Gilib-2 Manual Rev G with Piston
Contents
1. 9 Pin Connecting Jack o back Safety Tape r Q i Air Outlet Boss P ST io Flow Tube ma Bubble Initiate Button Sensor Block Locking Screws 2 Safety Tape Storage Tubing d Air Inlet Boss Bubble Generation Ring mo 0 Base Plate O Ring Base Plate Assembly 0 Figure 2 4 Wet Cell Assembly Exploded View Sensidyne Document No 850190M Rev G 15 SECTION THREE SETUP 3 1 SYSTEM SET UP 3 2 CELL ASSEMBLY SET UP This section describes the steps necessary to set up the Gilibrator 2 Calibration System This includes initial setup mounting the Cell Assembly connecting the ca bling adding soap solution to wet cell assemblies and setting up the sampling source Figure 3 1 shows how a complete Gilibrator 2 Calibration System may be con figured Prior to setup make certain you have properly con nected the battery charger to the Charger Jack in the Control Unit and to an appropriate AC wall outlet If the charger adapter is properly connected the Charge Indicator should light up If you plan to use the Gilibrator 2 in the field make certain the unit is fully charged at least 14 hours be fore operating the unit If you plan to use the unit in the lab G e near an AC wall outlet you can continue with setup and operation immediately IMPORTANT COMPATIBILITY NOTE Most flow cells desi2. Cable Assembly CE Base 9 Pin connector non CE Base 15 pin connector Control Unit Base cC NS Mounting Plate Printer PC Jack side of unit Display Q Charger Jack OFF Button ON Button Charging Indicator DELETE RESET Button Figure 2 1 Control Unit 10 Sensidyne Document No 850190M Rev G GILIAN GILIBRATOR 2 CALIBRATION SYSTEM SEIDEL FIVE mow Bgggu AVERAGE BBBB s SAMPLE BB LOW BAT WAIT ERROR Gi li 19172 4 4 PRIMARY FLOW CALIBRATOR v 5 2 T o o D Made in USA Patent Pending Figure 2 2 Liquid Crystal Display Sensidyne Document No 850190M Rev G 1 1 GILIAN GILIBRATOR 2 CALIBRATION SYSTEM 2 2 PISTON CELL ASSEMBLY 2 3 WET CELL ASSEMBLY The Piston Cell Assembly refer to Figure 2 2 is a single unit that need not be disassembled and requires very little maintenance The assembly contains a preci sion cylinder piston assembly A green Ready Light on the side of unit signals when the unit is ready and sampling may begin A Bleeder Valve located on top of the cell assembly is closed to provide the vacuum necessary to move the piston up the tube Secured to the flow tube and secured between the up per and lower portions of the cell assembly is the Sensor Rail refer to Figure 2 3 The Sensor Rail in cludes lower and upper infrared sensors used to time the movement of the piston through the flow cell
3. Electrical Specifications Power Source DC Battery SD VD ires eerie 16 Battery Charge Time Expected Battery Life Input Voltage sss Input Current eet Transmission Link Requirements Interface Connectors sanonu aas Sensidyne Document No 850190M Rev G Painted aluminum sheet metal Base Horizontal on flat surface ONT Button OFF Button DELETE RESET Button Display LCD Charge Indicator LED Flow 4 digit Average 4 digit Sample 2 digit Flow 0 9999 Average 0 9999 Samples 0 99 Low Bat Wait Error 1 Error 2 60 5 to 35 C 41 to 95 F 0 to 50 C 32 to 122 F 0 85 RH non condensing 0 100 RH non condensing Better than 196 Wet CelD Better than 396 Piston CelD Internal Battery Pack Rechargeable 14 hours over 300 charge recharge cycles 5 5 7 5 Vdc 50 60 mA RS 232 Charger Jack 2 1 mm barrel jack Connecting Jack Sensor Block DB 9 Wet Cell Connecting Jack Sensor Rail DB 15 Piston Cell Printer Jack DB 25 29 APPENDIX C RETURNED MATERIAL AUTHORIZATION Sensidyne maintains an instrument service facility at the factory to provide its customers with both warranty and non warranty repair Sensidyne assumes no liability for service performed by personnel other than S
4. emou Dilian Gilibrator 2 CALIBRATION SYSTEM OPERATION amp SERVICE MANUAL DE TWIST I VE 16333 Bay Vista Dr Clearwater FL 33760 800 451 9444 s 727 530 3602 727 539 0550 FAX www Sensidyne com Revision G e Document No 850190M LETTER FROM THE PRESIDENT Thank you for purchasing your new Sensidyne air monitoring product We stand behind all of the products we sell each Sensidyne product has been designed and manufactured to provide unparalleled service day after day Our professional staff has tested each unit under the strictest conditions possible to ensure success ful accurate results every time With the minimal care and maintenance described in this Operation amp Service Manual the Sensidyne product you have purchased will give you many years of reliable service Our only goal is that you are pleased with the quality performance and accuracy of your Sensidyne product Be assured of our complete and prompt answers to any questions you may have about this product since we are totally committed to providing you with fast responsive customer service and technical support If you ever have difficulty solving a problem with any Sensidyne product or if you are not 1009 satisfied with the service you receive from any level of our organization please let me know about it Call me at either of the numbers listed below and I will personally research your problem t
5. The movement of the piston up and down the flow tube provides the means for calculating an accurate flow rate As the piston moves past two infrared sen sors each sensor transmits a signal to the Control Unit indicating the passage of the piston Pulsation Damper This built in damper smooths out any pulsation within the airflow and reduces oscillation of the piston assur ing maximum accuracy The Piston Cell Assembly has a flow rate range from 1 to LPM IMPORTANT NOTE CE approved Control Unit Bases have 9 Pin cables and CANNOT be used with Piston Cells Non CE Control Unit Bases have 15 Pin cables and can be used with Piston Cells 12 The Wet Flow Cell Assembly refer to Figure 2 4 con sists Of a Bubble Generator and Sensor Block Each Bubble Generator is sized to produce a bubble film stretched across the diameter of the flow cell tube The bubble is carried by airflow from the bottom to the top of the tube As the bubble moves past two in frared sensors each sensor transmits a signal to the Control Unit indicating the passage of the bubble film A manual push button on the Flow Cell Assembly starts the bubble film on its travel up the tube Wet Cell Assemblies come in three sizes and can be used with both CE and non CE Control Base Units e Low Flow 1 to 250 ccm e Standard Flow 20 ccm to 6 lpm e High Flow 2 to 30 lpm 2 3 1 Bubble Generator Components The Bubble Generator uses a special soap soluti
