® Valco Instruments Co. Inc. Dynacalibrator Model 500 Instruction Manual Manufactured by: Valco Instruments Co. Inc. 8300 Waterbury Houston, TX 77055 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) Electrical Description...............................................................................................................................26 Maintenance...............................................................................................................................................27 Instrument Inspection and Cleaning........................................................................................27 Carrier Flow Rate Verification..................
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 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 Referring again to Figure 1, note that the dilution stream passes through scrubber #3 and feeds into differential pressure regulator DPR3. The Model 500 contains a dilution flow control valve and rotometer, plus a rotometer for SPAN 1 and SPAN 2 carrier flows. When energized, solenoid control valve SV1 opens to route carrier 1 flow to the mixing tee. Differential pressure regulator DPR1 maintains a fixed 3.2 psi pressure differential across the selected flow control valve and meter.
Introduction The Model 500 has four modes of operation – ZERO, SPAN 1, SPAN 2, and Both SPAN 1 and SPAN 2. When the calibrator mode is changed to ZERO, SPAN 1, or SPAN 2, a two position valve in the calibrator interrupts the sample input and substitutes the calibrator output to the analyzer. ZERO (neither SPAN 1 nor SPAN 2 on), SPAN 1, SPAN 2, and SPAN 1 + SPAN 2 can provide three points of calibration along with a zero reference.
Introduction Specifications ����������� ����������� �������������������������� ��������������������������������� ��������������������������� ����������������������� ���������������������������������� ���������������������������� ������������������������������������ ��������������������������� �������������������������������������� ���������������������������������� ����������������������������������� ������������������ ����������������� �������������� ������������������������������������������
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.
����������������� ������������� ����� ������ ������ ������ ����� ������ ����������� �������������� 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. All cartons and packing materials must be kept intact for the inspection.
Getting Started 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. • air flow around the unit’s cooling vents and rear panel fan intake is not blocked or restricted, particularly for the rack-mounted units.
Getting Started 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. If a plumbing connection is required, the block under the fitting heading is marked with an “X”; if there is no connection, the block is blank.
Getting Started 10 Carrier/Dilution Inlets All 500 Series Dynacalibrators are configured with either a single inlet (500-0-***) or a dual inlet (500-1-***) and therefore require an external source of pressurized gas. On dual inlet systems two different types of gas can be used – one for dilution and one for carrier. The most commonly used gas is dry air; however, dry nitrogen or any other comparably inert gas including ambient air may also be used.
Getting Started 11 ������� ������������ ���������� �������������� ��������� ��������� ���� ���������������� ����������� ���� ��������� ������� ��������� ���� ���� �� �������� ��������� �� ������ ��������� ����������� ������� ������������ ������ ����������� ���������� �� ���������� ������� �������������������� �������� ���� ������� �������������������� ���������� ��������� ���������� ������ �� ������������ ������� ������ ������� ������� �������� ������������ ����� Figure 4: Model
Getting Started 12 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 17). After a temperature set point is entered by either method, it is written to memory so that after a power failure the unit will return to the condition previously established.
13 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: Where: ��������������������� ����� � K = 24.
14 Initial Power-Up Connections 1. Plug the supplied power cord into the rear mounted power supply. Ensure that the power supply output cable is plugged into the interface board power connector. 2. Connect the carrier gas source (25 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.
15 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 16 Setting the Chamber Temperature via Serial Port (RS-232) Refer to the section titled “Serial Port Communications” on the next page. Installing the Permeation Device(s) 1. With the tool provided, rotate the panel lock screw 90° counterclockwise. 2. Remove the front panel oven cover to access the chamber cap. CAUTION: The permeation chamber cap may be warm to touch.
17 Serial Port Communication The Dynacalibrator Model 500 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 18 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 “dyna500”, and select an icon to associate with the file. Then click “OK”. . 5.
Serial Port Communication 19 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 dyna500 HyperTerminal screen (below).
Serial Port Communication 20 Click “Settings” 9. On the dyna500 Properties screen (above), click “Settings” to bring up the screen below. Click “ASCII Setup...
Serial Port Communication 21 10. Click “ASCII Setup” and set the parameters as indicated below. Click “OK”. 11. When the screen returns to Dyna500 HyperTerminal (page 19, bottom illustration), click “File”, then “Save” to save this Dynacalibrator Model 500 communications setup. The following text will be displayed in the HyperTerminal window when communication is first established with the Dynacalibrator Model 500: Parameters recovered. Program checksums ok.
22 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.
23 Shutdown Procedure Dynacalibrators are designed to operate continuously; however, if it is necessary to turn the unit off, use the following procedures: 1. With the tool provided, rotate the panel lock screw 90° counterclockwise. 2. Gently pull the front panel assembly out. CAUTION: The permeation chamber cap may be hot. If the calibrator has been in use, avoid exposure to gas vapors while opening the chamber cap. 3. Unscrew the chamber cap with the tool provided. 4.
24 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.
25 Plumbing Configurations There are two plumbing configurations available for Model 500 Dynacalibrators. The plumbing configuration is defined by the first digit of the 2-digit numerical suffix to the basic model number, e.g., Model 500-12 is equipped with plumbing configuration 1. The second digit of the 2-digit suffix defines the overall instrument gas flow capacity. A lower case letter is added to this number to indicate the carrier flow (and the orifice used).
26 Electrical Description The basic wiring of the Model 500 is shown schematically in Figure 8. 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.
27 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 28 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 14.
Maintenance 29 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.
30 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 24. 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 magnihelic pressure gauge.
31 5. Repeat steps 3 and 4 for each potential leak point in the suspect loop. 6. Tighten or remake any connection or joint that has been found to be leaking. Replace any component whose leak cannot be stopped by the tightening or remaking process. 7. Rerun the overall system leak checking procedure called out earlier in this section to ensure that all the leaks in the loop have been identified and repaired. 8.
32 Model Number Breakdown ����� � � � ���������������� ����������� ������������������ �������������������� ������������������� ���������������������������� � � �������������������������������� � � ���������������������������������������������������� � � �������������������������������������� � � �������������������������������������������������� � � ��������������������������������������������������� � � ������������������������������������������������������������� �������������������������� � � �������
33 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.