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Cambridge Sensotec Rapidox 1100ZR-H-PFC-E-E O

2

 Analyser Instruction 

Manual

  

 

Version 1.2 

1 

Last printed 22/07/2015 18:08:00 

 
 

1

 

Introduction 

 

The Rapidox 1100ZR-H-PFC-E (Z= zirconia sensor R=rear panel gas connections 
H=Heller PFC=Proportional Flow Control E=Ejector) oxygen analyser allows fast 

and accurate oxygen analysis over the oxygen range 1ppm to 100% O

2

.  The 

analyser provides continuous on-line oxygen analysis, with a typical response 
time of less than 4 seconds for a 90% response to a step change in gas 
compositions. 
 

The Rapidox 1100ZR-H-PFC-E is a fully integral unit complete with a vacuum 
ejector system that works off compressed air to give maintenance free sample 
pumping up to 1L.min

-1

. 

 
The sensor head is located inside the analyser and comprises a zirconia ceramic 

tube that needs to be heated to 650°C before it will conduct oxygen ions.  The 
analyser supplies heat to the sensor, which is controlled very accurately by a 
regulated power supply incorporated in the instrument.  An internally mounted 
pressure sensor compensates for any fluctuations in pressure or vacuum caused 
by differing flow conditions. 

 
The analyser is packed with features including programmable alarm circuits, 
programmable analogue outputs, easy calibration (user selectable gases), RS232 
communications and complete communications / data-logging software. 

2

 

Features 

 

 

Very fast measurement response (typically 4 seconds for a 90% response). 

 

 

Wide measurement range available (1ppm to 100% O

2

). 

 

 

Accuracy ± 1% of the actual measured oxygen or 0.5ppm whichever is greater. 

 

 

Easy calibration procedure requiring any two or three gas mixtures (ordinary 

room air is usually one). 

 

 

Low maintenance, sensor life expectancy typically 17,500 hours 

 

 

Vacuum ejector system for maintenance free sample pumping 

 

 

Large back-lit LCD display (16 x 2 characters). 

 

 

RS232, 0-10V and 4-20mA current loop outputs (both fully programmable). 

 

 

Fully programmable alarm circuits. 

 

 

Full data-logging software accessed via RS232 connection to a PC (RS485 

available on request). 

 

 

PIN code protection available 

 

Содержание Rapidox 1100ZR-H-PFC-E

Страница 1: ...ith Vacuum Ejector Heller Specific Version Instruction Manual Revision 1 2 Cambridge Sensotec Limited Unit 29 Stephenson Road St Ives CAMBS PE27 3WJ Tel 44 0 1480 462142 Fax 44 0 1480 466032 Mobile 07866 624236 Sales Cambridge Sensotec co uk ...

Страница 2: ...ambridge Sensotec Limited Date 15th April 2014 WEEE Regulations 2006 Cambridge Sensotec takes its responsibilities under the WEEE Regulations extremely seriously and has taken steps to be compliant in line with our corporate and social responsibilities In the UK Cambridge Sensotec has joined a registered compliance scheme WeeeCare WeeeCare registration number WEE MP3538PZ SCH UK users only If you ...

Страница 3: ...15 7 13 Setting the Baud Rate 16 7 14 RS232 RS485 Port 16 7 14 1 RS232 Protocol 17 7 14 2 RS485 protocol 19 7 15 Printing 19 7 16 Load Defaults 19 8 Rapidox Software Instructions 20 8 1 Software Installation 20 8 2 Getting Started 20 8 3 On Screen Help 21 8 4 Configuration Page 21 8 5 Reconfiguring the Analyser 22 8 5 1 Config 1 Screen 23 8 5 2 Config 2 Screen 24 8 5 3 Alarm Config Screen 25 8 6 O...

