XZone Service Manual 1.2

Service Manual X-zone 5000 v1.
Contents
1.
Introduction...................................................................................................................................... 3
1.1.
The Drger X-zone 5000 ............................................................................................................... 3
2.
Test tools.......................................................................................................................................... 3
3.
Hardware .......................................................................................................................................... 4
3.1.
X-zone disassembly ....................................................................................................................... 4
3.2.
X-zone assembly............................................................................................................................ 9
3.3.
Change of the covering plates screw type .................................................................................. 11
4.
Software.......................................................................................................................................... 12
4.1.
Configuration................................................................................................................................ 12
4.2.
Service commands....................................................................................................................... 13
5.
Test procedures (hardware/software) ......................................................................................... 14

5.1.
Relay ............................................................................................................................................ 14
5.2.
Pump flow .................................................................................................................................... 14
5.3.
Pump adjustment ......................................................................................................................... 15
5.4.
Echo server test commands (radio and RS485).......................................................................... 15
6.
Eventlogger and error codes........................................................................................................ 19
7.
Firmeware Update.......................................................................................................................... 20
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service_manual_X-zone_v1.2_en.doc
June 22, 2011
Revision v1.2 / Berndt; Held
1. Introduction
1.1.
The Drger X-zone 5000
The Drger X-zone 5000 is an Ex approved, quasi stationary alarm amplifier for the monitoring of
endangered areas. It can be used in Zone 0 and can communicate with up to 25 other X-zones wireless
or wired.
This document is the Service Manual. Content are repair and configuration of the X-zone. It is a
component from the following documents pool:
Service Manual:
Sales Manual:
Service Concept:
SIs:
TNs:
IfUs:
Software:
Spare parts list:
FAQ:
Reparation guide and configuration help

USPs, competition and market positioning
Service Packages, Trainings, Service Strategy
Service Information (Doris)
Technical Notes (D-World)
Instructions for Use (Doris and D-World)
CC-Vision (Service) (Lotus Notes and D-World)
Spare parts (Doris)
Frequently asked questions
2. Test tools
The necessary test tools are defined in the Test Certificate and mentioned in the test equipment list.
The RS485 cable can be build by oneself according to the IfU.
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3. Hardware
3.1.
X-zone disassembly
a) Loose the 6 screws (allen key 4) at the undersurface to open the X-zones chassis.
Tightening torque
120Ncm 30Ncm
The lower housing section is connected via main wiring loom with PCB main. The PCB for the electricity
supply is sealed in the lower housing section and cannot be changed singly.
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June 22, 2011
Now, there is access to:

Pump (8320652) via a plug the cable can be disconnected, the two screws are tightened
with 50Ncm 10Ncm.
Battery (8320644 resp. 8320646) fixed with 4 nuts and washers and with 120Ncm 30
Ncm.
Attention: Self- securing nuts. When replacing them, please use only new nuts!
The lower housing section (8320121) contains base, supply PCB (sealed) and cover plate;
for disassembly remove the battery and loose the plug.
For all further components the next layer has to be removed.

b) Loose the following 8 screws to disconnect the corpus from the handle:
Tightening torque
120Ncm 20Ncm
After the screws have been loosed, the upper torso can be taken-off:
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June 22, 2011
c) Subsequently, the contact block (2 screws - red) and the LED ring (4 screws blue) have to be
screwed off.
Now, the handle/upper housing section can be separated from the PCB.
Now, there is access to:
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Printed circuit board X-zone 5000 (8320601) incl. LEDs

Contact block (8320694) will be soldered lead-free on the PCB
June 22, 2011
Main line (8320737) connects PCB, rechargeable battery and output plugs (plugs are
component)
LED ring (8320125) plastic ring to relay the light produced from the LEDs
Upper housing section / handle (8320126)
Middle housing section / corpus (8320123) incl. loudspeaker
Attention:
When the contact block is changed it must be soldered lead-free.
Fixing the IR communication issue in the Draeger X-zone 5000 body top.
When having the body top separated into upper housing and middle housing you can reach for the
interior where the IR-interface is situated and connected to the main PCB with a flat ribbon cable
(before-picture, red arrow). Place the anti-static cardboard into the housing in a way that the ribbon is
entirely on the downside of the cardboard (after-picture).
Before
After
Alternatively, a cable strap can be used in a way to shorten the flat ribbon cable and consequently
prevent the cable from lying in between the IR communication area.
Cable strap
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June 22, 2011
Changing the main line and the printed circuit board

