ACD CAL-101 User manual

2024W.McMillanSt.
Tucson,Arizona85705USA
Telephone:[phone]
Fax:[phone]
TollFree:[phone]
Email:[e-mail]
Web:www.goACD.com
P/N 910-0601-00
AdvancedCalibrationDesigns,Inc.
InstructionManual
CalibrationGasGenerator
AdvancedCalibrationDesigns,Inc.
CAL-101

Instruction Manual
Gas Generator
Release I
TABLE OF CONTENTS
I. General Description Page 2
II. Start-Up Page 4
III. Normal Operation Page 5
IV. Non-Normal Operation Page 6
V. Cell Life Page 8
VI. Corrections to Volumetric Flow Page 9
VII. Maintenance Page 10
VIII. Accessory Items / Parts List Page 10
IX. Warranty Information Page 11
910-0601-00

WARNING:
This instrument generates calibration gas for toxic gas detectors. The
instruction manual should be read and understood prior to operation
of the instrument. Failure to operate the instrument correctly can lead
to improper calibrations.
This instrument conforms to the protection requirements of the EC
DIRECTIVE 89/336/EEC on Electromagnetic Compatibility (EMC), in
accordance with the provisions of Statutory Instrument 2372.
The following standards have been applied:
EN 50081-1
Emissions Standard (Residential Commercial and Light Industry)
EN 50082-1
Immunity Standard (Residential Commercial and Light Industry)

I. GENERAL DESCRIPTION
The CAL-101 is a small, battery-powered, portable electrochemical gas
generator designed to calibrate toxic gas sensors.
Fast warm-up time allows the instrument to be turned
off between remotely located sensors saving battery
life and avoiding generation of unwanted gas. The
CAL-101 uses the following components to produce
the calibration gas/air mixture:
Internal Micro Pump
A small air pump draws in ambient air to blend with the electrochemically
generated gas.
Electrochemical Generating Cell
The electrochemical generating cell contains an electrolyte solution and
either inert or consumable electrodes, depending upon the gas being
generated. A precise concentration of gas is produced when the CAL-101
supplies a known amount of current and a known amount of air continuously
to the cell.
Alkaline “AA” Batteries
A set of two fully charged alkaline “AA” batteries provides 10-12 hours of
operation. To replace the batteries, rst remove the cell then slide the battery
chamber in to allow the batteries to drop out the bottom of the instrument.
NOTE: Rechargeable batteries will provide substantially fewer hours
of operation and will self discharge while the instrument is in storage.
Users should also be aware that use of rechargeable batteries will void
the CSA approval of the CAL-101 for intrinsic safety.
Microprocessor-Based Circuitry
When powered-up, the microprocessor provides remaining cell and battery
life indication via the display LEDs. Low battery or exhausted cell conditions
are also indicated when the condition occurs. (See section IV Non-Normal
Operation.)
Page 2

ON/OFF Switch
The CAL-101 has no on/off switch. To use the instrument simply insert the
cell. To turn the unit off, simply remove the cell by pushing the cell eject
button located on the top of the instrument. When the unit is congured as
a 'bump' station, a modied generating cell is used. The 'bump' generating
cell is equipped with a switch to initiate a 'bump' cycle. In this conguration
the cell remains in the instrument and automatically turns off after a 30
second 'bump' cycle.
Delivery Hose
The instrument comes standard with a hose for delivering the gas to the
sensor calibration adapter. The air ow of the instrument is affected by the
hose length (and subsequent pressure drops through the hose) and must
be readjusted if alternative delivery hoses are used.
Page 3

