RS 213-0844 = DPI 603 20 BAR RS 215-0832 = DPI 603 10 BAR RS 215-0826 = DPI603 2 BAR DPI 603 PORTABLE PRESSURE CALIBRATOR USER MANUAL DPI 603 Portable Pressure Calibrator @ Druck Ltd 1395 This documents the progeny of Druck Limited ard may not, ether in part or whole, be copied or atherwise ‘eproducod, communicated in any way to third parias nor stored in ary Data Procassing system, without the express written authority of Druck Limited K184 Issue 2 iSAFETY ‘The Manufacturer has designed this product to be entirely safe when operated correctly. © Please pay close attention to the Safety Instructions outlined on this page and elsewhere in this manual. They have been designed to protect the user from Personal injury and the equipment from damage. © Potentially hazardous operations are indicated in the text by means of a hazard warning triangle. Specific warnings relating to each section of the manual are given at the beginning of that section. © Please observe the installation advice and any operational limits given in this, manual. @ This equipment must only be used for the purpose for which it was designed Pressure Safety Do not permit pressures greater than the Safe Working Pressure to be applied to the instrument. The specified Safe Working Pressure for the instrument is stated in the Specification section of this manual. Electrical Safety The instrument is designed to be completely safe when used with Options and Accessories supplied by the manufacturer for use with the instrument. Toxic Materials No toxic materials are employed in this equipment Repair and Maintenance ‘The instrument must be maintained, either by the manufacturer or a competent person. Please refer to supplier for details of approved service agents. Section 6 also gives a list of Druck Subsidiaries who will be able to assist and advise. Software Issue This User Manual supports Software Issue No. 1.XX cE This product meets the essential protection requirements of the relevant EEC directives. Further details of applied standards may be found in the product specification. K184 Issue 2 iiCONTENTS 1 INTRODUCTION Description 1.4 Instrument Specification Vat Pressure Specification Pressure Ranges Maximum Sate Working Pressure Accuracy (Pressure) Combined Non-Linearty, hysteresis and repeatability Pressure Temperature Effects Pressure Output 142 Electrical Specification Power Supplies Voltage Measurement Range Current Measurement Range Voltage Output Consiant Current Circuit Display Electrical Connections Power Adaptor/Charger Units Environmental Specification Options Accessories Applications Test Method Table 1.1 - Typical Calibration Configurations INSTALLATION Power Supply 1 Fitting Batteries (Figure 2.1) 212 Battery Charging 2.2 Instrument Configuration 224 User Units Configuration 2.3 Electrical Connections Electrical Safety Instructions 24 Pneumatic Connections 244 Pressure Safety Instructions 24.2 Connection 3 OPERATING INSTRUCTIONS 3.1. Introduction 3.2 Operator Controls 324 Zeroing The instrument 3.3. Set Up Display Mode 33.4 Set Pressure As Main Display 33.2 ‘Change Pressure Units Table 3.1 - Pressure Scale Units 333 Single Display 334 Set Dual Display, Voltage or Current with Pressure K184 Issue 2 iil ONDRRYOOOOSOENNNNANNRNN=— BESRSKIteoo 15 15 18 16 16 17 7 18 19 1934 3.5 354 35.2 3.5.3 3.5.4 355 41 4.2 4.241 43 44 444 442 45 4.6 461 4.6.2 54 5.2 54 - 55 Generating an Output Pressure Pressure Safety Instructions Procedure - Generate Output Pressure Electrical Measurements Electrical Satety Instructions: Voltage Measurements Current Measurements 24V D.C. Output Current Loop Tests Pressure Switch Tests CALIBRATION Calibration Check Calibration Adjustment General Procedures Checking Pressure Calibration Checking Electrical Calibration Voltmeter Current Pressure Calibration Electrical Calibration Voltage Range Current Range MAINTENANCE Safety Instructions Battery Replacement Fault Finding Cleaning Approved Service Agents K186 Issue 2 iv at at 21 21 22 22 22 25 25 26 26 a7 a7 27 28 30 30 31 33 33 33, 34INTRODUCTION Description The DPI 603 is a portable pressure calibrator, intended for use in remote locations for pressure testing and calibration of pressure devices and systems. This microprocessor based instrument uses an internally mounted pressure transducer to measure the pneumatic pressure applied to the outlet port. This pressure may be generated locally. The local pressure generation facilities are by means of a hand operated pump, capable of supplying pressures up to 20 bar gauge maximum and, optionally, by means of a manually operated changeover valve, negative pressures to -850 mbar gauge. The electrical features of the instrument include a fully isolated 24V de electrical output, a fully floating constant current source, a voltmeter and a milliammeter. The 24V de supply is capable of supplying a load current of 25mA and is designed to energise external devices (¢.g.) pressure transmitters. The fully floating constant current source is provided to enable the testing of ‘external current loops. The constant current source provides a controlled loop current of nominally 12mA and can be used in conjunction with the instrument's built-in 24V electrical output to provide 4 constant current source. It may also 'be usad in conjunction with an extemal power supply (30V max), ta sink a loop current of 12mA, The built-in, voltmeter and milliammeter provide electrical monitoring facilities. tis possible to configure the display to read pressure, voltage or current or, in dual display mode, to read pressure and current or pressure end voltage. In dual display mode, pressure is always the primary (top) display A dc input socket allows for the connection of a combined power adaptor/charger unit. Either alkaline D-cells or rechargeable