user guide - air quality monitoring equipment: ambient · pdf file ·...

1 Aeroqual AirCal 1000 User Guide V1.1

Aeroqual Limited 109 Valley Road, Mt Eden, Auckland 1024, New Zealand

Phone: +64 9 623 3013 Fax: +64 9 623 3012

Web: www.aeroqual.com

AirCal 1000 Portable Calibrator

User Guide V1.1


Table of Contents User Guide Revision History ...........................................................................................................................3 Overview ............................................................................................................................................................4 1. System Configuration .............................................................................................................................4

1.1. Pneumatics........................................................................................................................................................ 4 1.2. Front View ......................................................................................................................................................... 5 1.3. Back View.......................................................................................................................................................... 5 1.4. Internal View...................................................................................................................................................... 5 1.5. Specifications .................................................................................................................................................... 6 1.6. Enclosure Dimensions ....................................................................................................................................... 6

2. AirCal 1000 operating principle .............................................................................................................7 2.1. Dilution Ratio ..................................................................................................................................................... 7 2.2. Gas Cylinders .................................................................................................................................................... 7

3. Operation .................................................................................................................................................8 3.1. Getting Started .................................................................................................................................................. 8 3.2. Manual Operation .............................................................................................................................................. 8 3.3. AirCal 1000 V1.1 Software ................................................................................................................................ 9

3.3.1. Connect to PC 9 3.3.2. Manual Calibration 10 3.3.2. Automatic Calibration 12

3.4. Error Codes ..................................................................................................................................................... 12 3.5. Sensor Module Settings .................................................................................................................................. 13

4. Maintenance ......................................................................................................................................... 14 4.1. Care and Cleaning .......................................................................................................................................... 14 4.2. Maintenance schedule .................................................................................................................................... 14 4.3. Removal of Adsorbents ................................................................................................................................... 14 4.4. Flow check for MFC and MFM ........................................................................................................................ 15 4.5. Flow Calibration for MFC and MFM ................................................................................................................. 16

5. Warranty................................................................................................................................................ 17 5.1. What we will do ............................................................................................................................................... 17

6. Appendix ............................................................................................................................................... 17 6.1. Copyright ......................................................................................................................................................... 17 6.2. Compliance ..................................................................................................................................................... 18 6.3. Guidelines ....................................................................................................................................................... 19 6.4. Technical support ............................................................................................................................................ 19


User Guide Revision History

Current version: 1.1 Date released: August 2012 Description: User guide for AirCal 1000 This user guide is a newly created document for the use of the AirCal 1000 Portable Calibrator.

Date Revision number Description of change Affected pages


Zero air scrubber

Filter

Solenoid Span 1

Pump

Activated Carbon

Solenoid Span 2

Zero air in

Zero Air Scrubber

Overview

The AirCal 1000 is a portable calibrator instrument which enables zero and span checks for NO2, NOx, CO, SO2, H2S, PID, VOC, and NMHC channels. It includes:

1. Gas Dilution Module: 2 span gas inputs with a zero air mass flow meter (MFM) 0-3 SLPM and a mass flow controller (MFC) 0-50SCCM.

2. Zero Air Source: Scrubbing media activated carbon, Purafil chemisorbant and heated carulite 3. Power supply module: 100-240V AC to 12V DC 4. Carry case: For transport

Span gas cylinders and regulators are not included as standard. Aeroqual can specify mixtures and suggest a local supplier. IMPORTANT: COMPRESSED GAS REPRESENTS A HEALTH AND SAFETY RISK. ALWAYS ENSURE PERSONNEL ARE TRAINED AND THERE IS AN APPROPRIATE HEALTH AND SAFETY PLAN IN PLACE WHEN USING GAS CYLINDERS.