6. Calibration Panel Printer Module and all three Wet Cells All kits come with 15 Pin Control Base Unit except where noted Part No Description Piston Cell Kits 1 5 LPM 801868 1 Basic 115 VAC 801868 2 Basic 230 VAC 801868 3 Basic with Printer 115 VAC 801868 4 Basic with Printer 230 VAC 801869 1 Diagnostic 115 VAC 801869 2 Diagnostic 230 VAC 801869 3 Diagnostic with Printer 115 VAC 801869 4 Diagnostic with Printer 230 VAC High Flow Wet Cell Kits 2 30 LPM 800270 Basic 120 VAC 800270 2 Basic 230 VAC 800270 2 CE Basic 230 VAC 9 Pin CE Base Standard Flow Wet Cell Kits 20 cc 6 LPM 800271 Basic 115 VAC 800271 2 Basic 230 VAC 800271 2 CE Basic 230 VAC 9 Pin CE Base 800844 2 Diagnostic 115 VAC 800844 2 230 Diagnostic 230 VAC 800844 2 230 CE Diagnostic 230 VAC 9 Pin CE Base Low Flow Wet Cell Kits 1 cc 250 cc 800272 Low Flow Kit 115 VAC 800272 2 Low Flow Kit 230 VAC 800272 2 CE Low Flow Kit 230 VAC 9 Pin CE Base 800844 1 Diagnostic Kit 115 VAC 800844 1 230 Diagnostic Kit 230 VAC 800844 1 230 CE Diagnostic Kit 230 VAC 9 Pin CE Base Deluxe Kits includes all three Wet Cells 800275 Deluxe Kit 115 VAC 800275 2 Deluxe Kit 230 VAC 800275 2 CE Deluxe Kit 230 VAC 9 Pin CE Base 801804 Deluxe Kit No Printer 115 VAC 801804 1 Deluxe Kit No Printer 230 VAC 801804 1 CE Deluxe Kit No Printer 230 VAC 9 Pin CE Base 800844 4 Deluxe Diagnosti
7. E eene 16 3 22 Cabling COrin ctionS oet PR Te ee EUR GE ae a i ar e 20 3 2 3 Adding Soap Solution Wet Cell only cty 20 3 24 Sampling Source COnn CfiOI c ng eee 20 Sensidyne Document No 850190M Rev G 5 TABLE OF CONTENTS SECTION FOUR OPERATION 4 1 Piston Cell Operation ii tee Eee a i ere dere qt 22 22 Eeer E lee 22 4 2 Wet TER EEN 23 E Ae Start Ud EE 23 4 2 2 Bubble GeneratiOT T TT E 1111k kg 23 42 3 e e EE 23 SECTION FIVE MAINTENANCE 5 1 StOrage 4 0 QU EE 24 5 2 Piston Cell Maintenance RANNER 24 5 3 Wet Cell Maintenance TT TH Hs SH HH KH gen g nen nen ky 25 5 3 1 General MaintenanCe xx eee ee erect tres ea e ERE eres 25 532 Damper Plate Diaphragm 25 5 5 5 Additional Wet Cell Maintenance mene 25 SECTION SIX APPENDICES Appendix A Parts List 27 Appendix B Specifications ng HH ngu 29 Appendix C Returned Material Authorization 30 LIST OF FIGURES Dials Control Unit 424 A db deste epe ttis a dee Pe Sapte codes 10 2 2 LiquidiGrystal DISpl y is t INTR ete rede T S Ta 11 2 5 Piston Gell Assembly eae dtu e LEaRdE 13 2 4 Wet Cell Assembly Exploded View nh HH HH HH H 15 3 1 Gilibrator 2 System Set Up ge
8. return address purchase order shipping and billing information RMA number a description of the problem encountered with your instrument and any special instructions All prices are subject to change without notice If this is the first time you are dealing directly with the factory you will be asked to prepay or to authorize a COD shipment Send the instrument prepaid to SENSIDYNE 16333 BAY VISTA DRIVE CLEARWATER FL 33760 USA ATTENTION Service Department RMA 30 SERVICE OPTIONS The Sensidyne Service Department offers a variety of service options which will minimize costly interruptions and maintenance costs These options include initial training on site technical assistance and full factory repairs Sensidyne has developed several programs which offer options best suited to your applications and needs For further information contact the Sensidyne Service Department at the following numbers 800 451 9444 e 727 530 3602 e 727 538 0671 Service Fax Sensidyne Document No 850190M Rev G ISO 9001 on Certificate No 970084 ETE Lies T NUES 16333 Bay Vista Dr Clearwater FL 33760 800 451 9444 727 530 3602 727 539 0550 FAX www Sensidyne com Revision G e Document No 850190M
9. shortly after this message appears NOTE Batteries must be fully charged for unit to function properly WAIT Indicates there is a flow measurement in progress ERROR 1 Indicates trouble with the Flow Cell connection or ad justment ERROR 2 If this message appears call the factory 2 1 3 Interface Components Charging Jack A 2 1 mm barrel jack that supports a standard AC DC charger adapter With the charger adapter the unit can be operated while continuously plugged into an wall socket Or the charger can be used to charge the unit overnight 14 hours prior to operation in the field Printer Jack A 25 pin printer connector allows the unit to be con nected to a a Thermal Printer b a PC compatible dot matrix or ink jet printer c an PC computer The jack connects to a printer using a standard DB 25 to Centronics printer cable A Gilibrator 2 Flow Monitor ing Software Kit is available The kit includes an oper ating manual special cable and software Cable Assembly The 9 Pin or 15 pin cable assembly connects to the Connecting Jack located on the back of the flow cell as sembly On piston cell assemblies the cable directly connects to the cell assembly 15 pin jack Wet cell as semblies require a 15 to 9 pin adapter NOTE Only non CE Control Bases with 15 Pin cable assemblies can be used with Piston Cells Sensidyne Document No 850190M Rev G 9 GILIAN GILIBRATOR 2 CALIBRATION SYSTEM