D-cells can be fitted to power the instrument. When alkaline cells are fitted, the instrument is configured to inhibit the charging facility. K184 Issue 2 11.1. INSTRUMENT SPECIFICATION 1.1.1 Pressure Specification Pressure Ranges “110 1 bar gauge (Overpressure to 4 bar max) “110 2 bar gauge (Overpressure to 8 bar max) -1 to 10 bar gauge (Overpressure to 26 bar max) -1 to 20 bar gauge (Overpressure to 25 bar max) Maximum Safe Working Pressure 25 bar Accuracy (Pressure) Combined non-linearity, hysteresis and repeatability Alll pressure range versions + 0.075% Full Scale Pressure Temperature Effects All versions (0° to 40°C) £05 % (T.E.B) Pressure Output Type Handpump and Volume Adjuster Pump Range 1 to 20 bar gauge Pressure/Vacuum Changeover Manual Switch (Only with Pressure/Vacuum Option) 1.1.2 Electrical Specification Electrical Safety Meets EN61010-1 as applicable. Power Supplies External d.c. supply 3.5 to 12V (Max) d.c. Internal batteries 4x0 Cell Battery life Standard D-Cell 20 hours approx Alkaline D-Cell 70 hours approx Nicad (4 Ah) 18 hours approx Battery charge current (NiCad only) 400A K184 Issue 2 2Voltage Measurement Range Maximum voltage Accuracy Input current Input impedance ‘Temperature coefficient Current Measurement Range Maximum current ‘Accuracy Sense resistance ‘Temperature stability Voltage Output Output Voltage 450V dc. 40.15% of reading, +0.02% F.S. 20 WA max 5 MO. 40.01% of reading per °C 455mA dc. 40.075% of reading, +0.005% F.S. 109 40.01% of reading per °C 2AV dc., +0.5V Maximum Supply Current 25mA Constant Current Circuit Nominal current 12mA dc. ‘Maximum external voltage source 30V de. Polarity bipolar Output fully floating Display Main display 5 x 7 segment characters Secondary Display Electrical Connections Test Connections Power Adaptor/Charger 1.1.3. Environmental Specification Temperature Operating Storage EMC 16 Aipha/Numeric characters 4mm Socket 2.1mm concentric plug -10° to +50°C. -20° to +70°C. This equipment complies with the European EMC directive and meets EN50081-1 Emissions NS0082-1_ Immunity WARNING: The equipment is designed for use in @ Glass A industrial environment. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. K184 Issue 2114 1S Pressure Media Clean, dry gas Weight 42kg Dimensions 195 mm (Wide) x 320 mm (Deep) x 126mm (high) Options A - Pressure/Vacuum Capability ‘A manually operated valve, located between the pump and volume adjuster, Permits the pump to generate negative pressures. Pressure/Vacuum Changeover Manual Changeover Valve Negative Pressure Capability -850 mbar Positive Pressure capability As instrument full scale B - Rechargeable Batteries Ni-Cad rechargeable cells can be supplied, complete with an external charger unit. Battery Size D-Cell Battery Capacity 4 Ampere Hour Operating Period (With fully charged cells) 18 Hours Approx Power Adaptor/Charger Units Four power adaptoricharger units can be supplied depending on input supply voltage requirements. Frequency range (all types} 48 to 65 Hz Power output (al types) 9V dc. at 500mA Power input 230V a.c (U.K.) Part No. 191-054 Power input 230V a.c (Europe) Part No. 191-057 Power input 100V a.c. (Japan) Part No. 191-062 Power input 120V a.c. (U.S.) Part No. 191-055 Accessories ‘The standard DP! 603 instrument is despatched with the following items: User Manual (K184, Part No. 197-211) User Guide (K187, Part No. 197-217) Calibration Certificates Sot of Test Leads 1 set of 4, standard type, O-cells (Not fitted) Camying Case K184 Issue 2 41.2 APPLICATIONS By combined use of the independent pressure and electrical functions, the instrument can be used ina number of ways. The following sections outline a few of the more common applications. 1.2.1, Test Method Generally, the instrument is used to either generate, positive or (optionally) negative pressures, for calibrating extemal devices or to measure an applied pressure. The electrical functions of the instrument can be used to provide an excitation supply for external devices, to measure voltages and currents generated by extemal devices and to provide a fully floating constant current supply for current loop test appiications. For all types of device connected to the DP! 603 instrument, the following set-up procedure should be adopted. @ Ensure that the vent valve on the instrument is open. @ Make the pressure connection between the instrument and the device under test. @ Make the electrical connections between the instrument and the device under test. Use only the recommended 4mm plug connections to connect to the instrument. DO NOT PUSH BARE WIRES INTO THE SOCKETS. © Switch the instrument ON. @ Zero the pressure range and voltage or current ranges as required © Check the test set up before applying any pressures. Note: The Maximum safe working pressure must NOT be exceeded. © Close the vent valve and carry out the required test (calibration). Table 1.1 details the types of test that can be carried out with the DP! 603. The figure number quoted in the table refers to the drawing which shows the corresponding connections to the instrument. K184 Issue 2 5Transmitter Calibration Loop test, 12mA current source Loop Test, Externally Powered, 12mA Currant Source Pressure Switch Testing Table 1.1 - Typical Calibration Configurations SET DUAL DISPLAY ' PRESSURE/CURAENT Figure 1.1 - Transmitter Calibration K184 Issue 2 64 ZomA INDICATOR LOAD READS APPROX 50% FULL SCALE SET MAIN DISPLAY TO CURRENT Loor Figure 1.2 - Loop Test, 12mA Current Source S0V de. (max) SUPPLY ‘SET MAIN DISPLAY ‘TO CURRENT DISPLAY/TRANSMITTER, Figure 1.3 - Loop Test, Externally Powered, 12mA Current Source K164 Issue 2 7SWATCH OPEN - CURRENT ZERO SET DUAL DISPLAY PRESSURECURRENT SWITCH CLOSED - CURRENT 12m8 “PRESSURE ‘SWITCH Uk I) =e > Leaving cortets ost tr ing pied wl shorn baty ie Figure 1.4 - Pressure Switch Testing 184 Issue 2 82. INSTALLATION 21 Power Supply The instrument can be powered from internal batteries or from an (optional) external power adaptor/charger unit. Four D-cells are supplied with each instrument. These may be either standard dry cells, alkaline cells or rechargeable Nicad calls, depending upon the option ordered. 