Mensor CPC4000 Operating Manual

Industrial Pressure Controller

CPC4000

Operating Instructions

Industrial Pressure Controller CPC4000 PN 0019008001G • 03/2018

Industrial Pressure Controller
CPC4000

This Warning symbol indicates that danger of injury for
persons and the environment and/or considerable damage

!

Warning

!

Caution

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Notice

(mortal danger, danger of injury) will occur if the respective
safety precautions are not taken.

This Caution symbol indicates danger for the system and
material if the respective safety precautions are not taken.

This Notice symbol does not indicate safety notices but
information for a better understanding of the facts.

2 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

Table of Contents

1. General Information 8

1.1 Warranty 8

1.2 Important Notice 8

1.3 Radio Frequency Emission Notices 8

1.3.1 FCC Emission Notice 8

1.3.2 CE Emission Notice 9

1.4 Trademarks and Copyrights 9

1.5 Software License Agreement 9

1.6 Mensor Service Plus 9

1.6.1 After the Warranty 9

1.6.2 Calibration Services 9

1.6.3 Certications and Accreditations 9

1.7 Packaging for Shipment 9

2. Safety Notices 10

2.1 User Responsibilities 10

2.2 General Safety Notices 10

2.3 Warnings and Caution Notices 11

3. General Description 12

3.1 Features 12

3.2 Turning On 13

3.3 Front Panel 14

3.3.1 Power Switch 14

3.3.2 USB Port 14

3.4 Display 15

3.5 Chassis Assembly 16

3.5.1 Control Module 16

3.6 Electrical Block Diagram 17

4. Specications  18

4.1 Measure Specication 18

4.2 Base Instrument 19

4.3 Approvals and Certicates 20

4.4 Working Ranges of the Controller Modules 20

5. Installation 21

5.1 Unpacking the Instrument 21

5.2 Dimensions (mm)/ inches 22

5.3 Mounting 23

5.4 Rear Panel 23

Operating Instructions - CPC4000 3

Industrial Pressure Controller
CPC4000

5.4.1 Pressure Connections 23

5.4.2 Supply Port 24

5.4.3 Exhaust Port 24

5.4.4 Vent Port 24

5.4.5 Measure/Control Port 24

5.4.6 Reference Port 24

5.4.7 Barometric Reference Port 24

5.5 Remote Communication Connections 24

5.6 Power Up 24

6. Local Operation and Setup 25

6.1 General Operation 25

6.1.1 Setup Applications 25

6.1.2 Display Screen Features 25

6.2 Initial Setup 26

6.2.1 Contact and Version Information Application 26

6.2.2 Language Selection 26

6.3 Application Selection and Parameter Inputs 27

6.4 Applications 28

6.4.1 Home Application 28

6.4.1.1 Range Hold / Autorange 29

6.4.1.2 Control Setpoint 29

6.4.1.3 Units and Pressure Type 33

6.4.1.4 Bar Graph 33

6.4.1.5 Auxiliary Displays 33

6.4.1.6 Zero Button 35

6.4.1.7 Tare Button 36

6.4.1.8 Operating Mode Selection 37

6.4.2 Settings Application 38

6.4.2.1 Languages 38

6.4.2.2 Brightness 39

6.4.2.3 Volume 39

6.4.2.4 User Base Units / Base Units Multiplier 40

6.4.2.5 Barometer Units 40

6.4.2.6 Conguration 41

6.4.3 Control Settings Application 42

6.4.3.1 Control Behavior 43

6.4.3.2 Rate Setpoint 43

6.4.3.3 Stability Parameters 44

4 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

6.4.3.4 Control Volume 44

6.4.3.5 Control Limits 45

6.4.3.6 Vent Rate 45

6.4.3.7 Rate Stability Parameters 46

6.4.3.8 Detection Flags 47

6.4.4 Display Settings Application 48

6.4.4.1 Reading Filter 48

6.4.4.2 Reading Resolution 49

6.4.4.3 Cal Functions 49

6.4.4.4 Zero Reference Standard 50

6.4.5 Programs Application 51

6.4.5.1 Edit Programs 51

6.4.6 Favorites Application 53

6.4.7 Information Application 53

6.4.8 Troubleshooting Application 54

6.4.9 Remote Application 55

6.4.9.1 Remote Command Set 55

6.4.9.2 Remote Communication Settings 56

6.4.10 Step Settings Application 58

6.4.10.1 Preset Steps 59

6.4.11 Leak Test Application 60

6.4.12 Burst Test Application 61

6.4.13 Service Application 62

6.4.14 Unlocked Service Application 63

7. Remote Operation 64

7.1 Command Set 64

7.2 IEEE-488 64

7.2.1 IEEE-488.2 Commands 64

7.3 Ethernet 65

7.4 Serial 66

7.4.1 Serial Cable Requirements 66

7.5 Mensor Command Set 67

7.5.1 Command and Query Format 67

7.5.2 Command Set Denitions 67

7.5.3 Output Formats 68

7.5.4 Mensor Command Set and Queries 68

7.5.5 Units Command Syntax for Measurement Units 79

7.5.6 Error Messages 80

Operating Instructions - CPC4000 5

Industrial Pressure Controller
CPC4000

7.6 SCPI Command Set 80

7.6.1 SCPI Commands and Queries 80

7.6.2 Error Messages 83

7.7 DPI 510 Emulation Command Set 85

7.7.1 DPI 510 Supported Commands and Queries 85

7.7.2 DPI 510 Unsupported Commands and Queries 87

7.7.3 DPI 510 Measurement Units 88

7.8 GE PACE (SCPI) Emulation Command Set 89

7.8.1 SCPI GE Supported Commands and Queries 89

