December 2018

AT4011E, Rev. 05

User’s Guide

AVL i CAL CFO

Software-Release 1.024
Copyright 2018 AVL Emission Test Systems, Neuss - Germany

The contents of this document may not be reproduced in any form or communicated to any third party without the
prior written consent of AVL. While every effort is made to ensure its correctness, AVL assumes no responsibility
neither for errors and omissions which may occur in this document nor for damage caused by them.
All mentioned trademarks or registered trademarks are owned by their respective owners.

All rights reserved.

 Warnings and Safety Instructions 3

Warnings and Safety Instructions

This manual contains important warnings and safety instructions, which must be
observed by the user.
The device is intended exclusively for an exactly defined use which is described
in the manual. The manual also explains the essential prerequisites for the appli-
cation and operation of the device as well as the safety measures to ensure
smooth operation. AVL can offer no warranty nor accept any liability if the
product is used in applications other than those described and if the necessary
requirements are not met and the safety instructions not followed.
The device may only be used and operated by personnel, who, due to their qual-
ifications, are capable of observing the necessary safety measures during opera-
tion.
Any accessories and equipment used with the product must be supplied or
approved by AVL. Since this is a device whose measurement results depend not
only on the correct functioning of the device but also on a series of boundary
conditions, it is necessary that the results delivered by the device be subjected to
assessment (e.g. plausibility check) by an expert before additional measures
relating to the measurement delivered are taken.
Any adjustment and maintenance work necessary on instruments when open
and under voltage must be carried out by a professional technician who is aware
of the dangers.
Repairs to the device may be carried out at the manufacturer's location or by
qualified service personnel only.
When the device is in use, an expert must ensure that neither the object under
test nor the testing equipment is operated under conditions that may lead to
injury or damage.
The critical flow orifice AVL iCAL CFO was built according to the state of the art
and the recognized safety rules and regulations. Nevertheless, its use may
constitute a risk to the health and safety of users or third parties and adversely
affect the system and other property values if it is
 operated by staff who have not been trained or instructed,
 not used as intended,
 maintained or serviced inappropriately.

WARNING

Danger of death from electrical voltage

Only use original fuses with the prescribed amperage!
In case of faults in the electrical power supply, switch the device off
immediately!

Work on electrical devices or tools may only be performed by trained electricians

or trained people – under the direction and supervision of a trained electrician –
and only according to the electrical engineering standards.
The electrical equipment of the device must be inspected and checked regularly.
Defects such as loose connections and charred cables must be remedied imme-
diately.

AVL iCAL CFO — User’s Guide

4 Warnings and Safety Instructions

WARNING

Danger of explosion
Due to the ignition of an explosive mixture of ambient air and escaping gas there
is a danger of personal injury and damage to property.
Ensure there is sufficient circulation and ventilation in the room in which the
device is operated.
Monitor ambient air with appropriate measure (LEL sensor).
Do not switch off or remove exhaust and ventilation equipment when the system
is running.
Connect the gas outlet correctly. The connections and the system to be tested
must not have any leaks.
Keep away from open flames or other sources of ignition.

WARNING

Danger of poisoning
Leaking gas leads to the danger of poisoning.
Ensure there is sufficient circulation and ventilation in the room in which the
device is operated.
Monitor ambient air with appropriate measure (CO sensor).
Do not switch off or remove exhaust and ventilation equipment when the system
is running.
Connect gas outlet correctly. The connections and the system to be tested must
not have any leaks.

CAUTION

Hazard due to escaping compressed gas

Compressed gas with a pressure up to 7500 hPa is applied to the gas connector.
Escaping gas while dissembling the connector can cause injury and hearing
disorder.
Previous to dissembling the connector, the gas supply line has to be closed and
depressurized.

When handling gases, the applicable regulations and the manufacturer’s mate-
rial safety data sheets for these substances must be heeded and adhered to with
respect to storage, handling, use, and disposal!
Heed applicable regulations for the handling, storage, and transport of
compressed gas bottles. Eating, drinking, smoking or storage of food in rooms
containing chemicals is forbidden.

No. Formula Name MAC LEL/UEL [in

% by vol-
[ppm] ume of air]
1 CO Carbon 30 12.5-75
monoxid
e
2 C 3H 8 Propane 1000 2.1-9.5

Tab. 1 MAC and LEL/UEL of gases

AVL iCAL CFO — User’s Guide

 Warnings and Safety Instructions 5

Always observe the relevant safety instructions for span gas bottles.
The device must not be operated in potentially explosive atmospheres.
Safe operation can only be ensured if the device is installed and commissioned
by qualified personnel in accordance with the instructions given in this manual.

Information

The device must be set up in such a way that it can be easily disconnected from
the mains at any time. If necessary, provide for an emergency stop switch.

NOTICE

Before connecting up and operating the device, read carefully and observe the
supplied user's guide and the user's guides supplied with the additionally used
devices.
Ensure that all connections are made in accordance with the installation instruc-
tions described in this user's guide and the user's guides supplied with the addi-
tionally used devices. Flawless and reliable operation of the device can only be
guaranteed if these requirements are met.
All work on electrical components or lines, as well as device installation, may
only be performed by trained personnel in accordance with the VDE standards
(VDE = the German Association for Electrical, Electronic and Information Tech-
nologies).

NOTICE

Replaceable power cords must not be replaced by insufficient rated power

cords.

AVL iCAL CFO — User’s Guide

6 Warnings and Safety Instructions

AVL iCAL CFO — User’s Guide

 Table Of Contents 7

Table of Contents
Warnings and Safety Instructions................................................................................................................ 3

1 What You Should Know.................................................................................................. 11

1.1 Information for the Operator ................................................................................................... 11

1.2 Intended Use .......................................................................................................................... 11

1.3 Warranty ................................................................................................................................. 12

1.4 Exemption from Liability ......................................................................................................... 12

1.5 Product-specific Information ................................................................................................... 13

1.6 About This Documentation ..................................................................................................... 13

1.6.1 Abbreviations and Glossary Terms................................................................................... 14
1.6.2 Typographic Conventions ................................................................................................. 14
1.6.3 We Want to Hear from You............................................................................................... 15

2 Scope of Delivery ............................................................................................................ 17

2.1 Standard Scope of Delivery.................................................................................................... 17
2.1.1 Versions ............................................................................................................................ 17

2.2 Optional Components............................................................................................................. 17

2.2.1 Injection Nozzle................................................................................................................. 17
2.2.2 Trolley ............................................................................................................................... 18
2.2.3 Desktop Housing............................................................................................................... 19

2.3 Transport, Storage, Packaging............................................................................................... 19

3 Installation ....................................................................................................................... 21
3.1 Assembly ................................................................................................................................ 21

3.2 Commissioning ....................................................................................................................... 22

3.2.1 Gas Connections .............................................................................................................. 23
3.2.2 Connection to Power Supply............................................................................................. 23

4 Set-up and Function........................................................................................................ 25

4.1 Functional Principle of a Critical Orifice.................................................................................. 26

4.2 Volume Flow Calculation ........................................................................................................ 26

4.3 Operation................................................................................................................................ 28

4.4 Flow Chart .............................................................................................................................. 28

5 Overview .......................................................................................................................... 29
5.1 Connections and Operating Elements.................................................................................... 29

AVL iCAL CFO — User’s Guide

 Table Of Contents 8

5.1.1 Screen and Keypad .......................................................................................................... 29

5.1.2 Gas Connections .............................................................................................................. 29
5.1.3 Interface Description ......................................................................................................... 30
5.1.4 Connections for External Valves....................................................................................... 30

5.2 Setting Flow Rate Manually via LC Display............................................................................ 31

5.3 Setting Flow Rate Automatically via AK ................................................................................. 31

6 Display and Operation .................................................................................................... 33

6.1 Display.................................................................................................................................... 33

6.2 Membrane Keypad ................................................................................................................. 33

6.2.1 Operating with Cursor Keys and Enter Key ...................................................................... 33
6.2.2 Operating with Function Keys ........................................................................................... 34
6.2.3 Querying or Changing Parameters ................................................................................... 34
6.2.4 Entering the Password...................................................................................................... 34
6.2.5 Software Version............................................................................................................... 34

6.3 Menu Structure ....................................................................................................................... 34

6.4 Flow Mask .............................................................................................................................. 36

6.4.1 Standby [F1] ..................................................................................................................... 37
6.4.2 Measuring Values [F5] ...................................................................................................... 37

6.5 Manual Operation [F2]............................................................................................................ 38

6.5.1 General ............................................................................................................................. 38
6.5.2 Flow Rate [F1]................................................................................................................... 41
6.5.3 Gas [F2] ............................................................................................................................ 42
6.5.4 Operations [F3] ................................................................................................................. 42
6.5.5 Integration [F6].................................................................................................................. 43
6.5.6 Access Levels [F7]............................................................................................................ 44
6.5.7 Measurement [F8]............................................................................................................. 45
6.5.8 Parameters [F9] ................................................................................................................ 46
6.5.9 Versions [F10]................................................................................................................... 62

7 AK Commands for Remote Control............................................................................... 63

7.1 AK Command Format............................................................................................................. 63

7.2 Query Commands .................................................................................................................. 64

7.2.1 ACAT Calibration Date...................................................................................................... 64
7.2.2 ACFO Calibration Polynomial - Current Nozzle and Current Gas .................................... 64
7.2.3 AFDA Duration of Operation ............................................................................................. 65
7.2.4 AGAS Span Gas and Density ........................................................................................... 65
7.2.5 AIKG Main Volume Integral Value since SINT.................................................................. 65
7.2.6 AIKO Main Volume Integral Value since SINT or since Last AIKO Command ................. 65
7.2.7 AKEN Device ID................................................................................................................ 65
7.2.8 AMAB Mass Integral Value Dependent on One or All Bags ............................................. 66
7.2.9 AMBE Measuring Range .................................................................................................. 66
7.2.10 AMDT Measured Data ...................................................................................................... 66
7.2.11 ANOR Standardization Base ............................................................................................ 66
7.2.12 ANUM Serial Number ....................................................................................................... 67
7.2.13 ASEK Measured Value from Sensor................................................................................. 67

AVL iCAL CFO — User’s Guide

 Table Of Contents 9

7.2.14 ASTF Error........................................................................................................................ 67

7.2.15 ASTZ Status ..................................................................................................................... 67
7.2.16 AVAB Volume Integral Value Dependent on One or All Bags .......................................... 67
7.2.17 ASWP Nozzle Switching ................................................................................................... 68

7.3 Control Commands................................................................................................................. 68

