Druck DPI 612 Portable Pressure Calibrator User Guide

Druck DPI 612 Portable Pressure Calibrator

Introduction
The DPI 612 is a battery-powered instrument for electrical measure and source operations. You can use the touch-screen to display the different parameters. The DPI 612 instrument measures and displays, via user interchangeable PM 620 pressure modules, Pneumatic or Hydraulic Pressure/Vacuum generated by the instrument. The type and range of pressure generation is dependent on the model selected.
Models
The DPI 612 models are listed below together with the recommended PM 620 pressure module rating.

DPI 612-PFX (plex Pneumatic Calibrator)

• Range: –950 mbar to 20 bar (–13.5 to 300 psi)
• PM 620: 2 to 20 bar (3 to 300 psi)

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DPI 612-PFP (plex Pro Pneumatic Calibrator)

• Range: –950 mbar to 100 bar (–13.5 to 1500 psi)
• PM 620: 20 to 100 bar (300 to 1500 psi)

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DPI 612-HFP (flex Pro Hydraulic Calibrator)

• Range: 0 to 1000 bar (0 to 15,000 psi)
• PM 620: 200 to 1000 bar (3000 to 15,000 psi)

Safety
The manufacturer has designed this equipment to be safe when operated using the procedures detailed in this manual. Do not use this equipment for any other purpose than that stated, the protection provided by the equipment may be impaired.
This publication contains operating and safety instructions that must be followed to make sure of safe operation and to maintain the equipment in a safe condition. The safety instructions are either warnings or cautions issued to protect the user and the equipment from injury or damage.
Use qualified technicians* and good engineering practice for all procedures in this publication.

• Pressure
  Do not apply pressures greater than the maximum working pressure to the equipment.

• Toxic Materials
  There are no known toxic materials used in the construction of this equipment.

• Maintenance
  The equipment must be maintained using the procedures in this publication. Further manufacturer’s procedures should be done by an authorized service agents or the manufacturer’s service departments.

• Technical Advice
  For technical advice contact the manufacturer.

Symbols Description

• This equipment meets the requirements of all relevant European safety directives. The equipment carries the CE mark.
• This symbol, on the equipment, indicates that the user should read the user manual.
• This symbol, on the equipment, indicates a warning and that the user should refer to the user manual. Ce symbol, sur l’ apparel, seton advertisement qui in deque que l’ utile aster droit consulter le Manuel d’ utilization.
• USB ports: Type A; Mini-type B connector.
• On / Off
• Ground (Earth)
• Do not dispose of this product as household waste. Use an approved organization that collects and/or recycles waste electrical and electronic equipment. For more information, contact one of these: – Our customer service department: Druck.com
  • Your local government office.

Note: More marks and symbols are specified in the User Manual (Drack DPI 612 Pressure Calibrator, 109M4017).

General Warnings

WARNING Before using this instrument, read and understand the “Safety” section, the user manual and the instructions for the accessories / options / equipment you are using it with. Read and understand the applicable local safety procedures. It is dangerous to ignore the specified warnings. It is dangerous to ignore the specified limits for the instrument or to use the instrument when it is not in its normal condition. Use the applicable protection and obey all safety precautions. Do not use the instrument in locations with explosive gas, vapor or dust. There is a risk of an explosion. Do not use damaged equipment and use only original parts supplied by the manufacturer.

• A qualified technician must have the necessary technical knowledge, documentation, special test equipment and tools to carry out the required work on this equipment.

Electrical Warnings
WARNING To prevent electrical shocks or damage to the instrument, do not connect more than 30 V between the terminals, or between the terminals and the ground (earth).
This instrument uses a lithium-ion rechargeable battery pack or optional standard AA size batteries. To prevent an explosion or fire, do not short circuit, crush or disassemble.
To prevent battery leakage or heat generation, only use the Drack specified battery, power supply and battery charger. The power supply is only specified for operation in the temperature range 0 to 40 °C (32 to 104 °F).

Pressure Warnings
WARNING It is dangerous to attach an external source of pressure to a DPI 612 pressure station. Use only the internal mechanisms to set and control pressure in the pressure station.
To prevent a dangerous release of pressure, isolate and bleed the system before disconnecting a pressure connection.