7.8.2 Error Messages 97

7.9 USB Software Upgrade 98

8. Options 99

8.1 Barometric Reference (CPX-A-C4-6) 99

8.1.1 Gauge Pressure Emulation 99

8.1.2 Absolute Pressure Emulation 99

8.1.3 Emulation Mode Accuracy 99

8.1.4 Barometric Reference Calibration 100

8.1.5 Barometric Reference Specications 100

8.2 Additional Transducers (CPR4000) 100

8.2.1 Secondary Transducer Installation 100

8.3 Rack Mount Kit (CPX-A-C4-R) 100

8.4 Fittings 101

8.5 Remote Calibration 101

8.5.1 Remote Calibration Kit for Internal Transducers (CPX-A-C4-4) 101

8.5.2 Barometric Reference Calibration Sled (CPX-A-C4-5) 102

8.5.3 External Calibration Procedures 102

8.6 Automatic Contamination Prevention System 103

8.6.1 Automatic CPS Installation 104

8.6.2 Automatic CPS Specication 105

8.6.2.1 Technical Specication 105

8.6.2.2 Dimensions [mm]/in 106

8.6.3 Automatic CPS Operation 106

8.7 Contamination Prevention Accessories 108

8.7.1 Coalescing Filter (CPX-A-C4-9) 108

8.7.2 Block and Bleed Valve (CPX-A-C4-8) 109

8.8 Pressure Booster 110

9. Maintenance 111

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Industrial Pressure Controller
CPC4000

9.1 Beyond the Warranty 111

9.2 Spare Parts 111

9.3 Transducer Removal 112

9.3.2.1 Barometric Reference Removal 113

10. Calibration 115

10.1 Calibration Services by Mensor or WIKA worldwide 115

10.2 Environment 115

10.3 Pressure Standards 115

10.4 Media 115

10.5 Setup 116

10.6 Calibration Data 117

10.7 One Point Cal Application 117

10.8 Two Point Cal Application 118

10.9 Linearization 119

10.10 Head Pressure 121

11. Technical Assistance 122

11.1 Options 122

11.2 Logging 123

11.2.1 Remote Logging 123

11.2.2 Pressure Logging 124

11.3 Touchscreen Calibration 125

11.4 Usage 126

12. Appendix 127

12.1 Measurement Units 127

12.2 Conversion Factors, PSI 128

12.3 Conversion Factors, Millitorr 129

12.4 Conversion Factors, Pascal 130

Operating Instructions - CPC4000 7

Industrial Pressure Controller
CPC4000

1 General Information

1.1 Warranty

All products manufactured by Mensor are warranted to be free of defects in workmanship and materials for

a period of two year from the date of shipment. No other express warranty is given, and no armation of

Seller, by words or actions, shall constitute a warranty. SELLER DISCLAIMS ANY IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSES WHATSOEVER. If any defect
in workmanship or material should develop under conditions of normal use and service within the warranty
period, repairs will be made at no charge to the original purchaser, upon delivery of the product(s) to the
factory, shipping charges prepaid. If inspection by Mensor or its authorized representative reveals that the
product was damaged by accident, alteration, misuse, abuse, faulty installation or other causes beyond the
control of Mensor, this warranty does not apply. The judgment of Mensor will be nal as to all matters con­cerning condition of the product, the cause and nature of a defect, and the necessity or manner of repair.
Service, repairs or disassembly of the product in any manner, performed without specic factory permis­sion, voids this warranty.

MENSOR MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MANUAL, INCLUDING,
BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. Mensor shall not be liable for errors contained herein or for incidental or con­sequential damages in connection with the furnishing, performance, or use of this material.

1.2 Important Notice

The product specications and other information contained in this manual are subject to change without

notice.

Mensor has made a concerted eort to provide complete and current information for the proper use of

the equipment. If there are questions regarding this manual or the proper use of the equipment, contact
Mensor at:

Mensor WIKA Alexander Wiegand SE & Co. KG
201 Barnes Drive Alexander-Wiegand-Straße 30
San Marcos, TX 78666 D-63911 Klingenberg / Germany
tel: [phone] tel: [phone]
1-800-984-4200 (USA only) website: www.wika.de
website: www.mensor.com fax: [phone]
fax: [phone] email: [e-mail]
email: [e-mail]

[e-mail]

1.3 Radio Frequency Emission Notices

WARNING: USE SHIELDED CABLES TO CONNECT EXTERNAL DEVICES TO THIS

!

Warning

1.3.1 FCC Emission Notice

INSTRUMENT TO MINIMIZE RF RADIATION.

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant
to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and used in accordance with the in­struction manual, may cause harmful interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference in which case the user will be required to cor­rect the interference at his or her own expense.

