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
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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)

11
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
2.1 LEAK TESTING
Before using the Calibration Panel, follow steps below
to provide ensure reliable operation and valid data col-
lection.
NOTE
When using the Diagnostic Calibrator Flowtubes, it is
important to maintain the panel in a vertical position.
1) Connect a 3-foot length of 1/4" ID tubing to the
Pump Suction Fitting (B4).
2) Open valves (V3) and (V4) several turns (counter-
clockwise).
3) Set the Flowmeter Selector Valve (V2) to the “FM1”
position. The position of the Load Selector Valve
(V1) is not important at this time.
4) Place finger over the air inlet fitting (B1).
5) Apply mouth suction to one end of the 3-foot
length of 1/4" ID tubing to achieve a pressure of
approximately 20" H2O, as indicated on the Pres-
sure Gauge, and seal off tubing (pinch or plug the
tubing securely).
6) If the pressure reading on the Pressure Gauge de-
cays less than two divisions per minute, the leak-
age rate is acceptable. If leakage is detected, try se-
lecting a different flowtube “FM2” or “FM3”. This
will help to isolate the leak. If leakage is detected,
set (V2) to “FM2” and repeat the entire procedure.
If no leakage is found, it means the total system is
intact and that the leakage found in the previous
step lies in the tubing and fittings systems from
(V2) through flowtube and connector block (V1).
If leakage is still present, it indicates there is leak-
age in the system prior to (V2).
7) If a system leakage is present, repeat the leak test
with the Load Selector Valve in each of its remain-
ing positions. Set (V2) to “FM3” and repeat the pro-
cedure by applying suction to (B4) with (B3)
blocked off. If no leakage is observed, this verifies
the system is tight and that the leakage observed
was induced by leakage within plumbing systems
from the flow path of (V2) to (B1). Fix the leak in
the appropriate section such that no leakage is ob-
served. At this point repeat the leakage test with
the Load Selector Valve (V1) in all positions. If leak-
age is observed in any of these positions, refer to
the leakage testing procedure in Section 4.1.2.
8) After the “loading” section of the panel has been
tested, the leak test should be repeated with the
Flowmeter Selector Valve (V2) in positions “FM2”
and “FM3”. For this part of the test, the Load Selec-
tor Valve (V1) may be set in any position.
SECTION TWO
SYSTEM SET-UP

12
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
2.2 FLOWTUBE CALIBRATION
The rotameter flowtubes provided in this kit have
been pre-tested for sensitivity and accuracy and are
within +5% of full scale. For example, if the flowtube
is rated at 4 liters full scale, then the flow accuracy at
any reading may have an error of .05 times 4000 cc or
200 cc. Readings of 3000 cc on the scale, which have
not been corrected, can have an actual flow of 2800 to
3200 cc. The same is true of a reading at 500 cc,
which can have an actual flow as low as 300 cc for
the low end or a reading as high as 700 cc.
This illustrates that it is preferable to read these
flowtubes in the upper 1/3 of the flow range as the per-
centage of error is less (5% vs. 40%). Calibrating against
primary standards will allow you to rate the desired
flow to the rotameter reading within about a 3% accu-
racy. Good operating and maintenance techniques rec-
ommend these flowmeters be checked against a pri-
mary standard, buret and stop watch or a Gilian Gili-
brator Calibrator, approximately every 4 months.
To perform calibration of the rotameter flow tubes fol-
low the steps below (refer to Figure 1.1). Numbers in
brackets correspond to numbers shown in Figure 1.1:
1) Connect the pump to the Air Outlet Fitting (B4) [5]
and set the Load Selector Valve (V1) [4] to the “By-
pass” position.
2) Set the Flowmeter Selector Valve (V2) [10] to the
flowtube being calibrated and connect the suction
side of the Gilibrator-2 (or bubble burette) to the
Air Inlet Fitting (B1) [7].
3) Set the pump flow rate to 1000 cc/min. by adjust-
ing the pumps flow control.
4) Calculate the observed reading on the flowtube
vs. the real value obtained from the precision
flowmeter.
5) Repeat Steps 2 and 3 at suitable incremental flow
rates (i.e., 1000, 1500, 2000, 2500 & 3000 cc/min.).
Additional points may be taken to simulate an ac-
tual desired flow value.
6) Using standard graphing techniques, plot the “Ob-
served” reading (horizontal axis) vs. the “Actual”
reading (vertical axis).
7) To utilize the plotted curve, select the flow desired
from the actual reading, shift horizontally to the
curve and then vertically down to the observed
reading, which is the value to which the pump
should be set.
• Using the Calibration Plot
The plots shown in Figure 2.1 are fictitious and are
used only as examples. You will generate your own
calibration plot following the above steps.
In Figure 2.1, the X-axis has been labeled “Observed
Flow” (as seen on the calibrator panel flowtube) and
the Y-axis has been labeled “Actual Flow” (as seen on
the precision flowmeter).
To determine the “Actual Flow” from an observed read-
ing, do the following:
1) Find the observed value on the X-axis.
2) Follow an imaginary line vertically until it inter-
sects with the calibration plot line.
3) Follow another imaginary line horizontally from
the point on the plot until it intersects with the Y-
axis. This is the actual flow rate corresponding to
the observed flow rate.

