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Advanced Calibration Designs Inc CAL 2000LT Advanced Calibration Designs Inc 2024 W McMillan St Tucson Arizona 85705 USA Telephone 520 290 2855 Fax 520 290 2860 Toll Free 800 737 0223 Email acd goACD com Web www goACD com P N 910 0603 LT Calibration Gas Generator Instruction Manual
Instruction Manual Cal 2000 LT Calibration Gas Instrument TABLE OF CONTENTS I General Description Page 2 II Normal Operation Page 7 III Menu Options Page 11 IV Maintenance Page 12 V Troubleshooting Page 13 VI Standard Warranty Page 15 VII Accessory Items Parts List Page 17 VIII Instrument Specifications 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
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 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
I GENERAL DESCRIPTION The Cal 2000 LT is a battery powered portable electrochemical 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 to insure proper calibration gas concentrations The Cal 2000 LT 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 Electrochemical Generating Cell The electrochemical generating cell 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 cell Each cell has a built in memory chip that tells the Cal 2000 LT instrument what type and concentration of gas is to be generated and how much cell life is remaining The electronics board mounted to the cell should never be removed from the cell Removal of this board will void warranty and destroy the cell Due to the design characterization of the cell the unit must be oriented flat on the units feet for correct concentration output Page 2
Cell Installation and Removal There are no tools required by the end user for service of the instrument The electrochemical cells are shipped separate of the unit and should be installed on receipt To install the cell 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 cell is keyed to ensure proper alignment into the instrument When installed the circuit board of the cell should be flat with the bottom of the instrument Push up on the clear window at the back of the instrument to eject the cell Page 3
Alkaline C Batteries A set of four fully charged heavy duty alkaline C batteries provides approximately 10 hours of operation Note Rechargeable or light duty batteries can be used but they give significantly less operating time Using re chargeable batteries will also void the CSA safety certification during the time of their use Microprocessor Based Circuitry The Cal 2000 LT has microprocessor based circuitry that performs several different operations and offers the user many different features The microprocessor tracks cell and battery usage monitors the air flow rate and controls the cell and pump to give the correct ppm and flow rate In addition to English every Cal 2000 LT is capable of providing menu displays in French German and Spanish See section III Menu Options for instructions on how to change the menu language Digital Display The Cal 2000 LT 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 Page 4
Nylon Carrying Case The Cal 2000 LT comes with a convenient durable nylon carrying case It is adjustable to be worn as a hip pack or the belt strap can be reattached to be worn around the neck or over the shoulder The top of the carrying case is clear plastic allowing the unit to be operated while within the case and there is a convenient front pocket for storage of additional cells or the delivery hose Mass Flow Sensor The Cal 2000 LT has a built in mass flow sensor that measures the flow rate of the instrument This information is used to control the pump to provide the desired flow rate The flow meter should be calibrated against a primary mass flow standard every 12 to 24 months Internal Charcoal Filter An internal charcoal filter is provided to scrub contaminated air and provide a clean baseline for the calibration gas generated This filter should be replaced on a yearly basis and is removed by pulling out the grey 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 Page 5
Optional items available for the Cal 2000 LT include AC Adapter The Cal 2000 LT 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 available for storage and shipping of the Cal 2000 LT 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 cells Extension Hoses Longer sample hoses may be purchased for use with the Cal 2000 LT 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 Page 6
II NORMAL OPERATION 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 I Copyright 2003 Please Note If you would like to change the language of the menus see section III Menu Options Foreign Language Option for instructions The instrument will display the Serial Number and Cell Number followed by the manufactured date Serial 0000001 Cell 000001 Manufactured 01 Aug 2003 Calibration Date 01 Aug 2004 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 cells which are field replaceable The following status screens indicate the remaining cell life battery status and flow rate Cell Life 009 Hrs 59 Mns Battery Status 100 remaining Flow 0 5 lpm Immediately after the flow rate screen appears the ppm screen appears Output 5 ppm Page 8
Once the flow and concentration have been displayed the instrument will enter the stabilization period and the display will alternate between the following three screens Stabilizing Standby 146 sec 5 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 5 ppm 00 00 07 Page 9
