Michell Instruments QMA401 User manual

QMA401
Trace Moisture Analyzer
User’s Manual
97450 Issue 2
March 2018

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Use this information when contacting Michell Instruments for service purposes.
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© 2018 Michell Instruments
This document is the property of Michell Instruments Ltd. and may not be copied or
otherwise reproduced, communicated in any way to third parties, nor stored in any Data
Processing System without the express written authorization of Michell Instruments Ltd.
QMA401
For Michell Instruments' contact information please go to
www.michell.com

QMA401 User’s Manual
iv 97450 Issue 2, March 2018
1 INTRODUCTION ................................................................................................1
1.1 General .............................................................................................................. 1
1.2 Theory of Operation ........................................................................................... 2
1.3 Sample Gas Path ................................................................................................ 2
1.4 Internal Sampling Options ................................................................................... 3
2 INSTALLATION ..................................................................................................6
2.1 Analyzer Storage Instructions .............................................................................. 6
2.2 Unpacking the Instrument ................................................................................... 6
2.3 Electrical Requirements ....................................................................................... 7
2.4 Rear Panel Connections ...................................................................................... 7
2.5 Pressure Safety .................................................................................................. 9
2.6 Connection of Gas Supplies ................................................................................. 9
3 OPERATION ....................................................................................................12
3.1 General Operational Information ........................................................................ 12
3.2 First Time Operation ......................................................................................... 12
3.2.1 Regulating Sensor Pressure.......................................................................... 13
3.2.2 Analyzer Setup ............................................................................................ 14
3.3 Menu Structure ................................................................................................ 15
3.4 Description of Measured Parameters .................................................................. 16
3.5 Main Screen .................................................................................................... 16
3.5.1 Large Display Mode ..................................................................................... 18
3.5.2 Full Screen Graph ........................................................................................ 18
3.6 Main Screen Sub Menus .................................................................................... 19
3.6.1 Warning Screen .......................................................................................... 19
3.6.2 Logging Screen .......................................................................................... 20
3.6.3 Alarm Screen .............................................................................................. 21
3.6.4 Field Calibration Screen ............................................................................... 22
3.6.5 Monitor Screen ........................................................................................... 26
3.7 Settings Menu ................................................................................................. 27
3.7.1 Measurement Screen ................................................................................... 28
3.7.2 Pressure Input ............................................................................................ 31
3.7.3 Outputs Screen ........................................................................................... 34
3.7.4 HMI Screen ................................................................................................ 35
3.7.5 Real Time Clock Screen ............................................................................... 36
3.7.6 Software Communications Screen................................................................. 37
3.7.7 Ethernet Screen .......................................................................................... 37
3.7.8 Field Calibration History ............................................................................... 37
3.7.9 About Screen .............................................................................................. 38
3.8 Sampling Guidelines ......................................................................................... 39
3.9 Measurement Cycle .......................................................................................... 42
3.10 Calibration Cycle ............................................................................................... 44
Contents
Safety .............................................................................................................................. viii
Warnings ................................................................................................................... viii
Electrical Safety ......................................................................................................... viii
Pressure Safety .......................................................................................................... viii
Hazardous Materials (WEEE, RoHS2 & REACH) ............................................................. viii
Calibration (Factory Validation) ......................................................................................ix
Repair and Maintenance ...............................................................................................ix
Abbreviations ...................................................................................................................... x

