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1. 88r 32921 L Sss3JHAAY K245 Issue No 3 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 2 9 Aeronautical Option Range 1 SUPPLY OUTLET VENT SUPPLY OUTLET VENT O OOO ner O OOO Figure 2 11 Altimeter Checks Typical Pressure Range 35 1310 mbar abs 1 0 38 68 inHg Range 1 Range 2 SUPPLY OUTLET VENT SUPPLY OUTLET VENT 5 zs O OO O G O O GO O Open to Atmosphere Static Figure 2 12 Check Airspeed Indicator or MACH meter Notes 1 Select Go To Ground to ensure zero pressure before connecting the ASI or Mach meter 2 Reference port on Range 1 is common for Range 1 and 2 monifolds K245 Issue No 3 2 15 2 Installation Static Altitude Pitot Range 2 g Range 2 1310 mbar 38 68inHg abs 2 bar 30 psi Range 1 SUPPLY OUTLET VENT O O 0 O G Range 1 SUPPLY OUTLET VENT OO OO G SUPPLY OUTLET VENT O O OO SUPPLY OUTLET VENT O OO O 7 bar g 100 psi g 1 bar 15 psi 550 mbar g 2 25 bar g 16 2 inHg g 33 psi g Figure 2 13 Example Connection of Two Instruments for Airspeed and Altimeter Testing Notes 1 Good control can onlu be establish with the correct source supplu pressure High source pressure can cause violent jumps in the output pressure that can damage rate sensitive equipment connected to the system Low source pressure can cause poor stability of the output
2. Rate of climb G d the required Altitude Press Eai ENTER to confirm Set Rate of Climb ROC Press this soft keu to highlight the Aim vqlue entru box on the ROC displou The numeric keu pad may be used to input the required ROC set point Press ENTER to confirm ROC Tupe Timed ROC can be used to produce an accurate measurement of ROC over specified period in seconds Instantaneous ROC shows the current ROC value on the display With the Aim Altitude and the ROC set press Control again to start the change to the new aim value Go to Ground Pressing this soft keu option makes the instrument control the altitude to ZERO feet metres 1013 25 mbar at the currently set ROC for safe disconnection Task Aeronautical Timed Rate 60 S K245 Issue No 3 3 28 Druck DPI 515 Precision Pressure Controller Calibrator User Manual CAS Measure Mode Press Mode and select CAS from the menu The display shows CAS in the upper window and rate of Speed acceleration in the lower window Both windows show the current value in large characters CAS Control Mode Press Mode and select CAS from the Calibrated Air Speed FS 1000kts 0 0 Go to Rate of speed Ground 0 0 kts sec Task Aeronautical menu Press Control the display shows the aim value entry boxes together with the Set CAS and Set Rate soft boxes Set CAS Press this soft keu to highlight the Aim vql
3. 3 5 Set up Selections Two set up selections provide access to the instrument set up menus User and Supervisor The User set up provides direct access by the operator with the Supervisor set up accessed only by a four digit PIN Press Set up on the key pad and the display shows four selections User Supervisor Calibration and Status next to the corresponding soft keys on the right of the display screen Help User frequently changed settings Supervisor settings usually made during installation Callibration settings for maintenance Status tells you about this instrument Supervisor Calibration Status Set up 2 1 1 Selections 2 Message window 2 Help window The upper part of the screen shows the HELP window describing the sub menus available in these four selections The upper line of the messoge window shows the menu option in use Pressing the appropriate soft key selects the appropriate menu when selected e g User the display shows more selections in the soft boxes on the right of the screen and the message window changes to show Set up User When selected e g Units the display shows selections in the soft boxes on the right of the screen the upper line of the message window changes to show Set up Units A message line appears at the bottom of the message window prompting the user s next action To return to the User selections press Exit on the key pad To r
4. Connector Type Connector Type Instrument Signal RS232 Function Direction Terminology S j e ee ee S sf 2 gt re fie io RTS O P a RLSD g DCD internall Not used DCE Ready internall Chassis Shell Shell Screen Table 2 1 RS232 Connections K245 Issue No 3 2 10 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Software Handshaking Note Use software handshaking as the only recommended communications method For software handshaking between the instrument and a computer or printer that uses a 9 pin D type port connection proceed as follows Use a straight 9 way to 9 way male to female connector cable Connect the cable between the computer communications port and the instrument s 9 way D type RS232 port connector as shown in Figure 2 8 Use the Set up Supervisor Comms menu see Section 6 6 to set up the required RS232 parameters Note Use a 9 way to 25 way adaptor for a computer with 25 way communications port RLSD RXD TXD DTR GND DCR RCS CTS COMPUTER DPI 515 Figure 2 8 RS232 9 way connections Software Handshaking K245 Issue No 3 2 11 2 Installation Hardware Handshaking Note Onlu use hardware handshaking when necessaru Use software handshaking as the only recommended communications method For hardware handshaking between the instrument and a computer that uses a 9 pin D type port connection proceed as follow
5. 304 387 4417 Bellofram Europe 9 Castle Park Queens Drive Nottingham NG2 1AM IMI Norgren Ltd PO Box 22 Eastern Avenue Lichfield Staffordshire England WS13 6SB Tel 44 0 115 9933300 Fax 44 0 115 9933301 Tel 01543 265000 Fax 01543 265811 Norgren Inc 5400 South Delaware St Littleton Colorado 80120 1663 Tel 1 303 794 2611 Fax 1 303 795 9487 Drager Tescom www tescom europe com www tescom com Drager Tescom Unit 5 Coatbank Way Coarbridge Strathclyde Scotland ML5 3AG Tel 01236 440884 Fax 01236 434740 K245 Issue No 3 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Swagelock www swagelock com Hydrotechnik www hydroteknik co uk Swagelock UK Manchester Valve amp Fitting Company Science Park North Birchwood Warrington Cheshire WA3 7WF Hydrotechnik UK Ltd Unit 10 Easter Park Lenton Lane Nottingham NG7 2PX Tel 01925 822662 Fax 01925 820129 Tel 44 0 115 9933300 Fax 44 0 208741 9935 K245 Issue No 3 Table 6 2 Suppliers of Ancillary Equipment 6 Reference qnd Specification Vacuum Sustem Parts The parts list below lists a typical system to supply vacuum enabling the control of sub atmospheric pressures by the DPI 515 instrument Part numbers quoted in the table are taken from the BOC Edwards Vacuum Products 2000 Catalogue Description Part Number Qu
6. This equipment meets the requirements of all relevant European safety C directives The equipment carries the CE mark When disposing of this equipment consider the re use of the following major materials Sheet metal case parts steel Front panel rotary control rack handles ABS Monifolds to 70 bor 1000 psi Aluminium 6082 Abbreviations The following abbreviations are used in this manual the abbreviations are the same in the singular and plural abs Absolute ABS Acrylonitrile butadiene styrene a c Alternating current ALT Altitude BSP British pipe thread CAS Calibrated airspeed CSK Countersunk d c Direct current DPI Digital Pressure Instrument e g For example etc And so on Fig Figure ft Foot g Gauge Hg Mercury HTS High tensile steel Hz Hertz IAS Indicated airspeed i e That is IEC International Electrotechnical Commission IEEE 488 Institute of Electrical and Electronic Engineers standard 488 data in Inch kg Kilogram kts knot LCD Liquid crystal display m Metre mA Milliampere max Maximum mbar Millibar min Minute or minimum mm Millimetre mV Millivolts No Number NPT National Pipe Thread Para Paragraph PDCR Pressure transducer Ps Static pressure psi Pounds per square inch Pt Total pressure Pitot PTX Pressure transmitter Abbreviations continued Qc Differential pressure Ps Pt QFE Local atmospheric pressure QNH Barometric pressure at sea level ROC
7. 13 Head pressure value 14 Tare value 15 Pressure reading N Units 14 053 aa 6 15 In controlled mode no over I s Tare 0 50000 Heads 3 937 St Q J ZAUTO 14 T Setpoint 14 05 Process 13 psi rAP B Rate 0 20000 psi s a Task Basic 10 9 K245 Issue No 3 3 Operation Controlling to a new set point Note To change the set point value press the control key and using the numeric keys or jog control set the new set point value If necessary use the delete key to remove the last digit in the set point value display field When the display shows the new set point value press the control key The display shows the pressure value changing as the instrument AP controls to the new set point at the set rate of change cA PA The activity indicator shows the progress of the instrument 11 controlling within the rate of change limits IT Status Indicator KL CA Controller activity CC Controller condition cc PC PA Pressure activity PC Pressure condition IT In limits tolerance In normal controlled pressure conditions the status indicator stays within the in limits tolerance band Ifthe status indicator moves outside the in limits tolerance band this can be caused by either a leak in the system or a change in supply pressure D shows the difference between the current pressure reading and the set point value o
8. 22 psi and press Control The screen displou changes os follows The status window changes to show Changing Pressure The runner icon if enabled activates The activity indicator if enabled displays the current pressure and controller condition When the controller achieves the selected pressure set point the screen display changes as follows The status window changes to Controlled Pressure The runner icon in q stonding position The octivitu indicator shows the controlled pressure within the in limits tolerance Caution Using the vent function can damage rate sensitive equipment connected to this controller Enter a set point of ambient zero pressure and use the controller to reduce pressure before selecting VENT g On completion of testing press the Vent soft key to reduce the system pressure to near atmospheric pressure This feature should be used to reduce system pressure to a safe value before disconnecting the Unit Under Test Notes 1 The vent opens for approximately 5 to 10 seconds 2 Always use the vent function before disconnecting pressure equipment from the outlet port h Press the measure key to switch off the controller K245 Issue No 3 3 11 3 Operation Aeronautical option The aeronautical option is a specialised application of the DPI 515 instrument refer to 3 9 Leak testing This task applies a test pressure to an external system to find any leaks in a system connect
9. Issue No 3 6 9 6 Reference qnd Specification Comms Selects q communication port and parameters for operation and either the RS232 or the IEEE 488 port only one may be used The user can select appropriate settings for communicating with the control computer PC and the required command protocol Note Recommended command protocol SCPI Publication K257 SCPI Manual can be downloaded from www DPI515 com Power Up With Normal selected the instrument powers up in Measure mode With Regulator selected the instrument powers up in Control mode at a pre selected set point value Note When using Regulator mode be sure to disable the Idle Timeout feature Timeout Presets the times for automatically changing from control to measure mode Note Controller timeouts can save supply gas extending control valve life and minimising acoustic noise Idle Timeout starts when the controller achieves the set point after the set time the instrument changes to measure mode Fill Timeout storts when o new set point is entered The controller must achieve the in limits set point within the fill timeout interval Not achieving the in limits set point causes the instrument to change to measure mode Note This may be a system fault e g a large leak in the system connected to the instrument The controller can keep the set point within the in limits tolerance with small system leaks Vent Timeout starts when Vent i
10. Mach Reference Pressure Ua Units The reference pressure con be set to a fixed value for the static Ps pressure The instrument then calculates CAS and Mach number values based on this reference pressure CAS and Mach Control Mode Press Mode and select CAS MACH from the menu Press Control and Calibrated Air Speed FS 1000kts Mod the display shows the CAS aim value 2S entry box 0 0 Set kts CAS Press this soft keu to highlight Go to the Aim vqlue entru box on the Ground Airspeed displqu The numeric 0 0 key pad mou then be used to enter the required CAS value Ref 1006 53 mbar Mach a Press ENTER to confirm With the Aim CAS and the Rate set L Units press Control again to start the change to the CAS Aim at a rate of change set in CAS control mode Go to Ground Pressing this soft key option makes the instrument control the airspeed to ZERO Mach 0 K245 Issue No 3 3 31 3 Operation 3 7 Sensor Calibration Module Option The SCM option module provides an interface for the direct connection of a wide variety of pressure transducers transmitters When connected the DPI 515 instrument with the supporting SCM software can be used to calibrate these devices BASIC BASIC Units Vent Range Process Gauge Absolute L Units mbar bar psi mH20 kPa Mpa Vent Yes No Range Auto Range SCM 2 bar g 20 bar g Pr
11. RnSnDnCninFn N3 lt ln Limit Status gt nn N4 nEnJnVnnnnUaaaa Note Secondary addressing is not supported Reset Conditions NO DO FO 10 1 RO SO W002 Format Upper and lower case are equivalent Spaces and equal signs are ignored before numeric values Spaces commas semi colons and colons are ignored before and after commands This section describes the differences between the DPI 510 communications protocol and the DPI 515 emulation protocol SO is always bar S1 is always psi S2 is always kPa Message terminator is CR LF on RS232 and CR LF EOI on IEEE Presets set to 0 10 20 30 40 50 60 70 80 90 100 110 kPa Ratios set to 0 10 20 30 40 50 60 70 80 90 100 110 JO is always Variable rate J1 is always Auto rate which is max rate with no overshoot J2 is always Max rate TBA On the DPI 510 some commands are only accepted in Remote mode In emulation mode they are always accepted The Zero command 01 takes much longer to execute on a DPI 515 opens zero valve etc No daisy chaining no addressed mode over RS232 No interrupt packets over RS232 No dialogue mode on RS232 Pe O 0 9 4 O n GI M LA LA LA LA Ln E G rS All commands for the Ruska 7000 Series controllers are emulated bu the DPI 515 Refer to the relevant Ruska controller manual for details To select this protocol use Setup Supervisor Comms Protocol SCPI 7000 K245 Issue No 3 6 17 6 Reference qnd Specificatio