13
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
Figure 2.1
Calibration Plot Example
5
4
3
2
1
12345
ACTUAL FLOW IN LPM (GILIBRATOR-2)
OBSERVED FLOW IN LPM (ROTAMETER)
10,000 ft. Elevation at 60°F
Standard Conditions
2 miles deep in a mine shaft at 140°F

14
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
SECTION THREE
PUMP SET-UP & OPERATION
3.1 PUMP PERFORMANCE CHECK
The pump performance check is a test of the pump’s
constant flow control system.
The following procedure is for a three-flowtube
(High/Low Flow) Calibrator Panel. If you have a
single-flowtube (High Flow) configuration, the
flowtube will normally be found in position marked
“FM2” on the panel. This applies to standard Gilian
calibrator configurations. If the flowtube is not in that
position, simply switch the Flowmeter Selector Valve
[10] to the appropriate “FM” position.
Refer to Figure 1.1 for the location of various compo-
nents. Numbers in brackets correspond to numbers in
Figure 1.1.
1) Connect a 3-foot length of 1/4” ID tubing from the
Air Outlet Fitting (B4) to the pump’s air inlet
source.
2) Set the Load Selector Valve (V1) to the “Bypass”
position.
3) Set the pump flow rate to 1 LPM through flowtube
position “FM1”. (For specific pump flow rate set-
ting operations, refer to the manual that comes
with your pump).
4) Open the Low Flow Adjust valve (V4) several
turns. (Open by turning the valve counterclock-
wise). Note that this action will have no effect at
this time.
5) Switch the Load Selector Valve (V1) to the Low
Flow Adjust position (V4).
6) To simulate a 20” H2O filter loading (back-pres-
sure), set the pressure to 20” H2O by turning the
Low Flow Adjust Valve (V4) clockwise. If the pump
is properly calibrated, the reading on the flowtube
will change by no more than a +5%.
7) If the change is greater than 5%, refer to the pump
calibration procedure in your pump manual.
8) Unload the simulated load from the pump and re-
check the set flow rate.
9) Set Load Selector Valve (V1) to “Bypass” and adjust
the pump to 3 LPM on “FM1”.
10) Open the “High Flow Adjust” valve (V3) several
turns. (Open by turning counterclockwise).
11) Set Load Selector Valve (V1) to the High Flow Ad-
just position (V3).
12) To simulate a 10” H2O filter loading (back pres-
sure), set the pressure to 10” H2O by turning the
High Flow Adjust Valve (V3) clockwise. If the
pump is properly calibrated, the reading on the
flowtube will change by no more than a +5%.
13) If the change is greater than 5%, refer to the pump
calibration procedure in your pump manual.
14) Unload the back-pressure from the pump and re-
check the set flow rate.
This completes the pump performance check. If the
pump has passed, you may set the desired flow rate
and proceed with sampling.

