Fluke GFS2102 User Manual

Download

Page 1

GFS2102™

Gravimetric Flow Standard

Operation and Maintenance Manual

Page 2

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Pressurized gases are potentially hazardous. Energy stored in these gases can be released unexpectedly and with extreme force. Pressurized systems should be assembled and operated only by personnel who have been instructed in proper safety practices.

Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments, a

Fluke Company 4765 East Beautiful Lane Phoenix Arizona 85044-5318 USA.

DH Instruments makes sincere efforts to ensure the accuracy and quality of its published materials; however, no warranty,

expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the English version and other language versions, the English version predominates.

DH Instruments, DH, DHI, GFS2102, GFS Tools, AMH, LCM, MFC-CB, molbloc and molbox are trademarks, registered and otherwise, of DH Instruments, a Fluke Company

Swagelok and Nupro are registered trademarks of the Swagelok Company. Krytox is a registered trademark of the Dupont de Nemours Company. Windows, Excel, Word are registered trademarks of the Microsoft Corporation.

Products described in this manual are manufactured under international patents and one or more of the following U.S. patents: 6,701,791, 5,142,483, 5,257,640, 5,331,838, 5,445,035. Other U.S. and international patents pending.

Document No. 550149a 071129 Printed in the USA

Page 3

AABBLLEE OOFF

OONNTTEENNTTS

TABLE OF CONTENTS ...............................................................I

TABLES................................................................................ VII

FIGURES................................................................................IX

ABOUT THIS MANUAL........................................................... XIII

1. INTRODUCTION ................................................................. 1

1.1 SPECIFICATIONS ...................................................................................................................................1

1.1.1 GFS2102 GENERAL SPECIFICATIONS.......................................................................................................1

1.1.2 GFS2102 MASS BALANCE SPECIFICATIONS ...........................................................................................2

1.1.3 LCM AMBIENT CONDITIONS MEASUREMENT SPECIFICATIONS...........................................................2

1.1.3.1 PRT BALANCE AMBIENT TEMPERATURE MEASUREMENT ................................................................2

1.1.3.2 TH PROBE REFERENCE GAS CYLINDER SURROUNDINGS AMBIENT CONDITION

1.1.3.3 INFRARED PROBE REFERENCE GAS CYLINDER SURFACE TEMPERATURE MEASUREMENT.....2

1.1.3.4 AMBIENT CONDITIONS MEASUREMENT...............................................................................................2

1.1.3.5 BALANCE READING TIME MEASUREMENT...........................................................................................2

1.1.4 MFC-CB SPECIFICATIONS..........................................................................................................................3

1.1.5 FLOW MEASUREMENT SPECIFICATIONS.................................................................................................3

MEASUREMENT .......................................................................................................................................2

2. SYSTEM OVERVIEW ........................................................... 5

2.1 BALANCE AND AMH-GFS2102..............................................................................................................6

2.2 REFERENCE GAS CYLINDER ASSEMBLY...........................................................................................8

2.2.1 REFERENCE GAS CYLINDER.....................................................................................................................8

2.2.2 CYLINDER SUPPORT...................................................................................................................................9

2.2.3 REFERENCE GAS CYLINDER CONNECTOR...........................................................................................10

2.2.4 REGULATOR ASSEMBLY..........................................................................................................................11

2.2.5 REFERENCE GAS CYLINDER CASE........................................................................................................11

2.3 GFS DRAFT ENCLOSURE AND VIBRATION ISOLATION TABLE.....................................................12

2.4 LABORATORY CONDITIONS MONITOR (LCM)..................................................................................13

2.5 MFC-CB .................................................................................................................................................13

2.6 GFS TOOLS...........................................................................................................................................14

2.7 HEAT EXCHANGER..............................................................................................................................14

2.8 GFS-FS REFERENCE GAS CYLINDER FILL STATION......................................................................14

2.9 MASS FLOW CONTROLLERS .............................................................................................................14

2.10 MOLBLOC MOLSTICS (OPTIONAL)....................................................................................................15

2.11 MASS SET (OPTIONAL).......................................................................................................................15

3. INSTALLATION ................................................................ 17

3.1 UNPACKING AND INSPECTION ..........................................................................................................17

3.1.1 GRANITE VIBRATION ISOLATION TABLE AND STAND..........................................................................17

3.1.2 GFS DRAFT ENCLOSURE AND SYSTEM ACCESSORIES......................................................................18

3.1.3 LABORATORY CONDITIONS MONITOR...................................................................................................19

3.1.4 MFC-CB .......................................................................................................................................................19

3.1.5 GFS-FS REFERENCE GAS CYLINDER FILL STATION............................................................................19

3.1.6 GFS MASS BALANCE.................................................................................................................................20

3.1.7 AMH-GFS2102.............................................................................................................................................20

3.1.8 REFERENCE GAS CYLINDER ASSEMBLIES...........................................................................................21

3.1.9 SYSTEM CONTROLLER.............................................................................................................................22

Page 4

GFS2102™ OPERATION AND MAINTENANCE MANUAL

3.1.10 MS-2102-0.7 MASS SET OR MS-2102-CAR MASS CARRIER..................................................................23

3.1.11 MOLSTICS...................................................................................................................................................23

3.2 SITE REQUIREMENTS..........................................................................................................................23

3.2.1 GFS2102 SYSTEM ......................................................................................................................................23

3.2.2 GFS-FS REFERENCE GAS CYLINDER FILL STATION............................................................................25

3.3 SETUP ...................................................................................................................................................26

3.3.1 POSITION THE VIBRATION ISOLATION TABLE......................................................................................26

3.3.2 INSTALL DRAFT ENCLOSURE ON VIBRATION ISOLATION TABLE......................................................27

3.3.3 SETUP LCM.................................................................................................................................................28

3.3.4 SETUP MFC-CB ..........................................................................................................................................29

3.3.5 SET UP THE SYSTEM CONTROLLER (PC) ..............................................................................................29

3.3.6 VERIFY GFS CALIBRATION DATA............................................................................................................29

3.3.7 ASSEMBLE REFERENCE GAS CYLINDER(S)..........................................................................................30

3.3.8 ENTER REFERENCE GAS CYLINDER DATA...........................................................................................32

3.3.9 INSTALLATION OF REFERENCE MASS ON MASS PLATE.....................................................................32

3.3.10 INITIAL BALANCE AND AMH BASE SETUP.............................................................................................34

3.3.11 SETUP BALANCE LOCATION....................................................................................................................35

3.3.12 AMH POSITION FINE ADJUSTMENT.........................................................................................................36

3.3.13 SETUP PROBE LOCATIONS......................................................................................................................38

3.3.14 PREPARE THE HEAT EXCHANGER..........................................................................................................39

3.3.15 CONNECT THE DUT FLOW PATH.............................................................................................................40

3.3.16 CONNECT GAS CONVEYANCE LOOP......................................................................................................41

4. OPERATION..................................................................... 43

4.1 GENERAL OPERATING PRINCIPLES .................................................................................................43

4.1.1 GFS2102 MEASUREMENT PRINCIPLE.....................................................................................................43

4.1.2 GAS DEPENDENT MASS RANGES AND CYLINDER SIZE SELECTION ................................................44

4.1.3 AUTOZERO..................................................................................................................................................46

4.1.4 GFS2102 DATA COLLECTION METHODS AND CONVENTIONS............................................................46

4.1.4.1 ACCUMULATIONS ..................................................................................................................................46

4.1.4.2 SAMPLES ................................................................................................................................................46

4.1.4.3 AVERAGES AND BEST FITS..................................................................................................................47

4.1.5 SETTINGS FOR FLOW SAMPLING............................................................................................................47

4.1.5.1 SETTING UP STARTING AND ENDING SAMPLE TOLERANCE...........................................................48

4.2 MANUAL GFS TOOLS OPERATION....................................................................................................48

4.2.1 READING THE BALANCE...........................................................................................................................48

4.2.2 AMH OPERATION.......................................................................................................................................49

4.2.3 BALANCE ZERO AND SPAN ADJUSTMENT............................................................................................49

4.3 REFERENCE GAS CYLINDER FILLING ..............................................................................................49

4.3.1 TRANSPORTING THE REFERENCE GAS CYLINDER ASSEMBLY.........................................................49

4.3.2 EVACUATING AND RINSING .....................................................................................................................50

4.3.3 CONNECTING TO GFS-FS .........................................................................................................................50

4.3.4 FILLING THE CYLINDER............................................................................................................................51

4.4 CONSIDERATIONS FOR MAKING RELIABLE MEASUREMENTS.....................................................53

4.4.1 COOLING AND CONDENSATION AT HIGH FLOW...................................................................................53

4.4.2 STABILITY OF AMBIENT CONDITIONS....................................................................................................53

4.4.3 COMPARING REFERENCE AND DUT MEASUREMENTS USING FLOW VS. MASS CALCULATIONS 54

4.4.4 LEAKS .........................................................................................................................................................54

4.4.4.1 LEAK TEST OPTION IN A TEST DEFINITION........................................................................................55

4.4.4.2 SEMI-AUTOMATED LEAK TEST.............................................................................................................55

4.4.4.3 SEMI-AUTOMATED LEAK TEST TO MANUAL ISOLATION POINT ......................................................55

4.4.5 FLOW CONTROL AND STABILITY............................................................................................................56

Page 5

TABLE OF CONTENTS

5. GFS TOOLS SOFTWARE ................................................... 57

5.1 MAIN DISPLAY AND FEATURES.........................................................................................................57

5.1.1 OVERVIEW..................................................................................................................................................57

5.1.2 MAIN MENU BAR........................................................................................................................................57

5.1.2.1 [RUN]........................................................................................................................................................57

5.1.2.2 [SETUP] ...................................................................................................................................................58

5.1.2.3 [TOOLS] ...................................................................................................................................................58

5.1.2.4 [DATA]......................................................................................................................................................58

5.1.2.5 [WINDOW]................................................................................................................................................59

5.1.2.6 [HELP]......................................................................................................................................................59

5.1.3 STATUS BAR...............................................................................................................................................59

5.1.4 MAIN TOOLBAR..........................................................................................................................................60

5.1.4.1 RUN TEST TOOLS ..................................................................................................................................60

5.1.4.2 RUN DISPLAY TOOLS ............................................................................................................................60

5.1.4.3 DATA ACQUISITION TOOLS ..................................................................................................................61

5.1.5 RUN SCREENS ...........................................................................................................................................63

5.1.5.1 OVERVIEW..............................................................................................................................................63

5.1.5.2 GFS RUN SCREEN .................................................................................................................................64

5.1.5.3 GFS DIAGNOSTICS RUN SCREEN........................................................................................................68

5.1.5.4 BALANCE OUTPUT RUN SCREEN........................................................................................................70

5.1.5.5 AMBIENT CONDITIONS RUN SCREEN.................................................................................................71

5.1.5.6 DUT/REFERENCE COMPARISON RUN SCREEN.................................................................................72

5.1.5.7 DEVICE OUTPUT RUN SCREEN............................................................................................................73

5.1.5.8 SPY WINDOWS.......................................................................................................................................74

5.1.5.9 MOLBOX OUTPUT RUN SCREEN..........................................................................................................75

5.1.5.10 TARE MOLBOX........................................................................................................................................77

5.1.5.11 MFC-CB RUN SCREEN...........................................................................................................................78

5.1.5.12 DATA GRID RUN SCREEN.....................................................................................................................79

5.1.5.13 DATA PLOT RUN SCREEN.....................................................................................................................79

5.2 [TOOLS] MENU.....................................................................................................................................80

5.2.1 OVERVIEW..................................................................................................................................................80

5.2.2 [OPTIONS]...................................................................................................................................................80

5.2.2.1 [RUN TEST] TAB......................................................................................................................................80

5.2.2.2 [INITIALIZE TEST] TAB............................................................................................................................83

5.2.2.3 [END TEST] TAB......................................................................................................................................84

5.2.2.4 [DATA FILE] TAB .....................................................................................................................................85

5.2.2.5 [DATA GRID] TAB....................................................................................................................................87

5.2.3 [UNIT OF MEASURE CONVERTER] ..........................................................................................................89

5.2.4 [REMOTE COMMUNICATIONS].................................................................................................................89

5.2.5 [PROCESS GAS EDITOR]..........................................................................................................................90

5.2.6 [CHANGE GFS AMH STATE]......................................................................................................................91

5.2.7 [PC TIMER CALIBRATION] ........................................................................................................................91

5.3 [DATA] MENU........................................................................................................................................91

5.3.1 OVERVIEW..................................................................................................................................................91

5.3.2 [VIEW DATA FILE]......................................................................................................................................91

5.3.3 [PLOT DATA]...............................................................................................................................................93

5.3.3.1 PLOT TOOLBAR......................................................................................................................................93

5.3.3.2 PLOT OPTIONS MENU ...........................................................................................................................94

5.3.3.3 CREATE/EDIT PLOTS.............................................................................................................................94

5.3.3.4 PLOT POINTS..........................................................................................................................................96

5.3.4 [REPORT DATA].........................................................................................................................................98

5.4 DATA FILES ..........................................................................................................................................99

5.4.1 OVERVIEW..................................................................................................................................................99

5.4.2 DATA FILE CREATION ...............................................................................................................................99

5.4.3 NAMING AND STORING DATA FILES.......................................................................................................99

5.4.4 DATA FILE STRUCTURE..........................................................................................................................100

5.5 [SETUP] MENU ...................................................................................................................................102

5.5.1 OVERVIEW................................................................................................................................................102

5.5.1.1 SETUP SELECTOR...............................................................................................................................102

5.5.1.2 EDITOR TOOLBAR................................................................................................................................102

5.5.2 [SETUP], [TEST]........................................................................................................................................104

5.5.2.1 CREATING TEST DEFINITIONS...........................................................................................................104

5.5.2.2 EDITING TEST DEFINITIONS...............................................................................................................105

5.5.2.3 TEST POINT SEQUENCE.....................................................................................................................105

5.5.2.4 [PRE-TEST] TAB....................................................................................................................................105

5.5.2.5 [CONTROL]............................................................................................................................................107

5.5.2.6 [DATA]....................................................................................................................................................108

5.5.2.7 [AUTOZERO]..........................................................................................................................................110

Page 6

GFS2102™ OPERATION AND MAINTENANCE MANUAL

5.5.2.8 [OPTIONS] .............................................................................................................................................111

5.5.2.9 [COMMENT]...........................................................................................................................................112

5.5.3 [DUT ].........................................................................................................................................................113

5.5.3.1 [HEADER] TAB ......................................................................................................................................114

5.5.3.2 [CALIBRATION] TAB..............................................................................................................................116

5.5.3.3 [COMMUNICATIONS] TAB....................................................................................................................117

5.5.3.4 REMOTE COMMAND EDITOR..............................................................................................................120

5.5.3.5 [OUTPUT] TAB.......................................................................................................................................125

5.5.3.6 [COMMENT] TAB...................................................................................................................................128

5.5.4 [SUPPORT HARDWARE]..........................................................................................................................129

5.5.5 [REFERENCE GAS CYLINDER]...............................................................................................................129

5.5.6 [CONFIGURATION]...................................................................................................................................131

5.5.6.1 [SYSTEM]...............................................................................................................................................131

5.5.6.2 GFS AMH...............................................................................................................................................133

5.5.6.3 [LIMITS]..................................................................................................................................................134

5.5.6.4 [LCM]......................................................................................................................................................135

5.5.6.5 [BALANCE].............................................................................................................................................136

5.5.6.6 [INTERFACE].........................................................................................................................................137

5.5.7 [CALIBRATION].........................................................................................................................................138

5.5.7.1 [TIME/MASS]..........................................................................................................................................138

5.5.7.2 [AMBIENT] .............................................................................................................................................139

5.5.7.3 [TH PROBE #2]......................................................................................................................................140

5.5.7.4 [TH PROBE #3]......................................................................................................................................141

5.5.7.5 [EXTERNAL PRT] ..................................................................................................................................141

5.5.7.6 [IR PROBE] ............................................................................................................................................142

5.6 [RUN] MODES.....................................................................................................................................142

5.6.1 RUN TEST..................................................................................................................................................143

5.6.2 RUN MANUAL TEST.................................................................................................................................147

5.6.3 RUN DIAGNOSTIC TEST..........................................................................................................................149

5.7 CALCULATIONS .................................................................................................................................149

5.7.1 OVERVIEW................................................................................................................................................149

5.7.2 ERRORS....................................................................................................................................................149

5.7.3 TOLERANCE.............................................................................................................................................150

5.7.4 AUTOZERO CORRECTION ......................................................................................................................150

5.7.5 REFERENCE CYLINDER BUOYANCY.....................................................................................................151

5.7.6 FULLY COMPENSATED MASS................................................................................................................153

5.7.7 AVERAGE FLOW......................................................................................................................................154

5.7.8 BEST FIT FLOW........................................................................................................................................154

5.7.9 INTEGRATED MASS.................................................................................................................................155

5.7.10 %READING GFS TOLERANCE................................................................................................................155

5.7.11 SAMPLE RATE..........................................................................................................................................157

6. GENERAL MAINTENANCE, ADJUSTMENTS, AND STORAGE .159

6.1 SUMMARY...........................................................................................................................................159

6.2 AMH-GFS2102 PLATE POSITIONING POSTS LUBRICATION.........................................................159

6.3 REFERENCE GAS CYLINDER ALIGNMENT.....................................................................................160

6.3.1 CHECK REFERENCE GAS CYLINDER ALIGNMENT.............................................................................160

6.3.2 ALIGNMENT OF THE REFERENCE GAS CYLINDER.............................................................................161

6.4 PREPARING THE REFERENCE GAS CYLINDER ASSEMBLY FOR SHIPMENT OR LONG TERM

STORAGE............................................................................................................................................162

6.5 REFERENCE GAS CYLINDER HYDROSTATIC TESTING................................................................163

6.6 REMOVING OR REASSEMBLING THE CYLINDER CARRIER.........................................................163

6.6.1 REMOVING THE CYLINDER CARRIER...................................................................................................164

6.6.2 REASSMBLING THE CARRIER TO THE CYLINDER..............................................................................164

6.7 CHECK/CHANGE FLUID IN HEAT EXCHANGER..............................................................................165

6.8 RELEVEL SYSTEM SURFACES.........................................................................................................165

6.9 LEAK CHECK THE FLOW PATH........................................................................................................165

Page 7

TABLE OF CONTENTS

7. MAINTENANCE OF TRACEABILITY AND RECALIBRATION ...167

7.1 PRINCIPLES OF GFS2102 TRACEABILITY MAINTENANCE...........................................................167

7.2 [PC TIMER CALIBRATION] ................................................................................................................167

7.3 MOLBOX AUTOZ AND TARE OPERATIONS.....................................................................................167

7.4 REFERENCE MASS RECALIBRATION..............................................................................................167

7.5 LABORATORY CONDITIONS MONITOR (LCM) RECALIBRATION.................................................168

7.5.1 OVERVIEW................................................................................................................................................168

7.5.2 AS RECEIVED DATA REVIEW .................................................................................................................169

7.5.3 LCM TIME VERIFICATION OR ADJUSTMENT........................................................................................169

7.5.3.1 PRINCIPLE ............................................................................................................................................169

7.5.3.2 LCM TIME VERIFICATION....................................................................................................................169

7.5.3.3 LCM TIME ADJUSTMENT.....................................................................................................................170

7.5.3.4  EQUIPMENT REQUIRED.................................................................................................................170

7.5.3.5  OPERATION.....................................................................................................................................170

7.5.4 AMBIENT P, T, H SENSOR ADJUSTMENT.............................................................................................171

7.5.4.1 PRINCIPLE ............................................................................................................................................171

7.5.4.2 ENCLOSURE PRESSURE SENSOR....................................................................................................172

7.5.4.3 AMBIENT TEMPERATURE SENSOR...................................................................................................173

7.5.4.4 RELATIVE HUMIDITY SENSOR............................................................................................................174

7.5.5 TH PROBE ADJUSTMENT........................................................................................................................175

7.5.5.1 TH PROBE TEMPERATURE SENSOR.................................................................................................175

7.5.5.2 TH PROBE RELATIVE HUMIDITY SENSOR........................................................................................176

7.5.6 EXTERNAL PRT TEMPERATURE ADJUSTMENT ..................................................................................177

7.5.7 INFRARED (IR) CYLINDER TEMPERATURE ADJUSTMENT.................................................................178

7.5.8 LCM OHMIC MEASUREMENT SYSTEM VERIFICATION........................................................................179

7.5.9 STANDARD RESISTOR MEASUREMENT AND ADJUSTMENT.............................................................181

7.5.10 LCM REMOTE COMMAND FOR AUTOMATION......................................................................................182

7.6 MOLBOX RECALIBRATION...............................................................................................................183

7.7 MFC-CB RECALIBRATION.................................................................................................................183

7.8 BALANCE RECALIBRATION..............................................................................................................183

7.8.1 INTERNAL BALANCE CALIBRATION......................................................................................................183

7.8.2 GFS TOOLS ZERO AND SPAN CALIBRATION.......................................................................................183

7.8.3 VERIFICATION BY MASS CARRIER........................................................................................................184

8. TROUBLESHOOTING .......................................................185

8.1 OVERVIEW..........................................................................................................................................185

9. APPENDIX ......................................................................187

9.1 GLOSSARY .........................................................................................................................................187

9.2 TYPICAL TEST SETUPS.....................................................................................................................188

9.3 WARRANTY STATEMENT..................................................................................................................189

Page 8

GFS2102™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

Page 9

TABLES & FIGURES

AABBLLEES

Table 1. GFS2102 packing list...................................................................................................................17

Table 2. Draft enclosure and system accessories list ...............................................................................18

Table 3. LCM parts list................................................................................................................................19

Table 4. MFC-CB parts list..........................................................................................................................19

Table 5. GFS-FS fill station parts list ..........................................................................................................20

Table 6. GFS mass balance parts list........................................................................................................20

Table 7. AMH-GFS2102 parts list...............................................................................................................21

Table 8. Reference gas cylinder assemblies’ parts lists............................................................................22

Table 9. MS-2102-0.7 mass set parts list..................................................................................................23

Table 10. MS-2102-CAR mass carrier parts list........................................................................................23

Table 11: Maximum mass available for flow testing for various GFS2102 supported gases.....................45

Table 12. Main Toolbar, Run Test Tools ...................................................................................................60

Table 13. Main Toolbar, Run Display Tools...............................................................................................61

Table 14. <Control> Toolbar, Data Acquisition Options ............................................................................ 62

Table 15. GFS Control Panel Fields..........................................................................................................65

Table 16. GFS System Display Fields.......................................................................................................67

Table 17. GFS Control Toolbar icons .........................................................................................................67

Table 18. GFS Diagnostics Fields .............................................................................................................69

Table 19. Balance Output Run Screen Fields ..........................................................................................70

Table 20. GFS Ambient Conditions Run Screen Fields ...........................................................................71

Table 21. DUT/Reference Comparison Run Screen Fields......................................................................73

Table 22. Spy Window Information............................................................................................................75

Table 23. <molbox Output> Run Screen Fields.........................................................................................76

Table 24. Tare molbox Fields ....................................................................................................................78

Table 25. MFC CB Fields...........................................................................................................................79

Table 26. Options, [Run Test] Tab Fields..................................................................................................81

Table 27. Options, [Initialize Test] Tab Fields............................................................................................83

Table 28. Options, [End Test] Tab Fields ..................................................................................................85

Table 29. Options, [Data File] Tab Fields ..................................................................................................86

Table 30. Options, [Data Grid] Tab Selections..........................................................................................89

Table 31. Data File Viewer Options...........................................................................................................92

Table 32. Data Plot Toolbar.......................................................................................................................93

Table 33. Custom Plot Editor Fields ..........................................................................................................95

Table 34. Plot Points General Tab Fields..................................................................................................97

Table 35. Plot Points Best Fit Tab Fields...................................................................................................98

Table 36. Data Files Types........................................................................................................................99

Table 37. Data File Data Field Optional Selections.................................................................................100

Table 38. Data File Structure...................................................................................................................101

Table 39. Editor Toolbar Features...........................................................................................................103

Table 40. Test Editor, [Pre-Test] Tab, <Leak Test> Fields......................................................................106

Table 41. Test Definition Editor, Point Sequence Tab, [General] Child Tab Fields.................................107

Table 42. Test Definition Editor [Data] Tab Fields...................................................................................109

Table 43. Test Definition Editor [AutoZero] Tab Fields............................................................................111

Table 44. Test Definition Editor [Options] Tab Fields..............................................................................112

Table 45. DUT Editor, [Header] Tab Fields .............................................................................................114

Page 10

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Table 46. Device Editor, [Calibration] Tab Fields ....................................................................................117

Table 47. Device Editor, [Communications] Tab Fields..........................................................................119

Table 48. Remote Command Editor, [Command] Tab Fields..................................................................123

Table 49. Remote Command Editor, [Global Settings] Tab Options.......................................................124

Table 50. DUT Editor, [Output] Tab Fields ..............................................................................................126

Table 51. Tolerance Type Choices..........................................................................................................127

Table 52. Device Type Options................................................................................................................129

Table 53. Reference Cylinder Editor Fields.............................................................................................130

Table 54. GFS Configuration Editor [System] Tab Fields........................................................................132

Table 55. GFS Configuration Editor [GFS AMH] Tab Fields ...................................................................133

Table 56. GFS Configuration Editor [Limits] Tab Fields .......................................................................... 134

