Ridzewski Zr-Ox MKII User manual

Operating Manual
O2Analyser Zr-Ox MKII
© 2003 by Ridzewski GmbH
Ridzewski GmbH – Waldstrasse 26 - 86485 Biberbach - Germany
Fon: [phone] Fax: [phone] Email: [e-mail] www.ridzewski.de
English version: February 2010

Contents
1 Introduction
2 Safety instructions
2.1 Warnings
2.2 Suggestions
3 Connections
3.1 Description of unit-interfaces
3.2 Labels
4 Instructions
4.1 Commissioning
4.2 Use of keypad
4.3 Initiate the measurement
4.4 Adjustment of the flow rate of the sensor
4.5 Adjustment of the alarm-levels
4.6 Adjustment of the analog-output
5 Maintainance
5.1 Replacement of the filter-cartridge* (*Special accessory)
6 Calibration
6.0 Description of calibration
6.1 Calibration
7 Technical Data
7.1 Sensor and flow-through-system
7.2 Unit parameters
8 Troubleshooting
8.1 Troubleshooting
9 Spareparts
9.1 Wearing part
9.2 Accessoires
10 menus
10.1 Mainmenu
10.2 Parameters
10.3 Alarms
10.4 Hardwaretest
10.5 Settings
10.6 Calibration
Page 1

1 Introduction
The Zr-Ox MKII is a µ-prozessor controlled, high precise unit for the measurement of oxygen-
concentrations in the range of 0,1ppm to 99,9% in many industrial processes*. The measured
value is displayed on the frontplate of the unit, given out as an analog-output** (standard 0/2-10
VDC or 0/4-20 mA signal) or via the RS232. The unit has a intuitive menu-structure, which
allows the user to set all important parameters and also to configure the unit according his
individual requirements within a few minutes.
Zr-Ox MKII has 3 relays built in, to indicate an alarm e.g. in case of low or high concentration
or faulty flow rate or system failure. The relays may be programmed as open or close contacts.
Zr-Ox had been designed among others, for monitoring the oxygen concentration in soldering-
machines. In the soldering process a continous monitoring of the oxygen-concentration very
important.
Following technical features make the Zr-Ox extraordinary:
-measuring range of 1ppm to 99,9% O 2 with automatic change of ranges
-extremly fast response time to changing oxygen concentrations
-longtime stable ZrO 2 sensor with 12-month calibration period
-calibration of the sensors with up to 7 calibration gases plus air (20,9%)
-external start of measuring by using a 12-24 VDC - signal
-analog-output of 0-10 VDC or 0-20 mA output configurable
- built in membrane sampling pump
-automatic control of the flow of the measuring gas
-posibillity of measuring up to 5 measuring points
-RS232- Interface to exchange data with PC
* no combustible, aggressive or corrosive gases allowed
** depending on the configuration version
Ridzewski GmbH – Waldstrasse 26 - 86485 Biberbach - Germany
Fon: [phone] Fax: [phone] Email: [e-mail] www.ridzewski.de
Page 2

2 Safety instructions
2.1 Warnings
Only skilled and authorized personal is allowed to open and maintain the unit.
Opening of the unit may be dangerous due to high voltage. The unit must have a
connection to earth. According to the regulations of EU with regards to EMC, only
shielded cables (except the power cable) may be connected to the unit.
The shield must be connected to the housing.
Please avoid strong vibrations, shock or extrem changes of temperature
2.2 Suggestions
Frequently power on/off will shorten the life-time of most of the components. If
possible, leave the unit continuosly on.
Check the calibration of the regulary periods (e. g. once per month).
The unit should measure in ambient air aprox. 20,9 % and in pure nitrogen
(depending of the purity) between 1 and 10 ppm oxygen. A concentration reading
difference of approx. 0,5 % in ambient air is normal and is caused by the logarithmic
signal-output of the sensor.
Every 12 month the unit should be calibrated with certified gases.
Please contact your distributor or Ridzewski GmbH in Ellgau (adress on the second
page).
To encrease the life-time of the sensor, we suggest to operate the unit with the
suitable measuring gas filter.
Ridzewski GmbH – Waldstrasse 26 - 86485 Biberbach - Germany
Fon: [phone] Fax: [phone] Email: [e-mail] www.ridzewski.de
Page 3

