SMC Networks Rapidox SF6 6100 Instruction Manual
SF6 6100 Pump Back Analyser
Instruction Manual
SMC
5840 S. Memorial Drive
Suite 208
Tulsa, Oklahoma
74145
Tel. 918-622-5725
Fax. 918-664-2073
sales@noramsmc.com
Warnings
Electrical Shock Hazard
Do NOT remove internal metal panel
There are no user-serviceable parts in this unit
Do not attempt to repair the analyser yourself
Refer all servicing to qualified personnel
The unit should not be exposed to extreme temperatures
< -5°C or > +50°C (< +23°F or > +122°F)
Normal operating temperature is +5°C to +35°C (+41°F
or +95°F)
Do not operate the unit with the carry case lid closed
Avoid direct sunlight exposure
Do not use liquid cleaners, aerosols or solvents to clean
the case
Use a damp cloth for cleaning with the power cable
disconnected
Do not use this equipment near water
Only use fingers to touch and operate the display panel
Make sure any ventilation slots and the fan on the side
panel are free of obstruction
This unit is NOT designed for use in life support
No responsibility can be held for injury or loss of life
Always use a tube connected to the gas outlet (4) which
situations or any use that is not specified by the
manufacturer.
caused by inappropriate use of this equipment.
is vented to atmosphere when working with gases that
may by toxic or injurious.
Warnings
HF & SO2 are toxic and can be fatal if inhaled
HF & SO2 cause severe skin burns
HF causes severe damage to the eyes
H2S & CO are toxic and can be fatal if inhaled
Read the MSDS sheets carefully before working with
these toxic gases
HF and SO2 are extremely corrosive to the respiratory
tract
Read the MSDS sheets carefully before working with
these corrosive gases
H2S and CO are extremely flammable in high
concentrations
Long term exposure to CO causes organ damage
SO2, HF and H2S are harmful irritants to the eyes, skin
and respiratory tract even in small doses
Very toxic to aquatic life
Contents
1 Introduction ........................................................................................................................................... 4
2 Technical Specification ...................................................................................................................... 5
3 Analyser Description .......................................................................................................................... 7
4 Getting Started ...................................................................................................................................... 8
4.1 Battery Charging .......................................................................................................................... 8
4.2 Advisory Screens ......................................................................................................................... 9
5 Performing a Test ............................................................................................................................. 10
5.1 Main Screen Display ................................................................................................................ 10
5.2 Setting the Test Parameters ................................................................................................. 10
5.3 Preparing the Analyser ........................................................................................................... 11
5.4 Sampling ....................................................................................................................................... 13
5.5 Results and Finishing .............................................................................................................. 14
5.6 Notes about Dewpoint Measurements ............................................................................. 15
6 Operational Description ................................................................................................................. 17
6.1 Main Screen................................................................................................................................. 17
6.2 Live Graph Display ................................................................................................................... 18
6.3 Line Purge Option ..................................................................................................................... 18
6.4 Pump Back Option .................................................................................................................... 20
6.5 Start Delay ................................................................................................................................... 21
6.6 Working with Pre-Loaded Test Parameters .................................................................. 22
6.7 Working with SF6 and N2 mixtures .................................................................................... 23
6.8 Working with SF6 and Air mixtures................................................................................... 24
6.9 Working with SF6 and CF4 mixtures .................................................................................. 25
7 Rapidox Menu System .................................................................................................................... 27
7.1 Calibrate ....................................................................................................................................... 27
7.2 Data-Logging .............................................................................................................................. 31
7.3 Auto Abort ................................................................................................................................... 34
7.4 Sampling Modes ........................................................................................................................ 35
7.5 Timed Mode ................................................................................................................................ 36
7.6 Continuous Mode ...................................................................................................................... 38
7.7 Set Units ....................................................................................................................................... 39
7.8 Date & Time ................................................................................................................................ 39
7.9 Passwords ................................................................................................................................... 40
8 Options Menu System ..................................................................................................................... 43
8.1 Data Transfer ............................................................................................................................. 43
8.2 System Control .......................................................................................................................... 47
8.3 Gas Cylinder Testing ................................................................................................................ 48
8.4 Auto N2 System Clean .............................................................................................................. 49
8.5 Language ...................................................................................................................................... 49
8.6 Screen Colour ............................................................................................................................. 50
8.7 Screen Brightness ..................................................................................................................... 51
8.8 Diagnostics .................................................................................................................................. 51
8.9 Restore .......................................................................................................................................... 52
8.10 About ......................................................................................................................................... 52
9 Troubleshooting ................................................................................................................................ 53
10 Warranty .............................................................................................................................................. 56
10.1 Conditions of Warranty: .................................................................................................... 56
1 Introduction
The Rapidox SF6 6100 Pump Back is a battery-powered “zero emission” SF6 multigas
analyser capable of measuring multiple gases simultaneously in a rugged and portable case.