Страница 4: ...its 36 9 15 Oxygen Scale 36 9 16 Second Y Axis 36 9 17 Loading an Old Run 37 9 18 Printing Graphs 37 9 19 Data Logging in the Background 37 9 20 Pausing the Data Logging 37 9 21 Changing the Data Logging Parameters Mid run 37 9 22 Working with Spreadsheets 38 9 23 Disaster Recovery 38 9 24 DDE Protocols 38 10 Troubleshooting 40 10 1 Warranty 41 10 2 Conditions of Warranty 41 11 Appendix 1 Proporti...

Страница 5: ... very accurately by a regulated power supply incorporated in the instrument An internally mounted pressure sensor compensates for any fluctuations in pressure or vacuum caused by differing flow conditions The analyser is packed with features including programmable alarm circuits programmable analogue outputs easy calibration user selectable gases RS232 communications and complete communications da...

Страница 6: ...uracy 1 of the actual measured oxygen content or 0 5ppm whichever is greater Outputs O2 voltage 0 10V user programmable into minimum 5kΩ O2 current 4 20mA current loop user programmable into maximum 500Ω O2 PID control 4 20mA current loop user programmable into maximum 500Ω OR 0 10V user programmable into minimum 5kΩ O2 high and low alarms Relay circuits fully user programmable All data and parame...

Страница 7: ...near water Avoid touching the LCD display as this may cause permanent damage Make sure the rear ventilation slots and the fan on the rear panel are free of obstruction There are no user serviceable parts in this unit Do not attempt to repair yourself Refer all servicing to qualified Cambridge Sensotec personnel 6 Warning This unit is NOT designed for use in life support situations No responsibilit...

Страница 8: ...o terminals labelled PFC Valve 4 20mA and Supply Valve In Figure 3 Rear Panel Terminal Strip 1 PFC Valve 4 20mA These connections provide the 4 20mA signal to control the gas valve The signal is generated by the PID control loop parameters entered by the user 2 Supply Valve In This connection requires a 12 24V connection from the oven to indicate when it is operation The PFC output is disabled whe...

Страница 9: ...tering the analyser The ejector may become clogged if unclean gas is used Push the gas sample tube 6mm OD 4mm ID to the GAS IN 3 connector and fit the retaining collar hand tight Repeat for the GAS OUT 4 connector should an outlet tube be required If you are using the Rapidox to measure gas from a compressed source i e from a gas bottle then please make sure you carefully adjust the gas regulator ...

Страница 10: ...ay shows O Range Press Pressure Reading is 1000mbar and 1000mbar Display shows the normal pressure reading in mbar bar kPa torr or psi Pressure Reading is 1000mbar Display shows U Range Press Pressure sensor has failed completely or become disconnected Display shows Fault Press With the word Fault flashing Table 2 Different display possibilities depending on the sensor reading 7 5 Menu Access Pass...

Страница 11: ...nel keypad 2 to access the menu system The calibration function is option 1 on the menu list which can be scrolled using the UP and DOWN arrows Press ENT again to enter the calibration menu Use the UP and DOWN arrows to select O2 HIGH O2 MIDDLE or O2 LOW and press ENT to proceed The top line of the display shows the current calibration gas stored and the bottom line of the display shows the prompt...

Страница 12: ...eventually returns to run mode it will use the existing calibration 4 Note that the analyser should ideally be calibrated at normal ambient pressure If the pressure correction mode is set to AUTO then it is still possible to perform an accurate calibration at pressures other than ambient However above 25mbar gauge or below 25mbar gauge the display will flash and P will display to warn you that the...

Страница 13: ...es approximately five seconds and the LCD display shows the progress of the operation Once finished the analyser will take a moment to re stabilise The sensor is cleaned each time the unit is switched on prior to operation If you are operating in gases with large amounts of soot there is a risk that the sensor surfaces will become contaminated with particulates which will impair performance if all...

Страница 14: ... the digit and the RIGHT arrow to progress until the correct value is displayed When done press ENT to proceed to the next setting 6 CONTACTS The relay outputs can be set to either normally open N O or normally closed N C The factory default is N O meaning the contacts will close when an alarm condition occurs Press ENT to save all the above settings for the selected alarm Alarm 2 can be set in ex...

