Sabio 2010D User manual

MODEL 2010D
GAS DILUTION CALIBRATOR
OPERATIONS MANUAL
I N S T R U M E N T S

MODEL 2010D OPERATIONS MANUAL
________________________________________________________________
COPYRIGHT
Copyright 2004-2013, Sabio Instruments, Inc. All rights
reserved. However, any part of this document may be reproduced
for Sabio Instruments, Inc. customer usage with Sabio
Instruments, Inc. cited as the source.
NOTICE TO USER
The information in this manual has been carefully checked and is
believed to be accurate. However, Sabio Instruments, Inc.
assumes no responsibility for any inaccuracies that may be
contained in this manual. In no event will Sabio Engineering,
Inc. be liable for direct, indirect, special, incidental or
consequential damages resulting from any defect or omission in
this manual, even if advised of the possibility of such damages.
The contents of this manual and the specifications herein may
change without notice or obligation.
GOVERNING LAW
Laws of the state of Texas, USA govern this agreement.
The information presented in this manual is for reference only.
This manual may contain or reference information and products
that may be protected by copyrights and/or patents. No license
is conveyed under the rights of Sabio Instruments, Inc. or
others.

Table of Contents
Section 1 Introduction.................................... 1-1
User Benefits .......................................... 1-1
Standard Features ....................................... 1-3
Optional Features ....................................... 1-3
Model 2010D Gas Dilution Calibrator Specifications ....... 1-4
Section 2 Getting Started ................................ 2-1
Unpacking and Power Application ......................... 2-1
Start-Up ................................................ 2-1
Standby Operation Upon Power Up ......................... 2-1
User Interface .......................................... 2-1
Initial Configuration of the Model 2010D ................. 2-3
System Operation and Maintenance Precautions ............ 2-3
Section 3 System Operations .............................. 3-1
Front Panel Guide ....................................... 3-1
Main Screen Layout ...................................... 3-8
Main Menu Topics ........................................ 3-11
Using the 2010D Screens .................................. 3-12
Edit Screens ............................................ 3-13
Section 4 Installation.................................... 4-1
Placement ............................................... 4-1
Environment ............................................. 4-1
Source Gas Cylinder Selection ........................... 4-2
Diluent Selection ....................................... 4-4
Source and Diluent Port Usage ........................... 4-4
Dilution Calibrator Pneumatic Connections ............... 4-5
Power ................................................... 4-7
Parallel Printer Data Port .............................. 4-7
Keyboard Port ........................................... 4-9
RS-232 Serial Communications Port 1 ..................... 4-9
RS-232 Serial Communications Port 2 ..................... 4-10
RS-232 Serial Communications Cable, Model 2010D to PC..... 4-10
RS-232 Serial Communications Cable, Model 2010D to Modem . 4-11
Status Input/Output Port ................................ 4-12
Instrument Audit Analog Input/Output Port ............... 4-13
Air Source Activation Port .............................. 4-14
Ethernet Port ........................................... 4-15
USB Host Port ........................................... 4-15