Depending on the configuration the analyser can measure up to eight parameters including
sulphur hexafluoride (0-100% SF6), sulfur dioxide (0-100ppm* SO2), dew-point (60/20°Cdp H2O), carbon tetrafluomethane (20-80% CF4), hydrogen fluoride (0-10ppm HF),
air (0-100%), carbon monoxide (0-100ppm) and hydrogen sulphide (0-100ppm). In
addition, the SF6 compartment gas pressure is displayed on-screen as well as some other
selectable parameters.
* 0-500ppm is available on request
The sample gas can be used if the inlet pressure is between 0.3 bar and 10.0 bar.
The analyser has a full pump back facility allowing any gas stored inside the analyser to be
re-pressurised and returned to the SF6 compartment. The sample hose and storage bag can
be vacuum purged before testing to ensure no mixing of contaminated gas occurs. During
the testing cycle no SF6 can escape into the atmosphere.
The sampled gas is stored inside a special flexible bag held within the analyser. This bag
inflates and deflates during the testing cycle and can be used to store any SF6 that is not to
be pumped back afterwards. The bag is constructed from a material that is highly resistant
to moisture or air penetration. Various safety features are in place to prevent the bag from
over-filling during use.
The analyser has a built-in PC and all functions are accessed via a 7” touch screen panel.
The analyser is fully automatic and will run in various sampling modes where sample gas is
drawn into the analyser via a special FEP-lined sample hose and DILO couplings. The gases
pass through the various sensors and data is processed and displayed on the screen. The
analyser is fitted with a printer, alarms, data-logging functions and USB output.
The portability of the analyser is achieved by means of two lithium battery packs (one for
the main operation and one for the pump back) which can be charged on any worldwide
mains power. The unit will run for up to eight hours on the battery before recharging is
required. The unit will also run directly on mains power while the battery is recharging.
Up to twenty pump back cycles can be performed on a single charge.
2 Technical Specification
Rapidox SF6 6100 Pump Back Analyser
Mains Voltage for charging 90-260Vac 50/60 Hz
Main Lithium Battery Operation
Pump back Lithium
Battery Operation
Analyser dimension 570mm (w) X 470mm (d) X 280mm (h)
Weight 21 kg without accessories
Gas Storage Bag 5 Litres capacity at sea level
Sample Time 8 minutes
Display 7” full colour PC touch screen
Up to 8 hours on a single charge
5-7 hours to fully charge from flat
Up to 20 pump back cycles on a single charge
(depending on the final gas pressure)
5-7 hours to fully charge from flat
Warm up time 15 minutes at 20°C
Temperature -10°C to 40oC
Normal operating conditions
Minimum Gas Inlet Pressure 0.3 bar
Maximum Gas Inlet Pressure 10 bar
Maximum Pump Back Pressure 10.5 bar
Data Output Via USB memory stick or thermal printer
Sampling Timed or Continuous modes
SF6 Sensor (infra red)
SO2 Sensor (electrochemical)
H2O Sensor (polymer)
CF4 Sensor (balance)
HF Sensor (electrochemical)
Air (electrochemical O2 sensor) or N2
(balance)
CO & H2S Sensor (electrochemical)
Calibration
Data-logging
Fuse 1 (main PC) T3.15A H250V 20mm anti surge
Fuse 2 (compressor) T16A H250V 20mm anti surge
Humidity 10 to 90% RH
Pressure 800 to 1100 mbar absolute.
