Fluke E-DWT-10000-AF User Manual

E-DWT-10000-AF

Electronic Deadweight Tester

Operation and Maintenance Manual

NSN 6685-01-566-1341

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

High pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases can be released unexpectedly and with extreme force. High pressure systems should be assembled and operated only by personnel who have been instructed in proper safety practices.

This instrument is not to be operated in any other manner than that specified by the manufacturer.

form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments, a

Fluke Company 4765 East Beautiful Lane, Phoenix AZ 85044-5318, USA. DH Instruments makes sincere efforts to ensure accuracy and quality of its’ published materials; however, no warranty, expressed

or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the English version and other language versions, the English version predominates.

Products described in this manual are manufactured under international patents and one or more of the following U.S. patents: 5,142,483; 5,257,640; 5,331,838; 5,445,035. Other U.S. and international patents pending.

AutoRange, AutoZ, DH Instruments, DH, DHI, CalTool, COMPASS, E-DWT, RPM4-E-DWT, QDUT, Q-RPT and SDS are trademarks, registered and otherwise, of DH Instruments, a Fluke Company.

Document No. 3338242 DHI Document No. 550166b 080624 Printed in the USA

AABBLLEE

OONNTTEENNTTS

TABLE OF CONTENTS ...............................................................I

TABLES.................................................................................. V

FIGURES................................................................................VI

ABOUT THIS MANUAL............................................................ VII

1. INTRODUCTION ................................................................. 1

1.1 PRODUCT OVERVIEW ...........................................................................................................................1

1.2 SPECIFICATIONS ...................................................................................................................................2

1.2.1 GENERAL SPECIFICATIONS.......................................................................................................................2

1.2.2 BATTERY AND CHARGER PACK...............................................................................................................3

1.2.3 PRESSURE MEASUREMENT SPECIFICATIONS .......................................................................................3

1.2.3.1 REFERENCE PRESSURE TRANSDUCERS (RPT) .................................................................................3

1.2.3.2 ON-BOARD BAROMETER ........................................................................................................................4

1.3 VIEWS AND SCHEMATICS ....................................................................................................................4

1.3.1 E-DWT-10000-AF VIEWS..............................................................................................................................4

1.3.1.1 FRONT VIEW.............................................................................................................................................4

1.3.1.2 REAR VIEW ...............................................................................................................................................5

1.3.2 RPM4-E-DWT REFERENCE PRESSURE MONITOR VIEWS......................................................................5

1.3.2.1 FRONT PANEL ..........................................................................................................................................5

1.3.2.2 REAR PANEL.............................................................................................................................................6

1.3.3 BATTERY/CHARGER PACK VIEWS ...........................................................................................................6

1.3.4 E-DWT-10000-AF DIMENSIONS...................................................................................................................7

1.3.5 E-DWT-10000-AF HYDRAULIC SCHEMATIC..............................................................................................7

2. INSTALLATION .................................................................. 9

2.1 UNPACKING AND INSPECTION............................................................................................................9

2.1.1 REMOVING FROM PACKAGING .................................................................................................................9

2.1.2 INSPECTING CONTENTS.............................................................................................................................9

2.2 SITE REQUIREMENTS..........................................................................................................................10

2.3 SETUP ...................................................................................................................................................10

2.3.1 PREPARING FOR OPERATION.................................................................................................................10

2.3.2 SETTING UP AUTOTEST FILES ................................................................................................................10

2.4 OPERATIONAL CHECK........................................................................................................................11

2.4.1 RPM4-E-DWT PRESSURE MEASUREMENT ............................................................................................11

2.4.2 E-DWT PRESSURE GENERATION AND CONTROL ................................................................................11

2.5 SHORT TERM STORAGE.....................................................................................................................12

2.6 LONG TERM STORAGE, PREPARATION FOR SHIPPING.................................................................13

3. OPERATION..................................................................... 15

3.1 GENERAL OPERATING PRINCIPLES.................................................................................................15

3.1.1 MULTIPLE RANGES (HI AND LO Q-RPT, AUTORANGE)........................................................................15

3.1.2 PRESSURE READY/NOT READY..............................................................................................................16

3.1.3 AUTOMATED TEST AND CALIBRATION SEQUENCES ..........................................................................16

3.1.4 TYPICAL OPERATING SEQUENCE TO RUN A TEST ..............................................................................16

3.2 TEST PORT CONNECTION ..................................................................................................................17

3.2.1 RPM4-E-DWT ATM PORTS ........................................................................................................................18

3.3 BATTERY/CHARGER PACK................................................................................................................18

3.4 SELECTING THE HI OR LO Q-RPT......................................................................................................19

3.5 PRESSURE GENERATION AND ADJUSTMENT.................................................................................22

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

3.5.1 FILLING AND PRIMING, RESERVOIR PUMP............................................................................................22

3.5.2 PRESSURE GENERATION AND ROUGH ADJUSTMENT, VARIABLE VOLUME ...................................23

3.5.3 PRESSURE FINE ADJUSTMENT, FINE ADJUST VALVE ........................................................................24

3.6 RPM4-E-DWT USER INTERFACE........................................................................................................24

3.6.1 MAIN RUN SCREEN....................................................................................................................................24

3.6.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL........................................................................26

3.6.3 OPTIONAL REMOTE [ENT] (ENTER) FOOTSWITCH ...............................................................................26

3.6.4 SOUNDS......................................................................................................................................................27

3.7 RPM4-E-DWT DIRECT FUNCTION KEYS............................................................................................27

3.7.1 SUMMARY...................................................................................................................................................27

3.7.2 [RANGE]......................................................................................................................................................28

3.7.3 [UNIT]...........................................................................................................................................................29

3.7.4 [MODE] ........................................................................................................................................................30

3.7.5 [AUTORANGE]............................................................................................................................................30

3.7.6 [LEAK CK]...................................................................................................................................................32

3.7.7 [DISPLAY]....................................................................................................................................................33

3.7.7.1 AVG (AVERAGE).....................................................................................................................................34

3.7.7.2 RATE........................................................................................................................................................35

3.7.7.3 DEV (DEVIATION) ...................................................................................................................................36

3.7.7.4 RPT ..........................................................................................................................................................37

3.7.7.5 HI/LO........................................................................................................................................................38

3.7.7.6 FREEZE ...................................................................................................................................................38

3.7.7.7 CLEAN .....................................................................................................................................................39

3.7.8 [HEAD].........................................................................................................................................................39

3.7.9 [SDS]............................................................................................................................................................41

3.7.10 [AUTOZ].......................................................................................................................................................41

3.7.11 [ENT] (RUN AUTOTEST) ............................................................................................................................42

3.7.11.1 AUTOTEST INITIALIZATION...................................................................................................................43

3.7.11.2 TEST EXECUTION ..................................................................................................................................44

3.8 [SETUP].................................................................................................................................................46

3.8.1 <1RANGE> ..................................................................................................................................................46

