druck dpi 601 portable pressure indicator/calibrator user manual

druck dpi 601 portable pressure indicator/calibrator user manual
DRUCK DPI 601
PORTABLE PRESSURE INDICATOR/CALIBRATOR
USER MANUAL
O Druck Limited 1995
This document is the rpoperty of Druck Limited and may not be copied or other
wise reproduced, communicated in any way to third parties, nor stored in any Data
Processing System without the express written authority of Druck Limited.
K049 Issue No. 7
DPI 601 User Manual
SAFETY
This publication contains information and warnings that must be followed for
the safe operation and to maintain the instrument in a safe condition. Use
competent personnel and good engineering practice for all procedures and
practices in this publication.
The operator must not use this instrument for any other purpose than that
stated. Use the pressure medium stated in this publication; do not use any
other medium without consulting DRUCK.
Do not apply a pressure greater than 150% of the full-scale pressure of the
pressure range of the instrument. For the hydraulic actuator version this
value is 130% of the full-scale pressure range of the unit. Applying an
excessive pressure, greater than that stated, can cause injury, damage the
Instrument and the user system and equipment.
K049 Issue No.7
Abbreviations
A
ce
COM
diff
°C
°F
DC
DP
DPI
DMM
Err
FS
GND
Hz
IEC
Iss
kg
kHz
Abbreviations are the same in the singular and plural.
Ampere
cubic centimetre
common (connection)
differential
degrees centigrade
degrees Fahrenheit
direct current
decimal point
digital pressure indicator
digital multimeter
error
full-scale
ground (earth)
Hertz
International Electrical Council
issue
kilo-gram
kilo-Hertz
liquid crystal display
link
milli Ampere
milli bar
maximum
minimum
milli-metre
milli-Volt
mega ohm
micro Ampere
nano Ampere
number
Ohm
printed circuit board
reference
variable resistor
Society of Automotive Engineers
second
signal
socket
United Kingdom
United States of America
Volt
transmitter voltage
K049 Issue No. 7
iv DPI 601 User Manual
Contents
1 INTRODUCTION -......eceeeenenenanerrnncicecee reee eee eeoto reee ereorecenenecceas near cecreenereeceeceorerenes 1
1.1 SPOCITICATION .….….....…..…rrrrrerecrrerscereensersersarersassanarassrserersaraneransra rence rende canencaerraA en cuee 1
2 SO EN 5
2.1 POWEr SUPPÎY EN 5
2.2 Pneumatic Supply .................... 2... EEE SEELE REES HERR ERKERKREEEEEEEEEELEERREREREE 6
3 OPERATION Loci eee cee rere este terre se saeeeeseesanessaseee sane sesressssessses 7
3.1 Modes of Operation ss. reco eee ee erre acero a eee reee remere ra 7
3.2 Key Functions .....................i.ie. ee eee re ercer acer ee ercer errar era Earn o enana aerea 7
33 Pressure MeasurOment …………....….……rrrserssrsesseencasasnenneeneensencansensenrenpenranaa nana sn re 12
34 Electrical Measurement............................... re. "e Lecce eee reee acen nee ere sance 12
3.5 Power Output ....................eeireree e eee ere R ene eee eereeareana rene erererereareeceroneee 13
3.6 Analogue Output ..................—.. EEE EEE RR acer EEE EEE REES TEEN 14
4 CALIBRATION .................enercinecacenea ina rn ener reee eee era rarea ere eeececaeeceenereRa erre reee 15
4,1 Procedure .......................rmiimeee earn RER EEE BEER racL aerea enera eee errar eee eee 15
5 OPTIONS -............... ee. nn ire eee ener aer rrerereeL ar erecerarare reeececeeceeeereae rre rer ere as 19
5.1 AL-1'(147-11(e- E cece estes tte e eee eeeees eens seseeeeesess seats sess sees se seers as 19
5.2 Hydraulic Actuator Version ....................0. eee RD O RR RR eee ee ee eee eee eee 19
6 MAINTENANCE ....................n.cericenceio encore cesen aio reeeeeaae re areLeo receeeecee eee erre 21
6.1 General ..........................eeee setters essere serene terete saesssenteseseeesee sess sense ees st esses 21
6.2 Battery Replacement .........................0rermmeec DO Dee eee eee ee reee 21
6.3 Fuse Replacement ...........................— 2... ee ae ree ere errar eee eee eer ee rmrerereeLes 21
64 Fault Finding .........................eeeeeercern rene einer rre area ree raeceeaearerereee arenero erre eceeLes 24
6.5 CIGANING ….…..…….………rrrrorsarsencssnsens aoserseescennanrenseneanenean annenrane a eecnenent ane eenene near 25
6.6 (7. - ….…....…...………rccrcorrsrrrrerencer covarsarnensarencesrerrasanearanenessraenr serrer renverser necessaire 25
7 HYDRAULIC ACTUATOR VERSION ................-.....m.e.ieremece eee er ae e 27
7.1 Introduction ..............._...e.eereme ecc ren ooo ocre rarar aereas eernea a ERA rte e rones oererere eres oeceeaes 27
7.2 Specification ............................erieceece e ree errr serene reese e ares assess serene sense essesens 27
73 Hydraulic Oil VISCOSItY ……….………………srsescrensensensesasensracavnsreneanenenarannrnrenenen renverser see … 29
74 OPEFAtION ….....….….….….….….…r…crercerssrsssenvorsrsensasrarseoseneranransassenvenenne enr are vcasen essences 29