2.1.1 Fitting Batteries (Figure 2.1) D0 NOT ATTEMPT TO CHARGE ORY CELL SATTERIES, THIS INSTRUMENT IS CONFIGURED BY DEFAULT TO INHIBIT BATTERY CHARGING WHEN DRY CELLS ARE FITTED. CHECK CONFIGURATION (REFER TO SECTION 2.2) BEFORE CONNECTING THE EXTERNAL POWER UNIT/CHARGER. Caution: @ = Old batteries can leak and cause corrosion. © Never leave discharged batteries in the instrument. To fit the batteries, refer to Figure 2,1 and proceed as follows. @ Turn the instrument over to expose the battery compartment. © Release the battery cover retaining screws and raise the cover to expose the battery compartment. @ — Fitthe batteries as shown ir Fig 2.1 observing the polarity indicated © Tighten the captive screws, turn the instrument over and switch the instrument on by pressing the VO key. The instrument will bleep and an indication should appear on the display. During the start-up period, the battery status will be reported (e.9.) Battery O.K. It dry cells are fitted and a Battery Low indication is given, replace them immediately with new cells. © Check that the instrument is correctly configured for the type of cells, fitted (Refer to Section 2.2) Note: ifrechargeablo cells are fitted, they may not initialy be tully charged and may give rise to @ Battery fow indication. Fit the power adaptoricharger unit and charge the batteries, (refer to Section 21.2), K184 Issue 2 9CAPTIVE SOCKET SCREW FIT SIZE D. IEC R20. ALKALINE OR RECHARGEABLE 1 BATTERIES Figure 2.1 - Battery Compartment K184 Issue 2 102.4.2. Battery Charging It rechargeable cells are fitted, proceed as foliows. Check configuration (see Section 2.2), to ensure that the instrument is Configured for NiCad batteries. Remove the dust cover from the power inlet socket (see Fig 2.2) and insert the power uniticharger output connector. Input level is 9V de at SOOmA, centre pole negative. A set of fully discharged batteries will require 14 hours to recharge. 2.2 Instrument Configuration The instrument configuration function allows it to be configured for operation from standard dry cells or rechargeable iiCad cells. It also enables the special (USER) units conversion factor to be set up for units selection {refer to Section 2.2.1). To set up the instrument configuration, proceed as follows. . Switch the instrument on by pressing the WO key. Immediately press the P and Zero keys together. The instrument responds by briefly displaying Battery O.K. and Configuration. It then prompts for a PIN number to be entered (e.9.), Enter PIN: 000 Enter a valid configuration PIN number. Initially, this PIN number is set to 123. A lasting cursor appears over the first digit position. Press the P? key 40 Scroll through the digits 0 through 9 and when the correct digit for this position is displayed, press the I-+ key to move to the next digit position. Scroll through the numbers using the PT key and when the correct digit for this position is displayed, use the |-> key to move to the final digit position. Select the final digit by using the PT key. When the full PIN has been entered, press the Ve- Key to accept the entered PIN. If the PINs incorrectly entered, access to the Configuration function is denied. The configuration status of the batteries is now reported (2.9) Battery: Dry In this configuration, battery charging is inhibited when the external power uniticharger Is connected. To accept the configuration as reported, press the Ve key. To change the configuration, press the PT key. The indicated status will now change as follows (€.9.), Battery: Nicads In this configuration, battery charging is enabled. The internal battories will automatically be charged when the external power unit/charger is connected. To accept the configuration, prass the Ve~ key. K184 Issue 2 W2.2.1. User Units Configuration Following selection and acceptance of the battery type, the conversion factor for the special (USER) units, selectable under the pressure units menu {see Section 3.3.2), is displayed (2.9.), USER Pa : 10000 This indicates that curently, 7 USEA unit = 10000 Pa Set the required conversion factor at the first cursor position by using the PT key. Use the I-+ key to move along to the next cursor position and repeat the process for this digit. When all the digits hava been entered, check the displayed conversion factor is correct and press the Ve- key to accept the entered value. 2.3 Electrical Connections(Figure 2.2) © — Electrical Satety Instructions WHEN THE INSTRUMENT IS POWERED FROM LOW VOLTAGE DC (¥, 500mA) ENSURE THAT THE CORRECT VOLTAGE AND POLARITY IS USED. USE ONLY THE MANUFACTURER'S RECOMMENDET ADAPTOR/CHARGER UNIT. POWER Electrical connections are made to the panel located on the top end of the instrument, (refer to Figure 2.2}. These comprise the following. @ External power adaptor/charger unit (2.1 mm concentric plug, centre pole negative) @ — 24V de, 25mA max, fully floating supply (Red +ve, Black -ve). © Loop test constant current (12mA) source sink (both terminals yellow - non polarity sensitive) © Volimeter and miliammeter inputs (Black{com}, Red (V +ve), Rad (1 +ve). Connections to the sockets are made via 4mm piugs and matching test leads are supplied with the instrument. Caution: Use 4mm plugs, do not push bare wires into the sockets. K184 Issue 2 12©)000 0000 sare Aime oe Figure 2.2 - Instrument Connections 2.4 Pneumatic Connections K184 Issue 2 Pressure Safety Instructions ALWAYS CHECK FOR TRAPPED PRESSURE BEFORE CONNECTIONIDISCONNECTION OF PRESSURE COUPLINGS. ENSURE THAT CORRECTLY RATED PIPES AND FITTINGS ARE USED. Connection To connect up to the instrumant’s output port, proceed as follows. ° Open the instrument's vent valve and ensure that the pressure supply or the external system to be connected to the instrument is at zero pressure before connection. Fit the pressure input/output line to the output por, fiting a bonded seal between the pressure union and the output port. The output port has a G% thread. Ensure that the coupling is tight. 