3.8.1.1 SAVING AN AUTORANGE RANGE ........................................................................................................46

3.8.1.2 DELETING AUTORANGE RANGES .......................................................................................................47

3.8.2 <2RES> (RESOLUTION).............................................................................................................................47

3.8.3 <3STAB> (STABILITY) ...............................................................................................................................48

3.8.4 <4UL> (UPPER LIMIT) ................................................................................................................................49

3.8.4.1 OVER PRESSURE FUNCTION...............................................................................................................49

3.8.5 <5ATEST>....................................................................................................................................................50

3.8.5.1 DATA........................................................................................................................................................50

3.8.5.2 FILE..........................................................................................................................................................51

3.9 [SPECIAL] .............................................................................................................................................53

3.9.1 <1AUTOZ>...................................................................................................................................................54

3.9.2 <2REMOTE>................................................................................................................................................55

3.9.2.1 <1COM1, 2COM2> ..................................................................................................................................56

3.9.2.2 <3IEEE-488>............................................................................................................................................56

3.9.2.3 <4FORMAT>............................................................................................................................................56

3.9.2.4 <5RS232 SELF-TEST>............................................................................................................................56

3.9.3 <3HEAD>.....................................................................................................................................................57

3.9.4 <4SDS>........................................................................................................................................................57

3.9.5 <5PREFS> ...................................................................................................................................................57

3.9.5.1 <1SCRSVR> ............................................................................................................................................58

3.9.5.2 <2SOUND> ..............................................................................................................................................58

3.9.5.3 <3TIME>...................................................................................................................................................59

3.9.5.4 <4ID>........................................................................................................................................................59

3.9.5.5 <5LEVEL> (SECURITY) ..........................................................................................................................60

3.9.6 <6PUNIT>.....................................................................................................................................................62

3.9.7 <7INTERN>..................................................................................................................................................63

3.9.7.1 <1BARO>.................................................................................................................................................64

3.9.7.2 <2READRT> ............................................................................................................................................64

3.9.7.3 <3RPT2X>................................................................................................................................................65

3.9.7.4 <4LO VNT> ..............................................................................................................................................65

3.9.7.5 <5LOG>....................................................................................................................................................65

3.9.8 <8CAL>........................................................................................................................................................66

3.9.9 <9RESET> ...................................................................................................................................................66

3.9.9.1 <1SETS>..................................................................................................................................................66

3.9.9.2 <2 UNITS> ...............................................................................................................................................67

3.9.9.3 <3ATEST>................................................................................................................................................67

3.9.9.4 <4 CAL> ...................................................................................................................................................67

3.9.9.5 <5 ALL>....................................................................................................................................................68

TABLE OF CONTENTS

4. REMOTE OPERATION ....................................................... 69

4.1 OVERVIEW............................................................................................................................................69

4.2 INTERFACING.......................................................................................................................................69

4.2.1 RS232 INTERFACE.....................................................................................................................................69

4.2.1.1 COM1.......................................................................................................................................................69

4.2.1.2 COM2.......................................................................................................................................................70

4.3 PROGRAMMING FORMATS.................................................................................................................70

4.3.1 PROGRAM MESSAGE FORMAT ...............................................................................................................70

4.3.2 ERROR QUEUE...........................................................................................................................................71

4.3.2.1 USI NG Q U E R Y T Y P E C O M M A N D S...................................................................................................71

4.4 COMMANDS..........................................................................................................................................72

4.4.1 PROGRAMMING MESSAGES....................................................................................................................72

4.4.2 ERROR MESSAGESS.................................................................................................................................73

4.4.3 PROGRAM MESSAGE DESCRIPTION OVERVIEW..................................................................................74

4.4.4 PROGRAM MESSAGE DESCRIPTIONS....................................................................................................75

5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION ............... 93

5.1 OVERVIEW............................................................................................................................................93

5.2 RPM4-E-DWT MAINTENANCE.............................................................................................................93

5.2.1 AUTOZERO OF Q-RPTS .............................................................................................................................93

5.2.2 ADJUSTMENT OF THE ON-BOARD BAROMETER..................................................................................94

5.3 RPM4-E-DWT Q-RPT CALIBRATION...................................................................................................94

5.3.1 PRINCIPLE ..................................................................................................................................................94

5.3.1.1 PA AND PM COEFFICIENTS ..................................................................................................................95

5.3.2 EQUIPMENT REQUIRED............................................................................................................................95

5.3.3 SET-UP AND PREPARATION ....................................................................................................................96

5.3.4 RECOMMENDED CALIBRATION POINT SEQUENCE .............................................................................96

5.3.5 RPT CALIBRATION USING CALTOOL FOR Q-RPTS SOFTWARE.........................................................97

5.3.6 EDITING AND VIEWING Q-RPT CALIBRATION INFORMATION.............................................................97

5.3.7 Q-RPT ADJUSTMENT WITHOUT CALTOOL FOR Q-RPTS SOFTWARE................................................98

5.4 E-DWT MAINTENANCE........................................................................................................................99

5.4.1 E-DWT OVERHAUL.....................................................................................................................................99

5.5 E-DWT REPAIR...................................................................................................................................100

5.5.1 REMOVING RPM4-E-DWT FROM THE E-DWT .......................................................................................100

5.5.2 OPENING AND CLOSING THE RPM4-E-DWT ENCLOSURE.................................................................101

5.5.3 RELOADING EMBEDDED SOFTWARE INTO RPM4-E-DWT FLASH MEMORY...................................101

5.5.4 RE P L A C I N G THE E - D W T H I G H P R E S S U R E R UPTU R E D I S K ...................................................... 102

5.5.5 RPM4-E-DWT SUBASSEMBLY DESCRIPTION AND LOCATION.................................................104

5.5.5.1 MICRO BOARD......................................................................................................................................105

5.5.5.2 DRIVER BOARD....................................................................................................................................105

5.5.5.3 ON-BOARD BAROMETER ....................................................................................................................105

5.5.5.4 Q-RPT MODULE....................................................................................................................................105

5.5.5.5 DISPLAY ................................................................................................................................................106

5.5.5.6 COOLING FAN.......................................................................................................................................106

5.5.6 HYDRAULIC SCHEMATIC OF Q-RPT MODULE.....................................................................................106

5.6 ILLUSTRATED PARTS BREAKDOWN ..............................................................................................106

5.6.1 E-DWT-10000-AF ILLUSTRATED PARTS BREAKDOWN ......................................................................106

5.6.2 E-DWT-10000-AF DETAILED HYDRAULIC SCHEMATIC.......................................................................109

5.6.3 RPM4-E-DWT A70M/A7M-AF ILLUSTRATED PARTS BREAKDOWN...................................................111

6. TROUBLESHOOTING .......................................................115

7. APPENDIX ......................................................................119

7.1 UNIT CONVERSION............................................................................................................................119

