Sensotec Rapidox 1100ZR3-H-PFC User manual

Rapidox 1100ZR3-H-PFC
Oxygen Analyser
(Heller Version)
Instruction Manual
Revision 1.2
Cambridge Sensotec Limited
Unit 29 Stephenson Road
St Ives
CAMBS
PE27 3WJ
Tel. [phone]
Fax [phone]
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Cambridge Sensotec Rapidox 1100ZR3-H-PFC O2Analyser Instruction Manual
Declaration of Conformity
Manufacturer: Cambridge Sensotec Ltd.
Unit 29 Stephenson Road
St Ives
Cambs
PE27 3WJ
Product Names: Rapidox portable oxygen gas analyser
Model Numbers: RX1100ZR3-H-PFC
Conform to the following specifications:
EMC: EN 61326:2006 Electrical equipment for measurement,
control and laboratory use
Declaration: I declare that the above products conform to the applicable
requirements of the LVD Directive 2006/95/EC and the EMC Directive 2004/108/EC
and is CE marked accordingly.
Signature:
Name: Dr. Mark Swetnam
Title: Managing Director
Company: Cambridge Sensotec Limited
Date: 16th December 2013
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 have purchased any electronic or electrical product from
Cambridge Sensotec since 2007 and would like to dispose of it correctly under the
WEEE scheme, please contact us and we will be happy to either arrange the
collection of the waste or have it returned to our offices for recycling. All our in-
house manufactured products are scheme compliant and carry the WEEE label
indicating that it is NOT allowed to be disposed of in a landfill site.

Cambridge Sensotec Rapidox 1100ZR3-H-PFC O2Analyser Instruction Manual
Contents
1. Introduction .......................................................................................................... 1
2. Features ................................................................................................................. 1
3. Heller Specific Features........................................................................................ 2
4. Technical Specification........................................................................................ 3
5. Precautions............................................................................................................ 4
6. Warning ................................................................................................................. 4
7. Rapidox Operating Instructions........................................................................... 4
7.1 PFC Connections ........................................................................................... 5
7.2 The Rapidox Analyser - Menu System......................................................... 6
7.3 Getting Started............................................................................................... 6
7.4 Display Behaviour ......................................................................................... 6
7.5 Pump Control................................................................................................. 7
7.6 Menu Access / Passwords ............................................................................. 7
7.7 Rapidox Calibration....................................................................................... 8
7.8 Programming the Multiplex........................................................................ 10
7.9 Cleaning the Sensor..................................................................................... 11
7.10 Alarms.......................................................................................................... 12
7.11 Analogue Outputs........................................................................................ 13
7.12 Setting the Display Units ............................................................................ 17
7.13 Setting the Display Options ........................................................................ 17
7.14 Pressure Correction Mode........................................................................... 18
7.15 Setting the Baud Rate .................................................................................. 18
7.16 RS232 / RS485 Port...................................................................................... 19
7.16.1 RS232 Protocol ..................................................................................... 19
7.16.2 RS485 protocol ..................................................................................... 21
7.17 Printing......................................................................................................... 21
7.18 Load Defaults ............................................................................................... 22
8. Rapidox Software Instructions........................................................................... 23
8.1 Software Installation ................................................................................... 23
8.2 Getting Started............................................................................................. 23
8.3 On-Screen Help ........................................................................................... 24
8.4 Configuration Page ...................................................................................... 24
8.5 Reconfiguring the Analyser ........................................................................ 25
8.5.1 Config 1 Screen ........................................................................................ 26
8.5.2 Config 2 Screen ........................................................................................ 27
8.5.3 Alarm Config Screen................................................................................ 28
8.6 On-Screen LCD ............................................................................................ 29
8.7 Remote Calibrating and Cleaning............................................................... 30
8.8 Calibration Error Messages ......................................................................... 31
8.9 Software Utilities......................................................................................... 32
8.10 Setting Analyser Date and Time................................................................. 33
8.11 Log Diagnostics For ..................................................................................... 33
8.12 Show / Hide LCD ......................................................................................... 33
8.13 Image Grabber.............................................................................................. 33
9. Data-Logging Software........................................................................................ 34