General Cautions
CAUTION To prevent damage to the display, do not use sharp objects on the touch-screen. Removal of power without appropriately shutting down the DPI 612 can lead to loss of date and time; if it happens, reset the date and time upon restart. To prevent damage to the DPI 612 and PM 620 module, only use it within the specified pressure limit. To prevent damage to the instrument, do not allow dirt into the pressure mechanism. Clean any attached equipment before connection. This instrument is not suitable for permanent outdoor installation.

Overview

Parts List

Refer to Figure A1 and the table below:

3.1

| PFX, PFP models only: Pressure/vacuum selector to set the pump operation: pressure (+), vacuum (–).
| | | 4| Test port: To attach the device under test.

PFX PFP HFP Item Description

• Pneumatic pressure release valve to release pressure in the system.
• PFP models only: Pneumatic refill valve. Close it to seal off the device pressure and refill the pressure mechanism.
• CH1 connectors for: Voltage (V); Current (mA+, mA-); Switch operation.
• Isolated CH2 connectors for: Voltage (V); 24 V loop power supply (24 V).
• Liquid Crystal Display (LCD): Color display with touch-screen. To make a selection, lightly tap on the applicable display area.
• Optional accessory (not shown): Pressure connection for a relief valve (PRV). A blanking plug is standard.
• Pressure and electrical connections for a PM 620 module (not shown): DPI 612 models PFX and PFP: Seal the pressure connection with a blanking plug (Part: IO620-BLANK) or a PM 620 module. HFP models only: The pressure connection seals itself.
• HFP models only: Hydraulic refill valve (not shown): Close it to seal off the device pressure and refill the pressure mechanism with fluid.
• Hand straps.
• +5 V DC power input socket. This supply also charges the optional battery pack.
• USB type A connector for connections to external peripherals (USB flash memory or optional external modules).
• USB mini-type B connector for communication with a computer.

Preparation for Use

Installing the Battery

1. Remove the battery cover by unscrewing the retaining screw and lifting the cover upwards.
2. Insert the CC3800GE rechargeable battery into the compartment as shown in Figure A3.
3. Refit the battery cover by locating the lugs of the cover (A) at an angle into the slots and close the compartment as shown in Figure A3.
4. Refit the battery cover retaining screw.

Power Adaptor

WARNING Use the power adaptor supplied with the instrument (Part no. IO620-PSU). Use of other power adaptors may cause over-heating, this can result in a fire.
Do not let the power adaptor come into contact with any moisture or liquids.

1. Install an accessible power isolator to use as the disconnecting device in the power adaptor supply circuit.
2. The power adaptor input power supply range: 100 – 240 VAC, 50 to 60 Hz, 300 – 150 mA, Installation Category II.
3. The power adaptor must be supplied by a fused or overload-protected power supply.
4. Connect the power adaptor to the instrument.
5. Switch the power supply on.

External Pressure Connection

Use an applicable method to seal the external pressure connections, and then tighten to the applicable torque.

Attach the pressure adaptor to the DPI 612 and tighten to finger tight.

Power Modes

Power On

1. From OFF – momentarily press the power button until  the logo appears. Refer to Figure A2, Item 1.

Power Off

• Press and Release the Power Button:
• Select SWITCH OFF from the POWERDOWN OPTIONS window displayed.

Note: SWITCH OFF can also be achieved by pressing and holding the power button until the screen is blank. Use SWITCH OFF to preserve the battery capacity when the instrument is not in use for extended periods of time.

Standby Mode

Use GO TO STANDBY between jobs to provide a quick start-up.

1. Press and Release Power button:
2. Select GO TO STANDBY from the POWERDOWN OPTIONS window displayed.

Power up from Standby Mode

When powered up from the standby mode, instrument always opens the last screen shown before going to standby mode.

DASHBOARD Navigation

The application DASHBOARD allows quick selection of a function without menus or special keys. The DASHBOARD icons represent the functional applications of the DPI 612, for example, the CALIBRATOR application. Touch the appropriate icon to start the application.

Functions

To change the measure and source functions select the button from the calibrator application screen to enter the TASK menu. Select CALIBRATOR in the TASK menu to choose from a library of pre-configured TASKs appropriate for common tests. For example: Select the following TASK to test a pressure transmitter and provide 24 V loop power.

To save a TASK in FAVOURITES select the check box, shown below, followed by .

To create a custom TASK select CUSTOM TASK and manually configure the required measure and source functions. CUSTOM TASK tasks can be saved for future use by adding them to FAVOURITES using the Save function in the TASK MENU. Refer to Figure A8 for TASK MENU and calibrator function windows.

