Michell Instruments XZR500 Operating Manual

XZR500ST

Oxygen Analyzer

User’s Manual

97137 Issue 8

April 2017

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Use this information when contacting Michell Instruments for service purposes.

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XZR500

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www.michell.com

© 2017 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

Processing System without the express written authorization of Michell Instruments Ltd.

XZR500 User’s Manual

Contents

Safety ...............................................................................................................................vii

Electrical Safety .......................................................................................................... vii

Pressure Safety ........................................................................................................... vii

Temperature ............................................................................................................... vii

Toxic Materials ............................................................................................................ vii

Repair and Maintenance .............................................................................................. vii

Calibration .................................................................................................................. vii

Safety Conformity ....................................................................................................... vii

Abbreviations .................................................................................................................... viii

Warnings .......................................................................................................................... viii

1 INTRODUCTION ................................................................................................1

1.1 System Description ............................................................................................. 1

1.1.1 Measurement Principle .................................................................................. 1

1.1.2 Zirconia ........................................................................................................ 1

1.1.3 The MSRS .................................................................................................... 2

1.1.4 XZR500 MSRS Assembly ............................................................................... 2

1.2 General Remarks ................................................................................................ 3

1.2.1 Sensor Head and Probe ................................................................................. 3

1.2.2 Control Unit .................................................................................................. 4

1.3 Specifi cations .................................................................................................... 6

1.3.1 General ........................................................................................................ 6

1.3.2 Optional Equipment ....................................................................................... 8

1.3.3 Options ........................................................................................................ 8

2 INSTALLATION ..................................................................................................9

2.1 General Mounting Precautions ............................................................................ 9

2.2 Probe Mechanical Installation .......................................................................... 10

2.3 Control Unit Mechanical Installation ................................................................... 13

2.4 Wiring ............................................................................................................. 13

2.4.1 Cable Specifi cations ..................................................................................... 13

2.4.2 Connection of the Cable (supplied) to the Control Unit ................................... 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 ........................................................................................................... 16

3.1.1 Analog Output ............................................................................................ 16

3.1.2 Alarms ....................................................................................................... 16

3.2 Start-Up ........................................................................................................... 17

3.3 Display, Confi guration and Adjustment ............................................................... 18

3.3.1 Visualization Menu [*] ................................................................................. 18

3.3.2 Set-up [ - ] ................................................................................................. 21

3.3.2.1 Access code 0.12 - quick settings ........................................................... 22

3.3.2.2 Access code 0.20 - advanced settings ..................................................... 24

3.3.3 Calibration [+] ............................................................................................ 29

3.3.3.1 Recommended Calibration Gas ............................................................... 29

3.3.3.2 Regulating the Calibration Flow Rate ...................................................... 29

3.3.3.3 Calibration Procedure ............................................................................ 30

iv 97137 Issue 8, April 2017

XZR500 User’s Manual

4 MAINTENANCE ................................................................................................34

4.1 Preventative Maintenance - Cleaning .................................................................. 34

4.2 Replacement Of The XZR500 MSRS .................................................................. 35

4.3 Replacement of the Furnace .............................................................................. 37

4.4 Replacement of the XZR500 Microcontroller Card ................................................ 38

4.5 Replacement of Fuses ....................................................................................... 38

4.6 Error Messages ............................................................................................... 39

5 SPARE PARTS ..................................................................................................41

Figures

Figure 1 Zirconia Principle ........................................................................................1

Figure 2 The MSRS and its K Thermocouple ..............................................................2

Figure 3 XR500 MSRS ..............................................................................................2

Figure 4 XZR500 Sensor Head & Probe .....................................................................3

Figure 5 Digital Display Panel ...................................................................................4

Figure 6 Main Display ..............................................................................................4

Figure 7 Control Unit .............................................................................................5

Figure 8 Probe Installation .....................................................................................10

Figure 9 Probe Head Orientation .............................................................................10

Figure 10 Flange Gasket Orientation .........................................................................11

Figure 11 Tubular Counter Flange Position ................................................................11

Figure 12 Inner Tube Orientation ..............................................................................12

Figure 13 Hex Screw Locations .................................................................................14

Figure 14 Probe Wiring Diagram ...............................................................................15

Figure 15 Calibration Flow-Chart...............................................................................33

Figure 16 XZR500 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 Installation of the Ejector/Heating System .................................................55

Figure 22 Enclosure for Controlling the Ejector Heating - General Wiring Diagram ........56

Figure 23 XZR500 Flange and Back Flange (Optional) ................................................59

Figure 24 Insulators (Flange and Rear Sealing Screw) ................................................59

Figure 25 Mounting Plate Dimensions ....................................................................... 60

Figure 26 Wiring of the Second 4-20 mA Output ........................................................62

Michell Instruments v

XZR500 User’s Manual

Tables

Table 1 Control Keys...............................................................................................5

Table 2 Maximum Temperature of Gases .................................................................. 7

Table 3 Cable Specifi cations .................................................................................. 13

Table 4 Connection of the Control Unit................................................................... 13

Table 5 Access codes 0.12 & 0.20 ......................................................................... 21

Table 6 Alarm Set-Point Examples ......................................................................... 23

Table 7 Fuse Replacement .................................................................................... 38

Appendices

Appendix A Technical Specifi cations ..............................................................................43

Appendix B Confi guration for the RS232 Port (Optional) .................................................45

Appendix C Calculation of CO

Appendix D XZR500 Sensor Head and Probe General Dimensions ...................................50

Appendix E Back Flushing System (optional) .................................................................52

Appendix F Heated Flue Gas Ejection System (Optional) ................................................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

Appendix J Quality, Recycling & Warranty Information ...................................................66

Appendix K Return Document & Decontamination Declaration ........................................68

....................................................................................48

2

vi 97137 Issue 8, April 2017

XZR500 User’s Manual

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 230 V AC or 115
V AC, 50/60 Hz. Refer to labels on instrument or calibration certifi cate.

Pressure Safety

DO NOT permit pressures greater than the safe working pressure to be applied to the instrument.
The specifi ed 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. DO NOT open the enclosure of the
probe during operation. Switch off the analyzer fi rst and wait for at least 30 minutes.

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 interval for the analyzer is 6 to 12 months depending on the application
in which the instrument is used.

Safety Conformity

This product carries the CE mark and meets the requirements of relevant European safety directives.

Michell Instruments vii

Abbreviations

The following abbreviations are used in this manual:

AC alternating current

A Ampere

°C degrees Celsius

°F degrees Fahrenheit

Hz hertz

kg kilogram(s)

l/hour liters per hour

mA milli Ampere

mbars millibars

mm millimeter(s)

ppm parts per million

XZR500 User’s Manual

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 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 electric shock.

viii 97137 Issue 8, April 2017

XZR500 User’s Manual

1 INTRODUCTION

XZR500 Series Oxygen Analyzers are designed to measure the oxygen content in
fl ue gases between 0.01% and 25% O
performance, increasing equipment service life and surveying emissions, thereby
contributing to protecting the environment.

XZR500 Oxygen Analyzers can be used for several applications such as monitoring
combustion in power plants, incineration of industrial or domestic waste, incineration of
VOC, control of processes, etc.

Please read this manual carefully before starting up the analyzer. It is recommended
that you go through this manual again after the fi rst use to enable optimal use of the
XZR500.

1.1 System Description

1.1.1 Measurement Principle

INTRODUCTION

. They allow for the improvement of a boiler’s

2

Michell Instruments’ aim is to provide the best measurement solutions for any
given industrial process or laboratory application. In the case of oxygen control and
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 built-in metal reference, this means it can operate for very
long periods without any requirement for re-calibration against a reference gas. As a
result the XZR500 has very low lifetime costs compared to other oxygen analyzers.

In addition to providing reliable and hassle free operation, the MSRS also delivers
excellent accuracy, class-leading linearity and, due to its small size, has a superior
response speed.

The operating principle of the MSRS is explained in detail as follows:

1.1.2 Zirconia

Zirconia is a solid electrolyte. At high temperatures
it conducts oxygen ions. An electrochemical voltage
develops between the two platinum-plated surfaces
of the zirconia in contact with two different gaseous
oxygen partial pressure (Pp) atmospheres. This voltage
follows the Nernst equation, expressed as:

E =

where R and F are constants

E = Nernst voltage (V)
T = temperature (°K)
Pp = oxygen partial pressures

RT
4F Ppref.

ln

Ppmeas.

Figure 1

Zirconia Principle

Michell Instruments 1

INTRODUCTION

By setting the oxygen reference pressure and measuring voltage E and temperature T,
you can deduce the oxygen partial pressure you want to measure.

XZR500 User’s Manual

The volumetric concentration (expressed here in O
between the oxygen partial pressure (Ppmeas) and the atmospheric pressure (Ptot).

There is an optional ambient pressure sensor available for higher accuracy measurements.

1.1.3 The MSRS

Unlike conventional “air reference” zirconia sensors the MSRS uses the equilibrium
status of an internal metal oxide to provide a reference. Therefore, this built-in metallic
reference sensor does not require any reference gas.

Figure 2

%vol.) is determined by the ratio

2

O2 %vol. =

Ppmeas.
Ptot.