0-100% scale
+/- 0.5% full scale accuracy
0-100ppm (or 0-500ppm) scale
+/- 2% full scale accuracy
-60 to +20°Cdp
+/- 2°Cdp of reading accuracy
Optional display corrected to 20°C available
>20 <80% scale
calculated as a balance gas
0-10ppm scale
+/-2% full scale accuracy
0-100% scale
+/-2% full scale accuracy
0-1000ppm scale
+/- 2% full scale accuracy
Calibration by the user using zero and span gases.
Not H2O sensor*
Continuous on-board data-logging downloadable via
USB
3 Analyser Description
1
2
4
3
6
7
8
9
10
5
11
12
13
1
4
1
5
Figure1: Layout of the SF6 6100 Pump Back Analyser
1. Main display and touch screen menu system
2. Thermal printer
3. Sample gas inlet (via closed coupled fitting)
4. Earth fixing point
5. Gas flow indicator on the display
6. Power on/off switch
7. LED battery charging lights
8. USB memory stick port
9. Fuse holders (see Table 1)
10. Mains inlet
11. 18V charging point (using special vehicle charging adapter)
12. Service Connection Point
13. Ventilation Slot
14. Cooling Fan
15. Bypass Port
4 Getting Started
The two labelled fuses will be removed for transportation safety reasons. There are two
fuses located in fuse holders labelled with the values listed in Table 1. This completely
isolates the lithium batteries. These fuses are different and must not be mixed up. The
fuses should be inserted into the correct holders (9) and fixed into position before first use.
Remove the fuses temporarily if you are transporting the analyser by air. If you require the
analyser to be earthed during operation, please connect your earth lead to the earth fixing
point (4).
Open the Peli-case fully and switch on the Rapidox using the switch (6). The analyser
screen will boot up and the display will show readings from the sensors after
approximately sixty seconds.
Note that if the analyser was previously being used in “Continuous” mode, then the
warning picture shown in Figure 2 number 5 will be displayed on the screen during boot
up. This is to remind you that the gas is free flowing out of the bypass port, and a separate
gas recovery system should be attached.
4.1 Battery Charging
The analyser can run on battery OR mains power. When on mains power and the battery is
charging the LEDs (7) will show a red colour. This will eventually turn orange and finally
green when the unit is fully charged. There is an on-screen battery life meter which shows
the remaining battery life and indicates if the unit is charging or not. It takes between five
and seven hours to fully charge a flat battery depending on operational circumstances.
To charge the battery, attach the IEC mains lead to the mains socket on the side of the
analyser (10). Alternatively, an optional vehicle charger can be used with the 18V charging
point (11). Note that you must leave the lid open when on charge as the cooling fan will
operate to vent the battery compartment.
Lithium batteries need to be charged carefully and the analyser is fitted with various safety
features to make sure the batteries do not over heat during a charge. The temperature of
the batteries is measured and should it exceed safe limits the charger circuit will disable
itself. The LED will flash slowly to indicate it is too hot to charge. This may occur if the unit
is used in very hot countries. Please place the unit in a cool location such as an air
conditioned office to charge correctly.