12. can be supplied in parallel The SCM option contains a set of test leads see the connection details below D type pin no Cable colour Cable function Connector colour Blue 24V OUT Blue Yellow 10V OUT Yellow Green OV OUT Green Brown 11V IN Red Brown 11V IN Black Violet 135 mV Red Violet 135 mV Black White 25 mA IN Red o O N O O El WwW N White 25 mA IN Black Not used 1 The ends of the test lead terminate in standard 4mm plugs and a pair of test probes one red one black enables connection to the units under test 2 Allow at least 2 minutes after applying power to the unit under test before taking readings Readings taken before the 2 minutes warm up will be inaccurate Alternatively arrange for continuous power to the unit under test K245 Issue No 3 2 Installation Single Pressure Transmitter Figure 2 14 Connect the coble of the tronsmitter to the SCM interface Connect the pressure port of the transmitter directly to the outlet port of the instrument SCM 1 24V OUT ce 3 OV OUT Link 0V OUT Green 9 25 mA IN to 25mA IN White 8 25 mA IN Vent Supply Outlet Figure 2 14 Single Pressure Transmitter Test Set up K245 Issue No 3 2 18 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Multiple Pressure T
13. enhanced measurement stability for the following pressure ranges 750 1150 mbar a 22 34 inHg a 35 1310 mbar a 1 39 inHg a 35 2620 mbar a 1 77 inHg a 35 3500 mbar a 1 100 inHg a Precision 0 01 full scale including non linearity hysteresis repeatability and temperature effects over 10 C to 40 C 50 F to 104 F Measuring stability 0 01 full scale per annum Note This option cannot be ordered with either Option A or C K245 Issue No 3 6 21 6 Reference qnd Specification Option F1 LabVIEW Driver Software driver for LobVIEW Option G1 Filter Set Single Range Instrument Set of in line filters for the pressure supply and outlet Option G2 Filter Set Dual Range Instrument Set of in line filters one for each pressure supply and outlet Option H Pressure Controller Sensor Calibration Module Excitation Voltage Output 10V dc regulated and 24V dc unregulated Measurement Input Range 135mvV absolute Accuracy over 10 to 28 C 50 to 82 F 0 02 rdg 0 002 full scale Accuracy over 10 to 45 C 50 to 113 F 0 035 rdg 0 002 full scale Range 135mV compensated Accuracy over 10 to 28 C 50 to 82 F 0 01 rdg 0 002 full scale Accuracy over 10 to 45 C 50 to 113 F 0 015 rdg 0 002 full scale Range 0 to 11V Accuracy over 10 to 28 C 50 to 82 F 0 02 rdg 0 002 full scale Accuracy over 10 to 45 C 50 to 113 F 0 035 rdg 0 002 full scale Range 0
14. instrument The cooling air outlet at the top left hand corner of the rear panel of the instrument must not be covered or obstructed Allow a free flow of air around the instrument especially at high ambient temperatures A POSITIVE suppty Fu Range Lt SCALE 2 Figure 2 5 Rack mounting Procedure Slide the two support orms into the slots either side of the reor panel Locate the two handle brackets on the side of the instrument and secure with the two screws and washers Support the instrument and connect the cables and pipes Locate and slide the instrument into the rack Secure the instrument in the rack Secure the two rear support arms to the rear tappings of the rack K245 Issue No 3 2 6 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 2 6 Electrical connections WARNINGS 1 THE GROUND LEAD GREEN YELLOW OF THE INSTRUMENT MUST BE CONNECTED TO THE AC SUPPLY PROTECTIVE SAFETY GROUND 2 ISOLATE THE POWER SUPPLY BEFORE MAKING ANY ELECTRICAL CONNECTIONS TO THE REAR PANEL 3 ISOLATE THE POWER SUPPLY BEFORE REMOVING THE INSTRUMENT S COVERS General The instrument must be connected to the correct electrical power supply as stated on a label next to the power connector See section 6 Reference and Specification Make sure that the power supply is off before connecting the power cable Requirements for rack mounted instruments Install an isolator i
15. pressure and may not meet control specifications for accuracy 2 When not testing an altimeter the reference port can be opened to atmospheric pressure ASI calibration checks can be done relative to atmospheric pressure 3 When ASI calibration checks require an altitude above atmospheric pressure use a shut off valve to isolate the port or blank off the altimeter test port or connect a serviceable altimeter to enable control of static pressure i The reference port is active for all ranges via the connection on range 1 of the instrument only ii The reference port of range 2 is blanked off and unused 4 When only testing altimeters use a shut off valve to isolate the port or blank off the ASI test port or connect a serviceable ASI K245 Issue No 3 2 16 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 2 10 Sensor Calibration Module The following details the test configurations for amplified output transducers millivolt output transducers and multiple transducer transmitter testing A rear panel 15 way D Type connector provides the outputs inputs comprising two regulated power supply outputs 24V for current loop applications a protected extension of the internal 24V supply and a regulated 10V dc supply for the excitation of external transducers Internally the instrument has a return line resistance of 0 15 W The SCM can supply a maximum current of 200 mA this limits the maximum number of sensors that
16. required CAS aim press control MACH a E gt Enter required MACH aim press control CAS and MACH Enter required CAS aim press control Controls altitude down to zero ROC Type Timed Use Jog control to set time sec Use Jog control to set ROC aim units sec L Units Aeronautical Pressure Select required unit Actual units displayed depends on Set up Rate Select required rate K245 Issue No 3 3 27 3 Operation Altitude Measure Mode Press Mode and select Altitude from the menu The display shows Altitude in the upper window and Rate of climb in the lower window Both windows show the current value in large characters Rate of climb Ground The ROC type soft key permits the 0 rate of climb display to be rapidly updated Instant or to measure ROC ft sec averaged over a pre set time period Timed The latter method results in a lower noise reading Altitude FS 80000 288 ft Go to Task Aeronautical Timed Rate 60 S Altitude Control Mode Press Mode and select Altitude from the menu Press Control the display shows the aim value entry boxes together with the Set Altitude and Set ROC soft boxes Set Altitude Altitude Press this soft keu to highlight the Aim vqlue entru box on the Set Altitude displqu The numeric l Altitude key pad may be used to input Go to
17. sensitive components handle with extreme care Table 4 2 Replacement Parts List ae Description Fuse T2 0A 176 066 Control Valve 0 to 10 bar 0 to 150 psi 176 067 Switching Valve 0 to 10 bar 0 to 150 psi 079 061 Bolts M3 socket head high tensile steel countersunk 176 065 Control Valve gt 10 to 70 bar gt 150 to 1000 psi 176 067 Switching Valve gt 10 to 70 bar gt 150 to 1000 psi 079 061 Bolts M3 socket head high tensile steel countersunk 176 072 Control Valve 70 to 210 bar 1000 to 3000 psi Switching Valve not fitted 079 030 Bolts M4 socket head high tensile steel countersunk K245 Issue No 3 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 4 6 Fuse Replacement Fig 4 1 Replace the fuse when detailed in Section 5 Testing and Fault Finding Set the power switch 4 to OFF Isolate the power supply to the instrument and disconnect the IEC power supply connector 1 Note To gain access to rack mounted instruments it may be necessary to partially or completely withdraw the instrument Isolate pneumatic supplies and de pressurise all pressure supply inlet and outlet lines Remove the fuse carrier 2 from the power supply input socket assembly 5 and replace the fuse cartridge Note Fit the correct type of fuse detailed in Table 4 2 Refit the fuse carrier 2 in the power supply inlet socket assembly 5 Reconnect the IEC po
18. specific tare value can be selected or the current displayed pressure reading can be captured as the tare value The display shows the selected tare value in the pressure window 0 Pressure can be expressed as a percentage of full scale or as a percentage of a specified span K245 Issue No 3 6 5 6 Reference and Specification 6 4 Valve Assembly Description O O OQ Located on the inside of the rear panel a manifold assembly provides pressure measurement and control for a pressure range Each assembly comprises a metallic manifold pressure transducers and solenoid actuated pneumatic valves Every manifold assembly has two control valves termed apply and release Low pressure 70 bar 1000 psi and below manifold assemblies have two switching valves termed zero and isolation There are two different types of manifold assembly a low pressure manifold pressures up to 70 bar 1000 psi and a high pressure manifold pressures gt 70 bar to 210 bar gt 1000 to 3000 psi Manifold 2 High tensile fixing screws 4 per valve Zero switching valve 4 Isolation switching valve 5 Release control valve Apply control valve 7 Brown cables 8 Red cables Orange cables 10 Yellow cables Figure 6 1 0 70 bar 0 1000 psi Manifold Assembly K245 Issue No 3 6 6 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 1 Manifold 2 High tensile fixing screws 4 per valve 3 Release control va
19. to 25 mA Accuracy over 10 to 28 C 50 to 82 F 0 03 rdg 0 005 full scale Baan over 10 to 45 C 50 to 113 F 0 05 rdg 0 005 full scale absolute range refers to the accuracy when using an external supply voltage for the sensor under test range includes error compensation for internal regulated 10 volts excitation voltage essential for proportional strain gauge sensors K245 Issue No 3 6 22 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 6 9 Return Goods Material Procedure Should the unit require calibration or become unserviceable it can be returned to the nearest GE Service Centre listed at gesensing com Please contact our Service Department either by phone fax or E mail to obtain a Return Goods Authorisation RGA or in the USA Return Material Authorization RMA providing the following information Product i e DPI 515 Serial number Details of defect work to be undertaken Calibration traceability requirements Operating conditions Safety Precautions You must also tell us if the product has been in contact with anything hazardous or toxic and the relevant COSHH or in the USA MSDS references and precautions to be taken when handling Important notice Service or calibration by unauthorized sources will affect the warranty and may not guarantee further performance Packaging Procedure 1 The instrument should be at zero ambient pressure Set the power switch to off Shut off t
20. with pressure changing to set point Control mode pressure at set point AUTO Tare 0 50000 Tare value set to 0 50000 and enabled selected by Process soft key Displayed when autorange enabled Filter Filter enabled selected by Process soft key Per cent reading of full scale or set span selected by Process soft key Head 10 0000 cm Head value set to 10 cm height difference between instrument and UUT Runner Pressure change in progress enabled and disabled in Setup User Display Wait indicator Instrument stopped performing internal function Message window set point 120 59 bar Set point at value of 120 59 in current selected units can be changed using the Displays Task function with instructions for setting a parameter or an operation numeric key pad or jog control Rate 30 bar s Rate at value of 30 bar s in current selected units per second can be changed using the numeric key pad or jog control Key to display 1 Status 1 2 y 2 Set point value ra i 3 Alarm indicator aa ES sn nits 000 0 mH 5 In controlled mode no over B j ose shoot or fast Tare 0 50000 bar p 6 Filter ON g l 10 0000 cm S k Q Lo N ie 7 Autorange i S Setpoint 1000 00 mbar Process I 8 Wait indicator nf 9 Runner Rate 0 20000 bar s 8 10 Rate value Task Basic 11 Message window 12 Activity indicator 13 Head p
21. 1 in pressure UNITS 1 TO pressure VALUE 2 in pressure UNITS 2 calculate as follows VALUE 2 VALUE 1 x FACTOR 1 FACTOR 2 Note The conversion factor for pressure units referenced 1 are calculated for a water temperature of 4 C Pressure units referenced 2 are calculated for a water temperature of 68 F these units are normally used in the USA CONTENTS Section Title Page 1 DESCRIPTION saena TRT N RR eae ee eee 1 1 1 1 siea 1 1 2 INSTALEATION a ton Wie unus poe ae a A 2 1 2 1 PACKAGING E ics 5222 spa sanki ce asdeti odes een Salas ae lela lee cea 2 1 2 2 Packaging for Storage or Transportation 2 1 2 3 Preparation for USC ccccec Sus uusha 9 Tuya 2 1 2 4 Pneumatic connections 2 2 2 5 Se anlel lale TTT 2 6 2 6 Electrical connections 2 7 2 7 RS232 Interface a rr de oe 2 10 2 8 IEEE 488 Interface 2 13 2 9 Aeronautical Option 2 15 2 10 Sensor Conditioning Module Option 2 17 3 OPERATION u uuu Hos Ea seis A uqsuy EA wie teak 3 1 3 1 Preparation a atus a a ania a AEE EE 3 1 3 2 Q ick Referent iscan eae he ee eG a 3 2 3 3 First Time Operators a y g 0 9 44h20 eska deen E us 3 3 3
22. 15 Precision Pressure Controller Calibrator User Manual 4 4 1 4 2 4 3 4 4 Maintenance Introduction This section contains the routine maintenance and procedures to replace components detailed in Section 5 Testing and Fault Finding and listed in Table 4 2 Table 4 1 Maintenance Tasks Task Period Visual Inspection Daily before use Cleaning Weekly Test Before use Calibration 12 months may change depends on usage e g rack mounted bench top and environment e g humidity dust Visual Inspection Inspect the external of the instrument and associated equipment for obvious signs of damage dirt and ingress of moisture If necessary clean the instrument as detailed below Cleaning Clean the instrument every week Clean the front panel with a damp lint free cloth and mild detergent Caution Do not use solvents for cleaning Calibration The instrument should be withdrawn from service and returned to the manufacturer or calibration facility To find the date of the last calibration press SETUP Status Calibration history Do not use an instrument with out of date calibration K245 Issue No 3 4 1 4 Maintenance 4 5 Replacement Parts Use only the replacement parts listed in Table 4 2 WARNING ISOLATE THE INSTRUMENT POWER SUPPLIES BEFORE REMOVING THE COVERS WITH POWER APPLIED THE INSTRUMENT CONTAINS LETHAL VOLTAGES Caution This instrument contains static
23. 303 AISI 430FR Non Butyl Rubber polyethylene polyurethane K245 Issue No 3 6 18 Druck DPI 515 Precision Pressure Controller Calibrator User Manual above 70 bar 1000 psi Aluminium Bronze CA 104 in lieu of Aluminium 6082 Reference Port in oddition to qbove brass qnd silicon rubber Filters Stainless steel 316 and copper Measurement Stability 0 02 of reading per annum for ranges between 25 and 350 mbar 0 74 and 10 34 inHg 0 01 of reading per annum for ranges between 0 7 and 210 bor 10 and 3000 psi Controller Stability For ranges between 0 7 and 70 bor 10 and 1000 psi better than 0 001 of span For pressures above 70 bor 1000 psi better than 0 0015 of span For pressures below 0 7 bar 10 psi better than 0 003 of span Controller Response Less than 5 seconds into a 50 cm 3 cu in volume up to 10 full scale steps within 20 ppm of set point settling fast rate max Gas Consumption The sustem consumes supplu gos onlu in control mode The sustem uses no gos in measure mode or when the instrument powers down Warm up Time 15 minutes to specificotion Panel Large area high contrast emissive graphics LCD Readout 9999999 maximum updated every 0 6 seconds Pressure Units 24 scale units plus one user defined Languages English French German Italian Portuguese and Spanish Option A Barometric Reference Pressure reference Normally atmosp
