Bullseye Precision Gauge User Manual.docx

KJL-205A
Operation Manual
YOU MUST READ THIS MANUAL BEFORE USE
2
Table of Contents
1.
Section 1: Overview ................................................................................................................................. 3
2.
Section 2: Quick Start ........................................................................................................................... 4
3.
Section 3: Installation ......................................................................................................................... 5
4.
Section 4: Connections ........................................................................................................................ 6
5.
Section 5: Set Points ............................................................................................................................... 6
6.
Section 6: Analog Out ........................................................................................................................... 7
7.
Section 7: Field Calibration .............................................................................................................. 8
Calibration Procedure .................................................................................................................................... 8
8.
Section 8: Troubleshooting ............................................................................................................. 8
9.
Section 9: Servicing and Maintenance ...................................................................................... 9
Gauge tube servicing ..................................................................................................................................... 9
Maintenance.................................................................................................................................................... 9
Notes on calibration .................................................................................................................................... 10
10. Section 10: Accuracy ............................................................................................................................. 10
11. Section 11: Specifications ................................................................................................................. 10
12. Section 12: Understanding Torr ................................................................................................. 12
13. Section 13: TERMS OF USE, LIMITED WARRANTY & LIABILITY WAIVER ...................... 14
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Section 1: Overview
The Kurt J. Lesker KJL-205A, is a rugged, modern vacuum measurement instrument
designed to make vacuum measurement easy through the use of a familiar meter
movement. Electronically, it is a highly accurate digital vacuum gauge utilizing fieldproven thermocouple vacuum sensor technology.
Portable
● Optional all metal case protects meter movement & electronics
● Field-proven thermocouple vacuum sensing technology
Precise
● Excellent intra-tube accuracy when utilizing KJL-6000SS thermocouple gauge
tube
● Field calibratable
Reliable
● Very simple electronics
● Easy to understand
Features:
● Movement scale with range focused on the most useful range of interest for
industrial vacuum: below 500 millitorr
● International Power supply
● Designed to meet CE specifications
● 5 Volt Analog output
● 24 VDC 1 Amp Type C ( common, normally open, normally closed ) relay contact
● Field replaceable sensor
Options:
•
KJL-205A – Panel mount gauge that includes KJL-6000SS sensor, sensor cable
and power supply
•
KJL-205ANT – Panel mount gauge that includes sensor cable and power supply
(no sensor/tube)
•
KJL-205ABM – Bench top gauge that includes KJL-6000SS sensor, sensor cable
and power supply
•
KJL-205ABM3X – Bench top gauge that includes (1) KJL-6000SS sensor, (3) sensor
cables and a power supply with the ability to switch between (3) KJL-6000SS
sensors. Additional KJL-6000SS sensors should be purchased as necessary.
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Section 2: Quick Start
A simple and intuitive gauge, yet modern implementation.
Unpack and Confirm: verify you’ve received everything you ordered
The vacuum instrument contains the following components:
1. Vacuum gauge with an international power supply, and 10’ of sensor cable with Octal
connector
2. Thermocouple Vacuum Gauge Tube if ordering anything but KJL-205ANT
3. Quick Start guide or (this) User Manual
KJL-205ABM
KJL-205A
Easy to use steps:
1. Plumb the thermocouple sensor into the system to be measured, taking care to keep the
stem down
2. Install the display into its table top or benchtop location
3. Connect the power and gauge tube
4. Read vacuum!
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Section 3: Installation
If the KJL-205A or KJL-205ANT is purchased, it needs to be mounted. Please use the graphic below
for guidance.
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Section 4: Connections
The only required connections for operations are power and sensor. The connections are already
made in the KJL-205ABM and KJL-205ABM3X units that come fully installed in a metal enclosure, and
there is no need to disassemble the unit. The only reason you would disassemble a KJL-205ABM or
KJL-205ABM3X enclosure would be to access the analog output and relay connections.
5V power
Set Point
Set
Span
Adjust
-10mv
Zero
Adjust
N.O.
Comm
N.C.
Calibrate
mv
(-) Analog
+Analog
Sensor
Connection
Set Point
Switch
Analog Out
Adjust
+10mv
Section 5: Set Points
This gauge is equipped with a control option where a relay is activated when the gauge falls below
the set point.