The MSRS and its K Thermocouple

The MSRS is a very small cylinder, 3mm in diameter and 10mm long. A K thermocouple,
placed closed to the MSRS, measures its temperature with great precision. This design
leads to extremely high accuracy and very good resistance to thermal shocks. It also
increases the lifetime of the sensor.

1.1.4 XZR500 MSRS Assembly

The MSRS and its K thermocouple are placed inside an aluminum tube. The MSRS head
is attached to an assembly plate to allow for easier fi eld servicing, see

1. aluminum tube

Figure 3

below.

2. O2 reference wire with blue mark

3. O2 reference wire with red mark

4. + thermocouple wire with green mark

5. - thermocouple wire with white mark

Figure 3

XR500 MSRS

2 97137 Issue 8, April 2017

XZR500 User’s Manual

1.2 General Remarks

The analyzer is made up of a measurement probe and a Control Unit.

1.2.1 Sensor Head and Probe

The semi in-situ arrangement consists of the following elements:

• Sensor head, containing MSRS, sensor furnace, cable connection &
calibration port.

• Probe, comprising of an inner and outer tube to allow fl ow of sample from
fl ue to sensor.

The sample gas is returned to the fl ue practically unchanged in composition and
condition. This is due to the very small amount of sample required to diffuse into the
sensor furnace.

INTRODUCTION

The gas fl ow is shown by the arrows in

Figure 4

below. In this example, the stack is

vertical and the fl ue gas fl ow direction is upwards.

Using the Pitot tube effect, gases enter through the hole near the tip of the outer tube
and circulate in the space between the outer tube (25, 2) and the inner tube (23).
During this process the gases contact the sensor through diffusion. They then fl ow into
the inner tube and to the fl ue via the bevelled edge.

The tubes are fi tted so that the bevelled edge of the inner tube and the holes of the
outer tube face in opposite directions.

17

10

15

16

14

13

19

8

25

6

2

18

21

12

11

1

3

24

4

5

28

29

9

27

23

20

22

1 Sensor housing 11 XZR500 connector block 20 M6 Nut for fi xing XZR500 probe plate

2 Outer tube 12 SS bulkhead union for cal.gas 21 M6 washer

3 Sealing head 13 2 sealing ferrules 22 M6 lock washer

4 XZR500 furnace 14 Nut for fi xing bulkhead union 23 Inner tube

5 XZR500 MSRS 15 Stainless steel plug 24 VITON 8 x 2.5 O-ring

6 Gasket for fl ange (x2) 16 M8 lock washer 25 Outer tube

7 Gasket for wheel 17 Cable gland 26 Locking ring

8 Inter-tubes gasket 18 M8 spacer 27 Gasket for plug

9 Gasket for sealing screw 19 CHC 6x25 screw for fi xing

10 TRF 3x16 screw for connector 29 Inter-tube gasket

Figure 4

XZR500 sensor attachmt plate

XZR500 Sensor Head & Probe

28 Big rear nut

26

7

Michell Instruments 3

INTRODUCTION

The XZR500 MSRS (5) assembly is placed perpendicular to the tubing system. The
XZR500 furnace (4) and the XZR500 MSRS (5) are placed inside a cast aluminum
enclosure which is made of two parts sealed with a 5mm diameter viton O-ring. It is
dust proof and waterproof and can be mounted outdoors. The cable gland (17) is made
of brass.

The whole set is mounted on the stack with a steel fl ange which is welded on the
XZR500 outer tube. Michell Instruments can provide an optional mounting kit containing
a counter fl ange with threaded rods (if needed please refer to Appendix G).

All the gaskets (6, 7, 8 and 9) placed on the tubes are made of carbon fi ber.

A high temperature “gasket box” type device guarantees that the sealing head is airtight.

For dimensions of the measuring probe see Appendix D.

1.2.2 Control Unit

The Control 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-controller and a display PCB. The output
signals and alarms are all accessed through the Control Unit.

XZR500 User’s Manual

Oxygen concentration is displayed on the screen as default and has one decimal
point as standard (a second decimal place can be requested as an option). Other
parameters available through the HMI are Furnace Temperature, Thermocouple Junction
Temperature, MSRS Voltage and Ambient Pressure (in mbars), if the optional pressure
sensor is ordered.

Confi guration of alarms and output signals as well as calibration functions are all carried
out through the HMI of the Control Unit.

The digital display panel of the analyzer is shown in

-

*

Figure 5

Digital Display Panel

+

Figure 5

.

O2 Concentration

xx.xx%

Figure 6

The instrument display is divided into two lines. The upper line is the descriptive line
and the bottom line displays the measured values or the function keys.

Main Display

4 97137 Issue 8, April 2017

XZR500 User’s Manual

The function keys are located below the display and are used to select operations
from the main menu level, to enter sub-menu levels and to select and enter parameter
variables within those menu levels. The function key panels are shown in
Table 1 describes the operation of the keys.

Key Function

[*] Enter or select key. Operation of this key from the front-page display causes

the selection menu to be displayed
[+] Value up key. 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

The analog output signal can be set in 0-20 mA or 4-20 mA. The scale is confi gurable
in the range of 0.01-25% O

Table 1 Control Keys

.

2

INTRODUCTION

Figure 5

and

The system provides three alarms on relay contact: a general failure alarm and two
threshold alarms with user-confi gurable set-point (action high and low) and hysteresis.

Figure 7

Cable

Control Unit

The cable connecting the control unit and the probe supplies the furnace with power
and it relays the MSRS temperature and voltage measurements to the Control Unit.

The standard cable length is 6 meters long (optional, up to 100 meters).

Michell Instruments 5

INTRODUCTION

1.3 Specifi cations

1.3.1 General

• Microcontroller: Motorola 68HC12

• Inlet converter: analog, 16 bits resolution, 0.0015% linearity error,

with fi lter and embedded calibrator

• Outlet converter: analog, 12 bits resolution, ±1 bit linearity error

XZR500 User’s Manual

• Display resolution: 0.1% O

(or 0.01 % on request and during

2

calibration)

• The 3-button keypad and digital interface allow:

Reading

Continuous display of the oxygen concentration to one decimal place (option
of second dp). Other parameters available through the HMI are Furnace
Temperature, Thermocouple Junction Temperature, MSRS Voltage and
Ambient Pressure (in mbars), if the optional pressure sensor is ordered.

Confi guration

Confi guring of the test gas value, activation direction 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 associated scale and the factory settings. (For
other parameters see specifi c Appendix.)

• Output signal: 0-20 mA or 4-20 mA (user-selectable) galvanic isolation
(500 V), linear and programmable, output range can be selected between

0.01% and 25% O

2

• Output impedance: > 1 k Ω

• Alarms: contacts are normally closed, dry and potential-free, the cutting

power is max. 10 W (up to 100 V or up to 0.5 A):

1. General failure alarm warning of furnace under temperature (20°C
below the instruction), thermocouple separation, problems with
RAM backup after a re-set or adjustment error

2. Threshold alarms, with programmable activation direction and
hysteresis

• Consumption: 110 VA

• Ingress and impact protection:

Electronic enclosure: IP52 and IK05
Probe: IP53 and IK05

• Storage temperature: between -10 and +70°C

6 97137 Issue 8, April 2017

XZR500 User’s Manual

• Dimensions (mm):

Control Unit: 300 x 300 x 200 (w x h x d)
Sensor Head: 135 x 290 x 670 (w x h x d) (standard model)
Probe: 400, 600 or 900mm in length, with an outer diameter of 40mm

• Weight:

Control Unit: Approximately 7 kg
Sensor Head: Approximately 3 kg
Probe: Approximately 2-6 kg (dependant upon length & material of

• Power 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)

INTRODUCTION

construction)

• Maximum temperature of the sample gases (Table 2):

Model Tubing Materials Gas Properties

XZR500 /SS 304 L stainless steel Tmax = 700°C

XZR500 /IL Inconel 600 Tmax = 1000°C
XZR500 /HR HR160 Tmax = 1000°C and corrosive gases
XZR500 /HC Hastelloy C2000 Tmax = 600°C and corrosive gases
XZR500 /CC Ceramic Tmax = 1300°C

XZR500 /HL Halar coating Tmax = 150°C

Table 2 Maximum Temperature of Gases

• Minimum speed of the sample gases: 0.5 m/s

Michell Instruments 7

INTRODUCTION

1.3.2 Optional Equipment

• Tubular counter-fl ange for fi xing the probe to the stack (see Appendix G)

• Flange insulation (to prevent condensation forming)

• Extra length of cable (up to 100 meters)

• Calibration and verifi cation kit

• Back fl ushing system: for cleaning the probe tubes when fl ue gases are
very dusty (see Appendix E)

• Flue gas ejector system with heating (see Appendix F)

• Rear insulation

1.3.3 Options

XZR500 User’s Manual

• Self-calibration

• 115 V / 60 Hz power supply

• RS232 interface (see Appendix B)

1. Transmits all data straight from/to a computer terminal, i.e: O
concentration, furnace temperature, MSRS voltage, ambient
temperature and pressure.