15
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
3.2 PUMP CHECKOUT
This is a test of the pump’s fault system, which is de-
signed to activate if the flow rate can not be main-
tained to +/-5% of set flow.
In this procedure, the pump will be tested prior to
field deployment. At this time, the appropriate
flowtube range should be selected with the Flowtube
Selector Valve (V2), the inlet of the pump is con-
nected to the Air Outlet Fitting (B4) and should be set
to the required flow rate.
(The Load Selector Valve (V1) should already be in the
“Bypass” position.). Now rotate the Load Selector Valve
to the High Flow Adjust position (V3).
Turn the value (V3) clockwise until the required pres-
sure drop is obtained. There will be less than 5% devia-
tion between this flow and the previously set flow. For
pumps with an “instant faulting” feature, continue turn-
ing the valve (V3) clockwise until the increased load
pressure causes the pump’s fault light to activate.
Turn the High Flow Adjust Valve (V3) counterclock-
wise until the pump’s fault light to go out. Observe the
flowtube reading. This reading should be within 5% of
the set point.
Turn the High Flow Adjust Valve (V3) clockwise until
the pump’s fault light comes on again. Note the time it
takes for the fault light to come back on again. This
time must with the specification listed in your pump’s
operation manual.
If your pump does not have an instant fault feature,
you must calculate the flow rate deviation manually.
Example:
You are checking the flow rate at 2000 cc/min.
(2.0 LPM). Calculate the deviation by taking 5% of
2000 cc, or 100 cc. Subtract this from 2000 cc to
get 1900 cc/min. (1.9 LPM) Continue to increase
the back pressure on the pump by turning the
High Flow Adjust Valve (V3) clockwise until the
flowtube reads 1900 cc/min. Wait 2 minutes.
• If the pump does not fault, increase the pres-
sure to reduce the reading in the flowtube to
1800 cc/min. (10%) Wait another 2 minutes.
• If the pump does not fault during this time,
you may use the pump, however, you test the
pump again at the end of the sampling period
to ensure that the flow rate has not deviated by
more than 5%.
• If the pump does fault, then the pump should
hold the flow rate constant even at higher back
pressures within reason (i.e., 5-7%).
3.2.1 Load Simulation
In this procedure, the load is simulated using either
The High Flow Adjust Valve (V3) or the Low Flow Ad-
just Valve (V4).
Changes in flow rate associated with pressure drops are
easily monitored by switching the Load Selector Valve
(V1) back and forth between load simulation (at V3 or
V4) and “Bypass”. Either of these modes will adjust to
provide a pressure drop indication on the pressure
gauge. Alternating from a “load” position to the “By-
pass” allows the constant flow capabilities of the sam-
pler to be monitored.
3.2.2 Pressure Drops & Pressure Loads
In this operating mode, select the appropriate
flowtube range for the test (FM1, FM2, or FM3).
Turn on the pump and turn the Flowmeter Selector
Valve (V2) to the desired flowtube.
Note the reading on the pressure gauge. This is going
to be your tare (baseline) reading.
Connect the sampling device with a piece of tubing to
the Air Inlet Fitting (B1). The pressure drop associated
with this new load will register on the pressure gauge.
This allows you to check the pressure drop associated
with your sampling device both prior to sampling and
at the end of sampling period. From this you can deter-
mine the load pressure for you pump in order to
maintain a constant flow rate.

16
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
LOW FLOW SAMPLER
Patent Pending
MODEL LFS-113DC
TIME (MIN)
FLOW ADJ
DUAL
MODE
S/N–
PN 800098–
ON
OFF
B
F
Gilian Product
Sensidyne, Inc.
Clearwater, FL Made in USA
LISTED 17G9
MODEL LFS-113D / LFS-113DC
®
Personal Air Sampler
Intrinsically Safe Portable Air Sampling Pump for use in
Hazardous locations: Class I Groups A,B,C,D; Class II
Groups E,F,G; Class III. Temperature Code T3.
WARNING
Substitution of components may impair Intrinsic Safety.
Use only with UL Listed Portable Air Sampling Pump
Battery Pack.
LFS-113
PUMP
GILIBRATOR OR GILIBRATOR-2
PRECISION FLOWMETER
UNIVERSAL
CALIBRATION PANEL
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
Figure 3.1
Typical Calibration Set-Up