75 ClOANniNG ………..….…….……...……carrsscreerrerssersersrrarr anses sance ennenaeeneneevane e eee sees ee eee eee eee .. 35
7.6 (e; IEEE 35
K049 Issue No.7
Contents (contd)
ILLUSTRATIONS
Figure 1, Instrument CONNECtIONS .…..…....….…..….…..………errsssrrssrnserenmesserssaconareanaaana nana rann rennes sant nanas 6
Figure 2, Instrument CONTrOIS _............………rsrrrscccererransensamseevessenentenrancensemrannennaen sante san cenaan acces 8
Figure 3, Key-pad and Display …………..……..…….……ererecrricrssnsreoransesearenrrsararssasnsarencapacerane sance nan a cen0ee 9
Figure 4, Battery Compartment ........................se=e)0íio rece RR IR RT DO ATENOOoreereeceNerreCeNeneme 22
Figure 5, Internal Assembly ........................i0.ieceoeuece e e eL RR NERD eCeC A rene TeereTrONAUrAneceemee 23
Figure 6, Hydraulic Actuator Version ....................._..11d:::s66- 6, er e RENA A ea eeceere recerca eerreDe 28
Figure 7, Hydraulic Actuator Version Instrument Controls ................................ en DD DDD. 30
Figure 8, Hydraulic Actuator Version Priming Accessories .....................=.......e0. eee. ereenveneo 31
TABLES
Table 1 Replacement fuses .......................11i.i0i000eei DI IRON eN Tee ree rReerareceeeanereprarereae 24
Table 2 Error messages ......................e.eemi0cie IDR enn Ne reEerEraEereran an eaeooeeenerereeNees 24
Table 3 Suitable hydraulic oils ...................=.0.....ec.meiiiia rece cerrara ao reorerrrecaremTarereaes 27
Table of pressure units and conversion factors ..............................er 10m me OTÉZ Rear cover
K049 Issue No. 7
Introduction 1
1.1
INTRODUCTION
The Druck DPI 601 instrument is a portable, pressure indicator and calibrator.
The microprocessor-based instrument uses an internal transducer to meas-
ure and display pneumatic pressures applied to the connection port. The
instrument also produces voltages for externally connected transducers and
transmitters and measures the resulting outputs.
An input socket allows for the connection of a combined power supply and
battery charger. Input and output sockets provide for the connection of
external transmitters and transducers.
A pneumatic hand-pump, volume adjuster and vent valve may also be fitted
as options to meet user requirements. A further option, the hydraulic
actuator version, produces high pressure using specific fluids.
Specification
Accuracy (integral transducers)
Combined non-linearity, hysteresis and repeatability
70 mbar to 35 bar range.......................ee.ee.eiiriirerececca e nan. +0.05% FS
35 bar to 700 bar range .................................eee0 0. eecirererer eee +0.1% FS
Maximum working pressure ....................................—..... 150% FS
Resolution
Instrument <100 mbar FS.............................eermec ce eee. 0.01% FS
Instrument >100 mbar FS........................e......er mice rece eee. 0.005% FS
Dimensions
774: reese 320 Mm x 195 mm x 125 mm
Weg terre 4 kg nominal (changes with options fitted)
Power Supplies
internal power ar EEE Deere. 4 x Size D (IEC R20)
EN zinc-carbon/alkaline/nickel-cadmium batteries
Usual battery life .......... 50 hours (with no load on power output terminals)
Battery charging ..............................e.. eee eee. nickel-cadmium batteries
RES usual charge current 400 mA (14 hours)
External Power .........................e......... encore ene. 3.5 to 14 Volts at 100 mA
TE 9 Volts DC at 500 mA
Power PIUQ are 2.1mm power plug, centre -ve supplying the
penuveveneneneenoeeo eee. instrument and recharging the nickel-cadmium batteries
Signal SOCKets ......................... 1.1100... EEE EEE RER BEER REES EEE 4 mm
K049 Issue No. 7
2 DPI 601 User Manual
Environment
Operating temperature ........................e ==... ecc. -10 to +50°C
Storage temperature ......................-—.——..ee=ee.evvívreiereere: "20 10 +60°С
Calibrated temperature ...........................-—.eeeermiisíiiir 0 to +40°C
Pollution dOGre® ……..….…..….....…..…......…rsrrercensenrersensenrreneerrersanaennar crane ne caca ven 2
Temperature Effects
SPAN (0°C to +40°C averaged referred to 23°C)
Gauge and differential ..... + 0.006% of reading/°C for 70 mbar to 60 bar
Gauge over 6O bar …………….….…..…...…..…...…...……rssercrrsnsnrarrenseenenas een erese + 0.4% FS
ADSOIULB TT + 0.3% FS
Voltage Range
Maximum input and read-out..............................e.eeier ens 50V DC
2V RANGE
Áccuracy ................eveiiim ee +0.07% of reading +2 digit *
Load current ......................—... eee. ee erre eee recen. 200 nA max
Input resistance .......................e.e...... erre rr eee rear reee ene 10 MO
Temperature stability ...........................—....... +0.0075% of reading/°C ©
20V RANGE
Accuracy ................ee.....meeoecere eee +0.07% of reading +2 digit *
Load Current ................. À HA MAX
Input resistance ............................... ercer eri e errene reee ercer. 10 MO
