BEAMEX POC4 User manual

Instruction Manual for
AUTOMATIC PRESSURE
OUTPUT MODULE POC4
Dear user,
We have made every effort to ensure the accuracy of the
contents of this manual. Should any errors be detected, we
would greatly appreciate to receive suggestions to improve the
quality of the contents of this manual.
The above not withstanding, we can assume no responsibility
for any errors in this manual or their eventual consequences.
We reserve rights to make modifications to this manual without
any further notice.
For more detailed technical data about POC4, please contact
the manufacturer.
© Copyright 1997, 2006
OY BEAMEX AB
Ristisuonraitti 10
68600Pietarsaari
FINLAND
Tel +358 - 10 - 5505000
Fax +358 - 10 - 5505404
E-mail: [email protected]
Internet: http://www.beamex.com
8889700 / UEPOC4S / 000886

Operation panel (front panel)
Connection panel (rear panel)
ANALOGUE
OUTPUT OPTIONAL
INTERFACE RS232 IEEE488 CALIBRATION
MODE
VENT SOURCE OUTLET
SUPPLY INPUT
G1/8
0 1
STACKING
0 1
Type: POC4
Serial number: 250
REFERENCE
M5
ELECTRICALSAFETY
INSTRUMENT MUST BE CONNECTED TO
PROTECTIVE EARTH/GROUND CONDUCTOR.
PNEUMATIC SAFETY
SOURCE PRESSURE MAY LEAK TO THE OUTPUT PORT UNDER
FAULT CONDITION. ENSURE PNEUMATIC SUPPLY IS
ISOLATED AND VENTED WHEN NOT IN USE.
MAXIMUM SOURCE PRESSURE = 125% FULL SCALE
88 to 264 V
50/60 Hz
60 VA MAX
FUSES T2.0 A

CONTENTS
PART A GENERAL
1 GENERAL OVERVIEW ...........................................................................................................A - 1
1.1 Unpacking and Inspection..................................................................................................A - 2
1.2 Safety..................................................................................................................................A - 3
2 FUNCTIONAL DESCRIPTION................................................................................................A - 4
2.1 General...............................................................................................................................A - 4
2.2 Instrument Electronics........................................................................................................A - 4
2.2.1 Digital Electronics.........................................................................................................A - 4
2.2.2 Analogue Circuit Operation..........................................................................................A - 5
3 INSTALLATION .......................................................................................................................A - 7
3.1 Safety Instruction................................................................................................................A - 7
3.1.1 Input/Output Connections.............................................................................................A - 7
3.2 Electrical Connections........................................................................................................A - 8
3.2.1 Electrical Safety Instructions........................................................................................A - 8
3.2.2 Power Supply Connections..........................................................................................A - 8
3.3 Communications Interface Connections............................................................................A - 9
3.4 Pressure Connections......................................................................................................A - 10
3.4.1 Pressure Safety Instructions ......................................................................................A - 10
3.4.2 Connection..................................................................................................................A - 10
4 CALIBRATION.......................................................................................................................A - 12
PART B OPERATION
1 GENERAL ............................................................................................................................... B - 1
2 USING POC4 TOGETHER WITH BEAMEX PRESSURE CALIBRATORS......................... B - 2
2.1 Serial communication.........................................................................................................B - 3
2.1.1 Beamex pressure calibrator settings............................................................................B - 3
2.1.2 POC4 settings ..............................................................................................................B - 4
3 TROUBLESHOOTING............................................................................................................ B - 5

