Druck DPI 610, DPI 615 IS Operating Manual

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Sensing & Inspection Technologies

Druck DPI 610/615 IS

Intrinsically Safe Portable Pressure Calibrator

User manual - K0430

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English

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WARNING

Before operating this intrinsically safe instrument, read the safety instructions and

the special conditions stated on the ATEX certificate (Appendix 2)

Safety

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 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.

www.gesensinginspection.com

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.

Symbols

This equipment meets the requirements of all relevant European safety directives. The equipment carries the CE mark.

This symbol, on the instrument, indicates that the user should refer to the user manual. This symbol, in this manual, indicates a hazardous operation.

This symbol, on the instrument, indicates do not throw-away in domestic bin, hazardous material, dispose correctly in accordance with local regulations.

i K0430 Issue No. 2

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K0430 Issue No. 2 ii iii K0430 Issue No. 2

Page 5

ATEX Approved Models Introduction

These instructions detail the requirements for using the DPI 610 IS and DPI 615 IS intrinsically safe pressure calibrator in a hazardous area. Read the whole publication before starting.

Markings

II 1 G.................................................................... Equipment group & category

Ex ia IIC T4 Ga..................................................................Hazardous location markings

BAS02ATEX1174X................................................................................ Certificate number

1180..................................................................................................................................CE Mark

DPI 61X IS ......................................................................................Specific apparatus type

(Pressure Range in mbar or psi........................................Full-scale pressure rating

Druck LTD. Groby LE6 OFH, UK.................... Manufacturer's name and address

SN *******/YY-MM.................................. Serial number and date of manufacture,

Year-Month.

Requirements and Conditions Batteries WARNING: Only replace batteries in a safe area.

• Power supply use only 6 x LR14 (C): Duracell MN1400-LR14, Procell lndustrial

MN1400-LR14, Energizer E93.KR14.C.AM2, Energizer Industrial EN93 or Varta 4014 LR14.C.AM2.

Special Conditions for Safe Use

1. The DPI 61X IS Series Pressure Calibrator is not capable of withstanding the 500V r.m.s. electric field strength test between the external connectors and frame of the apparatus as required by Clause 6.4.12 of EN 50020 and this must be taken into account when using the apparatus for input measurements in a system.

2. The outer enclosure may contain light metals in the form of aluminium, magnesium, titanium or zirconium. Therefore, the apparatus must be installed in such a manner as to prevent the possibility of it being subject to impacts or friction. An optional carrying case is case is available for transporting the pressure calibrator to and from the location of use. When the carrying case is used, special condition for safe use item #2 does not apply.

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Electrical Parameters

Maximum Output Parameters at the External Measurement Connectors:

lin (SK1) Vin (SK2) SwitchIn (SK3)

Uo= 1.1V d.c.

= 0.16 mA d.c.

= 0.15 mW

= 0.05 µF

= 0

= 1.1V d.c.

= 0.11 µA d.c.

= 0.03 µW

= 0

= 1.1V d.c.

= 12 mA d.c.

= 11 mW

= 0.05 µF

= 0

lout (SK6) RS232 External Transducer

Uo= 7.9V d.c.

= 0

= 0.1 mH

= 7.6V d.c.

= 82 mA d.c.

= 162 mW

= 0

= 250V

= 7.6V d.c.

= 155 mA d.c.

= 0.43 W

= 0.15 µF

= 0.9 mH

= 8.6 µF

= 0.3 mH

The output parameters at sockets SK1, SK2 and SK3 do not exceed the values specified in Clause 5.4, Simple Apparatus, of EN 50020.

Maximum Safe Input Parameters: Sockets SK1, SK2, SK3 and SK6

Ui= 30V li= 100 mA P

= 1.0W

Installation WARNING: Do not use tools on the pressure calibrator that might cause

incendive sparks - this can cause an explosion.

• Provide additional protection for equipment that may be damaged in service.

• Installation should be carried out by qualified plant installation technicians in compliance with the latest issue of EN 60079-14.

Declaration Requirements

The DPI 610 IS and DPI 615 IS pressure calibrators are designed and manufactured to meet the essential health and safety requirements not covered by the EC Type Examination Certificate BAS02ATEX1174X when installed as detailed above. The intrinsically safe pressure calibrators are designed and manufactured to protect against other hazards as defined in paragraph 1.2.7 of Annex 11 of the ATEX Directive 94/9/EC.

K0430 Issue No. 2 iv

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Specification

Safe working pressure

20 bar range (300 psi) 1.75 x full-scale 350 bar range (5000 psi) 1.2 x full-scale 400 bar range (6000 psi) 1.5 x full-scale All other ranges 2 x full-scale

Accuracy

Combined non-linearity, hysteresis and repeatability

±70 mbar range (2 inHg) 0.05% F.S. up to ±150 mbar (4.4 inHg) 0.05% span 200 mbar to 20 bar (3 psi to 300 psi) [Calibrator]): 0.025% F.S. 35 bar to 700 bar (500 psi to 10000 psi) [Indicator] 0.025% F.S. 70 bar to 400 bar (1000 psi to 6000 psi) [Hydraulic] 0.025% F.S.

Pressure Ranges

Refer to the pressure range matrix in the data sheet .

Temperature Effects

±0.004% of reading/°C (averaged over -10° to +40°C w.r.t. 20°C) ±0.002% of reading/°F (averaged over +14° to 104°F w.r.t. 68°F)

Power supply

Batteries 6 x 1.5 V C cells, alkaline (up to 60 hours nominal use at 20°C)

Voltage Inputs

Range: ±30V Accuracy ±0.05% rdg, ±0.004% F.S. Resolution 100µV max

Current Inputs

Range: ±55mA Accuracy ±0.05% rdg, ±0.004% F.S. Resolution 1µA max

Current sink

Range: 24mA Accuracy ±0.05% rdg, ±0.01% F.S. Resolution 1µA max

Display

Size: 60 x 60 mm (2.36” x 2.36”) LCD Graphics Reading ±99999, update rate 2 readings/sec

Environment

Operating Temperature: -10°C to 50°C (+14°F to 122°F) Calibrated Temperature: -10°C to 40°C (+14°F to 104°F) Storage Temperature: -20°C to 60°C (-4°F to 140°F) Calibration Temperature: 21°C ±2°C (70°F ±4°F)

Sealing

Sealed to IP54 (NEMA 4)

Physical

Size: 300 x 170 x 140 mm (11.8” x 6.7” x 5.5”) Weight: 3 kg (6.6lb)

v K0430 Issue No. 2

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Introduction

General

Description of Procedures 1

Summary of Functions

Using this Guide 2

OPERATOR CONTROLS 3 DISPLAY 3 HARD KEY FUNCTIONS 4 SOFT KEYS 5 CURSOR KEYS 5 ELECTRICAL CONNECTIONS 6

Getting Started

Fitting Batteries 7 Switching On 7 Change Pressure Units 8 Voltage and Current Measurement 8 Typical Calibration Set-up (Pressure to Voltage) 9 Zero Display Reading 9

Task Selection

Task Key 10 Using Task Functions 10 Set Units 10 Cal Mode (DPI 615 instruments only) 11 Basic Mode (Task BASIC) 11

Taking Measurements

Pressure Transmitter (P-I) Task 12 Voltage Output Pressure Transmitter (P-V) Task 12 Pressure Converter (P-P) Task 13 Current to Pressure Converter (I-P) Task 14 Pressure Switch Test (P-Switch) Task 14 Pressure to Display (P-Display) Task 15 Leak Test (Leak Test) Task 16 Transmitter Simulator (TX SIM) Task 17 Relief Valve Test (REL VALVE) Task 18

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Advanced Task

General 19 Select Input 19 Ambient Temperature Measurement 19 Process Functions 20 Tare Process Function 21 Min/Max Process Function 22 Filter Process Function 22 Flow Function 23 % Span 23 Select Output 24

Electrical Outputs (Loop Power) 24

mA Step 25 mA Ramp 26 mA Value 27 Define New Task 28 Clear Task 28

Memory Operations

Saving Display or Data Log 29 Store Operations (Screen Snapshots) 29 Recalling Stored Data (Screen Snapshots) 29 Datalog Operations 30

Auto Log (Timer) 30

Manual Logging 30 Recall Data Log Files 31 Uploading Data Log Files 32 Delete Data Log and Procedure Files 32 Downloading Procedure Files (DPI 615 instruments only) 33 Running Procedure Files (DPI 615 instruments only) 34 Recalling Data Files (DPI 615 instruments only) 35

Using Set-up

General 36 Store Mode 36 Contrast 36 Settings - Select Set-up Option 37

Units 37

Define Special Units 37

Language 38

RS232 38

Powerdown 39

Calibration 39

vii K0430 Issue No. 2

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Date and Time (Real Time Clock) 40

