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Instruction Manual Cal 2000 Calibration Gas Instrument TABLE OF CONTENTS VERSION 2 0 SOFTWARE REVISIONS 2 I GENERAL DESCRIPTION 3 II NORMAL OPERATION DIFFUSION MODE 7 III NORMAL OPERATION SAMPLE DRAW MODE 11 IV MENU OPTIONS 12 V MAINTENANCE 12 VI TROUBLESHOOTING 13 VII STANDARD WARRANTY 15 VIII ACCESSORY ITEMS PARTS LIST 16 WARNING This instrument generates calibration gas for toxic gas detectors The instruction manual should be read and understood prior to operation of the instrument Failure to operate the instrument correctly can lead to improper calibrations Page 1

This instrument conforms to the protection requirements of the EC DIRECTIVE 89 336 EEC on Electromagnetic Compatibility EMC in accordance with the provisions of Statutory Instrument 2372 The following standards have been applied EN 50081 1 Emissions Standard Residential Commercial and Light Industry EN 50082 1 Immunity Standard Residential Commercial and Light Industry VERSION 2 0 SOFTWARE REVISIONS Capable of supporting all new electro chemical generating sources as they are developed Initially NH3 and NO2 Intelligent adaptive warm up times depending on gas and concentration change Warm up time has been much reduced Reduced purge time accompanied by increased purge flow rate Removal of generating source during purge will immediately shut the unit off for quick change over from gas to gas By setting the unit to 0 LPM and 0 PPM the unit will operate as a digital mass flow meter Removal of Quick cal feature Reduced flow capabilities in sample draw to 1 5 LPM from 5 0 LPM Page 2

I GENERAL DESCRIPTION The Cal 2000 is a battery powered portable electro chemical gas generator designed to calibrate toxic gas sensors Fast warm up time allows the instrument to be turned off between remotely located sensors saving battery life and avoiding generation of unwanted gas A built in mass flow sensor provides accurate flow control and the ability to measure externally provided sample draw flow rates The Cal 2000 uses the following components to produce the calibration gas air mixture Internal Micro Pump A small rotary vane micro air pump draws in ambient air to blend with the generated gas The pump may be disabled for use in calibrating sample draw instruments Electro chemical Generating Source The electro chemical generating source contains an electrolyte solution and either inert or consumable electrodes depending upon the gas being generated A precise concentration of gas is produced when a known amount of current and a known amount of air is supplied continuously to the source Each source has a built in memory chip that tells the Cal 2000 instrument what type and range of gas can be generated and how much source life is remaining The electronics board mounted to the source should never be removed from the source Removal of this board will void warranty and destroy the source Due to the design characterization of the source the unit must be oriented flat on the units feet for correct concentration output Page 3

Source Installation and Removal There are no tools required by the end user for service of the instrument The electro chemical sources are shipped separate of the unit and should be installed on receipt To install the source remove the bottom cover of the instrument This is done by pulling each of the plunger feet on the bottom of the instrument Once all of the plungers have been pulled out the bottom cover is simply removed from the instrument The source is keyed to ensure proper alignment into the instrument When installed the circuit board of the source should be flat with the bottom of the instrument Push up on the clear window at the back of the instrument to eject the source Page 4

Alkaline C Batteries A set of four fully charged heavy duty alkaline C batteries provides 2030 hours of operation at 5 LPM Note Rechargeable or light duty batteries can be used but they give significantly less operating time Microprocessor Based Circuitry The Cal 2000 has microprocessor based circuitry that performs several different operations and offers the user many different features The microprocessor tracks source and battery usage monitors the air flow rate and controls the source and pump to give the selected PPM and flow rate In addition to English every Cal 2000 is capable of providing menu displays in French German and Spanish See section IV Menu Options for instructions on how to change the menu language Digital Display The Cal 2000 has a liquid crystal display LCD located on the front of the instrument This display is protected by a thin clear plastic cover that is part of the front label and may be replaced if it becomes scratched or unclear POWER and SELECT The POWER and SELECT switches are momentary push button type switches activated through the front membrane panel They are physical switches mounted directly on the circuit board Delivery Hose The instrument comes standard with a three 3 foot long inch diameter Norprene hose for delivering the gas to the sensor or calibration adapter The hose has a male quick connect adapter for easy attachment to the instrument Mass Flow Sensor The Cal 2000 has a built in mass flow sensor that measures the flow rate of the instrument This information is used in two ways With the pump engaged it is used to control the pump to the desired flow rate over a range of 0 2 to 1 0 LPM With the pump disabled it is used to measure the air flow rate drawn through the Cal 2000 by an external pump This information is used to adjustthe source current to the desired PPM The flow meter should be calibrated against a primary mass flow standard every 12 to 24 months Page 5

