Met One Instruments CAL-200 User manual

USER MANUAL
metone.com
CAL-200
Dilution Calibrator
Version 1.0

Met One Instruments is now part of the Acoem Group. The Met One
range of gas analyzers was originally developed by Acoem under
the brand name Ecotech Serinus® Cal 1000, 2000 & 3000.
For the purposes of expediting the availability of Met One gas
analyzers to Met One customers around the world; Met One
Instruments have chosen to use the original Ecotech Serinus® Cal
1000, 2000 & 3000 operating manual.
Although the name of the Met One instrument is dierent, the
analyzer itself has remained unchanged and meets the strictest
quality and performance requirements expected of Met One
equipment. All the information presented in this manual is current,
including analyzer specications and operating principles.
Met One will update this manual to reflect the new branding
convention in due course.

Serinus Cal 1000, 2000 & 3000 User Manual 1.0
Page 3
Table of Contents
Manufacturer’s Statement ...........................................................................................................................................10
Safety Requirements ....................................................................................................................................................11
Warranty.......................................................................................................................................................................11
Service and Repairs.......................................................................................................................................................12
Service Guidelines ............................................................................................................................................12
CE Mark Declaration of Conformity..............................................................................................................................13
Claims for Damaged Shipments and Shipping Discrepancies .......................................................................................14
Damaged Shipments ........................................................................................................................................14
Shipping Discrepancies.....................................................................................................................................14
Contact Details .................................................................................................................................................14
Internationally Recognised Symbols on Ecotech Equipment........................................................................................15
Manual Revision History...............................................................................................................................................16
1Introduction....................................................................................................................... 17
1.1 Description .......................................................................................................................................................17
1.2 Specifications ...................................................................................................................................................17
1.2.1 Dilution & Span Flows..........................................................................................................................17
1.2.2 Power...................................................................................................................................................18
1.2.3 Operating Conditions...........................................................................................................................18
1.2.4 Communications..................................................................................................................................18
1.2.5 Physical Dimension ..............................................................................................................................19
1.2.6 Ozone Generator [Serinus Cal 2000] ...................................................................................................19
1.2.7 Photometer [Serinus Cal 3000]............................................................................................................19
1.3 Nomenclature ..................................................................................................................................................20
1.4 Background/Theory..........................................................................................................................................21
1.4.1 Dilution Theory ....................................................................................................................................21
1.4.2 Ozone Photometer Theory [Serinus Cal 3000] ....................................................................................22
1.4.3 Explanation Photometer Transfer Standards.......................................................................................23
1.5 Instrument Description ....................................................................................................................................24
1.5.1 Common Components.........................................................................................................................24
1.5.2 Serinus Cal 1000 Components .............................................................................................................27
1.5.3 Serinus Cal 2000 Components .............................................................................................................28
1.5.4 Serinus Cal 3000 Components .............................................................................................................30
2Installation......................................................................................................................... 37
2.1 Initial Check......................................................................................................................................................37
2.1.1 Packaging.............................................................................................................................................37
2.1.2 Manual Handling..................................................................................................................................37
2.1.3 Opening the Instrument ......................................................................................................................37
2.1.4 Items Received.....................................................................................................................................38
2.2 Installation Notes .............................................................................................................................................39
2.3 Instrument Set-up ............................................................................................................................................39
2.3.1 Setting-up a Serinus Cal .......................................................................................................................39
2.3.2 Setting-up a Serinus Cal 3000 ..............................................................................................................40
2.3.3 Pneumatic Connections .......................................................................................................................41
2.3.4 Power Connection ...............................................................................................................................42
2.3.5 Diluent Gas ..........................................................................................................................................42

Serinus Cal 1000, 2000 & 3000 User Manual 1.0