8 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

1.3.2 CE Emission Notice

This equipment is of the emission class A, intended for operation in industrials environments. It can
cause interference under certain circumstances if operated in other environments, i.e. residential or com­mercial areas. In this case, the user may be asked to take appropriate measures to correct it.

1.4 Trademarks and Copyrights

Mensor is a registered trademark of Mensor, LP. All other brand and product names are trademarks or
registered trademarks of their respective companies. ©2015, Mensor, LP. All rights reserved.

1.5 Software License Agreement

This product contains intellectual property, i.e., software programs, that are licensed for use by the end
user/customer (hereinafter “end user”).

This is not a sale of such intellectual property.

The end user shall not copy, disassemble or reverse compile the software program.

The software programs are provided to the end user “as is” without warranty

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Notice

of any kind, either express or implied, including, but not limited to, warranties

ofmerchantabilityandtnessforaparticularpurpose.Theentireriskofthe

quality and performance of the software program is with the end user.

Mensor and its suppliers shall not be held to any liability for any damages suered or incurred by the end

user (including, but not limited to, general, special, consequential or incidental damages including dam-

ages for loss of business prots, business interruption, loss of business information and the like), arising

from or in connection with the delivery, use or performance of the software program.

1.6 Mensor Service Plus

If you have problems and you don’t nd the answer in this manual, contact Mensor at 1-800-984-4200

(USA only) or 1-512-396-4200 for personal assistance, or at any of the contact addresses listed on the
rear cover of this manual. We are ready to help.

1.6.1 After the Warranty

Mensor’s concern with the performance of this instrument is not limited to the warranty period. We pro-

vide complete repair, calibration and certication services after the warranty for a nominal fee.

1.6.2 Calibration Services

In addition to servicing our own products Mensor can perform a complete pressure calibration service,
up to 30,000 psi, for all of your pressure instruments. This service includes an accredited calibration.

1.6.3 CerticationsandAccreditations

Mensor is registered to ISO 9001:2008. The calibration program at Mensor is accredited by A2LA, as
complying with both the ISO/IEC 17025:2005 and the ANSI/NCSL Z540-1-1994 standards.

1.7 Packaging for Shipment

If the product must be shipped to a dierent location or returned to Mensor for any reason through a com­mon carrier it must be packaged properly to minimize the risk of damage.

The recommended method of packing is to place the instrument in a container, surrounded on all sides
with at least four inches of shock attenuation material such as styrofoam peanuts.

Operating Instructions - CPC4000 9

Industrial Pressure Controller
CPC4000

2 Safety Notices

2.1 User Responsibilities

To ensure safety, the user must make sure that:

• The system is used properly, no dangerous media are used and that all technical specications are

observed.

• The system is operated in perfect operating condition.

• This operation manual is legible and accessible to the user at the system’s location.

• The system is operated, serviced and repaired only by authorized and qualied personnel.

• The operator receives instruction on industrial safety and environmental protection, and is knowledge­able of the operating instructions and the safety notices contained therein.

2.2 General Safety Notices

The system should only be operated by trained personnel who are familiar with

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Notice

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Warning

this manual and the operation of the instrument.

WARNING: A condition for trouble-free and safe operation of this system is proper
transport, proper storage, installation, assembly and proper use as well as careful
operation and maintenance.
Any operation not described in the following instructions should be prohibited.
The system must be handled with care required for an electronic precision instru-

ment(protectfromhumidity,impacts,strongmagneticelds,staticelectricityand

extreme temperatures). Do not insert any objects into the instrument.
The system is powered via the power cable with a voltage that can cause physi­cal injury. Even after disconnecting the system from the power supply, dangerous
voltages can temporarily occur due to capacitance.
Extreme care must be taken with pressure connections when using hazardous or
toxic media.
Repairs must only be performed by authorized service personnel.

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Notice

10 Operating Instructions - CPC4000

Additional safety notices are found throughout this manual.

Industrial Pressure Controller
CPC4000

2.3 Warnings and Caution Notices

WARNING: HIGH PRESSURE! High pressure gases are potentially hazardous.
Energy stored in these gases and liquids can be released suddenly and with

!

Warning

!

Warning

!

Warning

extreme force. High pressure systems should be assembled and operated only by
personnel who have been trained in proper safety practices.

WARNING: NOT EXPLOSION PROOF! Installation of this instrument in an area
requiring devices rated as intrinsically safe is not recommended.

WARNING: POSSIBLE INJURY! The tubing, valves, and other apparatus attached
to the gauge must be adequate for the maximum pressure which will be applied,
otherwise physical injury to the operator or bystanders is possible.

!

Caution

!

Caution

!

Warning

CAUTION: USE THE PROPER PRESSURE MEDIUM! Use only clean, dry, non-corro-

sivegasesunlessotherwisespeciedbyMensor.Thisinstrumentisnotdesigned

for oxygen use.

CAUTION: As with most sensitive electronic equipment, switch the power switch

obeforeconnectingordisconnectingtoapowersourcetopreventdataloss.Do
notpositiontheequipmentsothatitisdiculttodisconnectthepowerjack.

