RKI Instruments Data Cal 2000 User Manual
Data Cal 2000
Operator’s Manual
Part Number: 71-0097RK
Revision: D
Released: 11/3/11
RKI Instruments, Inc.
Warranty
RKI Instruments, In c. warrant s gas alarm equi pment sold by us to be free
from defects in materials and workmanship, and performance f or a
period of one year from date of shipment from RKI Instruments, Inc. Any
parts found de fective within that period will be repaired or replaced, at our
option, free of charge. This warranty does not apply to tho se items which
by their nature are subject to deterioration or consumption in normal
service, and which must be cleaned, repaired, or replaced on a routine
basis. Examples of such items are:
Absorbent cartridges Batteries
Pump diaphragms and
Filter elements
valves
Fuses
Warrant y is voi ded by abuse including mechanical damage, alteration,
rough handling, or repairs procedures not in accordance with the
instruction manual. This warranty indicates the full extent of our liability,
and we are not responsible for removal or replacement costs, local repair
costs, transportation costs, or contingent expenses incurred without our
prior approval.
HIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER
T
WARRANTIES AND REPRESENTATIONS, EXPRESSED OR IMPLIED, AND
ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF RKI
NSTRUMENTS, INC. INCLUDING BUT NOT LIMITED TO THE WARRANTY
I
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN
NO EVENT SHALL RKI INSTRUMENTS, INC. BE LIABLE FOR INDIRECT,
INCIDENTAL, OR CONSEQUENTIAL LOSS OR DAMAGE OF ANY KIND
CONNECTED WITH THE USE OF ITS PRODUCTS OR FAILURE OF ITS
PRODUCTS TO FUNCTION OR OPERATE PROPERLY.
This warranty covers instruments and parts sold to users only by
authorized distributor s, dealers, and represen tatives as appoin ted by RKI
Instruments, Inc.
We do not assume indemnification for any accident or damage caused
by the operation of this gas monitor and our warranty is limited to
replacement of parts or our complete goods.
Warranty
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
System Requirement s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Docking Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DM-2001, DM-2003, and DM-2009 Docking Modules . . . . . . . . . . . 7
Communication Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-Gas Mix Calibration Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Demand Flow Regulator & 3 ft. Tube . . . . . . . . . . . . . . . . . . . . . . . 13
10 ft. Exhaust Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Data Cal 2000 Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Setting the Docking Module Configuration Switches . . . . . . . . . . . 14
Mechanical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installing the Data Cal 2000 Docking S tation Software . . . . . . . . . . . 21
Launching the Data Cal 2000 Software . . . . . . . . . . . . . . . . . . . . . . . . 23
Overview of the Data Cal 2000 Software . . . . . . . . . . . . . . . . . . . . . . . 24
Data Cal 2000 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Main Program Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table of Contents
Setting Up the Data Ca l 2000 Software . . . . . . . . . . . . . . . . . . . . . . . . 27
Setting Up the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Viewing the Pre-Defined Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 32
Adding and Updating Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Setting Up the Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connecting Instruments to the Data Cal 2000 . . . . . . . . . . . . . . . . . . . 38
Bump Testing Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Calibrating Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Deleting Instrument s From the Main Window . . . . . . . . . . . . . . . . . . . 48
Charging Instruments With The Data Cal 2000 . . . . . . . . . . . . . . . . . . 48
Logs Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Viewing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Deleting Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Alarm Trend Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Event Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Interval Trend Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Memo Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Bump Test Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Instrument/Module Function Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Open Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Edit Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Edit Function, Memo Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Download Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Clear Logs Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Reset Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Table of Contents
Power Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Configuration Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Parameter Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Database Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Sensor Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Password Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Optimizing the Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
CAUTION: Read and understand this manual before using the
Data Cal 2000. Also read and understand the
Model GX-2001, Model GX-2003, and Model GX2009 Operator’s Manuals included with each
instrument.
Table of Contents
Introduction
The Data Cal 2000 Docking Station is a comprehensive and reliable
system that provides charging, data downloading, configuration updating,
calibration, and bump testing for the GX-2001, GX-2003, and GX-2009
gas detectors. It is designed for use with a Windows-based PC and the
Data Cal 2000 Docking Station Software.