Temperature stability ...................... A + 0.0075% of reading/°C ©
50V RANGE
Accuracy ..................e.meseoecici reee. +0.07% of reading +2 digit *
Load current ....................ee EEE 20 pA max
Input resistance ............................... merecer eee aerea eee 10 MQ
Temperature stability +0.0075% of reading/°C à
Current Range
Maximum input and read-out..........................—....— reee cer... 30MA
DC
ACCUTACY cerro. +0.1% of reading +1 digit *
Sense resistance ....................-........-... eri eee ee e De. 10 Q
Temperature stability +0.0075% of reading/°C ©
* Over 90 days at calibration temperature
a Averaged over calibration temperature range
K049 Issue No. 7
Introduction 3
Power Output
Maximum combined load .............................eereemeerrer e enenenenerecereererevera 30
mA
+24V Output
Accuracy ......................ireceneccacereree reconoce eee errar rereomees +5%
Temperature stability ................................e.ieenen eres E0.02%PC
+10V Output
ÁAccuracy ........... e... eee enero nece rece ee ree ee erre ereoerenarerer reee +0.1%
(Adjustable by an internal potentiometer)
Temperature stability ane +0.005%°C
Analogue Output
0/1 (:]7| anna ranren annees 2 Voits full-scale
(calibrated to pressure scale S1)
BandwidtN ve EEE EEE rarararr eee 2kHz (-3db)
Minimum 1080 ser EEE EEE EEE 1000 Q
Accuracy
basic performance without compensation typically ................ +0.2% FS
Temperature error band ae +0.5% FS
erereovoreocanecenea reee ercer recaen over calibrated temperature range 0 - 40°C
Stability (over three months)............................... eee ere. +0.02% FS
Note: Continuing development sometimes necessitates specification changes without notice.
K049 Issue No. 7
4 DPI 601 User Manual
Blank page
K049 Issue No. 7
Installation 5
2
2.1
INSTALLATION
Power Supply
The instrument can be powered from internal batteries or from an
external supply.
internal Batteries
Four 1.5V Size D batteries power the instrument. These can be either
primary batteries or nickel-cadmium rechargeable batteries. An inter-
nal 500mA fuse protects the instrument against incorrect battery
connection (i.e., reverse polarity). To replace the fuse follow the
procedures in Section 6. The batteries will be charged if: external 9V
supply is connected, link LK3 on the PCB is removed and the charge
key is pressed.
WARNING
DO NOT ATTEMPT TO CHARGE DRY CELL BATTERIES. TO
AVOID ACCIDENTAL CHARGING, LINK LK3 IS FITTED WHEN
DRY CELLS BATTERIES ARE USED.
CAUTION:
CAUTION:
>» Old batteries can leak and cause corrosion.
Never leave run down batteries in the instrument.
External Supply (Figure 1)
A combined power supply and battery charger supplying 9V at 500mA
can be plugged into the socket labelled POWER at the rear of the
instrument. An internal 1 amp fuse is fitted to protect the instrument
circuits. To replace the fuse follow the procedures in Section 6.
Power Output (Figure 1)
> Do not exceed the maximum load.
Do not short circuit the output sockets.
The instrument supplies two DC power outputs.
24V and 10V DC supplies are available from the sockets labelled
OUTPUT 24V, 10V and OV. The voltage is fully floating and supplies a
load of 20mA at each socket and a maximum combined load of 30mA.
K049 Issue No. 7
6 DPI 601 User Manual
2.2 Pneumatic Supply
WARNING
COMPRESSED GAS CAN, IN CERTAIN CIRCUMSTANCES, BE
LETHAL. WHEN CONNECTING AND DISCONNECTING
COMPRESSED GAS SUPPLY LINES, ENSURE THAT THE
SOURCE PRESSURE IS TURNED OFF AND THE PRESSURE
LINES ARE VENTED. PROCEED WITH CARE.
Pneumatic Connection (Figure 1)
A single inlet port connection locates on the front of the instrument
and is G1/8 (female) or 1/8" 27 NPT (female).
Pressure input connector
4 mm input/output G1/8 female or
socket \ / /8 - 27 NPT female
Na |
7
e. 0000000
mA COM V 24V 10V ov
POWER = - PUTZ OUT outPuUT=—
17 J
EXTERNAL
ADAPTOR/CHARGER 5.5 mm
D.C. POWER
SOCKET || Е
2.1 mm (centre -ve) =F
95mm —a
.1 mm
e Lp
to
Figure 1, Instrument Connections
K049 issue No. 7
Operation 7
3 OPERATION
3.1 Modes of Operation (Figure 2)
The modes of operation are:
O Measuring pressure using the internal transducer.
O Supplying electrical excitation for external pressure transducers and
transmitters and measuring the resulting electrical outputs.
© Generating pressure with the integral hand-pump (pneumatic option).
O Generating hydraulic pressure with the integral screw-press
(hydraulic actuator version).
The following description of instrument operation refers to each key function.
3.2 Key Functions (Figure 3)
Power ON/OFF key
Press this key and the display shows all LCD segments and symbols,
the instrument produces an audible tone for approximately 2 seconds.
After the power-up routine the instrument always enters pressure
scale S1. The microprocessor continuously monitors the keys. An
audible tone acknowledges each key press, the instrument changes to
the corresponding mode and display.