10. to read display simultaneous display of flow rate flow average and number of samples taken dis play indicators for LOW BAT WAIT ERROR 1 and ERROR 2 and automatic power shutoff when the unit is inactive for 15 minutes You can also specify the number of samples to be taken 5 to 95 in 5 sample increments Gilibrator 2 Calibration System Kits include either a Wet or Piston Cell Assembly Control Unit Base either CE or non CE approved Battery Charger Tubing and Soap Solution amp Dispenser Wet Cells only A 15 to 9 pin adapter is included with the non CE Control Base to allow it to operate with existing 9 pin Wet Cell As semblies Interchangeable Flow Cell Assemblies are available as follows e Piston Cell 1 to 5 LPM e Low Flow Wet Cell 1 to 250 cc m e Standard Flow Wet Cell 20 cc m to 6 LPM e High Flow Wet Cell 2 to 30 LPM To be a primary standard all values must be absolute and measured as absolute A primary standard airflow measurement is a volume divided by a time interval as performed by the Control Unit of the Gilibrator 2 The volume V is measured volume of space between two infrared sensors The time t is that interval needed for an object soap film bubble or piston cell piston to travel between the two sensors which bound the volume Thus the volume per unit of time V t becomes the flow rate Because the electronic clock is far more accurate than the volume measure ments the volume measure
11. 15 Pin Cable Control Base Unit 9 Pin Cable CE Control Base upgrade for use with Piston Cell call Customer Service Non CE applications only Piston Cell Assembly 1 to 5 LPM can only be used with non CE Control Bases effective 7 1 99 DB15 to DB9 Adapter for use with Wet Cells Low Flow Wet Cell Assembly 1 250 cc m Standard Flow Wet Cell Assembly 20 cc m 6 LPM High Flow Wet Cell Assembly 2 30 LPM Storage Tubing Low Flow 3 16 ID x 5 16 0D x 1 1 2 length Storage Tubing Standard Flow 1 4 ID x 7 16 0D x 2 3 4 length Storage Tubing High Flow 1 4 ID x 7 16 0D x 4 1 2 length Safety Tape 10 ft Flow Cell Soap Solution 8 oz Soap Dispenser Bottle Standard Carrying Case Gilibrator 2 Battery Pack Gilibrator Battery Pack Operation amp Service Manual Sensidyne Document No 850190M Rev G APPENDIX B SPECIFICATIONS SPECIFICATIONS General Specifications Base Unit ConstructiOon Unit Orientation c GD Tadica OS c I uitae Display Data uates Display RAanges uo iae fe Display Messages m Viewing Angle 9 90 Performance Specifications Operating Temperature Storage Temperature pt Operating Humidity Storage Humidity sse A CCULACY jis eoi ir OE PER TOU dk
12. 50190M Rev G GILIAN GILIBRATOR 2 CALIBRATION SYSTEM PISTON CELL 15 Pin Connector back IMPORTANT NOTE effective 7 1 99 CE approved Control Unit Bases have 9 Pin cables and CANNOT be used with Piston Cells Non CE Control Unit Bases have 15 Pin cables and can be used with Piston Cells 9 Pin Connector 15 to 9 Pin Adapter Necessary only if using a 15 Pin Base Thermal Printer Ser 9 Pin Pin or Connector 15 Pin Go Connector llla PC compatible Dot Matrix or Ink Jet Printer Centronics Cable Charging Jack Printer Jack Giliam ilibrator 2 DELETE PRIMARY FLOW CALIBRATOR Air Sampling Pump using 1 4 Tubing s Control Unit Battery IBM PC Computer amp Printer Charger through Gilian Cable Figure 3 1 Gilibrator 2 System Setup Sensidyne Document No 850190M Rev G 1 GILIAN GILIBRATOR 2 CALIBRATION SYSTEM 18 pg Select the appropriate Cell Assembly and lower it onto the Mounting Plate Align the Mounting Pins on the Cell Assembly bottom with Mounting Slots on the Mounting Plate see Figure 3 3 for top view If alignment is correct the Cell Assembly bottom should mount flush with the Mounting Plate Grasp the lower portion of the Cell Assembly and rotate it in the direction of the arrow until it clicks into place NOTE Always grasp lower por
13. ON FOUR OPERATION 4 1 PISTON CELL OPERATION 4 1 1 D 2 3 4 5 6 7 IMPORTANT NOTE CE approved Control Unit Bases have 9 Pin cables and CANNOT be used with Piston Cells Non CE Control Unit Bases have 15 Pin cables and can be used with Piston Cells Start Up Press the ON and DELETE RESET buttons simulta neously Adjust the sample size by pressing the DELETE RE SET button The sample size can range from 5 to 95 in steps of 5 Press the ON button The unit will go through its inital start up sequence When the Ready Light green LED goes on the unit is ready for operation Close the Bleeder Valve to begin operation of the cell pston The unit will measure and record the number of samples set in Step 2 When that number is reached the piston will continue to operate but no more data will be recorded on the display WARNING Do not open the Bleeder Valve while samples are being taken This will cause the next reading and the average to be in error It is okay to open the Bleeder Valve AFTER the last sample has been taken To take another set of samples press the DELET RESET button 22 If a printer is used be sure it has completed its printing sequence before pressing the DELETE RESET button When this button is pressed for less than 1 second a negative symbol appears on the Control Unit display The printer also initiates a line showing this subtrac tion I
14. R DIRECT INDIRECT CONSEQUENTIAL INCIDENTAL OR OTHER DAMAGES RESULTING FROM THE SALE AND USE OF ANY GOODS AND SELLER S LIABILITY HEREUNDER SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF ANY GOODS FOUND DEFECTIVE THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE OR FOR A PARTICULAR PURPOSE WHICH ARE EXPRESSLY DISCLAIMED 4 Sensidyne Document No 850190M Rev G TABLE OF CONTENTS PREFACE Packinoe List Ew a a E RO ute es Re ee 3 Notes E eoe aha dieu et edat ou e Pe bu db eu d D qu ERR 4 LB 7 1 11 11 Cs 7 SECTION ONE INTRODUCTION 1 1 Overview EE e div eee temet tete pe eie te betel A 8 1 2 Theory of Op ration oie CL ego pA asp Dee dd 8 SECTION TWO COMPONENTS 2 1 Control Unit odes tete e sad eder ei e edt erc RA 9 2 41 1 Buttons Se Indicators iia e reser Ret peret ees sre eye ee 9 2 1 2 i Display Characters a tore ee tree ted std 9 2 1 3 Interface Components eese cette ri eee den Od ni e G i 9 2 2 Piston Cell Assembly d e ee ttes ee ell vedere ate vua 12 2 3 Wet Cell Assembly ue ehe Ee 12 2 8 4 Bubble Generator Components eee eee eene 12 LILA Sensor Blocked eq reb a edt dee eh ate 14 SECTION THREE SET UP 3 1 System AUD E 16 3 2 Gell Assembly Set Up echt e EENS 16 3 2 1 Cell Assembly Mounting rescriere e nen
