SERVICE MANUAL FOR
Contents
1. Spare parts MPC Please see exploded view 1 100449 Label 15 BAR 200 PSI 1 100462 Label MPC 140 BAR 2000 PSI 2 100448 Keyboard MPC 7 60 PPC02 Main board complete 10 60C072 CPU 12 60V010 Screw 2 9 x 6 5 mm 13 65 V994 Connector for transducer 14 60R253 Transducer for 140 and 200 BAR 19 60V011 Screw M4 x 10 mm 24 60V027 Screw 3 x 25 mm 25 60C310 Temperature sensor 26 60V623 Screw M4 x 6 mm 27 101899 Spring leaf 7 x 24 x 0 4 29 60R262 Transducer for 15 BAR 30 60V005 See ring type J20 36 60D474 Filter board 102739 00 Date 11 12 96 Page 1 tolerancer Eira standarder AMETEK m mes HTR mm was serios m ILF 45 42958800 961106 Emnebetegnelse Erstatning for oOo Exploded view Rev nr Pressure calibrator 1 00531 01 5 Boa 5 9 5 2 o 58 35 49 12 vo 2 a x 5 x 5 o f This drawing is the property of Ametek It must not be used co L TRANSDUCER POWER SOURCE M N PRESSURE PRESSURE SIGNAL TRANSDUCER AMPLIFIER R TEMPERATURE SENSOR THIS DRAWING IS THE PROPERTY OF AMETEK IT MUST NOT BE USED COPIED OR HANDED TO ANY THIRD PARTY OR OTHERWISE DISPOSED OF WITHOUT EXPRESS PERMISSION IN WRITING CHANGE BY CAD SYSTEM ONLY DETECTUR Jj K VOLTAGE REFERENCE ANALOG SWITCH P I V CONVERTER SCALE P oeno Q V V CONVERTER EDIT C EDIT2. and disconnect the pressure source The calibrator then has to be temperature compensated 100313 01 06 11 1996 3 5 DENMARK A S 2 0 Maintenance 2 1 3 Temperature compensation low temp Insert the calibrator in a temperature box with a delta on at least 10 lower than the ambient temperature It is recommended to calibrate at approx 5 C Connect the pressure source to the calibrator Set the pressure to 0 BAR 0 PSI In order to start the temperature calibration switch off the calibrator Then press and hold down the Unit and lt mA V gt softkeys at the same time and switch on the calibrator If the temperature delta is less than 10 an error message occurs If the delta is OK then enter the CODE note the temperature and press lt Hold Reset gt Then the display will show one of following BAR or PSI BAR PSI 0 0 0000 0 0 000PSI IN 524288 IN 524288 Press Unit for entering the first value 100 0 0000BAR 100 0 000PSI IN 524288 IN 524288 Set the pressure to 100 96 of full scale 100 0 0000BAR 100 0 000PSI IN 943718 IN 943718 Enter the exact value by using the special softkeys When Unit is pressed for 100 the values are stored and the calibrator goes back to normal operation 20 000 BAR 290 08 PSI 0 000mA 25 00 L 0 000mA 25 00 L 100313 01 06 11 1996 4 5 DENMARK A S 2 0 Maintenance 2 1 4 Temperature compensation high temp Insert
3. minimum of one year as from date of using the instrument in general service If you decide to check and or re calibrate the pressure calibrator always use certified test equipment only and secure proper contact between your test probe and the well of the calibrator The following test and repair information has been issued to the best of our knowledge at the time of issue but if you have further questions please never hesitate to contact us AMETEK DENMARK A S Gammemgardsvej 87 DK 3520 Farum Denmark Tel 45 42 95 35 22 Fax 45 42 95 80 83 The operation and technical specifications are stated in the user manual USER MANUAL FOR Marine Pressure Calibrator MPC 15 amp MPC 140 Order no 102256 102746 00 12 12 1996 1 1 DENMARK A S 1 0 General 1 2 ELECTRICAL DESCRIPTION Please see drawing Block diagram No 100315 The battery A is connected to the power unit B which supplies all the other circuits The microprocessor C is able to pull down the power unit B The processor is linked directly to the display E keyboard F and A D converter H It also controls the signals to the visual alarm unit G and the peak detection unit O The processor also has a serial communication which can be used for RS232 if a voltage adapter is used The visual alarm unit G which consists of a beeper and a LED is controlled by the processor C The watch dog unit D gives an ind
