GasCal 1100
Dilution Calibrator
User Manual
Version: 3.5
September 2012
www.ecotech.com
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GasCal 1100 User manual 3.5
Introduction
Table of Contents
DILUTION CALIBRATOR .......................................................................................................... 1
CE MARK DECLARATION OF CONFORMITY ...................................................................... 12
THIS DECLARATION RELATES IS IN CONFORMITY WITH THE FOLLOWING EUROPEAN UNION
DIRECTIVES: ................................................................................................................... 12
1
INTRODUCTION ....................................................................................................... 15
1.1 DESCRIPTION ............................................................................................................ 15
1.2 SPECIFICATIONS ......................................................................................................... 15
1.2.1 DILUTION AND SPAN FLOWS .............................................................................................. 15
1.2.2 OZONE GENERATOR ......................................................................................................... 15
1.2.3 PHOTOMETER OPTION ...................................................................................................... 16
1.2.4 INTERFACE ...................................................................................................................... 16
1.2.5 SYSTEM .......................................................................................................................... 16
1.3 BACKGROUND/ THEORY .............................................................................................. 17
1.3.1 DILUTION THEORY............................................................................................................ 17
1.3.2 GAS PHASE TITRATION (GPT) THEORY (OPTION)................................................................... 18
1.3.3 OZONE PHOTOMETER THEORY (OPTION) ............................................................................. 18
2
INSTALLATION ......................................................................................................... 21
2.1 INITIAL CHECK ........................................................................................................... 21
2.2 MOUNTING/SITING.................................................................................................... 21
2.3 INSTRUMENT SETUP.................................................................................................... 21
2.3.1 POWER .......................................................................................................................... 21
2.3.2 DILUENT GAS .................................................................................................................. 22
2.3.3 SOURCE GAS ................................................................................................................... 22
2.3.4 OUTPUT PORTS ............................................................................................................... 23
2.3.5 DIGITAL INPUT/OUTPUT (J5) ............................................................................................. 23
2.3.6 RS-232 SERIAL COMMUNICATIONS .................................................................................... 25
2.3.7 DILUENT CONTROL (J6) .................................................................................................... 25
2.3.8 SETTING INSTRUMENT ID .................................................................................................. 26
2.3.9 PURGE FOR GAS LINES ...................................................................................................... 27
3
OPERATION............................................................................................................. 29
3.1 MODE OF OPERATION ................................................................................................ 29
3.1.1 AUTOMATIC MODE........................................................................................................... 29
3.1.2 MANUAL MODE ............................................................................................................... 29
3.2 GENERAL OPERATIONAL INFORMATION ........................................................................... 30
3.2.1 KEYBOARD & DISPLAY ...................................................................................................... 30
3.2.2 EDITING FIELDS................................................................................................................ 31
3.2.3 SERIAL PORT MENU NAVIGATION ....................................................................................... 31
3.3 MAIN SCREEN ........................................................................................................... 32
3.3.1 STANDBY SCREEN............................................................................................................. 32
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Introduction
GasCal 1100 User manual 3.5
3.3.2 ZERO SCREEN .................................................................................................................. 32
3.3.3 SPAN SCREEN .................................................................................................................. 32
3.3.4 OZONE SCREEN ............................................................................................................... 33
3.3.5 MANUAL MODE SCREEN .................................................................................................... 33
3.4 MENUS AND SCREENS ................................................................................................. 33
3.4.1 STATUS MENU ................................................................................................................ 34
3.4.2 SETUP MENU .................................................................................................................. 36
3.4.3 MANUAL MENU .............................................................................................................. 42
4
CALIBRATION .......................................................................................................... 45
4.1 MFC CALIBRATION .................................................................................................... 45
4.2 OZONE CALIBRATION .................................................................................................. 49
5
MAINTENANCE........................................................................................................ 51
5.1 MAINTENANCE TOOLS ................................................................................................. 51
5.1.1 MAINTENANCE SHEETS ..................................................................................................... 51
5.2 MAINTENANCE SCHEDULE ............................................................................................ 54
5.3 MAINTENANCE PROCEDURES ........................................................................................ 54
5.3.1 LCD CONTRAST ADJUST .................................................................................................... 54
5.3.2 PARAMETER CHECK .......................................................................................................... 54
5.3.3 PARTICULATE FILTER CHECK ............................................................................................... 55
5.3.4 LEAK CHECK .................................................................................................................... 55
5.3.5 A/D CHECK/ADJUSTMENT ................................................................................................ 56
5.3.6 OZONE CHECK ................................................................................................................. 57
5.3.7 MFC CHECK.................................................................................................................... 57
5.3.8 HIDDEN MENU ................................................................................................................ 58
6
OPTIONS ................................................................................................................. 61
6.1 TRANSFER STANDARD ................................................................................................. 61
6.1.1 OZONE POINT SETUP EXAMPLE: .......................................................................................... 63
6.1.2 PHOTOMETER ASSISTED GPT. ............................................................................................ 64
6.1.3 OZONE FLOW CALIBRATION ............................................................................................... 66
6.1.4 OZONE PHOTOMETER CALIBRATION .................................................................................... 67
6.1.5 UV LAMP REPLACEMENT PROCEDURE. ................................................................................. 68
APPENDIX A - SERIAL PORT COMMANDS ........................................................................ 73
APPENDIX B PARTS LIST................................................................................................. 77
APPENDIX C – MASS FLOW CORRECTION FACTORS ......................................................... 79
APPENDIX D – DIGITAL I/O CONNECTOR LIST .................................................................. 81
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GasCal 1100 User manual 3.5
Introduction
List of Figures
Figure 1 Dilution Theory for GasCal ........................................................................................................ 17
Figure 2 Rear Connections ...................................................................................................................... 24
Figure 3 Microprocessor board location ................................................................................................ 26
Figure 4 Microprocessor board .............................................................................................................. 26
Figure 5 Jumper arrangement for GasCal ID .......................................................................................... 27
Figure 6 GasCal Menu System ............................................................................................................... 34
Figure 7 GasCal casing removal procedure ............................................................................................ 46
Figure 8 Calibration Setup ...................................................................................................................... 46
Figure 9 Original coefficient fields .......................................................................................................... 47
Figure 10 Mass flow controller characterisation graph .......................................................................... 48
Figure 11 Ozone Generator Characterisation Graph ............................................................................ 49
Figure 12 Main Data worksheet ............................................................................................................. 52
Figure 13 Component Layout ................................................................................................................ 57
Figure 14 Gascal front case with hidden menu button highlighted ....................................................... 58
Figure 15 GasCal transfer standard component diagram....................................................................... 62
Figure 16 Ozone flow calibration setup .................................................................................................. 66
Figure 17 Ozone Photometer layout ...................................................................................................... 69
Figure 18 Ozone Photometer Assembly ................................................................................................. 69
Figure 19 Ozone Photometer Cell Bracket Assembly ............................................................................. 69
Figure 20 Ozone Photometer Cell Assembly .......................................................................................... 70
Figure 21 Trouble Shooting Flow Chart .................................................................................................. 71
List of Tables
Table 1 Maintenance schedule ............................................................................................................... 54
Table 2 Parameters with nominal value and tolerances ........................................................................ 55
Table 3 Ozone point setup...................................................................................................................... 63
Table 4 NO gas setup .............................................................................................................................. 64
Table 5 NO point setup (GPT) ................................................................................................................. 64
Table 6 NO2 point setup (GPT)................................................................................................................ 65
Table 7 Native Serial Commands ............................................................................................................ 73
Table 8 Dasibi dot commands ............................................................................................................... 74
Table 9 A/D Voltage Numbering ............................................................................................................. 74
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Introduction
GasCal 1100 User manual 3.5
Manufacturer’s statement
Thank you for selecting the GasCal 1100 Dilution Calibrator. The GasCal 1100 is
designed primarily as a Dilution Calibrator used in conjunction with gas cylinders to
supply precise concentrations of span gas to gas analysers. The GasCal 1100 should
give many years of trouble free service if installed, used and maintained correctly. By
following the guidelines contained in this manual and with the implementation of a
good quality-assurance program, the user can create accurate and reliable Gas
concentrations. Please ensure that you read the safety and warranty detail as they
contain important information for the user. If, after reading this manual you have
any questions or you are still unsure or unclear on any part of the GasCal 1100 then
please do not hesitate to contact Ecotech.
Ecotech also welcomes any improvements that you feel would make this a more
useable and helpful product then please send your suggestions to us here at
Ecotech.
Please help the environment and recycle the
pages of this manual when finished using it.
Notice
The information contained in this manual is subject to change without notice.
Ecotech reserves the right to make changes to equipment construction, design,
specifications and /or procedures without notice.
Copyright © 2011. All rights reserved. Reproduction of this manual, in any form, is
prohibited without the written consent of Ecotech Pty Ltd.
Page | 6
GasCal 1100 User manual 3.5
Introduction
Warranty
This product has been manufactured in an ISO 9001, AS/NZS 4801: 2001 and ISO
14000 and facility with care and attention to quality, safety and environment.
The product is subject to a 12-month warranty on parts and labour from date of
shipment (the warranty period). The warranty period commences when the product
is shipped from the factory. Lamps, fuses, batteries and consumable items are not
covered by this warranty.
Each calibrator is subjected to a vigorous testing procedure prior to despatch and
will be accompanied with a parameter list and a multipoint calibration check thereby
enabling the calibrator to be installed ready for use.
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Introduction
GasCal 1100 User manual 3.5
Service & repairs
Our qualified and experienced technicians are available to provide fast and friendly
service five days a week, Monday to Friday. You can speak to a real person regarding
any questions you have about your unit and we will respond within 48 hours.
Service Guidelines
In the first instance, please call or email us if you are experiencing any problems or
issues with your unit.
Contact our Service Response Centre via email on service@ecotech.com.au or call
+61 (0) 3 9730 7848
If we cannot resolve the problem through technical support, please email the
following information:
•
•
•
•
•
•
•
Name and phone number
Company name
Shipping address
Quantity of items being returned
Model number/s or a description of each item
Serial number/s of each item (if applicable)
A description of the problem. For example, if a factory repair is needed, or the
reason you are returning the equipment (eg, sales return, warranty return, etc)
• Original sales order or invoice number related to the equipment.
When you email us we will assign a Return Material Authorization (RMA) number to
your shipment and initiate the necessary paperwork to process your equipment
within 48 hours.
Please include this RMA number when you return equipment, preferably both inside
and outside the shipping container. This will ensure you receive prompt service.
Page | 8
GasCal 1100 User manual 3.5
Introduction
WARNING
Safety requirements
•
•
•
•
•
•
•
•
•
•
•
To reduce the risk of personal injury caused by electrical shock, follow all
safety notices and warnings in this documentation.
This instrument contains lamps which emit dangerous UV radiation. Do not
look directly at these lamps whilst operating.
If the equipment is used for purposes not specified by Ecotech, the
protection provided by this equipment may be impaired.
Replacement of any part should only be carried out by qualified personnel,
only using parts specified by Ecotech. Always disconnect power source before
removing or replacing any components.
Take care when removing the front panel. The keyboard ribbon cable can be
easily damaged (qualified personnel only).
If installed in a 19" rack, be sure to support the GasCal securely on a rackmounted shelf.
Dry, clean and filtered source gas should be supplied to the GasCal at a
regulated pressure of between 20 and 25 psig (140 kPa - 170 kPa). Damage
will occur if the pressure exceeds 30 psig (170 kPa).
One of the output ports must be connected to vent in order to avoid
pressurising the unit
The current sunk from the digital output bits should be at least 1mA but must
not exceed 20 mA. Serious damage to the calibrator will result if this occurs.
The GasCal is not designed for use with explosive or flammable gases. A risk
of ignition exists due to the current-heated coil within the MFCs. Under no
circumstances should these gases be used with the GasCal.
If the equipment is used for purposes not specified by the manufacturer, the
protection provided by this equipment may be impaired.
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Introduction
GasCal 1100 User manual 3.5
Claims for Damaged Shipments and Shipping
Discrepancies
Damaged shipments
1. Inspect all instruments thoroughly on receipt. Check materials in the
container(s) against the enclosed packing list. If the contents are damaged
and/or the instrument fails to operate properly, notify the carrier and
Ecotech immediately.
2. The following documents are necessary to support claims:
a.
b.
c.
d.
