Valco Instruments Co. Inc. 500 User manual

Valco Instruments Co. Inc.
9/13
Dynacalibrator
Model 500
Instruction Manual
Valco Instruments Co. Inc.
800 · 367· 8424 sales
713 · 688· 9345 tech
713 · 688· 8106 fax
[email protected]
VICI AG International
Schenkon, Switzerland
Int + 41 · 41 · 925· 6200 phone
Int + 41 · 41 · 925· 6201 fax
[email protected]
North America, South America, and Australia/Oceania contact: Europe, Asia, and Africa contact::
®
Manufactured by:
Valco Instruments Co. Inc.
8300 Waterbury
Houston,TX 77055

Attention
Radiant heat warning
Entanglement warning
Electrical warning
Symbols used in this document

Table of Contents
Introduction
General Description.......................................................................................................................... 1
Dynacal® Permeation Devices...................................................................................................... 1
How to Use This Manual.................................................................................................................. 1
Basic Design ........................................................................................................................................ 1
Options ................................................................................................................................................. 4
Input Configurations............................................................................................................. 4
Rack Mount Options.............................................................................................................. 4
Special Customer Options................................................................................................... 4
Specifications...................................................................................................................................... 5
Getting Started ........................................................................................................................................... 6
Initial Receiving Inspection/Check.............................................................................................. 6
Unpacking the Dynacalibrator..................................................................................................... 6
Concealed Damage .......................................................................................................................... 7
Unit Location.......................................................................................................................................8
Permeation Device Conditioning................................................................................................ 8
Rear Panel Connections .................................................................................................................. 9
Supply Inlet............................................................................................................................... 9
Span and Zero Outlets.......................................................................................................... 9
Overflow Vent .......................................................................................................................... 9
Front Panel Controls and Indicators .........................................................................................10
Calculations................................................................................................................................................13
Initial Power Up.........................................................................................................................................14
Connections ......................................................................................................................................14
Chamber Temperature ..................................................................................................................14
Setting the Chamber Temperature Manually........................................................................15
Setting the Chamber Temperature Limit Switch .................................................................15
Setting the Chamber Temperature via Serial Port (RS-232) .............................................16
Installing the Permeation Device(s)..........................................................................................16
Serial Port Communication ..................................................................................................................17
Setting Up Serial Communication via HyperTerminal®.....................................................17
Entering Commands ......................................................................................................................21
Analyzer Calibration................................................................................................................................22
Shutdown Procedure..............................................................................................................................23
Advanced Theory of Operation...........................................................................................................24
Plumbing Configurations.............................................................................................................25
Configuration 0 .....................................................................................................................25
Configuration 1 .....................................................................................................................25

Table of Contents (continued)
Electrical Description..............................................................................................................................26
Maintenance..............................................................................................................................................27
Instrument Inspection and Cleaning .......................................................................................27
Carrier Flow Rate Verification......................................................................................................28
Dilution Flowmeter Calibration..................................................................................................28
Chamber Temperature Calibration ...........................................................................................29
Troubleshooting.......................................................................................................................................30
Electrical Troubleshooting ...........................................................................................................30
Pneumatic Troubleshooting........................................................................................................30
Leak Detection Fluid Method...........................................................................................30
Component Isolation Method .........................................................................................31
Model Number Breakdown..................................................................................................................32
Warranty .....................................................................................................................................................33

1
Introduction
General Description
VICI Metronics Dynacalibrators®use Dynacal®permeation devices to generate
the precise gas concentrations necessary for calibrating air pollution analyzers,
monitors, and other instruments that measure gas concentrations in the parts-
per-million range and lower.
Dynacalibrators are available in four models, each with a large variety of
optional features to fit a wide range of calibration requirements. All critical
factors, such as permeation rates, gas flow rates, and permeation chamber
temperatures are calibrated against standards traceable to the National Institute
of Standards and Technologies.
Model 500 specifications are listed on page 5.
Dynacal Permeation Devices
Metronics Dynacal permeation devices are the simplest and most reliable
method for supplying a source of trace quantities of various gases.They can
accommodate virtually any requirement for generating low concentrations of
gases. Permeation rates from thousands of ng/min down to fractional parts of a
ng/min are possible.The devices can be supplied filled with any one of hundreds
of different compounds, both organic and inorganic.
How to Use This Manual
This manual provides installation, operation, and maintenance information for
all configurations of the Model 500. The identification tag on the rear panel of
every Dynacalibrator is stamped with the unit’s complete model number, which
reflects the exact unit configuration. A chart on the last page of the manual
explains the model numbers.
Basic Design
The Model 500 contains three calibrated gas regulating systems – two carrier
systems and one dilution system. Each fixed flow carrier system includes a per-
meation chamber containing the permeation device. The temperature of each
chamber controls the permeation rate of the calibration gas from the perme-
ation device. Each chamber temperature is set and monitored at the front panel,
or remotely by serial communication. Each chamber temperature is adjustable
from 30°C (or 2°C above ambient, whichever is higher) to 110°C.
Each carrier stream can be selected independently, or both carriers can be added
together with the dilution stream. The dilution gas stream is pumped through
an adjustable valve and a flowmeter to the mixing tee for each carrier stream.
Front panel access to the valve and flowmeter permits the user to accurately
set the dilution stream flow rate that will be mixed with the selected carrier
stream(s), thereby controlling the concentration of the calibration gas available
at the outlet port of the calibrator