Section 5 Operation ...................................... 5-1
Performing Automatic Calibrations ....................... 5-1
Calibrating Multiple Analyzers in One Calibration ....... 5-1
Performing Manual Calibrations .......................... 5-2
Predefined Operator Stepped Manual Calibration .......... 5-2
Timer Stepped Manual Calibration ........................ 5-4
Viewing Calibration Status .............................. 5-5
Performing Manual Calibrations using the Status Screen 5-7
Viewing Diagnostic Information ........................ 5-10
The Analog Input Screen ................................. 5-10
The Analog Output Screen ............................... 5-11
The Internal Control Outputs and User Digital I/O Bits .. 5-11
Section 6 Model 2010D Calibration Set-Up .................. 6-1
Set Up Gases ............................................ 6-2
Set Up Gas Standards ................................... 6-3
Diluent and Source Port Assignments .................... 6-4
Introduction to Initializing Calibration Sequences ...... 6-6
Defining Calibration Sequences .......................... 6-8
Setting up Sequence Points for Single-Gas Sequences
(Page 2 and 3) .......................................... 6-11
Setting up Sequence Points for Multi-Gas Sequences
(Page 2 and 5) .......................................... 6-14
Auto Calibration Set-up ................................. 6-19
Scheduling Automatic Calibrations ....................... 6-20
Digital I/O Group Set-up ................................ 6-21
Assigning Sequence Start Patterns ....................... 6-24
Assigning Point Start Patterns .......................... 6-25
Setting the Time and Date ............................... 6-27
Section 7 Serial Communications........................... 7-1
Operating Modes ........................................ 7-1
Prerequisites ........................................... 7-2
Configuring the Modem ................................... 7-3
Setting Up the Com Ports ................................ 7-4
Setting Up the Remote Terminal .......................... 7-6
Setting Up the Command Protocol ......................... 7-7
Configuring the Computer for Terminal Mode............... 7-9
Operating the Model 2010D Remotely using Terminal Mode.... 7-11
Disconnecting ........................................... 7-12
Operating the Model 2010D Remotely using Command Mode..... 7-13
The Monitor Labs Protocol ............................... 7-13
Number Representation (Floating Point) .................. 7-14
Digital Word Representation ............................. 7-14
Command Structure ....................................... 7-15
Starting and Ending Commands ............................ 7-15
Command Words ........................................... 7-15
Calibrator Address ...................................... 7-16
Data Fields ............................................. 7-16
Data Verification Fields ................................ 7-16

Response Structure ...................................... 7-18
Commands ................................................ 7-19
Monitor Labs Commands ................................... 7-19
Common Data and Parameter Fields for Commands ........... 7-19
Command Summary.......................................... 7-20
Error Codes ............................................. 7-20
Stop (S) ................................................ 7-21
Purge (P) ............................................... 7-21
Timed Sequence (TS) ..................................... 7-23
Manual Sequence (MS)..................................... 7-23
Get Status (GS) ......................................... 7-24
Section 8 Internal Calibrations............................ 8-1
Viewing Calibration Data ................................ 8-5
Manually Entering Polynomial Coefficients ............... 8-5
Manually Entering a Calibration Table ................... 8-6
Performing an Interactive Calibration ................. 8-7
Editing Calibration Data ................................ 8-8
Selecting Device Parameters ............................ 8-9
Interactively Calibrating Mass Flow Controllers ......... 8-9
Interactively Calibrating the Ozone Generator ........... 8-11
Section 9 Internal UV Ozone Photometer..................... 9-1
Description ............................................. 9-1
Theory of Operation ..................................... 9-1
Installation ............................................ 9-3
Operation ............................................... 9-3
Setup Options ........................................... 9-9
Photometer Calibration .................................. 9-17
Ozone Servo Control Adjustments ........................ 9-19
Routine Maintenance ..................................... 9-21
Leak Check .............................................. 9-22
Photometer Flow Check / Adjustment ...................... 9-23
Schematics
Flow Diagram ............................................ S-1
Warranty