1. System Configuration

1.1. Pneumatics

Note 1: The AirCal 1000 should be connected to the test instrument using the inert T fitting which is provided. This will ensure the test instrument is sampling the gas flow at atmospheric pressure Note 2: Ensure the filter is connected to the zero air inlet to minimise damage to the pump by particulate matter

Exhaust

Gas Cylinders

Diluted gas out

Purafil

Heated Carulite

MFM MFC

Internal components

External components

Port 1

Port 2


1.2. Front View

1.3. Back View

1.4. Internal View

Top Bottom

Heated Carulite Catalyst MFC

Purafil chemisorbant

Activated Carbon Pump

Diluted gas outlet NEVER BLOCK THIS OUTLET Display

RS232 Serial Port

On/Off Switch

12 VDC Input Gas/Span inlets

MFM


236

30

20 20

278

67

17

132

55

Top

Rear

Front

Side (tilted)

Side

Handles

12 VDC IN

15

236

30

20 20

278

67

17

132

55

Top

Rear

Front

Side (tilted)

Side

Handles

12 VDC IN

15

1.5. Specifications

Zero air generator.

Purafil chemisorbant – SOx, , NOx, O3, H2S, Activated Carbon - Hydrocarbons Heated Carulite Catalyst – CO note: CO2 is not scrubbed

Maximum Delivered Flow rate 2.0-2.5 LPM

Span Gas Operating Pressure 10-15psi

Max Input Pressure 140psi

Gas Connections Span ports – 1/8” Swagelok compression fitting Zero air/ Gas out – ¼” Kynar compression fittings

MFC Range 0-50 sccm

MFM Range 0-3 SLPM

Flow Accuracy < 1% of full scale

Span gas inputs 2

Recommended span gas mixtures (contact Aeroqual for more detail)

20 ppm NO2 / Air 1000 ppm CO / Air 1000 ppm Isobutylene / Air 100 ppm SO2 / N2 20 ppm NO / N2 100 ppm H2S / N2 multi-gas mixtures 20 ppm NO, 100 ppm SO2

Electric Connection 100-240V AC to 12V DC

Display 4 Line Alphanumeric

Outputs RS232 (DB9 port) Cable and USB adaptor supplied

Dimensions 422 x 422 x 148

Weight 12kg

Enclosure Material Aluminium and Steel Powder coating

Instrument Carry Case Impact and water resistant, 515 x 430 x 200

Conformity

1.6. Enclosure Dimensions


2. AirCal 1000 operating principle

2.1. Dilution Ratio

The AirCal system delivers a controlled concentration of calibration gas for calibration of ambient gas instruments. To do this the calibration gas inside the cylinder is mixed with zero air, which is generated by the scrubbing material inside the AirCal 1000. The calibration gas is therefore diluted by the zero air to provide a given concentration which is directed into the test instrument. The concentration of calibration gas is calculated using a dilution ratio which is determined by the zero air and cylinder gas flow rates.

The zero air generator will deliver a flow rate of approximately 2 – 2.5 LPM. The flow rate of the zero air is monitored using a mass flow meter (MFM).

The flow rate of the cylinder gas is controlled dynamically using a mass flow controller (MFC). The cylinder gas flow rate can range from between 5 – 45 ml/min

-1 The MFC will adjust the flow of the

calibration gas so as to maintain a user defined dilution ratio according the equation:

The user dilution ratio needs to be calculated in order to deliver the required concentration of calibration gas. Example: If 10ppm of CO was required and the cylinder concentration is 1000ppm, then the required dilution ratio would be 100. The dilution ratio of 100 will be entered into the relevant section, either in the PC software or manually on the instrument screen and the MFC flow rate will automatically adjust to meet the desired calibration gas concentration.

