User`s Manual - Applied Measurement and Control
Contents
1. EERE ENES neni 10 1 34 39 Zero Gas Concentration uu se sees eec uct iw ee 10 7 14 Span Gas Concentration u Su S S S Ea M 10 VIII Maintenari eB uobis ua Rex s REAPER vC u MEN ERE EN Eu DRRRAS E 12 IX Troubl iie 12 9 1 Typical Calibration 12 X Spare Parts and Accessories 13 10 1 5 13 10 2 vcccscninacccwscnssasasianescancscndsssassndecccorsebansssseneahepansevencebucsteuysuanesnoioacaisanvarsnenbonnaeeasaayeaceie 14 10 2 1 Zero Gas Regulator M11982ZX ce eee tette territorio denos 15 10 2 2 Pressure Regulator 1132 222224 0 0 0000 15 10 2 3 Pressure Gauge 1132 15 10 2 4 Zero Gas Pressure Switch 113 24 4 4 1 nennen nnn 16 10 25 FUSES AMAT SZ IAG 16 Appendix Wiring Diagram AC4 to 550 to ZR22G 17 Appendix B Wiring Diagram to AV550 to ZR22G2. 19 YOKOGAWA 4 IM 11M6D2 02E A 2nd Edition INTRODUCTION This manual details the operating instruction for the Yokoga wa Model AC4 AC8 Automatic Calibration Unit and the integration with the AV550G Zirconia Oxygen Averaging Converter IMPORTANT The maximum input pressure for the span and zero gases is 35 psig Exceeding 35 psig may result in damage to the AC4 AC8 ll OVERVIEW The AC4 AC8 Automatic Calibration System is designed to work with the AV550G Oxygen Averaging Converter provid ing accurate automatic or semi automatic calibration of the ZR22 Zirconia Oxide Detector The AC4 AC8 is assembled with plumbing flow control hardware and internal solenoid wiring necessary to calibrate up to four or eight probes respectively The end user need only provide plumbing to the individual probes calibration gases and interconnection wir ing between the calibration unit and the converter Initial setup of the auto cal unit is further simplified by the use of manual overrides for all solenoids The overrides coupled with the flow regulation for each probe allow for fast balancing of each calibration line Each probe also has its own flow meter and flow control for the reference air flow 2 1 Models AC4 AC8 Multi Channel Automatic Calibration UStandard Specifications Operating Pressure 20 psi Maximum Pressure 35 psi Flow meter range 0 15 to 1 LPM separate flow meter for cal gas and reference air
3. Flow rate Cal Gas 0 6 LPM Reference Air 0 8 LPM Cal tubing 1 4 copper standard 1 4 stainless steel optional Gas connection 1 4 FNPT Voltage 110 VAC 50 60 Hz standard Ambient temp 80 C 176 F maximum Weight Approximately 40 Ibs 18 kg Construction Enclosure Reference gas Consumption Cal Gas Consumption Zero amp Span NOTE Instrument air is used for both span calibration gas and reference air Outdoor installation Indirect sunlight NEMA 4 or NEMA 4X 0 8 LPM per probe 0 6 LPM per probe during calibration only Model and code AUTO CALIBRATION UNIT FOR AV 550G AC4 4 Channel System AC8 8 Channel System ENCLOSURE 4 NEMA 4 5 NEMA 4X PLUMBING C Copper tubing brass fittings S Stainless steel tubing and fittings REFERENCE AIR FLOW METER R U Reference air flow meter OPTIONS 8 Stainless Steel Tag Ill INSTALLATION 3 1 LOCATION The following guidelines should be used when selecting a location for the auto calibration unit 1 The unit must be easily accessible for maintenance and inspections 2 The unit must be near the ZR22 probes as practical This will minimize the length and amount of tubing required for plumbing 3 Ambient temperature will not exceed 80 C 176 4 Humidity is moderate and no corrosive gases are present 5 Minimal presence of vibration 6 Availability of 120 VAC and clean dry
4. This sets the oxygen concentration of the zero gas used for calibration Enter the value from the label of the correspond ing gas bottle 7 1 4 Span Gas Concentration This sets the oxygen concentration of the span gas used for calibration When the instrument air supply is used as the span gas enter 2196 O2 NOTE When the instrument air supply is to be used as a span gas cool the gas to 20 C below the dew point to remove moisture oil mist and dust from the air If this air purification is not per formed the accuracy of the calibration may be affected Setting Procedure 1 From the Calibration setup display select Zero gas conc and the numerical data entry is display is displayed Enter the oxygen concentration of the zero gas used for cali bration For example enter 0 98 vol O2 as 00098 2 From the Calibration setup display select Span gas conc and the numerical data entry is display is displayed Enter the oxygen concentration of the span gas used for calibration For example enter 21 vol 6 O2 as 02100 3 Calibration time setting If the mode is Man Select Hold time This is the output stabilization settling time required from calibration end until measurement is reentered During this time the calibration gas is switched to measurement gas and the measurement gas is allowed time to stabilize Setting range is from 00 min to 60 min 59 sec The analog outputs of individual channel