Date Format 40

Set Date 40

Set Time 40

Calibration

General 41 Calibration Check 41 Calibration Adjustment 41 Guide to Calibration Procedures 41 Test Equipment 42 Using the Calibration Menu 43 Change PIN 43 Calibrate Internal Ranges 43 Internal Pressure Range 44 Voltage Input Range (5 Volts) 45 Voltage Input Range (30 Volts) 47 Current Input Range (55 mA) 49 Current Output Range (24 mA) 51 Ambient Temperature Channel 54 Calibrate External Sensors 55 Add External Sensor 56

Hydraulic Calibrator Versions

Introduction 59 Safety Instructions 60 Preparation for Use 60 Bleeding the System 61 Operation 62 Draining the Hydraulic Fluid 62 Flushing, Replenishing or Changing the Hydraulic Fluid 63

Appendix 1 - Datalog File Example

Typical Uploaded Datalog File (DPI 610) 67 Typical Uploaded Procedure Data File (DPI 615) 68

Appendix 2 - ATEX Certificate of Conformity

K0430 Issue No. 2 viii

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INTRODUCTION Summary of Functions

General

The DPI 610 IS and DPI 615 IS intrinsically safe instruments measure and display pneumatic and hydraulic pressure applied to the test port. Pressure measurement can be absolute, gauge and sealed gauge and in ranges from 2.5 mbar to 700 bar (1.0 inH

to 10000 psi). Calibrator versions of this instrument contain pneumatic or hydraulic pressure generation components to produce pneumatic pressure ranges between -1 to 20 bar (-

14.5 psi to 300 psi) and hydraulic pressure ranges up to 400 bar (6000 psi) Using external electrical connections, the DPI 610 IS and DPI 615 IS intrinsically safe instruments measure ±30 volts d.c. and ±55 mA. An integral sensor provides measurement of ambient temperature. Additional sensors (option B1) connect to an external connector and extend the pressure measurement range and include differential pressure measurement. The DPI 615 instrument has an RS232 connector to enable downloading of test data to a compatible documenting system. Six alkaline C size batteries, IEC Type LR14, power the instrument.

Important Notice

Zinc-carbon and zinc-chloride cells must NOT be used in this instrument.

Use only the battery types as shown in the table on page 7.

Description of Procedures

The procedures apply to both the DPI 610 IS and the DPI 615 IS instruments unless otherwise stated. In the procedures in this manual, hard (fixed function) and soft (variable function) key operations are shown in bold type : TASK and F1. These statements mean press the TAS K key and press the F1 key. Soft key operations can be assigned to both the F1 and F2 keys. Where a specific soft function is referred to it is written in bold italics (e.g.) PROCESS. This instrument has a number of operating modes that are described in simplified form in the following sections. Diagrams accompanying the procedures give typical selection sequences and shaded controls indicate that this control key should be pressed in the appropriate sequence. Diagrams should be read from left to right, top to bottom where appropriate. A shaded display soft box indicates that the function key immediately below that soft box should be pressed (either F1 for the left hand soft box or F2 for the right).

In the above diagram the following key sequence is indicated. (a) Press the F2 key (the key immediately below the UNITS soft box).

(b) Use the Up and Down cursor keys (only) to select the required option. (If all keys

shaded, use all these keys to select or enter data).

1 K0430 Issue No. 2

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INTRODUCTION Summary of Functions

Using This Guide

The following key symbols are used in the procedure diagrams:

Shaded cursor keys indicate that a combination of these four keys, Up, Down, Left and Right should be used to (e.g.) enter an alpha numeric value or to select a function.

Indicates the ENTER key. Used to confirm an operation or a selection. Shading indicates key operation.

Exit key, used to clear current menu selection and return to next menu level above current level. Used as an escape key from current operation. Shading indicates key operation.

Hardkey (total 7). Legend beside key symbol indicates function. Shading indicates key operation.

Maximum Instrument Ratings

The following table shows the maximum measurement input ratings of the instrument which should not be exceeded.

PRESSURE 120% FULL SCALE

VOLTAGE 30 V d.c.

CURRENT 55 mA d.c.

Note 1: The display flashes if the input pressure, voltage or current overrange.

Note 2: Max applied voltage for external loop supply = 30V dc (see page 8).

K0430 Issue No. 2 2

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PRESSURE INT

bar

VOLTAGE

F2F1

CURRENT

PRESSURE

UNITS

max 30V

TASK: BASIC

DPI 615 IS

PRESSURE INT

bar

VOLTAGE

CURRENT

UNITS

PRESSURE

TASK: BASIC

Input display

Output display

Soft boxes

Status display

INTRODUCTION Summary of Functions

OPERATOR CONTROLS (Figure 1 and 2)

These divide into two groups, the operator/display controls (Figure 1) and the pressure/ vacuum generation components (Figure 2). The operator controls and a typical display, common to all instrument versions, is shown below.

1 Display 2 Electrical Measurement Input Sockets 3 Cursor Keys 4 Enter Key 5 Function (soft) Keys 6 Hard Keys 7 On/Off Key

Figure 1 - DPI 610/615 IS Key-pad

DISPLAY

The display and key-pad of the instrument divides into four distinct sections. The two main sections of the display are used to show an input and an output. The remaining two sections show the status display area and define the soft key functions. A typical display is shown below:

3 K0430 Issue No. 2

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INTRODUCTION Summary of Functions

HARD KEY FUNCTIONS (Fig. 1)

Key Function

I/O

SETUP*

ZERO

INPUT*

TAS K

OUTPUT*

STORE*

RECALL*

This key selects the instrument ON and OFF. 7

The

SETUP

configuration parameters that are set-up to certain default parameters on delivery.

The the display reading is within 5% of zero. Attempts to zero a larger offset result in an error message,

The

The different types of external device calibration. There are twenty task configurations available, eleven pre-programmed configurations and nine user def ined configurations

The

Depending upon how the instrument’s is used either to store up to 20 display screens (in or to manually log a screen in

This key recalls a previously stored screen to the display. Depending on the snapshot of a previously stored screen or data log file. In mode, selection displays the last screen stored. By using the cursor keys, the operator can scroll either forward or back through memory locations.

key provides access to the instrument’s general

ZERO

key zeroes either the selected input or output display, only if

INPUT

key selects the input parameter to be displayed. 18, 19

TAS K

key rapidly configures the instrument for a number of

OUTPUT

key selects the output parameter to be displayed. 24-27

DATALOG

STORE

mode set-up, operation of this key recalls either the

Zero too large.

STORE

mode is set-up, this key

mode.

SNAPSHOT

mode),

STORE

Page

reference

29, 36

28, 31, 35

The

ENTER

EXIT

conjunction with the soft keys, accepts a given selection.

The keys to exit from the current screen or menu level, to the level immediately preceding it. To quit completely from any menu level, press

key either enters data (accept entered data), or, in

EXIT

key operates in conjunction with all the other hard and soft

EXIT

until the

MEASURE/SOURCE

screen is displayed.

* These key functions are not available in BASIC mode

K0430 Issue No. 2 4

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INTRODUCTION Summary of Functions

SOFT KEYS (Fig. 1)

Three soft keys, designated F1, EXIT and F2, are situated immediately below the display as shown below. These keys have their function allocated by the instrument software which is indicated in the bottom of the display (Voltage for F1 and Units for F2 in this example). They are used to select menu (program) options and are fully described under the appropriate section headings.

CURSOR KEYS (Fig. 1)

The cursor keys consist of a block of four keys, designated up , down , left , and right . In programs where options need to be selected from a list, (e.g.) the TAS K

selection program, the up and down cursor keys are used to highlight one of the options, from which it can be selected by the ENTER key. In TA SK mode, where more than one page of options are provided, the left , and right cursor keys will switch between pages.

1 Test port, connect to unit under test 2 Hard keys 3 Cover (external interfaces) 4 Electrical inputs 5Cursor keys 6Function (soft) keys 7 Release valve (releases pressure through 8) 8 Vent port 9 Select positive or negative pressure 10 Pump 11 Fine pressure adjuster

Figure 2 - DPI 610/615 IS Calibrator Controls

5 K0430 Issue No. 2

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USERS232

INSAFE

AREAONLY

PRESSURE INT

bar

VOLTAGE

F2F1

CURRENT

UNITS

INPUTS

OUTPUTS

PRESSURE

max 30V

CAT II

TASK: BASIC

DPI 615 IS

INTRODUCTION Summary of Functions

ELECTRICAL CONNECTIONS

1 Cover, closed when

not using connectors

2 External transducer

3 RS232 connector

4Temperature sensor

Figure 3 - Electrical System Connections

Measurement inputs and Source outputs are made via the control panel sockets as shown below:

1 Status window 2 Input window 3 Electrical measurement input sockets 4Output window

Figure 4 - Electrical Measurement Inputs/Source Outputs

K0430 Issue No. 2 6

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PRESSURE INT bar

VOLTAGE

CURRENT

UNITS

PRESSURE

TASK: BASIC

Manufacturer Type No.