7.3.1 SBPF Start Volume Integration for the Bag Pair............................................................... 68
7.3.2 SBPS Stop Volume Integration Depending on Bag Pair................................................... 68
7.3.3 SDST Set Flow Rate......................................................................................................... 68
7.3.4 SGAS Set Span Gas ........................................................................................................ 68
7.3.5 SINT Start Volume Integration .......................................................................................... 69
7.3.6 SMAN Manual................................................................................................................... 69
7.3.7 SPAU Pause ..................................................................................................................... 69
7.3.8 SMGA Measurement ........................................................................................................ 69
7.3.9 SREM Remote Control ..................................................................................................... 69
7.3.10 SRES Reset...................................................................................................................... 69
7.3.11 STBY Standby .................................................................................................................. 70

7.4 Setting Commands ................................................................................................................. 70

7.4.1 EFDA Duration of Operation ............................................................................................. 70
7.4.2 EGAS Span Gas and Density ........................................................................................... 70
7.4.3 EKEN User Part of Device ID ........................................................................................... 70
7.4.4 ENOR Standardization Base ............................................................................................ 71

7.5 Error Numbers via AK............................................................................................................. 71

7.6 Example of How to Perform a Test......................................................................................... 72

8 Calibration........................................................................................................................ 73

9 Maintenance and Cleaning ............................................................................................. 75

10 Return and disposal........................................................................................................ 77

11 Technical Data ................................................................................................................. 79

11.1 Device Specifications ............................................................................................................. 79

Index.............................................................................................................................................................. 81

AVL iCAL CFO — User’s Guide

10 Table Of Contents

AVL iCAL CFO — User’s Guide

 What You Should Know 11

1 What You Should Know

This user's guide is intended to provide essential assistance in the successful
and safe operation of the critical flow orifice deviceAVL iCAL CFO. The user's
guide contains important instructions for operating the device safely, properly,
and economically. Adhering to these instructions will prevent hazards, reduce
repair costs, and minimize down-times, and it will increase the reliability and life
span of the device.
The user's guide must always be kept handy near the critical flow orifice and
must be read and applied by all persons entrusted with work with/on the critical
flow orifice device, e.g.:
 Operating, including rigging
 Troubleshooting during work-flow
 Elimination of production waste, care
 Disposal of consumables and auxiliary materials
 Maintenance (servicing, inspection, repairs)
 Transport

1.1 Information for the Operator

This user's guide is an integral part of the system. The operator shall take care to
ensure that the operating staff take note of these guidelines.
The user’s guide must be completed by the operator so that it includes operating
instructions based on the relevant national regulations concerning accident
prevention and environmental protection, including information about supervi-
sory and reporting duties for the consideration of operational particularities, e.g.
with respect to work organization, work-flows, and personnel deployed.
In addition to the user’s guide and the binding regulations concerning accident
prevention that apply in the place of use, the recognized technical rules for safe
and professional work must also be followed.
The operator/user of the critical flow orifice device must not make any changes,
additions or modifications to the critical flow orifice which might adversely affect
its safety without prior approval of AVL. This also applies for the installation and
adjustment of safety facilities and valves as well as for performing welding work
on pressure-retaining parts.
Any spare parts being put to use must comply with the technical requirements
specified by AVL. This is always guaranteed if you use original spare parts.
Use trained or instructed personnel only. Ensure clearly defined responsibilities
for personnel with regard to operation, rigging, maintenance, and servicing!
Specify the extent of the machine operator's responsibilities and allow him/her to
decline unsafe instructions from third parties!

1.2 Intended Use

This product is designed to suit the purpose of the application described in this
manual. No liability and warranty can be assumed if the safety measures and
requirements are neglected or if the product is applied outside the described
purpose of application.

AVL iCAL CFO — User’s Guide

12 What You Should Know

1.3 Warranty
The manufacturer assumes no liability for damage and breakdowns that result
from a failure to adhere to the user’s guide.
The user’s guide must be completed by the operator so that it includes operating
instructions based on the relevant national regulations concerning accident
prevention and environmental protection, including information about supervi-
sory and reporting duties for the consideration of operational particularities, e.g.
with respect to work organization, workflows, and personnel deployed.
In addition to the user’s guide and the binding regulations concerning accident
prevention that apply in the place of use, the recognized technical rules for safe
and professional work must also be followed.

Information

The warranty becomes void if the device is not maintained annually by AVL
Services or by a maintenance technician trained by AVL. During such mainte-
nance, the device is checked, repairs are done and a calibration is performed.

The warranty is also voided in the event of:

 Improper use
 Use of non-approved operating resources
 Improper connection and preceding work that is not part of the scope of
delivery and services
 Use of non-original spare parts and accessories
 Retrofitting that is not agreed upon with AVL
 Failure to perform prescribed maintenance work
 Performance of welding work on pressure-retaining parts

Information

There is a description of the necessary maintenance work in Chapter Mainte-

nance and Cleaning on page 75.

Information

The operator of the AVL iCAL CFO is recommended to conclude a maintenance

contract with the relevant AVL country organization. This will ensure that the AVL
iCAL CFO is maintained by our service staff on a regular basis and that any
necessary wear and spare parts are supplied without long delivery times and
that the availability of the entire test bed is ensured.

1.4 Exemption from Liability

All technical information, data or operating instructions contained in this user's
guide comply with the latest standards of technology on the date of printing and
have been written to the best of our knowledge under due consideration of our
previous experience and knowledge.
We reserve the right to make technical modifications as part of the further devel-
opment of the exhaust gas measuring system which is the subject of this user's
guide. No claims can be deduced from the information, illustrations and descrip-
tions contained in this user's guide.

AVL iCAL CFO — User’s Guide

 What You Should Know 13

No liability shall be taken for any damages or disruption of operation caused by

operating errors, failure to comply with this user's guide or unprofessional
repairs. We expressly point out that only original spare parts and accessories
approved by AVL may be used. This applies analogously also to assemblies in
use that were produced by other manufacturers.
The installation and/or use of non-approved spare parts and accessories and
any unauthorized conversions and changes are not permitted for safety reasons
and shall exclude the liability of AVL Emission Test Systems GmbH for any such
resulting damages.
AVL Emission Test Systems GmbH shall be liable for any errors or omissions on
our part, not including further claims arising in the context of the warranty obliga-
tions detailed in the agreement. Claims for damages shall be excluded, irrespec-
tive of the legal grounds of such claims.
Translations are made to the best of our knowledge. No liability is assumed for
translation mistakes, even if the translation was made by us or ordered by us.
Only the original version is binding.
The text-based or graphical representations do not necessarily correspond to the
scope of delivery and/or that of a possible spare parts order. The drawings and
graphics are not to scale.

1.5 Product-specific Information

The AVL iCAL CFO is used to check the tightness of CVS dilution systems and
SHED chambers. For this purpose, a defined volume flow (l/min) of a pure gas
[propane (C3H8) or carbon monoxide (CO)] is produced and introduced into the
exhaust gas and air bag of a CVS system or injected into a SHED chamber.
Next, an emissions measuring system is used to analyze the bags or SHED
chamber in view of their gaseous components. If the measured concentration of
the span gas does not match the expected value, the system is leaky. The
expected concentration value results from the ratio of the injected gas to the air
present (dilution air in the CVS, ambient air in the SHED).
Intended use also includes adhering to the instructions described in the user's
guide:
 on safety
 on operation
 on maintenance / servicing
The device series AVL iCAL CFO comprises four different versions that are
described in this documentation:
 iCAL CFO Light Duty, Low Emission
 iCAL CFO Light Duty
 iCAL CFO Medium Duty
 iCAL CFO Heavy Duty
For more detailed information on the different versions, please see Chapter
Versions on page 17

1.6 About This Documentation

Target Group This documentation is intended for the operating personnel working with this
system.
 Operating the AVL iCAL CFO
 Troubleshooting during work-flow

AVL iCAL CFO — User’s Guide

14 What You Should Know

 Maintenance (servicing, inspection, maintenance)

 Transport
Personnel in charge of activities on the device must have read and understood
the user’s guide, especially Chapter Warnings and Safety Instructions.
The following is recommended with respect to personnel:
 Use trained or instructed personnel only.
 Document training and instruction in writing and keep these records.
 Every user must have read and understood this user’s guide and must
operate the exhaust gas measurement system as described in the user’s
guide. The operator should have this confirmed in writing.
Contents and This user's guide is crucial to the successful and safe operation of the device.
Scope Adhering to these instructions will prevent hazards, reduce repair costs and mini-
mize downtimes, and it will increase the reliability and life span of the device.
The user’s guide must therefore always be kept in the immediate vicinity of the
device.

1.6.1 Abbreviations and Glossary Terms

CVS Constant Volume Sampler
CFO Critical Flow Orifice
LE Low Emission application
SHED Sealed Housing for Evaporative Determination
LD Gross vehicle weight < 6.5t (Light Duty)
MD Gross vehicle weight < 12t (Medium Duty)
HD Gross vehicle weight > 12t (Heavy Duty)
smlpm Standard milliliter per minute

1.6.2 Typographic Conventions

Safety Messages:

WARNING

Indicates a hazardous situation which – if not avoided – could result in death or

serious injury.

CAUTION

Indicates a hazardous situation which – if not avoided – could result in minor or

moderate injury.

Additional Safety Symbols:

Danger due to harmful or irritating substances

Notice:

AVL iCAL CFO — User’s Guide

 What You Should Know 15

NOTICE

This text indicates situations or operation errors which could result in property
damage or data loss.

Information

This text indicates important information or operating instructions. Ignoring these

instructions will make it more difficult or prevent you from successfully
completing the actions described in this documentation.

Standard text styles:

Bold Parameters; control elements in windows and
dialog boxes; important text/important text
-passages
Italics Cross references; foreign language or new terms;
wild-cards for elements that need to be entered
by the user, i.e. characters or text. If you read, for
example, macro name, you are required to type
the name of a macro.
UPPERCASE LETTERS Operating modes
Courier Programming examples; source code
Times New Roman Formulas
Menu | Option Descriptions of procedures for selecting a menu
or menu command

Lists:
1. Instructions
2.
• One-step instructions
 Unordered series of concepts, items or options


–
–

1.6.3 We Want to Hear from You

Your comments and suggestions help us to improve the quality and practical
relevance of our manuals.
If you have any suggestions for improvement, please send them to:
[email protected]
We appreciate your feedback!

AVL iCAL CFO — User’s Guide

16 What You Should Know

AVL iCAL CFO — User’s Guide

 Scope of Delivery 17

2 Scope of Delivery
Please understand that not all of the device's versions and options can be
described in every detail in this user's guide. If you need additional information or
you have a special problem that was not explained in sufficient depth in this
user’s guide, please contact your local sales office or representative.