Original freight bill and bill lading
Original invoice or photocopy of original invoice
Copy of packing list
Photographs of damaged equipment and container
You may want to keep a copy of these documents for your records also.
Refer to the instrument name, model number, serial number, sales order
number, and your purchase order number on all claims. Upon receipt of a
claim, we will advice you of the disposition of your equipment for repair or
replacement.
Shipping Discrepancies
Check all containers against the packing list immediately on receipt. If a shortage or
other discrepancy is found, notify the carrier and Ecotech immediately. We will not
be responsible for shortages against the packing list unless they are reported
promptly.
Page | 10
GasCal 1100 User manual 3.5
Introduction
Contact Details
Head Office
1492 Ferntree Gully Road, Knoxfield VIC Australia 3180
Phone: +61 (0) 3 9730 7800 Fax: +61 (0) 3 9730 7899
Email: info@ecotech.com.au
Service: service@ecotech.com.au
www.ecotech.com
Page | 11
Introduction
GasCal 1100 User manual 3.5
CE
Mark Declaration of Conformity
This declaration applies to the GasCal1100 series Gas Calibrators as manufactured by
Ecotech Pty. Ltd. of 1492 Ferntree Gully Rd, Knoxfield, VIC, 3180, Australia.
This declaration relates is in conformity with the following European Union
Directives:
Council Directive of 15 December 2004 on the approximation of the laws of
Member States relating to electromagnetic compatibility (2004/108/EC)
The following standard was applied:
EN 61326-1:2006
Electrical Equipment for measurement, control
and laboratory use – EMC Requirements – Part
1: General requirements.
•
Immunity Requirements EN61326-1
IEC-61000-4-2 Electrostatic discharge immunity
IEC-61000-4-3 Radiated RF immunity
IEC-61000-4-4 Electrical fast transient burst immunity
IEC-61000-4-5 Surge immunity
IEC-61000-4-6 Conducted RF Immunity
IEC-61000-4-11
Voltage dips and interruption immunity
•
Electromagnetic compatibility EN61326-1
CISPR-11
Radiated RF emission measurements
CISPR-11
Mains Terminal RF emission measurements
IEC-61000-3-3 Mains Terminal voltage fluctuation
measurements
IEC-61000-3-2 Power Frequency harmonic measurements
Council Directive of 12 December 2006 on the harmonization of the laws of
Member States relating to electrical equipment designed for use within
certain voltage limits (2006/95/EC)
The following standard was applied:
EN 61010-1:2001
Safety requirements for electrical equipment,
for measurement control and laboratory use –
Part 1: General requirements
•
For protection against:
Electric shock or burn
Mechanical HAZARDS
Excessive temperature
Spread of fire from the equipment
Effects of radiation, including laser sources and sonic and
ultrasonic pressure
Page | 12
GasCal 1100 User manual 3.5
Introduction
Internationally recognised symbols used on
Ecotech Equipment
Earth (ground) terminal
IEC 417, No. 5017
Caution, hot surface
IEC 417, No. 5041
Caution, refer to
accompanying documents
ISO 7000 - 0434
Caution, risk of electric shock
ISO 3864, No. B.3.6
Page | 13
Introduction
GasCal 1100 User manual 3.5
Manual Revision History
Ecotech Manual ID:
Manual PN:
Current Revision:
Date released:
Description:
MAN 0033
ECO-GC1100MAN
3.5
September 2012
User Manual for the GasCal 1100
This manual is a newly created document for use of the GasCal 1100 Gas Calibrator.
Edition
3.01
3.02
Date
October 2005
June 2006
Summary
Second dilution MFC info added
Flow temp added
GasCal multigas bottle calculation
notes added
Dasibi commands included
Differences between GasCal 1000
and 1100 explained
Flow standard info added
Maintenance section updated
Affected Pages
13
20
22
44
4
45
51-58
3.03
June 2006
3.1
July 2007
Redesign and reformatting of
manual.
all
3.2
October 2007
Updated warnings
v
3.3
February 2010
Included setting GasCal ID
Updated parts list
26
77
3.4
March 2011
Included transfer standard option
information
61
3.5
September
2012
Manual update with updated part
numbers and additional information
on transfer standard. Updates for CE
all
Page | 14
GasCal 1100 User manual 3.5
1
Introduction
Introduction
1.1 Description
The GasCal 1100 has been designed as a stand-alone dilution calibrator specifically
for environmental applications and should give many years of trouble free service
provided that it is installed, used and maintained correctly. The GasCal can be used
in conjunction with many different gas analysers (CO, CO2, O3, NOx, NOy, NH3, SO2,
etc) to provide precise and constant volumes of zero air or dilutions of various span
gas. The GasCal is available as a portable unit that can be transported from location
to location or most effectively, used within an integrated ambient or emissions gas
monitoring station. The GasCal is used in conjunction with regulatory traceable
gases, zero air generators and/or ozone generators. The GasCal can be optionally
fitted with a Gas Phase Titration (GPT) and ozone photometer for the accurate
creation and delivery of ozone concentrations.
Note: For a GasCal 1000 with software above 3.0 this
manual is applicable except that the screen will only be a
two line LCD.
1.2 Specifications
1.2.1 Dilution and Span flows
Range:
Input dilution gases:
Input source gases:
Dilution Mass Flow Controller:
Source Mass Flow Controller:
Flow Accuracy (constant temp):
Flow Repeatability:
Linearity:
Operating Gas Pressure:
Zero Drift:
Response Time:
Output Manifold:
Dilution Ratio:
1 standard 170-200 kPa(g)
1 to 4 as standard 140-170 kPa(g)
0-10splm (std), 0-2, 0-5splm or 0-20 (optional)
0-50sccm (std), 0-20, 0-100 sccm or 2L
(optional)
Within 1% of full scale
Within 0.15% of full scale
Within 0.15% of full scale
100-200 kPa
< 0.58% per year
< 5 seconds
4 output ports standard (8 optional)
Variable 20:1 to 2000:1 (std)
1.2.2 Ozone Generator
Output
Repeatability:
50 ppb to 1000 ppb at 3 slpm
< 1% short term (24 hours)
5% long term at constant temperature and
humidity
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Introduction
GasCal 1100 User manual 3.5
1.2.3 Photometer option
Ranges:
Linearity:
Precision:
Zero drift:
Span drift:
0 – 1000 ppb
< 1% of full scale
+/- 3 ppb or 1% of reading whichever is greater
+/- 2 ppb per day, < 3 ppb per year
< 1% per day, < 3% per year
1.2.4 Interface
Programming:
Programmable Calibrations:
Digital inputs:
Digital Input Types:
Digital Outputs:
Display:
Memory:
Via front panel keypad or computer
10 separate programmable sequences
20 separate programmable points
8 digital input bits can start/stop calibration
sequences
Relay contact closures or TTL logic inputs
8 digital output bits send status and alarms
Four line illuminated display
Non volatile protected, automatic startup after
power failure (in automatic mode).
1.2.5 System
Operating Temperature:
Maximum Elevation:
Input Voltage:
Power Consumption:
Dimensions:
Weight:
Page | 16
0° – 50°C (20° - 35°C for optimum performance)
3000m above sea level
100 - 240V AC (Auto Ranging)
47-63 Hz
80VA max
19” Rack mount
(135mm H x 450mm W x 440mm D)
(Rack mounting drawer optional extra)
11kg
GasCal 1100 User manual 3.5
Introduction
1.3 Background/ Theory
1.3.1 Dilution Theory
The GasCal operates on the principle that when a known quantity of source gas is
measured with a known quantity of carrier gas then the resultant mixture can be
calculated. The assumption relies on the conservation of mass which occurs if there
is no chemical interaction between the source gas and the carrier gas. We can say
that:
Mass flow rate in = Mass flow rate out
or
Concentration x Flow Rate In = Concentration x Flow Rate Out
Figure 1 Dilution Theory for GasCal
So a mass balance can be arranged in that:
CSOURCE x mSOURCE + CDILUENT x mDILUENT = COUTPUT x mOUTPUT
Where
C = Concentration
m = Mass flow rate
As the diluent is always chosen as a “zero gas”, the term CDILUENT is always zero. This
simplifies the equation to:
CSOURCE x mSOURCE = COUTPUT x mOUTPUT
We can also say that mOUTPUT = mSOURCE + mDILUENT and thus the equation becomes:
CSOURCE x mSOURCE = COUTPUT x (mSOURCE + mDILUENT)
This can then be rearranged to give:
COUTPUT = CSOURCE x mSOURCE / (mSOURCE + mDILUENT)
This is the governing equation used in the operation of the GasCal. The mass flow
rates of the source gas and diluent gases are accurately measured using mass flow
controllers. Suppliers usually certify the source gas cylinder concentration, allowing
the concentration of the output to be calculated easily.
Page | 17
Introduction
GasCal 1100 User manual 3.5
The GasCal is also able to be fitted with a second source Mass flow Controller. This
second controller is generally 20% of the primary dilution MFC and is used for
diluting at small ranges, <5% of primary MFC range. The second source MFC can also
be used to boost the dilution of primary MFC when large dilutions are warranted.
1.3.2 Gas Phase Titration (GPT) Theory (option)
This section outlines relevant theory for GasCals containing an optional ozone (O3)
generator. This generator is specifically designed for use during a Gas Phase Titration
(GPT) calibration. This type of calibration is most often used when calculating the
efficiency of nitrogen dioxide (NO2) to nitric oxide (NO) converters such as those
used in oxides of nitrogen (NOx) analysers. Since stable NO2 sources are difficult to
source and maintain, an alternative is to mix known quantities of NO with ozone.
The governing reaction in GPT analysis is:
O3 + NO → NO2 + O2
Within normal operating conditions of the GasCal, it can be readily assumed this
reaction is 100% efficient. Since the concentrations of O3 and NO are known, reliable
and stable concentrations of NO2 can be produced. Please refer to your analyser
manual for specific instructions.
It is important to realise that the ozone generator built into some models of the
GasCal is designed for GPT converter efficiency checks only. These efficiency checks
require a stable source of ozone, the actual concentration of ozone is of lesser
importance. In order to obtain the desired stability levels necessary for GPT checks
one must run the ozone point for at least 30 minutes to obtain a sufficiently stable
output.
Note: An ozone point should be run for at
least 30 minutes for a stable output to be
achieved.
1.3.3 Ozone Photometer Theory (option)
This section outlines relevant theory for GasCals containing an optional ozone (O3)
photometer. This photometer is specifically designed for use with ozone analysers.
The ozone photometer accurately measures and controls the ozone concentration
generated by an internal ozone generator allowing it to be used as a transfer
standard for the calibration of ozone analysers.
In order to obtain the desired stability levels necessary for ozone analyser
calibrations one must run the ozone point for at least 30 minutes to obtain a
sufficiently stable output.
Page | 18
GasCal 1100 User manual 3.5
Introduction
In ambient air monitoring applications, precise ozone concentrations called
standards are required for the calibration of ozone analysers. Ozone standards
cannot be stored for any practical length of time due to the reactivity and instability
of the gas. Therefore, ozone concentrations must be generated and “verified” on
site. When the monitor to be calibrated is located at a remote monitoring site, it is
necessary to use a transfer standard that is traceable to a more authoritative
standard.
A transfer standard is defined as a transportable device or apparatus which, together
with associated operational procedures, is capable of accurately reproducing
pollutant concentration standards or of producing accurate assays of pollutant
concentrations which are quantitatively related to a higher level and more
authoritative standard. The transfer standard’s purpose is to transfer the authority
of a Level 1 pollutant standard to a remote point where it is used to verify or
calibrate an air monitoring analyser.
The U.S. EPA identifies the family of standard reference photometers (SRPs) as Level
1 standards. Beyond the SRPs, all standards are considered transfer standards and
are numbered (starting with 2) based on their “distance in the traceability chain”
from a verification against a Level 1 standard. With each additional level, the number
of standards available is multiplied. Each standard is traceable through a chain of
“higher” standards to the Level 1 standard.
The majority of transfer standards include both ozone generators and photometers.
Therefore, it is strongly suggested that:
• Level-2 standards and/or standards used in the verification of other transfer
standards include both a generation device and a photometer. (EC9811, GasCal
1100TS)
• Level-3 standards be, at a minimum, a photometer. (Serinus 10, EC9810, EC9810B).
The level 3 standard can be a photometer and generator (EC9811 or GasCal 1100TS)
but should not be just a generator.