The purpose of this manual is to explain how to set up and use the Data
Cal 2000 Docking Station and the Data Cal 2000 Docking Station
Software. You will learn how to:
• install and launch the software
• install the hardware
• set up the Data Cal 2000 software and hardware
• download data from the GX-2001, GX-2003, and GX-2009
• perform a bump test
• perform a calibration
• view, print, and save data
• change instrument parameters
• change data logging parameters
• use the Data Cal 2000 to charge an instrument
CAUTION: The GX-2001, GX-2003, and GX-2009 detect
oxygen deficiency and elevated levels of oxygen,
combustible gases, carbon monoxide, and
hydrogen sulfide, all of which can be dangerous or
life threatening. When using the GX-2001,
GX-2003, and GX-2009 you must follow the
instructions and warnings in the O perator’s Manual
1 • Introduction
for each instrument to assure proper and safe
operation of the unit and to minimize the risk of
personal injury.
CAUTION: The operator of this instrument is advised that if t he
equipment is used in a manner not specified in this
manual, the protection provided by th e equipment
may be impaired.
System Requirements
To use the Data Cal 2000 and the Data Cal 2000 Docking Station
Software, your personal computer must meet the following requirements:
• Operating Systems: Windows® 98, Windows® ME, Windows®
®
2000, Windows NT
• Processor: IBM
equivalent minimum
4.0, or Windows® XP.
®
compatible PC running Pentium® 2 processor or
• Memory: 32 MB RAM minimum
• Hard Disk Space: 32 MB minimum
• CD-ROM Drive
System Requirements • 2
Specifications
Table 1: Dat a Cal 2000 Specifications
Input Power 115 VAC, 50/60 Hz
Environmental
Conditions
Number of
Docking Modules
Applicable
Instruments
Number of Calibration Gas
Cylinders
• For Indoor Use Only
• -10° C to 40° C, below 80% Relative Humidity, NonCondensing
Up to 10 docking modules
• GX-2001
• GX-2003
• GX-2009
Up to 5 calibration gas cylinders and one zero air cylinder
3 • Specifications
Description
The Data Cal 2000 consists of the following components:
• Data Cal 2000 Docking Station
• DM-2001 Docking Module for GX-2001
• DM-2003 Docking Module for GX-2003
• DM-2009 Docking Module for GX-2009
• RS-232C serial communication cable for connection of the docking
station to a computer
• RS-485 serial communication cables for connection of the docking
station to a docking module and for daisy chain connection of
additional docking modules to each other
• Power cord
• A 4-gas mix calibration cylinder (optional)
• Demand flow regulator with 3 foot tube (optional)
• 10 ft. exhaust tube
• A Windows based PC compatible computer (user supplied) with the
Data Cal 2000 Docking Station Software loaded
The docking station is designed to be used on a table top with t he DM2001, DM-2003, and/or DM-2009 docking modules extend ing to the rig ht
of the docking station as shown in Figure 1 below. Any combination of
docking modules may be used up to a total of 10. If a laptop computer is
used, it may be placed on top of the docking station if desired.
Up to 1 0 docking modules may b e installed i n any
combination of DM-2001's,DM-2003's, and DM-2009's.
Docking Station
POWER FAULT
Data Cal 2000
DM-2001
DM-2003
DM-2009
Figure 1: Data Cal 2000
Description • 4
Docking Station
The docking station manages the calibration, bump test, and informatio n
exchange functions of the Data Cal 2000 once they have been initiated
through the software.The status LED’s are on the front panel. The power
switch and hose barb fittings for connection of calibration gas cylinders
and routing of calibration gas to the docking modules are located on the
back panel. Cable connectors for connecting the docking station to a
computer and to docking modules are also located on the back panel.
Three recesses are located on the right side of the docking station that
mate with tabs on the docking modules. These recesses allow table top
assembly of a docking module to the docking station.
Front Panel
Docking Station
POWER
The two status LED’s are located on the f r ont panel in the upper left
corner. The left LED is green and is the POWER LED. It is on when the
docking station is turned on. The right LED is red and is t he FAULT LED.
It is on when there is a communication error or some hardware problem
that affects communication between the docking station and the
computer or the docking station and the modules.
