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Table of Contents User Guide Revision History... 3 Overview... 4 1. System Configuration... 4 1.1. Pneumatics... 4 1.2. Front View... 5 1.3. Back View... 5 1.4. Internal View... 5 1.5. Specifications... 6 1.6. Enclosure Dimensions... 6 2. AirCal 1000 operating principle... 7 2.1. Dilution Ratio... 7 2.2. Gas Cylinders... 7 3. Operation... 8 3.1. Getting Started... 8 3.2. Manual Operation... 8 3.3. AirCal 1000 V1.1 Software... 9 3.3.1. Connect to PC 9 3.3.2. Manual Calibration 10 3.3.2. Automatic Calibration 12 3.4. Error Codes... 12 3.5. Sensor Module Settings... 13 4. Maintenance... 14 4.1. Care and Cleaning... 14 4.2. Maintenance schedule... 14 4.3. Removal of Adsorbents... 14 4.4. Flow check for MFC and MFM... 15 4.5. Flow Calibration for MFC and MFM... 16 5. Warranty... 17 5.1. What we will do... 17 6. Appendix... 17 6.1. Copyright... 17 6.2. Compliance... 18 6.3. Guidelines... 19 6.4. Technical support... 19 2
User Guide Revision History Current version: 1.2 Date released: August 2012 Description: User guide for AirCal 1000 This user guide is a newly created document for the use of the AirCal 1000 Portable Calibrator. Date Revision number Description of change Affected pages 9 July 2014 1.2 Added note on warm up time for Carulite Scrubber 5, 6, 8. 3
Overview The AirCal 1000 is a portable calibrator instrument which enables zero and span checks for NO2, NOx, CO, SO2, H2S, PID, VOC, and NMHC channels. It includes: 1. Gas Dilution Module: 2 span gas inputs with a zero air mass flow meter (MFM) 0-3 SLPM and a mass flow controller (MFC) 0-50SCCM. 2. Zero Air Source: Scrubbing media activated carbon, Purafil chemisorbant and heated carulite 3. Power supply module: 100-240V AC to 12V DC 4. Carry case: For transport Span gas cylinders and regulators are not included as standard. Aeroqual can specify mixtures and suggest a local supplier. IMPORTANT: COMPRESSED GAS REPRESENTS A HEALTH AND SAFETY RISK. ALWAYS ENSURE PERSONNEL ARE TRAINED AND THERE IS AN APPROPRIATE HEALTH AND SAFETY PLAN IN PLACE WHEN USING GAS CYLINDERS. 1. System Configuration 1.1. Pneumatics Zero air in Filter Pump Internal components External components Exhaust Port 1 Activated Carbon Port 2 Purafil Zero Air air Scrubber scrubber Solenoid Span 1 Solenoid Span 2 Heated Carulite Gas Cylinders MFC MFM Diluted gas out Note 1: The AirCal 1000 should be connected to the test instrument using the inert T fitting which is provided. This will ensure the test instrument is sampling the gas flow at atmospheric pressure Note 2: Ensure the filter is connected to the zero air inlet to minimise damage to the pump by particulate matter 4
1.2. Front View Display Diluted gas outlet NEVER BLOCK THIS OUTLET RS232 Serial Port On/Off Switch 1.3. Back View 12 VDC Input Gas/Span inlets 1.4. Internal View Top MFM MFC Bottom Heated Carulite Catalyst (requires 30 minute warm up to reach full efficiency) Activated Carbon Pump Purafil chemisorbant 5
1.5. Specifications Purafil chemisorbant SOx,, NOx, O 3, H 2 S, Activated Carbon - Hydrocarbons Zero air generator. Heated Carulite Catalyst CO (30 minute warm up required) note: CO 2 is not scrubbed Maximum Delivered Flow rate 2.0-2.5 LPM Span Gas Operating Pressure 10-15psi Max Input Pressure 140psi Gas Connections Span ports 1/8 Swagelok compression fitting Zero air/ Gas out ¼ Kynar compression fittings MFC Range 0-50 sccm MFM Range 0-3 SLPM Flow Accuracy < 1% of full scale Span gas inputs 2 Recommended span gas mixtures (contact Aeroqual for more detail) Electric Connection Display Outputs 20 ppm NO2 / Air 1000 ppm CO / Air 1000 ppm Isobutylene / Air 100 ppm SO2 / N2 20 ppm NO / N2 100 ppm H2S / N2 multi-gas mixtures 20 ppm NO, 100 ppm SO2 100-240V AC to 12V DC 4 Line Alphanumeric RS232 (DB9 port) Cable and USB adaptor supplied Dimensions 422 x 422 x 148 Weight 12kg Enclosure Material Aluminium and Steel Powder coating Instrument Carry Case Impact and water resistant, 515 x 430 x 200 Conformity 1.6. Enclosure Dimensions 20 20 236 17 Handles 278 Top 67 55 Side (tilted) 132 Front 15 Side 12 VDC IN Rear 30 6