• Level-4 and greater can be an ozone generation device. (eg GasCal 1100GPT)
Ozone Transfer Standards also require routine calibration against a higher transfer
standard. The U.S. EPA recommends the following calibration frequencies.
Regional Standard Reference Photometer - once per annum
Ozone Level 2 Transfer Standard - once per year or after repair
Ozone Transfer Standard Level 3 and greater - At beginning and end of ozone
season or every 6 months whichever is less.
Ecotech is able to offer a Level 2 or greater ozone calibration service.
Page | 19
Introduction
GasCal 1100 User manual 3.5
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GasCal 1100 User Manual 3.5
2
Installation
Installation
2.1 Initial check
Verify that the serial number label on the documentation and the serial number(s)
on the instrument match.
Check to make certain your instrument arrived undamaged. If you find damage,
report it as described in the preface, on the page titled Claims for Damaged
Shipments and Shipping Discrepancies in this user manual.
Analysers are shipped ready to power up. Occasionally, however, rough handling
during shipment causes dislodged PC boards, disconnected cables, or incorrectly
positioned switches. Verify that your instrument is in operating condition by
removing the lid and inspecting all cables and tubing ensuring they are connected
properly.
Note: Do not alter any other components within
the instrument.
2.2 Mounting/Siting
The GasCal 1100 should be mounted in a dry, clean area away from direct heat
sources. Adequate ventilation should also be provided to ensure overheating does
not occur. Although a rugged device, clean and air-conditioned environments will
provide the best operating conditions for the GasCal. The GasCal can be ordered as
either a bench-top model or 19” racks mount. If installed in a 19” rack, be sure to
support the GasCal on a rack-mounted drawer (optional extra) or a suitable user
supplied rack mounted shelf, as the front mounting plate will not support the full
weight of the GasCal. Allow at least 1” clearance above the unit to provide
ventilation. Allow adequate space at the back of the calibrator for connectors and
heat dispersion through rear vents. All connections are made from the rear.
Note: If installed in a 19” rack, be sure
to support the GasCal securely on a
rack-mounted shelf.
2.3 Instrument setup
2.3.1 Power
The GasCal 1100 can operate between 100 and 240 Volt AC power at a frequency
range of either 47 to 63 Hz. The selection of voltage is made automatically so there is
no need to switch the voltage as in earlier models. The maximum power
consumption of the GasCal 1100TS is approximately 80W. After warming up, the
GasCal will consume less power at approximately 60W.
Page | 21
Installation
GasCal 1100 User manual 3.5
A protective Earth must be provided via the IEC AC power plug and the
chassis should be connected to ground via the earth lug provided on the
back panel of the calibrator. A power conditioner is recommended
when the GasCal is to be used in remote areas or areas where the power supply is
unreliable.
2.3.2 Diluent Gas
Diluent gas is typically a clean, unreactive gas used to dilute reactive samples via the
Diluent Port. Dry, filtered gas should be supplied to the GasCal at a regulated
pressure of between 25 and 30 psig (170 kPa – 200 kPa). The required flow rate
depends upon the particular Mass Flow Controller (MFC) employed, but a value of
10 000 sccm is typical. A ¼” Teflon/nylon tube should be inserted into the self locking
and sealing port for connection. Please note that the diluent gas is used to produce
zero air if no span gas is selected.
Note: Dry, clean and filtered diluent gas should be supplied to the
GasCal at a regulated pressure of between 25 and 30 psig (170 kPa
– 200 kPa).
Damage will occur if the pressure exceeds 40 psig (275 kPa).
2.3.3 Source Gas
The span gases should connect via the source gas port(s), labelled S1 to S4. Dry,
clean and filtered source gas should be supplied to the GasCal at a regulated
pressure of between 20 and 25 psig (140 kPa – 170 kPa). The required flow rate
depends upon the particular Mass Flow Controller (MFC) employed, but a value of
50 sccm is typical. 1/8” stainless steel tubing should be used with the supplied
fittings. Only ¾ of a turn is required after finger tightening the nut. Serious damage
may result from over-tightening. The standard GasCal 1100 has four source gas
inputs, however, some models only have one. If the “purge” option is used (section
2.3.9), span port 4 is designated the purge exhaust and cannot be used as a gas
input.
Note: Dry, clean and filtered source gas should be supplied to the
GasCal at a regulated pressure of between 20 and 25 psig (140
kPa – 170 kPa).
Damage will occur if the pressure exceeds 30 psig (207 kPa).
Page | 22
GasCal 1100 User Manual 3.5
Installation
2.3.4 Output Ports
There are four output gas ports available on the GasCal, labelled O1 to O4. Diluted
source gas is sent to each of the four ¼” output ports. Chemically inert Kynar fittings
have been used and should be finger tight only. If any of the output ports are not
used, they should be sealed with the supplied Kynar nut. One of the output ports
must be connected to vent in order to avoid pressurising the unit. Damage to the
equipment may occur if the output circuit is pressurised.
Note: One of the output ports must be
connected to vent in order to avoid
pressurising the unit
2.3.5 Digital Input/Output (J5)
The digital input/output port is a DB-50 connector. These digital input/output bits
can be used to control pre-programmed calibration sequences by contact closures or
TTL logic inputs (5VDC). Likewise, the status of the calibrator can be sent to another
device via the digital output TTL signals on this port. Status alarms may also be sent
to this port.
Contact closures or TTL logic may be used to control the digital input bits. A bit can
be programmed as either active “high” (5 VDC) or active “low” (0 VDC). “High” can
be either 5 VDC or TTL logic high. Likewise, “low” can be either 0 VDC or TTL logic
low. The TTL device contact closure must be capable of sinking 1 mA of current per
bit.
Digital output bits can be programmed as either active when high or active when
low. “High” in this case will be TTL logic high and, likewise, “low” will be TTL logic
low. The current sunk from the digital output bits should not exceed 20 mA. Table 1
shows the pin assignments for the digital input/output connector.
Note: The current sunk from the digital output
bits should be at least 1mA but must not exceed
20 mA. The voltage on these pins must not
exceed 5VDC.
Serious damage to the calibrator will result if
this occurs.
Note: If the Digital Inputs are connected directly to some other
device such as a data logger which has TTL outputs, then a
100ohm resistor should be placed in series with this connection
in order to prevent damage to either devices. An example of this
is when the Gascal digital inputs are connected to Digital Outputs
OP4, OP5, OP6 or OP7 on the Ecotech 9400TP Termination Panel.
Page | 23
Installation
GasCal 1100 User manual 3.5
Figure 2 GasCal 1100 rear connections
Figure 3 GasCal 1100TS rear connections
Page | 24
GasCal 1100 User Manual 3.5
Installation
2.3.6 RS-232 Serial Communications
The GasCal 1100 can be controlled and programmed using the RS-232
communications port provided. The GasCal 1100 acts as a DCE device (similar to a
modem) and can be connected to any DTE device (PC or data logger) via a standard
modem cable. A standard “off the shelf” 9 pin RS-232 cable can be used to connect
the 9-pin female “D” connector on the calibrator to the DTE device. Standard DCE
wiring is employed (transmits on pin 2 (RD) and receives on pin 3 (TD). Settings for
serial communication must be:
Baud Rate:
4800 bps
Data Bits:
8
Parity: None
Flow Control: None
Stop Bits:
1
The TD signal is tri-state, allowing the GasCal 1100 to be connected to the same
serial port as some gas analysers regardless of their baud rate settings.
CONNECTOR J1
PIN
J1-2
J1-3
J1-5
SIGNAL
RD Receive Data
TD Transmit Data
Digital Common
Note: RS232 communication settings are:
4800 baud rate, 8 data bits, No parity, 1 stop
bit
2.3.7 Diluent Control (J6)
When used together, a standard RS-232 9 pin serial cable can connect an Ecotech
8301-LC Zero Air Source and the GasCal 1100. This connection is to be made
between J6 on the GasCal 1100’s rear panel and the 8301-LC.
The 8301-LC Zero Air Source can be replaced by another source that utilises the
12VDC signal that is sent to the Diluent Control port when the air source is to be
activated. When using a customised source, the current draw should be limited to 25
mA. Inductive loads such as solenoids and mechanical relays must have scrubber
diodes connected in parallel with their coils. The diode cathode should be connected
to J6-6.
Note: The current sunk from the zero air source control port
should not exceed 25 mA. Inductive loads should have protection
diodes fitted.
Damage to the calibrator will result if these precautions are not
followed
Page | 25
Installation
GasCal 1100 User manual 3.5
CONNECTOR J6
PIN
J6-2
J6-6
SIGNAL
Zero Air On (12VDC)
Analog Ground
2.3.8 Setting instrument ID
In order to set the GasCal ID, the following steps need to be taken:
1. Turn instrument off and disconnect power cable
2. Find the microprocessor board (shown in Figure 4)
Figure 4 Microprocessor board location
3. Remove cables from board then remove board from instrument
4. Change the pins on JP1 (shown in Figure 5) to make the appropriate ID
number (Figure 6)
5. Replace board, and reconnect cables.
Figure 5 Microprocessor board
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GasCal 1100 User Manual 3.5
Installation
Figure 6 Jumper arrangement for GasCal ID
2.3.9 Purge for Gas Lines
The software includes a purge option that allows venting of gases without the
danger of contaminating other gas sources. With the software option enabled, one
input port becomes a purge exhaust port. Without the option enabled, gas from one
source line may react with gas from another source at the incorrect time, causing a
change in output concentrations.
If activated, the selected gas port will be purged for a set period of time whenever
input gas is changed.
If the purge option is used, input port 4 becomes the purge exhaust port and is to be
connected to an exhaust line through the purge orifice. The exhaust line should be
connected to an exhaust manifold venting to a suitable location outside.
Page | 27
Installation
GasCal 1100 User manual 3.5
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Page | 28
GasCal 1100 User manual 3.5
3
Operation
Operation
3.1 Mode of Operation
The calibrator has two basic modes of operation: Automatic mode and Manual
mode.
3.1.1 Automatic mode
In Automatic mode the GasCal 1100 operates selecting one of the predefined (up to
20) calibration “points”. Each point defines one or more of the following parameters:
Output Gas Type
Output Flow Rate
Output Concentration
Output Ozone Concentration
Output Units
Digital Input Trigger
Digital Status Indicator
Thus, up to 20 different points can be defined for zero, spans of various
concentrations and various GPT points. Each of the points can be activated by a
different digital input bit pattern. Different digital output bit patterns may be used to
indicate the status of the point (on/off) or to generate an alarm status or control
output for external devices. Points can be automated within a “sequence”, a
sequence will automatically step through a number of predetermined points.
Multiple sequences can be set up and used on command in a similar fashion to a
point.
3.1.2 Manual mode
In this mode the input control lines are ignored. The same pre-programmed points
can be turned on and off from the keypad or by RS232 command. Once triggered a
point will remain on until; it is manually changed, times out, or the mode is changed
to automatic. Manual mode can be turned on and off from the keypad or by RS232
command. On power-up the calibrator is by default in automatic mode.
In the Manual mode menu the user may operate the GasCal without the need to
have an external device initiating the desired calibration point. Also, the user may
request specific source gas flows and diluent gas flows without having to set a
specific point. This option is extremely useful for flow calibrations and audits.
Page | 29
Operation
GasCal 1100 User manual 3.5
To use the Manual mode one must first change the Manual mode option to YES.
Once selected the user can either select a pre determined point/sequence or specific
gas flows. A point/sequence can be selected by entering the point number in the Set
Point or Set Sequence entries. A timeout period can also be specified which will
return the GasCal to automatic mode after a set number of minutes. If time is
specified as “0” (zero) in the timeout entry the GasCal will stay in Manual mode
indefinitely. Individual flows can also be requested by entering a number in the Set
flow entries. For a source gas, the source gas number must also be selected.
Note: The Manual Mode will remain activated until the
mode is either disabled or the user set timeout activates.
Caution should be taken to ensure the manual mode is not
left activated accidentally.
3.2 General operational information
3.2.1 Keyboard & Display
GasCal comes standard with a 4 line, 20 character LCD display along with a custom
membrane type keypad. The backlit LCD display has a variable contrast control (see
section). The keyboard consists of six keys enabling quick access and programming to
all of the menus:
Note: GasCal 1000 contains only a
two line LCD display not a 4 line.
Moves cursor to the previous menu item or, in an input field, moves the cursor to
the next choice or increments the digit in a numerical or text field.