Table 57. GFS Configuration Editor [LCM] Tab Fields............................................................................135

Table 58. GFS Configuration Editor [Balance] Tab .................................................................................136

Table 59. GFS Configuration Editor [Interface] Tab Fields......................................................................137

Table 60. Calibration Editor [Time/Mass] Tab Fields...............................................................................138

Table 61. Calibration Editor [Ambient] Tab Fields...................................................................................139

Table 62. Calibration Editor [TH Probe #2] and [TH Probe #3] Tab Fields .............................................140

Table 63. Calibration Editor [External PRT] Tab Fields...........................................................................142

Table 64. Calibration Editor [IR Probe] Tab Fields..................................................................................142

Table 65. Mechanical maintenance procedures......................................................................................159

Table 66. Troubleshooting checklist ........................................................................................................185

Table 67. DHI Authorized Service Providers ...........................................................................................189

Page 11

TABLES & FIGURES

IIGGUURREES

Figure 1. GFS2102 system.......................................................................................................................... 5

Figure 2. Reference gas cylinder resting on GFS balance and AMH-GFS2102.........................................6

Figure 3. AMH reference mass plate...........................................................................................................7

Figure 4. Balance mass tray supporting the reference gas cylinder ...........................................................7

Figure 5. Reference gas cylinder assembly...................................................................................................8

Figure 6. 1.5 liter and 1.1 liter reference gas cylinder assemblies .............................................................. 9

Figure 7. Reference gas cylinder support..................................................................................................10

Figure 8. Reference gas cylinder connector..............................................................................................10

Figure 9. GFS draft enclosure on vibration isolation table......................................................................... 12

Figure 10. Laboratory Conditions Monitor .................................................................................................13

Figure 11. GFS-FS Reference gas cylinder fill station ..............................................................................14

Figure 12. Typical layout of overall GFS2102 system at site of use..........................................................25

Figure 13. Installation of draft enclosure doors..........................................................................................28

Figure 14. LCM rear panel connections.....................................................................................................28

Figure 15. Reference gas cylinder assembly...............................................................................................30

Figure 16. Reference gas cylinder connector............................................................................................31

Figure 17. Regulator assembly position before and after tightening.........................................................32

Figure 18. Reference Mass Legs (Spherical (x 2) and Flat)......................................................................32

Figure 19. Location of balance positioning bracket mounting holes..........................................................34

Figure 20. GFS balance rear panel connections.......................................................................................34

Figure 21. GFS balance inside AMH with mass tray installed..................................................................35

Figure 22. Checking height and level of gas conveyance loop connections using loop alignment tool....36

Figure 23. Reference Gas Cylinder resting on balance. AMH top plate installed; reference

Figu r e 2 4 . View of cylinder support legs through AMH top plate. ...........................................................37

Figu r e 25 . Temperature probe positions around reference gas cylinder. .................................................39

Figure 26: Heat Exchanger, Low ................................................................................................................39

Figure 27: Heat Exchanger unassembled ..................................................................................................40

Figure 28: Single, Low flow molstic.............................................................................................................40

Figu r e 2 9 . GFS-FS reference gas cylinder fill station connections............................................................50

Figure 30. Reference gas cylinder connector..............................................................................................51

Figure 31. <Status Bar>.............................................................................................................................59

Figure 32. Test Status................................................................................................................................59

Figure 33. Progress Indicator.....................................................................................................................59

Figure 34. Main Toolbar - Display while idle..............................................................................................60

Figure 35. Manual Averaging Options .......................................................................................................62

Figure 36. <Average Setup>......................................................................................................................63

Figure 37. GFS Run Screen ......................................................................................................................64

Figure 38: GFS Control Panel section of GFS Run Screen .......................................................................65

Figure 39: GFS System Display section of GFS Run Screen ....................................................................66

Figure 40. GFS Control Toolbar section of GFS Run Screen ...................................................................67

Figure 41. GFS Diagnostics Run Screen...................................................................................................69

Figure 42. Balance Output Run Screen....................................................................................................70

Figure 43. GFS Ambient Conditions Run Screen.....................................................................................71

Figure 44. DUT/Reference Comparison Run Screen...............................................................................72

mass plate uninstalled.............................................................................................................37

Page 12

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Figure 45. Device Output Run Screen.......................................................................................................74

Figure 46. Spy Window Screen .................................................................................................................74

Figure 47. <molbox Output> Run Screen..................................................................................................75

Figure 48. molbox Output Run Screen in Tare Mode................................................................................77

Figure 49. MFC-CB Run Screen................................................................................................................78

Figure 50. Data Grid Run Screen ..............................................................................................................79

Figure 51. Data Plot Run Screen...............................................................................................................80

Figure 52. Options, [Run Test] Tab............................................................................................................81

Figure 53. Options, [Initialize Test] Tab.....................................................................................................83

Figure 54. Options, [End Test] Tab............................................................................................................84

Figure 55. Options, [Data File] Tab............................................................................................................86

Figure 56. Options, [Data Grid] Tab...........................................................................................................88

Figure 57. Direct Remote Communication.................................................................................................90

Figure 58. Change GFS AMH State ..........................................................................................................91

Figure 59. Data File Viewer .......................................................................................................................92

Figure 60. [Data], [Plot Data File] Screen..................................................................................................93

Figure 61. Custom Plot Editor....................................................................................................................95

Figure 62. Plot Points display ....................................................................................................................97

Figure 63. Plot Points Best Fit Tab............................................................................................................98

Figure 64. Setup Selector ........................................................................................................................102

Figure 65. Editor Toolbar .........................................................................................................................103

Figure 66. Test Definition Editor, Point Sequence...................................................................................105

Figure 67. Test Definition Editor [Control] Tab ........................................................................................107

Figure 68. Test Definition Editor [Data] Tab ............................................................................................109

Figure 69. Test Definition Editor [AutoZero] Tab.....................................................................................110

Figure 70. Test Definition Editor [Options] Tab........................................................................................111

Figure 71. Test Definition Editor, [Comment] Tab ...................................................................................113

Figure 72. DUT Editor, [Header] Tab.......................................................................................................114

Figure 73. DUT Editor, [Calibration] Tab .................................................................................................116

Figure 74. Date Selection ........................................................................................................................117

Figure 75. DUT Definition Editor [Communications] Tab.........................................................................118

Figure 76. Remote Command Editor.......................................................................................................121

Figure 77. DUT Device Edit [Output] Tab................................................................................................125

Figure 78. %Reading Tolerance..............................................................................................................127

Figure 79. %Span Tolerance...................................................................................................................127

Figure 80. %Span or %Reading (Greater of)...........................................................................................128

Figure 81. %Span + %Reading ...............................................................................................................128

Figure 82. DUT Device Edit [Comment] Tab ...........................................................................................129

Figure 83. Reference Cylinder Editor ......................................................................................................130

Figure 84. GFS Configuration [System] Tab............................................................................................131

Figure 85. GFS Configuration [GFS AMH] Tab.......................................................................................133

Figure 86. GFS Configuration [Limits] Tab ..............................................................................................134

Figure 87. GFS Configuration [LCM] Tab................................................................................................135

Figure 88: Remote interface settings window...........................................................................................136

Figure 89. GFS Configuration [Balance] Tab...........................................................................................136

Figure 90. GFS Configuration [Interface] Tab..........................................................................................137

Figure 91. Calibration [Time/Mass] Tab...................................................................................................138

Figure 92. Calibration [Ambient] Tab.......................................................................................................139

Figure 93. Calibration [TH Probe #2] Tab................................................................................................140

Figure 94. Calibration [TH Probe #3] Tab................................................................................................141

Page 13

TABLES & FIGURES

Figure 95. Calibration [External PRT] Tab...............................................................................................141

Figure 96. Calibration [IR Probe] Tab......................................................................................................142

Figure 97: Run Test - Setup Test Definition window ................................................................................143

Figure 98: Run Test - Select Test Definition Window...............................................................................144

Figure 99: Run Test - Select DUTs window..............................................................................................144

Figure 100: Run Test - Configure DUT Device window............................................................................145

Figure 101: Run Test - Setup Flow Controller window.............................................................................145

Figure 102: Run Test - Configure MFC Device window...........................................................................146

Figure 103: Run Test - Initializing Test Instruments window....................................................................146

Figure 104: Run Manual Test - Setup Manual Test window.....................................................................147

Figure 105: Accumulation Sample Setup window .................................................................................... 148

Figure 106: US-DOT and European Reference Gas Cylinder labels....................................................... 163

Figure 107. Reference gas cylinder carrier..............................................................................................164

Figure 108. Time Calibration window .......................................................................................................170

Figure 109. Calibration Time/Mass tab.....................................................................................................171

Figure 110: LCM default front panel display.............................................................................................172

Figure 111. Ambient sensors adjustment tab...........................................................................................173

Figure 112: LCM TH probe front panel display.........................................................................................175

Figure 113. TH Probe #2 adjustment tab..................................................................................................176

Figure 114. External PRT adjustment tab.................................................................................................178

Figure 115. LCM IR probe front panel display..........................................................................................179

Figure 116. IR Probe adjustment tab........................................................................................................179

Figure 117. View of main board socket J19 or top view of calibration cable...........................................182

Page 14

GFS2102™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

Page 15

ABOUT THIS MANUAL

BBOOUUTT

This manual provides the information necessary to operate a GFS2102 gravimetric mass flow calibration standard to make gas mass flow measurements. It also provides additional recommendations and information to help you optimize use of the GFS2102 system and take full advantage of it’s many features and functions.

Before using the manual, take a moment to familiarize yourself with the Table of Contents structure. Set up of a GFS2102 system should not be attempted without using Section 3. All first time GFS2102 users should read Section 4. There is a glossary of common terms in Section 9.1, a troubleshooting guide in Section 1, and a chart of typical test settings in Section

(CAUTION) is used throughout the manual to identify user warnings and cautions.

(NOTE) is used throughout the manual to identify operating and applications advice and

additional explanations.

[ ] indicates direct function keys or objects (e.g., [RANGE]) on an instrument front panel keypad or in a software user interface.

HHIISS

AANNUUAAL

Manual Conventions

< > indicates instrument front panel screen displays or labels in a software user interface (e.g., <1yes>)

Page 16

GFS2102™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

Page 17

1. INTRODUCTION

11.

GFS2102 measures gas mass flow by measuring the loss of mass from a reference gas cylinder over a measured period of time. The reference gas cylinder assembly rests on the GFS mass balance and flow is transmitted from the cylinder through a flow path designed to have minimal effect on the balance mass measurement. Balance mass and time measurements and a number of ambient conditions are all read using a component of the GFS2102 system called LCM, the Laboratory Conditions Monitor. Since test times may be long, a special automated mass handling platform is used to load a fixed reference mass on the GFS balance at intervals thoughout the test to quantify and remove any effects from balance drift over time.

All measurement functions of the GFS2102 system are operated by a system controller (personal computer) running GFS Tools software. The system is made up of several individual components working together and controlled by GFS Tools.

NNTTRROODDUUCCTTIIOON

1.1 SPECIFICATIONS

1.1.1 GFS2102 GENERAL SPECIFICATIONS

Power Requirements

Operating Temperature Range Humidity Range

Weight

Granite table and stand

Rest of system

Dimensions

Enclusure on Granite Table w/ stand

Supported Gases

Flow Measurement Range

All other gases

Pressure Connections

outlet flow path from enclosure

Reference Gas Cylinder Pressure Limit CE Conformance

Balance

LCM

MFC-CB

LCM

MFC-CB

GFS-FS

He, H2

100 to 240 VAC, 50 to 60 Hz, 27 W max. consumption 100 to 240 VAC, 50 to 60 Hz, 40 W max. consumption 85 to 264 VAC, 50 to 60 Hz, 36 W max. consumption

15 to 25 °C 5 to 70% RH, non-condensing

320 kg (700 lb) approx. 70 kg (150 lb) approx.

150 cm H x 90 cm W x 60 cm D (58 in. x 36 in. x 24 in.) 8 cm H x 22.5 cm W x 20 cm D (3.1 in. x 8.9 in. x 7.9 in.) 8 cm H x 22.5 cm W x 20 cm D (3.1 in. x 8.9 in. x 7.9 in.)

20 cm H x 41.4 cm W x 20 cm D (7.9 in. x 16.3 in. x 7.9 in.) Nitrogen (N2), Air, Argon (Ar), Carbon Monoxide (CO), Helium (He),

Oxygen (O2), Carbon Dioxide (CO2), Carbon Tetrafluoride (CF4), Ethane (C2H6), Ethylene (C2H4), Fluoroform (CHF3), Hexafluoroethane (C2F6), Hydrogen (H2), Methane (CH4), Nitrous Oxide (N2O), Sulfur Hexafluoride (SF6), Xenon (Xe)

at least: 100 sccm to 10 slm

10 sccm to 10 slm 1/8” Swagelok tube fitting or equivalent, with adaptor to

1/4” Swagelok tube fitting or equivalent 20 MPa (3000 psi)

Available, must be specified.

Page 18

GFS2102™ OPERATION AND MAINTENANCE MANUAL

1.1.2 GFS2102 MASS BALANCE SPECIFICATIONS

Operating temperature range

Operating humidity (maximum)

Resolution

Mass Uncertainty

15 to 30 °C

70% RH, non-condensing

0.1 mg 10 ppm of span or better

1.1.3 LCM AMBIENT CONDITIONS MEASUREMENT SPECIFICATIONS

1.1.3.1 PRT BALANCE AMBIENT TEMPERATURE MEASUREMENT

Temperature:

Range

Uncertainty

1.1.3.2 TH PROBE REFERENCE GAS CYLINDER SURROUNDINGS

AMBIENT CONDITION MEASUREMENT

Temperature:

Range

Uncertainty

Relative Humidity:

Range

Uncertainty

[°C] 15 to 30

± 0.1

[°C] 15 to 30

± 0.2

5 to 95 %RH ± 10 %RH

1.1.3.3 INFRARED PROBE REFERENCE GAS CYLINDER SURFACE

TEMPERATURE MEASUREMENT

Temperature:

Range

Uncertainty

[°C] 0 to 30

± 2.2

1.1.3.4 AMBIENT CONDITIONS MEASUREMENT

Pressure:

Range

Uncertainty

Temperature:

Range

Uncertainty

Relative Humidity:

Range

Accuracy

[kPa] 70 to 110 ± 0.2

[°C] 15 to 30 ± 1.0

5 to 95 %RH ± 10 %RH

1.1.3.5 BALANCE READING TIME MEASUREMENT

Time:

32 ppm

Page 19

1. INTRODUCTION

1.1.4 MFC-CB SPECIFICATIONS

ANALOG OUTPUT

Voltage Range

Voltage Accuracy

Voltage Resolution

Current Range

Current Accuracy

Current Resolution

0 to 6.000 VDC ± 0.015 % FS

0.1 mVDC 4 to 20 mA ± 0.025 % FS

0.4 μA

ANALOG INPUT

Voltage Range

Min/Max Measurable Voltage

Voltage Accuracy

Voltage Resolution

Current Range

0 to 6.000 VDC

- 0.25/6.00 VDC ± 0.015 % FS 1 mVDC 4 to 20 mA

1.1.5 FLOW MEASUREMENT SPECIFICATIONS

Repeatability Measurement Uncertainty

less than ± 0.05% of reading less than ± 0.1% of reading

Page 20

GFS2102™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

Page 21

2. SYSTEM OVERVIEW

22.

GFS2102 is a primary gravimetric gas flow measurement standard. It is intended for use in calibrating gas flow transfer standards or other flow devices requiring a very low uncertainty reference. GFS2102 is recommended when low uncertainty is the primary requirement of a flow measurement. GFS2102 covers the range of 10 sccm to 10 slm in most gases. All measurement functions of the GFS2102 system are managed by a system controller (personal computer) running GFS Tools software. The system is made up of several individual components working together and controlled by GFS Tools, which is the user interface for the GFS2102 instrument.

YYSSTTEEMM

VVEERRVVIIEEW

Figure 1. GFS2102 system

1. Precision mass balance 8. Catenary gas conveyance loop

2. Reference mass 9. Laboratory conditions monitor

3. AMH-GFS2102 automated mass handler 10. MFC control box

4. IR probe 11. Flow terminal (for device under test)

5. Reference gas cylinder 12. Mass flow controller

6. Ambient conditions probe 13. Device under test

7. Ambient conditions probe

GFS2102 measures gas mass flow by measuring the loss of mass from a reference gas cylinder over a measured period of time. The reference gas cylinder assembly rests on the GFS mass balance that is placed on a vibration isolation table and inside an insulated draft enclosure. Flow is transmitted from the cylinder and out through the enclosure wall in a flow path designed to cause minimal effect on the balance mass measurement.

Page 22

GFS2102™ OPERATION AND MAINTENANCE MANUAL

In order to mitigate mass measurement errors due to balance drift over time, the balance sits inside an automated mass handling platform assembly, AMH-GFS2102, that allows the cylinder assembly to be lifted off the balance, and a reference mass to be loaded on the balance, without interrupting the flow measurement.

The Laboratory Conditions Monitor (LCM) is a central piece of hardware for GFS system operation. It performs several different functions for the system. These include measurement of temperature under the AMH platform, measuring temperature and humidity surrounding the reference gas cylinder, measuring the temperature of the reference gas cylinder, actuating the AMH platform movement, measuring ambient pressure and recording the precise time at which each balance reading is taken. Another piece of support hardware, MFC-CB is used for sending flow command signals to the flow controllers, and possibly reading the device under test if the device has a voltage output.

2.1 BALANCE AND AMH-GFS2102

GFS2102 measures the changing reference gas cylinder mass using a high precision 2.3 kg range mass balance. It is a mass comparator type balance, so there is no significant deflection of the mass tray while the mass load is placed on it. The balance has a digital serial output which is read by the LCM.

In a typical mass measurement, the balance can be zeroed, or tared, immediately before placement of the mass, and the measurement can be made relatively quickly after zeroing. Since gravimetric gas flow measurements can require up to several hours or days for some gases and flow ranges, the balance’s stability over time and level of influence from surrounding conditions becomes very significant to GFS2101 measurements.

A key to reaching the desired level of uncertainty using GFS2101 is to eliminate or minimize the uncertainty due to drift of the mass balance over time. In order to quantify and correct for the balance drift, a specialized automated mass handling platform called AMH-GFS2102 has been developed to allow the GFS balance to be AutoZeroed at selected intervals during a flow measurement. The AMH alternately lifts the reference gas cylinder assembly off the balance, loads a fixed reference mass in its place for measurement, and returns the reference gas cylinder assembly without interrupting the flow measurement.

Figure 2. Reference gas cylinder resting on GFS balance and AMH-GFS2102

Page 23

2. SYSTEM OVERVIEW

The reference mass is approximately 2.0 kg, which is close to the mid point between a full 1.1 liter reference gas cylinder and an empty 1.5 liter reference gas cylinder, so that the balance is checked and corrected for drift at a mass load that is close to the cylinder mass being measured. The balance readings are then corrected for any drift that has occurred since the last time a balance zero or AutoZero were checked.

Figure 3. AMH reference mass plate

AMH-GFS2102 lifts the reference gas cylinder vertically only 3 mm when unloading it from the balance so that the gas flow is not disturbed and no unnecessary deflection of the gas conveyance loop takes place. The standard balance mass tray has been replaced with a custom mass tray that uses a three point locating system to assure consistent physical placement of the reference gas cylinder on the balance during and after each balance AutoZero process (see Section 4.1.3).

Figure 4. Balance mass tray supporting the reference gas cylinder

The reference gas cylinder and reference mass are loaded and unloaded from the balance by two AMH plates that are keyed to lift one of the components when the plate is raised and allow it to rest on the balance when the plate is lowered. The plates move vertically along two posts on the AMH base that orient them, and are raised and lowered by three cams on two shafts in the AMH base which contact rollers that support each plate. A small motor is included in the AMH base to turn the shafts, which are actuated by 12V valve drivers in the LCM.

Page 24

GFS2102™ OPERATION AND MAINTENANCE MANUAL

2.2 REFERENCE GAS CYLINDER ASSEMBLY

The GFS2102 reference gas cylinder assembly is built around a high pressure carbon fiber composite cylinder. In addition to the cylinder itself, the assembly includes a cylinder support, a cylinder connector with fill port and valve, and a two stage welded regulator assembly.

Figure 5. Reference gas cylinder assembly

1. Reference gas cylinder 3. Reference gas cylinder connector

2. Regulator assembly 4. Cylinder support

The reference gas cylinder is a metrological component of the GFS2102 system. Each cylinder assembly is individually tested to determine the internal volume of the assembly. This information, along with the external volume and coefficients of thermal and pressure expansion, allow proper calculation of an air buoyancy correction on the measured mass value and the total mass of test gas available in the cylinder. The characteristics of each cylinder are included on a technical data report that accompanies a new cylinder assembly and must be entered in GFS Tools software (see Sections 3.3.8 and 5.7.5 for more information).

The components of the reference gas cylinder assembly are designed or selected to be possible so that the mass of the test gas makes up a relatively large portion of total measured mass on the balance, allowing sufficient resolution on the measurement of the mass change during the test. The components of the GFS2102 reference gas cylinder assemblies are described below.

light

2.2.1 REFERENCE GAS CYLINDER

The cylinders used for GFS are composite cylinders made with a thin aluminum internal lining, wrapped in carbon fiber in epoxy resin for strength and covered with a fiberglass lining and gel coat finish for resistance to abrasion, impact and UV degradation. The fiber composite design allows them to be lighter than most high pressure cylinders, so a smaller percentage of the total filled cylinder assembly mass comes from the cylinder itself.

Page 25

2. SYSTEM OVERVIEW

There are two different reference gas cylinder sizes offered with the GFS2102 system, a 1.1 liter cylinder and a 1.5 liter cylinder. The two cylinders are offered to accommodate the greatly varying gas densities that can be used with the system (see Section 4.1.2). The cylinders are rated for a maximum working pressure of 20 MPa (3000 psi) for the 1.1 liter cylinder and 31 MPa (4500 psi) for the 1.5 liter cylinder. During manufacturing, the cylinders undergo a hydraulic pressure test up to 1.5 times the rated operating pressure.

The cylinders are delivered with appropriate labeling to meet European or US-DOT requirements depending on the location of the GFS2102 end user.

Figure 6. 1.5 liter and 1.1 liter reference gas cylinder assemblies

The cylinders’ design life is 15 years from the date of manufacture. At that time, the cylinders should be replaced. Hydrostatic testing should also be performed on the cylinders every 5 years to ensure safe operation.

Do not expose the reference gas cylinder to temperatures above 56 °C (133 °F). If you suspect that a reference gas cylinder has been heated to temperatures of 56 °C or more, it must be hydrostatically retested and fully re-qualified before further use. Reference gas cylinders exposed to or with evidence of exposure to heat in excess of 72 °C (162 °F) must be condemned and removed from service.

Avoid letting the cylinder come in contact with strong solvents or cleaning agents, vehicle fluids or corrosive materials as the composite material may be damaged.

For safety, heat dissipation and to maximize the life of the cylinder, filling of the reference gas cylinder should be performed as described in section 4.3. Also see section 2.8 for an overview on the GFS Fill Station.

2.2.2 CYLINDER SUPPORT

The reference gas cylinder is supported on the GFS balance by a custom assembly whose three legs pass through the two plates of the AMH and rest directly on the balance mass tray.

Page 26

GFS2102™ OPERATION AND MAINTENANCE MANUAL

The three leg design of the cylinder support and the custom balance tray make up a locating system for the reference gas cylinder so that it is placed on the balance tray in the same way each time it is set down, to optimize the repeatability of mass measurements. The foot of each leg of the cylinder support is a ruby sphere which is press-fit into the steel support leg. The spheres help to minimize friction as the reference gas cylinder assembly is placed on the balance tray and guided into its resting position.

Figure 7. Reference gas cylinder support

The cylinder support is made of stainless steel legs threaded into a machined aluminum body. Six threaded, spring-loaded pins located around the top ring of the cylinder support are used to attach the support to the reference gas cylinder. Rubber pads are used to protect the cylinder from damage where the pins make contact.

2.2.3 REFERENCE GAS CYLINDER CONNECTOR

The reference gas cylinder connector is a threaded cylinder plug that provides the connection to the cylinder’s regulator assembly and also has a built-in fill port and valve so that the cylinder can be filled without removing the regulator assembly.

Figure 8. Reference gas cylinder connector

1. Fill valve 3. Regulator stem port

2. Fill port

Page 27

2. SYSTEM OVERVIEW

The regulator stem port and the fill port connections are both DH200 coned and threaded connectors. This type of fitting is suitable for pressures beyond the reference gas cylinders maximum operating pressure and the connection can be broken and reconnected many times. The regulator stem port will rarely be disconnected, but the fill port will be used frequently for cylinder refills.

The fill valve is a threaded plug which operates a valve pin with an o-ring seal. The valve opens or closes the flow path to the fill port so that the fill port connection can be broken and reconnected while the cylinder is under pressure. To open the valve, it is not necessary to turn the valve any more than ½ turn. If the valve is fully backed out counter-clockwise while the cylinder is under pressure, the valve could dislodge from the cylinder connector dangerously. The valve is designed to start venting through a side vent approximately 3 turns before release as a warning.

See Section 4.3 for reference gas cylinder filling instructions.

To open the valve, it is not necessary to turn the valve any more than ½ turn. If the valve is fully backed out counter-clockwise while the cylinder is under pressure, the valve could dislodge from the cylinder connector dangerously. The valve is designed to start venting through a side vent approximately 3 turns before release as a warning.