7.1.1 PRESSURE................................................................................................................................................119

8. WARRANTY ....................................................................121

8.1 OVERVIEW..........................................................................................................................................121

9. GLOSSARY .....................................................................123

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

OOTTEES

TABLES & FIGURES

AABBLLEES

Table 1. E-DWT-10000-AF packing list ....................................................................................................... 9

Table 2. Settings and what they are specific to (range, measurement mode, Q-RPT, system)................16

Table 3. Summary of RPM4-E-DWT function key operation.....................................................................27

Table 4. Settings made by AutoRange......................................................................................................31

Table 5. Security levels..............................................................................................................................61

Table 6. UNIT function - available units of measure..................................................................................63

Table 7. READRT – display update rates..................................................................................................64

Table 8. Reset – Sets.................................................................................................................................67

Table 9. Reset – Cal ..................................................................................................................................68

Table 10. Reset – All..................................................................................................................................68

Table 11. COM1 pin designations and connections..................................................................................69

Table 12. COM2 DB-9F pin designations..................................................................................................70

Table 13. Program message list ................................................................................................................72

Table 14. Error #s and descriptions...........................................................................................................73

Table 15. Calibration point sequence for A7M and A70M Q-RPTs........................................................... 97

Table 16. E-DWT exterior illustrated parts breakdown (see Figure 16) .................................................107

Table 17. E-DWT internal illustrated parts breakdown (see Figure 17)..................................................108

Table 18. E-DWT-10000-AF, detailed hydraulic schematic illustrated parts breakdown

Table 19. RPM4-E-DWT rear panel, external view illustrated parts breakdown

Table 20. RPM4-E-DWT Q-RPT assembly, internal view illustrated parts breakdown

Table 21. RPM4-E-DWT overall, interior view illustrated parts breakdown

Table 22. RPM4-E-DWT display assembly, interior view illustrated parts breakdown

Table 23. Troubleshooting guide .............................................................................................................115

Table 24. Pressure unit of measure conversion coefficients ...................................................................119

Table 25. DHI Authorized Service Providers ...........................................................................................121

(see Figure 18) ......................................................................................................................109

(see Figure 19) ......................................................................................................................111

(see Figure 20) ......................................................................................................................112

(see Figure 21) ......................................................................................................................113

(see Figure 22) ......................................................................................................................114

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

IIGGUURREES

Figure 1. E-DWT-10000-AF front view.........................................................................................................4

Figure 2. E-DWT-10000-AF rear view ......................................................................................................... 5

Figure 3. RPM4-E-DWT reference pressure monitor front panel ................................................................5

Figure 4. RPM4-E-DWT reference pressure monitor rear panel.................................................................6

Figure 5. Battery/charger pack front and rear E-DWT-10000-AF dimensions.............................................6

Figure 6. E-DWT-10000-AF dimensions......................................................................................................7

Figure 7. E-DWT-10000-AF hydraulic schematic ........................................................................................7

Figure 8. Battery pack/charger...................................................................................................................19

Figure 9. E-DWT-10000-AF front view.......................................................................................................21

Figure 10. E-DWT-10000-AF hydraulic schematic ....................................................................................21

Figure 11. MAIN RUN screen display fields...............................................................................................25

Figure 12. Keypad layout...........................................................................................................................26

Figure 13. RPM4-E-DWT removal from E-DWT......................................................................................101

Figure 14. RPM4-E-DWT internal view....................................................................................................104

Figure 15. Hydraulic schematic RPM4-E-DWT Q-RPT Module ...............................................................106

Figure 16. E-DWT exterior view................................................................................................................107

Figure 17. E-DWT internal view................................................................................................................108

Figure 18. E-DWT detailed hydraulic schematic.......................................................................................110

Figure 19. RPM4-E-DWT rear panel, external view illustrated parts breakdown.....................................111

Figure 20. RPM4-E-DWT Q-RPT assembly, internal view illustrated parts breakdown...........................112

Figure 21. RPM4-E-DWT overall, interior view illustrated parts breakdown.............................................113

Figure 22. RPM4-E-DWT display assembly, interior view illustrated parts breakdown............................ 114

ABOUT THIS MANUAL

BBOOUUTT

This manual is intended to provide the user with the basic information necessary to operate an E-DWT-10000-AF electronic deadweight tester (Portable Hydraulic Gauge Calibrator). It also includes a great deal of additional information provided to allow you to optimize the use of the instrument and take full advantage of its many features and functions.

Before using the manual, take a moment to familiar ize yo urself with the Tab le of Conten ts struc ture: Sec tions

1.1, 2 and 3. Section 4 is for remote communication with the RPM4-E-DWT from an external computer.

tion 5 p

Sec to trou

For those of you who “don’t read manuals”, go directly to Section 2.3 to set up your E-DWT and then go to Section 3.1.4 for a typical test procedure. This will get you up and running quickly with a minimal risk of causing damage to yourself or your new instrument. THEN… when you have questions or start to wonder about all the great features you might be missing, get into the manual!

(CAUTION) is used in throughout the manual to identify user warnings and cautions.

rovides maintenance and calibration information. Section 6 is a quick troubleshooting guide. Use it

bleshoot unexpected E-DWT behavior based on the symptom of that behavior.

HHIISS

AANNUUAAL

Manual Conventions

(NOTE) is used throughout the manual to identify operating and applications advice and additional explanations.

[ ] indicates direct function keys (e.g., [RANGE]).

< > indicates RPM4-E-DWT screen displays (e.g., <1yes>).

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

OOTTEES

1. INTRODUCTION

11.

NNTTRROODDUUCCTTIIOON

1.1 PRODUCT OVERVIEW

E-DWT-10000-AF is an electronic deadweight tester designed to replace mechanical piston-cylinder based deadweight testers with a lighter weight, easier to use alternative. The E-DWT is designed to be used in the lab or instrument shop or to be taken into the field for performing in-situ calibrations and tests. This high performance hydraulic pressure calibration system combines an electronic reference pressure monitor and manually operated pressure generation and control hardware in a single, compact and rugged package. E-DWT offers the ease of use and precision of continuous, real time electronic pressure measurement with the simple and direct pressure control of high quality manual pressure hardware.

The electronic reference pressure monitor is a special version of DHI’s RPM4, designated RPM4-E-DWT A70M/A7M-AF. RPM4-E-DWT A70M/A7M-AF covers the range from 0 to 10 000 psi gauge pressure using two high precision quartz reference pressure transducers (Q-RPTs) and an on-board barometer to measure pressure.

RPM4-E-DWT A70M/A7M-AF is controlled locally by the operator using its front panel display, keypad and foot pedal or remotely by a computer using ASCII character command strings over its RS-232 interface.

RPM4-E-DWT A70M/A7M-AF uses an AutoRange feature to automatically select the most appropriate Q-RPT and to optimize the E-DWT setup to cover the desired range of operation. A half-turn valve isolates and protects the Lo Q-RPT from high pressure when the Hi Q-RPT is in use. Visual and audible indicators assist the operator in setting the shut off valve correctly.