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2.3.6 Source Gas........................................................................................................................................... 43
2.3.7 Output Ports........................................................................................................................................ 43
2.3.8 Exhaust Port ........................................................................................................................................ 43
2.3.9 Purge for Gas Lines.............................................................................................................................. 43
2.3.10 Communications Connections............................................................................................................. 44
2.4 Transporting/Storage....................................................................................................................................... 44
3Operation ...........................................................................................................................47
3.1 Warm-Up ......................................................................................................................................................... 47
3.2 Theory of Operation ........................................................................................................................................ 47
3.2.1 Running a Point or Sequence .............................................................................................................. 48
3.2.2 Operation ............................................................................................................................................ 48
3.3 General Operation Information ....................................................................................................................... 61
3.3.1 Keypad & Display................................................................................................................................. 61
3.4 Home Screen ................................................................................................................................................... 63
3.5 Menus & Screens ............................................................................................................................................. 64
3.5.1 Quick Menu......................................................................................................................................... 64
3.5.2 Mode................................................................................................................................................... 65
3.5.3 Main Menu.......................................................................................................................................... 65
3.5.4 Gas Supply Menu ................................................................................................................................ 66
3.5.5 Edit Gas Standards Menu .................................................................................................................... 66
3.5.6 Edit Gas Standard Menu...................................................................................................................... 67
3.5.7 Points & Sequencing Menu ................................................................................................................. 67
3.5.8 Define Points Menu............................................................................................................................. 67
3.5.9 Define Point Menu .............................................................................................................................. 67
3.5.10 Define Sequences Menu ..................................................................................................................... 70
3.5.11 Define Sequence Menu ....................................................................................................................... 70
3.5.12 Manual Operation Menu..................................................................................................................... 71
3.5.13 Manual Point Menu ............................................................................................................................ 71
3.5.14 Manual Flow Menu ............................................................................................................................. 72
3.5.15 Analyser State Menu ........................................................................................................................... 72
3.5.16 Status Menu ........................................................................................................................................ 73
3.5.17 Temperature Menu............................................................................................................................. 75
3.5.18 Pressure & Flow Menu ........................................................................................................................ 75
3.5.19 Voltage Menu...................................................................................................................................... 76
3.5.20 General Settings Menu........................................................................................................................ 76
3.5.21 Calibration Menu ................................................................................................................................ 77
3.5.22 Pressure Calibration Menu.................................................................................................................. 77
3.5.23 Ozone Calibration Menu ..................................................................................................................... 77
3.5.24 MFC Calibration Menu ........................................................................................................................ 78
3.5.25 Service Menu....................................................................................................................................... 78
3.5.26 Diagnostics Menu................................................................................................................................ 79
3.5.27 Digital Pots Menu................................................................................................................................ 79
3.5.28 Internal Pump Menu ........................................................................................................................... 80
3.5.29 Valve Menu ......................................................................................................................................... 81
3.5.30 Tests Menu.......................................................................................................................................... 82
3.5.31 Digital Input Test Menu....................................................................................................................... 82
3.5.32 Digital Output Test Menu.................................................................................................................... 82
3.5.33 Calculation Factors Menu.................................................................................................................... 82
3.5.34 Communications Menu ....................................................................................................................... 83
3.5.35 Data Logging Menu ............................................................................................................................. 83
3.5.36 Serial Communication Menu............................................................................................................... 84

Serinus Cal 1000, 2000 & 3000 User Manual 1.0