QMA401 User’s Manual
Michell Instruments v
4 MAINTENANCE ................................................................................................46
4.1 Removal and Replacement of the Power Supply Fuse .......................................... 47
4.2 Removal and Replacement of the Dryer Module .................................................. 47
5 CALIBRATION ..................................................................................................49
5.1 Traceability ...................................................................................................... 49
6 APPLICATION SOFTWARE OVERVIEW ...............................................................51
6.1 System Requirements ....................................................................................... 51
6.2 System Connection ........................................................................................... 51
6.3 Getting Started ................................................................................................. 52
6.3.1 Connection Method (Serial Connection (RS485 or USB) .................................. 53
6.3.1.1 RS485 Connection ................................................................................. 53
6.3.1.2 USB Connection .................................................................................... 53
6.3.1.3 Modbus TCP Connection (Ethernet) ....................................................... 53
6.4 Main Window ................................................................................................... 54
6.5 Using the Chart ................................................................................................ 55
6.5.1 Chart Options Window ................................................................................. 56
6.6 Data Logging ................................................................................................... 57
6.6.1 Configuring Logging Start Time .................................................................... 58
6.6.2 Configuring Logging Stop Time .................................................................... 58
6.6.3 Starting the Log .......................................................................................... 58
6.6.4 Viewing a Log ............................................................................................. 58
6.7 Parameters / Field Calibration ............................................................................ 58
6.7.1 Field Calibration .......................................................................................... 59
7 SHIPPING .......................................................................................................60
7.1 Preparation for Shipping and Packing ................................................................. 60
Tables
Table 1 Main Screen Parameters ............................................................................. 17
Table 2 Alarm Screen Parameters .......................................................................... 21
Table 3 Calibration Screen Parameters ...................................................................22
Table 4 Monitor Screen Parameters .......................................................................26
Table 5 Measurement Screen Parameters ...............................................................28
Table 6 Outputs Screen Parameters ....................................................................... 34
Table 7 HMI Setup Screen Parameters ...................................................................35
Table 8 Real Time Clock Screen Parameters ........................................................... 36
Table 9 Software Communications Screen Parameters..............................................37
Table 10 Ethernet Screen Parameters ...................................................................... 37
Table 11 Modbus Register Map ................................................................................ 72

QMA401 User’s Manual
vi 97450 Issue 2, March 2018
Figures
Figure 1 Measurement System .................................................................................2
Figure 2 Internal Sampling Options ...........................................................................5
Figure 3 Power Connection .......................................................................................7
Figure 4 Rear Panel Connections ..............................................................................8
Figure 5 Typical Gas Connections ............................................................................10
Figure 6 Initializing Overlay ....................................................................................12
Figure 7 Display During Heating Period ...................................................................12
Figure 8 Typical Display .........................................................................................14
Figure 9 Menu Structure ........................................................................................15
Figure 10 Main Screen .............................................................................................16
Figure 11 Large Display Mode ..................................................................................18
Figure 12 Full Screen Graph .....................................................................................18
Figure 13 Status Screen ...........................................................................................19
Figure 14 Logging Screen ........................................................................................20
Figure 15 Front Panel ..............................................................................................20
Figure 16 Alarm Screen ...........................................................................................21
Figure 17 Field Calibration Screen .............................................................................22
Figure 18 Field Calibration Screen 2 ..........................................................................24
Figure 19 Field Calibration Screen 3 ..........................................................................24
Figure 20 Field Calibration Screen 4 ..........................................................................25
Figure 21 Field Calibration Screen 5 ..........................................................................25
Figure 22 Monitor Screen .........................................................................................26
Figure 23 Settings Menu Screen ...............................................................................27
Figure 24 Measurement Screen ................................................................................28
Figure 25 Carrier Gas Screen ....................................................................................29
Figure 26 Measurement Screen ................................................................................30
Figure 27 External Options .......................................................................................31
Figure 28 Fixed Options ...........................................................................................32
Figure 29 Atmos. Option ..........................................................................................32
Figure 30 User Gas Setup Screen .............................................................................32
Figure 31 Outputs Screen ........................................................................................34
Figure 32 HMI Screen ..............................................................................................35
Figure 33 Real Time Clock Screen .............................................................................36
Figure 34 Software Communications Screen ..............................................................37
Figure 35 Ethernet Screen .......................................................................................37
Figure 36 Calibration History Screen .........................................................................38
Figure 37 About Screen ...........................................................................................38
Figure 38 Measurement Cycle (Phase 1) - Dried Sample Flow .....................................42
Figure 39 Measurement Cycle (Phase 2) Calibration Flow ...........................................43
Figure 40 Calibration Cycle (Phase 1) - Dried Sample Flow .........................................44
Figure 41 Calibration Cycle (Phase 2) - Sample Flow ..................................................45
Figure 42 Typical QMA401 Calibration Certificate .......................................................50

