WIKA CPC3000 User Manual
Operating Instructions
Pneumatic High-Speed Pressure Controller
CPC3000
Pneumatic High-Speed Pressure Controller Model CPC3000 Version 1.1
Pneumatic High-Speed Pressure Controller CPC3000
Warning
Caution
Notice
This Warning symbol indicates that danger of injury for persons and the
environment and/or considerable material damage (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.
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Contents
1. General notices 5
1.1 FCC Radio frequency emission notice
1.2 Software license agreement
1.3 Accreditations
1.4 Packaging for Shipment
2. Safety notices 7
2.1 User Responsibilities
2.2 General safety notices
2.3 Safety notices regarding operation
3. Product description 10
3.1 Proper use
3.2 Features
3.3 Turning on the CPC3000
3.4 Front panel
3.5 Main menu
3.5.1 Keys, Tabs, Check Boxes, Labels/Graphics
3.6 Front Panel Variations and Navigation
3.6.1 Operating modes
3.7 Main menu setpoint entry options
4. Specifications 17
5. Installation 18
5.1 Introduction
5.2 Unpacking of the system
5.3 Dimensions of the available version in mm
5.4 Installation of the system
5.5 Rear panel
5.6 Pressure connections
5.7 Function of pressure connections
5.8 Electrical connections
5.8.1 Connecting the power supply and turning on the instrument
5.8.2 Connecting the Communications interfaces
6. Starting operation 23
7. Operation via Touch-screen 24
7.1 Setting the operating language
7.2 Display configuration
7.3 Setpoint Entry
7.4 Operating modes
7.5 Data Entry
7.6 Pressure unit, Pressure mode and Emulation mode
7.7 Bar Chart
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7.8 SETUP Menus
7.8.1 SETUP Display
7.8.2 SETUP Control
7.8.3 SETUP Remote
7.8.4 SETUP Info
7.8.5 SETUP Service
8. Remote Operation 40
8.1 Remote SETUP
8.2 Remote SETUP - Ethernet
8.3 Remote SETUP - USB
8.4 Remote SETUP - IEEE-488
8.5 Remote Command Set
8.5.1 Mensor Command Set
8.5.2 PCS 400 Commands Emulated
8.5.3 PCS 200 Commands Emulated
8.5.4 DPI 510 Commands Emulated
8.5.5 IEEE 488.2 Commands
8.5.6 SCPI Commands
9. Trouble-shooting measures 56
9.1 Table: Fault description and measures
10. Re-calibrating and servicing 58
11. Removal of the system 59
12. Transport of the system 60
13. Storage of the system 61
14. Placing out of service 62
15. Appendix 63
1. Table - Measurement Units
2. Table - Conversion factors, Pascal
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1. General notices
In the following chapters detailed information on the pneumatic high-speed pressure control-
ler model CPC3000 and its proper use can be found.
Should you require further information, or should there be problems which are not dealt with
in detail in the manual, please contact the following address:
WIKA Alexander Wiegand SE & Co. KG
Alexander Wiegand Strasse
D-63911 Klingenberg
Tel. +49 - (0) 93 72 / 132-9986
Fax +49 - (0) 93 72 / 132-217
E-mail: testequip@wika.de
All integrated pressure sensors are calibrated.
The warranty period for the pneumatic high-speed pressure controller model CPC3000 is 24
months according to the general terms of supply of ZVEI.
All guarantee claims lapse if the system is put to improper use or if the operating instructions
are not observed or if an attempt is made to open the system.
We also point out that the contents of these operating instructions does not form part of an
earlier or existing agreement, assurance or legal relationship or is meant to change these. All
obligations of WIKA Alexander Wiegand SE & Co. KG result from the respective sales contract
and the general business terms of WIKA Alexander Wiegand SE & Co. KG.
WIKA is a registered trade mark of WIKA Alexander Wiegand SE & Co. KG. All other brand
and product names are trademarks or registered trademarks of their respective companies.
We reserve the right to effect reasonable changes on the basis of technical improvements.
Any reproduction of this manual or parts thereof by any means is prohibited.
Version key regarding firmware and respective manual
Manual Firmware
V1.1 V 1.0
© 2009 Copyright WIKA Alexander Wiegand SE & Co. KG.
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1.1 FCC Radio frequency emission notice
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 interfer-
ence 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.
Use shielded cables to connect external devices to this instrument to minimize
rf radiation.
