Sensidyne Gilian 800565 Series User manual

1000 112th Circle N, Suite 100 • St. Petersburg, Florida 33716
[phone] • [phone] • [phone] (FAX) • www.sensidyne.com
Revision C • Document No. F-PRO-1260
5.0
4.0
3.0
2.0
1.0
0.5
200
150
100
50
40
30
20
50
45
40
35
30
25
20
15
10
5
UNIVERSAL PUMP CALIBRATOR
P/N_________________ S/N_________________
HIGH FLOW ADJ.
V3
LOAD
SELECTOR
VALVE
V1
BYPASS
LOW FLOW ADJ.
V4
B4
B1
FLOWMETER
SELECTOR
VALVE
V2
FM1 FM2 FM3
20
10
0
020 40 60 80 100
30
40
INCHES OF WATER
cm of water
MAX. PRESSURE 15 PSIG
DWYER INSTRUMENTS, INC.
MICH. CITY, IND. 46360 U.S.A
PAT.
3,397,319 3,862,416
4,011,759 4,347,744
12-193588-02
MAGNEHELIC
MAX. PRESSURE
15 PSIG (100 kPa)
MAX.
TEMPERATURE
140 ° F (60 ° C)
CAUTION
Gilian®LAB & FIELD
CALIBRATOR SYSTEM
INSTRUCTION MANUAL
for the following models:
800565-(*)
800573-3
800783-3
800884

3
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
PACKING LIST
The following items are shipped with the Gilian Lab & Field Calibrator System :
• Calibrator Panel (with 3 rotameter flow tubes)
• Carrying Case †
• Sampling Pump †
• Gilibrator-2 Precision Flowmeter †
† Not included with Calibrator Panel only model (PNº 800573-3) or
Lab Stand Calibrator (PNº 800873-3)
ALWAYS check to make certain
you have received all of the items listed above.
If you have any questions or need assistance,
contact your Sensidyne Distributor, or call
[phone]
or
[phone]

4
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
PROPRIETARY NOTICE
This manual was prepared exclusively for the owner of the Gilian Lab & Field Calibrator System. The material
within this manual is proprietary information of Sensidyne, LP and is to be used only to understand, operate, and
service the instrument. By receiving this document, the recipient agrees that neither this document nor the infor-
mation disclosed within nor any part shall be reproduced or transferred, physically, electronically or in any form
or used or disclosed to others for manufacturing or for any other purpose except as specifically authorized in writ-
ing by Sensidyne, LP.
COPYRIGHT NOTICE
© 1997-© 2008 All Rights Reserved. Sensidyne, LP. No part of this document may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any language in any form by any means without the prior
written permission of Sensidyne, LP.
TRADEMARK NOTICE
Sensidyne, the Sensidyne logo, Gilian, and the Gilian logo are registered trademarks. These trademarks are
protectedthroughuseandregistrationintheUnitedStates.Thetrademarksandservicemarksusedinthisdocument
are the property of their respective companies and are used only for informational and explanatory purposes.
DISCLAIMER
THE SELLER ASSUMES NO RESPONSIBILITY WHATSOEVER, TO ANY PARTY WHOSOEVER, FOR ANY
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH RECEIVED BY OR RESULTING FROM, IN
WHOLE, OR IN PART, THE IMPROPER USE, INSTALLATION, OR STORAGE OF THIS PRODUCT BY THE
USER, PERSON, FIRM, ENTITY, CORPORATION OR PARTY NOT ADHERING TO THE INSTRUCTIONS
AND WARNINGS OR NOT ADHERING TO ALL FEDERAL, STATE, AND LOCAL ENVIRONMENTAL AND
OCCUPATIONAL HEALTH AND SAFETY LAWS AND REGULATIONS.
THE SELLER SHALL NOT BE LIABLE FOR DIRECT, INDIRECT, CONSEQUENTIAL, INCIDENTAL OR
OTHER DAMAGES RESULTING FROM THE SALE AND USE OF ANY GOODS AND SELLER’S LIABILITY
HEREUNDER SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF ANY GOODS FOUND DEFECTIVE.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT
NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE OR FOR
A PARTICULAR PURPOSE WHICH ARE EXPRESSLY DISCLAIMED.