Energizer Industrial Type EN93

Energizer Type E93.LR14.C.AM2

Duracell Type MN1400-LR14

Varta No.4014 Type LR14.C.AM2

Procell Industrial Type MN1400-LR14

1Cover fixing

screws.

2Six alkaline C

cells, see table.

Only use the battery type in the table.

3 Low battery

indication.

Getting Started

Fitting Batteries

WARNING: BATTERIES MUST ONLY BE FITTED IN A SAFE AREA.

USE ONLY THE BATTERIES SPECIFIED IN THE TABLE.

Caution: Old batteries can leak and cause corrosion. Never leave discharged batteries in

Switching On

Press the I/O switch on the front panel and proceed as follows:

The first time that the instrument is powered up, it will power-up in BASIC mode with the main screen displaying voltage in the input display area and pressure in the source display area. To switch to Current as input, press F1 as shown. Similarly, F1 to return to

Voltage.

Note: No other keys are active in this mode and the instrument can only be reconfigured

by pressing the TASK key and selecting another mode.

the instrument. Old batteries should be treated as hazardous waste and

disposed of accordingly.

7 K0430 Issue No. 2

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55mA

Vin

mA in

mA Sink

max 30V

max

55mA

Vin

mA in

mA Sink

max 30V

max

Current

Maximum input current = 55mA dc (at 30 V dc)

Voltage

Maximum applied voltage = 30V dc.

Getting Started

Change Pressure Units

To change the pressure units proceed as follows. If the four units displayed are not the units required, press TAS K and select any task, other than BASIC, press SETUP and proceed as detailed on page 36. To return to BASIC mode, press TAS K and select BASIC.

In BASIC mode, the unit is configured to carry out basic Pressure to Voltage (P to V) or Pressure to Current (P to I) tests, a typical test procedure follows:

Voltage and Current Measurements

Connect the electrical input sockets as follows for voltage and current measurements. Use the test leads provided and DO NOT push bare wires into the sockets.

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PRESSURE INT

bar

VOLTAGE

F2F1

EXIT

CURRENT

PRESSURE

UNITS

Max30V

CATII

TASK:BASIC

DPI 615 IS

Getting Started

Typical Calibration Set-up (Pressure to Voltage)

Connect a device under test to the instrument as shown below:

A - External pressure source (indicator instruments only) B - Pressure regulator C - Pressure/voltage device D - Barrier E - Excitation 10V F - Safe area

• General Procedure

Use the hand-pump to pressurize the system to the required level as indicated on the display. Allow the display to settle and screw the volume adjuster in or out as a fine adjustment to the required pressure. Record the input: Voltage, reading at each applied pressure.

Zero Display Reading

Both the input and output readings can be set to zero by using the ZERO key and if the displayed reading is within 5% of zero. To zero either the INPUT or OUTPUT displays, proceed as follows:

9 K0430 Issue No. 2

Page 20

Task Selection

Task Key

The TASK key is used to set-up the instrument for a number of specific types of test. There are two modes BASIC and ADVANCED and nine other specific types of test which automatically configure the instrument on selection from the TAS K menu. The tasks available under the TASK menu are held on three pages shown below. To select a task from the menu, press the TASK key, position the cursor over the required task and press the ENTER key as shown below. Use the right/left cursor keys to switch between pages.

Using TASK Functions

Specific tasks are selected as shown above. The following diagrams show how to connect the unit under test (UUT) for each task selectable under the TA SK menu.

Input and output units, where applicable, can be selected by pressing either the INPUT or

OUTPUT keys as shown below.

Set Units

Note: If the four units displayed are not the units required, press SETUP, select SETTINGS

and refer to select regular units on page 37.

K0430 Issue No. 2 10

Page 21

0.00

2000.00

OUTPUT

MAX. ERROR

ERROR TYPE

CHANGE

VALUE

psi

4.00

20.00

LINEAR

0.05%

%span

SELECT VALUE

psi

TASK : P-I DATALOG

24V OFF

..........

. %span FAIL

TURN OFF CAL MODE

TURN ON

CAL MODE

TASK : P-I DATALOG

24V OFF

..........

psi

Task Selection

Cal Mode (DPI 615 versions only)

Cal mode, which is available in tasks P-I, P-P, P-V, P-P, P-DISPLAY and P-SWITCH, provides a method of setting up test parameters manually. Downloaded test procedures can also automatically set up and turn on the Cal Mode function. The method of turning on and setting up Cal Mode is shown below for a P-I task. A similar method can be used for all the other tasks applicable to the Cal Mode function.

Pressing the F1 key (TURN ON CAL MODE), provides the set-up screen for the CAL mode. Initially, the cursor is placed in the UUT SPAN field to allow the required span range to be entered. The corresponding values for the UUT output parameter (current) are then set, followed by the maximum error value and error type (%rdg or % span). When all test parameters have been set-up, the screen changes to display the input and output and the test results. The test result can only be displayed to within a range of ±9.99%. If the test result is outside this range, either the left pointing (-ve error) or right pointing (+ve error) chevrons are displayed. Within this error band, the actual tolerance value is displayed. Test results can either be stored as snapshots or logged as data log files, depending on how the instrument has been set-up.

Basic Mode (Task BASIC)

This instrument will power-up in this mode the first time that it is used. To select BASIC from any other task, press the TA SK key and select BASIC and press the ENTER key.

BASIC mode is fully described in the Getting Started, section (see page 7).

11 K0430 Issue No. 2

Page 22

PRESSUREINT

bar

CURRENT

TASK:P-I SNAPSHOTMODE

DPI 615 IS

F2F1

EXIT

Max30V

CATII

PRESSURE INT

bar

VOLTAGE

F2F1

EXIT

CURRENT

PRESSURE

UNITS

Max30V

CATII

TASK:BASIC

DPI 615 IS

Taking Measurements

Pressure Transmitter (P-I) Task

Select the P-I task from the task menu and connect the Unit Under Test (UUT) to the calibrator as shown below:

A - External pressure source (indicator instruments only) B - Pressure regulator C - Pressure to current device D - Barrier E - External supply F - Safe Area

• If required, select the output units as described on page 10.

• If applicable, turn on Cal Mode and set-up test parameters as detailed on page 11.

Voltage Output Pressure Transmitter (P-V) Task

Select the P-V task from the task menu and connect the Unit Under Test (UUT) to the instrument as shown below:

A - External pressure source (indicator instruments only) B - Pressure regulator C - Pressure to voltage device D - Barrier E - External supply F - Safe Area

• If required, select the output units as described on page 10.

• If applicable, turn on Cal Mode and set-up test parameters as detailed on page 11.

K0430 Issue No. 2 12

Page 23

USERS232 INSAFE AREAONLY

Taking Measurements

Pressure Converter (Pressure to Pressure) Task

Select the P-P task from the task menu and connect the Unit Under Test (UUT) to the calibrator as shown below. Testing a converter requires one pressure to be applied to the unit under test (UUT) and another (converter output) to be measured. The additional measurement is provided by the external transducer option.

Method

• Connect the UUT to the instrument as shown below. Plug the external transducer into the instrument as shown below:

A - External pressure source (indicator instruments only) B - Pressure regulator C - External pressure source D - Pressure to pressure device E - External transducer

• Press the TASK key and select the P-P task. Providing the external transducer has been calibrated and its parameters stored in the instrument, the display will show External pressure in the input window and calibrator Output pressure in the output window. If an error message “NO SENSOR OR CAL INVALID” is displayed, this indicates that the external transducer has not been entered and/ or calibrated with the instrument. Refer to page 56 for details of adding an external transducer. If an external transducer change is made, switch the

calibrator off and then on to load new transducer data.

• If required, select the input and output units as described on page 10.

• If applicable, turn on Cal Mode and set-up test parameters as detailed on page

11.

13 K0430 Issue No. 2

Page 24

PRESSURE INT

bar

OUTPUT

NEW VALUE

CURRENT

TASK: I-P SNAPSHOT MODE

F2F1

EXIT

Max30V

CATII

DPI 615 IS

PRESSURE INT

bar

F2F1

RUN

CONTACTSTATE

max30V

TASK: P-SWITCH SNAPSHOT MODE

DPI 615 IS

Taking Measurements

Current to Pressure Converter (I-P) Task

A - External pressure source B - Pressure to current device (24V) C - Barrier D - Safe area E - External supply

•Use the up and down cursor keys to adjust the loop current to the required value. Alternatively, press ENTER and use cursor keys to enter a finite value. Cursor keys can then be used to nudge the output either up or down. If required, change pressure units with INPUT key. A flashing CHECK LOOP message indicates either an open circuit supply loop (or no external supply).

Pressure Switch Test (P-SWITCH) Task

A - External pressure source B - Pressure regulator C - Pressure switch under test

• Contact state will be shown on display. When contacts close, buzzer sounds.