15. Unit the sampling source and any attached output devices if applicable If the unit is to be used daily remove the air sampler connection If using a Wet Cell Assembly connect the Storage Tubing to both the Air Outlet Boss upper and Air Inlet Boss lower Plug in the battery charger and connect it to the Control Unit Charging Jack Re charge the unit overnight 14 hours for next day us age Long Term If the Gilibrator is not to be used for long periods of time use the following procedures to keep the unit in proper working order 1 Disconnect the Cable Assembly from the connec tor on the Cell Assembly 2 Remove the Cell Assembly from the Control Unit Base in the reverse order in which it was mounted 3 Wet Cell only Pour the soap solution out of the Flow Cell through the Air Inlet Boss To do this hold the Wet Cell Assembly horizontally Air Inlet Boss closest to ground and then tilt the assembly until the Air Inlet Boss is tipped downward at a 45 angle 4 Wet Cell only Continue holding the Flow Cell Assembly horizontally until all of the soap solu tion has poured out 24 The Piston Cell Assembly is virtually maintenance free As such the Piston Cell should not be disassembled In the rare event that maintenance on the Piston Cell is needed return the unit to the factory see Appendix C for information on obtaining a Returned Material Authorization You should return the unit to the fact
16. ated on the back of the Wet Cell refer to figure 2 4 Be sure to properly match up the connectors before engaging Connect the appropriate optional printer or computer cable to the Printer Jack located on the left side of the Control Unit Make certain the cable and Printer Jack connectors match up before making a complete con nection Once the cable has been properly connected turn on the printer or computer and make certain it is prepared to receive data before turning on the Gilibra tor 2 unit 3 2 3 Adding Soap Solution Wet Cell only WARNING Only use Soap Solution Part No 800450 with the Flow Cell Assembly Use of other soap solutions can damage the Flow Cell Add soap solution to the unit as follows 1 Remove the Storage Tubing from the Air Outlet Boss see Figure 2 3 of the Flow Cell Fill the dis penser bottle provided with Gilibrator soap solu tion Using the rubber Storage Tubing as a funnel slowly add soap solution from the dispenser refer to Figure 3 4 20 2 The amount of soap needed is determined by de pressing the Bubble Initiate Button and holding it down in the lower position Continue to add enough soap solution until the angled edge at the bottom of the Bubble Generator Ring is immersed in the solution CAUTION Do Not Overfill 3 After filling is completed the rubber Storage Tub ing may be removed completely Recap the soap dispenser bottle for later use NOTE If
17. ation and Service Manual must be read and understood by eacb user before operating tbis product or using its accessories in order to ensure proper and safe use and installation of this product and to ensure familiarity with the proper treatment and safety procedures in the event of an accident DO NOT remove cover or alter any label or tag on this product its accessories or related products DO NOT operate this product should it malfunction or require repair Operation of a malfunctioning product or a product requiring repair may result in serious personal injury or death DO NOT attempt to repair or modify the instrument except as specified in the Operation and Service Manual If repair is needed contact the Sensidyne Service Department to arrange for a Returned Material Authorization CRMA Use ONLY genuine SENSIDYNE replacement parts when performing any maintenance procedures described in this manual Failure to do so may seriously impair instrument performance Repair or alteration of the product beyond the scope of these maintenance instructions or by anyone other than an authorized SENSIDYNE serviceman could cause the product to fail to perform as designed and persons who rely on this product for their safety could sustain severe personal injury or death ALWAYS turn off the instrument before changing any batteries ONLY use Soap Solution Part No 800450 with the a Wet Flow Cell Assembly Use of other soap solutions can damage the Fl
18. c Kit 115 VAC 800844 4 230 Deluxe Diagnostic Kit 230 VAC 800844 4 230 CE Deluxe Diagnostic Kit 230 VAC 9 Pin CE Basel Important Note CE approved Control Unit Bases have 9 Pin cables and CANNOT be used with Piston Cells Non CE Control Unit Bases have 15 Pin cables and can be used with Piston Cells Sensidyne Document No 850190M Rev G 2 7 APPENDIX A PARTS LIST Accessories Part Number Item Description Printer Module Kit 115 VAC includes printer paper charger amp cable assembly 800274 800274 230 Spares 700721 850260 850082 850262 850260M 801841 200904 200914 401984 7017010 400674 400794 1 Printer Module Kit 230 VAC includes printer paper charger amp cable assembly Printer only Flow Monitoring Software Kit for Windows includes cable software amp manual PC Interface Cable only Program Disk Set only Software User Manual only Deluxe Carry Case for 3 cells Latex Tubing 18 Standard High Flow 1 4 ID x 7 16 OD 2pieces Latex Tubing 18 Low Flow 1 8 ID x 7 16 0D 2 pieces Gilibrator 2 AC Charger Adapter 115 VAC Gilibrator 2 AC Charger Adapter 230 VAC Gilibrator AC Charger Adapter 115 VAC Gilibrator AC Charger Adapter 230 VAC Part Number Item Description 28 850190 850190 1 850190U 801858 850268 800267 1 800266 1 800265 1 200789 200666 200649 800331 800450 400667 800402 700560 400692 850190M Control Base Unit
