ZX-440XL
Liquid Fuel Analyzer
User’s Manual
Version 2.0
This manual provides you the information needed to operate the
ZX-440XL Liquid Fuel Analyzer.
ZELTEX, INC.
130 Western Maryland Parkway
Hagerstown, Maryland 21740
USA
Phone: 301-791-7080
Fax: 301-733-9398
E-mail:
© Zeltex, Inc. 2007
Table of Contents
Table of Contents 2
WARNING 3
Introduction 4
Appearance and Part Names 4
Other Parts and Accessories 5
System Setup 5
Printer Paper Installation 6
Sample Holder Procedure 6
Using the ZX-440XL 8
Measuring a Sample 8
Changing Products 9
Adjusting the Calibration 9
Adjusting the Date and Time 10
Resetting Automatic ID Number 11
Adjusting Number of Read Cycles 11
Listing of Products 12
Printing Constituent Data 12
Printing a Line Feed 12
Connecting to a Computer 13
Adjusting the Brightness 13
Adjusting the Contrast 13
General Specifications 15
Glossary 16
Appendix 1: Analyzed Sample Form 17
Appendix 2: Applying Sample Holder Labels 18
WARNING
THE ZX-440XL LIQUID FUEL ANALYZERS ARE NOT
EXPLOSION-PROOF:
REASONABLE CARE MUST BE USED IN HANDLING THESE INSTRUMENTS.
ALL SAMPLES SHOULD BE CONTAINED IN SAMPLE HOLDERS FOR SAFETY.
Introduction
Appearance and Part Names
Other Parts and Accessories
The ZX-440XL is shipped with the following parts and accessories. Contact Zeltex if you would like to purchase additional accessories.
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· ZX-440XL
· 3 Sample Holders with Lids
· 6 Extra Sample Holder Labels
· A/C Line Cable
· RS232 Cable
· 1 Amp, Slo-Blow fuse
· 4 Rolls of Printer Paper
· Calibration Software CD
· Quick Start Manual
· User’s Manual
· Calibration Manual
· Calibration Numbering Setup Manual
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System Setup
Follow these steps to install the ZX-440XL Liquid Fuel Analyzer:
1) Place the ZX-440XL on a sturdy table.
2) Place the supplied line cord into the universal socket that is built into the back of the ZX-440XL.
3) Assure that the ZX-440XL is properly grounded.
If the AC wall outlet has a true ground terminal then the ZX-440XL will be grounded. If the AC outlet is not firmly traceable to the earth, then a separate ground must be installed in order for the ZX-440XL to perform properly.
4) Avoid Electrical Noise
Electrical machinery may cause "noise" on an AC power line. Although the ZX-440XL has been designed to be relatively immune to such electrical noise, instrumentation or generators being cycled on and off may interfere with the ZX-440XL performance.
In facilities with unusually poor power regulation, an external power supply regulator or line filter should be used.
5) Install the Printer Paper (see Printer Paper Installation)
6) Turn on the On/Off Switch.
7) Allow the ZX-440XL to warm up.
All optical instruments require a warm-up period to insure that the optics and electrical systems have stabilized at operating temperature. Once turned on, the ZX-440XL requires approximately twenty minutes to warm-up prior to performing measurements
Printer Paper Installation
1) Press the Printer Paper Eject Button to open the paper cover.
2) Set a roll of paper into the printer as shown in the figure below.
3) Close the paper cover by pressing both ends of the cover with the edge of the paper emerging from the printer from the paper cutter.
Sample Holder Procedure
To ensure accurate readings, follow these procedures when dealing with the sample holders.
· Clean sample holders inside and out with alcohol or soap and water. Dry thoroughly before use. Note that acetone may be used, but avoid getting acetone on sample holder label.
· Check to assure sample holder label is not peeling or torn. (Replacement labels are available.
· Make sure inside of sample chamber is clean. Use a small amount of soapy water on a paper towel or cotton swab. Do not use acetone in the chamber.
· Be sure that the windows in the chamber are clean and free of obstructions.
CAUTIONS:
· Never use sample holders without lids.
· Never pour gasoline into sample holder while sample holder is in sample chamber.
· Always fill sample holder above the fill line.
Using the ZX-440XL
Measuring a Sample
1) Switch power to ON and allow the instrument at least twenty minutes to warm up.
