GE Druck DPI612 User manual

GE
Measurement and Control
© 2014 General Electric Company. All Rights Reserved.
Specifications are subject to change without notice. GE is a
registered trademark of General Electric Company. Other company
or product names mentioned in this document may be trademarks
or registered trademarks of their respective companies, which are
not affiliated with GE.
Druck DPI612
Portable Pressure Calibrator
User Manual – 109M4017
g

User Manual Druck DPI612
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Revision History
This document supersedes all previously issued versions, providing new
or revised information. The most recent publication can be determined
by comparing the last three characters at the end of the part number
and the date issued.
DPI 612 Portable Pressure Calibrator User Manual
Part Number: 109M4017
Revision
Level
Date
Issued General Description of Changes
Revision - 07/08/15 First Release

User Manual Druck DPI612
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Contents
1INTRODUCTION ..............................................................................................................................8
EQUIPMENT IN THE BOX..................................................................................................81.1
OBSERVANCE OF THE USER MANUAL .......................................................................81.2
GENERAL SAFETY PRECAUTIONS.................................................................................81.3
WARNINGS.......................................................................................................................... 101.4
ELECTRICAL SAFETY ........................................................................................................ 101.5
RECHARGABLE BATTERY WARNINGS ..................................................................... 111.6
PRESSURE WARNINGS...................................................................................................141.7
OVERVOLTAGE CATEGORY........................................................................................... 151.8
PREPARING THE INSTRUMENT...................................................................................151.9
1.9.1 Initial Checks............................................................................................................ 15
1.9.2 Install Rechargeable Battery and Cradle................................................... 15
1.9.3 Install Dry Cell Batteries ..................................................................................... 17
PARTS.....................................................................................................................................191.10
1.10.1 DPI 612 ....................................................................................................................... 19
1.10.2 Test Port.....................................................................................................................21
1.10.3 Pressure Release Valve....................................................................................... 22
1.10.4 SELECTOR DPI 612 pFlex & pFlexPro (20 & 100 bar)............................ 22
1.10.5 Pump ...........................................................................................................................22
1.10.6 Volume Adjuster..................................................................................................... 23
1.10.7 Refill Valve.................................................................................................................25
1.10.8 Priming Pump DPI612 hFlexPro (1000 bar)............................................... 25
ACCESSORIES:....................................................................................................................261.11
1.11.1 Carry Case (P/N IO612-CASE-3)...................................................................... 26
1.11.2 Rechargeable Battery pack (P/N CC3800GE)........................................... 26
1.11.3 Rechargeable Battery and adaptor kit (P/N IO61X-BAT-KIT)............ 26
1.11.4 Rechargeable Desktop Charger (P/N CX6100GE).................................. 26

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1.11.5 Mains Adaptor (P/N IO620-PSU) .....................................................................26
1.11.6 USB Cable (P/N IO620-USB-PC).......................................................................27
1.11.7 IDOS to USB Converter (P/N IO620-IDOS-USB)........................................27
1.11.8 USB to RS 232 Cable (P/N IO620-USB-RS232)..........................................27
1.11.9 Dirt Moisture Trap 20 bar (P/N IO620-IDT621).........................................27
1.11.10 Dirt Moisture Trap 100 bar (P/N IO620-IDT622)......................................27
1.11.11 Pneumatic Hose (PN IO620-HOSE-P1 / IO620-HOSE-P2)...................28
1.11.12 Hydraulic Hose (PN IO620-HOSE-H1 / IO620-HOSE-H2) ....................28
1.11.13 Low Pressure Pneumatic Hose (PN IOHOSE-NP1 / IOHOSE-NP2) ..28
1.11.14 Pressure Adaptor set ...........................................................................................29
1.11.15 Comparator Adaptor (P/N IO620-COMP)....................................................29
1.11.16 Pressure Module (P/N IPM620-***)................................................................29
1.11.17 Pressure Relief Valve (PRV) ................................................................................30
DRUCK DPI612, MODES.................................................................................................311.12
1.12.1 Power ON...................................................................................................................31
1.12.2 Power OFF.................................................................................................................31
1.12.3 Power up from Standby Mode ........................................................................32
NAVIGATION .......................................................................................................................321.13
1.13.1 Set Date, Time and Language.........................................................................32
1.13.2 Themes .......................................................................................................................33
1.13.3 DRUCK DPI612 Manual .......................................................................................33
SOFTWARE AND FIRMWARE UPGRADES...............................................................331.14
1.14.1 Viewing Software Revision................................................................................33
1.14.2 Upgrading the Software.....................................................................................33
1.14.3 Upgrade the Application Software................................................................34
1.14.4 Upgrade the Operating System and Boot Loader Software. ...........34
MAINTENANCE...................................................................................................................351.15
1.15.1 Cleaning .....................................................................................................................35
1.15.2 Replace the Batteries...........................................................................................35