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3.5.37 Analog Input Menu ..............................................................................................................................84
3.5.38 Analog Output Menu ...........................................................................................................................85
3.5.39 Digital Output Menu ............................................................................................................................86
3.5.40 Network Menu.....................................................................................................................................87
3.5.41 Bluetooth Menu...................................................................................................................................88
3.5.42 Advanced Menu...................................................................................................................................88
3.5.43 Hardware Menu...................................................................................................................................89
3.5.44 MFC Installation Menu ........................................................................................................................89
3.5.45 Parameter Display Menu .....................................................................................................................90
4Communications................................................................................................................ 91
4.1 RS232 Communication .....................................................................................................................................91
4.2 USB Communication ........................................................................................................................................92
4.3 TCP/IP Network Communication (optional) .....................................................................................................92
4.3.1 Network Setup.....................................................................................................................................94
4.3.2 Port Forwarding on Remote Modem/Router Setup ............................................................................94
4.3.3 Airodis Setup to Communicate with Serinus .......................................................................................95
4.4 Digital/Analog Communication ........................................................................................................................95
4.4.1 Analog Outputs....................................................................................................................................96
4.4.2 Analog Inputs.......................................................................................................................................97
4.4.3 Digital Status Outputs..........................................................................................................................97
4.4.4 Digital Status Outputs..........................................................................................................................97
4.5 Logging Data.....................................................................................................................................................99
4.5.1 Configure Instrument Internal Logging................................................................................................99
4.6 Using Airodis Software to Download Data .......................................................................................................99
4.6.1 Connecting the Serinus to your PC ......................................................................................................99
4.6.2 Installing Airodis ................................................................................................................................102
4.6.3 Configuring Airodis ............................................................................................................................102
4.7 Serinus Remote App/Bluetooth .....................................................................................................................108
4.7.1 Installation .........................................................................................................................................108
4.7.2 Connecting to the Instrument ...........................................................................................................109
4.7.3 Control Serinus Instrument................................................................................................................110
4.7.4 Real-Time Plot....................................................................................................................................111
4.7.5 Download...........................................................................................................................................112
4.7.6 Get Parameters..................................................................................................................................113
4.7.7 Preferences........................................................................................................................................114
5Calibration ....................................................................................................................... 117
5.1 MFC Calibration..............................................................................................................................................117
5.1.1 MFC Pre Calibration Setup.................................................................................................................119
5.1.2 MFC Calibration .................................................................................................................................119
5.2 Ozone Flow Calibration ..................................................................................................................................119
5.3 Pressure Calibration .......................................................................................................................................121
5.4 Ozone Generator Characterisation –Serinus Cal 2000 ..................................................................................122
5.5 Ozone Generator Characterisation –Serinus Cal 3000 ..................................................................................123
5.6 Photometer Calibration –Serinus Cal 3000 ...................................................................................................123
5.6.1 Photometer Pre Check.......................................................................................................................123
5.6.2 Photometer Calibration .....................................................................................................................124
6Service ............................................................................................................................. 125
6.1 Plumbing Schematic .......................................................................................................................................125
6.1.1 Plumbing Schematic Serinus Cal 1000 ...............................................................................................125

Serinus Cal 1000, 2000 & 3000 User Manual 1.0
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6.1.2 Plumbing Schematic Serinus Cal 2000............................................................................................... 126
6.1.3 Plumbing Schematic Serinus Cal 3000............................................................................................... 127
6.2 Maintenance Tools ........................................................................................................................................ 127
6.3 Maintenance Schedule .................................................................................................................................. 129
