Valco Instruments Co. Inc. Dynacalibrator Model 450 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 four 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 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 When the calibrator mode is changed to ZERO, SPAN 1, or SPAN 2 – either by remote command or the mode selector switch – SV3 energizes to interrupt the normal sample input and substitute the calibrator output stream through the stream outlet port. In these modes, excess calibration gas is dumped out the overflow vent to ensure that analyzers sensitive to sample feed pressure receive zero or span gas at near atmospheric pressure.
Introduction 4 Figure 2 summarizes the Model 450 output flow configurations. When the mode selector switch is in the REMOTE position with no remote inputs, the calibrator defaults to the STANDBY mode. Remote inputs can then change the mode to ZERO, SPAN 1 or SPAN 2. Referring again to Figure 1, note that the dilution stream passes through scrubber #2 and feeds into differential pressure regulator DPR2.
Introduction 5 Remote monitoring station Sample inlet 450 Dynacalibrator Span 1 Sample inlet Span 2 Stream outlet Remote Zero Standby Zero Recorder Span 1 Standby Gas analyzer Span 2 Remote control panel Figure 3: Model 450 single sample remote application
Introduction 6 calibration output of the calibrator to the inlet port of each of the analyzers. The calibrator chamber may contain two permeation devices with different trace gases – one for each analyzer. The output of the permeation chamber is fed to a mixing tee, where the calibrated dilution stream is added to set the final concentration. The combined stream is then fed through another tee to the rear panel overflow vent and span outlet.
Introduction 7 Specifications
8 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 9 Figure 5: 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 10 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 11 Rear Panel Connections Getting Started 11 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 Rear Panel Connections must be stored or returned to VICI. Remove all shipping caps and shipping plugs from the rear panel bulkhead fittings.
Getting Started 12 Supply Inlet All Dynacalibrators except those with -1X input configurations (separate carrier and dilution inlet ports) are equipped with a supply inlet fitting. Those with -0X input configurations (no internal pump) must have the supply inlet connected to an external pressurized source of carrier and dilution gas, such as an external pump, a cylinder of compressed gas, etc.
Getting Started 13 so a source of pressurized gas must be connected to its carrier inlet and its dilution inlet. On the remaining three input configurations, these inlets are part of the gas stream bypass loops, discussed in a later paragraph. However, the bypass loops may be left disconnected, and since they are downstream from the internal pump, external pressurized gas sources may be connected to the dilution inlet and/or the carrier inlet.
Getting Started 14 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 15 .15 DYNACALIBRATOR .10 30° SHUTDOWN .
16 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 folowing equation: Where: K = 24.
17 Initial Power-Up Connections 1. Connect a 24 VDC power source to the rear panel power input connector. (We offer a suitable power supply as an option: PN I-X-PS150-24V-KIT.) 2. If you do not have the pump option: Connect the carrier gas source (15 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 18 Setting the Chamber Temperature Manually To read the current set point: press and hold the button. To read the chassis environment temperature: press and hold the button. 1. To set the desired temperature, simultaneously press the and buttons, then release them. The PNL light will start flashing, indicating the controller is in the temperature set mode. 2. Use the and buttons to reach the desired temperature set point. NOTE: Maximum temperature set point is 110°C; minimum is 30°C. 3.
Initial Power-Up 19 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 main power switch. 2. With the tool provided, rotate the panel lock screw 90° counterclockwise. 3. Remove the front panel oven cover to access the chamber cap. CAUTION: The permeation chamber cap may be warm to touch.
20 Serial Port Communication The temperature of the Dynacalibrator Model 450 can be monitored and controlled remotely by means of a serial port DB-9 female (DCE) 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.
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 “dyna450”, 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 dyna450 HyperTerminal screen (below).
Serial Port Communication 23 Click “Settings” 9. On the dyna450 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 Dyna450 HyperTerminal (page 22, bottom illustration), click “File”, then “Save” to save this Dynacalibrator Model 450 communications setup. The following text will be displayed in the HyperTerminal window when communication is first established with the Dynacalibrator Model 450: Parameters recovered. Program checksums ok.
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 its 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; such as 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 11) draws gas in through the supply inlet on the back panel and delivers it to accumulator AC1. The accumulator smooths out pressure pulses, with the back pressure regulator providing continuous pressure regulation to cover the dynamic range required. The output of the accumulator is passed through filter F1, and split by the tee into carrier and dilution streams.
Advanced Theory of Operation 30 Figure 12: Diagram of configuration 3 Figure 13: Diagram of configuration 4
Advanced Theory of Operation 31 Configuration 5 in this configuration (Figure 14), pump P1 draws gas in through the supply inlet on the back panel and delivers it to accumulator AC1. The accumulator smooths out pressure pulses, with the back pressure regulator providing continuous pressure regulation to cover the dynamic range required.
32 Electrical Description The basic wiring of the Model 450 is shown schematically in Figure 15. 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 Metronics for a replacement cord.
33 Maintenance Since 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 17.
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 and electrical drawings included there will provide significant help. Most gas flow problems can be isolated to a particular component, using a low-pressure air source and a magnihelic pressure gauge. A volt-ohmmeter is adequate for checking the majority of the electrical circuits.
Troubleshooting 37 Pneumatic Troubleshooting There are two reasonably direct methods that can be used to troubleshoot leaks in a Dynacalibrator, each with its advantages and disadvantages. The first method, using leak detection fluid, (Leak-Tek, Snoop, soap solution, etc.) is relatively fast but is somewhat messy and requires careful cleanup after the leak is located and repaired. The second method, isolating components by breaking connections, can consume more time but does not require cleanup.
Troubleshooting 38 3. Starting at the air source end of the suspect loop, break a fitting and, using an appropriate adapter, connect the leak checker gauge to the upstream side of the disconnected joint. 4. Open the valve on the air source and slowly charge the unit until the gauge reads 20 inches of water. Close the valve on the air source. 5. Monitor the gauge for at least 30 seconds. If the reading does not change, there are no leaks in this path to this point. Proceed to Step 7.
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.