2. Allows the setting of test gas value and starting the analyzer
calibration sequence.

3. Allows the changing of the alarm type, level and hysteresis, the
fail safe value, setting of the furnace temperature, the upper
scale adjustment, the signal output and scale, and starting the
self cleaning.

2

8 97137 Issue 8, April 2017

XZR500 User’s Manual

2 INSTALLATION

2.1 General Mounting Precautions

• Place the probe as close as possible to the process (without breaching
the fl ame front).

• Prevent ambient air from entering the stack upstream or at the probe
tapping point and interfering with the measurement. Make sure all the
gaskets are placed and tightened
for calibration gas inlet (

NOTE: The stainless steel plug - or any 1/8” sealing ferrule -
should be tightened up by hand and then tightened again using a
7/16” spanner, turning only 1/8th of a turn so as not to damage
the connection.

• Avoid placing the probe near cleaning devices or elements that create
vibrations and are liable to disturb the measurement.

• Voltage should be applied to the analyzer immediately after the instrument
is fi xed on the stack so that the furnace can start heating. This will avoid
condensation at cold points where dirt could aggregate and clog up the
probe tubes. For the same reason, we recommend leaving the analyzer
powered up 24 hours a day, 365 days a year.

Figure 4

(Figure 4)

(15)).

INSTALLATION

, and tighten-up the SS plug

• The part of 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 of the probe (optional).

NOTE:

Ceramic probes require special handling.

Please read the following note carefully.

Ceramic Probes:

Special care must be taken when handling ceramic probes due to their fragile
nature. Inspect the probes thoroughly before inserting into stack. If they
have been damaged in transit, contact your Michell offi ce or distributor
immediately and inform them of the situation. Take photographic evidence
of the damage to the probe, and of the packaging, on the day of delivery.

On insertion ensure that the probe does not impact with the side of the orifi ce.
Once installed, it is not recommended to remove the probe. If removal is
unavoidable due to maintenance, then allow the probe several hours to fully
cool to ambient temperature and extract slowly.

Consideration for placement of the probe is essential. Avoid the fl ame front,
violently turbulent sections of the duct/fl ue, proximity to dampers, or where
falling refractory could strike the probe. Excessive vibrations must be avoided
as ceramic is a brittle material.

Incorrect handling or placement of the probe will invalidate the warranty.

Michell Instruments 9

INSTALLATION

2.2 Probe Mechanical Installation

e. Probe head

}

g. Gasket for locking ring

}

h. Locking ring

}

i. Rear nut

3 marks to indicate

}

the bevelled edge

Nut

}

}

}

Gasket

5°

}

j. Gasket

Horizontal line

}

}

f. Inner probe tube

}

Bevelled edge

}

XZR500 User’s Manual

d. Gasket for flange

}

c. Outer tube

}

b. Gasket for flange

}

}

Gas Inlet hole

a. Tubular
counter flange

}

Figure 8

The XZR500 is simple to set-up. Follow the instructions below:

1. Weld the tubular counter-fl ange (a) onto the stack. Follow the orientation
shown below to ensure that the probe head is set in a vertical position.
Slope the tubular counter-fl ange (a) slightly (maximum 5 degrees) so that
condensed water can go back to the process. The probe is fi tted with a PN6
DN15 type fl ange (4 x 11mm diameter holes, placed on a 55mm diameter
circle). Pay special attention to the orientation and slope especially if the
counter fl ange/nozzle with fl ange is provided by the customer.



055mm

Probe Installation



055mm



055mm

9

88

5°

Figure 9

10 97137 Issue 8, April 2017

Probe Head Orientation

XZR500 User’s Manual

2. Place the outer probe (c) with the fl ange gasket (b) according to the
drawing in

Figure 8



Process ow

INSTALLATION

. The gas inlet hole should face the process fl ow.

Process ow





Gas inlet
hole

Gas inlet



hole

Figure 10

3. Mount the probe head (e) with the fl ange gasket (d) on to the tubular
counter-fl ange (a). Secure the tubular counter fl ange, fl ange for outer
tube and fl ange of the probe head together by secure nuts onto four bolts
on the counter fl ange.

e. Probe head



Flange Gasket Orientation

d. Gasket for flange



b. Gasket for flange



a. Tubular



counter flange

Figure 11

Michell Instruments 11

Tubular Counter Flange Position

INSTALLATION

4. Place the gasket onto the inner tube (f) and insert into the probe head
(e) (see
faces the opposite direction to the gas inlet hole on the outer tube (c) as
shown below. There are three marks on the other end of the inner tube
to indicate the orientation of the bevelled edge (see

Figure 8).

f. Inner tube

XZR500 User’s Manual

Make sure the bevelled edge of the inner tube tip

Figure 12).

c. Outer tube



Bevelled edge







Gas inlet hole

   

Process ow

Figure 12

5. Place the locking ring (h) with the locking ring gasket (g), the rear nut
(i) and the inner tube gasket (j) accordingly on the rear of the probe
head. (See

6. Put insulation between process and the probe head if necessary.

Figure 8)

If the back fl ush option is chosen, then the orientation

must be reversed. This is because the inner tube becomes

the inlet so any dust build up will happen in the inner

tube. When the back fl ush is operated, it clears the tube

Inner Tube Orientation

more effi ciently.

12 97137 Issue 8, April 2017

XZR500 User’s Manual

2.3 Control Unit Mechanical Installation

INSTALLATION

The Control Unit is supplied with lugs for fi tting on the wall (see

2.4 Wiring

2.4.1 Cable Specifi cations

The standard analyzer is supplied with 6 meters of cable. Longer cable lengths are
available up to 100 meters. The electrical connections are as follows:

brown
brown

green (+)
white (-)

blue (reference)

red (measurement)

Figure 7).

Only authorized personnel should open the control unit.

Take all precautionary measures to avoid accidents

related to electrostatic shocks.

} 2 wires to supply the power to the furnace
} 2 wires for measuring the thermocouple voltage
} 2 wires for measuring the MSRS voltage

Table 3 Cable Specifi cations

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 (supplied) to the Control Unit

Connect the supplied cable - using the end with 7 wires (including ground wire) - as
follows:

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

(red)

2

(blue)

2

NC

+TC (green)

-TC (white)

Ref. 0

Meas. 0

+mA Output

From the sensor

-mA OutputNCNC

0/4-20mA

Output

NC

Furnace power brown

Furnace power brown

General fault alarm

General fault alarm

to the

sensor

(furnace)

Alarm 1

Alarm 1

Alarm 2

Alarm 2NC230 N

to the Mains

Vac P

Earth

J4 Left connector: measurement
J5 Right connector: power and alarms

CABLE

(supplied)

Table 4 Connection of the Control Unit

Both the ground wire of the supplied cable and the earth wire from the mains must

be connected to the copper bar near the cable gland.

Michell Instruments 13

INSTALLATION

2.4.2.1 Connection to the Mains

Use shielded cable (2 x 1.5mm² max.) that is terminated appropriately. Follow the
Table 4 wiring diagram (pins 48, 49 and 50).

Connect both the screen and the earth wire to the copper bar near the cable gland.

2.4.2.2 Connection of the 0/4-20 Output

We suggest that shielded cable (2 x 0.75mm²) is 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

XZR500 User’s Manual

We suggest that shielded cable is used and terminated appropriately. Follow the Table
4 wiring diagram (pins 41 to 46).

Connect the screen and the earth wire to the copper bar near the cable gland.

2.4.3 Connection of the Cable to the Sensor Head

Unscrew the three hex head screws at locations shown below to open the case of the
XZR500 probe head and access the terminal block.







Figure 13

Hex Screw Locations

14 97137 Issue 8, April 2017

XZR500 User’s Manual

INSTALLATION

Connect the end of the cable - using the end with 6 wires - according to the
wiring diagram.

MSRS

Blue

Ref. -TC +TC M F F

Blue

___________

White

White

___________

Green

Green

___________

Red

Red

___________

Furnace

Brown

___________

Brown

___________

Figure 14

probe
connector

Supplied Cable

Figure 14

Probe Wiring Diagram

Michell Instruments 15

OPERATION

3 OPERATION

XZR500 User’s Manual

The MSRS is a fragile element - keep the sensor free from any

shock. Any measurements that need to be done at the MSRS

terminals must be done very carefully in order to prevent

irreversible damage to the sensor.

NEVER attempt to measure the resistance between the MSRS

reference terminal and another terminal

Use a voltmeter with impedance >1000 MΩ for measuring

the voltage between the MSRS measurement and reference

terminals

3.1 Outputs

3.1.1 Analog Output

The output signal is 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 the set temperature), thermocouple separation, problem with RAM
backup after a re-set or adjustment error.

• 2 threshold alarms, with programmable activation direction and hysteresis.

The activation of a threshold alarm can be identifi ed when the corresponding green LED
turns off on the Control Unit.

The activation of the general fault alarm can be identifi ed when all the three green LEDs
turn off on the Control Unit.

The contacts are normally closed, dry and potential-free. The maximum switched load
is 10 W for each contact (up to 100 V or up to 0.5 A).

16 97137 Issue 8, April 2017

XZR500 User’s Manual

3.2 Start-Up

After fi nishing and verifying the connections, power up the analyzer.