2. AirCal 1000 operating principle 2.1. Dilution Ratio The AirCal system delivers a controlled concentration of calibration gas for calibration of ambient gas instruments. To do this the calibration gas inside the cylinder is mixed with zero air, which is generated by the scrubbing material inside the AirCal 1000. The calibration gas is therefore diluted by the zero air to provide a given concentration which is directed into the test instrument. The concentration of calibration gas is calculated using a dilution ratio which is determined by the zero air and cylinder gas flow rates. The zero air generator will deliver a flow rate of approximately 2 2.5 LPM. The flow rate of the zero air is monitored using a mass flow meter (MFM). The flow rate of the cylinder gas is controlled dynamically using a mass flow controller (MFC). The cylinder gas flow rate can range from between 5 45 ml/min -1 The MFC will adjust the flow of the calibration gas so as to maintain a user defined dilution ratio according the equation: The user dilution ratio needs to be calculated in order to deliver the required concentration of calibration gas. Example: If 10ppm of CO was required and the cylinder concentration is 1000ppm, then the required dilution ratio would be 100. The dilution ratio of 100 will be entered into the relevant section, either in the PC software or manually on the instrument screen and the MFC flow rate will automatically adjust to meet the desired calibration gas concentration. 2.2. Gas Cylinders To achieve the best performance from the AirCal 1000 it is important to connect gas cylinders with gas concentrations which are appropriate for the calibration being performed. Example cylinder concentrations are as follows: Gas Recommended Cylinder concentration ppm Maximum Concentration Achievable ppm CO 1000 20 2 NO / NO2 20 0.4 0.04 PID / NMHC 1000 20 2 SO2 / H2S 100 2 0.2 Note: The recommended dilution ratio range is between 50 and 500 Minimum concentration achievable ppm 7
3. Operation The AirCal 1000 is designed for easy set up and usability. Zero air and span checks can be carried out manually or programmed to initiate automatically at selected time intervals. These options can be configured using the AirCal 1000 PC software or on the instrument itself using the buttons on the front panel. NOTE: The AirCal1000 contains a heated Carulite scrubber for the removal of CO, this scrubber operates at elevated temperatures and requires 30 minutes to reach full CO scrubbing efficiency. 3.1. Getting Started 1. Unpack unit 2. Plug 100-240V AC to 12V DC power supply pack into rear socket on AirCal 1000 and connect to mains 3. Connect the outlet to the instrument under test using the supplied T fitting to ensure the instrument samples at atmospheric pressure. Caution: never block the outlet flow of the Aircal 1000. Internal damage may occur. 4. Fit the supplied filter to the zero air inlet to ensure the pump does not get damaged by dust 5. Connect the gas cylinders to Port 1 and Port 2 safely using regulators. Adjust the inlet pressure to 10-15 PSI. Caution: do not over pressurise. 6. Turn on the power switch on the front panel Note: Fluorocarbon (PTFE, FEP or PFA) tubing and fittings should be used for all sample lines 3.2. Manual Operation On start up the screen will show the MFC and MFM flow rates in cubic cm. Selecting main menu will give you the option to run a manual or automatic calibration. Under the Manual option zero air and span checks can be initiated. Selecting Port 0 will initiate the zero air check. In this setting the dilution ratio should be set at 0. Selecting either Port 1 or 2 will initiate the span check. The dilution ratio will need to be calculated (refer to Section 2) and entered. Select Start to begin the checks Under the Auto Run option there is the option to show or modify schedules. The schedules will need to be set up initially by selecting modify schedules and entering the information for each run. A run may include up to 5 points including zero air which is defined as Port 0. A maximum of 3 runs can be configured for automatic calibration. The process is similar to set up on the PC software. The Point, Port, Dilution ratio, Run time and Run frequency need to be set using the buttons on the front panel. 8
Once the schedule has been set up, initiate the schedule by pressing start on the Auto Run menu. 3.3. AirCal 1000 V1.1 Software Alternatively, the AirCal 1000 can be controlled via the PC software. Computer Requirements CD-ROM Drive RS232 serial port or USB RS232 serial port converter Windows OS version 2000 or later Minimum 100 Mb of spare hard drive space Recommended 512 Mb RAM or more Recommended 1 GHz processor speed or faster 3.3.1. Connect to PC Connect the serial cable between the AirCal 1000 and the computer and install the AirCal 1000 V1.1 zip file from the supplied CD. Launch the AirCal 1000 PC software: 1. Select Communication Port and choose the correct Com port on the PC. Note this will be created when the serial port convertor is plugged in. You may need to install the convertor drivers. 2. Select Test Connection to check the AirCal 1000 has connected successfully 3. Select Update Real Time Clock to synchronize the AirCal 1000 clock with the computer date/time. This will only need to be carried out the first time the instrument is set up. Once the connection has been created and the date/time has been updated the software is ready to use.. 9