2.2. Gas Cylinders

To achieve the best performance from the AirCal 1000 it is important to connect gas cylinders with gas concentrations which are appropriate for the calibration being performed. Example cylinder concentrations are as follows:

Note: The recommended dilution ratio range is between 50 and 500

Gas Recommended Cylinder concentration ppm

Maximum Concentration Achievable ppm

Minimum concentration achievable ppm

CO 1000 20 2

NO / NO2 20 0.4 0.04

PID / NMHC 1000 20 2

SO2 / H2S 100 2 0.2


3. Operation The AirCal 1000 is designed for easy set up and usability. Zero air and span checks can be carried out manually or programmed to initiate automatically at selected time intervals. These options can be configured using the AirCal 1000 PC software or on the instrument itself using the buttons on the front panel.

3.1. Getting Started 1. Unpack unit 2. Plug 100-240V AC to 12V DC power supply pack into rear socket on AirCal 1000 and connect to

mains 3. Connect the outlet to the instrument under test using the supplied T fitting to ensure the

instrument samples at atmospheric pressure. Caution: never block the outlet flow of the Aircal 1000. Internal damage may occur.

4. Fit the supplied filter to the zero air inlet to ensure the pump does not get damaged by dust 5. Connect the gas cylinders to Port 1 and Port 2 safely using regulators. Adjust the inlet pressure

to 10-15 PSI. Caution: do not over pressurise. 6. Turn on the power switch on the front panel

Note: Fluorocarbon (PTFE, FEP or PFA) tubing and fittings should be used for all sample lines

3.2. Manual Operation

On start up the screen will show the MFC and MFM flow rates in cubic cm. Selecting main menu will give you the option to run a manual or automatic calibration.

Under the Manual option zero air and span checks can be initiated.

Selecting Port 0 will initiate the zero air check. In this setting the dilution ratio should be set at 0.

Selecting either Port 1 or 2 will initiate the span check. The dilution ratio will need to be calculated (refer to Section 2) and entered.

Select Start to begin the checks

Under the Auto Run option there is the option to show or modify schedules.

The schedules will need to be set up initially by selecting modify schedules and entering the information for each run.

A run may include up to 5 points including zero air which is defined as Port 0.

A maximum of 3 runs can be configured for automatic calibration.

The process is similar to set up on the PC software. The Point, Port, Dilution ratio, Run time and Run frequency need to be set using the buttons on the front panel.


Once the schedule has been set up, initiate the schedule by pressing start on the Auto Run menu.

3.3. AirCal 1000 V1.1 Software Alternatively, the AirCal 1000 can be controlled via the PC software. Computer Requirements

CD-ROM Drive

RS232 serial port or USB – RS232 serial port converter

Windows OS version 2000 or later

Minimum 100 Mb of spare hard drive space

Recommended 512 Mb RAM or more

Recommended 1 GHz processor speed or faster

3.3.1. Connect to PC

Connect the serial cable between the AirCal 1000 and the computer and install the AirCal 1000 V1.1 zip file from the supplied CD. Launch the AirCal 1000 PC software:

1. Select Communication Port and choose the correct Com port on the PC. Note this will be created when the serial port convertor is plugged in. You may need to install the convertor drivers.

2. Select Test Connection to check the AirCal 1000 has connected successfully 3. Select Update Real Time Clock to synchronize the AirCal 1000 clock with the computer date/time.

This will only need to be carried out the first time the instrument is set up. Once the connection has been created and the date/time has been updated the software is ready to use.

.


3.3.2. Manual Calibration

Zero Check (Port 0)

Select Zero Check then select start reading to initiate the zero air check

Readings will be taken every minute

Allow for the sample gas to stabilise (15 minutes). Be aware that there may be some fluctuation in the MFM measurement (±5ml/min)

To stop the data recording select Stop Reading. The data can then be cleared or exported to a spread sheet.

To stop the zero check completely select Stop Check

Span Check (Port 1 or 2)

Select Span Check

Select the span check port from the drop down menu Note: Each gas cylinder connected will have a defined port assigned to it. Both ports are labelled clearly on the back of the instrument.