Moves cursor to the next menu item or, in an input field, moves the cursor to the
previous choice or decrements the digit in a numerical or text field.
Selects the menu choice or selects the field for input.
Moves the cursor to the previous page or screen
Leaves a field without making a change or returns the cursor to the main screen.

Confirms a menu item or a field selection to the microprocessor
The combination of these keys enables the user to rapidly manoeuvre through the menu structure.
Page | 30
GasCal 1100 User manual 3.5
Operation
3.2.2 Editing Fields
To edit a particular field, use the Select key to edit the menu item. Please note that
some menu items are not editable, such as voltages and other status indicators.
Once editing has begun:
Press Select to select the next character to the right.
Press Page Up to select the character to the left.
Press Up to increase the value of the selected character.
Press Down to decrease the value of the selected character.
Press Exit to quit editing without saving the parameter.
Press Accept (return arrow) to save the parameter and quit editing.
The available characters vary according to the parameter type:
Type
Number
Integer
String
Mask
Yes/No
Characters in ascending order
0 1 2 3 4 5 6 7 8 9 space -.
(“-“ available only in the first position)
0 1 2 3 4 5 6 7 8 9 space
space!"#$%&'()*+,-./0123456789:;<>?
@ABCDEFGHIJKLMNOPQRSTUVWXYZ
X01
YES NO(Select and PgUp have no effect)
3.2.3 Serial Port Menu Navigation
It is also possible to operate the GasCal via a RS232 connection. Utilising a terminal
program with the communication settings at 4800 baud, 8 data bits, no parity, one
stop bit, the user can program and operate the GasCal from a laptop or remotely.
The software accepts the following ASCII characters as local keystrokes:
Keyboard Key
GasCal Key
Right Arrow
Left Arrow
Up Arrow
Down Arrow
Esc
Enter
Select
Page Up
Up
Down
Exit
Accept (return arrow)
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Operation
GasCal 1100 User manual 3.5
3.3 Main screen
The main screen shows the current status of the calibrator and has five different
appearances depending on the current operation of the calibrator.
3.3.1 Standby Screen
The screen will display the following when in standby mode:
Ecotech
GasCal 1100
3.3.2 Zero Screen
The screen will display the following when the calibrator is delivering zero gas only
with no source gas:
Point 01
Flow = 3001
Zero
In this screen the point number and the total diluent flow are displayed.
3.3.3 Span Screen
The screen will display the following when the calibrator is delivering zero gas mixed
with source gas. By scrolling down more status information can be obtained from the
subsequent lines.
Point 01
305
Flow = 3001
Zero Flow = 2937
Source Flow = 64.2
NO
ppb
sccm
In this screen the point number and the source gas are shown along with the output
concentration of diluted source gas. Also shown on this screen are the total flow
rates, the zero flow rate and the source gas flow rate.
Page | 32
GasCal 1100 User manual 3.5
Operation
3.3.4 Ozone Screen
The screen will display the following when the calibrator is delivering zero gas, ozone
and/or source gas. By scrolling down more status information can be obtained from
subsequent lines.
Point
NO
NO
Ozone
Flow
Zero Flow =
Source Flow =
O3 Source =
01
O3
305ppb
340ppb
3001
2937
64.2
30.0 ppm
In this screen the point number, source gas and ozone are shown along with the
output concentration of diluted source gas and ozone. Shown also are the total flow
rates, the zero flow rate, the source gas flow rate, the undiluted ozone output from
the ozone generator and the voltage being supplied to the ozone generator.
Note: the reaction of ozone with any source gas is not
taken into consideration, and the concentrations indicated
are prior to mixing.
3.3.5 Manual mode screen
The following screen is displayed when in manual mode. When in manual mode the
instrument automatically displays the flow of the Zero, Span 1 and Span 2 gases.
When GPT option is installed additional Ozone flow and O3 SRC CONC are displayed.
ZERO FLOW =
OZONE FLOW*
O3 SRC CONC*
SPAN FLOW 1
SPAN FLOW 2
0
0
0
0
0
* Only visible with GPT option
3.4 Menus and screens
To begin using the GasCal 1100, a number of different parameters must be
programmed into the unit. This section of the manual shows the user a step by step
method of setting up the GasCal 1100. To access these items press the Select button
while on the main screen. The following menu choices will appear:
Status
Setup
Manual
S/W Version



V3.09
Page | 33
Operation
GasCal 1100 User manual 3.5
*only visible when GPT option installed
Figure 7 GasCal Menu System
3.4.1 Status Menu
The Status menu displays information about current operation of the GasCal. Using
the cursor keys, move the cursor to the Status option and press Select to access this
menu. Once selected the following menu options will appear:
System
Alarms
Page | 34


GasCal 1100 User manual 3.5
Operation
3.4.1.1 System
The following items appear in the system status menu.
Status OK
Lamp Cur.
Lamp Temp.
P.T. Temp.
+5 V.
+12V
-12V
+15V
-15V
Ch. Temp.
Trig. Word
YES
0.109
50.08
50
5.02
11.74
-11.87
15.076
15.02
32.627
111111
Status OK
The Status OK entry is the logical “and” sum of all of the parameters shown below.
If any of the parameters are not within tolerance then the Status OK entry will
show NO. These parameters are non-editable and simply display their value. The
following table shows the tolerances for these values.
Parameter
Nominal Value
Tolerance
Lamp Temperature*
(Lamp Temp)
Permeation Tube Temp*
(P.T. Temp)
+5V
+12V
-12 V
+15V
-15 V
Chassis Temperature
(Ch Temp)
50 degC
+/- 0.5 deg when warm
50 degC
+/- 0.5 deg when warm
5 Volts
12 Volts
-12 Volts
+15 Volts
-15 Volts
25 degC
+ 0.4, - 0.2 V
+/- 1.5 V
+/- 2.0 V
+/- 0.5 V
+/- 0.5 V
+/- 15 degC
* Only valid when option installed and unit has been running for more than 30
minutes
Trig. Word
The Trig. Word entry shows the current state of the digital input bits from external
triggering device (Logger, analyser etc). These input bits can be compared to the
input bits that are expected to be received via the 25 pin connector.
Note: The “Status OK” entry in the Status menu is
the sum of all alarm conditions and provides an
overall status of the GasCal
Page | 35
Operation
GasCal 1100 User manual 3.5
3.4.1.2 Alarms
The following items appear in the alarm status menu:
Low Flow
Under Range
Over Range
Lamp Temp
Perm Temp
NO
NO
NO
NO
NO
Each entry shows current alarm condition of the above items. If outside the set
tolerance the alarm will be set to YES. Also, an asterisk (∗) will be shown on the right
hand side of the top line of the main screen to indicate an alarm condition. This
asterisk is the sum of all alarms and will be displayed if any of these alarms are
active.
Parameter
Low Flow
Under Range
Over Range
Lamp Temp
Perm Temp
Alarm activated if:
Less than 95% of set point
Less than 5% of FS flow
Greater than 100% of FS flow
Lamp Temp tol. exceeded
Perm Temp tol. exceeded
3.4.2 Setup Menu
Using the cursor keys, move the cursor to the Setup option and press select to
access this menu. Once selected the following menu options will appear:
Points
Gases
Sequences
Alarms
Serial Port
Purge (Sec)
No Point O/P
No Seq. O/P
Flow Temp.





5
00000000
XXXXXXXX
0
3.4.2.1 Points
In the points menu the user may edit any of the 20 points. Pressing the Select button
with one of the points highlighted displays the following menu: “PX” corresponds to
point number “X”, e.g., P15 is the fifteenth point.
P1
P1
P1
P1
P1
P1
P1
*only visible when GPT option installed
Page | 36
Gas No.
Flow
Conc
O3 Conc.*
Units
Trigger
Status
GasCal 1100 User manual 3.5
Operation
PX Gas No.
This option selects which source gas to use in the dilution
(1...10). If the point is to be used to supply Zero gas or Diluent
gas only then use 0 for this parameter.
PX Flow
This variable selects the total flow required for this point.
Remember that this total flow must be between 10 and 100%
of the diluent mass flow controller maximum (typically 10 000
SCCM).
PX Conc
This variable sets the concentration of the diluted gas for this
point. The requested concentration must be such that the
span gas flow is within 10 – 100% of the source gas mass flow
controller maximum (typically 50 sccm).
PX O3 Conc
This variable sets the concentration of ozone produced for this
point. The requested concentration must be within the limits
specified in the GasCal calibration certificate.
PX Units
Use this variable to select the concentration units for the point
in question. Select from %, ppm, pphm and ppb
PX Trigger
This option allows the user to set which digital input bit
pattern will be used to activate and deactivate this point. Each
bit is represented from left to right beginning with bit 1 and
ending in bit 8. Possible values for these entries are:
0
1
X
PX Status
Activate when digital input bit is low
Activate when digital input bit is high
Ignore
This option allows the user to set which digital output bit
pattern will be used to signal the status of the point (on or
off). Each bit is represented from left to right beginning with
bit 1 and ending in bit 8. Possible values for these entries are:
0
1
X
Set digital output bit low when point activated
Set digital output bit high when point activated
Not used
Page | 37
Operation
GasCal 1100 User manual 3.5
3.4.2.2 Gases
In this menu the user can define the names and concentrations of the source gases 1
to 10. Note that some GasCal’s come with only one source gas port.
Gas 1 Name
Gas 1 Conc
Gas 1 Units
MFC factor
Gas 1 Source
GAS1
0
ppm
1.
1
Gas X Name
Each gas should be identified by a name (up to six characters) such as “SO2” or “NO”.
The concentration should also be entered for the gas.
Gas X Conc
The concentration of the source gas (bottle) should be entered into this field.
Gas X units
Enter the units which the source gas concentration is measured in; choose between
ppm, pphm, ppb.
MFC factor
The mass flow correction factor should be entered in for any gas that is different
from the default nitrogen (1) or the dilution gas. A table of these correction factors
can be found in Appendix C. If the required carrier gas does not appear in this table
please contact Ecotech Pty. Ltd. for the required factor.
Gas X source
This field denotes which source port the gas is attached to. If the purge function is
not used then Source can be from 1 to 4, otherwise 1 to 3.
Note: For multi-component mixtures all gases will use the same Source (input port).
The GasCal 1100 can automatically calculate the correct concentration of each
chemical in mixtures for each different point providing that the correct bottle
concentrations are entered within the Gas X Conc field.
Note: A mass flow correction factor must be entered for
gases which have a balance other than the factory standard
of Nitrogen (1).
Page | 38
GasCal 1100 User manual 3.5
Operation
3.4.2.3 Sequences
The GasCal can be programmed to automatically cycle through a number of points,
one after the other. This is called a Sequence. Up to ten sequences can be defined,
each cycling through up to five points. The Period of the sequence defines the time
each point is activated for.
After selecting a sequence number from the sequence menu the following screen is
displayed:
Seq1 Trig
Seq1 Status
Period (min)
1st point
2nd point
3rd point
4th point
5th point
XXXXXXXX
XXXXXXXX
100
3
4
17
8
0
Where “SeqX” refers to the sequence numbered “X”
SeqX Trig
This option allows the user to set which digital input bit pattern will be used to
activate and deactivate this sequence. Each bit (shown as an X above) is represented
from left to right beginning with bit 1 and ending in bit 8. Possible values for these
entries are:
0
1
X
Activate when digital input bit is low
Activate when digital input bit is high
Ignore
SeqX Status
This option allows the user to set which digital output bit pattern will be used to
signal the status of the point (on or off). Each bit (shown as an X above) is
represented from left to right beginning with bit 1 and ending in bit 8. Possible
values for these entries are:
0
1
X
Set digital output bit low when point activated
Set digital output bit high when point activated
Not used
Period (min)
This is the number of minutes each point is activated for.
Nth point
These five numbers correspond to the points to be cycled through. No point will be
executed if the point value is zero.
Page | 39
Operation
GasCal 1100 User manual 3.5
3.4.2.4 Alarms
The alarm menu, found under Setup, lists alarms which can be enabled:
Low Flow
Under Range
Over Range
XXXXXXXX
XXXXXXXX
XXXXXXXX
Three alarms can be set to indicate abnormal conditions:
Any combination of the 8 digital output bits can be used for alarms. Each bit (shown
as an X above) is represented from left to right beginning with bit 1 and ending in bit
8. Possible values for these entries are:
0
1
X
Set bit low when alarm activated
Set bit high when alarm activated
Alarm does not change this bit
Note: Ensure that any alarm bit used has not been
previously assigned as a point status bit.