2.2.4 REGULATOR ASSEMBLY

Each reference gas cylinder assembly includes a two-stage pressure regulator assembly to deliver a well-regulated gas flow through the gas conveyance loop and out of the GFS draft enclosure. The regulator assembly is made up of two fixed pressure regulators on a welded assembly that is designed to be centered over the reference gas cylinder and to have a low center of gravity. The center support of the regulator assembly is a solid piece that does not conduct any gas flow. All of the flow follows the flow path to the side and through both regulators. On all reference gas cylinder assemblies, the first stage regulator is set to deliver downstream pressure of 1 MPa (150 psi). On 1.1 liter reference gas cylinder assemblies, the second regulator delivers 690 kPa (100 psi). On 1.5 liter reference gas cylinder assemblies, the second regulator delivers 550 kPa (80 psi).

2.2.5 REFERENCE GAS CYLINDER CASE

All the pieces for the reference gas cylinder assembly are delivered in a custom fill/carry case to provide a convenient way to store and carry the reference cylinder assembly around the laboratory. This case is designed to allow the user to fill the cylinder while it is resting in the case (with the case lid open) and provides adequate ventilation for the cylinder to cool during and after the filling operation. The reference gas cylinder assembly should NOT be shipped or transported for any distance outside the lab in the fill/carry case while the regulator assembly is installed on the cylinder or the cylinder is pressurized. If the unit encounters a significant shock while the reference gas cylinder with fully installed regulator assembly is inside the case, the vertical nipple of the regulator assembly could bend under the weight of the regulators, which may cause alignment problems for the cylinder assembly in the GFS system, and may compromise the strength of the tubing in a high pressure section of the regulator assembly. For assembling the reference gas cylinder, always follow the instructions in section 3.1.8. For filling the cylinder, always follow the instructions in Section

4.3.

Page 28

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Never ship an assembled or pressurized reference gas cylinder. Always follow the instructions in Section 6.4 for disassembling the reference gas cylinder for shipment.

Never leave a pressurized reference gas cylinder in a sealed case for an extended time. Leave the case unlatched if storing a pressurized cylinder.

2.3 GFS DRAFT ENCLOSURE AND VIBRATION ISOLATION TABLE

The GFS balance, AMH, and reference gas cylinder assembly are operated inside an insulated enclosure to isolate them from air drafts and rapid changes in temperature or humidity.

The entire enclosure is placed on a granite vibration isolation table, which further stabilizes the temperature inside the enclosure. The granite table top measures 600mm x 900mm x 150 mm (23.6” x

35.4” x 5.9”) and has ledges which are used as a connection point for the draft enclosure mounting

brackets. The table top rests on a steel stand.

Figure 9. GFS draft enclosure on vibration isolation table

Page 29

2. SYSTEM OVERVIEW

There are two pass through openings on the right side of the enclosure. One is for the exit of the flow path tube and ambient pressure tube, and the other is for electrical connections to the balance, AMH and internal temperature and humidity probes.

After the gas travels from the reference gas cylinder and through the gas conveyance loop it passes through a quick connector mounted on a bracket on the inside of the GFS draft enclosure. A tube leading from this connector passes inside the bracket, through an isolation valve, and down through the enclosure pass through opening below. The vertical position of the quick connector on the enclosure bracket is adjustable. The height of the quick connector at the outlet of the reference gas cylinder assembly is different for 1.1 liter and 1.5 liter cylinders and also may not be consistent among cylinders of the same size. Therefore it may be necessary to adjust the quick connector on the on the draft enclosure bracket to keep the ends of the gas conveyance loop level. It is important that the loop ends are level so that no unintended forces are imparted to the cylinder while its mass is being measured.

Three probe positioning arms are mounted on the inside of the back wall of the draft enclosure. The adjustable arms hold the two TH probe devices and IR temperature probe in proper positions relative to the reference gas cylinder assembly to get accurate measurements of the cylinder’s surface and surrounding conditions.

A loop alignment tool is delivered with the GFS draft enclosure to help in positioning the AMH so that the loop takes its ideal natural shape, minimizing the possibility of unintended forces applied to the reference gas cylinder while it is on the balance.

2.4 LABORATORY CONDITIONS MONITOR (LCM)

The LCM is the central data collection component of GFS2102. All GFS balance mass measurements are read by the LCM and the precise time of each balance reading is recorded using LCM’s calibrated on-board timer and passed on to GFS Tools software. Measurements of pressure, temperature and humidity in the vicinity of the reference gas cylinder and balance are needed for GFS Tools to calculate the instantaneous mass of the cylinder, corrected for air buoyancy, throughout the test. All of these measurements are made by the LCM using internal ambient condition measurements and probes that are placed in critical locations inside the GFS draft enclosure.

Figure 10. Laboratory Conditions Monitor

2.5 MFC-CB

MFC-CB is used for controlling flow setpoint signals to mass flow controllers included in the GFS2102 system. It may also be used for reading the output of a device under test that has an analog signal output. Communication with MFC-CB for controlling flow is supported automatically in GFS Tools software. For reading device under test (DUT) output, some configuration of MFC-CB and/or GFS Tools is needed (See Section 5.5.3). See the separate MFC-CB Operation and Maintenance Manual for details on MFC-CB.

Page 30

GFS2102™ OPERATION AND MAINTENANCE MANUAL

2.6 GFS TOOLS

The user interface for operating GFS2102 is GFS Tools software. GFS Tools handles all collection of data from the GFS system components and devices under test and calculation and reporting of mass flow and errors. Some operating principles of GFS Tools are described in Section 4.1 and 4.2 and GFS Tools is described in detail in Section 5.

2.7 HEAT EXCHANGER

At flows above 1 slm in N2, the calibration gas is discharging from the Reference Gas Cylinder quickly enough that the cooling of the gas from decompression can effect the regulator, MFC, and molbloc(s) downstream of the GFS. This in turn can effect the stability and control of the flow, and ultimately the overall accuracy. To significantly reduce these effects a heat exchanger is used. A fully assembled heat exchanger consists of a 3.2 Qt. stainless steel can filled with water or a water/antifreeze mix with approximately 7-10 feet of ¼” stainless tubing coiled up and submerged in the liquid. For shipping purposes the exchanger is shipped without liquid and needs to be prepared prior to use. Preparation of the heat exchanger is described in Section 3.3.14.

2.8 GFS-FS REFERENCE GAS CYLINDER FILL STATION

A specialized filling station is provided with the GFS2102 system to help users fill the reference gas cylinders safely and slowly with minimal heating of the cylinder. The design of the fill station allows the user to quickly set the desired fill pressure and the cylinder is filled at a slow rate that is controlled by a flow limiter. The user can view the set pressure that the cylinder will ultimately achieve and the current cylinder pressure as it fills.

Figure 11. GFS-FS Reference gas cylinder fill station

See Section 4.3 for details on GFS-FS operation and connections.

2.9 MASS FLOW CONTROLLERS

Four mass flow controllers are included with the GFS-2102 system. There are (1) 10 sccm MFC, (1) 100 sccm MFC, (1) 1 slm MFC, and (1) 10 slm MFC all adjusted to operate in these ranges for N2. These can be used for any gas that they can reasonably operate with by applying the K factors found in GFS Tools. When working with gases other than N2, in most cases a test will have to be sectioned into two or more tests in order to work with multiple MFC’s.

Page 31

2. SYSTEM OVERVIEW

2.10 MOLBLOC MOLSTICS (OPTIONAL)

If calibration of molblocs or MFC’s will be the primary use of the GFS, it is recommended to use molstics for the ease of setup. There are several types of molstics, but the two that ideally fit the GFS system are the single low flow (PN 401316) and single mid flow (PN 401244). These molstics each come with a filter, regulator, manual shutoff valve, molbloc cradles, and MFC supports.

Depending on the Reference Gas Cylinder selected, the output of the GFS is either 690 kPag (100 psig) or 550 kPag (80 psig). For most applications this pressure will need to be regulated down to an operational pressure before going through the device under test (DUT). For example, a LoP calibrated molbloc at 270kPaa (39 psia) or a HiP calibrated molbloc at 525kPaa (76 psia).

If molstics are not to be used, then at a minimum a filter, regulator, and manual shutoff valve are recommended, and consideration will have to be given to the varying height locations of these connections as well as those of any molblocs, MFC’s, or other DUT’s to be connected.

2.11 MASS SET (OPTIONAL)

If additional assurance is required to prove the balance is correctly operating in the range of normal use from 1.6kg to 2.3kg, then the mass carrier (MS-2102-CAR) or the mass set (MS-2102-0.7) which includes a mass carrier can be ordered. The carrier allows for a quick exchange with the Reference Gas Cylinder and is designed to weigh approximately 1.6kg in order to simulate an empty gas cylinder. The carrier provides a platform outside of the AMH for the placement of masses in order to check the balance performance without having to remove the plates of the AMH. The mass set includes three 200g masses and one 100g mass, which in combination allows for a measurement every 100g up to 2.3kg. For detailed instructions on the use of the mass carrier and masses see section 7.8.3.

Page 32

GFS2102™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

Page 33

3. INSTALLATION

33.

NNSSTTAALLLLAATTIIOON

3.1 UNPACKING AND INSPECTION

Check that all items included in the GFS2102 system are present and have NO visible signs of damage. A parts list of the major components supplied and how they are packed is provided in Table 1. Unpack and inspect the items following the instructions in Sections 3.1.1 to 3.1.11 and detailed parts lists in

GFS2102 packing list to Table 1.

Table 1. GFS2102 packing list

COMPONENT SHIPPED IN SECTION

Granite Table Top See below 3.1.1 N/A Granite Table Stand See below 3.1.1 N/A GFS draft enclosure corrugated container

Draft enclosure glass doors corrugated container 3.1.2 Table 2 Draft enclosure accessories corrugated container 3.1.2 Table 2 LCM and accessories corrugated container 3.1.3 Table 3 MFC-CB and accessories corrugated container 3.1.4 Table 4 mass flow controllers corrugated container 3.1.4 Table 2 Low flow molstic (optional) corrugated container 3.1.11 N/A Mid flow molstic (optional) corrugated container 3.1.11 N/A GFS Tools CD 3.1.9 Table 2 GFS-FS corrugated container 3.1.5 Table 5 GFS mass balance corrugated container 3.1.6 Table 6 AMH-GFS2102 (2) corrugated

Reference gas cylinder assembly (one or more may be delivered)

GFS2102 mass set molded transit case

System controller (2) corrugated

Accessories corrugated container 3.1.2 Table 2

in wood crate

containers molded transit case

in corrugated outer carton

containers

3.1.2 Table 2

3.1.7 Table 7

3.1.8 Table 8

3.1.10 Table 9

3.1.9 N/A

DETAIL

TABLE

3.1.1 GRANITE VIBRATION ISOLATION TABLE AND STAND

The granite vibration isolation table top weighs over 600 lb. (270 kg). Professional

assistance and special equipment are needed to move it into position in the laboratory.

Page 34

GFS2102™ OPERATION AND MAINTENANCE MANUAL

The granite vibration isolation table is generally drop-shipped directly from the manufacturer to the customer since it is very heavy item and does not require assembly or modification at DHI. It is best to make plans for the final location of the GFS system well before installation of the system so that the vibration isolation table can be put into place.

The granite table is shipped along with a 100 lb steel support stand. For use with the GFS2102 system, the table will be aligned so that the widest dimension is seen from the front of the system.

3.1.2 GFS DRAFT ENCLOSURE AND SYSTEM ACCESSORIES

The draft enclosure is shipped partially assembled in a wooden crate. It is first padded and packed inside a corrugated container, and then the container is packed inside the crate. The draft enclosure’s glass doors, probe supports and tubing are removed for shipping. Brackets and hinges for holding these items are pre-installed on the enclosure before shipping to simplify mounting them onsite.

To unpack: Remove top and sides from the wood crate. Open the corrugated container taking care not to damage the side of the draft enclosure. Remove the draft enclosure from the pallet. The draft enclosure is packed alone in the wooden crate.

Two glass doors are packaged separately from the draft enclosure in a corrugated container. Carefully open the container and remove the glass doors.

Accessories for the GFS draft enclosure are packed along with other GFS2102 system accessories in two separate corrugated containers. Open the corrugated containers and remove the accessories. Many of these will be individually wrapped inside the corrugated container to protect them from damage.

Table 2 details all items included in the GFS draft enclosure accessories accessories.

1 ea. GFS Draft enclosure with sidewall column preinstalled 402282 2 ea. Draft enclosure glass doors NPN 3 ea. Telescoping probe support arms NPN 3 ea. Support brackets for probe support arms NPN 1 ea. Loop alignment tool 124128 1 ea. Heat Exchanger, Low 402291 1 ea. Enclosure pressure transport tube (pre-attached to sidewall column) NPN 1 ea. External gas conveyance tube (pre-attached to sidewall column) NPN

1 ea. AMH-GFS2102 driver cable (pre-attached to sidewall column) NPN 1 ea. IR converter box cable (pre-attached to sidewall column) NPN

1 ea. 1/8” x 1/4” Swage reducing union NPN 2 ea. 1/16” Swage QC stem NPN 2 ea. 1/16” Swage plug NPN 1 ea. ¼” Swage to ¼” VCRF adaptor 102145 2 ea. O-ring 102070

4 ea. RS-232 cable

4 ea. Mass flow controllers NPN

Table 2. Draft enclosure and system accessories list

DESCRIPTION PART #

and system

100847

Or 100847-CE

Page 35

3. INSTALLATION

1 ea. GFS Tools CD NPN

3.1.3 LABORATORY CONDITIONS MONITOR

The LCM is delivered in a corrugated container with foam inserts. The LCM accessories are sealed in plastic and included in the same corrugated container.

Open the corrugated container and remove the accessories and LCM. You may wish to retain the foam inserts for future shipping.

Table 3 details all items included with the LCM.

Table 3. LCM parts list

DESCRIPTION PART #

1 ea. Laboratory Conditions Monitor 402290

Accessory kit including:

2 ea. TH Probe temperature and humidity probe with cable NPN

1ea. IR Probe with cable NPN 1 ea. PRT temperature probe with cable NPN 1 ea. Power cord with 100-240VAC to 12VDC adaptor (black) NPN

3.1.4 MFC-CB

The MFC-CB is delivered in a corrugated container with foam inserts. The MFC-CB accessories are sealed in plastic and included in the same corrugated container.

Open the corrugated container and remove the accessories and MFC-CB. You may wish to retain the foam inserts for future shipping.

Table 4 details all items included with the MFC-CB.

Table 4. MFC-CB parts list.

DESCRIPTION PART #

1 ea. MFC-CB 401710

Accessory kit including: 401712

2 ea. MFC cable, standard edge connect 102533 1 ea. Power Cord 100770 1 ea. Analog calibration cable 401256 1 ea. Operation and Maintenance Manual 550123

3.1.5 GFS-FS REFERENCE GAS CYLINDER FILL STATION

The GFS-FS reference gas cylinder fill station is shipped in a corrugated container along with an accessory kit that is sealed in plastic.

Open the corrugated container and remove the accessories and fill station. Table 5 details all items included with the GFS-FS.

Page 36

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Table 5. GFS-FS fill station parts list

DESCRIPTION PART #

1 ea. GFS-FS 402283

Accessory kit including:

1 ea. F1414-96 flex tube 400757 1 ea. F1550-96 flex tube 400863 1 ea. DH200 gland 100272 1 ea. DH200 collar 101200 1 ea. DH500 gland 100271 1 ea. DH500 collar 101201 1 ea. ¼” NPTF x ¼” Swage adaptor 101530

3.1.6 GFS MASS BALANCE

The GFS balance is delivered in a custom molded black foam insert inside a corrugated container along with the custom mass tray, which is individually wrapped inside the insert in the same container.

Carefully remove the insert from the corrugated container. The insert is a two piece design held together by two manually operated reusable buckle straps. Release the straps and remove the top piece of the insert. Carefully remove the mass tray and balance from the insert. Avoid imparting any excessive shock to the balance while handling.

Table 6 details all items included with the GFS balance.

Table 6. GFS mass balance parts list

DESCRIPTION PART #

1 ea. Mass balance NPN

Accessory kit including:

1 ea. Custom mass tray NPN 1 ea. Custom balance mounting bracket (to connect to AMH-GFS2102) NPN 1 ea. 100-240VAC to 12VDC power adaptor (white) NPN 1 ea. Power cord 100770 1 ea. User’s Manual NPN

3.1.7 AMH-GFS2102

The AMH-GFS2102 automated mass handler is shipped in two or more corrugated containers. There are 4 main parts to the AMH that are disassembled prior to shipment; The AMH base, the reference mass, reference mass plate and top plate.

To unpack: Remove each of the four AMH parts from the corrugated containers. The AMH base should be set so that the three adjustable feet support it. The two plates and reference mass can be placed directly on a table. Take care not to damage or scratch the reference mass and to keep it clean so that its calibration is not changed. See Sections 3.3.9 to 3.3.12 for AMH-GFS2102 assembly and positioning instructions.

Table 7 details all items included with the AMH-GFS2102.

Page 37

3. INSTALLATION

Table 7. AMH-GFS2102 parts list

DESCRIPTION PART #

1 ea. AMH-GFS2102 Automated Mass Handler Including: 402280 1 ea. AMH platform base NPN 1 ea. Reference mass assembly (Reference mass, mounting legs, screws) NPN 1 ea. AMH reference mass plate assembly NPN 1 ea. AMH top plate assembly NPN

3.1.8 REFERENCE GAS CYLINDER ASSEMBLIES

Reference gas cylinder assemblies are not included with the base GFS2102 system, so the customer has the option to purchase one or more with their system. Often, a set of two cylinder assemblies are ordered and delivered with the GFS system, one of the smaller 1.1 liter cylinder assemblies with 690 kPa (100 psi) output and one of the larger 1.5 liter cylinder assemblies with 550 kPa (80 psi) output to cover requirements for a variety of gases. For customers who expect a high rate of usage, two sets of cylinders are recommended so that for whatever size of cylinder is in use a second identical cylinder can be filled and prepared for use once the first is depleted. Each reference cylinder assembly is shipped in a black, molded plastic case in a corrugated liner. During shipment, the plastic case holds the disassembled cylinder unit and regulator assembly in place using a custom plastic and foam liner. Also packed inside the plastic case is a catenary gas conveyance loop that is held in a foam cutout in the case lid.

To unpack: Remove the plastic molded case from the corrugated liner. Open the case and inspect the reference gas cylinder, regulator assembly, and catenary gas conveyance loop. Both can be stored inside the case when not in use. When removed from the case, the cylinder assembly can be placed on a level surface resting on the cylinder support legs. Make sure the reference gas cylinder support is attached on the cylinder straight, so that the cylinder stands vertically. Follow the instructions in Section 3.3.7 for assembling the regulators with the reference gas cylinder.

Follow the instructions in Section 6.4 to disassemble the Reference Gas Cylinder for

hipment.

s Table 8 details all items included with each option of the Reference Gas Cylinder.

Page 38

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Table 8. Reference gas cylinder assemblies’ parts lists

DESCRIPTION PART #

1 ea. Gas conveyance loop included with every cylinder option NPN

Cylinder Option 1 US-DOT 1.1 Liter Reference gas cylinder assembly including:

1 ea. Reference gas cylinder, US-DOT 1.1 Liter 402284 1 ea. Reference gas cylinder connector NPN 1 ea. Regulator assembly, 690 kPag (100 psig) NPN

1 ea. Reference gas cylinder support, 1.1 Liter NPN 1 ea. Molded case with insert, 1.1 Liter

Cylinder Option 2 US-DOT 1.5 Liter Reference gas cylinder assembly including:

1 ea. Reference gas cylinder, US-DOT 1.5 Liter 402285 1 ea. Reference gas cylinder connector NPN 1 ea. Regulator assembly, 550 kPag (80 psig) NPN

1 ea. Reference gas cylinder support, 1.5 Liter NPN 1 ea. Molded case with insert, 1.5 Liter

Cylinder Option 3 European 1.1 Liter Reference gas cylinder assembly including:

1 ea. Reference gas cylinder, European 1.1 Liter 402286 1 ea. Reference gas cylinder connector NPN 1 ea. Regulator assembly, 690 kPag (100 psig) NPN

1 ea. Reference gas cylinder support, 1.1 Liter NPN 1 ea. Molded case with insert, 1.1 Liter

Cylinder Option 4 European 1.5 Liter Reference gas cylinder assembly including:

1 ea. Reference gas cylinder, European 1.5 Liter 402287 1 ea. Reference gas cylinder connector NPN 1 ea. Regulator assembly, 550 kPag (80 psig) NPN

1 ea. Reference gas cylinder support, 1.5 Liter NPN 1 ea. Molded case with insert, 1.5 Liter

NPN

3.1.9 SYSTEM CONTROLLER

The system controller consists of a personal computer, flat screen display, keyboard and pointing device (“mouse”). These are packed in (2) to (4) corrugated containers, depending on configuration.

The system controller is delivered with all necessary GFS2102 system software pre-loaded including GFS Tools™.

The part number of the system controller is 103388.

Page 39

3. INSTALLATION

3.1.10 MS-2102-0.7 MASS SET OR MS-2102-CAR MASS CARRIER

The MS-2102-0.7 mass set and the MS-2102-CAR mass carrier are not included in the GFS2102 base system but may be purchased with the system. The full mass set may be purchased, which includes a mass carrier, or the mass carrier may be purchased alone. Either option is packed in a molded plastic case inside a corrugated liner. The plastic case comes with a foam insert with custom cutouts to hold both the mass carrier and the four piece, 700 g mass set.

Table 9 details all items included with the MS-2102-0.7 mass set. Table 10 details just the MS-2102-CAR mass carrier and case.

Table 9. MS-2102-0.7 mass set parts list

DESCRIPTION PART #

1 ea. MS-2102-0.7 mass set including: 402288 3 ea. 200 g mass 123498 1 ea. 100 g mass 123496 1 ea. mass carrier NPN 1 ea. molded plastic shipping and storage case NPN

Table 10. MS-2102-CAR mass carrier parts list

DESCRIPTION PART #

1 ea. MS-2102-CAR mass carrier including: 402289 1 ea. mass carrier NPN 1 ea. molded plastic shipping and storage case NPN

3.1.11 MOLSTICS

The low flow molstic (PN 401316) and mid flow molstic (PN 401244) are not included in the GFS2102 base system but may be purchased with the system. Each molstic is “FIP”ed (Foamed In Place) individually inside corrugated containers. See section 3.3.15 for more information on molstics.

3.2 SITE REQUIREMENTS

3.2.1 GFS2102 SYSTEM

The environment required to operate the GFS2102 gravimetric flow standard within its estimated measurement uncertainty limits is generally that of a high level, physical metrology laboratory.

When selecting and preparing a site to set up the GFS2102 system, the following environmental influences should be considered:

Ambient conditions: To achieve optimum metrological performance, ambient conditions should be controlled and maintained within the following limits:

Temperature: 15 to 25 °C, with a minimized rate of change of temperature. Relative Humidity: 5 to 70% RH (non-condensing). Ambient Pressure: Minimize external influences that will cause barometric instability. Air Currents: Do not install the GFS2102 draft enclosure under a source of vertical air currents

such as an overhead air conditioning duct. These can exaggerate the magnitude and rate of changes in ambient temperature.

Page 40

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Vibration: Minimize local vibration. Excessive vibration will reduce the stability of the mass

and subsequent flow values measured by GFS2102. Following are other site selection criteria to consider: Overall footprint and system layout: The GFS2102 draft enclosure and vibration isolation

table should be set up in relation to the work surface for the device under test (DUT) as shown in Figure 12. As the draft enclosure is viewed from the front, the flow path exit the enclosure is on the right side. To minimize the volume of the flow path and number of connections, the GFS enclosure and table should be placed just to the left of the DUT work surface. The height of the flow path exit from the draft enclosure is approximately 40 in. from the floor. Both the enclosure and table are approximately 36 in. wide by 24 in. deep. The table top is 34 in. high and the top of the enclosure is 58 in. high.

Electrical power supply: Plan the supply of electrical power to the Control Cabinet. See Section 1.1.1 for GFS system electrical power requirements. Be sure to consider DUT electrical requirements also.

If low flow (<100sccm) tests will be performed on a regular basis and power interruptions, brown outs, or other power anomalies can occur, a battery backup UPS is recommended. At a minimum, the PC, balance, LCM, MFC-CB, and any units powering or interfacing with the DUT (i.e. molbox1) need to be on the battery backup.

from

Vacuum pump: Vacuum is not required for the operation of the GFS2102 system. If the device under test is a molbloc-S or other device that may be used with vacuum, plan to locate the vacuum pump so that heat, noise and vibration do not have negative effect on the system and consider electrical supply needs of the pump. The vacuum pump exhaust outlet should be allowed to exit the room where the GFS is located, preferably to the outdoors, particularly if the calibration gas is volatile or toxic.

A vacuum pump interconnect kit is normally ordered with a vacuum pump and includes a check valve to vent gas in the event of a power failure rather than over pressurizing the molbox1 pressure transducers. This check valve should also be connected to an exhaust vent.