Select a dilution ratio using the equation provided in Section 2

Press OK then select Start Reading

Readings will be taken every minute

The MFC flow rate will adjust to track to MFM flow rate. This will ensure the correct dilution ratio is maintained. The flow rates may take approximately 15 minutes to stabilise.

To stop the data recording select Stop Reading. The data can then be cleared or exported to a spread sheet.

To stop the span completely check select Stop Check


Note: The dilution ratio can be checked manually using the following equation:


3.3.2. Automatic Calibration

Calibration can be configured to be carried out automatically at a set time for a chosen running period. The process is similar to the manual operation.

Select Calibration Configuration and right click to open the Run Scheduler.

The run schedule will need to be configured.

A run may include up to 5 points including zero air which is defined as Port 0.

A maximum of 3 runs can be configured for automatic calibration.

The user will need to define the dilution ratio for Port 1 and 2 as well as the run time.

The schedule can then be selected from the drop down menu to configure the calibration run frequency, day of week/month and start time.

Once all the parameters have been set click save then click read to ensure the run has been saved. Note: The information contained in the Calibration Configuration is stored on the AirCal 1000 and not on the PC containing the Aeroqual software. To remove a run, right click inside the run scheduler and select remove run. Note that run three will be removed first followed by run two and then run one. Once a run has been removed click save and then click read to make sure that the run has been removed.

3.4. Error Codes There are 3 error codes that can occur during the use of the AirCal 1000. They will show up on the instrument screen as well as in the PC software readings. Error 1 = Will be shown if the dilution ratio is set below 40 or above 1000– recommended dilution ratio range is 50 – 500 Error 2 = Will be shown if the MFM reading drops below 1000 ml/min – Check zero air inlet and flow path for blockage/leaks Error 3 = Will be shown if the MFC reading drops below 80% – Check cylinder gas inlet and flow path, may be due to insufficient pressure from cylinder, leaks or blockage


3.5. Sensor Module Settings

The Sensor Module Settings contain the calibration settings for the mass flow meters and controllers. They should not be altered except when the unit is being calibrated and you have access to high accuracy flow measurement. The password for access to the settings is “calibrate”. The Parameter list and meanings: H3 //not used TEMA //MFC Range x Gain (cc/min) TIMA //cylinder purge time in sec TEMR //span adjust time in sec TIMR //Number of MFM readings that are averaged H0 //MFM reading zero offset


H1 //not used H2 //not used PWMH //MFM reading interval for average (ms) PWML //MFC polling time (sec) Gain //MFM Gain

4. Maintenance

4.1. Care and Cleaning

Keep the AirCal 1000 dry. Avoid water and/or condensation as humidity and liquids containing minerals may corrode electronic circuits.

Do not use or store in dusty, dirty areas.

This unit is designed for use at temperatures between 5°C and 45°C. If you wish to use the monitor outside this range you will need an additional environmental enclosure. Sudden changes in temperature may cause condensation that may damage the electronic components.

Do not drop, knock or shake as this could lead to internal damage.

4.2. Maintenance schedule The AirCal 1000 has been designed to require minimal maintenance provided that the instrument is used correctly with clean, dry, filtered gas. The following section shows the common maintenance procedures and frequency:

Item Procedure Frequency

Inlet Filter Check and replace filter Monthly

Activated Carbon Remove and replace Yearly

Purafil Remove and replace Yearly

Mass Flow Controller Flow Check Flow Calibration

Quarterly Yearly

Mass Flow Meter Flow Check Flow Calibration

Quarterly Yearly

Note: Suggested intervals for maintenance procedures may vary with sampling intensity and environmental conditions.

4.3. Removal of Adsorbents

The Activated Carbon and Purafil capsules will need to be replaced yearly.

A zero air scrubber replacement kit can be purchased from Aeroqual. It will come with all the relevant fittings so it can be installed easily into the AirCal 1000.

To remove:

Unscrew top plate of AirCal 1000 via the 2 screws at the back of the instrument. The top plate should slide out easily.