3 Connections
3.1 Description of the Unit Interfaces
3.2 All Interfaces are labeld with corresponding stickers .
Ridzewski GmbH – Waldstrasse 26 - 86485 Biberbach - Germany
Fon: [phone] Fax: [phone] Email: [e-mail] www.ridzewski.de
Page 4
12 VDC out
and
analog-output
relay-outputs
12-24 VDC Input
for external pump on
signal
RS 232
main power
100-240 VAC / 47-63Hz
Gas-out Gas-in
measuring gas filter for the
absorbtion of hydrocarbons,
condensates and particles

4 Instructions
4.1 Commissioning
Please check the existing power (voltage) and frequency according to the
requirements of the unit. Additional electrical installations must be done by autorized
persons.
Connect the Zr-Ox to main power. After power-on a short selftest will run and the
unit begins to heat up the sensor. The heating-time is factory set at 25 minutes. The
heating-time can be changed by using the password 111111. During heatingup-time
there is no measurement possible.
When the sensor has its operating-temperature the display indicates „ready“.
After aprox. 45 minutes the sensor has its optimal operating-temperature.
4.2 Use of the keypad
Zr-Ox MKII was developed to measure oxygen in many industrial processes.
The anaylser is designed to measure in different applications by using only one unit.
Due to this it is possible, that several pushbuttons and menus are, according to the
unit configuration, enabled or disabled.
4.3 Start the measurement
The measuring process can be triggered via the arrow pushbuttons or by applying a
voltage of 12-24 VDC on inputs 7 and 8 (e.g., from an SPC).
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Keypad for entry of
values, letters, etc.
Display to indicate
measuring values and
all unit parameters
Arrow pushbuttons
to go through the
structure of menue.
Start and Stop
the measurement
Start the
measurement
Stop the
measurement

To start the measurement manually, make sure that the device is in the initial
state and that “Ready” is displayed.
When pressing the arrow pushbutton to the right, the measuring gas pump and
measuring starts, to stop it press the arow pushbutton to the left. Measuring in
ambient air, an oxygen concentration of approximately 20.9% should be displayed.
The accuracy should be +/- 1% of the measuring range. The Zr-Ox MKII also starts
measuring as soon as an external voltage is applied to the external signal input. The
later has priority over starting via pushbutton.
The measurement stopps when you press the arow pushbutton to the left, or the
voltage is no longer applied to the signal input.
4.4 Adjustment of the flow rate of the sensor
The built in mesuringgas pump is controlled electronically. Due to this the flow rate
throuh the sensor ist constant. The flow rate is factory set to120 ml/min. The flow rate
can be changed in the menu parameter (type in the password 111111. To change the flow
rate select menu „Parameter“. Push the arrow pusshbutton „left or right“ to get into
submenu „specified flow rate/Solldurchfluß“. Enter the new specified flow rate via the
keypad and confirm with „Enter". ATTENTION: to enter e.g. 150 ml/min, type in 150
and confirm with „Enter“. Press the arrow pushbutton up until the display shows
„ready“ It is possible that the concentration reading in air is +/- 2% of 20,9%, in this case
we recommend to make an offset-calibration. Please read chapter 6 to make an offset-
calibration.
4.5 Adjustment of the alarm levels
Mainly because the unit is used for on-line measurement of oxygen-concentrations
the Zr-Ox MKII has the possibility to alarm via relays, as soon as the concentration
raise above resp., below the set alarm levels. The built-in relays can be programmed as
closer or opener. With the relay you can activate e.g. an alarmlamp / horn etc.
To change the alarmlevels please select the menu „Alarm Sens1“ by pressing the
cursorbutton „up, rsp. down“. Select the submenu „Sens1 max bzw. Sens1 min“by
pressing the cursorbutton „left rsp. right“ and enter the low and high alarmlevels of the
allowed gas concentration via the keypad. To change the meterrange from ppm to %
and back, press the pushbutton „ESC“. Confirm the new value by pressing the button
„Enter“ bestätigen. Press the arrow pushbutton up or down until the display shows again
„ready“
14.6 Adjustment of the analog-output
Zr-Ox has a programmable analog-output with standard 0/4-20mA or 0/2-10 VDC signal
corresponding the measured oxygen-concentration. To adjust the concentration, for the
0mA resp. 0 VDC signal, select menu „analog-output1“ and then select submenu „min“.
Enter the value via the keypad and confirm by pressing the pushbutton „Enter“. The same
you adjust the high concentration, for the 20mA resp. 10 VDC signal. Select menu
„analog-output1“ and then select submenu „max“. Change the meter range from ppm to
% and reverse by pressing the button „ESC“. Press the arrow pushbutton up or down until
the display shows again „ready“
Note: To enter all menus of Zr-Ox, type 111111 under Password query and press
the key „ENTER"
Page 6