During 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 (after about 15
minutes), the system calculates the oxygen concentration and the result will appear on
the display.

OPERATION

Oven Temperature

Low alarm /xxx.x

Then the following default message appears:

O2 Concentration

xx.xx %

Michell Instruments 17

OPERATION

3.3 Display, Confi guration and Adjustment

During confi guration there is no data communication

between the Control Unit and the Sensor Head

and this could disturb the stability of the furnace
temperature. Make sure that the furnace temperature
is stable before confi guration and allow the analyzer’s

temperature to stabilize after confi guration.

To display the main selection menu, press and
hold the [*]

You can now select the option you need by
pressing one of the following keys:

[ *

] Enter key cycles displayed parameters

[ - ] Minus key to enter the set-up mode
[ + ] Plus key to enter the calibration mode

Enter key until the menu appears.

XZR500 User’s Manual

Your selection?

Visu * Cal + Set -

3.3.1 Visualization Menu [*]

The visualization menu displays the following parameters:

• O2 concentration

• Oven temperature in °C

• Temperature of the thermocouple cold junction in °C (ambient temperature)

• MSRS voltage

• Pressure value

Proceed as described above to enter the main selection menu. To scroll through the
parameter list use the [*]

It is not possible to change any values in the visualization menu. To change values go
to the set-up menu.

1. From the main menu, press and hold the

Enter key until the main selection

[*]
menu appears

Enter key as shown below.

Your selection?

Visu * Cal + Set -

2. Press the [*] Enter key from the main
selection menu to show the fi rst parameter:
O

concentration

2

O2 Concentration

xx.xx%

18 97137 Issue 8, April 2017

XZR500 User’s Manual

3. Press and hold the [*] Enter key again to
re-enter the main selection menu

4. Press the [*] Enter key from the main
selection menu to show the second
parameter: Oven temperature

5. Press and hold the [*] Enter key to re­enter the main selection menu

OPERATION

Your selection?

Visu * Cal + Set -

Oven temperature

xxx.x°C

Your selection?

6. Press the [*] Enter key from the
main selection menu to show the third
parameter: Ambient temperature

7. Press and hold the [*] Enter key to re­enter the main selection menu

Visu * Cal + Set -

Ambient temperature

xx.x°C

Your selection?

Visu * Cal + Set -

8. Press the [*] Enter key from the main
selection menu to show the fourth
parameter: Cell voltage

Cell voltage

xx.xx mV

Michell Instruments 19

OPERATION

9. Press and hold the [*] Enter key to re­enter the main selection menu

10. Press the [*] Enter key from the main
selection menu to show the fi fth parameter:
Absolute pressure

11. Repeating the process again will return
to the default displayed parameter: O2
concentration

XZR500 User’s Manual

Your selection?

Visu * Cal + Set -

Absolute pressure

xxxx.x mBar

O2 Concentration

xx.xx%

NOTE: If you do not press the [*]
one of the parameters, the display will automatically return to the default
display of O2 concentration.

Enter key within 30 seconds, while showing

20 97137 Issue 8, April 2017

XZR500 User’s Manual

3.3.2 Set-up [ - ]

The set-up mode is used for changing system control parameters, each of which are
selected from the set-up confi guration table. There are two different sets of setting
parameters. Quick settings are accessible under code 0.12, while advance settings are
accessible under access code 0.20.

OPERATION

Access

Code

0.12

0.20

Function Default

Setting

Std confi g. 0.30 0.00 N/A

Test gas value 8.00 % Sets the value of the calibration gas

Type Alarm 1 2.00 N/A

Level of Alarm 1 30.00

Type Alarm 2 2.00

Level of Alarm 2 30.00

Hysteresis 1.00

Fail safe value 0.00

Oven temp set

pt

Francais

English

Italiano

Offset room

temp

Room temp.

grad.

High adjust 0.00 Adjusts reading near 21%

0 or 4 - 20 mA

output

Rec. range low 0.01 % Sets the measuring range lower limit

Rec. range high 10.00 % Sets the measuring range higher limit

CO2 factor 0.00 % Enter the CO2 value

Gr 10.00

Ti 10.00

Offset pressure Pre-set mbar

Absolute
pressure

Cell cleaning Start the cell self-cleaning process

700.00 °C

English N/A Sets display language

3.00 N/A

10.00 N/A

4.00 N/A Sets the analog output signal

Pre-set mbar

measurement range

measurement range

measurement range

Unit Remarks

% of the

% of the

% of the

% of the output

scale

Resets the system to standard confi guration.
The default confi guration is restored. The
current parameters will be deleted. Usually
necessary after replacement of the micro
controller card. Do not change without
consulting factory

Sets alarm type. If value >1.00 high Alarm 1,
if value <1.00 low Alarm 1

Sets process trigger point for Alarm 1

Sets alarm type. If value >1.00 high Alarm 2,
if value <1.00 low Alarm 2

Sets process trigger point for Alarm 2

Sets relay hysteresis

Sets the fault alarm. If released, the output
signal switches to the selected value

Sets the oven temperature. Do not change
without consulting factory

Sets the offset set point for the MSRS T/C cold
junction. Do not change without consulting
factory

Sets the span set point. Do not change without
consulting factory

Factory setting. Do not change without
consulting factory

Factory setting. Do not change without
consulting factory

Sets the offset pressure. Do not change
without consulting factory

Sets the absolute pressure. Do not change
without consulting factory

Table 5 Access codes 0.12 & 0.20

Michell Instruments 21

OPERATION

3.3.2.1 Access code 0.12 - quick settings

From the main menu page, press and hold the

Enter key until the main selection menu

[*]
appears.

Press the [–] (Set-up menu) from the main
selection menu to show the Access code page.

XZR500 User’s Manual

Your selection?

Visu * Cal + Set -

Access code?

Using the [–] and [+] keys enter the 0.12 code
to access the quick settings and press the [*]

0.12

Enter key to confi rm the selection.

Standard Confi guration

The fi rst page under access code 0.12 is
for restoring the factory default standard
confi gurations.

A standard confi guration should be restored after replacing the microcontroller
card.

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 confi guration will change all the

parameters of the last set-up. Make sure you note down all

parameter values before executing the operation. After re-set

the analyzer is no longer calibrated.

Std confi g. 0.30

0.00

If a standard confi guration is not necessary leave the value as 0.00 and press the [*]

Enter key to go to the next page.

If a standard confi guration is necessary, enter 0.30 and press the [*]
activate the restoring process.

Calibration gas value

This page shows the current calibration gas
value. Use the [+] and [–] keys to modify the

value and press the [*] Enter key to confi rm the
selection and move to the next parameter.

NOTE: This value is in %. For example,

8.00 equals 8%.

Test gas value

Enter key to

8.00

22 97137 Issue 8, April 2017

XZR500 User’s Manual

Alarm 1

1. The ‘type of alarm’ screen is used to set­up the direction for the Alarms 1 and 2
to the values ‘High’ and ‘Low’. The ‘High’
alarm will be activated when increasing
the signal value to above the set-point
level. The ‘Low’ alarm will be activated by
decreasing the signal value to below the
set-point level.

Values higher than 1.00 indicate that the alarm type will be ‘High’. Values lower than

1.00 indicate that the alarm type will be ‘Low’. Press the [+] and [–] keys to modify
the value. Press the [*]

parameter.

2. Depending on the selection in step 1, the
next page shows High/Low set-point of
Alarm 1. Press the [+] and [–] keys to
modify the set-point and press the [*]

Enter key to confi rm the selection and

move to the next parameter.

OPERATION

Type Alarm 1

2.00

Enter key to confi rm the selection and move to the next

High Alarm 1

2.00

NOTE: If the alarm is set as Low alarm this page will display ‘Low Alarm 1’
accordingly

NOTE: This set-point value is in %. For example, 2.00 equals 2%. The value
can be set between 0 and 200%.

Alarm set-point = (alarm level/max value of the scale) x 100

Example 1:
Selected range is 1-1,000 ppm.
The desired alarm is at 600 ppm.

Example 2:
Selected range is 10-10,000 ppm.
The desired alarm is at 600 ppm.

Example 3:
Selected range is 1 ppm to 25%
logarithmic. The desired alarm is
at 600 ppm.

Table 6 Alarm Set-Point Examples

Calculation:
%= (600 ppm*100)
/1000 ppm = 60

Calculation:
%= (600 ppm*100)
/10,000 ppm = 6

Calculation:
%= (600 ppm*100)
/250,000ppm = 0.24

The set value has to be 60 as
600ppm represents 60% of
the range

The set value has to be 6 as
600ppm represents 6% of the
range

The set value has to be 0.24
as 600ppm represents 0.24%
of the range

Alarm 2

To confi gure Alarm 2, repeat steps 1 and 2 as shown in Alarm 1.

Michell Instruments 23

OPERATION

Alarm hysteresis

This page shows the value for the relay hysteresis
that is expressed in percentage oxygen. Press
the [+] and [–] keys to adjust the value. Press

the [*]
move to the next parameter.

Fail safe value

This page shows, in percentage, the fail-safe
value of the measurement range. This is the
percentage value that the 4-20 mA output will
go to under fault conditions. E.g. 100.00 means
the output will be 20mA (100%) under fault
conditions.