24. 4 Operation and Example Procedures 3 9 3 5 SOl UD SSIOCHONS euenire iae a ra e KOREA 3 22 3 6 Aeronautical Option 3 25 3 7 Sensor Conditioning Module Option 3 32 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 5 1 5 2 5 3 5 4 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 MAINTENANCE u toa A cay el Re apo squa Dante ches 4 1 UM FO CUICUON u usa uysal upa usya teu eedeabces gives vere EKE ese 4 1 Visual Inspection 4 1 CIB ANI uu ap u pas ee oe at a asua a 4 1 Callbrati liu u Dn uu hae stolen aie elke a eae ie ee 4 1 Replacement Parts 4 2 Fuse Replacement 4 3 Valve Replacement 4 4 ValVe Correcto M anoen e aia uba a Qa 4 11 TESTING AND FAULT FINDING r 5 1 lse esl taa aut ua apaq T R uusha ag eas Erie 5 1 Standard Serviceability Test 5 1 Falt Finding TTT 5 3 Approved Service Agents 5 4 REFERENCE AND SPECIFICATION 6 1 Installation ue uu nerie Ea a EEA a ua qapas satuan apus S 6 1 Operational Requi
25. F1 and F2 2 Refer to section 6 Reference and Specification for details of other system components K245 Issue No 3 2 4 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Range 1 Supply Outlet Silencer Unit under if no vac test Filter Fit silencer system pressure vent Pressure source 110 FS Range 1 Release Valve SE Filter Foreline trap Pressure source 110 FS Range 2 Conditioner Filter F2 lt gt Range 2 Supply Outlet Unit under test Filter VAC ON Figure 2 4 Pneumatic Connections above 70 bar 1000 psi The positive pressure supply needs to be regulated for each range The supply pressure should be 110 of the pressure range The pressure range supply rating label on the rear panel gives the required pressure supply value Refer to Section 6 Reference and Specification for the recommended regulators When connecting a number of instruments of differing ranges to a common pressure supply appropriate external pressure regulators must be fitted in each instrument supply line Note Instruments with a range above 100 bar 1450 psi must not have outlet ports connect together K245 Issue No 3 2 5 2 Installation 25 Rack mounting Figure 2 5 General There must be enough space at the rear of the instrument for all the cables and pipes The length of the cables and pipes must allow for the removal and fitment of the
26. GE Druck Pressure measurement for research amp industry Druck Limited Fir Tree Lane Groby Leicester LE6 OFH England Tel 0116 231 7100 DPI 515 Precision Pressure Controller Calibrator User Manual K245 Druck Limited 2005 This document is the property of Druck Limited and may not either in part or whole be copied or otherwise reproduced communicated in any way to third parties nor stored in any data processing system without the express written authority of Druck Limited Page 1 of 114 K245 Issue No 3 Amendment Record Software up issue to release 5 0 Addition of volume fill menu options Manual completely revised to GE format No details recorded on amendment sheet Approvals Engineering Marketing Publications Phil Bradley Julian Williams Paul Stephens Date Date Date Engineering Harbi Mankia Date Page 2 of 114 K245 Issue No 3 Print Instructions Print black on white double sided as supplied on disk Print on paper to 110 gsm Silverblade matt art wiro bind in 270 gsm covers Size 180 x 230 mm THIS PUBLICATION IS PRINTED EXTERNALLY THIS HARDCOPY IS NOT TO BE USED AS CAMERA COPY Page 3 of 114 K245 Issue No 3 Page 4 of 114 K245 Issue No 3 Do Not Print This Page Sensing Druck DPI 515 Precision Pressure Controller Calibrator User manual K245 English 1 1 to 6 26 Frangais KF245 pdf Deutsch KD245 pdf Italiano K 245 pdf Espanol KE245 p
27. ON HIGH PRESSURE UNITS THIS DISCHARGE CAN CAUSE PHSYICAL INJURY FIT THE SILENCER SUPPLIED OR AN EQUIVALENT COMPONENT TO DIFFUSE THE DISCHARGE Connection USA only Input supply 1 8 BSP 1 8 NPT supply 1 8 BSP 1 8 NPT Output 1 8 BSP 1 8 NPT Vent 1 8 BSP 1 8 NPT Reference M5 M5 Pressure supply Figure 2 1 1 The pressure supply must be clean dry gas nitrogen or air and at the correct pressure refer to the specification Section 6 2 Make sure that the user systems con be isolated and vented 3 Connect pressure and vacuum supplies to the SUPPLY and SUPPLY connection ports 4 Connect the Unit Under Test UUT to the required outlet connection port FULL SCALE POSITIVE SUPPLY outu FULLSCALE a VENT 15 179 BSP rad SUPPLy DD OO mA oO G 50 60 H OLS Figure 2 1 Pneumatic Connections K245 Issue No 3 2 2 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Each pressure range of the instrument requires a positive pressure supply Instruments operating in an absolute range or negative pressure range require a vacuum supply A vacuum supply should also be used for a fast response for instruments operating near atmospheric pressure Supply equipment Pneumatic supplies should have isolation valves and where necessary conditioning equipment Each positive pressure supply should be regulated at 110 of the pressure range stated on the pressure supply label An instr
28. Rate of climb RS232 Serial communications data standard SCM Sensor Conditioning Module SCPI Standard Commands for Programmable Instruments UUT Unit under test V Volts ve Positive ve Negative C Degrees Celsius Associated publications Druck publication K257 SCPI User Manual K283 DPI 515 Calibration Manual Symbols The equipment contains the following symbols to identify hazards This symbol on the equipment indicates that the user must refer to the user k manual This symbol in this manual indicates a hazard to the user This symbol in the equipment identifies static sensitive components handle A with extreme care Pressure unit bar Factor Pascal 100000 Pressure units and conversion factors Pressure unit Ibf ft2 Factor Pascal 47 8803 Ibf in psi 6894 76 inHg 3386 39 mH O 9806 65 inH O 1 249 089 mbar 100 ftH 0 1 2989 07 kgf cm 98066 5 atm 1013525 0 kgf m 9 80665 kgf cm 98066 5 mmHg 133 322 kgf m 9 80665 cmHg 1333 22 hbar 10000000 mHg mmH O 1 133322 0 9 80665 tont ft UK tonf in UK 107252 0 15444300 mH O 1 98 0665 1 inH O USA 2 ftH O USA 2 248 64135 2983 6983 100 kP mm 9806650 1000 kP cm 98066 5 1000000 kP m 9 80665 133 322 Unit Conversion To convert FROM pressure VALUE
29. an be cause by either a leak in the system or a change in supply pressure When the controlled pressure stays status indicator is within tolerance band the pressure at the outlet is within the limits set in Set up Supervisor In Limits If the controller status indicator is outside the tolerance band then this could indicate either a leak in the system or that the supply pressure differs from the pressure for which the control valves have been characterised K245 Issue No 3 5 Testing and Fault Finding 5 4 Approved Service Agents For the list of service centres visit out web site www gesensing com K245 Issue No 3 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 6 6 1 Reference and Specification Installation notes The DPI 515 pressure controller calibrator can be fitted with one or two pressure ranges Each range requires an independent pressure supply and set of connections with the exception of the reference connection this provides a reference to atmosphere for gauge sensors Each range must have the correct supply pressure and a suitable supply medium see 6 7 Specification The supply gas density and type does not affect the accuracy of pressure measurement Gas supply Each range requires a positive supply of 110 of range For absolute or negative gauge operation or if the installation requires a fast response around atmospheric pressure a vacuum source must be connected to the negativ
30. antity RV5 240V Vacuum Pump 91 litre min A653 01 903 1 EMF10 Mist Filter A462 26 000 1 NW25 NW10 Reducer fitting C105 14 436 2 NW10 T2 Fitting C105 11 411 1 IPVA1OEK Air Admit Valve Norm Open C417 21 000 1 Flexi SS NW10 hose 1M C105 11 287 4 NW10 Clamp C105 12 401 5 NW10 Seal C105 11 398 5 NW25 Clamp C105 14 401 3 NW25 Seal C105 14 398 3 NW16 10 C105 12 349 1 NW16 to NPT M Fitting SS C105 01 103 1 Foreline Trap FL20K 1 Supplier Address Telephone Fax BOC Edwards BOC Edwards Vacuum Technology Tel 01293 528844 Manor Royal Fax 01293 533453 www bocedwards com Crawley West Sussex England RH9 2LW BOC Edwards BOC Edwards Vacuum Technology USA Tel 1 978 658 5410 301 Ballard Vale Street Fax 1 978 658 7969 Wilmington MA 01887 USA Table 6 3 Suppliers of Vacuum System Parts K245 Issue No 3
31. ask When used for the first time the instrument powers up in basic task measure mode giving access to screen configuration as follows Note After the first time the instrument powers up in the last selected task before switching off Units Press the Units soft key to display a short list of six pressure units taken from a larger list which can be accessed under Set up User Units Special units can also be defined bu accessing Set up User User Defined Units Vent Press the Vent soft keu to reduce the sustem pressure to neor qtmospheric pressure Use this feature to reduce system pressure to a safe value before disconnecting the Unit Under Test Range Press the Range soft keu to select the Control Meosurement full scole range onlu used on dual range instruments In Autorange operation the controller selects the most appropriate range to provide the pressure for the set point selected This only works with dual range units below 70 bar 1000 psi Autorange only appears as an option if configured for connected ranges under Setup Supervisor System Standalone Process Selects display processing features that change the reading as follows eFilter The reoding con be filtered bu q custom low pass filter or the filter con be disabled default disabled Although the controller always works at a speed independent of the resolution and filter applying the filter appears to slow the controller action Tare A
32. change between gauge and absolute Task Barometric Reference Barometric Reference Units Units mbar bar psi Pressure measurement mH20 units selected in Setup kPa Mpa The barometric task only changes the barometric pressure units Select the units available on the soft keys for this option in the User set up K245 Issue No 3 3 17 3 Operation Test Program The test program task provides a facility for writing and executing test procedures Task Test Program Test Program Run Runs selected test program Set up Set up L gt New Edit Programming tools Copy Delete Step Runs test program in single step mode Selecting a test program from the Task menu displays all the task programs currently stored together with the Run Set up and Step function keys TEST PROGRAM Created 11 26 35 15 06 04 TEST 1 TEST 2 unused unused unused unused unused unused Task Test Program Test Program screen K245 Issue No 3 3 18 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Program To start a test program select the test program listed on the screen using the jog rotary control and press the RUN key When the program starts a Stop legend replaces the Run legend Press the Stop key at any time to stop the test program The Step function key allows the selected program to be
33. ck for correct pneumatic supply pressures Select Range select the range to be corrected Select Set up Calibration Enter PIN and press Enter Select Valve Correction and if the supply pressures are correct select YES The instrument starts the process of collecting data by measuring the performance of the apply valves and then the release valves Note This process takes between 10 minutes and 1 hour approximately to complete and depends on the pressure range The higher the range the longer the process When the instrument completes the data collecting process the display shows a message with a prompt to Accept Repeat or Quit Valve Correction Selecting Accept the instrument stores the new data and when next selected applies these corrections to the controller Selecting Repeat starts the process again Selecting Quit Valve Correction returns the instrument to the calibration menu without storing the new data K245 Issue No 3 4 11 4 Maintenance intentionally left blank K245 Issue No 3 4 12 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 5 Testing and Fault Finding 5 1 Introduction The DPI 515 contains a built in self test and diagnosis system that continuously monitors the performance of the unit At power up the system performs a self test This section details the standard serviceability test A fault finding table lists possible faults the probable cause an
34. command use the jog control to highlight the command on the display and press enter to write it into the program Place the Range Units Rate Settling and Resolution commands qt the start of the program this protects pressure sensitive UUT When selected certain commands require a value or selection to be set e g Range Rate Text the display shows a screen prompt for the appropriate setting K245 Issue No 3 3 19 3 Operation Example Program Changes to instrument settings made in a test program remain valid only for the test program The instrument reverts to the pre test settings on completion Note Step 1 LO OND FW PD 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26 27 28 K245 Issue No 3 Command Argument RANGE 2 5 BAR G UNITS MBAR RATE 100 RESOLUTION 5 SETTLING ZERO TEXT Operator instruction e g ZERO SET POINT 400 CONTROL IN LIMITS BEEP ON BEEP OFF MEASURE DWELL 30 set point 800 CONTROL IN LIMITS BEEP ON BEEP OFF MEASURE TEXT Operator instruction e g DWELL 30 BEEP ON BEEP OFF TEXT Operator instruction e g PAUSE VENT END Action Select 2 5 mbar g range Select units mbar Select rate 100 mbar min Display resolution 5 digits No overshoot Connect UUT Set point 400 mbar Controller ON Wait for In Limits Condition Beep on approx 1 sec Switch to Measure controller off Wait for 30 sec Set point 800 mbar Controlle
35. ct the electrical connections to the solenoid K245 Issue No 3 4 4 Druck DPI 515 Precision Pressure Controller Calibrator User Manual f g h i U k I m n Remove the four M3 socket head high tensile steel countersunk bolts 9 securing the valve body 5 to the manifold block 8 and lift the valve body clear of the manifold Discard the four M3 socket head HTS CSK bolts 9 Note Do not re use the original M3 socket head HTS CSK bolts 9 and only use the replacement parts listed in Table 4 2 Wipe the surface of the manifold clean Ensure that the valve seating area on the manifold block is clean and place the new valve body 5 into position over the fixing holes Insert the M3 socket head HTS CSK bolts 9 and initially screw in finger tight Carefully torque tighten in sequence to 1 2 Nm 10 62 Ibf in the M3 socket head HTS 1 s CSK bolts 9 4 2 Unless the valve solenoid is faulty refit the solenoid 3 over the valve body 5 replace the lock washer 2 and tighten the locking ring 1 Note If the spade terminal connectors 4 have become disconnected from the solenoid push the connectors back onto the solenoid terminals The connections to each valve are colour coded see Figure 4 2 Refit the top cover of the instrument and reconnect the power supply and the input and output pneumatic supplies Switch on the instrument and carry out a leak test see S