When changing the main line of the X-zone, pay attention to the correct positioning, see picture.
On the anti-static cardboard of the printed circuit board you can find coloured sticker for indicating, which
plug of the main line would have to be connected to which socket on the PCB. See also the picture below
to for the right assignment.
Attention:
When the output
plugs have to be
changed, order the
main line (sealed
output plugs
included in
delivery).
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June 22, 2011
3.2.
X-zone assembly
The assembly will be carried out in reverse order (see 3.1).
Attention:
The specified tightening torques must be used! Only in this case IP 67 can still be
guaranteed without any additional IP test.
If no torque is mentioned: tighten only hand-tight!
Attention:
Pay attention that all seals (e.g. O-rings) are fitted!
50 Ncm 10 Ncm
O - ring
50 Ncm 10 Ncm
(4x in total)
120 Ncm 30 Ncm

(6x in total)
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June 22, 2011
55 Ncm 5 Ncm
75 Ncm 10 Ncm
O-rings
350 Ncm 21 Ncm
350 Ncm 21 Ncm
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June 22, 2011
3.3.
Change of the covering plates screw type
It is possible to change the bow snap screws of the covering cap (8320674) for snap screws, which can
only be tightened by a torx wrench. Therewith, a simple detach of the covering cap without tools will be
difficult.
The screws are hold by an integrally moulded ring. A change consists of the following steps:
-
Cut through the old ring and remove the bow snap screw including the spring
Place the new screw type
Fit the spring from the opposite side
Press new ring e.g. with a wrench to the screw
Covering plate
Push new ring with e.g. a wrench over the conic head to
fix the spring and the screw
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June 22, 2011
4. Software
With the CC-Vision (Service) the instrument will be configured and with service instructions (only
available in the service version) all functions of the X-zone can be tested.
4.1.
Configuration
4.1.1.
Status
All warnings and failures will be displayed
4.1.2.
Alarms
Configuration of the alarm setting
Pattern:
Alarm pattern for A1, A2, error (separated by trigger (mother)

and follower (daughter); the pattern differs in direction of rotation
and amount of simultaneous illuminated LEDs
Audibility:
The loudness can be set within 8 steps or the horn can be

deactivated completely
Alarm transfer: Possibility to configure, which alarms and failures have to be

transferred to the daughters
Combination:
Alarm contact: Configuration for which alarms and failures the switching output
should change its condition
Configuration when acoustic and when optical warnings will be

activated, if a transferred alarm is received.
4.1.3.
Life signal
Configuration of the loudness, the frequency and the pattern of the life signal
4.1.4.
Status signal
Configuration of the status signals audibility (e.g. triggered by a pump flow test)
4.1.5.
Radio communication
Activate or deactivate the wireless mode
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Radio circuit number (only instruments within one radio circuit number can
communicate together)
Frequency (typically fixed, due to similar hardware 868MHz and 915Mhz can be
converted using the service version)
Transmitter power
The transmitter power can be set in four levels
June 22, 2011
4.1.6.
Battery
Information on battery voltage, capacity and battery type (12Ah or 24Ah)
4.1.7.
Eventlogger
4.1.8.
Instrument
Operating hours are displayed, additional information on the pump if installed
4.2.
Service commands
Below, only the necessary service commands are mentioned. Additional service commands can be
available, but they are not required for any service in the field.
The service mode will be activated via the button Enter Test Mode and will be deactivated by Leave
Test Mode. After 10 minutes the instruments automatically quits the test mode.
The commands will be sent with SEND. CLEAR deletes only the protocol.
4.2.1.
Status LED commands

Herewith, single LEDs resp. LED groups can be controlled to check the functions
4.2.2.
LED light ring commands

Light ring group trigger to test the red and green LED light ring
4.2.3.
Horn commands
Direct control of the horn in different, specified volumes to test the horn
4.2.4.
Pump ON / Pump OFF

Activating and deactivating the pump to test its function
4.2.5.
Pump adjustment mode ON / OFF

The pump adjustment mode is used to calibrate the internal flow sensor
4.2.6.
Confirm flow value

This command is used for the pump adjustment mode to confirm the flow
4.2.7.
Key mode ON / OFF

If a button is pressed, the status LEDs will illuminate. To test the both X-zone buttons
4.2.8.
Reset via external Watchdog

The X-zone will be re-started (this function is used also for the Leave Test Mode)
4.2.9.
Test switch relay ON / OFF

With this function the relay output can be changed
4.2.10.
Radio Tests (test and echo server)

Echo server: By this command the X-zone will be set into an echo server mode. In this mode
the X-zone will answer according a specified pattern to incoming signals
Test: With this command a test transmission (radio) will be triggered, to which an echo server
will respond. The result will be reported back to the CC-Vision.
4.2.11.
Wired Tests (socket 1/2 and echo RS485)

Echo RS485: With this command the X-zone will be set into an echo server mode. In this
mode the X-zone will respond according a specified pattern to incoming signals.
Socket 1/2: with this command a test transmission (RS485) will be triggered, to which an echo
server will respond. The result will be reported back to the CC-Vision.
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June 22, 2011
5. Test procedures (hardware/software)

