Druck DPI 605 - GE Measurement & Control
Contents
1. Y 3 A D Ha aK ab 1 DPI 605 Calibrator general view K139 Issue No 1 4 4 Druck DPI 605 Service Manual Pneumatic Equipment K139 Issue No 1 4 Parts List Power Supply Board K139 Issue No 1 Customer service Visit our web site www gesensing com2. CH channel contd continued CR carriage return DC direct current DVM digital volt meter DMM digital multimeter EPROM erasable program read only memory FS full scale ft feet ft min feet minute GRD ground earth Hz Hertz kg kilogram LCD liquid crystal display LED light emitting diode in Hg abs absolute pressure in inches of mercury kHz kilo Hertz max maximum MED medium sec second min minimum or minute Mohm mega ohm mbar milli bar mbar min milli bar minute mV milli Volt No number ve negative PCB printed circuit board PL plug ve positive PSU power supply unit PWM pulse width modulator RAM random access memory RF radio frequency RV variable resistor SW switch V Volt V ac Volts alternating current V dc Volts direct current K139 Issue No 1 1 Description 1 1 PART 1 DESCRIPTION Chapter 1 Description General Constructional Description Pneumatic Circuit Electronic Circuit K139 Issue No 1 1 2 Druck DPI 605 Service Manual General The DPI 605 calibrator generates and indicates pressures up to 20 bar gauge The instrument s primary pressure indicating range 20 bar gauge 21 bar absolute with the barometric option can be extended to 700 bar by external transducers In addition to generating pressure the instrument produces analogue voltages and currents These analogue outputs can be programmed to any level within the range of the instrument or be linearly related to the indicat
3. 1 a Note Druck DPI 605 Service Manual Fit a bonded seal to each of the two non return valves and screw into the holes in the end cap Take care not to over tighten the non return valves non return valve adaptor bonded seal bonded seal end fitting Fit a bonded seal over the thread of the non return valve and screw the adaptor onto the non return valve Fit a bonded seal over the thread of the union and screw the union into the adaptor Repeat this operation for the non return valve Using the tubing pliers connect and secure the nylon tubing onto the metal tubes of the unions Electronic Equipment Key pad Locate the studs of the key pad in the instrument case Locate the ribbon connector clamp over the ribbon connector and secure with pillar nut shake proof and plain washers Secure the key pad with the remaining pillars nuts shake proof and plain washers Display Board Align the board over the ribbon connector clamp and threaded studs Secure with the four screws shake proof and plain washers Note On earlier instruments it may be necessary to loosen the pillar next to the display board for alignment Main Board Carefully locate the board over the four threaded studs holes and secure with screws shake proof and plain washers Connect the key pad connector PL8 Connect the following connectors PL5 PL7 PL9 PL10 PL11 PL12 PL13 and if the pneumatic assembly is fitted conn
4. adjuster is a cylinder and piston assembly providing adjustment of the applied pressure The indicator version is similar to the calibrator but without the hand pump and volume adjuster Internally there is one transducer no solenoid valves or relief valve K139 Issue No 1 1 4 Druck DPI 605 Service Manual Pneumatic Circuit calibrator The pneumatic circuit consists of a hand pump connected to a pressure port through a series of latching solenoid operated control valves A volume adjuster and vent valve also connect to the pressure port The volume adjuster allows small adjustments of system volume to be made providing fine adjustments to output port pressure The vent valve allows the pressure in the pressure port to be vented to atmosphere The pressure at the pressure port is monitored by two digitally characterised transducers one LP senses pressure between 0 and 2 bar the other HP senses pressure between 0 and 0 bar When the pressure is below 2 bar protection valve SV4 is closed by the control system and the output of the LP sensor provides the system with pressure data When the system pressure is above 2 bar protection valve SV4 opens isolating the LP sensor from the pressure A relief valve V5 provides additional protection of the LP sensor protecting against pressure transients and if SV4 fails to operate Breather port Pressure vacuum reference pump changeover port valves gys I 4i sv
5. adjustment of the ammeter is a two point span and zero calibration The lower point is achieved by leaving the ammeter terminals disconnected The upper point is achieved by applying a current of approximately full scale between 49 and 51 mA and entering the precise value through the keyboard Nominal Applied Value Permissible Deviation mA 1 digit UOS 0 001 mA 0 001 30 001 30001 mA mT 20 001 mA 25 50 25 25 50 Table 6 Ammeter K139 Issue No 1 2 Servicing 2 23 Thermometer The thermometer function within the instrument is a measurement of resistance of an external temperature sensor which is then related to a defined law and interpreted as a temperature reading To calibrate the thermometer function apply two resistance values to the temperature probe input connector Connect a resistor of 174 2Q to the temperature probe input connector and enter the precise value through the keyboard Repeat this operation with a resistance of 82 20 Nominal Resistance Value Permissible Deviation Ohms 1 digit UOS 0 026 0026 002 Table 7 Thermometer Voltage Output Calibration adjustment of the voltage output is a two point calibration This is achieved by accurately measuring in turn two values of the output and entering the precise values through the keyboard The voltmeter is connected between output terminals B ve and C ve the nominal output voltag
6. for leaking Open the vent valve to release the pressure Switch Test Select switch test mode and observe the switch status changing from open to close when terminals A and B are connected together RS232 Port Link the data out to data in pin 1 to pin 3 and link CTS and RTS pin 2 to pin 5 on the RS232 port connector Use the built in RS232 self test facility to establish that the RS232 port is correctly functioning K139 Issue No 1 2 Servicing Chapter 7 Configuration Instrument Configuration 8 After changing a main board the instrument must be configured for the particular application Configuration involves the setting of the following parameters e Serial Number Country UK USA or Japan e Instrument type calibrator indicator or rack mounted To configure an instrument proceed as follows Defaults Battery Status Cal Test Serial No Country Instrument Switch the instrument to ON Press the SET UP key e Select Cal Test F4 from the set up menu The instrument will now prompt for entry of the current password as follows Cal Test Enter PIN number O Note Press the Set up key and not the ENT key for this next operation Enter the PIN of 777 on the numeric keyboard and press Set up This gives access to the factory Config Cal Test as follows Factory Config Cal Test Cal Test New PIN Config Select the Config option F4 from the menu the display sh