Low Flow
This alarm is activated when the rate of gas flow through one of the Mass Flow
Controllers is too low.
Under Range
This alarm indicates that the value of diluent flow or source gas flow for the active
point is too low. (Less than 10% of the full-scale limit)
Over Range
This alarm indicates that the value of diluent flow or source gas flow for the active
point is too high. (Greater than the full-scale limit)
3.4.2.5 Serial Port
The serial port menu allows terminal mode to be enabled.
Terminal
NO
When the Terminal mode is activated all of the information being displayed on the
screen is relayed to the RS232 port. A terminal device can be connected to this port
and the calibrator menus can then be accessed via RS232. The serial parameters for
the remote device should be set as follows:
Baud Rate:
Data Bits:
Parity:
Flow Control:
Stop Bits:
Page | 40
4800 bps
8
None
None
1
GasCal 1100 User manual 3.5
Operation
Commands can also be sent to the GasCal via the serial port, using DTE programs
such as Hyper-Terminal on a PC. This is extremely useful when upgrading the ROM
chip of the GasCal. The DUMP command can be used to extract and save all machine
settings before removal of the ROM, while the UPLOAD command can restore these
settings afterwards. See the complete list of commands found in Appendix A – Serial
Port Commands.
3.4.2.6 Purge Time
If Purge Time is set to 0 then the purge option is not used and all four source gas
ports are available.
If Purge Time is not 0, every time the active gas source port is changed the gas
source line and manifold are purged through port 4 for the number of seconds
specified.
3.4.2.7 No Point O/P
This field allows the user to enter an 8 bit code that will be output from the
instrument when there is no point operational. This allows other devices to detect
whether or not the GasCal is under operation. As above, the eight bits (numbered
from 1…8, left to right) can be set to 0, 1 or X. Setting a bit to 1 or 0 will cause the
machine to output this value when the condition is true. Setting a bit to X leaves the
bit unchanged.
3.4.2.8 No Seq. O/P
This field allows the user to enter an 8 bit code that will be output from the
instrument when there is no sequence operational. This allows other devices to
detect whether or not the GasCal is under operation. As above, the eight bits
(numbered from 1…8, left to right) can be set to 0, 1 or X. Setting a bit to 1 or 0 will
cause the machine to output this value when the condition is true. Setting a bit to X
leaves the bit unchanged.
3.4.2.9 Flow Temp.
The Flow Correction temperature (flow temp) is used as the standard temperature at
which flow rates are measured. Australian standard 0oC, United States standard
25oC.
Page | 41
Operation
GasCal 1100 User manual 3.5
3.4.3 Manual Menu
To access the Manual menu, press the Select button when in the main screen. The
following menu choices will appear:
Status
Setup
Manual
S/W Version



V3.00
Using the cursor keys, move the cursor to the Manual option and press Select to
access this menu. Once selected the following menu options will appear
Manual Mode
Set Point
Set Sequence
Set Flow 1
Set Flow 2
Set Z. Flow
Set O3 Flow
Set O3 Src
Set Gas
Purge Port
Timeout (min)
NO
0
0
0
0
0
0
0
0
0
0
Manual Mode
The Manual mode can be set to either Yes or No. Setting the Manual Mode to yes
allows the user to manually control the GasCal from the Manual menu’s fields below.
The manual mode will override the automatic mode points/sequences which will
recommence when returned to automatic mode.
Set Point †
This field allows the user to manually set which point they wish to run (enter the
number of the point set up in the points menu 3.4.2.1).
Set Sequence †
This field allows the user to manually set which sequence they wish to run (enter the
number of the point set up in the sequence menu 3.4.2.3).
Set Flow 1
This field allows the user to manually set the flow rate (cc) of the span gas. Gas type
will be set in the Set Gas field below.
Set Flow 2
This field allows the user to manually set the flow rate (cc) of the second span gas
(optional). Gas type will be set in the Set Gas field below.
Set Z Flow
This field allows the user to manually select the diluent flow (cc).
Page | 42
GasCal 1100 User manual 3.5
Operation
Set O3 Flow*
This field allows the user to manually select the ozone gas flow (cc).
Set O3 Src*
This field allows the user to manually select the concentration (ppm) of O3 produced
by the GasCal when the Set O3 Flow field above is set to 100.
Set Gas
This field opens the gas specified within the gases menu (section 3.4.2.2) for the
manual flow set above.
Purge Port
Manually selects the port which is to be purged i.e. purge 1 = purge port 1 using the
purge port (4).
Timeout (min)
This field allows the user to set the time the instrument will stay in manual mode.
Selecting 0 will keep the instrument in manual mode indefinitely.
† If purge option is activated then instrument will purge before starting sequence/point.
* Only visible when GPT option installed
Page | 43
Operation
GasCal 1100 User manual 3.5
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GasCal 1100 User Manual 3.5
4
Calibration
Calibration
4.1 MFC Calibration
Instruments required:
• 1. Flow standard-1100 or
2. Mass Flow measurement device or
3. Volumetric flow measurement device with a temperature probe and a
pressure sensor.
It may be necessary occasionally to re-calibrate the mass flow controllers of the
GasCal. In order to do this a flow device having an accuracy of equal to or better
than 1% must be used. In instances where multiple GasCal’s must be calibrated, the
Ecotech Flow Standard is specifically designed for this process (see Flow Standard
manual for calibration procedure). The output of the mass flow controller should be
connected directly to the flow measurement device. If the measurement device is a
volumetric device both the temperature of the gas and the barometric pressure
need to be accurately measured in order to calculate the mass flow.
Pre-calibration procedure
1. Download data and record all parameters/fields from the GasCal (perform
serial dump).
2. Power down the GasCal and remove the main supply.
3. Remove the top cover of the GasCal by
a. Remove the side panels by using a screw-driver to pop open the end
(A).
b. Pull the side panel off removing it from its Velcro attachment for both
sides (B).
c. Now remove the lid by using a spanner or screw driver to lift the tabs
(C & D) on each end (front and back) of the GasCal sides.
d. Lift the lid up carefully ensuring to remove the earth wire.
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Calibration
GasCal 1100 User Manual 3.5
Figure 8 GasCal casing removal procedure
4. Once the cover is removed select a mass flow controller to check and connect
the flow device directly to the output of the mass flow controller as shown in
Figure 9.
Figure 9 Calibration Setup
5. Restart the instrument by reattaching power and turning switch on. Leave
instrument for 30 minutes to warm up and condition to testing environment.
6. Once the hardware setup has been completed, enter the hidden menu (see
section 5.3.8)
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GasCal 1100 User Manual 3.5
Calibration
7. In the hidden menu select MFC Coeff option and record the old coefficient
values for the MFC being calibrated (coeff 0-2). These old coefficients should
be entered into the MFC Pre-Post worksheet within the Maintenance
spreadsheet as shown in Figure 10 below.
8. Set the coefficients of the mass flow controllers being calibrated to the
following:
MFCX Coeff 0 = 0
MFCX Coeff 1 = Full scale flow
5
MFCX Coeff 2 = 0
X can be 1, 2, 3 or 4.
See Figure 14 for the location of each mass flow controller.
Figure 10 Original coefficient fields
Calibration procedure
For each of the mass flow controllers being calibrated perform the following
procedure:
1. Connect diluent air to the diluent port as well as span port 1 (via a T-piece).
Note: Do not over pressurise the unit,
Do not exceed 2 bar (29 psi) pressure
2. Enter the Setup Menu then gases menu and specify gas 10 to use Span port 1
[Gas10 Source: 1].
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Calibration
GasCal 1100 User Manual 3.5
3. In the Manual menu enable “Manual mode”, set the flow controller being
calibrated to full-scale:
• For the diluent mass flow controller (MFC 1) set “Z.Flow “to full-scale.
• For the ozone mass flow controller (MFC 2) set “O3 flow” to full
scale.*
• For the source mass flow controller (MFC 3) set “set flow1” to fullscale and “set gas” to 10.
• For the second source mass flow controller (MFC 4) set “set flow2” to
full-scale and “set gas” to 10.*
*only valid when option installed
4. Using the spreadsheet complete all of the ten set points from full scale to 0,
recording the measured flow, temperature and pressure.
5. A graph will automatically be drawn and a 2nd order polynomial will be fitted
to the data as shown in Figure 11. The r2 value should be greater than 0.9995.
The worksheet will then automatically generate a new set of coefficients.
Voltage Vs Measured Flow
6000.00
y = 0.3333x 2998.4818x + 1.1667 +
R21.0000 =
Measured Flow (sccm)
5000.00
4000.00
Measured Flow
3000.00
Poly. (Measured Flow )
2000.00
1000.00
0.00
0.0
1.0
2.0
3.0
4.0
5.0
6.0
Voltage(V)
Figure 11 Mass flow controller characterisation graph
6. The polynomial coefficients are then the exponents of the equation below
which can then be entered into the GasCal directly.
Y = MFCX coeff 2 (x2)+ MFCX coeff 1 (x)+ MFCX coeff 0
7. Once completed enter the new coefficients into the GasCal by entering the
hidden menu and selecting the MFC coeff option. Using the maintenance
worksheet complete a post check with the new coefficients. The mass flow
controllers should be within 1% of their full-scale values.
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GasCal 1100 User Manual 3.5
Calibration
4.2 Ozone Calibration
The ozone generator needs to be calibrated for it to produce reliable and accurate
O3 concentrations.
1. To do this, (see section 5.3.8)
2. In the hidden menu record the existing O3 coefficients. Then set the
coefficients to the following values:
O3 Coeff 0 = -10
O3 Coeff 1 = 10
O3 Coeff 2 = 0
3. Referring to the original factory calibration for the O3 generator, record the
ozone concentration for point 1 and 10.
4. Open the maintenance worksheet select the ozone calibration tab and enter
the factory points into point 1 and 10 of the ozone concentration row. This
will give you a set of 10 points to calibrate the ozone generator.
5. Run the point for at least 30 min with the output being measured by an
accurate ozone-recording device.
6. Enter O3 reading in the O3 average row of the ozone calibration worksheet
making sure the reading has stabilised.
7. The spreadsheet will automatically calculate the O3 Gen concentration
however this can easily be calculated by multiplying the O3 concentration by
flow and dividing by 100. Once you have completed all 10 points
8. A graph will automatically be drawn and a 2nd order polynomial will be fitted
to the data as shown in Figure 12. The r2 value should be greater than 0.9995.
The worksheet will then automatically generate a new set of coefficients.
O3 Volt vs O3 Conc
60
50
2
y = 0.634276x + 16.564002x - 21.393082
2
R = 0.999998
ppm
40
30
20
10
0
1.250
1.750
2.250
2.750
3.250
3.750
V
Figure 12 Ozone Generator Characterisation Graph
Page | 49
Calibration
GasCal 1100 User Manual 3.5
9. The polynomial coefficients are then the exponents of the equation below
which can then be entered into the GasCal directly.
Y = O3 coeff 2 (x2)+ O3 coeff 1 (x)+ O3 coeff 0
10. Once completed, enter the new coefficients into the GasCal by entering the
hidden menu and changing the O3 coeff 0, 1 and 2. Using the maintenance
worksheet complete a post check of the function of the ozone generator. The
O3 output should be within 5% of the requested output.
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GasCal 1100 User Manual 3.5
5
Maintenance
Maintenance
Note: The maintenance procedures outlined below should be
used in conjunction with the GasCal Maintenance spreadsheet,
available from the Ecotech website.
5.1 Maintenance tools
To perform general maintenance on the GasCal 1100 the user will be required to
carry the following equipment:
• One of the following equipment should be used:
o Flow standard-1100
o Flow measurement device (measures temperature and pressure)
o Volumetric flow meter and temperature probe and Pressure probe.
• Flat head screw driver
• Snoop (or other leak detection equipment).
• 9/16 spanner
• 7/16 spanner
• 1/4 swage lock fittings
• 1/8 swage lock fittings
5.1.1 Maintenance sheets
This maintenance sheet is used to perform checks and calibrations of the various
components of the GasCal 1100. The Maintenance sheet comprises six work sheets,
the first (Main Data) worksheet is used for yearly checks of communication interface,
parameters and Leak checks. The next three worksheets labelled MFC Pre-Post, MFC
graphs and MFC calibration are used to perform pre and post-check and calibrate
individual Mass Flow Controllers. These three worksheets should be replicated by
copying and pasting new worksheets (tabs) into the existing spreadsheet for the
amount of MFC’s being checked/calibrated i.e. if three MFC’s being calibrated then 3
X MFC pre-post, MFC Graphs and MFC Calibration should be created and labelled
appropriately. The last two worksheets relate to a check/calibration of the ozone
generator.