2.1 Standard Scope of Delivery

 1 AVL calibration unit iCAL CFO
 1 power cable
 1 user's guide (AT4011E)
 1 calibration report
 1 CFO accessory kit (pressure reducer, network cable, probe, tube incl. fit-
ting)
 1 packaging
When unpacking, check that the contents are correct and that all parts ordered
are provided.

2.1.1 Versions
The following versions are available:
iCAL CFO Light Duty, Low Emission (iCAL CFO LD-LE)
– CO 80 – 560 smlpm
– C 3H 8 50 – 430 smlpm

iCAL CFO Light Duty (iCAL CFO LD):

– CO 240 – 2050 smlpm
– C 3H 8 180 – 1570 smlpm

iCAL CFO Medium Duty (iCAL CFO MD):

– CO 380 – 2950 smlpm
– C 3H 8 320 – 2240 smlpm

iCAL CFO Heavy Duty (iCAL CFO HD):

– C 3H 8 1 – 10 slpm
There are also options that can be added to the devices; for details, see Chapter
Optional Components on page 17.

2.2 Optional Components

There is a series of options available for the iCAL CFO which extend its scope of
functions. See below for a list.

2.2.1 Injection Nozzle

The CFO probe with deflecting plate (2-mm nozzle and a distance of 2 mm to the
deflecting plate) supports the flow behavior of the gas that is injected into the
tunnel.

AVL iCAL CFO — User’s Guide

18 Scope of Delivery

Fig. 1 Side view of injection nozzle

Fig. 2 Front view of injection nozzle

1 Deflecting plate
2 Nozzle

2.2.2 Trolley
By mounting the iCAL CFO onto a trolley, the device can be used at different
places and easily moved from one place to another. The trolley also offers addi-
tional space for storing any necessary connecting cables or tubing.

AVL iCAL CFO — User’s Guide

 Scope of Delivery 19

Fig. 3 View of trolley

2.2.3 Desktop Housing

The iCAL CFO is also available with desktop housing. For the desktop version,
the metal housing usually used for 19" cabinets is placed into an outer casing
which is suitable for being placed on top of a table. This does not affect access to
the front operating panel or the iCAL CFO connections at the back.

2.3 Transport, Storage, Packaging

Storage For certain purposes, e.g. to prevent corrosion damage, it is absolutely neces-
sary for the device to be kept in rooms with an ambient temperature of 5 °C to
50 °C and at a maximum relative humidity of 80% (non-condensing).
Packaging and Note that gas connections not connected must be sealed before transport so
Transport that they are dust-proof. Never leave a gas connection open. Leave the device in
the packaging until it is time to assemble it.
Always use the original packaging for transport.
The following instructions are general ones and must be heeded during transport
and storage of the device. Furthermore, always observe the valid accident
prevention guidelines and the following markings on the packaging and boxes.

Top

Fragile

Keep dry

AVL iCAL CFO — User’s Guide

20 Scope of Delivery

Center of gravity

Sealed packaging

Do not insert fork lift here

NOTICE

During transport, do not subject the device to hard blows. Handle carefully, espe-
cially when lifting and lowering. All gas inlets and outlets must be sealed.

AVL iCAL CFO — User’s Guide

 Installation 21

3 Installation

Information

The assembly and installation must always be performed by specially trained

and qualified AVL personnel only.

3.1 Assembly

WARNING

Danger of explosion
Due to the ignition of an explosive mixture of ambient air and escaping gas there
is a danger of personal injury and damage to property.
Ensure there is sufficient circulation and ventilation in the room in which the
device is operated.
Monitor ambient air with appropriate measure (LEL sensor).
Do not switch off or remove exhaust and ventilation equipment when the system
is running.
Connect the gas outlet correctly. The connections and the system to be tested
must not have any leaks.
Keep away from open flames or other sources of ignition.

NOTICE

Take care to follow the instructions on assembly and place of installation to

ensure flawless operation of the system.

• If a 19" cabinet is used: Guarantee sufficient air supply for the ventilation.
• Maintain sufficient distance to warm air ventilators, heaters, and
high-voltage devices.
• Install the device horizontally.
• Install the device in a vibration-free area.
• Only set the unit up in gas-monitored rooms.
• The ambient air must be clean and free of heavy metals.
• Do not operate the device at heavily fluctuating temperatures.
• Protect the device from direct sunlight and contact with water. In particular,
do not place any containers with liquids on top of the device or next to it, as
the containers could leak or topple over causing liquid to enter the device,
which could lead to short circuits.
• Adhere to the ambient conditions specified in the Technical Data.
For an overview of the back panel with gas-related and electrical connections,
see Chapter Connections and Operating Elements on page 29.

AVL iCAL CFO — User’s Guide

22 Installation

NOTICE

When using gas bottle pressure regulators and supply hoses, we recommend
using new ones only and not old ones that have become dirty from prolonged
use.

Observe the following points:

 For a connection hose use a Teflon hose or a stainless steel tube with an
outer diameter of 6 mm.
 Make sure to avoid contamination with grease or oil!

NOTICE

Flawless operation of the unit can only be guaranteed if the device is used by
qualified personnel and if the instructions specified in this manual are observed
during the system's installation and commissioning.

Handling It is absolutely necessary to adhere strictly to the safety measures for handling
poisonous and flammable gases. In addition, the local safety standards and fire
department standards or other (e.g. plant-internal) regulations must be heeded
and adhered to during operation.

3.2 Commissioning
For commissioning, proceed as follows:
1. Unpack the device.
2. Close any gas connections that are not used (SWAGELOK).
3. Connect the RS232 and/or TCP interface.
4. Check whether your power supply connection delivers the voltage required
for the iCAL CFO.
The voltage is indicated on the back of the device next to the power
connection socket. These voltage levels must match.
5. Make sure that you use gas bottle pressure regulators within their specified
flow ranges.
The iCAL CFO requires a stable inlet pressure within the specified inlet
pressure limits.
If you set flow rates that are too low, please note that most of the gas
bottle pressure regulators are not designed for such low flow rates and
might become unstable. The iCAL CFO does, however, require a
stable inlet pressure, at least for a period of 30 seconds. If slower
changes occur, the device is capable of compensating them accord-
ingly.
If you happen to have this type of gas bottle pressure regulator, you
might be able to tackle the problem by providing an additional bypass
flow downstream of the gas bottle pressure regulator to achieve a
higher flow rate. It might also be helpful to place a disk with a very
small diameter at the outlet of the gas bottle pressure regulator in order
to get the gas bottle pressure regulator back into its control range.
Please ask the manufacturer of your gas bottle pressure regulator what
could be done.
6. Connect the device to the power supply.
7. Set up the serial or network interface.
For more detailed information, please read the sections below and additionally
the sections:

AVL iCAL CFO — User’s Guide

 Installation 23

– Gas Connections on page 29

– Interface Description on page 30

3.2.1 Gas Connections

Please observe the safety instructions specified in the relevant material safety
data sheets whenever you use these gases.
 To learn how to use the fittings correctly, please follow the SWAGELOK
instructions provided in their manuals.
 To achieve short response times, make sure the gas lines are short. For
high-precision measurements, we recommend using lines made of stainless
steel and not Teflon.
 Any fittings not in use must be closed with a gas-tight sealing plug (e.g. by
SWAGELOK).

3.2.2 Connection to Power Supply

The device can be operated at two different power supply voltages: 100-120
VAC at 50/60 Hz or 230 V at 50 Hz. Before connecting the device to the power
supply, compare the voltage and frequency values of the device and the power
supply.
Supply voltage tolerances:
 100-120 VAC ±10 %
 230 VAC ±10 %
The supply voltage that needs to be connected is indicated on the back of the
device.

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24 Installation

AVL iCAL CFO — User’s Guide

 Set-up and Function 25

4 Set-up and Function

The unit is mounted inside a standard 19'' housing. It requires 3 rack units and a
depth of 450 mm (17.7'').

Fig. 4 AVL iCAL CFO front view

The iCAL CFO is used to check the tightness of the CVS dilution system in emis-
sion testing. A defined volume flow (l/min) of a pure gas (100% C3H8 or CO) is
applied to the CVS system upstream of the mixing point. In the CVS system, this
gas is diluted as defined in the flow settings. Analysis devices are used to
measure the resulting gas concentration of the gas mixture in order to confirm
the tightness of the CVS system.
The injected volume flow is produced by combining critical sonic nozzles with
differently calibrated flow rates. Their level of precision is better than 0.4%. The
pressure of the used gas is controlled by a high-precision pressure regulator with
high long-term stability.
The iCAL CFO is able to be remote-controlled by a host computer via the TCP/IP
interface (alternatively, also serially via RS232 V24) in accordance with the AK
protocol.
.

8
2

7 3

4
6

Fig. 5 AVL iCAL CFO interior view

AVL iCAL CFO — User’s Guide

26 Set-up and Function

The iCAL CFO device consists of the following components:

1 Flame trap
2 Temperature sensor
3 Outlet pressure sensor
4 Inlet pressure sensor
5 Valves
6 Proportional valve for pressure control
7 Critical orifices
8 Inlet filter

All system components that come into contact with gas are made of stainless
steel (V4A) or noble metals. The seals are made of Viton and the tubing is made
of PFA.

4.1 Functional Principle of a Critical Orifice

A Venturi nozzle through which gas flows is called a critical orifice (or sonic
nozzle) if the flow velocity in the smallest nozzle cross section reaches the
gas-specific speed of sound. This is the case if the ratio of absolute inlet pres-
sure P1 to outlet pressure P2 is equal to or greater than 2.

P-----1  2
 P2 
To calculate the mass flow rate through a critical orifice that operates in the sonic
range, apply the following equation:

P1
Q m = -------  K gas
T
In this equation, Kgas represents the specific gas factor in relation to N2 and T
the absolute gas temperature.
The mass flow through the critical orifice is independent of inlet pressure (e.g.
the counter-pressure produced by a connected analyzer) as long as the ratio of
absolute inlet pressure P1 to outlet pressure P2 is greater than or equal to 2. This
allows very precise and stable gas flow rates. The cylindrical nozzle body that
contains the critical orifice and the critical orifice itself are made of stainless
steel. The individual nozzles are protected from foreign particles by stainless
steel filters.

