CleanAIR 0724 5 Channel Calibrator and SGDM System User Manual
- June 9, 2024
- CleanAIR
Table of Contents
CleanAIR 0724 5 Channel Calibrator and SGDM System
IMPORTANT
BEFORE YOU BEGIN READ THIS!!!
READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE USING THIS SYSTEM!
SAVE THESE INSTRUCTIONS!!!
- To Avoid Accidents…
- Keep your work area clean and well lit.
- Keep unauthorized personnel away.
- Exercise common sense.
- Electrical Safety…
- Do not operate in combustible environments.
- DO NOT operate these products when wet or in water.
- ALWAYS be sure that the components of this system are operating with the correct voltage (120V).
- Never remove a grounding prong or modify a plug.
- Do not abuse the power cord or plug. Remove by handling plug only.
- Personal Safety…
- Stay alert and pay attention to what you are doing.
- Dress appropriately. Wear the appropriate personal safety devices.
- Calibration and/or flue gases can be hazardous to human health. Be sure that all lines are properly vented to an open area.
- Check the system for leaks after installation.
- Equipment Maintenance…
- Maintenance and repairs should be performed only by one of Clean Air Express’s trained technicians.
Customer Feedback
Clean Air Engineering takes pride in our quality products and services. We
strive to provide the highest quality products and services in the industry.
We realize the importance of end user input in the continual improvement of
our products and services. Customer feedback is of paramount importance. We
encourage your feedback with any suggestions or problems that can help us
improve our performance. A customer feedback form is available online at
http://www.cleanair.com/About/feedback.html. To emphasize our commitment to
quality products and complete customer satisfaction, Clean Air Engineering’s
manufacturing division, CAE Express, offers what we feel is the best and most
comprehensive warranty in the environmental industry.
Safety
Safety should always be considered first, and proper safety procedures should be followed.
Harmful Gas Inhalation
Some calibration gases can be potentially fatal if inhaled (e.g. carbon
monoxide). Be sure to use the system outside or in a well ventilated area. If
you suspect that your system may be leaking, do not use it.
Electrical Shock
The 5 Channel Calibrator is powered by a standard 120 VAC line, thus
potentially fatal shocks are possible. It is no more dangerous than many
household appliances in this regard; however, care must be taken to avoid
shock. Before performing any maintenance on this item or an assembly
containing it, turn off and unplug all components from the 120 VAC line.
Principles of Operation
The 5 Channel Calibrator can be combined with the Sample Gas Distribution
Module as shown below. The 5 Channel Calibrator is designed to interface CEM
analyzers with five individual calibration gases. The gases can be controlled
manually or remotely to flow through one of two calibration ports. The SGDM
distributes sample gas to four analyzers. The design of the two allows for
installation into a standard 19″ instrument rack.
System Components
5 Channel Calibrator
See Figure 1a and Figure 1b.
Sample Gas Distribution Module
See Figures 2a and 2b
System Operation
Setup
-
Connect calibration gases to the five ports labeled “CAL GAS IN” (5).
-
Connect the device to be calibrated (e.g. probe tip) to the port labeled “CAL GAS OUT – A” (6).
-
Connect the “CAL GAS IN” on the SGDM (2-11) to the 5 Channel Calibrator’s “CAL GAS OUT – B” (6)
NOTE: The “A” and “B” options on the knob denoted the letters above the “CAL GAS OUT” ports. -
Connect the sample line to the “SAMPLE IN” port on the back of the SGDM (2-10). The sample gas must be clean and dry before it reaches this device. In most cases, a gas conditioner will be necessary to remove moisture.
-
Plug in the devices if you have not already done so.
Calibration
-
Probe Tip Calibration
- Select the desired calibration gas using the calibration gas output selector knob (3).
- Using the calibration output selector (4) on the 5 Channel Calibrator, select “A.”
- Using the flow meter on the 5 Channel Calibrator (1), adjust the calibration flow to 1-2 LPM higher than the stack flow rate (in the range of 1-10 liters per minute).
-
Analyzer Calibration
-
Select the desired calibration gas using the calibration gas output selector knob (3).
-
Using the calibration output selector (4) on the 5 Channel Calibrator, select “B.”
-
Press the green “CAL MODE” button on the SGDM (2-4).
NOTE: While in CAL Mode, the SGDM will vent any sample gas.
NOTE: While in CAL Mode, the “CAL MODE” button will be lit. -
Using the flow meter on the 5 Channel Calibrator (1), adjust the calibration flow to the 1-2 LPM higher than the stack flow rate (in the range of 1-10 liters per minute).
-
Using the SGDM’s flowmeters (2-1) adjust the flow of calibration gas to the analyzers.
-
Sample Gas Distribution
- Cease the flow of any calibration gases. Allow a few seconds for them to vent from the systems if necessary.