30 Pressure Scale key
Pi Press one of the PRESSURE SCALE keys to change the units of
pressure measurement, the display shows the measured pressure.
The instrument is delivered with the three PRESSURE SCALE keys
programmed to measurement units requested by the customer and
chosen from the table on the rear cover.
Volts key
This key selects the external DC voltage input range. The 2/20/50V DC
input is auto-ranged to give the best resolution. The voltage reading for
the 2V range is X.XXXX, 20V range is XX.XXX and for 50V range XX.XX.
The V symbol is shown on the display. There is no over-range indication
for the 50 V range. Pressing a pressure scale key returns the instrument
to pressure measurement. The following functions can be used in this
mode: zero, peak, % and square root.
K049 Issue No. 7
DPI 601 User Manual
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K049 issue No. 7
Operation 9
OVERLOAD
L
PRESSURE
MEASUREM
SCALE S1
ТА ===
30mA
ZERO
= me | /
BATTERY — | =8 8 В 8 But
ZERO OFFSET
APPLIED ONOFE BATTERY “BATTERY SQUARE ROOT OF
V and mA onl READING OR
( N CONTROL CONDITION CHARGE SPECIAL FUNCTION
[pr eor] | — Vprerral pressions mo/caton]
u
e y + A |0o/ | — LOW PASS
/ ZN BEACH Rend — (7 FILTER
ENT
PRESSURE PRESSURE 'SSURE Ш
SCALE SCALE CALE
51 52 53
и у \ /
Y
PEAK ZERO DISPLAY VOLTAGE AND
MAXIMUM (with other keys CURRENT
AND MINIMUM — applies offset) MEASUREMENT
Figure 3, Key-pad and Display
mA key
Press the mA key to select the current measurement mode. The
instrument measures and displays the DC current input, at the rear
of the instrument, labelled INPUT mA and INPUT COM. The
instrument can measure up to 30 mA maximum; an over-range
input is indicated by a blank display and the OR >> symbol. Press-
ing a pressure scale key returns the instrument to pressure
measurement. The following functions can be used in this mode:
zero, peak, % and square root.
Zero key
When in the pressure measurement mode, press the ZERO key
and one of the PRESSURE SCALE keys together and the instru-
ment corrects for the transducer ZERO offset. The instrument
subtracts the stored ZERO offset value from all subsequent pres-
sure readings and displays the difference.
When in the voltage measurement mode, press the ZERO key and
the instrument stores the voltage measurement value and the
display shows zero. The instrument subtracts the stored voltage
measurement value from all subsequent voltage readings and
displays the difference. The display shows the Z symbol to indicate
this function.
K049 Issue No. 7
10
DPI 601 User Manual
PEAK
К
When in the current measurement mode, press the ZERO key and
the instrument stores the current measurement value and the
display shows zero. The instrument subtracts the stored current
measurement value from all subsequent current readings and
displays the difference. The display shows the Z symbol to indicate
this function. When PEAK is selected, pressing the ZERO key
resets the PEAK reading.
Peak key
Press the PEAK key, the display shows the maximum PEAK read-
ing value together with the À and a flashing @ symbol.
Press the PEAK key again and the display shows the minimum
PEAK reading value together with the 2 and a flashing @ symbol.
Press the PEAK key again and the PEAK function switches off.
This function can be selected for pressure scales S1, S2 or S3 and
electrical ranges V and mA.
% key
This key switches the % function on and off. The reading on the
display is expressed as XXX.XX percent of full-scale. The display
shows the % symbol. For pressure scales S1, S2 or S3, the full-
scale = 100% and zero pressure = 0%. This can be varied to order,
for instance 3 - 15psi, 0.2 - 1bar can be displayed as 0 - 100%. For
VDC range 2V = 100% and OV = 0%. For mA range 20mA = 100%
and 4mA = 0%. This function can be selected for pressure scales
S1, S2 or S3 or Vor mA ranges. Selecting other ranges will not
affect the function relevant to a particular range.
Filter key
This key switches the low pass filter function on and off. The
fluctuating pressure reading is filtered and display shows the =
symbol. The filter time constant is approximately 10 seconds for
fluctuating pressure below 10% of full-scale. This function can be
selected for pressure scales S1, S2 or S3. Selecting other ranges
will not affect the function relevant to a particular pressure scale.
K049 Issue No. 7
Operation 11
Square Root key
This key switches the square root function on and off. The display
shows the square root of the reading and S symbol. This function
can be selected for any of the pressure scales $1, S2 or S3 or
electrical ranges V or mA. Selecting other ranges will not affect the
function relevant to a particular range. For special order instru-
ments the function of this key may be varied.
Battery Condition key
Press this key and the display shows the battery condition as a
percentage value of full charge in the ranges:
0 - 25%
25 - 50%
50 - 75%
75 - 100%
The display also shows the BATTERY symbol. This symbol flashes
if battery condition is below 25% of full charge. The selection of
another mode cancels the battery condition function.
Battery Charge key
WARNING
DO NOT ATTEMPT TO CHARGE DRY CELL BATTERIES
To charge the rechargeable batteries, connect the 9V battery
charger and press the key rechargeable batteries will now charge
and the display shows the LIGHTNING symbol. Charging continues
for approximately 14 hours and then automatically switches off.