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 The instrument will purge itself of gas for 300 seconds and then automatically shut off 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 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 I Copyright 2003 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 Flow Rate Select Option The CAL 2000 LT is shipped from the factory set at either 0 5 LPM or 1 0 LPM depending on what was specified when the unit was ordered To change this in the field the following screen can be used Select Flow Rate 0 5 LPM 1 0 LPM Note that the CAL 2000 LT cells read this setting on the instrument and will work correctly at either flow rate Page 11
IV MAINTENANCE The electrochemical cells of the CAL 2000 LT require periodic maintenance to provide optimum performance It is recommended that the electrolyte solution be replaced on an annual basis If the instrument is returned with the cell 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 cell as described in section I General Description Cell 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 The electrolyte in the electrochemical cells can also dehydrate over time in dryer climates A low electrolyte level will ultimately result in a Cell Failure warning Since only water is evaporated and the electrolyte salts are remaining in solution it is only necessary to replenish the electrolyte with distilled or de ionized water Ordinary tap water as well as many bottled waters should not be used as it contains chemicals and minerals that could contaminate the cell Replenishing the cell with water is similar in procedure to replacing the electrolyte shown above but the remaining electrolyte is not removed before the replenishment water is added Page 12
V 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 This fuse can be shorted out if the batteries have been removed from the instrument with a metallic object such as a screwdriver If the protective fuse has been blown contact the factory 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 Flow too low Flow too high accompanied by an audible beep Accurate air flow is critical to an 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 Page 13
Cell Failure accompanied by an audible beep There are two possible causes for a cell failure One cause is that the instrument has not detected a cell The other is that a high voltage has been detected across the cell If the cell is not initially detected by the processor the unit will display cell failure and immediately shut down without entering purge mode This failure can happen either because a cell is not inserted connection to the cell is not made or due to a failure of the circuit board on the generating cell The cell failure alarm will also engage if the microprocessor detects an abnormally high cell 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 cell has been plugged in correctly and the electrolyte level has been confirmed to be sufficient contact the factory and or replace the cell Cell is used up accompanied by an audible beep The cell life has expired and the display will show no time remaining on the cell Page 14
VI 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 Electrochemical type generating cells 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 electrochemical Cal 2000 LT cells and their standard warranty when installed in equipment manufactured and supplied by Advanced Calibration Designs Inc Page 15
10 Hour Generating Cells 1 Chlorine One year or 10 hours of use 2 Hydrogen Sulfide One year or 10 hours of use 3 Hydrogen Cyanide One year or 10 hours of use 4 Hydrogen One year or 10 hours of use 25 Hour Generating Cells 1 Chlorine One year or 25 hours of use 2 Hydrogen Sulfide One year or 25 hours of use 3 Hydrogen Cyanide One year or 25 hours of use 4 Hydrogen One year or 25 hours of use Page 16
VII ACCESSORY ITEMS PARTS LIST The following items are available as accessories for the CAL 2000 LT P N Description 113 0402 00 Male Hose Barb Quick Connector 1 8 OD hose 150 4121 00 Charcoal Filter Element one each 150 4131 00 Charcoal Filter Element package of 12 362 0600 00 AC Adapter 115 VAC US style plug 7 5VDC 300 mA 400 0600 LT Main Circuit Board Assembly 400 0703 00 Power Circuit Board Assembly 510 2000 LT Chlorine Cell 510 2050 LT Hydrogen Sulfide Cell 510 2070 LT Hydrogen Cyanide Cell 510 2090 LT Hydrogen Cell 700 0600 03 Pump Low Flow Rotary Vane 6 VDC 715 0403 0X 3 Foot Hose w connector low flow 1 4 OD 715 0405 0X 5 Foot Hose w connector low flow 1 4 OD 730 0615 00 Hard body Water Resistant Padded Carrying Case 910 0603 LT Instruction Manual Page 17
VIII SPECIFICATIONS Chlorine Cl 2 1 25 ppm Hydrogen H 2 1 25 ppm Hydrogen Cyanide HCN 1 25 ppm Hydrogen Sulfide H 2S 1 25 ppm ppm concentration must be specified when ordering cell Air Flow Rate 0 5 or 1 0 LPM f l o w r a t e m u s t b e s p e c i f i e d w h e n o r d e r i n g C A L 2 0 0 0 LT Warm up time to 90 Approximately 5 minutes L x W x H 8 5 x 4 25 x 3 0 21 6 x 10 8 x 7 6 cm Weight 3 lbs 1360 g Operating Temperature 0 C to 50 C Relative Humidity intermittent use 0 100 Accuracy 10 Repeatability 5 Battery Power 4 alkaline C Battery Life 10 hours CSA Certified Intrinsically Safe Class I Division 1 Groups A B C D European Standards approval for Zone 0 Page 18
Advanced Calibration Designs Inc CAL 2000LT Advanced Calibration Designs Inc 2024 W McMillan St Tucson Arizona 85705 USA Telephone 520 290 2855 Fax 520 290 2860 Toll Free 800 737 0223 Email acd goACD com Web www goACD com P N 910 0603 LT Calibration Gas Generator Instruction Manual