17
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
3.3 PUMP CALIBRATIONS FOR MODELS
GILAIR-3 & 5 AND HFS-113 & 513
In these Gilian samplers the flow rate control is de-
rived by using the DC motor of the pump as the load
sensor which provides a dependable means of provid-
ing constant flow. This system requires adjusting the
slope and intercept to provide proper linearity for the
system. As such, this linearity is provided by the use
of two flow calibration points.
3.3.1 High Flow Calibrations
The Diagnostic Calibrator is set up to check electronic
calibration over the range 0.5–5.0 liters. For HFS-513,
GilAir/GilAir-5 and HFS-113 samplers, please refer to
their respective operation manuals for specific calibra-
tion ranges and adjustment procedures.
This procedure properly calibrates the electronic flow
control system in the pump. Calibrating high flow rates
requires adjusting the flow control compensation po-
tentiometers of the Back-pressure Compensation Sys-
tem (BCS) in the pumps.
These potentiometers are adjusted at 2 flow rate points:
• at 1 LPM for HFS-113 & GilAir (1.5 LPM for
HFS-513)
• at 3 LPM for HFS-113 & GilAir (4 LPM for HFS-
513)
*) In this mode, turn the Flowmeter Selector Valve
(V2) to the appropriate flowtube. Connect the
pump tubing to the Air Inlet Fitting (B1).
*) Set the Load Selector Valve (V1) to “Bypass” (refer
to Figure XX).
*) Turn on the pump and adjust the flow rate to either
1 or 1.5 LPM (depending on your pump model).
*) Turn the Load Selector Valve (V1) to “Low Flow
Adjust” (V4) (refer to Figure XX) to simulate the ap-
propriate back pressure on the pressure gauge. Ad-
just the Low Flow Adjust Valve (V4), as needed, to
maintain a constant flow rate when switching be-
tween “Bypass” and “Low Flow Adjust” modes.
*) Adjust the pump flow rate to either 3 or 4 LPM (de-
pending on your pump model).
*) Turn the Load Selector Valve (V1) to “High Flow
Adjust” (V3) (refer to Figure XX) and adjust until
proper back pressure is observed.
*) Note any changes in the flow rate. Adjust the high
flow pump compensation potentiometer so as to
maintain a constant flow rate when switching be-
tween the “Bypass” and “High Flow Adjust” modes.

18
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
3.3.2 Low Flow Control System Calibrations
This procedure applies to HFS-113 & HFS-513 sam-
plers with low flow capability and GilAir/GilAir-5 sam-
plers with Multi-Flow Modules in the “On” Position.
The suction/pressure regulator in conjunction with a
manifold provides the means for setting low flow
To determine or check these pressures, set sampler
flow rate, (between 1–1.5 LPM), blocking the pump in-
let and setting a back pressure of 20–21” H2O for HFS-
113 & HFS-513 pumps and 16” H2O for GilAir/GilAir-5
pumps, indication on the pressure gauge.
In this set up, the pump is connected to inlet (B4) and
the Load Selector Valve (V1) is set to “Bypass”.
Block the Air Inlet Fitting (B1). The flow rate will drop
to zero and the pressure gauge will peg at 20-21” H2O.
This can also be accomplished by closing (clockwise)
either the “High Flow Adjust” (V3) or “Low Flow Ad-
just” (V4) and then positioning the “Load Selector
Valve” to either position.
The GilAir with a constant-pressure module can be
checked in the same manner except there is no adjust-
ment for the suction/pressure, only verification.
The suction/pressure should be greater than 16” H2O.
To determine the stability of the regulator in all of the
above cases, set the Load Selector Valve (V1) to “By-
pass”, shut the Low Flow Adjust Valve (V4) by turning
fully clockwise, then set the Flowmeter Selector Valve
(V2) to the High flow range flowtube and connect the
sampler to the Air Inlet Fitting (B1).
Turn sampler ON and adjust the flow to 1 LPM HFS-113
& GilAir and 1.5 LPM for the HFS-513.
Turn the load selector valve to the “Low Flow Adjust”
position (V4). Be sure valve is shut off.
The regulator should go up to approximately 20-21”
H2O for HFS-113, 24-25” H2O for HFS-513 and a mini-
mum of 16” H2O for GilAir. If the pressures are out of
specifications, the pump should be leak checked and
the “Low Flow Adjust” reset to apply the proper pres-
sure range.
NOTE
It is imperative that flow rates are in the approximate
range, and flowtubes must be calibrated to determine
this.