WARNING: Detachable main power supply cord with inadequate ratings should

notbeused.SeeSection4.0-Specicationsforpowerratings.

CAUTION: ESD PROTECTION REQUIRED. The proper use of grounded work
surfaces and personal wrist straps are required when coming into contact with
exposed circuits (printed circuit boards) to prevent static discharge to sensitive
electronic components.

Additional Warning and Caution notices are found throughout this manual.

Operating Instructions - CPC4000 11

Industrial Pressure Controller
CPC4000

3 General Description

The CPC4000 Industrial Pressure Controller is a single-channel / multi-range automatic pressure con­troller designed to test and calibrate a variety of pressure devices such as pressure gauges, pressure
switches, sensors, transducers and transmitters in either absolute or gauge pressure modes. The
CPC4000 can have up to two highly stable precision transducers and an optional barometric reference.
The CPC4000 is available as a desktop or a rack mountable instrument.

Figure 3.1 - Desk top version

3.1 Features

Here is a short list of signicant features designed into the CPC4000:

• Up to two highly stable, temperature compensated, internal pressure transducers.

• Broad operating pressure range from -15 … 3,045 psig/ -1 … 210 bar or 0 … 3,060 psia/ 0 … 211 bar

absolute.

• 0.02% Intelliscale-50 accuracy.

• An optional removable / interchangeable internal high accuracy barometric reference transducer

providing gauge pressure emulation for absolute ranges and absolute pressure emulation for gauge
ranges.

• Auto-ranging between the two pressure transducers to provide seamless transition between all

ranges.

• 7” Color LCD with touch screen.

• Leak test and burst test application.

• Multiple languages; change the language for on-screen text and number/date formats by simply

touching one of the “national ag” icons available in the setup screen.

• Desk top or rack mount

• Local operation, or command and read remotely.

12 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

3.2 Turning On

You can conrm that your CPC4000 is operational right now. Apply power to the power connector on the

rear of the instrument with the included power cord, remove any plastic plugs from the rear panel pres­sure ports, and press the power switch to ON. The system will go through an initialization process, which
takes about 30 seconds, and then a display will appear similar to the screen shown below.

Power Switch
ON/OFF

Earth Ground! Any power adaptors or surge protection devices that negate the

!

Caution

protective earth ground should not be used. The power cord must be accessible
and contain a protective earth ground. Do not position the equipment so that it is

diculttoremovethepowercord.

Ventilation!Donotblockairowtoventilatingfanslocatedonrearofinstrument.

!

Caution

To see information about the conguration of your new CPC4000, touch the Next Page Button [ ]
then the Information Application (App) icon [ ] on the menu and a window will appear listing the
Mensor customer service contact, model number and the transducers that are installed. Press the
Previous Page Button [ ] then the Home App [ ] to return to the main screen.

Information Application

Operating Instructions - CPC4000 13

Industrial Pressure Controller
CPC4000

3.3 Front Panel

The CPC4000 front panel includes a 7” color LCD with touch screen. Operator input is accomplished by
pressing the words or symbols and the App icons presented on the display. There is a single discrete on/
o button and a USB port on the right hand side. The front panel also shows the model number designa­tion and brand logos.

3.3.1 Power Switch

The power switch is a two-state device with an action similar to that of a ball point pen. Push the button
with enough force to latch it in to turn the unit ON. Push it again to release it to turn the system OFF.

If power to the instrument is interrupted while ON it will shut down until the power is

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Notice

3.3.2 USB Port

The front panel USB port acts like the Host USB and is intended for future expansion or software up­grades.

restored, then immediately resume operation.

14 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

3.4 Display

The display is made up of two sections. In the main screen (“Home Application”), the left three fourths
shows the operating screen with the control channel. The control channel displays the active pressure
reading, units, mode (absolute or gauge), active range of the internal transducer, pressure control set­point, a bar graph (if enabled), a zero or tare button (if enabled) and any auxiliary displays that have been
chosen. The right one fourth of the screen has Application Icons (“Apps”) for setting general instrument
settings, control settings, display settings, program settings, favorites plus a “Next Page” butt
that, when pressed, shows a second and third page of icons for information, troubleshooting, remote
communication, step setting, leak test, burst test and service applications.

Active transducer

range

Optional Zero or Tare

Current Value

Optional Bar graph

Units and Mode

on [ ]

Auxiliary Displays

{

Operating Modes

Operating Screen Settings Apps

Buttons, Labels and Windows: The CPC4000 touch screen has many buttons with relevant graphic
icons or text which, when pressed, will open a related window where changes can be made or informa­tion viewed. Some of these buttons will toggle from one state to another, others present choices or dis­play a numerical data entry screen. Text or icons that are displayed, but do not respond to being touched,
are called labels or windows. Operators will quickly become accustomed to the particular characteristics
of the frequently used buttons.

Main Screen: The main screen or “Home Application”, appears after power-up. This screen contains the

operating screen and Settings application screen. It will remain as congured after a power cycle.

Operating screen: The operating screen (left 3/4 of the screen) contains information relevant to the
measurement. Up to three auxiliary displays can be shown simultaneously along with the current pres­sure value. The operating mode of the instrument can be selected and changed in this screen between
“Measure”, “Control” and “Vent”.

Operating Instructions - CPC4000 15

Industrial Pressure Controller
CPC4000

3.5 Chassis Assembly

The chassis assembly is the housing for the system. The transducers are self-contained inside the chas­sis and can be replaced using basic hand tools. Figure 3.5 shows the top view of the chassis with the
cover removed.

Figure 3.5 – Chassis Assembly

3.5.1 Control Module

The control module is referred to as the “Solenoid Valve Regulator” (SVR Module). The SVR Module is
available in four variations depending on the working pressure range:

• Low Pressure SVR Module (LPSVR)

• Medium Pressure SVR Module (MPSVR)

• High Pressure SVR Module (HPSVR)

• Extra High Pressure SVR Module (EPSVR)

Pressure limits for all of these are specied in Section 4, Specications.

Each control module includes platforms for up to two high performance pressure transducers, CPR4000,
which are traceable to NIST standards. Both of these transducers can be used in conjunction with the
highly stable pressure regulator to produce a precise output. Each transducer includes its own on-board
compensation and calibration data so that any transducer can be replaced in the instrument without
requiring a recalibration.

Figure 3.5.1 – Pressure Transducer

16 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

3.6 Electrical Block Diagram

Figure 3.6 – Electrical Block Diagram

Operating Instructions - CPC4000 17

Industrial Pressure Controller
CPC4000

4 Specications

Accuracy specications presented herein are obtained by comparison with primary standards traceable
to a national metrology institute or recognized international standard organization. These specications

are obtained in accordance with the ISO Guide to the Expression of Uncertainty in Measurement (GUM).
The calibration program at Mensor is accredited by the American Association of Laboratory Accreditation
(A2LA) as complying with both the ISO/IEC 17025:2005 and the ANSI/NCSL Z540-1-1994 standards. If
there is an exception to the requirements and recommendations of Z540 during a calibration the excep-

tion is noted on the individual calibration certicate.

Mensor reserves the right to change specications without notice.

4.1 MeasureSpecication

Reference pressure transducer model CPR4000

Pressure range Standard Optional

Accuracy

Gauge pressure 0 ... 0.35 to 0 ... 210 bar

Bi-directional pressure -0.17 ... 0.17 to -1 ... 210 bar

Absolute pressure

Precision

Calibration interval 365 days 365 days

Optional barometric reference

Function The barometric reference can be used to switch pressure types 6), absolute <=> gauge. With gauge

Measuring range 8 …. 17 psi abs. (552 … 1,172 mbar abs.)

Pressure units 39 and two freely programmable

1) It is dened by the total measurement uncertainty, with the coverage factor (k = 2) and includes the intrinsic performance of the instrument, the measurement uncertainty of the reference

2) FS = full span

3) 0.02% IS-50 accuracy: Between 0 ... 50% of the full scale, the accuracy is 0.02% of half of the full scale value and between 50 ... 100% of the full scale, the accuracy is 0.02% of reading.

4) The minimum calibrated range of absolute transducer(s) is 600mTorr

5) It is dened as the combined eects of linearity, repeatability and hysteresis throughout the stated compensated temperature range

6) For a pressure type emulation, we recommend a native absolute pressure transducer, since the zero point drift can be eliminated through a zero point adjustment.

(1)

4)

5)

instrument, long-term stability, inuence of ambient conditions, drift and temperature eects over the compensated range with recommended zero point adjustment every 30 days.

0.02% FS

(0 ... 5 to 0 ... 3,045 psi)

(-2.5 ... 2.5 to -15 ... 3,045 psi)

0 ... 1 to 0 ... 211 bar abs.
(0 ... 15 to 0 ... 3,060 psi abs.)

0.008% FS 0.008% FS

pressure transducers the measuring range of the transducers must begin with -15 psi (-1 bar) in order to
carry out a complete absolute pressure emulation

2)

0.02% IS-50

0 ... 1 to 0 ... 210 bar
(0 ... 15 to 0 ... 3,045 psi)

-1 ... 10 to -1 ... 210 bar
(-15 ... 145 to -15 ... 3,045 psi)

0 ... 1 to 0 ... 211 bar abs.
(0 ... 15 to 0 ... 3,060 psi abs.)

3)

18 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

4.2 Base Instrument

Instrument

Instrument version Standard: desktop case

Dimensions See technical drawings

Weight approx. 127 kg (28 lbs) with all internal options

Warm-up time approx. 15 min

Display

Screen 7.0” color LCD with resistive touchscreen

Resolution 4 … 6 digits depending on range and units

Connections

Pressure connections 4 ports with 7/16”- 20 F SAE, 1 port with 1/8” F NPT and 1 port with 10-32 UNF female

Filter elements The instrument has a 40-micron lters on all pressure ports.