Cambridge Sensotec Rapidox 1100ZR3-H-PFC O2Analyser Instruction Manual
9.1 Introduction ................................................................................................. 34
9.2 Auto-Log Feature ......................................................................................... 34
9.3 Setting up the Data Logger.......................................................................... 34
9.4 Running the Data Logger............................................................................. 36
9.5 Auto Date Stamped Files............................................................................. 36
9.6 Live Time Graphing Screen ........................................................................ 37
9.7 Main Graph Window................................................................................... 38
9.8 Plot Colours.................................................................................................. 38
9.9 Graph Titles and Labels .............................................................................. 39
9.10 Plot Co-ordinates ......................................................................................... 39
9.11 Last data point ............................................................................................. 39
9.12 Using the Cursor.......................................................................................... 39
9.13 Zooming ....................................................................................................... 40
9.14 Y-Axis Graph Units ..................................................................................... 40
9.15 Oxygen Scale ............................................................................................... 40
9.16 Second Y Axis.............................................................................................. 40
9.17 Loading an Old Run .................................................................................... 40
9.18 Printing Graphs............................................................................................ 41
9.19 Data Logging in the Background................................................................. 41
9.20 Pausing the Data Logging ............................................................................ 41
9.21 Changing the Data Logging Parameters Mid-run....................................... 41
9.22 Working with Spreadsheets ........................................................................ 41
9.23 Disaster Recovery ........................................................................................ 42
9.24 DDE Protocols .............................................................................................. 42
10. Troubleshooting .............................................................................................. 44
10.1 Warranty ...................................................................................................... 45
10.2 Conditions of Warranty:.............................................................................. 45
11. Appendix 1: Proportional Flow Control ........................................................ 47
11.1 Connections ................................................................................................. 48
11.2 Software Description................................................................................... 48
11.3 Prop. Flow Control tab ................................................................................ 49
11.4 SW Alarm Config tab................................................................................... 52
11.5 Data-logging with PFC................................................................................. 53

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1. Introduction
The Rapidox 1100ZR3-H-PFC (Z=zirconia sensor R=rear panel gas input 3=three
channel multiplexer H=Heller version PFC = Proportional Flow Control) oxygen
analyser allows fast and accurate oxygen analysis over the oxygen range 1ppm to
100% O2. 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 1100ZR3-H-PFC is a fully integral unit complete with a powerful
diaphragm pump to provide variable gas sampling up to approximately 1.2 litres
per minute. The analyser has three separate gas inlets that can be independently
programmed to sample gas sequentially OR in various combinations using manual
operation. This is referred to as the multiplex in this manual.
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 sample gas is collected from one or more of the
three gas inputs controlled by a series of electric solenoid valves.
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.
This version of the Rapidox is specially configured with PFC (Proportional Flow
Controller) output that that is programmed using the Rapidox software. See
Appendix 1 for more details.
2. Features
Multiplex gas analyser with three separate sample gas inlets
Very fast measurement response (typically 4 seconds for a 90% response).
Wide measurement range available (1ppm to 100% O2).
Accuracy ± 1% of the actual measured oxygen.
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
Powerful variable speed diaphragm pump fitted for sampling the gas

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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
Optional printer attachment
3. Heller Specific Features
Internal carbon trap fitted to the sample gas line
Heller model name on the boot up screen
Voltage input on rear panel to enable / disable the sample pump
Modified software
PFC control loop outputs

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4. Technical Specification
Property
Specification
Supply Voltage
90-260VAC, 50/60Hz
Power consumption
100W (max)
Analyser dimensions
350mm X 263mm X 150mm
Weight
4.0 kg
Display
16
6 play0mmimensions0/60 Hzed con
Warm up time
3-4 minutes at 20°C
Normal operating temperature
5-35°C
Sensor Range
1ppm to 100% O
2
taken from three
independent sample inputs.
Sensor Accuracy
±
1% of the actual measured oxygen
content
Outputs: O2voltage
0-10V (user-programmable) into minimum
5k
O2 current
4-20mA current loop (user-programmable)
into maximum 500