19. e plate into upper flow cell chamber 7 Apply Safety Tape around the lip of the Damper Plate Assembly 8 Replace the Sensor Block Assembly Secure the block to the Cell Assembly by tightening the lock ing screws CAUTION Never exert your body weight on the Bubble Generator to press the plate into place Excessive weight on the Cell Assembly may result in breakage Sensidyne Document No 850190M Rev G 5 3 2 Damper Plate Diaphragm Refer to Figure 4 1 and perform the procedure as fol lows 1 Remove the Safety Tape from around the lip of the Damper Plate assembly Using a small flat blade screwdriver remove the Damper Plate from the Upper Cell Chamber using the notch pro vided Remove the large O ring and the Pulsation Damper diaphragm 2 To replace center the new diaphragm over the Damper Plate aperture and roll the O ring over the diaphragm and into the O ring groove If wrinkles occur repeat the procedure to achieve a smooth placement 3 Bubble the O ring of Damper Plate and press into the Upper Cell Chamber Apply Safety Tape around the lip of the Damper Plate Assembly 5 3 3 Additional Wet Cell Maintenance Leakage Check The system should be leak checked at 13 H O by connecting a manometer to the outlet boss and evacuate the inlet to 13 H O No leakage should be observed Calibration It is recommended that the unit be re turned to the factory annually for calibration Contact the Sensidyne Se
20. eiert dera 60 17 3 2 Cell Assembly Mounting 3 D ViCW uc ng ng HH ky 18 3 3 Cell Assembly Mounting Top View HH kh 19 3 Adding Soap Solution Wet Cell c nh ee eren 20 5 1 Wet Cell Assembly Maintenance 26 6 Sensidyne Document No 850190M Rev G A WARNINGS A READ AND UNDERSTAND ALL WARNINGS BEFORE USE IMPORTANT COMPATIBILITY NOTE Most flow cells designed for the original Gilibrator base are compatible with the Gilibrator 2 base unit If your existing flow cell is not compatible with the Gilibrator 2 base the unit will display a false SAMPLE reading immediately after start up If this happens your flow cell needs to be returned to Sensidyne to be upgraded See Appendix C for more information Read and understand ALL warnings before using this product Failure to read understand and comply with ALL warnings could result in property damage severe personal injury or death Read and understand ALL applicable Federal State and Local environmental health and safety laws and regulations including OSHA Ensure complete compliance with ALL applicable laws and regulations before and during use of this product UNDER NO CIRCUMSTANCES should this product be used except by qualified trained technically competent personnel and not until the warnings Operation and Service Manual labels and other literature accompanying this product have been read and understood The Oper
21. ensidyne personnel To facilitate the repair process please con tact the Sensidyne Service Department in advance for assistance with a problem which cannot be remedied and or requires the return of the product to the factory All returned products require a Returned Material Au thorization RMA number Sensidyne Service Depart ment personnel may be reached at Sensidyne 16333 Bay Vista Drive Clearwater FL 33760 USA 800 451 9444 e 727 530 3602 727 538 0671 Service Fax All non warranty repair orders will have a minimum fee of 50 whether the repair is authorized or not This fee includes handling administration and technical ex penses for inspecting the instrument and providing an estimate However the estimate fee is waived if the re pair is authorized If you wish to set a limit to the authorized repair cost state a not to exceed figure on your purchase order Please indicate if a price quotation is required before authorization of the repair cost understanding that this invokes extra cost and handling delay Sensidyne s re pair policy is to perform all needed repairs to restore the instrument to its full operating condition Repairs are handled on a first in first out basis Your order may be expedited if you authorize an expediting fee This will place your order next in line behind or ders currently in process Pack the instrument and its accessories preferably in their original packing and enclose your
22. ervice the instrument By receiving this document the recipient agrees that neither this document nor the information disclosed within nor any part shall be reproduced or transferred physically electronically or in any form or used or dis closed to others for manufacturing or for any other purpose except as specifically authorized in writing by Sensidyne Inc COPYRIGHT NOTICE O 2000 Sensidyne Inc All rights reserved Information contained in this document is protected by copyright No part of this document may be photocopied reproduced ortranslated to another program or system without prior written authorization from Sensidyne Inc TRADEMARK NOTICE Sensidyne the Sensidyne logo Gilian and the Gilian logo are registered trademarks of Sensidyne Inc Gilibrator 2 and the Gilibrator 2 logo are trademarks of Sensidyne Inc The trademarks and service marks of Sensidyne Inc are protected through use and registration in the United States DISCLAIMER SENSIDYNE INC ASSUMES NO RESPONSIBILITY WHATSOEVER TO ANY PARTY WHOSOEVER FOR ANY PROPERTY DAMAGE PERSONAL INJURY OR DEATH RECEIVED BY OR RESULTING FROM IN WHOLE OR IN PART THE IMPROPER USE INSTALLATION OR STORAGE OF THIS PRODUCT BY THE USER PERSON FIRM ENTITY CORPORATION OR PARTY NOT ADHERING TO THE INSTRUCTIONS AND WARNINGS OR NOT ADHERING TO ALL FEDERAL STATE AND LOCAL ENVIRONMENTAL AND OCCUPATIONAL HEALTH AND SAFETY LAWS AND REGULATIONS THE SELLER SHALL NOT BE LIABLE FO
23. f a computer is connected this subtraction is shown on the computer screen 4 1 2 Flow Readout e Display The Control Unit displays the actual flow for each sample as well as the accumulative average flow rate across samples and the current sample number To delete an obviously false reading push the DELETE RESET button for about 1 second This automatically deletes the false information from the average The av erage and sample number revert back to the previous reading To re initiate the entire sequence push the DELETE RE SET button for at least 3 seconds This zeroes all samples and averages within the Control Unit and causes the printer or computer to index one line and reprint or re display the sequence headings This de notes the start of a new sequence e Printer The printer will print in sequence the flow average and sample number of each successive bubble read ing NOTE In order to use the Paper Feed function of the printer turn the Power Switch OFF and ON again Sensidyne Document No 850190M Rev G GILIAN GILIBRATOR 2 CALIBRATION SYSTEM 4 2 WET CELL OPERATION 4 2 1 Start Up Turn on the sampling source Depress the Bubble Initiate Button several times to wet the inner walls of the flow tube You will not be able to initiate a timing bubble without first priming the flow tube You will develop a feel for bubble gen eration with practice After the Fl
