ZX-44XL

Liquid Fuel Analyzer

User’s Manual Version 1.2

This manual provides you the information needed to operate the

ZX-44XL Liquid Fuel Analyzer.

ZELTEX, INC. 130 Western Maryland Parkway

Hagerstown, Maryland 21740

USA

Phone: 301-791-7080

Fax: 301-733-9398

E-mail: info@zeltex.com

© Zeltex, Inc. 2017

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Table of Contents Table of Contents .............................................................................................................. 2

WARNING ........................................................................................................................ 3

Introduction....................................................................................................................... 4

Appearance and Part Names ........................................................................................... 4

System Setup................................................................................................................... 5

Printer Paper Installation ................................................................................................ 6

Sample Holder Procedure ............................................................................................... 6

Using the ZX-44XL........................................................................................................... 8

Measuring a Sample........................................................................................................ 8

Changing Products .......................................................................................................... 9

Adjusting the Calibration................................................................................................ 9

Adjusting the Date and Time ........................................................................................ 10

Resetting Automatic ID Number .................................................................................. 10

Adjusting Number of Read Cycles ............................................................................... 11

Listing of Products........................................................................................................ 11

Printing Constituent Data.............................................................................................. 11

Duplicating a Product ................................................................................................... 11

Restoring Factory Settings............................................................................................ 12

General Specifications .................................................................................................... 13

Glossary ........................................................................................................................... 14

Appendix 1: Analyzed Sample Form .......................................................................... 15

Appendix 2: Applying Sample Holder Labels............................................................ 16

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WARNING

THE ZX-44XL 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.

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Introduction

Appearance and Part Names

(Front View)

(Back View)

Tablet/Display Power Tablet/Display

Sample Chamber

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Other Parts and Accessories

The ZX-44XL is shipped with the following parts and accessories. Contact Zeltex if you

would like to purchase additional accessories.

• ZX-44XL

• 3 Sample Holders with Lids

• 6 Extra Sample Holder Labels

• AC Adapter

• 2 Rolls of Printer Paper

• Quick Start Manual

• User’s Manual

• Calibration Manual

System Setup

Follow these steps to install the ZX-44XL Liquid Fuel Analyzer:

1) Place the ZX-44XL on a sturdy table.

2) Plug the supplied AC adapter into the back of the ZX-44XL and the other end into an

AC socket.

3) Assure that the ZX-44XL is properly grounded.

If the AC wall outlet has a true ground terminal then the ZX-44XL 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-44XL to perform properly.

4) Avoid Electrical Noise

Electrical machinery may cause "noise" on an AC power line. Although the ZX-

44XL has been designed to be relatively immune to such electrical noise,

instrumentation or generators being cycled on and off may interfere with the ZX-

44XL 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) Press on the On/Off Switch.

7) Press the Tablet Power Button until the display turns on. Once the Zeltex software

loads, press "Touch Here to Begin".

8) Allow the ZX-44XL to warm up.

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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-44XL requires

approximately ten 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 just a clean cloth. 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 or alcohol in the chamber.

• Be sure that the windows in the chamber are clean and free of obstructions.

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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.

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Using the ZX-44XL

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) Follow the prompt video on the screen. Press the yellow Measure Button. The

screen will display “Reading Standard”.

4) When prompted, 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

back alignment stripe on the instrument.

5) Carefully replace the light shield over the sample holder.

6) Press the Measure Button. The screen will display “Reading Sample”.

7) Remove the sample holder and rotate the sample to align the stripe on the sample

holder with the front alignment stripe on the instrument.

8) Carefully replace the light shield over the sample holder.

9) Press the Measure Button. The screen will display “Reading Sample”.

10) When prompted, remove the sample. Replace the light shield and press "Measure".

11) The screen will display “Reading Standard”, then the results will be displayed.

12) After the measurement is complete, repeat steps 2-11 to measure another fuel sample.

Note: The ZX-44XL has warnings for possible bad readings. See Next Page.

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Warning/Error Message Explanation

1) Instrument Too Hot or

Instrument Too Cold

The ZX-44XL 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.

3) Bad Curve This occurs when the wrong type of fuel is used or

there was an error during the reading (Removing

the lid too early for example.)

4) High Variance This occurs when there is a large difference

between the two sample readings.

Changing Products

The ZX-44XL stores multiple products internal memory. In any product, you can have

up to four constituents. Use the drop down menu where it says "Active Products" on the

top left to select the product you wish to analyze.