QMA401 User’s Manual
Michell Instruments vii
Appendices
Appendix A Technical Specification ...............................................................................62
Appendix B Calculating Conversion Factors for Gas Mixes ...............................................64
Appendix C Modbus Holding Register Map ....................................................................66
C.1 Set Points and Ranges .................................................................83
C.2 Gases for Gas Correction Values ...................................................84
Appendix D Quality, Recycling, Compliance & Warranty Information ................................ 86
Appendix E Return Document & Decontamination Declaration ........................................ 88

QMA401 User’s Manual
viii 97450 Issue 2, March 2018
Safety
The instrument is designed to be completely safe when installed and operated correctly in accordance
with the information provided in this manual.
This manual contains all the required information to install, operate and maintain this product. Prior
to installation and use of this product, this entire manual should be read and understood. Installation
and operation of this product should be carried out by suitably competent personnel only. The
installation and operation of this product must be in accordance with the instructions provided and
according to the terms of any associated safety certificates. Incorrect installation and use of this
product other than those described in this manual and other than its intended purpose will render
all warranties void.
This product meets the essential protection requirements of the relevant EU directives. Further
details of applied directives may be found in the product specification.
Electricity and pressurized gas can be dangerous. This product must be installed and operated only
by suitable trained personnel.
Warnings
!
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 and where particular attention to personal and
personnel safety must be observed.
DANGER
Electric
Shock Risk
Where this symbol appears in the following sections it is used to
indicate areas of potential risk of electric shock.
Electrical Safety
Ensure electrical safety is complied with by following the directions provided here and observing all
local operation & installation requirements at the intended location of use.
This product is completely safe when using any options and accessories supplied by the manufacturer
of this product for use with it. Refer to Section 2 (Installation) of this manual for further details.
Pressure Safety
For this product to operate satisfactorily, pressurized gas must be connected to it. Observe all the
information contained within this manual and all local operation & installation requirements at the
intended location of use. Refer to Section 2 (Installation) of this manual for further details.
Hazardous Materials (WEEE, RoHS2 & REACH)
This product does not contain or release any prohibited chemicals listed on the SVHC (Substances
of Very High Concern) Candidate List. During the intended normal operation of this product it is not
possible for the user to come into contact with any hazardous materials. This product is designed to
be recyclable except where indicated, see relevant sections in this manual for further details.

QMA401 User’s Manual
Michell Instruments ix
Calibration (Factory Validation)
Prior to shipment, the instrument undergoes stringent factory calibration to traceable standards.
Due to the inherent stability of the instrument, regular factory calibration is not required under
normal operating conditions. The instrument should perform reliably for many years with just basic
maintenance, housekeeping and regular field calibrations from the internal reference (moisture
generator) or a known external reference.
There are, however some consumables that will require periodic replacement.
• Moisture generator - typical lifetime of around 3 years.
• Desiccant column - typical lifetime of around 2 years, but this strongly
depends on the moisture content of the sample gas. The drier the sample
gas, the longer the lifetime of the desiccant.
Michell Instruments can provide a fully traceable factory calibration service for the instrument and it
is recommended that this is considered at intervals of every year of the analyzer's life. Please contact
your local Michell Instruments' office or representative for further details (www.michell.com).
Repair and Maintenance
Apart from user-replaceable components required for routine operational maintenance described
above, the analyzer must only be maintained either by the manufacturer or an accredited service
agent. Refer to www.michell.com for details of Michell Instruments’ worldwide offices contact
information.

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Abbreviations
The following abbreviations are used in this manual:
A ampere
AC alternating current
atm pressure unit (atmosphere)
bara pressure unit (=100 kP or 0.987 atm) (absolute)
barg pressure unit (=100 kP or 0.987 atm) gauge
°C degrees Celsius
°F degrees Fahrenheit
EU European Union
hr hour
Hz Hertz
IEC International Electrotechnical Commission
IP Internet protocol
ml/min milliliters per minute
mg/m3 milligrams per cubic meter
lbs/MMscf pounds per million standard cubic feet
mA milliampere
mins minutes
mmHg millimeter of mercury
Pa pascal
ppmV parts per million (by volume)
ppmW parts per million (by weight)
psia pound(s) per square inch (absolute)
psig pound(s) per square inch (gauge)
RH relative humidity
RS485/232 standards defining the electrical characteristics of drivers & receivers
RTC real time clock
RTU Remote Terminal Unit
SD storage device card
UART universal asynchronous receiver/transmitter
USB Universal Serial Bus
V Volts
" Inch
Δ delta
% percentage
Ω ohms