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INSTRUMENT RETURN....................................................................................................351.16
1.16.1 Returned Material Procedure .......................................................................... 35
1.16.2 Safety Precautions................................................................................................ 35
1.16.3 Important Notice ...................................................................................................36
1.16.4 Instrument Disposal in the European Union............................................ 36
1.16.5 For more information contact......................................................................... 36
ENVIRONMENT ..................................................................................................................361.17
MARKS AND SYMBOLS ON THE EQUIPMENT....................................................... 371.18
2OPERATIONS.................................................................................................................................38
COMMON OPERATIONS.................................................................................................382.1
2.1.1 Attach/Remove the device under test ........................................................ 38
2.1.2 Attach a Pressure Relief Valve ........................................................................ 40
2.1.3 Setting a Pressure Relief Valve ....................................................................... 41
DPI 612 PFLEX & PFLEXPRO PNEUMATIC PRESSURE OPERATIONS.......... 422.2
2.2.1 Introduction.............................................................................................................. 42
2.2.2 Release the Pressure ........................................................................................... 42
2.2.3 Vacuum or Pressure Operation DPI 612 pFlex (20 bar) .................... 43
2.2.1 Release Pressure DPI 612 pFlex (20 bar)................................................... 43
2.2.2 Vacuum or Pressure Operation DPI 612 pFlexPro (100 bar)............. 44
2.2.3 Release pressure DPI 612 pFlexPro (100 bar pump) ............................ 46
DPI 612 HFLEXPRO (1000 BAR) HYDRAULIC OPERATIONS. .......................... 462.3
2.3.1 First Use .....................................................................................................................47
2.3.2 Filling and Priming the Pump........................................................................... 47
2.3.3 Topping up the Hydraulic Fluid....................................................................... 48
2.3.4 Priming Sequence .................................................................................................49
2.3.5 Applying Hydraulic Pressure (1000 bar) ..................................................... 50
2.3.6 Release Hydraulic Pressure (1000 bar pump) ......................................... 51
2.3.7 Drain Excess Hydraulic Fluid............................................................................ 51
2.3.8 Drain all the Hydraulic Fluid............................................................................. 52

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CALIBRATOR OPERATIONS...........................................................................................542.4
2.4.1 Basic Calibrator Operation................................................................................54
2.4.2 Set the Function Utility Options ......................................................................60
2.4.3 Measurement Display Options........................................................................63
2.4.4 Example Procedures ............................................................................................64
PRESSURE CALIBRATION...............................................................................................692.5
2.5.1 Set up a Leak Test .................................................................................................70
2.5.2 Set the Pressure Module to Zero....................................................................72
2.5.3 Error Indications.....................................................................................................72
MEASURE PRESSURE: IDOS OPTION ........................................................................722.6
2.6.1 IDOS Option Assembly Instructions ..............................................................73
2.6.2 IDOS Function Procedures ................................................................................73
3DATA LOGGING OPERATION..................................................................................................75
SET-UP...................................................................................................................................763.1
OPERATION..........................................................................................................................773.2
FILE REVIEW........................................................................................................................783.3
FILE MANAGEMENT .........................................................................................................783.4
3.4.1 Transfer ......................................................................................................................78
3.4.2 Erase ............................................................................................................................79
3.4.3 Memory Status........................................................................................................79
DATA FORMAT....................................................................................................................793.5
4DOCUMENTATION......................................................................................................................81
ANALYSIS..............................................................................................................................814.1
SET-UP...................................................................................................................................824.2
4.2.1 Define the Reference Channel ........................................................................82
4.2.2 Define each Input Channel ...............................................................................82
ANALYSIS FUNCTION......................................................................................................844.3
RUN PROCEDURE .............................................................................................................844.4
4.4.1 Sequence to Upload and Download file.....................................................85