6.4 Maintenance Procedures............................................................................................................................... 129
6.4.1 Leak Check Serinus Cal 3000 ............................................................................................................. 129
6.4.2 UV Lamp Check Serinus Cal 3000 ...................................................................................................... 133
6.4.3 Cleaning............................................................................................................................................. 134
6.5 Bootloader..................................................................................................................................................... 134
6.5.1 Display Help Screen........................................................................................................................... 135
6.5.2 Communications Port Test ................................................................................................................ 135
6.5.3 Updating Firmware ........................................................................................................................... 135
6.5.4 Updating Firmware from USB Memory Stick .................................................................................... 135
6.5.5 Erase All Settings ............................................................................................................................... 136
6.5.6 Start Calibrator.................................................................................................................................. 136
7Troubleshooting...............................................................................................................137
7.1.1 Main Screen Error Messages............................................................................................................. 137
7.1.2 Ecotech Service Support Files –Backup Configuration and Parameters to USB ............................... 137
8Optional Extras.................................................................................................................139
8.1 Rack Mount Kit PN (E020116)........................................................................................................................ 139
8.2 TCP/IP PN (E020101)...................................................................................................................................... 143
8.3 Additional Source Ports PN (E020314) .......................................................................................................... 143
8.4 Additional Diluent Port PN (E020315) ........................................................................................................... 143
8.5 Second Source MFC PN (E020318-XX) ........................................................................................................... 143
8.6 Second Diluent MFC PN (E020316-XX) .......................................................................................................... 143
9Spare Parts and Schematics .............................................................................................145
9.1 Maintenance Kit PN (E020321, E020322, E020323) ...................................................................................... 145
9.2 Serinus Cal Service Kit.................................................................................................................................... 146
9.3 Consumables ................................................................................................................................................. 146
9.4 Instrument Parts List...................................................................................................................................... 147
9.5 Plumbing Schematic –D020034 .................................................................................................................... 150
9.6 Plumbing Schematic –D020035 .................................................................................................................... 151
9.7 Plumbing Schematic –D020036 .................................................................................................................... 152
9.8 Block Wiring Schematic –D020037 ............................................................................................................... 153
9.9 Block Wiring Schematic –D020038 ............................................................................................................... 154
9.10 Block Wiring Schematic –D020039 ............................................................................................................... 155
9.11 Valve Manifold............................................................................................................................................... 156
9.12 Mixing Manifold –H013185 .......................................................................................................................... 157
9.13 Mixing Manifold –H013185-01 ..................................................................................................................... 158
9.14 Photometer –H013100-01 ............................................................................................................................ 159
9.15 Bullet Valve –H010058.................................................................................................................................. 160

Serinus Cal 1000, 2000 & 3000 User Manual 1.0
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List of Figures
Figure 1 –Dilution Theory for Serinus Cal..............................................................................................22
Figure 2 –Ozone Transfer Standard Hierarchy......................................................................................24
Figure 3 –Solenoid Bullet Valve Operation ...........................................................................................25
Figure 4 –Serinus Cal 1000 Layout ........................................................................................................27
Figure 5 –Serinus Cal 2000 Layout ........................................................................................................28
Figure 6 –Ozone Generator Assembly...................................................................................................29
Figure 7 –Mixing Manifold Serinus Cal 2000.........................................................................................30
Figure 8 –Serinus Cal 3000 Layout ........................................................................................................31
Figure 9 –Mixing Manifold Serinus 3000...............................................................................................32
Figure 10 –Ozone Generator Assembly.................................................................................................33
Figure 11 –Flow Block Assembly ...........................................................................................................34
Figure 12 –Photometer Assembly .........................................................................................................35
Figure 13 –Lamp Type DIP Switch Setting.............................................................................................36
Figure 14 –Opening the Instrument......................................................................................................38
Figure 15 –Serinus Cal Back Panel.........................................................................................................39
Figure 16 –Installation of USB Memory Stick........................................................................................40
Figure 17 –Connecting the Output and Exhaust Ports Serinus Cal 3000 Only......................................41