5 Maintenance
5.1 Change of the filter cartridge
The Zr-Ox has normally a built-in measuring gas filter for the application in
soldering machines. This filter absorbes all elements, which could conterminate
the sensor or influence the measuring results, e.g. hydrocarbons. It is very
important to change this filter in regular periods.
Open the inspection glas, and screw out the used filter cartridge. Pay attention to
the O-ring – do not damage the O-ring. In case grease the O-ring with vaseline.
Take the new filter out of the package and screw it into the housing. Carefully
screw the inspection glas in.
IMPORTANT: Screw the inspection glass not too tight – if it is too tight, it
might be that it can be demaged and the system will be not tight.
New filter cartridges can be ordered via Ridzewski GmbH.
Please keep the filter cartridge in the packing until use.
THE OPERATION OF THE UNIT WITHOUT MEASURING
GAS FILTER WILL INVALID THE GUARANTEE OF THE
SENSOR, THE PUMP AND THE FLOWSYSTEM.
6 Calibration
6.1 Description of Calibration
Zr-Ox can be calibrated with up to7 calibration gases plus ambient air. For the
most applications 3 gases will be sufficent. Zr-Ox has a factory set calibration,
which can only be changed by the manufacturer. In certain circumstances this
setting can be re-enabled by the user. There is also the possibility to calibrate by
the user. Using the suitable password the user is able to calibrate the unit
according to his special requirements.
Attention: To calibrate the unit it is neccessary to use certified calibration gases. This
guarantees the highest accuracy. Please allow the sensor a heating time of at least 12
hours.
6.1 Calibration
The following gases are recommended for a general calibration:
100% O 2; 20.9% O 2; 1% O 2; 0.1% (1000ppm) O 2; 100 ppm O 2; N 2 (4.6)
Select the menu „calibration“. Here it is possible to select the factory settings –
e.g. in case of a faulty calibration. Quit by pressing „Enter“. Pressing the cursor
buttons „left or right“ you have the possibility to define up to 8 calibration gases.
Use the keypad to define the O 2 Kconcentration of the concerned gas and the
button „ESC“ to switch from ppm to %.
ATTENTION: To define a gas as 1%, select >001,00< + „Enter“. Lead the gas
through a T-connector (to avoid overpressure) into the unit via the input „gas in“
and then observate the EMK-value on the display. As soon as this value has
stabilized, confirm the shown value by pressing the „Enter“- button. Do so with
all other required gases. The unit sorts the gase from the top down to the
bottom.Finally store the calibration by pressing the „Enter“-button. Using the
cursorbutton „up or down“ to achieve the default-condition of the unit
After this procedure the unit is ready for measurements.
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7 Technical Data
7.1 Sensor and flow system
The sensor of the oxygen analiser Zr-Ox-unit is a Zirkonia typ. It is heated up to
~ 800 °C and a EMF (elektromotoric force as voltage) according the Nernstschen
Theorems will build, as soon as the oxygen-concentration at the measuring-
electrode isdifferent to the one at the reference-electrode. The EMF can be
approx. -40 mV in 100% O 2 and 240 mV in pure N 2 *.
The signal of the sensors will be amplified, linearized and adjusted to the
calibration by the µ-prosessor. The concentration value is then displayed
To minimize the influence of the cooling effect on the sensor, the flow rate is
kept at a constant level by using the built in measuringgas pump
The flow rate influences the calibration and should be kept at the factory
settings.
Zr-Ox has a built-in membrane pump, wich allows flow rates between 300 and
2000 ml/min, depending on the units-configuration. The high capacity of the
pump allows a fast transport of the test gas from far process areas. Only a very
small amount will flow through the sensor, the most of the gas will be fed via
bypass to the ambient or back to the process area.
To protect the sensor and the flowsystem against dangerous gases resp.other
contents of the process gases, a mearsuring gas filter must be installed at the
input of the analyser. The measuringfilter must be changed in regular periods.
7.2 Unit parameter
the exact specifications and technical data are listed in the appendix.
Ridzewski GmbH – Waldstrasse 26 - 86485 Biberbach - Germany
Fon: [phone] Fax: [phone] Email: [e-mail] www.ridzewski.de
Page 8

