Michell Instruments XZR500 Operating Manual
XZR500ST
Oxygen Analyzer
User’s Manual
97137 Issue 8
April 2017
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XZR500
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© 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
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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
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