Figure 18 –Switching the Battery On/Off..............................................................................................41
Figure 19 –Edit Gas Standard Menu (Example 1)..................................................................................49
Figure 20 –Gas Supply Menu (Example 1).............................................................................................49
Figure 21 –Gas Dilution Point Setup (Example 1)..................................................................................50
Figure 22 –Home Screen Running EXE 01 Point....................................................................................50
Figure 23 –Zero Point Setup..................................................................................................................51
Figure 24 –Home Screen Running EXE 02 Point....................................................................................52
Figure 25 –Edit Gas Standard Menu (Example 3)..................................................................................52
Figure 26 –Source Control Setup...........................................................................................................53
Figure 27 –Home Screen Running EXE 03 Point....................................................................................53
Figure 28 –Edit Gas Standard Menu (Example 4)..................................................................................54
Figure 29 –Gas Supply Menu (Example 4).............................................................................................55
Figure 30 –Titration Setup, with Ozone ................................................................................................56
Figure 31 –Home Screen Running EXE 04 Point....................................................................................56
Figure 32 –Titration Setup, without Ozone...........................................................................................56
Figure 33 –Home Screen Running EXE 05 Point....................................................................................57
Figure 34 –O3 Generator Setup ............................................................................................................58
Figure 35 –Home Screen Running EXE 06 Point....................................................................................58
Figure 36 –O3 Gen/Photometer Setup .................................................................................................59
Figure 37 –Home Screen Running EXE 07 Point....................................................................................60
Figure 38 –Titration Sequence Setup ....................................................................................................60
Figure 39 –Home Screen Running GPT 1 Sequence ..............................................................................61
Figure 40 –Front Panel ..........................................................................................................................61
Figure 41 –Home Screen .......................................................................................................................63
Figure 42 –Communication Ports..........................................................................................................91
Figure 43 –Multidrop RS232 Cable Example .........................................................................................92
Figure 44 –Example of Typical Network Setups....................................................................................93

Serinus Cal 1000, 2000 & 3000 User Manual 1.0
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Figure 45 –Example of Network Menu Setup....................................................................................... 94
Figure 46 –Port Forwarding Example ................................................................................................... 94
Figure 47 –LAN Network Set-Up (Airodis) ............................................................................................ 95
Figure 48 –WAN Network Set-Up (Airodis) .......................................................................................... 95
Figure 49 –25 Pin Rear Panel PCA (Default Jumpers Highlighted) ....................................................... 98
Figure 50 –External 25 Pin I/O Individual Pin Descriptions .................................................................. 98
Figure 51 –Installing Driver Software (Device Manager)...................................................................... 99
Figure 52 –Update Driver Popup ........................................................................................................ 100
Figure 53 –Update Driver Popup (Directory Location)....................................................................... 100
Figure 54 –Installing Driver Confirmation Prompt ............................................................................. 101
Figure 55 –Successful Driver Installation............................................................................................ 101
Figure 56 –Airodis Workspace Manager ............................................................................................ 103
Figure 57 –Adding a New Station ....................................................................................................... 103
Figure 58 –Adding a New Station ....................................................................................................... 104
Figure 59 –Station Configuration (Channel List)................................................................................. 105
Figure 60 –Error Status Notification................................................................................................... 105
Figure 61 –Downloading Data ............................................................................................................ 106
Figure 62 –Download Data Status ...................................................................................................... 106
Figure 63 –Data Visibility .................................................................................................................... 107
Figure 64 –Exporting Data .................................................................................................................. 107
Figure 65 –Data Download Complete................................................................................................. 108
Figure 66 –Downloading the App from Google Play Store................................................................. 109
Figure 67 –Bluetooth Pairing Request................................................................................................ 109
Figure 68 –Showing or Hiding the NumPad........................................................................................ 110
Figure 69 –Switching Analysis............................................................................................................. 111
Figure 70 –Real-Time Plot................................................................................................................... 112
Figure 71 –Plot of Downloaded Data.................................................................................................. 113
Figure 72 –Directory Settings ............................................................................................................. 114
Figure 73 –Logs Format ...................................................................................................................... 114
Figure 74 –Colour Theme Settings...................................................................................................... 115
Figure 75 –MFC Calibration Setup...................................................................................................... 118