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5CALIBRATION................................................................................................................................ 86
GENERAL ..............................................................................................................................865.1
CALIBRATION CHECK...................................................................................................... 865.2
CALIBRATION ADJUSTMENTS..................................................................................... 875.3
BEFORE STARTING ...........................................................................................................875.4
PROCEDURES: CURRENT (MEASURE)....................................................................... 885.5
PROCEDURES: CURRENT (SOURCE).......................................................................... 895.6
PROCEDURES: DC MV/VOLTS (MEASURE) ............................................................. 905.7
PROCEDURES: DC VOLTS (SOURCE)......................................................................... 915.8
PROCEDURES: PRESSURE INDICATOR .................................................................... 925.9
PROCEDURES: IDOS UPM .............................................................................................935.10
6ACCESSORY INSTRUCTIONS.................................................................................................. 94
DIRT MOISTURE TRAP 20 BAR (P/N IO620-IDT621)........................................... 946.1
6.1.1 Specification: ........................................................................................................... 94
6.1.2 Pressure connections:......................................................................................... 94
6.1.3 Operation: ................................................................................................................. 94
6.1.4 Cleaning: ....................................................................................................................95
DIRT MOISTURE TRAP 100 BAR (P/N IO620-IDT622)........................................ 966.2
6.2.1 Specification: ........................................................................................................... 96
6.2.2 Pressure connections:.........................................................................................96
6.2.3 Operation: ................................................................................................................. 96
6.2.4 Cleaning:.................................................................................................................... 97
7GENERAL SPECIFICATION....................................................................................................... 98
8TROUBLESHOOTING ...............................................................................................................101
DPI 612 PFLEX .................................................................................................................1018.1
DPI 612 PFLEXPRO.........................................................................................................1028.2
DPI 612 HFLEXPRO........................................................................................................1038.3
GENERAL ............................................................................................................................1048.4
9MANUFACTURER ......................................................................................................................105

User Manual Druck DPI612
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1INTRODUCTION
The Druck DPI612 is a battery-powered instrument for performing
pressure and electrical calibration operations. The Druck DPI612
also supplies the power and user interface functions for all optional
items. The DPI612 uses the PM620 pressure module to allow user
selection of the most suitable pressure range for the task.
EQUIPMENT IN THE BOX1.1
The following are the common items supplied with the Druck DPI612
•1/8” NPT & BSP pressure adaptors
•Set of four test leads
•Safety and Quick Start Guide
•Stylus
•Hand & Shoulder straps
Refer to DPI612 datasheet for full list of accessories supplied with
each DPI612 model.
OBSERVANCE OF THE USER MANUAL1.2
This manual contains safety and battery installation information for
the Druck DPI612. It is the responsibility of the customer to make
sure that all personnel operating and maintaining the equipment
are correctly trained and qualified. Before using the equipment, read
all sections of this User Manual paying particular attention to all
WARNINGS and CAUTIONS given in the Quick Start Guide.
GENERAL SAFETY PRECAUTIONS1.3
Read and obey all the operator's local health and safety regulations
and safe working procedures or practices when doing a procedure
or task.
•Use only the approved tools, consumable materials and spares to
operate and maintain the equipment.
•Use equipment only for the purpose for which it is provided.

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•Wear all applicable Personal Protective Equipment (PPE).
•Do not use sharp objects on the touch-screen.
•Observe absolute cleanliness when using the instrument.
•Severe damage can be caused if equipment connected to this
instrument is contaminated.
•Connect only clean equipment to the instrument. To avoid any
contamination, an external Dirt Moisture Trap (See Section 1.10.7)
is recommended
•Some liquid and gas mixtures are dangerous. This includes
mixtures that occur because of contamination. Make sure that the
equipment is safe to use with the necessary media.
•Read and obey all applicable WARNING and CAUTIONS signs.
•Make sure that:
oAll work areas are clean and clear of unwanted tools,
equipment and materials.
oAll unwanted consumable materials are disposed in
accordance with local health and safety and
environmental regulations.
oAll equipment is serviceable.

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WARNINGS1.4
•Do not ignore the specified limits for the instrument or its related
accessories. This can cause injuries.
•If the equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be
impaired.
•Do not use the instrument in locations with explosive gas, vapour
or dust. There is a risk of an explosion.
ELECTRICAL SAFETY1.5
•The DC input to the DPI612 is rated at 5V (+/-5%) 4 Amps.
•External circuits should have appropriate insulation to the mains.
•To prevent electrical shocks or damage to the instrument, do not
connect more than 30V CAT I between the terminals or between
the terminals and the ground (earth).
•This instrument uses a rechargeable battery pack or standard AA
size batteries. To prevent an explosion or fire do not short circuit.
•The power supply input range to the optional power supply unit is
100 – 260Vac, 50 to 60Hz, 250mA, installation category CAT II.
•When using the optional power supply unit, position the power
supply so as not to obstruct the supply disconnecting device.
•Note that the operating and storage temperature range of the
optional PSU does not match that of the DPI612. Mains PSU
operating temperature range 0°C to +40°C, storage temperature
range -40°C to +70°C.
•To make sure the display shows the correct data, disconnect the
test leads before power is set to ON or changing to another
measure or source function.
•Keep the leads free from all contaminants.