7. is selected for a portable instrument the display contrast is drastically reduced Other features e g Auto power off will no longer be available Press Exit Menu three times to quit Set up Set PIN number After configuring the new instrument set up the Cal test PIN number as follows This can be carried out directly from the SET UP menu or if the SET UP has been exited proceed as follows Switch the instrument to ON Defaults Press the SET UP key Battery e Select Cal Test F4 from the set up menu The instrument will now Status Cal Test prompt for entry of the current password as follows Cal Test Enter PIN number O K139 Issue No 1 2 Servicing 2 17 Enter the PIN of 777 on the numeric keyboard and press set up This gives access to the Factory Config Cal Test as follows Factory Config Cal Test Cal Test New PIN Config Select New PIN F3 enter the required PIN number and press ENT Example Note Enter new PIN number lt 3779 gt Pressing ENT sets no PIN If no PIN number is specified set the PIN to 123 to correspond with the factory installed PIN At the Verify new PIN Number prompt enter the new PIN via the numeric key pad and press ENT If the new PIN is correctly entered the instrument responds with Verification OK and exits the Set up menu If the new PIN is incorrectly entered at the Verify new PIN Number prompt the instrument responds wi
8. 2g 1 Baro relief Sensor valve Hand here i y es and pump J LP 08 4 sensor LP sensor ee protection valve HP sensor 6 Pump limit Vent port Pressure port KA Volume Vent valve adjuster Pneumatic circuit pressure selected After connecting the pressure port to a device or system under test output pressure is gener ated by closing the vent valve and using the hand pump When the hand pump is used air draws into the pump though SV2 Integral one way valves permit the flow of air though the pump K139 Issue No 1 1 Description 1 5 If negative pressure is required vacuum is selected from the keyboard which causes SV2 and SV3 to change over providing that there is no pressure at the pressure port When the hand pump is used air draws from the pressure port through SV2 into the inlet side of the pump The outlet side of the pump exhausts to atmosphere though SV1 SV3 and the breather port Breather port Pressure vacuum reference pump changeover port valves 2 2 E V5 Baro relief sensor l I 1 Hand pump 4 1 LP LP sensor 1 protection valve 7 gt sensor 0 Vent port pressure port Pump limit e Volume Vent valve adjuster Pneumatic circuit vacuum selected A pump limit valve SV1 blocks the outlet of the pump when a preset system pressure is reached Normally SV1 is close
9. GE Sensing Druck DPI 605 Precision pressure calibrator indicator Service manual K139 LB 35 5 Ke ANS Ves DAS Nig LES SOILED SY Druck DPI 605 Service Manual i DPI 605 SERIES PRECISION PRESSURE CALIBRATORI INDICATOR SERVICE MANUAL K139 K139 Issue No 1 Druck DPI 605 Service Manual INTRODUCTION General The aim of this publication is to provide information for the service of the Precision Pressure Calibrator Indicator DPI 605 This publication contains procedures which provide instructions to enable an operator to maintain the instrument in a serviceable condition It is divided into four parts and sub divided into chapters detailed in the table of contents The information in DESCRIPTION provides a detailed constructional and functional description of the instrument The instructions in SERVICING contain detailed routine maintenance dismantling inspection and assembling procedures Together with FAULT FINDING the condition and probable cause of a malfunction can be established The operator can carry out the recommended rectification procedures to return the instrument to a serviceable condition After rectification the integrity of the instrument can be verified by detailed testing and the accuracy by calibration The PARTS LIST itemises the parts of the unit that can be replaced It is intended for use in the provision and requisitioning of replacement parts SAFETY T
10. JEA PIOUS OS 17 SJOAUIP 05 19 9999 pueoghay 30 NO SJOAUP p eoqAay 59615 330 0 89 409 85 27220 9999 9 9996499298 186185 9119 lt 483 3 K139 Issue No 1 1 10 Druck DPI 605 Service Manual e Common Mode Signal Conditioning for External Transducers This provides a signal related to the temperature of the external transducer in the same way and for the same purpose as the indicator version fast pressure signal conditioning However the high speed ability requirement is not present for this signal and therefore the signal is processed by the slower Main multiplexer Main Amplifier A to D Convertor route 0 Pt 100 Signal Conditioning This takes the form of a constant current source the voltage developed across the Pt 100 sensor is then processed through the main measurement channel e Voltmeter Signal Conditioning This takes the form of an inverting amplifier with a switchable gain of x1 0 x0 1 x0 01 and x0 001 The appropriate gain for the input signal is selected by the microprocessor 0 Amplifier Signal Conditioning This is a current shunt of approximately 2 Ohms together with a self resetting fuse of 200 mA rating e Programmable Outputs The programmable outputs really one output configured by the microprocessor to be either voltage or current togeth
11. RT 3 FAULT DIAGNOSIS The dismantling and subsequent assembling of components for maintenance detailed in Chapters 3 and 5 respectively Reference is made to the appropriate chapter and paragraph for these operations and the subsequent testing and calibration detailed in Chapters 6 and 8 respectively K139 Issue No 1 2 4 Druck DPI 605 Service Manual Chapter 3 Dismantling General The purpose of this chapter is to detail the extent of dismantling procedures and must be used in conjunction with FAULT DIAGNOSIS in Part 3 Maintenance is carried out to ensure that the instrument remains in a serviceable condition Absolute cleanliness of the work area tools and equipment must be observed at all times Note Dismantling instructions for the Rack mounted version will be included at a later date Electronic Equipment All the electronic components are located in the case with the exception of the Power Supply Board which is located in the base of the case To gain access to the main components remove the base from the instrument Procedure e Turn the instrument upside down and unscrew the eight posi drive countersunk screws Release the two black clips and disconnect cable connector from Con 1 on the Power Supply Board Separate the base and case Power Supply Board The Power Supply Board locates in the instrument base Disconnect connectors PL1 and PL2 on the power supply board Four white plastic pegs secure the board t