II. START-UP
To start the generator, insert the generating cell. In the bump station
conguration, press the button protruding from the bottom of the cell.
The RED LEDs will light to indicate battery life remaining. All 10 LEDs
indicate fully charged batteries. If only one RED LED is observed, the
batteries are near depletion. During the battery test time, current is supplied
to the generating cell and the air pump is not turned on in an attempt to speed
up equilibrium time. This helps to saturate the generating cell with gas.
After the battery life indication, the pump will start to pump air through the
instrument and the GREEN LEDs will begin to ash approximately once
every 4 seconds. The ashing GREEN LEDs will indicate the time remaining
in the generating cell as follows:
 10 LEDs lit indicates that 2 hours remain on the cell.
1 LED lit indicates less than 12 minutes of calibration time remain.
These are the normal operating conditions for the CAL-101. Complete
equilibrium may take an additional two to ve minutes, depending upon the
type and amount of gas being generated and the operating conditions of
the instrument. In the bump station conguration the unit will automatically
shut off after thirty seconds.
When the generating cell is inserted, if all 10 green LEDs come on constant,
this indicates a cell failure. Remove the cell and wait for all LED’s to turn off,
then re-insert ensuring that the cell is fully inserted correctly and properly
aligned.
If the GREEN LEDs ‘ramp’ up and down from max to min this indicates that
the cell life is depleted and a new generating cell should be purchased.
At any time the instrument may be turned off by removing the generating
cell. The GREEN LEDs will all light indicating cell failure and the instrument
will then shut off.
Page 4

III. NORMAL OPERATION
After the desired equilibrium has been achieved, the instrument may be
used to perform gas calibration. The GREEN LEDs will continue to ash
ever 4 seconds indicating remaining cell life. While in normal operating
mode, the CAL-101 will run continuously and generate gas until either the
battery becomes discharged or the cell is consumed. (In the bump station
conguration the unit will run for thirty seconds then automatically turn off)
If the cell is consumed the green LEDs will 'ramp' max to min repeatedly
indicating the need for cell replacement. When this occurs, please refer to
the Non-Normal Operation section that follows.
Note: Changes in air pressure or temperature will affect the output of
the CAL-101 instrument. Before beginning any calibration please refer
to section VI. CORRECTIONS TO VOLUMETRIC FLOW- for important
adjustments needed to obtain accurate calibration gas.
The calibration gas is delivered through the calibration hose attached to the
CAL-101 via a quick connect coupling. A calibration adapter, or cup, which
is provided by the manufacturer of your gas detector, is usually attached
to the end of the delivery hose. This adapter or cup is then placed over
the gas sensor. Be sure not to restrict or block the delivery hose while the
pump is running. This method is used for calibrating diffusion type sensors.
Alternatively, the output gas may be collected into a gas collection bag
for calibrating sample draw instruments. If this method is used, it is
recommended that the instrument is allowed to ow into and out of the bag
via a “Y” connector. First, partially ll the bag with generated gas. Second,
attach the sample draw unit to the third side of the “Y” connector. The
sample draw instrument will draw from both the generator and/or the bag
depending upon the ow rate of the generator. Be sure to disconnect the
sample draw unit before the bag is completely emptied of gas.
An alternative method is to connect the “Y” adapter directly to the instrument
with no bag attached. This should only be used if the ow rate of the CAL-
101 is greater than that of the sample draw instrument, otherwise dilution
gas will also be drawn into the instrument reducing the calibration gas
concentration.
NOTE: Never attach a sample draw instrument directly to the end of
the CAL-101 delivery hose without a “Y” connector in between the two
instruments. This may cause damage to one or both of the air pumps
in the CAL-101 and/or sample draw instrument.
Page 5

Page 6
IV. NON-NORMAL OPERATION
If either the batteries or the generating cell become depleted, or the
generating cell is removed from the CAL-101, the instrument enters a non-
normal operating condition
Under a low battery condition, the RED LEDs will begin to ash. If the low
battery condition occurs during power up, the RED LEDs will ash dimly
for approximately 10 seconds and then the instrument will power down. If
the low battery condition occurs after start up, the instrument will simply
power down. It is recommended to replace depleted batteries with two "AA"
heavy duty Alkaline batteries for maximum operating life.
If the cell becomes depleted either at start or during calibration, the GREEN
LEDs will begin to 'ramp' up and down from max to min until the cell is
removed. No gas generation will occur during this cell depleted indication.
If there is an error in cell communication when inserted all green LED's
will come on constant indicating a cell failure. Remove the cell and wait for
all LED's to turn off then reinsert the cell ensuring proper alignment of the
pins. If the error continues check the pins and corresponding pads on the
cell for corrosion and attempt cleaning.
If the cell has been depleted, it should be removed and replaced with
a new generating cell. Please refer to the section on cell life for proper
instructions on replacing the generating cells. If the cell has not been
depleted, there may be a faulty electrical connection between the cell and
the instrument. Remove the cell and inspect the pins protruding from the
pump board and the corresponding pads on the cell board. Remove any
debris and or corrosion that may be present and reinsert the cell ensuring
proper alignment. If either the pins become damaged or non-repairable,
the pump board should be replaced..
The rate of airow through the instrument is critical for accurate gas
concentrations. The ow should be adjusted to 0.5 LPM (liters per minute)
STP (standard temperature and pressure) of sea level and 20oC. (see chart
in section VI) To trim the ow hold the magnetic screw driver over the ‘ow
trim’ area of the instrument indicated with a magnet symbol. The GREEN
LEDs will begin ashing at a once per second rate indicating the relative
power to the pump. As you hold the magnet over this area the pump will
continue to increase in speed (The LEDs will ramp up indicating the relative
power) until the magnet is removed. When the magnet is reapplied