QMA401 User’s Manual
Michell Instruments 1
INTRODUCTION
1 INTRODUCTION
1.1 General
The QMA401 Moisture Analyzer is designed to provide reliable, fast and accurate
measurement of trace moisture content in a wide variety of applications where keeping
moisture levels as low as possible is of critical importance.
The high-contrast LCD touchscreen display presents all measured data to the user in a
clear and understandable format. The main display incorporates a real-time trend graph
and alarm indicators based on the NAMUR 102 standard. A powerful and intuitive HMI
makes control, logging and configuration of analyzer parameters straightforward.
The instrument provides two user-configurable analog outputs, and ModBus RTU/TCP
communications, allowing it to interface with a SCADA DCS, or by a computer using the
dedicated application software. A pair of adjustable isolated alarm contacts allow the
QMA401 to be used for direct process control.
The QMA401 offers:
• ModBus RTU/TCP
• Datalogging to SD Card
• 2 user-configurable analog outputs
• Status and Process Alarms
Minimal & Straightforward Maintenance
Sophisticated instruments are often complicated and require experience and special care
in use, increasing cost of ownership. The QMA401 differs through its very uncomplicated
approach to field service; the desiccant column is easy to replace via the dryer service
panel on the rear of the instrument. The moisture generator has an average life span of
3 years before maintenance is required.
Automated Calibration for Continued Reliability
The QMA401 incorporates an integrated automatic calibration system for complete
user confidence. Periodic calibration checks of sensor performance can be initiated
on demand, or automatically (at user defined intervals and time of day), providing a
verification against the calibrated moisture generator or an external reference. The
moisture generator at the core of this system is supplied with a calibration traceable to
NPL and NIST.
During an internal calibration cycle, the Data Hold function will prevent any interruption
of dependant processes by holding the analog outputs at the same level for the duration
of the calibration.
Integrated Sample Handling Components
The QMA401 features an optional bypass arrangement to increase transport speed of
the sample.
A pressure regulator can also be specified to increase the range of acceptable input
pressure (rated to 300barg input pressure), and to protect the instrument against
pressure shocks.

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INTRODUCTION
1.2 Theory of Operation
The Quartz Crystal Microbalance (QCM) technology for moisture measurement is
based on monitoring the frequency of a hygroscopic-coated quartz crystal with specific
sensitivity to water vapor.
Bulk adsorption of water vapor onto the coated crystal causes an increase in the crystals
effective mass, modifying its oscillation frequency in a very precise and repeatable
manner. The frequency change is in proportion to the water vapor pressure in the
sample gas, providing a direct measurement of moisture content.
The sorption process is fully reversible with no long-term drift effect, giving a highly
reliable and repeatable measurement.
1.3 Sample Gas Path
The QMA401 measurement system must be supplied with gas at the required pressure
(to match that of its calibration) via the VCR connection on the rear of the instrument.
The flow is controlled automatically.
The sensor cell is located at the end of the sensor block and contains the sensor and
reference oscillators.
Figure 1 shows a schematic diagram of this sampling system:
Sample In
Sample Out
DD
HE1 HE2
V1 V2 V3
MFC
QCH
PS
MG
FC1 FC2 FC3
Key
DD Desiccant column MG Moisture generator
MFC Mass flow controller V1, V2, V3 Solenoid Valves
QCH Sensor cell HE1/HE2 Heat exchanger
PS Pressure sensor FC1 Flow control
Figure 1
Measurement System