• To run switch test, close vent valve and press the RUN (F1) key.

• Using the hand-pump, increase the applied pressure to just below the switch operating point. Screw the volume adjuster in until the switch operates (the operating pressure of the switch is then written to the display).

• Reduce pressure until the switch releases (indicated by the switch symbol). The release pressure is then written to the display and the hysteresis displayed.

K0430 Issue No. 2 14

Page 25

PRESSURE INT bar

F2F1

DISPLAY

CHANGE

VALUE

TASK : P-DISPLAY SNAPSHOT MODE

max30V

DPI 615 IS

Taking Measurements

Pressure to Display (P-DISPLAY) Task

P-Display is a special application of Data Log. To use this mode, select Data Log from the Store Mode menu as detailed on page 36. Connect the UUT to the instrument as shown below and, if required, turn on and set-up Cal Mode (see page 11).

A - External pressure source B - Pressure regulator C - Dial gauge under test

•Press TASK and select P-DISPLAY. If required, use OUTPUT key to change pressure units.

• Set-up a data log file as detailed on page 30.

Note: TRIGGER field, automatically set to KEYPRESS, cannot be changed.

• Apply a series of test pressures to the device under test. Enter displayed reading at each pressure and log each point:

• After logging final test point, terminate as follows:

15 K0430 Issue No. 2

Page 26

PRESSURE INT

bar

F2F1

RUN

CHANGE

VALUE

WAIT DURATION

STARTPRESS STOP PRESS

PRESS CHANGE LEAK RATE

secs secs

bar bar

bar bar/m

max30V

TASK: LEAK TEST SNAPSHOT MODE

DPI 615 IS

Taking Measurements

Leak Test (LEAK TEST) Task

A - External pressure source B - Pressure regulator C - Device/system under test

• If required, use the INPUT key to change pressure units.

• Set-up the leak test WAIT and DURATION times to the required values as shown below. A minimum wait period of 3 minutes is recommended.

• Close the vent valve and pressurize the device/system to the required LEAK TEST pressure.

•Press the RUN (F2) key to start the leak test. When completed, the beeper sounds and the leak test results are written to the display.

K0430 Issue No. 2 16

Page 27

Taking Measurements

Transmitter Simulator (TX SIM) Task

When used with an external voltage source (see page 24), provides a current output proportional to the calibrator’s measured output pressure (indicated pressure on indicator only version). Select task TX SIM. Press EXIT to skip set-up screen if parameters are correct.

On completion of Tx SIM set-up, the display is configured as follows :.

Connect an external power source to the output loop as detailed on page 24.

To subsequently change any of the Tx SIM scaling parameters, press CHANGE VALUE key (F1) to obtain the TX Simulation set-up display.

To change the pressure units, press INPUT and select the required scale units. If the required scale units are not listed, press SETUP, select SETTINGS and proceed as detailed on page 37.

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Page 28

PRESSURE INT

bar

RESET

MAXIMUM

MINIMUM

MAX/MIN

F2F1

PRESSURE INT

max30V

TASK: RELVALVE SNAPSHOT MODE

DPI 615 IS

Taking Measurements

Relief Valve Test (REL VALVE) Task

To carry out a relief valve test, press TAS K and select REL VALVE. Connect the output pressure port of the instrument to an external system as shown below:

A - External pressure source (indicator only) B - Pressure regulator C - Relief valve under test

• To change the pressure units, if required, press INPUT and select the required units using the cursor keys.

• Close the vent valve and, using the hand-pump or external pressure supply, apply pressure to the relief valve under test.

• When the relief valve operates, the maximum recorded pressure indicates the operating point of the valve.

• Record the test results.

Note: The STORE key can be used for this purpose. Use right cursor key initially,

followed by up/down keys to enter Snapshot text.

• Open vent valve to release test pressure.

Note: If using external pressure supply, isolate supply before opening the vent

valve.

K0430 Issue No. 2 18

Page 29

SELECT UNITS

SELECT AIR TEMPERATURE

INPUT

SELECT INPUT

PROCESS UNITS

UNITS

CELSIUS

FAHRENHEIT

AMBIENT TEMP

NO INPUT

Advanced Task Select Input

General

Advanced task allows the user to configure the instrument to monitor one of a number of different input measurements and outputs (sources). Additionally, five process functions, Tare, Max/Min, Filter, Flow and % Span can be applied to the input functions.

Select Input

To select an input channel, select ADVANCED task from the task menu. The display shows the list of the input selections and, if available, the PROCESS soft box (F1) and the UNITS soft box (F2). The following procedure shows the method of input channel selection and the method of changing units:

Note: Left/right arrow keys function as page up/down keys.

Refer to pages 20 to 23 for details of process functions.

Ambient Temperature Measurement

To set-up the instrument to read ambient temperature, proceed as follows:

Note: Ensure that the temperature reading has stabilised.

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Advanced Task Process Functions

Process Functions

If required, the following process functions are available on the input display but only in ADVANCED task. If the instrument is in any other mode i.e. BASIC or any other task mode, the input and output displays must first be configured in ADVANCED task.

Note: PROCESS functions are not available to the output channel.

A summary of the process functions follows.

• Tare Allows either the current display value or a manually

entered value to be tared off display parameter reading.

• Max/Min Displays running Max/Min and present display values

simultaneously. Resettable via F1 key.

• Filter Applies low pass filter function to displayed parameter.

Filter characteristics (Settling time and Band) are user programmable.

• Flow Applies square root function to displayed parameter.

• % Span Converts displayed parameter reading to a percentage of

span. Span definable via the F1 key.

Following selection of ADVANCED from the task menu, press the INPUT key. Use the up

or down cursor keys to select the required input. Press the PROCESS (F1) key and

use the left or right cursor keys to enable the process on/off:

Press ENTER to switch the process ON with existing settings or F1 to change process settings (where applicable).

K0430 Issue No. 2 20

Page 31

Advanced Task Process Functions

• Tare Process Function

To set-up a Tare function, enable TA RE from the process menu and press F1 to enter the Tare SETTINGS functions.

Disable TAR E by entering process menu and turning the function OFF.

Note: Last TARE setting is retained and will be applied when function is next

enabled.

Tare Current input Reading To tare-off the current display reading, proceed as follows:

Tare Off An Entered Value To tare-off an entered value current, proceed as follows:

Note: Display shows the last entered Tare Value.

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Advanced Task Process Functions

• Min/Max Process Function

To set-up an input display to show min/max and present input reading, enable MIN/MAX from the process menu and press F1 (SETTINGS) to provide RESET function. The display now shows the max/min values as follows:

Reset Max/Min display at any time by pressing the F1 key.

To quit max/min, press INPUT, select MAX/MIN from process menu and switch the function off.

• Filter Process Function

To apply the low pass filter to a selected input, enable FILTER from the process menu and press F1 (SETTINGS) to provide access to the filter parameters. Two settings are required, Time to Settle and Band. To examine the current filter settings and exit without change, press the EXIT key.

The set-up procedure is as follows:

K0430 Issue No. 2 22

Page 33

Advanced Task Process Functions

• Flow Function

To apply the flow function to a selected input, enable FLOW from the process menu and press ENTER. The square root symbol is displayed beside the input value to indicate that the FLOW function is active:

To cancel FLOW, press INPUT and turn function OFF at the process menu.

• % Span

To convert a selected input display from a numerical value to a percentage of fullscale reading, enable SPAN from the process menu and press F1 (SETTINGS) to provide access to the span definition parameters. Two span definitions are required, Zero and Full Scale.

To leave span at current setting, press EXIT.

To define zero and full-scale settings, proceed as follows.

To cancel % SPAN, press INPUT and turn function OFF at the process menu.

23 K0430 Issue No. 2

Page 34

55mA

Vin

mA in

mA Sink

max 30V CAT II

max

Advanced Task Select Output

Select Output

To display an output channel, select ADVANCED mode from the task menu. The display shows the list of output selections and, if available, the UNITS soft box (F2).

The following procedure shows the method of output channel selection from two pages of options. The second page can be obtained directly from the first by pressing the right

cursor key:

Note: Left/right arrow keys function as page up/down keys.

To change the output units (pressure channels only), select the channel with the cursor keys and press F2 before pressing ENTER.

Electrical Outputs (Loop Power)

All the electrical outputs, the output loop must be powered from an external supply (current sinking).

External connections to the front panel of the instrument are shown below.

A Load B Barrier C (External supply 30 V dc maximum) D Safe area

Current Sinking

K0430 Issue No. 2 24

Page 35

Advanced Task Select Output

mA Step

To select one of the electrical output programs, press the OUTPUT key and proceed as follows:

On selection of (e.g.) Linear, the output display window changes to show the selected program of output currents:

• Connect an external power source as shown on page 24.