Figure 76 –Port G: Test Flow Meter Shown Connected ..................................................................... 120
Figure 77 –Ozone Flow Calibration 80 sccm....................................................................................... 120
Figure 78 –Ozone Flow Calibration 80 sccm....................................................................................... 121
Figure 79 –Disconnect inlet of Photometer ....................................................................................... 122
Figure 80 –Solenoid Bullet Valve Operation....................................................................................... 125
Figure 81 –Serinus Cal 1000 Plumbing Schematic.............................................................................. 126
Figure 82 –Serinus Cal 2000 Plumbing Schematic.............................................................................. 126
Figure 83 - Serinus Cal 3000 Plumbing Schematic............................................................................... 127
Figure 84 –Minifit Extraction Tool –T030001 .................................................................................... 128
Figure 85 –Orifice Removal Tool –H010046 ...................................................................................... 128
Figure 86 –Leak Check Jig –H050069................................................................................................. 128
Figure 87 –Air Monitoring Test Equipment Kit (AMTEK) - Customisable........................................... 128
Figure 88 –Isolate Pressure Regulator................................................................................................ 130
Figure 89 –Leak Check: Manual Point Setup ...................................................................................... 130

Serinus Cal 1000, 2000 & 3000 User Manual 1.0
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Figure 90 –Leak Check: Full Test .........................................................................................................130
Figure 91 –Leak Check: Pump Bypass..................................................................................................131
Figure 92 –Leak Check: Isolate Photometer Valve States ...................................................................131
Figure 93 –Leak Check: Isolate Photometer Schematic ......................................................................132
Figure 94 –Leak Check: Isolate MFC’s Schematic................................................................................133
Figure 95 –Location of UV Lamp Fastening Grub Screw .....................................................................134
Figure 96 –Serinus Cal Memory USB File Structure ............................................................................138
Figure 97 –Separate Rack Slides..........................................................................................................139
Figure 98 –Assemble Inner Slide on Chassis .......................................................................................140
Figure 99 –Rack Mount Ears Fitted to Analyser ..................................................................................140
Figure 100 –Attach Rack Mount Adaptors to Outer Slides .................................................................141
Figure 101 –Test Fit the Rack Slide Assembly into your Rack .............................................................141
Figure 102 –Attach Slides to Front of Rack .........................................................................................142
Figure 103 –Slide Clips.........................................................................................................................143
List of Tables
Table 1 –Manual Revision History.........................................................................................................16
Table 2 –Digital Output States ..............................................................................................................86
Table 3 –Analog Outputs.......................................................................................................................96
Table 4 –Setting up a New Station via Airodis ....................................................................................104
Table 5 –Options Menu.......................................................................................................................111
Table 6 –Maintenance Schedule .........................................................................................................129
Table 7 –Serinus Cal 1000 Maintenance Kit (E020321).......................................................................145
Table 8 –Serinus Cal 2000 Maintenance Kit (E020322).......................................................................145
Table 9 –Serinus Cal 3000 Maintenance Kit (E020323).......................................................................145
Table 10 –Serinus Accessories Kit .......................................................................................................146
Table 11 –Serinus Cal Consumables....................................................................................................146
Table 12 –Instrument Parts List...........................................................................................................147
Table 13 –Advanced Protocol Parameter List .....................................................................................161
Table 14 –Native Serial Commands.....................................................................................................172
List of Appendices
Appendix A. Advanced Protocol Parameter List ..................................................................................161
Appendix B. Modbus Protocol .............................................................................................................171
Appendix C. Gascal Protocol ................................................................................................................172
Appendix D. Beer-Lambert Law............................................................................................................174

Serinus Cal 1000, 2000 & 3000 User Manual 1.0
Page 10
Manufacturer’s Statement
The Serinus Cal is designed primarily as a Dilution Calibrator used in conjunction with gas cylinders to
supply precise concentrations of span gas to gas analysers.
This User Manual provides a complete product description including operating instructions,
calibration, and maintenance requirements for the Serinus Cal 1000, 2000 & 3000.
Reference should also be made to the relevant local standards, which should be used in conjunction
with this manual. Some of these standards are listed in this manual.
If, after reading this manual you have any questions or you are still unsure or unclear on any part of
the Serinus Cal 1000, 2000 & 3000, please do not hesitate to contact Ecotech or your local Ecotech
distributor.
Please help the environment and recycle the pages of this manual when
you have finished using it.
Notice
The information contained in this manual is subject to change without notice. Ecotech reserves the
right to make changes to equipment construction, design, specifications and /or procedures without
notice.
Copyright © 2015 All rights reserved. Reproduction of this manual, in any form, is prohibited without
the written consent of Ecotech Pty Ltd.
CAUTION
Hazardous voltages exist within the calibrator. Do not remove or modify any of the
internal components or electrical connections whilst the mains power is on.
Ensure the mains power lead is maintained in a safe working condition.
The analyser lid should be closed during normal operation to comply with EMC
regulations.
CAUTION
The Serinus Cal 2000 and 3000 contain UV Lamps that emit harmful UV radiation. Be sure
to turn the instrument power off during UV lamp replacement or use UV protective
eyewear if necessary to adjust the lamps whilst operating.