QMA401 User’s Manual
Michell Instruments 3
INTRODUCTION
1.4 Internal Sampling Options
The QMA401 is available with a Pressure regulator, or a fast loop bypass with flow
control. Either of these options can be configured independently or together with either
an internal or external particulate filter:
• Pressure regulator
• Fast-loop bypass with flow control
DRYER
OVEN
GAS IN GAS OUT
FILTER
S0 - No sample system. With 15μm internal filtration
DRYER
OVEN
GAS IN GAS OUT
FILTER
PRESSURE
REGULATOR
S1 - Input pressure regulator. With 15μm internal filtration
DRYER
OVEN
GAS IN GAS OUT
FILTER
PRESSURE
REGULATOR
METERING
VALVE
S2 - Input pressure regulator and Fast-loop bypass with
flow control. With 15μm internal filtration

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INTRODUCTION
DRYER
OVEN
GAS IN GAS OUT
FILTER
METERING
VALVE
S3 - Fast-loop bypass with flow control. With 15μm internal filtration.
DRYER
OVEN
GAS IN GAS OUT
PRESSURE
REGULATOR
S4 - Input pressure regulator. External 15μm filter supplied
DRYER
OVEN
GAS IN GAS OUT
PRESSURE
REGULATOR
METERING
VALVE
S5 - Input pressure regulator and fast-loop bypass with
flow control. External 15μm filter supplied

QMA401 User’s Manual
Michell Instruments 5
INTRODUCTION
DRYER
OVEN
GAS IN GAS OUT
METERING
VALVE
S6 - Fast-loop bypass with flow control. External 15μm filter supplied
Figure 2
Internal Sampling Options

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INSTALLATION
2 INSTALLATION
2.1 Analyzer Storage Instructions
In order for this product to be functional upon installation it should be stored in accordance
with the guidelines below:
• The product must be housed in a sheltered area, out of direct sunlight and
rain.
• The product should be stored to minimize the possibility of sitting in ground
water.
• The temperature within the storage environment should be maintained
between -20 to +60°C (-4 to +140°F).
• The humidity within the storage environment must be non-condensing.
• The storage environment must not expose the analyzer to any corrosive
elements.
• The product may stay assembled with its sample conditioning system (if
supplied).
• All electrical and process connections should remain disconnected and capped.
• All protective coatings should remain in place until installation.
• For prolonged periods of storage, the lid of the packaging crate should be
removed to allow air to circulate.
• Any documentation supplied with the product should be removed from the
packaging crate and stored elsewhere to protect its integrity.
For the period from installation of the product to commissioning start-up, the following
precautions should be followed:
• The product and associated sampling system (if supplied) must remain
isolated from the process gas, and the enclosure should remain closed to
ensure ingress protection is maintained.
• If supplied, the sampling system enclosure heating/thermostat circuit should
be operated if the climatic temperature might fall below +5°C (+41°F).
• At time of start-up the procedures contained in the user manuals for both
analyzer and sampling system must be followed.
If the product was previously in service/operation then the following precautions should be
followed before storage:
• Upon isolation from the gas sample the entire system should be purged with a
dry nitrogen gas before powering down of the analyzer.
• All connections and ports (gas and electrical) to the analyzer or sample system
(if provided) should be capped.
• If the product is not removed from its location, the electrical grounding of the
analyzer should remain in place.
•

QMA401 User’s Manual
Michell Instruments 7
INSTALLATION
2.2 Unpacking the Instrument
Open the crate and carefully unpack the instrument.
NOTE: Retain the packaging in case the instrument is returned for factory
calibration or service.
The accessories box should contain the following items:
• Traceable calibration certificate
• SD memory storage card
• USB communications cable
• IEC power cable
• Application software CD
• User's manual
If there are any shortages please notify the supplier immediately.
2.3 Electrical Requirements
The QMA401 requires the following electrical supply:
• 85 to 264 V AC, 47/63Hz, 250 VA max
• Alarm outputs comprise four sets of changeover relay contacts, one set for
INTERNAL FAULTS, and three sets for PROCESS alarms. All contacts are rated
at 24 V, 1A. NOTE: THIS RATING MUST NOT BE EXCEEDED
Fuse
This product is provided with an internally mounted fuse. A replacement fuse can be obtained
by contacting Michell Instruments' technical support. Fuse rating = 5 x 20mm 3 A anti-surge
to IEC 60127-2.
DANGER
Electric
Shock Risk
Power Connection
The product is provided with an IEC C13 socket on the rear panel for mains power input.
This equipment must be supplied with a voltage between the range of 85 to 264 V AC,
47/63Hz, maximum required power is 140 W.
Figure 3 Power Connection