4. the calibrator in a temperature box with a delta on at least 10 higher than the ambient temperature It is recommended to calibrate at approx 45 Connect the pressure source to the calibrator Set the pressure to 0 BAR 0 PSI In order to start the temperature calibration switch off the calibrator Then press and hold down the Unit and lt Hold Reset gt softkeys at the same time and switch on the calibrator If the temperature delta is less than 10 an error message occurs If the delta is OK then enter the CODE note the temperature and press lt Hold Reset gt Then the display will show one of following BAR or PSI BAR PSI 0 0 0000 0 0 000PSI IN 524288 IN 524288 Press Unit for entering the first value 100 0 0000BAR 100 0 000PSI IN 524288 IN 524288 Set the pressure to 100 96 of full scale 100 0 0000BAR 100 0 000PSI IN 943718 IN 943718 Enter the exact value by using the special softkeys When Unit is pressed for 100 the values are stored and the calibrator goes back to normal operation 20 000 BAR 290 08 PSI 0 000mA 25 00 L 0 000mA 25 00 L Then remove the pressure and disconnect the pressure source and the calibrator is ready for use 100313 01 06 11 1996 5 5 DENMARK A S 3 1 TROUBLE SHOOTING 3 0 Repairs The software program will do automatic checks of the hardware signals It also performs a simple check of the calibration points Fol
5. 1996 1 1 DENMARK A S 2 0 Maintenance 2 1 SOFTWARE CALIBRATION PROCEDURE The calibration procedure consists of 2 calibration points high and low value for interpolation except the pressure calibration which consists of 6 points in order to compensate for nonlinearity of the transducer The pressure calibration is made in BAR but can be done in PSI if the unit is selected before the calibrator is switched OFF See User Manual section 4 0 Operation General functions In the calibration menus 4 of the softkeys have a different function The 4 keys are Softkey Function Activate for next digit The digit for changing is indicated by a blinking cursor Mean Peak Decrease the selected digit Zero the selected digit Units value and go to next point Safety precaution To reduce risks for errors when entering the interpolation points a safety precaution is built into the software The safety precaution only accepts the next calibration point if it differs and with a higher value from the previous entered calibration point Digital value The digital value will be shown in the display during the calibration This is to enable visual inspection that the input signal is stable and can be utilized as a calibration point However the resolution is so high that the digital input value can change 10 digits during a period of 30 seconds on a stable input signal D
6. F TO OTHER CIRCUITS H A D MICRO CONVERTER PROCESSOR SERIAL COM JOFRA INSTRUMENTS GAMMELG RDSVEJ 87 DK 3520 TLF 42958800 BATTERY Hb KEYBDARD l PRESSURE SWITCH SWITCH INPUT DISPLAY LI Pressure calibrator BLOCK DIAGRAM TRAVING NI 100315 10031501 KEYBOARD FUIL MAIN BOARD BATTERY SCALE DITA DTD THIS DRAWING IS THE PROPERTY OF AMETEK IT MUST NOT BE USED 961106 Pressure calibrator OF WITHOUT DUR EXPRESS PERMISSION IN WRITING 960221 WIRING DIAGRAM DRAWN EDIT C DRAWING N KEND xx CHANGE BY CAD SYSTEM ONLY xx gm MEG rs COPIED OR HANDED TO ANY THIRD PARTY OR OTHERWISE DISPOSED ers
7. SERVICE MANUAL FOR MPC Marine Pressure Calibrator all standard models AMETEK SF INSTAUMENTS AMETEK DENMARK A S Gammelgaardsvej 87 DK 3520 Farum Denmark Tel 45 42 95 35 22 Fax 45 42 95 80 83 102732 00 12 12 1996 DENMARK A S SERVICE MANUAL MPC This Manual applies to calibrators Type MPC XXX BAR From serial no XXXXXX 00001 For special calibrators please contact the factory TABLE OF CONTENTS Document Pgs 1 0 General 1 1 Introduction 102746 1 1 1 2 Electrical description 100312 1 1 2 0 Maintenance 2 1 Software calibration procedure 100313 1 5 2 1 1 Calibration CODE access procedure 2 1 2 Standard pressure calibration 2 1 3 Temperature compensation low temp 2 1 4 Temperature compensation high temp 3 0 Repairs 3 1 Trouble shooting 100314 1 2 3 2 Replacement of the transducer 100316 1 1 3 3 CPU replacement or program downloading 100317 1 1 4 0 Spare parts 4 1 Spare parts MPC 102739 1 1 5 0 Drawings No Rev Exploded view 100319 01 Block Diagram 100315 01 Wiring Diagram 100278 01 102732 00 12 12 1996 DENMARK A S 1 0 General 1 1 INTRODUCTION All pressure calibrators are produced from quality components by skilled staff Each pressure calibrator passes several tests during assembly and is finally inspected and tested following a special calibration procedure laid down by our technical management The performance of each pressure calibrator should apply for a