5.1.
Relay
The relay must be tested according to the test certificate using the service commands. This procedure
must be checked with a multimeter according to the following drawing.
If Test switch relay off:

XEXT2:
CO
6 and 5:
6 and 4:
high ohmic
continuous
NO
NC
If Test switch relay on:

XEXT2:
NO:
NC:
CO:
5.2.
6 and 5:
6 and 4:
normally open
normally closed
changeover
continuous
high ohmic
Pump flow
The pump can be activated via the service commands and the flow rate can be measured with a flow
meter (flow tube or electric flow meter). The flow should be 0.4 0.8 l/min.
Q.v. test certificate.
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June 22, 2011
5.3.
Pump adjustment
When a new pump is build in a pump adjustment must be performed. This is specified as follows:
Activate test mode at DUT (device under test)
Service command pump adjustment mode on (Pump status LED changes to Red + Green)
Connect flow tube/flow meter and reducing valve
Set the flow to 0.2 0.3 l/min
Execute the service command acknowledge flow value (pump status LED changes to a Red
flashing with 1Hz)
Reduce the flow for 2 seconds to 0% (pump status LED changes to a Green flashing with 1Hz)
Increase the flow for 2 seconds to 100% (pump status LED changes to Green)
The pump switches off automatically, the flow value will be stored and the adjustment mode will
be quitted.
The flow alarm level has been programmed successfully.
Attention:
After a performed pump adjustment the alarm level has to be tested. For this,
switch on the DUT and check with a reducing valve whether the alarm is triggered
in time (0.2 l/min < alarm level < 0.3 l/min)
5.4.
Echo server test commands (radio and RS485)
To test the radio and the wired transmission easily and effectively the so-called Echo Server can be used.
For this, an instrument (dummy) will be used as a test tool and will be put into the Echo Serve Mode.
This mode exists for the radio as well as for the wired communication. One instrument remains in the
Echo Server Mode for 10 minutes, before it leaves this automatically. Alternatively, the test as well as the
Echo Server Mode can be finished via Leave Test Mode.
Now, the DUT (device under test) can be triggered via service command to send a test signal. The Echo
Server will respond to this test signal (incl. field intensity). Subsequently, the DUT will forward the result
(successful or not [PASS/FAIL], received and sent field strength) to the CC-Vision, which will export the
results to a text.
The test procedure is as follows:
Radio test using the example of 868 MHz:
-
Activate the test mode of the dummy instrument
Sent the service command Set Echo Server (868MHz)
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June 22, 2011
Now, the dummy instrument is in Echo Server Mode and will respond to every test command (in
the Echo Server Mode the X-zone 5000 flashes green with 1Hz)
Activate the test mode at the DUT (device under test)
Send the service command Radio Test (868MHz)
Now, if the test has been completed successfully, the received or sent field strength is shown in
the protocol box (signal strength echo package and signal strength client). P for pass indicates
a successful test, otherwise a F for fail will be send.
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June 22, 2011
Exit test mode and

Echo Server Mode
P for PASS and

indicates a successful
transmission
Send command
Response
Received and sent
field strength
The following chart shows typical values for received and sent field strengths (which are in similar areas:
Meter
0
3
10
30
Field strength
~190
~165
~140
>100
The values are round figures and cannot act as a standard. However, the function of the instrument can
be evaluated. If the field strength collapses above average, a defect will be assumed.
Note:
The test mode can be left via the function Leave Test Mode.
However, after 10 minutes the test mode will be deactivated automatically.
Attention:
When the instrument is in the Echo Server Mode the keyboard is without function.
Also, the Echo Server Mode can be left via the function Leave Test Mode, or it
will be automatically deactivated after 10 minutes.
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June 22, 2011
Attention:
PASS only means, that the command has been transmitted successfully. There is
no information about the transmitting quality / power arising from this.
The wired transmission will be test in a similar way:
-
Active the test mode on the dummy instrument
Send the service command Set Echo Server (RS485)
Now, the dummy instrument is in Echo Server Mode and will respond to every test command (in
the Echo Server Mode the X-zone 5000 flashes green with 1Hz)
Activate the test mode at the DUT
Send the service command Wired Test (socket 1 XEXT1) resp. Wired Test (socket 2
XEXT2)
The response is shown in the protocol box (P for pass indicates a successful test, otherwise a F
for fail will be sent).
Response shows
P for PASS
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June 22, 2011
Note:
Socket 1: lower DUTs socket connected with the Echo Servers upper socket.
Socket 2: upper DUTs socket connected with the Echo Servers lower socket.
Note:
For a wired connection the validation of the PASS response is sufficient. If the
instrument sends a P, the test will be successful.
6. Eventlogger and error codes