12. ak in piping or connections Check pipes for connections permitted rate and obvious damage External leak in equipment Carry out leak detection procedures detailed in testing Internal leak in equipment Replace seals washers and rings in the pneumatic equipment Pressure readings erratic Worn seals or piston rings Replace seals and piston during pump and or volume rings in the pump and or adjuster operations volume adjuster Bore of pump and or volume Replace pump and or volume adjuster scored or worn Pneumatic Valve Fault Finding calibrator It is important that no pressure is in the system during this test The four solenoid valves of the instrument can be individually selected and operated To carry out a valve test enter the set up menu select test and then pneumatics The display shows a valve number above each function key Example Pressing F1 selects SV1 the display then shows an ON and OFF selection above the function keys and the name of the valve for SV1 pump limiting valve The valve can be selected and confirmed by the sound of the solenoid energising Note This procedure does not prove that the valve seat is forming an airtight seal After completion of this test the instrument must be reset by re cycling the ON OFF switch K139 Issue No 1 3 Fault Finding 3 3 Electrical Fault Finding Symptom Probable Cause Instrument will not switch ON Discharged batteries Connect charger o
13. d leaving the pump outlet port open When the alarm limit is reached the instrument control system closes SV1 blocking the outlet of the pump and preventing further operation of the pump K139 Issue No 1 1 6 Druck DPI 605 Service Manual Pneumatic Circuit Indicator The indicator version of the instrument differs from the calibrator it does not have a pressure generating system There are two types of pneumatic circuit for different pressure ranges Breather port reference port 1 E Vent port Pressure port Vent valve Pneumatic circuit indicator K139 Issue No 1 1 Description 1 7 Electronic Circuit The block diagram shows all the main functional electronic blocks within the instrument These are contained in two printed circuit board assemblies the power supply board assembly and the main board assembly Power supply board Based on a small board 140 mm x 90 mm approximately the power supply board comprises two separate switch mode power supplies ON OFF control logic and power input steering logic Power Input Steering Logic This allows one of three separate sources of power to be used AC power through an external battery charger eliminator This provides 12 V dc to the instrument and powers the instrument irrespective of batteries being fitted Rechargeable battery pack This powers the instrument for up to 20 hours before requiring re charge The battery pack can b
14. d values are the same as the calibrator version bar 1 digit UOS 0 025 reading 0 some 715 30025 reading 0 2 0 5 1 5 10 15 20 15 10 2 1 0 5 2 0 025 reading Table 1 Calibrator Internal Pressure Range Positive Pressure Permissible Deviation mbar 1 digit UOS 0 005m 200 2002556099 90 0025966999 800 002 2090 1111111110 0 025 reading BO 0025 60 30025 reading 40 30025 reading 0 025 reading C 10 05 mbar 200 400 800 1000 0 025 reading 800 i 400 200 Table 2 Calibrator Internal Pressure Range Negative Pressure K139 Issue No 1 2 20 Druck DPI 605 Service Manual Nominal Applied Value as Permissible Deviation 1 digit UOS per cent of full scale lt 70 bar 70 bar to lt 700 bar S E E TAE 30 08 reading 30 08 reading 30 08 reading 20 08 reading 1 0 08 reading 0 08 reading 10 08 reading 0 08 reading 01 SES 0 01 FS 0 016 FS Table 3 Indicator Internal Pressure Range and All External Pressure Ranges 0 05 reading 0 08 reading External Range Generally any Druck transducer operating from 5 V dc excitation with a nominal output of 100 mV can be fitted to the external port The instrument prompts the data required on installation i e serial number type absolute gauge or differential and
15. ducer and is used by the microprocessor to implement temperature compensation additional to that built into the transducer K139 Issue No 1 Description 1 9 6044 vod Puluonpuoo 2605 aa 8 5 ndu 1S0 5 pue sjndjno yndu NNa 1005 001 1 1005 2137 08433 489 8 5 4 4 493 5 4 La wesbelp 5786 9 25 2 2010 G09 Idd aan 5660 0 2528 6 0 0 09 40 9 3 vad Buluonipuoco 8 615 6 086 05 jeus 819 Buluon puos jeubis Jamod indino Suruorpuoo eqewuwe 6o1d Buluojipuoo euis pow uowwog sng WOdd 323 5 8 8 09 uen 1 x jdNn wu Joyydue uen uen yeubis TWO ueds Joyeiaueb 6 09 A ddns peus Jgonpsuel 1 nss d jse Buluonpuoo 8 8 5 pow uowwog 5101205 5 9 9840151081 payelos yeondo Aiquiessy 08 uen yooo 1994 pue WV 8c WNOUd3 92 2 05580010012 8 8 3 G 0 Y 9356 1 1119 493 5 1 dH uondo 9418 10 29 LOL 169 NO 0l 1 ajnpow 510891 04 05 1580 09 Ae dsiq PEOIN A Alp A Jamod 5 6 190 800 150150 ajqewweiboid JEMOd 9 JaMod SOA
16. e charged when the fitted in the instrument by using the battery charger eliminator Charging takes place with the instrument switched ON or OFF Alternatively the battery pack can be charged by directly connecting the battery charger into the battery pack The charging current is controlled by circuitry within the battery pack the full charge condition takes approximately 14 hours Prolonged charging of the batteries is not recommended as this can damaged the batteries Dry cells Six D size cells are fitted in place of the rechargeable battery pack Alkaline cells are recommended because of the high power consumption of the instrument The instrument circuitry prevents these batteries from being charged when the battery charger eliminator is connected to the instrument ON OFF Control Logic This circuitry continuously monitors the ON OFF key on the membrane keyboard If the instrument is OFF and the ON OFF key pressed the control logic turns ON the main switch mode power supply that powers the instrument When the instrument is ON and the key is pressed the microprocessor detects this action and finishes performing the current tasks and signals the ON OFF control logic to switch OFF the main switch mode power supply turning OFF the instrument Main Switch Mode Power Supply This is controlled by the ON OFF control logic and provides the main power supply to the instrument together with separate floating supplies used to power the