FAULT
D
ata
Cal 2000
Figure 2: Data Cal 2000 Front Panel
5 • Description
Back Panel
Fan Grill
MODULE
GAS OUT
PC(RS-232C)
AIR GAS1 GAS2 GAS3 GAS4 GAS5
FUSE(5A)
POWER
AC IN
AC100V-AC240V
Figure 3: Data Cal 2000 Back Panel
The power switch is a rocker switch and is located in the upper right
corner of the back pan el. The docking st ation is on when the upper half of
the switch, the “1” position, is pressed in, and of f when the lower half of
the switch, the “0” position, is pressed in.
All the gas fittings are located on the back panel. They are hose barb
type fittings that accept 3/16” inner diameter (ID) tubing. At the bottom
left of the back panel is the GAS OUT fitting. This fitting is used to route
calibration gas from the docking st ation to the docking modules. To the
right of the GAS OUT fitting is the AIR fitting. This fit ting is used to draw
fresh air while the Data Cal 2000 is performing a zeroing operati on during
bump testing or calibration.
To the right of the AIR fitting are five additional fittings of the same type
labeled GAS1, GAS2, GAS3, GAS4, and GAS5. These fittings are used
to connect up to 5 calibration gas cylinders that are defined using the
software. Usually, only one or two calibration cylinders will be needed.
Typical gas cylinders needed are a 4-gas mix of %LEL CH
or 3-gas mix of %LEL CH
%volume CH
TC sensor is installed on a GX-2003).
4
/CO and a %volume cylinder of CH4 (if t he
4/O2
4/O2
/CO/H2S
There are three connectors on the back panel. A DB-15 (15 pin)
receptacle in the upper lef t corner is used to connect the docking station
to the docking modules. It is labeled MODULE. A DB-9 (9 pin) plug to the
right of the MODULE connector is used to connect the docking st ation to
the serial port of a computer. It is labeled PC(RS-232C). A 3-pin
Description • 6
recessed plug in the lower right corner of the panel is used t o connect an
AC line cord. It is labeled AC IN.
A fuse holder is located to the left of the AC IN connector. It is labeled
FUSE(5A). The fuse holder consists of a panel mounting socket and a
quarter turn fuse holder. The fuse is a 5 amp, 5 mm x 20 mm fuse.
A cooling fan is located inside the docking stat ion on the ri ght side above
the fuse holder. It draws warm air out of the docking st ation to preve nt the
internal electronic components from overheating.
DM-2001, DM-2003, and DM-2009 Docking Modules
The docking modules are used to facilitate communication between a
GX-2001, GX-2003, or GX-2009 and the docking station and computer
and to apply fresh air and calibration gas to an instrumen t during a bump
test or calibration. They are also used to charge an instrument’s
rechargeable battery pack if one is installed. Two multi color LED’s, one
on the left front and one on the right front of a module, indicate the
operation status of the docking module.
Each module has three connection tabs on the left side near the bottom
of the module and three connection recesses on the right side near the
bottom of the module. The tabs from one module can be pushed into the
recesses on the docking station or on another module to mechanically
connect the module to the docking station or to another module. If
multiple modules are used, one of them will be connected to the docking
station and then each additional module will be connected to the end
module as shown below in Figure 4.
Docking Station
FAULT
POWER
ata
Cal 2000
D
Figure 4: Assembling Docking Modules to Data Cal 2000
Connect any DM-2001s and DM-2003s first and then connect any
DM-2009s. This will allow the exhaust lines for the DM-2001 and
DM-2003 to easily be daisy-chained together and routed to an exhaust
area with a single exhaust tube. Each DM-2009 must have a dedicated
exhaust tube which can be easily routed away without interfering in the
daisy-chain configuration of the DM-2001s and DM-2003s.
7 • Description
Calibration Gas
r
T
e
Fittings
Terminator Switch
Exhaust Fittings
ID Switch
Connector for
Cable From Other
Docking Module
Connector for
Cable from Data
Cal 2000 or Othe
Docking Module
Figure 5: Back of DM-2001 and DM-2003 Docking Module
Calibration Gas
Fittin gs
Exhaust
Fittin g
ID Switch
erminat or Switch
Connector for
Connector for
Cable From
Ot her Docki ng
Module
Cable From
Data Cal 2000
or Other
Docking Modul
Figure 6: Back of DM-2009 Docking Module
Two DB-15 connectors on the back of each module allow connection to
other docking modules or directly to the docking sta tion.