36. d the procedures to rectify the fault 5 2 Standard Serviceability Test The following procedure shows if the unit is serviceable and checks functions and facilities of the DPI 515 In this procedure All key presses are highlighted in BOLD and shown as identified on the front panel Key presses inside brackets e g units are soft key presses indicated on the screen Procedure 1 Connect the instrument as detailed in Section 2 Installation Connect a UUT or fit blanks to the output port or ports 2 Select Basic Task and proceed as follows a Select the required pressure range and units of pressure measurement from the soft boxes displayed b Dress the Control key The display changes to show set point and rate c The message window shows Confirm Change set point and press Control to start d Press the Rate soft key then press Value e Enter the required rate of pressure change on the key pad e g 0 1 bar s 1 5 psi and press Enter The display returns to the Control mode screen f Use the key pad to select the required set point e g 1 5 bar 22 psi and press Control 3 The screen display changes as follows The stotus window changes to show Changing Pressure The runner icon if enabled activates The activity indicator if enabled displays the current pressure and controller condition 4 When the controller achieves the selected pressure set point the screen display changes as follows The sta
37. df Portugu s KP245 pdf The General Electric Company All rights reserved Introduction This technical manual provides operating instructions for the Druck DPI 515 Precision Pressure Controller Calibrator Sqfetu The manufacturer has designed this equipment to be safe when operated using the procedures detailed in this manual Do not use this equipment for any other purpose than that stated This publication contains operating and safety instructions that must be followed to ensure safe operation and to maintain the equipment in a safe condition The safety instructions are either warnings or cautions issued to protect the user and the equipment from injury or damage Use suitably qualified technicians and good engineering practice for all procedures in this publication Pressure Do not apply pressures greater than the safe working pressure to the equipment Toxic Materials There are no known toxic materials used in construction of this equipment Maintenance The equipment must be maintained using the procedures in this publication Further manufacturer s procedures should be carried out by authorized service agents or the manufacturer s service departments Technical Advice For technical advice contact the manufacturer A qualified technician must have the necessary technical knowledge documentation special test equipment and tools to carry out the required work on this equipment
38. dows show the current value in large characters Mach aim value entry box with the Set Mach soft box Press this soft keu to highlight the Aim value entry box in the Mach window The numeric key pad may then be used to enter the required Mach aim Press ENTER to confirm K245 Issue No 3 FS 5 Mach 0 0048 Mach 0 0016 Mach s Ref 1006 53 mbar Go to Ground Ref Pressure Task Aeronautical FS 5 Mach 0 0048 Mach Barometer Task Aeronautical FS 5 Mach 0 0048 Mach AIM 0 0016 Ref 1006 53 mbar Mach s Go to Ground Ref Pressure Task Aeronautical Druck DPI 515 Precision Pressure Controller Calibrator User Manual Set Mach Press this soft key to highlight the Aim value entry box With the Mach Aim set press Control again to start the change to the Aim Mach Go to Ground Pressing this soft keu option makes the instrument control the airspeed to ZERO Mach 0 for safe disconnection CAS and Mach Measure Mode This mode enables the testing of combined speed indicators CAS Calibrated Air Speed FS 1000kts7 Mode Mach Press Mode and select CAS MACH from the menu The display 0 0 shows CAS in the upper window and kts Mach in the lower window Go to Go to Ground Groung Pressing this soft keu option makes the instrument control the airspeed to ZERO Mach Ref 1006 53 mbar a ae 0 for safe disconnection ee
39. e Controller Calibrator ii Power supply cable ili User manual this publication iv Silencer for each VENT port v Calibration certificate Packaging for Storage or Transportation To store the instrument or to return the instrument for calibration or repair as follows Pack the instrument as detailed in section 6 9 Reference and Specification To return the instrument complete the return goods materials procedure detailed in section 6 8 Reference and Specification Preparation for use Note Before operation remove protective film from the display The instrument can be used as a Free standing instrument positioned on q horizontal surface Rack mounted in a standard 19 inch rack using the rack mount accessory kit For free standing instruments use the two feet on the base to elevate the instrument to provide a better viewing angle To rack mount the DPI 515 instrument requires the rack mount accessory kit refer to section 2 5 K245 Issue No 3 2 1 2 Installation 2 4 Pneumatic connections WARNINGS TURN OFF THE SOURCE PRESSURE AND VENT THE PRESSURE LINES BEFORE DISCONNECTING OR CONNECTING THE PRESSURE LINES PROCEED WITH CARE ONLY USE EQUIPMENT WITH THE CORRECT PRESSURE RATING BEFORE APPLYING PRESSURE EXAMINE ALL FITTINGS AND EQUIPMENT FOR DAMAGE REPLACE ALL DAMAGED FITTINGS AND EQUIPMENT DO NOT USE ANY DAMAGED FITTINGS OR EQUIPMENT THE SUPPLY CONNECTION DISCHARGES FULL SYSTEM PRESSURE
40. e maximum outlet pressure When operating at positive or negative full scale there must be a pressure difference between supply and outlet to cause a gas flow K245 Issue No 3 6 1 6 Reference qnd Specification Operating near atmospheric pressure or below Any controller operating near atmospheric pressure or below requires q vacuum pump or other negative supply connected to the negative supply port for optimum performance Without a vacuum supply as the outlet pressure approaches atmospheric pressure the differential pressure approaches zero resulting in a reduced flow to the outlet Reduced flow causes an increase in the time to control to atmosphere especially with large user volumes and an increased overshoot at low pressures With a small zero offset stored in the instrument the controller may aim for a pressure slightly below atmospheric pressure and fail to reach this value With high pressure instruments above 70 bar 1000 psi the resolution around atmospheric pressure decreases and the overshoot and added time to reach zero are not significant Conclusion Use a vacuum supply for Absolute ranges Negative gauge ranges A vacuum supply improves Time to reduce sustem pressure qt pressures below 2 bor 30 psi full scole Control stability near atmospheric pressure Overshoot at low pressures K245 Issue No 3 6 2 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 6 2 Operat
41. e supply vent port for units above 70 bar 1000 psil The positive pressure supply requires a gas regulator for each range The range supply rating label gives the required supply value see recommended regulators in 6 8 Supply conditioning equipment Supplies should be provided with an isolation valve and any other necessary conditioning equipment Some supplies may need the removal of water oil or particulate contamination Any water in the compressed gas supply will be in vapour form i e non condensing and must be removed using a mist filter Oil must be completely removed as this causes a rapid deterioration of the control valve performance The compressed gas supply must not contain particulates and must be removed using a particulate filter Do not use a compressed gas supply containing corrosive material Systems without a negative supply Without a negative supply vacuum pump release the positive pressure from the system to atmosphere through the negative supply port The release from the negative port may be piped away to a place where this discharge causes no disturbance or hazard Alternatively a silencer may be fitted to the negative supply port to reduce acoustic noise and air flow On units above 70 bar 1000 psi the vent port provides the same function as the negative supply port The need for a negative supply General Supply pressures there must be a difference of 10 of full scale between the supply pressure and th
42. e to the pressure assigned to that key and controlled at the selected pressure K245 Issue No 3 pressure Druck DPI 515 Precision Pressure Controller Calibrator User Manual Switch test This function automates the testing of pressure switch devices Connect the pressure port of the switch to be tested to the appropriate outlet port Connect the switch contacts in series with the 24V dc output and the Logic Input Note The potential free logic input connections require a switching potential 24V max to be applied If necessary this can be an external d c source Set the switch test parameters in the Task Switch Test Set up menu including the test range and test rate of change Slower rates give more accurate results Task Switch Test Switch Test Switch Test Switch Test Switch Test Stop Pause Resume Release Pressure Releases pressure from the UUT Set up Set up Sets the switch test parameters Start Pressure Enter required value using the End Pressure numeric keys Rate Note This facility uses the rate of change of pressure set in the Basic task After the test the display shows the pressures at which the contacts open and close and the switch hysteresis the difference between the two switching pressures Before disconnecting the switch under test press the Release soft key to release any residual pressure DPI 515 Supply Outl
43. ection 3 Carry out the valve correction procedure as detailed in Section 4 4 K245 Issue No 3 4 5 4 Maintenance 1 Solenoid locking ring 2 Washer 3 Solenoid 4 Terminal spade 5 Valvebody 6 O ring 7 O ring 8 Manifold 9 M3 socket head HTS CSK bolt Figure 4 2 Low Pressure Manifold Valve Replacement K245 Issue No 3 4 6 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 10 Manifold 2 M3 socket head HTS CSK bolt 3 Zero valve assembly Isolation valve assembly 5 Release control valve 6 Apply control valve Brown cables 8 Red cables 9 Orange cables 10 Yellow cables Figure 4 3 0 70 bar 0 1000 psi Manifold Assembly K245 Issue No 3 4 7 4 Maintenance Procedure a b c d e f g h i U k Full scale pressures from 70 to 210 bar 1000 to 3000 psi Figure 4 4 and 4 5 The valve replacement procedure which is the same for both valves is as follows Note The Apply and Release control valves are a matched pair do NOT replace single valves Disconnect the supply pressure and vent all pressure from the instrument Switch off the controller and isolate the incoming power supply Remove the instrument top cover by removing the three securing screws from the top edge of the rear panel sliding the cover back and then up Identify the valves to be replaced from Figure 4 5 Unscrew the valve solenoid clamp nut 1 and remove it Lift the solenoid 2 clea
44. ed to the instrument This task sets the test pressure dwell time at the test pressure and the leak test time Leak test menu structure Task Leak Test L Leak Test Leak Test Leak Test Starts leak test Set up Set up Test Pressure Sets leak test parameters Dwell Time Use the numeric key pad Test Time to enter the required values At the start of the test the instrument applies a test pressure to the user system A dwell time allows the user system to stabilise CP changing pressure D dwell time Ik leak P pressure T time seconds TT test time up to 9999 seconds The instrument changes to measured mode and then records the pressure change during test time On completion the display shows the Start Pressure End Pressure Pressure Change and Leak Rate K245 Issue No 3 3 12 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Divider Select and set up the divider task by pressing Task Divider Set up The set up menu defines pressure span and then divides the span into q number of equal test points min 2 max 25 Alternatively using the Quick 10 selection the menu sets 10 equally spaced test points Divider menu structure Task Divider Divider Divider Divider B00 Actual values displayed 590 ee 680 depends on the divider values 770 selected in set up 860 more Set up Set up Hig
45. ent 3 OV OUT Link OV OUT Green 9 25 mA IN to 25 mA IN White 8 25 mAIN SWITCH 2 pole 3 way Blue kL I E sa 2B1 GE PTX 610 Red Excitation Pressure Blue Signal Return Manifold Figure 2 18 Multiple Pressure Transducer Test Set up K245 Issue No 3 2 21 2 Installation SCM 2 10V OUT Supply Outlet Vent e3 W our stm O O Be Q 135 mV Yellow Figure 2 19 Millivolt Output Pressure Transducer Test Set up Compensated Note Using the regulated 10V supply compensates the transducer output for variations in the supply Outlet Vent 135 mV 7 135mV Figure 2 20 Millivolt Output Pressure Transducer Test Set up Note When using an external supply the instrument cannot compensate for changes in transducer output due to power supply variations K245 Issue No 3 2 22 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 2 10V OUT Outlet Vent 3 ovouT 6 7 135 mV IN 135 mV IN Pressure Manifold Figure 2 21 Multiple Millivolt Output Pressure Transducer Test Set up Note This configuration uses the SCM 135mV Supply Corrected range The SCM 10V regulated supply connected in parallel provides permanent excitation to all the pressure transducers preventing errors from cold measuring elements K245 Issue No 3 2 23 2 Installation intentionally
46. et Vent z O O O DC Output Logic Input 24V max Pressure Switch Example Switch Test Connections K245 Issue No 3 3 15 3 Operation Pressure Cycling Programs the controller to apply low and high pressure values at a defined rate of pressure change for a defined number of cycles This facility exercises pressure gauges or similar equipment before calibration or testing Set the pressure cycling parameters in Task Pressure Cycling Set up Use the soft keys and numeric keys to set High Low Rate of pressure change and the number of Cycles Task Pressure Cycling L______ Pressure Cycling Pressure Cycling Starts pressure cycling mode Set up Set up High Enter the required pressure Low cycling parameters using the Rate numeric key pad Cycles Run When selected the controller performs a pressure cycle routine using the range outlet port and settings selected in the Basic task R rate of pressure change L low value set point H high volue set point N number of cucles P pressure K245 Issue No 3 3 16 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Barometric Reference The barometric reference option measures the barometric pressure at the reference port of Range 1 It permits the controller to operate in either gauge or absolute mode Select gauge or absolute in Basic mode The controller stops during a
