Block XZR400A2
2.9.3 D-Sub DE9 plug
This optional D-Sub DE9 type male plug (9 pin) is used to connect an RS485 or RS232
port.
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