List of Figures
2-1 Main Menu .......................................... 2-2
3-1 The Model 2010DFront Panel ......................... 3-2
3-2 The Main Screen .................................... 3-8
3-3 External Keyboard Shortcuts in Terminal Mode ....... 3-9
3-4 Examples of Data Entry Fields ...................... 3-13
4-1 Rear Panel ......................................... 4-6
5-1 Manual Sequence Selection Menu ..................... 5-3
5-2 The "Select a Point to Run" Screen ................. 5-3
5-3 The Sequence Status Screen ......................... 5-4
5-4 The Idle Status Screen ............................. 5-6
5-5 The Dilution Status Screen ......................... 5-6
5-6 The Ozone Status Screen ............................ 5-7
5-7 The GPT Status Screen .............................. 5-7
5-8 The Analog Input Diagnostic Screen ................. 5-10
5-9 The Analog Output Diagnostic Screen ................ 5-11
5-10 The Internal Control Outputs Diagnostic Screen ..... 5-12
5-11 The User Digital I/O Bits Diagnostic Screen ........ 5-12
6-1 New Gas Screen ..................................... 6-2
6-2 New Gas Standard Screen ............................ 6-3
6-3 Edit Port Assignments Screen ....................... 6-5
6-4 New Sequence Screen, Page 1 ....................... 6-8
6-5 New Sequence Screen (Single Gas, Page 2 of 3) ...... 6-11
6-6 New Sequence Screen (Multi-gas, Page 2 of 5) ....... 6-14
6-7 New Sequence Screen (Multi-gas, Page 3 of 5) ....... 6-17
6-8 The Edit Sequence Schedules Screen ................. 6-20
6-9 The Edit Digital I/O Group Assignments Screen ...... 6-23
6-10 Sequence Start Remote Activation Patterns Screen ... 6-24
6-11 Point Start Remote Activation Patterns Screen ...... 6-26
6-12 Set System Clock Screen ............................ 6-27
7-1 Port Set-up Screen ................................. 7-5
7-2 Remote Terminal Setup Screen ....................... 7-7
7-3 Command Model Setup Screen ......................... 7-7
7-4 File Transfer Status Screen ........................ 7-12
8-1 Comparison of Linearization Methods ................ 8-4
8-2 Calibration Menu ................................... 8-5
8-3 New Calibration Coefficients ....................... 8-6
8-4 New Calibration Table .............................. 8-6
8-5 Interactive Calibration ............................ 8-8
8-6 Device Parameters .................................. 8-9
8-7 Interactive Ozone Calibration ...................... 8-13
9-1 The Ozone Status Screen ............................ 9-4
9-2 The Photometer Diagnostic Screen, General .......... 9-6
9-3 The Photometer Diagnostic Screen, Detailed ......... 9-8
9-1 Ozone Status Screen ............................... 9-4
9-2 Photometer Diagnostics Screen, General ............ 9-6
9-3 Photometer Diagnostics Screen, Detailed ........... 9-8
9-4 Photometer Parameters, Page 1 of 3 ................ 9-10
9-5 Photometer Parameters, Page 2 of 3 ................. 9-13
9-6 Photometer Parameters, Page 3 of 3 ............... 9-15
9-7 Photometer, Edit Calibration Table ................. 9-17
9-8 Photometer, Interactive Calibration ................ 9-17
9-9 Photometer, Leak Check Setup ....................... 9-23
9-10 Photometer, Flow Check / Adjustment ................ 9-24

List of Tables
4-2 Parallel Printer Port Connections .................. 4-8
4-3 External Keyboard Port Connections ............. ... 4-9
4-4 Communications Port 1 Connections .................. 4-9
4-5 Communications Port 2 Connections .................. 4-10
4-6 Model 2010D to PC Connections ....................... 4-11
4-7 Model 2010D to Modem Connections .................... 4-11
4-8 Status Input/Output Port Connections ............... 4-12
4-9 Audit Port Connections ............................. 4-13
4-10 Air Source Activation Port Connections ............. 4-14
7-1 PC Keyboard Model 2010D Key Mapping ............... 7-11

Introduction Page 1-
1
_________________________________________________________________
Section 1 Introduction
Users can easily perform gas dilution, ozone, and GPT
calibrations with Sabio Instruments Inc.'s intelligent Model
2010D gas dilution calibrator. The Model 2010D was designed to
set a new government and industry standard of quality and
performance for gas calibrations. Enhanced with the latest
technology, Sabio's Model 2010D Gas Dilution Calibrator is an
uncomplicated and effective way to precisely control the
dilution of gas standards for calibration of ambient air and
source monitoring analyzers.
An easy-to-read display, with touch panel operation, user-
friendly menu software and sturdy hardware amenities make the
Model 2010D both highly practical and easy to operate. Each
Model 2010D component was selected or designed with great care to
meet Sabio's quality performance standards and government
environmental agency goals and requirements.
User Benefits
Quality Construction. Sabio selected very high quality, inert valves
for the source, permeation and dilution streams. The source and
permeation oven valves wetted surfaces are manufactured with inert
materials. To ensure the manifolds do not react with the gases, the
manifolds are made of inert materials. Sabio minimized dead space
in the valves and manifolds to assure fast rise times. A source
purge-valve is standard for sweeping trapped gas out of the source
manifold. Static mixers enhance homogeneous blending of diluent and
source gases and the reaction chamber meets EPA requirements.
Mass-flow controllers precisely meter all gas streams.
Modern technology means precision calibration. In combining superior
software, components and materials, Sabio's Model 2010D is
setting a new benchmark for precisely diluting gas standards.
Elemental design means no lengthy training period required. The design of
the Model calibrator makes it easy for non-technical personnel with
little or no specialized training to perform precise calibrations
of gas analyzers.