13K184 Issue 2 143 OPERATING INSTRUCTIONS 3.1 Introduction ‘The DPI 603 can, depending upon the pressure range chosen, calibrate at pressures up to 20 bar gauge. Section 1, Specification, gives delails of the pressure ranges available. The instrument has the facilities to generate both positive and negative output pressures (negative pressure facility optional), or to monitor applied external pressures. WARNING Do not exceed the Maximum Working Pressure of the instrument. (Refer to Section 1). Additionally, the instrument provides a fully isolated, 24V de electrical output for energising external devices (e.g.) transducers A cigital multimeter (MM) facility, comprising a 0 to SOV de voltmeter and a 0 to '55mA milliammeter is built into the instrument to permit monitoring of voltage and current signals. ‘A 12mA, fully isolated constant current source, provides an external current loop test facility. 3.2 Operator Controls (Figure 3.1) The operator controls for this instrument comprise five keys which are located on a membrane keypad as shown on Figure 3.1 Bijppi cos. eeae 7. non eaogh OB Seon J—e{ 5 20080 mber 9 owe OD @® @ Figure 3.1 - DPI 603 Keypad K184 Issue 2 153.2.1. Zeroing The Instrument The Zero key is used in conjunction with the PT, I> and Ve keys to zero any small offsets in the Pressure, Current and Voltage displays respectively. To zero a displayed function, press the appropriate function key and press Zero (e.g.), pressing P followed by Zero would zero the pressure display. A message (e.g.) Zeroing P is briefly written to the display as the operation is carried out. Note: If the display offset is > 5% of full scale reading, an error message Large Offset is displayed, indicating that the error is too large for the zero function The Zero key, when operated at the same time as the P key during the power up pariod, is used to select the Configuration mode, (refer to Section 2.2.) 3.3 Set up Display Mode The instrument display is divided into two sections, a main (large character, seven segment) display and a secondary (smaller, dot matrix) display. The main display located at the top of the display window and the secondary display at the bottom of the window. The following display modes are available. K184 Issue 2 Pressure as main display Voltage as main display Current as main display Dual display, Pressure main, votiage secondary Dual display, Pressure main, current secondary. 162.3.1. Set Pressure As Main Display This is the default display mode which is always entered when the instrument is ‘switched on. The display is as shown below. To set this display mode from any other display mode, proceed as follows. @ Press the P key once. A typical display is shown below (e.9.), DPIG603 Sam. Pts fae % FS 20008 mbar 9 ven 3.3.2 Change Pressure Units ‘When the instrument is delivered, a pressure unit will be allocated to the P key and the I key (e.g) mbar and psi. To display the units allocated to the function keys, press the P key. A typical display is shown below. cOnug a mbar ran @ > @® K184 Issue 2 7To change the units selected by either of these keys, press and hold the appropriate key until the allocated units legend starts to flash. Sequential pressing of that key will then scroll through the 24 units available for allocation to that key. ‘When the required unit is displayed, press one of the other function keys (P if the key is being set up, | if the P key is being set up, or the V key for either). The selected unit will now be allocated to the appropriate key. Table 3.1 gives a full list of the units available to each key. nit Symbol Woe * Pascal We io Pascal MPa reg Pascal rae bar oo logram per square cantmeve gin? ogra par square aie nits rinare of Mercy ent entire of Morey nti wae of Mercury mao miarote of water nko canter oF water mio reve of water tor 1/760 1 eam (1 en Meu) an axnosphere ps oun pe eavare eh one ‘aud ter po square foot inh inch of Meeury "008 Trak ol water ataS H,004 toot of wate @ 40 USER Special Unt Seo Soet82.1) 020 toch ot water @ 20° W020 {estat water @ 20-0 hea ect Panel Table 3.1. - Pressure Scale Units ‘The user units are for the selection of any special units conversion factor that may be required. Refer to Section 2.2.1 for datails of the procedure for setting up the conversion factor. K184 Issue 2 183.3.3 Single Display To set voltage or current as the main display. proceed as follows. @ ~~ Voltage: Press the V key. @ Current: Press the I key. A typical display is shown below. B prices sex, coagg z Voltmeter FS + SBU Poin Co Cy) 3.3.4 Dual Display, Voltage or Current with Pressure To set voltage or current with pressure as the main display, proceed as follows. © Pressure and Voltage: Press the V and P keys together. © Pressure and Current: Press the | and P keys together. When the two solection keys are pressed simultaneously, a long beep is emitted and pressure is displayed in the main display in the upper window and the selected electrical function in the lower window. A typical display is shown below. B)pricos ax. nnn UUUU % 23896V ber 9 omen K184 Issue 2 193.4 Generating An Output Pressure © Pressure Safety Instructions ALWAYS CHECK FOR TRAPPED PRESSURE BEFORE CONNECTION/DISCONNECTION OF PRESSURE