Press the [+] and [–] keys to adjust the value.
Press the [*]

The Access code page will appear.

Enter key to confi rm the selection and

Enter key to confi rm the selection.

XZR500 User’s Manual

Relay hysteresis

0.10

Fail safe value

0.00

3.3.2.2 Access code 0.20 - advanced settings

At the Access code page, use the [–] and [+]
keys to enter the 0.20 code to access the

advance settings and press the [*]
confi rm the selection.

Oven temperature set-point

This fi rst page under access code 0.20 is used
to set the temperature of the sensor oven.

CAUTION: Do not change the value without
consulting the factory.

Press the [*] Enter key to move to the next
parameter.

Languages

English, French or Italian can be selected as the
display language. There are separate pages for
each language.

Enter key to

Access code?

0.20

Oven temp set pt

700.00

English ?

No * Yes -

Press the [*]
language in use

Press the [–] key to change to the chosen
language

Enter key to stay with the current

French ?

Non * Oui -

Italiano ?

No * Si -

24 97137 Issue 8, April 2017

XZR500 User’s Manual

Offset compensation MSRS cold junction

This page shows the offset value for
compensation of the MSRS thermocouple cold
junction. The value is factory pre-set and may
vary for individual analyzers.

CAUTION: Do not change the value without
consulting the factory.

OPERATION

Offset room temperature

3.00

Press the [*]
parameter.

Span compensation MSRS cold junction

This page shows the span value for compensation
of the MSRS thermocouple cold junction.
The value is factory pre-set and may vary for
individual analyzers.

CAUTION: Do not change the value without
consulting the factory.

Press the [*]
parameter.

High Adjust

This page shows the ‘High adjust’ function that
allows the user to adjust the reading around
21% oxygen. The value is factory pre-set and
may vary for individual analyzers.

Enter key to move to the next

Enter key to move to the next

Room temp. grad.

10.00

High adjust

2.00

NOTE: The value is factory pre-set. It can
be changed when different calibration is
required.

After a calibration, let the air circulate
for approximately 15 minutes, and then
adjust this value to give a 21% oxygen
reading. If the calibration is done with air,
set the value to 0.00.

The equation to calculate the high adjust is:

HA = ((20.9 - O2reading) /O2 reading) * 100

e.g. If the analyzer display is 20.4%
HA = ((20.9 - 20.4) / 20.4) * 100 = 2.5

Press the [+] and [–] keys to adjust the value.
Press the [*]

and move to the next parameter.

Enter key to confi rm the selection

Michell Instruments 25

OPERATION

Output Signal

This page shows the available current ranges
for the signal output. Enter 0.00 for 0-20 mA
and 4.00 for 4-20 mA. Press the [+] and [–]

keys to adjust the value. Press the [*]
key to confi rm the selection and move to the
next parameter.

Measurement range – lower limit

This page shows the selected lower limit of the
measurement range. Press the [+] and [–] keys

to adjust the value. Press the [*]
to confi rm the selection and move to the next
parameter.

Enter

Enter key

XZR500 User’s Manual

0 or 4-20 mA

4.00

Rec. range low

0.01

NOTE: This value is in %. For example,

0.01 equals 0.01% O2.

Measurement range – upper limit

This page shows the selected upper limit of the
measurement range. Press the [+] and [–] keys

to adjust the value. Press the [*]

Enter key

to confi rm the selection and move to the next
parameter.

NOTE: This value is in %. For example,

10.00 equals 10% O

CO

factor

2

.

2

This page is used to enter the CO2 maximum
theoretical value of the fuel gas for CO

2

calculation. Press the [+] and [–] keys to adjust
the value. Press the [*]

Enter key to confi rm

the selection and move to the next parameter.
(See Appendix C)

Rec. range up

10.00

CO2 factor

0.00

26 97137 Issue 8, April 2017

XZR500 User’s Manual

Gr value

This value is for factory settings only.

CAUTION: Do not change the value without
consulting the factory.

OPERATION

Gr

10.00

Press the [*]
parameter.

Ti value

This value is for factory settings only.

CAUTION: Do not change the value without
consulting the factory.

Press the [*]
parameter.

Offset pressure

This page displays the offset pressure. The value
is factory pre-set and may vary for individual
analyzers.

Enter key to move to the next

Enter key to move to the next

Ti

10.00

Offset pressure

8.00

CAUTION: Do not change the value without
consulting the factory.

Press the [*]
parameter.

Absolute pressure

This page displays the absolute pressure.
The value is factory pre-set and may vary for
individual analyzers.

CAUTION: Do not change the value without
consulting the factory.

Press the [*]
parameter.

Enter key to move to the next

Enter key to move to the next

Abs. pressure

11.00

Michell Instruments 27

OPERATION

Cell self-cleaning

This function allows the analyzer to self-clean
the sensor cell. The cleaning process lasts for
one hour. The furnace is heated to 780°C in
order to clean itself and the MSRS. Remove the
inner probe tube to make the self-cleaning more
effi cient.

NOTE: During self-cleaning, the output
signal will be locked at the fail-safe value

If cell cleaning is not required, leave the value
at 0.00 and press the [*]

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 process. The following

[*]
messages will appear:

XZR500 User’s Manual

Cleaning cell

0.00

Enter key to skip this

The process can be stopped by pressing and
holding the [*]

automatically after the above 60 minute process
is completed. Once the cleaning process is
fi nished the furnace will start to cool down.

After about 10 minutes the temperature will
return to the set temperature.

Enter key or it will stop

Temperature Oven

Low alarm

Cleaning cell

End of control?

Cleaning cell

60 min

Cleaning cell

cooling

Cleaning cell

10 min

Temperature Oven

xxx.x°C

28 97137 Issue 8, April 2017

XZR500 User’s Manual

3.3.3 Calibration [+]

The XZR500 has been designed for simple operation. The calibration procedure is
extremely easy and can be performed within minutes. The analyzer is self-adjusting
during calibration. There are only a few steps that need to be carried out for the actual
calibration procedure.

3.3.3.1 Recommended Calibration Gas

NOTE: Please make sure that only gas of a known composition is used for
calibration of the XZR500. The gas cylinder must be certifi ed as to the exact
composition of the calibration gas.

Michell recommends the following calibration gas concentrations that can be ordered
from your analyzer vendor.

• 1G Calibration Kit with one gas cylinder (nitrogen with 8% oxygen
concentration)

OPERATION

• 2G Calibration Kit with two gas cylinders (nitrogen with 8% oxygen
concentration for calibration and nitrogen with 2% oxygen concentration
for verifi cation)

CALIBRATION GAS UNCERTAINTY:

Observe the uncertainties 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 analyzer.

NOTE: Prior to calibration, make sure that the ‘Test gas value’

in the access code 0.12 of the analyzer menu is the same as

the calibration gas value.

3.3.3.2 Regulating the Calibration Flow Rate

In order to perform the calibration it is recommended to arrange a temporary connection
with a regulator and isolation valve located at the calibration gas inlet on the analyzer.
Make sure the connection is as short as possible. A regulator and isolation valve are
supplied in the calibration kit.

Connect the calibration kit or your test gas cylinder to the calibration gas inlet

4 (12))

(0.12 to 0.18 l/min).

NOTE: Tighten up the stainless steel locking nut by hand and then tighten again
using a 7/16" spanner, for 1/8th turn so as not to damage the connection.

NOTE: During calibration the output signal is frozen at the last value measured
before the beginning of the calibration procedure.

. Use 1/8” tube and fi tting. NOTE: Ensure a fl ow of 7 l/hour (±2 l/hour)

(Figure

Michell Instruments 29

OPERATION

3.3.3.3 Calibration Procedure

Follow Sections 3.3.3.1 and 3.3.3.2 to connect the calibration gas to the analyzer (8%
oxygen bottle, if 1G or 2G is ordered). Do not switch on the calibration gas fl ow at this
time.

1. From the main page, press and hold the
[*] (Enter key) until the main selection
menu appears.

2. Press the [+] key from the main selection
menu to enter the calibration mode. The
fi rst page displays the ‘Test gas value’.
Make sure that the displayed value is the
same as the calibration gas.

NOTE: This value is in %. For
example, 8.00 equals 8%.

XZR500 User’s Manual

Your selection?

Visu * Cal + Set -

Test gas value

8.00

If the displayed value is not the same value
as the calibration gas, exit the calibration
mode from next page (‘Inject gas’) and
then go to ‘Test gas value’ under ‘Set­up 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.

3. This page shows the calibration start
command.

[*] – Starts the calibration process (go to
step 4)

[–] key – Cancels the calibration process
and exits the calibration mode. If the ‘Test
gas value’ needs to be modifi ed, then go
to ‘Test gas value’ under ‘Set-up menu’
Access code 0.12 to adjust it.

NOTE: Once the calibration process
starts (after pressing the [*] key),
the 4-20 mA output will be frozen
from this step until the end of the
purge procedure and will show the
last measured value.

Inject gas

Yes* No -

4. Open the test gas cylinder to introduce
the gas into the analyzer. Adjust the fl ow
to the recommended level of 7 l/hour (±2
l/hour) and ensure that the fl ow is stable.
Higher or lower fl ow rates could affect
the accuracy of the calibration as well as
further measurements.