47. eturn to the Set up menu press Exit twice or Set up once The User Set up menu provides facilities for programming frequently changed settings as follows K245 Issue No 3 3 22 Druck DPI 515 Precision Pressure Controller Calibrator User Manual K245 Issue No 3 Setup User User Zero ana era Zero all Zero a range Enable Disable Auto Zero Auto Zero Interval Units Pr bar a L bar Applies to any Pa function key hPa Selected unit nonea fe Press relevant pa key to select mbar kg cm2 inH2O inH2O4 ftH2O ftH2O4 inH2O60 USER1 Display Resolution Brightness Contrast Runner Runner Activity Monitor Actual ranges displayed set in instrument configuration Enter required value default 50 Enter required value default 50 Key enables disables function Key enables disables function Contd on Sheet 2 3 Operation K245 Issue No 3 From Sheet 1 Jog Resolution Settling More Time amp Date Head Correction User defined units Select required value Time 13 45 59 Date 21 06 2002 Date format DD MM YYYY ve Offset UUT above DPI515 Enter Head Correction ve Offset UUT below DPI515 Datum Line On Screen Pa unit Pa unit Druck DPI 515 Precision Pressure Controller Calibrator User Manual 3 6 Aeronautical Option The Aeronautical task enables control and meas
48. executed one step at a time To write q test program press the Set up soft key and select New To edit an existing program press Edit Enter a nome for the program using the text editor keys to select letter range and the jog control to select the letter within the range Use the right arrow key to move to the next character position Press enter on completion The display shows the line instruction with insert and delete selections Pressing insert changes the display to a list of the available programming commands Table 3 1 Test Program Commands Command Description Command Description set point Allows set point to be entered Text Sets screen message Dwell Specifies dwell time seconds Beep Beep on off In Limits Wait for In Limits condition Rate Value Specifies controller rate Range Specifies instrument range Rate Max Sets controller rate to maximum Zero Output zeroed Vent Instructs instrument to vent Control Selects Control mode Count Used in a loop to count the number of loop cycles Measure Selects Measure mode UP Logic Specifies change of state for external contacts as a halt condition Goto Used to set up a loop Enter Settling Used to specify overshoot program line number to go to requirements Pause Causes test program to pause Resolution Sets display resolution for user input Resume Units Selects required display units End Program end command To select a
49. f the DPI 515 instrument requires specific ancillary equipment such as regulators pressure fittings vacuum pumps oil mist filters foreline traps etc The following table lists parts and suppliers for many of the items required for correct installation This list is not a complete or mandatory listing it should be used an aid for sourcing the relevant components GE accepts no responsibility for the suppliers listed or the availability of parts or price Table 6 1 Pressure Regulators for Positive Source Supply Range Manufacturer Model 2 Oe S s al 200 mbar 2 bar Marsh Economatics 960 013 000 138 272 mbar 10 3 5 20 bar Drager 44 1111 24 0 35 415 35 bar Drager 44 1112 24 0 55 415 70 bar Drager 44 1113 24 0 7 105 415 100 to 210 bar Drager 44 1115 24 1 72 280 415 For pre regulation of low pressure regulators the Drager 44 1800 may be used it is also suitable for direct regulation of positive source pressures between 20 to 135 bar K245 Issue No 3 6 Reference and Specification Suppliers of Ancillary Equipment Supplier Address Telephone Fax Economatics www economatics co uk Economatics Epic House Damall Road Attercliffe Sheffield England S9 5AA Tel 0114 281 3344 Fax 0114 243 9306 Marsh Bellofram www marshbellofram com Norgren www norgren com Bellofram Corporation State Route 2 Box 305 Newell WV 26050 USA Tel 0800 727 5646 Fax
50. h Select the divider parameters Low Quick 10 gives ten 10 Number of Points readings of the entered span Quick 10 Select required Range Units Rate etc in Basic task When Divider is then entered from the Task menu these test point pressures are displayed in the soft key boxes By entering control mode the soft keys can be pressed to change to these test pressures and controlled at the selected pressure The jog control can be used to nudge the set point jog resolution in SETUP USER JOG RESOLUTION P pressure S steps R range K245 Issue No 3 3 13 3 Operation Preset The Preset function is similar to the Divider function except that using Task Preset Setup individual set point values can be defined for each soft box maximum 25 set points The jog control can be used to nudge the individual set point values jog resolution in SETUP USER JOG RESOLUTION Task Preset L Preset Preset Set up Preset 250 150 50 0 50 more Preset 250 150 50 0 50 more Preset values entered in set up Select relevant page and press a soft key Use the numeric keys to enter preset values The set up function displays a preset number pressing the soft key for that number assigns q pressure value to the key After setting all the required preset pressures enter control mode and then press a soft key to chang
51. he pneumatic pressure and vacuum supplies to the instrument Switch off and isolate the electrical power supply to the instrument Remove the instrument from the equipment rack to access the rear panel Disconnect the power supply cable and the pneumatic supply hose assemblies Stow the power supplu coble in the pockoging below Remove any pressure adaptors and silencers VENT ports 2 If available use the original packing material When using packing materials other than the original proceed as follows Fit protection to all the ports to prevent ingress of moisture and dirt Note Use the original red plastic plugs or low tack masking tape Wrap unit in polyethylene sheeting Select q double wall cardboard container Inside dimensions must be at least 15 cm 6 greater than the equipment The carton must meet test strength requirements of gt 125 kg 275 lbs K245 Issue No 3 6 23 6 Reference and Specification Protect all sides with shock absorbing material to prevent equipment movement within the container Seal carton with approved sealing tape Mark carton FRAGILE on all sides top and bottom of shipping container Environment The following conditions apply for both shipping and storage Temperature range 20 to 60 C 4 to 140 F K245 Issue No 3 6 24 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 6 10 Ancillary equipment The installation o
52. heric pressure but with gauge transducers fitted without barometric reference then q maximum of 1 5 bar 19 5 psi g can be applied Pressure media to be non condensing high purity gas only Flow All of the supply gas delivered to the load Moximum supplu flow when moking fast pressure steps con be estimoted from the control valve orifice size and considering the differential pressure at that moment Orifice sizes Q 10bar 0 150 psi 1 6mm 0 0629 in dia gt 10 70bar gt 150 1000psi 0 8mm 0 0315 in dia gt 70 210bar gt 1000 3000 psi gt 0 5mm 0 0197 in dia K245 Issue No 3 6 19 6 Reference qnd Specification Pressure Outlet Pressure within the specified positive and negative full scales 24 Vdc Output for energizing externol equipment Voltage 24 V dc 1 V at maximum current of 100 mA Logic Output Volt free relay contacts maximum current 100mA dc to 60 Hz Maximum of 30 volts between the contacts and ground Weight 9 kg 19 8 Ibs approximately Dimensions 390 mm 15 35 in wide x 132 mm 5 19 in high x 300 mm 11 81 in deep 3U high case Installation Retractable feet supplied for benchtop use Optional rack mounting kit for installation within o 19 inch rack system Pneumatic Connections 1 8 female BSP on Vent Supply and Outlet connections Reference connection M5 female Precision Note Precision assumes regular zeroing and includes non linea
53. ional requirements Special Note A contaminated UUT must have additional in line filters connected between the outlet port and the UUT to prevent contamination of the instrument Negative or Vacuum Supply The instrument must be configured to work with or without a negative supply see Setup Supervisor Negative supply The negative supply for absolute control does not need to be regulated The output recommended of the vacuum pump should be less than 35 mbar 1 04 inHg absolute Any variation between this and absolute zero will have little effect on instrument operation Oil Contamination Precautions must be taken against oil transfer to the instrument Recommended A venting solenoid connected to atmosphere and the pump When the pump supply is switched off the valve opens allowing atmospheric pressure to enter the pump directly rather than through the pipe to the instrument Note Without this arrangement oil may progressively move up the supply pipe and into the instrument Pump Performance Recommended for ranges above 2 bar 30 psi gauge positive full scale When installing a vacuum supply protect the vacuum pump against the discharge of positive pressure by the controller into the vacuum pump This may result in reducing vacuum pump performance Use a release valve in the negative supply to vent pressure to atmosphere if the vacuum pressure rises above atmospheric pressure The release valve should be installed on the instru
54. isplayed value applied as tare value Value Entered value applied as tare value Filter On Off Turns the Tare process on or off Filter Time Constant Sets and enables the Band required filter characteristics Gauge Enable Disable Absolute Gauge Gauge 0 3 barg Actual ranges displayed selected 2 5barg lat manufacture 35 barg Absolute L absolute K1 33bara Actual ranges displayed selected 36 bara at manufacture Value L Set rate value Rate 300 0 mbar s change using numeric key pad or ae jog control rate L maximum rate x controller may overshoot set point K245 Issue No 3 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Basic task To control pressure in the Basic Task proceed as follows a Select the required pressure range and units of pressure measurement from the soft boxes displayed b Dress the Control key The display changes to show set point and rate c The message window shows Confirm Change set point and press Control to start d Press the Rate soft key The display shows two options Value and Max Rate e Dress Value and enter the required rate of pressure change on the key pad e g 0 1 bar s 1 5 psi s and press Enter The display returns to the control mode screen f Use the key pad to select the required set point e g 1 5 bor
55. ith existing Druck instruments the DPI 510 and DPI 520 and the Ruska 7000 For further details refer to the relevant controller manual available on ge sensing com B lt value gt CU C1 DO D2 D1 Fxx 10 11 12 13 14 15 16 17 JO J1 J2 M NO N1 N2 N3 N4 O1 P lt value gt RO R1 R2 S0 S1 S2 S3 TO T1 U1 to U23 V lt value gt W lt value gt O to 11 O to 11 0 1 K245 Issue No 3 Set Tare amount Go to MEASURE mode Go to CONTROL mode Transmit Pressure Reading Transmit Set point Ignored Disable SRQ SRQ on In Limit SRQ on Error SRO on In Limit and Error SRQ on End of Conversion SRQ on Error and End of Conversion SRQ on In Limit and End of Conversion SRQ on In Limit Error and End of Conversion Set Pre programmed rate Unlock keyboard Set talk mode notation Zero Set Pressure Set point Unlock keyboard Lock keyboard Set pre programmed units Turn off Tare mode Turn on tare mode to value set to B B must be set first Set S4 units setting S4 changes current units immediately Set slew rate sets low overshoot mode Set In Limit wait time Set set point as fraction of P value Set pre programmed set point Disable error reporting Enable error reporting Druck DPI 515 Precision Pressure Controller Calibrator User Manual Response Formats NO lt Pressure or Setpoint gt lt REM LOC gt RnSnDn nn N1 lt Pressure or Setpoint gt nn N2 lt REM LOC gt
56. left blank K245 Issue No 3 2 24 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 3 3 1 Operqtion Preparation Make sure the electrical cables and pneumatic pipes comply with the installation requirements in Section 2 Carry out the following before use If necessary carry out the maintenance task detailed in Section 4 For bench top single instrument operation carry out the following 1 Moke sure the instrument power supplu switch on the reor panel is set to OFF 2 Connect the instrument to the electrical supply make sure the supply includes a connection to a protective earth 3 Inspect the pneumatic hoses for damage ingress of dirt and moisture Before use the instrument should be tested for first time users see section 3 3 for users requiring more operating detail see section 3 4 This section contains a quick reference chart detailing all the Key pad functions Further quick reference charts at the end of this section detail the set up menu Review and become familiar with the whole procedure before starting a process on a component or system K245 Issue No 3 3 1 3 Operation 3 2 Quick Reference Figure 3 1 A brief description of key pad functions and general display indications follows Key selection display Function and comments Pressure Window Displays state of the pressure outlet selected e g Value Measured Pressure Task
57. lve 4 Apply control valve 5 Brown cables 6 Locating spigot 7 Red cables Figure 6 2 gt 70 bar to 210 bar gt 1000 to 3000 psi Manifold Assembly 65 User Set up Zero During use the instrument pressure sensor can show small zero shifts caused by time and temperature changes A regular zeroing increases measuring precision A gauge pressure sensor can be zeroed immediately using the Set up User Zero Zero a range or Zero All function or by using the Auto Zero function to fully automate the process The auto zero interval needs to be set in hours On dual range units Zero All zeros both ranges Note With zero of small user volumes a small positive pressure offset may be seen after a zero operation maximum 0 2 mbar This real pressure change caused by the closure of the zeroing valve in the instrument does not affect precision Units Use soft keys to select the new units to be displayed in the Task Basic Units soft boxes K245 Issue No 3 6 7 6 Reference qnd Specification Display Allows the display parameters resolution brightness and contrast to be adjusted Resolution should be set to give an appropriate value for the measurement units and precision of the instrument normal setting six digits Too high a resolution may give an unstable reading If seven digits are selected then the filter should be used to stabilise the reading Enables and disables the runner and activity indicator icons on the task screen as
