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Please fill out the form(s) below for each instrument that has been purchased. Use this information when contacting Michell Instruments for service purposes. Product Name Order Code Serial Number Invoice Date Installation Location Tag Number Product Name Order Code Serial Number Invoice Date Installation Location Tag Number...
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.
XZR500 User’s Manual Abbreviations The following abbreviations are used in this manual: alternating current Ampere °C degrees Celsius °F degrees Fahrenheit hertz kilogram(s) l/hour liters per hour milli Ampere mbars millibars millimeter(s) parts per million Temperature Volt Watts Warnings The following general warnings listed below are applicable to this instrument. They are repeated in the text in the appropriate locations.
XZR500 User’s Manual INTRODUCTION INTRODUCTION XZR500 Series Oxygen Analyzers are designed to measure the oxygen content in flue gases between 0.01% and 25% O . They allow for the improvement of a boiler’s performance, increasing equipment service life and surveying emissions, thereby contributing to protecting the environment.
XZR500 User’s Manual 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. The volumetric concentration (expressed here in O %vol.) is determined by the ratio between the oxygen partial pressure (Ppmeas) and the atmospheric pressure (Ptot).
XZR500 User’s Manual INTRODUCTION 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.
XZR500 User’s Manual 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 5 mm diameter viton O-ring. It is dust proof and waterproof and can be mounted outdoors.
XZR500 User’s Manual INTRODUCTION 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 Figure 5 and Table 1 describes the operation of the keys.
XZR500 User’s Manual INTRODUCTION • 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 900 mm in length, with an outer diameter of 40 •...
XZR500 User’s Manual INTRODUCTION 1.3.2 Optional Equipment • Tubular counter-flange for fixing the probe to the stack (see Appendix G) • Flange insulation (to prevent condensation forming) • Extra length of cable (up to 100 meters) • Calibration and verification kit •...
XZR500 User’s Manual INSTALLATION INSTALLATION General Mounting Precautions • Place the probe as close as possible to the process (without breaching the flame 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 (Figure 4) , and tighten-up the SS plug for calibration gas inlet ( Figure 4 (15)).
XZR500 User’s Manual INSTALLATION Probe Mechanical Installation e. Probe head g. Gasket for locking ring 3 marks to indicate h. Locking ring d. Gasket for flange b. Gasket for flange the bevelled edge c. Outer tube f. Inner probe tube a.
XZR500 User’s Manual INSTALLATION Place the outer probe (c) with the flange gasket (b) according to the drawing in Figure 8 . The gas inlet hole should face the process flow. Process ow Gas inlet hole Gas inlet ...
XZR500 User’s Manual INSTALLATION Place the gasket onto the inner tube (f) and insert into the probe head (e) (see Figure 8). Make sure the bevelled edge of the inner tube tip faces the opposite direction to the gas inlet hole on the outer tube (c) as shown below.
XZR500 User’s Manual INSTALLATION Control Unit Mechanical Installation The Control Unit is supplied with lugs for fitting on the wall ( see Figure 7). Wiring Only authorized personnel should open the control unit. Take all precautionary measures to avoid accidents related to electrostatic shocks.
XZR500 User’s Manual INSTALLATION 2.4.2.1 Connection to the Mains Use shielded cable (2 x 1.5 mm² 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 0.75 mm²) is used and terminated appropriately.
XZR500 User’s Manual INSTALLATION Connect the end of the cable - using the end with 6 wires - according to the Figure 14 wiring diagram. MSRS Furnace probe Ref. connector Supplied Cable Probe Wiring Diagram Figure 14 Michell Instruments...
XZR500 User’s Manual OPERATION OPERATION 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...
XZR500 User’s Manual OPERATION Start-Up After finishing and verifying the connections, power up the analyzer. Oven Temperature During warm-up, the display shows: Low alarm /xxx.x 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.
XZR500 User’s Manual OPERATION Display, Configuration and Adjustment During configuration 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 configuration and allow the analyzer’s temperature to stabilize after configuration.
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XZR500 User’s Manual OPERATION Press and hold the [*] Enter key again to Your selection? re-enter the main selection menu Visu * Cal + Set - Enter Press the [*] key from the main Oven temperature selection menu to show the second parameter: Oven temperature xxx.x°C Press and hold the [*]...
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XZR500 User’s Manual OPERATION Enter Press and hold the [*] key to Your selection? re-enter the main selection menu Visu * Cal + Set - Enter Press the [*] key from the main Absolute pressure selection menu to show the fifth parameter: Absolute pressure xxxx.x mBar Repeating the process again will return...
XZR500 User’s Manual OPERATION 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 configuration 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.
XZR500 User’s Manual OPERATION 3.3.2.1 Access code 0.12 - quick settings From the main menu page, press and hold the Your selection? Enter key until the main selection menu appears. Visu * Cal + Set - Press the [–] (Set-up menu) from the main Access code? selection menu to show the Access code page.