T wo hose barb fittings tha t accept 3/16” ID tubing are loca ted in the upper
left corner of the back of each module and are each labeled CAL. GAS.
They allow sample gas connection t o the module and from t he module to
another module. The right fitting (as viewed from the back) is for
connection to the GAS OUT fitting on the docking station or to the left
fitting of the previous module in the system. The left fitting is for
connection to the next docking module in the system or, if the docking
Description • 8
module is the last one in the flow system, it is plugged with a push-on
plug that is supplied with the docking station.
A two port exhaust routing fit ting is located in the upper r ight corner of t he
back of the DM-2001 and DM-2003 modules. It allows routing of the
exhausted calibration gas from all DM-2001 or DM-2003 modules t o the
last module so the exhaust gas can be safely routed to a convenient
exhaust location. The DM-2009 module has only one exhaust fitting.
Exhaust from the DM-2009 may only be routed to an exhaust location
and cannot be routed to another module.
NOTE: Even though the exhaust gas can be routed to an area
to be safely dispersed, the docking station should still be
installed in a well ventilated area.
All three types of modules also includ e a 10-positi on rot ary switch, the ID
switch, above the right DB-15 connector, and a 2-position slide switch,
the terminator switch, above the lef t DB-15 connector. The ID switch set s
the ID number of a module from 0 - 9, for a maximum of 10 module IDs.
The terminator switch is set to the down position if the module is the last
module in the system and to the up position for any other module.
9 • Description
DM-2001 Docking Module
The GX-2001 fits into the DM-2001 module as shown in Figure 7 below.
The module includes a snap-on sample adapter for the GX-2001. The
exhaust port of the adapter is connected to a port on the front left of the
module by a short tube and the adapter’s inlet port is connected to a port
on the top rear of th e module by a coiled t ube. The sample adapte r snaps
onto the sensor side of the GX-2001 before the GX-2001 is installed into
the module.
DM-2001 DM-2001
Figure 7: DM-2001 Docking Module
H
HC
CO
O
2
2
S
Description • 1 0
DM-2003 Docking Module
Front Vie wTop View
To GX-2003 Exhaust Fitting
The GX-2003 fits into the module as shown in Figure 8 below. A coiled
black tube with a plastic push -on fit tin g resides in a recess in the lef t rea r
corner of the top of the module. The coiled tube routes gas to the
GX-2003 and extends to connect to the GX-2003’s inlet fitting. A straight
green tube comes out of the top of the module to the right of the coiled
tube and also has a plastic push-on fitting on its end. The fitting on this
tube is pushed onto the GX-2003 exhaust fitting and routes gas away
from the GX-2003.
To GX-2003 Inlet Fitting
Figure 8: DM-2003 Docking Module
DISPLAY
(ADJ)
AIR
RESET
SILENCE
(SHIFT)
DM-2003
11 • Description
DM-2009 Docking Module
The GX-2009 fits into the module as shown in Figure 9 below.
IR Port
Instrument Retaining
Tab
Instrument Cradle
Charging Contacts
CAL.
DM-2009 DM-2009
POWER
CHAR GE
CAL.
POWER
CHARGE
Figure 9: DM-2009 Docking Module
Communication Cables
The number of communication cables needed depends on how many
docking modules are used. Every system has at least two cable s, an RS232C cable with a DB-9 receptacle on each end (docking st ation cable
supplied with docking station) to connect the docking station to a
computer and an RS-485 cable with a DB-15 plug on each end (docking
module cable supplied with docking module) to connect the docking
station to the first docking module. For every additional docking module,
an additional RS-485 cable is needed to co nnect the additional module to
the previous module.
Description • 1 2
Power Cord
A three-pronged AC power cord is provided wit h t he Dat a Cal 2000. O ne
end connects to a standard AC wall outlet and the other end plugs into
the AC power socket on the back of the docking station.
4-Gas Mix Calibration Cylinder
The Data Cal 2000 may be ordered with or without calibratio n gas and a
demand flow regulator. The standard configuration of the Data Cal 2000
includes a demand flow regulator and one 58 liter 4-gas mix calibration
cylinder which typically cont ains 50% LEL CH
CO/25 ppm H
example if you need a % volume CH
S. If another cylinder is required for your system, for
2
cylinder for a 5-sensor G X-2003, it
4
will have to be ordered separately along with an additional demand flow
regulator.