To set the set point:
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Step 1. Press the set point switch. This redirects the meter movement to be controlled by the
potentiometer adjustment.
Step 2. While pressing the set point switch, adjust the set point adjustment until the meter
movement indicates the vacuum level at which that you’d like the relay to activate.
Step 3. Release the switch.
The relay may turn on or off a device depending on how it is wired to the type C contacts. Below is a
description of type C contacts:
1. Common – The common connection of a switch or circuit.
2. N.C. – Normally closed. This means that above the set point value there is a current path
between the common and the N.C. terminal. Put another way the switch is “ON” between
these 2 terminals. At the set point value and below (higher vacuum, lower pressure) the
connection is open. Put another way, the switch is “OFF” between the common and the
N.C. connection at higher vacuum (a lower vacuum reading).
3. N.O. – Normally open. This means that above the set point value there is no current path
between the common and N.O. connection. Put another way the switch is “OFF” between
these 2 terminals. When the vacuum indication goes below the set point value (higher
vacuum, lower pressure) the current path closes. Put another way the switch is “ON”
between the N.C. and N.O. connections at absolute vacuum readings below the set point
value.
Section 6: Analog Out
This gauge is equipped with an analog voltage output to indicate the pressure level. This analog
output uses voltage to simply communicate with PLCs, PCs and other control systems. Below are
some sample readings:
Volts
millitorr
mbar
Pa
0.10
2
.003
0.3
0.50
10
0.13
1.3
2.20
50
.067
6.7
3.30
100
.133
13.3
4.05
200
.267
26.7
4.40
300
.400
40
4.55
400
.533
53.3
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Section 7: Field Calibration
The KJL-205 family of products can be calibrated in the field provided that an accurate vacuum
instrument standard exists. Typically, that instrument standard should be 4x as accurate, or at the
very least much more accurate than the KJL-205A.
Calibration Procedure
1. With instrument not plugged in (not powered up), turn screw in middle of meter face (with
special tool) to center needle over “DOT” on far right side of scale face
2. Plug in 5 volt A/C adapter, connect cable to KJL-6000SS sensor. System must be < 1 millitorr.
Connect voltmeter (set to DC millivolts) to bottom two test pads labeled “10mV+” and “10
mV-“. SLOWLY adjust POT R2 “CALIBRATE” so meter reads 10.0 mV
3. Raise pressure to 200 millitorr. Adjust POT R1 “SPAN” so KJL-205A indicates 200
4. Pump system to 10 millitorr. Adjust POT R4 “ZERO” so the KJL-205A indicates 10. Caution
needed that vacuum system is holding at 10 mTorr
5. Re-check at 200 millitorr and adjust if necessary
Section 8: Troubleshooting
Here are a few trouble shooting steps:
Observation
Possible Causes
Meter stays at “●” on the right
This indicates the power off state. Verify the
supply is plugged into board power receptacle, and
the wall adapter is plugged in.
Meter stays near ATM
•
•
•
•
Verify the system pressure is indeed below
1000 millitorr
Verify that the tube being used is a KJL6000SS or DV-6 equivalent
Verify sensor cable connected to controller
and to tube
Verify KJL-6000SS tube is good
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Is the KJL-6000SS Sensor good?
1. Verify 18-20ohm resistance between pins 3
and 5
2. Verify 18-20 ohm resistance between pins
3 and 7
If zero ohms or open circuit is read, the tube
will need to be replaced
8
7
5
3
When I first turn the unit on, it starts near ATM,
then slowly moves down
This is normal operation due to the initial heating
of the filament
When I switch between sensors in the KJL205ABM3X, the needle starts high, then settles in
to vacuum reading.
This is normal operation due to the initial heating
of the filament.
Section 9: Servicing and Maintenance
Gauge tube servicing
In many cases, a gauge tube may become fouled with oil or other foreign matter. It is often possible
to restore the functionality of contaminated probes with cleaning. If the contaminant is known, the
tube should be filled with a fluid that is known to be a solvent to that contaminant. As an example,
ether is often effective in removing residues of some oils. Commercial carburetor cleaners are very
powerful solvents and are highly effective against some contaminants.
After cleaning with solvents, the gauge tube should be completely dried or flushed with a volatile
solvent to assure that it is dry prior to reinstalling it. If this is not done, contamination of the
system may result.