Page 41

3. INSTALLATION

Figure 12. Typical layout of overall GFS2102 system at site of use

3.2.2 GFS-FS REFERENCE GAS CYLINDER FILL STATION

The GFS-FS reference gas cylinder fill station may be located away from the flow measurement components of the GFS2102 system. Following are site selection criteria to consider for the GFS-FS:

GFS-FS dimensions and mounting: GFS-FS is designed so that it can be easily mounted to a wall or bench for convenient operation. The GFS-FS base if positioned on a vertical wall or surface, measures 20 cm (7.9 in.) high by 41.4 cm (16.3 in.) wide. The overall depth from the wall is 20 cm (7.9 in.) at the pressure regulator handle. The mounting holes are spaced center-to-center 38 cm (15 in.) across by 17.4 cm (6.9 in.) down and are designed to use M6 or ¼” bolts or screws. There is a keyhole feature to the upper holes that allows it to be hung while marking or installing the lower screws making it convenient for one person to install. When mounting GFS-FS, leave adequate room to access the gas connections on both the left and right side of the base. GFS-FS should be located in close proximity to both a high pressure gas supply and a workbench or surface where the reference gas cylinder can be safely placed during filling. The high pressure flex tubes delivered in the GFS-FS accessory kit for connecting GFS-FS to both the gas supply source and the reference gas cylinder are 8 feet (244 cm) in length. Unless alternate plumbing is fabricated to make these connections, the tubing lengths will define the limits for positioning the GFS, gas supply and reference gas cylinder during cylinder filling.

High pressure gas supply: The expected gas source to provide the supply for GFS-FS is a gas cylinder at approximately 18 MPa (2700 psi). The maximum supply pressure that can be connected to GFS-FS is 20 MPa (3000 psi). The supply media should be a clean, dry gas. Gas purity is an important factor in the quality of GFS2102 flow measurements, so the highest level of gas purity is recommended. Accurate measurement of 17 pure gases is supported with GFS2102. (See Section 4.1.2).

supply connection

The

on GFS-FS is a ¼” Swage bulkhead. An 8 ft (244 cm) flex tube with ¼” Swage connections and a ¼” Swage to ¼” NPT female adaptor are provided as GFS-FS accessories. To connect to this standard hardware, the user must provide a ¼” NPT male nipple or connector from the high pressure cylinder or other supply.

Page 42

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Safety: GFS-FS is used to perform recurring high pressure fills of the carbon fiber composite

reference gas cylinder. The fill pressure of the reference gas cylinder is within the safe operating pressure rating specified by the cylinders’ manufacturer, but ideally the cylinder filling should be performed in a location that minimizes the possible risks of injury due to the failure of any cylinder, tube or connector at high pressure. The design of GFS-FS allows filling of the reference gas cylinder to occur slowly so that the temperature of the cylinder remains low. The filling operation can be largely unattended once it is started. See Section

4.3 for safe cylinder filling procedures.

Ventilation: If any gas other than air is used to fill the reference gas cylinder, proper ventilation should be in place in the location where the reference gas cylinder is filled and the GFS2102 system is used. Volatile or toxic gases especially must be vented, and even inert gases present a real hazard to operators, especially in small spaces, if they force the oxygen levels in the room to drop.

Convenience to GFS2102 system: Minimizing the distance between the filling location and the GFS2102 system is desired since the reference gas cylinder must be transported between the two locations, often while pressurized. A molded plastic case is provided for each reference gas cylinder assembly to make transport of the cylinder safer and more convenient.

Vacuum availability: One method for ensuring gas purity after changing test gases in a reference gas cylinder or opening the cylinder to atmosphere is to evacuate the cylinder using vacuum before refilling (See Section 4.3.2). If this method will be used, the vacuum source and connection should be convenient to the cylinder filling location.

Never connect and open the reference gas cylinder to the vacuum pump while pressure remains in the cylinder or damage could occur to the vacuum pump. Always vent the cylinder to atmosphere first.

3.3 SETUP

Before setting up the GFS2102 system, see Section 3.2 for information on site requirements.

To set up the GFS2102 system, first unpack it following the instructions in Section 3.1. Then follow the set up instructions in Sections 3.3.1 to 3.3.14 sequentially.

3.3.1 POSITION THE VIBRATION ISOLATION TABLE

Refer to the Site Requirements section of this manual and then position the granite vibration isolation table where you want the table and draft enclosure (See Section 3.2). Take into consideration positioning for everything including granite table, GFS draft enclosure, and a lab bench for the LCM, MFC-CB, device under test, flow and computer. When possible, use a bubble (spirit) level and the four adjustable feet on the steel support stand to level the surface of the granite table surface.

controllers and other flow path hardware,

The granite vibration isolation table top weighs over 600 lb. (270 kg). Professional assistance and special equipment are needed to move it into position in the laboratory.

Page 43

3. INSTALLATION

3.3.2 INSTALL DRAFT ENCLOSURE ON VIBRATION

ISOLATION TABLE

Set the draft enclosure on the granite vibration

isolation table so that the open side with hinges for mounting the glass doors faces the front, and the pass through openings are on the right side when looking at the enclosure from the front. The bottom of the enclosure is open so that the top of the granite table is exposed.

Install the draft enclosure positioning brackets on the enclosure so that they hold the

granite table top under each ledge.

Remove the draft enclosure sidewall column by

removing the six screws that secure it. A 3 mm allen wrench should be used to remove the screws.

Connect the external flow conveyance tube to the

bottom of the isolation valve mounted inside of the sidewall column and run the remaining tube out through the flow path pass-through opening in the enclosure. It is important that this connection does not leak.

Connect the clear ambient pressure tube to the

barbed fitting on the inside of the enclosure sidewall column. Run the remaining tube out through the flow path pass-through opening in the enclosure.

Locate the two TH probe assemblies, one PRT probe

assembly, and one IR probe. These are all accessories of the LCM. Run the yellow cables for the two TH probes and the orange cable for the PRT probe through the utility pass-through opening so that the probes remain on the inside of the enclosure. Attach the white cable from the IR probe to the blue box mounted inside the sidewall column. Run the gray cable from the blue box out through the utility pass through opening in the enclosure.

One end of the AMH driver cable should be pre-mounted through a rubber grommet in the

enclosure sidewall column and attached to the inside of the column by a cable clamp. Make sure the other end is run through the utility pass-through opening in the enclosure.

Locate the DC volts power cord of the GFS balance power adaptor. Run it through the

utility pass-through opening also so that it can connect to the balance inside the enclosure. The power adaptor and AC power cord should remain on the outside of the enclosure.

Run one 9 pin D-sub cable through the utility pass-through opening of the draft enclosure.

The end of the cable with male pins should be inside the enclosure. Replace the draft enclosure sidewall column onto the side of the draft enclosure Locate the glass doors for the draft enclosure. Hang one door on the hinges and fasten

the two retainers into the hinge using two screws. Repeat for the other door. The hinges may need to be adjusted to allow the glass doors to sit level and flush with each other in the center. Adjust the doors to minimize the gap between the doors which could allow air currents to enter the draft enclosure and affect the balance measurements. When closed, the doors should be in contact with the rubber seal along the entire edge of the draft enclosure.

Page 44

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Figure 13. Installation of draft enclosure doors.

3.3.3 SETUP LCM

Place the LCM on a workbench, shelf, or on top of the enclosure and within reach of the

enclosure probe cables and connections (TH, PRT, IR, AMH driver, balance 9 pin D-sub, pressure tube).

Figure 14. LCM rear panel connections

Connect one TH probe yellow cable to the TH2 port on the rear panel of the LCM. Connect the other TH probe yellow cable to the TH3 port on the rear panel of the LCM. Connect the PRT probe orange cable to the T4 port on the rear panel of the LCM.

Connect the IR box grey cable to the IR port on the rear panel of the LCM. Slide the clear plastic enclosure pressure tube on to the barbed fitting of the ATM P1 port

of the LCM.

Connect the AMH driver cable to the DRIVERS port on the rear panel of the LCM. Connect a 9 pin D-sub cable from the COM1 port on the rear of the LCM to the COM1

serial port of the system controller (preferred) or to one port of the system controller’s USB serial adaptor.

Connect the 9 pin D-sub cable that runs into the draft enclosure to the COM2 port on the

rear panel of the LCM.

Connect the LCM power cord to the connector labeled 12 VDC on the LCM rear panel.

Page 45

3. INSTALLATION

3.3.4 SETUP MFC-CB

Place the MFC-CB on a workbench, shelf, or on top of the enclosure so that the MFC

cable can comfortably reach a mass flow controller in the system flow path near the device under test.

Connect a 9 pin D-sub cable from the COM1 port on the rear of the MFC-CB to one port

of the system controller’s USB serial adaptor.

Connect the power cord to the MFC-CB rear panel.

3.3.5 SET UP THE SYSTEM CONTROLLER (PC)

The system controller is a standard personal computer with flat screen display, keyboard and pointing device. These may be installed on the laboratory work surface near the GFS draft enclosure. It will help to have the PC within a close proximity to the rest of the system since there are at least two serial connections between the system controller and other components in the GFS system (via the USB serial adaptor).

GFS Tools software must be installed on the system controller and in general will be preinstalled by DHI.

Connect the USB serial adaptor to any convenient USB port on the system controller.

Serial connections for GFS2102 system

Use 9 pin D-sub cables to connect the following:

• Any COM port (COM1 is preferred) of USB serial adaptor to LCM COM1 port

• COM 2 port of LCM to COM port of GFS balance

• Any COM port of USB serial adaptor to MFC-CB COM 1 port

• Use any remaining COM ports of the USB serial adaptor to connect to DUT serial

connection, for example a molbox1 COM1 port.

3.3.6 VERIFY GFS CALIBRATION DATA

Certain calibration coefficients are stored in either the LCM, the TH probes or GFS Tools software, all of which should be verified to be correct before making measurements. Regardless of location, all coefficients can be viewed in GFS Tools by selecting the [Setup][Calibration] menu choice to access the Calibration Editor (see Section 5.5.7). Verify/enter the following data:

On the Time/Mass tab, verify that the Reference Mass and Reference Mass density field

entries match the data in the most recent reference mass calibration report. This mass value must be manually entered into GFS Tools each time the Reference Mass is recalibrated.

On the Ambient tab, verify that the Ambient Pressure, PRT Temperature (if used), and

ambient Humidity calibration data match the most recent LCM calibration report. These values are stored in the LCM and are read automatically from LCM into GFS Tools.

On the TH Probe #2 and TH Probe #3 tabs, verify that each set of data matches the TH

probe data in the most recent LCM calibration report. This data is stored inside each individual TH probe and is read by the LCM and into GFS Tools. The probes must be connected to the LCM to access the data.

Page 46

GFS2102™ OPERATION AND MAINTENANCE MANUAL

On the balance PRT tab, verify that the balance PRT calibration data matches the data

from the most recent LCM calibration report. This data is stored inside the LCM and is read automatically into GFS Tools.

On the balance IR tab, verify that the infrared probe calibration data matches the data

from the most recent LCM calibration report. This data is stored inside the LCM and is read automatically into GFS Tools.

3.3.7 ASSEMBLE REFERENCE GAS CYLINDER(S)

The GFS2102 reference gas cylinder assembly includes the reference gas cylinder, the regulator assembly, the reference gas cylinder connector, and the cylinder support. (See Figure 15.)

Figure 15. Reference gas cylinder assembly

1. Reference gas cylinder

2. Regulator assembly

Never ship the reference gas cylinder assembly in the fill/carry case while the regulator assembly is installed on the reference gas cylinder. This could lead to damage of the regulator assembly, potentially causing a failure of the regulator assembly tubing under high pressure.

Energy stored in high pressure gases can be released unexpectedly and with extreme force. High pressure systems should be assembled and operated only by personnel who have been instructed in proper safety practices.

The reference gas cylinder assembly will arrive from the factory with the regulator assembly disconnected from the rest of the cylinder assembly. All parts of the reference gas cylinder assembly are shipped inside the carry/fill case. The regulator assembly is packed in a custom foam cut-out inside the case to protect it from damage. The reference gas cylinder

3. Reference gas cylinder connector

4. Cylinder support

Page 47

3. INSTALLATION

connector is installed in the cylinder. Use the following steps to install the regulator assembly into the reference gas cylinder connector:

Remove the reference gas cylinder assembly and the regulator assembly from the

carry/fill case. Locate the regulator stem port of the connector. (See Figure 16.)

Figure 16. Reference gas cylinder connector

1. Fill valve 3. Regulator stem port

2. Fill port

Remove the DH200 gland and plug from the regulator stem port of the reference gas

cylinder connector and retain the gland.

The regulator assembly will be packaged with a steel collar that threads onto the

regulator stem. If the collar is already on the stem, it must be removed. The collar uses a left-hand thread.

Slide the gland from step onto the regulator stem with the threads facing down (away

from the regulators), and thread the collar back onto the stem below the gland. Engage the collar threads fully so that at least one thread shows between the collar and the coned end of the stem.

Place the regulator assembly on the reference gas cylinder assembly with the regulator

stem in the cylinder connector’s regulator stem port. The position of the regulator assembly should be such that when the fill port and valve on the cylinder connector face toward you, the exit tube of the regulator assembly with the quick connector faces to the right. Hand-tighten the DH200 gland into the cylinder connector.

Tighten the DH200 gland into the reference cylinder connector, using a wrench to hold

the cylinder connector. DO NOT use any type of pipe wrench or vise to hold the assembly by the carbon fiber body of the cylinder. You may want to use a cloth or other material to protect the finish on the reference cylinder connector from scratches.

Note: It is critical that the final position of the regulator assembly is such that the exit tube is lined up precisely with the leg of the reference cylinder support on the right side of the cylinder. View the whole assembly from the top to be sure they are aligned (See Figure 17). Tightening the DH200 gland will rotate the will be necessary to offset the regulator assembly before

regulator assembly a few degrees clockwise, so it

tightening so that it finishes in the

correct position.

Page 48

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Figure 17. Regulator assembly position before and after tightening

3.3.8 ENTER REFERENCE GAS CYLINDER DATA

Before making measurements, it is necessary to enter the technical data for each reference gas cylinder assembly you have into GFS Tools software. This data can be found on the technical data sheet that is delivered with each cylinder. Some of the data will be unique to each cylinder so failing to enter the correct data can result in errors in the air buoyancy correction that is made.

In GFS Tools, use the [Setup][Reference Gas Cylinder] menu choice to access the Reference Cylinder Editor. Fill in the Header Information and Cylinder Characteristics. See Section 5.5.5 for details on the GFS Tools Reference Cylinder Editor. The Cylinder Characteristics can be found on the Cylinder Technical Data sheet provided for cylinder.

each

3.3.9 INSTALLATION OF REFERENCE MASS ON MASS PLATE

Locate the reference mass and the AMH reference mass plate (the AMH plate with NO bubble level on the top surface). The reference mass MUST be installed with the side etched with the nominal mass and mass serial number facing AWAY from the AMH reference mass plate so that these identifiers are plainly visible once installation is complete and the legs will maintain the proper distance between the reference mass and AMH plate. The mounting legs are indexed similar to the reference gas cylinder, two of the legs have a spherical curve at one end and one has a flat. The legs with the spherical curve need to be mounted so they correspond to the chamfer and groove brass inserts in the AMH plate. The leg with the flat end corresponds to the flat brass AMH plate insert.

Figure 18. Reference Mass Legs (Spherical (x 2) and Flat)

Invert the AMH plate painted side

down on a flat surface, taking care not to damage the painted surface. Padding or cloth of some kind would help keep the surface from damage.

Step 1

Page 49

3. INSTALLATION

Install the mass hanger legs by

lifting one side of the AMH plate, and starting with the farthest hole place the corresponding leg (spherical to chamfer, flat to flat) through the hole. Continue this with the other two legs.

Step 2

Place the reference mass down on

the legs with the nominal mass and serial number facing up. Make sure the mass sits completely down on the legs.

Step 3

Secure the reference mass to the legs with the screws provided. If a screw is ever lost or

misplaced, never simply replace the screw: the reference mass will have to be recalibrated including the original legs and screws and the replacement screw.

When installing or uninstalling the reference mass, always keep careful track of the screws and mounting legs as these are an integral part of the calibrated reference mass, not only for mounting but also part of the total mass value. When recalibrating, all of these pieces (mass, three legs, three screws) must be calibrated as one mass. If a screw is lost or misplaced the entire assembly needs to be recalibrated with the replacement screw.

When picked up and carefully turned back over the reference mass should hang freely

and evenly below the plate.

Page 50

GFS2102™ OPERATION AND MAINTENANCE MANUAL

3.3.10 INITIAL BALANCE AND AMH BASE SETUP

Install the balance positioning bracket

around the two adjustable front legs of the balance. Thread the balance legs fully counterclockwise and remove them so that the legs can be passed through the holes in the bracket and threaded back into the balance. The bracket should be positioned so that the front portion angles upward to where it will attach to the AMH base.

Place the GFS balance on the granite surface inside the draft enclosure.

Figure 19. Location of balance

positioning bracket mounting holes

Place the AMH-GFS2102 base over the balance so that the base surrounds the

balance.

Connect the balance positioning bracket to the front wall of the AMH base using the two

screws and lock washers provided. The AMH belts must be gently pushed aside to access the holes in the AMH base. If you are unable to thread in the screws with the balance in place, it is possible to first connect the bracket to the AMH base only, then install the balance legs through the holes in the bracket while the bracket is already installed on the AMH base. Both methods require some dexterity, and great care should be taken not to shock or drop the balance while doing this.

Install the PRT probe through the PRT hole in the back wall of the AMH base. A set

screw accessible from the bottom of the AMH may have to be backed out to allow the PRT to slide in. Insert the PRT so that the end of the PRT is even with the center of the balance tray post. Tighten the set screw only enough to hold the PRT in place.

Connect the 9 pin D-sub cable in the enclosure to the serial port in the rear of the

balance.

Connect the balance power cord.

1. Balance power connection 2. Serial port

Figure 20. GFS balance rear panel connections

Turn the balance and AMH base together so that the balance positioning bracket is in

Page 51

3. INSTALLATION

front and the balance electrical connections are in the rear.

Connect the AMH driver cable that is permanently mounted to the GFS sidewall column

to the connector on the right side of the AMH base.

Install the custom balance mass tray into the keyed slot on the balance post. Note that

the mass tray can be placed into the keyed slot in two ways. The correct position for the mass tray is such that two legs of the tray are left of the center of the balance (viewed from the front, brass insert with flat recess closest to operator, brass insert with chamfered recess farthest from operator) and one leg is to the right of center (groove in brass insert).

Figure 21. GFS balance inside AMH with mass tray installed.

Using a level placed directly across the top of the balance mass tray, adjust the balance

feet so that the mass tray sits level in each direction. If there is a level indication on the body of the balance, disregard that level in favor of the level placed directly on the mass tray. When leveling, make sure that the balance legs are not hung up on the balance positioning bracket and the balance sits freely on the granite surface. Ideally, the bracket will make little or no contact with the balance legs.

Using a level, do a rough adjustment of the three adjustable feet on the AMH base so

that the sides of the base sit level.

The rough location of the AMH position is 13.3 cm (5¼”) from the sidewall column or

18.2 cm (7¼”) from the right side of the enclosure, and 12.9 cm (5 1/16 in.) from the back wall of the enclosure. Final adjustments to the AMH and balance position will be performed later when the AMH plates are installed.

3.3.11 SETUP BALANCE LOCATION

Place the reference gas cylinder on the balance

mass tray so that the quick connector on the regulator assembly is on the right side. Visually confirm that the reference gas cylinder assembly sits vertically. If it does not, adjust the cylinder position in the cylinder support, or adjust the balance feet to level the balance mass tray.

Move the balance and AMH base so that the

distance between the quick connect fittings on the reference gas cylinder assembly and the draft

A. Loop alignment tool.

enclosure sidewall column allows the correct shape of the catenary gas conveyance loop. The distance is set by using the loop alignment tool,

Page 52

GFS2102™ OPERATION AND MAINTENANCE MANUAL

which slips over the Swage nuts on each stem of the loop and should have little clearance between the hex shoulders of the two quick connect stems when they are connected.

If you connect the loop to check this distance, be

sure to consider that gas will begin to flow from a pressurized cylinder if the cylinder side of the quick-connect is connected first. It is possible to check this distance without connecting the loop by resting the loop in the alignment tool upside down and making sure the outlside surface of the hex shoulders on each quick connect stem fit between the quick connect bodies with little clearance.

Measure the distance between the ceiling of the

draft enclosure and the quick connect fitting on the reference gas cylinder assembly. This distance should match the distance from the bulkhead quick connect fitting on the draft enclosure sidewall column to the ceiling. If it is not the same, adjust the height of the quick connect on the sidewall column so that the flow conveyance loop will sit level.

Measure the distance from the back wall of the

enclosure to both quick connectors. Reposition the balance if necessary to ensure that the flow path will be parallel to the back wall.

B. Quick check using loop

alignment tool.

C. Checking loop connector height.

Figure 22. Checking height and

level of gas conveyance loop

connections

using loop alignment tool

3.3.12 AMH POSITION FINE ADJUSTMENT

Proper position of the AMH-GFS2102 assembly relative to the GFS balance is critical to making accurate mass and flow measurements under flowing conditions. When the reference gas cylinder is placed on the balance mass tray, the legs of the cylinder support must pass through the AMH plates without contacting the plates, so that the cylinder mass can be measured with the required sensitivity. This step must be performed AFTER section

3.3.11. Until the operator is fully accustomed to the setup, the steps in this section may have to be repeated several times for proper alignment.

During setup, it is necessary to have access to “live” balance output and control of the

AMH platform movement, so communication should first be established between a PC running GFS Tools software, the LCM which controls the drivers for the AMH-GFS2102, and the GFS balance. See section 4.2.1. Continue setup with the AMH state set to have the cylinder lowered.

After the proper balance location has been established (see Section 3.3.11), install the

AMH top plate onto the AMH base. The AMH top plate has a bubble level on the top surface, but no reference mass hanging from it. The top plate should be oriented so that the narrow holes for the reference gas cylinder support are aligned with the balance mass tray; two holes on the left and one on the right. Lower the top plate over the two steel posts on the front and rear of the AMH base. A tight tolerance is used for the fit of the plates over the two posts so that the plates stay well-aligned while moving vertically. Therefore, special care and some practice is required to slide the plates over the posts without binding. Holding the plates at the area of the holes, ensuring that the plate is held level and rocking slightly allows the plates to slide down into place. A light coating of a clean lubricant like Krytox® can be used on the posts if needed. A small tube of Krytox® is included with each new GFS system. When the top plate is fully in place, the three rollers under the plate can be seen resting directly on the camshafts in the AMH base.

Page 53

3. INSTALLATION

Verify the level position of the AMH top plate in both directions using a level. Also verify

the indication of the built-in level on the top plate. Adjust the top plate resting position or the AMH adjustable feet to level the top plate. The bubble level is adjusted initially at DHI but may shift during shipment. Adjust the bubble level if needed to match the separate level indication so that the built-in level can be used for future leveling.

Place the reference gas cylinder onto

the balance, passing the cylinder support legs through the holes in the top plate.

Recheck the distance between the

reference gas cylinder and the draft enclosure wall using the loop alignment tool as described in Section 3.3.11.

Visually check the position of the

reference gas cylinder assembly on the balance in relation to the AMH top plate. Through the center hole in the top plate the feet of the cylinder support can be seen resting on the balance mass tray. The rear left foot should be centered in a conical hole in the mass

Figure 23. Reference Gas Cylinder resting on

balance. AMH top plate installed; reference mass plate

uninstalled.

tray. The foot on the right should slide into the bottom of the straight groove of the right support on the mass tray. The front left foot will simply rest on a flat support. All three legs of the cylinder support should pass through the top plate without contact and appear centered in the holes in the plate.

Leaving the balance in place, make

small movements in the AMHGFS2102 base postion in order to ensure clearance of the reference gas cylinder legs and engage the cylinder

Figure 24. View of cylinder support legs

through AMH top plate.

support feet as described above.

Using the GFS Tools software, set the AMH to the Zero position (See Section 4.2.2).

Adjust the three legs of the AMH evenly to raise or lower the AMH over the balance so that the legs of the cylinder assembly are very close to but not touching the balance mass tray

Exercise (cycle) the AMH platform (See Section 4.2.2). While the AMH is in motion the

reference gas cylinder should remain vertical with only very slight or no lateral motion. Also, the feet of the reference gas cylinder support should set down on each cycle into the center of the conical hole and straight groove supports on the balance tray without much lateral sliding into place. The flat support is purposfully a large target to account for

any other alignment issues. Use the AMH to set the reference gas cylinder to rest on the balance (See Section 4.2.2). Close the doors of the draft enclosure. Using GFS Tools software, view the GFS balance

output. (See Section 4.2.1) The mass of the reference gas cylinder should be displayed

and should stabilize to well within 1 mg (0.001 g). If the indicated mass appears

unstable, the reference gas

cylinder may be making contact with the AMH plate and

further adjustments are needed. Open the doors of the draft enclosure. Remove the reference gas cylinder from the

balance and AMH and place it aside. Remove the top plate of the AMH and place it

Page 54

GFS2102™ OPERATION AND MAINTENANCE MANUAL

aside. The AMH should still be set for the position of the reference gas cylinder resting

on the balance even though it is not installed, this helps with the installation of the bottom

plate. Install the bottom AMH plate with the reference mass attached. The bottom plate

should be oriented so that the pass through holes for the reference gas cylinder legs are

aligned with the balance mass tray; two holes on the left and one on the right, and the

legs of the reference mass are just the opposite, two on the right and one on the left.