/12.0% oxygen/50 ppm
4
Demand Flow Regulator & 3 ft. Tube
The standard configuration of the Data Cal 2000 includes one demand
flow regulator with 3 feet of flexible polyurethane tubing. The demand
flow regulator screws onto a calibration cylinder and the tube is used to
connect the regulator to the appr opriate calibration gas f itting on the back
of the docking station. When the regulator senses a vacuum at its fitting,
it allows the gas from the cylinder to flow.
10 Foot Exhaust Tube
The Data Cal 2000 comes with a 10 foot 5/16” I.D. exhaust tube. This
exhaust tube is intended to be used as the collective exhaust for any
connected DM-2001s and DM-2003s. Any connected DM-2009s require
their own dedicated exhaust. Another 10 foot 5/16” I.D. tube is
recommended for each connected DM-2009. This extra tubing is not
included in the Data Cal 2000 kit or in the DM-2009 but can be
purchased from RKI Instruments, Inc.
Data Cal 2000 Hardware Setup
There are two parts to preparing the Data Cal 2000 Docking Station for
use: hardware setup and software setup.This section describes
hardware setup. The hardware setup consists of setting the docking
module configuration switches, simple mechanical assembly, cable
installation, and tubing installation.
13 • Data Cal 2000 Hardware Setup
Setting the Docking Module Configuration Switch es
The docking module configuration swi tches determine module ID and the
order in which the modules are physically installed. B efore using the Data
Cal 2000, you will need to set the configuration switches as described
below. If you are adding a module or modules to a syst em that is a lready
setup, make sure the system is setup as described below after the new
module or modules are added.
ID Switch
The ID switch is located above the right DB-15 connector on the back of
the docking module. It is a 10 position rot ary switch with settings from 0
to 9. A Data Cal 2000 may have up to 10 docking modules. Each module
in the system must have a unique ID for the system to work properly.
When you receive a Data Cal 2000, set the ID setting f or each modu le in
the system so that no two modules have the same ID. The IDs should be
set sequentially to make it easy to keep track of the IDs. For example, if
you have 5 modules in a system, the IDs should be set to 0, 1, 2, 3, & 4.
Although the system will still operate properly if ID numbers are skipped,
for example using IDs 0, 3, 4, 6, & 8, setting them sequentially makes it
easier to keep track of t he module IDs an d spot du plicate I D sett ings. I f it
is necessary to change the ID on a module, use a small flat blade
screwdriver to adjust the switch to the desired setting. A small arrow in
the middle of the switch points to the current ID setting.
Figure 10: ID Switch Setting
Data Cal 2000 Hardware Setup • 14
0
19
28
37
46
5
Termination Switch
Set switch to UP position if module IS NOT the last one.
Set switch to DOWN position if module IS the last one.
The termination switch is located above the left DB-15 connector on the
back of the docking module. It is a two position slide switch. The switch
position indicates whether the modu le is physically the last module in t he
installation or not. When the Data Cal 2000 is viewed from the front, the
last module in the installation is the module on the far right and it must
have the termination switch set to the down position for the Data Cal
2000 to operate properly. All other modules in the system must have the
switch set to the up position. If only one module is used in a system, that
module must have the termination switch set to the down position.
Figure 11: Termination Switch Setting
Mechanical Assembly
The Data Cal 2000 is designed for table top use. Perfor m the following
steps to assemble the docking station and docking modules.
1. Find a location that is well ventilated and near a window so that the
exhaust can be routed out of the window.
2. Find a table or other flat surface that is large enough to
accommodate the docking station and the number of modules in
your system.
15 • Data Cal 2000 Hardware Setup
3. Place the docking station on the flat surface with enough room to
the right of the docking station (whe n viewed from the fro nt) to fit all
of the docking modules side by side.
4. Place the first docking module to the right of the docking station
and line up the three tabs on the left side of the module with the
three recesses on the right side of the docking station.
5. Push the module toward the docking station so the tabs mate with
the recesses and the module is flush against the docking station. If
only one module is used in your system, then mechanical assembly
is done. If more modules are used in your system, continue with
step 6.
