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Auto Calibration

MagiKalTM - Automatic Sensor Calibration

MagiKal 1000
MagiKalTM, UnitKal-DX™ and MagiKal II Cuts Sensor Maintenance Cost!
(UnitKal-DX™ is a smaller version of MagiKalTM system. )

(MagiKal II is a stand-alone unit for automatic calibration.)

Rel-Tek's MagiKalTM system takes the labor out of gas sensor maintenance. Repetitive and tedious "manual" sensor recalibration can cost a bundle over the life of a system. It eliminates the costly labor that is otherwise paid out regularly for manually re-calibrating an array of gas sensors installed around your garage, plant, lab, tunnel or mine. MagiKalTM represents a modest extra investment at the outset, but pays for itself again and again over the years.

To cut the persistent manual calibration cost, Rel-Tek has pioneered in the development of automatic calibration equipment. The MagiKalTM features are now built into Rel-Tek's Millennia-DX monitoring and control software. Recent installations included two municipal vehicle maintenance garages in Detroit, MI -- one with 32 carbon monoxide sensors and the other with 16 methane sensors.

Automatic calibration runs can be scheduled for slow times, when taking a group of sensors out of service for 15-20 minutes -- the duration of a typical automatic calibration run -- is not a problem. The dedicated MagiKalTM equipment, which is permanently connected to up to 32 gas sensors, is 100% controlled by the remote monitoring computer. The complete zero/span calibration of an array of sensors is executed automatically, unattended and with zero labor.

Software MagiKal
MagiKalTM first disables alarms and then introduces zero and span calibration gas alternately into each sensor block through an array of distribution tubing. The computer precisely adjusts the zero and span values to within 1-bit (1/4096 or +/- .025%) resolution. Large tanks of zero and span cal gas provide references to NBS accuracy. A single set of tanks can supply gas for weekly calibrations of a 32-sensor array for a year or more -- a cost savings, compared with dozens of portable (manual cal) tanks that would otherwise be needed. Test reports can be printed showing all adjustments made, while flagging any sensors requiring special attention. Results are logged to hard disk for archival reference and off-line review. A graphic screen shows the calibration process.
In the past, figuring 15 minutes of labor for manually calibrating just one sensor, a facility with 100 sensors could spend 300 man-hours or more every year for monthly calibrations, easily reaching a $15,000 annual budget. Now, a MagiKalTM investment can pay for itself in less than a year.

Besides saving labor cost, MagiKalTM offers other benefits. The tedious and risky lifts and ladders needed to approach sensors -- usually sited in hard to reach places -- are avoided, thus eliminating a safety hazard. And, MagiKalTM avoids the downtime and trouble of shuffling vehicles, moving stored materials and the like to gain physical access to the sensors, a costly procedure. Then, too, MagiKalTM avoids the human errors that usually accompany manual testing. And, if there is ever a question of sensor accuracy, just key in an extra MagiKalTM run. Or"simply" set the program to calibrate every day.

Sensors need not all be of the same type, although, at the present, MagiKalTM processes just one type sensor on each calibration run. For a mix of sensors -- say, CO, CO2 and CH4 - one set of tanks can usually be custom mixed to cover all three sensor types. Multiple calibration runs are programmed to cover all sensor types. MagiKalTM can handle virtually any sensor array, whether in a cluster or strung out linearly as in a tunnel. Indeed, upcoming tunnel projects are calling for automatic calibration, because of the inconvenience and high cost of diverting traffic while recalibrating manually.

Software MagiKal Dolly
Rel-Tek's wheel-about "MagiKal TM -WA" scheme can further economize a large sensor installation. Mounting the cal gas tanks and control panel on a 4-wheeled cart permits the system to service any number of pre-configured sensor groups. This eliminates the multiple stationary MagiKal TM units, but requires someone to reposition the cart, make the two plug-in connections, and push the start button. The rest is automatic, and the attendant can leave for a half hour. Panel lights show the calibration process status. On completion, sensors are automatically returned to operation, and the threshold alarms and controls are re-activated.

MagiKal TM can easily be retrofitted to an existing Rel-Tek monitoring installation. Millennia-DX software runs on a PC under Windows-2000 , providing integrated data acquisition, remote networking, alarming, controls, graphics, logging and the like. Compatible field I/O cards assure 100% data transfer reliability and high speed. Originally developed for the rigors and multi-mile extent of underground mining, the robust system represents an integrated plant, lab, tunnel or mine monitoring/control package -- now including MagiKal TM . Patent is applied for. Hazardous area approvals are available.

Click here for MagiKal TM demonstration graph.

software MagiKal Unitkal


UnitKal-DX™ is a small version of Rel-Tek's MagiKal TM system. MagiKal TM was developed to calibrate up to 32 sensors at a time, ideal for above ground applications involving a large numbers of sensors concentrated in a particular locale. UnitKal-DX, however, was developed as an economical utility for mining, where sensors are scattered along a conveyor belt, and where only one or two sensors are within reasonable cal-gas delivery range.