30 97137 Issue 8, April 2017

XZR500 User’s Manual

5. The calibration process takes about 10
minutes. During calibration the screen
alternates, displaying two messages

- ‘running’ and the current value of
calibration.

Press the [*] key to fi nish the calibration
once this value is stabilized, otherwise the
calibration process will end automatically
after the 10 minutes time limit is reached.

The screen will then change to the
following:

6. After the calibration process the quality of
the calibration can be verifi ed by starting
the verifi cation process with 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 available - order code 2G.

OPERATION

Adjustment sequence

xx.xx

Adjustment sequence

running

Control gas?

Yes* No -

[*] key – continues with the verifi cation
process (go to step 7)

[–] key – skips the validation and
completes the calibration process (go to
step 8)

7. If the [*] key is pressed in step 6 this
screen is used to verify the calibration.
The page alternates between real-time
reading of the control gas and the option
to end the verifi cation.

Introduce the control gas to the inlet of
the analyzer. The calibration can then be
verifi ed simply by comparing the reading
with the real oxygen content of the control
gas.

Control gas?

Stop control?

Yes* No -

xx.xx

[*] key – Ends the verifi cation process and
moves to the next page

[–] key – No effect

Michell Instruments 31

OPERATION

8. Once the verifi cation step is completed
or skipped, the screen shows ‘Stop gas?’
to remind the user to switch off the
calibration/control gas.

Confi rm the fi nish of the calibration with
the [*] key and move to next page.

The calibration/control gas should now be
switched off and, if necessary, the process
gas reconnected back to the analyzer.

[–] key – No effect

9. After the analyzer leaves the calibration
mode the screen alternates, displaying
two messages - ‘Purge running’ and
the real live measurement of the purge
(process) gas. This procedure cleans all
the calibration gas in the analyzer. It takes
about 3 minutes.

XZR500 User’s Manual

Stop gas?

Yes * No -

Adjustment sequence

Purge running

At the end of the purge the 4-20 mA
output will be released.

Adjustment sequence

xx.xx

10. The purging process can be stopped after
one minute. Press the [*] key and hold
until the default main page appears.

If the following message is displayed the
analyzer calibration was not successful.
Press RESET
and [–] keys to cancel the message.

This may occur when:

(Figure 7)

or press the [+]

Fault

Calibration

• The O2 concentration of the calibration

gas is different from the value set in
‘Set-up menu’ Access code 0.12. Go to
‘Test gas value’ under ‘Set-up menu’
Access code 0.12 to adjust it. (Refer to
details in Section 3.3.2.1).

• The MSRS is faulty. It should be

replaced.

32 97137 Issue 8, April 2017

XZR500 User’s Manual

Your selection?
Visu* Cal+ Set -

Test gas value

8.00

d

d

OPERATION

+

The test gas value cannot be modified at this point.
In order to modify it, quit the process from ‘Inject Gas?’
page and set it in Access code 0.12

*

Inject gas?
Yes * No -

*

d

Adjustment sequence
running/Value

(*)

d

The adjustment process lasts 10 minutes but
it can be stopped after 1 minute by pressing the [*] key

Control gas?

-

Yes * No -

*

d

Control Gas Stop control?
Value Yes * No -

*

d

- :

quit calibration sequence

d

- :

No effect

d

Stop gas?

d

Yes * No -

*

d

Adjustment sequence
Purge running/Value

(*)

d

02 concentration
xx.x(x)%

Figure 15

- :

d

Purge sequence lasts 3 minutes but it can be stopped
after 1 minute by pressing the [*] key

Calibration Flow-Chart

No effect

Michell Instruments 33

MAINTENANCE

4 MAINTENANCE

4.1 Preventative Maintenance - Cleaning

The XZR500 should be periodically cleaned. The frequency of cleaning will depend
upon your application.

• Identify the 3 orientation marks on the inner tube and remove it (

4

(23)).

XZR500 User’s Manual

Figure

• Clean the inside of the outer tube (
backwards 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 afterwards have pressurized air blown
through the tube. Fit the inner tube of the probe back into the correct
position.

• Change the gaskets and tighten-up all the nuts frequently to prevent
contamination from outside air entering the stack.

• The probe should be removed at least once a year, e.g. during a factory
shutdown, to inspect the probe tubes. Clean them as necessary.

Figure 4

(2)) by moving the inner tube

34 97137 Issue 8, April 2017

XZR500 User’s Manual

4.2 Replacement Of The XZR500 MSRS

MAINTENANCE

• Remove the probe inner tube (

• Turn off the analyzer and disconnect the power lead.

• Wait until the furnace and sensor housing cool down (at least 45 minutes).

• Remove the cover of the sensor housing.

• Disconnect the cable.

• Disconnect the sealing head (

• Remove the MSRS (

• 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

• Replace the screws and tighten-up.

• Connect the MSRS and the cable according to the diagram (

• Power up the analyzer.

• Wait for one hour.

Figure 4

Figure 4

Figure 4

(5)).

(23)).

(3)).

Figures 17 and 18

).

Figure 16).

• Re-fi t the probe inner tube.

• Set self-cleaning (0.10 code).

• Wait for few hours before calibrating the analyzer (see Section 3.3.3).

Figure 16

XZR500 MSRS Mounting Diagram

Michell Instruments 35

MAINTENANCE

XZR500 User’s Manual

Figure 17

XZR500 Top View

Figure 18

XZR500 Side View

36 97137 Issue 8, April 2017

XZR500 User’s Manual

4.3 Replacement of the Furnace

MAINTENANCE

• Remove the probe inner tube (

• Turn off the analyzer and disconnect the power lead.

• Wait until the furnace and the sensor housing cool down (around 45 minutes).

• Remove the cover of the sensor housing.

• Disconnect the cable.

• Disconnect all the wires from the MSRS, the furnace and the connector block
(

Figure 4

• Remove the MSRS (

• Remove the sealing head (

MSRS

(11)).

Figure 4

Figure 4

(5)).

Figure 4

(23)).

(3)).

• Clean the sealing head if necessary.

• Loosen the probe mounting plate
fastener (

• Unscrew the corner plate (2 CHC
screws M6).

Figure 4

(19, 20)).

• Draw back the mounting plate.

O ring

Sealing
head

• Bring the attachment plate close to the corner plate.

• Fasten the corner plate by pushing it down so that the lock washers lay against
the furnace upper cheek.

• Tighten up the probe mounting plate fastener.

• Re-insert the clean sealing head with the new MSRS (Ref 204 011) and new
o-rings (Ref 108 006) (CAUTION: the head of the MSRS (1) has to stop

against the bearing of the sealing head body (3)). (See

• Connect the MSRS and the cable according to the diagram

• 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.

Figure 16.

)

(Figure 16).

• Replace the cover.

• Power up the analyzer.

• Wait for one hour.

• Re-fi t the probe inner tube.

• Set self-cleaning (0.10 code).

• Wait for a few hours before calibrating the analyzer (see Section 3.3.3).

Michell Instruments 37

MAINTENANCE

XZR500 User’s Manual

4.4 Replacement of the XZR500 Microcontroller Card

1. 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.

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

3. Disconnect the fl at cable from the microcontroller card.

4. Remove the faulty microcontroller card.

5. Fit the new microcontroller card.

6. Connect the fl at cable to the new card.

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

8. Restore the standard confi guration (see Section 3.3.2).

9. 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

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

Table 7 Fuse Replacement

38 97137 Issue 8, April 2017

XZR500 User’s Manual

4.6 Error Messages

This section explains the most common error messages that could appear during
operation:

1.

This message appears when the content of the EEPROM is corrupted. This problem can
occur when the microcontroller card is replaced with a non-compatible version. All the
adjustment parameters are lost. Press RESET (

• If the message does not disappear after RESET has been activated check
the microcontroller card (see Section 4.4).

O2 Concentration

Storing fault / Value

Figure 7)

MAINTENANCE

to cancel the message.

2.

Furnace temperature

Low alarm / Value

The message “Low alarm” alternates every 2 seconds with the value of the temperature
measured. It will appear when the furnace temperature is 20°C below the set temperature.

Probable cause(s):

• The analyzer was just powered up so the furnace is warming up.

Wait until the right temperature is reached.

• There is a short-circuit between the thermocouple’s threads, causing the
analyzer to measure the temperature of the short-circuit instead of the
furnace temperature.

Check the thermocouple threads to make sure they are not short-circuiting.

• If the red LED (heating indicator) is lit continuously, the furnace is under­powered.

Verify the analyzer’s power supply voltage.

• Faulty furnace.

Michell Instruments 39

MAINTENANCE

3.

Calibration error.

Probable cause(s):

• The calibration gas value that was stated in the parameter’s sequence in
Access Code 0.12 does not correspond to the actual calibration gas value.

XZR500 User’s Manual

Calibration

fault

Press RESET (
is the same as the actual calibration gas value (refer to Section 3.3.2.1).

• Faulty MSRS - this must be replaced

4.

Figure 7)

or check that the test gas value in Access Code 0.12

TC wire break

General alarm

Alternately with

Furnace temperature

“Value”

This message appears when there is a problem with the thermocouple or the
thermocouple wire.