Notice
1.2 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 of
any kind, either express or implied, including, but not limited to, warranties of
merchantability and fitness for a particular purpose. The entire risk of the quality
Notice
and performance of the software program is with the end user.
WIKA, Mensor and its suppliers shall not be held to any liability for any damages
suffered or incurred by the end user (including, but not limited to, general,
special, consequential or incidental damages including damages for loss of
business profits, business interruption, loss of business information and the
like), arising from or in connection with the delivery, use or performance of the
software program.
1.3 Accreditations
WIKA is registered to ISO 9001:2000. The calibration program at WIKA is accredited by DKD,
as complying with both the ISO/IEC 17025:2005 standards. All Mensor primary standards are
traceable to PTB.
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1.4 Packaging for Shipment
If the product must be shipped to a different location or returned to WIKA 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 10 cm of shock attenuation material such as styrofoam peanuts.
2. Safety notices
2.1 User Responsibilities
To ensure safety, the user must make sure that:
The system is used properly (refer to 3.1 "Proper use" in the chapter 3. "Product descrip-
tion"), no dangerous media are used and that all technical specifications are observed.
Safety mechanisms exist, which exclude any danger to persons or machinery through
improper pressurisation.
The system is only operated in perfect operative 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 staff which is authorised and quali-
fied to do so.
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 this manual and the operation of the instrument.
Caution
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.
Warning
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Any operation not described in the following instructions should be prohibited.The system must be handled with the care required for an electronic
precision instrument (protect from humidity, impacts, strong magnetic
fields, 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.
Pneumatic High-Speed Pressure Controller CPC3000
Extreme care must be taken with pressure connections when using
hazardous or toxic media.
Warning
Repairs must only be performed by authorized service personnel.
Additional safety notices are found throughout this manual.
2.3 Safety notices regarding operation
HIGH PRESSURE! High pressure gases are potentially hazardous. Energy
stored in these gases can be released suddenly and with extreme force.
High pressure systems should be assembled and operated only by person-
Warning
nel who have been trained in proper safety practices.
POSSIBLE INJURY! The tubing, valves and other apparatus attached to
the controller must be adequate for the maximum pressure which will be
applied, otherwise physical injury to the operator or bystander is possible.
Caution: use the proper pressure medium. Use only clean, dry non-corrosive gases. This instrument is not designed for oxygen use.
Caution
The user must use caution when controlling from a very high pressure
down to a very low pressure when a vacuum pump is connected to the
Vacuum/Exhaust port. Large volumes of gas may be present in the device
Warning
under test and will exhaust through the Vacuum/Exhaust port in excess
of the capacity of the internal relief valve, possibly causing damage to the
vacuum pump.
Caution
Warning
HIGH SOUND LEVELS! Pressures from 40 bar and up can generate sound
levels above 100 db for brief periods when they are exhausted directly to
atmosphere. If no muffling devices are attached to the VACUUM/EXHASUT
or VENT port, then ear protection is advised for personnel in the vicinity of
the instruments that will be operated under such conditions.
NOT EXPLOSION PROOF! Installation of this instrument in an area requiring devices rated as intrinsically safe is not recommended.
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 damage to sensitive electronic components.
Before the system is switched on, the user must verify that the system was
installed correctly and that all connections meet current regulations.
The user must ensure that all specifications such as supply voltage,
operating temperature, humidity, sensor-specific pressure media and
pressure ranges are observed.
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Before pressurizing, the user must ensure through appropriate protective
measures that the system or the device will not be overpressurized. When
working with or on an instrument, safety glasses should be worn.
Warning
In areas where the system is operated there must be sufficient air ventilation due to inert gases that will escape during use.
High pressure can accelerate parts in a manner that could be hazardous
and cause physical injury.
Additional warning and caution notes are included throughout this manual.
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3. Product description
3.1 Proper use
The Pneumatic High-Speed Controller model CPC3000 is a bench top or rack mounted Digital
Pressure Calibrator/Controller used for test and calibration of mechanical pressure gauges,
pressure switches, sensors, transducers, transmitters and any pressure related devices where
time to set point is the most critical requirement.
Only dry clean air or nitrogen should be used as the pressure medium.
Shop air should be avoided and corrosive, oxidizing, condensing, explosive
gasses should be strictly avoided.
Warning
The maximum permissible supply pressure at the SUPPLY port should be
10 % over full scale value of the sensor installed.