Remove the current zero air scrubber Purafil and Activaed Carbon Capsules. o Disconnect the tube connecting the pump to the Purafil capsule (See red arrow). o Unscrew the luer fitting connecting the Activated Carbon capsule to the Heated Carulite

capsule (See red arrow).

Unclip both the Purafil and Activated Carbon capsule and remove.


To replace:

The replacement capsules will be provided with the relevant fittings

Clip both capsules back into place and reconnect the correct tube to the pump and screw the luer fitting connectors to reconnect to each other and the Heated Carulite capsule

4.4. Flow check for MFC and MFM

To ensure correct and accurate operation of the AirCal 1000, periodic checks of the MFC and MFM are recommended between yearly calibrations.

To check the flow:

Remove the bottom plate of the AirCal 1000 via the 2 screws at the back of the instrument. The bottom plate should slide out easily.

Place the AirCal 1000 on its side so the MFC and MFM outlets are visible.

The MFC and MFM flow rates need to be measured separately.

Unscrew luer fitting

MFM outlet

MFC outlet

Disconnect tube from pump

Unscrew luer fitting

Pump

Activated Carbon Capsule

Purafil Capsules


Unscrew the luer fitting of the MFC outlet and connect to a flow meter.

A span check will need to be initiated to measure the flow rate of the MFC

The flow measurement recorded on the flow meter should be compared with the measurement recorded on the AirCal 1000.

The luer connector needs to be replaced securely and the same process carried out for the MFM outlet.

A zero air check will need to be initiated to measure the flow rate of the MFM Note 1: The MFC flow rate should be between 5-45 ml/min

-1 depending on the dilution ratio set

Note 2: The MFM flow rate should be between 2-2.5 LPM

If the flow rate has changed by more than 2% then you should consider getting the AirCal 1000 re-calibrated.

4.5. Flow Calibration for MFC and MFM This should only be done by an approved agent or laboratory with the correct flow calibration equipment. Please contact Aeroqual for the procedure.

MFC connection


5. Warranty

Aeroqual warrants this product to be free from defects in materials and workmanship for a period of 1 (one) year from the date of shipment from the factory. Consumable items such as pumps, filters and gas scrubber media are excluded from this warranty. This warranty is expressly limited to the original owner who purchases the equipment directly from Aeroqual or from an authorized Aeroqual dealer. Should your Aeroqual product need warranty service, you should return it to the dealer from whom it was purchased or contact Aeroqual.

5.1. What we will do

If, during the warranty period, this product fails to operate under normal use and service, due to improper materials or workmanship, Aeroqual subsidiaries, authorized distributors or authorized service partners will, at their option, either repair or replace the product in accordance with the terms and conditions stipulated herein.

Conditions

1. The warranty is valid only if the original receipt issued to the original purchaser by the dealer, specifying the date of purchase, is presented with the product to be repaired or replaced. Aeroqual reserves the right to refuse warranty service if this information has been removed or changed after the original purchase of the product from the dealer.

2. If Aeroqual repairs or replaces the product, the repaired or replaced product shall be warranted for the remaining

time of the original warranty period or for ninety (90) days from the date of repair, whichever is longer. Repair or replacement may be via functionally equivalent reconditioned units. Replaced faulty parts or components will become the property of Aeroqual.

3. This warranty does not cover any failure of the product due to normal wear and tear, damage, misuse, including but

not limited to use in any other than the normal and customary manner, in accordance with Aeroqual’s user guide for use, faulty installation, calibration and maintenance of the product, accident, modification or adjustment, events beyond human control, improper ventilation and damage resulting from liquid or corrosion.

