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INSTRUCTION MANUAL
1
SPAN GAS CALIBRATION KIT
MODEL CALKIT-2
INSTRUCTION MANUAL
October 1994
Rev.1 2
The purpose of the span gas calibration kit is to check the performance and provide
an accurate span calibration apparatus for all toxic gas & combustibles sensors used
in the instruments manufactured by Energy Efficiency Systems, Inc.

NOTE: Using certified calibration gas (2% accuracy) is the most accurate and
reliable method to ensure data integrity for emissions measurements.
The use of "pre calibrated sensors" is not reliable because electrochemical sensors
are known to drift with time, temperature and exposure to gas.
The use of "dilution systems" provides under the best conditions a 5% accuracy.
EPA protocol 1 gases are not available in small transportable cylinders.
The portable gas calibration kit supplied by EES, Inc. is designed to supply the
required span gas at the exact flow rate required by the instrument and at
approximately ambient pressure. This is important for proper sensor calibration,
because electrochemical sensors are sensitive to pressure fluctuations.

The span gas or gases supplied, depend on the type of instrument being used. All
gases are certified to have an accuracy of plus/minus 2% of the value indicated on the
face of the gas cylinder. If greater accuracy is required, you may disconnect one of
the transportable cylinders and connect a Protocol 1 cylinder to the calibration kit.
NOTE: If you use an external cylinder, make sure the cylinder's regulator is set for
a pressure of 600 PSI or less. (The stainless steel braided hoses have a maximum
capacity of 800 PSI!).

All cylinders supplied with the calibration kit are small transportable units containing
approximately 74 liters of the span gas at approximately 500 PSI.

All instruments require approximately a minimum of 4 minutes of span gas to carry
out a single calibration (NO
2
& SO
2
require 4 minutes) . Consequently, each cylinder
is shipped with sufficient gas for 12-15 calibrations.
NOTE: The model 3000 will normally require 2-3 additional minutes to reach 99%
of full scale when feeding NO
2
or SO
2
span gas. 3
When the span gas is exhausted, the cylinders should be disposed properly. THESE
CYLINDERS CANNOT BE REFILLED!

WARNINGS:

1.
Carry out span calibrations in a well ventilated area. Avoid inhaling the gas.
2.
Handle the gas cylinders carefully. Do not expose them to heat or shock. Do
not attempt to fill the cylinders. Do not use them for any other than the
intended purpose.
3.
Make sure the shutoff valves are shut tightly, before disconnecting any
cylinders.
4.
Do not attempt to remove the shutoff valves.
5.
Do not touch the primary regulator setting. 4
FIGURE 1
DESCRIPTION OF APPARATUS

Fig.1 shows a complete calibration kit with 4 gas cylinders attached to it, as it might
be used to calibrate an ENERAC model 3000. (For the model 2000 Combustion
Analyzer the kit contains 3 gas cylinders).
Each cylinder is under high pressure and is equipped with a shut off valve as shown.
When the cylinder is exhausted use a wrench to disconnect it at the CGA connector
as shown in fig. 1. 5
The other end of the CGA connector is connected to a stainless steel braided Teflon
hose that terminates in a check valve that is mounted on the gas manifold. The
purpose of the check valves is to prevent accidental mixing of the gases, if two of the
shut off valves are accidentally left open, simultaneously. A pressure gauge is also
connected to the manifold. When any one of the shut off valves is open the gauge
indicates the pressure in the open cylinder.
Remember that there will be approximately a 30 PSI drop in the cylinder used
following every calibration. Thus, you can estimate the number of calibrations left by
observing the pressure on the gauge when the cylinder valve is open.

The gas manifold is connected to a high pressure regulator whose outlet pressure is
fixed at approximately 10 PSI.