Very fast pressure changes can damage the sensor, due to mechanical
stress on the sensor; especially if the fast pressure change leads to an
internal pressure which is higher then the full scale of the internal sensor
(even if it is only for a fraction of a second). In some cases, the internal
relief valves cannot react quickly enough to protect the sensor.
Notice
Warning
The Internal pressure sensors have a calibration certificate (see enclosure:
calibration certificate) for the entire measuring chain.
The system is not suitable for use in areas with an explosion hazard.
If the CPC3000 is not used according to this manual, safe operation of the
system is not guaranteed.
The user of the system and not the manufacturer is responsible for all
personal and material damage resulting from improper use!
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3.2 Features
1. The CPC3000 will control (up scale or down
scale) into a 150 ml volume, to within
0.025 % of the set point, in 3 seconds or
less.
2. Accuracy of 0.025 % FS, one year calibra
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tion interval.
3. Lightweight compact case with bezel and
handle or 19" rack mount kit.
4. Manual operation via the color touch screen
and easy access to auxiliary screens allow
quick changes to the set point using the
"STEP" and "JOG" screens.
5. Remote operation over IEEE-488, USB 2.0,
or Ethernet.
6. Emulation of other conventional controllers.
7. An optional internal high accuracy baromet
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ric reference sensor for emulation of gauge
pressure and absolute pressure.
8. A large color SVGA LCD display with a
touch screen for intuitive operator interface.
9. Multiple languages.
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3.3 Turning on the CPC3000
The power switch is located on the rear of the instrument as shown in "Figure - Rear Panel".
Power Switch
Figure - Rear Panel
3.4 Front panel
The CPC3000 front panel (see above: "Figure - Front panel") includes a 7 inch colour SVGA
display featuring touch screen technology. Operator input is accomplished by pressing the
number, words or symbols presented on the display. There are no mechanical keypads or
switches on the front panel.
Figure - Front Panel
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3.5 Main menu
When the CPC3000 is powered up it takes about one minute for initialization, then displays a
screen similar to the "Figure - Initial Screen" below.
User defined control range limits
(configurable via SETUP-CONTROL)
SETUP menu
Stability indication
Current pressure value
Bar graph
Pressure Units
Operating mode
JOG key pad selection tab
STEP key pad selection tab
Numeric key pad selection tab
Numeric keypad
Delete selected set point
Delete last entered digit
Accept selected set point
Figure - Initial Screen
3.5.1 Keys, Tabs, Check Boxes, Labels/Graphics
Keys: There are two types of keys: those that act as a switch to change a condition and
those that open a data entry screen when pressed. Keys have borders with a three dimensional, shadowed effect (examples: , ). Throughout this
manual keys are represented with the displayed characters enclosed in brackets (Example
[MEASURE] ) or a description and the actual graphic icon (Example [SETUP] ). Pressing a key will have one of the following results: 1) instant, single step response, 2) continuously repeating steps while the key is held down, 3) the key will change colors indicating
that the associated function is active or 4) a data entry dialog box will open. Operators will
quickly become accustomed to the particular characteristics of the frequently used keys.
Tabs: Tabs are analogous to tabs in a notebook that allow switching quickly between relat-
ed screens. Tabs are keys that allow the operator to switch between a group of screens that
have a similar purpose, for example the tabs allow the operator to quickly
switch between three screens used to enter the setpoint.
Check Boxes: Check Boxes allow for the inclusion or exclusion of specific elements or
conditions.
Labels and Graphics: Labels and Graphics are text, or graphic that display information,
but do not respond to being touched (examples: ). They indicate
choices that have been made in the SETUP menus or indicate existing conditions as
pressure is controlled or measured.
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3.6 Front panel variations and navigation
Bar Graph: The bar graph shows the relative indication of the range of the internal sensor, the
user defined limits on the internal sensor, the unused portion of the internal pressure sensor
range, the setpoint and the magnitude of the actual controlled pressure. The user defined
control limits can be selected in the MAIN -> [SETUP] -> CONTROL SCREEN and can be
set to correspond to the range of the device under test. It is important to note that when
the STEP key pad is active in percent mode each step is a percent of the user defined
limit not the full scale of the internal sensor. This is useful when calibrating or testing
various range devices. "Figure - Bar Graph" shows the bar graph when the CPC3000 is in
control mode controlling a pressure at the setpoint.