4.2 Volume Flow Calculation

The standard volume flow Qs of a gas which flows through a nozzle at the speed
of sound (critical flow rate) is calculated based on pressure pi and the tempera-
ture ti of the gas at the nozzle inlet.

pi
Q s = K v -------
ti

But Kv can only be regarded as constant for a small range of pi. Outside of this
range, Kv is a function of pi, which is estimated with a polynomial as follows:

AVL iCAL CFO — User’s Guide

 Set-up and Function 27

2 N
Kv  pi  = a0 + a1 pi + a2 pi +  + aN pi

The polynomial coefficients are calculated from the calibration curve (see
Chapter Calibration on page 73). The curve is only valid for the media used for
the calibration and is based on a normalized temperature and a normalized pres-
sure (see below). Normally, a third- to fifth-order polynomial is used. It is also
possible to enter a linearization for the pressure and temperature sensors.
A sample j of the standard volume flow is calculated as follows:

Pj
Q sj = K vj  P j  ---------
Tj

To obtain the standard volume flow, which is based on a normalization basis

other than the one used for calibration, the volume flow must be brought to stan-
dard conditions by using the following correction factors for temperature and
pressure:

Ts
C t = -------
T cs

P cs
C p = -------
Ps

Ps and Ts are the new standard values. The calibration values are Pcs=1.01325
bar for inlet pressure and Tcs=293.15 K for inlet temperature. This results in the
new standard volume flow Q'sj

Q' sj = Q sj  C t  C p

To obtain the current volume flow, the following correction factors for tempera-
ture and pressure are used:

Tj
C atj = -------
T cs

P cs
C apj = -------
Pj
The current volume flow Qaj is therefore:

Q aj = Q sj  C atj  C apj

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28 Set-up and Function

4.3 Operation
With the help of display and keypad, it does not take long to learn how to operate
the device. Even so, we recommend reading the following chapters very care-
fully, so that you are familiar with all of the operating options.
The device left the factory in a safe and error-free condition. To ensure safe and
correct operation, all requirements relating to packaging, storing, transport and
delivery as well as correct installation must be fully met.
Operating Options The device can be operated using the keypad and the display attached to the
front of the device. To control the AK commands, please see Chapter AK
Commands for Remote Control on page 63.
For further details, see Chapter Display and Operation on page 33.

4.4 Flow Chart

Fig. 6 Gas flow chart

Designation Function
MV1, 2, 3 Solenoid valves
N1, 2 Critical orifices
P1 Pressure sensor inlet
P2 Pressure sensor outlet
SV1 Safety valve
PV1 Proportional valve
F1 Filter
T1 Temperature sensor
FR1 Flame trap
EV1, 2, 3 External valves (shut-off valve, gas selection
valve and bypass valve)

Tab. 1 Designations - flow chart

AVL iCAL CFO — User’s Guide

 Overview 29

5 Overview

NOTICE

Correct functioning is only ensured if the inlet pressure indicated in the data
sheet is met.

NOTICE

The temperature in the block containing the critical orifices and the sensors is
regulated internally. For the device to reach rated accuracy, it requires a
heating-up time of around 45 minutes.

For more detailed information on the functions, please refer to Chapters Manual
Operation [F2] on page 38 and AK Commands for Remote Control on page 63.

5.1 Connections and Operating Elements

5.1.1 Screen and Keypad

The LC display and the membrane keypad for manual control are on the front
panel.

Fig. 7 Front of the device

5.1.2 Gas Connections

At the back, the span gases (CFO IN) and the CFO gas outlet (CFO OUT) are
connected. The CFO gas outlet might optionally be on the front.
The connection for the reference pressure sensor (CFO REF) is only used for
maintenance purposes and must not be used by the customer. This connection
is used for calibrating the internal pressure sensor. The connection must be kept
closed.

Fig. 8 Back of the device

AVL iCAL CFO — User’s Guide

30 Overview

CAUTION

Hazard due to escaping compressed gas

Compressed gas with a pressure up to 7500 hPa is applied to the gas connector.
Escaping gas while dissembling the connector can cause injury and hearing
disorder.
Previous to dissembling the connector, the gas supply line has to be closed and
depressurized.

Information

It is strongly recommended to install an excess flow cut-off valve in the gas feed
line.

5.1.3 Interface Description

Ethernet The Ethernet interface (XF3) is the standard interface for host communication.
Serial RS232 An RS232 interface (XF4) ensures integration with older host systems.

Fig. 9 XF4 - RS232 connector

Pin Function
1 DCD
2 RxD
3 TxD
4 DTR
5 SG
6 DSR
7 RTS
8 CTS
9 RI

Tab. 2 Pin assignment RS232

5.1.4 Connections for External Valves

Optionally, three external 24 V valves (XG7, XG8, XG9) can be connected to the
iCAL CFO via a 5-pin diode plug with the following pin assignment.

Fig. 10 Socket pin-out 24 V valves

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 Overview 31

Pin Function
1 +24V
2 GND
3 not assigned

Tab. 3 Pin assignment 24V valve

Shut-off valve After switching on the device, a voltage of 24 V is applied at this connector. By
connecting a shut-off valve, a connected gas bottle can be closed automatically.
Socket designation: XG7: SHUT OFF VALVE
Connecting an This makes it possible to control an external valve, e.g. for a SHED application
external 3/2 valve (evaporative determination testing), in such a way that when the integrators are
switched on (see Chapter Control Commands on page 68) the gas can be
injected into the chamber. During the stabilization phase, the gas flows through
the valve into the extraction system. As a result, only so much gas is injected
that can be integrated.
Socket designation: XG8: BYPASS VALVE
Switching between This option allows switching between 2 gas bottles and is enabled by an addi-
C3H8 and CO tional 3/2-way valve. If C3H8 is selected on the device, no voltage is applied to
the output (0 V). If CO is selected, the voltage applied to this output is 24 V. (see
Chapter Parameters [F9] on page 46)
Socket designation: XG9: C3H8/CO SELEC. VALVE

5.2 Setting Flow Rate Manually via LC Display

1. Go to the Flow Mask and select the Main Menu by pressing [F2] .
2. Press [F2] to select the required gas.
3. Press [Back] to return to the Main Menu.
4. Call the "Set the Flow Rate" panel by pressing [F1].
5. Enter the required volume flow.
6. Press [Back] to return to the Main Menu.
7. Activate volume flow control by pressing [F8].

5.3 Setting Flow Rate Automatically via AK

1. Establish Ethernet communication (or, alternatively, serially) between the
host and the iCAL CFO (see Chapter AK Commands for Remote Control on
page 63)
2. SREM K0 puts device in Remote mode.
3. STBY K0 puts device into Standby mode.
4. SGAS K0 1 switches on Gas 1.
5. SDST K0 0.8 sets device volume flow to 0.8 slpm.
6. SMGA K0 activates volume flow control.
7. Allow the device to stabilize volume flow.
8. SINT K0 starts integrator and switches the external 3/2-way valve.

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32 Overview

AVL iCAL CFO — User’s Guide

 Display and Operation 33

6 Display and Operation

This section describes the basic operating elements and the structure of the
device's graphical user interface.
The operating concept was designed to meet the requirements of the AK
working group on the standardization of operator interfaces.

6.1 Display
The LC display is capable of a maximum pixel resolution of 240 x 128 and
displays maximally 16 lines at 30 characters per line in text mode. It has an inte-
grated back-light which can be switched on and off by pressing the key with the
lamp symbol.

6.2 Membrane Keypad

To operate the AVL iCAL CFO, a short-stroke keypad is used which is attached
to the front panel of the device.

8 3

7 4

6 5
Fig. 11 Membrane keypad

1 Function keys/numerical keys

2 Back to Main Menu
3 Cancel, Back to previous menu
4 Enter key. Ends input or opens selected field for input.
5 Arrow (cursor) keys for selecting a function or an input field and for
scrolling through possible input values.
6 Shift key: Numerical or function keys
7 Delete key, decimal point
8 Display back-light on/off

6.2.1 Operating with Cursor Keys and Enter Key

To start a function, select it with the cursor keys and activate it with the Enter key.
This manner of operation is suitable for beginners, because a short description is
displayed for each function. The current cursor position is indicated by a hori-
zontal bar.

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34 Display and Operation

6.2.2 Operating with Function Keys

When using the function keys to operate the device, the functions are started
directly by pressing the required function keys (F1 - F10). This manner of opera-
tion is suitable for experienced users, because this method is faster than with
using the cursor keys. With this method, however, no function description is
displayed.

6.2.3 Querying or Changing Parameters

To query or change parameters, activate the editing function by selecting the
required parameterization window and pressing the Enter key. The parameter
field has a black bar in the background and shows the cursor as an underscore
which can be moved using the right/left cursor keys. To change the displayed
value (number or letter) apply the up/down cursor keys.
Any changes made to the input field must be confirmed by pressing the Enter
key again. Then the input cursor disappears.
The OK function is in the top right corner of every parameter field. This function
is selected using the arrow keys. By pressing the Enter key after a change, the
changes are applied. After that, the changes are saved in the non-volatile
EEPROM memory.

6.2.4 Entering the Password

To access the Main Menu from any operating level, the correct password has to
be entered. For a description of the different access levels, see Access Levels
[F7] on page 44. The menu for entering the password is shown after activating
the chosen access level. The four-digit password is entered using the number
keys. After entering the correct password, the main menu for the respective
access level is shown. If the password you entered is incorrect, you are again
shown the Access Level menu. If no password is entered within 10 seconds, the
Access Level menu is hidden from view.

6.2.5 Software Version

After switching on the iCAL CFO an initialization window is shown, displaying the
software version and the unit's serial number. You may need this information
later. The current software version and the serial number can also be obtained in
the Access Level menu by pressing F2 and in the Manual Operation menu by
pressing F10 VERSIONS.

6.3 Menu Structure

Fig. 12 Menu structure, Main Menu

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 Display and Operation 35

Fig. 13 Menu structure, Manual Operation

AVL iCAL CFO — User’s Guide

36 Display and Operation

6.4 Flow Mask

After switching on the control unit, you are shown the Flow Mask. By pressing
the [Main] key you can access the Flow Mask from any given menu.

1 2 3

8 7 6

Fig. 14 Commands in the context menu

1 Device type: iCAL CFO

2 Current state
As there are more states than can be shown all at once, the display
switches between the states every second. The order and significance of
all states is described in Chapter 6.2.1 (Command ASTZ).
3 Operating mode
This field appears in all masks. There are three operating modes:
 1 horizontal line = Standard User
 3 horizontal lines = Pause
 4 horizontal lines = System Operator
4 Flow rate of iCAL CFO with current type of gas
A "#“ character indicates that the value is invalid.
5 Pressure and temperature at the inlet and temperature at the outlet
6 Input mode
This symbol is shown in all menus and masks.
F: Function keys
N: Number keys

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 Display and Operation 37

7 Function keys that allow you to display other menus or set the states (this
applies generally for all masks, however the displayed function keys are
not always the same):
F1: Standby. All functions can be canceled using this key. See Chapter
Standby [F1] on page 37
F2: For Manual Operation, see Chapter Manual Operation [F2] on
page 38
F3: For Remote Control via AK interface, see Chapter AK Commands for
Remote Control on page 63
F5: Shows further measured values; see Chapter Measuring Values [F5]
on page 37
8 Device error
If there are more than one pending errors, the error texts are shown one
after another in the bottommost row.