When the unit is running on battery power the LCD indicators (7) remain switched off until
the mains lead is re-connected.
compartment)
detached
separate gas recovery system
deactivated
4.2 Advisory Screens
During sampling, line purge and pump back the analyser checks to see if the sample line
hose is correctly fitted to ensure that the cycle works correctly and doesn’t allow any
contamination of the compartment gas with air, or any SF6 is allowed to escape into the
atmosphere. Various simple instructions are displayed on-screen to make it easy to follow
the correct sequence. These are as follows:
1) Shows how to correctly set up the analyser
for a line purge (line must be connected to
the Rapidox but NOT to the gas
3) Questions if the sample line doesn’t appear
to be connected to anything that has gas
pressure i.e. the sample line has become
2) Shows that the Rapidox sample line should
be connected to the pressurised gas
compartment ready to take a sample
4) Questions if the operator has disconnected
the sample hose from the gas compartment
before attempting a line purge
5) Analyser is running in continuous mode so
the bypass outlet should be connected to a
6) Asks for the external gas recovery system to
be disconnected once continuous mode is
5 Performing a Test
Tap on the
gas
of
Analyser Status
Gas inlet pr
essure
meter
Icon for using “Gas
See section
8.3
With the analyser switched on and ready, use this guide to prepare the machine for testing
and complete an analysis. All screens and menus are soft keys so to change or access
anything you gently press the screen with your fingertips. Pressing over the name of a gas
will open a live graph screen (see 6.2) showing the progress of the sample over time.
5.1 Main Screen Display
Flow Gauge
Indicator
Figure 2: Examples of different on-screen help messages you may encounter during operation. The screen
message includes text prompts explaining what action to perform.
User Editable
Test Location
User Editable IEC / CIGRE
Test Parameter
Message
Bottle” mode
Gas Storage Bag
Capacity
Battery Status
Analyser
Battery Status
Pump Back
5.2 Setting the Test Parameters
Timed tests are fixed at 8 minutes long to complete the testing correctly without filling the
bag to capacity. To set this option press MENU – SAMPLING and enter these parameters as
shown in Figure 4. Full details of this menu option are in section 7.4.
interest to produce
a live time graph
(6.2)
See section 6.4 for a
full description of
how to perform a
Pump-Back cycle
See Section 6.3 for a
full description of
how to Line Purge
Figure 3: Main screen just after boot up. The H2O sensor is still warming up which takes approximately 60
seconds. Note that not all sensors may be present in your equipment
Figure 4: Use this option to change the sampling method to “Timed” or “continuous” and set the sampling
duration and other options.
An initial set up is recommended as follows (see 7.4 for full details):
1) Measurement Mode: Set this to TIMED.
2) Sample Duration: This is fixed to 8 minutes and the option is greyed out
3) Start Delay: Set this to 0 unless you must walk away from the equipment before a
test starts. Please see section 6.5 for details on this function.
4) Line Purge: Set this to MANUAL.
5) Pump Back: Set this to AUTO if you are measuring gas from an in-service
switchgear or circuit breaker.
6) Print Results: Set this to AUTO so the printer will produce a report at the end of
the test.
7) Number of Tests: Set this to 1.
8) Location: If you want to name the location EDIT it now and it will be saved with
the results.
9) Test Parameter: Please refer to section 6.6 for details on this feature.
10) SF6 / CF4 mix in use: Only change this to YES if you are working with CF4 blends
otherwise leave it as NO. Selecting the wrong option will make the results
inaccurate. Please see section 6.9 for details on this function*
11) Make sure you press SET to save your choices.
*note that this feature will only be visible if it was specified at the time of order.
5.3 Preparing the Analyser
Make sure that the sample line hose is clean and dry. A brand new 2m long sample hose is
supplied pre-pressurised with dry SF
at 5bar pressure. Take the male end of the hose and
6
insert it into the Sample Gas Inlet as shown in Figure 5. Do NOT attach the other end to
anything yet. Use both hands to pull the knurled collar of the inlet coupling downwards as
you push the male fitting into place.