•Press RUN (F1) to run program. A flashing status display CHECK LOOP indicates a fault in the external loop i.e. supply fault or open circuit.

Note: The dwell time at each step is approximately 10 seconds.

•Press STOP (F1) when running to stop at any point. Press RUN (F1) to resume.

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Advanced Task Select Output

mA Ramp

Press the OUTPUT key and select mA Ramp as shown previously in mA Step.

• Define ramp required by entering START and END current values as shown below:

• Connect an external power source as shown on page 24.

•Press START (F1) to run the program. A status display CHECK LOOP indicates a fault in the external loop i.e. supply fault or open circuit.

Note: The ramp cycle (min to max or max to min), is approximately 60 seconds.

•Press STOP (F1) when running to stop at any point. Press CONTINUE (F1) to resume from point of pause or RESET (F2) to return to start point.

K0430 Issue No. 2 26

Page 37

Advanced Task Select Output

mA Value

Press the OUTPUT key and select mA Value from the output menu. The procedure is shown below:

• Connect an external power source as shown on page 24.

•Use up and down cursor keys to adjust output current level. While the loop is made, a status display indicates OK. A status display CHECK LOOP indicates a fault in the external loop i.e. supply fault or open circuit.

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Advanced Task Task Setup/Removal

Define New Task

To define a new task, proceed as follows.

•Select ADVANCED from TASK menu.

•Using the INPUT key, select the required input for the input display and set-up any process functions required.

•Using the OUTPUT key, select the required output for the output display.

•Press TASK and select free. Enter new task name as follows:

On completion of the this procedure, the display reverts to newly set-up task as shown.

Clear Task

To clear a user defined task, select TA SK and proceed as follows:

K0430 Issue No. 2 28

Page 39

Memory Operations Store

Saving Display or Data Log

In Store Mode three memory operations can be set-up: None, Snapshot and Datalog. Refer to Using SETUP for details.

Store Operations (Screen Snapshots)

To store any display (menu displays excepted), press the STORE key. This saves the current display to the next available location. Supporting text (10 characters) may be appended. Twenty memory locations are available on a cyclic buffer. When all 20 have been used, store operations overwrite existing locations, starting at Location 1.

Recalling Stored Data (Screen Snapshots)

To recall a previously stored display, press the RECALL key. This recalls the last display saved. Press the left or right cursor keys to recall the previous or next locations respectively. To exit RECALL, press the EXIT key.

29 K0430 Issue No. 2

Page 40

Memory Operations Datalog

Data Log Operations

Data Log is a special application of store mode which enables the calibrator to either automatically log displays at preset time intervals or to manually log a display on operation of the STORE key. Logged data is written to a user specified file.

To set-up a Data Log file, proceed as follows.

• Select a task, other than BASIC. If using ADVANCED, set-up the required output parameters.

•Use SETUP to select Data Log from the Store Mode Menu (See page 36).

Auto Log (Timer)

Press STORE and set-up the Data Log file parameters as shown below. Use CHANGE VALU E (F1) followed by cursor keys to set f ield values. For Auto Log, set-up TRIGGER field to PERIODIC.

Manual Logging

Enter the file details as shown above and select KEYPRESS for TRIGGER field. Screen reverts to displayed parameters showing set-up file as shown below:

• Use a combination of STORE and LOG NOW (F1) to log events as follows.

K0430 Issue No. 2 30

Page 41

Memory Operations Datalog

Recall Data Log Files

To recall a Data Log file to the display, ensure that DATA LOG is selected from the SETUP menu and proceed as follows:

Data Log files can be displayed either as text (stored screens) or in graphical form. To display as text, proceed as follows from the File Summary menu. Select Auto Step to automatically review each screen at 1 second intervals or use the left and right cursor keys to manually review.

To display logged data in graphical form, on screen, proceed as follows from the File Summary menu:

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Memory Operations Datalog

Uploading Data Log Files

WARNING

THE RS232 INTERFACE MUST ONLY BE USED IN A SAFE AREA

Connect the RS232 socket of the instrument into either the COM1 or COM2 port of the PC. Ensure that the RS232 parameters set in the PC match those of the instrument. The RS232 parameters of the instrument can be checked as detailed on page 38. Set up a file on the PC to receive the data, (e.g.) in the Windows® Terminal program.

To upload a file, proceed as follows. Appendix 1 gives details of a typical uploaded data log file.

Delete Datalog and Procedure Files

To delete a Data Log file, or a procedure file (DPI 615 instruments only), proceed as follows. Alternatively, to delete all logged files simultaneously, select ERASE ALL FILES (F2) at the erase screen.

K0430 Issue No. 2 32

Page 43

Memory Operations Datalog

Downloading Procedure Files (DPI 615 instruments only)

WARNING

THE RS232 INTERFACE MUST ONLY BE USED IN A SAFE AREA

Complete test procedures may be downloaded from a PC to the DPI 615 instrument via the RS232 port. A procedure consists of a number of Druck Universal Command Interface (DUCI) commands that are usually assembled by a linking management software application (e.g.) Druck Intecal.

Before downloading a procedure, the instrument must be in the REMOTE mode. To place the instrument into REMOTE mode, proceed as follows.

• Connect the instrument’s RS232 port to a free COM port on a PC.

• Make sure that the COMMS parameters of the PC match those of the instrument (refer to page 38).

• Make sure that the instrument is not already running a procedure. If it is, quit the procedure.

• Download the procedure. Procedures are stored in the Data Log directory.

The following sequence shows a typical download sequence that starts with the instrument in LOCAL mode.

After the procedure file has been downloaded, the instrument is usually returned to the LOCAL mode by the last command in the procedure file. If the instrument remains in REMOTE mode, switch it OFF and ON to reset it.

33 K0430 Issue No. 2

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Memory Operations Datalog

Running Procedure Files (DPI 615 instruments only)

To run a procedure, make sure that the instrument is set to Store mode, Data Log (see page 36), and proceed as follows:

After selecting F1, proceed by entering the User ID and Serial Number and then select F1 (Continue) and follow the on-screen procedural instructions:

When the test procedure for a given UUT has been completed, the result of running the first test is stored as an AS FOUND file. This file cannot be overwritten. Any subsequent tests on the device are stored as an AS LEFT file that is overwritten each time the procedure on this device is run.

When recalling the results of a procedure, the choice of AS FOUND or AS LEFT is provided (refer to page 35).

K0430 Issue No. 2 34

Page 45

Memory Operations Datalog

Recalling Data Files (DPI 615 instruments only)

Data or results files generated by running procedures are stored in the instrument’s data log directory. To recall a data file to the display, make sure that DATA LOG is selected from the SETUP menu and proceed as follows:

Use the cursor keys to select either the AS FOUND option or the AS LEFT option for display. AS FOUND is the result of the first run of a procedure and AS LEFT is the result of the last time the procedure was run. Procedure data files can be displayed either as text (stored screens) or in graphical form. To display as text, select the TEXT option (F1) from the directory and proceed as follows from the File Summary menu. Select screen at 1 second intervals or use the left or right cursor keys to manually review.

AUTO STEP (F1) to automatically review each

To transmit the selected logged data via the RS232 interface, connect the instrument to a free COM port on a compatible PC, ensure that the instrument’s RS232 parameters match those of the PC. To display logged data in graphical form, on screen, select GRAPH (F2) from the directory

and proceed as follows:

35 K0430 Issue No. 2

Page 46

Using Setup

General

SETUP mode is available in all modes except BASIC and permits the changing of the

following instrument parameters.

• Store Mode - None, Snapshot, Data Log.

•Contrast.

• Settings - Units, Language, RS232 parameters, Powerdown and Calibration Routines

(Refer to page 41 for calibration details).

• Date and Time (Real T ime Clock).

Store Mode

Select STORE MODE from the Set-up menu and select required mode as follows:

Contrast Select CONTRAST from the Set-up menu and proceed as follows:

K0430 Issue No. 2 36

Page 47

Using Setup

Settings - Select Setup Option To select one of the SETTINGS options from the set-up menu, proceed as follows:

Units

Select

UNITS from the SETTINGS menu and proceed as follows:

Define Special Units

Select UNITS from the SETTINGS menu and select SPECIAL UNITS and proceed as follows:

37 K0430 Issue No. 2

Page 48

Using Setup

Language Select the LANGUAGE version required from the SETTINGS menu and proceed as follows:

RS232 Select RS232 from the SETTINGS menu and proceed as follows:

Note: Communications default settings are shown above.

If a communications problem occurs at a particular baud rate, change the baud rate on the instrument and PC to a lower rate.

K0430 Issue No. 2 38

Page 49

Using Setup

Powerdown

Select POWERDOWN from the SETTINGS menu and proceed as follows:

If selected to TIMER mode, following a period of inactivity, the instrument automatically powers off after the preset TIMER period.

If selected OFF, auto power off is inhibited and once switched on, the instrument remains ON until it is manually switched OFF.