Via CC-Vision the eventlogger can be readout in the window Eventlogger (EL read-out).
Beside the information regarding switch-on, switch-off, pump connection, alarms etc. different error status
will be indicated. The different status can be decrypted as follows:
Hex-Codes
00 00 00 01
00 00 00 02
00 00 00 04
00 00 00 08
00 00 00 10
80 00 00 00
Binary Codes
20
21
22
23
24
231
Bit-Codes
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 31
X-Codes
X01
X02
X03
X04
X05
X32
With the following meaning:

Bit
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22-27
28
29
30
31
Meaning
X-am 5000 with Alkaline power supply unit
Communication disruption to the X-am 5000
Communication error rechargeable battery controller X-zone
Battery main alarm X-am 5000
Battery pre alarm X-am 5000
Charge current X-am 5000 too low ; I <= 100mA (at BAT-A1 X-am)
Pump adapter identified, but no pump assembled
Flow error
Change in state pump adapter in operating conditions
Check sum error program code
Flash bug parameter block: DB_INSTR_DW
Flash bug parameter block: DB_INSTR_USER
Flash bug parameter block: DB_MAINT
RAM test error
Defective ADC conversion
No contact to the switch box in Pairing Mode
Defective charging electronic
Rechargeable battery exhaustive discharged
*in the ON mode alarming via battery main alarm
Battery main alarm X-zone
Battery pre alarm X-zone
Device error X-am
Defective alarm patter X-am
NA
Battery main alarm (Silent alarm / instrument in standby)
X-zone battery exhaustively discharged (Silent alarm / instrument in standby)
Defective charging electronic (Silent alarm / instrument in standby)
Communication error battery controller X-zone (Silent alarm / instrument in standby)
All X-Codes are also mentioned in the Technical Handbook.

Examples:
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June 22, 2011
30.03.2010 10:19:07.000;Errorstatus changed (00 00 00 10,00 00 00 08);

This means, the status has been changed from:
00 00 00 10 = X05 = Bit 4 = Battery pre alarm X-am 5000
to
00 00 00 08 = X04 = Bit 3 = Battery main alarm X-am 5000
The sum will be shown, when two bits are set. If e.g. bit 4 and 3 from above mentioned example are set
simultaneously, the result will be as follows:
00 00 00 18 = X05+X04 = Bit4+Bit3
So, the conversion is analogue to X-am 7000 / Multiwarn II / Polytron 7000.
7. Firmeware Update
Firmeware updates can easily be done with CC Vision itself.
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June 22, 2011

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Service Manual X-zone 5000 v1.

The Drger X-zone 5000 ............................................................................................................... 3

X-zone disassembly ....................................................................................................................... 4

Change of the covering plates screw type .................................................................................. 11

Test procedures (hardware/software) ......................................................................................... 14

Pump flow .................................................................................................................................... 14

Pump adjustment ......................................................................................................................... 15

Echo server test commands (radio and RS485).......................................................................... 15

Eventlogger and error codes........................................................................................................ 19

June 22, 2011

Revision v1.2 / Berndt; Held

The Drger X-zone 5000

Reparation guide and configuration help

June 22, 2011

Revision v1.2 / Berndt; Held

June 22, 2011

Revision v1.2 / Berndt; Held

Now, there is access to:

For all further components the next layer has to be removed.

June 22, 2011

Revision v1.2 / Berndt; Held

Now, there is access to:

Printed circuit board X-zone 5000 (8320601) incl. LEDs

June 22, 2011

Revision v1.2 / Berndt; Held

June 22, 2011

Revision v1.2 / Berndt; Held

Changing the main line and the printed circuit board

June 22, 2011

Revision v1.2 / Berndt; Held

The assembly will be carried out in reverse order (see 3.1).

120 Ncm 30 Ncm

June 22, 2011

Revision v1.2 / Berndt; Held

350 Ncm 21 Ncm

350 Ncm 21 Ncm

June 22, 2011

Revision v1.2 / Berndt; Held

Change of the covering plates screw type

Place the new screw type

Fit the spring from the opposite side

Press new ring e.g. with a wrench to the screw

June 22, 2011

Revision v1.2 / Berndt; Held

Alarm pattern for A1, A2, error (separated by trigger (mother)

The loudness can be set within 8 steps or the horn can be

Alarm transfer: Possibility to configure, which alarms and failures have to be

Configuration when acoustic and when optical warnings will be

June 22, 2011

Revision v1.2 / Berndt; Held

Status LED commands

LED light ring commands

Pump ON / Pump OFF

Pump adjustment mode ON / OFF

Confirm flow value

Key mode ON / OFF

Reset via external Watchdog

Test switch relay ON / OFF

Radio Tests (test and echo server)

Wired Tests (socket 1/2 and echo RS485)

June 22, 2011

Revision v1.2 / Berndt; Held

5. Test procedures (hardware/software)

If Test switch relay off: