GE
Sensing & Inspection Technologies
Pressure Automated Calibration Equipment
User manual K0443
PACE5000
PACE6000
g
© The General Electric Company. All rights reserved
This technical manual provides operating instructions for the PACE Pneumatic Pressure Controllers.
The features shown and described in this manual may not be available on some models.
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 maximum working pressure to the equipment.
Toxic Materials
There are no known toxic materials used in construction of this equipment.
Maintenance
The equipment must be maintained using the procedures in this publication. Further manufacturer’s procedures should be carried out by authorized service agents or the manufacturer’s service departments.
Technical Advice
For technical advice contact the manufacturer.
* A qualified technician must have the necessary technical knowledge, documentation, special test equipment and tools to carry out the required work on this equipment.
K0443 Issue No. 3 |
i |
Abbreviations
The following abbreviations are used in this manual; the abbreviations are the same in the singular and plural.
abs |
Absolute |
a.c. |
Alternating current |
ALT |
Altitude |
BSP |
British pipe thread |
CAS |
Calculated airspeed |
CSK |
Countersunk |
d.c. |
Direct current |
DPI |
Digital Pressure Instrument |
e.g. |
For example |
etc. |
And so on |
Fig. |
Figure |
ft |
Foot |
g |
Gauge |
Hg |
Mercury |
HTS |
High tensile steel |
Hz |
Hertz |
IAS |
Indicated airspeed |
i.e. |
That is |
IEC |
International Electrotechnical Commission |
IEEE 488 |
Institute of Electrical and Electronic Engineers standard 488 data |
in |
Inch |
kg |
Kilogram |
kts/kn |
knot |
LCD |
Liquid crystal display |
m |
Metre |
mA |
Milliampere |
max |
Maximum |
mbar |
Millibar |
min |
Minute or minimum |
mm |
Millimetre |
mV |
Millivolts |
MWP |
Maximum working pressure |
No. |
Number |
NPT |
National Pipe Thread |
PACE |
Pressure Automated Calibration Equipment |
Para. |
Paragraph |
PDCR |
Pressure transducer |
PED |
Pressure Equipment Directive |
psi |
Pounds per square inch |
PTX |
Pressue transmitter |
K0443 Issue No. 3 |
ii |
ROC |
Rate of Climb |
RS232 |
Serial communications data standard |
SCPI |
Standard Commands for Programmable Instruments |
UUT |
Unit under test |
V |
Volts |
VFC |
Volts-free contact |
+ve |
Positive |
-ve |
Negative |
°C |
Degrees Celsius |
Associated publications
K0447 PACE 5000/6000 User Guide and Safety Instructions
K0450 PACE Series Calibration Manual
K0476 Pressure Control Module User Guide and Safety Instructions
K0472 Remote Communications Manual
K0469 Heritage Communications Manual - Instrument Emulation
Symbols
The equipment contains the following symbols to identify hazards.
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, on the instrument, indicates do not throw-away in domestic bin, hazardous material, dispose correctly in accordance with local regulations.
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K0443 Issue No. 3 |
iii |
Pressure units and conversion factors
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Pressure units |
Factor (hPa) |
Pressure units |
Factor (hPa) |
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mbar |
1.0 |
cmH2O @ 20°C |
0.978903642 |
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bar |
1000.0 |
mH2O @ 20°C |
97.8903642 |
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Pa (N/m2) |
0.01 |
kg/m2 |
0.0980665 |
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hPa |
1.0 |
kg/cm2 |
980.665 |
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kPa |
10.0 |
torr |
1.333223684 |
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MPa |
10000.0 |
atm |
1013.25 |
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mmHg @ 0°C |
1.333223874 |
psi |
68.94757293 |
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cmHg @ 0°C |
13.33223874 |
lb/ft2 |
0.4788025898 |
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mHg @ 0°C |
1333.223874 |
inH2O @ 4°C |
2.4908891 |
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inHg @ 0°C |
33.86388640341 |
inH2O @ 20°C |
2.486413 |
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mmH2O @ 4°C |
0.0980665 |
inH20 @ 60°F |
2.487641558 |
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cmH2O @ 4°C |
0.980665 |
ftH2O @ 4°C |
29.8906692 |
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mH2O @ 4°C |
98.0665 |
ftH2O @ 20°C |
29.836983 |
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mmH2O @ 20°C |
0.097890364 |
ftH20 @ 60°F |
29.8516987 |
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Unit Conversion
To convert FROM pressure VALUE 1 in pressure UNITS 1
TO pressure VALUE 2 in pressure UNITS 2, calculate as follows: VALUE 2 = VALUE 1 x FACTOR 1
FACTOR 2
Note:
The PACE instrument contains selectable pressure units and user defined units. Use the conversion factors to calculate a user defined unit from the table above. Refer to the data sheets SDS0001 or SDS0008 for the list of selectable pressure units.
K0443 Issue No. 3 |
iv |
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CONTENTS |
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Section |
Title |
Page |
1 |
Description...................................................................................................................... |
1-1 |
1.1 |
Introduction .................................................................................................................... |
1-1 |
2 |
Installation....................................................................................................................... |
2-1 |
2.1 |
Packaging........................................................................................................................ |
2-1 |
2.2 |
Packaging for Storage and Transportation..................................................... |
2-1 |
2.3 |
Preparation for Use..................................................................................................... |
2-1 |
2.4 |
Pneumatic connections ............................................................................................ |
2-2 |
2.5 |
Rack-mount option ..................................................................................................... |
2-7 |
2.6 |
Electrical connections................................................................................................ |
2-8 |
3 |
OPERATION...................................................................................................................... |
3-1 |
3.1 |
Preparation ..................................................................................................................... |
3-1 |
3.2 |
Power-up Sequence ................................................................................................... |
3-2 |
3.3 |
Measure Mode............................................................................................................... |
3-3 |
3.4 |
Control Mode.................................................................................................................. |
3-5 |
3.5 |
Operation and Example Procedures................................................................... |
3-8 |
3.6 |
Global Set-up ................................................................................................................. |
3-12 |
3.7 |
Barometric Reference Option................................................................................. |
3-13 |
3.8 |
Supervisor Set-up ........................................................................................................ |
3-14 |
3.9 |
Instrument Status ........................................................................................................ |
3-15 |
K0443 Issue No. 3 |
v |
4 |
MAINTENANCE............................................................................................................... |
4-1 |
4.1 |
Introduction .................................................................................................................... |
4-1 |
4.2 |
Visual inspection .......................................................................................................... |
4-1 |
4.3 |
Cleaning ........................................................................................................................... |
4-1 |
4.4 |
Test ..................................................................................................................................... |
4-1 |
4.5 |
Calibration....................................................................................................................... |
4-1 |
4.6 |
Replacement parts...................................................................................................... |
4-2 |
4.7 |
Fuse replacement........................................................................................................ |
4-2 |
4.8 |
Filter replacement ....................................................................................................... |
4-4 |
4.9 |
Pressure module replacement .............................................................................. |
4-5 |
5 |
TESTING AND FAULT FINDING................................................................................. |
5-1 |
5.1 |
Introduction .................................................................................................................... |
5-1 |
5.2 |
Standard Serviceability Test ................................................................................... |
5-1 |
5.3 |
Fault Finding................................................................................................................... |
5-2 |
5.4 |
Approved Service Agents ......................................................................................... |
5-3 |
6 |
REFERENCE AND SPECIFICATION .......................................................................... |
6-1 |
6.1 |
Installation notes.......................................................................................................... |
6-1 |
6.2 |
Operational Requirements ...................................................................................... |
6-4 |
6.3 |
Icons.................................................................................................................................. . |
6-6 |
6.4 |
Measure Set-up............................................................................................................. |
6-9 |
6.5 |
Control Set-up................................................................................................................ |
6-10 |
6.6 |
Global Set-up ................................................................................................................. |
6-11 |
6.7 |
Supervisor Set-up ........................................................................................................ |
6-12 |
6.8 |
Options.............................................................................................................................. |
6-15 |
K0443 Issue No. 3 |
vi |
6.8 |
Calibration....................................................................................................................... |
6-28 |
6.9 |
Communications - Instrument Emulation....................................................... |
6-29 |
6.10 |
Specification................................................................................................................... |
6-29 |
6.11 |
Return Goods/Material Procedure....................................................................... |
6-29 |
6.12 |
Packaging Procedure................................................................................................. |
6-30 |
K0443 Issue No. 3 |
vii |
intentionally left blank
K0443 Issue No. 3 |
viii |
PACE Pressure Controller User Manual
The PACE5000 single-channel and PACE6000 single/dual-channel, Pressure Automated Calibration Equipment measures and controls pneumatic pressures and displays, on a touch-screen, the pressure measurement and controller status. The touch-screen enables selections and settings in both measure and control modes. The instrument can be operated remotely through communication interfaces.
Figure 1-1 PACE5000 General view
Figure 1-2 PACE6000 General view
The rear of the instrument houses all the electrical and pneumatic output and input connections. The electrical connections provide an a.c. power supply, serial and parallel communication interfaces, d.c. output and logic input and output. The system pneumatic controller module contains a positive and negative pressure supply port, an output port, vent port and reference port.
K0443 Issue No. 3 |
1 - 1 |
1 Description
The instrument can be mounted in a standard 19 inch rack system (rack-mount option).
Figure 1-3 PACE5000 Rear view
Figure 1-4 PACE6000 Rear view
Options available for the PACE5000 and PACE6000 are detailed in datasheet SDS0001 (PACE5000) and SDS00008 (PACE6000).
Further information and notes on applications are available in section 6 of this manual and on the GE Sensing & Inspection web site at www.gesensinginspection.com.
K0443 Issue No. 3 |
1 - 2 |
PACE Pressure Controller User Manual
On receipt of the PACE5000 or PACE6000 check the contents of the packaging against the following list:
i)PACE5000 or PACE6000 Pressure Controller.
ii)Cable, power supply.
iii)User guide and CD (UD-0001) containing the full documentation suite.
iv)Pneumatic Control Module blanking plate (keep this plate for future use).
CAUTIONS:
1.AFTER REMOVING A CONTROL MODULE, USE A BLANKING PLATE TO KEEP THE FLOW OF COOLING AIR.
2.AFTER UNPACKING AN INSTRUMENT THAT HAS BEEN IN COLD CONDITIONS ALLOW TIME TO STABILISE AND ANY CONDENSATION TO EVAPORATE.
To store the instrument or to return the instrument* for calibration or repair carry out the following procedures:
1.Pack the instrument as detailed in section 6.8, Reference and Specification.
2.Return the instrument for calibration or repair complete the return goods procedure detailed in section 6.8, Reference and Specification.
*This procedure also applies to the pressure control module as a separate item.
The instrument can be used as a:
•Free-standing instrument positioned on a horizontal surface.
•Rack-mounted in a standard 19 inch rack using the rack-mount accessory option kit (refer to section 2.5).
For free-standing instruments, use the two front feet on the base to elevate the instrument to provide a better viewing angle.
Note: The cooling air outlet on the underside of the instrument must not be obstructed. Allow a free flow of air around the instrument, especially at high ambient temperatures.
K0443 Issue No. 3 |
2 - 1 |
2 Installation
2.4 Pneumatic connections WARNINGS:
TURN OFF THE SOURCE PRESSURE AND CAREFULLY VENT THE PRESSURE LINES BEFORE DISCONNECTING OR CONNECTING THE PRESSURE LINES. PROCEED WITH CARE.
ONLY USE EQUIPMENT WITH THE CORRECT PRESSURE RATING.
BEFORE APPLYING PRESSURE, EXAMINE ALL FITTINGS AND EQUIPMENT FOR DAMAGE. REPLACE ALL DAMAGED FITTINGS AND EQUIPMENT. DO NOT USE ANY DAMAGED FITTINGS AND EQUIPMENT.
Connection |
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adaptor |
Input |
supply + |
G 1/8 |
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supply - |
G 1/8 |
Output |
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G 1/8 |
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Vent |
G 1/8 |
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Reference |
G 1/8 |
Refer to the data sheets SDS0001 or SDS0008 for a complete range of adaptors.
Pressure supply (Figure 2-1)
1.The pressure supply must be clean, dry gas, nitrogen or air and at the correct pressure, refer to the specification (Section 6).
2.Ensure the user systems can be isolated and vented.
3.Connect pressure and vacuum supplies to the SUPPLY + and SUPPLY - connection ports.
4.Connect the Unit Under Test (UUT) to the required outlet connection port.
Example instrument
1 BSP connector 2 Bonded seal
Note: For instruments with NPT connections, use adequate pressure sealing.
Figure 2-1, Pneumatic Connections
K0443 Issue No. 3 |
2 - 2 |
PACE Pressure Controller User Manual
Installation
The instrument requires a positive pressure supply, instruments operating in an absolute range or negative pressure range require a vacuum supply. A vacuum supply should be used for a fast response for instruments operating near atmospheric pressure. For dual channel operation two independent pressure and vacuum supplies can be used.
Important notes
When using two pressure modules, make sure that the modules are compatible, refer to Section 4.9. All connections must comply with the Pressure Equipment Directive (PED).
When connecting the output ports of two pressure modules together make sure both are either:
•below 70 bar. OR
•between 100 to 210 bar.
To comply with the Pressure Equipment Directive (PED) do not mix these categories.
Supply equipment
Pneumatic supplies should have isolation valves and, where necessary, conditioning equipment. The positive pressure supply should be regulated to between 110% of the full-scale pressure range and MWP stated on the control module.
To protect the control module, for ranges above 100 bar, from over-pressure a suitable protection device (such as a relief valve or bursting disc) must be fitted to limit the applied supply pressure to below the MWP.
On instruments without a negative supply, the positive pressure discharges from the system to atmosphere through the negative supply port. Fit the diffuser to the negative port to diffuse airflow.
During system pressure vent operations, the pressure discharges from the system to atmosphere through the vent port. Fit a diffuser to the vent port to diffuse airflow.
K0443 Issue No. 3 |
2 - 3 |
2 Installation
Pneumatic Connection Examples (Figures 2-2 and 2-4)
These examples show a single channel connection detail using supply equipment described above.
SUPPLY |
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OUTLET VENT REF |
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a |
Figure 2-2, Pneumatic Connections without vacuum supply
Key to Figure 2-2
1 |
Pressure source |
2 |
Conditioner |
3 |
Filter |
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4 |
Regulate to between 110% full-scale and MWP |
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5 |
Diffuser * |
6 |
Unit under test |
7 |
Optional reservoir † |
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8 |
Protection device |
9 |
Optional differential connection |
a |
atmosphere |
Notes: Refer to Section 6 Reference and Specification for details of other system components.
*High pressure gas exhaust - depending on pressure range.
†Optimum controller transient response and minimum time to set-point may be degraded if either the pneumatic supply or vacuum system has restricted flow. Installing a reservoir volume, which has larger capacity than the load volume, located in close proximity to the controller supply ports can improve the controller response.
To protect the control module, for ranges above 100 bar, from over-pressure a suitable protection device (such as a relief valve or bursting disc) must be fitted to limit the applied supply pressure to below the MWP.
Optional differential connection kit.
K0443 Issue No. 3 |
2 - 4 |
PACE Pressure Controller User Manual
SUPPLY |
OUTLET VENT REF |
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11 |
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13 |
a |
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* |
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Figure 2-3, Pneumatic Connections with vacuum supply |
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Key to Figure 2-3
1 |
Pressure source |
2 |
Conditioner |
3 |
Filter |
4 |
Regulate to between 110% full-scale and MWP |
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5 |
Diffuser* |
6 |
Unit under test |
7 |
Optional reservoir † |
8 |
Protection device |
9 |
Optional differential connection |
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10 |
Oil mist trap |
11 |
Vacuum source |
12 |
Normally open electrical release valve |
13 |
Check valve ‡ |
a |
atmosphere |
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Notes:Refer to Section 6 Reference and Specification for details of other system components.
*High pressure gas exhaust - depending on pressure range.
†Optimum controller transient response and minimum time to set-point may be degraded if either the pneumatic supply or vacuum system has restricted flow. Installing a reservoir volume, which has larger capacity than the load volume, located in close proximity to the controller supply ports can improve the controller response.
‡Optional vacuum system kit.
To protect the control module, for ranges above 100 bar, from over-pressure a suitable protection device (such as a relief valve or bursting disc) must be fitted to limit the applied supply pressure to below the MWP.
Optional differential connection kit.
K0443 Issue No. 3 |
2 - 5 |
2 Installation
SUPPLY |
OUTLET VENT REF |
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11 |
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13 |
a |
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*
12
Figure 2-4, Pneumatic Connections with negative gauge pressure generator Key to Figure 2-4
1 |
Pressure source |
2 |
Conditioner |
3 |
Filter |
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4 |
Regulate to between 110% full-scale and MWP |
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5 |
Diffuser * |
6 |
Unit under test |
7 |
Optional reservoir † |
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8 |
Protection device |
9 |
Optional differential connection |
a |
atmosphere |
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10 |
Vacuum generator ‡ |
11 |
Source pressure (regulated compressed air supply) |
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12 |
Exhaust to atmosphere |
13 |
Check valve ‡ |
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Notes:Refer to Section 6 Reference and Specification for details of other system components.
*High pressure gas exhaust - depending on pressure range.
†Optimum controller transient response and minimum time to set-point may be degraded if either the pneumatic supply or vacuum system has restricted flow. Installing a reservoir volume, which has larger capacity than the load volume, located in close proximity to the controller supply ports can improve the controller response.
‡Optional negative gauge generator kit.
To protect the control module, for ranges above 100 bar, from over-pressure a suitable protection device (such as a relief valve or bursting disc) must be fitted to limit the applied supply pressure to below the MWP.
Optional differential connection kit.
K0443 Issue No. 3 |
2 - 6 |
PACE Pressure Controller User Manual
2.5 Rack-mount option (Figure 2-5) General
There must be enough space at the rear of the instrument for all the cables and pipes. The length of the cables and pipes must allow for the removal and fitment of the instrument. The cooling air of the instrument must not be obstructed. Allow a free flow of air through the equipment rack and around the instrument, especially at high ambient temperatures.
Example instrument
Figure 2-5 Rack-mounting
Procedure
• Locate and secure the back brackets |
to the rear of the equipment rack. |
• Unscrew and remove the four countersunk screws from each of the instrument side panels.
• Locate the two brackets on each side of the instrument and secure with the four countersunk screws.
• Support the instrument and connect the cables and pipes.
K0443 Issue No. 3 |
2 - 7 |
2 Installation
•Refer to the electrical connections below before finally fitting the instrument into the equipment rack.
•Temporarily locate and screw in the two spigots* to each side of the equipment rack.
•Locate and slide the instrument into the rack, locating the instrument on the spigots*.
•Secure the instrument in the equipment rack with two of the screws and washers (supplied).
•Remove the two spigots* and replace with the remaining two screws and washers (supplied).
2.6 Electrical connections WARNINGS
1.THE GROUND LEAD OF THE INSTRUMENT MUST BE CONNECTED TO THE AC SUPPLY PROTECTIVE SAFETY GROUND.
2.ISOLATE THE POWER SUPPLY BEFORE MAKING ANY ELECTRICAL CONNECTIONS TO THE REAR PANEL.
General
The instrument must be connected to the correct electrical power supply as stated on a label next to the power connector. Also see section 6 Reference and Specification.
Make sure that the power supply is off before connecting the power cable.
Requirements for rack-mounted instruments
•Install an isolator in the power supply circuit. The power supply connector and switch on the rear panel of the instrument will not be accessible.
•Set the power supply isolator to OFF. Connect the power supply and set the power supply switch to ON before sliding the instrument into the rack.
•Set the power supply isolator to ON .
Check that the front panel display shows the power-up sequence.
Connecting (Figure 2-6)
To connect the power supply to the instrument proceed as follows:
•Insert the IEC power connector (1) into the power supply connector at the rear of the instrument.
•Set the ON/OFF switch to ON.
•Check that the front panel display shows the power-up sequence.
K0443 Issue No. 3 |
2 - 8 |
PACE Pressure Controller User Manual
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1 |
IEC power connector 2 |
Fuse carrier |
3 |
Fuse |
Figure 2-6 Electrical Connections
Pressure Control Module Input and Output Connectors
24V DC Output @ 100mA maximum
Using a 4-way connector: |
pin “+” |
= |
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pin “-” |
= |
This facility can energise external equipment.
+24 Vdc
0 Vdc
An integral self-resetting fuse protects this output.
Logic (switch) Input |
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Using a 4-way connector: |
Input |
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Output |
This facility can be used to trigger the instrument from a pressure switch contact during the Pressure Switch Task (see Section 3.4). Connections are not polarised and can be connected either way. Integral opto-isolators protect this input circuit.
K0443 Issue No. 3 |
2 - 9 |
2 Installation
Communication Connections
Connect the appropriate connectors into the rear panel communications ports and, if appropriate, secure with the captive screws.
Note: The RS232 and IEEE 488 interfaces are both enabled at power-up. Set the required parameters in Supervisor Setup/communications menu, see Section 3.8.
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Figure 2-7, Communication Connectors |
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1 |
RS232 |
2 |
Canbus (option) 3 |
IEEE488 |
4 |
USB B |
5 |
USB A |
6 |
Ethernet (option) |
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RS232 Interface
When using the RS232 interface, a cable must be connected directly from the instrument to a suitable port on the computer in a ‘point to point’ link. The pin connections for the 9-pin D-type, RS232 connector and the relationship between the instrument and the RS232 control signals, together with device interconnection interface is shown in Table 2-1. The instrument is configured as Data Circuit Terminating Equipment (DCE).
K0443 Issue No. 3 |
2 - 10 |
PACE Pressure Controller User Manual
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Instrument |
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Control Line |
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Computer/Printer |
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Instrument |
Connector |
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Signal |
RS232 |
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Function |
9-way |
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Direction |
Terminology |
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D-type |
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9-way |
25-way |
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D-type |
D-type |
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Pin No. |
Pin No. |
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RxD (I/P) |
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3 |
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TxD |
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3 |
2 |
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TxD (O/P) |
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2 |
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RxD |
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2 |
3 |
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GND |
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5 |
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GND |
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5 |
7 |
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CTS (I/P) |
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7 |
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RTS |
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7 |
4 |
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RTS (O/P) |
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8 |
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CTS |
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8 |
5 |
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Pulled |
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RLSD |
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high |
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1 |
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1 |
8 |
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(DCD) |
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internally |
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Not |
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4 |
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DTR |
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4 |
20 |
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connected |
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Pulled |
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DSR |
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high |
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6 |
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6 |
6 |
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DCE Ready |
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internally |
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Equipment |
Connector |
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Cable |
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- |
1 |
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chassis |
shell |
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Screen |
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Table 2-1, RS232 Connections |
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Handshaking connections |
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Software handshaking use: |
TXD, RXD and GND. |
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Hardware handshaking use: |
TXD, RXD, GND, CTS, RTS and DTR. |
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K0443 Issue No. 3 |
2 - 11 |
2 Installation
IEEE 488 Interface
This interface complies with IEEE 488 standard. The IEEE 488 parallel interface connects a computer/controller to one or more PACE instrument and possibly other instruments. Up to 30 instruments can be connected through a high-speed data bus to the computer/controller.
Note: The length of each IEEE 488 cable must be less than 3 metres to comply with the EMC requirements, see Section 6 Reference and Specification.
Single Unit Installation (Figure 2-8)
Connect an IEEE 488 connector/cable assembly to the rear panel IEEE 488 connector of the instrument.
•Connect the other end of the connector/cable assembly to the IEEE 488 connector on the controller/computer.
•Change the IEEE 488 communication parameters as described in the Supervisor set-up (refer to Section 6.7).
Multiple Unit Installation (Figure 2-8)
To install multiple units use stacking plugs to link from first instrument to the second instrument. Proceed as follows.
•Connect a pair of IEEE 488 stacking connectors to the rear panel IEEE 488 connector of the instrument
1Connector to rear panel of first instrument.
2Connector from controller/computer.
3Connector to rear panel of second instrument.
•Connect the other end of one of the connectors to the IEEE 488 connector on the controller/ computer and the other connector into the next instrument
1
2
3
•Repeat this procedure for all the instruments in the system.
•Use the Supervisor set-up (communications) menu on each instrument to set-up the required communication parameters (refer to Section 3.8).
K0443 Issue No. 3 |
2 - 12 |
PACE Pressure Controller User Manual
Figure 2-8 - IEEE 488 Connection
K0443 Issue No. 3 |
2 - 13 |
2 Installation
intentionally left blank
K0443 Issue No. 3 |
2 - 14 |