A 24" length of Viton hose connects the outlet of the high pressure regulator to the
inlet of the "demand" regulator. The demand regulator is a device that it is designed
to supply automatically the span gas at the exact flow rate required by whatever
instrument is being calibrated. It does this with a minimum of pressure drop (typically
less than 4" W.C.).
NOTE: The use of the demand regulator yields a savings of 30-40% in the span gas
used, when compared with the by pass flow and flow meter method of earlier
calibration kits, while maintaining feed pressure near ambient.

The demand regulator functions in such a way that it will supply gas, only if a small
negative pressure is detected at its outlet. However, sometimes it may be desired to
supply gas at a positive pressure. A small pushbutton valve located on top of the
demand regulator will supply span gas, irrespective of the outlet pressure.
The outlet of the demand regulator is connected to a special fitting that can
accommodate the probes of any instruments manufactured by EES, Inc.
To feed the desired span gas to the instrument turn the unit on, insert the tip of the
probe to the probe fitting of the calibration kit and open the appropriate shut off valve
of the gas cylinder.
To turn the gas on or off use the shut off valve ! 6

NOTE: When no instrument is connected to the calibration kit there will normally be
no flow of gas even if one of the cylinder shut off valves may be open. However, it is
possible that a very small gas leak may exist through the demand regulator. You
should, therefore, always turn off the shut off valves to prevent loss of span gas. 7
SPAN CALIBRATION OF THE ENERACS
2000E & 3000
THE EMISSIONS PROBE WITH THE SINTERED FILTER ATTACHED MUST
BE ALWAYS CONNECTED TO THE UNIT WHEN CARRYING OUT A
CALIBRATION!

The following list describes the span gases that are typically supplied with the
calibration kit to calibrate the ENERACS model 2000E / 3000.
Carbon Monoxide
200 PPM CO, 1% CH
4
balance N
2
Combustibles
Nitric Oxide (NO)
200 PPM NO, balance N
2
Nitrogen Dioxide (NO
2
)
100 PPM NO
2
, balance N
2
Sulfur Dioxide
200 PPM SO2, balance N
2

Since the Model 3000 is a compliance level emissions analyzer, make sure that you
request from Energy Efficiency Systems to supply you with the proper concentrations
that are applicable to your emissions, as outlined in 40CFR60 of the EPA
regulations.
Fig.1 shows the typical setup for calibrating the model 2000E /3000.

You can carry out all span calibrations in sequence, or just one only, if you wish.
NOTE: Toxic sensor span calibration should be carried out in the order that they
appear on the display during span calibration. (CO > NO > SO
2
> NO
2
). This is
important for the mathematical cancellation of any residual cross sensitivities.
Feed the span gas to the instrument for TWO MINUTES (for the Model 3000 wait 3-4
minutes) prior to carrying out the span calibration, to make sure that steady state
conditions will have been reached by the end of the calibration period. 8
For span calibration of AMBIENT TEMPERATURE follow the directions in section
B below.

1.
SPAN GAS CALIBRATION
The sequence of the span gas calibrations that will appear on the instrument's display
is as follows:
a.
Combustibles
b.
Carbon monoxide
c.
Nitric oxide (NO)
d.
Sulfur dioxide
e.
Nitrogen dioxide (NO
2
)
f.
Ambient temperature.
NOTE: The Model 3000 executes the "ENERAC CALIBRATION PROTOCOL", every
time it is calibrated for CO, NO, NO
2
and SO
2
. For information on this protocol,
please consult your instruction manual.

To carry out a span calibration follow the steps below:

1.
Figure 1 shows the calibration apparatus and also how it is connected to
the ENERAC.
Do not connect the calibration kit to the Enerac yet.

2.
Connect the ENERAC's probe to the instrument and turn the unit on.
Make sure the battery is OK. Press the ENTER key to autozero the unit
and wait until the message
"INSERT PROBE"

appears on the display.

(The combustibles sensor usually needs a little more than 2 minutes allowed
by the autozero procedure for proper warm up. If you plan to carry out a
combustibles calibration, turn the unit off for 2 seconds and turn it back on. 9
Press the ENTER key again to autozero the unit!).
At the end of the AUTOZERO check the sens