5. Figure 5 1 AC8 Parts Listing IM 11 602 02 5 3 BALANCING PRESSURE DROPS IN THE CAL LINES For accurate calibrations the auto cal system must provide a fixed flow of zero gas and span gas 0 6 LPM pr 600cc min To do this the pressure drop from the AC4 AC8 to each probe must be the same regardless of the length of tubing run or number of probes To balance the pressure drops perform the following steps NOTE Perform all adjustments with a flat tip screwdriver 1 Ensure gas and instrument air are plumbed to the auto cal unit Pressure should be set at 20 psig 2 psig 2 Locate the block solenoid shown in Figures 5 1 and 5 3 Using a flat tip screwdriver turn the manual override screw on the block solenoid to the vertical position as shown in Figure 5 2 ZERO SPAN SOLENOID SOLENOID FOR NORMAL OPERATION AND MANUAL OVERIDE SCREWS MUST BE IN THE POSITIONS SHOWN MOUNTING SCREWS NORMAL Figure 5 2 Zero and Block Solenoid 3 Locate the cal gas flow meter in Figure 5 1 Turn the black adjuster knob to the maximum open position This fully opens the cal gas regulator allowing precise adjustments of flow rates 4 Locate the channel solenoid valve for the probe with the longest tubing run in Figure 5 1 Turn the manual override screw to the horizontal or ON position Refer to Figure 5 3 5 Each channel has its own flow adjustment screw located on the channel solenoid valve as shown in
6. 8 _ 8 58 218 GLAND PANEL E x s 5 5 5 m 2 3 58 9 o O 3 0 75 2 gt 00000 o ui dd s 2 57 65 5 Figure 3 1 AC4 AC8 Dimensional Drawing 3 3 GAS SOURCES Zero Gas Typically 196 oxygen balanced in nitrogen is used however an oxygen mixture between 0 596 and 896 is acceptable NEVER USE PURE NITROGEN FOR ZERO CALIBRA TION GAS A compressed gas cylinder containing the zero gas is fitted with a dual stage regulator Zero calibration gas cylinders with regulators may be purchased from a local compressed gas supplier Follow the operation and safety in structions as supplied from your gas supplier The maximum pressure of the calibration unit is 35 psi NOTE The compressed gas cylinder must have the same CGA connec tion fitting as the dual stage regulator see accessories Span Gas Typically a clean dry air source is recommended such as instrument air 20 696 oxygen An in line filter is recom mended to remove any moisture or dirt prior to the calibra tion unit A regulator must be attached to the instrument air Source in order to reduce the flow to an appropriate pressure 35 psig max prior to reaching the calibration unit Reference Air The reference air is the same air as the span gas Thus the reference air is also clean dry instrument air Unlike span gas which is use only during calibration reference air flows to the
7. instrument air 7 Adequate spacing for reference and zero gas plumbing 8 Not positioned in direct sunlight NOTE If ambient atmosphere contains corrosive gases or high dust the use of air purging is recommended 3 2 MOUNTING The unit is designed for wall mounting by securing the four standoffs with bolts Allow for sufficient space to connect the copper or stainless steel lines to both sides of the enclosure Input gases zero calibration gas and instrument air are connected to the left side while all probe connections cal lines and reference air are on the right side when facing the unit Refer to Figure 1 for mounting dimensions and required clearances IMPORTANT Care must be taken to mount the unit as level as possible to ensure the accuracy of the flow rates If the unit is not level the flow rates will not be accurate IM 11M6D2 02E A 15 75 1 4 FEMALE NPT 400 28 5 215 9 1 5 ALL MOUNT FEET o CALIBRATION SYSTEM YOKOGAWA 9 er e 1 75 44 45 e 1 75 44 45 er 1 75 44 45 el lo 1 75 44 45 er e 1 75 44 45 7 1 75 44 45 er 1 75 44 45 eb lo h k 4 6 6 168 2 o 22 05 560 17 0 431