Lower the bottom plate over the two steel posts on the front and rear of the AMH base. A

tight tolerance is used for the fit of the plates over the two posts so that the plates stay

well-aligned while moving vertically. As with the top plate, special care and some

practice is required to slide the plates over the posts without binding. Holding the plates

at the area of the holes, ensuring that the plate is held level and rocking slightly allows

the plates to slide down into place. A light coating of a clean lubricant like Krytox® can

be used on the posts if needed. Exercise the AMH platform again to ensure that the bottom plate is raising and lowering

evenly without binding. Set the AMH position to have the reference mass down. Install the AMH top plate. Install the reference gas cylinder. Close the doors of the draft

enclosure. Switch between the three states of the AMH: cylinder on the balance, reference mass on

the balance, and zero state (neither cylinder or reference mass on the balance). In any

of these states the balance output should be stable within 1mg (0.001g) and read a mass

value close to the nominal values for the reference mass or cylinder, or close to zero for

the zero state. If the cylinder value seems normal but the reference mass value is light or

unstable the AMH platform assembly may be too high and can be adjusted down by

small counterclockwise adjustments of the legs. If the zero state is reading a high mass

and or unstable value the AMH platform assembly may be too low and can be adjusted

up by small clockwise adjustments of the legs. Once the AMH height and alignment are correct, the legs can be locked in place with the

knurled brass lock nuts on the legs.

3.3.13 SETUP PROBE LOCATIONS

Use the telescoping probe positioning arms to hold the two TH probes and the IR temperature probe in the locations as shown in around reference gas cylinder.. It is important that the position of the three probes is consistent with the labeling and use in GFS Tools software because the measurements are used for different functions. The probe connected to the TH3 port on the LCM rear panel is used to determine the temperature of the air surrounding the reference gas cylinder for air buoyancy mass correction. The probe connected to the TH2 port is used to calculate the air buoyancy on the regulator assembly. The IR probe is used in part to calculate the pressure of the test gas inside the cylinder, to calculate the temperature expanded external volume in the cylinder, and to predict the possible onset of condensation due to cooling of the cylinder surface.

Figure 25. Temperature probe positions

Page 55

3. INSTALLATION

Figure 25. Temperature probe positions around reference gas cylinder.

1. TH Probe #2 2. TH Probe #3

3. IR Probe

Probe positions (not touching reference gas cylinder assembly):

• TH Probe #2 should be close to the bottom of the first stage pressure regulator.

• TH Probe #3 should be close to the side of the cylinder at mid cylinder height.

• IR Probe should be about 4 inches away from cylinder surface, pointed at the

cylinder surface at mid cylinder height.

3.3.14 PREPARE THE HEAT EXCHANGER

The heat exchanger will arrive without any liquid and will need to be prepared prior to its initial use. While water can be used alone, it is recommended to use a 50/50 mix of water and antifreeze due to the prolonged period of time that the liquid would be expected to remain in the exchanger.

Figure 26: Heat Exchanger, Low

Page 56

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Remove the fasteners holding the lid on the heat exchanger and pull the lid/coil out of the

exchanger (See Figure 27).

Figure 27: Heat Exchanger unassembled

If using straight water, distilled water is recommended. If using a water/antifreeze mix, prepare an

approximately 50/50% mixture of water to antifreeze.

full.

Fill the exchanger approximately 80%

Place the coil assembly in the liquid as far a possible while still being able to observe the liquid

level. If necessary add more liquid until the level is about ½” from the top of the exchanger.

If liquid spillage from the exchanger is a concern (i.e. frequent bumping or tipping) then

run a bead of caulk or gasket compound along the lip of the exchanger before placing the

lid completely on. Keep in mind this will complicate future liquid replacement.

A three point fastener system is used to secure the lid in place, and typically the lid will only go on in

one orientation that will allow alignment of all three holes in the lid with those in the can. Orient the

lid and place it on the can.

Install the screws through the holes and place the nuts on the screws. Tighten the screws

until snug.

The Heat Exchanger is now ready to use. When in use it should be between the outlet of the GFS and any downstream hardware such as a pressure regulator, MFC, or molbloc. To facilitate checking the fluid level, weigh the prepared Heat Exchanger and record the mass somewhere on the Exchanger (see Section 6.7).

3.3.15 CONNECT THE DUT FLOW PATH

molstic molbloc mounting systems are available to assist you in flow path setups on the GFS2102™ system. molstics provide an engineered solution to the practical issues of mounting the molbloc, connecting to the gas supply from the GFS, regulating the pressure and connecting the device to be tested. Highest quality components are integrated into a compact assembly to assure optimum molbloc/molbox performance.

Figure 28: Single, Low flow molstic

Page 57

3. INSTALLATION

molstics provide a quick means to connect to the gas supply output of the GFS. This is followed by a 2 micron (0.5 micron for low flow) filter to protect the downstream components. Then, an adjustable regulator sets and regulates optimum molbloc upstream pressure and protects the molbox transducers against accidental overpressure. The regulator range(s) supports all standard molbloc operating pressure ranges. A bellows shut-off valve, just before the molbloc, allows the gas supply to be shut-off for configuration changes and/or system leak checking. Special cradles support the molbloc(s). A connection and pads are provided downstream of the molbloc for mounting the MFC (mass flow controller), and/or another device under test.

There are low, mid and high flow versions of molstic. Only the single channel, low and midflow molstics are used with the GFS-2102 system. Low flow molstics use a unique, very high stability pressure regulator and minimize dead volumes. They are required for effective use of 2E2 and lower molblocs and can be used up to the 1E3 molbloc size. The mid flow molstics cover the ranges of all the molblocs from as low 2E2 up to the 3E4, and the low end ranges of molbloc-S.

If an appropriate molstic for the DUT is unavailable, then at a minimum an individual nonventing regulator and shutoff valve upstream of the DUT are required. If the DUT is a molbloc 1E3-L or below an LNI or equivalent regulator is recommended. If the DUT is larger than a 1E3-L then an appropriate standard non-venting regulator is recommended.

For an upstream molbloc, the recommended flow path is GFS, (heat exchanger when appropriate), regulator, shutoff valve, upstream molbloc, flow controller, and optionally a downstream molbloc.

For a downstream DUT, the recommended flow path is GFS, (heat exchanger when appropriate), regulator, shutoff valve, optional upstream molbloc, flow controller, and a downstream molbloc.

While the optional molblocs are not required, they help the flow controllers to operate more efficiently and can serve as a check standard. Both an upstream and downstream molbloc can be calibrated at the same time against the GFS.

3.3.16 CONNECT GAS CONVEYANCE LOOP

Connect the gas conveyance loop by connecting the quick-connect fittings at each end. If the flow path outside of the enclosure is prepared, then install the loop by first connecting the downstream side at the enclosure sidewall column quick-connector, then connecting the reference gas cylinder assembly quick-connector. Attempting to connect in the opposite order will cause gas to flow out of the cylinder into the enclosure until the downstream connection is made. Be careful not to disturb the position of the reference gas cylinder while making the connection. Use the loop alignment tool to align the connections and ensure the loop is parallel from end to end.

After connecting the gas conveyance loop, check again that a stable mass indication can be viewed in GFS Tools software before starting to flow. This indicates that the balance, cylinder and AMH are still in correct position.

Page 58

GFS2102™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

Page 59

4. OPERATION

44.

After the GFS2102 system has been setup, much of the operation of the system is done using the system controller running GFS Tools software. The features and operation of GFS Tools are described in detail in Section 5 of this manual. Section 4 is intended to provide a concise description of important GFS Tools selections and physical operations required for effective use of the GFS2102 system.

PPEERRAATTIIOON

4.1 GENERAL OPERATING PRINCIPLES

4.1.1 GFS2102 MEASUREMENT PRINCIPLE

GFS2102 is a gravimetric gas flow standard; that is, it measures the mass flow of a gas by measuring the change in the mass of gas contained in a reference gas cylinder over time as gas flows out of the cylinder. This simple principle makes it a truly fundamental primary mass flow standard. A benefit of the gravimetric principle is that the flow measurement is not strongly dependent on precise knowledge of the gas properties since mass and time are measured directly. Gas purity and knowledge of gas properties is typically important for the measurement made by any device being tested with GFS2102, but they do not contribute significantly to the uncertainty of the mass flow measured by GFS2102.

The uncertainty of mass flow measurements made with GFS2102 is dependent largely on its ability to measure the change in mass of the reference gas cylinder during the test. The measurement can be challenging because:

• The mass of gas flowed from the reference gas cylinder during one measurement is usually a small fraction of the total mass of the entire assembly on the balance, and thus the mass range of the balance. The high resolution of the balance is critical to allow GFS to perform at its best.

• The mass is changing throughout the measurement, which is not an ideal environment for mass balance operation.

• The reference gas cylinder must be connected to a fixed flow path to conduct the flow and so it cannot sit freely on the balance. Special effort has been made to minimize the potential impact this physical connection has on GFS mass measurements.

• Gravimetric flow measurements often require a very long time, up to hours or days, so considering the already extreme demand GFS has for resolution and precision on mass measurement relative to the balance range, drift in the balance indication over time easily becomes significant to GFS flow measurements and a special system must be used to eliminate its effects.

Time measurement is equally important to gravimetric flow measurements, but time is easier to measure with low uncertainty than is mass with the relatively low flow rates and long test times selected in the design of GFS2102. Recording of the precise time at which each mass measurement is made is a key aspect of mass and time measurement for GFS2102.

The design of GFS2102 effectively addresses the challenges above to deliver a gas flow measurement with very low uncertainty. Much of the expertise required from the user is to understand the factors that limit the range, convenience and performance of the system as different gases and flow rates are measured. Below are several general topics regarding use of the features of the GFS2102 system to optimize your results.

Page 60

GFS2102™ OPERATION AND MAINTENANCE MANUAL

4.1.2 GAS DEPENDENT MASS RANGES AND CYLINDER SIZE SELECTION

Table 11 shows the maximum mass for of each GFS2102 supported gas that will be available for flow testing after a reference gas cylinder fill. Typical supply cylinder fill pressures are listed in the table but actual fill pressures may vary from different gas suppliers and locations. If higher gas supply pressures are available to the user, then higher starting mass loads may be used, up to the limits imposed by the balance maximum mass range of

2.3 kg, and the maximum reference gas cylinder fill pressure and/or GFS-FS supply inlet

pressure of 20 MPa (3000 psi). For cylinder selection, the 1.1 liter cylinder with its 690 kPa (100 psi) regulated output is

optimal for all flow ranges with most gases except Helium, Hydrogen, or Sulfur Hexafluoride. The maximum nominal expected mass of an empty 1.1 liter cylinder is 1650 grams.

With the possible exception of Carbon Tetrafluoride, the 1.1 liter cylinder can not be overfilled at the typical supply cylinder fill pressures in Table 11.

The 1.5 liter cylinder with its 550 kPa (80 psi) regulated output is optimal for maximizing test mass and run time available with Helium, Hydrogen, lower regulated output pressure it is not ideal for the other gases in high flow or high pressure test conditions (i.e. 10 slm @ 525 kPa). This cylinder can also easily be overfilled with other gases if taken over the typical maximum fill pressures listed in Table 11 for the 1.5 liter cylinder. The maximum nominal expected mass of an empty 1.5 liter cylinder is 2100 grams.

or Sulfur

Hexafluoride, but due to the

The number of accumulations that can

be run from a typical cylinder fill varies depending on several factors, including flow regulation and dwell times, minimum gas pressures, the use and timing of Balance Zero and AutoZero

functions, flow stability, and other influences. These are not accounted for in the GFS Tools Test Editor “Minimum Required Test Mass”, this minimum being based only on the mass needed per accumulation, the number of accumulations per flow rate, and the number of flow rates. GFS Tools will warn of blatant overages where the actual Cylinder mass is less than the minimum required, but no more. It is recommended to plan on 25% of the total available mass to be used towards these unaccounted factors. For example; Nitrogen in the 1.1L cylinder could be up to 219 grams of gas mass, which would yield 164.25 grams of useable mass, or sixteen 10 gram accumulations.

Do not exceed the maximum reference gas cylinder fill pressure of 20 MPa (3000 psi).

Do not exceed the maximum gas mass of 650 grams for the 1.1 liter cylinder or 200 grams for the 1.5 liter cylinder. While exceeding these mass limits will not necessarily harm the precision balance, it will place the balance in an overload condition beyond its 2.3kg range and require gas mass to be bled off before a GFS accumulation can be successfully run.

Page 61

4. OPERATION

Table 11: Maximum mass available for flow testing for various GFS2102 supported gases.

GAS

SYMBOL

TYPICAL SUPPLY

CYLINDER FILL

PRESSURE

1.1 LITER CYLINDER

(MAXIMUM MASS 655g)

TYPICAL

MAXIMUM FILL

PRESSURE

TYPICAL

GAS

MASS

1.5 LITER CYLINDER

(MAXIMUM MASS 210g)

TYPICAL MAXIMUM

FILL PRESSURE

TYPICA

L GAS MASS

(psig) (MPa) (psig) (MPa) (g) (psig) (MPa) (g) Nitrogen N2 2640 18.2

Argon Ar 2640 18.2

Helium He 2640 18.2

Hydrogen H2 2640 18.2

Air Air 2640 18.2

Oxygen O2 2640 18.2

Carbon Dioxide CO2 830 5.7

Nitrous Oxide N2O 725 5.0 Carbon

Tetrafluoride

CF4 1595 11.0

Methane CH4 2400 16.6

2610 18

2320 16

2610 18

725 5

1560 10.8

2320 16

219

345

232

278

155

169

650

145

1680

1130

2610

2320

1610

1390

700

670

460

2320

11.6 199

7.8 200

18 41

16 18

11.1 200

9.6 199

4.85 200

4.65 199

3.2 198

16 197

Trifluoromethane CHF3 600 4.1 Sulfur

Hexafluoride

SF6 290 2.0

Hexafluoroethane C2F6 430 3.0

Ethylene C2H4 1600 11.0

Ethane C2H6 543 3.7

Carbon Monoxide CO 2000 13.8

Xenon Xe 800 5.5

580 4

290 2

435 3

725 5

435 3

1885 13

725 5

245

185

388

108

164

488

450

240

250

725

435

1670

3.1 197

1.69 199

1.75 196

5 147

3 81

11.5

300 2.1

199

194

Do not exceed the maximum reference gas cylinder fill pressure of 20 MPa (3000 psi).

Do not exceed the maximum gas mass of 650 grams for the 1.1 liter cylinder or 200 grams for the 1.5 liter cylinder. While exceeding these mass limits will not necessarily harm the GFS mass balance, it will place the balance in an overload condition beyond its 2.3kg range and require gas mass to be bled off before a GFS accumulation can be successfully run.

Page 62

GFS2102™ OPERATION AND MAINTENANCE MANUAL

4.1.3 AUTOZERO

In order for the GFS2102 mass measurements to be made with the precision and repeatability that is required for the system’s target flow uncertainties, the drift of the balance that occurs over time must be removed from the GFS mass measurements. The AMHGFS2102 platform allows a reference mass to be loaded on the balance at intervals throughout a flow measurement, without disturbing the gas flow, in order to check the balance for drift. The time interval at which this is done can be selected in GFS Tools.

Using AMH and the calibrated GFS reference mass, the balance zero and span can be calibrated at any time, and this function can be automatically programmed to occur before each flow measurement if desired. It is known that the primary type of drift that occurs in the balance over time is a “zero shift” and not a span error, so each time a new AutoZero is performed, subsequent mass readings use a corrected zero so that balance drift does not have a significant effect on the system’s ability to measure the critical mass change over long test times.

For low flows, which result in long test times, several AutoZero functions will occur during one measurement. For higher flows, often no AutoZero occurs. When a fixed time interval is selected for the AutoZero function to take place, the system will determine if and when it should be done during a test. (See Sections 5.5.2.7, 5.7.4).

4.1.4 GFS2102 DATA COLLECTION METHODS AND

CONVENTIONS

4.1.4.1 ACCUMULATIONS

During GFS2102 measurements, mass and time data is continuously collected from the time that the test is started until either the user or pre-set test limits end the measurement. Raw mass readings are taken from the balance and are corrected for drift by way of the AutoZero function and for air buoyancy. Since the gas is flowing out of the reference gas cylinder, the mass readings are successively smaller as the mass is depleted from the cylinder. Although the mass is in fact being depleted, we are actually interested in quantifying the amount of gas that is flowing through the GFS2102 hardware and the device under test, not the mass that is still contained in the cylinder, so the change in cylinder mass is reported by GFS Tools software as a positive value known as the accumulated mass. A single GFS flow measurement that is completed after a sufficient amount of mass and time change occurs is known as an accumulation.

In the scope of a typical multi-point flow device calibration, an accumulation would be the culmination of many samples into one final reading or data point at a given flow rate. It is possible to setup GFS Tools to take multiple accumulations at each flow point. For details on setting up GFS Tools tests, see Section 5.5.2.

4.1.4.2 SAMPLES

Throughout an accumulation, mass measurements are read from the balance at a rate of several readings per second. This is necessary to achieve good results at higher flows where the rate of mass change is relatively large. At low flows, the rate of mass change is so slow that short term noise, or perturbations, of mass output from the balance can cause more movement in mass values over a small time period than the actual flow does. If all of these mass measurements are translated into flow values, the effect would be a flow indication that is rapid and unstable looking. All of the high speed balance and time output is not used, less frequent updates of mass and time are selected for display and logging in

Page 63

4. OPERATION

the GFS Tools data files. These updates are known as samples. The rate of sampling is set by recording a sample at a fixed amount of mass change throughout the sampling period, so that only meaningful mass changes are used for flow calculation. Since a fixed amount of mass change is used to define the sampling interval, flow updates occur much faster at higher flows than at low flow rates. This is a logical characteristic of a system that is based on measurement

of changes in mass.

4.1.4.3 AVERAGES AND BEST FITS

Each reference flow rate that is displayed during and accumulation represents the system’s measurement of the average mass flow rate since the start of the accumulation. The total accumulated mass and total elapsed time is used to calculate mass flow. In an attempt to record new mass and time values as frequently as reliable values are available, some instability of the displayed mass flow and/or error of the device under test can be observed. This instability is partially due to actual instability in the flow that is controlled and partially due to limits in the system’s ability to read and synchronize mass, time and DUT output readings. This instability falls well within the limits of acceptable performance of the system, but it is clear that to achieve the best results that GFS2102 is capable of delivering, some averaging of the real-time mass flow indications should be done. When averaging is used, the resulting dynamic output is more stable and overall repeatability is improved between accumulations.

GFS Tools uses a rolling average mass value setup with a user-definable number of consecutive samples to be averaged. Although not recommended, if the user would like to use a real-time mass value instead, the rolling averaging time can be set to 1 sample (see Section 5.5.6.1).

Tools also uses a rolling average flow setup with a user-definable number

GFS of consecutive calculated flow instead, the rolling averaging time can be set to 1 sample (see Section 5.5.6.1).

A best fit of the mass vs. time curve is available for flow and flow error calculation in GFS Tools as well. This method uses a fit during an accumulation instead of just a rolling average of just a few, and appears to give the best repeatability possible, but the method is not as reliable when AutoZero updates occur during an accumulation because of discontinuity of mass measurements. The best fit flow may be a useful output for users when measuring high flow with short test times not requiring an AutoZero (see Section

5.1.5.6, 5.7.8).

samples to be averaged. If the user would like to use a real-time

of all of the calculated flow values

4.1.5 SETTINGS FOR FLOW SAMPLING

GFS2102 is a dynamic gravimetric flow standard, which means that changes in mass are measured and flow calculated “on the fly” as the gas is flowing. But the key benefit of the dynamic property of the system is not in the fact that real-time flow can be displayed. The ultimate goal of low-uncertainty flow measurement requires that a significant amount of mass and time are used in each accumulation, as with static gravimetric measurements. More important benefits of the dynamic system are that problems associated with starting and stopping the flow are eliminated since steady flow can be established before the measurement starts and the fact that the system can run multiple automated test points unattended. One could say that the only calculated flow rate or DUT flow error that is important for a GFS2102 accumulation is the one that is determined at the end of the accumulation when uncertainty is minimized. But it is instructive for the user to view the realtime changes in calculated flow or flow error as the accumulation progresses. It gives the user a guide as to how stable the calculated flow value is and when enough time and mass has accumulated to produce the very repeatable results.

Page 64

GFS2102™ OPERATION AND MAINTENANCE MANUAL

4.1.5.1 SETTING UP STARTING AND ENDING SAMPLE TOLERANCE

While the absolute value of the reference cylinder mass reading is not critical, the change in mass since the start of the accumulation is the key measurement. At any given time after the start of the accumulation, the accumulated mass divided by the elapsed time gives a value of the average mass flow for the accumulation up to that point. The mass flow would be the slope of a plot (or best fit line of the plot) of accumulated mass vs. elapsed time. At the beginning of the accumulation, relatively small variations in the mass or time readings will change the slope significantly. As more time and mass is accumulated, the slope becomes more consistent and any contributors to uncertainty in time or mass measurement become less significant. For this reason, calculated flow values are not usually displayed at the beginning of an accumulation. The initial calculated flow values are not meaningful and in the frequent cases where DUT flow errors are plotted throughout the accumulation, these large early error values cause scaling problems that do not allow easy viewing of the precise error values that result later in the accumulation.

To assist the user with determining useful limits on how much mass to deplete during an accumulation and when useful samples and flow calculations should begin during the accumulation, the GFS Tools test setup allows the user to select these starting and stopping points in terms of a predicted uncertainty of the flow value at that point. There is always an inherent trade off with gravimetric measurements between flow uncertainty and time taken for a measurement. This method helps the user get the results desired, maintain practical test times, and estimate how much mass must be used for each point.

The predicted uncertainty at which the user would like to end the accumulation is called the Ending Sample % Rdg Tolerance. When this value is entered in the Test Definition Editor, GFS Tools predicts the amount of mass that will be used for the accumulation and the amount of time needed for it and displays them. The user can also enter a fixed value of mass to use, and view a calculated Ending Sample % Rdg Tolerance. In the same Test Definition Editor tab, the user selects a Starting Sample % Rdg Tolerance, which defines the point at which the first flow sample is displayed and recorded. The time to reach this point is also displayed to help determine a reasonable selection. These entries in the Test Definition Editor are described in detail in Section 5.5.2.6.

4.2 MANUAL GFS TOOLS OPERATION

Using GFS Tools software, GFS2102 users can setup and run fully automated flow tests. However, since GFS Tools is the main user interface to GFS2102, frequently users will want to operate and read parts of the system without conducting a full flow test. Below, several functions are described that may be done manually using GFS Tools.

4.2.1 READING THE BALANCE

It is necessary to read the balance during setup of the GFS2102 system to ensure that it is communicating correctly and the positioning of the balance and AMH-GFS2102 allows stable mass indications. At any time, to quickly get a direct indication from the balance, first run a diagnostic test using [Run][Run Diagnostic Test]. During the diagnostic test initialization, most of the device setups and pre-test operations are automatically skipped to quickly take you to a point where the balance output and LCM conditions can be viewed. When the test is initialized, select the Balance Interface from the drop down menu option next to the [GFS] display toolbar button. Real time output of the balance is displayed.

Page 65

4. OPERATION

4.2.2 AMH OPERATION

For several reasons a user may want manual control of the AMH-GFS2102 platform movement to raise and lower the reference mass or reference gas cylinder. It is helpful to test the position and movement of the cylinder assembly and AMH during setup of the system. There are two ways to gain manual control of the AMH, one by using [Tools][Change GFS AMH State] within GFS Tools, or to start a diagnostic test as described above in Section 4.2.1. Select the icon for the GFS display. At the bottom GFS display window the four icons at the right allow access to all three AMH an option to continuously cycle the AMH through each position.

positions, and

of the

4.2.3 BALANCE ZERO AND SPAN ADJUSTMENT

Although the change in mass during an accumulation is more important than the absolute value of the mass, for a few reasons, it is desirable to zero the balance or to calibrate zero and span on the balance before the beginning of a test or accumulation. Zeroing the balance before starting allows easy viewing of the balance’s stability during an accumulation by viewing the size of the AutoZero correction each time an AutoZero is performed. Running a zero and span ensures that the slope of the balance output is as accurate as possible in the mass range where it will be relied on to measure a change in mass.

Icons are available in the GFS Tools, GFS display window that allow a user to quickly run a zero and span correction on the balance. The reference mass is used for the span and the states of zero or reference mass loaded are controlled by the AMH automatically so the process is easy and fast. (See Section 5.1.5.2.3) Users can also set up GFS Tools to automatically perform a balance zero and span function is reserved for occasional use and cannot be set to run automatically.

zero function

before each test or accumulation (see Sections 5.5.2.7, 5.2.2.1), but the

4.3 REFERENCE GAS CYLINDER FILLING

It will be necessary for the GFS2102 user to regularly refill the reference gas cylinders between tests. Filling of the cylinders is done using the GFS-FS reference gas cylinder fill station. The fill station is specifically designed for filling the reference gas cylinders at a slow rate so that heating of the cylinder is minimized. If the cylinder is filled to its working pressure quickly, the cylinder temperature may rise to 50 °C or more. The cylinders are designed and tested to withstand certain fast filling and levels of heating, but if the cylinder is heated to extremes the aluminum could separate from the carbon fiber/resin coating or such temperature instability will cause major GFS flow measurement problems unless the cylinder is completely cooled. It is better to fill the cylinder slowly and avoid excessive heating. Even after filling with GFS-FS, the cylinder may require more than one hour to completely cool. Frequent users of the system will find it efficient to have more than one cylinder of each size that they use so that one can be refilled and cooled while the other is in use. The following guidelines should be used for reference gas cylinder refills.