58. ment side of a volume which is approximately equal to the system volume The volume slows any rapid pressure rise giving the release valve time to open and the pump time to reduce the pressure Note A wide bore vacuum pipe can have enough volume and used with a release valve could provide the necessary overpressure protection K245 Issue No 3 6 3 6 Reference qnd Specification Venting Either a zero or vent operation uses the vent port Vent The system gas at the outlet pressure can be released from the vent port Unrestricted gas flow occurs in this operation Recommended Use a controlled method to reduce the system pressure at a controlled rate to near atmospheric pressure then select vent Zero During a zero operation only the internal volume of the instrument vents to atmosphere Recommended Do not obstruct the vent port To reduce acoustic noise and safely dampen gas exhaust a silencer may be fitted to the vent port Outlet port Caution Ranges above 70 bar 1000 psi must not be connected to the outlet of any other range Outlet ports of ranges above 70 bar 1000 psi must be connected separately to UUT The outlet port provides the controlled pressure output to the unit under test UUT Each range has one outlet port The outlet ports on a dual range instrument up to 70 bar 1000 psi can be connected together and then connected to the UUT Configure the instrument in SETUP Supervisor System Stand alone Refe
59. menu Controlled Pressure Changing Pressure and full scale range Help Window Displays a Help facility explaining functions of soft keys and gives instructions for Set up menu setting parameters Message Window Displays menu level and task in use Provides message line giving instructions for setting parameters or operation Soft keys Select menu functions Soft Boxes Displays the functions of the associated soft key Numeric Keys Sets the value for a parameter Exit Returns instrument to previous menu Task Displays Task menu enabling a new task to be selected Control and Measure Switches instrument between Control and Measure modes Set up Displays Set up menus Delete Deletes the last entered character from value entry box Enter Enters values set on screen display Jog Control Incremental control of display settings e g set point in control mode Preset and Divider set points and Display parameters Resolution Brightness and Contrast Display Shows task specific information such as current set point rate and test parameters When enabled shows instrument activity indicator CONTROLLED PRESSURE FS 1barg Ee Units 1000 00 mbar ae P N Setpoint 1000 00 mbar Task Basic iN m O N 1 2 3 1 Display panel 2 Message window 3 Pressure Help window 4 Softboxes 5 Soft keys 6 Key pad 7 Jog control Figure 3 1 Instrument Controls and Indications Druck DPI 515 Precision P
60. mode units selected in set up menu system venting Range 1 changing range Process Range 2 m s changing range Gauge Absolute set tare set filter set available ranges and options Gauge Absolute returns to measured pressure display example pressure range Key pad returns to measure mode see 3 4 task selection see below control mode see above measure mode see 3 5 set up menu removes last entered digit O Q WD sets numeric value K245 Issue No 3 3 4 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Soft keys in controlled pressure mode Press the control key and the instrument changes the soft keys to F units selected in set up menu system venting Vent MPa Range 1 changing range Process mbar Range 2 changing range Gauge Absolute mmHg set tare set filter set mmH2O available ranges and options Gauge Absolute available ranges and options Value a maximum rate set at the factory a 4 returns to measured pressure display Rate 300 00 mbar s example pressure range K245 Issue No 3 3 5 Status displays and messages Function and comments Measured pressure Changing pressure Controlled pressure Mode status Measure mode Control mode
61. n 6 8 Specification Standard Pressure Ranges 70 200 350 700 mbar 1 2 3 5 7 10 20 35 70 100 135 and 210 bar gauge 1 3 5 10 15 30 50 100 300 1000 2000 and 3000 psi gauge Gauge instruments available with negative calibration as an option Overrange 10 above full scale pressure range measure mode only Power supply 90 to 260V ac 50 to 60 Hz Power rating 60 VA Installation Class 2 Temperature Operating 5 C to 50 C 41 F to 122 F Calibrated 23 C 73 4 F Storage 20 C to 60 C 4 F to 140 F Environment Humidity 0 to 95 non condensing Vibration Compliant with Def Stan 66 31 8 4 cat 3 Shock Mechanical shock conforms to EN61010 Conformity BSEN61010 BSEN61326 1 97 23 EC CE marked Positive pressure Supply pressure depends on the full scale pressure rating of a specific range See rating label on rear of instrument for pressure range Negative pressure Atmospheric pressure or vacuum See Section 2 Installation Pressure Media Clean dry non corrosive gas typically air or nitrogen Particulate size should be filtered to less than 20 microns All oil mist must be removed Anu moisture must be non condensing Option G contains in line filters with 20 micron elements Materials in contact with pressure media to 70 bar 1000 psi Aluminium 6082 HE30 Bonded seals Nitrile Rubber Plugs Stainless Steel 316 Valve Parts AISI 302 AISI
62. n the power supply circuit The power supply connector and switch on the rear panel of the instrument will not be accessible Set the power supply isolator to OFF Connect the power supply and set the power supply switch to ON before sliding the instrument into the rack Connecting Figure 2 6 To connect the power supply to the instrument proceed as follows Insert the moulded IEC connector 1 into the power supply assembly 5 Set the ON OFF switch 4 to ON for rack mounted instruments set the power supply isolator to ON Check that the front panel display shows the power up sequence K245 Issue No 3 2 7 2 Installation Skea 2 FULLSCALE POSITIVE SUPPLY OUTLE T VENT 61 8 1 g BSP 1 IEC power connector 5 Power supply assembly 2 Fuse carrier 6 24 V dc output 3 Fuse 7 Logic input 4 ON OFF switch 8 Logic output Figure 2 6 Electrical connections 24V DC Output Using a 2 way connector pint 24 Vdc pin2 frame This facility can energise external equipment An integral self resetting fuse protects this output Logic switch Input Using a 2 way connector pint 5 Vdc pin2 24 Vdc This facility can be used to trigger the instrument from a pressure switch contact during the Pressure Switch Task see Section 3 4 Integral opto isolators protect this input circuit K245 Issue No 3 2 8 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Logic Outputs Using a 3
63. ndard serviceability test see Section 5 Testing and Fault Finding n Carry out the valve correction procedure as detailed in Section 4 8 1 Solenoid locking ring 2 Solenoid 3 Terminal spade 4 Valve body 5 Spigot 6 Spigot location 7 O ring 8 Manifold 9 M3 socket head HTS CSK bolt Figure 4 4 High Pressure Manifold Valve Replacement K245 Issue No 3 4 9 4 Maintenance 1 Manifold 2 M3 socket head HTS CSK bolt 3 Release control valve 4 Apply control valve 5 Brown cables 6 Locating spigot 7 Red cables Figure 4 5 gt 70 bar to 210 bar 1000 to 3000 psi Manifold Assembly K245 Issue No 3 4 10 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 4 8 Valve correction This facility in the calibration menu adjusts the pressure controller valves of the highest possible performance When pneumatic supply pressure sources are changed a valve correction must be carried out If the controller performance has deteriorated use this facility to restore performance Notes 1 The pneumatic supplies must meet the standard stated in the specification This valve correction feature makes adjustments to compensate for the pneumatic supplies 2 When using valve correction q vacuum pump must be connected to the negative supplu port and 0 blanking plug fitted to the Outlet port Procedure 1 2 3 4 5 6 7 8 9 Note Before using this facility carry out a leak test and che
64. ns a positive and negative pressure supply port an outlet port vent port and reference port The electrical connections provide an a c power supply serial and parallel communication interfaces d c output and logic input and output Note Two connectors identified as instrument bus are for factory use only The Druck DPI 515 can be used as a benchtop instrument or for mounting in a standard 19 inch rack system by using the rack mounting kit option D to adapt the instrument case K245 Issue No 3 1 Description The Druck DPI 515 uses the SCPI Standard Commands for Programmable Instruments communication protocol enabling a standardised communication codes with other instruments Additionally emulation supported command codes enable operation with other GE products Druck DPI 500 DPI 510 and DPI 520 controllers and the Ruska 7000 controller Options add to the abilities of the Druck DPI 515 these include a barometric reference negative calibration to minus 1 bar 15 psi enhanced absolute pressure performance and aeronautical units Further information and notes on applications are available on the Druck web site at www gesensing com and www DPI515 com K245 Issue No 3 1 2 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 2 2 1 2 2 2 3 Installation Packaging On receipt of the instrument check the contents of the packaging against the following list Packaging List i DPI 515 Pressur
65. ocess Tare Filter Gauge Absolute Gauge Only displayed when Barometric Option fitted Absolute Actual units displayeq selected in Set up Select required electrical range Actual units displayed selected in Set up Tares off the currently displayed value Tares off an entered value Turns the Tare process on or off Sets up the required filter characteristics Actual units displayed selected in Set up Actual units displayed selected in Set up K245 Issue No 3 Druck DPI 515 Precision Pressure Controller Calibrator User Manual A rear panel 15 way D Type connector provides the outputs inputs comprising two regulated power supply outputs 24V for current loop applications a protected extension of the internal 24V supply and a regulated 10V dc supply for the excitation of external transducers refer to Section 2 Installation SCM Option Task Enter the SCM option from the Basic Task by selecting Range and one of the SCM test options 135 mV 135 mV Supply Corrected 11V or 25mA and proceed as follows 1 Press Range and select the required range for the UUT e g 2 bar g Press Range again followed by SCM and then select the appropriate SCM function e g 25 mA Measured Pressure FS 2bar g 0 00035 0 00035 bar ssc ba Supply Corrected Measured Pressure FS 2bar g Task Basic Task Basic 2 After selection of SCM function
66. oints Check pneumatic supplies for correct pressures Check system for leaks In measure mode with output port sealed the pressure continues to increase or decrease Increasing pressure leaking Apply control valve Decreasing pressure leaking Release control valve Confirm by isolating supplies Contact approved service agent Instrument stops in Control mode when controlling to a new pressure Instrument stops in Control mode when controlling at a new pressure Fill time out enabled but time out period setting too short Dwell time out enabled but timeout period setting too short Instrument will not zero does not achieve set point control stability message Blocked or leaking zero valve Check for blockage Check clean or replace zero valve Instrument controlling to set point no pneumatic output Erratic or inaccurate zero Blocked isolation valve Check for blockage of isolation valve Check clean or replace isolation valve Leaking isolation valve Check clean or replace isolation valve Increased gas consumption Unstable control at set point or does not achieve set point System internal leak Carry out leak test at full scale pressure Worn control valve Replace control valves Table 5 1 Fault Location Note In normal controlled pressure conditions the status indicator stays within the tolerance band If the status indicator moves outside the tolerance band this c
67. p RS232 port to 9600 none XOn XOff Protocol Select required protocol Select Port Select required comms mode Contd on Sheet 3 K245 Issue No 3 6 13 6 Reference and Specification From Sheet 2 System L____ Power UP Timeout More Power on setpoint zero Regulator Enter required start up setpoint value Timeout Idle Timeout IS Enter required time sec Enables disables function Fill Timeout i Enter required time sec Vent Timeout Enter required time sec Logic Output Select required trigger event for Output 1 Select required trigger event for Output 2 K245 Issue No 3 Contd on Sheet 4 6 14 Druck DPI 515 Precision Pressure Controller Calibrator User Manual From Sheet 4 Factory settings Cancels all current settings Seton re and installs factory settings Negative Supply Select required negative supply Select required negative supply K245 Issue No 3 6 15 6 Reference qnd Specification 6 7 Communications instrument emulation The DPI 515 Precision Pressure Controller Calibrator can be remotely controlled using the SCPI Standard Commands for Programmable Instruments command language SCPI can be implemented over RS232 or IEEE 488 interfaces Refer to publication K179 for a complete listing and explanations of these commands Partial emulations are provided to give a measure of compatibility w
68. r of the valve body 4 Note Only disconnect the solenoid when replacing the solenoid Leave the solenoid electrically 3 connected for all other operations Remove and discard the four M4 socket head high tensile steel countersunk bolts 9 securing the valve body 4 to the manifold block 8 and lift the valve body clear of the manifold Wipe the surface of the manifold clean Make sure the valve seating area on the manifold block is clean Place the new valve body 4 in position using the spigot 5 to locate the valve Insert four new M4 socket head HTS CSK bolts 9 and initially tighten finger tight Note Do not re use the original M4 socket head HTS CSK bolts 9 and use only the replacement parts specified in Table 2 Carefully torque tighten in sequence to 2 0 Nm 17 7 Ibf in the M4 socket head HTS fr 3 CSK bolts 9 a Unless the valve solenoid is faulty refit the solenoid 2 over the valve body 4 and tighten the locking nut 1 Note If the spade terminal connectors 4 have become disconnected from the solenoid push the connectors back onto the solenoid terminals The connections to each valve are colour coded see Figure 4 5 K245 Issue No 3 4 8 Druck DPI 515 Precision Pressure Controller Calibrator User Manual I Refit the top cover of the instrument and reconnect the power supply and the input and output pneumatic supplies m Switch on the instrument and carry out a sta