- Press the green “CAL MODE” button on the SGDM (2-4) to enter Sample Mode. Be sure that it is NOT lit up.
- Using the SGDM’s flowmeters (2-1) adjust the flow of sample gas to the analyzers.
Control via a Remote Device
- Set the calibration output selector (4) to “A – AUTO”.
- Set the calibration gas output selector knob (3) to “AUTO”.
- Insert the 7 pin Amphenol plug from the remote device into the Amphenol input (9) on the back of the 5 Channel Calibrator.
- Insert the Amphenol from the remote device into the Amphenol input (2-9) of the SGDM.
- Plug in devices if you have not already done so.
- Using the flow meters (1, 2-1), adjust the flow rate.
- The input and output of the system can now be controlled with a remote device.
NOTE: The flow rates of the devices cannot be controlled via a remote device. Any changes must be performed manually.
Routine Maintenance and Inspection
CAUTION!! – Do NOT disassemble this product! For internal maintenance contact Clean Air Express.
Maintenance Issues
For any other maintenance issues, concerns, or questions, please contact Clean
Air Express at (800)-223-3977. Clean Air Express can also be reached by mail
at 212 N. Woodwork Lane Palatine, IL 60067; by fax at (847)-991-8924 or on the
web at http://www.cleanair.com/equipment/Express/main.html
Troubleshooting
| Problem | Cause(s) | Fix |
|---|---|---|
| Stops running | No power | Ensure that the system is plugged in |
| Blown fuse | Press the fuse back in | |
| Auto mode does not work correctly | Incorrect configuration | Be sure that the |
input selector and the output selector are both set to auto and that the
Amphenol connection is set.
System is leaking| Nuts and ferrules are
too tight or too loose.
| Be sure that the nuts and ferrules on the inputs and outputs are not over-
tightened or too loose.
| Internal
Leakage
| Send to Clean Air Express for
Maintenance.
Calibration gas is not reaching the correct location| Incorrect Configuration|
Be sure that the input selector and the output selector are both set to the
correct location.
| Closed Valves| Be sure that the flowmeter valves are opened.
Figure 3
Figure 4
Figure 5 
Figure 6 
CLEAN AIR ENGINEERING PARTS LIST
5 CHANNEL CALIBRATOR
May 22, 2008
Parent Part #: 0724 COMPONENT
| ****
DESCRIPTION
| ****
Type: F QTY
| ****
UM
| | ****
TYPE
---|---|---|---|---|---
0418SBU| BULKHEAD 1/4″T-1/4″T S.S.| 7.0| EA| | R
9102| 6 POSITION ROTARY SWITCH| 2.0| EA| | R
9735| 1/4 WATT PROBE DIODE MOTOROLA| 10.0| EA| | R
91053| RED INDICATOR LIGHT LEECRAFT| 6.0| EA| | R
35762| COSEL POWER SUPPLY| 1.0| EA| | R
9148| PANEL MOUNT FUSE HOLDER| 1.0| EA| | R
9109| 18 GAUGE POWER CORD 7′| 1.0| EA| | R
9423| 7 PIN FEMALE ASSY| 1.0| EA| | R
9761| SOLENOID 2 WAY 1/16 ORIFICE| 5.0| EA| | R
9759
| STAINLESS STEEL 12VDC SOLENOID 3 WAY UNIVERSAL| ****
2.0
| ****
EA
| | ****
R
| 1/16″ ORIFICE SS. BODY 12VDC| | | |
92831| 1/4″T-1/8″NPT KYNAR MALE| 14.0| EA| | R
| ELBOW ADAPTER| | | |
92832| 1/4″ TUBE-1/8″ PIPE MALE| 3.0| EA| | R
| KYNAR CONNECTOR| | | |
9195| KNOB FOR 1/4″ SHAFT AUGAT PKG| 2.0| EA| | R
| 50B 1/4| | | |
0073| RITTAL THUMB SCREW| 4.0| EA| | R
9748| FLOWMETER 1 – 10 LPM VALVED| 1.0| EA| | R
9291| 1/4″X1/4″X1/4″ TUBE UNION TEE| 4.0| EA| | R
97064
| KYNAR
4 AMP SLO BLOW FUSE