Internal Charcoal Filter An internal charcoal filter is provided to scrub contaminated air and provide a clean baseline for zeroing sensors This filter should be replaced on a yearly basis and is removed by pulling out the gray plunger at the top of the unit Spare filter elements can be purchased through ACD Note The charcoal filter must be fully installed into the instrument for correct operation Optional items available for the Cal 2000 include AC Adapter The Cal 2000 may also be operated from an AC adapter The AC adapter converts the AC voltage supplied from the main power lines to 6 VDC which is used in lieu of the batteries The adapter plugs into the instrument from the underside of the case directly into the power board and is independent of polarity If needed contact the factory for exact specifications of the AC adapter Hard Body Instrument Case A water resistant padded instrument case is provided for storage and shipping of the Cal 2000 The case is made out of rugged high impact resistant plastic and will help protect the instrument in harsh environments The foam insert may be customized to hold additional items like spare batteries and sources Page 6

Extension Hoses Longer sample hoses may be purchased for use with the Cal 2000 in lengths up to 20 feet Note the internal pump may not be capable of overcoming flow restrictions associated with extreme hose lengths when operating at 1 0 LPM II NORMAL OPERATION DIFFUSION MODE To start the generator press and hold the POWER switch located in the middle left front of the instrument until the display reads A C D approximately three 3 seconds Release the switch immediately thereafter The instrument will sequence through several screens as follows A C D 2 0 Copyright 2000 Please Note If you would like to change the language of the menus see section IV Menu Options Foreign Language Option for instructions The instrument will display the Serial Number and Source Number followed by the manufactured date Serial 0000001 Source 000001 Manufactured 01 Jan 2000 Calibration Date 01 Jan 2000 Page 7

The Calibration Date refers to when the instrument itself was last calibrated at the Factory It does not refer to the calibration date of the generating sources which are field replaceable The following status screens indicate the remaining source life and battery status Source Life 049 Hrs 59 Mns Battery Status 100 remaining x Output 000 PPM SELECT to change You may change the PPM by pressing the SELECT switch 10 to 50 PPM set 000 PPM You may adjust the PPM upwards by pressing the POWER switch arrow up or downwards by pressing the SELECT switch arrow down If you set the PPM to 000 PPM the instrument will not generate any gas although it will continue to pump The minimum and maximum PPM settings are dependent upon the flow rate and the type of generating source installed in the instrument The Cal 2000 will read the memory chip inside the generating source and automatically display the minimum and maximumPPM available for the flow rate that the instrument is set to The total range of the source is divided into three sub ranges to allow for appropriate resolution in each sub range For all sources excepting CLO2 and the Micro sources the sub ranges at 5 LPM are 5 to 1 PPM 1 0 to 10 0 PPM and 10 to 50 PPM When the end of a given range is reached pressing the appropriate up or down arrow will automatically Page 8

toggle the display to the next appropriate range Note that to obtain higher concentrations of gas simply reduce the flow rate of the instrument Once the flow and concentration have been set the instrument will enter the stabilization period and the display will alternate between the following three screens Stabilizing Standby 146 sec 1 00 PPM CL2 Standby 145 sec Flow 0 5 LPM Standby 144 sec When the instrument has finished counting down to zero 0 seconds it has reached 90 of its final output and will enter the gas generating mode In this mode the instrument will display the gas being generated the flow rate the PPM setting and the time while running at these settings as follows CL2 0 5 LPM 1 0 PPM00 00 00 At any time you may reset either the flow rate or the PPM rate by pressing the SELECT button and entering the status screens as described above When you are finished generating gas and wish to turn off the instrument press and hold the POWER switch until the purge screen is displayed Purging Standby 300 sec Page 9