6.4.1 Standby [F1]

If the [F1] key is pressed in the Flow Mask, the current activity (e.g. measuring,
calibrating) is canceled and the device goes to Standby mode. The hardware
and integrators (counters) are prepared for performing a measurement.

6.4.2 Measuring Values [F5]

By pressing the [F5] key in the Main Menu, you can switch through three
different masks with measuring values, one after the other.
The first mask shows the calculated flow rate, temperature, pressure at inlet,
mass flow and the control value of the control valve.

Fig. 15 Measuring Values 1 mask

 By pressing the [Back] key, you are shown the Flow Mask again.
 If you press [F5] again, the second Measuring Values mask is shown. This
one shows the pressure at the outlet, the calculated pressure ratio and the
K factor for the nozzle.

AVL iCAL CFO — User’s Guide

38 Display and Operation

Fig. 16 Measuring Values 2 mask

If you press [F5] a third time, you are shown the volume integrators.

Fig. 17 Integrators mask

Pressing [F5] brings back the Flow Mask.

6.5 Manual Operation [F2]

6.5.1 General
In Manual Operation mode, settings are adjusted and various activities (e.g. leak
checks) are executed. Via the AK interface, queries are still possible, but no
control functions are possible via AK and no settings can be changed.
The Manual Operation mode can be set in the Flow Mask (see Chapter Flow
Mask on page 36) by pressing [F2]. The Main Menu is shown.

AVL iCAL CFO — User’s Guide

 Display and Operation 39

1 2

6 5
Fig. 18 Main Menu

6.5.1.1 Menu Masks

For an example of a menu mask, see Fig. 18. The operating principle is the
same for all menu masks.

1 Menu name, action to be executed

2 Current access level (see Chapter Flow Mask on page 36)
3 Menu options
Each of the menu options can be selected by applying the up and
down arrow keys; by pressing the Enter key, the selected function is
activated. Alternatively, it is also possible to press the relevant func-
tion key directly (F1, F2, F6, F7, F8, F9 or F10).
4 Brief description of the selected function
5 Input mode
This symbol is shown in all menus and masks.
F: Function keys
N: Number keys
6 Previous menu, accessible via the [Back] key

By pressing the [Back] key, you are always taken back to the previous mask.
Pressing the [Main] key always displays the Flow Mask.

6.5.1.2 Parameter Masks

Parameter masks are for displaying, entering or modifying parameter values. An
example of a parameter mask:

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40 Display and Operation

Fig. 19 Example of a parameter mask

 In the large field in the middle you are shown all parameters that can be
changed. If there are more than one input fields, the required field is
selected using the up/down arrow keys. The active input field is marked by
a black bar.
 To change the value in the marked input field, press the Enter key. The input
field starts showing a flashing cursor (horizontal line underneath the first
character). The cursor is moved by using the right/left arrow keys. It is only
possible to change one value at a time (the value at the position of the
cursor). To enter a value, either enter it directly via the keypad or use the
up/down arrow keys to scroll through the values (this way you can also
enter special characters or letters). Either apply your input by pressing
Enter or press the [Back] key if you do not wish to apply the changed value.
 In the smaller field below, a short description of the selected value is shown.
Possible values are shown in square brackets.
 The [Back] key takes you back to the previous menu and the Main key to
the main view.

6.5.1.3 Discrete Selection Fields

Discrete selection fields are input fields where you can only enter one value from
a list of predefined values. In discrete selection fields, an upright double arrow is
shown after activating the input field by pressing the Enter key.
To change an entry in a discrete field, proceed as follows:
1. Select the field as described above and press the Enter key.
2. Next to the field you are now shown a double arrow. The possible values
are displayed and adjusted using the arrow keys.
3. Press the Enter key to apply the set values.
The following figure shows a mask with a menu and a discrete selection field.

AVL iCAL CFO — User’s Guide

 Display and Operation 41

Fig. 20 Example of a mask with a discrete selection field

6.5.2 Flow Rate [F1]

Fig. 21 Flow rate selection mask

1. This is where you can set the injected volume flow for the AVL iCAL CFO
device. The value must be within the specified range. For information pur-
poses, the standard temperature and standard pressure are shown.
2. Press [F1] or [Back] to return to the Main Menu.

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42 Display and Operation

6.5.3 Gas [F2]

Fig. 22 Mask for selecting span gas

1. This is where you can select a span gas (you can choose between two dif-
ferent gases). If you select a gas number, a description of the gas is shown
in the field below. On system start, the gas set last is used.
2. Press [F1] or [Back] to return to the Main Menu.

6.5.4 Operations [F3]

Fig. 23 Operations mask

This is where operations are performed relating to test location change and leak
check.
Move Device [F1] After activating this option, the device will skip the stabilization time and immedi-
ately switch to normal operation mode the next time it is switched on.

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 Display and Operation 43

Fig. 24 Move Device mask

Leak Check [F5] This is where the leak check is started for the device.

Fig. 25 Confirm Choice mask

Now wait until the device's status (status bar) has changed to SLEC. After this
has been accomplished, the valves at the outlet and inlet have to be closed. Any
errors occurring are displayed.

6.5.5 Integration [F6]

Pressing F6 in the Main Menu allows you to perform a mass/volume integration
during a measurement. The integral value is displayed after pressing F5 in the
main view three times.

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44 Display and Operation

6.5.6 Access Levels [F7]

Fig. 26 Access Level mask

The "F5 Reset to Default“ function is only shown in the System Operator
access level.
The default settings for passwords are:
 Standard user no password
 Pause 3333
 System operator 4444
These passwords should be changed immediately after commissioning (see
Chapter Diverse Settings on page 56).
Standard User [F1] In the Standard User level no changes can be made to the system configuration
or the parameter settings. No password needs to be entered for this access
level. The Standard User level is set automatically after starting the system.
To deactivate the System Operator access level and access to the corre-
sponding functions, either select the Standard User level or restart the system.
Pause [F3] This function puts the system in Pause state. All power consuming devices are
switched off. The password for Pause must be entered.

Fig. 27 Mask for entering the password

The password consists of 4 characters; the default setting is "3333“. For safety
reasons, asterisks are shown instead of characters. When the characters are
entered, each one is replaced by an "x". After you have entered the last char-
acter of the password, a mask is shown that allows you to start the pause:

AVL iCAL CFO — User’s Guide

 Display and Operation 45

Fig. 28 Mask for starting the pause

1. To cancel the process, press the [F2] key. You are taken back to the Access
Level mask (see Fig. 26 on page 44).
2. Press F1 to start the pause. The Main Menu is shown; in the upper right
corner the symbol of the access level "Pause" is shown.
If you wish to terminate the pause, press the [F1] key. The device is restarted.
System Operator In the System Operator access level, all control unit functions are available. To
[F4] switch to this access level, the appropriate password has to be entered (see
Fig. 27 on page 44). After entering the correct password, the Main Menu is
shown and the symbol for the System Operator access level is displayed in the
upper right corner. If an incorrect password is entered, the Access Level menu
(see Fig. 26 on page 44) is shown again and the access level remains the same.
The default setting for the system operator password is "4444“.
Reset to Default This function restores the default setting for the passwords. After that, the Stan-
[F5] dard User access level is set automatically.

6.5.7 Measurement [F8]

 F8 is pressed to start and stop measurements.
 When starting a measurement, the valves are opened and the gas flow of
the iCAL CFO is adjusted to the set flow rate. The flow rate must be set
before starting the measurement (see Chapter Flow Rate [F1] on page 41).
When stopping a measurement, the valves are closed, which stops volume
flow.
 F6 starts and stops the integration of the measured values (see Chapter
Integration [F6] on page 43).

WARNING

Danger of explosion
Due to explosions caused by escaping gas, there is a risk of injury and damage
to property.
Connect the gas outlet correctly. The connections and the system to be tested
must not have any leaks.

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46 Display and Operation

WARNING

Danger of poisoning
Leaking gas leads to the danger of poisoning.
Connect the gas outlet correctly. The connections and the system to be tested
must not have any leaks.

6.5.8 Parameters [F9]

This function is only available in the System Operator access level.

Fig. 29 The Parameter Menu

6.5.8.1 Nozzle Settings

First enter the nozzle number of the nozzle you wish to change:

Fig. 30 Mask for selecting nozzle number

Select:
 1 - for Nozzle 1
 2 - for Nozzle 2
 3 - for the nozzle combination 1 + 2

AVL iCAL CFO — User’s Guide

 Display and Operation 47

To cancel the process, press [F1] or the [Back] key to return to the Parameter
Menu or press the [Main] key to show the Flow Mask.
After selecting the nozzle, you are shown the Nozzle Settings mask.

Fig. 31 Nozzle Settings mask

Calibration This function enables you to display and change the coefficients of the calibra-
tion polynomial for the selected nozzle and a specific gas. First, the gas must be
selected:

Fig. 32 Mask for selecting gas

1. Select gas (1 or 2).

2. To cancel the process, press the [F1] key and return to the Parameter
Menu; press the [Back] key to return to the Nozzle Settings or press [Main]
to go back to the Flow Mask.
After selecting a gas number, you can set the polynomial coefficients:

AVL iCAL CFO — User’s Guide

48 Display and Operation

Fig. 33 Menu for setting the polynomial coefficients

1. Select the coefficient you wish to change from a0 to a5. The mask shown in
Figure 30 is displayed.
2. To cancel the process, press the [Back] key and return to the gas selection.
3. To delete the current calibration polynomial, press the [F8] key. The polyno-
mial coefficients are set to the initial values a0=a2=a3=a4=a5=0; a1=1 and
the Parameter Menu is shown again.

Fig. 34 Mask for entering the polynomial coefficients

4. Enter the new polynomial coefficient. The standard values are: a0 = 0.0; a1
= 1.0; a2 = 0.0; a3 = 0.0; a4 = 0.0; a5 = 0.0
5. The [Back] key will take you back to the previous mask and the [Main] key
will take you to the Flow Mask.
Range Mini- With these two functions you can enter the smallest and the greatest value of the
mum/Range measuring range for the selected nozzle.
Maximum

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 Display and Operation 49

Fig. 35 Mask for entering range minimum or maximum

1. Enter the new minimum and/or maximum for the nozzle measuring ranges.
The measuring ranges for your CFO can be found in Chapter Versions on
page 17.
2. The [Back] key will take you back to the previous mask (see Fig. 31 on
page 47) and the [Main] key will take you to the Flow Mask.

6.5.8.2 Gas Settings

This is where you can enter a gas description and the gas density after selecting
the gas number. The Help line will then display the description.