| ****
1.0
| ****
EA
| | ****
R
07241| 5 CHANNEL CALIBRATOR BACK| 1.0| EA| | R
| PLATE| | | |
07242| 5 CHANNEL CALIBRATOR FRONT| 1.0| EA| | R
| PLATE| | | |
9110SR| PLASTIC POWER CORD STRAIN| 1.0| EA| | R
| RELIEF AND NUT – BLACK| | | |
007111| RITTAL 3U SIDE MEMBER 220| 2.0| EA| | R
| DEEP| | | |
007113| RITTAL PERF. COVER 28HP X| 2.0| EA| | R
007115
| 220 DEEP
RITTAL COLLAR SCREW / SLEVE
| ****
4.0
| ****
EA
| | ****
R
0076| RITTAL PLASTIC GUIDE RAILS| 1.0| EA| | R
0724PCBD| PC BOARD FOR 5 CH. CALIBRATOR| 1.0| EA| | R
9445| 12 PIN CONNECTOR PC MOUNT| 2.0| EA| | R
35762B| COSEL OUTPUT HARNESS| 1.0| EA| | R
35762A| COSEL INPUT HARNESS| 1.0| EA| | R
Parent Part #: 9742
COMPONENT
| ****
DESCRIPTION
| Type: F
QTY
| ****
UM
| | ****
TYPE
---|---|---|---|---|---
0715RET| 1/4″ T HEX RETAINER| 10.0| EA| | R
0998| PORT CONNECTOR 1/4″ MET| 2.0| EA| | R
| SAMPLE R – STAINLESS STEEL| | | |
9742FP| SAMPLE GAS DELIVERY MODULE FRONT PLATE| 1.0| EA| | R
9742RP| SAMPLE GAS DELIVERY MODULE| 1.0| EA| | R
| REAR PLATE| | | |
99182| CHECK VALVE 10PSI – SS| 1.0| EA| | R
0418RSMC| UNION MALE 1/4″T-1/8″MNPT SS| 5.0| EA| | R
35001| SS MALE RUN TEE 5.0 EA R| | | |
0417SMRE| ELBOW MALE 1/4″T-1/8″MNPT SS| 5.0| EA| | R
0418SME| ELBOW MALE 1/4″T-1/4″MNPT SS| 2.0| EA| | R
0418SUT| UNION TEE 1/4″T S.S.| 3.0| EA| | R
0418SBU| BULKHEAD 1/4″T-1/4″T S.S.| 10.0| EA| | R
9220 1/4″| CAP FITTING WITH NUT AND FERRULE| 1.0| EA| | R
0418SUE| UNION ELBOW 1/4″T-1/4″T S.S.| 2.0| EA| | R
0418TF| FERRULE 1/4″ PTFE| 2.0| EA| | R
9149| FUSE CLIP| 2.0| EA| | R
0715PF| FILTER – DISPOSABLE W/KYNAR| 1.0| EA| | R
| BODY| | | |
9110SRB PLASTIC POWER CORD STRAIN RE- 1.0 EA
R LEIF (BLACK)
9109| 18 GAUGE POWER CORD 7′| 1.0| EA| R
9118| CIRCUIT BREAKER 5AMP 250 VOLT| 1.0| EA| R
35762| COSEL POWER SUPPLY| 1.0| EA| R
35762A| COSEL INPUT HARNESS| 1.0| EA| R
35762B| COSEL OUTPUT HARNESS| 1.0| EA| R
94271| STANDARD PLUG 9 PIN SIZE 13| 1.0| EA| R
94272| CABLE CLAMP SIZE 13| 1.0| EA| R
94273| STANDARD SQUARE FLANGE SIZE| 1.0| EA| R
| 13 RECEPTICLE 9 CONTACT| | |
9761| SOLENOID 2 WAY 1/16 ORIFICE| 1.0| EA| R
| STAINLESS STEEL 12VDC| | |
9759| SOLENOID 3 WAY UNIVERSAL 1/16″| 2.0| EA| R
9765| REGULATOR BACK PSI| 1.0| EA| R
9746| FLOWMETER .15-1 LPM VALVED| 4.0| EA| R
9748| FLOWMETER 1 – 10 LPM VALVED| 1.0| EA| R
9750| PRESSURE GAUGE 0 – 60 PSI| 1.0| EA| R
| PANEL MOUNT| | |
007111| RITTAL 3U SIDE MEMBER 220 DP| 2.0| EA| R
Parent Part #: 9742
COMPONENT
| ****
DESCRIPTION
| Type: F
QTY
| ****
UM
| | ****
TYPE
---|---|---|---|---|---
007114| RITTAL PERF. COVER 42HP X 220| 2.0| EA| | R
| DEEP| | | |
0769250| PTFE TUBING 1/4″OD./.125″ID.| 6.0| FT| | R
| 100FT CONT. LGTH. COIL (PTFE)| | | |
8906| KNOB 1/8″ SHAFT| 5.0| EA| | R
0418RSFC| CONNECTOR 1/4″T-1/8″FNPT S.S.| 1.0| EA| | R
9434M| AMP PIN PART# 66103-2| 6.0| EA| | R
Our Guarantee
Clean Air Engineering warrants products to be free from defects and
workmanship for a period of one year after delivery date. The remedy for
defective goods shall be repair or replacement of defective parts or payment
price of the goods for which damages are claimed, at Clean Air Engineering’s
option.
© Clean Air Engineering – July 2008
Questions? Contact us at 800-223-3977 or online at http://www.cleanair.com/equipment/Express/main.html