The instrument will purge itself of gas for 300 seconds and then automatically shut off If you remove the generating source at any time during the purge cycle the unit will shut off The generating sources should always be removed from the unit for storage At any time during this period you may turn the instrument back on by pressing the SELECT switch and entering the status screens as described above You must change either the flow rate or the PPM setting and then the instrument will immediately go to the stabilization screen and continue to run at the new settings The amount of stabilization time will depend upon how long the instrument was in the purge mode Page 10

III NORMAL OPERATION SAMPLE DRAW MODE The instrument may also be operated in a sample draw mode where the internal pump is disabled and the air is drawn through the instrument by an external pump This mode is used for calibrating sample draw instruments To enter the sample draw mode press the SELECT switch when the flow status screen is displayed Flow 0 5 LPM SELECT to change When the flowset screen appears adjust the flow to read0 0 LPM 0 2 to 1 0 LPM set 0 0 LPM The PPM output screen will then read 000 PPM You will be unable to set the PPM until the sample draw instrument has been attached to the outlet hose and a stable flow rate has been established While the instrument is waiting for the sample draw unit to be attached it will display the flow stabilization screen Stabilize flow Flow 0 000 LPM Once the instrument has achieved a stable flow rate it will alternate between the PPM air flow rate and stabilization screen as described previously At this point you may press SELECT to go to the status screens and adjust the PPM as described earlier If the flow rate changes significantly during this period the instrument will attempt to re stabilize at the new flow rate The instrument operates identically to the diffusion mode at this point WARNING Do not adjust the flow rate to more than 0 0 LPM while the Cal 2000 is attached to a sample draw unit or damage may occur to the instrument Also do not attach the Cal 2000 to pumps drawing more than 5 LPM Page 11

IV MENU OPTIONS Foreign Language Option The menu options can be adjusted to read in German French or Spanish To change the language start the unit as you normally would When the ACD screen appears A C D 2 0 Copyright 2000 press the SELECT button This will bring up the following screen English SELECT to change Press the SELECT button to choose the preferred language When the language is displayed press the POWER button to continue with the start up sequence ClO2 Source Reminder Screen After the Battery Status screen appears during the start up of the instrument if a ClO2 source is in the instrument a reminder message will appear to change the Chlorine Dioxide Electrolyte Electrolyte Exp Renew Often Please read section VI Source Maintenance for detailed information on changing your electro chemical generating source s electrolyte V MAINTENANCE The electro chemical sources of the CAL 2000 require periodic maintenance to provide optimum performance It is recommended that the electrolyte solution be replaced on an annual basis for most gases generated by the CAL 2000 The exception to this is the ClO2 electrolyte Page 12

Please refer to the instructions enclosed with every chlorine dioxide source or replacement electrolyte pack If the instrument is returned with the source on an annual basis to maintain NIST certification the electrolyte will be replaced by the factory The following steps should be taken to replace electrolyte a Remove source as described in section I General Description Source Installation and Removal b Unscrew solid fill plugs on reservoir and remove liquid c Use syringe provided with electrolyte to add liquid to within 1 8 inch from the bottom of fill hole Warning Do not over fill reservoir Trapped air must be allowed to escape through vent plug as fill screw is replaced Contact the factory for more information d Replace fill plugs CAUTION Both the electro chemical source and the alkaline batteries used in the CAL 2000 instrument contain corrosive chemicals In addition depending on the type of source being used the gas being generated can be corrosive The design of the instrument takes this into consideration and the 300 second purge cycle allows the corrosive gases to be swept out of the instrument It is important not to remove the generating source before this purge cycle is completed While it is not expected that the chemicals in the source or alkaline batteries will leak during normal operation it is recommended that both the generating source and the alkaline batteries be removed from the instrument if it is being stored for periods longer than one week between use VI TROUBLESHOOTING No Power To Instrument There are two common causes for the unit to not power up when the POWER switch is pressed for three seconds The most common is that the batteries are dead Try replacing the batteries with new alkaline batteries or try powering the unit from the AC power adapter The second most frequent cause for no power to the instrument is a blown protective fuse If the protective fuse has been blown contact the factory Page 13