8. D S L LCOLAOLLLLLLLLLLLL A 4AIAALLU LLZZLL LLL 1 L L SZ J Model AC4 AC8 Automatic Calibration Unit User s For Use With AV550G M anu al Oxygen Analyzer Averaging Converter l 3 ll Overview U U humun ah humu u u u u Q Q 3 2 1 Models AC4 AC8 Multi Channel Automatic Calibration 7 3 oes ssl ater 3 3 3 2 MOUMING 2 u 2 yusa toe raten itia tree cere 3 3 9 GAS SOUICBB ii or eerie ecce sa a S anukasqa ASI 4 S Nolo ES 5 IV Wiring ETE 6 4 1 Wiring the AC4 AC8 to AV550G Averaging 6 4 2 Pressure Switch M1133AR Set Point Procedure 6 Ve Initial Flow Rate Seta Mt 7 5 Checking Tor EoakS m a aqu S u hava n ds 7 5 2 Setting for Reference Air 7 5 3 Balancing Pressure Drops in the Cal Lines u 8 5A Calibration Glieck cto ciere ced tecto d cete ro eri teen 9 Programing TTE 9 Set Up Menus for Calibration from the AV550G Averaging Unit 9 MOGOS uuu u l 9 7 1 2 Calibration Setup
9. Figure 5 3 Ad just the flow adjustment screw for the probe so that the flow rate shown on the cal gas flow meter is 1 LPM 1000 cc min NOTE DO NOT use the cal gas flow meter s adjustment knob to make this flow rate adjustment If necessary increase the air pres sure 6 Turn the manual override on the channel solenoid for the probe to the OFF normal position 7 Repeat steps 4 5 and 6 for the remainder of the probes that are being used NOTE DO NOT use the cal gas flow meter s adjustment knob to make this flow rate adjustment Use the individual channel s flow adjustment screw to adjust for varying pressure drops in the tubing runs 8 After all flow rates have been set manually to 1 LPM turn the channel solenoid for the probe with the longest tubing run back ON to the manual override position making sure all others are OFF normal position shown in Figure 5 3 Turn the cal gas flow meter s adjustment knob to 0 6 LPM 600cc min ZERO SPAN BLOCK SOLENOID SOLENOID D OVERRIDE 9 Turn the manual override screw Figure 5 3 on the zero span solenoid three way solenoid to the 90 position This starts the flow of the zero gas Adjust the needle valve to the left of the three way solenoid so that the flow rate is 0 6 LPM 600cc min If 0 6 LPM is difficult to obtain it will be necessary to slightly increase the zero gas pressure to the unit WARNING Do not adjust th
10. Using Pressure Switch AND Relay Pressure Calibration Switch gt Relay gt Status Pressure Switch Used as Input to Relay Pressure Switch Relay Energized and CLOSED gt OPEN CEUIDRATE Relay Deenergized Pressure Switch DO NOT and OPEN CLOSED CALIBRATE Figure 4 2 Calibration Using Pressure Switch and Relay Flow Chart The recommended pressure switch configuration is to the high pressure side of the zero gas regulator This is preferred because it gives the earliest warning of a decrease in zero gas pressure The switch is threaded into the high pres sure purge port of the dual stage regulator on the zero gas cylinder 4 2 Pressure Switch M1133AR Set Point Procedure For the AC4 AC8 Autocal units a gas pressure set point is used to indicate that the calibration gas zero gas is low Pressure Switch M1133AR is a cylindrical style pressure Switch which uses a diaphragm or piston sensor to detect a pressure change The recommended set point is 200 psi on the fall At the predetermined set point a SPST switch actu ates converting a pressure signal into an electrical signal M1132ZX Dual Stage Regulator M1133AR Pressure Switch Figure 4 3 Pressure Switch and Dual Stage Regulator The following procedure is required to adjust the set point 1 Thread the pressure switch into the high pressure gauge port on the regulator 2 With power disconnecte