XZR500 User’s Manual OPERATION Alarm 1 The ‘type of alarm’ screen is used to set- Type Alarm 1 up the direction for the Alarms 1 and 2 to the values ‘High’ and ‘Low’. The ‘High’ alarm will be activated when increasing 2.00 the signal value to above the set-point level.
XZR500 User’s Manual OPERATION Alarm hysteresis This page shows the value for the relay hysteresis Relay hysteresis that is expressed in percentage oxygen. Press the [+] and [–] keys to adjust the value. Press 0.10 the [*] Enter key to confirm the selection and move to the next parameter.
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XZR500 User’s Manual OPERATION Offset compensation MSRS cold junction This page shows offset value Offset room temperature compensation of the MSRS thermocouple cold junction. The value is factory pre-set and may 3.00 vary for individual analyzers. CAUTION: Do not change the value without consulting the factory.
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XZR500 User’s Manual OPERATION Output Signal This page shows the available current ranges 0 or 4...20 mA for the signal output. Enter 0.00 for 0...20 mA and 4.00 for 4...20 mA. Press the [+] and [–] 4.00 Enter keys to adjust the value. Press the [*] key to confirm the selection and move to the next parameter.
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XZR500 User’s Manual OPERATION Gr value This value is for factory settings only. 10.00 CAUTION: Do not change the value without consulting the factory. Press the [*] Enter key to move to the next parameter. Ti value This value is for factory settings only. 10.00 CAUTION: Do not change the value without consulting the factory.
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XZR500 User’s Manual OPERATION Cell self-cleaning This function allows the analyzer to self-clean Cleaning cell the sensor cell. The cleaning process lasts for one hour. The furnace is heated to 780°C in 0.00 order to clean itself and the MSRS. Remove the inner probe tube to make the self-cleaning more efficient.
XZR500 User’s Manual OPERATION 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.
XZR500 User’s Manual 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 flow at this time. From the main page, press and hold the Your selection? [*] (Enter key) until the main selection...
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XZR500 User’s Manual OPERATION The calibration process takes about 10 Adjustment sequence minutes. During calibration the screen alternates, displaying messages xx.xx - ‘running’ and the current value of calibration. Press the [*] key to finish the calibration Adjustment sequence once this value is stabilized, otherwise the calibration process will end automatically running after the 10 minutes time limit is reached.
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XZR500 User’s Manual OPERATION Once the verification step is completed Stop gas? or skipped, the screen shows ‘Stop gas?’ to remind the user to switch off the calibration/control gas. Yes * No - Confirm the finish of the calibration with the [*] key and move to next page.
XZR500 User’s Manual OPERATION Your selection? Visu* Cal+ Set - The test gas value cannot be modified at this point. Test gas value In order to modify it, quit the process from ‘Inject Gas?’ 8.00 page and set it in Access code 0.12 ...
XZR500 User’s Manual MAINTENANCE MAINTENANCE 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 ( Figure 4 (23)). •...
XZR500 User’s Manual MAINTENANCE Replacement Of The XZR500 MSRS • Remove the probe inner tube ( Figure 4 (23)). • Turn off the analyzer and disconnect the power lead. • Wait until the furnace and sensor housing cool down (at least 45 minutes). •...
XZR500 User’s Manual MAINTENANCE Replacement of the Furnace • Remove the probe inner tube ( Figure 4 (23)). • Turn off the analyzer and disconnect the power lead. • Wait until the furnace and the sensor housing cool down (around 45 minutes). •...
XZR500 User’s Manual MAINTENANCE Replacement of the XZR500 Microcontroller Card While the power is on, note down the values of all the parameters (see Section 3.3.2). All settings and parameters will be lost when the faulty microcontroller card is changed. Turn off the power and disconnect the lead from the mains.
XZR500 User’s Manual MAINTENANCE Error Messages This section explains the most common error messages that could appear during operation: Concentration Storing fault / Value 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.
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XZR500 User’s Manual MAINTENANCE Calibration fault 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. Press RESET ( Figure 7) or check that the test gas value in Access Code 0.12 is the same as the actual calibration gas value (refer to Section 3.3.2.1).
XZR500 User’s Manual SPARE PARTS XZR-CKNG Calibration kit without gas cylinder Calibration kit with one gas cylinder ( approximately 8% ) XZR-CK1G Calibration kit with two gas cylinders ( approximately 2% and 8% ) XZR-CK2G XZR-CYL-02% 2% O bal. N gas cylinder as spare XZR-CYL-08% 8% O...
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XZR500 User’s Manual APPENDIX A Appendix A Technical Specifications 97137 Issue 8.1, January 2021...