O2 PID control
4-20mA current loop (user-programmable)
into maximum
500

All data and parameters
RS232 or RS485 - data streamed on
demand
Sample Pump
Long-life vacuum pump
Flow Rate
0-1.2 L.min-1
Max. gas temperature on input
60°C
Calibration
Requires 2 or 3 user-selectable gas
compositions (air is default plus another
two)
Table 1: Rapidox 1100ZR3-H-PFC technical specification

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5. Precautions
Make sure you read and understand these instructions and keep them safe for later
use. The unit should not be exposed to extreme temperatures < -5°C or > 60°C.
Normal operating temperature is 5-35°C. Avoid direct sunlight. Do not use liquid
cleaners, aerosols or solvents to clean the case. Use a damp cloth for cleaning. Do
not use this equipment 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 responsibility can
be held for injury or loss of life caused by inappropriate use of this equipment.
7. Rapidox Operating Instructions
Figure 1: Rapidox 1100ZR3-H-PFC front panel. Numbers are referred to in the text.
1
2
5
1
2
5

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Figure 2: Rapidox 1100ZR3-H-PFC rear panel. Numbers are referred to in the text.
7.1 PFC Connections
On the rear of the PFC coded machines are two terminals labelled “PFC Valve 4-
20mA” and “Supply Valve (In)”.
Figure 3: Rear Panel Terminal Strip
a) 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.
b) Supply Valve (In): This connection requires a 12-24V connection from the
oven to indicate when it is operation. The PFC output and the analyser
sample pump are disabled when there is no voltage signal present.
3
4
6
7
8
9
2
1
+ve
+ve
-ve
-ve

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7.2 The Rapidox Analyser - Menu System
All of the user-programmable functions are accessed via a menu system which is
controlled using the front panel Keypad (2). To access the menu press the ENT
button and to escape and return to the operating screen press ESC at any time.
The menu system flow chart is shown in Appendix 2 below.
7.3 Getting Started
Ensure that the Rapidox analyser is located away from extreme heat and dirt
environments. Plug the unit in to a suitable supply (noting the information on the
serial sticker and using the power cable supplied) using the rear power socket (8).
Make sure that the cooling fan (9) is not obstructed during operation.
Push the gas sample tube (6mm OD/4mm ID) on to any of the three
GAS IN (3) connectors on the multiplex and fit the retaining collar hand tight. If
other sample tubes are to be connected repeat this until all three sample points are
used. Repeat for the GAS OUT (4) connector should an outlet tube be required.
The pump will draw gas at a flow rate depending on the value set either in the
software or from the menu. The default setting is one hundred percent.
Turn the unit on using the red power switch on the front (5). The LCD (1) will
display the firmware version followed by the message “HEATING SENSOR”. The
sensor will take approximately four minutes to come up to temperature, after
which the Rapidox will begin to take measurements. The progress of the sensor
heater is shown in the form of a bar graph on the LCD (1).
Allow thirty minutes for the box to stabilise fully. This allows the components of
the analyser to reach a stable working temperature. During this warm-up period it
is common for the baseline oxygen to drift by a small amount, which may be
corrected by re-calibrating (see section 7.7).
7.4 Display Behaviour
Once at temperature the LCD display will show the oxygen reading (in percent or
ppm) on line 1. The bottom right corner of the LCD shows the three multiplex
inlets as circles “” representing “1,2,3” If a channel is currently being sampled
by the multiplex then this circle goes black e.g. “” to represent channel 1. If
the multiplex is in Manual mode then the word “MAN” alternates on the display
to remind you. See section 7.8 for a full description of the multiplex system. The
symbol AL1 or AL2 may also appear in the bottom right of the LCD if the alarm
system is enabled and an alarm condition applies. The oxygen sensor reading
may flash or show “O/Range” when its limits are reached, and error messages will
be displayed if there is a fault with the sensor. See Table 2 for more details:

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Oxygen Sensor Display Possibilities
O2Reading > 9999.9%
Display shows “O/Range”
O2Reading >0.5ppm and < 9999.9%
Display shows the normal oxygen reading in % or ppm
O2Reading <0.5ppm
Display shows <0.5ppm flashing
O2Reading is flashing
Indicates that the pressure sensor is out of range and
automatic pressure correction is on.
O2Sensor takes > 10 minutes to warm up
Display shows “Possible sensor Fault” because the sensor
heater is failing.
O
2
Sensor has failed completely or become
disconnected
Display shows “No sensor or sensor Fault”
O2 Sensor is OK but the pressure sensor is faulty and
the auto pressure correction mode is selected
Display shows “Fault” flashing.
Pressure Sensor Possibilities
Pressure Reading is >1000mbar
Display 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 Pump Control
Please note that the pump speed is fixed at 100% on Heller coded machines.
The flow rate of gas drawn into the analyser from the multiplex can be controlled
using the menu option 9: “Set Pump Flow”. The unit is supplied with the flow
rate set to 100% which equates to approximately 1.2 Litres per minute. If you
wish to change the flow rate press ENT and select menu option 10. Use the UP &
DOWN arrows to change the value from OFF – 100% in steps of 10% increments.
When using the unit with a pressurised (flowing) gas source the pump can be left
switched off. Note that on Heller units coded “PFC” the pump will be deactivated
if there is no voltage signal supplied to the supply valve (In) terminals on the rear
panel. Please see section 11.1 for further details.
7.6 Menu Access / Passwords
The analyser has an option to set a password that will restrict access to the menus.
The password menu is disabled by default in the factory. If you wish to password
protect the analyser press ENT and scroll down to the PASSWORD option (Menu
option 12). Pressing ENT again will ask you for the default password which is
“0000”. Enter this using the UP and DOWN arrows. Once the password has been
entered successfully you can chose between ENABLE and DISABLE in the menu
using the UP and DOWN keys.
The other option is to RESET the password to a new value. The password must be
4 digits long and can be any combination of numbers from 0-9. Make sure that the
new password is noted down!
If the password function has been enabled then in the future each time the menu
system is accessed then the password prompt will display. After the correct
password is entered then the full menu will be accessible. You can make as many
changes as you want to the options and only press ESC once you have finished.

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Pressing ESC takes you out of the password protected area and you will have to re-
enter the password to go back in again.
If the password has been forgotten please contact Cambridge Sensotec who will
advise you on how to recover it.
7.7 Rapidox Calibration
Please note that when calibrating you must apply calibration gas using Gas 1 input
only. Gas 2 and Gas 3 inputs are disabled in the calibration process to avoid cross
contamination via the multiplex.Disconnect any tubing from inlets Gas 2 & Gas 3
for complete isolation.
Full calibration is a simple procedure requiring only two or three gases (one of
which is normally air – 20.95%). The gas values are user-selectable and can be
changed by using the front keypad (2) or the communications software described
in section 8, and the calibration values can be stored on file for later use.
Care must be taken to calibrate the analyser so that, whenever possible, the range
of measurement lies between the two calibration point extremes. For example, if
you are working at 10ppm but have calibrated the analyser between 21% and
100% then the analyser will be inaccurate. You would need to calibrate at, say,
1ppm and 1000ppm to be sure of good accuracy. The procedure is as follows:
1) Bearing in mind the points made above, decide which two (or three) gases
you are going to use for calibration. If you are constantly working at a
particular range of compositions then it would be wise to obtain small
cylinders of calibration gas with analysis certificates. Cambridge Sensotec
can supply these. Press the ENT button on the front panel 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. The message “Use Calibration Gas on
Channel 1” is displayed for a moment. Use the UP and DOWN arrows to
select O2HIGH, O2MIDDLE or O2LOW 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 prompts. If the gas value is not what you
require you can edit the value (in ppm scientific notation) using the up and
down and right arrows on the keypad. The cursor flashes underneath the
digit to edit. For example air (20.95%) should be entered as 2.095E+05ppm
(209,500ppm). Note that you cannot go backwards to edit a digit to the left
of the cursor. Instead keep pressing the RIGHT button and the cursor will
wrap around back to the beginning. Alternatively press ESC to start again.
Press ENT when you are ready to proceed.