19
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
3.3.3 Regulator Stability Test
This test determines the stability of the system. Slowly
open the Low Flow Adjust (V4) until the flow is ap-
proximately 500 cc The pressure should change by no
more than 1.5” H2O.
3.3.4 GilAir (Constant Flow Module)
Connect a GilAir or GilAir-5 sampler to the Air Outlet
Fitting (B4).
*) Select the 200 cc flowtube position and set the
“Load Selector Valve” to the “Bypass” position. The
“Low Flow Adjust” (V4) should be open (counter-
clockwise).
*) Adjust the flow in the module to 100 cc and care-
fully note the ball position within the flowtube.
*) Slowly turn the “Load Selector Valve” from “By-
pass” to “Low Flow Adjust”.
*) Slowly close (V4) to approximately 23” H2O. The
flow rate will remain constant within 5% of the set
point and the pumps fault light should not light.
*) Continue closing the valve until the pump fault
light actuates. Back-off slightly and check the flow
deviation. It will be less than 5%.
*) Continue to close (V4) to approximately 30-35”
H2O or until the “Fault” light stays “On”. Once the
“Fault” light is “On”, do not adjust the valve any
further. The pump should stop within one (1)
minute after the red light actuates. This test can be
run in any flow range setting.
3.3.5 LFS-113 (Constant Flow Mode)
*) Connect an LFS-113 Pump to the Air Outlet Fitting
(B4).
*) set the selector valve to “Bypass” and select the 200
cc flow tube.
*) The “Low Flow Adjust” (V4) should be open
(counterclockwise).
*) Adjust the flow in the module to 100 cc and care-
fully note the ball position within the flowtube.
Slowly turn the “Load Selector Valve” from “By-
pass” to the “Low Flow Adjust” (V4).
*) Slowly close (V4) to approximately 23” H2O. The
flow should remain constant within 5% of the set
point and the pump fault light should not light.
*) Continue closing the valve until the pump fault
light activates. Back-off slightly and check the flow
deviation. It shall be less than 5%.
*) Continue to close (V4) to approximately 30–35”
H2O or until the red light stays “On”. Once the red
light is “On” do not adjust the valve any further.
The pump shall stop within 1 minute after the red
“Fault” light activates. This test can be run in any
flow range setting.

20
Gilian® LAB & FIELD CALIBRATOR SYSTEM
Sensidyne Document No. F-PRO-1260 (Rev C)
SECTION FOUR
SERVICE & MAINTENANCE
4.1 CALIBRATOR PANEL SERVICE
Refer to Figures 5 and 6. This procedure will guide you
in upgrading and testing a one flow meter calibrator
panel to a three flowmeter system. The item numbers
specified in the assembly instructions can be found in
the Calibrator Panel (1 flowtube and 3 flowtube) spare
parts.
4.1.1 Reconfiguration Procedure
1) Case model requires removal of four screws to un-
fasten panel.
2) Remove the following items:
• “V2” Hole plug (#1)
• Hole plugs (#2 &3)
• PVC tubing (#15)
• Elbow and TYGON¿ tubing (#4 &5)
• Screws, nuts and lock washers (#6, 7, &8)
3) Assemble two pieces of tubing (#9) onto the
flowtube manifold (#10) at back of panel.
4) Carefully insert two (2) flowtubes (#11, 12 or 13)
through top holes of the flowtube housing until
they engage on the lower manifold tubing.
NOTE
Make sure flow tube graduates are facing front.
5) Slide three (3) pieces of tubing (#9) onto upper
manifold (#19) and install onto the flowtubes at top
of flowtube housing and secure with two screws
(#20).
6) Rotate the selector valve (#17) to its furthest clock-
wise position and install through rear of panel
aligning selector valve to the “FM1” position. Se-
cure with three screws (#15).
7) Install three coupling tubes (#16) from upper mani-
fold to selector valve as shown, and one tubing
(#18) from damper (#21) to selector valve.
4.1.2 Leak Test
1) Set “V1” Load Selector Valve (#4) to “Bypass” posi-
tion and “V2” selector valve (#10) to the “FM1” po-
sition on the calibrator panel
2) Plug flow ports “B1”, “B2”, and “B3” then adjust
valves “V3” and “V4” to “OPEN” mode.
3) Connect suction line to “B1” connector port and
apply a 20” H20 suction load to the system. Verify
load on the panel pressure gauge (#2). Clamp suc-
tion line and let system stabilize about 15 seconds.
A maximum drop of 1” H20 or one division per
minute on the pressure gauge is acceptable. If ex-
cessive drop occurs, re-check system for leaks.
4) Repeat Step 3 with “V2” selector valve in “FM2”
and “FM3” positions.