LINES. ENSURE THAT CORRECTLY RATED PIPES AND FITTINGS ARE USED. © Procedure Generate Output Pressure To generate an output pressure, proceed as follows. ° ° Not K184 Issue 2 ‘Open the instrument's vent valve. Connect the external device/system to the output port. The output port uses a GY coupling. Use a Dowty washer between the output connector and the port On instruments to which the pressure/vacuum option is fitted, set the output selector switch, located between the handpump and the volume adjuster, to +ve or -ve as required. ‘Switch the instrument ON using the VO key. Set up the display to tead the required parameters as detailed in Section 3.3 and set the required pressure scale units by pressing the P key to display the units available and then using the P or I key to select the units required. Refer to Section 3.3.2 if required pressure units are not displayed, Close the vent valve. Press the Zero key followed by the P key to remove any zeto offset and zero the display. Use the handpump to pressurise the system to the required level. Allow the display to settle. Screw the volume adjuster in or out as a fine adjustment to the required pressure. Set up all the test pressures required in a simitar manner and open the vent valve betore disconnecting. WARNING: FOR INSTRUMENTS ON WHICH THE PRESSURE/VACUUM OPTION [S FITTED, DO NOT SWITCH DIRECTLY FROM A POSITIVE PRESSURE TO A NEGATIVE PRESSURE WITHOUT FIRST OPENING THE VENT VALVE. On instruments on which the pressure/vacuum option is fitted, if negative pressures are to be used, first open the vent valve before switching over the pressure output select switch to -ve. An overrange condition 1.8. > 1.20% Full Scale, causes the display to flash, 203.5 Electrical Measurements Electrical Safety Instructions DO NOT EXCEED THE MAXIMUM INPUT LIMITS (REFER TO SECTION + FOR DETAILS) WHEN THE INSTRUMENT IS POWERED FROM AN EXTERNAL SOURCE, CHECK THAT THE CORRECT VOLTAGE AND POLARITY ARE APPLIED TO THE INSTRUMENT. IT {S RECOMMENDED THAT ONLY THE MANUFACTURER'S POWER ADAPTOR/CHARGER UNIT BE USED FOR ‘THIS PURPOSE. USE TEST LEADS PROVIDED OR CORRECTLY TERMINATED WIRES TO MAKE CONNECTIONS TO THE 4mm INPUT/OUTPUT SOCKETS. BO NOT PUSH BARE WIRES INTO THE SOCKETS. FOR EMC COMPLIANCE, USE ‘THE PROVIDED TEST LEADS ONLY. 3.5.1. Voltage Measurements To select the voltage measurement mode, proceed as follows. ° Connect the test leads to the voltage measurement (V) input sockets located on the top end panel of the instrument, Red (+ve), Black (-ve). ‘Switch the instrument on Set the instrument to read voltage by pressing the V key. This will set the Voltage function as the main display reading. For a dual display, pressure with voltage, press the P and V keys together. (Refer also to Section 3.3.4). Note: An overrange condition ie. Applied Voltage > SOV. causes the display to flash. 3.5.2 Current Measurements: To select the current measurement mode, proceed as follows. ° Connect the test leads to the current () input measurement sockets located on the top end panel of the instrument, Red (+ve), Black (-ve). ‘Switch the instrument on. Set the instrument to read current by pressing the I key. This will set the Voltage function as the main display reading. For a dual dispiay, pressure with voltage, press the P and I keys together. (Refer also to Section 3.3.4). Note: An overrange condilion i.e. Applied Current >55mA, causes the display to flash. K184 Issue 2 a3.5.3 24V D.C. Output To use the 24V d.c. output, proceed as follows. © Connect the test leads to the current (I) input measurement sockets located on the top end panel of the instrument, Red (+ve), Black (-ve) ° Connect the external device to the instrument, observing the correct polarity Caution: Do NOT short the supply output terminals and OO NOT overtoad the output. The maximum current that can be supplied is 25mA © Switch the instrument ON. © To maximise battery life, disconnect the load from the instrument as soon as tests are completed. 3.5.4 Current Loop Tests To use the current loop test output, proceed as follows, © Connect the test leads to the current loop test sockets located on the top ‘end panel of the instrument. The current loop circuit is not polarity sensitive. © Connect the external device to the instrument. Figures 1.2 and 4.3, Section 1.2, give details of typical current sourcing and sinking applications, Note: The output is fully floating. © Switch the instrument ON. An output current of 12mA (50% full scale for 4 to 20mA current loop), will be output from the instrument 3.5.5 Pressure Switch tests Pressure switch tests can be carried out by using the loop test facility to monitor the state of the pressure switch contacts. Connection details are shown in Figure 1.4. To carry out a pressure switch test proceed as follows. © Connect the pressure switch to the instrument as shown in Figures 1.4, © Switch on the instrument and set up the display to read pressure and current by pressing the P and I keys simultaneously. K184 Issue 2 2© If monitoring normally open contacts, open the volume adjuster to approximately half way out, close the vent valve and pump up the pressure to just below the operating pressure of the switch. Screw in the volume adjuster until the switch operates (indicated by a loop current of 12mA. Record the operating pressure. Screw the volume adjuster out until the switch operates again (indicated by zero loop current). Record the pressure at which the switch operates. K184 Issue 2184 Issue 2 24at 42 CALIBRATION The instrument is supplied by the manufacturer, complete with calibration certificate(s). The re-calibration interval will depend on the total measurement uncertainty which is acceptable for a particular application. In order that the instrument remains within the quoted