PART C CONFIGURATION
1 GENERAL ............................................................................................................................... C - 1
2 BASIC SETUP MENU............................................................................................................. C - 3
2.1 Power Up........................................................................................................................... C - 3
2.2 Keyboard ........................................................................................................................... C - 4
2.3 Recalling/Replacing Default Settings................................................................................ C - 4
2.4 Controller Setup (Stability, Autospeed and Automax)...................................................... C - 5
2.4.1 Stability........................................................................................................................ C - 6
2.4.2 Autospeed.................................................................................................................... C - 7
2.4.3 Automax....................................................................................................................... C - 7
2.5 Setting a P.I.N. protection ................................................................................................. C - 8
2.6 Displaying the Software Version....................................................................................... C - 8
2.7 Self Test: Electronic .......................................................................................................... C - 9
2.8 Self Test: Pneumatic....................................................................................................... C - 10
2.9 Basic Setup Menu Flowsheet.......................................................................................... C - 11
3 COMMUNICATIONS SETUP ............................................................................................... C - 12
3.1 RS232 Setup................................................................................................................... C - 12
4 MORE SETTINGS................................................................................................................. C - 16
4.1 Scale................................................................................................................................ C - 16
4.2 Setup Zero....................................................................................................................... C - 17
4.2.1 Manual Zero............................................................................................................... C - 17
4.2.2 Timed Zero ................................................................................................................ C - 17
4.2.3 Auto Zero................................................................................................................... C - 17
4.3 Setpoint............................................................................................................................ C - 18
4.3.1 Value.......................................................................................................................... C - 18
4.3.2 Ratio and Preset........................................................................................................ C - 19
4.4 Rate ................................................................................................................................. C - 19
PART D MAINTENANCE
1 MAINTENANCE...................................................................................................................... D - 1
1.1 Safety Instructions............................................................................................................. D - 1
1.2 Fuse Replacement............................................................................................................ D - 2
1.3 Replace Vent, Source and Outlet Manifold Filters............................................................ D - 3
1.4 Cleaning............................................................................................................................. D - 3
1.5 Fault Finding...................................................................................................................... D - 3
1.5.1 Error Codes ................................................................................................................. D - 4
1.6 Approved Service Agents.................................................................................................. D - 5
APPENDIXES
1 INSTRUMENT SPECIFICATION.............................................................................................X - 1

A - GENERAL

POC4 - General A- 1
1 GENERAL OVERVIEW
POC4 is a automatic pressure output module intended for applications in
automatic pressure testing and calibration.
POC4 is used together with Beamex pressure calibrators PC104, PC106 and
PC106P. Instructions on how to use POC4 and Beamex pressure calibrators can
be found in Section B in this manual and in the user manual of the calibrator.
A rugged piezo resistive transducer measures pressure and is compensated to
standard or enhanced accuracy as required.
Dual loop control provides extremely accurate and repeatable setting of pressure
output.
The pneumatic control actuator achieves this level of control whilst also providing
fast response and very low gas supply consumption.
Only 2U of 19 inch rack is required to house the unit which is controlled remotely
by a host computer for fully automatic applications.
Pressure demands from a Beamex pressure calibrator via an RS232 interface are
converted by POC4 into a regulated pressure supplied from a line or bottle
source.
Option B provides negative pressure calibration.
POC4's RS232 interface also communicates with any computer equipped with a
suitable software for serial communication. The use of this additional feature is
described in a separate manual that is available from Beamex when requested.
NOTE!
Using POC4 together with Beamex pressure calibrators does not require any
knowledge of serial communication. All the necessary information for applications
with Beamex calibrators are included in this manual.

A- 2POC4 - General
1.1 Unpacking and Inspection
At the factory each new POC4 passes a careful inspection. It should be free of
scrapes and scratches and in proper operation order upon receipt. The receiver
should, however, inspect the unit for any damage that may have occurred during
transit. If there are signs of obvious mechanical damage, package contents are
incomplete, or the instrument does not operate according to specifications,
contact the purchasing sales office as soon as possible.
The standard accessories are as follows:
• POC4 Instruction manual
• Calibration Certificates
• Power Supply Lead
If you have to return the instrument to the factory for any reason, use the original
packing whenever possible. Include a detailed description of the reason for the
return.

POC4 - General A- 3
1.2 Safety
The Manufacturer has designed this product to be entirely safe when operated
correctly.
lPlease 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.
lPotentially 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. On the instrument, this symbol
indicates that the user should refer to the User Manual.
lPlease observe the installation advice and any operational limits given in this
manual.
lThis 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
During normal operation it is not possible for the user to come into contact with
any hazardous substance which might be employed in the construction of the
instrument. The use of hazardous materials in the construction of this instrument
has been minimized.
Repair and Maintenance
This publication contains information and warnings which must be followed for
safe operation and to maintain the equipment in a safe condition. Use qualified*
personnel and good engineering practice for all procedures in this publication.
The operator must not use this equipment for any other purpose than that stated.
Do not apply a pressure greater than the maximum pressure stated.
*A qualified person must have attended a product training course given by the
manufacturer or appointed agent and successfully completed the training
course on this equipment.