8. alibration in the User Manual section 5 4 It is also possible to download the new software to a new erased processor The processor is a MC68HC711E9 However the processor can not operate on the standard interface RS232C In order to run on the RS232C interface you have to use a voltage adapter This adapter can be supplied by AMETEK with a standard cable to the PC In order to download the software PPC LO you have to use a download program PROM EXE Both files will be supplied on a 372 floppy disk Before the program PROM EXE is executed place a jumper on J13 and connect J2 to a 12 Volt DC supply which is switched off Connect the voltage adapter to the interface connector J6 and the PC on COM1 Remove the foil connector from the print connector 21 and make a short circuit between pin 1 and 7 Execute the program and follow the instructions in the program The RESET is done by making a short circuit on J14 If the used CPU is former programmed and then erased there might be some former calibration values in the EEPROM In order to erase them press down the softkeys Mean Peak Zero Units and then switch on the calibrator Then release the softkeys lt Units gt should be the first released by the three Enter the CODE and press the softkey lt Hold Reset gt see section 2 1 1 doc no 100313 100317 01 06 11 1996 1 1 DENMARK A S 4 0 Spare parts POS PART NO DESCRIPTION 4 1
9. e the calibrator only uses the relative signal for compensation just note the temperature in the display The compensation accuracy is depended of the long term stability only In order to proceed the calibration procedure press the softkey lt Reset Hold gt 100313 01 06 11 1996 2 5 DENMARK A S 2 0 Maintenance 2 1 2 Standard pressure calibration The pressure source should be traceable and calibrated within the last 12 month and have an accuracy of 0 01 of Full Scale Connect the pressure source to the calibrator Set the pressure to 0 BAR 0 PSI In order to start the pressure calibration switch off the calibrator Press and hold down the lt Mean peak gt and lt Hold Reset gt softkeys at the same time and switch on the calibrator Enter the CODE note the temperature and press lt Hold Reset gt Then the display will show one of following BAR or PSI BAR PSI 0 0 0000BAR 0 0 000PSI IN 524288 IN 524288 Press Units for entering the first value 20 0 0000BAR 20 _ 0 000PSI IN 524288 IN 524288 Set the pressure to 20 of full scale 20 0 0000BAR 0 0 000PSI IN 608174 IN 608174 Enter the exact value by using the special softkeys Repeat this procedure for 4096 6096 80 and 100 of full scale When Units is pressed for 100 the values are stored and the calibrator goes back to normal operation 20 000 BAR 290 08 PSI 0 000mA 25 00 L 0 000mA 25 00 L Then remove the pressure
10. ication to the processor C if the power signal is bad and thereby resets the calibrator The switch input unit lt I gt gives an indication to the processor lt C gt if the sensor is open or closed The 20 bit A D converter lt H gt receives the input signal from an analog switch J and compares the signal to the reference voltage unit lt gt The analog switch lt J gt has 8 inputs mean pressure signal lt N gt mA signal lt P gt Vref lt K gt ground reference negative and positive peak signal lt O gt temperature signal lt R gt and volt signal lt Q gt The voltage reference unit lt K gt gives a stabile low drift voltage to the A D converter lt H gt the analog switch lt J gt and the power source to the transducer lt L gt The power source to the transducer L can give a current or voltage supply to the transducer M The transducer signal is amplified in the amplifier N and because the signal is measured 2 times each second a peak detection unit O is used The processor C resets the peak unit O when needed The current conversion unit P converts the current to the internal signal range for the A D converter lt H gt The voltage conversion unit lt Q gt converts the signal voltage to the internal signal range for the A D converter lt H gt The temperature unit lt R gt gives a signal which is used for the internal temperature software compensation 100312 01 06 11
11. igital signal for 0 Since the calibrator works both on positive and negative input signals the digital signal for 0 will typically lie between 500000 and 550000 Start calibration mode In order to start the calibration mode you have to press down two keys at the same time and then press the lt ON OFF gt key See the table below for which keys to press in order to do a specific calibration Note UM User Manual Calibration Keys Page Pressure standard Mean Peak amp lt Hold Reset gt 2 5 Pressure user lt Mean Peak gt amp Zero Section 5 2 UM Temp comp low lt Units gt amp mA V 4 5 Temp comp high Units amp lt Hold Reset gt 5 5 mA 0 and 50 lt Mean Peak gt amp mA V Section 5 3 UM V 0 and 30 lt Mean Peak gt amp Unit Section 5 4 UM 100313 01 06 11 1996 1 5 DENMARK A S 2 0 Maintenance 2 1 1 Calibration CODE access procedure To make sure that only authorized personnel has the possibility to make the standard calibration a safety CODE procedure is entered in the calibration procedure When the display shows SELF CALIBRATING release the softkeys which were activated Then the display will show following message ENTER CODE The user CODE is Units Units Zero lt Mean Peak gt Then the internal temperature will be shown in in the first line of the display TEMP 25 1 The absolute accuracy for the temperature can be 3 C wrong Sinc