Release the collar to lock in position. To release the coupling simply pull down on the
knurled collar and the hose will self-eject.
Pull the knurled collar down with your finger tips
before trying to attach the male hose fitting. Line up
the hose fitting before attempting to connect
Figure 5: Correct procedure for attaching the sampling hose to the analyser.
Push male coupling into the female firmly whilst
holding the collar down. Release the collar only
when fully engaged
As this is the first test it is recommended to perform a vacuum purge of the sample hose by
pressing the button labelled “Line Purge”. This will vacuum out any unwanted air from the
system and takes approximately 45 seconds to complete. You will see on-screen message
(see Figure 6) to remind you NOT to connect to the gas compartment. Once completed the
following message will show:
Connect the Rapidox sample hose to
the analyser but NOT the gas
compartment
Figure 6: Screen message displayed when attempting a line purge.
5.4 Sampling
Once the line purge is completed press SAMPLE to begin the test. You will be instructed
(see Figure 7) to connect the female coupling on the end of the hose to the gas
compartment using a DILO male coupling adapter (supplied).
Gas
compartment
pressure is OK
Connect the Rapidox sample hose to
the gas compartment to pressurise
the analyser with sample gas
Figure 7: Screen message displayed when performing a sample analysis.
Sample gas is
flowing
Storage bag is
empty
Figure 8: Screen message displayed when performing a Timed analysis. The test will take eight minutes to
Once the hose is correctly connected you will see the Gas Inlet Pressure Meter (see Figure
8) rise and the pressure display will indicate the gas compartment pressure. Note that
there must be a minimum pressure of 0.5bar to proceed. If the pressure is acceptable the
gauge will appear green. Press OK to continue.
A timer will appear on the screen and count down eight minutes. During this period the
SF6 gas will flow into the analyser at a rate of 0.5L.min-1. The black ball on the electronic
flow gauge will rise and settle in the mid-point (see Figure 8). Press “Graph” to see a live
display of the readings and “Abort” to cancel the test.
If at any time during the test, large amounts of toxic gases are detected and “Auto Abort” is
enabled then the test will stop mid-way with an advisory warning.
When the test is completed the results of the analysis will display on the screen and the
printer will produce a short summary report. If pump back is set to “Auto” the unit will
immediately begin pumping the gas back to the compartment.
complete.
5.5 Results and Finishing
With the test completed and all the gas pumped back the analyser storage bag will be
empty and the machine is ready for the next test. If multiple tests were selected, then the
cycle will repeat itself until everything is completed. Finally, the screen will indicate to the
user that it is safe to disconnect the hose from the gas compartment and then from the
Rapidox before moving on to the next location.
Note that if a sequence of repeated tests is performed it is not usually necessary to do a line
purge each time, as the hose is full of dry SF6 from the previous test.
Note that if you are testing very small volume circuit breakers at low pressures then it is
NOT recommended to do repeated testing as continual sampling and pumping back can
eventually make a noticeable change in the gas quality; particularly the overall moisture
content.
The following flow chart in Figure 9 shows the complete operational sequence for
performing a gas sample test with the Rapidox Pump Back Analyser.
5.6 Notes about Dewpoint Measurements
The dewpoint sensor fitted to this equipment is a special high speed polymeric type
designed for use in SF6. For optimal readings dewpoint is measured at compartment
pressure and the readings are then pressure corrected to atmospheric pressure
1013mbara.
The sensor itself is electronically “cleaned” regularly by the analyser to prevent
contamination building up and causing a drift of readings. At the start of each timed test
the sensor is cleaned. This takes approximately two minutes to complete and an additional
four minutes is then required to allow the readings to settle. In exceptional circumstances
the sensor will perform an advanced clean which takes up to six minutes to complete.
During this time no readings are visible on the plot or recorded in the data logger. The
logger will record the words “Clean” or “Adv. Clean” instead.