accuracy, itis suggested that i's calibration be checked at 90 day intervals. The DPI 603 is a very precise calibrator and measuring instrument and the test equipment and conditions of test must be suitable for the type of work. The usa of a Class A compensated deadweight tester is essential. The tests should be carried out in a controlled environment by a competent, trained parson. I, when the acouracy of the instrument is checked, it is found to fall outside the specification, calibration adjustment can be undertaken to compensate errors. The manufacturer offers a comprehensive and, if required, NAMAS accredited calibration service. Calibration Check ‘At the chosen interval, the instrument readings should be compared with a known standard. Any deviations between the instrument and the standard should be noted, taking due account of the traceability (accuracy to a National Standard). {f these deviations exceed the published tolerance. or any other suitable chosen perlormance standard, then the user may wish to carry out a calibration adjustment, The following sections in this chapter explain the method of calibration adjustment for both the pressure, voliage and current ranges. The pressure and electrical parameter calibration routines are built into the instrument's software, Calibration Adjustment Before carrying out any calibration adjustments, the results of the calibration check should be studied to determine the nature of the deviations to be adjusted. For pressure calibration, the use of a dead weight tester, having measured masses and correcting for temperature and gravity, is considered mandatory for this level of calibration. The work should be conducted in a controlled environment, with adequate stabilisation time prior to and during adjustment. Electrical calibration should be carried out using calibrated test equipment of equal, or preferably, higher accuracy than that of the instrument. K184 Issue 2 254.2.4 General Procedures 43 The following general hints are provided as a guide to calibration procedures. Do Use high quality Repeatable and Linear pressure sources and allow adequate stabilisation time before calibration (minimum 1 hour). Conduct the calibration in a temperature and preferably, humidity controlled environment. Recommended temperature is 21°C, 42°C. Use deadweight testers carefully and away from draughts. Checking Pressure Calibration VENT THE SYSTEM PRESSURE BEFORE DISCONNECTING OR CONNECTING ANY PRESSURE LINES. PROCEED WITH CARE. To check an instrument's pressure calibration, proceed as follows, @ Connect the outlet port of a pressure standard to the OUTLET port of the instrument under test. © Wait one hour to allow the instrument to stabilise. © Adjust the pressure standard to the most negative pressure value within the range of the instrument, Allow the applied pressure to stabilise © Record the output pressure of the pressure standard and the corresponding instrument reading (shown on the dispfay), © Repeat the application of test pressures for four increasing pressures, 1.¢. - F.S., Zero, 50% and 100% F.S., recording the corresponding instrument readings for each applied test pressure. © Commencing at Full Scale, repeat the application of test pressures in decreasing steps i.e, F.S, 50%, zero and -F.S. DO NOT VENT TO. ATMOSPHERE BETWEEN CONSECUTIVE POINTS. @ Calculate the percentage error of the instrument's pressure reading against the applied test pressures. © Check that the calculated values are within the accuracy fi Section 1 stated in K184 Issue 2 2644 Checking Electrical Calibration To check an instrument's electrical calibration, proceed as follows. 4.4.1 Voltmeter © Switch the DPI 603 instrument on. © Connect the instrument's test leads between the common (Black) and V (Red) test sockets. Connect the leads to a stable voltage source. © Connect the test equipment voltmeter across the voltage source (in parallet with the Instrument). © Set the voltage source to zero and record the voltages read on the instrument and the test instrument. If the test instrument shows zero and the DPI 603 instrument indicates a small offset, zero the instrument by holding the V key depressed whilst pressing the Zero key. © — Apply test voltages of OV, 12.5V, 25V and 50V, (measured on the test equipment), recording the corresponding instrument voltage reading for each applied voltage. © Calculate the percentage error of the instrument's voltage reading against the applied test voltage. © Check that the calculated values are within the accuracy limits stated in Section 1 4.4.2 Current @ Switch the DPI 603 instrument on. © Connect the instrument's test leads between the common (Black) and 1 (Red) test sockets. Connect the instrument in series with a test milliammeter to a variable current source. © Sethe current source to zero and record the current read on the instrument and the test instrument. If the test instrument shows zero and the DP! 603 instrument indicates a small offset currant, zero the instrument by holding the | key depressed whilst pressing the Zero key. © Apply test currents of Zero, 20mA, 40mA and S5mA, (measured on the test equipment), recording the corresponding instrument voltage reading for ‘each applied voltage. © Calculate the percentage error of the instrument's current reading against the applied test current. © Check that the calculated values are within the accuracy limits stated in Section 1. K184 Issue 2 ar4.5 Pressure Calibration Adjustment VENT THE SYSTEM PRESSURE BEFORE DISCONNECTING OR CONNECTING ANY PRESSURE LINES. PROCEED WITH CARE. ‘The pressure calibration routine requires the entry of three calibration pressures. Calibration data is not overwritten until all three calibration pressures have been entered and accepted. To abort a calibration run, without