2) A standard (empty chamber) reading must be done first. Make sure there is no sample holder in the sample chamber. Cover the chamber with the light shield. This shield must always be used when measuring a fuel sample or a standard; otherwise, the results will be incorrect.
3) Press the blue Measure Button. The screen will display “Reading Standard” and then “Insert sample, close lid, and press Measure”
4) Open the light shield and place the filled sample holder in the sample chamber, being careful to align the alignment stripe on the sample holder with the left alignment stripe on the instrument.
5) Carefully replace the light shield over the sample holder.
6) Press the blue Measure Button. The screen will display “Reading Sample” and then “Remove, turn, and replace sample and press Measure”
7) Remove the sample holder and rotate it to align the stripe on the sample holder with the right alignment stripe on the instrument.
8) Carefully replace the light shield over the sample holder.
9) Press the blue Measure Button. After the “Reading” takes place, the results will be displayed.
10) After the measurement is complete, repeat steps 2-9 to measure another fuel sample.
Note: The ZX-440XL has warnings for possible bad readings. See below:
Warning/Error Message / Explanation1) Instrument Too Hot or Instrument Too Cold / The ZX-440XL was set up with a temperature check. If the instrument temperature is too cold or too hot, these warnings will appear on the printout.
2) Too High or Too Low / This occurs when the reading for a particular constituent is outside the range of the calibration. The results of samples read that lie outside of the calibration range are not as reliable.
Changing Products
The ZX-440XL is allows you to have up to 10 products stored in internal memory. In any product, you can have between 1 and 3 constituents.
1) Turn instrument on.
2) Touch “MENU”
3) Touch “Change Products”
4) If the product you wish to load is not on the display, touch “Next” until it is.
5) Touch the product you wish to load. The product will be loaded and the ZX-440XL will return to the main display.
Adjusting the Calibration
The ZX-440XL has been carefully calibrated to measure accurately (the Octane calibration is traceable to Waukesha Knock Engines, ASTM test 2699 and 2700). The equation used is: Results = Bias + (Slope) (X), where X is the summation of the optical data multiplied by the constants. Some users may desire to have the ZX-440XL traceable to their own knock engines or labs. For those users the following adjustment procedures are provided:
1) Bias Adjustment (shifts all readings up or down the same amount)
2) Slope Adjustment (changes the angle of prediction line to agree with the new knock engine)
Before making any adjustments, you must first measure at least 5 samples for which you have laboratory analysis. These samples should also cover the range of the calibration. Once the samples have been measured, use the Statistical Analysis portion of the provided Calibration Software to determine if an adjustment is necessary. Print the Statistical Analysis and note the adjustment that the software recommends. If you are unable to use the Calibration Software or are simply uncomfortable with determining when an adjustment is necessary, feel free to use the Analyzed Sample Form found in Appendix 1 of this manual and contact Zeltex for assistance.
Once you have determined the adjustment to be made, follow these instructions for making an adjustment to the ZX-440XL:
1) Turn on the instrument.
2) Touch “MENU”
3) Touch “View/Modify Product”
4) Touch “Adjust Slope/Bias”
5) Touch the name of the constituent that you wish to adjust.
6) On the screen will appear “Slope: 1.00”.
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When adjusting only the Bias:
7) When the screen displays “Slope,” DO NOT change slope of 1.00! Touch “Done”
8) When the screen displays “Bias: 0.0” touch r and s to enter the Bias (No slope) number from the prediction printout. Touch “Done” when complete.
When adjusting the Slope and Bias:
7) When the screen displays “Slope: 1.00” touch r and s to enter the Slope number from the prediction printout. Touch “Done” when complete.
8) When the screen displays “Bias: 0.0” touch r and s to enter the Slope Bias number from the prediction printout. Touch “Done” when complete.
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9) The final adjustments will be shown on the display. Touch “Done” to return to the main screen.
Adjusting the Date and Time
1) Turn on the instrument.