Flow too low Flow too high accompanied by an audible beep Accurate air flow is critical toan accurate gas mixture The microprocessor and built in precision mass flow sensor continuously monitor the air flow If however a flow problem develops e g air blockage or kinked tubing which cannot be corrected within ten seconds the unit will display Flow too low If the problem cannot be cleared after an additional minute the instrument will enter the purge mode and then power down If the pump was not disabled prior to attaching an external pump device or the sample draw flow rate is greater than 5 0 LPM the unit will display Flow too high If the problem is not cleared within one minute the instrument will enter purge mode as above Source Failure accompanied by an audible beep There are two possible causes for a source failure One cause is that the instrument has not detected a source The other is that a high voltage has been detected across the source If the source is not initially detected by the processor the unit will display source failure and immediately shut down without entering purge mode This failure can happen either because a source is not inserted connection to the source is not made or due to a failure of the circuit board on the generating source The source failure alarm will also engage if the microprocessor detects an abnormally high source voltage condition One possibility for this high voltage is that one of the pins may be making a faulty electrical connection Another possibility is that the electrolyte level is too low For instructions on how to replenish the electrolyte refer to Section V Maintenance If this message continues after the source has been plugged in correctly and the electrolyte level has been confirmed to be sufficient contact the factory and or replace the source Source is used up accompanied by an audible beep The source life has expired and the display will show 0 source life remaining Replace the source Battery is low accompanied by an audible beep If battery power drops below 5 capacity the screen will flash Battery is low Replace the batteries or switch to AC power Page 14

VII STANDARD WARRANTY We warrant gas calibration equipment manufactured and sold by us to be free from defects in materials workmanship and performance for a period of one year from date of shipment Any parts found defective within that period will be repaired or replaced at our option free of charge F O B factory This warranty does not apply to those items which by their nature are subject to deterioration or consumption in normal service and which must be cleaned repaired or replaced on a routine basis Such items may include but are not limited to a Electro chemical type generating sources b Electrolyte c Batteries Warranty is voided by abuse including rough handling mechanical damage alteration or repair procedures not in accordance with the instruction manual This warranty indicates the full extent of our liability and we are not responsible for removal or replacement cost local repair costs transportation costs or contingent expenses incurred without our prior approval Advanced Calibration Designs Inc s obligation under this warranty shall be limited to repairing or replacing and returning any product which shall be returned to Advanced Calibration Designs Inc at its manufacturing facilities with transportation charges prepaid and which Advanced Calibration Designs Inc s Material Review Board examination shall disclose to its satisfaction to have been defective This warranty is expressed in lieu of any and all other warranties and representations expressed or implied and all other obligations or liabilities on the part of Advanced Calibration Designs Inc including but not limited to the warranty of fitness for a particular purpose In no event shall Advanced Calibration Designs Inc be liable for direct incidental or consequential loss or damage of any kind connected with the use of its products or failure of its products to function or operate properly The following is a listing of the available electro chemical Cal 2000 sources and their standard prorated warranty when installed in equipment manufactured and supplied by Advanced Calibration Designs Inc Sources All sources are warranted for one year or the source defined hours of use Page 15