Set Date, Time and Language

To access Date, Time and Language menus: DASHBOARD >> SETTINGS >> DATE

Themes

Two themes are available: Dark and Light; select the correct theme for the light level using: DASHBOARD >> SETTINGS >> THEME

Help

Select the HELP icon on the Dashboard to access the manual. All the information required to operate the Druck DPI 612 is in the HELP section of the Dashboard which is accessed by selecting: DASHBOARD >> HELP

Basic Electrical Operations

Refer to Figure A4 and the table below:

Pressure Operations

DPI 612-PFX: 20 bar (290 psi)

WARNING Pressurized gases and fluids are dangerous. Before connecting or disconnecting pressure equipment, safely release all the pressure.
CAUTION To prevent damage to the pressure station, do not let dirt get into the pressure mechanism. Before connecting equipment, make sure it is clean or use the applicable dirt trap.

Release the Pressure/Attach the Device Under Test

1. Open the pressure release valve (one turn) (Ref: Item 5).
2. Use the applicable adaptor to attach the device, (Ref: Figure A7).

Vacuum Operation

1. Set to vacuum operation (–) (Ref: Item 3.1).
2. Turn the volume adjuster to mid-range or fully clockwise (Ref: Item 2).
3. Seal the system (Ref: Item 5).
4. Set the approximate vacuum with the pump (Ref: Item 3).
5. Adjust the vacuum with the volume adjuster (Ref: Item 2).
6. On completion of test, open the pressure release valve one turn (Ref: Item 5) to release vacuum before disconnection of device under test.

Pressure Operation

1. Set to pressure operation (+) (Ref: Item 3.1).
2. Turn the volume adjuster to mid-range (Ref: Item 2).
3. Seal the system (Ref: Item 5).
4. Set the approximate pressure with the pump (Ref: Item 3).
5. Adjust the pressure with the volume adjuster (Ref: Item 2).
6. On completion of test, open the pressure release valve one turn (Ref: Item 5) to release pressure before disconnection of device under test.

DPI 612-PFP: 100 bar (1450 psi)

CAUTION Pressurized gases and fluids are dangerous. Before connecting or disconnecting pressure equipment, safely release all the pressure.
WARNING To prevent damage to the pressure station, do not let dirt get into the pressure mechanism. Before connecting equipment, make sure it is clean or use the applicable dirt trap.

Release the Pressure/Attach the Device Under Test

1. Fully open the refill valve (Ref: Item 5.1).
2. Open the pressure release valve (one turn) (Ref: Item 5).
3. Use the applicable adaptor to attach the device, (Ref: Figure A7).

Vacuum Operation

1. Set to vacuum operation (–) (Ref: Item 3.1).
2. Fully open the refill valve (Ref: Item 5.1).
3. Wind the volume adjuster to mid-range or fully clockwise (Ref: Item 2.1).
4. Seal the system (Ref: Item 5).
5. Set the approximate vacuum with the pump (Ref: Item 3).
6. Adjust the vacuum with the volume adjuster (Ref: Item 2.1).
7. On completion of test, open the pressure release valve one turn (Ref: Item 5) to release vacuum before disconnection of device under test.

Pressure Operation

1. Set to pressure operation (+) (Ref: Item 3.1).
2. Turn the volume adjuster to mid-range (Ref: Item 2.1).
3. Seal the system (Ref: Item 5).
4. Use the pump to set a pressure up to ≈20 bar (300 psi) (Ref: Item 3).
5. Open the refill valve (1 turn) (Ref: Item 5.1).
6. Increase or decrease the pressure with the volume adjuster (Ref: Item 2.1).
7. If increasing pressure the limit of travel is reached, close the refill valve (Ref: Item 5.1).
8. Wind the volume adjuster fully counter-clockwise. (Ref: Item 2.1).There is no change in pressure.
9. Refill the pressure mechanism with the pump (≈15 cycles) (Ref: Item 3).
10. Wind the volume adjuster clockwise until the pressure starts to increase (Ref: Item 2.1).
11. Continue to do steps 7 to 10 until you get the necessary pressure.
12. On completion of test, open the pressure release valve one turn (Ref: Item 5) to release pressure before disconnection of device under test.