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Scientific
Format
Meaning
Equivalent
ppm
Equivalent
Percent
1.000E+06ppm
1.000 x 1,000,000
1,000,000ppm
100.00%
2.095E+05ppm
2.095 x 100,000
209,500ppm
20.95%
1.000E+05ppm
1.000 x 100,000
100,000ppm
10.00%
1.000E+04ppm
1.000 x 10,000
10,000ppm
1.000%
1.000E+03ppm
1.000 x 1,000
1,000ppm
0.100%
1.000E+02ppm
1.000 x 100
100.0ppm
0.010%
1.000E+01ppm
1.000 x 10
10.00ppm
0.001%
1.000E+00ppm
1.000 x 1
1.000ppm
0.0001%
Table 3: Examples of common scientific format with their equivalent ppm and percent
values
2) The sensor needs to be exposed to the first calibration gas from a cylinder
(or exposed to ambient air, 20.95% if this is the calibration gas of choice)
using Gas 1 input on the rear. Allow several minutes to pass to flush the
sensor properly. Wait for the top line of the display (1) to become stable.
To complete the calibration press and hold the ENT button for two seconds.
During this time you will see a bar graph progress across the lower display.
The analyser will then recalibrate and display “O2recalibrated” and then
return to normal run mode. The display will now correctly read the value
of the first calibration gas. Note that if the ENT button is released before
two seconds have elapsed, the recalibration will be aborted and when the
analyser eventually returns to run mode it will use the existing calibration.
3) 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 pressure is either above or
below the range recommended for accurate calibration.
4) The analyser predicts the correct signal from the sensor during calibration
and if this is outside the range of expected values then the display will flash
and display “G?” to warn you that either the cal gas flowing over the sensor
is different to the value you have programmed OR the sensor may be old
and approaching the end of its life. Check before proceeding!
5) To calibrate against the second or third calibration gas, repeat the
procedure from 2 but this time press ENT followed by the UP or DOWN
button to scroll through to the “O2Middle” or “O2Low” screen. Flush the
sensor chamber with the second calibration gas allowing several minutes
for the new gas to flush through. Again please remember to always use
Gas1 input to apply calibration gas. Wait for the display to become stable
before pressing the ENT button for two seconds. The analyser will then
recalibrate and display “O2recalibrated” and then return to normal run
mode. The display will now correctly read the value of the calibration gas.
6) The analyser is now correctly calibrated and will read accurately between
these two calibration points. Note that this procedure can be performed
remotely using the software described in section 8. You can now repeat
this process for the third calibration gas if required.

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7) If at any time, you encounter difficulties and wish to restore the machine to
its factory set calibration, use the configuration software provided and load
the default settings (described in section 7.18 below). Each machine is
provided with a unique file that contains the factory settings. This is
located on the memory stick provided and is copied onto your PC during
the installation process.
8) Note that the three calibration points are independent of each other so you
can calibrate the analyser in any order you desire. However please note
that O2HIGH must always be greater than O2MIDDLE which must always
be greater than O2LOW. Typically the factory settings are: O2
HIGH=20.95%, O2MIDDLE=0.1% (1000ppm) and O2LOW=0.001%
(10ppm).
NB You must always perform a FULL calibration to achieve good accuracy.
7.8 Programming the Multiplex
The Rapidox 1100ZR3-H-PFC is fitted with three independent gas inlets on the
rear panel allowing up to three separate gas samples to be analysed. The
multiplex unit allows one or more of the sample gases to pass over the sensor and
can be programmed by the user to work automatically, sampling each gas in turn
for a given time, or manually where each gas inlet channel can in turn be switched
on or off:
1. Automatic:When the multiplex is set to Auto then each gas channel is
sampled for a set period of time (or switched off) by the user. The sequence
is repeated continuously until the user changes the program. For each gas
channel the user can select a sample time of 1,2,3,4,5,10,15,30 minutes or
1,2,6,12 or 24 hours. In addition the user can switch one of the channels
off. In this case the remaining two channels will sample alternatively. At
least two gas channels have to be on for the automatic mode to work. The
front LCD displays three circles indicating to the user which channel is
currently being sampled. If channel 1 circle is flashing then this indicates
that the closed loop output is under PFC control. See Table 4 for more
details.
2. Manual: When the multiplex is set to manual mode the user can set any
channel to “on” or “off”. Any possible permutation is allowed in this mode
including switching all three off. Note however in this instance the internal
pump will automatically switch off to preserve itself. This mode is useful if
only one single sample is required, or sampling the same gas from different
locations is desired. The front LCD displays three circles indicating to the
user which channel(s) is/are currently being sampled. In this mode the
letters “Man” also appear every few seconds to indicate that the analyser is
operating in this mode. If channel 1 is set to “on” and channels 2 and 3 are
set to “off” then the PFC closed loop is active and the channel 1 circle will

