DigiCal ™ Primary Calibrator

Model No: DG-5, DG-30

INSTRUCTION MANUAL
VERSION : 2

www.zefon.com
 Table of Contents

Section : Page

1. Analysis of Air Flow Calibration

a. Physics of Measurement…………………………….. 2
b. Accuracy of Gaseous Flow Measurements………….. 3

2. Principle of Operation and Features ……………………. 4-5

Important Information on Version : 2 ………… 6

3. Start Up Procedure……………………………………… 7

4. Calibration of Air Flow Sources

with the DigiCal………………………………………... 8

5. Calibrator Maintenance…………………………………. 9

6. Calibrator Verification………………………………….. 9

7. Power Supply…………………………………………… 10

8. Precautions / Warnings…………………………………. 10

9. Parts List ………………………………………………... 11

10 Service Information……………………………………... 12-13

Digical™ is a trademark of Zefon International

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 Section 1

Analysis of Air Flow Calibration

a. Physics of Measurements:
At room temperature, all gases obey - to a very close approximation - the
ideal gas equation PV = nRT, where P is the pressure in newtons per square
meter, V is the volume in cubic meters, n is the number of moles of gas,
R is the empirically determined gas constant with the approximate value
8.31 joules/mole degrees Kelvin and T is the temperature in degrees Kelvin.

The method of measuring flow rates in the DigiCal Calibrator is the

technique known as the soap film bubble test. A frictionless soap film is
suspended perpendicular to the air flow up a small bore tube. This film
forms a complete seal across the tube. The effect causes the soap film to
move along the tube at exactly the same rate as the air flow. Knowing a
measured distance and tube bore size, a volume can be calculated. Thus, a
flow rate can be determined by the movement of soap film across a fixed
volume per unit of time. This technique is classified as a Primary Standard.1

By comparing the four variables of the Ideal Gas Law against this detection
technique, the validity of measurement can be accessed. The volume (v) is
known and fixed therefore cannot change or be considered variable. The
mass (m) of the gas being measured is not changed in this technique as the
soap film is simply suspended across the tube cross section and moves with
the gas flow rate. Mass is not affected. This leaves pressure and
temperature. These are expressed by Boyle's Law P1V1 = P2V2 and Charles
Law V2 / V1 = T2 / T1. No pressure changes from the ambient during a test
as the soap film is practically frictionless. Temperature has no influence in
this type of flow measurement when all elements are at an ambient. This
includes the Calibrating device, the flow of gas and room temperature.
These conditions are the general circumstances in which tests are performed.

Conclusion: The detection method of measuring flow rates of gases over a

fixed volume per given unit of time is for all practical purposes independent
of all variables in the Ideal Gas Law. Thus, the DigiCal Calibrator serves as
a primary standard calibration method.

1
Lippman, Morton, "The Industrial Environment - its Evaluation and
Control," [U.S. Department of Health, Education and Welfare], NIOSH,
1973, Ch 11, 101 pp

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b. Accuracy of Gaseous Flow Measurements

To properly evaluate the accuracy of flowing gases, two parameters must

be considered. First, the steadiness of the flow rate must be known.
Practically every type of pump creates some pulsing of the flowing gases.
Second, the rate of flow can drift up and down over some range. Current
battery powered personal air sampling pumps use various techniques to
dampen pulsing and special circuitry to monitor pump speed, thereby,
attempting to generate constant and steady flows.
The DigiCal Calibrator is an automation of the "classic" technique of
using a soap film seal to measure flow over a predetermined volume in a
known time. A microprocessor, operating at 6 megahertz per second,
detects the passing of the soap film seal over the established flow tube
volume and automatically calculates the rate of flow. The typical
apparatus, 1,000 ml burette using a stopwatch, can be significantly
reduced in size since the microprocessor can detect and measure the speed
at 80 microsecond intervals. Compare this speed to a technician's
response time. With good precision on a stopwatch, he or she could be
repeatable within 50,000 microsecond (0.05 seconds), 625 times slower
than the microprocessor.
Consider this analysis: 1,000 cc burette NIST traceable; 0.01 second
stopwatch crystal controlled with clock accurate to + 15 sec per month;
1,000 cc/min steady flow source (constant flow + 1 cc/min).
Example: Measure the flow rate using 1,000 cc burette by a skilled
technician. All devices are at a constant room temperature.