The E-DWT includes the hardware necessary to fill the system under test with oil and generate and precisely adjust pressure across the E-DWT’s 10 000 psi (70 MPa) range.

The E-DWT-10000-AF system is delivered in a rugged, molded plastic transport case and includes two battery/charger packs.

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

1.2 SPECIFICATIONS

1.2.1 GENERAL SPECIFICATIONS

Power requirements:

To RPM4-E-DWT:

To 12 VDC AC to DC power

supply :

Temperature

Operating:

Storage:

Weight

E-DWT-10000-AF unit:

E-DWT system w/ accessories

in case:

Dimensions

E-DWT-10000-AF footprint:

E-DWT-10000-AF height:

System transport case:

Pressure range: 0 to 10 000 psi (70 MPa) gauge pressure

Operating medium: Oil (di-ethyl-hexyl sebacate)

Reservoir capacity: 300 cc (18 in.

Variable volume displacement: 3 cc (0.18 in.

Priming pump displacement: 3.7 cc (0.23 in.

12 VDC, 1.2 A 100 to 240VAC, 50-60 Hz

18 to 28 °C

- 20 to 70 °C

14 kg (30 lb) approx.

27.3 kg (60 lb) approx.

41.4 cm W x 37.1 cm D (16.3 in. x 14.6 in.)

26.9 cm (10.6 in.), 33.6 cm (13.2 in.) to max variable volume handle stroke

39.4 cm H x 79.5 cm W x 51.8 cm D (15.5 in. x 31.3 in. x 20.4 in.)

)

TEST pressure connection: DH500 female, adaptors to 1/4 in. and 1/8 in. NPT female included.

Pressure Limits: Maximum Working Pressure: 10 000 psi (70 MPa)

Communication ports: RS232 (COM1, COM2)

DH500 is a gland and collar type fitting for 6mm (1/4 in.) coned and left

hand threaded tubes equivalent to AE F250C, HIP HF4, etc.

Maximum Pressure Without Damage: 12 000 psi (83 MPa) Internal rupture disk burst pressure: 11500 psi (79 MPa)

When Lo Q-RPT is connected to TEST pressure:

Maximum Working Pressure: 1 000 psi (7 MPa) Maximum Pressure Without Damage: 2200 psi (15.2 MPa) Pressure relief valve setting: 1 500 psi (10.3 MPa)

Maximum priming pump pressure: 100 psi (700 kPa)

1. INTRODUCTION

1.2.2 BATTERY AND CHARGER PACK

Power Requirements 100 to 240 VAC, 50/60 Hz, 15 W max consumption

Operating Temperature Range 0 to 50 °C

Storage Temperature Range - 20 to 70 °C

Weight 2 kg (4.4 lb)

Dimensions 8 cm H x 22.5 cm W x 20 cm D (3.1 in. x 8.9 in. x 7.9 in.)

Battery Type Nickel metal-hydride

Battery Voltage 12 VDC

Battery Capacity Typical: 9000 mAh

Charge Time Full charge from empty, 14 to 16 hours approx.

Approx. Run Time, Full Charge 8 to 12 hours

Min: 8200 mAh

1.2.3 PRESSURE MEASUREMENT SPECIFICATIONS

1.2.3.1 REFERENCE PRESSURE TRANSDUCERS (RPT)

E-DWT-10000-AF is configured with two quartz reference pressure transducer (Q-RPT) modules to measure pressure.

The Q-RPTs are intrinsically absolute, operating against a sealed vacuum reference. Gauge pressure is defined by offsetting atmospheric pressure and applying dynamic compensation for atmospheric changes using the on-board barometer (see Section 3.9.1).

Warm Up Time 15 minute temperature stabilization recommended from

Compensated Temperature Range 5 to 35 °C

Operating Temperature Range 18 to 28 °C

A7M Q-RPT A70M Q-RPT

Maximum Range 1 000 psi (7 MPa) 10 000 psi (70 MPa)

Resolution 0.01 % of active range default.

Precision

Temperature effect

Predicted Stability

Measurement Uncertainty

1. Combined linearity, hysteresis, and repeatability.

2. Maximum influence of ambient temperature on indicated pressure from 0 to 50ºC

3. Predicted Q-RPT measurement stability limit (k=2) over two years assuming regular use of AutoZero function and short term stability between rezeroing. As stability can only be predicted and varies from Q-RPT to Q-RPT, stability for a specific Q-RPT should be established from experience.

cold power up.

User adjustable to 1 ppm of Q-RPT maximum or 10 ppm of active AutoRange, whichever is larger.

± 0.015 % of reading, or

0.045 psi, whichever is larger

± 0.0006% of span per ºC deviation from calibration

temperature (23ºC)

± 0.01% of reading or 0.02

psi, whichever is greater

± 0.1% of reading, or

0.1 psi, whichever is greater

± 0.015% of reading, or

0.45 psi, whichever is larger

± 0.01% of reading or 0.1

psi, whichever is greater

± 0.1% of reading, or

1.0 psi, whichever is greater

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

4. Maximum deviation of the Q-RPT indication from the true value of applied pressure including precision, predicted two year stability with rezeroing, temperature effect from 18 to 28 ºC and calibration uncertainty (assumes calibration reference uncertainty of ±0.02% of reading, k=2), combined and expanded (k=2) following the ISO “Guide to the Expression of Uncertainty in Measurement.”.

1.2.3.2 ON-BOARD BAROMETER

The measurement uncertainty of the on-board barometer is not significant to E-DWT measurement uncertainty. It is used only to measure small, short term changes in atmospheric pressure to provide dynamic compensation of the Q-RPT’s atmospheric pressure offset in gauge pressure measurement mode (see Section 3.9.1)

Sensor Technology: Micro-machined silicon

Warm Up Time: None required

Resolution: 0.1 Pa (0.000015 psi)