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flash to indicate this. See Table 4 for more details.
Symbol
Meaning

+/- “Man”
In automatic mode sampling channel 1 for selected time.
In manual mode channel 1 on and 2 & 3 off.
If the black circle is flashing then the closed loop output is under PFC control. If it is not
flashing then PFC closed loop control is suspended.

+/- “Man”
In automatic mode sampling channel 2 for selected time.
In manual mode channel 2 on and 1 & 3 off.
PFC closed loop control is suspended.

+/- “Man”
In automatic mode sampling channel 3 for selected time.
In manual mode channels 1 & 2 off and 3 on.
PFC closed loop control is suspended.

+ “Man”
In manual mode only all three channels are off. Note that the pump switches off if this mode
is set. PFC closed loop control is suspended.
 + “Man”
In manual mode only all three channels are on. PFC closed loop control is suspended.

+ “Man”
In manual mode only channels 1 & 2 on and 3 off. PFC closed loop control is suspended.
 + “Man”
In manual mode only with channels 1 & 3 on and 2 off. PFC closed loop control is suspended.
 + “Man”
In manual mode only with channels 1 off and 2 & 3 on. PFC closed loop control is suspended.
Table 4: Different permutations of channel indicator lights on the LCD
To program the multiplex press ENT on the keypad (2) and select menu option 2
using the up and down arrows or using the software described in section 8.6.
Press ENT to proceed. Use the UP and DOWN arrows to select “Auto” or
“Manual” and ENT to proceed. If “Auto” is selected then use the UP and DOWN
arrows to select a time period (1,2,3,4,5,10,15,30 minutes or 1,2,6,12,24 hours or
OFF) for each gas sample inlet in turn. If “Manual” is selected use the UP and
DOWN arrows to select “on” or “off” for each gas sample inlet in turn. Once all
three are programmed then the multiplex will start the sequence of sampling from
gas 1 inlet.
Note that you can only have one of the channels switched on at any time in the
auto mode. If “on” is selected then the option disappears from further menus as
you continue the programming sequence. You can have any combination of “off”
and “on” in manual mode.
7.9 Cleaning the Sensor
You can clean the sensor at any time by pressing ENT on the keypad (2) and
scrolling down to option 3 “Clean Sensor” or using the software described in
section 8.6. Press the ENT button to proceed. The screen displays “Clean
Sensor?”. Press ENT again and the cleaning will take place. The procedure takes
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 allowed to build up. The cleaning operation pumps oxygen
through the zirconia tube, which burns the particulates away from the sensor
surface.