12. ll PZD Gr 2 and remove the manifold ref 15 with the transducer Unscrew the transducer nut dismount the connector and replace the transducer Reassemble it in reverse order Please note Be sure that the cover plate ref 16 is on the outside of the box and coat the diode ref 25 with cool compound Remove RD2 on the Resistor platform ref 11 Connect a decade box on J12 Connect a voltmeter to TP1 and TP3 Set pressure on the transducer and find the resistor value on the decade box so that the signal is 2 V for 100 96 pressure Find the nearest value for the resistor RD2 in the E192 table Mount and solder the resistor in the Resistor platform Then recalibrate the calibrator for pressure and temperature compensation see doc no 100313 100316 01 06 11 1996 1 1 DENMARK A S 3 0 Repairs 3 3 CPU REPLACEMENT OR PROGRAM DOWNLOADING If there is made a new or special version of the software to calibrator the CPU IC3 has to be replaced The CPU is normally programmed by AMETEK but can be programmed by the customer For replacement just remove the old one and insert the new one in the socket NOTE Be sure that the pins at the corners of the IC are not touching each other When the IC is replaced then recalibrate the calibrator The pressure calibration with temperature compensation is shown in this manual section 2 1 doc no 100313 the current calibration in the User Manual section 5 2 and the voltage c
13. lowing messages can occur during an error condition Message Cause Action CS ERR IN EEPROM RE CALIBRATE OVERRANGE PRESSURE IS OUT OF ZERO RANGE LOW BATTERY PRESS ANY KEY TEMP ERROR ENTER CODE ERROR SELF CALIBRATING SELF CALIBRATING AND ZERO SETTING STANDARD CALIBR SELECTED USER CALIBRATION SELECTED OVERPRESSURE OUT OF RANGE 100314 01 Bad calibration The software has to show more than 6 digits readout for the input signal The range for zero offset is exceeded The battery voltage is below 7 Volts Too low deviation for the temperature in calibration Producer calibration protection The input signal or the value are the same for the next calibration point Only shown when the calibrator is switched on Message after zero offset activation Selection of producer calibration Selection of user calibration Pressure 20 higher than the calibration range Less than 50 LSB from the input span of the ADC 06 11 1996 Re calibrate calibrator Check the mA V input circuit If the message occurs with zero pressure change the transducer and re calibrate it Change battery If temperature deviation is OK then replace sensor and re calibrate Enter code Unit Unit Zero Mean Make sure that both the input signal and value are altered Release the button 1 2 DENMARK A S 3 0 Repairs 3 1 TROUBLE SHOOTING co
14. nt Message Cause Action Pressure The temperature sensor is Check the temperature measurement is not damaged sensor Enter calibration responding or not mode but switch off the unit correct when the temperature has been shown in the display If the sensor is damaged replace the sensor and re calibrate pressure Transducer error If temperature sensor is OK then replace transducer and re calibrate the pressure Signal measurement is Cable error Check cable from terminals to not responding or not filter PCB correct Filter PCB error Check filter PCB If the cable and filter PCB are in order replace main board and make a complete re calibration calibrator does not Keyboard error Check the keyboard and respond on keyboard cable operation If the keyboard is in order replace main board and make a complete re calibration Display error Check display and Display shows connector incorrect or no characters If the display is in order replace main board and make a complete re calibration 100314 01 06 11 1996 2 2 DENMARK A S 3 0 Repairs 3 2 REPLACEMENT OF THE TRANSDUCER Change the transducer See Exploded view Unscrew the 4 screws ref 24 Tool PZD Gr 1 and remove the battery part ref 21 Disconnect the battery connector ref 20 and the connector from the transducer Unscrew the screw ref 26 Toll hexagon key 2 5 and remove the bracket ref 27 Unscrew the 2 screws ref 19 To
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