Junray ZR-1610 On-line Cleanroom Particle Counter Calibration System
| Brand | Junray |
|---|---|
| Origin | Shandong, China |
| Manufacturer Type | Direct Manufacturer |
| Country of Origin | China |
| Model | ZR-1610 |
| Dimensions | 220 × 310 × 600 mm |
| Power Supply | AC |
| Display | 7-inch high-brightness capacitive touch screen |
| Operating Temperature Range | Wide-temperature industrial grade |
| Airflow Control Range | 2–5 L/min |
| Aerosol Generation | 4 independent constant-output nebulizers |
| Particle Size Channels | Simultaneous real-time acquisition across 6 calibrated size bins |
| Integrated Features | Built-in compressed air source, heated desiccant dryer, multi-stage filtration & humidity control, ESD- and impact-resistant enclosure |
| Compliance Reference | JJF XXXX–201X (Draft) “Calibration Specification for On-line Particle Counters”, GB/T 6167–2007 “Test Methods for Performance of Particle Counters”, JJF 1190–2008 “Calibration Specification for Particle Counters” |
Overview
The Junray ZR-1610 On-line Cleanroom Particle Counter Calibration System is a fully integrated, portable calibration platform engineered for traceable, in-situ verification of on-line airborne particle counters deployed in ISO Class 3–8 cleanrooms, pharmaceutical manufacturing suites, semiconductor fabrication environments, and controlled medical device production areas. Unlike benchtop calibration units requiring instrument removal, the ZR-1610 enables field-based, flow-through comparative calibration using the principle of concurrent parallel measurement: a reference-grade particle counter—traceably calibrated against NIST-traceable polystyrene latex (PSL) standards—is hydraulically and pneumatically coupled in series with the unit under test (UUT). This configuration ensures identical aerosol exposure conditions (flow rate, residence time, particle diffusion profile), minimizing inter-unit variability and enabling quantitative assessment of counting efficiency, size resolution, and zero-count stability per ISO 21501-4 and IEST-RP-CC006.2.
Key Features
- Integrated dual-stage air management system: built-in oil-free diaphragm compressor paired with a thermally regulated desiccant dryer and HEPA/ULPA pre-filtration, delivering ≤30% RH, oil-free, particle-free dilution air at stable 2–5 L/min (±1% full-scale repeatability).
- Four independently controllable PSL aerosol generators, each optimized for monodisperse output at nominal diameters of 0.1, 0.2, 0.3, 0.5, 0.7, 1.0, 2.0, and 5.0 µm—enabling sequential or simultaneous challenge across six user-selectable size channels.
- Ruggedized industrial enclosure with IP54-rated front panel, anti-static coating (surface resistivity <1×10⁹ Ω/sq), reinforced corner guards, and shock-absorbing mounting feet—certified for operation in ambient temperatures from –10 °C to +50 °C.
- 7-inch sunlight-readable TFT-LCD capacitive touchscreen with intuitive Chinese/English bilingual GUI; supports real-time overlay of UUT vs. reference counter histograms, deviation trending, and automated pass/fail flagging per JJF 1190–2008 acceptance criteria.
- On-board data logging (≥16 GB internal flash) with timestamped CSV export via USB-C; optional Ethernet/Wi-Fi module enables remote monitoring and integration into MES/QMS platforms supporting OPC UA or Modbus TCP protocols.
Sample Compatibility & Compliance
The ZR-1610 is compatible with all major makes and models of on-line particle counters utilizing light-scattering photometry (e.g., TSI, Climet, Lighthouse, Particle Measuring Systems, Kanomax), including those with isokinetic sampling inlets and continuous monitoring configurations. It meets the technical requirements defined in JJF XXXX–201X (Draft National Calibration Specification for On-line Particle Counters), GB/T 6167–2007, and JJF 1190–2008 for calibration uncertainty budgets, flow accuracy, size bin alignment, and counting efficiency verification. The system’s reference counter is factory-calibrated against PSL standards certified by CNAS-accredited laboratories (ISO/IEC 17025), with calibration certificates including expanded uncertainty (k=2) for each size channel. Full audit trails—including operator ID, calibration date, environmental parameters (T/RH), and raw count data—are retained to support GLP/GMP compliance and FDA 21 CFR Part 11 electronic record integrity requirements.
Software & Data Management
Junray CaliSuite™ v3.2 firmware provides embedded calibration workflow automation: automatic flow stabilization detection, aerosol ramp-up sequencing, synchronized data capture at 1 Hz resolution, and real-time calculation of relative counting error (RCE), size cutoff deviation, and false count rate. Exported datasets conform to ASTM E29–23 formatting conventions and include metadata headers compliant with ISA-88/ISA-95 data exchange standards. Optional cloud synchronization (via TLS 1.2–encrypted HTTPS) enables centralized calibration history tracking across multi-site facilities. All software modules undergo annual functional verification and are version-controlled with documented change logs available upon request for regulatory audits.
Applications
- Periodic performance verification of permanently installed particle monitors in Grade A/B pharmaceutical isolators and filling lines.
- Pre- and post-maintenance validation of HVAC-integrated particle sensors in microelectronics clean fabs.
- Commissioning support for new cleanroom builds requiring ISO 14644-1 classification reports with metrologically defensible instrument uncertainty budgets.
- Root-cause analysis during non-conformance events involving particle excursions—correlating sensor drift with environmental shifts or filter degradation.
- Training and competency assessment for facility engineers performing routine sensor health checks per ISO/IEC 17025 Clause 6.4.
FAQ
Does the ZR-1610 require external compressed air or nitrogen supply?
No—the system includes a maintenance-free, oil-free diaphragm compressor and integrated drying/filtration, eliminating dependency on facility gas utilities.
Can it calibrate particle counters with flow rates exceeding 5 L/min?
The ZR-1610 is designed for direct in-series calibration of instruments operating at ≤5 L/min. For higher-flow systems (e.g., 28.3 L/min), a flow splitter manifold kit (optional accessory ZR-FS28) must be used to maintain laminar, isokinetic sampling conditions.
Is the reference particle counter included in the base configuration?
Yes—the ZR-1610 ships with a factory-calibrated, NIST-traceable reference counter (model ZR-RC1000) mounted internally, with valid calibration certificate and uncertainty budget documentation.
How frequently must the ZR-1610 itself be recalibrated?
Annual recalibration of the reference counter and volumetric flow sensor is recommended; Junray provides accredited recalibration services with turnaround ≤10 business days and loaner unit availability.
Does the system support automated report generation compliant with Annex 1 (2022) requirements?
Yes—CaliSuite™ generates PDF reports containing instrument IDs, environmental conditions, raw data plots, pass/fail determinations per JJF 1190–2008, and digital signatures meeting ALCOA+ principles for data integrity.