Test Time Actual Flow Rate

1 60.06 sec 999.0 cc/min
2 60.00 1000
3 59.94 1001

Note: At 1,000 cc/min of flow + 0.06 is equal to 1 cc/min change or

+ 0.1 accuracy. Repeatability is strictly a function of the technicians skill.
Mathematically, it would seem 0.1% accuracy could be obtained using this
large volume and a skilled technician with a 1,000 cc/min. steady source.
Of course, if the volume is smaller than 1,000 cc or the flow is faster, the
percent of accuracy is further reduced by this manual method.
To summarize, the accuracy of measuring air flow relies on quality
measurement tools such as NIST traceable burette and crystal control
stopwatch. A constant air flow source and a reliable method of detection
are the final requirements to achieve repeatable and accurate flow
readings.

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 Section 2

Principle of Operation and Features

a. Detection Principle:
The DigiCal™ Calibrator utilizes the principle of measuring the
flow rate of gases over a fixed volume per unit of time. A Quartz
controlled timer is the timing device and the fixed volume is located
in the flow cell center tube. A microprocessor measures the time
for a frictionless soap film to travel from the first sensor to the
second sensor (infrared which detects the passage up the tube) and
then calculates the volume per unit of time. The results are
displayed in flow rate, cc/min. on a four digit liquid crystal display.
The decimal point floats to present the data in the proper range. The
timer is capable of detecting a soap film at 80 microsecond
intervals. This speed allows under steady flow conditions an
accuracy of +/- 0.5% of any display. The unique flow cell can
create a soap film over a range of 1 cc/min. to 6,000 cc/min. The
flow cell is spillproof when properly filled.

b. Understanding the Display Results

A unique feature of the microcomputer software program is data
display. On initiation, the DigiCal display will present 8888’s for 3
seconds and then display 0000’s with no decimal point indicated. A
series of ---- are displayed while a test is in progress. During
sequential tests, the previous reading is added to the current test, the
previous reading is added to the current test as a running total. The
letter A-appears after each test display the number in the averaging.
If the previous reading and current reading are different by more
than + 5% a series of EEEE's will flash four times on the display
and then display the actual last test result. The next flow readings
will start this averaging technique over again. If individual readings
are desired without averaging, the "ON" button may be pushed to
reset the unit to "0000" following each test. The flashing numbers
on the display after a test are for three seconds duration. The
purpose is to allow sufficient time for the soap to return to the
bottom reservoir.

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c. Battery saver

Another feature of the DigiCal™ Calibrator is the battery saver

"automatic shut down." If a test is not conducted within
approximately 7 minutes from turn on, the Calibrator will turn itself
off. Continuous use of the batteries is rated at 100 hours. The unit
may also be operated directly from the A/C charger when batteries
are low. All units should be given an initial 16 hour charge prior to
use. A low battery light will indicate when it is time to recharge the
battery. If stored for a period of 30 days or more, unit will require a
16 hour charge prior to operation.

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 IMPORTANT INFORMATION
Your Zefon DigiCal™ Calibrator has new
enhanced operational features.
Effective October 1, 2005 Version 2

FEATURES :

• Pressing the ON and OFF keys simultaneously will display

the Version of software code.

• An audible beep will be made upon pressing of key pads

and with the start and stop of bubble test. This beeping
feature may be turned off by holding the ON key for five
seconds.

• Each flow measurement is a true running average with the

current test being added to the previous test and divided by
the number of tests performed at that time. Average test
number is displayed after each bubble test as A-1, A-2 etc.
Pressing the ON key resets the averaging to start over and
displays the current test.

• Upon turn-on, the display is “8888” briefly, as a system

check, and then becomes “0000”.

• The circuit board has advanced technology for improved

accuracy and to maintain calibration with longer battery
life. Up to 100 hours of usage on an over night charge.