6. Place the next docking module to the right of the installed docking
module and line up the three tabs on the lef t side of the module with
the three recesses on the right side of the installed module.
7. Push the new module toward the installed module so the t abs mate
with the recesses and the new m odul e is fl ush against the installed
module.
8. Repeat steps 6 & 7 for each additional docking module.
CAUTION: Make sure that the last module in the system, the
one on the far right, has the t erminator switch se t to
the down position. If the last module does no t have
the terminator switch set to the down position, the
Data Cal 2000 will not operate properly.
Cable Installation
1. Install the RS-232C cable from the PC connector on the back of the
docking station to the serial port on a computer.
2. Plug the power cord into the power socket on the back of the
docking station. Do not connect the cord to an AC outlet at this
time.
3. Install a RS-485 cable from the MODULE connector on t he back of
the docking station to t he right ( when viewed f rom the b ack) DB- 15
connector on the back of the first module. If only one module is
Data Cal 2000 Hardware Setup • 16
used in your system, cable installatio n is done. If more modules are
used in you system, continue with step 4.
4. Install a RS-485 cable between each adjacent module from the left
connector of one module to the right co nnector of t he next modul e.
The module on the end will not have anything connect ed to the left
connector.
Tubing Installation
Module CAL. GAS Fitting Connections
Tubing
Install plug on last
CAL. GAS fitting.
MODULE
PC(RS-232C)
AIR GAS1 GAS2
GAS OUT
Figure 12: Calibration Gas Fitting Connections
1. Install a black tube (supplied with the docking station) between the
GAS OUT fitting on the back of the docking station and the right
(when viewed from the back of the module) CAL. GAS fitting on the
first docking module in the system, the one next to the docking
station.
If only one module is to be installed in the system, install the black
fitting plug that is supplied with the system to the left CAL. GAS
fitting of the module. If more modules are used in your system,
continue with step 2.
2. Install a black tube (supplied with the docking module) between t he
left CAL. GAS fitting of the first module and the right CAL. GAS
fitting of the next module in the system.
17 • Data Cal 2000 Hardware Setup
3. Repeat step 2 for each successive module in the system until you
Install plug over fitting.
w
get to the last module.
4. Install the black fitting plug on the left CAL. GAS f i tting of the last
module in the system.
Module Exhaust Fitting Connections
GX-2001 and/or GX-2003
Tubing,
Route to open area
here calibration gas
can be exhausted.
User Supplied
Tubing,Supplied with System
MODULE
PC(RS-232C)
AIR GAS1 GAS2
GAS OUT
Figure 13: Exhaust Fitting Connections
1. Install a clear fitting plug, supplied with the system, on the bottom
port of the exhaust fitting of the first module in the system.
2. Install a clear tube, supplied with the system, between the top
exhaust fitting port on the first module and the bottom exhaust
fitting port on the next module.
3. Repeat step 2 for each successive module in the system until you
get to the last module.
4. On the last module in the system, install the 5/16” ID flexible tube
that is included with the Docking Station on the top exhaust fitting
port and route the tube to a n ar ea whe re the calibrat ion gas can be
safely exhausted.
Data Cal 2000 Hardware Setup • 18
CAUTION: The maximum recommended length for the
exhaust tube is 10 feet. Do not use more than 10
feet of tubing for the exha ust tube or bump test and
calibration accuracy will be adversely affected. The
tube that is shipped with the Docking Station is 10
feet long.
GX-2009
MODULE
PPC (RS-232C)
AIR GAS 1 GAS 2
GAS OUT
Route to open area
where calibration gas
can be exhaus ted.
Tubing, User Supplied
Figure 14: Exhaust Fitting Connections
The DM-2009 only has one exhaust fitting instead of two like the
DM-2001 and DM-2003. Each DM-2009 in a Data Cal 2000 system
must have a dedicated exhaust tube.
Install the 5/16” ID flexible tube that is included with the DM-2009
on the exhaust fitting port and route the tube to an area where the
calibration gas can be safely exhausted.
CAUTION: The maximum recommended length for the
exhaust tube is 10 feet. Do not use more than 10
feet of tubing for the exha ust tube or bump test and
calibration accuracy will be adversely affected. The
tube that is shipped with the Docking Station is 10
feet long.