updating the existing calibration data, switch the instrument off, BEFORE accepting the final calibration pressure. To perform a pressure calibration proceed as follows. Connect the outlet port of a pressure standard to the instrument's Outlet port. ‘Switch the instrument OFF. Enter the Pressure calibration menu by pressing and holding the P key whilst switching the instrument on. The instrument now prompts for a password before allowing entry into the pressure calidration routine (e.g.), Enter PIN: 000 Caution: Do not enter the calibration function unless it is intended to carry out a calibration Enter a valid calibration PIN number. Initially, this PIN number is set to 123. A lashing cursor appears over the first digit position. Press the PT key to ‘scroll through the digits 0 through 9 and when the correct digit for this position is displayed, press the I> key to move to the next digit position Scroll through the numbers using the PT key and when the correct digit for this position is displayed, use the I-> key to move to the final digit position. Select the final digit by using the Pt key. When the full PIN has been entered, press the Ve key to accept the entered PIN, If the PIN is incorrectly entered, access to the pressure calibration function is denied Following correct entry of the PIN number, the calibration menu is displayed (2.9). Pressure Cal Edit value to press Zero Point 00133 Wait one hour to allow the instrument to stabilise. Apply the lowest pressure (-F.S.), (2.g.) -1 bar to the instrument from the pressure standard. K184 Issue 2 28@ Allow the applied pressure to stabilise. @ —_Toenter a vaiue for the zero point, edit the reading given on the display to the applied pressure by using the P (1) key to scrolt the first digit of the display reading through the digits © through @ until the correct digit is displayed. © Press the I (3) key to move the cursor to the next digit position and edit this digit to the required value by means of the P (1) key. Repeat until all digit positions have been edited to the correct value © Check the entered value and when satisfied, press the V (+) to accept the entered value. On acceptance of the zero value the instrument prompts for the next calibration pressure to be entered (e.9.), 50% 10.0000 Edit © Set the pressure standard to apply a pressure of 50% of positive full scale and allow the applied pressure to stabilise, @ Edit the pressure reading using the P (1) and | (-+) keys as described for Zero point above. @ Check the entered value and when satisfied, press the V {«-) to accept the entered value. On acceptance of the 50% F.S. value, the instrument prompts for the next calibration pressure to be entered (€.9.), 100% 20.0000 Edit @ Set the pressure standard to apply a pressure of 100% of positive full scale and allow the applied pressure to stabilise. © Edit the pressure reading using the P (1) and I (>) keys as described for Zero and 50% F.S. points above. © Check the entered value and when satisfied, pross the V (<-) to accept the entered value. On acceptance of the 100% FS. value, calibration is complete and the old calibration data is overwritten. The following prompt is givene.g.), Cal done © Repeat the calibration check to see that the correction has been effective. K184 Issue 2 294.6 Electrical Calibration Adjustment The electrical calibration routines require the entry of two signals for both the Voltage and the Current measuring circuits. Calibration ata for each measurement channel is not overwritten until both calibration parameters have been entered and accepted. To abort a calibration run, without updating the existing calibration data, switch the instrument off, BEFORE accepting the second calibration parameter. 4.6.1 Voltage Range To perform calibration of the voltage measurement channel, proceed as follows. Connect the instrument test leads to the common (Black) and the V (Red) test sockets. Connect the instrument terminais in parallel with a calibrated digital voltmeter, preferably of greater accuracy than the instrument. ‘Switch the instrument OFF. Enter the Voltage catibration menu by pressing and holding the V key whilst switching the instrument on. The instrument now prompts for a password before allowing entry into the voltage calibration routine (e.9.}, Enter PIN: 000 Caution: Do not enter the calibration function uniess it is intended to carry out a calibration. Enter a valid calibration PIN number. Initially, this PIN number is set to 123. A flashing cursor appears over the first digit position. Press the Pt key to scroll through the digits 0 through 9 and when the correct digit for this position is displayed, press the I key to move to the next digit position. Scroll through the numbers using the PT key and when the correct digit for this position is displayed, use the I> key to move to the final digit position. Select the final digit by using the PT key. When the full PIN has been entered, press the Ve key to accept the entered PIN, If the PIN is incorrectly entered, access to the voltage calibration function is denied. Following correct entry of the PIN number, the voltage calibration menu is displayed (e.9.). Apply Short Reading Value 000012 Short out the instrument terminals Edit the voltage reading given ‘on the instrument display to that given an the DVM by using the P (*) key to scroll the first digit of the display reading through the digits 0 through 9 until the correct digit is displayed. K184 Issue 2 30© Press the I{-) key to move the cursor to the next digit position and edit this Gigit to the required value by means of the P (1) key. Repeat until ali digit positions have been edited to the correct value. © Check the enterad value and when satisfied, press the V (<-) to accept the entered value. On