Note: Instruments without rechargeable batteries have link LK3
on the PCB fitted which disables the charge function.
K049 issue No. 7
12 DPI 601 User Manual
3.3 Pressure Measurement
The pressure measurement mode is selected by pressing the S1 or S2
or S3 key. The display shows the pressure applied at the pneumatic
port. An overpressure is indicated by an audible tone and the display
showing Err2 and flashing OR>>.
Pressing a pressure key and Z key together zeroes the display and
stores the transducer offset. If the offset is outside the nominal range
when the keys are pressed, the display shows Err 3. Check there is
no pressure in the system or adjust internal coarse zero offset potenti-
ometer RV6.
To convert to other units of pressure measurement see the table on
the rear cover. In this mode the functions of low pass filter, peak, %
and square root can be used.
3.4 Electrical Measurement
CAUTION:
To avoid damage to the instrument:
» Use caution when working with DC voltages.
» Ensure test leads are in good condition.
» Always replace fuses with the correct type and
rating.
» Do not exceed the maximum input limits.
Voltage Measurement
The voltage measurement mode is selected by pressing V key. The
external DC voltage to be measured is connected to the input sockets
V (red) and COM (black). The 2/20/50V DC input is auto-ranged to give
the best resolution on the display. There is no over-range indication for
the 50V range. Functions zero, peak max/min, % or square root can
be used in this mode.
K049 Issue No, 7
Operation 13
Current Measurement
The current measurement mode is selected by pressing mA key. The
external DC current to be measured is connects to the input sockets
mA (Yellow) and COM (black). An over-range is indicated by a blank
display and OR>> symbol on the display. In this mode the functions of
zero, peak, % and square root can be used.
An internal 100mA fuse protects the instrument against over-current in
the current range. To replace a fuse follow the procedures in Section 6.
3.5 Power Output
The instrument produces voltage and current for external transducers
and transmitters.
Output Socket Load
24V Brown 20mA *
OV Green
10V Blue 20mA *
ov Green
* Maximum combined load 30mA. Overloading this output can
affect instrument operation.
Note: Battery life can be extended by disconnecting the load from the
circuit when not required.
The outputs are floating. The +24 Volt output is protected by an
internal 50 mA fuse. If an internal fuse blows refer to section 6 for
fuse replacement instructions.
K049 Issue No. 7
14 DPI 601 User Manual
3.6 Analogue Output
The analogue option voltage of 2 Volts equates to the full-scale pres-
sure of pressure scale S1.
| Output Socket Load |
An out White 1000 Q +
Com Black
+ Minimum load
K049 Issue No. 7
Calibrati
on 15
4 CALIBRATION (Figures 3 and 4)
Calibration adjustment is carried out by adjusting the appropriate
potentiometer located on the PCB.
The following equipment and materials are required.
Note: Equivalent substitutes may be used.
© Variable power source
© Pressure standard
O Digital multimeter (DMM)
©
CAUTION:
>»
Varnish for locking variable resistors
The PCB is fitted with CMOS static sensitive devices.
4.1 Procedure
Calibration must be performed in the following sequence. Unscrew
the six captive, cap-head socket screws (3 mm AF) in the rubber fest
and remove the base to gain access to the PCB.
Electrical calibration
1.
2.
Switch on the instrument and select V DC range.
Connect a link between the input sockets V (red) and COM
(black).
Check the display and, if necessary, adjust potentiometer RV7
for a reading of 0.0000.
Disconnect the link.
Connect a variable power source to the input sockets +ve to V
(red) and -ve to COM (black).
Adjust the variable power source to approximately -2 volts; this
is the full-scale value. Apply the voltage to the instrument.
K049 Issue No. 7
16 DPI 601 User Manual
7. Check that the instrument display value agrees with the applied
voltage within the accuracy statement in the specification.
O If the values do not agree proceed as follows:
|. Connect the DMM +ve to the test point marked V on the
PCB and -ve on COM (black) input socket.
il. Adjust potentiometer RV3 until the display reading agrees
with the applied voltage within the accuracy statement
detailed in the specification.
ME, Disconnect the DMM.
Note: The 20 V and 50 V ranges should automatically be within the accuracy
statement detailed in the specification.
8. Select mA range and connect a link between the input sockets
mA (yellow) and COM (black).
9. Check the display and, if necessary, adjust potentiometer RV8
for a reading of 0.000.
10. Disconnect the link.
Note: The 30 mA range should automatically be within the accuracy statement.
K049 Issue No, 7
Calibration 17
Pressure calibration
1.
2.
10.
11.
12.
Select pressure measurement scale S1.
Connect the pressure standard to the input connector.
Connect the DMM +ve to output socket An OUT (white) and -ve
on COM (black) input socket.
Adjust the pressure standard to zero pressure.
Check the display and, if necessary, adjust potentiometer RV6
for a reading of zero.
Check the reading of the DMM. If necessary, adjust potentiom-
eter RV9 for a reading of zero.
Adjust the pressure standard to the full-scale pressure.
Check the displayed reading is within specification. If neces-
sary, adjust potentiometer RV5 for the correct pressure reading.
Check the reading of the DMM. If necessary, adjust potentiom-
eter RV10 for a reading of 2 Volts.
Disconnect the DMM.
: The other two pressure scales and linearity error should automatically
be within specification.
Using varnish, lock RV3, RV4, RV5, RV6, RV7, RVs, RV9 and
RV10.