Pressure port adapters Standard: without

Barometer port adaptors Standard: barb tting

Permissible pressure media Dry, clean air or nitrogen (ISO8573-1:2010 Class 5.5.4 or better)

Wetted parts Aluminum, brass, 316 and 316L stainless steel, Buna N, FKM/FPM, PCTFE, PEEK, PTFE, PPS,

Overpressure protection Safety relief valve xed to reference pressure transducer and adjusted to specic measuring range

Permissible pressure

Supply port 110% FS or 0.69 bar (10 psi), whichever is greater

Measure/Control port max. 105 % FS

Voltage supply

Power supply AC 100 ... 120 V, 50/60 Hz; AC 220 ... 240 V, 50/60 Hz

Power consumption max. 150 VA

Permissible ambient conditions

Storage temperature -20 ... 70 °C (-4 ... 158 °F)

Humidity 5 … 95 % r. h. (relative humidity, non-condensing)

Compensated temperature range 15 … 45 °C (59 ... 113 °F)

Mounting position horizontal

Control parameter

Control stability < 0.005% FS of the primary range, in precision mode

Control mode precision, high speed and custom

Control time 10 s (regarding a 10% FS pressure increase above atm. in a 50 ml test volume, in high speed mode)

Control range 0 ... 100% FS

Minimum control pressure 0.0017 bar (0.025 psi) over exhaust pressure or 0.05% FS whichever is greater

Overshoots < 1% FS in high speed control mode (typical <0.1% FS in precision control mode)

Test volume 50 ... 1,000 ccm

Communication

Interface Standard: Ethernet, IEEE-488, USB, RS-232.

Command sets Mensor, WIKA SCPI, others optional

Response time approx. 100 ms

Internal program up to 24 sequences of 99 steps each

Option: 19” rack-mounting kit

Option:

6 mm tube tting, 1/4” tube tting, 1/4” female NPT ttings, 1/8” female NPT ttings or 1/8” female

BSP ttings

Option: 6mm tube tting, 1/4“ tube tting

glass-lled epoxy, RTV, ceramic, silicone, silicone grease, Urethane

Operating Instructions - CPC4000 19

Industrial Pressure Controller
CPC4000

4.3 ApprovalsandCerticates

EC declaration of conformity

EMC directive

Low voltage directive EN 61010-1

RoHS directive 2011/65/EU, article 4

Certicate

Calibration

7) Warning! This is class A equipment for emissions and is intended for use in industrial environments. In other environments, e.g. residential or commercial installations, it can intefere with

other equipment under certain conditions. In such circumstances the operator is expected to take the appropriate measures.

8) Calibration in a horizontal position/operating position.

4.4 Working Ranges of the Controller Modules

7)

8)

EN 61326-1 emission (group 1, class A) and interference immunity (industrial application)

Standard: A2LA calibration certicate (standard on factory)
Option: DKD/DAkkS calibration certicate

Bi-directional or gauge pressure [bar (psi)]

1)

-1 (-15) 0 3.4 (50) 10 (150) 100 (1,500) 210 (3,045)

LPSVR MODULE ±0.17 bar (±2.5 psi)

MPSVR MODULE ±0.35 bar (±5 psi)

HPSVR MODULE -1 ... 5 bar (-15 ... +75 psi)

Absolute pressure [bar (psi)]

2)

2)

2)

EPSVR MODULE -1 ... 10 bar (-15 ... +150 psi)

1)

2)

0 4.4 (65) 11 (165) 101 (1,515) 211 (3,060)

LPSVR MODULE 0 ... 1 bar (0 ... 15 psi)

MPSVR MODULE 0 ... 1 bar (0 ... 15 psi)

HPSVR MODULE 0 ... 6 bar (0 ... +90 psi)

1) Mixing of absolute pressure and gauge pressure transducers in a module is not possible.

2) Smallest acceptable transducer range

For controlling absolute pressure a vacuum pump connected at the exhaust port is required.

2)

2)

2)

EPSVR MODULE 0 ... 11 bar (0 ... 165 psi)

2)

20 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

5 Installation

!

Warning

5.1 Unpacking the Instrument

In addition to functional testing, each unit is inspected for appearance prior to leaving the factory. Upon
receipt, please examine the instrument for shipping damage. Report any apparent damage to the carrier
immediately.

In addition to this manual you should have:

• CPC4000 Industrial Pressure Controller

• Power Cord

• Fitting adapters ordered

• Any accessories ordered

• An envelope containing the calibration certicate(s)

• A Quick Start Guide for all Mensor products

• A USB drive containing all Mensor manuals

WARNING: READ THESE INSTRUCTIONS BEFORE INSTALLATION!

Operating Instructions - CPC4000 21

Industrial Pressure Controller
CPC4000

5.2 Dimensions (mm)/ inches

Front view Side view

19” rack mount

Rear Panel

22 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

5.3 Mounting

The instrument can be set up on a desk top or it can be rack-mounted. Rack mount hardware is optional
on the CPC4000 (see Section 5.2 Dimensions and Section 8, Options).

The special transducers used in the CPC4000 are relatively insensitive to tilt and vibration. However to
further assure stability and accuracy, avoid mounting the instrument on surfaces subject to excessive mo­tor or machinery vibration.

5.4 Rear Panel

Five pneumatic pressure ports are located across the rear panel. Any instrument containing sub-atmo­spheric pressure ranges needs a vacuum pump to be connected at the exhaust port. The instruments
with pressures above or at atmospheric pressures will have the exhaust port open. Next to the ventilation

fan is a 10-32 UNF tting which is connected to the barometric reference if installed. Below the ventilation

fan is the connection to drive the automatic contamination prevention system. Positioned on the right side
is a remote communication connections; RS-232, Ethernet, IEEE- 488, USB along with the USB host
connection.