Страница 15: ...V 100 O2 then 5V would indicate an oxygen reading of 50 O2 The scaling of this example is shown in the following plot from which other intermediate values can also be read This setting is more suitable for medium to high ranges of oxygen or where the user wishes to monitor oxygen over a narrow range Figure 4 Graph showing the linear output mode option for oxygen The following general formulae can ...

Страница 16: ...on the red line shows the limitations of using the linear oxygen output mode over the same range Figure 5 Graph showing the logarithmic output mode option for oxygen blue compared with linear mode red The following general formulae can be used to calculate the oxygen from the voltage or current outputs when set to the log output mode Output type Formula for calculating log10 O2 from analogue outpu...

Страница 17: ...eral formulae can be used to calculate the oxygen sensor raw voltage O2mV from the voltage or current outputs when set to the raw sensor voltage output mode Output type Formula for calculating sensor mV from analogue output signal 0 10V O2mV Vout 10 O2mVH O2mVL O2mVL 4 20mA O2mV mAout 4 16 O2mVH O2mVL O2mVL Where O2mVL user setting of oxygen mV for 0V or 4mA output O2mVH user setting of oxygen mV ...

Страница 18: ...0mA Voltage 2 0 10V 1mA 0 625V Fault There is a sensor fault on the oxygen sensor and or the temperature sensor has a fault condition and or the pressure mode is set to automatic pressure compensation active and the pressure sensor has a fault condition De activated 2mA 1 25V Start up The analyser is still initialising De activated 2 5mA 1 5625V Sensor under range The sensor reading is under range...

Страница 19: ...nits Once selected press ENT to store and return to run mode 7 11 Setting the Display Options The user can select the LCD refresh rate and the format of the line 2 display using the keypad or the software provided Scroll down the menu to option no 6 Set up Display and press ENT Use the UP DOWN arrows to select either the LCD refresh rate or Line 2 Options 1 LCD Refresh Interval The frequency of th...

Страница 20: ...reading of oxygen concentration that will only be affected by changes in gas composition and not gas pressure Note that when this mode is activated the user will be asked to enter a value for the current ambient pressure to slightly improve the accuracy of the correction The factory default is 1013mbar which is the average ambient pressure for the UK The ambient pressure at your location will depe...

Страница 21: ...he front panel keypad on the Rapidox This setting is stored in EEPROM Connection Connect to RS232 socket at the back of the Rapidox using a 9 way D type plug Signals are as follows Rapidox D type Socket PC PLC Pin 2 Data Out Data In RX Pin 3 Data In Data Out TX Pin 5 Common Gnd Common Gnd Figure 8 Rapidox RS232 pin configuration All other pins 1 4 6 7 8 9 Don t care Reading Data Data is read using...

Страница 22: ...perature within 10 minutes from power up This may be due to the age of the sensor or because a high thermal conductivity gas is being used Response No sensor or sensor fault CR LF Meaning Sensor is not connected or there is a fault in the sensor Response d2 959E 05 1 426E 01 2 000E 00 23 19 40 14 01 00 ALM1 2 0 CR LF Meaning d means data is being sent 2 959E 05 is Oxygen reading in ppm data separa...

Страница 23: ...r is first connected or turned on a start up message like the one displayed on the LCD when the Rapidox is switched on will be printed and will look like this Cambridge Sensotec Ltd Rapidox 1100ZR H PFC E Oxygen Analyser S N 2100942 FW v 01 03 03 01 7 16 Load Defaults If you make a mistake programming the Rapidox it is possible to restore the machine back to its factory settings by loading the uni...

Страница 24: ...connecting devices to this operating system can be problematical at best Note that software is regionally aware and will therefore accept and display data using the decimal separator that is set in the PC s Regional Settings in the Control Panel For example in the UK or US you might enter the value 2 5 in continental Europe this would normally be entered as 2 5 assuming the PC s Regional Settings ...