Refit the base and secure with the six captive, cap-head socket
screws (3 mm AF) in the rubber feet.
K049 Issue No. 7
18
DPI 601 User Manual
Blank page
K049 Issue No. 7
Options 19
5 OPTIONS
5.1 Pneumatics
The instrument can be fitted with a hand-pump, volume adjuster and
vent valve or any combination of these items to allow for pressure
generation. With the pneumatic system connected and the instrument
in pressure measurement mode, close the vent valve and use the
hand-pump to generate the required pressure. The volume adjuster
screws in and out to make fine adjustments to the pressure. Addition-
ally, a pressurefvacuum switch can be fitted with the hand-pump to
generate pressure (20 bar max) or vacuum (-750 mbar gauge max). On
Instruments with pressure ranges up to 360 mbar a pressure relief
valve, venting inside the case, is fitted protecting the transducer from
over-pressure. |
Nota: To prolong seal life, it is recommended that the pressure/vacuum
switch is only operated below 10 bar.
5.2 Hydraulic Actuator Version
This version of the instrument provides manual generation of hydraulic
pressure details are contained in section 7.
K049 Issue No. 7
20
DPI 601 User Manual
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K049 Issue No. 7
Maintenance 21
6.2
6.3
MAINTENANCE
General (Figures 4 and 6)
Maintenance is carried out to ensure that the instrument remains in a
serviceable condition. Absolute cleanliness of the work area, tools and
equipment must be observed at all times.
Battery Replacement
The batteries are located in a separate compartment in the base unit.
1. To gain access to the battery compartment unscrew the two screws
securing the hinged lid.
2. Replace batteries and observe the correct polarity.
Fuse Replacement
CAUTION:
» The PCB is fitted with CMOS static sensitive devices.
>> Always replace fuses with the correct type and rating.
The instrument is protected by internal fuses located on the PCB. The fuses
are identified on the PCB by the label FS with a number as follows:
© FS1, 100mA protects the instrument against over-current and FS1,
spare fuse.
FS2, 1A fuse protects the instrument circuit.
FS3, 50mA fuse protects the power output.
FS4, 500mA fuse protects the instrument against incorrect battery
connection (i.e., reverse polarity).
O The battery compartment contains a fused link, 25 SWG rated at 15A,
connected in series with the cells. The fused link protects the re-
chargeable nickel-cadmium batteries against short-circuit.
1. Fuse
Remove the base as detailed in to gain access to the PCB, replace the
appropriate fuse. Refit the base and secure with the six captive,
caphead socket screws (3 mm AF) in the rubber feet.
K049 Issue No. 7
22 DPI 601 User Manual
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K049 Issue No. 7
23
Maintenance
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K049 Issue No. 7
24 DPI 601 User Manual
6.3 Fuse Replacement (contd)
2. Fuse Link
The fuse link is 25 SWG (0.508mm) or 24 AWG (0.511mm) 15A wire
linking the two sets of batteries in series. The link is soldered in
position and protected with heat-shrink tubing.
Table 1, Replacement Fuses
FS 1 ОТ 100 mA QUICK-BLOW 195-089
FS2 1A ANTI-SURGE 195-054
FS 3 50 mA QUICK-BLOW | 195-011
FS 4 500 mA ANTI-SURGE | 195-014
6.4 Fault Finding
If an operating error condition exists, the instrument automatically generates
an appropriate message shown on the display as Err X; where X is the error
number,
The following table shows the error code displayed, the error condition and
the remedial action.
Table 2, Error Messages
or 0 - No error
err 1 - No error
err 2 Over-pressure Reduce applied pressure
em 3 Zero outside the nominal range | Check that no pressure applied at
pressure port, adjust RV6
err 4 - No error
err5 Неда! Function not allowed
Replacement of parts, testing and further information is contained in the
Druck service manual K129. Otherwise, if the instrument fails to perform to
specification, return it to the manufacturer or approved agent.
K049 Issue No. 7
Maintenance 25
6.5 Cleaning
Clean case with damp cloth and mild detergent.
6.8 Storage
Note: For the hydraulic actuator version and before this procedurs, carry out the
procedures detailed in section 7 the hydraulic actuator version section.
1. Before storage, access the battery compartment and remove the
batteries (see 6.3).
2. The instrument must be stored in a dry, dust-free atmosphere, free
from corrosive fumes which may damage the internal components
3. Storage must be in standard atmospheric pressure and humidity.
The storage temperature range is detailed in paragraph 1.1.
K049 Issue No. 7
26 DPI 601 User Manual
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K049 Issue No. 7
Hydraulic Actuator Version 27
7 HYDRAULIC ACTUATOR VERSION
7.1 introduction
This version of the DPI 601 instrument provides manual generation of
hydraulic pressure and consists of a screw-press with a priming pump
and priming shut-off valve.
The internal hydraulic parts are brass, stainless steel, copper,
flourocarbon rubber (Viton). The hydraulic fluid must be compatible
with the internal parts.
7.2 Specification
TRANSDUCER
Pressure ranges eK EEE e DD DD 0 to 160 bar
eocorenoeooceneacooocoreraneoooccocererencoroncecavoracenressaceaco se recareraceeoe recorre eccene reee 0 to 400 bar
Over-range reading ....................=.....eeseerer ere re e EEE 130% FS (nominal)
Resolution | ................ eee e ee reee ere ere er ere ee ren ee. 0.01% FS
Combined linearity, hysteresis and repeatability ........................................e... e... +0.05% FS
HYDRAULIC SYSTEM
Hydraulic volume ........................ irene eee ere recreo reee rre reee. 17 cc (approx.)