1.3 VIEWS AND SCHEMATICS

1.3.1 E-DWT-10000-AF VIEWS

1.3.1.1 FRONT VIEW

1. TEST port (DH500F)

2. Reservoir cap vent valve

3. Priming pump

4. Reservoir cap

5. Reference pressure monitor (RPM4-E-DWT)

6. Test shut off valve and fine pressure adjustment 7 ‘Lo Q-RPT shut off’ valve position prompt LED

Figure 1. E-DWT-10000-AF front view

8. Lo Q-RPT shut off valve

9. ‘Lo Q-RPT active’ valve position prompt LED

10. ‘Lo Q-RPT active’ caution indicator

11. Reservoir shut off valve

12. Variable volume (pressure generation)

13. Variable volume piston position indicator

1. INTRODUCTION

1.3.1.2 REAR VIEW

1. Reservoir cap

2. Priming pump

3. Reservoir cap vent valve

4. TEST connection (DH500 F)

Figure 2. E-DWT-10000-AF rear view

5. Power connection (12 VDC)

6. Footswitch (remote [ENT]) connection (footswitch not included)

1.3.2 RPM4-E-DWT REFERENCE PRESSURE MONITOR VIEWS

1.3.2.1 FRONT PANEL

1. Pressure ready/not ready indicator

2. 2 x 20 vacuum fluorescent display

3. Remote activity indicator

Figure 3. RPM4-E-DWT reference pressure monitor front panel

4. Cursor control keys

5. Multi-function keypad

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

1.3.2.2 REAR PANEL

1. 12VDC power supply connection

2. Accessories connector (to E-DWT rear panel FOOTSWITCH and LEDs)

3. COM2 connector

4. COM1 connector

5. Fan

Figure 4. RPM4-E-DWT reference pressure monitor rear panel

6. TEST(+) pressure port, Lo Q-RPT

7. TEST(+) pressure port, Hi Q-RPT

8. ATM pressure port, Lo Q-RPT

9. ATM pressure port, Hi Q-RPT

10. Product label (bottom of case)

1.3.3 BATTERY/CHARGER PACK VIEWS

1. Cooling fan

2. 12VDC output connector (to E-DWT)

3. IEC power connection

4. ON/OFF switch (ON – battery connected to charger; OFF - battery connected to 12 VDC output/E-DWT)

Figure 5. Battery/charger pack front and rear E-DWT-10000-AF dimension s

5. Charge level indicator

6. Charge level check switch

7. Battery charging indicator (green – charging; green flashing – fully charged.

1. INTRODUCTION

1.3.4 E-DWT-10000-AF DIMENSIONS

Figure 6. E-DWT-10000-AF dimensions

1.3.5 E-DWT-10000-AF HYDRAULIC SCHEMATIC

1. TEST port

2. System pressure rupture disc

3. Reservoir

4. Reservoir vent valve

5. Priming pump

6. Test shut off and fine adjustment valve

7. Lo Q-RPT shut off valve

Figure 7. E-DWT-10000-AF hydraulic schematic

8. Lo Q-RPT pressure relief valve

9. Reservoir shut off valve

10. Variable volume

11. Lo Q-RPT (ref pressure transducer)

12. Hi Q-RPT (ref pressure transducer)

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

OOTTEES

2. INSTALLATION

22.

NNSSTTAALLLLAATTIIOON

2.1 UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

E-DWT-10000-AF complete with accessories is delivered in a reusable, molded plastic shipping container with polyurethane inserts to hold it in place.

Remove the E-DWT-10000-AF and its accessories from the shipping container and remove each element from its protective plastic bag.

Retain the shipping container for repacking the E-DWT to take it into the field or to ship it

for recalibration or repair.

2.1.2 INSPECTING CONTENTS

Check that all items are present and have no visible damage. If damage is noted, report it to your Receiving Department for appropriate action.

A new E-DWT-10000-AF includes all items listed in Table 1.

Table 1. E-DWT-10000-AF packing list

DESCRIPTION PART NO.

E-DWT-10000-AF electronic deadweight tester 3322392

ACCESSORIES: 3338865

1 ea. Transport case (with inserts) (used for original

shipment) 2 ea. Battery/charger pack 3338787 1 ea. Battery/charger pack to E-DWT power cable 3335937 2 ea. Power cord (7.5 ft) 3133781 1 ea. 12 VDC power supply pack 3335610 4 ea. Handle, variable volume 3329907 1 ea. DH500 M x 1/4 in. NPT F adaptor 3335561 1 ea. DH500 M x 1/8 in. NPT F adaptor 3142684 1 ea. E-DWT-10000-AF Documentation Disk including:

• E-DWT-10000-AF Operation and Maintenance Manual, p/n 550166

1 ea. Calibration Report 3152121 1 ea. Test Report (included only if the E-DWT-10000-AF

is delivered under AFMETCAL contract FY2333-07M-0025)

1 ea. General Accessories Disk 3139043

3329777

3338256

3338793

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

2.2 SITE REQUIREMENTS

Install E-DWT-10000-AF on a flat, stable surface at a convenient height. If using the battery/charger pack, consider its placement.

When used with its battery/charger pack, E-DWT-10000-AF requires no external support facilities. If not using the battery, an electrical power source of 100 to 240VAC, 50-60 Hz is required.

2.3 SETUP

2.3.1 PREPARING FOR OPERATION

To prepare E-DWT-10000-AF for check out and operation:

Remove the protective plastic sheet from the front panel display. Familiarize yourself briefly with the E-DWT front and real panels and controls (see

Section 1.3.1).

Connect the 12 VDC power supply pack to a source of 100 to 240V, 50-60 Hz AC power

and to the 12 VDC connection on the rear of the E-DWT; or, use the battery/charger pack and cable if battery has been charged (see Section 3.3).

cting power causes the RPM4-E-DWT to power up.

Con

Observe the front panel display as the RPM4-E-DWT initializes, error checks and goes to

the MAIN RUN screen (see Section 3.6.1). If the RPM4-E-DWT fails to reach the main run screen, service observed and contact a DHI Authorized Service Provider (see Section 1, Table 25).

ck that o

Che red LED should NOT be ON). If neither of the green LEDs lights, check that the 12 pin circular connector on the rear panel of the RPM4-E-DWT itself is properly connected to

the J1 ACC. connector. Install the four variable volume handles into the variable volume hub on the front of the E-DWT. Leave the stainless steel plug in the top surface TEST port. Check that the gland holding

the plug is tight. Check/Set Security Level

RPM4-E-DWT has a security system based on user levels. By default, the security

system is set to “low”, which includes access restriction to internal calibration coefficients,

and there is no password required to change the security level. See Section 3.9.5.5 for

information on

the security level that is appropriate for the RPM4-E-DWT and set a password if desired.

RPM4-E-DWT is delivered with the security level set to “low” to avoid inadvertent altering of critical internal settings but with access to changing security levels unrestricted. It is recommended that the low security level be maintained at all times and password protection be implemented if control over setting of security levels is desired.

ne of the two green Valve Status LEDs on the front of the E-DWT is lit (the

the security level system. As part of the RPM4-E-DWT startup, determine

is required. Record the sequence of operations and displays

2.3.2 SETTING UP AUTOTEST FILES

E-DWT’s RPM4-E-DWT supports automated test/calibration sequences. AutoTest sequence parameters for testing specific DUTs can be stored in File AutoTest files and recalled to run a test. Consider setting up File AutoTest files for frequently tested DUTs as part of the E-DWT set up process (see Section 3.1.3).

2. INSTALLATION

2.4 OPERATIONAL CHECK

2.4.1 RPM4-E-DWT PRESSURE MEASUREMENT

See Figure 1 and Figure 7 for an E-DWT view and schematic when following this procedure.