2
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Introduction
As indicated in Figure 1, the carrier stream passes through scrubber #1 and
micron line filter LF1 to the differential pressure regulator DPR1. The scrubber
contains specially-activated charcoal designed for broad-based scrubbing action.
This scrubbing medium is particularly effective in removing sulfur dioxide and
other sulfur compounds.
The differential pressure regulator and carrier flow restrictor FR1 together
provide a highly stable carrier stream flow rate to the permeation chamber.
The flow rate through the orifice is a function of the pressure differential across
it; this differential is maintained at 3.2 psi by DPR1.
Figure 1: Model 500 plumbing schematic
The output of the permeation chambers is fed forward to SV1 and SV2, respec-
tively. When the front panel switches are ON for SPAN 1 and/or SPAN 2, then the
respective carrier flows are routed through the valves’ C and NC ports and to the
mixing tee, where the calibrated dilution stream is added and mixed into it to set
the final concentration. When neither SPAN 1 nor SPAN 2 are selected, both SV1
and SV2 are de-energized, and the chamber output passes through its C and NO
ports to the chamber vent. The dilution stream alone then passes through the
mixing tee. The output of the mixing tee is split by another tee and fed to the
overflow vent and solenoid control valve SV3.
The overflow vent is usually left open, but can be plumbed to an external
exhaust port. Any exhaust plumbing must be sized so that it doesn’t cause any
increased pressure into the analyzer under calibration.

3
Introduction
Referring again to Figure 1, note that the dilution stream passes through
scrubber #3 and feeds into differential pressure regulator DPR3. The Model 500
contains a dilution flow control valve and rotometer, plus a rotometer for SPAN 1
and SPAN 2 carrier flows. When energized, solenoid control valve SV1 opens to
route carrier 1 flow to the mixing tee. Differential pressure regulator DPR1 main-
tains a fixed 3.2 psi pressure differential across the selected flow control valve
and meter. The flow rate through the selected flowmeter is then a function of this
fixed pressure differential and the carrier flow control orifice FR1. The desired
dilution flow, set using FCV2, is mixed with any selected permeation chamber
output to provide a final output concentration.
Figure 2: Model 500 output flow configurations
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

4
The Model 500 has four modes of operation – ZERO, SPAN 1, SPAN 2, and Both
SPAN 1 and SPAN 2. When the calibrator mode is changed to ZERO, SPAN 1, or
SPAN 2, a two position valve in the calibrator interrupts the sample input and
substitutes the calibrator output to the analyzer.
ZERO (neither SPAN 1 nor SPAN 2 on), SPAN 1, SPAN 2, and SPAN 1 + SPAN 2 can
provide three points of calibration along with a zero reference. The ZERO mode
vents the outputs from the permeation chamber through an exhaust port so that
only the dilution stream passes through the mixing tee to the stream outlet port
and into the analyzer for zero point calibration.
The SPAN 1 mode mixes the carrier stream with the dilution stream from a high-
flow control valve and flowmeter for low output concentrations of the trace
gas. In the SPAN 2 mode, a low-flow control valve and flowmeter are substituted
for the high flow components in the dilution stream to produce high output
concentrations of the trace gas. Front panel access to the control valves for each
of the two dilution flow-meters permits the user to accurately set both a low and
high output concentration and switch between them and zero air for the three-
point check.
Options
The following paragraphs provide general information on each, with more
detailed information found in “Advanced Theory of Operation” on page 24.
Input Configurations
The Dynacal 500 series is available with either single or dual gas supply. Both
plumbing configurations rely on external feed gas supplies and regulators. The
two gas inlet system allows for different gases to be used for carrier and dilutent.
Both systems are available with nominal maximum flow capacities from 1 to 20
liters per minute.
Rack Mount Options
The standard Dynacalibrator is packaged in a free-standing case with carrying
handles, for bench use. The units may also be packaged for mounting in a
standard 19" equipment rack.
Special Customer Options
Special options, identified by the“S”at the end of the model number, are not
covered in this basic manual. If your Dynacalibrator is equipped with a special
option, the required additional information will be found on the Special Option
Sheets in the back of this manual.The Special Option Sheets carry the serial
number of the Dynacalibrator to which they apply.
Introduction

5
Introduction
Specifications
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
































6
Getting Started
Every Dynacalibrator is completely calibrated, thoroughly tested and inspected,
and carefully packed prior to shipment. The carrier has assumed responsibility
for its safe delivery upon acceptance of the shipment.
Initial Receiving Inspection/Check
On receipt of your unit, before signing the waybill and releasing the carrier’s
agent, inspect the shipment for the following:
1. The number of cartons received tallies with that on the waybill.
2. The weight of the shipment agrees with that on the waybill.
3. There is no visible evidence of damage to the shipment or its containers.
4. Check the condition of the shock sensors on the sides of the box. If any
indicator is tripped please note this with the carrier immediately.
Any discrepancies to the above must be clearly described on the waybill and
signed by the carrier’s agent. Failure to adequately describe such external
evidence of loss or damage may result in the carrier refusing to honor any
subsequent claim.
Unpacking the Dynacalibrator
After the initial receiving inspection and check, the Dynacalibrator may be
unpacked. A carefully sized and mated pair of shipping cartons have been
designed to ensure against any damage to the Dynacalibrator while it is in
transit. Use the following procedures to remove the instrument from the
packaging, referring to Figure 3 as necessary.
Save all the packing materials – both cartons, the eight
corner blocks, and the two inner carton supports – for any
future shipment of the Dynacalibrator.
1. Neatly slit the shipping tape along the edges of the flaps on the top of the
carton with a knife. Do not try to pull or tear the tape.
2. Open the outer carton and remove the four corner blocks on top of the inner
carton.
3. Neatly slit the shipping tape along the edges of the flaps on the top of the
inner carton with a knife. Take care to penetrate the tape with the knife only
far enough to cut it. The Dynacalibrator is directly beneath the flaps.
4. Carefully lift the Dynacalibrator out of the inner carton.