Bar graph shows relative indication of:
Range of the Internal sensor
User defined limits
Unused portion of the internal sensor range
Setpoint
Current pressure reading
Figure - Bar Graph
3.6.1 Operating modes
Press to select mode:
MEASURE
In MEASURE mode, the instrument measures the pressure connected to the MEASURE
port (on changing from CONTROL mode: the last controlled pressure will be held/sealed in
the connected test assembly).
CONTROL
In CONTROL mode the instrument provides a very precise pressure at the MEASURE port.
VENT
VENT opens MEASURE port to atmospheric pressure.
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Optional elements can be chosen in the [SETUP-DISPLAY] screen explained in chapter 7.8.1
of this manual. Each optional element is displayed in the area below the pressure units.
Area for optional
elements
Communication status
Optional barometric reference display
Figure - Optional Display elements
Navigation to the SETUP screens is achieved pressing the Icon. SETUP "Figure -
SETUP Display Screen" shows the SETUP screen with the display table activated. Other
tabs at the bottom are used to navigate to additional SETUP screens. SETUP screens will be
discussed in detail in chapter 7.8 of this manual.
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Figure - SETUP Display Screen
Pneumatic High-Speed Pressure Controller CPC3000
3.7 Main menu setpoint entry options
Pressure setpoint entry options are chosen using the tab keys .
"Figure - Numeric Keypad" shows the main menu with the numeric keypad selected.
Figure - Numeric Keypad
"Figure - STEP Keypad" shows the main menu with the STEP keypad selected.
Figure - STEP Keypad
"Figure - JOG Keypad" shows the main menu with the JOG keypad selected.
Figure - JOG Keypad
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4. Specifications
Specifications CPC3000
Pressure ranges bar -1 ... +70 (depending on sensor)
Pressure types Absolute, gauge or bi-directional ranges
Precision % FS < 0.015
Accuracy % FS < 0.025
Pressure units 33 selectable and 2 freely definable
Control stability % FS < 0.004
Slew rate sec.
Control range % FS 0 up to 100
Test volume ccm 50 ... 1,000 (without throttle)
Pressure ports mm 4 ports with 7/16"- 20 F SAE. incl. 6 mm tube fitting adaptors
Filter elements 40 micron filter element included in each pressure port
Permissible pressure media clean dry non-corrosive gases
Wetted parts aluminium, brass, 316 and 316L stainless steel, Buna N, FPM/FKM,
Overpressure protection safety relief valve
Instrument version desk top/optional: incl. rack mounting kit
Screen 7.0" colour LCD with touch-screen
Resolution digits 4 ... 6
Internal measuring rate 1/sec 25
Display update 1/sec 4
Warm-up time min approx. 15
Digital Interface Ethernet, IEEE-488, USB
Command sentences Mensor, SCPI, others optional
Power Supply V AC 100 … 240, 50-60 Hz
Energy Consumption VA maximum 90
Permissible pressure
Supply port % FS ~ 110
Measure/Control port % FS max. 105
Permissible
Operating temperature °C 10 … 50
Storage temperature °C 0 ... 70
Air humidity % 0 … 95 (relative humidity without moisture condensation)
Operating position Horizontal or slightly tilted
Compensated temperature
range
Weight kg approx. 9.1
Dimensions mm see technical drawings
CE-mark Conformity certificate
Calibration* Incl. factory calibration certificate 3.1 per DIN EN 10 204
°C 15 …. 45
< 3 (with a sudden pressure increase of 10 % FS in a 150 ml test volume)
glass filled epoxy, RTV, Nylon, Ceramic
* Calibration in a horizontal position.
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5. Installation
5.1 Introduction
The initial installation of the CPC3000 includes the following steps: Unpack the system, place
it in a suitable workspace, connect it, switch it on and configure.
5.2 Unpacking the system
Unpack all components of the CPC3000 carefully and check the parts for damage. Report
any damage immediately to the forwarding agent.
Apart from any additional components ordered, a shipment consists of:
CPC3000 controller
¼" and 6 mm tube fitting adapters
Main cable
Manual with calibration certificates in the enclosure
Optional: recommend Interface cable or any other accessories ordered
5.3 Dimensions of the available version in mm
Front view Side view
Rear view
The instrument can be set up on a table top or it can be rack-mounted. Rack mount adapters
are optional on the CPC3000 and require an adapter panel.
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5.4 Installation of the system
The installation site must meet the following conditions:
Operating Temperature: 10 to 50 °C
Humidity: 0 to 95 % relative humidity non-condensation
Flat, horizontal location; secure fixed working surface (desk top model) or installation in a
19" rack mount.