8 Troubleshooting
8.1 trouble shooting
8.2 Analyser does not operate, no measurement possible.
Test the power supply (voltage, current, frequency) and check the
mainpower-cable and fuses.
8.3 Analyser operates, no measurement possible.
Heating up time not over (normally 25 min).
Wait until „ready“ is displayed.
Or: Analyser is not in the „ready" condition.
Press pushbuttons „arrow up or down“ to get into the „ready" condition.
8.4 Analyser operates, measurement is possible, O 2- value of air does not correspond
to the value of 20,9%.In case that the display shows less than 1ppm, please
contact the manufacturer. Check the calibration. Change the filter cartridge; it is
probably saturated with hydrocarbons or faulty.
8.5 Analyser operates, measurement ist possible. Displayed O 2- value is e.g. <1 ppm
or >80% indicates, that the analyser is measuring out of the calibrated ranges.
Please contact the manufacturer.
8.6 Analyser operates, measuring value, after heating up time, is <0,1 ppm.
The sensor is faulty. Please send the analyser to the manufacturer.
9 Spare Parts
9.1 Parts Subject to Wear
Filter cartridge for measuring gas filter, Order no. MGFP-AK
9.2 Accessories
Measuring gas filter, complete with filter cartridge, Order no. MGFK-AK
Ridzewski GmbH – Waldstrasse 26 - 86485 Biberbach - Germany
Fon: [phone] Fax: [phone] Email: [e-mail] www.ridzewski.de
Page 9

10 Menus ( on Frontpanel)
10.1 Main menus
menustructure Main menu
Heating Displayed after powering up the analyser.
Wait 025 Min
Htg.time 025 Min By pressing the pushbutton arrow down you get to all menus.
Operation Press the pushbutton arrow right/left for pump on/off.
Ready
Ready Measuring continuously, carry on by pressing pushbutton arrow
Cont. meas. left or arrow down.
SE1 20.95 % O2
Password query First type in 111111, then press key ENTER for confirmation.
****** Then go to the menus with the arrows up or down.
Parameters menu parameters
Warmup time
act: 025 Min
Alarm menu alarms
Sensor 1
HiLim. 030 %
LoLim. 000.2 ppm
Hardware test menu hardware test
Pump
Off
Adjustments menu adjustments
Display Measurem.
%, ppm
Orig.-Calibr.SE1 menu calibration.
KW1 077.0 %
-28.23 mV cal
-1.45 mV act
Serial Number menu serial number (only factory service personal)
Device
941000–00046
Password setting menu password setting (only factory service personal)
Passw 1 customer
xxxxxx
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10.2 Menu Parameters
Menu Parameters
For better overview the menus are displayed vertically.
Menu Parameters Press pushbuttons arrows right/left to the different menu
points.
Displayed with factory settings of parameters.
Changes or inputs save pressing the pushbutton ENTER.
Delete input with pushbutton ESC.
Change of values or parameters pressing pushbutton ESC.
Parameters Factory set time is 25 min
Warmup time
act: 25 Min
Parameters Factory set 0 sec. Delay of analoge output.
Delaytime
act: 00 sek
Parameters Either flow- or power control, factory setting.
Pump mode
Powercontrol
Parameters Setting of flow control, factory setting.
Flow-control
nom.: 120 ml/Min
act. : 113 ml/Min
Parameters
Pumppower Pre setting of pump power in % to
Ist: 100 % control pump, factory setting.
Ist: 132 ml/Min
Parameters Parameter for spot measurements only, factory setting.
Time Sample
00 sec
Parameters Setting in % or ppm of the analog output either 0-10V or
Analogout SE1 0-20 mA.
HiLim. 2000.0 ppm
LoLim. 0002.0 ppm
Parameters Change the analog output from 0/4-20 mA to 0/2-10V
Switch Analogout depending on option.
Ausg. 0 – 20 mA
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10.3 Menu alarms
For better overview the menus are shown vertically.
Menu alarms Press pushbuttons arrows right/left to the different menu
points.
Displayed with factory settings of parameters.
Changes or inputs save pressing the pushbutton ENTER.
Delete input with pushbutton ESC.
Change of values or parameters pressing pushbutton ESC.
Alarms Setting of first concentration alarm.
Sensor 1
HiLim. 030.00 %
LoLim. 0000.2 ppm
Alarms Setting of second alarm (prealarm)
Sensor 1 (pre)
HiLim. %
LoLim. Ppm
Alarms Setting of flow alarm.
Flow
HiLim. 200 ml/Min
LoLim. 050 ml/Min
Alarms Choice of setting as latched or unlatched.
Flow
unlatched
Alarms Choice of setting as on or off
Buzzer
On
Alarm1 Select concentration- or flow alarm
Relais 1 Relais 1 make or brake contact.
* * * Not factory defined.
make contact Each relais can be set maximum with the following at * positions
S1 P1 Flow
*S1 = Alarm sensor 1, first concentration alarm
*P1 = Alarm sensor 1, second concentration alarm (pre alarm)
*Flow = Flow alarm
- Alarm Relais 2 and 3 see alarms relais 1 -
Alarms Output of 10V or 20 mA at analog out when
Analogout 1 100% 100 % flow- or concentration alarm
Alarms Output of 10V or 20 mA at analog out when
Analogout 2 100% 100 % flow- or concentration alarm
(option only with a second sensor)
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10.4 Menu Hardwaretest
For better overview the menus are shown vertically.
Menu hardwaretest Press pushbuttons arrows right/left to different menu points.
Displayed with factory settings of parameters.
Changes or inputs save pressing the pushbutton ENTER.
Delete input with pushbutton ESC.
Change of values or parameters pressing pushbutton ESC.
Hardware test Test of sampling pump. On/off pressing pushbutton ESC.
Pump
Off
Hardware test Test of solenoid valve 1. On/off pressing pushbutton ESC.
VA 1 up to 5 valves (all as an option).
Off
Hardware test Test of relay 1. On/off pressing pushbutton ESC.
RE 1 3 relais installed.
Off
Hardware test Test of keyboard.
Keyboard 1
Hardware test Test of analog output 1. On: 10 V DC. Off 0 V DC.
Analogout 1
Off
Hardware test Test of pump
Pump
Off
10.5 Menu Settings
Menu settings Press pushbuttons arrows right/left to different menu points.
Displayed with factory settings of parameters.
Changes or inputs save pressing the pushbutton ENTER.
Delete input with pushbutton ESC.
Change of values or parameters pressing pushbutton ESC.
Settings Change values reading on display,
Units Value shown in %, ppm or both
%, ppm
Settings Display of actual date
Date
Settings Display of actual time
Time
Settings Display of actual language
Language
Page 13