Probable cause(s):

• The thermocouple’s connection between the electronic system and the
sensor is cut.

• Faulty thermocouple - replace the MSRS.

40 97137 Issue 8, April 2017

XZR500 User’s Manual

5 SPARE PARTS

XZR-CKNG Calibration kit without gas cylinder
XZR-CK1G Calibration kit with one gas cylinder (
XZR-CK2G Calibration kit with two gas cylinders (
XZR-CYL-02% 2% O2 bal. N2 gas cylinder as spare
XZR-CYL-08% 8% O
XZR500-FUR Spare part furnace for fl ue 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
XZR500-103002 Microcontroller card (% K)
XZR500-108001 Gasket for XZR500 fl ange (x2)
XZR500-209154 Gasket for XZR500 fl ange (x10)
XZR500-108002 Gasket for XZR500 wheel
XZR500-209143 Inner Tube Gaskets (x10)
XZR500-209144 Rear Nut Gaskets (x10)
XZR500-104003 XZR500 Cable (per meter)
XZR500-203006 XZR500 furnace
XZR500-109015 SS bulkhead union
XZR500-109004 1/8’’ SS plug

bal. N2 gas cylinder as spare

2

approximately 8%

)

approximately 2% and 8%

)

Michell Instruments 41

APPENDIX A

XZR500 User’s Manual

Appendix A

Technical Specifi cations

42 97137 Issue 8, April 2017

XZR500 User’s Manual

Appendix A Technical Specifi cations

Sensor Type

Measurement Principle

Performance

Gas Requirements Typical exhaust gas
Measurement Range 0.01 to 25% Oxygen
Accuracy Better than ± 2% of reading
Response Time Gas speed 0.8m/s: T90 <100s

Repeatability ± 0.1%
Fidelity 1% per month
Linearity Better than ± 1%
Sample Flow Rate Flue gas at 0.5 m/sec (17.65 ft/s) minimum rate
Maximum Sample Pressure Depending on application
Maximum Sample

Temperature

Zirconium oxide sensor with metallic sealed reference and K Type
T/C

Gas speed 2m/s: T90 <60s

1300°C (2372°F) (see probe selection in Wetted Materials below)

APPENDIX A

Outputs

Output Signal

Output Load Over 1000 Ω
Self-diagnostics Included in readout
Output Ranges Freely confi gured between 0.01 to 25%

Alarms

Display Resolution

Power Supply 110 V (100 to 120) 50/60 Hz or 220 V (190 to 240) 50 Hz
Power Consumption 110 VA
Ambient Temperature Range 0 to +55°C (+32 to +131°F)
Sensor Temperature 700°C (1292°F)
Operating Humidity 5 to 90% RH without condensation

One 0/4 to 20 mA linear with galvanic insulation output
2nd optional output

2 alarms; user adjustable (10W)
1 fault alarm

0.1% in standard
(0.01% on request)

Physical

Dimensions

Weight 10 to 15 kg depending on application

Wetted Materials
(Maximum temperature)

Probe Lengths 0.4, 0.6 and 0.9m (15.75, 23.62, 35.43”)
Installation Stack and wall mounting

Housing Ingress Protection

300 x 300 x 200mm (control)
290 x 135 x 650mm (sensor)

304 L Stainless steel (700°C) (1292°F)
Inconel 600 (1000°C) (1832°F)
HR160 (600 to 1000°C) (1112°F to 1832°F)
C2000 (600°C) (1112°F)
Halar coating (120°C) (248°F)
Ceramic (1300°C) (2372°F)

Weather proof enclosure to sensor: IP53
Control unit: IP52

Michell Instruments 43

APPENDIX B

XZR500 User’s Manual

Appendix B

Confi guration for the

RS232 Port

(Optional)

44 97137 Issue 8, April 2017

XZR500 User’s Manual

Appendix B Confi guration for the RS232 Port (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

APPENDIX B

• pin 3 pin 3

• pin 5 pin 5

• strap 7-8 strap 7-8

Commands:

_ corresponds to the spacing bar

 corresponds to the return key

Michell Instruments 45

APPENDIX B

Mnemonic ASCII Value

XZR500 User’s Manual

_OXY

_TEM

_UMV

_ANV

_ALR

_CAL

_FIN

_ACQ

_ETA

E_ETA_X.XX

_STP

E_STP_XXX.XX

_AL1

E_AL1

_AL2

E_AL2

_NET

_YYY
_TCA
_BRK

_PAB

O2 concentration

Furnace temperature
MSRS voltage
Ambient temperature
K1, K2, K3 Relay status

K1 + K2 + K3 = from 0 to 7
(1) (2) (4)

Sets self-calibration after 10 minutes bleed RECEIPT

Sets a 5 minutes bleed in case of failure in calibration RECEIPT

Acknowledges the alarms
Display of calibration gas value
Sets calibration gas value
Display of furnace temperature set point
Sets furnace temperature
Displays fi rst alarm level
Sets fi rst alarm level
Displays second alarm level
Sets second alarm level
Starts self cleaning
Unknown entry
Measured furnace temperature + coef. due to adjustment
Allows:

Ending the bleed during calibration
Ending self-cleaning and starting cooling down

Value of atmospheric pressure

XX.XX or

X.XXE XX

XXX.XX
XXX.XX

XX.XX

X

PURGE?

DEFAULT
RECEIPT

XX.XX

X.XX
XXX.XX
XXX.XX
XXX.XX

XX.XX

XXX.XX

XX.XX

RECEIPT

ERROR

XX.XX

XX.XX

XXXX.XX

46 97137 Issue 8, April 2017

XZR500 User’s Manual

APPENDIX C

Appendix C

Calculation of CO

2

Michell Instruments 47

APPENDIX C

Appendix C Calculation of CO2

The formula below shows how to calculate CO2 knowing the oxygen content and the
fuel burned:

CO

= K2 * (20.9-O2)/20.9

2

where K2 is absolute max CO2

XZR500 User’s Manual

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 specifi ed, CO2 factor equals 0. When this factor is more than 10,
the display will indicate the calculated CO2.

In measuring mode, the display will show:

Concentration CO2 xx.x%

Concentration O2 xx.x%

48 97137 Issue 8, April 2017

XZR500 User’s Manual

APPENDIX D

Appendix D

XZR500 Sensor Head and

Probe

General Dimensions

Michell Instruments 49

APPENDIX D

XZR500 User’s Manual

Appendix D XZR500 Sensor Head and Probe General Dimensions

S

290mm (11.41”)

S

S

Figure 19

260mm (10.24”)

XZR500 Sensor Head & Probe General Dimensions

97mm (3.82”)

S

S

S

X = 400, 600 or 900mm

S

133mm (5.24”)

S

S

290mm (11.41”)

S

X

S

S

Probe Version

Outer Tube Dimensions

Outer Diameter x Wall Thickness

Inner Tube Dimensions

Outer Diameter x Wall Thickness

Stainless Steel 33.4 x 3.37mm (1.31 x 0.13”) 13.7 x 1.65mm (0.54 x 0.06”)

Inconel 33.4 x 2.77mm (1.31 x 0.11”) 13.7 x 2.24mm (0.54 x 0.08”)

HR160 & C2000 33.4 x 3.38mm (1.31 x 0.13”) 13.7 x 1.65mm (0.54 x 0.06”)

Ceramic 30 x 2.5mm (1.18 x 0.09”) 14 x 5mm (0.55 x 0.19”)

50 97137 Issue 8, April 2017

XZR500 User’s Manual

APPENDIX E

Appendix E

Back Flushing System

(Optional)

Michell Instruments 51

APPENDIX E

Appendix E Back Flushing System (optional)

The pressurized probe cleaning system comprises:

• A steel housing containing electronics and a connector block.

• A CD Rom for programming the automaton.

• An electro-valve with a connection to place on the back of the 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 drawing below:

XZR500 User’s Manual

h. Locking ring

}

i. Rear nut

g. Gasket for locking ring

}

3 marks to indicate

}

the bevelled edge

}

Nut

}

}

}

Gasket

5°

}

}

j. Gasket

Horizontal line

f. Inner probe tube

}

Bevelled edge

}

e. Probe head

}

d. Gasket for flange

}

c. Outer tube

}

b. Gasket for flange

}

}

Gas Inlet hole

a. Tubular
counter flange

}

Figure 20

52 97137 Issue 8, April 2017

Position of the Probe

XZR500 User’s Manual

The output signal is frozen when the fl ushing sequence starts, it is free after t3.

The electro-valve opens after t1 during t2. Factory settings are:

• t1 = 2 seconds

• t2 = 3 seconds

• t3 = 20 seconds

Apply pressure (5-6 bars) during a short time (t2). The operator will decide the
frequency of cleaning, once every hour to once a month, according to the conditions of
use (factory setting = see the notice of the automaton).

NOTE: t2 should be short. Instead of leaving the 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 fl ow of cold air would cool the
inside of the probe and this might encourage corrosion.