69. r on Wait for In Limits Condition Beep on approx 1sec Switch to Measure controller off Wait for beep record pressure Wait for 30 sec Beep on approx 1 sec Min pressure allowed 785 mbar WAIT press Resume to continue Vent Program end Druck DPI 515 Precision Pressure Controller Calibrator User Manual Programming Loops To program a loop use the Goto command Include the Count command in the loop for counting the number of loop cycles Note The test program commands do not include tests for conditional jumps to stop a test program from looping the Stop soft key must be pressed by the operator Example of programming a loop K245 Issue No 3 RANGE UNITS RATE RESOLUTION SETTLING TEXT ZERO SET POINT CONTROL IN LIMITS BEEP ON BEEP OFF MEASURE DWELL SET POINT CONTROL IN LIMITS BEEP ON BEEP OFF MEASURE COUNT VENT GOTO END 2 5 MBAR G MBAR 100 5 ZERO Operator instruction e g 400 30 800 Select 2 5 mbar g range Select units mbar Select rate 100mbar min Display resolution 5 digits No overshoot Connect UUT Set point 400 mbar Controller ON Wait for In limits condition Beep on approx 1 sec Switch to measure controller off Wait 30 sec Set point 800 mbar Controller on Wait for In limits condition Beep on approx 1sec Switch to measure controller off Increment loop counter Vent Loop back to program line 9 Program end 3 Operation
70. ransmitter Testing Figure 2 15 Connect each transmitter to the pressure manifold Connect the inlet port of the pressure manifold directly to the outlet port of the instrument At each applied pressure switch in turn each transmitter into the current loop either manual or automatic multiplexing SCM 1 24V OUT Outlet Vent a pa 3 oVOUT Link OV OUT Green 9 25 mA IN to 25 mA IN White 8 25 mA IN SWITCH 2 pole 3 way GE PTX 610 Red Excitation Pressure Blue Signal Return Manifold Figure 2 15 Multiple Pressure Transmitter Test Set up Note The 4mm test plugs can be connected together by inserting the pin of one into the end of another To link pins 3 and 9 insert the black connector connected to the white lead labelled 25mA IN into the Green OV connector K245 Issue No 3 2 19 2 Installation 3 wire and 4 wire Amplified Output Pressure Transducers Figures 2 16 and 2 17 24V OUT Outlet Vent OV OUT Link 11V IN Brown 11V IN to OV OUT Green 11V IN Signal Excitation 24V OUT Outlet Vent OV OUT I 11V IN 11V IN OV Signal Signal Excitation PMP4010 di C Figure 2 17 4 wire Amplified Voltage Pressure Transducer Test Set up Excitation K245 Issue No 3 2 20 Druck DPI 515 Precision Pressure Controller Calibrator User Manual BLU 24V OUT Outlet V
71. rements 6 3 SE T y a S lel GN aes ona es Be Casa us 6 5 Valve Assembly Description 6 6 User SetuP uya ua aa HRAN ET TN 6 7 S pervisor Set P uuu a ataqa aa phausi a AE IAR EE ees 6 9 Communications Instrument Emulation 6 16 Specificato a E A EE EE E Ee EAE NEEL 6 18 Return Goods Material Procedure sese 6 23 Ancillary Equipment I 6 25 vi Druck DPI 515 Precision Pressure Controller Calibrator User Manual 1 1 1 Description Introduction The Druck DPI 515 Precision Pressure Controller Calibrator measures and controls pneumatic pressure and displays on an LCD screen the pressure measurement and controller status A key pad next to the display enables manual selections and settings in both measure and control modes The instrument can be operated remotely through serial or parallel communication interfaces The instrument can contain one or two pneumatic measure control channels of different pressure ranges RE FS 1 bard Units Q CONTROLLED PRESSUI 0 0 0 0 om mbar AUTO ange T sanr 1000 00 Bar i d Figure 1 1 DPI 515 General view The rear panel houses the electrical and pneumatic output and input connections Each pneumatic channel up to 70 bar 1000 psi maximum contai
72. rence Port The reference port provides the negative pressure to the gauge sensor and to the barometric reference Option A Gauge sensors range 1 or range 2 use this port identified as Reference Connection For gauge sensors without a barometric reference small pressures can be applied see 6 7 Specification All other pressure measurement requires the port to be opened to atmosphere When in gauge mode the instrument shows the pressure difference between the reference and outlet ports Note This is not true differential operation as there is no differential calibration of the sensor The transducer of the barometric reference option senses atmospheric pressure via the reference port when enabled the port MUST be open to atmosphere The reference connection should be actively used for precision low pressure measurement The instrument controls pressure relative to the pressure at the reference port An atmospheric pressure change causes the controller to adjust the pressure and appears at K245 Issue No 3 6 4 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 6 3 the pressure outlet as apparent instability To keep a stable controlled pressure the reference port should be connected to a large volume with a small leak to atmosphere This dampens any atmospheric pressure changes The controller and UUT references should be connected together to provide a common reference to atmosphere Basic t
73. required Note These display icons have no effect on controller operation Jog Increment Sets the resolution of the rotoru control for trimming the set point Settling Sets how the controller achieves a set point No Overshoot controller changes pressure slowlu and does not go beuond set point Note This function can be used for UUT that have hysteresis errors Fast controller changes pressure as fast as possible and may go beyond set point overshoot Note Use this function for optimum speed Time amp Date Sets instrument clock and calendar Head Correction Corrects display pressure for the height difference between instrument and UUT Special Units Permits the user to define q set of units bu following the screen prompts Up to two special units may be programmed bu selecting a Pascal multiplier A five character name can be assigned K245 Issue No 3 6 8 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 6 6 Supervisor Set up The Supervisor menu provides facilities for programming settings These are usually made during installation as follows Note A PIN protects the Supervisor menu against unauthorised use Each instrument on delivery contains the factory set PIN 0268 To continue protecting the supervisor set up menu the PIN should be changed as soon as possible In Limits A tolerance value at the set point When the controller achieves the set point the inst
74. ressure value 14 Tare value 15 Pressure reading ne 11 10 9 K245 Issue No 3 Status displays and messages Function and comments Mode status Measured pressure Changing pressure Controlled pressure Measure mode Control mode with pressure changing to set point Control mode pressure at set point AUTO Tare 0 50000 Displayed when autorange enabled Tare value set to 0 50000 and enabled selected by Process soft key Filter Filter enabled selected by Process soft key Per cent reading of full scale or set span selected by Process soft key Head 3 9370 in Head value set to 3 937 in height difference between instrument and UUT Runner Pressure change in progress enabled and disabled in Setup User Display Wait indicator Instrument stopped performing internal function Message window set point 14 053 psi Displays Task function with instructions for setting a parameter or an operation Set point at value of 14 053 in current selected units can be changed using the numeric key pad or jog control Rate 0 20 psi s Rate at value of 0 20 psi s in current selected units per second can be changed using the numeric key pad or jog control Key to display 1 Status 2 Set point value 3 Alarm indicator 4 Range 5 shoot or fast 6 Filter ON 7 Autorange 8 Wait indicator 9 Runner 10 Rate value 11 Message window 12 Activity indicator
75. ressure Controller Calibrator User Manual 3 3 First Time Operators The following sequences of operation should be used by first time operators and by operators that use the instrument occasionally For regular operators familiar with the instrument go to section 3 4 Note The following sequence is an example the values and selections displayed depend on the range s and options enabled in the instrument To control pressure the outlet port must be connected to a UUT or a blanking plug fitted The UUT must be of the correct pressure rating or the instrument set to limit the set point value to a safe pressure Set the power supply to ON and the power up routine starts 1 The display first shows 2 After a short time the display shows the start of the power up sequence the instrument carries Please Wait out a self test If the test finds a Self test in progress fault the display shows an error refer to section 5 Fault Finding and Testing 3 After a successful self test sequence the system changes to measure mode The display changes to measured pressure showing the parameters selected in Set up 2 1 FS 1 bar g p 1000 00 Vent mbar Range Process Gauge Absolute Task Basic 3 1 Mode 2 Range 3 Message window 4 Pressure reading 4 The instrument is now ready for use K245 Issue No 3 3 3 3 Operqtion Soft keus in measure
76. ressure before the pitot pressure for increasing and decreasing airspeed values K245 Issue No 3 3 25 3 Operation Aeronautical Task Select the Aeronautical task from the Task menu The display shows four menu items Mode Press the mode soft keu to select an operating mode such as Altitude or Speed Units The Units soft key provides access to either the Aeronautical or Pressure units At any time the units can be changed between pressure and pressure converted to aeronautical units The display shows the outlet pressure converted to Altitude CAS or Mach using BS 2G 199 1984 conversions and assuming standard atmospheric conditions Based on tables from ICAO Standard Atmosphere 1964 Reference Pressure Press this keu to select the required reference pressure This con be either the barometric pressure from the instrument s internal barometric sensor or any numeric value e g 1013 25 mbar 29 92 inHg Go to ground Press this key to return the instrument and any unit under test UUT connected to it safely to ground pressure at a controlled timed rate K245 Issue No 3 3 26 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Task Aeronautical Aeronautical Mode Only available if option fitted Go to Ground ROC Type Set ROC Units Select required mode and press control Mode Altitude Enter required altitude aim press control I Enter
77. rity hysteresis repeatability and temperature effect between 18 C and 28 C 65 F and 82 F add 0 004 full scale for 10 C to 45 C 50 F to 113 F 0 01 full scale from 700 mbar to 210 bar 10 psi to 3000 psi 0 03 full scale below 700 mbar 10 psi Option C1 Altitude Range Control and measurement of altitude ft and m and vertical speed rate of climb ft min m min m sec hm sec Range 3000 to 80 000 feet K245 Issue No 3 6 20 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Option C2 Airspeed Range Control and measurement of airspeed and rate of airspeed kts kts hr mph km hr km min and Mach Mach Number Range 910 knots Option C2 Altitude and Airspeed Range Both ranges as above on a dual range instruments Option D Rack Mounting Kit Includes side and rear supporting brackets for 19 inch rack systems Option E1 Low Absolute Pressure Enhanced Performance single range An enhanced measurement stability for the following pressure ranges 750 1150 mbar a 22 34 inHg a 35 1310 mbar a 1 39 inHg a 35 2620 mbar a 1 77 inHg a 35 3500 mbar a 1 100 inHg a Precision 0 01 full scale including non linearity hysteresis repeatability and temperature effects over 10 C to 40 C 50 F to 104 F Measuring stability 0 01 full scale per annum Option E2 Low Absolute Performance Enhanced Performance dual range An
78. rument controls within this tolerance value It does not affect controller stability or precision The instrument uses the in limits flag when performing a control task such as Leak Test Switch Test and Pressure Cycling Note In remote control RS232 or IEEE488 the control computer can be used to interrogate the in limits register to confirm the controller has achieved set point Set point Limits Defines the limits of pressure the user con enter as a set point useful for protecting sensitive UUT Limit applies regardless of the pressure range in use Lock Lock Jog Disables the rotary control Used when the control might be accidentally operated Lock Task Allows any combination of tasks to be disabled Note Restricts operation of the instrument to specific tasks or functions ideal for production procedures Language Provides q choice of display messages in English French German Spanish Italian Portuguese or Japanese PIN Changes the Supervisor PIN enter the existing PIN then the new PIN ond confirmotion of the new PIN Note Confirmation of the new PIN permanently replaces the old PIN Record this new PIN and keep this record on a safe place Alarms One or two pressure alarms can be set An alarm triggers when the pressure exceeds the High Alarm or falls below the Low Alarm A buzzer sounds when the alarm triggers and the alarm symbol bell appears on the display K245
79. s Use a straight 9 way to 9 way male to female connector cable Connect the cable between the computer communications port and the instrument s 9 way D type RS232 port connector as shown in Figure 2 9 Use the Set up Supervisor Comms menu see Section 6 6 to set up the required RS232 parameters Note Use a 9 way to 25 way adaptor for a computer with 25 way communications port GND COMPUTER DPI 515 Figure 2 9 RS232 9 way Connections Hardware Handshaking K245 Issue No 3 2 12 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 2 8 IEEE 488 Interface Figure 2 10 This interface complies with IEEE 488 2 HS standard The IEEE 488 parallel interface connects a computer controller to one or more DPI 515 instruments and possibly other instruments Up to 30 instruments can be connected through a high speed data bus to the computer controller To connect up the IEEE 488 interface proceed as follows The length of each IEEE 488 cable must be less than 3 metres to comply with the EMC requirements see Section 6 Reference and Specification Single Unit Installation Fig 2 10 Connect an IEEE 488 connector cable assembly to the rear panel IEEE 488 connector of the instrument Connect the other end of the connector cable assembly to the IEEE 488 connector on the controller computer Change the IEEE 488 communication parameters as described in the Set up Comms Menu refer to Section 6 6 M
80. s selected and allows time for the complete system to de pressurize to atmospheric pressure Note Not achieving full de pressurization may be a system fault Logic Outputs Selects the type of response and condition of the two logic outputs These operate when Vent commond selected Range chonge selected A high or low alarm high low activates A command from the control computer PC received Factory Settings Restores instrument settings to factoru default Note Does not affect PIN settings K245 Issue No 3 6 10 Druck DPI 515 Precision Pressure Controller Calibrator User Manual Calibration The calibration menu provides facilities for programming settings for maintenance as follows Note A PIN protects the Calibration menu against unauthorised use Each instrument on delivery contains the factory set PIN 4321 To continue protecting the supervisor set up menu the PIN should be changed as soon as possible Change Cal PIN Changes the Calibration Personal Identification Number PIN Enter the existing PIN the new PIN and confirmation of the new PIN Sensor Correction Selects the range for a calibration routine Valve Correction Performs valve correction routine The Status menu provides the user with informotion obout the instrument os follows Hardware Build Displays ranges of sensors calibrated with the instrument and the options fitted Software Build Display