Adjusting the Calibration

The ZX-44XL has been carefully calibrated to measure accurately (the Octane calibration

is traceable to Waukesha Knock Engines, ASTM test D2699 and D2700). 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-44XL 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

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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-44XL:

1) Press "Product Information".

2) Select the constituent to adjust.

3) Press "Adjust (CON) Calibration".

4) Press “Adjust Slope/Bias”

When adjusting only the Bias: When adjusting the Slope and Bias

5) When the screen displays “Slope,” DO

NOT change slope of 1.00!

6) Press the number next to "Bias

Adjustment and enter the number from the

prediction printout. Press "Done" when

complete.

5) Press the number next to "Slope

adjustment" and enter the Slope number

from the prediction printout. Press "Done"

when complete.

6) Press the number next to "Bias

Adjustment and enter the Slope Bias

number from the prediction printout. Press

“Done” when complete.

7) The final adjustments will be shown on the display. Press “Done” to return to the

main screen.

Adjusting the Date and Time

1) Press "Instrument Settings"

2) Use the dialog to set the time and date.

Resetting Automatic ID Number

This will set the automatic consecutive numbering back to 1.

1) Press "Instrument Settings."

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2) Press "Reset Auto ID number."

Adjusting Number of Read Cycles

The ZX-44XL 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) Press "Instrument settings."

2) Use the "Number of Cycles per Reading" drop down box to set the number of

readings.

Listing of Products

The ZX-44XL allows the user to easily obtain a printed listing of products available in

the instrument.

1) Press "Product information."

2) Press "Print product listing."

Printing Constituent Data

The ZX-44XL allows the user to easily obtain a printed listing of the constants for each

product.

1) Press "Product information."

2) Select the constituent to print out.

3) Press “Print Calibration”

Duplicating a Product

The ZX-44XL allows the user to duplicate a product so that adjustments can be made to

the duplicated product without affecting the original calibration.

1) Press "Product information."

2) Choose the product to duplicate from the dropdown menu at the top.

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3) Press "Duplicate Product"

4) Select the vacant space to put the duplicated product.

Restoring Factory Settings

If something should happen to your calibration you can reset the ZX-44XL to the factory

settings.

1) Press "Product information."

2) To restore the settings for a particular calibration, choose the constituent of the

product you wish to restore and press "Restore Factory Calibration."

3) To all calibrations, press "Restore All Factory Calibration."

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General Specifications

1. MEASUREMENT

Measuring Principle: Near-Infrared Transmittance using 16 wavelengths covering the

range from 810 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: 20.5" by 11 3/8" by 5 3/8". (53cm by 30cm by 16cm)

5. WEIGHT

16 lbs. (about 7 kilos)

6. SAMPLE SIZE

200 mL with 75mm wavelength

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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..

IDs – 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.

Optical Data (ODs) –The data obtained by the instrument from each of its filters which

it then applies to the above equation to calculate the results.

Precision – Refers to how closely the same sample repeats its readings in a given

instrument

Reduce / Reduction – See Multiple Linear Regression

Regression – See Multiple Linear Regression

RON – Research Octane Number

Slope and Bias – More than just an average overall shift of the calculated results from

the ideal laboratory values. A Slope and Bias adjustment will compensate for this.

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Appendix 1: Analyzed Sample Form

SEND TO: Zeltex, Inc. USA, FAX NO.: 1-301-733-9398

FROM: Company name, Country ___________________________________________

CONTACT PERSON: (please print) _________________________________________

PHONE: Country code ________ Number __________________________________

FAX: __________________________________________________________________

Enter in the Analyzed Sample columns, ten (10) samples that have been analyzed by your

lab. In the corresponding columns, enter the ZX-44XL readings for the same samples.

Fax to Zeltex for advice concerning any needed adjustments.

Samp.

#

LAB

CON 1

44XL

CON 1

LAB

CON 2

44XL

CON 2

LAB

CON 3

44XL

CON 3

1

2

3

4

5

6

7

8

9

10

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Appendix 2: Applying Sample Holder Labels

1) Locate the seam that runs from the top to the bottom of the sample holder. This seam

is where you will start the new label.

2) Carefully place lead edge of the label along the seam of the sample holder, making

sure the label will be on the flat surface all the way around the sample holder, as close

to the bottom as possible.

3) Apply the label to the sample holder, stretching slightly as applied. Do not pull too

tightly.

4) Wrap completely around the sample holder, trying to smooth out air bubbles as you

go.

5) Once the label has met the other side, press down the end securely. The edges do not

need to line up exactly, but they should be close.