Maintenance
Your vacuum instrument should give you many years of trouble-free service. There are no regularly
scheduled maintenance intervals. If consistent accuracy is required, it is recommended that the
gauge, tube, cable and power supply be returned for a yearly calibration check.
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Notes on calibration
The instrument is calibrated in nitrogen, which has thermal properties virtually identical to air. Other
gasses will affect the readings by an amount proportional to the thermal conductivity of the gases. In
most cases, the gases present in a vacuum system will be air, nitrogen, or oxygen, and no
appreciable errors will occur.
Certain other gases, however, have thermal conductivity significantly greater than air and will cause
the instrument to read higher than the actual amount of pressure.
Examples of such gases are water vapor, fluorocarbon refrigerants, and acetone. Conversely, other
gasses have thermal conductivity significantly lower than air and will cause the instrument to read
lower than actual pressure. Examples of such gases include helium, oxygen and to a lesser extent,
CO2.
When interpreting readings using gasses other than air, it should be borne in mind that the Vacuum
Gauge reads absolute pressure—that is the opposite of vacuum. Thus, a lower numerical reading
actually is a higher level of vacuum.
Section 10: Accuracy
Instrument Repeatable Accuracy
Range
Accuracy
1~99 millitorr
+/- 2 millitorr or 20%
100~1000 millitorr
+/- 15%
Section 11: Specifications
Time to resolve
2 seconds to decade, 20 seconds to full accuracy
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Input Voltage
5.0 Volts DC external power, 110/220VAC 50-60 Hz
using supplied power adapter
Maintenance Interval
1-10 years depending on use
Overall Dimensions, front panel
2.75 in high, 3.6 in wide, 2.3 inches deep
Ambient Operating range
32°F to 100°F
Relay Contacts
Type C (Normally Open, Common and Normally
Closed) 24VDC, 1 Amp
Measurement Media
Clean Dry Air or Nitrogen
Certifications:
RoHS; CE Certified, third party with KJL-6000SS tube:
EMC Emissions:
•
•
•
•
CFR 47 FCC Part 15 Subpart B Class B
emissions requirements (USA)
EN 55011:2009:/A1:2010 Group 1 Class B ISM
emissions requirements (EU)
EN 61000-3-2:2006/A1:2009/A2:2009 limits
for harmonic current emissions (equipment
input current up to and including 16A per
phase)
EN 61000-3-3:2008: Limitation of voltage
fluctuations and flicker in low-voltage supply
systems for equipment with rated current p
to and including 16A
EMC Emissions and Immunity:
•
Face
EN 61326-1:2013 EMC requirements for
Electrical equipment for measurement,
control and laboratory use – General Use
2.87” high x 3.7” wide
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Depth
0.42"
Face Thickness
3.5" Face to Rear + cable bend
3.08 surface to rear + bend
3.1" Face to rear of boot
2.68" surface to rear
2.95" Face to rear + cable
bend without boot
2.53" Sfc to rear +
cable bend, no boot
Spare Parts
Sensor: KJL-6000SS
Power Supply: PS-TCGAU-1
10’ Sensor Cable: KJL615TC-RCH10
30’ Sensor Cable: KJL615TC-RCH30
50’ Sensor Cable: KJL615TC-RCH50 (requires
calibration adjustment)
Section 12: Understanding Torr
This instrument and many similar instruments are calibrated in microns or "milliTorr." It is
appropriate to discuss what microns are and to relate microns to other measures of pressure and
vacuum. Microns are not really a measure of vacuum at all, but rather of absolute pressure.
The pressure of the atmosphere is 14.696 or approximately 14.7 pounds per square inch at sea
level. One TORR is an absolute pressure of one millimeter of mercury. A milliTorr is equal to
one thousandth of a TORR. A MICRON is the same as a milliTorr.
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This pressure is due to the weight of all of the air in the earth's atmosphere above any particular
square inch. This 14.696 PSI is equivalent to the pressure produced by a mercury column of
approximately 29.92 inches high or .76 meters (~ 3/4 of a yard) or 760 millimeters of mercury.
Atmospheric pressure varies greatly with altitude. It decreases approximately 1 inch of mercury per
thousand feet of altitude. It also varies widely with local weather conditions. (Variations of one half
inch in a single day are common.) The word “vacuum” means pressure lower than atmosphere or
"suction." However, in describing negative pressure, the atmosphere is only a satisfactory reference
if we are dealing with values of vacuum down to about 27 inches of mercury. Below that, it is much
more useful to talk in terms of absolute pressure, starting from absolute zero. The Vacuum Gauge
does just this.
