WIKA CPC3000 User manual
CPC3000
High-Speed Pneumatic Pressure Controller
Operating Instructions - CPC3000 PN 0018043001P • 08/2015
Operating Instructions
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC30002
This Warning symbol indicates that danger of injury for persons and the
environment and/or considerable material damage (mortal danger, danger of
injury) will occur if the respective safety precautions are not taken.
This Caution symbol indicates danger for the system and material if the
respective safety precautions are not taken.
This Notice symbol does not indicate safety notices but information for a
better understanding of the facts.
Warning
!
Caution
!
Notice
i
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC3000 3
Table of Contents
1. General information 7
1.1 Warranty 7
1.2 Important notice 7
1.3 FCC radio frequency emission notice 8
1.4 European radio frequency emission notice 8
1.5 Trademarks and copyrights 8
1.6 Software license agreement 8
1.7 Accreditations 9
1.8 Packaging for shipment 9
2. Safety notices 9
2.1 User responsibilities 9
2.2 General safety notices 10
2.3 Warnings and caution notices 10
3. Product description 13
3.1 Proper use 13
3.2 Features 14
3.3 Turning on the CPC3000 15
3.4 Front panel 15
3.5 Main menu 16
3.5.1 Keys, tabs, check boxes, labels/graphics 16
3.6 Front panel navigation and variations 17
3.6.1 Operating mode 17
3.7 Main menu setpoint entry options 19
21
5. Installation 23
5.1 Introduction 23
5.2 Unpacking the system 23
5.3 Mounting (Rack mount kit option) 23
5.4 Installation 24
5.5 Rear panel 25
5.6 Pressure connections 25
5.7 Function of pressure connections 26
5.8 Electrical connections 27
5.8.1 Connecting the power supply and turning on the instrument 27
5.8.2 Connecting the communications interfaces 27
6. Starting operation 29
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC30004
7. Local operation 31
7.1 Setting the operating language 31
7.2 Display configuration 31
7.3 Setpoint entry 33
7.4 Operating modes 36
7.5 Data entry 39
7.6 Pressure unit, pressure mode and emulation mode 39
7.7 Bar chart 40
7.8 Setup menus 40
7.8.1 Setup display 41
7.8.2 Setup control 42
7.8.3 Setup remote 43
7.8.4 Setup info 44
7.8.5 Setup service 45
7.8.5.1 Zero (non-password protected) 45
7.8.5.2 Unlock setup for calibration and regulator adjustment 46
7.8.5.3 Change Password 47
7.8.5.4 Calibrate sensor or optional barometer 48
7.8.5.4.1 Calibration data 49
7.8.5.4.2 Edit calibration 50
7.8.5.4.3 Live calibration 51
8. Remote Operation 52
8.1 Remote setup 52
8.2 Remote setup - Ethernet 52
8.3 Remote setup - USB 53
8.4 Remote setup - IEEE-488 53
8.5 Remote command set 54
8.5.1 Mensor command set 54
8.5.2 PCS 400 commands emulated 61
8.5.3 PCS 200 commands emulated 63
8.5.4 DPI 510 commands emulated 64
8.5.5 IEEE 488.2 commands 65
8.5.6 SCPI commands 66
8.5.7 Output Formats 68
9. Trouble-shooting measures 69
9.1 Table: fault description and measures 69
10. Re-calibrating and servicing 71
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC3000 5
11. Removal of the system 72
12. Transport of the system 73
13. Storage of the system 74
14. Placing out of service 75
15. Appendix 76
Sales and service international 77
Measurement units 81
Conversion factors, pascal 82
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC30006
NOTES
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC3000 7
1. General information
1.1 Warranty
All products manufactured by Mensor are warranted to be free of defects in workmanship and
materials for a period of one year from the date of shipment. No other express warranty is given,
and no affirmation of Seller, by words or actions, shall constitute a warranty. SELLER DISCLAIMS
ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR
PURPOSES WHATSOEVER. If any defect in workmanship or material should develop under condi-
tions of normal use and service within the warranty period, repairs will be made at no charge to
the original purchaser, upon delivery of the product(s) to the factory, shipping charges prepaid.
If inspection by Mensor or its authorized representative reveals that the product was damaged
by accident, alteration, misuse, abuse, faulty installation or other causes beyond the control
of Mensor, this warranty does not apply. The judgment of Mensor will be final as to all matters
concerning condition of the product, the cause and nature of a defect, and the necessity or
manner of repair. Service, repairs or disassembly of the product in any manner, performed without
specific factory permission, voids this warranty.
MENSOR MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MANUAL, INCLUDING,
BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE. Mensor shall not be liable for errors contained herein or for incidental
or consequential damages in connection with the furnishing, performance, or use of this material.
1.2 Important notice
Since product improvement is a continuous process at Mensor, we reserve the right to change
specifications and other information contained in this manual without notice.