2) Touch “MENU”
3) Touch “Date/Time”
4) Set the Date
a) Touch the month, a square will be placed around it. Touch r and s to adjust it.
b) Touch the day, a square will be placed around it. Touch r and s to adjust it.
c) Touch the year, a square will be placed around it. Touch r and s to adjust it.
d) Touch “Done”
5) Set the Time
a) Touch the hour, a square will be placed around it. Touch r and s to adjust it.
b) Touch the minute, a square will be placed around it. Touch r and s to adjust it.
c) Touch AM/PM, a square will be placed around it. Touch r and s to adjust it.
d) Touch “Done”
Resetting Automatic ID Number
This will set the automatic consecutive numbering back to 1.
1) Turn on the instrument.
2) Touch “MENU”
3) Touch “Next Page”
4) Touch “Instrument Options”
5) Touch “Reset Sample Number”
6) The screen will display “Sample Number reset to 1”
Adjusting Number of Read Cycles
The ZX-440XL is designed to allow you to use between 1 and 9 repetitions to get the maximum accuracy with the minimum time needed for your samples.
Zeltex recommends that you use two repetitions on fuel samples for the best accuracy.
1) Turn on the instrument.
2) Touch “MENU”
3) Touch “View/Modify Product”
4) Touch “Set Number of Cycles”
5) Touch r and s to adjust the number of cycles
6) Touch “Done” to return to the main screen.
Listing of Products
The ZX-440XL allows the user to easily obtain a printed listing of products available in the instrument.
1) Turn on the instrument.
2) Touch “MENU”
3) Touch “View/Modify Product”
4) Touch “Print Product List”
5) When the printing is complete the ZX-440XL will return to the main screen.
Printing Constituent Data
The ZX-440XL allows the user to easily obtain a printed listing of the constants for each product.
1) Turn on the instrument.
2) Touch “MENU”
3) Touch “View/Modify Product”
4) Touch “Print Constituent Data”
5) Touch the constituent that you would like to print.
6) When the printing is complete the ZX-440XL will return to the main screen.
Printing a Line Feed
1) Turn on the instrument.
2) Touch “MENU”
3) Touch “Next Page”
4) Touch “Printer Options”
5) Touch “Line Feed” to print a line feed. Repeat as necessary.
6) Touch “Cancel” to return to the main screen.
Connecting to a Computer
The ZX-440XL comes with Calibration Software that allows you to create your own calibrations, make backups of the current calibration, and view the optical data for a sample. To do this you must connect the ZX-440XL to the computer using the supplied RS-232 Cable and put the ZX-440XL into Data Link mode.
1) Connect the RS-232 cable to the RS-232 Port on the back of the ZX-440XL.
2) Connect the RS-232 Cable to a free RS-232 port on the computer.
3) Turn on the instrument.
4) Touch “MENU”
5) Touch “Data Link”
Adjusting the Brightness
1) Turn on the instrument.
2) Touch “MENU”
3) Touch “Next Page”
4) Touch “Display Options”
5) Touch “Adjust Brightness”
6) Touch r and s to adjust the brightness.
7) Touch “Done” when complete.
Adjusting the Contrast
1) Turn on the instrument.
2) Touch “MENU”
3) Touch “Next Page”
4) Touch “Display Options”
5) Touch “Adjust Contrast”
6) Select the contrast that works best for you.
7) Touch “Done” when complete.
General Specifications
1. MEASUREMENT
Measuring Principle: Near-Infrared Transmittance using 32 wavelengths covering the range from 604 nanometers to 1045 nanometers.
2. PRINTER OUTPUT
Measured Results with time, date, and identification number
3. AC Power Requirements
100 to 240 VAC, 50/60 Hz with autoswitching
4. DIMENSIONS
Main Body: 16 x 16 x 12 inches
5. WEIGHT
22 lbs.
6. SAMPLE SIZE
200 mL with 75mm wavelength
Glossary
Accuracy – Refers to how closely the readings of the known samples match the samples’ predetermined lab values in a given instrument.
Bias – The average overall shift of the calculated results from the ideal laboratory values. A Bias Adjustment will compensate for this.
Constants (also referred to as K values) – Figures determined during calibration of the instrument which are used in the equation:
Result = K0 + (K1OD1 + K2OD2 + . . . KNODN)
Constituent – One of the properties of the product being measured, such as RON or MON..
Data Link – The mode that the ZX-440XL must be in to communicate with the Calibration Software.
ID’s – The identification numbers of the samples.
MON – Motor Octane Number
Multiple Linear Regression (MLR) – The mathematical process to fit the optical data to the lab data.