Check that one of the two green Valve Status LEDs on the front panel of the E-DWT is lit

(the red LED should NOT be ON). If neither of the green LEDs on the E-DWT front panel lights, check that the 12 pin circular connector at the rear of the RPM4-E-DWT itself is properly connected to the J1 ACC. connector.

Let the RPM4-E-DWT warm up with power ON for approximately 15 minutes. Open the reservoir vent valve by turning it CCW. Open the reservoir shut off valve by turning it CCW.

Put the lo Q-RPT shut off valve into the Lo Q-RPT Active position (turn fully CCW) . This

opens the Lo and Hi Q-RPTs to the E-DWT TEST port.

Use [RANGE] (see Section 3.7.2) to select the Lo Q-RPT. If desired, change the

pressure unit of measure using [UNIT] (see Section 3.7.3).

The value indicated should be near zero. Press [AutoZ]. This runs AutoZ to zero the Q-

RPT reading (see Section 3.7.10). Upon return to the main run screen, observe that the indication of measured pressure h E-DWT may need repair.

as zeroed. If the display fails to zero properly, the

Use [RANGE] to select the Hi Q-RPT (see Section 3.7.2) and repeat the zeroing process.

If the display fails to zero properly, the E-DWT may need repair.

It is normal for RPM4-E-DWT to indicate a value other than zero when vented when gauge mode is first entered or ranges are changed, especially if AutoZ is OFF, RPM4-E-DWT has been OFF for some time or its location has changed.

2.4.2 E-DWT PRESSURE GENERATION AND CONTROL

Perform RPM4-E-DWT pressure measurement operational check (see Section 2.4.1) before the pressure generation and control check.

Refer to Figure 9 and Figure 10 when following this procedure.

Check that there is calibration fluid (di-ethyl hexyl sebacate) in the E-DWT reservoir (the

E-DWT is supplied with the reservoir full).

Open the reservoir vent valve by rotating it CCW. Open the reservoir shut off valve. Set the variable volume to start position. Rotate variable volume handles CCW until red

of variable volume piston position indicator on top of E-DWT is fully retracted.

Put the Lo Q-RPT shut off valve into the Lo Q-RPT Active position (rotate valve fully CCW).

This opens the Lo and Hi Q-RPTs to the E-DWT pressure generation and control system. Use [RANGE] (see Section 3.7.2) to select the Lo Q-RPT. If desired, change the

pressure unit of measu

With the Lo Q-RPT connected, never exceed pressure of 1000 psi (7 MPa) or the Lo Q-RPT could be permanently damaged. If the red CAUTION indicator flashes and/or an audible alarm sounds, immediately reduce pressure to avoid damaging an E-DWT Q-RPT.

re using [UNIT] (see Section 3.7.3).

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

Check that the stainless steel plug is installed in the E-DWT TEST port and that the gland

holding the plug is tight.

Slowly lift the reservoir pump handle and then depress at moderate speed with firm, even

pressure. With a brief delay, the pressure indicated by the RPM4-E-DWT should rise. If the pressure does not rise above 20 psi (130 kPa), it is likely there is air in the E-DWT hydraulic circuit, most likely in the low pressure PFA tubing between the reservoir and the rest of the system. It is normal for the pressure to drop when the reservoir pump is released since the pump is vented by releasing it.

Close the reservoir shut off valve and check that the test shut off valve is open. Slowly rotate the variable volume CW and observe the RPM4-E-DWT display. The

indicated pressure should increase. Slowly increase the pressure to 1000 psi (7 MPa) and stop. The pressure should decrease, more and more slowly, and eventually stabilize. If the pressure decreases indefinitely (more than 5 minutes), there is probably a leak in the E-DWT and it may require service.

Rotate the variable volume handle CCW to reduce pressure to about 100 psi (700 kPa)

and open the reservoir shut off valve.

Put the Lo Q-RPT shut off valve into the Lo Q-RPT Shut Off position (valve rotated fully CW).

This isolates the Lo Q-RPT from the E-DWT pressure generation and control system.

If the red CAUTION indicator flashes and/or an audible alarm sounds at any time, immediately reduce pressure to avoid damaging an E-DWT Q-RPT.

Close the reservoir shut off valve and check that the test shut off valve is open. Slowly rotate the variable volume CW and observe the RPM4-E-DWT display. The

indicated pressure should increase. Slowly increase the pressure to 10 000 psi (70 MPa), stop and wait. The pressure should decrease, more and more slowly and eventually stabilize. If the pressure decreases indefinitely (more than 5 minutes), there is probably a leak in the E-DWT and it may require service.

Rotate the variable volume handle CCW to reduce pressure to about 100 psi (700 kPa)

and open the reservoir shut off valve.

2.5 SHORT TERM STORAGE

The following is recommended for short term storage (not shipping or transport) of E-DWT-10000-AF:

• Open the reservoir shut off valve.

• Disconnect power.

Use [RANGE] (see Section 3.7.2) to select the Hi Q-RPT.

2. INSTALLATION

2.6 LONG TERM STORAGE, PREPARATION FOR SHIPPING

The following is recommended for long term storage and/or shipping of E-DWT-10000-AF:

E-DWT-10000-AF is designed to be shipped with its reservoir full of calibration fluid. If the instructions

below are followed carefully, it is not necessary to empty the reservoir prior to shipment.

• IMPORTANT: Close the reservoir cover fully by rotating it CW until snug, with reservoir vent valve aligned with CLOSE position.

• IMPORTANT: Close the reservoir shut off valve by rotating it CW until snug.

• IMPORTANT: Plug the TEST port.

• Remove (by unscrewing) the four variable volume handles on the front of the E-DWT.

• Close the test shut off valve.

• Place the E-DWT-10000-AF in the custom shipping/storage case in which it was delivered.

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

OOTTEES

3. OPERATION

33.

PPEERRAATTIIOON

3.1 GENERAL OPERATING PRINCIPLES

3.1.1 MULTIPLE RANGES (HI AND LO Q-RPT, AUTORANGE)

The E-DWT-10000-AF’s Reference Pressure Monitor (RPM4-E-DWT) has two Quartz Reference Pressure Transducers (Q-RPTs). The A70M (10 0 00 psi) Q-R PT is des igna ted th e Hi Q-RPT. The A7M (1 000 psi) Q-RPT is designated the Lo Q-RPT. Which Q-RPT is currently active is indicated continuously by characters in the upper right hand corner of the MAIN RUN screen and most other screens.

Each RPM4-E-DWT Q-RPT has a default range which is its maximum range. Additional ranges, lower than the Q-RPT’s maximum, may also be created using AutoRange and AutoTest (see Sections 3.7.5, 3.1.3). Ranges created using AutoRange are temporary but may be save

d with all their settings for reactivation (see Section 3.8.1).