Original features of “EEEE” being displayed, if the reading has

changed by ±5 % from previous reading or is out of the flow
range remains in Version 2.

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 Section 3

Start Up Procedure
A. Read the previous section of Principle of Operation if unfamiliar with
device.
B. Soap volume is not critical, therefore a measured amount is not necessary.
The proper amount is that which is sufficient to create a bubble. Simply pour
a small amount of soap through the bottom nipple to thoroughly cover the
bottom of the flow cell and attach air source to nipple (bottom nipple for
pressure, top nipple for vacuum). Excessive amount of soap may cause a
continuous stream of bubbles to go up the center tube at high flows.

C. Wet flow cell by connecting a pump flowing at 1000 to 2000 cc/min. Initiate
soap film up center tube by rapidly pressing button down and releasing.
Repeat this procedure until bubble doesn't break. The tube is now wet and
tests at any range may be conducted. One minute warm up time is all that is
required of the DigiCal.

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 Section 4

Calibration Of Air Flow Sources

With The DigiCal™ Calibrator
These instructions apply to all models. The range for each are:
Model DG-5 = 1.000 to 6000cc/min
Model DG-30 = 0.1 to 30.00 LPM

The instructions relate to industrial hygiene air sampling. It, basically, applies
to any gases flow rate measurements.
1. Start the pump and allow approximately 5 minutes to stabilize. Perform
this step before connecting to flow cell as air flow dries center tube if
bubbles are not initiated at intervals.
2. Connect sampling medium to pump by obtaining proper hose adapters
for connecting tubing to flow cell. The flow cell hose connectors will
accept two common sizes of vinyl tubing (1/4" and 5/16"). A "Luer"
fitting is incorporated in the upper hose connector. The upper port is for
vacuum and the bottom for pressure. When the upper port is connected
to vacuum, the lower port must be open to the atmosphere. Conversely,
when the lower port is connected to pressure, the upper port must be
open to free air. Never make bubble test with bottom hose connected in
series (in line with sampling filter).
3. Wet the flow cell as described in Section 3.
4. Begin Calibration:
Depress plunger into cell and quickly release.
Different flow rate can require quicker or slower release of the button.
5. Carefully observe the bubble passing through the sensor zone. Only a
single straight bubble, perpendicular to the tube wall, is necessary for an
accurate test. If several bubbles go up to the tube at once it will not
effect the test data because the first sensor will not reset until the final
sensor has been tripped. A good technique is to watch the bubble pass
up the tube to ensure a good test has been conducted.
6. Observe the display. A number will be displayed. The decimal point
will be appropriately placed. Read section 2-b on features concerning
data display.
7. After a 3 second delay from the time the final sensor is tripped another
test can be performed.
8. Repeat Steps 5 through 8 for minimum of 3 tests.
Note : If difficulty is encountered in making a clean single soap film rise up
the center tube :
a. Check level of soap in flow cell (Section 3-C).
b. If soap is cloudy (not clear), change the soap solution and
clean flow cell.

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 Section 5

Calibrator Maintenance
General Information:
To clean the flow cell, simply remove the three screws holding the flow
cell to the bottom of the case. Remove the flow cell and gently flush
with tap water. To prevent scratching the acrylic flow cell, wipe "only"
with a soft cloth. Do not allow center tube, where sensors detect soap
film to be scratched or get dirty. NEVER clean with ACETONE. Use
only soap and warm water. When cleaning prior to storage, allow flow
cell to air dry. Shake any access water from cell prior to reattaching to
base of DigiCal Calibrator.
If stubborn residue persists, remove the bottom plate. Squirt a few drops
of soap into slot between base and flow cell to ease removal. Gently
insert a coin or flat screw driver into the ridge between the bottom plate
and chamber using leverage around the circumference of the cell until
the bottom plate is removed. Upon realigning, note scribe mark near one
of the screw inserts on bottom plate and align this mark with scribe mark
on flow cell near air hose inlet. Again, wet O-ring with soap prior to
installation.
To reassemble, realign flow cell in case with hose nipples pointing to
back of case and reinstall the three bottom screws.