11. back side of the zirconium cell and should be used at all times IMPORTANT When the instrument air has a nitrogen backup used for air failure instrument air for the reference gas should not be used this instance the probe must use either bottled air 20 6 oxygen balanced in nitrogen or natural convection for reference air flow IM 11 602 02 3 4 PIPING NEMA 4X 1 4 FEMALE NPT INSTRUMENT AIR ZERO GAS 35 psig MAX Figure 3 2 Piping Gases to the Auto Cal Unit Piping or tubing is required from the instrument air line and zero gas cylinder to the calibration unit Standard tubing is _ O D Outside Diameter copper or stainless steel Stainless steel is preferred as it is less likely to develop leaks The separate tubing for both the instrument air and zero gas are connected to the two separate 1 4 FNPT brass or stainless fittings on the LEFT side of the calibration unit Piping Gases to ZR22 Probes The tubing to the ZR22 probes is run from the RIGHT side of the calibration unit to each of the ZR22 probes as shown in Figure 2 Quarter inch 1 4 tubing should be used between the auto cal unit and the probes It is important to note 1 the reference air tubing is connected to the REF IN port at the probe 2 cal gas tubing is connected to the CAL IN port on the probe The REF IN and CAL GAS ports are located on the bottom of the ZR22 probe junction box The check gas and reference air
12. ce Auto Calibration starts It is performed for all installed chan nels so the interval needs to be larger than the sum of span and zero calibration times plus settling tines for all channels The Start date and Start time are for the first calibration in the Auto Calibration cycle repeated at the calibration inter val To set 2004 June 21 at 1 30 pm set Start date to YY 04 MM 06 DD 21 and Start time to HH 13 MM 30 Setting Procedure 1 From the Calibration Setup display select Timing and the display shown in Figure 7 4 appears In this example Mode is set to Auto 2 Select items and enter numerical values as required Chan 2 output hold Chan 1 removed from average Chan 2 removed from average on span gas zero gas on Calibration timing Hold time 2 0 05 Cal time 2 0 0s Interval 1d 00h Startdate 22 06 04 Starttime 11 00 Figure 7 4 Calibration time setting NOTE When setting keep the following points in mind 1 When calibration is to be started by a contact input signal the contact input signal on the Input Contacts display needs to be defined and enabled 2 The starting of Auto Calibration may be delayed by the status of the channel to be calibrated or by the status of other channels as explained by table 7 1 IM 11 602 02 12 3 If the calibration interval is shorter than the sum of the stabilization time plus calibrat
13. d slide the cover on the switch toward the electrical termination while twisting it to over come friction 3 Connect the power to the terminal or leads 4 Insert a flat head screwdriver 1 8 into the adjustment slot and turn counterclockwise to increase the setting or clockwise to decrease the setting IM 11 602 02 For setting on fall apply pressure equal to normal system operating pressure Reduce source pressure to set point value Turn the adjustment clockwise until switch clicks circuit across N C black and COM white closes For setting on rise apply desired pressure and turn adjustment left until switch clicks circuit across N O red and COM white terminal closes 5 After completing adjustments slide the cover closed over the adjustment compartment Recheck the set point value 6 Wire the pressure switch Normally Open to the AC4 AC8 terminals at the calibration unit that are labeled PS Remove the jumper across the PS terminals V INITIAL FLOW RATE SETUP 5 1 CHECKING FOR LEAKS Before considering your calibration unit operational it is a good idea to check for leaks along the full distance of the cal line tubing Additionally perform a cal check to confirm that the gases are plumbed correctly to each probe 1 Plug all the cal and reference air lines at the probes This requires disconnecting the fitting at the ZR22 Probe and plugging the tubing 2 Set the flow rate of the Ze
14. dures refer to the AV550G manual Section 12 IM 11 602 02 13 X SPARE PARTS AND ACCESSORIES 10 1 SPARE PARTS Refer to figure 10 1 for a list of replacement parts for the AC4 AC8 Auto Calibration Unit BLOCK SOLENOID ZERO SPAN SOLENOID M1132GP _ CAL GAS FLOWMETER M1132GM M1132CC NEEDLE VALVE BEC C M1132GK O H U CHANNEL MANIFOLD O t o WIT H MANUAL OVERRIDE D FLOW ADJUSTER TY _ euo M1132BY 4 Channel ENS REFERENCE GAS FLOWMETERS J M11392B2 8 Channel M1132CC eem ases oem o Pl Figure 10 1 1 Zero Span Solenoid M1132GM 2 Channel Manifold M1133BY 4 CHANNEL M1133BZ 8 CHANNEL 3 Needle Valve M1132GK BRASS M1132BX STAINLESS STEEL 4 Reference Cal Gas Flow Meters M1132CC BRASS M1132ZC STAINLESS STEEL IM 11 602 02 14 10 2 ACCESSORIES 10 2 1 Zero Gas Regulator M1132ZX This regulator controls the gas pressure of the zero gas cylinders before it reaches the calibration unit The dual stage regula tor is highly recommended for services which require a near constant delivery pressure as the calibration source decays See M1133AR Air diffusion and absorption desorption and off gassing are minimized because of its stainless steel construction NOTE This regulat