Figure 5.4 A – Rear Panel

5.4.1 Pressure Connections

Warning! The pressure connections must be installed according to the following

instructions, observing the relevant regulations. The installation is to be per-

!

Warning

formed by trained, authorized personnel, knowledgeable in the safety regulations
for working on pneumatic/hydraulic systems.

Five pressure connections are on the rear panel. Plugged connections are not used.

i

Notice

All pressure ports on the rear apart from the Vent Port are female 7/16 - 20 SAE/MS straight threads per

MS16142 and SAE J514 table 14. Connected adaptors require a tube tting boss seal with an o-ring per
MS33656. Mensor can provide a variety of adapter ttings (see Section 8 Options) with the instrument.
Do not use sealant on ttings sealed with an o-ring. The integrity of each seal is particularly important

since even microscopic leaks can cause errors in pressure measurements.

Operating Instructions - CPC4000 23

Industrial Pressure Controller
CPC4000

5.4.2 Supply Port

The pressure supplied to the pressure connection labeled “Supply” should be approximately 10% higher
than the full scale of the highest pressure transducer installed in the controller or 10 psi, whichever is
greater (see section 6.2.1).

5.4.3 Exhaust Port

The pressure connection labeled “Exhaust” is for the vacuum supply. In a gauge pressure version it can
be left open to atmospheric pressure.

5.4.4 Vent Port

The pressure connection labeled “Vent” is the exhaust port where the system pressure is vented to the

atmosphere under certain conditions. This port has a breather vent installed that acts like a muer. Leave

this port open.

5.4.5 Measure/Control Port

The Measure/ Control port (when in the Control mode) supplies pressure that is precisely controlled by
the controller. In the Measure mode, a pressure applied to the Measure/Control port is measured by the
internal transducers.

5.4.6 Reference Port

The pressure connection labeled “Reference” is the reference port, it is available to connect to the refer­ence side of the transducer. This port is normally left open to atmosphere but may be connected to a
stable reference pressure. In an absolute pressure transducer this port is not used.

5.4.7 Barometric Reference Port

The Barometric Reference port is connected to the optional internal barometer and should be left open to
atmospheric pressure.

5.5 Remote Communication Connections

See Section 7, Remote Operation, for connections and commands for operation over IEEE-488, Ether­net, USB or RS-232 ports.

5.6 Power Up

Apply power to the power connector on the rear of the instrument using the power cord included, and
switch the power switch on the front of the unit ON. The instrument will go through an initialization pro­cess and system check. As soon as the system check is completed the system will default to a screen

similar to the one shown in Section 6.1.2 - Display Screen Features. The main screen may be congured
in many dierent ways but initially it will be in a default conguration. Subsequently, the unit will power
up in the conguration that it was in when last powered o. Allow at least 15 minutes of warm up before

performing critical pressure measurements.

Donotpositiontheequipmentsothatitisdiculttoremovethepowercord.Theinstrument

is not intended for connection of long-distance lines, i.e. lines within a building that are longer
than 30 m, or that leave the building (including lines of outdoor installations).

24 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

6 Local Operation and Setup

6.1 General Operation

This section describes the procedures for operating the CPC4000 from the front panel. Instructions for
operating the device remotely from an external computer are covered in Section 7, Remote Operation. By
following the procedures provided in these two sections and Section 10, Calibration, you can expect your
CPC4000 to deliver maximum accuracy and dependability for many years of useful service.

6.1.1 Setup Applications

Conguration of the CPC4000 is achieved by changing settings accessed through the Application (“App”)

buttons. Local operation is accomplished by observing the data presented in the display. The appearance
and functionality of the display can be changed by pressing the App button for the related function. After
an app has been chosen, a set of related parameters will appear. After choosing one of these param­eters, a set of selections related to that parameter will appear or a data entry keypad.

The desired selection or data can be entered here.

6.1.2 Display Screen Features

The screen shown below provides an overview of the features shown on the display after initialization.
The left three fourths of the display contains the area where information is displayed (in this case the
Home Application) and the right one fourth contains the selection icons for each application. A zero or
tare button, bar graph and auxiliary displays (Peak, Rate, Rate Setpoint, Uncertainty, Units or Barometer)
will appear in the Home App if activated. All of the CPC4000 screen features are described in more detail
throughout this manual. The active App is represented in a lighter gray color as compared to the other
Apps.

Active transducer

range

Optional Zero or Tare

Current Value

Optional Bar graph

Units / Pressure Type

Auxiliary Displays

Operating Modes

{

Operating Screen Settings Apps

Figure 6.1.2 – Display Screen Features

Operating Instructions - CPC4000 25

Industrial Pressure Controller
CPC4000

6.2 Initial Setup

Section 6.2.1 and 6.2.2 are provided rst so that the operator can initially check the information screen to

verify the installed components and to change the language if needed.

6.2.1 Contact and Version Information Application

Navigate to the App selection area by pressing the Next Page button [ ] at the right bottom
under the App buttons. This gives access to the second page of the App selection area. Press
the Information App button [ ] to display Mensor contact, installed transducers, installed
regulator along with instrument and software version information.