Calibration

Refer to page 41 for a full description of the calibration procedures.

39 K0430 Issue No. 2

Page 50

Using Setup

Date and Time (Real Time Clock)

Date Format

To set-up the real time clock, select DATE & TIME from the set-up menu and, using the key, set the required date format:

Set Date

Select DATE from the DATE & TIME menu and, using the cursor keys, change the date as shown below. The up and down keys change the numerical value of the selected digit (indicated by the underline cursor) and the left and right keys select the required digit position.

Set Time

Select TIME from the DATE & TIME menu and, using the cursor keys, change the time as shown below. The up and down keys change the numerical value of the selected digit (indicated by the underline cursor) and the left and right keys select the required digit position.

K0430 Issue No. 2 40

Page 51

Calibration

General

The instrument is supplied by the manufacturer, complete with calibration certificate(s). A calibration period of 12 months is recommended. The actual calibration interval depends on instrument usage and the total measurement uncertainty acceptable for the specified application.

The DPI 610 IS and DPI 615 IS are very precise measuring instruments and the test equipment and conditions of test must be suitable for the type of work. A Class A compensated deadweight tester must be used. The calibration check and calibration adjustment should be carried out in a controlled environment by a calibration technician*.

The manufacturer offers a comprehensive and, if required, UKAS accredited calibration service.

* A calibration technician must have the necessary technical knowledge,

documentation, special test equipment and tools to carry out the calibration work on this equipment.

Calibration Check

At the chosen calibration interval, the instrument readings should be compared with a known pressure standard. The recommended method starts at 0, increasing in 20% steps to 100% full-scale and then decreasing in 20% steps to 0. Note any deviations between the instrument and the pressure standard and consider traceability (accuracy to a National Standard). If, after a calibration check, the results exceed the tolerance in the specification (or other suitable performance standard), carry out a calibration adjustment.

Calibration Adjustment

If the instrument is operating correctly, only zero and full-scale calibration will vary. Any excessive non-linearity or temperature effects indicate a fault. The instrument should be returned to a qualified service agent.

Guide to Calibration Procedures

• Use high quality Repeatable and Linear pressure sources and allow adequate

thermal stabilization time before calibration (minimum 1 hour).

• Conduct the calibration in a temperature controlled and preferably, humidity

controlled environment. Recommended temperature is 21°C, ±2°C (70°F, ±4°F).

• Use deadweight testers carefully and away from draughts.

• Review and become familiar with the whole calibration procedure before

commencing the calibration process.

• The calibration routines cannot be accessed when the instrument is in BASIC mode.

Use the TA SK key to select another mode (e.g.) ADVANCED before accessing the

CALIBRATION mode.

41 K0430 Issue No. 2

Page 52

Calibration

Test Equipment

The calibration procedures require the following test equipment.

Test Equipment and Instrument Parameter/Range

Digital Voltmeter - 5V input ±30 *ppm ±1 digit ±10 *ppm ±5µV

Digital Voltmeter - 30V input ±45 *ppm ±1 digit ±11 *ppm ± 110 µV

Digital milliammeter - 55mA input ±150 *ppm ±4 digit ±100 *ppm ± 1nA

Digital milliammeter - 24mA output ±150 *ppm ±4 digit ±160 *ppm ± 1nA

Precision thermometer - ambient temperature ±0.2°C ± 0.1°C ±1 digit

Deadweight tester - pressure internal/external Class A deadweight <0.025%

Calibration Equipment

Accuracy

Calibration

Uncertainty

*ppm = parts per million

Table 1 Internal/External Pressure Transducer Verification

Nominal applied value as a %

of ±full-scale

0% (10% for absolute ranges) ± 0.025% FS

20% ± 0.025% FS 40% ± 0.025% FS 60% ± 0.025% FS 80% ± 0.025% FS

100% ± 0.025% FS

80% ± 0.025% FS 60% ± 0.025% FS 40% ± 0.025% FS 20% ± 0.025% FS

0% (10% for absolute ranges) ± 0.025% FS

Permissible deviation

K0430 Issue No. 2 42

Page 53

SELECT OPTION

CALIBRATION

EXT SENSORS

CHANGE PIN

INT RANGES

Vvt

SET NEW PIN

SET NEW PIN AGAIN

Enter New PIN

5432

Enter New PIN

Calibration

Using the Calibration Menu

The calibration routines are selected from the Settings menu as detailed on page 37. Enter the calibration PIN code, initially set to 4321, press and the display shows the calibration menu.

PIN security

To prevent unauthorised access, it is recommended that the PIN code be changed as soon as possible.

Change PIN

To change the PIN code, select CHANGE PIN from the calibration menu and proceed as follows:

Note: To set and verify a new PIN, the new PIN code must be entered twice.

• If the second code entered differs from the first, the new PIN will not be set.

Calibrate Internal Ranges

Select the INT RANGES from the menu as shown above and follow the calibration procedure on the display.

43 K0430 Issue No. 2

Page 54

VOLTAGE IN

Calibration

Internal Pressure Range

Use the following procedure for calibrating the internal pressure range.

Note: If calibrating the hydraulic calibrator version, the calibrator must first be primed as

detailed on pages 57 to 64.

(1) Connect the outlet port of the instrument to a pressure standard. (2) Allow the instrument’s temperature to stabilize for a minimum of 1 hour. (3) Switch the instrument on, enter CALIBRATION mode and select INT RANGES from

the CALIBRATION menu and then PRESSURE INT.

(4) Apply zero pressure and store the zero point:

(5) Close the vent valve, apply full-scale pressure and store the full-scale point:

(6) Press the ENTER key to accept the calibration. Press the EXIT key four times to

(7) Check calibration by applying test pressures in Table 1, page 42.

K0430 Issue No. 2 44

quit CALIBRATION and SETUP modes.

Page 55

SELECT CAL OPTION

SELECT RANGE

30 VOLTS

5 VOLTS

CALIBRATION

VOLTAGE IN

CURRENT IN CURRENT OUT

PRESSURE INT

TEMPERATURE

55mA

Vin

mA in

mA Sink

max 30V

max

Cal V

DVM

Calibration

Voltage Input Range (5 Volts)

Use the following procedure for calibrating the internal 5 Volt range. (1) Switch the instrument on, enter CALIBRATION mode and select INT RANGES from

the CALIBRATION menu shown on page 43.

(2) Select 5V range for calibration:

(3) Link the voltage input terminals with a short lead and enter the zero point:

(4) Remove the shorting link from the voltmeter terminals, connect the Vin terminals

of the instrument to a variable voltage source and connect a digital voltmeter across the source:

45 K0430 Issue No. 2

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Calibration

(5) Set the variable supply voltage to 5V ± 0.1V and enter the measured full-scale

voltage applied:

(6) Press the ENTER key to accept the calibration. Press the EXIT key once to return

to the calibration menu or four times to quit the CALIBRATION and SETUP modes.

(7) Verify the instrument calibration by applying the test voltages given in Table 2

(page 48), to the voltmeter (after both voltage ranges have been calibrated).

(8) Disconnect the calibration/test equipment.

K0430 Issue No. 2 46

Page 57

SELECT CAL OPTION

SELECT RANGE

30 VOLTS

5 VOLT S

SELECT CAL OPTION

CALIBRATI ON

VOLTAGE IN

CURRENT IN CURRENT OUT

PRESSURE INT

TEMPERATU RE

CALIBRATING VOLTAGE

RANGE +/- 30V

Apply nominalzero value

Press ENTER key when applied value is stable

SET VALUE

CHANGE

VALUE

RUN

CALIBRATING VOLTAGE

RANGE +/- 30V

CALIBRATING VOLTAGE

RANGE +/- 30V

EnterApplied Value:

Store zero point ?

YES NO

55mA

Vin

mA in

mA Sink

max 30V

max

Cal V

DVM

Calibration

Voltage Input Range (30 Volts)

Use the following procedure for calibrating the internal 30 Volt range. (1) Switch the instrument on, enter CALIBRATION mode and select INT RANGES from

the CALIBRATION menu as shown on page 43.

(2) Select 30V range for calibration:

(3) Link the voltage input terminals with a short lead and enter the zero point:

(4) Remove the shorting link from the voltmeter terminals, connect the Vin terminals

of the instrument to a variable voltage source and connect a digital voltmeter across the source:

47 K0430 Issue No. 2

Page 58

CALIBRATING VOLTAGE

RANGE +/- 30V

Apply nominalFSvalue

Press ENTER key when applied value is stable

SET VALUE

CHANGE

VALUE

RUN

CALIBRATING VOLTAGE

RANGE +/- 30V

EnterApplied Value:

CHANGE

VALUE

RUN

CALIBRATING VOLTAGE

RANGE +/- 30V

EnterApplied Value:

CALIBRATING VOLTAGE

RANGE +/- 30V

Store FS point ?