Hydraulic fluid .........................eeenrieicea reee eee ceras eee eee eee. demineralised water
OF O TT one of the hydraulic oils listed in Table 3
Operatingtemperature .............................e.eeerire demineralised water +5 to +50%C
OF eoroeroonaccorcacaconereecaneoracaneneoceneroraecacer oo raroocecceocnerereceooeneeececooa oil -10 to +50%C
Pressureconnection ...................e...eiree erre ee e Deere eee G1/8 Female
OF nrenenaconrnooooccontareecoooneasoneneoaoneraotocren on oeercorercenrrceceaoacevenerecoones 1/8" NPT Female
Maximum working preSSUrO ass 130% FS
The following table gives the S.A.E. classification or equivalent only as guide to viscosity.
Table 3, Suitable Hydraulic Oils
VG 10 5W Tellus R10 Nuto H10 | Velocite No. 6 |
МС 15 Tellus T15 Nuto H15 {-
Tellus V15
VG 22 Tellus 22 Nuto H22 |DTE22
Tellus R22
VG 32 10W Tellus V32 Nuto H32 |DTE Oil light
DTE24
VG 37 Tellus 37
Tellus R37
Tellus T37
Tellus Y37
Equivilant clean hydraulic fluid can be used, if in doubt consult Druck.
K049 Issue No. 7
DPI 601 User Manual
28
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K049 Issue No. 7
Hydraulic Actuator Version 29
7.3
Hydraulic Oil Viscosity
It is essential for good operation and accuracy of the instrument to use
the correct hydraulic mineral oil of the appropriate viscosity. The more
viscous oils give a low fall-rate at high pressures (i.e., above 100 bar),
less viscous oils give increased sensitivity at low pressures. The
recommended S.A.E. viscosity for general use is 10W.
Operation
The following procedures must be carried out by a competent
person.
The instructions given in this section include the steps that must be
carried out before and after use. The section contains information and
warnings that must be followed to ensure the safe operation and
maintain the instrument in a safe condition.
WARNINGS
HYDRAULIC FLUID IS INJURIOUS. OBSERVE RELEVANT
HEALTH AND SAFETY PRECAUTIONS. USE APPROPRIATE
PROTECTIVE BARRIERS AND EYE PROTECTOR.
BEFORE APPLYING PRESSURE, EXAMINE ALL FITTINGS
AND EQUIPMENT FOR DAMAGE AND ENSURE THAT ALL
EQUIPMENT IS TO THE CORRECT PRESSURE RATING.
CAUTION:
»
Observe absolute cleanliness when using this instrument.
Severe damage can be caused If equipment connected to this
instrument is contaminated. Connect only clean pressure
gauges to the instrument. To avoid any contamination an exter-
nal filter is recommended.
Do not exceed the maximum working pressure stated in the
Specification.
Preparation
1.
2.
3.
Place the instrument on a horizontal surface.
Switch on the instrument and select the required units of measurement.
Connect the pressure gauge assembly (with a bleed valve) to be tested
to the pressure connection port.
During the following operations prepare for fluid spillage, use a suitable
receptacle for collecting the spillage.
K049 Issue No. 7
30 DPI 601 User Manual
PRESSURE CONNECTION
with blanking plug
DECREASE
PRIMING PUMP
MN — PRIMING/FLUID INLET
CONNECTION
with blanking plug and seal
Figure 7, Hydraulic Actuator Version Instrument Controls
Priming and Bleeding the System
The hydraulic system needs to be primed and bled free of air.
Note: Demineralised water is used to test the instrument at manufacture.
On shipment, the hydraulic assembly, will have traces of
demineralised water in the system.
CAUTION:
» Do not mix hydraulic fluids.
> Use only recommended fluids.
Priming the system (Figure 7 and 8)
1. Connect the pipe assembly, with a bonded seal, to the priming/fluid
Inlet connector. Locate the other end of the pipe in the fluid reservoir.
Note: The reservoir must contain clean hydraulic fluid.
K049 Issue No. 7
Hydraulic Actuator Version 31
2.
Connect the other pipe assembly, with a bonded seal, to the pressure
port. Connect the other end of this pipe assembly to the pressure
gauge to be tested or if priming and bleeding the instrument locate the
pipe end in the fluid of the reservoir.
Turn the priming shut-off valve knob anticlockwise to fully open the
shut-off valve. Open the pressure gauge assembly bleed valve.
Turn the screw-press to the fully clockwise position.
Carefully push down the priming pump plunger to the bottom of the
stroke or until fluid is seen coming out of the pressure port pipe as-
sembly or the pressure gauge bleed valve.
Close the pressure gauge assembly bleed valve. If necessary, fill or
top-up the reservoir with clean fluid.
Slowly turn the screw-press anticlockwise to draw fluid into the sys-
tem; at the same time topping-up the reservoir making sure that fluid
can always be seen in the reservoir. Continue until the screw-press is
in the fully anticlockwise position.