6.2.2 Language Selection

Pressing the settings application button will open a screen where the language, display bright-

ness, volume, user base units/multiplier and conguration loading/saving, can be changed. The

current language selections available are shown in the table below. Additional language choices
will appear on the screen after pushing the Next Page button [ ]:

Language Country

English USA

German Germany

French France

Spanish Spain

Italian Italy

Chinese China

English Great Britain

German Switzerland

French Switzerland

Spanish Mexico

Russian Russia

Korean Korea

English Canada

French Canada

Polish Poland

Japanese Japan

Figure 6.2.1 – Information

26 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

6.3 Application Selection and Parameter Inputs

The application selection/input area on the right one fourth of the screen (see Figure 6.1.2 - Display
Screen Features) is the area where setup, information, calibration, service and other Apps can be cho­sen. Multiple pages of application selections can be accessed by pressing the Next Page button [
] or by pressing the Previous Page button [ ]. A series of horizontally placed circles on the bottom
right represents the number of pages and indicate the active page by a larger circle. As each App is cho­sen, related application parameters will appear on the left three fourths of the screen along with the name
of the application, and a reduced size icon in the top title section. When a parameter is chosen, related
selections, sliding scales or a data entry key pad will appear in the input area on the right where the appli­cation selection buttons were previously displayed. An example of each type of input is shown below. To
return to the App selection menu, simply press the Menu button [ ] above the input area. The purpose
and use of each selection and menu is intuitively apparent and will become second nature with minimal
exposure to the menu structure.

App Title

Menu Button

Input Title

Operating Instructions - CPC4000 27

Industrial Pressure Controller
CPC4000

6.4 Applications

6.4.1 Home Application

The Home App is the normal operation screen. This application is dierent from the others in
that it is not used to setup the conguration but is used to monitor the pressure applied to the

installed transducers and the device under test through the measure / control port.

The screen in gure 6.4.1-A shows the basic Home App in an instrument. The user can change the

display to show multiple auxiliary displays by pressing the auxiliary button on the left corner of the screen

(gure 6.4.1-B). The Units button is always displayed. When the Units button is pressed a selection of
imperial and metric units will be displayed on the right (gure 6.4.1-C); notice that the Units button has a

lighter background when the selection menu is active. If a barometric reference is installed, the Mode but­ton, described below, will toggle from Gauge to Absolute mode when pressed.

Figure 6.4.1-A – Basic Home App

Figure 6.4.1-B – Single Channel Display Figure 6.4.1-C – Pressure Units

28 Operating Instructions - CPC4000

Industrial Pressure Controller
CPC4000

6.4.1.1 Range Hold / Autorange

The Range Hold / Autorange button allows the user to select the active range. By clicking the Range Hold
button, the user can select the active transducer from the primary and secondary transducers or utilize
the “Autorange” feature to let the instrument automatically select the active range based on the current
pressure value.

Range Hold button

Figure 6.4.1.1 – Mode Label

6.4.1.2 Control Setpoint

The Setpoint button allows the user to enter the desired pressure value to be controlled by the instru­ment. There are multiple ways of entering the control setpoint: numeric keypad, step increments, percent­age entry, digital step or a program data entry. These methods can be accessed by the user by pressing
the “Setpoint” button and the various setpoint entry methods can be navigated with the Next Page [ ]
and Previous Page [ ] buttons.

Setpoint button

Figure 6.4.1.2 – Setpoint Button

Operating Instructions - CPC4000 29

Industrial Pressure Controller
CPC4000

6.4.1.2.1 Numeric Keypad

The rst entry method provides 10 digits for numeric entry, plus the decimal point and a sign key (gure

6.4.1.2.1). The sign key [+/-] will toggle between positive and negative values. Each stroke on the key pad
will echo in the blue input value window above the pad. A change between plus and minus values [+/-]
can be entered at any time during the string entry. Pressing the Enter [ ] button will accept the value
and it will become the setpoint.

If the input window holds an illegal value when the Enter button is pressed the system will respond with
an error tone and the entry will turn red. When that happens determine the cause of rejection, delete the
entry using the Delete [ ] button and then enter a valid number. The setpoint can only be entered
within the minimum and maximum control range set in the Control Settings App (section 6.4.3.5). These
limits are shown above the numeric entry keypad.

Min & Max
setpoint values

Figure 6.4.1.2.1 – Numeric Keypad Setpoint Entry

6.4.1.2.2 Step Increments

The second entry method allows the user to enter the setpoint in the same way as the Numeric Keypad
by keying in the value and then pressing the Enter [ ] button. The user can then enter the desired
value of step increment and press the Step Up [ ] or Step Down [ ] button, without pressing the
Enter button. This number will then be used to decrease or increase the existing setpoint value. Subse­quent touches of the Step Up or Step Down button will continue to increase or decrease the setpoint by
the step value. If the Enter button is pressed the newly entered value will register as a new setpoint value
on the Home Screen rather than a step value.

Figure 6.4.1.2.2 – Numeric Keypad with Step Increments

30 Operating Instructions - CPC4000