81. s versions of software for the instrument Calibration History Displays a list of instrument calibration dates K245 Issue No 3 6 11 6 Reference and Specification Setup Supervisor Enter Supervisor PIN In Limits L F jn Limits x i Select required value In Limits Maximum value 1 Setpoint Limits __ Setpoint Limits Upper Enter Upper Limit Value Lower Enter Lower Limit Value Enable Disable Enable Disable function Lock L Lock Lock Unlock Jog Enables disables jog control Lock Tasks Lock unlock task selected by jog cursor control Unlocks all locked tasks Language L Language English French German Spanish Italian Select required language More PIN L BIN Old PIN Enter existing PIN number New PIN Enter new PIN number 4 digits Confirm PIN Re enter new PIN number More Contd on Sheet 2 K245 Issue No 3 6 12 Druck DPI 515 Precision Pressure Controller Calibrator User Manual From Sheet 1 Alarms L Alarms 7 Alarm High Pressure Enter Upper Alarm Limit Value Alarm Low Pressure Enter Lower Alarm Limit Value Enable Disable Enable Disable function High Alarm Enable Disable Enable Disable function Low Alarm Enter Address 0 to 31 Enter Value 0 to 50 RS232 Use Jog control to set rate Use Jog control to set parity Use Jog control to set mode Restores standard settings to 9600 none none Sets u
82. the display shows the transmitter output Press Control ani s to display set point and Rate setting windows 0 00035 bar Process Gauge Absolute Current 4 0004 mA Task Basic Rate 3 Set the required set point either by direct entry from the key pad followed by Enter or Measured Piessure FS 2bargs bu rototing the Jog control followed bu Enter 0 00035 bar Setpoint 1 50000 Rate 0 50000 bar sec Process Gauge Current 4 0004 mA Absolute Task Basic Confirm change Setpoint press Control to start Rate K245 Issue No 3 3 33 3 Operation 4 Press the Rate key Select the required rate of change of pressure either by direct entry from Resear i bat g the key pad followed by Enter or by rotating 0 00035 the jog control followed by Enter bar Alternatively select MAX for maximum rate of Setpoint 1 50000 change Rate bar sec Current 4 0004 mA Task Basic 5 Press Control to start the test The display shows the activity monitor and the instrument Measured Pressure Peseta g controls the applied pressure to the set point 1 00750 at the preset rate bar Setpoint 1 50000 6 At the end of testing enter a set point of zero Rate 0 50000 bar sec or ambient pressure to safely return to Gare 14 6668 mA ground pressure at a controlled timed rate e K245 Issue No 3 3 34 Druck DPI 5
83. this valve symbol shows the working effort of the apply and release valves The higher the pointer b the more the work rate of the apply valve The lower the pointer gt the more the work rate of the release valve Controlling to ambient zero pressure Use the numeric keys or jog control and set the new set point value of ambient or zero pressure When the display shows the new set point value press the control or enter key The display shows the pressure value changing as the instrument controls to the new set point at the set rate of change When the display shows ambient or zero pressure press the measure key to switch off the controller and return to measure mode Note The instrument stays in measure mode showing the pressure measured at the outlet port K245 Issue No 3 3 8 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 3 4 Operation and Example Procedures Introduction Before operation the instrument must be connected to the correct electrical and pneumatic supplies as detailed in Section 2 Installation Switch the instrument ON and after a short time the display shows measured pressure mode except when regulator mode is selected in the Basic Task screen A dual range instrument always starts in the higher pressure range Measure and Control Modes The instrument operates in two modes Measure or Control Pressing the Measure key selects Measure mode the instrument works as a precision press
84. tus window changes to Controlled Pressure The runner icon in q standing position The activity indicator shows the controlled pressure within the in limits tolerance K245 Issue No 3 5 1 5 Testing and Fault Finding Caution Using the vent function may damage rate sensitive equipment connected to this controller Use the controller to reduce pressure to ambient zero before selecting VENT g Press the Vent soft key to reduce the system pressure to near atmospheric pressure This feature should be used to reduce system pressure to a safe value before disconnecting the Unit Under Test Notes 1 The vent opens for approximately 5 to 10 seconds 2 Always use the vent function before disconnecting pressure equipment from the outlet port h Press the measure key to switch off the controller K245 Issue No 3 5 2 Druck DPI 515 Precision Pressure Controller Calibrator User Manual 5 33 Fault Finding Check the fault conditions and solutions listed in the following table before contacting gesensing com or a recommended Service Agent Fault Solution Power supply connected display not lit Check rear panel switch set to on Check fuse and if necessary replace Check power supply fuse UK models only and if necessary replace 24 V DC output intermittent Internal self resetting fuse operating Reduce load current to specified value Instruments functions but does not reach all set p
85. ue entru box on the Airspeed displqu The numeric key pad may be used to enter the required airspeed set point Press ENTER to confirm Set Rate Press this soft keu to highlight the Aim value entry box in the Rate of Speed window The numeric key pad may be used to enter the required Rate of Speed set point Press ENTER to confirm Calibrated Air Speed FS 1000kts 0 0 Rate of speed Task Aeronautical With the Aim CAS and the Rate set press Control again to start the change to the CAS Aim Go to Ground Pressing this soft key option makes the instrument control the airspeed to ZERO for safe disconnection of the Unit Under Test UUT K245 Issue No 3 3 Operation Mach Measure Mode Press Mode and select MACH from the menu The display shows Mach in the upper window and Rate Rate of Mach acceleration in the lower window Both windows have a current value display in large characters Only the Rate window has a reference Ref value in smaller characters Mach Reference Pressure The reference pressure can be set to a fixed value for the static Ps pressure The instrument then calculates Mach number values based on this reference pressure The static Ps connection can remain open to atmosphere pressure Mach Control Mode Press Mode and select MACH from the menu Press Control the display shows Mach in the upper window and rate in the lower window Both win
86. ultiple Unit Installation Figure 2 10 To install multiple units use stacking plugs to link from first instrument to the second instrument Proceed as follows Connect a pair of IEEE 488 stacking connectors to the rear panel IEEE 488 connector of the instrument Connector to rear panel of first instrument Connector from controller computer Connector to rear panel of second instrument Connect the other end of one of the connectors to the IEEE 488 connector on the controller computer and the other connector into the next instrument Repeat this procedure for all the instruments in the system Use the Set up Comms menu on each instrument to set up the required communication parameters Refer to Section 6 6 K245 Issue No 3 2 13 2 Installation aNNOY9 91901 ve AWVus SISSVHO c L LL GND Ez OL GND zz 6 GND LZ 8 GND 02 2 GND 61 9 GND 84 801a 9 L ZOIC SL 9OId bL uvg SOIC L snivis Leis void cold cola Lold v C L 318vVN3 2 LOW2HI Nati L NOILLNALLV N1V LL LSANOAY 39144939S OYS OL YV310 SOVSYSLNI 241 ASILNAGI HO qN3 102 q31d3OOV VLVG LON YAN viva HOS AAYY LON GSYN ava Viva Ava 6 S 8 Z 9 RR OWO LD N GQNNOWD 91901 JNWY HJ4 SISSYH LONG AO saa aana 2 14 Figure 2 10 IEEE 488 Connection suafa
87. ument using a negative supply must be enabled in the set up menu On instruments without a negative supply the positive pressure discharges from the system to atmosphere through the negative supply port A silencer can be fitted to the negative port to reduce airflow noise Pneumatic Connection Examples Figures 2 2 2 3 and 2 4 These examples show a dual range instrument for a single range instrument use range 1 connections Option G contains the in line filters F1 and Fe Range 1 Range 2 Outlet Vent Supply Outlet Vent O O O O Re Supply Filter Silencer Unit under test Pressure source 110 FS Range 1 Conditioner Regulate to 110 FS Range 2 Figure 2 2 Pneumatic Connections up to 70 bar 1000 psi without vacuum supply Note CONNECTED RANGES must be enabled when connecting the outlet ports together This applies to instrument ranges of 70 bar 1000 psi and below Enabled in SETUP SUPERVISOR SYSTEM CONNECTED RANGES K245 Issue No 3 2 3 2 Installation Supply Outlet Vent Supply Outlet Vent O Unit under Unit under Pressure source 110 FS Range 1 Conditioner Release Valve e Damping Filter Volume Vacuum source H gt O Foreline trap Pressure source 110 FS Range 2 Conditioner Figure 2 3 Pneumatic Connections up to 70 bar 1000 psi with vacuum supply Notes 1 Option G includes in line filters
88. ure indicator and shows the pressure measured at the outlet port Pressing the Control key selects Control mode the instrument works as a precision pressure controller and shows the controlled pressure measured at the outlet port Pressing the Task key enables various pre determined functions Task key Basic nautical Pressure Leak cycling Test Test Program Divider Preset The message window at the bottom of the screen shows Task Select prompting for a selection of an option from one of the soft Keys When selected e g Basic the display shows the soft key options for the task Units Vent Range and Process and the upper line of the message window changes to display Task Basic The status window at the top of the screen displays Measured Pressure K245 Issue No 3 3 9 3 Operation BASIC Basic Task Selections BASIC Units Vent Range Process Gauge Absolute L Only available with the barometric option Rate Only available in control mode Units mbar bar e psi Actual units displayed mH20 selected in user set up menu kPa Mpa Vent CAUTION Yes Yes causes the vent valve to open and USE THIS FACILITY No pressure to equalize with atmospheric WITH CARE Range ae a Actual ranges displayed selected 36 barg at manufacture Process Tare L are Reading Current d
89. urement of altitude and airspeed in aeronautical units such as feet and metres altitude and knots mph km h airspeed This task utilises dual pressure displays to show the parameter and the rate of change of Altitude Airspeed Mach and Airspeed with Mach number The Aeronautical Task enables the testing and calibration checking of aeronautical indicators and system components by controlling and displaying values and rates in aeronautical units The instrument automatically selects the appropriate pressure ranges for altitude and airspeed normally 1 3 bar 19 5 psi absolute and 2 0 bar 30 psi differential respectively Cautions 1 Do not exceed the maximum pressures stated in the appropriate Component Maintenance Manual for the unit under test 2 Carefully de pressurize all pipes to atmospheric pressure before disconnecting and connecting to the unit under test Example of Two Instruments for Altitude and Airspeed Testing Figure 2 13 This example shows how two instruments can be used to simultaneously generate altitude and airspeed Cautions 1 Before testing set the rate of change for both DPI 515 Instruments to a safe value A high rate of change can damage sensitive aeronautical components Refer to the appropriate Component Maintenance Manual for the unit under test 2 In this example configuration negative airspeed can be generated this can damage an airspeed indicator To prevent negative airspeed apply the static p
90. way connector 1_2_3 pin 1 output pin 2 common pin 3 output Pin 1 and 3 volt free contacts of relays RL1 and RL2 Example connections RL1 h RL2 1 PLC Note Between each set of contacts a resistor capacitor filter circuit restricts the upper operating frequency see Section 6 Reference and Specification Computer Connections Fit the appropriate connectors into the rear panel communications port and secure with the captive screws Note Only one interface can operate at a time Set the required communications type in SETUP SUPERVISOR COMMS PORT menu see Section 6 6 9 Q SAFETY co N sult handbook Instrume fore in oe KEEP a AN po nop E od ation AR O NOT coi aan dad D POSITI ee SN T ee RANGE da te H FULL spa Pi 70 bar LE POSITIVE SUPPLy RANGE FULL Scale VENT 618 yp BSP _ RS232 IEEE 488 Figure 2 7 RS232 and IEEE 488 Connections K245 Issue No 3 2 9 2 Installation 27 RS232 Interface When using the RS232 interface a cable must be connected directly from the instrument to a suitable port on the computer in a point to point link Table 2 1 shows the pin connections for the 9 pin D type RS232 connector the RS232 control signals and the computer printer interconnection The instrument is configured as Data Circuit Terminating Equipment DCE instrument Control Line Computer Printer
91. wer supply connector 1 Refit and reconnect rack mounted units as detailed in Section 2 Installation Switch on the power supplu and set the power supplu switch to ON The instrument should now be operational If the fuse blows immediately on switch on contact the manufacturer or Service Agent K245 Issue No 3 4 3 4 Maintenance FULL SCALE POSITIVE SUPPLY RANGE FULL SCALE 1 IEC power supply connector 2 Fuse carrier 3 Fuse 4 Power supply switch 5 Power supply inlet socket assembly Figure 4 1 Power Supply Fuse Replacement 4 7 Valve Replacement Replace a valve when detailed in Section 5 Testing and Fault Finding Procedure Full scale pressures below 70 bar 1000 psi Figure 4 2 and 4 4 A similar valve replacement procedure applies to all the valves located on this manifold Note The Apply and Release control valves are a matched pair do NOT replace single valves a Disconnect the supply pressure and vent all pressure from the instrument b Switch off the controller and isolate the power supply c Remove the instrument top cover by removing the three securing screws from the top edge of the rear panel sliding the cover back and then up d Identify the valve to be replaced from Figure 4 2 e Unscrew the valve solenoid locking ring 1 and remove the locking ring and the lock washer 2 Lift the solenoid 3 clear of the valve body 5 Note There is no need to disconne

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