4.3.1 TRANSPORTING THE REFERENCE GAS CYLINDER ASSEMBLY

The reference gas cylinder assembly is used to contain very high pressure gas and should be handled with care, especially when it is filled. The risk of high pressure cylinders becoming projectiles when stems or valves are broken off is well documented. A molded plastic case is provided with each reference gas cylinder assembly for the purpose of storage and transport.

Page 66

GFS2102™ OPERATION AND MAINTENANCE MANUAL

The cylinder support, connector and regulator assembly can all remain attached to the cylinder while it is placed in the plastic case. The assembly can be carried to the location of the GFS fill station, filled and returned to the GFS2102 work area all inside the case.

Do not ship the reference gas cylinder while pressurized or with the regulator assembly

attached. See Section 6.4 for instructions on preparing a cylinder for shipment.

4.3.2 EVACUATING AND RINSING

When the test gas used in the reference gas cylinder will be changed from one test to the next, or when the cylinder has sat for a long time between tests and may be fully or partially filled with air, some action is needed to ensure that the cylinder is refilled with a pure gas for further testing. Do not rely on the quick connect fitting on the regulator assembly to provide a positive shutoff from gas leaving or entering the cylinder if the quick connector has no stem connected. Stems with plugs are provided with the GFS2102 system to allow a positive seal to the cylinder to be made when a filled cylinder sits disconnected from the flow system.

Evacuation

When switching gases, an effective way to produce a pure gas fill with the new gas is to first evacuate the cylinder using vacuum. If a vacuum pump is used for cylinder evacuation, it is important that either a dry pump is used, or precautions are taken to avoid any backflow of pump oil into the cylinder assembly. Under low vacuum conditions with little flow, molecular backflow of oil vapor from an oil lubricated pump to upstream components is common. It is not necessary to use a pump that generates a low ultimate vacuum, especially if some “rinsing” of the cylinder is done.

Rinsing

Whether using vacuum or not, a good way to ensure a pure gas fill is to also do some “rinsing” of the cylinder during filling. Rinsing refers to partially filling the cylinder with the new gas, then venting it until close to atmospheric pressure and refilling again. When starting from an evacuated cylinder, doing this one time up to 700 kPa (100 psi) or more and venting would be sufficient. When starting from atmospheric pressure with remains of the previous gas in the cylinder, a filling and draining two to three times to this pressure before filling would ensure sufficient purity.

4.3.3 CONNECTING TO GFS-FS

Figure 29.

1. 4T Swage supply connection 2. 2NPTF exhaust connection 3. DH500 connection to cylinder tube

GFS-FS reference gas cylinder fill station connections

Page 67

4. OPERATION

Figure 30. Reference gas cylinder connector

1. Fill valve 3. Regulator stem port

2. Fill port

Use the following steps to make connections from the reference gas cylinder to GFS-FS

• Be sure that the GFS-FS pressure regulator is fully backed out.

• Make sure that reference gas cylinder fill valve is closed.

• Connect ¼” Swage flex tube to gas pressure supply of no more than 20 MPa (3000 psi)

using Swage to NPTF adaptor or other connections as needed. Do not apply pressure from supply source at this point.

• Connect the other end of the ¼” Swage flex tube to the Supply port on GFS-FS

• Apply pressure from the supply to the GFS-FS. Pressure supplied to GFS-FS supply

port must be no more than 20 MPa (3000 psi).

• Remove the fill port plug from reference gas cylinder connector.

• Connect the DH200 fitting of the flex tube to the reference gas cylinder connector fill port

but do not tighten at this time to allow for purging the supply lines in Section 4.3.4.

•

Connect the DH500 fitting of the flex tube to the Reference Cylinder port on GFS-FS.

• An

exhaust connection is available to optionally vent to an exhaust tube in case of

overpressure or while backing the regulator off.

4.3.4 FILLING THE CYLINDER

• Check Table 11 in Section 4.1.2 to determine the desired reference gas cylinder fill

pressure for the test gas being used.

• Rest the reference gas cylinder assembly in its carrying case with the lid of the case

open during filling. This will provide a convenient place for the assembly to set and allows adequate ventilation of the cylinder during filling. The cylinder will rise in temperature temporarily as high pressure gas is added to it.

• To purge the lines with pure gas between the supply cylinder and Reference Cylinder,

turn the GFS-FS regulator clockwise until gas can be heard venting from the reference gas cylinder fill port DH200 connection that was left loose in Section 4.3.3. Allow a few moments (~5 seconds) for purging, then tighten the DH200 connection.

Page 68

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Always set the Adjusted Output prior to opening the fill valve. It is important to follow the next steps exactly in order. There are two concerns if the fill valve is opened before the Adjusted Output is set: 1) residual pressure in a cylinder being refilled will flow backwards from the cylinder and out the Fill Station exhaust port; or 2) an evacuated bottle has the potential to pull ambient air in before the pure fill gas is applied, which would contaminate the gas sample slightly.

• Turn the GFS-FS regulator clockwise to bring the indicated pressure on the Adjusted

Output gauge to the desired reference gas cylinder fill pressure. As there is little volume in the fill station and no flow yet, the Reference Cylinder gauge will fairly quickly match the Adjusted Output gauge.

• Open the fill valve of the reference gas cylinder fill connector. To open the valve, it is not

necessary to turn the valve any more than ½ turn counter-clockwise. If the valve is fully backed out while the cylinder is filling or is under pressure, the valve could dislodge from the cylinder connector dangerously. As a safety feature, the valve is designed to start venting through a side hole approximately two full turns prior to dislodging as an audible warning that an unsafe condition is occurring.

To open the valve, it is not necessary to turn the valve any more than ½ turn. If the valve is fully backed out counter-clockwise while the cylinder is under pressure, the valve could dislodge from the cylinder connector dangerously. The valve is designed to start leaking through a side vent hole two turns before release as an audible warning that an unsafe condition is occurring.

• Once the fill valve is opened, the indicated pressure on the Reference Cylinder gauge will

rapidly drop to the actual pressure in the cylinder, and then will slowly approach the Adjusted Output pressure over the course of several minutes. If the fill station is in a location where it is safe from disturbance by untrained persons, it can be left unattended while filling. During filling and discharging, some movement of the reference gas cylinder’s composite overwrapping may occur and this may generate some noise, often described as snapping or popping. This is normal.

• When the cylinder has reached the desired fill pressure, close the reference gas cylinder

fill valve.

• Turn the GFS-FS regulator counter-clockwise to reduce the Reference Gas Cylinder

adjust pressure to zero. Any remaining pressure in the connections to the reference gas cylinder will be vented.

• Disconnect the DH200 fitting from the reference gas cylinder fill port, reinsert the fill plug

into the fill port, and tighten the fill plug.

• To transport the reference gas cylinder assembly back to the GFS2102 work area,

securely close and latch its case and transport it inside the case.

• The reference gas cylinder temperature will be elevated after filling. It should be left

open to the surrounding air to cool off for at least one hour before use. Best results will be obtained only when the cylinder has reached room temperature before starting an accumulation. A test can be started immediately if the Pre-Test Time Delay feature is used to delay the automated test from running until the cylinder has had a chance to cool (See Section 5.5.2.4).

Page 69

4. OPERATION

The design life of the GFS reference gas cylinders is 15 years from the date of manufacture. After 15 years the cylinders should be discarded and replaced. Hydrostatic testing should also be performed on the cylinders every 5 years to ensure safe operation.

4.4 CONSIDERATIONS FOR MAKING RELIABLE MEASUREMENTS

4.4.1 COOLING AND CONDENSATION AT HIGH FLOW

At flows above 2 slm, the fast discharge of gas pressure from the reference gas cylinder causes a fairly rapid drop in the temperature of the cylinder and regulator assembly. This cooling in itself does not create a large measurement problem for the GFS2102 system since the air temperature surrounding the cylinder is measured to account for changes in air buoyancy. This correction is a small contributor to uncertainty of GFS2102 flow measurements. Also the design of the balance and AMH platform and the granite tabletop keep the balance at a relatively constant temperature even under high flow conditions.

But a very significant problem can result if the temperature of any surface of the reference gas cylinder assembly drops below the local dew point, causing water to condense on the assembly. The added mass of the condensation makes reliable mass measurements impossible. As a solution, an infrared (IR) probe is positioned to read the surface temperature of the reference gas cylinder and used to predict when condensation is a risk (See Section 3.3.13, 5.1.5.5). When the IR probe is detecting a temperature within 3°C of the dew point, a “D” is displayed in the circular Ready/Not Ready indicator in the GFS Run Screen (See data file.

A secondary consideration occurs for gases that have a higher tendency to cool such as CO2 or N2O. For these gases the first stage of the dual regulators attached to the cylinder assembly will cool far faster than the cylinder itself. The surface area of this regulator is far less than that of the cylinder, but if the temperature drops below the local dew point condensation can occur at this localized point and it will make the mass measurements less reliable. Since the IR probe is adjusted for the infrared emissivity of the cylinder, it cannot be used to read the temperature of the first regulator.

To assist the system in overcoming these issues while maintaining automation, a “Pause Flow” function is available in the options of a test setup. This function allows the test to complete an accumulation and then pause for a user set predetermined amount of time, usually 30 – 60 minutes, before proceeding with the next accumulation, thus allowing the cylinder and regulator to warm back up and lower the risk of condensation (See Section

5.5.2.8).

Table 15 in Section 5.1.5.2.1) and is also logged to the Status column in the

Main

4.4.2 STABILITY OF AMBIENT CONDITIONS

The automated nature of the GFS2102 system allows users to select the time to run test that is best suited to making the best measurements. Two common examples of changing conditions that can be avoided are a warm cylinder that has been recently filled and needs to cool, or a laboratory area which experiences significant changes in temperature and humidity throughout the day. Often when lab personnel leave the workplace, the laboratory experiences a reduction in both temperature and humidity over the course of a few hours. Outdoor conditions may also contribute to laboratory changes. Using a test start time delay feature in GFS Tools software, the user can program a test to begin at a time when environmental transients are minimized so that the GFS system, DUT and flow controller all have the best chance to perform at their highest level. The possibility of unattended

Page 70

GFS2102™ OPERATION AND MAINTENANCE MANUAL

operation and programmed start times allows a user to complete a test overnight using a cylinder freshly filled at the end of the workday, when the user would otherwise have to wait until the next day. (See Section 5.5.2.4)

4.4.3 COMPARING REFERENCE AND DUT MEASUREMENTS

USING FLOW VS. MASS CALCULATIONS

The GFS2102 system makes a direct measurement of the mass that flows from the reference gas cylinder during operation. At the end of an accumulation, an accurate measure of the total accumulated mass, or the average mass flow over the total elapsed time, is available. GFS Tools software reads and records the flow output from the device under test during an accumulation and calculates both the average DUT flow and the total mass measured by the DUT by integrating all of the mass flow values from the DUT. Our assumption is that the output of the DUT is a mass flow measurement, not a totalized mass. So the user has an opportunity to compare the reference and DUT measurements in either total mass or mass flow terms. A pure view of the gravimetric nature of the GFS2102 system may lead one to suspect that using total mass eliminates some time-related uncertainty from the GFS measurement and is a more correct choice. But when the logging of measurements from both the reference and DUT are considered, it is apparent that using the average mass flow is likely to produce the best result.

Although every effort is made to integrate the DUT flow over a time period that matches the time used for the GFS measurement, the update rate of the readings from the DUT will force some interpolation between DUT values in order to match the DUT timing to that of the GFS. Also, any delay or error in timing the start and stop times of the GFS and DUT will result in some finite error that can be significant. The case is worst at higher flows. When the average DUT flow is used instead, a very good measure of the average DUT flow over a time period that is very close to that of the GFS measurement can be obtained. The time measurement-related errors that affect the GFS average flow measurement are handled within the GFS system to produce very good results when flow output is used for comparisons.

4.4.4 LEAKS

Leaks are of great concern when using the GFS2102. Any loss of gas mass between the Reference Gas Cylinder and the DUT(s) will impinge upon the accuracy of the measurements. It is recommended to test the flow path for leaks often, particularly with every hardware setup change, i.e. every time a different molbloc, MFC, molstic, Reference Gas Cylinder or catenary tube is used, or a heat exchanger is installed in the flow path.

This section describes three methods to check for leaks: an automated leak check in a test definition; a semi-automated leak check of the flow path up to the isolation valve; and a semiautomated leak check to a external manual isolation valve placed in the flow path by the user. Regardless of the method used, the user must establish what the maximum “acceptable” leak rate can be for the gas and flow rate to be tested. When the uncertainty of the GFS accumulation is analyzed, if a leak was detected and could not be eliminated, the error contributed by the leak should be treated as an asymmetrical distribution because a leak would always be in one direction: gas can leak out of the system, but it cannot leak in.

To establish the significance of a leak, or what amount of leak would be acceptable during a test, the user must consider the gas being tested, the minimum flow point of the gas during the test, the uncertainty target being sought, and the amount of time to get a valid leak test result. Using a 1E2-L molbloc as an example being tested in Nitrogen, a typical minimum flow of 10% of full scale is 10 sccm (2.084E-1 mg/s), and if the user is seeking less than

0.02% effect from a potential leak then a leak rate under 0.002 sccm (4.168E-5 mg/s) would be acceptable. In order to ensure a valid leak test result, the leak test should run a minimum of 10% of the accumulation time of the lowest flow point: if the accumulation takes 26 hours the leak test should run for AT LEAST 2.6 hours, if the accumulation takes 10 hours the leak test should run for AT LEAST 1 hour.

Page 71

4. OPERATION

4.4.4.1 LEAK TEST OPTION IN A TEST DEFINITION

This leak test option checks for leaks in the Reference Gas Cylinder, though the catenary tube, and up to the isolation valve in the GFS enclosure sidewall column.

Once an acceptable limit in flow has been established as described above with a minimum time for a valid result, these values can be entered on the Pre-Test tab of a Test Definition as detailed in Section 5.5.2.4. The leak test will occur based upon the options selected as defined in that section.

4.4.4.2 SEMI-AUTOMATED LEAK TEST

This operation is similar to 4.4.4.1 in that it checks for leaks in the Reference Gas Cylinder, though the catenary tube, and up to the isolation valve in the GFS enclosure sidewall column, but it is run outside of a test definition in manual mode.

The user must still establish an acceptable leak limit and minimum time, but these values could be determined at any time up to the point where the user is ready to end the test.

The semi-automated leak test is performed as follows:

A manual test is run as outlined in Section 5.6.2, steps 1 to 6. If the user

wishes to record the leak test data then a data file is opened as in Section

5.6.2, step 7.

In order to keep the isolation valve closed, a flow point should NOT be set as

in Section 5.6.2, step 8.

An accumulation is started per Section 5.6.2, step 9, but in the accumulation

setup window a large starting tolerance (~5%) that results in a short starting time, a flow value, and a mass to deplete greater than 1 gram are all entered. The flow and mass values actually entered are irrelevant as the system will ideally be neither flowing nor depleting mass, but the setup will not continue with zero or null values. The “OK” button is selected to continue.

The test is allowed to continue for the minimum time established to get an

accurate result. If the data is being recorded to a data file, the “Take Point” options as in Section 5.6.2, Step 10 need to be defined.

Once the minimum time has elapsed, the user must judge the significance of the “Depleted Mass/Time” calculated flow value reported in mg/s on the GFS Diagnostics run screen (see Section 5.1.5.3) against the minimum test flow in mg/s.

The leak test can be aborted at any time by using the “Stop” icon.

4.4.4.3 SEMI-AUTOMATED LEAK TEST TO MANUAL ISOLATION POINT

This leak test is nearly identical to Section 4.4.4.2 except a flow point will be requested, which will open the isolation valve and pressurize the flow path to the point where the user has chosen to install a manual isolation valve. Other than the regulators on the Reference Gas Cylinder, the flow path for the leak test should not include a regulator or the regulator needs to be bypassed as it has the potential to continue to bleed pressure through and cause a false leak indication.

If an MFC is in the flow path included in the leak check then the user must ensure that the setpoint is high enough to fully open the MFC valve and allow the pressure to equalize across the MFC or a leak could be falsely indicated. An

Page 72

GFS2102™ OPERATION AND MAINTENANCE MANUAL

MFC should never be used as the isolation valve as MFC’s are not designed as shutoff devices.

Since this type of leak test can result in the full output pressure of the Referece Gas Cylinder reaching the molbox(s), the molbox pressure tubes should be disconnected from the molbloc(s) in the flow path to prevent overpressure and damage to the molbox pressure transducers. The molboxes should be leak tested separately per the molbox1 Operation and Maintenance Manual.

The semi-automated leak test is performed as follows:

A manual isolation valve is installed in the flow path and is closed. A manual test is run as outlined in Section 5.6.2, steps 1 to 8. Step 7 can be

bypassed if the user does not wish to record the leak test data to a data file. When setting a flow point as in Step 8, a value close to the maximum of the MFC should be chosen.

An accumulation is started per Section 5.6.2, step 9, but in the accumulation

setup window a large starting tolerance (~5%) that results in a short starting time and a mass to deplete greater than 1 gram are entered. The flow value will be automatically transferred from the set point, and the mass value actually entered is irrelevant as the system will ideally be neither flowing nor depleting mass, but the setup will not continue with zero or null values. The “OK” button is selected to continue.

The test is allowed to continue for the minimum time established to get an

accurate result. If the data is being recorded to a data file, the “Take Point” options as in Section 5.6.2, Step 10 need to be defined.

The leak test can be aborted at any time by using the “Stop” icon.

4.4.5 FLOW CONTROL AND STABILITY

Poor flow control and flow stability can impact the integration of DUT mass, leading to inaccurate results.

The GFS2102 is delivered with 4 mass flow controllers (MFC’s) calibrated for Nitrogen use. The MFC’s are typically designed to be able to work in the gas they are calibrated for down to 5% of full scale, but for the GFS2102 it is recommended to switch to a lower range MFC if operating below 10% of full scale for improved flow control and stability.

The k-factor adjusted N2 range of the MFC should be kept in mind when using the GFS2102 with a gas other than N2. For example: an AERA MFC with a 10-100% flow range of 1001000 sccm when used with Sulfur Hexafluoride (SF6, k-factor of 0.263) would have a working equivalent flow range of 26.3-263 sccm. K-factors can be found and if necessary altered under [TOOLS][PROCESS GAS EDITOR] for the manufacturer of the MFC.

Page 73

5. GFS TOOLS SOFTWARE

55.

GGFFS

OOOOLLSS

OOFFTTWWAARRE

5.1 MAIN DISPLAY AND FEATURES

5.1.1 OVERVIEW

The GFS Tools main screen contains the interface between the program setup and all of the data acquisition run screens. When the program is first started, the main screen displays without any child windows. Only after a menu option is selected does the screen update to display the corresponding window. The following features are available on the main screen:

Main menu bar To access all GFS Tools menus and functions. Status bar At the bottom of the screen that contains information on the status of

test execution.

Run mode display To indicate the current GFS Tools run mode. Main toolbar Provides quick access to runtime program displays and functions. Several individual run screens Are available when running to provide real time data

acquisition information.

5.1.2 MAIN MENU BAR

The main menu bar is divided into six separate selections. Each menu item is summarized below and covered in detail in various sections of this manual.

5.1.2.1 [RUN]

[Run Test] Initialize and run a Test Definition. Test Definitions are

pre-defined test scripts. See Section 5.6.1 for detailed information on using this mode.

[Run M

[Run Diagnostic Test] Display a real time output of the

anual Test] Initialize and run a manual test. Manual tests provide

monitoring and control features without a pre-defined test script. Manual tests also support data acquisition. See Section 5.6.2 for detailed information on using this mode.

LCM sensor and the balance. Options are provided to allow the user to change the state of the AMH. Diagnostic tests are provided to allow a test operator quickly monitor and manipulate the GFS system without a complete initialization. GFS flow data cannot be acquired in this mode of operation. See Section 5.6.3 for additional information on this mode.

outputs

xit] Close GFS Tools.

Page 74

GFS2102™ OPERATION AND MAINTENANCE MANUAL

5.1.2.2 [SETUP]

All of the necessary program setup features are contained in this menu choice. The ability to create Test Definitions and DUT Definitions, and options to configure and change the calibration of the GFS are possible choices in the

[Setup] menu.

est] Create, edit, view and delete Test Definitions using the Test Editor.

UT] Create, edit, view and delete DUT Definitions using the DUT Device

[D Editor.

upport Device] Create, edit, view and delete non-DUT devices using the

Support Device Editor. Typically flow controllers and instruments used define the controller setup point are defined by this option.

eference Gas Cylinder] Create, edit, view and delete Reference Gas Cylinder

Definitions using the Reference Gas Cylinder Editor.

onfiguration] View and edit options effecting core GFS functionality. This

includes communication, timing, sampling and tolerance criteria. [Calibration] View and edit the calibration of the LCM sensors, reference mass,

balance and PC clock.

5.1.2.3 [TOOLS]

[Options] Select options to customize GFS Tools behavior (see 5.2.2).

nit of Measure Converter] Run the Unit of Measure Converter. This tool not

only acts as a convenient unit converter, it also provides the ability to create custom flow units. On-line help is available in the Unit of Measure Converter by accessing the [Help] menu within the tool. (see 5.2.3).

emote Communications] Send and receive remote commands manually

using the Direct Remote Communication tool (see 5.2.4).

rocess Gas Editor] Open the Process Gas Editor to define manufacturer

[P specific gas relationship information. On-line help is available in the Process Gas Editor by accessing the [Help] menu within the tool (see 5.2.5).

hange GFS AMH State] Manipulate the GFS AMH or the isolation valve without

running a test (see 5.2.6). [PC Time Calibration] Run an automatic comparison of the internal PC clock

with the LCM clock (see 5.2.7).

5.1.2.4 [DATA]

[View Data File] View a GFS Tools Data File using the Data File Viewer (see

5.3.2). The ASCII text file and a data grid is used to display the information in the Data File.

lot Data File] Plots information from GFS Tools Data Files using the Plot

Tool. The Plot Tool provides features to create custom 2D and 3D plots (see

5.3.3).

eport Editor] Run the COMPASS Report Editor to generate a report from a

Test Data File (see 5.3.4).

Page 75

5. GFS TOOLS SOFTWARE

5.1.2.5 [WINDOW]

Options to select, tile or cascade active GFS Tools run screens are provided by this menu choice, or an active window that is hidden can be brought to the front by selecting it from the list at the bottom. Use the Main Toolbar, display icons to display run screens that are not already active.

5.1.2.6 [HELP]

Access on-line help and the <About GFS Tools > dialog for version information.

5.1.3 STATUS BAR

The Status Bar is located at the bottom of the main screen. In all run modes, GFS Tools flashes information related to the current status of test execution on this display. While running tests, two panels and a progress indicator also display with status information on the current test step and point. The red panel on the left displays the current major test step: setting target flow, AutoZero, etc. The blue panel indicates the minor test step: stability test, dwell, taking point, etc.

Figure 31. <Status Bar>

Clicking either of the inset panels of the status bar or using the [Back] or [Next] toolbar options displays the Test Status form. This form lists the current test status when running a Test Definition, including the current point in a test relative to the maximum number of points as well as the status of the leak test if included in the test.

Figure 32. Test Status

The progress indicator is a visual indication of the relationship between the current test point and the number of points in a test. The indicator is a progress bar located across the bottom of the run screen just above the status bar. The left side of the progress bar represents 0 progress and the right side represents 100 %. Each test point increments the progress indicator. When [Skip Back] and [Skip Forward] buttons are used, the progress indicator also reflects the current position.

Figure 33. Progress Indicator

Page 76

GFS2102™ OPERATION AND MAINTENANCE MANUAL

5.1.4 MAIN TOOLBAR

The Main Toolbar in GFS Tools is used as a shortcut to many menu options and is used to control test execution. The options that are visible and enabled on the toolbar vary with the active run mode. There are four distinct sections of the toolbar. Each of these sections is described in the following tables.

Figure 34. Main Toolbar - Display while idle

5.1.4.1 RUN TEST TOOLS

The Run Test Tools section of the Main Toolbar, controls test execution. The icon selections allow tests to begin, end, pause and rapidly move through test steps. Table 12 lists the run tool icons.

Table 12. Main Toolbar, Run Test Tools

ICON DESCRIPTION

Run Test

Step Back

Step Forward

Pause

Abort

This feature is a shortcut to the Main Toolbar [R selected for the first time it will initiate the [Run Test] mode. If selected after another type of test has been run it will run that same test again. When GFS Tools is running a test, this option is disabled.

Causes the current test point to be interrupted and the test point sequence to step back to the most recent target output step. Subsequent clicks cause the test to step back one point for each click. This feature is used to repeat points when needed in [R do not have a defined point sequence to skip through.

Step Back does not step back through pre-test operations such as the leak test or pre test delay.

Causes the current test point to be interrupted and the test point sequence to step forward to the next step in a point sequence. This feature only moves forward up to the take data step of the highest point executed. The limitation is to ensure that data is logged at each point and points are not skipped entirely. Most often this feature is used to skip through the test dwell step or to move on to the next accumulation or flow point before the active accumulation is complete.

Suspends test execution and remote communications with all devices being used by GFS Tools. Use this feature to allow front panel access to a device while running a test. Click [Pause] again to resume operation.