15. e 5 psig above set point 1 of water Less than 0 2 psig for 25 psi change 250 psig Less than 6 SCFM 0 to 60 psi 1 4 NPT Body Die cast aluminum alloy Diaphragm Nitrile elastomer and nylon fabric Trim Brass zinc plated steel acetyl 4 0 Ibs 1 8 kg The purpose of this gauge is to indicate the pressure of instrument air entering into the AC4 AC8 Figure 10 5 119 30 2 1 4 NPT Figure 10 5 Reference Air Gauge M1132ME Gauge Size 2 50mm Measuring Range 0 to 60 psi Connection 1 4 FNPT Weight 0 5 Ibs 0 2 kg IM 11M6D2 02E A 16 10 2 4 Zero Pressure Switch M1133AR Figure 10 2 6 The pressure switch is used to alert the Operator via a contact input that the zero gas cylinder needs to be replaced before the cylinder is empty The recommended connection is to the high pressure side of the zero gas regulator Refer to Figure 4 1 Figure 10 2 6 Zero Pressure Switch M1133AR Adjustable Set Point Ranges Dead Band Over Range Proof Pressure Storage Temperature Ambient Temperature Set Point Repeatability Switch Output Electrical Rating Enclosure Electrical Connection Pressure Connection Mounting Weight Approvals 10 2 5 Fuses M1132HG 30 to 575 psi on fall 50 to 600 psi on rise 8 to 60 psi 2 500 psi 3 000 psi 40 F to 180 F 40 C to 82 C O F to 160 F 18 C to 71 C 1 of span One SPDT either NC or NO Rated to 5 amps res
16. e cal gas flow meter or the flow adjustment screw on the individual channel solenoids 10 Confirm that all channel solenoid overrides for all used probed are turned back to the normal position as shown in Figure 5 3 IM 11 602 02 11 Turn the block solenoid and the zero span solenoid to the normal position WARNING If reference air is used during calibration the reference air must remain ON after calibration FLOW ADJUSTMENT SCREW PRESET FOR NORMAL OPERATION THE MANUAL OVERRIDE SCREW MUST BE IN THE VERTICAL POSITION FOR OVERRIDE THE MANUAL OVERRIDE SCREW MUST BE IN THE HORIZONTAL POSITION MOUNTING SCREW NORMAL OPERATION OVERRIDE Figure 5 3 Typical Channel Solenoid 5 4 CAL CHECK The purpose of performing a cal check at this time is to con firm that the calibration gas and reference air are plumbed correctly for each probe along with confirming that enough time was allowed for the cal gas to flow at the probe s cell tip Refer to the AV550G Instruction Manual for calibration codes and procedures VI PROGRAMMING All programming for the AV550G Averaging Unit is done through the display module Please refer to the AV550G Instruction Manual IM 11M12D01 01E Section 9 for ad ditional details The following is a brief description of setup procedures The ZR22G Probe is calibrated by applying two known gas standards In most applications the zero gas is around 196 oxygen w
17. ents noise caused by a low voltage pressure switch signal from being run in the same cable as the 120 VAC solenoid signal The relay is prewired as NORMALLY CLOSED NC to contact input 1 at the control card terminal 7 and 9 of the AV550G Contact check Output contact ch Output contact ctrl Solenoid valve contacts Input contacts Input contacts Input contact 1 Open g z Input contact 2 Open 4 lt Figure 4 1 AV550G Input Contact Screen WARNING When the relay is deactivated the unit will not calibrate The relay remains closed unless a 120 VAC source is connected to energize it Terminal 7 of the relay provides 120 VAC Neutral voltage is connected to terminal 2 of the relay from the AC4 AC8 calibration unit The relay switch is designed to OPEN when energized as depicted in the flow diagram shown in Figure 4 2 A pressure Switch input completes the 120 VAC signal used to energize the relay which is wired at the calibration unit as Normally Open NO where Open Low or Zero tank pressure AC4 AC8 unit is prewired with the jumper in place so that the relay will be energized and OPEN However if the pres sure switch input is used then remove the jumper between the terminals labeled PS at the calibration unit s terminal strip and attach the pressure switch The pressure switch is wired as normally open Calibration