5
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
TABLE OF
CONTENTS
PREFACE
• Packing List .......................................................................................................................... 3
• Notices ...................................................................................................................................4
• WARNINGS........................................................................................................................... 7
SECTION ONE: INTRODUCTION
1.1 Overview ..................................................................................................................... 8
1.2 Theory of Operation ................................................................................................. 9
1.3 Components ............................................................................................................... 9
SECTION TWO: SYSTEM SET-UP
2.1 Leak Testing ...............................................................................................................11
2.2 Flowtube Calibration ...............................................................................................12
SECTION THREE: PUMP SET-UP & OPERATION
3.1 Pump Performance Check ......................................................................................14
3.2 Pump Checkout ........................................................................................................15
3.2.1 Load Simulation .............................................................................................15
3.2.2 Pressure Drops & Pressure Loads.................................................................15
3.3 Pump Calibrations ...................................................................................................17
3.3.1 High Flow Calibrations .................................................................................17
3.3.2 Low Flow Calibrations ..................................................................................18
3.3.3 Regulator Stability Test ..................................................................................19
3.3.4 GilAir (Constant Flow Module) ....................................................................19
3.3.5 LFS-113 (Constant Flow Mode).....................................................................19

6
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
SECTION FOUR: SERVICE & MAINTENANCE
4.1 Calibrator Panel Service ..........................................................................................20
4.1.1 Reconfiguration Procedure ...........................................................................20
4.1.2 Leak Test ........................................................................................................20
4.2 Flowtube Cleaning ...................................................................................................23
APPENDICES
Appendix A: Parts List .................................................................................................... 24–25
Appendix B: Returned Material Authorization ................................................................26
LIST OF FIGURES
1.1 Lab & Field Calibrator Panel: Front View .............................................................10
2.1 Calibration Plot Example .........................................................................................13
3.1 Typical Calibration Set-Up.......................................................................................16
4.1 Calibrator Panel: Front View ..................................................................................21
4.2 Calibrator Panel: Rear View ...................................................................................22
LIST OF TABLES
1.1 Available Lab & Field Calibrator Models ..................................................................8
TABLE OF
CONTENTS

7
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
READ AND UNDERSTAND ALL WARNINGS BEFORE USE
Read and understand ALL warnings before using this product. Failure to read, understand, and comply with
ALL warnings could result in property damage, severe personal injury, or death.
Read and understand ALL applicable Federal, State, and Local environmental health and safety laws and
regulations, including OSHA. Ensure complete compliance with ALL applicable laws and regulations before
and during use of this product.
UNDER NO CIRCUMSTANCES should this product be used except by qualified, trained, technically
competent personnel and not until the warnings, Operation Manual, labels, and other literature accompa-
nying this product have been read and understood.
Each user MUST READ AND UNDERSTAND the Operation Manual before operating this product in order
to ensure proper and safe use and installation of this product and to ensure familiarity with the proper
treatment and safety procedures in the event of an accident.
DO NOT remove or alter any label or tag on this product, its accessories, or related products.
DO NOT operate this product should it malfunction or require repair. DO NOT attempt to repair or modify
the product, except as specified in the Operation Manual. Operation of a malfunctioning product, or a
product requiring repair may result in serious personal injury or death. If repair is needed, contact Sensidyne
Service to arrange for a Returned Material Authorization (RMA).
ONLY use genuine Sensidyne®replacement parts when performing any maintenance procedures provided
in this manual. Failure to do so may seriously impair instrument performance. Repair or alteration of the
product beyond the scope of these maintenance instructions, or by anyone other than authorized
Sensidyne®serviceman, will void the warranty, and could cause the product to fail to perform as designed
and persons who rely on this product for their safety could sustain severe personal injury or death.
This unit is designed for measuring and monitoring air flow rates and measuring back-pressure for the
calibration of air flow instrumentation. The unit should only be operated while it is in a vertical position for
optimum performance and accuracy.
WARNINGS !

8
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
SECTION ONE
INTRODUCTION
1.1 OVERVIEW
The Gilian Diagnostic Calibrator provides a fast and ac-
curate method for the testing and calibration of con-
stant flow samplers. The system is available in “Field
Case”, “Lab Style” or “Panel Only” configurations.
• Performance Features
• Diagnostic capability for analyzing
pump performance.
• Accurate means of setting flow rates.
• Rapid verification of sampler flow rates.
• Pump calibration check.
• Load simulation and indication of pressure
drops associated with those loads.
• Complete deployment check of air samplers.
The Diagnostic Calibrator is available in two configura-
tions: “single-flowtube” or “triple-flowtube.” The
single-flowtube model is used for high flow sampling
range (particulates) where typical sampling ranges can
be 0.5 to 5 LPM.
Table 1.1
Available Lab & field Calibrator Models
The triple-flowtube model provides two additional
flowtubes and a selector valve. It is ideal for calibration
and testing low flow sampling ranges (gas hazards)
where flows can be from 20 to 800␣ cc per minute. Addi-
tional flowtubes are available to customize the calibra-
tor flowtube range to meet the users needs.
• Specifications
Flow Rates: (variable in 5 steps)
0.5 - 5000 cc/min
0.4 - 4000 cc/min
50 - 800 cc/min
30 - 300 cc/min
20 - 200 cc/min
10 - 100 cc/min
2 - 50 cc/min
Accuracy: ±5% Full scale
Pressure Measurements: 0 to 40 inches H2O
.oNtraP †noitpircseD
4-565008 cc05–5.0,cc002–02,cc008–05,lenaPhtiwesaCgniyrraC,SFL
565008 cc05–5.0,cc002–02,MPL4–4.0,lenaPhtiwesaCgniyrraC,riAliG
8-565008 cc05–5.0,cc002–02,MPL5–5.0,lenaPhtiwesaCgniyrraC,5-riAliG
3-565008 cc05–5.0,cc002–02,MPL5–5.0,lenaPhtiwesaCgniyrraC,315-SFH
488008 cc05–5.0,cc002–02,MPL5–5.0,lenaPhtiwesaCgniyrraC,2-rotarbiliG
3-375008 cc05–5.0,cc002–02,MPL5–5.0,oL/iH,ylnolenaProtarbilaC
3-387008 cc05–5.0,cc002–02,MPL5–5.0,oL/iHrotarbilaCdnatSbaL
sebutwolffoegnaretelpmocA.sebutwolfegnarwoldnahgihhtiwemocsrotarbilaClenaP†
stnemeriuqercificepsrofelbaliavasi