Страница 25: ... COM port settings in Device Manager accessed by clicking START Settings Control Panel In PFC versions of the Rapidox an additional panel is displayed at the foot of the main software window as shown in Figure 10 See Appendix 1 for full details of this feature Figure 10 Additional panel displayed when running a PFC enabled analyser 8 3 On Screen Help You can access the on screen help facility at a...

Страница 26: ...is file is also located on the memory stick that came with the machine Normally this file is located in My Documents directory but if the software cannot locate it then it will ask you for the serial number to help it search With the correct rxc file loaded into the Read columns simply click copy to transfer the defaults into the edit boxes and then click any of the three Write button to load them...

Страница 27: ...e unit for pressure measurement The default setting is MBAR 6 Pressure Correction Mode See section 7 12 for a full description Use the drop down menu to select NONE AUTOMATIC or MANUAL The default setting is NONE 7 Operating Mode Not available for the Rapidox 1100ZR H PFC E 8 Auxiliary Output Parameter Not available for the Rapidox 1100ZR H PFC E 9 LCD Refresh interval Use the drop down menu to se...

Страница 28: ... 10ppm would be approximately 180mV 15 O2 Analogue Output 0V 4mA 10V 20mA Use these two boxes to set the High and Low oxygen values for the analogue outputs 6 on the rear panel For example if you want 4mA to represent 1 and 20mA to represent 21 then enter these two values into the appropriate boxes The value can be entered either in or ppm depending on the units selected The default is The default...

Страница 29: ...he alarm circuit 20 Audible Alarm This option enables or disables the audible buzzer fitted to the Rapidox internally When an alarm condition occurs the buzzer will emit a continuous noise to alert the operator 21 Visible Alarm This option enables or disables the visual warning on the front LCD When enabled and an alarm condition occurs the message AL1 or AL2 will flash in the lower right hand cor...

Страница 30: ...instrument to benefit from the changes 8 6 On Screen LCD It is possible to display an LCD emulator on the desktop of your PC This reproduces exactly the display on the Rapidox unit and is convenient if you are some distance away from the machine To activate the LCD select the UTILITIES menu and select the LCD on option This will display a small window showing the LCD that can be positioned indepen...

Страница 31: ...e reading on the LCD stabilise This is extremely important to perform a successful and accurate calibration The software uses the three calibration gas values already stored in the Rapidox as a starting point These are typically High 20 95 Middle 0 1 and Low 0 001 as set in the factory but may be different if the user has recalibrated with other gas values in the past Either way you are given an o...

Страница 32: ...n process by selecting the Middle and Low gases in the same manner 8 8 Calibration Error Messages During the calibration process described in 7 7 above it is possible to receive screen error messages as described here 1 Bad Sensor Reading The Rapidox software makes a prediction of the expected sensor mV for each calibration gas value entered If the mV signal coming from the sensor is out of the ex...

Страница 33: ...ctor see below Note that the above are only advisories and you can proceed with the calibration if you believe everything is checked and correct 8 9 Software Utilities The utilities menu is located on the main file menu as shown below Figure 18 Software Utilities Menu 8 9 1 Setting Analyser Date and Time The current date and time of your PC are displayed on the configuration screen and can be load...

Страница 34: ...x program directory This file name includes the serial number date and time to make it easily recognisable Please e mail this file to support cambridge sensotec co uk together with a description of the problem Figure 19 Example of a diagnostics file name and the storage location 8 9 3 Show Hide LCD Use these options to display or hide the on screen LCD display as shown in Figure 11 The software re...

Страница 35: ...g facility is also included which has many powerful features Note that the data logging facility will only function if the analyser is in NORMAL run mode 9 2 Auto Logging Feature A special feature of this software is an Auto Log option which can be selected from the tab labelled Data logging If this option is selected then the next time the software is started the data logger will begin automatica...