17. e hand pump Remove the o ring from the end fitting Remove the rubber piston ring and anti extrusion ring from the piston If necessary unscrew the piston from the pump plunger Note On later instruments Loctite thread sealant is used to secure the piston Volume Adjuster 8 Unscrew the grub screw and remove the volume adjuster knob Unscrew and remove the retaining nut remove the volume adjuster from the instrument case Unscrew and remove the two connections from the end fitting of the volume adjuster Disconnect the connector PL3 on the main board Using two spanners restrain the volume adjuster and unscrew the 20 bar transducer Note On earlier instruments there are no flats for a spanner on the volume adjuster Use a strap wrench to restrain the volume adjuster 0 Unscrew and withdraw the body of the volume adjuster Remove the rubber piston ring from the piston Vent Valve 8 Using a small screwdriver remove the centre cap of the vent valve knob Unscrew and remove the centre nut retaining the vent valve knob Slacken the large nylon nut retaining the strap securing boss unscrew and withdraw the strap securing boss Collect the large nylon retaining nut and washer 8 Using a spanner unscrew the nut securing the vent valve to the case Withdraw the vent valve from the case K139 Issue No 1 2 6 Druck DPI 605 Service Manual Transducer 20 bar Disconnect the transducer connector PL3 f
18. ectors PL2 PL3 PL4 PL10 Note Make sure PL3 and PL4 are connected to the 20 bar and 2 bar transducers respectively K139 Issue No 1 2 POQ 2 12 Druck DPI 605 Service Manual Power Supply Board Locate the power supply board over the four white plastic pegs press the board firmly on the pegs Each peg should click when the board is in place Connect PL 1 and 2 on the power supply module connector Connect the ribbon connector from the main board PL6 Final Assembling Make sure that the ribbon connectors and wires are not trapped fit the base to the instrument and secure with the eight countersunk screws K139 Issue No 1 2 Servicing 2 13 Chapter 6 Testing General e The following tests should be carried out whenever it is necessary to establish serviceability The tests together with Fault Diagnosis should indicate the extent of any dismantling Equipment The following test equipment is required and must be used as directed Note Equivalent substitutes may be used Pressure standard 8 Digital Voltmeter DVM Pneumatic Test The tests should be carried out if any part of the pneumatic circuit has been disturbed When an indicator instrument requires testing use an external regulated pressure source Calibrator Open the vent valve Switch on and zero the instrument turn the volume adjuster to a mid way position Close the vent valve turn the
19. ed pressure the relationship is programmable to a defined straight line A digital multimeter is built into the instrument permitting independent monitoring of voltage and current signals External connections are provided for a Pt 100 temperature probe and RS232 serial data link The indicator version of the DPI 605 instrument is available with a primary pressure range up to 350 bar It has all the operational features of the calibrator but without the pressure generating facility DPI 605 Indicator Version DPI 605 Calibrator Version K139 Issue No 1 1 Description 1 3 Constructional Description The DPI 605 calibrator indicator comprises an instrument case and base assembled together to enclose pneumatic and electronic equipment The instrument base is a moulded polyethylene case that houses a power supply board and in a separate compartment a battery pack On the outer surface of the case two rubber feet locate in grooves and are secured to the case A set of re chargeable batteries locate into a moulded container A flush fitting connector locates on the moulded container and aligns with a corresponding connector in the battery pack compartment Spring metal connection strips allow for a set of non rechargeable alkaline batteries A metal lid secured by two captive screws secures the battery compartment The instrument case is a moulded polyethylene case with integral handle that houses the main electronics board pn
20. either of the switch mode power supplies in the power supply board Main Multiplexer This takes all the analogue signals to be measured by the instrument and under microprocessor control selects the signal to be routed through the main amplifier Main Amplifier This is a high precision instrumentation amplifier used to amplify the selected signal by a factor of approximately twenty Main A to D Convertor This takes the output from the main amplifier and converts it to a twenty bit number for the microprocessor to read Fast Pressure Common Mode Signal Conditioning for the High Pressure Transducer Signal This block can be configured to implement one of two tasks Fast Pressure Signal Conditioning For the Calibrator version of the instrument this block is configured by links and resistors to provide a pressure signal with high bandwidth The low resolution 8 bit fast A to D convertor built into the microprocessor continuously monitors the pressure and promptly operates the solenoid valves This is particularly important in the case of the low pressure transducer protection valve Common Mode Signal Conditioning For the indicator version of the instrument where there are no solenoid valves fitted a fast pressure signal is not required The block is re configured to provide a signal related to the common mode voltage of the transducer fitted in the high pressure transducer position This is in turn related to the temperature of the trans
21. ent This is carried out to correct any residual error left after completing the three procedures This is achieved by selecting 1 point from the barometric reference calibration menu and entering the accurate pressure of the day K139 Issue No 1 2 Servicing 2 21 Nominal Applied Value Permissible Deviation mbar 1 digit UOS 0 om 800 550 75 90 00 Table 4 Barometric Option Electrical Calibration Voltmeter The voltmeter is auto ranging in the normal operation but during calibration adjustment each of the four individual ranges is separately adjusted A two point span and zero calibration is carried out on each range The zero point is achieved by shorting out the voltmeter input terminals The upper point is achieved by applying a positive dc voltage of approximately the full scale value for the range and entering the precise value through the keyboard The appropriate voltages for each range are as follows Range Voltage 100 mV 95 to 105 mV 1 Volt 0 99 to 1 01 Volts 10 Volts 9 9 to 10 1 Volts 50 Volts 45 to 48 Volts K139 Issue No 1 2 22 Druck DPI 605 Service Manual Permissible Deviation Volts 1 digit UOS 0 01 reading 0 01 reading 0 1 0 1 1 0 01 3001 reading 001 reading 30 01 reading 40 01 reading D 5 Table 5 Voltmeter Ammeter Calibration