24. gned for the original Gilibrator base are compatible with your new Gilibrator 2 base unit If your existing flow cell is not compatible with the Gilibra tor 2 base the unit will display a false SAMPLE reading immediately afterstart up Ifthis happens yourflow cell needs to be returned to Sensidyne to be upgraded See Appendix C page 30 for more information 16 3 2 1 Cell Assembly Mounting Refer to Figures 3 2 amp 3 3 Perform the following steps to mount the Cell Assembly CAUTION Always mount or remove the Cell Assembly by grasping and rotating only the lower part of the assembly 1 The Control Unit Base should be positioned on a flat level surface 2 Select the appropriate Cell Assembly Piston Low Standard or High 3 Grasp the lower portion of the Cell Assembly and move it to the Mounting Plate on the Control Unit 4 With the front of the Cell Assembly facing right see Figure 3 2 lower the assembly onto the Mounting Plate on the Control Unit 5 Align the Mounting Pins on the Flow Cell with the Mounting Slots on the Mounting Plate see Figure 3 3 If alignment is successful the bottom of the Flow Cell should mount flush with the Mounting Plate 6 While grasping only the lower portion of the Flow Cell Assembly rotate it in a clockwise direction until it clicks into place The front of the Cell As sembly should face toward the display on the Control Unit Sensidyne Document No 8
25. initiates a line showing this subtrac tion If a computer is connected this subtraction is shown on the computer screen 4 2 3 Flow Readout e Display The Control Unit displays the actual flow for each sample as well as the accumulative average flow rate across samples and the current sample number To delete an obviously false reading push the DELETE RESET button for about 1 second This automatically deletes the false information from the average The av erage and sample number revert back to the previous reading To re initiate the entire sequence push the DELETE RE SET button for at least 3 seconds This zeroes all samples and averages within the Control Unit and causes the printer or computer to index one line and reprint or re display the sequence headings This de notes the start of a new sequence e Printer The printer will print in sequence the flow average and sample number of each successive bubble read ing NOTE In order to use the Paper Feed function of the printer turn the Power Switch OFF and ON again 23 SECTION FIVE STORAGE amp MAINTENANCE 5 1 STORAGE 5 2 PISTON CELL MAINTENANCE The Gilibrator 2 is designed so that little maintenance is required However periodic cleaning calibration and replacement of the Damper Diaphragm on the Wet Cell Assembly may be required to ensure years of trouble free operation e Short Term Turn Off the Control
26. ker is a secondary chamber in the upper section of the flow cell that provides the travel ing soap bubble a rapid expansion path This is instru mental in breaking the bubble It also prevents exces sive wall wetting by the soap film and allows it to flow back into the base of the cell Storage Tubing The anti spill storage tubing connects the upper and lower cell chambers and prevents the soap solution from evaporating Evaporation can may cause the soap solution concentration to change CAUTION If transporting a Wet Cell Assembly by plane be sure to disconnect the Storage Tubing from either the Air Outlet Boss upper or Air Inlet Boss lower This prevents the Flow Cell Assembly from becoming pressurized and possibly causing a rupture within the Bubble Generator 14 2 3 2 Sensor Block Surrounding the flow tube and secured between the upper and lower chamber of the bubble generator is the Sensor Block refer to Figure 2 4 The block in cludes lower and upper infrared sensors used to time the movement of bubbles through the Flow Cell This block is secured to the Bubble Generator Assembly with two locking screws allowing easy removal of the Sensor Block for Flow Cell maintenance Sensidyne Document No 850190M Rev G BUBBLE GENERATOR GILIAN GILIBRATOR 2 CALIBRATION SYSTEM Damper Plate Pulsation Damper Damper Plate O Ring Spacer Assembly ES Sensor Block 2F Bubble Breaker Plate
27. ment accuracy determines the overall accuracy of the unit The Gilibrator 2 consists of two elements the Flow Cell Assembly Ceither Wet or Piston and the Control Unit Base The function of the Flow Cell Assembly is to provide a means for measuring an object soap film bubble or piston cell piston traveling up a flow tube through a known volume of space Measurement of the travel time is done by means of top and bottom infrared sensor pairs mounted along the flow tube The volume bound by these sen sors is set accurately to a primary volume standard As the object bubble or piston moves up the tube it trips the bottom sensor pair As it moves further up the tube it trips the top sensor pair The time differ ence between the bottom and top sensors becomes the elapsed travel time This timing information along with the volume information is sent to the micropro cessor in the Control Unit Base The calculated flow and sample information are then displayed directly on the Liquid Crystal Display 8 Sensidyne Document No 850190M Rev G SECTION TWO 2 1 CONTROL UNIT The Control Unit refer to Figures 2 1 amp 2 2 contains a crystal controlled microprocessor timing system This type of microprocessor used in conjunction with the built in software provides an extremely accurate method for calculating the flow rate parameters The Control Unit contains the following components 2 1 1 Buttons amp Indicat