9
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
1.2 THEORY OF OPERATION
The Gilian Lab and Field Calibrator provides a simple
means for analyzing pump performance, checking
pump calibration, simulating loads, rapid check-out
and deployment of samplers, and verification of sam-
pler flow rates to insure that samplers meet perfor-
mance specifications.
In operation, air passes through a flowtube, as directed
by the flowtube selector valve (triple-flowtube model),
is applied to a load valve or bypass section which
provides a means of instantly loading/unloading the
pump flow and is then directed through the internal
pressure gauge and into the pump’s outlet boss. By
monitoring flow and observing the load change condi-
tions, pump performance data can be collected.
In each area of pump diagnostics, the calibrator pro-
vides the versatility to meet calibration and flow check-
ing requirements. This also includes directly simulating
the load in the loading section or by placing the actual
load (i.e., the sampling media) downstream of the
flowtube which then gives direct pressure drop read-
ings and flow information about the loading source.
1.3 DIAGNOSTIC PANEL TYPES
1.3.1 Single-Flowtube Configuration
Refer to Figure 1. Air enters the calibrator through boss
(B2), passes through flow tube “FM2” and is bypassed
or applied to the inlet of valve (V3) and (V4) as deter-
mined by the position of the Load Selector Valve (V1).
Air leaves the Load Selector Valve, is directed to the
pressure gauge and exits the system via boss (B4)
which is connected to the pump’s air inlet boss.
1.3.2 Triple-Flowtube Configuration:
Refer to Figure 2. In the triple-flowtube configuration,
air enters the panel through (B1), (B2) or (B3) and, as
directed by “Flow Selector Valve” (V2), passes through
“FM1”, “FM2” or “FM3”. It is then bypassed or applied
to the inlet valves (V3) or (V4) as directed by the posi-
tion of the Load Selector Valve (V1). Air leaves the
Load Selector Valve and is directed to the Pressure
Gauge and leaves the panel via boss (B4). The panel
allows the operator to monitor pressure drops associ-
ated with specific sampling media and, in the pump di-
agnostic mode, allows complete pump performance
checkout.

10
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
Figure 1.1
Lab & Field Calibrator Panel: Front View
5.0
4.0
3.0
2.0
1.0
0.5
200
150
100
50
40
30
20
50
45
40
35
30
25
20
15
10
5
UNIVERSAL PUMP CALIBRATOR
P/N_________________ S/N_________________
HIGH FLOW ADJ.
V3
LOAD
SELECTOR
VALVE
V1
BYPASS
LOW FLOW ADJ.
V4
B4
B1
FLOWMETER
SELECTOR
VALVE
V2
FM1 FM2 FM3
20
10
0
020 40 60 80 100
30
40
INCHES OF WATER
cm of water
MAX. PRESSURE 15 PSIG
DWYER INSTRUMENTS, INC.
MICH. CITY, IND. 46360 U.S.A
PAT.
3,397,319 3,862,416
4,011,759 4,347,744
12-193588-02
MAGNEHELIC
MAX. PRESSURE
15 PSIG (100 kPa)
MAX.
TEMPERATURE
140 ° F (60 ° C)
CAUTION
Calibration
Panel
Flowmeter
Selector (V2)
Single Flowtube
(FM2)
Single Flowtube
(FM3)
Single Flowtube
(FM1)
Protective
Flowtube
Window
Air Inlet
Fitting
Pressure
Gauge
High Flow
Adjust
Valve (V3)
Load
Selector
Valve (V1)
Low Flow
Adjust
Valve (V4)
Air Outlet
Fitting (B4)