22. er with the switch test input forms a large sub system on the main board assembly The whole sub system is galvanically isolated from the rest of the instrument by one of the switch mode power supplies in the power supply board Optical isolators are fitted on the main board for the exchange of control and data signals with the microprocessor When a programmable output is requested through the key board the microprocessor turns on the switch mode power supply After waiting a short time the signal conditioning circuitry is set to either current or voltage output and a number is sent to the serial input D to A convertor in order to set the output to the required value The isolated feedback circuit is activated and this allows the continuous measurement of the actual output and readjustment to compensate for variations due to load changes Switch Test Input This provides through signal conditioning circuitry an input where the state of a simple switch or logic signal may be monitored by the instrument RS232 Port This provides the digital communication interface for the instrument It is galvanically isolated from the rest of the instrument in order to avoid any earth ground loop problems when using the interface to connect the instrument to other equipment such as data loggers or computers e Display Contrast Control The contrast of the display is settable through the keyboard at any time the microprocessor sending the appropriate signa
23. es are 10 and 90 of full scale Permissible Deviation Volts 1 digit UOS l Table 8 Voltage Output K139 Issue No 1 2 24 Druck DPI 605 Service Manual Current Output Calibration adjustment of the current output is a two point calibration This is achieved by accurately measuring in turn two values of the output and entering the precise values through the keyboard The ammeter is connected between output terminals B ve and C ve the nominal output currents are 10 and 90 of full scale Nominal Current Output Permissible Deviation mA 1 digit UOS 20 0059 FS 0 005 FS 0 005 FS 0 005 FS 0 Table 9 Current Output 4 K139 Issue No 1 3 Fault Finding PART 3 FAULT DIAGNOSIS Chapter 1 Fault Diagnosis General Procedure K139 Issue No 1 3 2 Druck DPI 605 Service Manual CHAPTER 1 Fault Diagnosis General The following procedures are to be used in conjunction with the testing detailed in Part 2 Chapter 6 and should indicate the most probable cause of the defect and the recommended rectification Procedure The following procedures list symptoms the probable cause and the recommended action The replacement of the components referred to are detailed in Part 2 Chapters 3 and 5 dismantling and assembling respectively Pneumatic Equipment Fault Finding Symptom Probable Cause Action Leak greater than the Le
24. eumatic assembly and the pneumatic and electrical connections The pneumatic equipment is mounted on a shaped and drilled bracket The pneumatic circuit consists of a vent valve hand pump and volume adjuster all connected together with small bore tubing to a manifold Two pressure transducers one mounted on the end of the volume adjuster the other on the bracket measure pressure at the pressure port The manifold houses four solenoid valves and connections for the small bore tubing The hand pump and volume adjuster locate through holes in the bracket and instrument case and are secured to the instrument case by nuts screwed on the hand pump and volume adjuster end fittings Knobs are attached to the piston rods of the hand pump and volume adjuster The vent valve locates through a hole in the upper surface of the instrument case and is attached by a nut A knob is attached to the spindle of the vent valve and secured by a nut A plastic cap inserted in the top of the knob covers the securing nut The outlet bore of the vent valve is threaded to receive a strap securing boss With the vent valve closed the hand pump generates pneumatic pressure The volume adjuster provides fine adjustment of the generated pressure The vent valve controls a partial or complete de pressurisation of the system Turning anti clockwise opens and clockwise closes the valve The hand pump generates pressure enabling the instrument to calibrate a pressure gauge The volume
25. he vent valve in the instrument case and temporarily secure with the nut Locate the crinkle washer strap attachment and black spacer over the strap securing boss Insert the assembled strap securing boss into the instrument case locate the white nylon washer and retaining nut over the end of the strap securing boss Align the strap securing boss with the port of the vent valve and screw boss into the port Secure the strap securing boss with the white nylon retaining nut Tighten the nut securing the vent valve Locate the knob over the vent valve spindle and secure with centre retaining nut Fit the centre cap in the knob Locate the washer and a new bonded seal on the union and screw the union into the vent valve port Using the pliers reconnect the pipe to the union K139 Issue No 1 2 Servicing 2 9 Transducer 2 bar Screw the retaining nut onto the union of the transducer locate and secure the transducer on the mounting bracket Screw the union onto the transducer union Connect the transducer to PL4 on the main board 8 Using the tubing pliers connect the nylon tubing with the relief valve fitted to the union Transducer 20 bar Fit a bonded seal to the transducer union and tightly screw the transducer into the end of the volume adjuster Connect the transducer to PL3 on the main board Volume Adjuster Fit a new rubber piston ring to the piston If necessary fit the piston on the pis
26. his publication contains information and warnings which must be followed to ensure the safe operation and to maintain the equipment in a safe condition Use qualified personnel and good engineering practice for all procedures and practices in this publication The equipment must not be used for any other purpose than that stated ASSOCIATED DRUCK PUBLICATIONS K136 DPI 605 USER MANUAL K151 DPI 6058 USER MANUAL K139 Issue No 1 Contents LIST OF CONTENTS PART 1 DESCRIPTION Chapter 1 Description Contents General Constructional Description Pneumatic Circuit Electronic Circuit PART 2 SERVICING Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Introduction Contents General Routine Maintenance General Dismantling General Electronic Equipment Pneumatic Equipment Cleaning and Inspection Procedure Assembling General Pneumatic Equipment Electronic Equipment Testing General Configuration Instrument configuration Calibration General Pressure Calibration Electrical Adjustment Calibration Adjustment PART 3 FAULT FINDING Chapter 1 Fault Finding PART 4 PARTS LIST Chapter 1 Parts List K139 Issue No 1 iv Druck DPI 605 Service Manual ABBREVIATIONS Note Abbreviations are the same in the singular and plural abs absolute AC alternating current A to D analogue to digital BS British Standard C degrees Celsius