Страница 36: ... down menu A small text box appears in which you can type a text message This note is then saved as a header in the data file set and can be viewed along with the data You can either choose to have data logged continuously until Stop is selected from the Data Logger menu or you can choose to set a time limit for data logging by checking the box labelled Time Limit setting the duration in the Run F...

Страница 37: ...nterrupts The data file is stored with a date suffix in brackets in yy mm dd format This feature ensures that data is saved periodically in sensible sized files This will prevent the computer from crashing and will also ensure that the data is small enough to fit into an Excel spreadsheet As an example the user wishes to run the data logger for seven days recording every minute starting at lunchti...

Страница 38: ... in progress You can select Run and Stop from the Data Logger menu to begin and end data logging and the window can be minimised to and restored from the task bar while logging data To close the window and return to the main data logging page select Close Plot from the File menu or click on the close window button The features of the graph window are described below Figure 22 Live time graphing sc...

Страница 39: ...dit mode The text can then be modified Similarly to change the title of the graph place the mouse pointer over the title and click once to edit If you choose not to enter a title the graph will display the path and filename of the run as the new title once the run has finished Note that these changes are only temporary and will be overwritten by the defaults if a new run is started or the graph wi...

Страница 40: ...graph window will change to Zoom box co ordinates and an extra set of co ordinates labelled X2 and Y2 will appear showing the co ordinates in X and Y units of the second corner of the zoom rectangle as you drag the mouse pointer The plot will zoom and auto scale when you release the mouse button This can be repeated if you wish to zoom in even further To zoom back to the original size select Zoom ...

Страница 41: ... out 9 19 Data Logging in the Background It is possible to begin data logging and then minimise the windows to continue working with another application To minimise the graph simply click on the minimise button on the blue title bar at the top of the window You can then use the ALT TAB keys to take you to other programmes already running To return to the graph simply maximise from the start menu b...

Страница 42: ...amme default However when entering the file name you can instead select a csv extension the programme will register the last used file extension as the new default The csv extension is recognised by MS Excel so that opening the file will automatically run MS Excel and this may be of benefit if your regional decimal separator is period rather than comma However if your decimal separator is comma yo...

Страница 43: ...state for reason 4 to indicate sensor fault and 5 to indicate under range error Current O2 Level in RAPIDOX Main lbl_PCNT_O2 Set to 1 when not measuring see Error state for reason 4 to indicate sensor fault and 5 to indicate under range error Error state indication Error ID Description Error ID 5 O2 Range Error 4 Sensor Fault 3 No available com ports 2 Communication problem 1 No analyser found 0 A...

Страница 44: ...that are way off the expected values A Check to make sure which calibration gases are selected Are they the same as the actual gases you used to perform the calibration If not you must recalibrate the analyser or re load the factory defaults to get you going again Q The sensor does not read 20 9 21 0 in air actual value is 20 95 A If the room air is very humid it will slightly affect the observed ...

Страница 45: ...lyser but will be good enough to get you started again 10 1 Warranty The Rapidox analyser has been carefully tested and inspected before shipment and is guaranteed to be free from defective materials and workmanship for a period of twelve months from date of purchase The sensor head is replaceable and has a life expectancy in excess of 17 500 hours However if the analysis gas contains corrosive ga...

Страница 46: ... be returned to the Seller s premises at the Purchaser s expense if so requested by the Seller d Any repaired or replaced goods shall be redelivered by the Seller free of charge to the original point of delivery but otherwise in accordance with and subject to these Conditions of Sale e Alternatively the Seller shall be entitled at its absolute discretion to refund the price of the defective goods ...

Страница 47: ...es a degree of tuning and learning once the system is up and running to make sure the oxygen set point is stable A badly tuned PFC could oscillate badly or not reach the desired set point at all The additional features are bolted on to the main software supplied with all Rapidox analysers and the new software screens are described here 11 1 Connections On the rear of the PFC coded machines are two...