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7.10 Alarms
The Rapidox is fitted with two independent and fully programmable alarm relay
outputs, which can be programmed to be either normally open N/O (closes on
alarm) or normally closed N/C (opens on alarm). You have the option of assigning
each alarm to the oxygen, or pressure (internal) as well as enabling the alarm relay
circuits, enabling an audible buzzer and enabling a visual warning on the screen.
The alarms can be programmed by the user via the keypad (2) on the front panel
or using the software provided (section 8.5.3 ). To change the alarm settings scroll
down the menu to no. 4 “Set Alarms” and press ENT. Now use the UP & DOWN
arrows to select “Alarm 1” or “Alarm 2” and press ENT. The next screen shows
the message “Assign To:”. Use the UP and DOWN arrows to select O2, or Pressure
depending on which measurement you want the alarm to work with, and press
ENT to proceed. The default is O2.
The next settings configure the behaviour of the alarm. Use the UP & DOWN
arrows to select ON or OFF for the following parameters:
1. OUTPUTS: This enables the rear panel relay outputs when ON is selected
2. AUDIBLE: This enables or disables the audible buzzer inside the unit
which will sound in an alarm condition
3. VISIBLE: This enables or disables warning messages on the LCD screen on
the front of the Rapidox. During an alarm condition either “AL1” or “AL2”
(or a combination of both) will flash at the bottom right hand corner of the
display.
4. POLARITY: This determines whether you are setting a rising or falling
alarm. Use the arrows to change the direction of the alarm to up or down.
A rising alarm means that the alarm will be silent at values below the set-
point but as soon as the value rises above the set-point the alarm will be
triggered
5. SETPOINT: The current alarm set-point is displayed in scientific notation
with a flashing cursor under the first digit. Use the UP & DOWN arrows to
change 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 exactly the same way as described above and both alarm
circuits are completely independent of each other. Note that you must programme
all the parameters for each alarm for the settings to be saved. The bottom line of
the LCD will display “Alarm x set” (where ‘x’ is the selected alarm channel) to

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confirm that the settings have been saved.
The alarm circuit relays are accessed via the terminal block on the rear panel and
are clearly labelled. Alarm 1 is assigned to the terminals labelled “Alarm High”
and Alarm 2 is assigned to the terminals labelled “Alarm Low”. The relay circuit
is rated at 24V 0.5amps maximum. Under certain conditions (e.g. the sensor
becomes disconnected) the Rapidox will set the alarm channel to OFF to prevent
false alarms, and the relay contacts for the affected channel will go to the
programmed N/O or N/C setting. For more information please refer to Table 5 in
section 7.11 below.
7.11 Analogue Outputs
The Rapidox analyser provides various analogue outputs. The standard industrial
analogue outputs (0-10V and 4-20mA) for both oxygen, and internal pressure are
accessible via the terminal block (6) on the rear panel. These outputs have a 12
bit resolution (approximately 1 in 4000) and the lower and upper values are fully
user-programmable using the keypad (2) or the software provided (section 8). In
the case of oxygen, three output mode options are provided for setting the outputs,
in order to give the user maximum flexibility:
1. LIN (ppm): The linear oxygen output mode setting produces an output that is
scaled linearly between 0 and 10V (or 4 and 20mA). So, for example, if the
scale is set 0V = 0% O2and 10V = 100% O2then 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
"Lin(ppm)"
Linear output mode
0
1.25
2.5
3.75
5
6.25
7.5
8.75
10
010 20 30 40 50 60 70 80 90 100
O
2
(%)
O
2
Volts output
4
6
8
10
12
14
16
18
20
O
2
mA output

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The following general formulae can be used to calculate the oxygen from the
voltage or current outputs when set to the linear output mode:
Output type Formula for calculating oxygen from analogue output signal
0-10V O
2
= V
out
/ 10 * (O
2H
- O
2L
) + O
2L
4-20mA O
2
= (mA
out
– 4) / 16 * (O
2H
- O
2L
) + O
2L
Where: O2L = user setting of oxygen for 0V or 4mA output 1
O2H = user setting of oxygen for 10V or 20mA output 1
Vout = the measured voltage output in volts
mAout = the measured current output in mA
1O2, O2L and O2H must all be in the same units.
2. LOG (ppm): This setting produces an output that is scaled logarithmically
between 0V and 10V (or 4 and 20mA). So, for example, if the scale is set to 0V
= 0.0001% (1 ppm) and 10V = 100% (1,000,000 ppm) then 5V would indicate
an oxygen reading of 0.1% (1000 ppm). This scale is more suitable for large
ranges of oxygen down to very low ppm levels. The scaling of this example is
shown in the blue line in following plot, from which other intermediate values
can also be read. For comparison, 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:
"Log(ppm)": Log output mode
0
1.25
2.5
3.75
5
6.25
7.5
8.75
10
0.0001 0.001 0.01 0.1 110 100
O
2
(%)
O
2
Volts output
4
6
8
10
12
14
16
18
20
-4 -3 -2 -1 012
log(O
2
(%))
O
2
mA output