27. instrument RS232 port 8 Auxiliary Switch Mode Power Supply This is controller by the microprocessor so that it is only active when the programmable outputs of the instrument are in use It provides power solely for the programmable outputs and the associated circuitry K139 Issue No 1 1 8 Druck DPI 605 Service Manual Main Board Assembly This board is the heart of the instrument a description of the main blocks is given below Microprocessor This controls all instrument functions The program for the microprocessor is held in EPROM of either 256 kilobytes or 512 kilobytes The calibration and set up data for the instrument is stored in EEPROM 8 kilobytes 128 kilobytes of RAM provides for data log storage some set up storage and general purpose RAM for the use of the microprocessor A real time clock provides time and date information A built in lithium battery supports the real time clock and the RAM when the instrument is switched OFF RPT Interface This provides signal conditioning of the temperature and frequency output of the RPT together with power control for the RPT To conserve instrument battery life power is removed when the RPT is not in use Valve Drivers The valve drivers provide either positive or negative going control signals to either open or close the latching solenoid valves Power for the valves is supplied through the valve drivers from the batteries or battery charger eliminator and not through
28. l to the contrast control circuitry In addition to the interfacing between the display module and the microprocessor the circuitry provides the required temperature compensation of the contrast voltage to the display in order to make it readily legible over the operating temperature of the instrument K139 Issue No 1 2 Servicing Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 PART 2 SERVICING Introduction General Special Tools and Materials Routine Maintenance General Cleaning Inspection of Instrument Further Maintenance Dismantling General Electronic Equipment Pneumatic Equipment Cleaning and Inspection Procedure Cleaning Inspection of Instrument Inspection of Pneumatic Components Printed Circuit Boards Assembling General Pneumatic Equipment Electronic Equipment Power Supply Board Final Assembling Testing General Equipment Pneumatic Test Configuration Calibration General Calibration Adjustment Electrical Adjustment Calibration Adjustment of Pressure Ranges K139 Issue No 1 2 2 Druck DPI 605 Service Manual Chapter 1 Introduction General Routine maintenance is carried out to ensure that the equipment remains in a serviceable condition To rectify faults dismantling will be required To determine the extent of dismantling refer to FAULT DIAGNOSIS This will establish the condition of the equipment or the m
29. o the base Press in turn each peg to release the board Main Board PCB e Disconnect the following connectors from the main board PL1 PL2 PL3 PL4 PL5 PL7 PL8 PL9 PL10 PL11 PL12 and PL13 Unscrew and remove the four screws securing the main board and collect the four shake proof and plain washers e Carefully remove the main board from the instrument case Display Board Remove the main board for access Unscrew and remove the four screws securing display board and collect the four shake proof and plain washers Remove the display board Note It may be necessary to loosen the pillar next to the display board K139 Issue No 1 2 Servicing 2 5 Key Pad 0 Using a 5 5 mm spanner unscrew and remove the four pillars and four nuts collect the eight shake proof and eight plain washers Collect the ribbon connector clamp and remove the key pad Pneumatic Equipment Procedure Using the tubing pliers carefully disconnect the appropriate tubing from the pneumatic equipment to be removed After disconnecting collect and retain the small spring tubing clamps Hand pump Unscrew and remove the hand pump knob Unscrew and remove the retaining nut remove the hand pump from the instrument case 0 Unscrew and remove the non return valves complete with bonded seals from the end fitting of the hand pump Restrain the hand pump end fitting and unscrew and withdraw the body of th
30. or mounting nuts for security of attachment Ensure that the connector pins clean and show no signs of distortion or corrosion Examine all electronic components for signs of overheating and security of attachment K139 Issue No 1 2 8 Druck DPI 605 Service Manual Chapter 5 Assembling General Ensure all parts are clean before assembling Absolute cleanliness of the work area tools and equipment must be observed at all times After assembling the unit must be tested in accordance with Chapter 6 and if necessary calibrated in accordance with Chapter 8 Ensure that all cables and ribbon connectors are routed correctly and do not protrude or foul Carry out the leak test and pneumatic test procedure after re assembly of the pneumatic component is complete Pneumatic Equipment Manifold Valve Assembly a Make sure that the mating surfaces of the solenoid valve and manifold are clean before assembly Insert the two screws in the solenoid valve and locate the plate washer over the screws Make sure the holes in the plate washer align with the holes in the valve face Secure the assembled valve with the two screws Torque load the screws to 60 cNm 5 3lbf in Locate the manifold valve assembly on the pneumatic assembly and secure with two screws When the pneumatic assembly is complete and installed connect the following connectors to the main board PL2 PL3 PL4 and PL10 Vent Valve a Locate t