If the cell has been depleted, it should be removed and replaced with
a new generating cell. Please refer to the section on cell life for proper
instructions on replacing the generating cells. If the cell has not been
depleted, there may be a faulty electrical connection between the cell and
the instrument. Remove the cell and inspect the pins protruding from the
pump board and the corresponding pads on the cell board. Remove any
debris and or corrosion that may be present and reinsert the cell ensuring
proper alignment. If either the pins become damaged or non-repairable,
the pump board should be replaced..
The rate of airow through the instrument is critical for accurate gas
concentrations. The ow should be adjusted to 0.5 LPM (liters per minute)
STP (standard temperature and pressure) of sea level and 20oC. (see
chart in section VI) To trim the ow hold the magnetic screw driver over
the 'ow trim' area of the instrument indicated with a magnet symbol. The
GREEN LEDs will begin ashing at a once per second rate indicating the
relative power to the pump. As you hold the magnet over this area the pump
will continue to increase in speed (The LEDs will ramp up indicating the
relative power) until the magnet is removed. When the magnet is reapplied
to the area, the pump speed will decrease (the LEDs will also ramp down
indicating the relative power) until the magnet is again removed. Each time
the magnet is removed and reapplied the ow will change from increasing to
decreasing. This is how the ow rate of the instrument should be adjusted
to obtain 0.5LPM STP. Once the ow is adjusted the instrument will save
the ow data and return to that ow rate for future use
Page 7

Page 8
V. CELL LIFE
The generating cell is consumed during the operation of the unit. Cells
can be purchased for two hours of generation time. Once a cell has been
depleted, it may be replaced with a new cell to provide additional calibration
time. Replacement cells may be stored in their containers in a cool, humid
area for several years under most conditions.
Different types of generating cells can be used with each instrument, both
in the type of gas and in the concentration of the gas being generated. The
microprocessor reads the type of gas and the ppm output of the cell from a
memory chip embedded in the cell body. It then adjusts the current for the
proper gas output. For a complete list of correct cell part numbers, please
refer to the parts list at the end of this manual.
To replace the generating cell in the instrument, press down rmly on the
'cell eject' button at the top of the instrument.. The generating cell plugs
directly up into the cell chamber. Ensure that the pads on the cell board
align with the corresponding pins on the pump board. Care must be taken
when replacing the cell to ensure that the locating pin seats in the alignment
hole of the cell.
Make sure to line up the electrode pins with the corresponding sockets. Do
not force the cell into the cell chamber if it is not properly aligned, otherwise
the pins may become damaged rendering the cell and/or instrument useless.
Note: The generating cells contain very small amounts of acidic
solution and should be disposed of as per local regulations. For more
information, please contact the factory.

VI. CORRECTIONS TO VOLUMETRIC FLOW
Changes in altitude and temperature can cause changes in air density,
thus affecting the output of the CAL-101. The output of the CAL-101 was
calibrated to STP (standard temperature and pressure) of sea level and
20°C. To compensate for differences in altitude or temperature from STP,
the following tables should be utilized:
Note: Altitude and Temperature are cumulative, i.e., you must correct
for both factors to obtain the most accurate calibration.
Altitude Correction Table Temperature Correction Table
Altitude Corrected Out-
put (multiply by)
Temperature
(°C) Corrected (multiply by)
0 1.000 -30 0.829
1000 1.038 -20 0.863
2000 1.076 -10 0.898
3000 1.116 0 0.932
4000 1.158 10 0.966
5000 1.202 20 1.000
6000 1.248 30 1.034
40 1.068
50 1.102
Example:
At 3200 feet with a temperature of 29°C. The corrected volumetric ow
rate is
.5 LPM x 1.116 x 1.034 = .577 LPM (volumetric)
Page 9

