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Rapidlogger User Manual (English)

       

5    Maintenance

For ATEX installations all electrical and electronic maintenance to the system needs to be performed in accordance with the EN 60079-17 latest edition standard.  Software and firmware maintenance is detailed below.

5.1   Reformatting SD flash memory card

The SD card installed inside the inner enclosure of the Rapidlogger records data continuously when the system is powered on.  Data points are recorded at 1, 5, 10 or 60 second intervals depending on the recording rate selected by the user.  Depending on the recording rate and the number of data variables selected, the internal SD card can get filled up in anywhere from a few days to a month.  Once the card is filled up internal data recording stops until the data from the card is downloaded and the card erased.

In order to download files and erase the card the menu option Rapidlogger Hardware should be selected from the Rapidlogger PC program.  The PC needs to be connected to the Rapidlogger system via an Ethernet cable and be able to communicate with it.  Once the menu option is selected the following window appears on the PC screen. 

Rapidlogger Utility Window

Clicking on the Ping button allows the user to ensure that a Rapidlogger Unit is present at the IP address specified in the "Host" box.  In order to erase the SD memory card simply press the Erase SD button on the Rapidlogger Utility.

Alternately the user can also erase the SD card from the Rapidlogger front panel by pressing F6, F6, F5, F5.  This erases the SD card in the Rapidlogger Unit.

5.2   Calibration

All of the sensor inputs on the Rapidlogger are factory calibrated to be best industry practice.  The unit can be recalibrated by the users if proper calibration equipment is available.  

If traceable calibration is required it is available at the factory.  This is only needed by customers requiring an NIST traceable certification due to contractual obligations with their client.

In order to perform a normal calibration to correct or prove the sensor inputs on the Rapidlogger Unit the following equipment is required.

·       A PC with Rapidlogger Utility installed and operations

·       A frequency generator or calibrator

·       A calibrated current source (4-20mA) or milli-ampere current generator

·       Miscellaneous hookup wires to inject the calibrated signals into the Rapidlogger signal inputs

Calibrating the Analog Sensor Inputs

 

The first step is to remove all sensors etc attached to the analog inputs.  After this connect the milli-ampere calibrator to the analog input on the Rapidlogger.  For a three wire current calibrator connect the power wire to the Rapidlogger 24V DC output, connect the ground wire to the Rapidlogger DC ground connector, and the milliamp signal wire to the Rapidlogger mA1 input.  For a two wire current calibrator connect the positive terminal to the Rapidlogger 24VDC output and the signal/ground connector to the Rapidlogger mA1 input.   Turn the analog current calibrator on at the 4mA setting. 

 

Now place the Rapidlogger unit in the Analog Diagnostics mode (Press F6, F6, F5, F1).  A screen will appear on the Rapidlogger unit that would display the current analog input values.  The first analog input should read 4mA or a value very close to it.  Change the settings of the analog current calibrator to generate 16mA, the analog reading on the Rapidlogger screen should now read 16mA or a number close to it.  If the error is in an acceptable range then no calibration is required.  For example for a 10000psi (4-20mA)pressure transducer connected to the analog input an error of 0.01mA represents a 6.25 psi error in the sensor reading at full scale.  This number was calculated by dividing 10000 (the sensor range in psi) by 16 (the signal full scale output in mA) and again by 0.01(the signal error in mA).    If the error is not acceptable then calibration is required.

To start the calibration process, make sure that the Rapidlogger Utility is running and ready.  Press System Setup to reach the following screen.

Rapdilogger Setup Screen Options

On this screen enter 1.000 as the Analog Calibration Factor, Do not press the calibrate button yet.

On the Rapidlogger screen place the Rapidlogger unit into calibration mode by pressing F8 from the analog diagnostics screen.  The screen on the Rapidlogger Unit will not indicate that it is in calibration mode.  It will also display the current calibration constant.  Write this number down.   Now press the calibrate button of the Rapidlogger Utility. The new calibration factor will now appear on the Rapidlogger Unit screen.  The next step is to calculate the correct calibration factor on the screen.  A suggested calibration factor would be automatically displayed on the screen.  Enter the suggested value in the Analog Calibration Factor box on the Rapidlogger Utility and press the Calibrate button. 

The suggested calibration factor value is calculated by the system assuming that a calibrated 16mA current source is being used as input to the mA1 terminal on the Rapidlogger Unit.  Other calibration current values can be used but then it is up to the user to calculate the calibration factor.

Verifying calibration on the Frequency Sensor Inputs

The first step is to remove all sensors etc attached to the frequency inputs.  After this connect the ground wire from the calibrated frequency input to the DC Ground terminal on the Rapidlogger unit.  Now connect the frequency output wire from the calibrated frequency generator to the F1 input on the Rapidlogger Unit.  Set the signal voltage level to between 12 to 24 VDC, and output a 1 kHz square wave.

Now place the Rapidlogger unit in the Digital Diagnostics mode (Press F6, F6, F5, F2).  A screen will appear on the Rapidlogger unit that would display the current digital and frequency input values.  The reading for frequency 1 should read 1000Hz.  If the signal is very different then calibration of the frequency input signals is required.  Please consult technical support at the factory for help.