31. ost probable cause of its malfunction Absolute cleanliness of the work area tools and equipment must be observed at all times Discard all o rings and bonded seals when removed from the equipment Special Tools and Materials Note Equivalent substitutes may be used The following special tools are required and must be used as directed TABLE 2 1 SPECIAL TOOLS Part No Description Usage 251 004 Pliers tubing Helical tubing clamps Wrench strap Pneumatic equipment The following materials are required Note Equivalent substitutes may be used TABLE 2 2 MATERIALS Material Specification Usage Foam cleaner Cleaning Lint free cloth Cleaning Acetone Cleaning Compressed air Cleaning Grease RS Components multi purpose Assembling Thread sealant Loctite 648 Assembling K139 Issue No 1 2 Servicing 2 3 Chapter 2 Routine Maintenance General Routine maintenance is limited to cleaning and visual inspection Cleaning Clean the case with damp lint free cloth and mild detergent Clean the electrical connections using foam cleaner and a soft brush Remove any dirt or debris from the instrument Inspection of Instrument Examine the unit generally for signs of corrosion and damage Examine the electrical connectors for cracks to the insulation damage to the socket connections and cleanliness Further Maintenance No further maintenance procedures are required unless a fault in the unit occurs refer to PA
32. ows the options under Config Configuration O Serial No Country Instrument Serial No Select Serial No F1 from the configuration menu and at the prompt Serial Noll enter the required serial number refer to the label on the base and press ENT Press Exit Menu to return to the configuration menu K139 Issue No 1 2 16 Druck DPI 605 Service Manual Country Select Country F2 from the configuration menu The instrument responds by displaying the three options available UK USA Japan Select the required option by pressing the appropriate function key e g UK F1 The selected version will then be displayed in the status line above the function key UK Version UK USA Japan Selecting the country option has the effect of setting the default units for the pressure reading as follows Country F1 F2 F3 F4 UK bar psi inH O mbar USA psi inHg inH O kPa Japan kg cm inH O mmHg mbar Instrument Select Instrument from the configuration menu The instrument responds by displaying the options available Indicator Calibrator Rack mount Select the required option by pressing the appropriate function key e g Calibrator F2 The instrument responds by displaying the instrument status above the function keys and requesting entry of then instrument type Calibrator Version Commercial IS e Select the appropriate version by pressing the relevant key e g Commercial F1 Note If the rack mount version
33. r replace Alkaline batteries Switches OFF after short Batteries almost discharged Recharge or replace period of time No data transfer on RS232 Difference in comms set up Check comms set up must be between instrument and the same at both ends external system Printer will not print Printer power or comms Check printer supply and set up Incorrect printer comms set up selected Cannot select external External transducer fault Exit the current mode and transfer re enter or reset instrument by switching ON and OFF K139 Issue No 1 4 Parts List 4 1 PART 4 PARTS LIST K139 Issue No 1 4 2 Druck DPI 605 Service Manual PARTS LIST The following list gives details of all the parts that are available to the user The parts are itemised to assist the user in locating each part In general parts list are in order of disassembly and are indented to show the relationship to the next higher assembly The NI in the description column indicates the items that are not illustraited The quantity shown is the quantity required for one instrument The cost of these parts is issued on a separate price list KIT SHIPPING INCLUDING OPTION F NI MANUAL USER K136 NI CASE CARRY NI KIT TEST LEAD NI PACK BATTERY OPTION F NI ADAPTOR RS232 605 NI a e 9 anv 1 K139 Issue No 1 4 Parts List 4 3 Kic WA ME
34. required full scale value Make sure the existing linearity and temperature compensation TC points are cleared for the external transducer any stored values gives spurious data affecting future readings A two point span and zero calibration should be carried out followed by a linearity check If the linearity check is not within specification a linearity calibration adjustment must be performed TC points are not required for non digitally characterised transducers Barometric Reference Each barometric transducer is supplied with 20 sets of data A data set consists of 18 device constants with the serial number and checksum The data 18 constants serial number and checksum must be entered through the keyboard A mistake made entering the data results in a checksum violation message e The frequency measurement must be calibrated by measuring the instrument s internal reference frequency nominally 10MHz and entering the exact value through the keyboard The frequency signal is measured on PL14 between pin 2 ve and pin 3 OV e The diode measurement must be calibrated by measuring the diode voltage and entering the exact value through the keyboard The voltage signal is measured on PL16 between pin 1 ve and pin 2 OV When these three procedures are complete the instrument should display the barometric pressure 1 mbar e The final stage of calibration adjustment of the barometric reference is the single point adjustm
35. rom the main board Using two spanners restrain the volume adjuster and unscrew the transducer Note On earlier instruments there are no flats for a spanner on the volume adjuster Use a strap wrench to restrain the volume adjuster Transducer 2 bar Disconnect the transducer connector PL4 from the main board Using a spanner restrain the transducer slacken the retaining nut and remove the transducer Manifold valve Assembly Procedure To access this assembly the complete pneumatics assembly must be removed Using the tubing pliers carefully disconnect the appropriate tubing from the pneumatic assembly After disconnecting collect and retain the small spring tubing clamps Unscrew and remove the knob and retaining nut of the hand pump Unscrew the grub screw and remove the volume adjuster knob Unscrew and remove the retaining nut e Disconnect the following connectors from the main board PL2 PL3 PL4 and PL10 Carefully lift out the complete pneumatic assembly 0 Unscrew and remove the two screws securing the manifold valve assembly Disconnect the cable assembly from the assembly mM Toremove a solenoid valve from the assembly unscrew and remove two screws securing the solenoid to the manifold K139 Issue No 1 2 Servicing 2 7 Chapter 4 Cleaning and Inspection Procedure To enable a component to be visually inspected for damage and signs of malfunction each component must be thoroughly cleaned u