DPI 612-HFP: 1000 bar (14,500 psi)

WARNING Pressurized gases and fluids are dangerous. Before connecting or disconnecting pressure equipment, safely release all the pressure. Ensure that the system is bled of excess air before operation. If the item under test has a large volume, pre-fill with the pressure fluid to ensure that trapped air is kept to a minimum.
CAUTION To prevent damage to the pressure station, do not let dirt get into the pressure mechanism. Before connecting equipment, make sure it is clean.

Release the Pressure

Refer to Figure A5 and procedure below:

1. Turn the Refill valve fully counter-clockwise (Ref: Item 11).
2. Turn the Release Valve Stem counter-clockwise, then fully clockwise (Ref: Item 5).

Note: Fill the reservoir before attaching the device.

Filling, Priming

CAUTION Ice in the pressure mechanism can cause damage. If the temperature is less than 4 °C (39 °F), drain all water from the DPI 612-HFP. When using the DPI 612-HFP for the first time, fill the reservoir with the correct hydraulic fluid (Fluid type: Demineralized water or a mineral oil (Recommended ISO viscosity grade ≤ 22)). Fill and prime the pressure station. If new, remove the red plastic blanking cover from the Test port.

Fill the reservoir using the procedure that follows:

1. Turn the Refill valve fully counter-clockwise (Ref: Item 11).
2. Turn the Volume adjuster fully clockwise (Ref: Item 2.1).
3. Turn the Release Valve Stem fully counter-clockwise (Ref: Item 5).
4. Remove the Priming pump piston/Release valve stem assembly.
5. Fill the reservoir with the recommended fluid, (Fluid type: Demineralized water or a mineral oil (Recommended ISO viscosity grade ≤ 22)) 25 mm approximately from the top.
6. Re-fit the Priming pump piston/Release valve stem assembly
7. Turn the Release Valve Stem fully clockwise (Ref: Item 5).
8. Turn the Refill valve fully clockwise, until finger tight (Ref: Item 11).
9. Turn the Volume adjuster fully counter-clockwise (Ref: Item 2.1).
10. Turn the Volume adjuster 5 turns clockwise (Ref:  Item 2.1).
11. Operate the Priming pump until the air is expelled and fluid is visible at the Test port.
12. Fit the “Item under test” to the Test port use the existing adaptor or the applicable AMC adaptor and applicable seals.
13. Operate the Priming pump and prime the system to a maximum pressure of 10 bar (145 psi).
14. Turn the Volume adjuster (Ref: Item 2.1) clockwise, until the required pressure is indicated.
15. Turn the refill valve (Ref: Item 11) fully counter-clockwise to allow full pressure control.
16. On completion of test, open the pressure release valve one turn (Ref: Item 5) to release pressure before disconnection of device under test.

Attach the Device Under Test

1. Open the refill valve fully counter-clockwise (Ref: Item 11).
2. Open the pressure release valve counter-clockwise (Ref: Item 5).
3. Use the applicable adaptor to attach the device, (Ref: Figure A7).

Specification

General

+10 °C to +30 °C (optimized calibration specification)
0 °C – 40 °C with optional mains power supply.
Storage temperature| –20 °C to 70 °C (–4 °F to 158 °F)
Ingress protection| IP54 (EN 60529)
Operating humidity| 0% to 90% Relative Humidify (RH) non-condensing.
|
Operating altitude| Maximum 2000 meters (6560 ft)
EMC| EN 61326
Electrical safety| EN 61010-1
Power adaptor| Input range: 100 – 240 VAC, 50 to
60 Hz, 300 – 150 mA, Installation Category II.
Batteries (Rechargeable| Li–ion 14.1Wh Drack Part number: CC3800GE. Nominal voltage 3.7 V 3800 mAh Charge temperature: 0 °
to 40 °C (32 ° to 104 °F) Discharge
temperature: –10 ° to 60 °C (14 ° to 140 °F). For best battery performance, keep the temperature less than 60 °C (140 °F).
Batteries (Non- rechargeable)| 8 × AA Alkaline
Pressure safety| Pressure Equipment Directive – class: sound engineering practice (SEP) for group 2 fluids.
Pollution degree| 2
Operating Environment| Indoor use only. Not rated for use in potential explosive atmospheres.
Pressure media| Not rated for oxygen or other explosive gases or liquids.

Leak Rates

0.005 bar/min at 95 % vacuum

DPI612-PFP| 0.02 bar/min at 100 bar

0.005 bar/min at 95 % vacuum

DPI612-HFP| 1 bar/min at 1000 bar

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