3.3.2. Manual Calibration Zero Check (Port 0) Select Zero Check then select start reading to initiate the zero air check Readings will be taken every minute Allow for the sample gas to stabilise (15 minutes). Be aware that there may be some fluctuation in the MFM measurement (±5ml/min) To stop the data recording select Stop Reading. The data can then be cleared or exported to a spread sheet. To stop the zero check completely select Stop Check Span Check (Port 1 or 2) Select Span Check Select the span check port from the drop down menu Note: Each gas cylinder connected will have a defined port assigned to it. Both ports are labelled clearly on the back of the instrument. Select a dilution ratio using the equation provided in Section 2 Press OK then select Start Reading Readings will be taken every minute The MFC flow rate will adjust to track to MFM flow rate. This will ensure the correct dilution ratio is maintained. The flow rates may take approximately 15 minutes to stabilise. To stop the data recording select Stop Reading. The data can then be cleared or exported to a spread sheet. To stop the span completely check select Stop Check 10
Note: The dilution ratio can be checked manually using the following equation: 11
3.3.2. Automatic Calibration Calibration can be configured to be carried out automatically at a set time for a chosen running period. The process is similar to the manual operation. Select Calibration Configuration and right click to open the Run Scheduler. The run schedule will need to be configured. A run may include up to 5 points including zero air which is defined as Port 0. A maximum of 3 runs can be configured for automatic calibration. The user will need to define the dilution ratio for Port 1 and 2 as well as the run time. The schedule can then be selected from the drop down menu to configure the calibration run frequency, day of week/month and start time. Once all the parameters have been set click save then click read to ensure the run has been saved. Note: The information contained in the Calibration Configuration is stored on the AirCal 1000 and not on the PC containing the Aeroqual software. To remove a run, right click inside the run scheduler and select remove run. Note that run three will be removed first followed by run two and then run one. Once a run has been removed click save and then click read to make sure that the run has been removed. 3.4. Error Codes There are 3 error codes that can occur during the use of the AirCal 1000. They will show up on the instrument screen as well as in the PC software readings. Error 1 = Will be shown if the dilution ratio is set below 40 or above 1000 recommended dilution ratio range is 50 500 Error 2 = Will be shown if the MFM reading drops below 1000 ml/min Check zero air inlet and flow path for blockage/leaks Error 3 = Will be shown if the MFC reading drops below 80% Check cylinder gas inlet and flow path, may be due to insufficient pressure from cylinder, leaks or blockage 12
3.5. Sensor Module Settings The Sensor Module Settings contain the calibration settings for the mass flow meters and controllers. They should not be altered except when the unit is being calibrated and you have access to high accuracy flow measurement. The password for access to the settings is calibrate. The Parameter list and meanings: H3 //not used TEMA //MFC Range x Gain (cc/min) TIMA //cylinder purge time in sec TEMR //span adjust time in sec TIMR //Number of MFM readings that are averaged H0 //MFM reading zero offset 13
H1 H2 PWMH PWML Gain 4. Maintenance //not used //not used //MFM reading interval for average (ms) //MFC polling time (sec) //MFM Gain 4.1. Care and Cleaning Keep the AirCal 1000 dry. Avoid water and/or condensation as humidity and liquids containing minerals may corrode electronic circuits. Do not use or store in dusty, dirty areas. This unit is designed for use at temperatures between 5 C and 45 C. If you wish to use the monitor outside this range you will need an additional environmental enclosure. Sudden changes in temperature may cause condensation that may damage the electronic components. Do not drop, knock or shake as this could lead to internal damage. 