Verifying calibration on the Totalizer Inputs

The totalizer inputs on the Rapidlogger do not need to calibrate in the field.  Their proper calibration can be verified in the field as follows.

The first step is to remove all sensors etc attached to the frequency inputs.  After this connect the ground wire from the calibrated frequency input to the DC Ground terminal on the Rapidlogger unit.  Now connect the frequency output wire from the calibrated frequency generator to the F1 input on the Rapidlogger Unit.  Set the signal voltage level to between 12 to 24 VDC, and output a 1 kHz square wave.  Now place the Rapidlogger unit in the Digital Diagnostics mode (Press F6, F6, F5, F2).  A screen will appear on the Rapidlogger unit that would display the current digital and frequency input values.  The reading for Total 1 should read increase by exactly 1000 counts every second.  If the user has access to a pulse generator that can generate a fixed number of pulses then this can be used to confirm the totalizer operation also.

Verifying calibration on the Encoder Inputs

The first step is to remove all sensors etc attached to the encoder inputs.  After this connect a known good rotary encoder to the Rapidlogger as follows.  The ground wire from the encoder should connect to the DC Ground terminal on the Rapidlogger unit.  The power wire from the encoder should connect to the 5VDC output terminal on the Rapidlogger.  The encoder channels A and B should be connected to the Q1A and Q1B terminals on the Rapidlogger. 

Now place the Rapidlogger unit in the Digital Diagnostics mode (Press F6, F6, F5, F2).  A screen will appear on the Rapidlogger unit that would display the current digital and frequency input values.  The reading for Quadrature 1 should read exactly 0.  Now rotate the encoder exactly 1 complete turn.  The number of quadrature counts shown on the screen should be exactly equal to 4 times the rated encoder resolution.

 

 

5.3   Uploading new system software

5.3.1 Generation 1 units

In order to upload new firmware to the Rapidlogger a serial interface cable and a firmware download program is required.  Do not attempt to upload new firmware to the Rapidlogger unless specifically instructed by the technical support contact.  Connect the interface cable to the serial port connector on the Rapidlogger.  Now connect the other end of the serial cable to the serial port of the PC.  Now run the Flashtools program that has been supplied with the new firmware by technical support.  Power up the Rapidlogger unit.  Press the S3 switch and keep it depressed, now press S1 switch and release it.  Now release the S3 switch.  The Rapidlogger is now in firmware upload mode and ready to accept firmware download from the Flashtools program.  Once upload is complete you can power cycle the Rapidlogger to enable the new firmware to run.

Uploading new Rapidlogger system software

5.3.2 Generation 2 units

In order to upload new firmware to the Rapidlogger a Ethernet cable and a firmware download program is required.  Do not attempt to upload new firmware to the Rapidlogger unless specifically instructed by the technical support contact.  Connect the interface cable to the Ethernet port connector on the Rapidlogger.  Now connect the other end of the Ethernet cable to the Ethernet port of the PC or via a Ethernet hub. 

Now run the AutoUpdate program on the PC, this program is included on the CD that accompanies the unit.  Select the IP address of the Rapidlogger System to be updated.  This is normally 192.168.0.5.  Now select the replacement firmware file and click the update button.  The program will update the firmware and display a dialog box to this effect once the update is complete.  This will only take about 1-2 minutes.

Uploading new system software Rapidlogger Generation 2 units

 

5.4   Replacing a CPU module

The Rapidlogger CPU module is replaceable in case there is damage to the CPU or you need to replace the module to use new firmware.  The replacement of the CPU module is a delicate process that can only be done by an experienced electronics technician.  The CPU module is static sensitive.  It should only be replaced when the unit is on a static safe workbench.

Do not attempt to replace the CPU module on the Rapidlogger unit unless specifically instructed by the technical support contact.  In order to replace the module make sure that the power to the unit is off and the power cable has been disconnected.  Now using a very small screwdriver remove the two white plastic screws that hold the module in place.  Note the orientation of the CPU module on the board.  With very little force and using a slight rocking motion remove the CPU module.  Gently install the new CPU module while being careful to align the two connectors on the bottom and making sure that the module orientation is correct.  The module should install easily without excessive force.  The bottom surface of the module circuit board should be flush with the top of the two white spacers.  Install the two white nylon screws.  The unit is now ready to be powered up.

5.5   Recommended Spare parts

Following is a list of recommend spare parts for supporting between 1 and 5 systems

00-91903         Rapidlogger Main Board with CPU

00-91713         Rapidlogger LCD display

00-92041         Rapidlogger DC UPS 12V Battery

00-92011         Rapidlogger DC UPS Power board

00-91929         Pressure Sensor

00-92192         Inductive proximity sensor

00-92168         Cable common over molded, detachable

00-92169         Cable Prox overmolded, detachable 100ft

00-92167         Cable Viatran overmolded, detachable 100ft

5.6   Repair and Service

For repair and service of the unit please contact sales@rapidlogger.com

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