APPENDIX E

t3

t1

t2

t0

Make the connections as follows:

t0 beginning of the cycle, 4-20mA freezing
t1 time between the beginning of the cycle

and the valve opening

t2 duration for which valve is open
t3 duration of 4-20 mA freezing

>

• terminals 1 & 2: 230V-50Hz mains power supply

• terminals 3 & 4: wiring of electro-valve

• terminals 5 & 6: to connect with terminals 37 and 38 in the Control Unit

To modify the monitoring sequence of the fl ushing system, please refer to the manual
supplied with the automaton.

Michell Instruments 53

APPENDIX F

XZR500 User’s Manual

Appendix F

Heated Flue Gas

Ejection System (Optional)

54 97137 Issue 8, April 2017

XZR500 User’s Manual

Appendix F Heated Flue Gas Ejection System (Optional)

The optional fl ue gas ejection system with heating is suitable for particularly severe
conditions of measurement. i.e. high stack gas temperature and high dust content.
In these cases a version without the inner probe tube can be used. A compressed air
ejection system draws the fl ue gases through the probe tube and heating minimizes
probe clogging. The system must be supplied with dry and de-oiled compressed air at
a pressure that can be adjusted between 0 and 3 relative bars.

The synoptic diagram of the installation follows. The system comprises:

• An XZR500 Sensor Head, without inner probe tube

• An air-ejector with adjustable fl ow placed at the sensor rear side. It is
heated and insulated

• An enclosure for controlling the ejector heating

• An intermediate junction box in case there is a large distance between
the probe and the regulation enclosure

APPENDIX F

• A compressed air connecting system

• Michell Instruments does not supply the system for cleaning the
compressed air and regulating the inlet pressure: the pressure regulator
should supply pressure between 0 and 3 bar.

Supply of compressed air
(CAUTION - PRESSURE
REGULATOR REQUIRED)

i

Heating
regulation
enclosure

Flue gas
exhaust

Control

Unit

i

STACK

Sensor

Head

i

Heated ejector

230 VAC Supply

Figure 21

Installation of the Ejector/Heating System

Michell Instruments 55

APPENDIX F

1.5mm2 Brown

2

Blue

1.5mm

XZR500 User’s Manual

F1

6A

2

1.5mm

Blue

2

1.5mm

Brown

5

6

1.5mm2
Blue

2

Regulator
CB100

11 12

Green

1

2

4

5

-

3

1.5mm
Brown

L1 3+

T1 4

2

2

1.5mm
Brown

1

White

Compensated cable
TC-K

Connector
TC-K

Figure 22

2

3

1

230V/6A Supply

5

6

4

To the heating insulator

Enclosure for Controlling the Ejector Heating - General Wiring Diagram

Confi guring the CB100 temperature regulator:

• Verify the display when powering up the regulator.

• To 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 seconds

- Press the “SET” and R/S” keys: at “CODE”, enter code “0000”

- Get to S L 4, enter code “0000”

- Get to S L 5, enter code “0000”

• Adjustment of high threshold, still in the confi guration menu:

- Validate with the “SET” key up to “CODE”, enter code “1”

- Press the “SET” key

- At “SLH”, set the high-temperature maxi=203°C (using the scroll

keys and the “SET” key)

- At “SLL”, set the low-temperature (mini 150°C)

- Validate with the “SET” key up to “CODE”, enter code “0” and set

back S L 4

and S L 5 at 1

- To exit press “SET” and “R/S” keys

56 97137 Issue 8, April 2017

XZR500 User’s Manual

Specifi c preventive maintenance for the optional heated ejector:

Because of the high rate of dust present in this kind of application, regular preventive
maintenance is essential.

Because blocking is likely to occur in the heated ejector it should be cleaned out regularly
to prevent it from getting completely clogged up. A small stick (like a welding stick) or
a metal swab should 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 optimize the installation and reduce the risk of clogging, mount the probe
on a small fl ange. We recommend Michell Instruments’ optional counter-fl ange - see
Appendix G). Provide proper insulation for both the fl ange and the ejector.

Application and wiring examples:

APPENDIX F

230V Supply

4-20mA Output

Control Unit (201030)

d

400 x 600 P200 Polyester enclosure

d

Cable (104003)

d

TC-K Compensated cable (104059)

d

2 x 1.5mm² PRFE shielded cable (104069)

d

Michell Instruments 57

APPENDIX G

XZR500 User’s Manual

Appendix G

Mounting Options

58 97137 Issue 8, April 2017

XZR500 User’s Manual

Appendix G Mounting Options

G.1 Tubular Counter Flange and Insulators

Up

h

h

APPENDIX G

100mm (3.93”)

g

40mm (1.57”)

g

Figure 23

g

g

g

70mm (2.75”)

80mm (3.14”)

h

55mm (2.16”)

g

g

XZR500 Flange and Back Flange (Optional)

MADE OF TWO HALF-SHELLS ALUMINUM PROTECTIVE COVER (ISOXAL 8/10)

A.A.

175mm

g

Ø185mm

g

h

Ø85±2

37mm (1.45”)

gh

h

M8 SS STUD

(x4 at 90

A

g

h

o

)

CLOSED INSULATOR

GLASS WOOL (PS1713 ISOVER)

Aluminum protective cover (ISOXAL 8/10)

A.A.

80

h

40

h

h

h

Glass wool PS1713 (ISOVER)

h

A

g

A

g

h

30

h

110mm

h

50

30

h

h

g

h

h

h

h

h

h

30

h

110mm

50

h

h

h

h

30

A

Figure 24

Insulators (Flange and Rear Sealing Screw)

Michell Instruments 59

APPENDIX G

G.2 Mounting Plate Dimensions

100cm (39.3”)

45° 45°

100cm (39.3”)

XZR500 User’s Manual

4cm (1.6”) 30cm (11.8”)

M8

(x4 at 90°)

ø55

Figure 25

ø40

Mounting Plate Dimensions

60 97137 Issue 8, April 2017

XZR500 User’s Manual

APPENDIX H

Appendix H

Second 4-20mA Output

Michell Instruments 61

APPENDIX H

Appendix H Second 4-20 mA Output

The optional 2nd analog output allows acquisition of a linear 4-20 mA current
corresponding to the 0.1% - 25% scale (this scale cannot be changed).

This 4-20 mA output 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

2nd 4-20 mA Output Connector

XZR500 User’s Manual

Electronic Card

h

- +

27 28

Connector Connector

29

Figure 26

39

38

Wiring of the Second 4-20 mA Output

For the connection use
shielded cable 2 x 0.75mm².
Bare 8mm of the wire end on
the terminal’s side and
connect the braid to the
copper bar near the cable
gland.

50

62 97137 Issue 8, April 2017

XZR500 User’s Manual

APPENDIX I

Appendix I

Automatic Calibration

(Optional)

Michell Instruments 63

APPENDIX I

Appendix I Automatic Calibration (Optional)

The analyzer can be automatically calibrated, if this function has been purchased, and
can be as simple as pressing a button to start up the sequence. This assumes that the
calibration gas is connected permanently and the cal gas value is properly confi gured
in the electronics.

The sequence can be initiated by either using the keys at on the control unit or via your
computer with RS232 interface (refer to Appendix B).

The calibration sequence lasts 5 minutes.

The output signal is frozen at its last value before setting the sequence and is unfrozen
at the end of the purging sequence.

XZR500 User’s Manual

64 97137 Issue 8, April 2017

XZR500 User’s Manual

APPENDIX J

Appendix J

Quality, Recycling

& Warranty

Information

Michell Instruments 65

APPENDIX J

XZR500 User’s Manual

Appendix J Quality, Recycling & Warranty Information

Michell Instruments is dedicated to complying to all relevant legislation and directives.
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

• Confl ict Minerals

• FCC Statement

• Manufacturing Quality

• Modern Slavery Statement

• Pressure Equipment Directive

• REACH

• RoHS2

• WEEE2

• Recycling Policy

• Warranty and Returns

This information is also available in PDF format.

66 97137 Issue 8, April 2017

XZR500 User’s Manual

APPENDIX K

Appendix K

Return Document &

Decontamination Declaration

Michell Instruments 67

APPENDIX K

XZR500 User’s Manual

Appendix K Return Document & Decontamination Declaration

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IMPORTANT NOTE: Please complete this form prior to this instrument, or any components, leaving your
site and being returned to us, or, where applicable, prior to any work being carried out by a Michell
engineer at your site.

Instrument Serial Number
Warranty Repair? YES NO Original PO #
Company Name Contact Name

Address

Telephone # E-mail address
Reason for Return /Description of Fault:

Has this equipment been exposed (internally or externally) to any of the following?
Please circle (YES/NO) as applicable and provide details below

Biohazards YES NO
Biological agents YES NO
Hazardous chemicals 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 method of cleaning/decontamination

Has the equipment been cleaned and decontaminated? YES NOT NECESSARY
Michell Instruments will not accept instruments that have been exposed to toxins, radio-activity or bio-hazardous

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Work will not be carried out on any unit that does not have a completed decontamination declaration.

Decontamination Declaration

I declare that the information above is true and complete to the best of my knowledge, and it is safe for Michell
personnel to service or repair the returned instrument.

Name (Print) Position

Signature Date

F0121, Issue 2, December 2011

68 97137 Issue 8, April 2017

http://www.michell.com