The ranges av and/or created

An RPM4-E-DWT range i range, its current unit of measure and its full scale pressure. The range screen is:

1. Q-RPT designator.

2. Type of range. DF for the Q-RPT’s default range; AR for a range created by AutoRange.

3. Q-RPT position designator.

4. Current pressure unit of measure.

5. Full scale pressure

Most settings made in an RPM4-E-DWT range, such as unit of measure, display resolution and stability setting are specific to the range. Settings selected while one range is active apply to that range and not to other ranges. The range specific settings are stored with the range and recalled whenever the range is made active. This makes setting up ranges a convenient way to store and recall frequently used operating configurations. See Table 2 for a listing of RPM4-E-DWT system specific.

ailable on the RPM4-E-DWT are accessed using [RANGE] (see Section 3.7.2)

using [AutoRange] (see Section 3.7.5).

s identified by a range screen showing the Q-RPT used by the

Active A70M DF Hi psi 10000g

adjus

tments and settings and whether they are range, Q-RPT or

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

Table 2. Settings and what they are specific to

(range, measurement mode, Q-RPT, system)

SETTING PURPOSE SPECIFIC TO SECTION

[Unit] Set pressure unit of measure Range 3.7.3 [Display] Set bottom line display function System 3.7.7 [Head] Set fluid head correction height, fluid, unit of

[SDS] Not used in this RPM4-E-DWT model Not used None [AutoZ] Run AutoZ Q-RPT and measurement mode 3.7.10 Resolution Set pressure display resolution Range 3.8.2 Stability Set Ready/Not Ready stability test. Range 3.8.3 Upper Limit Set upper and lower pressure limit alarm Range and measurement mode 3.8.4 AutoZ AutoZ, ON/OFF, set and view values Q-RPT and measurement mode 3.9.1 Screen Saver,

Sound, Time, ID, Level

Cal Various Q-RPT and barometer calibration

measure

Set system user preferences System 3.9.5

functions, including turning off absolute and negative gauge modes

System 3.7.8

Q-RPT or barometer 5.2.2

3.1.2 PRESSURE READY/NOT READY

There is a Ready/Not Ready indicator LED on the RPM4-E-DWT front panel to the left of the display. It is intended to provide the user with a clear and objective indication of when a stable pressure has been achieved. Ready is indicated when the current stability (rate of change) of pressure is less than the stability limit. The user can set the stability limit (see Section 3.8.3) or the stability limit can be set automat Sections 3.7.5, 3.1.3). The Ready indication

is often used when comparing the

ically by a Au

toRange or AutoTest (see

RPM4-E-DWT and a test device to indicate when a valid reading can be made. The Ready/Not Ready LED indications are:

<Green > Pressure Ready The pressure stability is within the stability limit. <Red> Pressure Not Ready The pressure stability is NOT within the stability limit.

The default stability criterion is 0.01% of full scale of the active range per second.

3.1.3 AUTOMATED TEST AND CALIBRATION SEQUENCES

The RPM4-E-DWT AutoTest function supports “Quick” and “File” automated calibration sequences. These automatically AutoRange the RPM4-E-DWT, setting its resolution, stability limit and upper limit based on the characteristics of the device under test. They also prompt the user through the increments of the calibration sequence and log calibration data. The AutoTest function should be used for most common calibration tasks, especially calibration of analog pressure gauges.

3.1.4 TYPICAL OPERATING SEQUENCE TO RUN A TEST

The typical operating sequence to run a test is as follows:

AutoZero the RPM4-E-DWT:

Disconnect the E-DWT TEST port. Close the reservoir shut off valve.

3. OPERATION

Press [AutoZ] on the RPM front panel (see Section 3.7.10).

Connect the system under test/DUT to the E-DWT TEST port. Use [HEAD] to enter the fluid head correction for the difference in height between the

E-DWT TEST port and the DUT reference level if significant (see Section 3.7.8).

Fill and prime the system under test/DUT (see Section 3.5.1):

Open the test system/DUT at the highest point possible. Use the filling and priming pump to fill the test system. Close the test system/DUT when all air has been purged.

Use [AutoRange] (see Section 3.7.5) or [AutoTest] (see Section 3.1.3) to set up the

RPM4-E-DWT for the test to be run.

Set zero gauge pressure to the DUT by opening the reservoir cap vent valve, the

reservoir shut off valve and the TEST shut off valve. The RPM4-E-DWT indication may not be zero if the DUT reference height is different from the E-DWT reference height.

Set the next pressure. Close the reservoir shut off valve. Check that the TEST shut off

valve is open. Use the variable volume and fine adjustment valve to set pressure as needed (see Sections 3.5.2, 3.5.3).

When

the DUT is stable, read the reference pressure applied from the RPM4-E-DWT.

After the last pressure, return to zero by opening the reservoir shut off valve. The

RPM4-E-DWT indication may not be zero if the DUT reference height is different from the E-DWT reference height.

3.2 TEST PORT CONNECTION

A single, high pressure TEST port is provided on the top of the E-DWT. The test port connection is a DH500 F. DH500 is a gland and collar type fitting for 1/4 in. (6 mm) coned

and left hand threaded tube. DH500 is equivalent to AE F250C, HIP HF4, etc. The E-DWT-10000-AF system is delivered with two adaptors to adapt the DH500 F TEST port fitting to

1/4 in. NPT F or 1/8 in. NPT F.

USE THE CORRECT PRESSURE CONNECTORS: The E-DWT TEST port fitting is a DH500 F (see Section 1.2.1). It is NOT a 1/8 in. NPT F. Never use a fitting other than the corresponding male fitting in these connectors. Damage to the connectors and dangerous failure under pressure could result from using incorrect fittings.

DO NOT APPLY PRESSURE UNTIL YOU ARE FAMILIAR WITH OPERATION: The E-DWT-10000-AF TEST port can connect internally to both the RPM4-E-DWT’s 1 000 psi (7 MPa) and 10 000 psi (70 MPa) Q-RPTs. The LO Q-RPT SHUT OFF valve on the front of the E-DWT isolates the low pressure Q-RPT when the high pressure Q-RPT is in use. Do not apply pressure to the E-DWT until you are familiar with its operation and know how to protect the low pressure Q-RPT from overpressure (see Section 3.4). FAILURE TO PROTECT THE LOW

SURE Q-RPT FROM OVERPRESSURE MAY DESTROY IT. DAMAGE DUE TO Q-RPT OVERPRESSURE IS NOT

PR COVERED BY THE PRODUCT WARRANTY.

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

3.2.1 RPM4-E-DWT ATM PORTS

The ATM ports on the RPM4-E-DWT Q-RPT modules are connected to the RPM4-E-DWT’s internal barometer to assure that the RPM4-E-DWT gauge pressure measurements are relative to ambient pressure. These ports should always be left completely unobstructed and open to atmosphere.

NEVER plug, obstruct or connect a supply pressure to the RPM4-E-DWT Q-RPT module ATM

ports. This may adversely affect operation and AutoZeroing functions.