28. o ensure that it is resolved in a manner that is satisfactory to you Your satisfaction with our products and service is of the utmost importance to me Sincerely Carl M QZZUCQ Carl Mazzuca President Sensidyne Inc 800 451 9444 727 530 3602 Fax 727 539 0550 The following are shipped with the Gilian Gilibrator 2 Calibration System Standard Kits Control Unit Base Flow Cell Assembly Piston or Wet High Flow Standard Flow or Low Flow AC Charger Adapter shipped with non CE control base units Tubing Small Carrying Case Soap Solution amp Dispenser Wet Cells only Calibration Certificate Operation and Service Manual ALWAYS check to make certain you have received all of the items listed above If you have any questions or need assistance contact your Sensidyne Sales Representative or call 800 451 9444 OR 727 530 3602 IMPORTANT NOTE effective 7 1 99 CE approved Control Unit Bases have 9 Pin cables and CANNOT be used with Piston Cells Non CE Control Unit Bases have 15 Pin cables and can be used with Piston Cells Sensidyne Document No 850190M Rev G 3 GILIAN GILIBRATOR 2 CALIBRATION SYSTEM PROPRIETARY NOTICE This manual was prepared by Sensidyne Inc exclusively for the owner of the Gilian Gilibrator 2 Calibration System The material within this manual is the proprietary information of Sensidyne Inc and is to be used only to understand operate and s
29. on to generate the bubbles This specially compounded low residue soap is designed to provide high film strength and compatibility with the materials used in the Flow Cell Assembly WARNING Only use Soap Solution Part No 800450 with the Wet Cell Assembly Use of other soap solutions can damage the Flow Cell Pulsation Damper This built in damper smooths out any pulsation within the airflow and reduces oscillation of the bubble film assuring maximum accuracy Sensidyne Document No 850190M Rev G GILIAN GILIBRATOR 2 CALIBRATION SYSTEM Bleeder Valve Tube to Pump Sensidyne Document No 850190M Rev G Tube to Pump Bleeder Valve Green LED CAUTION DO NOT close this valve until Green A CLOSE OPEN A Ready Light sido Es of cell lights up o o e qe y Gilian gm Gilibrator PISTON CELL ASSEMBLY Made by ae m m a SENSI Y TUE Ready Light Piston 15 pin Connector Figure 2 3 Piston Cell Assembly 5 E EM Ea S D Y a lt 4 zi o E 2 a 13 GILIAN GILIBRATOR 2 CALIBRATION SYSTEM Bubble Initiate Button This push button lowers the Bubble Generator Ring into the soap solution reservoir When the button is released the ring lifts out of the soap solution and a film bubble is generated across the opening of the flow tube Bubble Breaker The Bubble Brea
30. ors The ON and OFF buttons turn the Control Unit on and off The DELETE RESET button has three functions Pressing for 1 second deletes the most recent read ing from the running average It resets the average and sample number to the previous reading If a printer is connected a minus symbol is printed and the average returns to the previous value If a com puter is connected a minus symbol is displayed on the computer monitor and the average returns to the pre vious value Pressing for 3 seconds resets the current readings to zero and initiates a new sampling sequence If a printer is connected it prints a new header If the Flow Monitoring Software is running its graph will clear and a new sampling sequence will start Pressing simultaneoulsy with the ON button sets the sample size The sample size is adjusted in 5 sample increments by repeatedly pressing DELETE RE SET ragne 5 95 Charge Indicator This LED lights up when the batteries are charging 2 1 2 Display Characters FLOW This shows the flow rate in either cubic centimeters per minute ccm or liters per minute Ipm depend ing on the Flow Cell Assembly used AVERAGE Shows the average flow rate for the samples taken SAMPLE Shows the number of samples taken MAX 99 COMPONENTS LOW BAT This warning is displayed if insufficient battery charge remains to operate the unit properly If the battery is not recharged the unit automatically shuts off
31. ory annually for recalibration Contact the Sensidyne Service Depart ment for an RMA number information and pricing refer to Appendix C NOTE The first recalibration is due one year from the date you receive your Gilibrator 2 regardless of the date on the certification sheet Sensidyne Document No 850190M Rev G GILIAN GILIBRATOR 2 CALIBRATION SYSTEM 5 3 WET CELL MAINTENANCE WARNING Never use alcohol acetone or any other harsh cleaners to clean the bubble generator cell 5 3 1 General Maintenance 1 Refer to Figures 2 4 and 4 1 Remove the Sensor Block by loosening the 2 holding screws and slid ing the block out and away from the Cell Assem bly 2 Remove the Safety Tape from the lip of the Damper Plate Assembly 3 Using a small flat blade screw driver lift off the Damper Plate using the notch between the upper chamber and the lid 4 Remove the Spacer and then the Bubble Breaker Plate This gives complete access to the interior of the Flow Cell Tube Run clear water through the cell until the water exiting the cell runs clear Rock the cell back and forth to empty out all ex cess water 5 Replace the Bubble Breaker Plate and center the Air Outlet Boss with the plate s largest hole Insert the spacer 6 To replace the Damper Plate assembly moisten the O ring with soap solution and then press the Damper Plate into the top of the Upper Cell Chamber Use your fingers to firmly squeez