Страница 48: ... warm up cycle of the Rapidox typically four minutes It is normal in this stage to have the nitrogen gas valve opened to its maximum to allow the oxygen level to be reached as quickly as possible The value is entered in terms of a percentage 0 100 where 0 means the signal is 4mA and the valve is fully closed and 100 means the signal is 20mA and the valve is fully open A typical setting would be 99...

Страница 49: ...e of 100 means that the valve can be allowed to open fully if so required by the PFC 29 Min Flow Control Value This is the opposite parameter to 4 allowing the user to set a minimum amount that the gas valve can be opened in terms of a percentage 0 100 A value of 0 means the valve can fully close if so required by the PFC Note that for obvious reasons the minimum value must be smaller than the max...

Страница 50: ... channel Rapidox 1100ZR3 analyser that is fitted with a multiplexer It introduces a time delay in seconds which allows gas from channels 1 2 3 to flush away before the PFC starts controlling once again 35 PFC Mode Select an option from OFF ON or MONITOR ONLY The default is ON If OFF is selected then the PFC sends a fixed 4mA to the gas valve commanding it to stay closed If ON is selected then the ...

Страница 51: ... Enabled or Disabled to activate the alarms on this channel The default is Disabled 37 CH1 Alarm 1 Set Point The current units or ppm are displayed by the text and can be changed using the Units drop down menu Enter a set point for the first software alarm here For example for an alarm set point at 30 O2 enter 30 into the edit box Note that alarm 1 is triggered when RISING above this value 38 CH1 ...

Страница 52: ...he sample pump will create a vacuum and the low flow warning alarm will trigger below this point 11 5 Data logging with PFC The existing Rapidox software will data log the PFC output in the same way as oxygen or pressure With the PFC enabled the data log page will look like Figure 3 with the column PFC recording the PFC control value as a percentage where 100 indicates the gas valve is fully open ...

Страница 53: ...Cambridge Sensotec Rapidox 1100ZR H PFC E O2 Analyser Instruction Manual Version 1 2 49 Last printed 22 07 2015 18 08 00 Figure 28 Graph page showing how to select and display the PFC value ...

Страница 54: ...E 05ppm O2 O2 calibrated 1 030E 03ppm O2 O2 calibrated 1 000E 01ppm O2 O2 calibrated Displays message for 1 5 seconds 2 Clean Sensor prompts 1 Clean Sensor prompts 4 Cleaning Sensor ENT Edit O2 High Edit O2 Medium Edit O2 Low Cleaning Sensor Sensor cleaned Displays message for 1 5 seconds ESC Back to Menu List No changes ENT 3 Set Alarms Prompts 1 Set Alarm 1 Prompts 2 Assign to O2 Prompts 2 Optio...

Страница 55: ...tions Auto Pressure N2 Bal Exp ppm Auto ppm Pressure psi All units set Displays message for 1 5 seconds Pressure bar prompts 6 Line 2 Options prompts 2 Refresh Interval prompts 2 L2 Pressure prompts 5 Interval 0 3 s prompts 5 L2 Pressure Line 2 set Interval 0 3 s LCD refresh set ENT Displays message for 1 5 seconds Continued from page 1 ENT ENT ENT ENT ENT ENT ENT ENT ENT ENT ENT ENT ENT Displays ...

Страница 56: ... ENT Back to Menu List Changes Applied Continued from page 2 Prompts 1 Prompts 2 Prompts 3 Prompts 4 Prompts 6 ENT OK ESC Back Prompts 5 Change ENT Next ESC Back Change ENT OK ESC Back Change Select Char ENT OK ESC Back Scroll Menu ENT Next ESC Back Scroll Menu ENT Next ESC Exit ESC Back to Menu List No changes 9 Load Defaults prompts 1 Load Defaults prompts 4 Defaults Loaded ENT Displays message ...

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