Mensor has made a concerted effort to provide complete and current information for the proper
use of the equipment. If there are questions regarding this manual or the proper use of the equip-
ment, contact either Mensor or WIKA:
Mensor
201 Barnes Drive
San Marcos, Tx 78666
Tel: 1.512.396.4200 or 1.800.984.4200 (USA only)
Web site: www.mensor.com
Fax: 1.512.396.1820
E-mail: sales@mensor.com
tech.support@mensor.com
quality@mensor.com
WIKA Alexander Wiegand SE & Co. KG
Alexander-Wiegand-Straße 30
D-63911 Klingenberg / Germany
Tel: (+49) 93 72/132-9986
Web site: www.wika.de
Fax: (+49) 93 72/132-8767
E-mail: [email protected]
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC30008
1.3 FCC radio frequency emission notice
Warning
!
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference when
the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user
will be required to correct the interference at his or her own expense.
Use shielded cables to connect external devices to this instrument to minimize
RF radiation.
1.4 European radio frequency emission notice
Warning
!
EN 55022 (or CISPR 22)
WARNING! This is a class A emission device. This equipment may cause radio
interferences in residential environments. The operator may be required to
make appropriate corrective measures.
EN 55011 (or CISPR 11)
WARNING! This is a class A emission device intended for operation in an
industrial environment. It can cause interference under certain circumstances
if operated in other environments e.g. residential or commercial areas. The
operator may have to take appropriate corrective measures.
1.5 Trademarks and copyrights
WIKA is a registered trademark of WIKA Alexander Wiegand SE & Co. KG. Mensor is a registered
trademark of Mensor.
© 2006, Mensor. All rights reserved.
Notice
iAll other brand and product names are trademarks or registered trademarks
of their respective companies.
1.6 Software license agreement
This product contains intellectual property, i.e., software programs, that are licensed for use by the
end user/customer (hereinafter “end user”).
This is not a sale of such intellectual property.
The end user shall not copy, disassemble or reverse compile the software program.
Warning
!
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC3000 9
Notice
iThe software programs are provided to the end user “as is” without warranty
of any kind, either expressed or implied, including, but not limited to, warran-
the quality and performance of the software program is with the end user.
WIKA, Mensor and its suppliers shall not be held to any liability for any damages suffered or
incurred by the end user (including, but not limited to, general, special, consequential or incidental
damages including damages for loss of business profits, business interruption, loss of business
information and the like), arising from or in connection with the delivery, use or performance of the
software program.
1.7 Accreditations
Mensor is registered to ISO 9001:2008. The calibration program at mensor is accredited by A2LA,
as complying with both the ISO/IEC 17025:2005 and the ANSI/NCSL Z540-1-1994 standards. All
Mensor primary standards are traceable to NIST.
1.8 Packaging for shipment
If the product must be shipped to a different location or returned to Mensor for any reason through
a common carrier it must be packaged properly to minimize the risk of damage.
The recommended method of packing is to place the instrument in a container, surrounded on all
sides with at least four inches of shock attenuation material such as styrofoam peanuts.
2. Safety notices
2.1 User responsibilities
To ensure safety, the user must make sure that:
The system is used properly (refer to "3.1 Proper use" in the section "Product description"), no
dangerous media are used and that all technical specifications are observed.
Safety mechanisms exist, which exclude any danger to persons or machinery through improper
pressurization.
The system is operated in perfect operating condition.
This operation manual is legible and accessible to the user at the system's location.
The system is operated, serviced and repaired only by staff who are authorized and qualified to
do so.
The operator receives instruction on industrial safety and environmental protection, and is
knowledgeable of the operating instructions and the safety notices contained therein.
The power cord is the disconnection device. Its outlet should be accessible and contain a
protected earth ground.
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC300010
2.2 General safety notices
The system should only be operated by trained personnel who are familiar
with this manual and the operation of the instrument.
A condition for trouble-free and safe operation of this system is proper
transport, proper storage, installation, assembly and proper use as well as
careful operation and maintenance.
Any operation not described in the following instructions should be
prohibited.
The system must be handled with the care required for an electronic precision
electricity and extreme temperatures). Do not insert any objects into the
instrument.
The system is powered via the power cable with a voltage that can cause
physical injury. Even after disconnecting the system from the power supply,
dangerous voltages can temporarily occur due to capacitance.
Although the contacts of the integrated relays located at the back of the
instrument are only approved for small electric currents, dangerous voltages
or currents can occur in the case of faults or failures.
Extreme care must be taken with pressure connections when using hazardous
or toxic media.
Repairs must only be performed by authorized service personnel.
Additional safety notices are found throughout this manual.
2.3 Warnings and caution notices
HIGH PRESSURE! High pressure gases are potentially hazardous. Energy
stored in these gases can be released suddenly and with extreme force. High
pressure systems should be assembled and operated only by personnel who
have been trained in proper safety practices.
POSSIBLE INJURY! The tubing, valves and other apparatus attached to the
controller must be adequate for the maximum pressure which will be applied,
otherwise physical injury to the operator or bystander is possible.