Fig. 36 Mask for selecting gas

1. Choose gas 1 or gas 2. Next, the mask in Fig. 37 will open.

2. To cancel, press F1 or the [Back] key to return to the Parameter Menu or
press [Main] to return to the Flow Mask.
After selecting the gas number, a mask will appear where you can change the
gas description and the text for the gas density.

AVL iCAL CFO — User’s Guide

50 Display and Operation

Fig. 37 Gas Settings menu

Gas Description After selecting the gas description in the mask shown in Fig. 37, the following
mask is displayed:

Fig. 38 Mask for entering the gas description

1. Enter a new description string.

2. By pressing the [Back] key, you are taken back to the previous mask.
Pressing the [Main] key displays the Flow Mask.
Gas Density The density for the selected gas is set in the following mask:

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 Display and Operation 51

Fig. 39 Mask for entering the gas density

1. Enter the new gas density value.

2. By pressing the [Back] key, you are taken back to the previous mask.
Pressing the [Main] key displays the Flow Mask.

6.5.8.3 Sensor Settings

First, the sensor signal must be selected:

Fig. 40 Sensor Selection menu

 Inlet Pressure [F1]

 Inlet Temperature [F2]
 Outlet Pressure [F3]
After that, the following settings are possible:

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52 Display and Operation

Fig. 41 Sensor Settings menu

Sensor Lineariza- Each sensor can be calibrated using a fourth-degree or lower polynomial:
tion
x' = a0 + a1x + a2x2 + a3x3 + a4x4
The standard values are: a0, a2, a3, a4 = 0; a1 = 1 (no correction).

Fig. 42 Menu for setting the polynomial coefficients for sensor linearization

 The coefficients a0 to a4 are entered as described in Fig. 33 and Fig. 34.

 Pressing F8 deletes the current polynomial and you are taken back to the
mask shown in Fig. 41.
Sensor Minimum Enter the new minimum. The standard value is 0 kPa.

AVL iCAL CFO — User’s Guide

 Display and Operation 53

Fig. 43 Mask for entering the sensor minimum

Sensor Maximum Enter the new maximum. The standard value is 600 kPa.
Sampling Interval The value for the sampling interval indicates at which time interval the measured
values are sampled by the sensors. The standard value is 100ms.

Fig. 44 Mask for entering the sampling interval

Averaging The averaging value indicates the number of individual measured values the
displayed average is calculated from.
In whichever Sensor Settings sub-menu you may be, the [Back] key will always
bring you back to the mask shown in Fig. 41, and the [Main] key will take you
back to the Flow Mask.

Information

The Sampling Interval and Averaging values can affect flow control speed and
should therefore not be changed.

The standard values for the individual sensors are:

AVL iCAL CFO — User’s Guide

54 Display and Operation

Inlet pres- Inlet tem- Outlet

sure perature pressure
Calibration a0, a1, a2, a3, a4 0,1,0,0,0 0,1,0,0,0 0,1,0,0,0
Sensor minimum 0 kPa 223.15 K 0 kPa
Sensor maximum 600 kPa 623.15 K 250 kPa
Sampling interval 100 ms 500 ms 1000 ms
Averaging 1 1 1

Tab. 4 Standard sensor values

6.5.8.4 Display Settings

Fig. 45 Display Settings menu

Units This function allows you to change the units with which the measured values are
to be displayed. Please note that it will only change the value output displayed;
these settings have no effect on the entry of parameters via LCD and the AK
interface.

Fig. 46 Mask for setting display units

Select the unit you wish to change by using the arrow keys. Press Enter and use
the arrow keys to select the unit you require. Press the Enter key again to apply
your selection.

AVL iCAL CFO — User’s Guide

 Display and Operation 55

Standard settings:

Physic. Quantity Unit

Volume Flow slpm (standard liters per minute)
Mass Flow gpm (grams per minute)
Volume sl (standard liter)
Mass g (grams)
Pressure kPa (kilopascal)
Temperature K (Kelvin)

Tab. 5 Standard unit settings

Language This function allows you to set the language.

Fig. 47 Mask for setting language

After choosing the language, the Flow Mask appears and the Standard User
access level is set.
Update Rate This parameter allows you to set at which time interval the measuring values
mask is updated.

Fig. 48 Mask for setting the update rate

The value is specified in milliseconds. The standard value is 1000 ms (1 Hz).

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56 Display and Operation

6.5.8.5 Nozzle Switching

Fig. 49 Nozzle switching points

The values on the Nozzle Switching mask indicate which nozzle is switched.
Until the flow rate specified under Nozzle1 is reached, the first nozzle remains
switched. At higher flow rates, yet no higher than the flow rate specified under
Nozzle2, the second nozzle remains switched. For flow rates any higher, both
nozzles are switched.
The value is specified in slpm separately for both gases.

6.5.8.6 Diverse Settings

Fig. 50 Diverse Settings menu

Passwords This function allows you to change the system passwords.

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 Display and Operation 57

Fig. 51 Menu for changing passwords

Select the password you wish to change and press the Enter key. A mask will
appear where you can enter a new password.

Fig. 52 Mask for entering the new password

1. Enter the new password. The password must consist of 4 characters. The
default settings are:
– Pause 3333
– System operator 4444
2. The [Back] key will take you back to the mask shown in Fig. 51 and the
[Main] key will take you to the Flow Mask.
Standardization The Standardization Base panel specifies the standard values for pressure and
Base temperature which are used to calculate the flow rate. There are two standard-
ization bases, the Factory Base and the Conversion Base.

Information

The calibration data for the AVL iCAL CFO are based on the Factory Base. If the
Factory Base values are changed, the device has to be re-calibrated.

By default, the Conversion Base values are the same as the Factory Base
values. If the conversion values are changed, the flow rate is standardized to the
set pressure and temperature values. This makes it easier to use the AVL iCAL

AVL iCAL CFO — User’s Guide

58 Display and Operation

CFO with devices that have a standardization base other than the AVL iCAL
CFO calibration.

Fig. 53 Menu for setting the Standardization Base

1. The discrete field specifies whether the values apply for the Default Base or
the Conversion Base. To toggle between the two bases, select the discrete
field with the arrow keys and set the required standardization base using
the arrow keys. Confirm your choice with the Enter key.
2. Then choose whether the temperature or the pressure value is to be
changed. Press [F1] or [F2] or select the required function using the arrow
keys. The permissible range for temperature and pressure is shown in the
Help line whenever the respective function is selected.
3. Press the Enter key to show the mask for entering the new value. The input
masks for temperature and pressure look similar.

Fig. 54 Mask for changing a standardization value

1. Enter the new standard temperature and/or the new standard pressure. The
standard values are 293.15 K for temperature and 101.325 kPa for pres-
sure.
2. The [Back] key will take you back to Fig. 53 and the [Main] key will take
you to the Flow Mask.
Duration of This function enables you to set the Max. Measurement Time and the Flow
Operation Stabilization Time. (The Flow Stabilization Time function is described under
Stabilization Criterion on page 59.)

AVL iCAL CFO — User’s Guide

 Display and Operation 59

Fig. 55 Menu for setting duration of operation

After selecting a function and pressing the Enter key, a mask is shown where
you can enter the relevant value.

Fig. 56 Mask for entering Max. Measurement Time

1. The standard value for Max. Measurement Time is 600 s and the standard
value for Flow Stabilization Time is 10 s.
2. The [Back] key takes you back to the previous mask (Fig. 55) and the
[Main] key takes you to the Flow Mask.
Stabilization The Stabilization Criterion specifies the maximum permitted deviation of the
Criterion actual flow rate from the demand flow rate. If this tolerance is exceeded, the
actual flow rate is output with the prefix '#'. The stabilization criterion is used both
for setting the flow rate and during the measurement.
The stabilization criterion has the following effects:
 While the new flow rate is being set, the AVL iCAL CFO displays the status
SDST (setting flow rate).
 The system waits until the deviation of the actual flow rate from the demand
rate is within the value specified as stabilization criterion. During this period,
the actual flow rate is displayed with the prefix '#'.
 Now the stabilization time starts (see parameter Duration of Operation on
page 58). The flow rate is considered stable if, during this period, the devia-
tion of the actual value from the demand value is within the tolerance speci-
fied by the stabilization criterion. The '#' character disappears from the
output as soon as the flow rate is within the tolerance range. The SDST
status, however, indicates that the level setting is not yet complete.

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60 Display and Operation

 Once the flow rate is stable, the device switches to the SMGA status
(starting measurement).
The stabilization criterion also determines the maximum permissible deviation of
the actual flow rate from the demand value during a measurement. If this toler-
ance is exceeded, the output flow rate value has the prefix '#'.

Fig. 57 Mask for entering the Stabilization Criterion

1. Enter the stabilization criterion. The standard value is 1 %.

2. The [Back] key will take you back to the Diverse Settings menu and the
[Main] key takes you to the Flow Mask.
EEPROM Opera- This function allows you to make irreversible changes to the system configura-
tions tion, for example you can delete the calibration data.

Fig. 58 EEPROM Operations menu

1. If you activate the "Erase EEPROM" option, all parameter values saved in
the EEPROM are deleted and the standard values are loaded. This also
applies to the calibration data.
2. The [Back] key will take you back to the Diverse Settings menu (Fig. 50)
and the [Main] key takes you to the Flow Mask.
Host Interface This function allows you to change the parameters of the serial and network
interface (TCP/IP, optional) to the host computer.

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 Display and Operation 61

Fig. 59 Mask for setting the parameters for the host interface

COM [F2]

Fig. 60 Mask for setting the parameters for the serial interface

The serial interface parameters have to be entered in the following order: Baud
Rate, Parity, Data Bits, Stop Bits, Flow Control. The standard setting is:
"19200,N,8,1,0" (19200 baud, no parity check, 8 data bits, 1 stop bit and flow
control inactive)

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62 Display and Operation

TCPIP [F3]

Fig. 61 Mask for setting the parameters for the TCP/IP interface

To use the network, it is first necessary to set the TCP/IP address and the mask.
The port required for AK communication is also adjusted here. New settings are
not applied until the device is restarted.

6.5.9 Versions [F10]

F10 displays the version information on the current hardware and software.

Fig. 62 Mask for displaying version information

1. The [Back] key will take you back to the Main Menu.
2. Pressing the Enter key or the [Main] key displays the Flow Mask.