At the back of the instrument sufficient air circulation must be provided for to avoid an
accumulation of the heat conducted to the outside via the fan.
During operation, pressure escapes through the VENT port in the back of the instrument.
Personnel should not have access to the rear VENT and EXHAUST port during operation.
Avoid the following influences:
Direct sunlight or proximity to hot objects
Unstable installation position
Mechanical vibration
Proximity to sources of strong electromagnetic fields, such as high tension appliances,
mobile telephones or mains
Soot, steam, dust and corrosive gases
Environment with explosion hazard, inflammable atmospheres
Pressure supply requirements:
Stable supply pressure 10 % higher than the full scale of the internal transducer
Permissible media: dry, clean air or nitrogen
Vacuum: min. 50 litres/min (if required)
An angle of inclination of the system of more than 3 degrees can cause a deviation in the measured pressure and should be avoided. Zeroing the unit at the
angle of inclination will nullify this deviation.
Notice
Applying supply pressure higher than the recommended pressure can
cause permanent damage to the control channel!
Warning
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5.5 Rear panel
Four pneumatic pressure ports are located on the rear panel (see below: "Figure - Rear
panel"). Positioned on the left are the ethernet and RS-232 and GPIB connector, the off/on
switch, the line fuses, and a protective grill covering the ventilating fan.
Fan
Mains input socket
Micro fuse
Power supply
5.6 Pressure connections
The pressure connections must be installed according to the following
instructions, observing the relevant regulations. The installation should be
performed by persons familiar with, and who can work according to, the
Warning
safety regulations for working on pneumatic/hydraulic systems.
Ethernet USB
IEEE-488.2
Figure - Rear panel
Supply Port
Measure/Control Port
Reference Port
Vent
Exhaust/Vacuum Port
When making up a connection to an o-ring adapter port use a back-up wrench
to prevent over-stressing the threads in the manifold block.
Notice
All of the pressure ports on the rear are female 7/16 - 20 SAE/MS straight threads per
MS16142 and SAE J514 table 14.
They require a tube fitting boss seal with an o-ring per MS33656.
WIKA provides female 1/4 inch and 6 mm tube fittings with the instrument.
The pressure connections can be made to these adapters with the proper mating hardware.
Do not use sealant on fittings sealed with an o-ring.
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5.7 Function of pressure connections
MEASURE/CONTROL port
Below the label "MEASURE/CONTROL" is a pressure connection. In MEASURE mode
this connection connects the pressure applied to the internal sensor where the pressure
is measured (within the range of the internal sensor). In CONTROL mode this connection
supplies an output pressure controlled by the internal regulator at the commanded setpoint.
SUPPLY port
Below the label "SUPPLY" is a pressure connection. This connection should be supplied
with a pressure that is approximately equal to 110 % of the full scale pressure of the internal sensor. In other words, 10 % above the full scale pressure of the internal sensor
“SUPPLY Pressure” in the specifications chapter for supply pressure and pressure media
requirements.)
EXHAUST/VACUUM port
Below the label "EXHAUST/VACUUM" is a pressure connection.
If a sub-atmospheric control pressure is required a vacuum pump must be connected to
this port. Otherwise, this port may be left open to atmosphere.
(see
The user must use caution when controlling from a very high pressure
down to a very low pressure when a vacuum pump is connected to the
exhaust port. Large volumes of gas may be present in the device under
Warning
test and will exhaust through the EXHAUST/VACUUM port in excess of
the capacity of the internal relief valve, possibly causing damage to the
vacuum pump.
VENT outlet
Below the label "VENT" is the pressure outlet. In VENT mode the pressure within the system
is released through this outlet.
HIGH SOUND LEVELS! Pressures from 40 bar and up can generate sound
levels above 100 db for brief periods when they are exhausted directly to
atmosphere. If no muffling devices are attached to the EXHAUST/VACUUM
Warning
and VENT port, then ear protection is advised for personnel in the vicinity
of the instruments that will be operated under such conditions.
REFERENCE port
On gauge units this port is connected to the reference side of the transducer, and on
absolute units it is internally capped. This port is normally left open to atmosphere.
The controller must be protected from over pressure.
Warning
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Pipes, couplings and other components used for connecting the supply
exhaust and the MEASURE/CONTROL port must be suitable for the application and rated for the applied pressures.
The user must ensure that the pressure media are clean and dry. If necessary, the internal sensors and mechanisms must be protected by using a
liquid trap or coalescing filter.
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