19 • Data Cal 2000 Hardware Setup
Docking Station Calibration Gas Fitting Connections
The calibration gas fittings on the back panel of the docking station are
designed to be used with calibration gas cylinders that are fitted with
demand flow regulators. The AIR fitting may be used with a demand flow
regulator and a cylinder of zero emissions air, but this is not normally
necessary since the docking station will generally be in a fresh air area.
The types of calibration gas cylinders used depend on the gas sensors
installed in the GX-2001’s, GX-2003’s, and GX-2009’s being connected
to the docking station. Typically a 4-gas mix will be used if all or most
instruments being connected to the system are 4-gas units. If any
GX-2003’s that a re 5-sen sor unit s a re bei ng connected, a %vo lume CH4
cylinder will also be needed. Use Table 2 below as a guide in determining
which and how many calibration gas cylinders are appropriate for your
system.
Table 2: Recommended Gas Cylinders
Typical Instrument Types
GX-2001
LEL/Oxy/H2S/CO
GX-2001
LEL/Oxy/CO
GX-2001
LEL/Oxy/H2S
GX-2003
LEL/Oxy/H2S/CO
GX-2003
%V ol CH4/LEL CH4/Oxy/H2S/
CO
GX-2003
LEL/Oxy/CO
Recommended Calibration Gas
Cylinder(s)
4-gas mix with CH4/Oxy/H2S/CO
3-gas mix with CH4/Oxy/CO
4-gas mix with CH4/Oxy/H2S/CO
4-gas mix with CH4/Oxy/H2S/CO
• 4-gas mix with CH4/Oxy/H2S/CO
• %Volume CH4 in air
3-gas mix with CH4/Oxy/CO
GX-2003
LEL/Oxy/H2S
4-gas mix with CH4/Oxy/H2S/CO
Data Cal 2000 Hardware Setup • 20
Table 2: Recommended Gas Cylinders
Typical Instrument Types
GX-2009
LEL/Oxy/H2S/CO
GX-2009
LEL/Oxy/CO
GX-2009
LEL/Oxy/H2S
1. If the area around the calibration station is not considered a fresh
air area, an area free of combustible and toxic gases and of normal
oxygen content, 20.9%, install a tube on the AIR fitting on the back
of the docking station and route it to a fresh air area or connect a
cylinder of zero air to the fitting using a demand flow regulator.
2. Install the demand flow regulator(s) on the calibration gas
cylinder(s).
Recommended Calibration Gas
Cylinder(s)
4-gas mix with CH4/Oxy/H2S/CO
3-gas mix with CH4/Oxy/CO
4-gas mix with CH4/Oxy/H2S/CO
3. Connect the demand flow regulator for each calibration gas
cylinder that will be used with th e docking st ation to the desired gas
port, GAS1, GAS2, GAS3, GAS4, or GAS5. These ports must be
defined in the docking station software during the software setup.
See “Setting Up the Solenoids” on page 36.
Installing the Data Cal 2000 Docking
Station Software
1. Launch Windows®.
2. Exit from all applications and open windows.
3. Insert the Data Cal 2000 Docking Station Software Installation CD
into your computer’s CD-ROM drive.
4. The Docking Station InstallShield Wizard comes up to guide you
through installation. Click Next to proceed to the License
Agreement window.
21 • Installing the Data Cal 2000 Docking Station Software
5. Read the license agreement and click the agreement acceptance
selection box, then click Next to proceed to the Customer
Information window.
6. Enter a user name and organization, then click Next to proceed to
the Destination Folder window.
7. The default installation folder (C:\ Program Files\Docking S tation\) is
displayed. If you want to install the software in the default folder
continue with step 8. If you want t o install the software in a different
location, click Change and choose a new installation folder now
and then continue with step 8.
8. Click Next to proceed to the Ready to Insta ll the Program window.
9. Review the installation settings. I f t hey are acceptable, click Install
and the installation process will begin. If you want to change
installation settings, click Back and change them to the desired
settings.
10. During software installation, the installation program may find
newer versions of Windows files on your computer than those in
the Installation CD. If this happens, t he insta llation soft ware will ask
you if you want keep these newer files. Click Yes to do so.
11. Follow the on-screen instructions to complete software installation.
Installing the Data Cal 2000 Docking Station Software • 22
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