Within these sheets there are two main fields, unshaded fields and shaded fields.
Unshaded fields are present for the user to fill in the appropriate figure they have
calculated/received. The shaded fields are calculation fields where the program will
use the figures entered into unshaded fields to calculate the result. These results can
be used to check whether the instrument is within specifications, and will allocate it
either a pass or fail.
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Maintenance
GasCal 1100 User manual 3.5
5.1.1.1 Main Data
Figure 13 Main Data worksheet
The Main Data worksheet is used to complete the general checks and calibrations of
the Ecotech GasCal 1100. There are four fields at the top of this sheet which are
filled out individually each time a check/calibration is performed. These fields are
linked to the other worksheets and will be automatically filled out.
1.
GasCal Model
The GasCal Model section is used to fill in the model GasCal the
technician is using (1000 or 1100) as well as the version of firmware on
the instrument. These are strictly for documentation and do not affect
the calculations within this application.
2.
A/D Check
The A/D Check is to check that the analogue to digital converter is within
specification.
DVM reading R23:
Digital volt meter reading from resistor 23
(refer section 5.3.5)
GasCal Vol 13:
GasCal Voltage (see hidden menu section 5.3.8)
Difference (<0.1):
Difference between DVM reading and GasCal
voltage (automatically calculated)
DAScale (1 ±0.1):
Automatically calculated parameter that should
be approx 4V (± 10-20%)
3.
Parameter Check
The parameter check section is used to give an instantaneous pass or fail
assessment of the lamp temperature and voltages displayed in the status
menu see section 5.3.2.
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GasCal 1100 User Manual 3.5
Maintenance
5.1.1.2 MFC Pre-Post
This worksheet is used for checking the flow against 10 set points and
calculating the full scale error to determine whether the flow is within
the set tolerance.
5.1.1.3 MFC Graphs
This worksheet presents a graphical representation of the error
calculated within the MFC Pre-Post worksheet. These graphs show the
error at each set flow as a line graph.
5.1.1.4 MFC calibration
This worksheet is used to calibrate the Mass Flow Controller using
default coefficients at a measured flow and known voltage, to
calculate a new set of coefficients from a second order polynomial
equation.
5.1.1.5 Ozone Pre-Post
This worksheet is used for checking the ozone concentration against
10 set points and calculating the full scale error to determine whether
the concentration is within the set tolerance.
5.1.1.6 Ozone Calibration
This worksheet is used to calibrate the ozone calibration using default
coefficients at a measured concentration and known voltage, to
calculate a new set of coefficients from a second order polynomial
equation.
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Maintenance
GasCal 1100 User manual 3.5
5.2 Maintenance schedule
The GasCal 1100 has been designed to ensure trouble free operation. If the GasCal
has been properly installed and has been used with clean, dry, filtered gas, minimal
maintenance will be required. The following section shows the common
maintenance steps and their frequency:
Interval (samples)*
As required
Monthly
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Table 1 Maintenance schedule
Item
LCD Contrast
Parameter
Particulate Filter
Leak Check
A/D Check/Adjustment
MFC Check
MFC Calibration
Ozone Check
Ozone Calibration
Procedure
Adjust
Check
Check
Check
Adjustment
Check
Perform
Check
Perform
Page
54
54
55
55
56
57
45
57
49
* Suggested intervals for maintenance procedure may vary with sampling intensity and environmental
conditions.
5.3 Maintenance procedures
5.3.1 LCD Contrast Adjust
The LCD contrast is changed by adjusting the variable potentiometer located behind
the front panel. To access this remove the 6 screws visible on the front panel and
carefully swing the front panel outwards from the left while maintaining the right
hand side of the panel in position. This should be done to minimise the chance of
damaging the keypad ribbon and connector. The potentiometer is visible on the first
PCB from the right and this should be adjusted with an isolated screwdriver.
Note: Always take appropriate precautions
when working on electronic equipment.
Note: Take care when removing the front panel.
The keyboard ribbon cable can be easily
damaged.
5.3.2 Parameter Check
A check of system voltages and temperatures should be made monthly to ensure the
GasCal is operating correctly. These values can be found in the Status  System
menu. The following table gives the tolerances for these values:
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GasCal 1100 User Manual 3.5
Parameter
Maintenance
Table 2 Parameters with nominal value and tolerances
Lamp Temperature*
Permeation Tube Temp*
+5V
+12V
-12 V
+15V
-15 V
Chassis Temperature
Nominal Value
Tolerance
50 degC
50 degC
5 Volts
12 Volts
-12 Volts
+15 Volts
-15 Volts
25 degC
+/- 0.5 deg when warm
+/- 0.5 deg when warm
+ 0.4, - 0.2 V
+/- 1.5 V
+/- 2.0 V
+/- 0.5 V
+/- 0.5 V
+/- 15 degC
* Only valid when option installed and unit has been running for more than 30 minutes
5.3.3 Particulate filter Check
A yearly check should be made on the diluent particle filter which is housed inside
the calibrator. This can be inspected by first powering down the GasCal and
removing main supply. Then, remove the top cover of the GasCal via the method
used in section 4.1. Once removed, the filter will be visible between the mass flow
controllers and the diluent outlet ports on the rear of the instrument. Refer to Figure
14 for more detail.
5.3.4 Leak Check
An annual leak check of the unit is recommended. The simplest method is to apply
source gas to one of the source gas inlets and plug all outlet ports, including the
diluent port. Activate a source either manually or by using a pre-defined point so
that the GasCal is pressurised by the source gas. Once the source gas pressure has
stabilised, back the cylinder pressure off using the regulator adjustment and observe
the source gas line pressure. Record this reading and leave the GasCal for
approximately 10 minutes. After 10 minutes the pressure shown should not have
changed by more than 2 psi.
If pressure does not drop then there is no leak within the instrument.
If the pressure has changed by more than 2 psi
1. Power down the unit and disconnect from mains supply.
2. Once power has been removed source gas should be isolated from the rest of
the GasCal, as the source gas solenoid will now be closed.
3. In this way, leaks can be identified as being before or after the solenoid valve.
4. If the leak is found to be after the solenoid valve (most probable), then apply
source or diluent gas to one of the input ports or diluent ports and check for
leaks in the same manner.
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Maintenance
GasCal 1100 User manual 3.5
5. A suitable leak check fluid can be used however ensure power has been
removed from the GasCal.
6. When a leak is found repair or replace problem area if possible, if this is not
possible or the operator is unsure how to competently repair return
instrument to Ecotech.
7. Also ensure that any liquid used for leak checking is completely dried before
power is re-applied to the GasCal.
5.3.5 A/D Check/Adjustment
From time to time the A/D converter will need adjustment and should be checked
yearly. This is done by first powering down the GasCal and removing main supply.
Remove the top cover of the GasCal via the method used in section 4.1. Take care to
disconnect the ground strap located on the inside from left-hand corner of the lid.
Once removed, locate the main A/D board which is first from the right hand side of
the GasCal (when looking form start). At the top of this card ¾ of the way from the
front are situated two test points labelled AGND and +12V. Place the “+ lead “ of a
previously calibrated digital voltmeter on the leg of the resistor R23 close to the
+12V terminal and the “ – lead” on the AGND terminal. Power up the GasCal and
allow it to warm up for at least half an hour. Enter into the hidden menu (see section
5.3.8). Select “Voltages” and, using the down arrow, locate “Voltage 13“. Enter this
voltage into the GasCal Vol 13 field (A/D check within the Data Sheet tab of the
worksheet) along with the voltmeter reading into the DVM reading R23 field. The
reading should agree to within +/- 0.01 volts of the DVM measurement, if not either
contact the Ecotech service department.
Note: Adjust the potentiometer VR1 located to the right of the
AGND test point until the two values agree, this should only be
performed by a qualified technician and will result in the need
for MFC and Ozone generator recalibration.
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GasCal 1100 User Manual 3.5
Maintenance
Figure 14 Component Layout
5.3.6 Ozone Check
To ensure correct and accurate operation of the ozone generator, a yearly check is
recommended. The concentration should be within 2% of full-scale (1ppm). Open up
the supplied maintenance spread sheet and select the ozone pre-post tab. Run the
point for at least 30 min with the output being measured by an accurate ozonerecording device. Enter O3 reading in the O3 Ref Average row of the table making
sure the reading has stabilised. If on completion of the ozone pre check the full scale
error exceeds 2% the ozone generator needs calibrating.
5.3.7 MFC Check
To ensure correct and accurate operation of the GasCal, a yearly check of the mass
flow controller operation is recommended. The mass flow controllers should be
within 1% of their full-scale values. If the values fall outside of this tolerance, the
mass flow controller coefficients need to be recalculated. See section 4.1 for this
procedure. If the values fall outside of 5% of full-scale, the mass flow controller being
tested will need to be replaced. The following procedures show the required steps to
calibrate each mass flow controller.
Note: that the mass flow controllers are referenced to
0 deg C and 1013.25 hPa pressure.
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Maintenance
GasCal 1100 User manual 3.5
Open up the supplied maintenance spread sheet and create copies of the MFC tabs
for each extra MFC being tested, refer to section 4.1.
Connect a flow meter to one of the output ports on the GasCal and block all others
For each of the mass flow controllers being calibrated perform the following
procedure:
Connect diluent air to the diluent port as well as span port 1. Then enter the Setup
Menu and specify gas 10 to use Span port 1
Enable “Manual mode”, set the flow controller being calibrated to full-scale:
• For the diluent mass flow controller (MFC 1) set “Z.Flow “ to fullscale.
• For the ozone mass flow controller (MFC 2) set “O3 flow” to full
scale.*
• For the source mass flow controller (MFC 3) set “set flow1” to fullscale and “set gas” to 10.
• For the second source mass flow controller (MFC 4) set “set flow2” to
full-scale and “set gas” to 10.*
* Only valid when option installed
Using the spread sheet complete all of the ten set points from full scale to 0,
recording the measured flow, temperature and pressure.
5.3.8 Hidden Menu
To enter the hidden menu press the space between and slightly above, (20mm), the
up and down arrows (shown in Figure 15) and the Select key
Hidden Menu
Hidden Menu
Voltages
Test
MFC Coeff.
ILamp Const
P Temp Const
P Temp Offs
L Temp Const
L Temp Offs
O3 Coeff 0
O3 Coeff 1
Page | 58
Figure 15 Gascal front case with hidden menu button highlighted
Menu
Menu
Menu
Editable Number
Editable Number
Editable Number
Editable Number
Editable Number
Editable Number
Editable Number
Voltage monitoring menu
GasCal factory test menu
MFC coefficients menu.
Voltage to current conversion
Factor for lamp current monitor
Gain for permeation thermistor.
Offset for permeation thermistor
Gain for ozone thermistor.
Offset for ozone thermistor
a0 value for O3 gen polynomial
a1 value for O3 gen polynomial
GasCal 1100 User Manual 3.5
O3 Coeff 2
O3 Max volts
O3 Min volts
O3 Flow
2nd Gas MFC
Editable Number
Editable Number
Editable Number
Editable Number
Yes/No
Maintenance
a2 value for O3 gen polynomial
Max allowed O3 generator volts
Min allowed O3 generator volts
Ozone flow setpoint.
Sets second MFC option.