If the analyser is operated in continuous mode, then the cleaning will happen automatically
every thirty minutes. The initial clean cycle will begin five minutes after the analyser is
powered on. During any clean cycle the continuous mode will display “Please Wait” on the
main screen which will disappear once the cleaning is complete.
The dewpoint reading displayed on the screen shows the units as °Cdp but this is calculated
as frost point when readings are below 0°C. Although there is no actual frost generated on
a capacitive sensor surface, the readings are calculated as frost point so direct comparisons
can be made with a chilled mirror analyser. This is important because the difference
between “over ice” and “over water” calculations become significant in very dry
measurements. All CIGRE and IEC test standards are in terms of frost point “over ice”
regardless of the measurement method.
As well as recording the absolute dewpoint at room temperature it is possible to display an
equivalent dewpoint corrected for temperature at 20°C This options features in the Units
menu and the unit can be accessed by tapping on the main screen over the displayed unit.
Tap the screen with your finger to change from “°Cdp@RT” to “°Cdp@20°C”.
Figure 9: Operational Flow Chart
6 Operational Description
6.1 Main Screen
Figure 10: Main operation screen (RED) configured with just three sensors, showing sensor readings with
side panel (YELLOW) indicating the gas flow, bag, battery and pressure status
During sampling the target gas flow is factory set to 0.5L.min-1 and this is displayed on the
side panel using the electronic gauge (Figure 10 – YELLOW) . The inlet gas pressure and
the gas analysis readings are also displayed on the side panel. At the top of the main screen
(Figure 10 – RED) is information about the name of the test location and the type of
standard test being performed. These can be edited and selected in the menu system
(section 7.4). Press “Sample” to begin a test. Press “Menu” to enter the analyser menu
screen and “Print” to produce a printout of the data as seen on the display.
Press “Line Purge” to vacuum purge the sample hose. This removes any air already inside
the hose before a test is performed. You will be prompted to attach the hose before
proceeding. A full description of this feature is in section 6.3.
Pressing “Pump Back” will allow you to return the gas inside the analyser to the gas
compartment. On pressing this button you will be prompted what to do before pump back
commences. See section 6.4 for a more detailed description of the pump back feature.
A status message will display in the top right hand corner to indicate what the machine is
doing. For example, the display might show “Testing Sample 1 of 3……” if multiple cycles
have been selected.
During a test, a button labelled “Abort” appears instead of “Print”. This can be pressed at
any time to stop the cycle.
The gas storage gauge will give you an indication of how full the internal storage bag is.
The bag will hold up to five litres of gas at standard temperature and pressure. This is
more than sufficient capacity to complete a single eight-minute timed test in normal
atmospheric conditions including at high altitude. In exceptional atmospheric conditions
or during calibration the bag may become full prematurely and testing will stop. The gauge
will change red to indicate “Bag Full” and no further testing will be allowed until a pump
back cycle has been performed. To empty the bag, press the “Pump Back” button and you
will be prompted to make the correct connections before pump back commences. Note
that if there is any residual gas inside the bag and you attempt to perform a timed test, the
unit will show a message indicating that a pump back is required before proceeding.
If you want to see a live chart of any of the channels finger tap over the live reading display
of the gas / measurement of interest and the display will change:
6.2 Live Graph Display
To view a live graph recording of the gas values or compartment pressure, press on the
appropriate label on the main display and the graph function will open. The main panel
shows a live display graph of the reading from the sensor. Use the “Esc” button to return to
the main display screen and the “Prev” & “Next” buttons to change the sensor you are
viewing. Each gas type is assigned a colour and this is shown in Figure 35 below.
Figure 11: Pressing on any gas name on the main screen will display a live graph of that measurement.
6.3 Line Purge Option
Pressing this button will activate the line purge feature. This uses a vacuum to remove all
the air from the special sample hose that is supplied with the analyser. It is recommended
to do a line purge of your hose at the start of a day’s testing to ensure no air gets mixed in
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