10.6 Menu Calibration
For better overview the menus are shown vertically.
Menu calibration Press pushbuttons arrows right/left to different menu points.
Displayed with factory settings of parameters.
Changes or inputs save pressing the pushbutton ENTER.
Delete input with pushbutton ESC.
Change of values or parameters pressing pushbutton ESC.
Orig.-Calibr. SE1 Display calibration parameter 1. Maximal 8
KW1 077.96 % calibration parameters (gases) possible.
-28.22 mV kal
-3.22 mV act
Orig.-Calibr. SE1 Display calibration parameter 1. Maximal 8 calibration
KW8 00.1 % parameters possible.
. 170.22 mV kal
168.21 mV act
Orig.-Calibr. SE1 ONLY after pressing the Enter key, all calibration
Load Calibration parameters where stored in memory !
yes=enter
Ridzewski GmbH – Waldstrasse 26 - 86485 Biberbach - Germany
Fon: [phone] Fax: [phone] Email: [e-mail] www.ridzewski.de
Page 14

Specifications and technical data*
Oxygen analyser with Zirconia sensor:
Sensor type Zirconia
Measuring range: 0,1 ppm - 99.9 % O2
Sensor temperature: approx. 800 °
Heating up time: minimum 15 min., optimum 45 Min.
Calibration: recommanded every 12 month
minimum 2 calibration gases
Response time/sensor: approx. 35 msec.
Response time/analyser: 20.9 % - 10 ppm in < 1 minute
Accuracy: +/-2 % of calibrated range
Sensor flow: 150 ml, electronically controlled pump
Flow measurement: differential pressure sensor
User interface: LED-display, 16 digits, 4 lines and keybpad
with 16 pushbuttons; set up of analyser parameters
and calibration through menus
option: Windows-based user software
Fault detection: analyser temperature, broken connections, system fault
Alarms: 2x concentration alarm, 1x system alarm,
flow alarm, all 3 alarms fully programmable
Relays rated for: max. 230 VAC, 3A
Analogue output: 0/4 - 20 mA or 0/2 - 10 VDC, programmable
Interfaces: RS 232, analogue modem, CAN bus
Housing: Aluminium, ½ - 19-inch rack mounting,
3 HU
Weight: approx. 7 kg
Power supply 100-240 VAC / 47-63Hz
Environmental conditions
Temperature range: functioning 0-50 degrees C, storage temperature 5-50 degrees C
Humidity: functioning 95% RAH, storage < 75%
*We reserve us the right to change or modify our product specifications at any time without
notice.
Ridzewski GmbH – Waldstrasse 26 - 86485 Biberbach - Germany
Fon: [phone] Fax: [phone] Email: [e-mail] www.ridzewski.de
Page 15