AVL iCAL CFO — User’s Guide

 AK Commands for Remote Control 63

7 AK Commands for Remote Control

The iCAL CFO can be remote controlled by a host computer via the Ethernet
interface (XF3) on the back of the device. Alternatively, remote control is also
possible via the serial RS232 connection (XF4). Communication is established in
accordance with the AK protocol specifications.
To set the host interface, see Chapter Diverse Settings on page 56

7.1 AK Command Format

All datasets have to start with STX (02H) and end with ETX (03H), regardless of
whether they are (received) commands or (transmitted) responses. It is also
necessary to send a Don't-Care byte (e.g. "_") with every dataset.
The commands must have the following format:

Byte Content
1 STX
2 Don’t Care
3..6 Command (e.g. "SREM")
7 .. 7+n-1 Command parameter (e.g. "K0")
7+n ETX

Tab. 6 General AK command format

AK commands consist of 4 characters. Although not part of the protocol, three

types of commands have been agreed upon:
EXXX Setting commands
AXXX Query commands
SXXX Control commands

After an AK command, there must always be a blank and the command parame-
ters must also be separated by blanks. Example: AMBE K0 1
After such a command is sent to the control unit, the control unit returns a
response. The response format is always the same, regardless of which type of
command was sent:

Byte Content
1 STX
2 Don’t Care
3..6 Command (e.g. "SREM")
7 Blank
8 Error status
9.. 9+n-1 Response parameter
9+n ETX

Tab. 7 General AK response format

The error status code is 0 if there is no error in the system. Every time the
system errors change, the status code increases by 1 (also if the error was elim-
inated and there is still at least one error left in the system). If the status code is
9 and the error status changes with at least one error left in the system, it is reset
to 1.

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64 AK Commands for Remote Control

An unknown command is always acknowledged with "????". Example: SARS 0

Legend for the following commands

Letter Example Description

s SREM s Error status byte
n SMGA Kn Channel number (1..n)
a, b, ... ENOR K0 a b Parameter

7.2 Query Commands

General syntax:
Axxx K0 <Parameter>
The channel ID K0 comes after every Axxx command and is separated by a
blank. No other channels are accepted. Optional parameters are separated from
each other by blanks.

7.2.1 ACAT Calibration Date

Command Response Description

ACAT K0 ACAT s d t Query calibration date.
d = date, format YYYYMMDD
t = time, format hhmm

7.2.2 ACFO Calibration Polynomial - Current Nozzle and Current Gas

Command Response Description

ACFO K0 [n g] ACFO s a1 .. a5 Query for the calibration polynomial of a nozzle/gas combi-
nation.
n = Nozzle (1-3)
1 = Nozzle 1
2 = Nozzle 2
3 = Nozzle 1 + Nozzle 2
g = Gas (1/2)
If n and g are not specified, the polynomial for the current
nozzle/gas combination is returned.
a1 .. a5 = polynomial coefficient

AVL iCAL CFO — User’s Guide

 AK Commands for Remote Control 65

7.2.3 AFDA Duration of Operation

Command Response Description

AFDA K0 cd AFDA s d Query duration of operation.
cd = function
SMGA = max. measurement time
SDST = stabilization time after starting a measurement or
changing the flow rate settings during a measurement
d = duration [s]

7.2.4 AGAS Span Gas and Density

Command Response Description

AGAS K0 [gi] AGAS s g d Query span gas name and density
gi = gas number (0 or empty = all span gases)
g = gas name
d = density [kg/m³]

7.2.5 AIKG Main Volume Integral Value since SINT

Command Response Description

AIKG K0 AIKG s v v = volume [l], independent of AIKO command

7.2.6 AIKO Main Volume Integral Value since SINT or since Last AIKO Command

Command Response Description

AIKO K0 AIKO s v v = volume [l], independent of AIKG command

7.2.7 AKEN Device ID

Command Response Description

AKEN K0 AKEN s GTyp SWVer OSVer Queries device ID.
User GTyp = device type (“iCAL-CFO”)
SWVer = software version (always "ver“ and version
number: e.g. “ver1.030”)
OSVer = operating system version (e.g. "OS3.036")
User = user-specific part (e.g. "AVL_iCAL_CFO“) (25 char-
acters maximum)

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66 AK Commands for Remote Control

7.2.8 AMAB Mass Integral Value Dependent on One or All Bags

Command Response Description

AMAB K0 AMAB s M1 .. Mn M1 .. Mn = mass integral values for all bags [g]
AMAB K0 0 AMAB s M1 .. Mn M1 .. Mn = mass integral values for all bags [g]
AMAB K0 n AMAB s V n = bag number
V = mass integral value for bag n [g]

7.2.9 AMBE Measuring Range

Command Response Description

AMBE K0 c AMBE s a b Queries measuring range of a measurement point.
c = measurement point
0 = inlet pressure [kPa]
1 = outlet pressure [kPa] (optional)
3 = block temperature [K]
16 = Nozzle 1 [l/min]
17 = Nozzle 2 [l/min]
a = range minimum in the respective unit
b = range maximum in the respective unit

7.2.10 AMDT Measured Data

Command Response Description

AMDT K0 AMDT s q pi ti po Queries measured values.
q = current standard flow [l/min] based on the set standard-
ization base (see ANOR and ENOR), '#' prefixed if invalid
pi = current inlet pressure [kPa]
ti = current block temperature [K]
po = current outlet pressure [kPa]

7.2.11 ANOR Standardization Base

Command Response Description

ANOR K0 ANOR s tn pn Query of standardization base.
tn = standard temperature [K ]
tp = standard pressure [kPa]

AVL iCAL CFO — User’s Guide

 AK Commands for Remote Control 67

7.2.12 ANUM Serial Number

Command Response Description

ANUM K0 ANUM s x Query of serial number.
x = serial number

7.2.13 ASEK Measured Value from Sensor

Command Response Description

ASEK K0 c ASEK s v Query of the corrected measured value from a sensor.
c = measurement point
0 = inlet pressure [kPa]
1 = outlet pressure [kPa]
3 = block temperature [K]
v = corrected measured value

7.2.14 ASTF Error

Command Response Description

ASTF K0 ASTF f f1 .. fn Query of pending errors
n = number of errors
f1..fn = error number

7.2.15 ASTZ Status

Command Response Description

ASTZ K0 ASTZ s ins devs bps1 bps2 Query of AK status.
bps3 bps4
ins = remote status (SREM / SMAN)
devs = process status (SBPF / SBPS / SDST / SKAL /
SKAS / SMGA / SPAU / SRES / STBY)
bps1..4 = bag pair status 1.. 4 (SBPF / SBPS / STBY /
XXXX)

7.2.16 AVAB Volume Integral Value Dependent on One or All Bags

Command Response Description

AVAB K0 AVAB s V1 .. Vn V1 .. Vn = volume integral values for all bags [l]
AVAB K0 0 AVAB s V1 .. Vn V1 .. Vn = volume integral values for all bags [l]
AVAB K0 n AVAB s V n = bag number
V = volume integral value for bag n [l]

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68 AK Commands for Remote Control

7.2.17 ASWP Nozzle Switching

Command Response Description

ASWP K0 n ASWP s P1 P2 n = gas number
P1 = lower switching point [slpm]
P2 = upper switching point [slpm]

7.3 Control Commands

General syntax:
Sxxx Kn <Parameter>
The channel ID K0 comes after every Sxxx command and is separated by a
blank. No other channels are accepted. Optional parameters are separated from
each other by blanks.

7.3.1 SBPF Start Volume Integration for the Bag Pair

Command Response Description

SBPF K0 n SBPF s Starts volume integration for a bag pair.
n = bag pair

7.3.2 SBPS Stop Volume Integration Depending on Bag Pair

Command Response Description

SBPS K0 SBPS s Stops volume integration for the current bag pair.

7.3.3 SDST Set Flow Rate

Command Response Description

SDST Ko q SDST s Sets flow rate
q = flow rate [l/min]

7.3.4 SGAS Set Span Gas

Command Response Description

SGAS K0 g SGAS s Sets calibration gas.
g = gas number

AVL iCAL CFO — User’s Guide

 AK Commands for Remote Control 69

7.3.5 SINT Start Volume Integration

Command Response Description

SINT K0 SINT s Starts volume integration.

7.3.6 SMAN Manual

Command Response Description

SMAN K0 SMAN s Switches device to manual operation. No E and S
commands (except for SREM) are accepted by the AK
interface.

7.3.7 SPAU Pause

Command Response Description

SPAU K0 SPAU s Switches device to Pause.

7.3.8 SMGA Measurement

Command Response Description

SMGA K0 SMGA s Starts measurement.

7.3.9 SREM Remote Control

Command Response Description

SREM K0 SREM s Switches device to remote control.

7.3.10 SRES Reset

Command Response Description

SRES K0 SRES s Resets device.

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70 AK Commands for Remote Control

7.3.11 STBY Standby

Command Response Description

STBY K0 STBY s Switches device to Standby.

7.4 Setting Commands

General syntax:
Exxx Kn <Parameter>
The channel ID K0 comes after every Exxx command and is separated by a
blank. No other channels are accepted. Optional parameters are separated from
each other by blanks.

7.4.1 EFDA Duration of Operation

Command Response Description

EFDA K0 cd d EFDA s Sets duration of operation.
cd = function
SMGA = max. measurement time
SDST = stabilization time after starting a measurement or
changing the flow rate settings during a measurement
d = duration [s] (0 = no time control)

7.4.2 EGAS Span Gas and Density

Command Response Description

EGAS K0 gi g d EGAS s Sets span gas name and density
gi = gas number (1/2)
g = gas name
d = density [kg/m³]

7.4.3 EKEN User Part of Device ID

Command Response Description

EKEN K0 user EKEN s Sets user-specific part of the AKEN command.
user = User ID

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 AK Commands for Remote Control 71

7.4.4 ENOR Standardization Base

Command Response Description

ENOR K0 t p ENOR s Sets standardization base.
t = standard temperature [K ]
p = standard pressure [kPa]

7.5 Error Numbers via AK

Information

The following table contains a list of all error codes of the control unit. At the
occurrence of an error, the error codes are sent via the AK interface (see ASTF
Error on page 67) and the error text is shown in the bottom line of the display
(see Chapter Flow Mask on page 36)..