4.2. Maintenance schedule The AirCal 1000 has been designed to require minimal maintenance provided that the instrument is used correctly with clean, dry, filtered gas. The following section shows the common maintenance procedures and frequency: Item Procedure Frequency Inlet Filter Check and replace filter Monthly Activated Carbon Remove and replace Yearly Purafil Remove and replace Yearly Mass Flow Controller Mass Flow Meter Flow Check Flow Calibration Flow Check Flow Calibration Quarterly Yearly Quarterly Yearly Note: Suggested intervals for maintenance procedures may vary with sampling intensity and environmental conditions. 4.3. Removal of Adsorbents The Activated Carbon and Purafil capsules will need to be replaced yearly. A zero air scrubber replacement kit can be purchased from Aeroqual. It will come with all the relevant fittings so it can be installed easily into the AirCal 1000. To remove: Unscrew top plate of AirCal 1000 via the 2 screws at the back of the instrument. The top plate should slide out easily. Remove the current zero air scrubber Purafil and Activaed Carbon Capsules. o Disconnect the tube connecting the pump to the Purafil capsule (See red arrow). o Unscrew the luer fitting connecting the Activated Carbon capsule to the Heated Carulite capsule (See red arrow). Unclip both the Purafil and Activated Carbon capsule and remove. 14
Purafil Capsules Unscrew luer fitting Pump Activated Carbon Capsule Unscrew luer fitting Disconnect tube from pump To replace: The replacement capsules will be provided with the relevant fittings Clip both capsules back into place and reconnect the correct tube to the pump and screw the luer fitting connectors to reconnect to each other and the Heated Carulite capsule 4.4. Flow check for MFC and MFM To ensure correct and accurate operation of the AirCal 1000, periodic checks of the MFC and MFM are recommended between yearly calibrations. To check the flow: Remove the bottom plate of the AirCal 1000 via the 2 screws at the back of the instrument. The bottom plate should slide out easily. Place the AirCal 1000 on its side so the MFC and MFM outlets are visible. The MFC and MFM flow rates need to be measured separately. MFM outlet MFC outlet 15
Unscrew the luer fitting of the MFC outlet and connect to a flow meter. A span check will need to be initiated to measure the flow rate of the MFC The flow measurement recorded on the flow meter should be compared with the measurement recorded on the AirCal 1000. The luer connector needs to be replaced securely and the same process carried out for the MFM outlet. A zero air check will need to be initiated to measure the flow rate of the MFM Note 1: The MFC flow rate should be between 5-45 ml/min -1 depending on the dilution ratio set Note 2: The MFM flow rate should be between 2-2.5 LPM MFC connection If the flow rate has changed by more than 2% then you should consider getting the AirCal 1000 re-calibrated. 4.5. Flow Calibration for MFC and MFM This should only be done by an approved agent or laboratory with the correct flow calibration equipment. Please contact Aeroqual for the procedure. 16
5. Warranty Aeroqual warrants this product to be free from defects in materials and workmanship for a period of 1 (one) year from the date of shipment from the factory. Consumable items such as pumps, filters and gas scrubber media are excluded from this warranty. This warranty is expressly limited to the original owner who purchases the equipment directly from Aeroqual or from an authorized Aeroqual dealer. Should your Aeroqual product need warranty service, you should return it to the dealer from whom it was purchased or contact Aeroqual. 5.1. What we will do If, during the warranty period, this product fails to operate under normal use and service, due to improper materials or workmanship, Aeroqual subsidiaries, authorized distributors or authorized service partners will, at their option, either repair or replace the product in accordance with the terms and conditions stipulated herein. Conditions 1. The warranty is valid only if the original receipt issued to the original purchaser by the dealer, specifying the date of purchase, is presented with the product to be repaired or replaced. Aeroqual reserves the right to refuse warranty service if this information has been removed or changed after the original purchase of the product from the dealer. 2. If Aeroqual repairs or replaces the product, the repaired or replaced product shall be warranted for the remaining time of the original warranty period or for ninety (90) days from the date of repair, whichever is longer. Repair or replacement may be via functionally equivalent reconditioned units. Replaced faulty parts or components will become the property of Aeroqual. 