18. in the zero correction values When changing gases it is also necessary to check the zero gas flow rate It is recommended that periodic inspections are performed to insure a sufficient supply of calibration gases when the pressure switch input is not used Also periodic checks verify that the flow rate of the calibration gases to the indi vidual oxygen detector probes have not been accidentally changed It is important that the zero gases flow at a rate of 0 6 LPM 600mL min while the reference air instrument air flows at 0 8 LPM 800mL min Refer to Section 10 of this manual for a listing of spare parts for the AC4 AC8 IX TROUBLESHOOTING 9 1 TYPICAL CALIBRATION PROBLEMS 1 Gas does not flow to the probe f reference air is used then the reference air flow meters should show 0 8 LPM at all times If the reference air flow meters do not show 0 8 LPM then confirm that the instru ment air has been turned on by checking the regulator gauge 10to 35 psi e Confirm override screws are in the NORMAL mode for the block solenoid and all channel solenoids e Turn block solenoid to the manual position Cal gas flow meter should show 0 6 LPM If cal gas flow meter shows 0 LPM turn the black knob on the flow meter to open the flow meter Set flow rates for all probes as according to proce dures shown in Section 5 of this manual 2 Flow meter will not go to 0 8 LPM for reference air Turn the flow rate adjustment knob onl
19. ion time the second calibra tion start time will conflict with the first calibration In such a case the second calibration will not be conducted When both zero and span calibrations are to be performed the calibration time is double that required for a single zero or span calibration 4 If the Calibration Interval is et to DD 00 HH 00 then auto Calibration will not be performed 5 If the start date is set before the current date then Auto Calibration will not start 6 Cal Time of Calibration timing display will be equalized to Check time of Semi auto ind Chk display other anas Purging Other Indication Blowback in Maintenance CAL chan CAL chan CAL chan other inwarmup ERR check in now channel other channel channel status status disabled Man Cal x x x x x x x x SemiAuto x x x x x x x x AutoCal Wait Wait Wait Wait Wait x x x X Cannot perform calibration Wait Wait until other command finishes before starting calibration Table 7 1 When Auto Calibration conflict with Other Commands MAINTENANCE Because of the AC4 AC8 unit s simplified construction no routine maintenance is required other than replacing the calibration gas when necessary When cal gas cylinders are changed refer back to Section 7 1 2 Calibration Setup Pro cedure Failure to perform the Calibration Setup Procedure upon replacing cal gases will result in an error
20. istive and 15 amps inductive 75 PF at 125 and 120 VAC 1 4 HP Aluminum with irradiate finish rated for 100 hours of salt spray One SPDT output 1 4 NPTF 5ft cable 1 8 NPTM NPTM pressure connection 120z 340g UL 508 listed E42272 CSA C22 2 No 14 1987 LR 9690 Two fuses are imbedded in the power supply input terminals of the AC4 and AC8 calibration units Current Rating Slow Blow Time Size Approvals 1 amp 100 4hours maximum 135 1 hour maximum 200 5 second maximum 14 x 1 1 4 L UL Listed CSA approved IM 11M6D2 02E A APPENDIX A IM 11 602 02 18 IM 11 602 02 APPENDIX B IM 11 602 02 20 IM 11 602 02
21. ith the balance nitrogen The span gas is instru ment air 20 95 96 oxygen The zero gas concentration must be certified so the exact concentration can be programmed into the AV550G memory Calibration values required for full auto calibration operations are stored in the menu of the AV550G For additional information refer to Chapter 8 of the AV550G manual for a full explanation of all parameters Shipping time default setting for zero gas is 196 oxygen and for span gas is 21 Figure 6 1 Item Initial value Mode Manual Points Span Zero Zero gas conc 1 00 Span gas con 21 00 Hold time 3 min 00 sec Cal time 3 min 00 sec Interval 1 days 00 hrs Starting date yy01mmo01dd01 Starting time hhOOmmoO Figure 6 1 VII SET UP PROCEDURES 7 1 Mode There are three calibration modes for zero and span calibra tion manual mode semi automatic mode started from the display or started by contact input using preset calibration time and stabilization settling time and auto calibration at preset intervals Restrictions related to each mode are described here When Manual Mode is selected In this mode only Manual calibration can be performed Contact input used to start semi auto calibration has no ef fect Auto calibration does not start at auto calibration start time When Semi Auto Mode is selected In this mode manual calibration or semi automatic calibration can be performed Auto ca