QMA401 User’s Manual
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INSTALLATION
2.4 Rear Panel Connections
ANALOGUE
OUTPUT
G
ALARMS 3 - 4
NC3
OP2-
MODBUS
USB
NO4
NC4
COM3
NO3
AB
ALARMS 1 - 2
NC1
COM2
NO2
NC2
COM1
NO1
MODBUS 485 EXTERNAL
PRESSURE
COM4
OP2+
OP1-
OP1+
+24V
SIG
SERIAL NUMBER
POWER:
85-264V AC
47-63Hz 100VA
T2.5
1
2
3456789
1Power Connection IEC Power Socket, On/Off Switch & Fuse
2Electrical Connections #1
USB
RS485
(Modbus)
A
B
G
Alarms 1 & 2
NC1
NO1
COM1
NC2
NO2
COM2
Alarms 3 & 4
NC3
NO3
COM3
NC4 Analyzer Status Alarm
NO in warning/fault condition
NC no warning / no fault
NO4
COM4
3Bypass Flow Adjustment
4Ethernet
5Electrical Connections #2
External
Pressure
+24V
Signal
Analog Output
OP1+
OP1-
OP2+
OP2-
6Inlet Pressure Control
7Dryer Module Access Panel
8Gas Outlet
9Gas Inlet
Figure 4 Rear Panel Connections

QMA401 User’s Manual
Michell Instruments 9
INSTALLATION
2.5 Pressure Safety
!
WARNING:
This product is used in conjunction with pressurized gases.
Observe pressurized gas handling precautions.
!
WARNING:
Pressurized gas is dangerous and should only handled by
suitably trained personnel.
DO NOT permit pressures greater than the specified safe working pressure to be applied
directly to the instrument.
!
For the calibration to remain valid the QMA401 must be
operated at the pressures specified on the calibration
certificate (typically a sample pressure of 1 barg (14.5
psig), with the outlet at atmospheric pressure). When using
the pressure control option, the cell pressure should never
exceed the maximum stipulated operating pressure of 1
barg (14.5 psig).
2.6 Connection of Gas Supplies
Sample gas connections are made via the gas inlet and outlet 1/4" VCR ports located on
the rear panel of the instrument as shown in Figure 5 . All connections should be made
with high quality stainless steel tubing.
NOTE: No external gas couplings are supplied with the analyzer but can
be ordered as an accessory by contacting Michell Instruments - see www.
michell.com for contact details.

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INSTALLATION
SAMPLE
OUTLET
7
8
96
5
4
3
21
NOTE: Items 1 to 6 are not
supplied with the unit, and
only illustrated to show a
typical gas coupling.
Figure 5 Typical Gas Connections
Making a connection to the 1/4" VCR fitting:
1. Clip the gasket and its retaining ring (8) over the end of the VCR adaptor
(5) .
2. Locate the end of the VCR adaptor (5), fitted with the gasket (8) over the
VCR port (9) and screw the locking nut (7) finger tight to fix the adaptor
to the port.
3. Tighten the locking nut (7) one eighth of a turn.
Connection to a VCR to 1/4" Swagelok tube adaptor:
(available as an accessory)
1. Cut ¼” stainless steel tubing (1) to the correct length and, if necessary,
bend to shape to suit the location of the instrument. NOTE: To facilitate
ease of connection to the adaptor (5), at least 75mm (3 in) of the
tubing coming out of the adaptor must be straight.
2. Clean off any burrs or metal shavings adhering to the tubing.
3. Pass the tubing (1) through the locking nut (2), and the back ferrule (3).
4. Place the front ferrule (4) over the stainless steel tubing (1), bevelled end
towards the adaptor (5).
5. Insert the stainless steel tubing (1) as far as it will go into the adaptor (5)
and tighten up the locking nut (2) finger tight.
6. Hold the adaptor (5) flats with a spanner and tighten up the locking nut
(2). This action compresses the front ferrule (4) and back ferrule (3) onto
the tubing to form a gas tight seal. Caution: Do not overtighten as
this could cause the ferrules to crack and destroy the integrity
of the seal.