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Section 13: TERMS OF USE, LIMITED WARRANTY & LIABILITY WAIVER
Kurt J. Lesker Company offers all of its products with the following terms and conditions and notices as follows. By accepting
and/or using a Kurt J. Lesker Company product, you hereby acknowledge and agree to the following terms and conditions, and
acceptance of these terms and conditions are a condition precedent to any purchase/sale agreement between you and Kurt J. Lesker
Company.
Exclusive Obligation: The Kurt J. Lesker Company product you are purchasing has been designed for a specific use within a set
of suitable operating conditions, as set forth in its User Manual, or as indicated otherwise by Kurt J. Lesker Company. Any use of
the Kurt J. Lesker Company Product for any purpose or under any conditions, other than those specified, shall render any limited
warranty void, and shall expressly invalidate any liability of Kurt J. Lesker Company for damages as a result of such misuse. User
limitation: You may not modify, copy, distribute, transmit, display, perform, reproduce, publish, license, create derivative works
from, transfer, or sell, any information, software, products or services obtained from or created by Kurt J. Lesker Company to any
third party, without the express written consent of Kurt J. Lesker Company to do otherwise. Any violation of this provision shall
give rise to an indemnification of Kurt J. Lesker Company by you, for any third party claims arising out of such violation. 1 Year
LIMITED Warranty: All Kurt J. Lesker Company products are warranted against any manufactured defect for a period of (365)
days from date of purchase, unless such product is a custom-work for you and not a standard Kurt J. Lesker Company product.
Any product qualifying as a custom-work shall not be warranted against any defects for any purpose, and your acceptance of such
custom-work shall relieve Kurt J. Lesker Company of any liability for any purpose. WITH THE EXCEPTION OF THE LIMITED
WARRRANTY ABOVE, YOU AGREE ANY Kurt J. Lesker Company PRODUCT IS PROVIDED AS IS, EXCLUSIVE OF
ANY WARRANTY, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY,
FITNESS FOR A PARTICULAR PURPOSE, NON-INFRINGEMENT, OR ANY OTHER WARRANTY, EXPRESSED OR
IMPLIED. Limitation Of Liability: You agree and acknowledge, Kurt J. Lesker Company shall have no liability to you
whatsoever for any direct, indirect, punitive, incidental, special consequential damages arising out of or connected with the use or
misuse of its products. In particular, given the nature of Kurt J. Lesker Company products, you agree and acknowledge, under no
circumstances whatsoever shall Kurt J. Lesker Company be liable to you for any consequential damages for damage to any nonKurt J. Lesker Company product or service, arising from the failure, use or misuse of a Kurt J. Lesker Company product, including,
but not limited to, any vacuum system, engine, vehicle, factory, or the like. In the event, a court of law with proper jurisdiction
finds Kurt J. Lesker Company liable to you for any purpose, you agree and acknowledge Kurt J. Lesker Company’s maximum
liability shall not exceed the purchase price of one unit of product giving rise to such liability, or $250.00, whichever is greater.
Entire Obligation: These terms and conditions express the entire obligation of Kurt J. Lesker Company with respect to its products.
If any part of these terms and conditions are deemed void, invalid, unenforceable or illegal, including, but not limited to, the
warranty disclaimers, liability disclaimers and liability limitations set forth above, then the unenforceable clause or sentence may
be disregarded with the remainder of these terms and conditions valid and enforced. In the event the unenforceable clause or
sentence leaves a void in these terms and conditions, a provision closely matching the intent of the unenforceable provision should
be deemed inherent within these terms and conditions, slightly modified to render such provision valid and enforceable. General:
These terms and conditions are governed by the laws of the State of Pennsylvania, USA. You hereby consent to the exclusive
jurisdiction and venue of the Courts of Pennsylvania, in all disputes arising out of or relating to the use of this product. Use of this
product is unauthorized in any jurisdiction that does not give effect to all provisions of these terms and conditions. Modification
of Terms and Conditions: Kurt J. Lesker Company reserves the right to change the terms, conditions, and notices under which
their products are offered.
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