22. libration does not start at auto calibration start time When Auto Mode is selected Any calibration mode is valid A caution Indication check mode of Auto cannot coexist with Auto Calibration mode Therefore if the mode of indication Check is set to Auto you cannot set the mode of Calibration to Auto and vice versa lt Setting Procedure gt 1 From the basic panel display if you touch the Setup key the Execution Setup display appears Select Maintenance 2 From the Maintenance display select CalibrationSetup the Mode amd you can selct Manual Semi Auto or Auto in the selection drop down that appears Figure 7 1 IM 11M6D2 02E A 10 Calibration setup Mode Points Semi Auto Auto Zero gas conc 98 Span gas conc 21 00 v Timing hi initiali 1 Cal history initialize Either Span or Zero or both calibrations can be performed Normally select both Span Zero Figure 7 1 Calibration Mode Setting 7 1 2 Calibration Setup Procedure Setting Procedure From Maintenance t Calibration setup display select Points then a selection window opens and Span Zero Span or Zero may be selected Figure 7 2 Calibration setup Mode Auto Points Spam cerr Zero gas 2Pan 98 Enter Zero Span gas conc Timing Cal history initialize Figure 7 2 Procedures for Setting Calibration Mode 7 1 3 Zero Gas Concentration
23. or is used on a zero gas cylinder with CGA 580 connection The Cylinder connection must be CGA580 used for 596 oxygen balanced in nitrogen m I Figure 10 2 Zero Gas Regulator M1132ZX Maximum Inlet Pressure Operating Temperature Range Bonnet Vents Inlet Outlet Connection Purge Ports Weight Material of Construction Delivery pressure Range Flow Capacity Air Gauges 3 000 psig 40 F to 200 F 1 8 NPTF CGA 580 with 1 4 NPTM 1 4 NPT Female 4 7 lbs 1 75 kg Body 316L Stainless Steel Diaphragm 316L Stainless Steel Seat Seal Tetzel Teflon Kel F Gauges 316L Stainless Steel Bonnet brass nickel plated 2 to 75 psig 300 scfh Delivery O to 100 psig Cylinder pressure 0 to 3 000 psig 2 diameter ISOMETRIC IM 11M6D2 02E A 15 10 2 2 Pressure Regulator M1132KD This general purpose regulator is used to adjust the pressure of instrument air entering the AC4 AC8 Figure 10 4 2 10 24 UNC MOUNTING HOLES 1 4 NPT GAUGE PORT 1 4 NPT 63 5 Figure 10 4 Pressure Regulator M1132KD Flow Capacity Exhaust Capacity Sensitivity Effect of Supply Pressure Variation Maximum Supply Pressure Air Consumption Output Range Port Size Materials Weight 10 2 3 Pressure Gauge M1132ME 20 SCFM 33 6m hr at 100 psig supply 20 psig outlet 0 1 SCFM 0 17m hr downstream pressur
24. ports require a 1 4 FNPT fitting 1 4 FEMALE NPT er i PROBE 1 CAL GAS i i PROBE 2 3 i PROBE 4 PROBE 5 PROBE 6 He PROBE 8 Flexible stainless steel hose is recommended for the connection between the ZR22 and the tubing This will allow for probe movement due to thermal expansion of the duct IMPORTANT To prevent leakage all compression fittings should be installed per manufacturer s recommendations In addition to this a check valve is usually installed on the cal gas inlet of the ZR22 probe to protect the cal tubing from moisture contamination IM 11M6D2 02E A IV WIRING 4 1 Wiring the AC4 AC8 to the AV550G Averaging unit Please refer to appendix A for the system configuration drawing Solenoid Relay and Pressure Switch wiring connections The AC4 AC8 uses 120VAC 60 Hz for all solenoids Al though two internal 1 amp fuses are provided for the 120 VAC terminal an external 5 amp circuit breaker is recom mended Included with each fuse is an LED that is activated when the fuse is blown Recommended wiring is 14AWG run in conduit If conduit is not used wiring should have a suitable jacket to meet environmental and regulatory codes The ACA unit requires a maximum of 8 conductors whereas the AC8 requires 12 conductors NOTE A 120 VAC relay included with NEMA 4 enclosure shown at ter minal K1 is required at the AV550G if a pressure switch is used This prev