Introduction Page 1-
2
_________________________________________________________________
A complete calibration system. The Model 2010D Calibration System
makes use of embedded microprocessor technology to enhance the
accuracy and control features of the calibration system. The
Model 2010D is designed to be used manually, automatically or
semi-automatically by remote control to conduct calibrations.
The unit features an optional internal ozone generator. An
optional permeation oven and UV absorption photometer are also
available.
Versatile programming options. The calibrator has the capability to
produce and store in memory 20 calibration sequences, with up to 20
levels of source/dilution in each sequence. Users employ the front
panel membrane keypad or serial port to input calibration parameters.
A bright, easy-to-read, 25-line x 80-character display shows
calibration and system configuration information.
Additional features include continually updated display of dilution
and source information, local and remote calibration control,
eight-port output manifold with port connections for up to seven gas
analyzers, and portable and 19-inch rack mounting options.
The Model 2010D's precision ozone generator is suitable for use
as a transfer standard for ozone calibrations or can be used for
performing nitrogen dioxide calibrations by means of gas phase
titration (GPT). The ozone generator eliminates the need for an
additional ozone transfer standard to conduct audits or perform
calibrations.
The Model 2010D's ozone generator's advanced electronic
circuitry and propriety photo detector enable the ozone
generator output to be so stable and accurate that the need for
a photometer is eliminated.
The internal UV absorption photometer option is a complete UV ozone
analyzer that can be used independently for monitoring ozone
production.
The Model 2010D external permeation oven option is an effective
tool for generating precise gas concentrations for calibrating a
wide range of gas analyzers. The large oven capacity
accommodates many types and sizes of permeation devices. An
internal clean air supply, precise mass flow controller and
temperature controller ensures a highly accurate gas
concentration process.

Introduction Page 1-
3
_________________________________________________________________
Standard Features
Embedded 32-bit microprocessor, 42 button membrane key pad,
25 line x 80-character color TFT display and user-friendly,
menu-driven software
Serial communications port, with selectable communications
protocols:
Monitor Labs Protocol
LEADS Compatibility via Dot Commands
Modbus Protocol
Parallel printer port
User digital inputs/outputs (8 standard, expandable to 24) for use
as remote control inputs or status outputs
Gas dilution system featuring the finest inert valves and mass flow
controllers for control and precise metering of source and diluent
gases
Internal data storage via removable 4 GB SD Memory Card
Optional Features
Precision ozone generator
Internal UV absorption photometer
External permeation oven
Ethernet and USB ports
PC-based remote operation and data retrieval software (Sabio Comm)
Rack Mount kit
Carrying Handles
Pelican waterproof carrying case with built-in handles
The Model 2010D design exceeds the United States EPA calibration
method requirements. Dilution components are calibrated with
standards and test equipment traceable to the National Institute of
Standards and Technology (NIST).

Introduction Page 1-
4
_________________________________________________________________
Model 2010D Gas Dilution Calibrator Specifications
Pneumatics:
Flow accuracy + 1.0% of full scale
Flow repeatability + 0.15% of full scale
Flow linearity + 0.5% of full scale
Diluent:
Mass flow controller range 0 - 10 SLPM (Optional 0 - 20 SLPM)
Input pressure 20 - 30 PSIG
Port 1, normally air (Optional Port 2, user defined)
Source:
Mass flow controller range 0 - 100 SCCM (Optional 0 - 20 SCCM,
0 - 50 SCCM, 0 - 200 SCCM, 0 - 500 SCCM, 0 - 1 SLPM, 0 - 2 SLPM)
Optional second source mass flow controller
Input pressure 15 - 30 PSIG
Four gas cylinder input ports (Optional two additional ports)
Source manifold purge port
Optional external permeation oven input port
Usable dilution ratio varies with flow controller selection, add
a second source flow controller for wider dynamic range
Solenoid valves for diluent, source and purge ports
Eight calibration gas output ports
Optional output solenoid valve
GPT reaction chamber meets EPA requirements
Attains 95% of Set Point in less than 60 Seconds
Wetted surfaces are composed of stainless steel, Teflon, Peek,
Halar or glass; all ports Swagelok or equivalent; Viton and Calrez
seals