acceptance of the zero value the instrument prompts for ‘the next calibration voltage to be entered (@.9.). Reading Value 49.9997 @ Remove the short and apply a test voltage of SOV (Full Scale). © Edit the instrument's voltage reading to give the same value as that indicated on the DVM , using the P (7) and t (-+) keys as described above. @ Check the entered value and when satisfied, press the V («-) to accept the entered value. On acceptance of the FS. value, voltage calibration is ‘complete and the old calibration data is overwritten. ‘The following prompt is given (9), Cal done © Repeat the voltage calibration check to see that the correction has been effective. Current Range To perform calibration of the current measurement channel, proceed as follows. © Connect the instrument test leads to the common (Black) and the | (Red) test sockets. Connect the instrument terminals in series with a calibrated digital miliammeter, preferably of greater accuracy than the instrument, © Switch the instrument OFF. © Enter the Current calibration menu by pressing and holding the | key whilst switching the instrument on. The instrument now prompts for @ password before allowing entry into the current calibration routine (2.9.), Enter PIN: 000 Caution: Do not enter the calibration function uniess it is intended to carry out a calibration. K184 Issue 2 31@ —_ Entera valid calibration PIN number. Initially, this PIN number is set to 123. A flashing cursor appears ovet the first digit position. Press the P7 key to scrolt through the digits 0 through 9 and when the correct digit for this position is displayed, press the I+ key to move to the next digit position. Scroll through the numbers using the PT key and when the correct digit tor this position is displayed, use the 1» key to move to the final digit position. Select the final digit by using the P? key. When the full PIN has been entered, press the Ve key to accept the entered PIN. If the PIN is incorrectly entered, access to the current calitration function is denied. @ Following correct entry of the PIN number, the curent calibration menu is displayed (2.9.). Apply Open Circuit Reading Value 00002 © Edit the current reading given on the instrument display to that given on the DVM (Zero) by using the P (7) key to scroll the first digit of the display reading through the digits 0 through 9 until the correct digit is displayed. @ Pras the I{-») key to move the cursor to the next digit position and edit this it to the required value by means of the P (1) key. Repeat until all di positions have been edited to the correct value © Check the entered value and when satisfied, press the V (<-) to accept the entered value. On acceptance of the zero value the instrument prompts for the next calibration voltage to be entered (e.9.), Apply Known | 49.9997 © Connect the series connected instrument and DVM to a current source. Adjust the current source to give an output of SSmA. © Edit the instrument's current reading to give the same value as that indicated on the digital mitiammeter , using the P (7) and | (>) keys as described above. e Check the entered value and when satisfied, press the V (€-) to accept the entered value. On acceptance of the F.S, value, current calibration is complete and the old calibration data is overwritten. The following prompt is given (e.9.). Cal done © Repeat the current calibration check to see that the correction has been effective. K184 Issue 2 325 MAINTENANCE ‘There are no user serviceable parts on the DP! 603 instrument. 5.1 Safety Instructions © Observe the general safety procedures detailed at the beginning of this User Manual. © This instrument must only be serviced by a Druck approved service organisation or by a competent person. Section 5.4 details a list of Druck subsidiaries worldwide. @ Do not use replacement parts other than those supplied by the manufacturer or manufacturer's agent. 5.2 Battery Replacement The instrument's batteries are located in the base of the instrument. The method of replacing the batteries is outlined in Section 2.1. 5.3 Fault Finding During normal operation, if an error condition occurs, an appropriate warning will bbe written to the display screen. The following operational warnings may be given 'rochargoabe cts tod, connect charge. Itty cal tte, switch of and replace bavaros. Se Ssed0n 2) Offeot for estoct For Voiaga and Current eleconneet function aide range of Zero hoy | solenetar oe milamametar tore Zeroing For prossur, open vert valve belors atemping w Zere In the event of an instrument malfunction, it can be returned to the Druck Service Department or Druck Agent for repair. A service charge price listis available which details the charges associated with various service functions. 5.4 Cleaning Ctean the instrument case with a damp cloth and mild detergent. DO NOT USE ANY TYPE OF SOLVENT FOR CLEANING PURPOSES K184 Issue 2 335.5 Approved Service Agents ‘The following are approved Service Agents for Druck Instruments. FRANCE, JAPAN Druck SARL, Druck Japan KK, 26 Rue Edith Cavell, Madie Corp Building 8, 924000 Courbevoie, 2.4-14 Kichijyoji-Honcho, France. Musashino, Tokyo 180, Tel: (1) 43 84 24 75 Japan Fax: (1) 43 34 86 08 Tel: 422 20 7123 GERMANY Fax: 422 20 7155 UK Druck Messtechnik GmbH, Lessingstrasse 12, 61231 Bad Nauheim, Druck Litd., Germany Fir Tree Lane, Groby, Tel: 6032 35028 Leicester, Fax: 6032 71123 LE6 OFH. HOLLAND Tel: 0116 231 4314 Fax: 0116 232 0309 Druck Nederland B.V., usa Postbus 232, Zuideinde 37, 2991 LJ Barendrecht, Druck Incorporated, ‘The Netherlands, 4 Dunham Drive, New Fairfiold, Tel: 1806 11555 Connecticut 06812, Fax: 1806 18131 USA. ITALY Tel: 203 746 0400 Fax: 203 746 2494 Druck Italia St. Via Capecetatro 11, 20148 Milano, Italy. Tot: 2 48707166 Tel: 2 48705568 K184 Issue 2 34