A- 4POC4 - General
2 FUNCTIONAL DESCRIPTION
2.1 General
The POC4 instrument is a single channel automatic pressure output module,
designed to be programmed from an external computer system. No user controls
are provided on the instrument, its local keyboard being used only for Set-up,
Calibration and Maintenance operations. The use of these functions are
described in Sections C, D and E respectively.
Digital programming of the instrument is effected via a RS232 serial interface.
When using POC4 together with Beamex pressure calibrators, no programming
or specific commands are required. The calibrator supervises the use of POC4.
POC4 can be configured in a number of different ways as detailed in Section C.
This section also details the installation procedures.
2.2 Instrument Electronics
2.2.1 Digital Electronics
The instrument draws its power supplies from an internal power supply unit which
is, in turn, powered from an external AC source.
An internal microprocessor system controls the RS232 communications channel.
One RS232 port is provided and one optional IEEE 488 channel (not applicable
with Beamex calibrators). The RS232 port has three inputs: one is used for the
communications channel. The other optional RS232 inputs two are not required
when using POC4 together with Beamex pressure calibrators. The use of the
optional IEEE488 channel and the optional RS232 ports are not discussed in this
manual.
The microprocessor system also controls the flow of data to the instrument’s
display. The display is a two line (20 characters/line) liquid crystal dot matrix type.
Operationally, it is used to display pressures, functions and messages.
A keyboard, linked to the microprocessor, provides a user interface for Setup and
Calibration purposes only. It is not used for normal operation, all operational
commands being sent from the connected pressure calibrator.

POC4 - General A- 5
Control of the Analogue to Digital (A-D) Converters used in the analogue and
valve control circuits is effected via the microprocessor system’s bi-directional
control bus. A simplified description of the analogue control channel follows.
OPTIONAL
INTERFACE
IEEE 488
INTERFACE
OPTIONAL
INTERFACE
OPTIONAL
INTERFACE
BEAMEX
PRESSURE
CALIBRATOR
BI-DIRECTIONAL
CONTROL BUS
TO ANALOGUE
CIRCUITS
IEEE 488 BUS
RS232
INPUT
OPTIONAL
INTERFACE
(REAR)
OPTIONAL
INTERFACE
(FRONT)
DAISY
CHAIN
SWITCHING
NETWORK
POWER
SUPPLY
UNIT
MICROCONTROLLER
SYSTEM
DISPLAY
KEYBOARD
POWER TO
ANALOGUE & DIGITAL
CIRCUITS
AC POWER
2.2.2 Analogue Circuit Operation
Output pressure control is effected by means two solenoid operated valves. One
of these valves, the Apply valve, controls the application of a source pressure to
the output manifold. The other valve, the Release valve, releases the output
pressure. The output pressure is controlled by modulating the drive to each of
these valves, controlling their relative on/off times. An Isolation valve, also
controlled by the microprocessor, is used to isolate POC4 from the external
pneumatic system. The output pressure of POC4 (external system pressure when
the isolation valve is open), is measured by a suitably scaled, internally mounted,
pressure transducer.
Pressure demands to POC4 are sent via the RS232 communications interface
and decoded by the microprocessor. The decoded demand is sent to the Setpoint
A-D converter, processed (with other loop control terms) and applied to an error
amplifier. The other input to the error amplifier is the transducer output signal,
(representing the actual pressure at the output).
The error amplifier produces a bipolar error signal proportional to the magnitude
and direction of the error between the Setpoint demand and the actual output of
POC4. This error is first processed by an Error Signal Processing circuit, under
the control of the microprocessor, to drive a pulse width modulator. The output of
the pulse width modulator drives the Apply and Release valves to change the
output pressure in an appropriate direction to correct the error i.e. to equalize the
setpoint demand and pressure feedback signals. A temperature feedback signal