Page 10
VII. MAINTENANCE
CAUTION
Both the electrochemical cell and the alkaline batteries used in the
CAL-101 instrument contain corrosive chemicals. While it is not
expected that the chemicals in the cell or alkaline batteries will leak
during normal operation, it is recommended that both the cell and
the batteries be removed from the instrument if it is being stored for
periods longer than one week between use.
VIII. ACCESSORY ITEMS/ PARTS LIST
The following items and spare parts are available for the CAL-101:
Part Number Description
113-0400-00 Quick connect outlet tting, body,
panel mount
400-0000-00 Circuit board for CAL-101
Processor
400-0001-00 Circuit board for CAL-101 Interface
400-0002-00 Circuit board for CAL-101 pump
assy
510-0101-00 Chlorine generation cell, 2 hour,
specify ppm
510-0101- 05 Hydrogen sulde generation cell, 2
hour, specify ppm
510-0101- 07 Hydrogen cyanide generation cell,
2 hour, specify ppm
510-0101-09 Hydrogen generation cell, 2 hour,
specify ppm
510-0102-00 BUMP Chlorine generation cell, 2
hour, specify ppm
510-0102- 05 BUMP Hydrogen sulde generation
cell, 2 hour, specify ppm
510-0102- 07 BUMP Hydrogen cyanide
generation cell, 2 hour, specify ppm
510-0102-09 BUMP Hydrogen generation cell, 2
hour, specify ppm
730-0101-00 Hard-body, water proof, padded
accessory case
910-0601-00 Instruction manual, CAL-101

IX. STANDARD WARRANTY
We warrant gas calibration equipment manufactured and sold by us to be
free from defects in materials, workmanship and performance for a period
of one year from date of shipment. Any parts found defective within that
period will be repaired or replaced, at our option, free of charge, F.O.B.
factory. This warranty does not apply to those items which by their nature
are subject to deterioration or consumption in normal service, and which
must be cleaned, repaired, or replaced on a routine basis.
Such items may include:
a. Electrochemical type generating cells
b. Batteries
Warranty is voided by abuse including rough handling, mechanical damage,
alteration, or repair procedures not in accordance with the instruction
manual. This warranty indicates the full extent of our liability, and we
are not responsible for removal or replacement cost, local repair costs,
transportation costs or contingent expenses incurred without our prior
approval.
Advanced Calibration Designs, Inc.’s obligation under this warranty shall
be limited to repairing or replacing, and returning any product which shall
be returned to Advanced Calibration Designs, Inc. at its manufacturing
facilities, with transportation charges prepaid, and which Advance Calibration
Designs, Inc.’s Material Review Board examination shall disclose to its
satisfaction to have been defective.
This warranty is expressed in lieu of any and all other warranties and
representations, expressed or implied, and all other obligations or liabilities
on the part of Advanced Calibration Designs, Inc. including, but not limited to,
the warranty of tness for a particular purpose. In no event shall Advanced
Calibration Designs, Inc. be liable for direct, incidental or consequential loss
or damage of any kind connected with the use of its products or failure of
its products to function or operate properly.
The following is a listing of the available electrochemical CAL-101 cells
and their standard warranty when installed in equipment manufactured and
supplied by Advanced Calibration Designs, Inc.
Chlorine, Hydrogen, Hydrogen Sulde, and Hydrogen Cyanide
- 2 Hour Cell - 2 hour of use
Page 11

Page 12
Manufactured by:
Advanced Calibration Designs, Inc.
2024 W. McMillan St.
Tucson, Arizona 85705 USA
Phone: [phone] - Fax: [phone]
Int'l Phone: [phone] - Fax: [phone]
Web site: www.GoACD.com - E-mail: [email protected]

2024W.McMillanSt.
Tucson,Arizona85705USA
Telephone:[phone]
Fax:[phone]
Toll Free:[phone]
Email:[e-mail]
Web:www.goACD.com
P/N 910-0601-00
AdvancedCalibrationDesigns,Inc.
InstructionManual
CalibrationGasGenerator
AdvancedCalibrationDesigns,Inc.
CAL-101