36. sing the appropriate cleaning agents and methods Cleaning Clean the case with damp lint free cloth and mild detergent Clean the electrical connections using foam cleaner and a soft brush Remove any dirt or debris from the instrument Note All new components should be cleaned before fitting Inspection of Instrument Examine the unit generally for signs of damage Examine the wiring for signs of overheating damaged insulation and security Examine the terminals of electrical components for security of attachment and signs of damage Inspection of Pneumatic Components Examine the piston of the hand pump for wear Make sure the piston ring and split backing ring show no signs of wear or splitting Examine the o ring located in the non return valve housing of the pump for damage and wear Examine the plunger of the volume adjuster for wear Ensure that the plunger sealing ring shows no sign of wear or splitting Examine the bore of the hand pump and volume adjuster for signs of scoring and wear Printed Circuit Boards Cleaning Partially immerse the printed circuit board in a bath of Acetone and brush using a soft brush Partially immerse the printed circuit board in a bath of clean Acetone remove and allow to dry Inspection Examine the printed side of the printed circuit board for signs of cracks and corrosion Ensure that the printed circuits are firmly bonded to the boards over the complete area Examine the connect
37. stment of Pressure Ranges Ratio Calibration adjustment of ratio is achieved by measuring the voltages PDCR Supply and Span Cal Sig and entering the precise values through the keyboard PDCR Supply and Span Cal Sig signals are with respect to PL15 pin 3 0 V on PL15 pin 1 and pin 2 respectively Pressure calibration adjustment must be carried out after this change Pressure Calibration The standard 20 bar version of the instrument has two digitally characterised transducers 0 to 2 bar gauge and 2 to 20 bar gauge Linearity and temperature compensation data is contained in each internal transducer It is only necessary to perform a two point span and zero calibration check To maintain instrument accuracy in vacuum a negative calibration check 1 bar should be performed Negative pressures are applied by connecting a positive pressure to the reference port Connect a pressure standard to the outlet port and apply pressures detailed in table 1 Check that all the points are within the stated tolerance K139 Issue No 1 2 Servicing 2 19 8 If a point is outside the tolerance a full linearity adjustment must be performed on the low pressure range transducer This adjustment must include one of the five points at 1 bar 1 bar applied to the reference port Indicator Version The standard indicator version contains one non digitally characterised transducer which connects to PL3 on the main board Procedures an
38. th PIN numbers do not agree and exits the Set up mode and any old PIN number is returned K139 Issue No 1 2 18 Druck DPI 605 Service Manual Chapter 8 Calibration General The following procedures should be carried out whenever it is necessary to establish accuracy of the instrument Note The tolerances stated in this chapter do not include the 90 day stability tolerance detailed in the data sheet Equipment The following equipment is required and must be used as directed Note Equivalent substitutes may be used 0 Pressure standard e Digital Voltmeter DVM Datron 1061A Voltmeter or DMM20 ATE Datron 4700 Calibrator For current measurement use resistance standard type RS3 as current shunt For thermometer calibration use precision resistors of 0 01 accuracy Frequency counter Barometric option calibration only Calibration Adjustment To access the calibration adjustment functions use the Cal Test selection in the set up menu Press set up key and select F4 for Cal Test Press the ENT key or enter the PIN In the CAL menu there are three selections Ratio a special calibration adjustment to enable the instrument to make very accurate and stable pressure readings from the Druck digitally characterised transducers fitted in the instrument Pressure For accessing all pressure related calibration adjustments Electrical For accessing all electrical related calibration adjustments Calibration Adju
39. ton rod and screw the end cap on the piston rod Lightly lubricate the bore of the body tube and the piston with grease Carefully insert the piston into the body tube and screw the end cap onto the body tube 8 Lightly lubricate a new o ring with grease and fit into the groove in the internal bore of the end fitting Screw the end fitting onto the assembled body 6 Fit a bonded seal to each of the three adaptors and screw into the holes in the end Cap Note Take care not to over tighten the adaptors Fit a bonded seal to the transducer union and tightly screw the transducer into the end of the volume adjuster Temporarily locate the assembled volume adjuster on the pneumatic assembly bracket Using the tubing pliers connect and secure the nylon tubing to the adaptors of the vol ume adjuster with the small spring clamps Hand pump Fit a new rubber piston ring and anti extrusion ring to the piston Note The anti extrusion ring is fitted nearest the piston rod If necessary apply thread sealant to the threads of the piston rod and screw the piston on the piston rod Lightly lubricate the bore of the body tube and the piston with grease Carefully insert the piston into the body tube and screw the end cap onto the body tube 8 Lightly lubricate a new o ring with grease and fit into the groove in the internal bore of the end fitting Screw the end fitting onto the assembled body K139 Issue No
40. volume adjuster clockwise and check the pressure reading increases Operate the hand pump to approximately half scale pressure 8 Turn the volume adjuster anticlockwise and check the pressure reading decreases Make sure that the pressure reading change is smooth Release the pressure by opening the vent valve Pump Blocking Set the safety limit to 5 bar close the vent valve operate the hand pump and make sure that the pump blocking operates Release the pressure by opening the vent valve 8 Reset the safety limit to 22 bar Leak Test Calibrator Close the vent valve and carefully operate the hand pump for the following values Select the leak test mode and set 5 minute wait time and 1 minute test time The permissible leak rate for the pressure range are 20 bar gauge 0 0040 bar minute 2 bar gauge 0 0020 bar minute 1 bar gauge 0 0015 bar minute K139 Issue No 1 2 14 Druck DPI 605 Service Manual Leak Test Indicator Close the vent valve and apply pressure for the following values Select the leak test mode and set 5 minute wait time and 1 minute test time The permissible leak rate for the pressure ranges are 0 02 of full scale minute Leak Detection If a leak is present switch off the instrument and disconnect the power supply Protect the electronic components from moisture contamination when using the leak detector spray Using leak detector spray check the pneumatic system
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