XZR500 User’s Manual APPENDIX A Appendix A Technical Specifications Sensor Type Zirconium oxide sensor with metallic sealed reference and K Type Measurement Principle Performance Gas Requirements Typical exhaust gas Measurement Range 0.01...25% Oxygen Accuracy Better than ± 2% of reading Response Time Gas speed 0.8m/s: T90 <100s Gas speed 2m/s: T90 <60s...
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XZR500 User’s Manual APPENDIX B Appendix B Configuration for the RS232 Port (Optional) 97137 Issue 8.1, January 2021...
XZR500 User’s Manual APPENDIX B Appendix B Configuration 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: •...
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XZR500 User’s Manual APPENDIX B Mnemonic ASCII Value _OXY concentration XX.XX or X.XXE XX Furnace temperature _TEM XXX.XX _UMV MSRS voltage XXX.XX _ANV Ambient temperature XX.XX _ALR K1, K2, K3 Relay status K1 + K2 + K3 = from 0 to 7 _CAL...
XZR500 User’s Manual APPENDIX C Appendix C Calculation of CO Michell Instruments...
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XZR500 User’s Manual APPENDIX C Appendix C Calculation of CO The formula below shows how to calculate CO knowing the oxygen content and the fuel burned: = K2 * (20.9-O )/20.9 where K2 is absolute max CO Set K2 factor in Access code 0.20, pressing the + and - keys, i.e., for coal, capture 18.39.
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XZR500 User’s Manual APPENDIX D Appendix D XZR500 Sensor Head and Probe General Dimensions Michell Instruments...
XZR500 User’s Manual APPENDIX D Appendix D XZR500 Sensor Head and Probe General Dimensions 133mm (5.24”) 97mm (3.82”) X = 400, 600 or 900mm 260mm (10.24”) Figure 19 XZR500 Sensor Head & Probe General Dimensions Outer Tube Dimensions Inner Tube Dimensions Probe Version Outer Diameter x Wall Thickness...
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APPENDIX E XZR500 User’s Manual Appendix E Back Flushing System (Optional) Michell Instruments...
XZR500 User’s Manual 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.
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APPENDIX E XZR500 User’s Manual The output signal is frozen when the flushing sequence starts, it is free after t3. The electro-valve opens after t1 during t2. Factory settings are: • t1 = 2 seconds • t2 = 3 seconds •...
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XZR500 User’s Manual APPENDIX F Appendix F Heated Flue Gas Ejection System (Optional) 97137 Issue 8.1, January 2021...
XZR500 User’s Manual APPENDIX F Appendix F Heated Flue Gas Ejection System (Optional) The optional flue 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 flue gases through the probe tube and heating minimizes probe clogging.
XZR500 User’s Manual APPENDIX F 1.5mm Brown 1.5mm Blue 1.5mm Blue 1.5mm Brown 1.5mm 1.5mm Brown Blue Regulator CB100 11 12 Compensated cable TC-K 1.5mm Brown Connector TC-K 230V/6A Supply To the heating insulator Figure 22 Enclosure for Controlling the Ejector Heating - General Wiring Diagram Configuring the CB100 temperature regulator: •...
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XZR500 User’s Manual APPENDIX F Specific 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.
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XZR500 User’s Manual APPENDIX G Appendix G Mounting Options 97137 Issue 8.1, January 2021...
APPENDIX G XZR500 User’s Manual Appendix G Mounting Options Tubular Counter Flange and Insulators 37mm (1.45”) 100mm (3.93”) M8 SS STUD (x4 at 90 55mm (2.16”) XZR500 Flange and Back Flange (Optional) Figure 23 MADE OF TWO HALF-SHELLS ALUMINUM PROTECTIVE COVER (ISOXAL 8/10) A.A.
XZR500 User’s Manual 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: •...
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APPENDIX I XZR500 User’s Manual Appendix I Automatic Calibration (Optional) Michell Instruments...
XZR500 User’s Manual 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 configured in the electronics.
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APPENDIX I XZR500 User’s Manual The default factory settings are: • t1 = 1 week • t2 = 20 minutes • t3 = 10 minutes During a short interval (t3), the gas flow should be at 7l/h +/- 2l/h. You can set the frequency of auto-adjustment (daily, monthly, yearly or customized) according to the operating conditions.
XZR500 User’s Manual APPENDIX I Adjusting the Sequence Parameters Some timing can be changed manually on the automaton (see below). To do so, press the menu key and then use the same key to select the Parameters menu: This gives access to the timing parameters. Modification of PERIODICAL TIMING R00B046 When the timing name R00B046 is blinking, use the (–>) and (<–) keys to bring the cursor to the number of the cycle you want to change and select it with the (+) and...
XZR500 User’s Manual APPENDIX J 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: •...
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APPENDIX K XZR500 User’s Manual Appendix K Return Document & Decontamination Declaration Michell Instruments...
XZR500 User’s Manual APPENDIX K Appendix K Return Document & Decontamination Declaration Decontamination Certificate 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.
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