YES NO

CALIBRATING VOLTAGE

RANGE +/- 30V

RESULTS m=1.395879e-05 c =-7.128004e+00

Applied Measured

0.0000 526380

29.984 873988

Calibration Complete

Press ENTER to continue

Calibration

(5) Set the variable supply voltage to 30V ±0.1V and enter the measured full-scale

voltage:

(6) Press the ENTER key to accept the calibration. Press the EXIT key four times to

quit the CALIBRATION and SETUP modes.

(7) Verify the instrument calibration by applying the test voltages given in Table 2 to

the voltmeter (after both voltage ranges have been calibrated).

(8) Disconnect the calibration/test equipment.

Voltage Calibration 30V Range Verification Tolerances Voltage Calibration 5V Range Verification Tolerances

Applied Voltage Permissible Deviation Applied Voltage Permissible Deviation

-30 ± 0.05% rdg, ± 0.004% FS -5 ± 0.05% rdg, ± 0.004% FS

-24 ± 0.05% rdg, ± 0.004% FS -4 ± 0.05% rdg, ± 0.004% FS

-18 ± 0.05% rdg, ± 0.004% FS -3 ± 0.05% rdg, ± 0.004% FS

-12 ± 0.05% rdg, ± 0.004% FS -2 ± 0.05% rdg, ± 0.004% FS

-6 ± 0.05% rdg, ± 0.004% FS -1 ± 0.05% rdg, ± 0.004% FS 0 ± 0.05% rdg, ± 0.004% FS 0 ± 0.05% rdg, ± 0.004% FS 6 ± 0.05% rdg, ± 0.004% FS 1 ± 0.05% rdg, ± 0.004% FS

12 ± 0.05% rdg, ± 0.004% FS 2 ± 0.05% rdg, ± 0.004% FS 18 ± 0.05% rdg, ± 0.004% FS 3 ± 0.05% rdg, ± 0.004% FS 24 ± 0.05% rdg, ± 0.004% FS 4 ± 0.05% rdg, ± 0.004% FS 30 ± 0.05% rdg, ± 0.004% FS 5 ± 0.05% rdg, ± 0.004% FS

Table 2 Electrical Voltage Input Calibration Tolerances

K0430 Issue No. 2 48

Page 59

55mA

Vin

mA in

max 30V

max

Calibration

Current Input Range (55 mA)

Use the following procedure for calibrating the current input range. (1) Switch the instrument on, enter CALIBRATION mode and select INT RANGES from

the CALIBRATION menu as shown on page 43.

(2) Select CURRENT IN range for calibration:

(3) Open circuit the mA in terminals and enter the zero point:

(4) Connect the mA in terminals of the instrument to a variable current source and

connect a digital milliammeter in series with the supply:

49 K0430 Issue No. 2

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Calibration

(5) Set the input current to 55 ±0.1mA and enter the measured full-scale input

current:

(6) Press the ENTER key to accept the calibration. Press the EXIT key four times to

quit the CALIBRATION and SETUP modes.

(7) Verify the instrument calibration by applying the test currents given in Table 3 to

the milliammeter.

(8) Disconnect the calibration/test equipment.

Current Calibration, 55mA Range Verification Tolerances

Applied Current (mA) Permissible Deviation

-55 ± 0.05% rdg ± 0.004% FS

-45 ± 0.05% rdg ± 0.004% FS

-35 ± 0.05% rdg ± 0.004% FS

-25 ± 0.05% rdg ± 0.004% FS

-15 ± 0.05% rdg ± 0.004% FS

-5 ± 0.05% rdg ± 0.004% FS 0 ± 0.05% rdg ± 0.004% FS 5 ± 0.05% rdg ± 0.004% FS

15 ± 0.05% rdg ± 0.004% FS 25 ± 0.05% rdg ± 0.004% FS 35 ± 0.05% rdg ± 0.004% FS 45 ± 0.05% rdg ± 0.004% FS 55 ± 0.05% rdg ± 0.004% FS

Table 3 Electrical Current Input Calibration Tolerances

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55mA

Vin

mA in

mA Sink

max 30V

max

Voltage source

Calibration

Current Output Range (24 mA)

Use the following procedure for calibrating the current output range.

(1) Switch the instrument on, enter CALIBRATION mode and select INT RANGES from

the CALIBRATION menu as shown on page 43.

(2) Select CURRENT OUT range for calibration:

(3) Connect a digital milliammeter to the instrument as shown below.

Note: This procedure requires an external supply.

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Measure 90% FS - output

Press ENTER key when applied value is stable

Store Cal point?

YES NO

Enter Measured Current:

RUN

OUTPUT

PRESSURE

mA STEP mA RAMP

mA VALUE

SELECT OUTPUT

INT

PRESSURE EXT

UNITS

TASK:ADVANCED SNAPSHOT MODE

VOLTAGE

TASK:ADVANCED SNAPSHOT MODE

Calibration

(4) Measure the 10% full-scale output current and enter the value measured on the

external milliammeter:

(5) Measure the 90% full-scale output current and enter the value measured on the

external milliammeter

(6) Press the ENTER key to accept the calibration. Press the EXIT key four times to

quit the CALIBRATION and SETUP modes.

(7) Verify the instrument’s output current calibration by setting up the loop test

currents as shown in Table 4 and checking the set values against the milliammeter standard.

(8) Connect an external voltage source shown on page 51, press the OUTPUT key,

select mA Value:

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VOLTAGE

TASK:ADVANCED SNAPSHOT MODE

VOLTAGE

TASK:ADVANCED SNAPSHOT MODE

VOLTAGE

TASK:ADVANCED SNAPSHOT MODE

Calibration

(9) Set the loop output current to 5 mA as shown below and check that the output

current, measured by the milliammeter standard is within the limits given in Table

(10) Repeat (9) for all output values given in Table 4.

Current Output Calibration, 24mA Range Verification

Applied Current (mA) Permissible Deviation

0 ± 0.05% rdg ± 0.01% FS 5 ± 0.05% rdg ± 0.01% FS

10 ± 0.05% rdg ± 0.01% FS 15 ± 0.05% rdg ± 0.01% FS 20 ± 0.05% rdg ± 0.01% FS 24 ± 0.05% rdg ± 0.01% FS 20 ± 0.05% rdg ± 0.01% FS 15 ± 0.05% rdg ± 0.01% FS 10 ± 0.05% rdg ± 0.01% FS

5 ± 0.05% rdg ± 0.01% FS 0 ± 0.05% rdg ± 0.01% FS

Tolerances

Table 4 Electrical Current Output Calibration Tolerances

(11) Disconnect the calibration/test equipment.

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Calibration

Ambient Temperature Channel

Use the following procedure for calibrating the ambient temperature measurement channel. (1) Switch the instrument on, enter the CALIBRATION mode and select

TEMPERATURE:

(2) Allow the instrument’s temperature to stabilize in the calibration environment for

at least one hour.

(3) Read the environmental temperature on a calibrated digital thermometer and

enter the recorded value as shown below. Example shown for a measured ambient temperature of 21.5° Celsius.

Note: Only one temperature point is required.

(4) Press the ENTER key to accept the calibration. Press the EXIT key once to return

to the calibration menu or four times to quit the CALIBRATION and SETUP modes.

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INT RANGES

CHANGE PIN

EXT SENSORS

Calibration

Calibrate External Sensors

Use the following procedure for calibrating external pressure sensors.

(1) Connect the required external transducer to the EXT TRANSDUCER socket located

on the rear of the instrument.

(2) Allow the instrument’s temperature and the temperature of the external

transducer to stabilize in the calibration environment for a minimum of 1 hour.

(3) Switch the instrument on, enter CALIBRATION mode and select EXT SENSORS

from the CALIBRATION menu:

(4) Select the transducer to be calibrated from the transducer menu using the

cursor keys and press ENTER:

(5) Connect the pressure standard to the inlet of the external transducer, apply the

If the sensor to be calibrated is not in the directory, or no sensors are listed in the directory, press the F1 key (ADD NEW SENSOR). This will place the sensor in the directory, allowing it to then be selected.

zero point pressure and store the zero point:

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(6) Apply the full-scale pressure to the external transducer and store the full-scale

CALIBRATING PRESSURE EXT

RANGE 20000 kPa g

CALIBRATING PRESSURE EXT

RANGE 20000 kPa g

CALIBRATING PRESSURE EXT

RANGE 20000 kPa g

Apply nominal FS value

Press ENTER key when applied value is stable

CHANGE VALUE

(FS) point.

(7) Release the applied pressure and disconnect the pressure reference. Press the

ENTER key to accept the calibration. Press the EXIT key once to return to the calibration menu or four times to quit the CALIBRATION and SETUP modes.

(8) Check the calibration of the external transducer by applying the test pressures as

detailed in Table 1, page 42.

