Valco Instruments Co. Inc. Dynacalibrator Model 340 Instruction Manual Manufactured by: Valco Instruments Co. Inc. 8300 Waterbury Houston, TX 77055 Rev 9/13 North America, South America, and Australia/Oceania contact: Valco Instruments Co. Inc. 800 · 367· 8424 713 · 688· 9345 713 · 688· 8106 valco@vici.com sales tech fax Europe, Asia, and Africa contact:: VICI AG International Schenkon, Switzerland Int + 41 · 41 · 925· 6200 Int + 41 · 41 · 925· 6201 info@vici.
Symbols used in this document Attention Radiant heat warning Entanglement warning Electrical warning
Table of Contents Introduction General Description.......................................................................................................................... 1 Dynacal® Permeation Devices...................................................................................................... 1 How to Use This Manual.................................................................................................................. 1 Basic Design .....................................................
Table of Contents (continued) Advanced Theory of Operation ...........................................................................................................27 Plumbing Configurations .............................................................................................................27 Configuration 0 .....................................................................................................................28 Configuration 1 .......................................................
1 Introduction General Description VICI Metronics Dynacalibrators® use Dynacal® permeation devices to generate the precise gas concentrations necessary for calibrating air pollution analyzers, monitors, and other instruments that measure gas concentrations in the partsper-million range and lower. Dynacalibrators are available in three models, each with a large variety of optional features to fit a wide range of calibration requirements.
Introduction 2 As indicated in Figure 1, the carrier stream passes through scrubber #1 and 30-micron line filter LF1 to the differential pressure regulator DPR1. The scrubber contains specially-activated charcoal designed for broad-based scrubbing action. This scrubbing medium is particularly effective in removing sulfur dioxide and other sulfur compounds. The differential pressure regulator and carrier flow restrictor FR1 together provide a highly stable carrier stream flow rate to the permeation chamber.
Introduction 3 The flow rate through the flowmeter needle valve is a function of the differential pressure across it and the setting of the dilution flow control valve. This differential is maintained at 3.2 psi by DPR2. The needle valve is adjustable at the front panel. The calibrated output of the dilution flowmeter mixes with the permeation chamber output to provide the final output concentration.
Introduction 4 Options The following paragraphs provide general information on each, with more detailed information found in “Advanced Theory of Operation” on page 27. Input Configurations There are six different input plumbing configurations available. The units may be equipped with or without an internal pump. Units without internal pumps can be supplied with one or two gas supply inlet ports (carrier and dilution).
Introduction 5 Specifications
6 Getting Started Every Dynacalibrator is completely calibrated, thoroughly tested and inspected, and carefully packed prior to shipment. The carrier has assumed responsibility for its safe delivery upon acceptance of the shipment. Initial Receiving Inspection/Check On receipt of your unit, before signing the waybill and releasing the carrier’s agent, inspect the shipment for the following: 1. The number of cartons received tallies with that on the waybill. 2.
Getting Started 7 § Figure 3: Dynacalibrator packaging Concealed Damage Concealed damage is damage which is not apparent until after the equipment has been unpacked and examined or tested. In the event that concealed damage is discovered, a written request for inspection must be forwarded to the carrier’s agent within 15 days of the delivery date.
Getting Started 8 Unit Location In general, the Dynacalibrator should be as close as possible to the analyzer to be calibrated, as long as: • the ambient temperature is at least 2°C below the selected operating temperature of the permeation chamber. • ambient temperature variations are minimal. • exposure to precipitation and condensation is minimized. • ambient particulate levels are minimal. (In the event that dust is prevalent, the unit should be equipped with a Metronics Particulate Filter Assembly.
Getting Started 9 Rear Panel Connections Remove all shipping caps and shipping plugs from the rear panel bulkhead fittings. All these hardware items should be saved for reuse if the Dynacalibrator must be stored or returned to VICI. The connections available on the rear panel of the different models and configurations are listed in Table 1.
Getting Started 10 On all units with an internal pump, the supply inlet port is internally connected directly to the suction side of the pump. Since the output of the pump is equipped with a particulate filter and activated-charcoal scrubbers, the supply inlet port should normally be left unconnected, completely open, and clear of any obstructions, except as noted below for dusty environments. If you need to alter the carrier and/or dilution streams by adding filters, scrubbers, dehydrators, etc.
Getting Started 11 Bypass Loops Only those Dynacalibrators with internal pumps are equipped with fittings for bypass loops in either or both the carrier and dilution streams (input configurations -3X, -4X and -5X). The fittings – labeled CARRIER OUTLET, CARRIER INLET, DILUTION OUTLET, and DILUTION INLET – are downstream from the pump, so the loops must be completed in order for the internal pump to be used .