Causes the <Abort Test> confirmation pop-up to appear to abort the test that is running.

un] menu choice. When

un Test] mode. Not functional with Manual tests as they

5.1.4.2 RUN DISPLAY TOOLS

Run Display Tools provide toolbar features that relate to GFS Tools run screens. Each of the toolbar icons forces the corresponding run screen to the top of the display. Run display tools are available based on the current run mode and the data acquisition state of an active test.

Page 77

5. GFS TOOLS SOFTWARE

Table 13. Main Toolbar, Run Display Tools

ICON DESCRIPTION

View Test

Causes the Test Definition Editor to display in the main screen with the information corresponding to the active Test Definition (see 5.5.2). This allows complete information on the current test procedure to without interrupting the test. This feature is available only in [R mode.

be reviewed

un Test]

Do not confuse this option with the [Open Test Editor] toolbar shortcut. It is not possible to edit a Test Definition while a test is running.

GFS

Run Screen

Press the button to display the GFS Run Screen. Use the drop down menu choice next to the button to display the GFS

Diagnostics, Ambient Conditions or the Balance Interface run screens.

Device Run

Screen Display

Generates a popup menu to allow the selection of the desired Device Run Screen to display (see 5.1.5.7). The selected Device Run Screen automatically displays the [Tools], [Options], [Run Test] tab, the displayed Run Screen may or may not allow direct control of the device (see 5.2.2.1).

There are several different run screens. Each DHI product has it’s own run screen

to support it’s unique features. All other non-DHI devices use a common run screen that lists the device’s raw output and corresponding final output.

in the main window. Depending on the selections of

Click outputs on the various run screens to get a list of options that apply to the output. Display unit of measure and resolution can be changed for most outputs.

DUT/Reference

Comparison

Data Grid

Display the DUT/Reference Comparison Run Screen. This display provides convenient, real time, error information calculated for each DUT compared to the active reference (see 5.1.5.2).

Display the Data Grid with the data logged for the current test. The drop down arrow next to the image allows the selection of data from other DUTs to display when a test is executed with more than one DUT.

The information displayed in the grid can be modified by using [Tools], [Options], [Data Grid] (see 5.2.2.5). Changes made during a test will not reflect in the current test.

Data Plot

Display the Plot Tool loaded with data from the current test. No new Data Files can be loaded in the Plot Tool while a test is running. Data from all active Data Files or any one Data File is plotable while running a test. Use the toolbar on the Plot Tool to generate the desired plot (see 5.3.3).

5.1.4.3 DATA ACQUISITION TOOLS

In [Run Manual Test] run mode, data can be acquired based on the selection of data acquisition tools that will appear on the Main Toolbar in this mode. The first requirement is to open a Data File by using the [Create Data File] function. After the file is selected, the remainder of the data acquisition options are enabled. To log a data point, simply choose the appropriate toolbar button. Points can be taken individually, averaged individually and averaged automatically. When the run mode is ended or a new Data File is created, the [Options], [End Test] and

Page 78

GFS2102™ OPERATION AND MAINTENANCE MANUAL

[Options], [Data File] selections are activated (see 5.2.2.3 and 5.2.2.4). This

allows test notes to be entered and empty test files to be deleted.

When a Data File is created in [Run Manual Test] mode, data points can be taken without the constraints of a specific test sequence, however, the resulting Data File is identical to files generated with the [Run Test] option. Therefore, reports and plots can be created from the Data File.

Using any of the automatic data logging options can result in very large Data Files. These are files with significantly greater than 1000 data points per flow accumulation. GFS Tools was not intended to manipulate such files. Lower performance PC’s will experience significant delays in generating reports and plots of large Data Files. Therefore, use of the plotting and reporting functions with very large Data Files is not recommended. Instead, export the Data File to a spreadsheet application for further analysis.

The table below describes each of the data acquisition toolbar options in detail.

Table 14. <Control> Toolbar, Data Acquisition Options

ICON DESCRIPTION

Create Data File

Log a single data

point

Average and take

1 point

Press this button to create a new Data File. A standard windows filebox allows the selection of the Data File name and location. The choices in [Options], [Data File] determine the default file naming convention and file location. It also specifies whether or not to automatically name the file and avoid the filebox prompt.

A separate Data File is created for every active DUT. If there are no DUTs, only one Data File is created and no DUT information is logged.

Logs the instantaneous output of all devices to the Data File. This is identical in function to using a 0 averaging time in a test. All non-automated devices must have their outputs entered in the <Manual Data Entry > window.

Average all devices according to the active averaging method. This is identical to averaging data during a test. Both automatic and manual averages can be used to average the data. The drop down arrow displays a menu that lists the automatic and manual averaging options. The option with an “*” preceding it is the active averaging mode.

To change the automatic averaging time select it in the menu and enter the desired averaging time in the input box that follows. Data can be automatically averaged from 1 to 9999s.

Figure 35. Manual Averaging Options

Page 79

5. GFS TOOLS SOFTWARE

ICON DESCRIPTION

Log 1 point at

fixed intervals

Logs an instantaneous data point at fixed time intervals. When the icon is pressed, an input box displays to allow entry of the time interval. GFS Toolsl automatically logs a data point when the option is pressed and repeatedly logs data points at the specified time interval until the [Abort Data Acquisition] button is pressed or the test is aborted. Taking data in this manner is the best way to monitor the evolution of error over a flow accumulation.

The output of all manual entry devices must be entered for every data point logged. This minimizes the automation provided by this function.

Taking data at short time intervals can quickly result in a very large Data File.

Average and log

points at fixed

intervals

Averages all device outputs and logs the results at fixed time intervals. When the icon is pressed the <Average Setup> window displays to allow entry of the averaging time and the interval between averages. After the entry, GFS Tools automatically begins averaging data. When the average is complete, the results are logged and the countdown to the next average begins. When the time specified as the <Timed Point Interval(s)> has been reached, another averaging cycle begins. This process is repeated until the [Abort Data Acquisition] button is pressed or the run mode is closed. Taking data in this way can be convenient when trying to mimic a test that includes multiple readings per point.

a very large Data File.

data acquisition.

Abort data

acquisition

Press this icon to abort data acquisition at fixed intervals or a point currently being averaged.

Changing the state of the system while a point is in progress may lead to faulty data logged in the Data File.

5.1.5 RUN SCREENS

Taking data at short time intervals or averages can quickly result in

Press the [Abort Data Acquisition] option to abort fixed interval

Figure 36. <Average Setup>

Never use other Toolbar features when this icon is enabled.

5.1.5.1 OVERVIEW

GFS Tools uses several different run screen types to display output information

while in a run mode. Use the Run Display choices on the Main Toolbar to display a specific run screen. Click and drag the border of a run screen to adjust its size. Closing, minimizing or maximizing any of the run screens has no affect on the run mode. A test continues to run even if all run screens are closed. The

ndow] menu includes cascade and tile options for common default displays.

[Wi

The combination of these features makes the user interface totally customizable.

Page 80

GFS2102™ OPERATION AND MAINTENANCE MANUAL

By default, each run window is displayed in the last used size and position. To preserve the display or run screens, simply end a test by pressing [Abort]. Do not close run screens before ending a test.

Change the unit of measure, display resolution or view a strip chart by rightclicking any displayed output and selecting the desired function. Right-click any output and select the [Strip Chart] option to create a strip chart using the selected output.

Some run screens have toolbars and allow manual input of output information. Others are simple displays of device raw and final outputs. Most numeric outputs support unit and resolution changing as well as strip charting. Access these features by clicking any of the numeric displays.

5.1.5.2 GFS RUN SCREEN

The GFS Tools GFS Run Screen is the equivalent of an instrument front panel. The GFS Run Screen is the main interface and front panel of the GFS system. Through this interface system functions are controlled and readings are observed. The display and toolbar contain all functions necessary to determine the state of the GFS and change the flow or AMH state.

The GFS Run Screen is opened by pressing the [GFS] button on the GFS Tools Main Toolbar. The screen can be resized and repositioned as desired.

The run screen has three main sections:

1. Control Panel: The Control Panel is for reading and controlling the GFS

system.

2. System Display: The System Display is an animated operational schematic of

the GFS system to provide real time information on system status.

3. GFS Control Toolbar: The GFS Control Toolbar buttons are for controlling

GFS specific functions.

Figure 37. GFS Run Screen

The features on the GFS Run Screen are summarized in the tables below.

Page 81

5. GFS TOOLS SOFTWARE

5.1.5.2.1 GFS Control Panel

The GFS Control Panel is the main information interface to the GFS system. The display contains all the most basic information to determine the state of the GFS and change the flow. Included are specific instrument outputs, flows, time, and accumulated mass. The information and fields are summarized in the table below.

Figure 38: GFS Control Panel section of GFS Run Screen

Table 15. GFS Control Panel Fields

FEATURE DESCRIPTION

Ready/Not Ready

Circular

Indicator

Calibration Gas

Use this indicator as a quick reference to determine the uncertainty on the GFS flow. The indicator will be one of 3 colors and may include text in the display . The color codes are listed below.

Green – The GFS accumulated the final tolerance mass defined by the sample criteria.

Blue - The GFS accumulated the starting sample tolerance mass defined by the sample criteria.

Red – The GFS is either Idle, has an error or has not accumulated enough mass to reach the starting sample tolerance.

Text that displays within the indicator are used to describe system errors or warning condition. Use [Setup][Configuration][Limits] to modify the limits used to generate the warnings.

Z – The balance PRT has changed temperature more than the configured limit. An AutoZero operation or a Balance Zero operation should be performed to correct for any drift in the balance.

C - The cylinder temperature probe (TH Probe #3) has a rate of change of temperature that exceeds the configured limit. This can happen under high flow conditions. Abort flow control and allow the cylinder to reach equilibrium before continuing.

D – The infrared temperature from the surface of the cylinder has reached the dew point. Water vapor buildup on the reference gas cylinder ultimately results in a lower mass flow rate from the GFS. The extra mass of water reduces the net mass loss of the cylinder for a given period of time. This condition will occur under sustained high flow conditions. When this limit displays, abort flow control and wait for the cylinder to reach equilibrium.

E – One or more of the ambient sensor probes on the LCM is not responding properly. Make sure that all probes on the LCM are properly connected. The error may also be the result of faulty calibration data.

P – The calculated reference gas cylinder pressure is below 200psi. Below this value pressure regulation in the cylinder loop is no longer consistent and can lead to faulty flow data. Re-fill the cylinder to remedy the situation.

T – The temperature difference between ProbeTH1 and ProbeTH2 exceeds the limit defined by [Setup][Configuration][Limits]. Verify that the probe calibration data is valid. Both probes must be securely connected to the LCM and positioned next to the GFS. (see section 3.3.13, Setup probe locations)

The current calibration gas selected at the start of a manual test or defined in a Test Definintion.

Page 82

GFS2102™ OPERATION AND MAINTENANCE MANUAL

FEATURE DESCRIPTION

The rolling average flow of the GFS. The value displayed in this field is

Flow

identical to the value displayed on the GFS Diagnostics Display <Roll Avg Flow> field.

Accumulated

Mass

Target Flow

Regulate Flow

(Optional Check

Box with

Numeric Entry

Field)

Enclosure

Pressure

Enclosure

Temperature

Enclosure

Humidity

Elapsed Time

Time Remaining

Flow Tolerance

The mass accumulated by the GFS for the active accumulation. When an accumulation is complete the last value remains on the display but does not change.

The current GFS target flow. When running a manual test enter a flow value in this field and press [Enter] to change the target flow.

The regulate flow option is present to allow GFS Tools to dynamically adjust the set point of a flow controller to achieve a nominal flow rate in either the first or second DUT. If running a manual test, when the option is checked a pop-up window displays allowing flow regulation to DUT1 or DUT2. The entry field next to the check box is used to specify the regulation adjustment interval. This is the time in seconds between set point adjustments. A value greater than 2s is recommended as that is the time required for a molbox1 flow update.

The pressure as output by the LCM ambient pressure sensor.

The temperature as indicated by the LCM TH Probe #3 temperature sensor. This probe should be placed in close proximity to the reference gas cylinder. The enclosure temperature is used for the air buoyancy correction on the reference gas cylinder.

The humidity as indicated by the LCM TH Probe #3 humidity sensor. The enclosure humidity value is used to determine the dew point temperature.

The elapsed time since the current accumulation officially started. This time does not include times associated with pre accumulation options such as Time Delay, AutoZero and Balance Zero operations. Those functions occur before the accumulation actually begins.

The predicted time remaining to complete the active accumulation. The value is calculated based on the current GFS flow rate, mass used and the required accumulation mass. At lower flow rates this indication may change dramatically until enough mass is accumulated to stabilize the prediction.

The approximate GFS Flow tolerance. The value is composed of the mass and time components of the GFS uncertainty as defined in [Setup][Configuration][LCM] and [Balance].

5.1.5.2.2 GFS System Display

The GFS System Display is an animated operational schematic of the GFS system including what object is currently on the balance, specific information on the DUT(s), and the Target Mass to be accumulated. The information and fields are summarized in the table below.

Three black lines graphically represent the flow of the gas from the Reference Gas Cylinder through the flow path “tube” and past the DUT(s) before resetting back to the cylinder. The lines move slowly at low flows and progressivly faster at higher flows. This is a animated representation only and is not based on the actual flow of gas.

Figure 39: GFS System Display section of GFS Run Screen

Page 83

5. GFS TOOLS SOFTWARE

Table 16. GFS System Display Fields

FIELD DESCRIPTION

Mass of Gas

(far left center)

Balance Output

Display

(far lower left)

Cylinder Icon

molbox1 / BSN: The molBloc Serial Number of the DUT molbloc attached to the molbox1.

Mass Error:

Flow Error:

Target Mass:

The calculated mass of gas in the GFS Reference Gas Cylinder available for use, in grams. This value is calculated from the Instantaneous Mass minus the “Mass of evacuated cylinder assembly” value of the currently selected Reference Gas Cylinder.

The instantaneous uncorrected output of the balance in grams.

When shown indicates that in the current AMH state the Balance Output Display is indicating the mass of the Reference Gas Cylinder.

When no icon is present above the Balance Output Display, the AMH is in the zero/unloaded position where nothing is on the balance and the Balance Output indication should be close to zero.

When a long rectangular icon is present above the Balance Output Display, the AMH is in the Reference Mass position and the Balance Output indication should be close to the mass value of the Reference Mass.

The % reading error between the accumulated masses of the GFS and the DUT(s). The % reading error between the averaged flows of the GFS and the DUT(s). The total mass to be accumulated by the GFS for the active accumulation before the

test will end or the next accumulation will initialize.

5.1.5.2.3 GFS Control Toolbar

The Control Toolbar is used for GFS specific operation. The toolbar is the main source of system control for Manual Test operation. Use of the toolbar during test definitions is not required or desirable in most situations.

FEATURE DESCRIPTION

Figure 40. GFS Control Toolbar section of GFS Run Screen

Table 17. GFS Control Toolbar icons

Start a flow accumulation. When an accumulation is started, the accumulation sample setup dialog displays allowing the operator to specify the starting and ending sample tolerance values and the flow rate. The information entered determines the total mass to deplete and the test time.

Abort the active flow accumulation. When abort accumulation is pressed, no final accumulation operations are taken.

AutoZero the GFS. The GFS AMH lowers the reference mass onto the balance and determines a correction for any drift in the balance since the last Balance Zero or AutoZero.

Page 84

GFS2102™ OPERATION AND MAINTENANCE MANUAL

FEATURE DESCRIPTION

Zero the balance by removing all mass from the balance and setting the stable residual mass to 0. A balance zero runs automatically before all tests begin.

Use the drop down menu choice next to the button to display the GFS Zero and Span Balance option to zero the balance as described above, then lower the Reference Mass to check or adjust the Mass Span Multiplier (see Section

5.5.7.1).

Set the GFS AMH state to load the reference gas cylinder onto the balance.

Set the GFS AMH state to load the reference mass onto the balance. The mass indicated on the balance display represented the reference mass.

Set the GFS AMH state to remove all mass from the balance. This is the zero condition.

Cycle the GFS AMH. It is important to cycle the AMH after system setup or when the reference gas cylinder is changed. The cycle operation helps to realign miss aligned mechanical components.

Abort the active GFS AMH cycle. This button is available only when a cycle is active.

The red icon indicates the isolation valve is closed, clicking on this will switch to the black icon and Activate (open) the isolation valve in the flow path. The black icon indicates the valve is open and will Deactivate (close) the isolation valve and switch to the red icon. This button is available only when a cycle is active.

5.1.5.3 GFS DIAGNOSTICS RUN SCREEN

The GFS Diagnostics run screen is used to view incremental flow calculation values used by the GFS. Access this display by selecting the drop down menu option next to the [GFS] display toolbar button. All data relevant to the gravimetric flow is available on the display. This feature is provided for trouble shooting purposes only. The information displayed is logged in an SDF file when the option is enabled.

Page 85

5. GFS TOOLS SOFTWARE

Figure 41. GFS Diagnostics Run Screen

Table 18. GFS Diagnostics Fields

FEATURE DEFINITION

Instantaneous Mass

Corrected Mass

Starting Corrected Mass

AutoZero Correction

Mass as directly output by the balance with the format specified in the balance setup. The AutoZero and buoyancy corrected instantaneous mass. The corrected mass value when the accumulation was started. The AutoZero correction that represents the drift of the balance. A count down to the

left of this field displays the time to the next AutoZero when timed AutoZero operations are active.

Mass Span Correction

The mass span multiplier. In addition to the buoyancy correction, mass span multiplier is applied to the Instantaneous Mass to get the Corrected Mass. The value remains a constant throughout a test unless the <Zero and Span balance> option is selected from the Control Toolbar on the GFS Run Screen.

Cylinder Pressure

The calculated gas pressure in the reference gas cylinder. The pressure is based on the cylinder properties specified in the Reference Cylinder Editor, the current total mass of the cylinder, and the current Calibration Gas.

Depleted Mass/Time

The difference between the corrected mass (g) and starting corrected mass over the elapsed time (s). Dividing these two numbers results in the current mass flow in mg/s.

Flow determined by the depleted mass divided by the elapsed time in the current flow

Flow

unit of measure.

Best Fit Flow

The running Best Fit flow of the balance. The value is Not the <Average Flow> flow and will only compare to the average flow when the flow is very stable. The values are calculated as though the “Y” axis were depleted mass and the “X” axis were corresponding elapsed time. Each new balance output generates a new point on the plot, new depleted mass and corresponding elapsed time. The best fit of all data on the plot forced through zero yields a slope that is the mass flow.

This field should be ignored when an AutoZero takes place during an accumulation. The AutoZero correction typically results in a mass change in a short amount of time. This value unfairly biases the running best fit.

Rolling Avg Flow The flow determined by the rolling average of the <Flow> value. This value is logged

Accumulated Mass

in the data file as the Reference Flow and displays as the <GFS Flow> on the GFS run screen. The duration of the rolling average is controlled by the GFS Tools configuration.

The accumulated mass of the balance. The value here is identical to the mass value in the <Depleted Mass/Time> field. The information is repeated here for convenience.

Page 86

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Dew Point Temperature

Status

The current dew point temperature calculated from the Enclosure Temperature, Enclosure Pressure, and Relative Humidity.

Higher flows decrease the temperature of the reference gas cylinder. As the temperature approaches the dew point, moisture will build up on the reference gas cylinder. The moisture increases the mass of the balance therefore decreasing the calculated flow. Use [Setup][Configuration][limits] to define a dew limit to avoid taking data when moisture is on the reference gas cy

Status information specific to GFS operation displays in this field. This information is not always the same as the information displayed on the status bar.

point approach

linder.

5.1.5.4 BALANCE OUTPUT RUN SCREEN

The Balance Output run screen is a display specific to balance related information. Access this display by selecting the drop down menu option next to the [GFS] display toolbar button. Use this display to troubleshoot the balance or to perform maintenance operations. Use the tools on this display when running Manual or Diagnostic Tests only. Use the GFS AMH manipulation options on the GFS run screen to ensure that the AMH is in a state such that the balance operation is valid.

It is the users’ responsibility to set the proper GFS AMH state prior to using the manual balance options. Leaving the AMH in the wrong state can over-range the balance or yield an erroneous calibration.

When the [Balance Calibration] option is used, the [Setup][Configuration][Time/Mass]<Mass Span Multiplier> must be set back to 1. Failure to reset this correction back to one will yield erroneous results.

Figure 42. Balance Output Run Screen

Table 19. Balance Output Run Screen Fields

LABEL DESCRIPTION

Tare the balance. This option is equivalent to pressing the tare button on a balance terminal (not provided). No AMH state manipulation operations are imposed before taring. This feature is provided for balance specific operation only.

Balance Tare

Balance Zero

For normal system operation use the [AutoZero] button on the GFS run screen.

Zero the balance. This option is equivalent to pressing the zero button on a balance terminal (not provided). No AMH state manipulation operations are imposed before taring. This feature is provided for balance specific operation only.

For normal system operation use the [Balance Zero] button on the GFS run screen.

Page 87

5. GFS TOOLS SOFTWARE

Run the internal calibration on the balance. During this process the balance lowers an internal calibration mass and makes a span correction. Do not confuse this correction with the span correction performed by GFS Tools. The Balance Calibration correction

Balance

Calibration

adjusts coefficients internal to the balance affecting the instantaneous mass output by the balance. The GFS Tools span correction is applied to the instantaneous balance output.

After using this option, the user must re-set the [Setup][Calibration][Mass/Time]<Mass Span Multiplier> back to 1 or rerun the GFS Tools Zero and Span function. Failure to do so will result in an erroneous correction being applied to the balance output leading to erroneous data.

5.1.5.5 AMBIENT CONDITIONS RUN SCREEN

All sensory information obtained by the LCM is displayed on the Ambient Conditions run screen. Access this display by selecting the drop down menu

option next to the [GFS] display toolbar button. The ambient conditions information is grouped by sensor and function on the

display. Use this feature to verify and to compare LCM sensory output information. Not all values displayed are directly used by GFS Tools to determine GFS flow. The information is provided to simplify the calibration processes.

Change the unit of measure and resolution of all ambient output values by clicking the displayed output value. One unit and resolution setting is imposed on all similar ambient output values. For example all temperature measurements will display in the same unit of measure with the same format.

Figure 43. GFS Ambient Conditions Run Screen

Table 20. GFS Ambient Conditions Run Screen Fields

LABEL DESCRIPTION

Ambient Pressure

Ambient Humidity

Ambient pressure as measured by the LCM internal ambient pressure sensor. The sensor is pneumatically connected to the enclosure interior.

Ambient humidity as indicated by the LCM internal humidity probe. This output indicates the ambient humidity surrounding the LCM. This output is not directly used by GFS Tools.

Page 88

GFS2102™ OPERATION AND MAINTENANCE MANUAL

LABEL DESCRIPTION

Ambient

Temperature

Regulator Probe

(TH2)

Cylinder Probe

(TH3)

Cylinder Surface

Probe (IR)

External PRT (T4)

Ambient temperature as indicated by the LCM internal temperature probe. This output indicates the ambient temperature surrounding the LCM. This output is not directly used by GFS Tools.

The temperature and humidity of the LCM external TH Probe #2. The value should indicate the temperature and humidity surrounding the regulator assembly at the top of the reference gas cylinder. The temerature value is used for the air buoyance correciton of the regulator assembly connected to the top of the reference gas cylinder.

The temperature and humidity of the LCM external TH Probe #3. The value should indicate the temperature and humidity surrounding the reference gas cylinder. The temperature output is used to perform an air buoyancy correction on the reference gas cylinder.

The temperature output of the LCM infrared temperature probe. The temperature output is used for the thermal expansion correction of the reference gas cylinder. The temperature output also generates a warning in the GFS status indicator when the temperature output approaches the current dew point temperature.

The temperature output of the external LCM PRT. This PRT is used to measure the temperature of the air surrounding the Reference Mass. The output of this probe is used to perform the air buoyancy correction of the Reference Mass required for AutoZero.

5.1.5.6 DUT/REFERENCE COMPARISON RUN SCREEN

This run screen contains a simple display of errors of all DUTs compared to the GFS. The most common error output information is available on this display. The information on the display is organized into rows and columns. The columns separate different pieces of information. With the exception of the <%Rdg Error> row, the rows separate the different devices. The first row is always the GFS, the remaining rows alternate between DUT and %Rdg Error for the different DUT comparisons to the GFS. Up to 2 simultaneous DUTs are supported by GFS Tools.

Change the unit of measure and resolution of reference and DUT outputs by right-clicking the output and selecting the desired function. Right-click any output and select the [Strip Chart] option to create a strip chart using the selected output.

Figure 44. DUT/Reference Comparison Run Screen

The display features of the DUT/Reference Comparison Run Screen are listed in the table below.

Page 89

5. GFS TOOLS SOFTWARE

Table 21. DUT/Reference Comparison Run Screen Fields

LABEL DESCRIPTION

Red, Blue, or

Green Circular

Indicator

Inst. Mass/ Mass

Inst. Flow /

Average Flow

Best Fit Flow

Displays to indicate the current GFS tolerance state. The indicator is always red when an accumulation is not active. When an accumulation is active, the indicator is one of 3 colors. Each color represents a specific tolerance state for the active accumulation.

• Red – Not enough time and or mass has been used to reach the starting sample tolerance.

• Blue – Enough mass and time have been used to start sampling.

• Green – The ending sample tolerance was reached. All GFS flows are in the

final averages and the accumulation will end soon.