3. This warranty does not cover any failure of the product due to normal wear and tear, damage, misuse, including but not limited to use in any other than the normal and customary manner, in accordance with Aeroqual s user guide for use, faulty installation, calibration and maintenance of the product, accident, modification or adjustment, events beyond human control, improper ventilation and damage resulting from liquid or corrosion. 4. This warranty does not cover product failures due to repairs, modifications or improper service performed by a non- Aeroqual authorized service workshop or opening of the product by non-aeroqual authorized persons. 5. The warranty does not cover product failures which have been caused by use of non-aeroqual original accessories. 6. This warranty becomes void if a non-aeroqual approved power supply is used. 7. Tampering with any part of the product will void the warranty. 8. Aeroqual makes no other express warranties, whether written or oral, other than contained within this printed limited warranty. To the fullest extent allowable by law all warranties implied by law, including without limitation the implied warranties of merchantability and fitness for a particular purpose, are expressly excluded, and in no event shall Aeroqual be liable for incidental or consequential damages of any nature whatsoever, however they arise, from the purchase or use of the product, and including but not limited to lost profits or business loss. 9. Some countries restrict or do not allow the exclusion or limitation of incidental or consequential damage, or limitation of the duration of implied warranties, so the preceding limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights, which may vary from country to country. 6. Appendix 6.1. Copyright Copyright Aeroqual Limited. All rights reserved. Reproduction, transfer, distribution or storage of part or all of the contents of this document in any form without the prior written permission of Aeroqual Limited is prohibited. Aeroqual and Aeroqual Limited Making the Invisible Visible are registered trademarks of Aeroqual Limited. Other product and company names mentioned herein may also be trademarks or trade names. 17
Aeroqual operates a policy of continuous development. Aeroqual reserves the right to make changes and improvements to any of the products described in this document without prior notice. Under no circumstances shall Aeroqual be responsible for any loss of data or income or any special, incidental, consequential or indirect damages howsoever caused. The contents of this document are provided "as is". Except as required by applicable law, no warranties of any kind, either express or implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose, are made in relation to the accuracy, reliability or contents of this document. Aeroqual reserves the right to revise this document or withdraw it at any time without prior notice. The availability of particular products may vary by region. Please check with the Aeroqual dealer nearest to you. Aeroqual Limited 2010. All rights reserved. 6.2. Compliance 1. The Aeroqual AirCal 1000 complies with EN 61000-6-1:2001 2. The Aeroqual AirCal 1000 complies with EN 61000-6-3:2001 3. The Aeroqual AirCal 1000 complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) these devices may not cause harmful interference, and (2) these devices must accept any interference received, including interference that may cause undesired operation. NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio/tv technician for help. 18
6.3. Guidelines USE SENSIBLY Use only as per this user guide. USE AEROQUAL APPROVED SERVICE Only approved service personnel must work on this product. ACCESSORIES Use only approved accessories. Do not connect incompatible products. CONNECTING TO OTHER DEVICES When connecting to any other device, read the appropriate user guide for detailed safety instructions. Do not connect incompatible products. HEALTH AND SAFETY IN THE WORKPLACE This product requires the application of compressed gases. Aeroqual does not guarantee user safety. An appropriate Health and Safety plan should be in place.. 6.4. Technical support Technical information, service and spare parts are available through your distributor. In addition, worldwide technical support is available from Aeroqual Ltd. Please contact: Aeroqual Limited 109 Valley Road, Mt Eden, Auckland 1024, New Zealand Phone: +64 9 623 3013 Fax: +64 9 623 3012 Email: technical@aeroqual.com 19