Hidden Voltage Menu (for factory use only)
V0
Non-Editable Number Displays the voltage on A/D ch. 0
…
…
…
V15
Non-Editable Number Displays the voltage on A/D ch. 15
Hidden Test Menu (for factory use only)
SetZeroFlow
Non-Editable Number Zero flow
SetGasFlow
Non-Editable Number MFC1 flow
SetGasFlow1
Non-Editable Number MFC2 flow
SetGasFlow2
Non-Editable Number MFC3 flow
SetO3Flow
Non-Editable Number O3 MFC flow
UVLACU
Non-Editable Number Displays O3 lamp current
DASCALE
Non-Editable Number Displays D/A / A/D ratio
Zero Flow
Non-Editable Number Displays zero flow
Ozone Flow
Non-Editable Number Displays ozone flow
Src. Flow 1
Non-Editable Number Displays source MFC1 flow
Src. Flow 2
Non-Editable Number Displays source MFC2 flow
Hidden MFC Coefficient Menu
MFC1 coeff0
Editable Number
MFC1 coeff1
Editable Number
MFC1 coeff2
Editable Number
MFC4 coeffN
Editable Number
MFC1 coefficient ao
MFC1 coefficient a1
MFC1 coefficient a2
MFC4 coefficient aN
Where “N” equals 0, 1 or 2
Page | 59
Maintenance
GasCal 1100 User manual 3.5
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Page | 60
GasCal 1100 User Manual 3.5
6
Options
Options
6.1 Transfer Standard
The Transfer standard option for the GasCal 1100TS provides the GasCal with both
an ozone generator for the creation of ozone and an ozone photometer to measure
the concentrations created. This allows the GasCal 1100TS to be used as a reference
standard for ozone analysers as well as run GPT calibrations of ozone with precise
dilution rates.
Components
There are a number of changes to the GasCal 1100TS structurally to incorporate the
transfer standard option. The main component removed from a standard GasCal is
the Ozone MFC. This component has been replaced with the ozone generator
pressure regulator which controls the flow of ozone in conjunction with an orifice.
Below is a summary of the new components within the GasCal 1100TS transfer
standard and a diagram showing their location within the instrument.
Ozone photometer
The ozone photometer is a non-dispersive ultraviolet (UV) photometer which
switches between measuring ozone with and without an ozone scrubber. It then
calculates the ratio of transmitted light between the two signals providing an
accurate and reliable measure of ozone concentration.
Sample pump – Ozone photometer
The sample pump for the ozone photometer draws sample gas through the ozone
photometer, It is controlled by the GasCal 1100TS microprocessor.
Flow control valve – Ozone photometer
This valve is used to set a flow rate of 500 cc\min at the inlet of the ozone
photometer. It has been configured as a bypass flow and has been set at the factory.
Isolation valve – ozone photometer
This isolation valve is controlled by the GasCal 1100TS microprocessor module. This
valve opens during the photometer operation and is closed during non-photometer
operations.
Ozone scrubber (measurement) – ozone photometer
The ozone scrubber selectively destroys ozone but allows other common
absorbances such as SO2 and aromatics to pass through. This component should be
replaced if the ozone photometers readings are lower than expected during
Page | 61
Options
GasCal 1100 User Manual 3.5
calibration checks. A spare scrubber assembly is supplied with the instrument part
number ZTW-OEM106L
Ozone generator
The ozone generator consists of a pressurized chamber, ozone producing ultraviolet
lamp, heater thermistor assembly, gas inlet and outlet fittings and critical orifice.
Together these components produce ozone which is then fed into a Teflon mixing
chamber.
Pressure regulator – Ozone generator
The pressure regulator is factory set to approximately 1.5 bar. The pressure
regulator maintains a constant pressure in front of a critical orifice to maintain the
constant ozone generator flow of 100 sccm
Figure 16 GasCal transfer standard component diagram
Page | 62
GasCal 1100 User Manual 3.5
Options
Operation
6.1.1 Ozone point setup example:
This example demonstrates the steps required to setup an ozone point for the
purpose of calibrating an external ozone analyser. Within the Setup  Points menu
choose a unique point (# represents the point number) to assign as an ozone point,
and then fill in the following fields.
Table 3 Ozone point setup
Field
P # Gas No
Value
0
P # flow
3000
P # Conc
0
P# O3 conc
Photometer
400
yes
GPT
No
P# Unit
P# Trigger
P# Status
ppb
xxxxxxx
xxxxxxx
Explanation
This selection is only required for span cylinder
selection and not applicable for straight ozone
calibrations
This is the total output flow from the GasCal 1100TS
in sccm
This selection is only required for span cylinder
selection and not applicable for straight ozone
calibrations
This is the ozone value requested
This will enable the ozone photometer to measure
and control ozone generation
Only used when performing NO2 calibrations when
using a NO gas cylinder
Choose units for the concentration set
Refer to trigger in section 3.4.2.1
Refer to status in section 3.4.2.1
Test newly created ozone point.
1.
Supply zero grade air to the diluent port of the GasCal 1100TS ensure the
supplied air is maintained at a pressure of 2 bar.
2.
Ensure one of the other output ports is connected to a vent line and any
unused ports are blocked.
3.
The ozone photometer pump will begin running.
4.
Press exit, the front screen will display:
a. The point being run
b. Ozone photometer readings
c. Zero air flow
d. Ozone source concentration.
5.
After 15 minutes the ozone output should be close to the ozone set point
confirming its stability
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Options
GasCal 1100 User Manual 3.5
6.1.2 Photometer assisted GPT.
This procedure improves the ozone set point accuracy during GPT calibration
routines. If GPT and photometer are enabled then the initial ozone set point will run
as two parts:
• Firstly the ozone generator will produce the ozone concentration to that set
within the ozone set point in Table 5 below
• The ozone photometer will shut down and hold the ozone concentration
steady
• The second part introduces NO gas into the system which reacts with the
ozone creating the NO2 required
Note: As a time saving feature if a point including ozone is run at a later
time (with identical flow, ozone set point and without power
interruption) then the ozone photometer feedback phase will be
bypassed (checking the ozone concentration) and the ozone generator
set point control will continue on the previous setting.
Below is a description of how to setup the photometer assisted GPT with fields that
are required to be set up in tables.
1.
Enter the following menu: Setup  Gases, if the NO cylinder has not already
been set up in the GasCal set the fields as show below.
Table 4 NO gas setup
Field
Gas # name
Value
NO
Gas # conc
65.6
Gas # units
MFC factor
ppm
1
Gas # source
1
2.
Operation
Enter a name to represent the cylinder used to
perform GPT tests
Enter the NO gas concentration reported on the
cylinders certificate
Select the units used in the cylinder certificate
Normally set to 1 as majority of gas in cylinder is
N2
Enter the physical source port # that the cylinder
is connected to
Now re-enter the points menu (Setup  points) and create an NO point
Table 5 NO point setup (GPT)
Field
P # Gas No
Value
1
P # flow
3000
P # Conc
450
Page | 64
Explanation
This selection is only required for span cylinder
selection and not applicable for straight ozone
calibrations
This is the total output flow from the GasCal2000
in sccm
This selection is only required for span cylinder
GasCal 1100 User Manual 3.5
P# O3 conc
Photometer
0
No
GPT
No
P# Unit
P# Trigger
P# Status
ppb
xxxxxxx
xxxxxxx
3.
Options
selection and not applicable for straight ozone
calibrations
This is the ozone value requested
This will enable the ozone photometer to measure
and control ozone generation
Only used when performing NO2 calibrations
when using a NO gas cylinder
Choose units for the concentration set
Refer to trigger in section 3.4.2.1
Refer to status in section 3.4.2.1
Finally create still within the points menu create an NO2 point with the as
shown below
Field
P # Gas No
Value
1
P # flow
3000
P# Conc
450
P# O3 conc
400
Photometer
Yes
GPT
Yes
P# Unit
P# Trigger
P# Status
ppb
xxxxxxx
xxxxxxx
Table 6 NO2 point setup (GPT)
Explanation
This selection is only required for span cylinder
selection and not applicable for straight ozone
calibrations
This is the total output flow from the GasCal2000
in sccm
Enter the required concentration of NO for the
GPT test
Enter the required ozone concentration for the
GPT test Note must be less than NO
concentration
This will enable the ozone photometer to measure
and control ozone generation
This field is used for performing NO2 calibrations
when using an NO gas cylinder
Choose units for the concentration set
Refer to trigger in section 3.4.2.1
Refer to status in section 3.4.2.1
Page | 65
Options
GasCal 1100 User Manual 3.5
Calibrations
Once the GasCal 1100TS has been commissioned an ozone generator calibration
should be performed but no ozone flow calibration is required (only required during
routine maintenance).
This function is to characterize the generator to the new conditions as the zero air,
relative humidity, temperature, altitude (pressure), and UV lamp condition will
directly impact of the generators output.
6.1.3 Ozone flow calibration
Note: This procedure replaces section 4.2
Equipment required:
Mass flow meter
Procedure:
1. Ensure instrument is powered off
2. Supply 2 bar of pressurized zero air to diluent port.
3. Remove the top cover of the GasCal (see steps 1-3 in section4.1)
4. Disconnect the ozone generator tubing form the t-piece (shown in Figure 17
on the left)
5. Connect the flowmeter to the T-piece as shown in on the right picture in
Figure 17)
Figure 17 Ozone flow calibration setup
6. Power up GasCal. Leave instrument to warm up for at least 30 minutes.
7. Record the flow measurement which should be 100 ± 5 sccm (Standard
temperature 0ºC)
8. If the flow is outside 100 ± 5 sccm then adjust the pressure regulator (turning
the knob left or right to adjust flow) inside the GasCal until 100 ± 5 sccm is
obtained.
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GasCal 1100 User Manual 3.5
Options
9. Power down GasCal
10. Disconnect flow meter and reconnect ozone generator output to 1/8” tee
fitting
11. Replace the top lid
12. Ozone flow calibration complete
6.1.4 Ozone Photometer calibration
1. Connect an external ozone transfer standard to one of the ports on the gas
output manifold (if the external ozone transfer standard requires external
reference air ensure it is connected to the same air source used by the GasCal
1100 TS).
2. Run an ozone point at 100% of range (normally 500 or 1000ppb) with
photometer active (minimum 2 hours). See section 6.1.1 to set up ozone
point.
3. If the ozone point is seen to be greater than ±2 % then an adjustment will
need to be made.
4. If it is determined that an adjustment is required then start a photometer
calibration. To activate a photometer calibration enter the Calibration menu
 Photometer. The ozone generator will output a high concentration of
ozone (approximately 1.2ppm).
5. The display will show the current photometer value in the “photo value” field
in ppm. Allow your reference ozone photometer to stabilize (approximately
45 minutes) and then enter the reading from the external ozone transfer
standard into the “when stable” field, then select next
6. The ozone generator will now output a low ozone concentration (approx
0.1ppm). Allow your reference ozone photometer to stabilize (approximately
30 minutes) and then enter the reading from the external ozone transfer
standard into the “when stable” field, then select next.
7. This completes the Photometer calibration.
Page | 67
Options
GasCal 1100 User Manual 3.5
Troubleshooting
The ozone photometer is designed to be nearly maintenance free. This is due to it
being idle for most of the time. The photometers pump will only run during a
calibration sequence that specifically calls for ozone production feedback.
Parts with a limited lifetime, that may require attention, include the solenoid valve
and the UV lamp.
Should the solenoid valve (PN H040013) fail, the ozone readings will be zero,
however if it was only partially switching then the ozone reading would be lower
than expected but not zero.
Should the UV lamp fail, the ozone readings will become erratic. If this occurs then
the lamp \ driver assembly PN C020114 will need to be replaced.
6.1.5 UV lamp replacement procedure.
•
•
•
Disconnect the GasCal power and gas lines
Remove the lid and locate the sample inlet fitting, exhaust port (silicon tube),
9 pin D connecter, 12 volt power plug and disconnect.
Locate the three screws that fasten the ozone photometer to the chassis and
remove the screws.
inlet
Exhaust port
Page | 68
D connector
power
Ozone photometer’s
mounting screws
GasCal 1100 User Manual 3.5
Options
Figure 18 Ozone Photometer layout
•
•
Lift the assembly out and place it on an anti static work bench.
Remove all electrical and pneumatic fittings between the cell assembly and
the main assembly. Note for better access remove the four screws that hold
display assembly.
Figure 19 Ozone Photometer Assembly
•
Remove the six screws that fasten the cell to cell bracket.
Remove screws here
Figure 20 Ozone Photometer Cell Bracket Assembly
Page | 69
Options
•
GasCal 1100 User Manual 3.5
Disassemble cell assembly and locate the UV lamp and driver assembly. Pay
attention to its mounting position now carefully remove component and
replace with the new part.
Lamp driver
UV Lamp
Figure 21 Ozone Photometer Cell Assembly
•
•
•
•
•
•
Re assemble cell assembly ensuring not to crush any of the wiring.
Remount cell to bracket connect all of the electrical and pneumatic
connections to cell.
Remount display assembly.
Fit ozone photometer back into calibrator chassis and reconnect the sample
inlet fitting, exhaust port (silicon tube), 9 pin D connecter, 12 volt power plug.