Turn the priming shut-off valve knob clockwise to fully close the shut-
off valve. |
UNIT-UNDER-TEST
BONDED SEAL
PRESSURE
PORT —[
HOSE
ZE RESERVOIR
LC к
Figure 8, Hydraulic Actuator Version Priming Connections
K049 Issue No. 7
32 DPI 601 User Manual
Bleeding the system
NOTES
1: If the reservoir empties of fluid, air will enter the system.
2: If the priming pump is operated without the reservoir connected or the
reservoir empty air enters the system
1. Slowly turn the screw-press clockwise to bleed the system free of air.
Observe the hydraulic fluid coming out of the pipe assembly located in
the reservoir, stop turning the screw-press when no air bubbles can be
seen in the fluid.
2. When no air is seen in the fluid or if the screw-press is in the fully
clockwise position, slowly turn the screw-press anticlockwise to draw
fluid into the system.
3. If necessary, repeat the priming and bleeding operations until the fluid
is free of air and the screw-press is fully anticlockwise.
4. When connecting the instrument to a system with pipe-work (i.e., with
a large volume), fluid must be forced into the system. Proceed as
follows:
I. Connect the pressure port pipe assembly to the system.
i. Open the bleed screw or connection to prime the system.
iii. Turn the priming shut-off valve knob anticlockwise to fully open
the shut-off valve. Push down the priming pump to force fluid
into the system until fluid is seen coming out of the bleed
screw or connection.
iv. If the priming pump is pushed to the fully down position
without fluid being seen at the bleed screw or connection,
more fluid is required.
У, Close the bleed screw or connection and open the priming
valve. Carefully pull up the priming pump plunger and at the
same time top-up the reservoir making sure that fluid can
always be seen in the reservoir. Repeat the operations until
the system is primed.
vi. When the system is fully primed, it must be bled using the
bleed screw or connection. Proceed with the following:
5. Open the pressure gauge assembly bleed valve and slowly turn the
screw-press clockwise to bleed the system observe fluid coming out.
K049 Issue No. 7
Hydraulic Actuator Version 33
6.
10.
Close the bleed valve when no air is seen in the fluid coming out of the
bleed valve or if the screw-press is in the fully clockwise position.
Slowly turn the screw-press fully anticlockwise to draw fluid into the
system.
If necessary, open the bleed valve and repeat operations 5 and 6 until
the system is free of air and the screw-press is in fully anticlockwise
position. Turn the priming shut-off valve knob clockwise to fully close
the shut-off valve.
Close the pressure gauge assembly bleed valve.
Disconnect the priming pipe assembly and remove the reservoir.
Do not pull up the knob of the priming pump plunger as air may enter
the system.
For gauge instruments, carry out a zero of the instrument as detailed in
the operation section of the manual.
Pressure readings
1.
Turn the screw-press clockwise to generate pressure and anticlock-
wise to reduce pressure. When taking a pressure reading make sure
that the reading is sufficiently stable.
NOTES
a. When hydraulic fluid flows through a restriction there is an
increase in temperature that affects the pressure of the fluid.
Allow sufficient time for the reading to stabilize.
b. A pressure drop or fall rate depends on the viscosity of the
hydraulic fluid Table 1. A leak rate can be expected, typically
0.3bar/10sec at 350 bar.
С. If the instrument is taken from one environmental condition to
be used in another, changes in temperature will affect the
pressure reading. Allow sufficient time for the instrument's
hydraulic system to attain ambient temperature.
When the test is complete reduce the pressure in the system to zero
by turning the screw-press fully anticlockwise then turn the shut-off
valve anticlockwise.
Remove the pressure gauge assembly.
Fit the blanking plug to the pressure connection port.
Carry out storage procedures.
K049 Issue No. 7
34 DPI 601 User Manual
Replenishing or Changing Hydraulic Fluid
If the hydraulic fluid needs replenishing or changing proceed as follows:
Emptying the system
1. Remove the blanking plug from the pressure connection port.
2. Turn the shut-off valve fully clockwise. Turn the instrument onto the
side (pressure connection port nearest workbench). Place receptacle
below the pressure port connection to collect hydraulic fluid.
3. Drain the system by slowly depressing the priming pump plunger.
Turn screw-press fully clockwise.
Flushing
If necessary, flush the system to remove any contaminants.
a. With priming pump plunger fully depressed, turn the shut-off
valve anticlockwise and connect the priming pipe assembly.
b. Refill the priming pump reservoir with clean hydraulic fluid of
the same type as the original fluid. Lift up priming pump
plunger and unscrew fully anticlockwise the screw-press make
sure the reservoir is always full of hydraulic fluid.
С. Empty the system again and, if necessary, repeat the flushing opera-
tion until all the contaminants are removed.
After draining, dry the system.
Nota: Dry, compressed air is recommended for this operation. Obey local safety
regulations when using compressed air.
Fillina 4!
1. Fill the system with clean hydraulic fluid via the prime pump reservoir.
Nota: The instrument system volume is approximately 17 cc.
K049 Issue No. 7
Hydraulic Actuator Version 35
7.5
7.6
Cleaning
For instruments using approved hydraulic oil, clean the case, instru-
ment controls with lint-free cloth and white spirit.
Storage
Empty the system then dry the system.
Refit the pressure connection blanking plug.
Fit the priming pump blanking connection and seal to the priming
pump connector.
For further details of storage see paragraph 6.6.
K049 issue No. 7
36
DPI 601 User Manual
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K049 Issue No. 7
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