Section 6

Calibrator Verification
The calibrator is factory calibrated using a standard traceable to National
Institute of Science and Technology (N.I.S.T.). Attempts to verify
calibrator against a glass one liter buret should be conducted at 1000cc/
min. for maximum accuracy. The calibrator is linear throughout the
entire range due to the detection technique of “fixed volume per unit of
time.” See Section 1 for principle of operation.

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 Section 7

Power Supply
1. The battery supply utilizes 4 Nicad batteries. The unit will operate
up to 100 hours on a fully charged battery. The unit may also be
operated directly from the AC charger when batteries are low.

2. Low battery light will indicate the power supply is too low for
accurate results.

3. Charge battery pack for 16 hours minimum using the standard

charger supplied with the unit.

4. A special power saving feature is the Automatic Shut Off. After 7

minutes of non-use, the DigiCal Calibrator will shut off
automatically.

Section 8

Precautions / Warnings
1. Avoid the use of chemical solvents on flow cell, calibrator case
and faceplate. Generally, soap and water will remove any dirt.
Use of chemicals can result in a damaged cell requiring
replacement and calibration.
2. Never pressurize the flow cell at any time with more than 25
inches of water pressure. Overpressurizing can cause leaks in the
cell resulting in erroneous flow readings.
3. CAUTION: Do not leave A/C adapter plugged into calibrator
when not in use as this could damage the battery supply.
4. NOTE: Hose fitting covers help to reduce evaporation of soap in
the flow cell when not in use.
5. Use only DigiCal Calibrator Soap. It is a precisely concentrated
and sterilized solution formulated to provide a clean, frictionless
soap film bubble over the wide, dynamic range of the calibrator.
The sterile nature of the soap is important in the prevention of
residue build-up in the flow cell center tube, which could cause
inaccurate readings. Do not use any other soap.

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 Section 9

Parts List

A/C adapter charger 120V 655112

230V 655168

Soap solution 655273

(8 oz. bottle of soap)

Instruction manual 655103

Air inlet caps (Pkg. of 655102

two)

Calibrator battery pack 655169

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 WARRANTY

The Seller warrants to the Purchaser that any equipment

manufactured by it and bearing its name plate to be free
from defects in material or workmanship, under proper
and normal use and service, as follows: if, at any time
within 1 year from the date of sale, the Purchaser
provides proof of purchase and notifies the Seller that in
his opinion, the equipment is defective, and returns the
equipment to the Seller's originating factory prepaid,
and the Seller's inspection finds the equipment to be
defective in material or workmanship, the Seller will
promptly correct it by either, at its option, repairing any
defective part or material or replacing it free of charge.
If inspection by the Seller does not disclose any defect
in material or workmanship, the Seller's regular charges
will apply. This warranty shall be effective only if
installation and maintenance is in accordance with our
instructions and written notice of a defect is given to the
Seller within such period. This warranty is exclusive
and is in lieu of any other warranties, written, oral or
implied; specifically, without limitation, there is no
warranty, of merchantability or fitness for any purpose.
The liability of the Seller shall be limited to the repair or
replacement of materials or parts as above set forth.

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 LIMITATION OF LIABILITY

The seller shall not be liable of any claim for

consequential or special loss or damage arising or
alleged to have arisen from any delay in delivery or
malfunction or failure of the equipment. The Seller's
liability for any other loss or damage arising out of or
connected with the manufacture, sale or use of the
equipment sold, including damage due to negligence,
shall not in any event exceed the price of the equipment
supplied by us.

Zefon International Inc. reserves the right to make

changes at any time, without notice, in prices, colors,
materials, specifications, and models; and to discontinue
models.

COPYRIGHT PROTECTION OF DOCUMENT

Copyright © 2011, Zefon International Inc.
This operating and service manual and the data enclosed
herein are not to be reproduced or used, in whole or in
part, by anyone without the written permission of Zefon.
International Inc.

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Zefon Customer Service 1-800-282-0073
Email: [email protected]

Zefon International
5350 SW 1st Lane
Ocala, Florida 34474, USA

P-MAN001 REV02 2/3/2011

ZEFON DigiCal™