Connect electrical and gas lines to the calibrator and connect an ozone
analyser to the calibrator output port.
Run an ozone point over night with photometer enabled. This allows the new
lamp to burn in and for the pneumatic system to condition. Check operation
to ensure the external ozone analyser is measuring a stable ozone value close
to the current set point.
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GasCal 1100 User Manual 3.5
Options
Ozone generators output is not
stable or not reaching set-point
Run point for
20 minutes
The GasCal is available in a
number of configurations and
operating modes.
For example if the calibrator is
equipped with the ozone
monitor and the ozone point
running has photometer
enabled then the ozone set
point range is 5 to 1000 ppb.
At a flow rate of 3 slpm.
If however you are running a
basic O3 generator, set point
range is 50 to 1000 ppb @ 3
slpm.
There are other
configurations available such
as high output pressurized
generators and general O/P
pressurized generator
therefore you will need to
check the specification of
your particular GasCal. Set
ozone point to value within
the range of the Gascal.
Has point run
long enough to
stabilize?
No
Yes
No
No
Has ozone output
stabilized?
Yes
Is the ozone set
point within
operating range for
current
configuration?
Problem solved
Yes
Is zero air
connected to the
Gascal dry and
pressure regulated
to 2 bar?
Replace desiccant in
zero air line. Set
external pressure
regulator to 2 bar
No
Yes
No
Has problem
been solved?
Yes
Disable photometer
control
Yes
Is photometer
mode enabled?
Problem solved
No
Has ozone
generator output
stabilized?
No
Contact Ecotech for
further support.
Yes
Go to ozone photometer trouble shooting guide.
Figure 22 Trouble Shooting Flow Chart
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GasCal 1100 User Manual 3.5
Options
AAppppeennddiixx AA -- SSeerriiaall PPoorrtt CCoom
maannddss
mm
The GasCal 1100 has a number of in built serial functions that will respond when
interrogated. All commands are prefixed by a digit 0…7 corresponding to the unit ID.
This is set by three jumpers on the microprocessor board. The factory default for this
ID is 0. This system allows multiple GasCals to be connected and controlled to the
same DTE controller. Note that all commands are in upper case. In this list, lowercase letters are placeholders, e.g., “nn” refers to a two digit number. Since most
commands mimic the in-built menu system, more information on the output/input
types can be found in the Software section of this manual. Unless otherwise stated,
all responses conclude with a carriage return line feed. (CR LF)
Native Serial Commands
Command
iREMOTE=ON
iREMOTE=OFF
iDUMP
iUPLOAD
iMFCn?
iMFCn=c0,c1,c2
2ND MFC FLAG=n
iSETFLOWn=
PURGE TIME=time
iMANUAL=ON
iMANUAL=OFF
iT?
iT=nn
iGASnn?
Table 7 Native Serial Commands
Description
Turns on remote mode
Turns off remote mode
Outputs setup parameters(see below)
Inputs setup parameters(see below)
Outputs coefficients for MFC n
Inputs coefficients for MFC n
Sets the 2nd MFC flag (n=0 or 1)
Sets flow for MFC n
Sets purge time in seconds
Turns on Manual mode
Turns off Manual mode
Outputs timeout (minutes)
Inputs timeout (minutes)
Outputs gas n parameters
Response
none
none
c0,c1,c2
OK
OK
iGASnn=name,conc,units,mf
cfactor,source
iSETPOINTnn
iPOINTnn?
iPOINTnn=
src,flow,conc,o3conc,
units,imask,omask
iSQnn?
Inputs gas n parameters
OK
OK
Timeout in minutes
OK
name,conc,units,
mfcfactor,source
OK
Turns on point nn
Outputs point nn parameters
Inputs point nn parameters
OK
src,flow,conc,o3conc,
OK
Outputs sequence nn params.
iSQnn=
imask,omask,period,point1,
2,3,4,5
iSOLn=ON
iSOLn=OFF
iOZONE=ON
iOZONE=OFF
iOZONE=c0,c1,c2
iOZONE?
iO3 MIN VOLTS=n
iO3 MAX VOLTS= n
iV?
Inputs sequence nn params.
imask,omask,period
point1,2,3,4,5
OK
Turns on solenoid n
Turns off solenoid n
Turns on ozone
Turns off ozone
Sets ozone coefficients
Returns ozone coefficients
Inputs minimum O3 voltage
Inputs maximum O3 voltage
Outputs flow voltages
OK
OK
OK
OK
OK
c0,c1,c2
none
none
v0,v1,v2
Page | 73
iVInn?
iSTATUS?
iVER?
iNPMASK?
iNPMASK=mask
iNSMASK?
iNSMASK=mask
iLOW FLOW ALARM
MASK=mask
iOVERRANGE ALARM
MASK=mask
iUNDERRANGE ALARM
MASK=mask
Dasibi dot commands
Command
.21<cr>
.21<sp><cr>
.21<sp>nn<cr>
.21<sp>99<cr>
.22<cr>
.22<sp><cr>
.22<sp>nn<cr>
Outputs a/d voltage nn
Outputs status and any alarms
Outputs software version
Outputs “no point output” mask
Inputs “no point output” mask
Outputs “no sequence output” mask
Inputs “no sequence output” mask
Inputs low flow alarm mask
voltage (see below)
'Point active' or 'Idle'
Vn.nn
mask (no CRLF)
none
mask (no CRLF)
none
none
Inputs over range alarm mask
none
Inputs under range alarm mask
none
Table 8 Dasibi dot commands
Description
Response
Return current point number
Start point nn
Abort current point/sequence
.21<sp>nn<crlf>
.21<sp>nn<crlf>
.21<sp>99<crlf>
Return current sequence
Start sequence nn
.22<sp>nn<crfl>
.22<sp>nn<crfl>
A/D voltage numbering
i=
n=
nn =
name
units
MFC numberingc0, c1, c2 =
mask =
unit ID. Ddefault value = 0
one digit number used for gas num, solenoid num
two digit number used for point num
MUST be 6 characters in length (can include spaces)
1=ppb, 2=pphm, 3=ppm, 4=%
1 = zero, 2 = ozone, 3 = spangas 1, 4 = spangas 2
polynomial coefficients- val = c2*v^2 + c1*v + c0
a digital output/input bit mask
Table 9 A/D Voltage Numbering
Voltage Number
Function
00
MFC1 O/P voltage
01
MFC2 O/P voltage
02
MFC3 O/P voltage
03
MFC4 O/P voltage
04
lamp current monitor
05
lamp temp monitor
06
perm. tube temp monitor
07
+12v monitor v = 4.9*v07
08
+5v monitor v = 2v08
09
-12v monitor v = 4.9*v09
10
+15v monitor v = 4.9*v10
11
-15v monitor v = 4.9*v11
12
analogue ground
13
chassis temp T = 100*v13 - 273
14
d/a ref- should be approx 4v
15
ground offset
Page | 74
GasCal 1100 User Manual 3.5
Options
The DUMP command sends parameters in the following format:
MFC1=
MFC2=
MFC3=
MFC4=
ZERO MW=
GAS01=
GAS02=
GAS03=
GAS04=
GAS05=
GAS06=
GAS07=
GAS08=
GAS09=
GAS10=
POINT01=
POINT02=
POINT03=
POINT04=
POINT05=
POINT06=
POINT07=
POINT08=
POINT09=
POINT10=
POINT11=
POINT12=
POINT13=
POINT14=
POINT15=
POINT16=
POINT17=
POINT18=
POINT19=
POINT20=
OZONE=
-5.676, 1989.978,2.16
-0.44, 18.918,.142
0.062, 20.352,-0.038
0,10,0
0.998
NO ,99.14,3, 1,1
CO ,9956,3, 1,1
SO2 ,94.98,3, 1,1
GAS4 ,0,3, 1.,1
GAS5 ,0,3, 1.,2
GAS6 ,0,3, 1.,3
GAS7 ,0,3, 1.,1
GAS8 ,0,3, 1.,2
GAS9 ,0,3, 1.,3
GAS10 ,100,3, 1.,1
1,3000,0,0,3,1011XXXX,XXXXXXXX
1,3000,0.4,0,3,0111XXXX,XXXXXXXX
3,2500,0,200,0,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
0,0,0,0,3,XXXXXXXX,XXXXXXXX
-13.775, 10.642,1.661
O3 MIN VOLTS= 1.2
O3 MAX VOLTS= 3.8
LOW FLOW ALARM MASK=XXXXXXXX
OVERRANGE ALARM MASK=XXXXXXXX
UNDERRANGE ALARM MASK=XXXXXXXX
2nd MFC FLAG=1
PURGE TIME=2
END
This can be captured to a text file as a record of the current setup.
When the UPLOAD command is sent, the GasCal will wait for a file in the above
format. It will change the setup parameters (this takes about 10 sec) and respond
with “OK”.
This allows a calibrator to be set up by editing the parameter file then uploading it.
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GasCal 1100 User Manual 3.5
Options
AAppppeennddiixx BB PPaarrttss LLiisstt
Description
Casing
GasCal front panel (includes
metal panel and keypad label)
Electrical
Switching power supply
LCD Screen
Source Solenoid
Ozone Generator
Heater 30W/Thermistor
assembly
UV Lamp
Circuit Boards
Processor
EPROM – GC1100 GPT
EPROM – GC1100
Interface
Solenoid
O3_driver
Ecotech Part No.
ECO-GC20
H050019
CIR-3605
REL-1061
ECO-GC100050
ECO-GC100060
CIR-1351
S040002
S040003
CIR-1356
CIR-1366
CIR-1361
Mass Flow Controllers*
MFC
ZUN-UFC180-XXX
Filters
DFU filter
F010005
* Where XXX is the full-scale flow rate (be sure to specify sccm or
slpm). For example, 050 sccm or 005 slpm.
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GasCal 1100 User Manual 3.5
Options
AAppppeennddiixx CC –– M
w ccoorrrreeccttiioonn ffaaccttoorrss
Maassss fflloow
Name Plate Gas
Chemical Symbol
MFC Factor
Air
Ammonia
Butane
Carbon Dioxide
Carbon Monoxide
Ethane
Helium
Hydrogen Sulphide
Methane
Nitric Oxide
Nitrogen
Nitrogen Dioxide
NH3
C4H10
CO2
CO
C2H6
He
H2S
CH4
NO
N2
NO2
0.998
0.790
0.261
0.736
1.000
0.475
1.399
0.839
0.752
0.972
1.000
0.779
Oxygen
Propane
Sulphur Dioxide
O2
C3H8
SO2
0.977
0.331
0.687
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GasCal 1100 User Manual 3.5
Options
AAppppeennddiixx D
O ccoonnnneeccttoorr lliisstt
Diiggiittaall II//O
D –– D
Pin Number on
DB50 Connector
1
34
18
2
35
19
3
36
20
4
37
21
5
38
22
6
39
23
7
40
24
8
41
25
9
42
26
10
43
27
11
44
PIN Number for J5
Connector*
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
J5-9
J5-10
J5-11
J5-12
J5-13
J5-14
J5-15
J5-16
J5-17
J5-18
J5-19
J5-20
J5-21
J5-22
J5-23
J5-24
J5-25
J5-26
J5-27
J5-28
J5-29
J5-30
J5-31
J5-32
Signal
Digital Output Bit 1
Digital Ground
Digital Output Bit 2
Digital Ground
Digital Output Bit 3
Digital Ground
Digital Output Bit 4
Digital Ground
Digital Output Bit 5
Digital Ground
Digital Output Bit 6
Digital Ground
Digital Output Bit 7
Digital Ground
Digital Output Bit 8
Digital Ground
Digital Input Bit 1
Digital Ground
Digital Input Bit 2
Digital Ground
Digital Input Bit 3
Digital Ground
Digital Input Bit 4
Digital Ground
Digital Input Bit 5
Digital Ground
Digital Input Bit 6
Digital Ground
Digital Input Bit 7
Digital Ground
Digital Input Bit 8
Digital Ground
*Cable with DB50 connectors is provided. J5 connectors may also be
used, however, note the different pin numbering system.
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GasCal 1100 User Manual 3.5
Options
1492 Ferntree Gully Road, Knoxfield VIC
Australia 3180
Phone: +61 (0) 3 9730 7800
Fax: +61 (0) 3 9730 7899
Email: info@ecotech.com.au
Service: service@ecotech.com.au
www.ecotech.com
Page | 83
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