Introduction Page 1-
5
_________________________________________________________________
Ozone Generator:
Output range 0.05 - 1.0 PPM at 5 SLPM instrument flow (Optional
extended output range 0.05 - 1 PPM at 10 SLPM instrument flow)
Accuracy + 2% of set point or + 3 PPB at 5 SLPM
Nominal ozone flow of 100 SCCM maintained within + 1 SCCM by
precision flow controller
UV lamp maintained at 50 + 0.1 oC
Optional UV optical servo control loop
Optional UV absorption photometer
Internal UV Absorption Photometer Option:
Ozone monitoring ranges 100 PPB to 20 PPM full scale
Linearity + 1 PPB or + 1 percent of full scale, whichever is
greater
Precision + 1 PPB
Lower detectable limit 0.8 PPB
Zero drift for 24 hours and 30 days less than 1 PPB
Span drift for 24 hours and 30 days less than 0.5 percent of reading
Lag time less than 10 seconds
Rise and fall time of 95 percent of final reading less than 60 sec
at 500 SCCM sample flow rate
Nominal flow rate of 500 SCCM monitored by mass flow meter
Internal sample vacuum pump
Recorder and data acquisition system analog outputs
Operating temperature 5o- 40 oC
Calibration Definitions:
Twenty user defined calibration sequences with up to 20 points per
sequence
Calibrations may be gas blends, ozone or GPT
Two diluent gas definitions and 20 source gas standard definitions
Twenty timer-driven calibration routines that perform predefined
calibration sequences on a calendar of events

Introduction Page 1-
6
_________________________________________________________________
Operation Modes:
Manually through use of print panel 42-button membrane keypad and
display, external user supplied keyboard or optional RS232 or USB
ports
Automatically by remote contact closures, internal timer or RS232
or USB ports
Electronics:
32-bit RISC CPU with SD Card interface for storage of software and
user configuration; battery-backed real-time clock; 32-bit
floating point math computations; capacity for future
enhancements
Co-processor CPU for precise dilution and valve control
42 button membrane keypad
640 X 480 pixel color graphic TFT Liquid Crystal Display
PWM servo loops for precise control of UV lamp intensity and
temperature levels
User IO and Networking
8 Status input/outputs standard, expandable to 24 programmable
status I/O bits for control and monitoring of calibrator functions
Optional solenoid drivers for interfacing with six 3 watt 24 VDC
instrument calibration solenoids
Up to two serial data communications ports
Optional Centronics parallel printer port
Optional external PS2 keyboard printer port
Compressed air source control circuit provides switched 5 VDC, 12
VDC or 24 VDC
Optional Network Interface Card for connection to Ethernet,
Internet and USB networks
Power:
Standard 96 - 264 VAC, 150 - 300 VA, 50/60 Hz operation
Mechanical:
Size 5.2" (13.3 cm) high X 17" (43.2 cm) wide X 20" (49.5 cm) deep.
Size varies with rack mount kit and other options
Weight:
-Basic calibrator with ozone generator 19 lbs. (8.6 kg)
-With ozone generator and photometer 24 lbs. (10.9 kg)

Introduction Page 1-
7
_________________________________________________________________
Miscellaneous:
Temperature 5 - 40 oC
Automatic restart on power up
Warm-Up time less than 30 minutes
Diagnostic routines for system calibration, checkout and leak
testing
Accessories and Options:
Internal UV Ozone Photometer
External Model 1001 or Model 1001P Compressed Air Source
External Model 2500 Permeation Unit
Rack mount kit for 19" (48.3 cm) equipment racks
High-impact plastic transport case
Flow calibration standard
Specifications subject to change without notice