3.3 BATTERY/CHARGER PACK

E-DWT-10000-AF is delivered with two (2) 12 VDC battery/charger packs to supply power to the E-DWT’s reference pressure monitor.

The battery/charger pack combines a battery and battery charger.

To Charge the Battery

To charge the battery, connect the battery/charger pack to a 100 to 240 V, 50/60 Hz power supply using the supplied power cable and turn on the charger power switch. The green CHARGE indicator light goes on to indicate that battery charging is in progress. Allow 14 to 16 hours for the battery to charge fully.

When the battery charger power switch is in the ON position, the battery is connected to the charger, not the 12VDC output. When the battery charger switch is in the OFF position, the CHARGE indicator light goes off, and 12VDC battery output is supplied to the 12VDC connection.

The battery may be charged while the battery/charge pack is connected to the RPM4-E-DWT.

To preserve battery life, if run the battery down completely before recharging it and do not charge more

than 16 hours. Do not leave power connected to the battery continuously.

To Use the Battery/Charger Pack to Supply the RPM4-E-DWT

After charging the battery, connect the 12VDC connection of the battery/charger pack to the 12VDC connection on the E-DWT rear panel.

Turn the battery/charger pack power switch to OFF (when AC power is connected to the battery/charger pack, the power switch must be OFF for 12VDC power to be output).

To Check the Battery Charge Level

To check the current charge level of the battery, press the BATTERY CHECK toggle switch on the battery/charger pack front panel. Observe the BATTERY CHECK indicator lights. All three lights are lit when battery is fully charged. If no light or one light is on, the battery should be recharged.

3. OPERATION

1. Cooling fan

2. 12VDC output connector (to E-DWT)

3. IEC power connection

4. ON/OFF switch (ON – battery connected to charger; OFF - battery connected to 12 VDC output/E-DWT)

Figure 8. Battery pack/charger

5. Charge level indicator

6. Charge level check switch

7. Battery charging indicator (green – charging).

3.4 SELECTING THE HI OR LO Q-RPT

Selection of the active Q-RPT in the RPM4-E-DWT is made using the RPM4-E-DWT front panel’s [RANGE] key and E-DWT LO Q-RPT SHUT OFF valve.

When the Hi Q-RPT is active, the Lo Q-RPT must be isolated from the E-DWT’s pressure generation and control system to avoid destroying it by overpressure.

The E-DWT’s Lo Q-RPT shut off valve and visual and audible indicators, assist the operator in performing the correct operations to shut off and protect the Lo Q-RPT when the Hi Q-RPT is in use.

 OPERATION

See Figure 10 for an E-DWT schematic. Numerical references in this Section refer to Figure 9. The Lo Q-RPT is connected to or shut off from the rest of the E-DWT by the Lo Q-RPT shut off valve that

is operated using the valve knob. The proper valve position for the Q-RPT selected is prompted by the

Valve Position LEDs (7, 9). The Lo Q-RPT shut off valve (8) isolates and protects the Lo Q-RPT from the TEST port when it is

closed (knob fully CW) and opens the Lo Q-RPT to the TEST port when it is open (knob fully CCW). The Valve Position LEDs (7, 9) indicate the position in which the valve knob should be set based on the

current Q-RPT selection on the RPM4-E-DWT . If the Hi Q-R PT is selected, the LO Q-RPT SHUT O FF LED (7) is lit indicating that the valve knob should be turned fully CW to close the valve, protecting the Lo Q-RPT from high pressure. If the Lo Q-RPT is selected, the LO Q-RPT ACTIVE LED (9) is lit indicating that the valv e knob should be turned fully CCW to open the valve, connecting the Lo Q-RPT to the test pressure.

E-DWT-10000-AF OPERATION AND MAINTENANCE MANUAL

The E-DWT Lo Q-RPT shut off valve (8) must always be in the closed position (knob fully CW) when operating at pressure greater than 1 000 psi (7 MPa).

The CAUTION LO Q-RPT ACTIVE LED (10) is used to indicate that the Lo Q-RPT is active and provide an alert when the Lo Q-RPT is active but a Hi Q-RPT range is selected on the RPM4-E-DWT.

The CAUTION LO Q-RPT ACTIVE LED (10) is driven by the value of pressure currently measured by the Lo Q-RPT , it is not driven by the valve position as there is no sensing of the valve position.

The CAUTION LO Q-RPT ACTIVE LED (10) has three possible conditions:

• LED is OFF: The Lo Q-RPT is NOT active. The Lo Q-RPT is considered active when it measures a

pressure greater than about 100 psig (700 kPa).

• LED ON continuously: The Lo Q-RPT IS active (exposed to pressure greater than 100 psi) and the

Lo Q-RPT is selected on the RPM4-E-DWT. The LED is lit as a reminder that the Lo Q-RPT is active and pressure over its maximum working pressure of 1 000 psi (7 MPa) should n ot be applie d.

• LED is flashing ON/OFF accompanied by high frequency beeps and <!!LO Q-RPT ACTIVE!!>

displayed by RPM4-E-DWT: Lo Q-RPT IS active and the Hi Q-RPT is selected on RPM4-E-DWT. The Lo Q-RPT should NOT be exposed to pressure when the Hi Q-RPT is selected. Exposing the Lo Q-RPT to pressures for which the Hi Q-RPT is normally used, will overpressure and damage the Lo Q-RPT Vent pressure from the RPM4-E-DWT and shut off the Lo Q-RPT with the Lo Q-RPT shut off valve before continuing to use the Hi Q-RPT.

If the Hi Q-RPT is selected with the Lo Q-RPT active, RPM4-E-DWT goes into an alarm condition to avoid accidental overpressure of the Lo Q-RPT while using a Hi Q-RPT. The pressure on the Lo Q-RPT must be reduced to less than 100 psig (700 kPa) so that the CAUTION LO Q-RPT ACTIVE LED is OFF before shutting the Lo Q-RPT shut off valve and selecting the Hi Q-RPT.

The E-DWT pressure relief valve (Figure 10, Ref 7) is set to open at 150% of the RPM4-E-DWT Lo Q-RPT maximum range. When the pressure applied to the Lo Q-RPT reaches approximately 1 500 psi (10 MPa), the pressure relief valve will open exhausting oil to the reservoir and reducing pressure. Prior to opening the pressure relief valve, the RPM4-E-DWT will have gone into an overpressure condition (see Section 3.8.4.1). If an overpressure condition occurs, reduce pressure as soon as possible. The pressure relief valve will reseat automatically and close when pressure is reduced.

Do NOT overpressure the Lo Q-RPT. The Lo Q-RPT may be damaged beyond repair by pressure greater than 1 300 psi (9 MPa). Q-RPT damage from overpressure is logged in user and factory maintenance pages and is not covered by the product warranty. The E-DWT pressure relief valve should only be considered a last resort means of protecting the Lo Q-RPT. Following proper operating procedures, the Lo Q-RPT should never be over pressured.

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