VIII ACCESSORY ITEMS PARTS LIST Source Definitions for CAL 2000 510 2000 00 00 50 hr 05 50 hr micro 10 10 hr 15 10 hr micro 20 100 hr 00 Chlorine 20 Nitrogen dioxide 50 Hydrogen sulfide 60 Chlorine dioxide 70 Hydrogen cyanide 90 Hydrogen Sources PPM ranges are specified for 5LPM flow The range expands inversely with flow Note New gases will be available as they are developed Part Number Item Description Capacity Hrs PPM Range Adjustable 510 2000 10 Cl2 chlorine 10 0 5 50 510 2000 00 Cl2 chlorine 50 0 5 50 510 2000 20 Cl2 chlorine double life 100 0 5 50 510 2000 15 Cl2 chlorine micro 10 0 05 1 0 510 2000 05 Cl2 chlorine micro 50 0 05 1 0 510 2000 25 Cl2 chlorine micro 100 0 05 1 0 510 2060 10 ClO2 chlorine dioxide 10 0 5 5 510 2060 00 ClO2 chlorine dioxide 50 0 5 5 510 2060 20 ClO2 chlorine dioxide double life 100 0 5 5 510 2090 10 H2 hydrogen 10 0 5 50 510 2090 00 H2 hydrogen 50 0 5 50 510 2090 20 H2 hydrogen double life 100 0 5 50 510 2050 10 H2S hydrogen sulfide 10 0 5 50 510 2050 00 H2S hydrogen sulfide 50 0 5 50 510 2050 20 H2S hydrogen sulfide double life 100 0 5 50 510 2050 15 H2S hydrogen sulfide micro 10 0 05 1 0 510 2050 05 H2S hydrogen sulfide micro 50 0 05 1 0 510 2050 25 H2S hydrogen sulfide micro double life 100 0 05 1 0 510 2070 10 HCN hydrogen cyanide 10 0 5 50 510 2070 00 HCN hydrogen cyanide 50 0 5 50 510 2070 20 HCN hydrogen cyanide double life 100 0 5 50 510 2070 25 HCN life hydrogen cyanide micro double 100 0 1 2 0 510 2070 15 HCN hydrogen cyanide micro 10 0 1 2 0 Page 16

Part Number Item Description Capacity Hrs PPM Range Adjustable 510 2070 05 HCN hydrogen cyanide micro 50 0 1 2 0 510 2020 15 NO2 nitrogen dioxide micro 10 0 5 5 510 2020 05 NO2 nitrogen dioxide micro 50 0 5 5 Accessories Part Number Item Description 150 0121 00 Charcoal filter element 150 0131 00 Charcoal filter element package of 12 362 0600 00 Continuous operation adapter 115VAC with US plug 193 0101 01 Electrolyte ClO2 15 ml vial 193 0101 05 Electrolyte ClO2 15 ml vial 5 pack 193 0101 10 Electrolyte ClO2 15 ml vial 10 pack 193 0101 25 Electrolyte ClO2 15 ml vial 25 pack 113 0402 00 Hose connector insert hose barb quick connect 715 0405 0X Hose with quick connect 5 730 0215 03 Hard body case CAL 2000 CAL 2000LT 113 0400 00 Outlet fitting body 1 8 NPT quick connect 106 0603 00 Plunger feet fastener Page 17

IX SPECIFICATIONS Ammonia NH3 0 5 to 50 PPM Chlorine Cl2 5 50 0 PPM Chlorine Dioxide ClO2 0 5 5 0 PPM Chlorine Micro Source Cl2 0 05 1 0 PPM Hydrogen H2 0 5 50 0 PPM Hydrogen Cyanide HCN 0 5 50 0 PPM Hydrogen Sulfide H2S 0 5 50 0 PPM Hydrogen Sulfide Micro Source H2S 0 05 1 0 PPM Nitrogen Dioxide NO2 0 5 5 PPM PPM is variable with flow rate output given at 1 2 LPM Air Flow Rate with internal pump Sample draw rate with pump disabled Useful Source Life Warm up time to 90 LxWxH Weight Operating Temperature Relative Humidity intermittent use Accuracy Repeatability Battery Power Battery Life 0 2 to 1 LPM 0 1 to 1 2 LPM 10 50 or 100 hours depending on purchased source Note sources do not degrade when not in use Varies depending on concentration change Always less than approximately 5 minutes 8 5 x 4 25 x 3 0 21 6 x 10 8 x 7 6 cm 3 lbs 1360 g 0 C to 50 C 0 100 10 5 4 alkaline C 20 30 hours 5 LPM CSA Certified Intrinsically Safe Class I Division 1 Groups A B C D European Standards approval for Zone 0 Page 18

Manufactured by Advanced Calibration Designs Inc 2024 W McMillan Street Tucson Arizona 85705 USA Phone 520 290 2855 Fax 520 290 2860 Int l Phone 001 520 290 2855 Fax 001 520 290 2860 email ACD goacd com website www GoACD com Page 19