Getting Started Page 2-
1
Section 2 Getting Started
This section introduces the customer to the Model 2010D and
presents a few guidelines for getting started using the unit.
Unpacking and Power Application
Remove the Model 2010D from its shipping container and check the
unit for damage. Contact the shipping company immediately if the
unit sustained damage in transit. Check the packing list to
verify that all items were received. Retain the original
shipping container for warranty returns.
Temporarily place the unit on a table or counter top in a convenient
spot for easy access to the front control panel. Locate the power
cable and connect it to the rear panel power receptacle. Plug the
other end of the power cable into a suitable AC power outlet.
Start-Up
On most Models of the 2010D, the power switch is located on the
lower right hand corner of the rear panel next to the power cord
inlet connector. Some units may have a power switch located on
the lower right hand corner of the front panel. Depress the
rocker switch to energize the unit.
The display should illuminate in a few seconds and initialization
messages should appear on the display. In approximately one minute
the main menu screen should be displayed.
When under power, the Model 2010D pneumatics and electronics
will begin their warming sequence.
Standby Operation Upon Power Up
Upon application of power to the Model 2010D, the unit defaults
to Standby Mode. In this mode, the Model 2010D is ready to
receive user commands from the front panel or external keyboard,
execute preprogrammed calibration sequences, accept commands from
the RS232 serial communications ports or invoke sequences based
on status information received from the status input/output
ports.

Getting Started Page 2-
2
User Interface
After the Model 2010D has finished it's power-up sequence, the
screen shown in Figure 2-1 will be displayed on the 2010D's front
panel. The operation of the Model 2010D is similar to operation
of many popular Windows applications. The front panel touch
buttons are used in conjunction with the display when entering
Model 2010D commands. The touch buttons are active at all times
when the unit is under power. Section 3, "System Operations",
describes in more detail general guidelines for operating the
Model 2010D.
Figure 2-1 The Main Screen

Getting Started Page 2-
3
Initial Configuration of the Model 2010D
Before the Model 2010D can perform calibrations, it must be
configured for the intended application. Following is the list
of tasks that must be accomplished in order to place the unit in
proper working order.
[1] Set the Model 2010D's time and date to local time as described
in the Subsection "Setting the Time and Date" in Section 6.
[2] Select the source gas and diluent gas. This is covered in the
"Installation" section of the manual which begins on page 4-1.
[3] Determine source and diluent port usage on the rear panel of
the Model 2010D. This is covered in the "Installation"
section of the manual which begins on page 4-1.
[4] Set up the 2010D for your specific calibrations. The "Model 2010D
Calibration Set-up" section, starting on page 6-1, covers this
topic.
[5] Verify and/or calibrate the flow controllers and the ozone
generator. This topic, covered in the section titled
"Calibrating Model 2010D Components", starts on page 8-1.
System Operation and Maintenance Precautions
Care should be taken to leave factory set parameters unchanged.
Altering factory parameters can result in improper operation or even
damage to the unit. Improper use of the diagnostic routines can
also result in damage to the Model 2010D.
When performing maintenance on the Model 2010D, Power should be
removed. Tools and small loose parts could cause damage to the unit
if they come in contact with electrical circuits.
Anti static procedures should be used at all times when working with
electronic components.

System Operations Page 3-
1
Section 3 System Operation
This section presents general information about the operation of
the Model 2010D Calibration System.
Front Panel Guide
The Model 2010D front panel consists of a twenty-five line by
eighty character electroluminescent or color display, an optional
power switch and forty two buttons for system operation. A drawing
of the 2010D's front panel is shown in Figure 3-1.
The front panel buttons are used for entering commands and
information into the Model 2010D. Provision is also made to
support a standard IBM PC compatible PS2 style keyboard (which
plugs into the rear panel). If an external keyboard is used,
each of the front panel buttons have equivalent keys. In
addition, there are several shortcuts available on an external
keyboard that are impractical or unavailable from the front
panel.
Following the front panel drawing is a listing of the 2010D
front panel buttons and their functions. If the equivalent
external key is not obvious from the button name, it is
indicated in parentheses.

System Operations Page 3-
2
Figure 3-1 The Model 2010D Front Panel