Error Code Description Text on LC Display

11 An OCC device command error OCC Command
12 Internal OCC error in communicating with the oper- OCC OS Error
ating system (sensor calibration)
13 An error was delivered from an OCC device OCC Device Error
(internal program communication)
14 Some OCC protocol error (syntax error) OCC Protocol
36 Non-compatible OCC protocol version OCC Version
150 Tried to activate a non-existing nozzle stage Wrong Valve Stage
153 Tried to activate a non-existing ball valve Wrong Ball Valve
154 Tried to activate a non-configured gas Wrong Gas
200 Error reading or writing one byte value of the EEPROM Byte
EEPROM (internal error)
201 Error reading or writing a four byte value of the EEPROM Long/Float
EEPROM (internal error)
202 Error reading or writing a string value of the EEPROM String
EEPROM (internal error)
210 Tried to adjust a digital output that is not used by Wrong Digital Output
the system
211 Tried to adjust an analog input (sensor) that is not Wrong Sensor
used by the system
214 Tried to run wrong or non-existing process (internal Wrong Process
error)
215 Tried to access non-defined EEPROM data group EEPROM Group
216 Tried to access non-defined EEPROM group posi- EEPROM Position
tion
217 Illegal value for EEPROM position (string too long) EEPROM Value
218 Tried to operate a non-existing bag pair Wrong Bag Pair

Tab. 8 Error codes via AK

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72 AK Commands for Remote Control

Error Code Description Text on LC Display

219 Tried to adjust a non-existing main flow stage Wrong Main Stage
225 The pressure ratio between the inlet and outlet of Non-Choked Venturi
the venturi is too low
for correct measurement
228 An operation took too long Operation Time Limit
231 Problem in communication due to wrong host inter- Host Communication
face configuration
232 Wrong TCP/IP configuration TCPIP Configuration
240 An unknown OCC command was received via Unknown Command
Center OCC interface
241 An unknown OCC group was received via Center OCC Group
OCC interface
254 Heat exchanger out of temperature range Temperature Limit

Tab. 8 Error codes via AK

7.6 Example of How to Perform a Test

To run a leak check, the following commands are sent to the AVL iCAL CFO.
While it is being run, AMDT and ASTZ are queried cyclically.

1. SREM K0
2. STBY K0
3. SDST K0 1.55
4. SGAS K0 1
5. SMGA K0
6. Wait for status SMGA in ASTZ.
7. Fill bag, wait
8. STBY K0

AVL iCAL CFO — User’s Guide

 Calibration 73

8 Calibration
Intervals The calibration of the nozzles is valid for 1 year; then (in accordance with ISO
9000) the device has to be inspected and, if necessary, re-calibrated. The cali-
bration results are recorded in the calibration report (see example Fig. 63) and
are kept together with the device.

Fig. 63 Example of a calibration report

The switching point from Nozzle 1 to Nozzle 2 is calculated as follows:

Switching point = (maximum flow rate Nozzle 1 [lpm] + minimum flow rate Nozzle
2 [lpm]) / 2
Accordingly, the following applies for the nozzles:
Nozzle 1: (flow rate > min. flow rate Nozzle 1) and (flow rate < switching point)
Nozzle 2: (flow rate >= switching point) and (flow rate < max. flow rate Nozzle 2)

AVL iCAL CFO — User’s Guide

74 Calibration

Nozzle 1+ 2: Flow rate >= maximum flow rate Nozzle 2

Information

The current device flow rate is calculated based on pressure, temperature and
the K-Factor (see Chapter Volume Flow Calculation on page 26)

The nozzles' valid flow ranges can be queried using the AK command (ASWP
Nozzle Switching on page 68) or manually via the LCD/keyboard (Nozzle
Switching on page 56).

Example
Nozzle 1: 0.2 - 0.6 lpm
Nozzle 2: 0.4 - 1.3 lpm
Switching point = (0.6 + 0.4 ) lpm / 2 = 0.5 lpm
I.e.
Nozzle 1: 0.2 < flow rate <= 0.5
Nozzle 2: 0.5 < flow rate <= 1.3
Nozzle 1 + 2: Flow rate > 1.3

AVL iCAL CFO — User’s Guide

 Maintenance and Cleaning 75

9 Maintenance and Cleaning

NOTICE

The device must be sent in for maintenance once a year. Maintenance jobs must
be performed exclusively by AVL personnel. The device contains no installed
parts that need to be replaced by the user.

Provided that there are no malfunctions at the time, the annual maintenance of
the iCAL CFO is carried out according to the following scheme:
 Eliminate any existing errors
 Perform the jobs in the maintenance list
 Electrical testing
 Physical testing
For the maintenance itself, a maintenance report is created.

Component Detail T C S Note

Gas supply Valves X X Replace if
required
Filter X X Replace if
required
Nozzle X X
Seals X X Replace if
required
Hoses X X
Pressure sensors X X
Temperature sensors X X
Electrical testing X
Physical testing X

Tab. 9 Maintenance schedule

T Testing
C Cleaning
S Setting

Information

To clean the surfaces, exclusively use a cloth moistened with water.

NOTICE

Prior to operate the device after a repair or service schedule, at least once a
year, a leak check has to be executed. A harmless gas (e. g. nitrogen) has to be
connected and used instead of the injection gas (C3H8/CO) during this. For infor-
mation how to execute a leak check, see Operations [F3] on page 42

AVL iCAL CFO — User’s Guide

76 Maintenance and Cleaning

AVL iCAL CFO — User’s Guide

 Return and disposal 77

10 Return and disposal

Only for EU
countries NOTE

Do not put power tools in domestic waste!

Do not put power tools in domestic waste!

According to the European Directive 2002/96/EC about electrical and electronic

waste and is implementation in national law, no longer usable power tools must
be collected separately and taken for recycling in accordance with the environ-
mental regulations.

Equipment Return AVL Emission Test Systems takes back its measuring systems provided the AVL
Emission Test Systems return conditions are fulfilled.
The take-back obligation applies to equipment which is operated within the EU.
AVL Emission Test Systems does not bear the costs for the dismantling and the
transport.
Individual components, e. g. IT parts can be sent to AVL Emission Test Systems
after consultation with the Technical Service.
Disposal of our equipment using the municipal collection points is basically not
permitted.
Please bear in mind that the equipment will be dismantled manually and the
disposal personnel must not be endangered in doing so.
Return Conditions Liquids (condensate bottle if present) must be removed and disposed of by the
customer. Service gas lines must be decoupled and the measuring system
prepared for the transport.
The customer is obligated to inform AVL Emission Test Systems about this in
writing before shipment.
Non-EU Countries Take power tools, accessories, and packaging to collection points where they will
be recycled in an environmentally safe manner in accordance with the environ-
mental regulations applicable in the country of operation.
Substances For a list of the substances contained in the devices, please contact AVL.
contained in the
equipment

AVL iCAL CFO — User’s Guide

78 Return and disposal

AVL iCAL CFO — User’s Guide

 Technical Data 79

11 Technical Data

11.1 Device Specifications

Dimensions 19’’ housing, 3 rack units, 45 cm mounting depth

(˜ 480 × 130 × 450 mm)
Weight 12 kg
Power supply 100–120 VAC ±10 % 50/60 Hz
230 VAC ±10 % 50 Hz
Power consumption 175 W
Overvoltage cate- II
gory
Fuses 125 V: Microfuse slow blow 5 × 20 mm 2.5 A
250 V: Microfuse slow blow 5 × 20 mm 1.25 A
User interfaces Serial RS232 V.24, 10/100MBit Ethernet
Ambient conditions Temperature: 5–35 °C (41–95 °F)
rel. air humidity: up to 80 % relative humidity, no condensation
maximal height above sea level: 2000 m
vibration-free
Storage conditions Temperature: 5–50 °C (41–122 °F)
rel. air humidity: up to 80 % relative humidity, no condensation
Inlet gas C3H8 (C0, N2 on request)
Inlet pressure 7 ±0.5 bar rel.
Main inlet filter 15 µm
Max. outlet pressure Approx. half the control pressure upstream of the critical orifice
Outlet volume flow iCAL CFO Light Duty, Low Emission (iCAL CFO LD-LE):
CO 80 – 560 smlpm
C 3H 8 50 – 430 smlpm
iCAL CFO Light Duty (iCAL CFO LD):
CO 240 – 2050 smlpm
C 3H 8 180 – 1570 smlpm
iCAL CFO Medium Duty (iCAL CFO MD):
CO 380 – 2950 smlpm
C 3H 8 320 – 2240 smlpm
iCAL CFO Heavy Duty (iCAL CFO HD):
C 3H 8 1 – 10 slpm
Stabilization time Approx. 40 sec with Medium and Light Duty device
Approx. 2 min. with Heavy Duty device
Flow accuracy iCAL CFO LD:
0.3% of the set flow rate
iCAL CFO MD:
0.3% of the set flow rate
iCAL CFO HD:
0.5% of the set flow rate
Max. injection time 10 minutes
Pressure measure- 0–7 bar abs., non-linearity and hysteresis ±0.04 % F.S.
ment

Tab. 10

AVL iCAL CFO — User’s Guide

80 Technical Data

Temperature PT100, class A: dt= ± (0.15 + 0.002 x T)

measurement valid for temperatures between –200 °C and +650 °C
Gas connections 1/4" or 6 mm Swagelok
Material of parts Stainless steel (V4A), seals made of Viton, hoses made of PFA
carrying gas
(internal)

Tab. 10

AVL iCAL CFO — User’s Guide

 Index 81

Index
A linearization … 52
access level load default setting for passwords … 45
setting … 44
average … 53 M
main key … 33
B main menu … 39
manual operation
back key … 33
general operation … 38
MD … 14, 17
C measuring values … 37
calibration … 47 membrane keypad … 33
Calibration Date … 64
calibration polynomial … 47, 64 N
change of test location … 42
command format … 63 network interface … 30, 62
control commands … 68 nozzle settings … 46

D O
discrete selection fields … 40 operations … 42
display … 33
display settings … 54 P
displayed units … 54 parameter menu … 46
Disposal … 77 password
duration of operation … 58 change … 56
entering … 44
E pause … 44
EEPROM operations … 60
entering access authorization … 44 Q
error query commands … 64
via AK … 71
Ethernet … 30, 62 R
range … 52
F remote control … 63
flow mask … 36 RS232 … 30, 61
flow rate
setting … 41 S
safety messages … 5
G sampling interval … 53
gas selecting span gas … 42
connection … 29 sensor settings … 51
density … 50 serial interface … 30, 61
description … 50 Serial Number … 67
settings … 49 setting commands … 70
standard
H pressure … 57
temperature … 57
HD … 14, 17
host interface … 60, 63 standard user … 44
system operator … 44
I
T
Initial Commissioning … 77
TCP/IP interface … 30, 62
typographic conventions … 14
K
keypad … 33 U
update rate … 55
L
language … 55 V
LD … 14, 17
LD-LE … 14, 17 version … 34
leak check … 43 versions … 62
volume flow

AVL iCAL CFO — User’s Guide

 Index 82

calculation … 26
setting … 31
volume integrators … 38

W
warranty … 13

AVL iCAL CFO — User’s Guide

FOR FURTHER INFORMATION PLEASE CONTACT:

AVL Emission Test Systems GmbH

Graf-Landsberg-Straße 1c, D-41460 Neuss, Germany
Phone.: +49 2131 / 5124-0, Fax: +49 2131 / 5124-111
www.avl.com/ets