Add External Sensor

To add an external sensor to the directory of external sensors, proceed as follows:

Digitally compensated transducers will be downloaded into the directory as soon as the F1 key is operated. Data for other types can be edited by selecting EDIT (F2). If the data cannot be edited a warning message (INVALID ACTION) is displayed.

K0430 Issue No. 2 56

• Connect the required external transducer to the EXT TRANSDUCER socket located on the rear of the instrument.

Page 67

Hydraulic Calibrator Versions

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Hydraulic Calibrator Versions Operation

Introduction (Figure A1)

These versions of the DPI 610 and DPI 615 intrinsically safe calibrators provide manual generation of hydraulic pressure and consist of a screw-press with a priming pump and isolation valve.

1 Isolation valve 2 Priming port 3 Bleed hose assembly 4 Priming pump 5 Screw-press 6 Bonded seal 7 UUT/system under test

Figure A1 - DPI 610/615 IS HC Connections

The internal hydraulic parts are brass, stainless steel, copper, nylon and fluorocarbon rubber (Viton). The hydraulic fluid can be either demineralized water or one of the hydraulic fluids listed below:

Caution: Only use the recommended hydraulic fluids.

DO NOT mix hydraulic fluids.

ISO 3448 Viscosity

grade

VG10 5W Tellus R10 Nuto H10 Velocite No. 6 VG15 Tellus T15

VG22 Tellus 22

VG32 10W Tellus V32 Nuto H32 DTE Oil Light

VG37 Tellus 37

Approx. SAE

Viscosity

Classification

Shell

Tellus V15

Tellus R22

Tellus R37 Tellus T37 Tellus V37

Esso

(Exxon)

Nuto H15

Nuto H22 DTE 22

Table A1 - Recommended Hydraulic Fluids

Mobil

DTE 24

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Hydraulic Calibrator Versions Operation

Safety Instructions WARNING HYDRAULIC FLUID IS INJURIOUS. OBSERVE RELEVANT HEALTH AND SAFETY

PRECAUTIONS. USE APPROPRIATE PROTECTIVE BARRIERS AND EYE PROTECTION.

BEFORE APPLYING PRESSURE, EXAMINE ALL FITTINGS AND EQUIPMENT FOR DAMAGE AND ENSURE THAT ALL EQUIPMENT IS TO THE CORRECT PRESSURE RATING.

DO NOT EXCEED THE MAXIMUM WORKING PRESSURE OF THE INSTRUMENT (INDICATED ON START-UP SCREEN AT SWITCH-ON).

Caution: Observe absolute cleanliness when using the instrument .

Severe damage can be caused if equipment connected to this instrument is contaminated. Connect only clean equipment to the instrument. To avoid any contamination, an external filter is recommended.

Preparation for Use (Figure A1)

• Use an appropriate seal and connect the bleed hose assembly (3) to the priming port.

• Make sure that the screw-press (5) is wound fully in (clockwise).

• Make sure that the isolation valve (1) is open (fully counter clockwise).

• Use a bonded seal (6) and connect the unit or system under test (7) to the pressure port.

WARNING

MAKE SURE THAT THE CONNECTING LINE TO THE EXTERNAL DEVICE OR SYSTEM IS CAPABLE OF WITHSTANDING THE LINE PRESSURE TO BE APPLIED.

Note: A bleed point must be provided on the external device.

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Hydraulic Calibrator Versions Operation

1 Bleed hose assembly 2 Priming pump 3 Screw-press 4 UUT/system under test 5 UUT bleed valve 6 Isolation valve O- Open C- Closed

Figure A2 - Priming/Test Set-up

Bleeding the System (Figure A2)

Before any measurements can be made, the hydraulic system needs to be primed and bled free of air. During the following operations, prepare for fluid spillage and provide a suitable receptacle for collecting the spillage.

1. Prepare for use as detailed on page 62.

2. Fill a suitable container with clean hydraulic fluid and place the bleed hose assembly

(1) connected to the priming port into the fluid.

3. Open the UUT bleed valve (5) and, if possible, fit a hose to the bleed point and locate

the hose end in a container of the same hydraulic fluid.

4. Use the priming pump (2), to pump hydraulic fluid into the instrument and the

connected system. Monitor the hydraulic fluid level, ensuring that the bleed hose assembly (1) stays below the fluid level and is not allowed to suck in air. Top-up hydraulic fluid level as necessary.

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Hydraulic Calibrator Versions Operation

5. Continue use of the priming pump (2) until only hydraulic fluid and no air is expelled

from the bleed point.

6. Close the UUT bleed valve (5) when the priming pump (2) is at the bottom of its stroke

(fully pushed in) and slowly wind out the screw-press (3) to its fullest extent to draw in further hydraulic fluid (approx. 7cc or 0.43 in

7. Switch the instrument ON and, still using the priming pump (2), pressurize the

system to approximately 2 bar (30 psi).

8. Close the isolation valve (6) disconnect the bleed hose assembly (1) from the priming

port.

Operation

To obtain a pressure reading, proceed as follows.

1. Switch the instrument ON and select the required TASK.

2. Rotate the screw-press clockwise to increase the applied pressure.

Note: When hydraulic fluid is compressed and flows through a restriction, there is an

increase in temperature that affects the pressure. Allow sufficient time for this pressure reading to stabilize before recording or logging a reading.

3. After testing, reduce the pressure in the system to zero by turning the screw-press

counter clockwise. Before disconnecting the UUT, open the isolation valve.

4. Remove the connection to the UUT and fit a blanking plug into the instrument’s

pressure port. Clean any spilt fluid off the instrument case.

Draining the Hydraulic Fluid (Figure A3)

To drain the hydraulic fluid from the instrument, proceed as follows:

1. Turn the isolation valve (4) fully counter clockwise. Turn the instrument onto the left

hand side (pressure port nearest to the work bench). Place receptacle below the pressure port to collect hydraulic fluid.

2. Drain the system by slowly winding in the screw-press (3) and then depressing the

priming pump (2) plunger to expel any fluid remaining in the instrument.

3. If necessary, apply an air line to the priming port to clear any remaining fluid out of

the instrument.

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Hydraulic Calibrator Versions Operation

Flushing - Replenishing or Changing the Hydraulic Fluid (Figure A3)

If necessary, to remove any contaminants, flush out the hydraulic system as follows.

a. Connect the bleed hose assembly (1) to the priming port and a bleed hose to the

pressure port as shown below:

1 Bleed hose assembly 2 Priming pump 3 Screw-press 4 Isolation valve O - Open C - Closed

Figure A3 - Flushing/Filling Connections

b. Fill the priming fluid container with clean hydraulic fluid of the required type. Use

the priming pump (2), to pump fresh hydraulic fluid through the system until clean hydraulic fluid, free of air bubbles, emerges into the container at the output port. Discard the contaminated fluid expelled during this process.

c. Remove the bleed hose assembly (1) located to the output port and, to prevent

the ingress of any contaminant, fit a blanking plug in its place.

d. Close the isolation valve (4) and remove the bleed hose assembly (1) from the

priming inlet.

e. Clean off any surplus oil that may have spilled onto the instrument casing.

The instrument is now ready for operation or storage. If storing, apply a label detailing the type of hydraulic fluid contained in the instrument. For long term storage, it is

recommended that the instrument be drained and stored empty.

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Appendix 1

DATA LOG FILE EXAMPLE

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Typical Uploaded Data log File (DPI 610)

The following gives details of a typical data file upload.

FILENAME: TEST 5 DATE: 21/10/2006 TIME: 15:58 TRIGGER: KEYPRESS AMBIENT TEMP : 24.1 C

NO. OF POINTS 11 RECORD TYPE 0 CURRENT mA PRESSURE INT bar

3.902 0.008 -0.65 %span 21/10/2006 15:58:55

6.076 2.311 1.42 %span 21/10/2006 16:00:03

7.598 4.404 0.47 %span 21/10/2006 16:00:57

8.085 5.023 0.41 %span 21/10/2006 16:01:45

9.949 7.249 0.94 %span 21/10/2006 16:02:42

13.002 11.300 -0.23 %span 21/10/2006 16:03:30

17.005 16.102 0.77 %span 21/10/2006 16:05:00

17.766 17.106 0.51 %span 21/10/2006 16:06:07

17.812 17.105 0.80 %span 21/10/2006 16:07:49

18.532 17.965 1.00 %span 21/10/2006 16:16:35

20.007 20.212 -1.02 %span 21/10/2006 16:18:23

The Record Type number contained in the header is a 16-bit field, with the individual bits representing result formats as detailed below. Record Type 1 P-Display Record Type 2 Switch Test Record Type 4 Leak Test Record Type 8 Input channel: Min/Max ON Record Type 120 Combination of all input process functions Record Type 896 Combination of all output process functions Record Type 1024 mA step mode Record Type 2048 mA value mode Record Type 4096 mA ramp mode Record Type 8192 no input selected Record Type 16384 no output selected

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