Getting Started 12 Front Panel Controls and Indicators The section entitled “Advanced Theory of Operation” beginning on page 27 includes more detailed information on the interrelation of the front-panel controls and indicators with the internal pneumatic and electrical flow of the units. MAIN POWER switch, indicator, and circuit breaker The push-button switch provides primary power to all circuits. The LED indicator lights when main power is on.
Getting Started 13 .15 DYNACALIBRATOR .10 30° MODEL 340 120° SHUTDOWN .
14 Calculations Concentration of the permeant compound in the span outlet stream is inversely proportional to the carrier flow rate through the chamber. It is determined using the following equation: ª Where: § « K = 24.
15 Initial Power-Up Basic Connections 1. Plug the power cable from the main power connector on the rear panel of the calibrator to a 110 VAC power source (220 VAC with Model 340-C). 2. If you do not have the pump option: Connect the carrier gas source (50 psi maximum pressure) to the carrier inlet on the rear panel. If this is a dual inlet system: Connect appropriate source gases to the carrier inlet and dilution gas inlet.
Initial Power-Up 16 The front panel displays the current chamber temperature and the control status of the instrument, indicated by the PNL and TMP lights. (Refer to Figure 4 on page 13.) The chamber temperature can be set manually through the controls on the front panel or remotely through RS-232 communication. (Refer to the chapter entitled “Serial Port Communications” on page 20).
Initial Power-Up 17 Setting the Chamber Temperature via Serial Port (RS-232) Refer to the section titled “Serial Port Communications” on page 20. Installing the Permeation Device(s) 1. Turn off the heater power switch. 2. With the tool provided, rotate the panel lock screw 90° counterclockwise. 3. Gently pull the front panel assembly out. CAUTION: The permeation chamber cap may be warm to touch.
18 Verifying Operation 1. Connect a piece of tubing of the proper length to the span outlet fitting on the rear panel, leaving the analyzer end of the tubing disconnected. Ensure that all other tubing is properly connected. 2. Adjust the permeation chamber temperature to deliver the required rate of permeation. 3. Gently turn the dilution flow control knob clockwise until you encounter the stop indicating the needle valve is fully closed, then open it three turns counterclockwise.
Verifying Operation 19 9. Check that there is gas flow out of the overflow vent and the stream outlet, but not out of the chamber vent. 10. If remote control will be used, turn the mode selector switch to the REMOTE position, and program the unit for ZERO mode. 11. Check that there is gas flow out of the chamber vent, overflow vent, and stream outlet. 12. Program the unit for the SPAN mode. 13. Check that there is gas flow out of the overflow vent and the stream outlet, but not out of the chamber vent.
20 Serial Port Communication The Dynacalibrator Model 340 can be monitored and controlled remotely by means of a serial port connection and a terminal emulation program such as HyperTerminal.® The unit is controlled by entering two-character commands, shown in the table below. Commands may be either upper case or lower case. Parameters enclosed in brackets ([ ]) are optional. Note that for enable/disable commands, the states indicated by an “*” are the defaults at power-up.
Serial Port Communication 21 2. Click “Cancel”. Since no modem is involved, this information is not necessary. The following screen will appear: 3. Click “OK”, which reveals the next screen: 4. Enter a name, such as “dyna340”, and select an icon to associate with the file. Then click “OK”. . 5.
Serial Port Communication 22 6. Select the appropriate COM port and click “OK” to bring up this screen: 7. Set the port parameters as indicated above, and click “OK”. 8. Now we are at the dyna340 HyperTerminal screen (below).
Serial Port Communication 23 Click “Settings” 9. On the dyna340 Properties screen (above), click “Settings” to bring up the screen below. Click “ASCII Setup...
Serial Port Communication 24 10. Click “ASCII Setup” and set the parameters as indicated below. Click “OK”. 11. When the screen returns to Dyna340 HyperTerminal (page 22, bottom illustration), click “File”, then “Save” to save this Dynacalibrator Model 340 communications setup. The following text will be displayed in the HyperTerminal window when communication is first established with the Dynacalibrator Model 340: Parameters recovered. Program checksums ok. Initializing SPI . . . ok Initializing A/D . .
25 Analyzer Calibration After the power-up procedure has been completed and the chamber temperature and permeation device have reached equilibrium, the Dynacalibrator is ready to be connected to the analyzer being calibrated. Use a minimum length of tubing for the connection, and make sure none of the calibrator’s vents are blocked. 1. Place the Dynacalibrator in the ZERO mode. 2. Connect the calibrator’s stream outlet to the input of the analyzer.