32. ow Cell Piston Cell Warning Do not close the bleeder valve on the piston cell assembly until the green ready light LED lights up IMPORTANT NOTE effective 7 1 99 CE approved Control Unit Bases have 9 Pin cables and CANNOT be used with Piston Cells Non CE Control Unit Bases have 15 Pin cables and can be used with Piston Cells Sensidyne Document No 850190M Rev G 7 SECTION ONE INTRODUCTION 1 1 OVERVIEW 1 2 THEORY OF OPERATION The Gilian Gilibrator 2 Calibration System is an easy to use Primary Standard for the calibration of air sampling equipment The system includes a high accuracy elec tronic flowmeter that provides instantaneous air flow readings and cumulative averaging of multiple samples Three Wet Cell Assemblies and one Piston Cell Assem bly provide a wide range of flow rates and are easily in terchangeable using twist on off mounting A crystal controlled microprocessor Control Unit is de signed for accurate data readings A dual function DELETE RESET button on the Control Unit subtracts er roneous readings to ensure accurate data or can can cel the current readings completely A printer interface on the Control Unit allows you to output the sampling results to a printer or PC com puter Windows compatible Gilibrator 2 Flow Moni toring Software is available that allows you to collect store and plot flow samples Features of the Gilibrator 2 Calibration System include an easy
33. ow Tube walls have been primed Push the ON button on the Control Unit Wait approximately 10 seconds while the unit conducts self tests and sends a header line to the printer or computer if one is con nected 4 2 2 Bubble Generation 1 For optimum bubble generation depress the Bubble Initiate Button and hold to initiate the first bubble to travel up the flow tube Release the but ton to initiate a second bubble to travel up the Flow Tube Repeat this process to obtain addi tional readings This will be the standard proce dure to making clean consistent bubbles 2 Asthe bubble rises up the Flow Tube it initiates a timing sequence when it passes the lower sensor and completes the timing sequence when it passes the upper sensor The timing information is then transmitted to the control unit where the necessary calculations are performed and a flow reading appears on the display IMPORTANT If a bubble breaks before the time sequence is com pleted timing will continue until another bubble is generated to trip the upper sensor This causes an erroneous reading and should be subtracted from the average by pressing the DELETE Button for about 1 second Sensidyne Document No 850190M Rev G If a printer is used be sure it has completed its printing sequence before pressing the DELETE RESET button When this button is pressed for less than 1 second a negative symbol appears on the Control Unit display The printer also
34. rvice Department for an RMA num ber information and pricing refer to Appendix C NOTE The first recalibration is due one year from the date you receive your Gilibrator 2 regardless of the date on the certification sheet System Transportation When transporting the unit especially by air it is important that one side of the seal tube which connects the inlet and outlet boss be removed thereby allowing for equalizing internal pres sure within the generator Do Not transport unit with soap solution or storage tubing in place CAUTION Do Not Pressurize the Cell Assembly Excessive pres sure may cause the cell to rupture resulting in personal injury 25 GILIAN GILIBRATOR 2 CALIBRATION SYSTEM x Pulsation Damper COS uL Bubble Breaker Plate e Damper Plate Damper Plate O Ring o em Largest Hole W Qi EA P t Safety Tape Upper Cell Chamber Flow Tube Figure 5 1 Wet Cell Assembly Maintenance 26 Sensidyne Document No 850190M Rev G APPENDIX A PARTS LIST Calibration Kits Basic Control Unit Battery Charger Carrying Case Calibration Certificate Manual and a Flow Cell Pis ton Cell or a Low Standard or Higb Flow Wet Cell witb tubing soap solution and dispenser Diagnostic Basic kit plus Calibration Panel Deluxe Basic kit plus Printer Module and all tbree Wet Cells Deluxe Diagnostic Basic kit plus
35. the Wet Cell Assembly is not going to be used for an extended period of time reinstall the rubber Storage Tubing between the inlet and outlet bosses This pre vents the solution from evaporating and altering the soap concentration in the solution WARNING If you are shipping the Wet Cell you must remove the rubber Storage Tubbing between the inlet and outlet bosses 3 2 4 Sampling Source Connection Connect the air sampler to be calibrated to the Air Out let Boss of the Wet Cell Assembly or the Inlet Tube on the Piston Cell Assembly Use 1 4 ID tubing in either case WET CELL NOTE A liquid trap between the sampler and the Wet Cell Assembly is recommended This prevents moisture from carrying over into the sampler during continuous cali bration periods Sensidyne Document No 850190M Rev G GILIAN GILIBRATOR 2 CALIBRATION SYSTEM Flow Tube Bubble Initiate Button O Air Inlet Boss Bubble Generator Soap Solution Reservoir now empty Storage Tube Fully press amp hold Bubble Initiate Button while filling reservoir Angled Edge Fill Soap Solution Reservoir until bottom of Bubble Generator Ring is immersed in the solution Figure 3 4 Adding Soap Solution Wet Cell 21 Sensidyne Document No 850190M Rev G SECTI
36. tion when mounting or removing the Flow Cell Figure 3 2 Cell Assembly Mounting 3 D View Sensidyne Document No 850190M Rev G GILIAN GILIBRATOR 2 CALIBRATION SYSTEM IMPORTANT Mounting Pins amp Mounting Slots should match up Cell Assembly base shaded area Mounting Pins lt lt Mounting Slots dark area Mounting Plate white area 8900 AVERAGE BBBB z SAMPEZ HE WAIT ERROR 8 98 Dd 191011d Gilibr tor 2 e DELETE See PRIMARY FLOW CALIBRATOR Figure 3 3 Cell Assembly Mounting Top View Sensidyne Document No 850190M Rev G 19 GILIAN GILIBRATOR 2 CALIBRATION SYSTEM 3 2 2 Cabling Connections IMPORTANT Turn off the unit before connecting any cables If you are using a Piston Cell Assembly insert the 15 Pin Interface Plug directly into the Connecting Jack lo cated on the back of the Piston Cell refer to Figure 2 3 Be sure to properly match up the connectors be fore engaging If you are installing a Wet Cell Assembly on a 15 Pin Control Base insert the 15 Pin Interface Plug from the Control Base into the 15 to 9 pin adapter Insert the adapter into the Connecting Jack located on the back of the Wet Cell refer to Figure 2 4 Be sure to properly match up the connectors before engaging If you are installing a Wet Cell on a 9 Pin Control Base insert the 9 Pin Interface Plug from the Control Base directly into the Connecting Jack loc
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