25. ro Gas and Instrument Air to 20 psig using the regulators BLOCK SOLENOID ZERO SPAN SOLENOID M1132GM M1132GP 3 Locate the block solenoid shown in Figure 5 Using a flat tip screwdriver turn the manual override screw on the block solenoid to the 90 position as shown in Figure 5 2 4 Turn the channel solenoid valve s manual override screw to the horizontal or ON NOT NORMAL position for Uall probes in use See Figure 5 1 and 5 3 5 Apply leak detection spray on all compression fittings and bends of the cal line tubing for all probes Spray both the reference air and cal gas line s 6 Inspect the full length of the cal lines to determine if there is a leak Repair any leaks 7 After repairing the leaks if any turn all probe channel solenoids and the block solenoid to the NORMAL position as shown in Figure 5 2 and 5 3 8 Unplug tubing at the ZR22 probe s and reconnect 5 2 SETTING REFERENCE AIR FLOW Locate the reference flow air meters in Figure 5 1 Adjust the black flow adjustment knob on each reference air flow meter to 0 8 LPM 800cc min NOTE Reference air flow should be adjusted before the calibration adjustments are made CAL GAS FLOWMETER M1132CC NEEDLE VALVE M1132GK REFERENCE GAS FLOWMETERS M1132CC E CHANNEL MANIFOLD WIT H MANUAL OVERRIDEAN D FLOW ADJUSTER M1132BY 4 Channel M1132BZ 8 Channel
26. s which are under calibration remain Output Hold status from the start of cali bration until the end of the stabilization settling time and their output is not included in the averaging group calcula tions during this time If the mode is in Semi Auto In addition to the above Hold output stabilization settling time there is also a Cal Time setting This is the setting time from when calibration gas flow is started until calibra tion is performed The same time setting is used for both Zero and Span calibration Setting range is from 00 min to 60 min 59sec Calibration time and stabilization time and analog output status are shown on the calibration timing chart of Figure 7 3 below For solenoid valve SV piping and wiring refer to Section 5 of AV550G manual IM 11 602 02 11 Cal start in Chan 1 Span CAL CAL time Chan 1 Zero CAL CAL time Chan 1output hold i I i Stabilization Chan 2 Span CAL CAL time 2 Zero Cal CAL time Chan 2 output hold i Stabilization i Average output SV Chan 1 contact off SV Chan 2 contact off SV Chan 2 contact span gas on zero gas on CAL start Figure 7 3 If the mode is Auto In addition to the above Hold output stabilization settling time Cal Time setting there is also Cal Interval Start date and Start time The Automatic Calibration Interval can be set in the range 00 days 00 hrs to 255 days 23 hrs on
27. y NOT the override Screw Only one channel should be in the manual override posi tion All other probes should be in the normal position Check the pressure regulator at the gas source If the pressure is below 14 psi increase pressure in increments of 5 psi and adjust reference flow meters DO NOT in crease pressure to greater than 35 psi If more than 35 psi is needed attempt to move the calibration box closer to the probes without compromising safety or the ambient operat ing temperature of the auto cal unit Tubing outside diameter O D should not be greater than 1 4 Tubing runs should not be in a T position and should remain separate for each probe Check for leaks at compression fittings All NPT fittings should have Teflon tape on the threads to prevent leaks 3 Flow meter will not go up to 0 6 LPM for cal gas e Same solution as above except make adjustment to the cal gas flow meter 4 Wrong gas flowing to the probe Confirm that gases are plumbed correctly at the left side of the calibration unit Turn the override screw on the three way solenoid to the normal position Perform a cal check in semi auto calibration mode See Section 5 IMPORTANT When performing an actual automatic or semi automatic cali bration and a calibration alarm occurs it is necessary to reset the channel Instead recalibrate the channel to remove the cali bration alarm For additional troubleshooting proce
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