4. This warranty does not cover product failures due to repairs, modifications or improper service performed by a non-

Aeroqual authorized service workshop or opening of the product by non-Aeroqual authorized persons. 5. The warranty does not cover product failures which have been caused by use of non-Aeroqual original

accessories. 6. This warranty becomes void if a non-Aeroqual approved power supply is used. 7. Tampering with any part of the product will void the warranty. 8. Aeroqual makes no other express warranties, whether written or oral, other than contained within this printed

limited warranty. To the fullest extent allowable by law all warranties implied by law, including without limitation the implied warranties of merchantability and fitness for a particular purpose, are expressly excluded, and in no event shall Aeroqual be liable for incidental or consequential damages of any nature whatsoever, however they arise, from the purchase or use of the product, and including but not limited to lost profits or business loss.

9. Some countries restrict or do not allow the exclusion or limitation of incidental or consequential damage, or

limitation of the duration of implied warranties, so the preceding limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights, which may vary from country to country.

6. Appendix

6.1. Copyright

Copyright Aeroqual Limited. All rights reserved. Reproduction, transfer, distribution or storage of part or all of the contents of this document in any form without the prior written permission of Aeroqual Limited is prohibited.

“Aeroqual” and “Aeroqual Limited – Making the Invisible Visible” are registered trademarks of Aeroqual Limited. Other product and company names mentioned herein may also be trademarks or trade names.


Aeroqual operates a policy of continuous development. Aeroqual reserves the right to make changes and

improvements to any of the products described in this document without prior notice.

Under no circumstances shall Aeroqual be responsible for any loss of data or income or any special,

incidental, consequential or indirect damages howsoever caused.

The contents of this document are provided "as is". Except as required by applicable law, no warranties of

any kind, either express or implied, including, but not limited to, the implied warranties of merchantability and

fitness for a particular purpose, are made in relation to the accuracy, reliability or contents of this document.

Aeroqual reserves the right to revise this document or withdraw it at any time without prior notice. The

availability of particular products may vary by region. Please check with the Aeroqual dealer nearest to you.

© Aeroqual Limited 2010. All rights reserved.

6.2. Compliance

1. The Aeroqual AirCal 1000 complies with EN 61000-6-1:2001

2. The Aeroqual AirCal 1000 complies with EN 61000-6-3:2001

3. The Aeroqual AirCal 1000 complies with Part 15 of the FCC Rules. Operation is subject to the

following two conditions: (1) these devices may not cause harmful interference, and (2) these

devices must accept any interference received, including interference that may cause undesired

operation.

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital

device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable

protection against harmful interference in a residential installation. This equipment generates, uses

and can radiate radio frequency energy and, if not installed and used in accordance with the

instructions, may cause harmful interference to radio communications. However, there is no

guarantee that interference will not occur in a particular installation. If this equipment does cause

harmful interference to radio or television reception, which can be determined by turning the

equipment off and on, the user is encouraged to try to correct the interference by one or more of the

following measures:

— Reorient or relocate the receiving antenna.

— Increase the separation between the equipment and receiver.

— Connect the equipment into an outlet on a circuit different from that to which the receiver is

connected.

— Consult the dealer or an experienced radio/TV technician for help.


6.3. Guidelines

USE SENSIBLY Use only as per this user guide.

USE AEROQUAL APPROVED SERVICE Only approved service personnel must work on this product.

ACCESSORIES Use only approved accessories. Do not connect incompatible products.

CONNECTING TO OTHER DEVICES When connecting to any other device, read the appropriate user guide for detailed safety instructions. Do not connect incompatible products.

HEALTH AND SAFETY IN THE WORKPLACE This product requires the application of compressed gases. Aeroqual does not guarantee user safety. An appropriate Health and Safety plan should be in place.

.

6.4. Technical support

Technical information, service and spare parts are available through your distributor. In addition, worldwide technical support is available from Aeroqual Ltd. Please contact: Aeroqual Limited 109 Valley Road, Mt Eden, Auckland 1024, New Zealand Phone: +64 9 623 3013 Fax: +64 9 623 3012 Email: [email protected]

mailto:[email protected]

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