When not accumulating, the instantaneous uncorrected balance mass displays for the GFS and no mass information displays for any other field.

When an accumulation is active, the column name changes to <Mass Used>. The column indicates the depleted mass according to the GFS and DUTs. The <%Rdg Error> row indicates the error as determined by comparing the integrated DUT mass used to the GFS mass used.

When not accumulating, the GFS has no instantaneous flow. The instantaneous value measured by the DUTs is listed in this column. There is no error information when an accumulation is not active.

When an accumulation is active, the column name changes to <Average Flow>. The GFS rolling average flow displays along with the average flow of each DUT. The <%Rdg Error> row indicates the error as determined by comparing the DUT Average flow to the GFS flow.

When not accumulating, this column does not display information. There is no error or best fit flow when an accumulation is not active.

When an accumulation is active, the GFS best fit flow displays along with the average flow of each DUT. The <%Rdg Error> row indicates the error as determined by comparing the DUT Average flow to the GFS best fit flow. This error comparison is valid when the GFS is running at higher flows or in any situation in which AutoZero was not activated during the test.

5.1.5.7 DEVICE OUTPUT RUN SCREEN

A Device Output Run Screen is created for each non-DHI device. All outputs of a device that are in use have a final output display on one row and all corresponding raw outputs on the next row. The label next to each output is the specified <Final Output Label> and the raw output type defined in the output specific setup of the device.

Controllers display <Final Set> fields with white backgrounds. Right-Click these fields to enter a new target output value. Entering output information into these fields automatically updates the target (setpoint) of the controller. Any associated remote commands are automatically issued by GFS Tools to set the entered target. It is assumed any output entered is in the current display unit of measure.

Outputs that require manual entry have a white background for the <Raw

Output> field. Entering a value in these fields automatically updates the <Final Output>. It is assumed any output entered is in the current display unit of

measure. Devices that have a remote interface also support the use of Spy Windows (see

5.1.5.8). These display output specific commands and responses used by GFS Tools to communicate with a device. Each output has it’s own Spy Window. This makes it easy to view the commands used to generate a specific output or response in GFS Tools. To view a Spy

Window, click the <Final Output> of any

output and select [Spy Window] from the popup menu.

Page 90

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Change the unit of measure and resolution of the final output by clicking the output and selecting the desired function. Click any output and select [Strip Chart] to create a strip chart using the selected output.

GFS Tools converts the specified final output of a device to the specified display unit of measure. By default, the display unit is the test specified unit or the unit defined in the device setup. It depends on the type of output and the active run mode. For this reason, the output displayed in GFS Tools will not necessarily match the output displayed on the device.

Figure 45. Device Output Run Screen

5.1.5.8 SPY WINDOWS

A Spy Window exists for each device output that requires remote commands. Spy Windows are accessed by right clicking a Final Output on a Device Output Run Screen and selecting the [Spy Window] menu choice. This feature is provided to troubleshoot or analyze remote communications. The caption of the Spy Window contains the device name and interface being spied on. Use the information in the <Command>, <Raw Response>, and <Manipulated Response> fields to determine if GFS Tools is properly configured for the remote device. The command/response information is updated real time as long as the interface is active and GFS Tools is not paused.

Figure 46. Spy Window Screen

Pay close attention to the device interface in the spy window caption. If the interface displayed does not correspond to the actual device interface, there is a configuration problem in GFS Tools or the wrong Spy Window is being viewed. The actual device interface used can be modified during Test Initialization.

Page 91

5. GFS TOOLS SOFTWARE

Table 22. Spy Window Information

FRAME LABEL DESCRIPTION

Command The exact command sent by GFS Tools over the device interface. The

Raw Response The unmanipulated response to the <Command> value issued. This field

Manipulated

Response

command terminator is the only portion of the command that is typically not visible. For set commands, make sure the command and set value are properly formatted.

should always be blank if the command does not have a response. The <Manipulate Response> option setup in the Remote Command

Editor is used to format the <Raw Response> (see 5.5.3.4.4). The numeric specifically troubleshooting, make sure the value displayed includes the correct device output information.

result is displayed in this field and logged as data. Responses not

used by GFS Tools do not have a value in this field. When

5.1.5.9 MOLBOX OUTPUT RUN SCREEN

If a molbox1 or molbox RFM is used as a DUT or as a support device to DUT or controller, the molbox Output run screen is an available run screen choice. The run screen displays a real time update of molbox output information. The <molbox Output> run screen can be very useful for troubleshooting.

Always use the molbox Output run screen instead of the molbox front panel to view real time molbox output information. The units of measure on the display may not always correspond to the units of measure indicated on the display of the molbox.

Table 23 provides information on each field of the molbox Output run screen.

When a molbloc-S does not have a valid back pressure ratio (BPR), the displayed flow is N/A.

Figure 47. <molbox Output> Run Screen

Page 92

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Table 23. <molbox Output> Run Screen Fields

LABEL DESCRIPTION

Red/Green Circle

Flow

Reynolds Number

Upstream Pressure

Downstream

Pressure

Differential Pressure

Temperature

Output Active molbox analog output. As with the <Set>, this value is used only when the

Switchbox molbox MFC switchbox control and measurement channels. The format is <Set

K Factor

Stability Setting

molbloc

molbox flow Ready/Not Ready indicator (see the molbox Operation and Maintenance Manual, Ready/Not Ready Section). The circle is green when molbox flow is ready and red when not ready.

Instantaneous molbox flow rate of change in unit of flow per second.

Rate

molbloc flow in the current test unit of measure. Reynolds number of the flow through the molbloc as calculated by the molbox. Pressure read by the molbox upstream pressure transducer. Pressure read by the downstream molbox pressure transducer.

The pressure drop across the molbloc that is currently being used by the molbox to calculate flow.

The differential pressure is the difference between the molbox upstream and downstream RPTs (in molbox RFM, it may be the measurement made by the microrange RPT). The molbox determines the differential pressure and outputs it to GFS Tools..

BPR is the back pressure ratio, downstream pressure/upstream pressure. This field

BPR

is present only when the DUT is a molbloc-S. The value displayed is either the measured ratio or N/A when the value is not measured. The molbox front panel BPR setting determines whether or not BPR is measured or if the 2 molbox RPTs are averaged. Refer to the molbox operation and maintenance manual for more information.

The molbloc temperature as calculated by the molbox from the average of the molbloc upstream and downstream PRT’s.

Active molbox flow set point. This value is used only when the molbox is equipped

Set

with the MFC control option and is used as the analog supply to a flow controller. For manual tests change target flow set point by using the GFS Run Screen. For trouble shooting purposes, change the set point by entering a new set point value and pressing [Enter].

molbox is equipped and used in to support an analog flow controller or DUT.

Channel . Measurement Channel>. This field has no value if the molbox does not have the MFC control option and an MFC switch box is not in use.

Active DUT gas conversion value in use by the molbox. The value is specified during Test Initialization. Change the value in Manual Test operation by entering a new K Factor and pressing [Enter]. See the molbox Operation and Maintenance Manual, K Factor Section, for details on the use of K factors.

Active molbox calibration gas. When running a Manual Test, this value can be

Gas

changed using t h e t o olbar at th e b o t t o m of the disp l a y. In all ot h e r r u n modes, the test gas is selected during test initialization.

Active Ready/Not Ready stability criterion in the molbox. This value is fixed by the Test Definition in use when in Run Test mode. In all other run modes, the stability setting can be changed by entering a new stability setting and pressing [Enter]. See the molbox Operation and Maintenance Manual, Ready/Not Ready Section, for additional information.

The serial number and molbox channel of the active molbloc. The molbloc channel displays only when a two channel molbox is the active reference.

Page 93

5. GFS TOOLS SOFTWARE

LABEL DESCRIPTION

Tare the molbox. Use this option when running a Manual Test to tare the RPTs of a molbox1 or molbox RFM (see 5.1.5.10). This feature does not apply to molbloc-S ty

pe flow elements

Change the active molbloc channel by using the drop down arrow next to the button. When the button is pressed, the active molbloc channel is simply re-loaded.

Change the active molbox calibration gas. Changing this gas does not affect the GFS test gas. This option is intended to help troubleshoot problems and assist in the calibration of blended gases.

5.1.5.10 TARE MOLBOX

The tare molbox feature is represented by the toolbar icon: See the molbox Operation and Maintenance Manual, Tare Section, for complete

information and recommendations on molbox pressure transducer taring. This function executes the molbox tare function. When pressed, a message

displays allowing the selection of the tare pressure: upstream or downstream. After this selection, the molbox’s internal valves are actuated to set up the tare configuration. The current pressure measured by the molbox pressure transducers is displayed on the molbox Output run screen. When the pressure is stable, the circular ready indicator will change to green and the tare button is enabled. Press [Tare] to activate the current value. The <Status Bar> displays <Tare Complete> after the tare is set. The tare display on the molbox Output run screen does not automatically close after the tare function has been executed. This allows the tare to be repeated as many times as desired. Use the close control box or the <Continue> button to complete the tare process and resume normal operation.

See Table 24 for information on each of the tare molbox panel fields.

Figure 48. molbox Output Run Screen in Tare Mode

Page 94

GFS2102™ OPERATION AND MAINTENANCE MANUAL

Table 24. Tare molbox Fields

LABEL DESCRIPTION

Red/Green Circular

Ready Indicator

Pressure Rate (Pa/s)

Differential Pressure

Previous Tare (Pa)

Microrange Pressure

Previous Microrange

Tare (Pa)

Downstream

Pressure

Upstream Pressure

This indicator is green only when the pressure rate of change is within the molbox’s internal tare rate criterion. In this state, the <Tare> button is enabled. When the indicator is red, the <Tare> button is disabled.

Current differential pressure rate of change. Non-tare corrected differential pressure. After taring, this pressure value should be

equivalent to the <Previous Tare> display.

(Pa)

Value of the old tare. This value is updated each time the tare button is pressed. Curent molbox RFM microrange option pressure. If the microrange is not supported by

the molbox, this field displays as N/A. After taring, this pressure value should be

(Pa)

equivalent to the <Previous Microrange Tare> display. Value of the old microrange tare. If the microrange is not supported by the molbox,

N/A is displayed Instantaneous downstream pressure. This value is corrected by 1/2 of the current tare

value. Instantaneous upstream pressure. This value is corrected by 1/2 of the current tare value.

5.1.5.11 MFC-CB RUN SCREEN

If a MFC-CB is used to measure the output of a DUT or to control flow by supplying an analog set point, the MFC-CB run screen is an available run screen choice. The run screen displays a real time update of analog output information on the MFC-CB channels that are in use. The MFC-CB run screen can be very useful for troubleshooting.

Table 25 provides information on each field of the MFC-CB OUTPUT run screen.

Use the Target Flow field on the GFS Run Screen to change the flow set point of a controller. The ability to change the analog set point of the MFC-CB using the MFC-CB run screen is provided for troubleshooting purposes.

Only MFC-CB channels specifically activated during Test Initialization are enabled on the MFC-CB run screen.

Figure 49. MFC-CB Run Screen

Page 95

5. GFS TOOLS SOFTWARE

Table 25. MFC CB Fields

LABEL DESCRIPTION

Output

Set Point

Set Point Target

Buttons

The measured analog output of the MFC-CB channel. The output unit of measure is based on the DUT or flow controller used.

The measured analog set point of the MFC-CB channel. The output unit of measure is based on the test flow controller that uses the MFC-CB

The target analog output. Change the value when running a manual test by entering a new target output and pressing [Enter].

The toolbar buttons are disabled when running tests in GFS Tools.

5.1.5.12 DATA GRID RUN SCREEN

While in a run mode with at least one Data File open, the Data Grid Run Screen is available to display the list of points taken and data associated with each point. Every point up to the current point in the current test cycle is displayed in this grid. The unit of measure for many data types is specified in the corresponding column header. As with the other run screens, the grid display is scalable.

As a test progresses, the current point is automatically highlighted and selected in the grid. Use the options on the [To prevent the automatic selection of the current test point. When automatic selection is ON, and the grid is scrolled to the top to view points taken earlier in the test, completion of a new point forces the grid back to the last point.

ols], [Options], [Data Grid] tab to

The data types logged and how they are ordered in the grid can be customized (see

5.2.2.5). Any or all of the different data at run time in the Data Grid Run Screen. The

items logged during a test can be displayed

order of points logged in the Data File is not affected by the grid display. By default, GFS Tools displays a common set of data. The [D

ata],[View Data File] option and the Data File Viewer always displays

all data columns logged to the file in the embedded grid (see 5.2.7).

Figure 50. Data Grid Run Screen

5.1.5.13 DATA PLOT RUN SCREEN

When running a test, the Data Plot Run Screen can be used to display a variety of graphs of the data currently logged in the Data File. The graph can be changed or printed without affecting test execution. Unlike the [D File] graphing function, no new Data File(s) can be selected (see 5.3.3). However, all other functions supported by the graphing tool are available during tests. Each point taken during a test causes the

graph to update with the current

test point information. If the <Force grid selection> option on the [To

ptions], [Grid] tab is not selected, the current cycle test data is not

automatically displayed on the plot unless that cycle is specifically selected for plotting. For example, if flow point 3 of a 10 point test is currently plotted, and the

ata], [Plot Data

ols],

Page 96

GFS2102™ OPERATION AND MAINTENANCE MANUAL

test is executing point 7, the results of point 7 do not appear in the plot unless flow point 7 is selected using the [Plot Properties] toolbar option.

5.2 [TOOLS] MENU

5.2.1 OVERVIEW

The [Tools] menu provides features to customize and troubleshoot GFS functions. Most menu choices in the [Tools] menu are available when running a test as well as when the system is idle.

5.2.2 [OPTIONS]

5.2.2.1 [RUN TEST] TAB

The [Tools], [Options], [Run Test] tab is used to set user preferences affecting the run test part of test execution. Various aspects of run test behavior can be changed using this feature. When selections are complete, click [OK] to save changes or select another tab to change other options.

The balance zero and AutoZero choices made on this tab affect Manual Tests

only. Each Test Definition contains a unique set of zero and AutoZero options.

Figure 51. Data Plot Run Screen

The purpose of the [Run Test] tab fields and settings as well as instructions on how to use them are provided in Table 26.

Page 97

5. GFS TOOLS SOFTWARE

Figure 52. Options, [Run Test] Tab

Table 26. Options, [Run Test] Tab Fields

FEATURE DESCRIPTION

Zero Balance/

AutoZero Setup

(option box)

AutoZero at end of

of accumulation

(check box)

AutoZero at timed

interval

(check box)

There are 3 automatic zero choices. The selections effect how the GFS is set to zero before an accumulation begins. The choices effect manual tests only, where a Test Definition contains a unique set of AutoZero choices. GFS and DUT samples are not taken until all preaccumulation options are complete. Any option selected will occur in addition to an initial balance zero that GFS Tools performs to establish the amount of gas mass available for tests. If Zero balance is selected, but the accumulation will begin within 5 minutes of this zero, GFS Tools will NOT zero the balance again.

• Do not use any pre accumulation options- There are no specific zero operations perfomed when an accumulation begins.

• AutoZero at start of accumulation- The GFS AutoZero function is run before the accumulation begins.

• Zero balance at start of accumulation- The balance is set to zero before the accumulation begins.

After the required accumulation mass is consumed, a final AutoZero is performed when this option is selected. The accumulation is forced to continue until at least one more sample from the GFS is taken.

It is not recommended to use this option for long accumulations that may require a large correction. The resultant shift in data makes error plots created during the accumulation less useful. It is also makes it more difficult to troubleshoot problems.

Select this option to run the AutoZero at a timed interval. In typical laboratory environments, an AutoZero should run approximately every 300 seconds (5 minutes). This minimizes the absolute drift correction and provides a more continuous accumulation error plot. In very stable environments this interval can be extended.

Page 98

GFS2102™ OPERATION AND MAINTENANCE MANUAL

FEATURE DESCRIPTION

Save AutoZero

information to file

(check box)

Save SDF file for

each accumulation

(check box)

Allow manual GFS

manipulation when

running a Test

Definition

(check box)

Delay timed point

collection until GFS

takes a data sample

(check box)

Abort timed point

collection when accumulation is

aborted

(check box)

Abort flow control

when accumulation

is aborted

(check box)

Abort accumulation

after target mass is

reached

(check box)

All information used to determine the AutoZero correction is saved to a delimited text file when this option is selected. The resultant file is used to validate and quantify the corrections determined by the AutoZero process. All AutoZero files are automatically saved in the \AutoZ directory relative to the root data file directory selected in [Tools][Options][Data File] and have an “.atz” extenstion.

The file is not handled by GFS Tools. Analysis of the AutoZero files requires a separate spreadsheet application such as MS Excel.

The SDF file (Sample Data File) provides a complete account for all outputs and calculations used to determine flow from the GFS and DUTs. Check this option to create a SDF file for each flow accumulation. Use this option to troubleshoot problems or to verify GFS Tools calculations.

When this option is selected, the SDF file for the GFS is automatically saved in a \SDF directory relative to the root data file directory selected in [Tools][Options][Data File]. SDF files for a DUT are saved in the same directory as the DUT data file and have an “.sdf” file extension.

SDF files are not manipulated by GFS Tools. Analysis of the SDF files requires a separate spreadsheet application such as MS Excel.

Check this option to allow a user to use the run time toolbars on the GFS Run Screen and other device run screens when running a Test Definition. By default this option is not selected. The choices selected in the Test Definition govern the test process. However, there are times in which manual user interaction is more efficient. For example a user may manually adjust the target flow or AutoZero the GFS when a test is active.

Check this option to allow GFS Tools to trigger timed point sampling only after the GFS has started to sample data. This choice affects manual tests only. By default this option is selected.

Depending on the sample setup, a significant amount of time may be required to collect the first sample. Un-check this option to log data during this pre-sample period. Although a GFS flow will not be available, valuable information on the changes in ambient conditions and the AutoZero correction can be used.

Check this option to allow GFS Tools to automatically stop timed point collection when the GFS accumulation is complete. This option affects manual tests only. By default this option is selected, however it may be desirable to uncheck this option to log additional ambient conditions information after the accumulation is complete.

Check this option to set the flow to zero after the accumulation is complete. This option affects manual tests only. Do not select this option when multiple accumulations will be used at the same flow rate. The intended use of this option to save cylinder gas when a long duration unattended accumulation is performed.

Check this option to end the flow accumulation after the target mass is reached. If the option is not checked, user intervention is required to stop the accumulation. This option affects manual tests only. By default this option is checked.

Page 99

5. GFS TOOLS SOFTWARE

5.2.2.2 [INITIALIZE TEST] TAB

The [Tools], [Options], [Initialize Test] tab is used to set user preferences affecting the initialization portion of test execution. The test initialization steps can be adjusted to avoid extra prompts and/or checks performed during the test initialization process.

The purpose of the [Initialize Test] tab fields and settings as well as instructions on how to use them are provided in Table 27. When selections are complete, click [OK] to save changes or select another tab to change other options.

Figure 53. Options, [Initialize Test] Tab

Table 27. Options, [Initialize Test] Tab Fields

FEATURE DESCRIPTION

Verify remote SN of

DHI DUT’s

(check box)

Set DUT molbox to

test gas and unit of

measure

(check box)

Prompt for

MFC-Switchbox

(check box)

Disable entry of K

factors for DHI

products

(check box)

Displays a warning when DHI device setup SN and remote SN do not match The serial number of a DH Instruments device that has the <Auto Detect> setup option enabled is automatically read during test initialization. This serial number is automatically compared to the serial number specified in the device definition. If this option is checked, a warning message displays when the serial numbers do not match. This is an easy way to help guarantee that the proper instruments are used during tests.

Do not check this option if the serial number specified for DH instruments products includes information other than the serial number of the device.

Check this option to force GFS Tools to change the unit of measure and gas information of a DUT molbox to the settings required by the GFS during test initialization.

Check this option when an MFC switchbox will be used with the system. An option to select the MFC switchbox channel is available when configuring a device during test initialization.

Check this option to always use 1 as the K factor for a DHI molbloc DUT. This option is provided to help avoid logging erroneous or inconsistent data caused by an incorrect K factor.

Page 100

GFS2102™ OPERATION AND MAINTENANCE MANUAL

FEATURE DESCRIPTION

Disable entry of K

factors for non DHI

products

(check box)

Un-check (recommended) this option to automatically populate the K factor field of a non DHI product (such as an MFC) with the K factor information stored in the Process Gas Editor. If the manufacturer gas information is not sotred in the Process Gas Editor, the K factor field is enabled for user entry. Use the [Tools][Process Gas Editor] menu choice to update gas information for a specific manufacturer.

5.2.2.3 [END TEST] TAB

The [Tools], [Options], [End Test] tab is used to set user preferences affecting operations that occur to conclude a test sequence.

The purpose of the [End Test] tab fields and settings as well as instructions on how to use them are provided in Table 28. When selections are complete, click [OK] to save changes or select another tab to change other options.

Selecting a fixed repeat point delay, deactivating the test notes and enabling the auto report generation can allow an automated test to run and generate a complete report without user intervention.

Figure 54. Options, [End Test] Tab

Fluke GFS2102 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

ABOUT THIS MANUAL

1. INTRODUCTION

1.1 SPECIFICATIONS

1.1.1 GFS2102 GENERAL SPECIFICATIONS

1.1.2 GFS2102 MASS BALANCE SPECIFICATIONS

1.1.3 LCM AMBIENT CONDITIONS MEASUREMENT SPECIFICATIONS

1.1.3.1 PRT BALANCE AMBIENT TEMPERATURE MEASUREMENT

1.1.3.4 AMBIENT CONDITIONS MEASUREMENT

1.1.3.5 BALANCE READING TIME MEASUREMENT

1.1.4 MFC-CB SPECIFICATIONS

1.1.5 FLOW MEASUREMENT SPECIFICATIONS

2. SYSTEM OVERVIEW

2.1 BALANCE AND AMH-GFS2102

2.2 REFERENCE GAS CYLINDER ASSEMBLY

2.2.1 REFERENCE GAS CYLINDER

2.2.2 CYLINDER SUPPORT

2.2.3 REFERENCE GAS CYLINDER CONNECTOR

2.2.4 REGULATOR ASSEMBLY

2.2.5 REFERENCE GAS CYLINDER CASE

2.3 GFS DRAFT ENCLOSURE AND VIBRATION ISOLATION TABLE

2.4 LABORATORY CONDITIONS MONITOR (LCM)

2.5 MFC-CB

2.6 GFS TOOLS

2.7 HEAT EXCHANGER

2.8 GFS-FS REFERENCE GAS CYLINDER FILL STATION

2.9 MASS FLOW CONTROLLERS

2.10 MOLBLOC MOLSTICS (OPTIONAL)

2.11 MASS SET (OPTIONAL)

3. INSTALLATION

3.1 UNPACKING AND INSPECTION

3.1.1 GRANITE VIBRATION ISOLATION TABLE AND STAND

3.1.2 GFS DRAFT ENCLOSURE AND SYSTEM ACCESSORIES

3.1.3 LABORATORY CONDITIONS MONITOR

3.1.4 MFC-CB

3.1.5 GFS-FS REFERENCE GAS CYLINDER FILL STATION

3.1.6 GFS MASS BALANCE

3.1.7 AMH-GFS2102

3.1.8 REFERENCE GAS CYLINDER ASSEMBLIES

3.1.9 SYSTEM CONTROLLER

3.1.10 MS-2102-0.7 MASS SET OR MS-2102-CAR MASS CARRIER

3.1.11 MOLSTICS

3.2 SITE REQUIREMENTS

3.2.1 GFS2102 SYSTEM

3.2.2 GFS-FS REFERENCE GAS CYLINDER FILL STATION

3.3 SETUP

3.3.1 POSITION THE VIBRATION ISOLATION TABLE

3.3.3 SETUP LCM

3.3.4 SETUP MFC-CB

3.3.5 SET UP THE SYSTEM CONTROLLER (PC)

3.3.6 VERIFY GFS CALIBRATION DATA

3.3.7 ASSEMBLE REFERENCE GAS CYLINDER(S)

3.3.8 ENTER REFERENCE GAS CYLINDER DATA

3.3.9 INSTALLATION OF REFERENCE MASS ON MASS PLATE

3.3.10 INITIAL BALANCE AND AMH BASE SETUP

3.3.11 SETUP BALANCE LOCATION

3.3.12 AMH POSITION FINE ADJUSTMENT

3.3.13 SETUP PROBE LOCATIONS

3.3.14 PREPARE THE HEAT EXCHANGER

3.3.15 CONNECT THE DUT FLOW PATH

3.3.16 CONNECT GAS CONVEYANCE LOOP

4. OPERATION

4.1 GENERAL OPERATING PRINCIPLES

4.1.1 GFS2102 MEASUREMENT PRINCIPLE

4.1.2 GAS DEPENDENT MASS RANGES AND CYLINDER SIZE SELECTION

4.1.3 AUTOZERO

4.1.4.1 ACCUMULATIONS

4.1.4.2 SAMPLES

4.1.4.3 AVERAGES AND BEST FITS

4.1.5 SETTINGS FOR FLOW SAMPLING

4.1.5.1 SETTING UP STARTING AND ENDING SAMPLE TOLERANCE

4.2 MANUAL GFS TOOLS OPERATION

4.2.1 READING THE BALANCE

4.2.2 AMH OPERATION

4.2.3 BALANCE ZERO AND SPAN ADJUSTMENT

4.3 REFERENCE GAS CYLINDER FILLING