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Output type Formula for calculating log10(O2) from analogue output signal
0-10V log
10
(O
2
) = V
out
/ 10 * log
10
(O
2H
/ O
2L
) + log
10
(O
2L
)
4-20mA log10(O2) = (mAout – 4) / 16 * log10(O2H / O2L) + log10(O2L)
Where: O2L = user setting of oxygen for 0V or 4mA output 2
O2H = user setting of oxygen for 10V or 20mA output 2
Vout = the measured voltage output in volts
mAout = the measured current output in mA
2O2, O2L and O2H must all be in the same units.
Note: O2= 10 log(O2)
3. RAW (mV): This setting is for certain customers who like to monitor the raw
sensor EMF signal. The signal from a sensor goes from approximately -50mV
at 100% O2through zero at approx 5% O2and to +1000mV at extremely low O2
levels. So, for example, if the scale is set to 0V (output) = -50mV (sensor
voltage at approximately 100% O2) and 10V (output) = 250mV (sensor voltage
at approximately 1ppm O2) then 5V would indicate a sensor voltage of 100mV.
The scaling of this example is shown in the following plot, from which other
intermediate values can also be read.
Figure 6: Graph showing the raw sensor mV output mode option for oxygen
The following general 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:
"Raw(mV)"
Sensor mV output mode
0
1.25
2.5
3.75
5
6.25
7.5
8.75
10
-50 050 100 150 200 250
Raw sensor voltage (mV)
O
2
Volts output
4
6
8
10
12
14
16
18
20
O
2
mA output

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Output type Formula for calculating sensor mV from analogue output signal
0-10V O
2mV
= V
out
/ 10 * (O
2mVH
- O
2mVL
) + O
2mVL
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 for 10V or 20mA output
Vout = the measured voltage output in volts
mAout = the measured current output in mA
To modify the oxygen analogue output range scroll down the menu to option 5
“Set Outputs” and press ENT. Use the UP & DOWN arrows to select the output
type either “lin(ppm)”, “log(ppm)” or “raw(mV)” and press ENT. You can now edit
the lower and upper values using the UP & DOWN and RIGHT arrows. Once
programmed the new values remain in the memory until they are edited again in
the future.
Note that the voltage (0 to 10V) and current (4 to 20mA) outputs are locked
together, so that these outputs cannot be set independently of each other. In
normal operation therefore, 0V output always corresponds to 4mA and 10V
always corresponds to 20mA output.
During initial warm up of the Rapidox when the display reads the serial number
the output sent to the rear terminal for oxygen will stay at 2mA (1V) which is the
standby signal. If at any stage a sensor becomes disconnected internally, or the
signal exceeds the measurable range for that sensor, then the display will indicate
there is a fault and the outputs will change to 1mA (0.5V) which is the sensor fault
signal. This will recover as soon as the sensor is reconnected and the fault
cleared. Additional current and voltage signals are provided by the analyser to
give an indication of various conditions and these are described in Table 5 below,
together with the status of the alarms during the condition:
O2Analogue Outputs
Description Explanation Alarms (3)
Current (1)
(4-20mA)
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.
Active
3mA
1.875V
Sensor over range
The sensor reading is over range.
Active
3.5mA 2.1875V Sensor operating out of
specification
The sensor reading is in range but the
temperature sensor reading is out of
range, and/or the pressure mode is set
to automatic (pressure compensation
active) and the pressure sensor is out
of range.
Active
4 to 20mA 0 to 10V Normal operating output
The O
2
sensor and associated (1)
sensor(s) are operating normally and
readings are in range.
Active
Table 5: Analogue output settings and alarm status for certain conditions