26 Shutdown Procedure Dynacalibrators are designed to operate continuously; however, if it is necessary to turn the unit off, use the following procedures: 1. Turn off the heater power switch. 2. With the tool provided, rotate the panel lock screw 90° counterclockwise. 3. Gently pull the front panel assembly out. CAUTION: Use specific and appropriate precaution when opening the calibrator oven.
27 Advanced Theory of Operation Dynacalibrator operation is based on the principle of mixing a known mass flow of gas derived from a permeation device with a metered stream of clean carrier/ dilution gas to generate a precise concentration of span gas. User-selectable calibration gases originate from Dynacal permeation devices which are maintained at a user-selectable constant temperature within the Dynacalibrator’s permeation chamber.
Advanced Theory of Operation 28 this number to indicate the carrier flow (and the orifice used). Refer to page 4 for information about the available flow capacity ranges. Many of the plumbing components of the Dynacalibrator are rated for the different flow capacities of items such as for the main pump, the dilution flowmeter, etc. The following discussion disregards these differences and describes the basic flow through the unit in relative terms.
Advanced Theory of Operation 29 Configuration 2 Pump P1 (Figure 7) draws gas in through the supply inlet on the back panel and delivers it to accumulator AC1. The accumulator smoothes out flow fluctuations generated by the pumping action and provides a port for releasing pump backpressure through pressure relief valve RV1, set at 5 psig. The output of the accumulator is passed through 5-micron filter F1, and split by the tee into carrier and dilution streams.
Advanced Theory of Operation 30 § © © Figure 8: Diagram of Configuration 3 § © © Figure 9: Diagram of Configuration 4
Advanced Theory of Operation 31 Configuration 5 in this configuration (Figure 10), pump P1 draws gas in through the supply inlet on the back panel and delivers it to accumulator AC1. The accumulator smoothes out flow fluctuations generated by the pumping action and provides a port for releasing pump backpressure through pressure relief valve RV1, set at 5 psig.
32 Electrical Description The basic wiring of the Model 340 is shown schematically in Figure 11. Dynacalibrators are powered from a benchtop style transformer on the rear panel. This is a switcher-style supply that allows a range of input voltage and frequency from 100 to 240 VAC at 50-60 Hz. The power supply steps the voltage down and regulates the output to 24 VDC. If the cord end type is inappropriate for your locale, please contact VICI for a replacement cord.
33 Maintenance Since the Dynacalibrators are designed for and generally used in applications that require continuous service, a planned routine maintenance program is highly recommended. Routine maintenance consists of inspection, cleaning, calibration, and leak checks. The table below lists the recommended checks and maintenance frequencies for continuous and non-continuous use.
Maintenance 34 9. Inspect all assembly mountings for loose hardware, and tighten as necessary. 10. Rinse the fan screen and fan filter in clean water and blow dry with lowvelocity air. 11. Reinstall the fan, fan filter, fan screen brackets, and fan screen using the four screws, lockwashers, and hex nuts. 12. Replace the top cover of the unit and return it to service according to the procedures on page 15.
Maintenance 35 Chamber Temperature Calibration Prior to shipment, the permeation chamber digital temperature control is calibrated against the temperature of the gas in the permeation chamber using an NIST-traceable PRT, (platinum resistance thermometer). The results of this calibration have been supplied with your instrument. At this point, it is helpful to give an overview of the total calibration process. A multiple point measurement is made with excursions to the extremes of range.
36 Troubleshooting If you intend to perform detailed troubleshooting on your Dynacalibrator, please first read the section entitled “Advanced Theory of Operation” which starts on page 27. The flow diagrams included there will provide significant help. Most gas flow problems can be isolated to a particular component using a lowpressure air source and a pressure gauge.
Troubleshooting 37 4. Isolate the leak by using a small quantity of leak detection fluid on each possible leak point in the suspect loop. Watch carefully for the bubbling or foaming effect that characterizes a leak. Most leaks that arise under internal pressures of 20 inches of water will be small. Because of this, be sure to watch carefully for a full 30 seconds before concluding that the point being tested does not leak. 5. Repeat steps 3 and 4 for each potential leak point in the suspect loop. 6.
Troubleshooting 38 7. Once a section of the loop has been determined to be leak free, go to the next fitting downstream of the point of the previous check and repeat the previous procedure starting at step 3 above. When the end of the loop has been reached by the previous sequential troubleshooting procedure, this check can be considered completed. For reference, the end of the loop is the point where, in the initial leak checking procedure, the Leak Checker gauge was placed. 8.
39 Model Number Breakdown
40 Warranty This Limited Warranty gives the Buyer specific legal rights, and a Buyer may also have other rights that vary from state to state. For a period of 90 calendar days from the date of shipment, VICI Metronics Inc. (hereinafter Seller) warrants the goods to be free from defect in material and workmanship to the original purchaser.