Caution: use the proper pressure medium. Use only clean, dry non-corrosive
gases. This instrument is not designed for oxygen use.
Warning
!
Warning
!
Caution
!
Warning
!
Caution
!
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC3000 11
The user must use caution when controlling from a very high pressure down
to a very low pressure when a vacuum pump is connected to the exhaust port.
Large volumes of gas may be present in the device under test and will exhaust
through the Exhaust/Vacuum port in excess of the capacity of the internal
relief valve, possibly causing damage to the vacuum pump.
HIGH SOUND LEVELS! Pressures from 600 psig and up can generate sound
levels above 100 db for brief periods when they are exhausted directly to
then ear protection is advised for personnel in the vicinity of the instruments
that will be operated under such conditions.
NOT EXPLOSION PROOF! Installation of this instrument in an area requiring
devices rated as intrinsically safe is not recommended.
Caution: ESD protection required. The proper use of grounded work surfaces
and personal wrist straps are required when coming into contact with exposed
circuits (printed circuit boards) to prevent static discharge damage to sensi-
tive electronic components.
Before the system is switched on, the user must verify that the system was
installed correctly and that all connections meet current regulations.
are observed.
Before pressurizing, the user must ensure through appropriate protective
measures that the system or the device will not be overpressurized. When
working with or on an instrument, safety glasses should be worn.
due to inert gases that will escape during use.
High pressure can accelerate parts in a manner that could be hazardous and
cause physical injury.
Additional warning and caution notes are included throughout this manual.
Caution
!
Warning
!
Warning
!
Warning
!
Warning
!
Warning
!
Warning
!
Warning
!
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC300012
NOTES:
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC3000 13
3. Product description
3.1 Proper use
The CPC3000 High-Speed Pneumatic Pressure Controller is a bench top or rack mounted
Digital Pressure Calibrator/Controller used for test and calibration of mechanical pressure
gauges, pressure switches, sensors, transducers, transmitters and any pressure related devic-
es where time to set point is the most critical requirement.
Only dry clean air or nitrogen should be used as the pressure medium.
Shop air should be avoided and corrosive, oxidizing, condensing, explosive
gases should be strictly avoided.
The maximum permissible supply pressure at the supply port should be
10% over full scale value of the sensor installed.
Very fast pressure changes can damage the sensor, due to mechanical
stress on the sensor; especially if the fast pressure change leads to an
internal pressure which is higher then the full scale of the internal sensor
(even if it is only for a fraction of a second). In some cases, the internal relief
valves cannot react quickly enough to protect the sensor.
measuring chain.
The system is not suitable for use in areas with an explosion hazard.
If the CPC3000 is not used according to this manual, safe operation of the
system is not guaranteed.
The user of the system and not the manufacturer is responsible for all
physical and material damage resulting from improper use!
Warning
!
Warning
!
Warning
!
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC300014
3.2 Features
Below is a short list of significant features designed into the CPC3000:
1. The CPC3000 will control (up scale or down
scale) into a 150 ml volume, to within 0.025%
of the set point, in 3 seconds or less.
2. Uncertainty of 0.025% FS or optional 0.025%
IS-50, 180 or 365 day calibration interval
(respectively).
3. Lightweight compact case with handle.
4. Manual operation via the color touch screen
and easy access to auxiliary screens allow
quick changes to the set point using the
"step" and "jog" screens.
5. Remote operation over IEEE-488, USB, or
Ethernet.
6. Emulation of other qualified controllers.
7. An optional internal high accuracy baromet-
ric reference sensor for emulation of gauge
pressure and absolute pressure.
8. A large color LCD display with a touch screen
for intuitive operator interface.
9. Multiple languages.
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC3000 15
3.3 Turning on the CPC3000
The power switch is located on the rear of the instrument as shown in Figure - "Rear Panel".
Figure - Rear Panel
3.4 Front panel
The CPC3000 front panel, shown in Figure - "Front Panel", includes a 7 inch color display featuring
touch screen technology. Operator input is accomplished by pressing the number, words or symbols
presented on the display. There are no mechanical keypads or switches on the front panel.
Figure - Front Panel
Power Switch
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC300016
3.5 Main menu
When the CPC3000 is powered up it takes about 40 seconds for initialization, then displays a
screen similar to the Figure - "Initial Screen" below.
Figure - Initial Screen
3.5.1 Keys, tabs, check boxes, labels/graphics
Keys:There are two types of keys: those that act as a switch to change a condition and
those that open a data entry screen when pressed. Keys have borders with a three dimen-
sional, shadowed effect (examples: , ). Throughout this
manual keys are represented with the displayed characters enclosed in brackets ( Example:
[MEASURE] ) or a description and the actual graphic icon (example: ). Press-
ing a key will have one of the following results: 1) instant, single step response, 2) continu-
ously repeating steps while the key is held down, 3) the key will change colors indicating that
the associated function is active or 4) a data entry dialog box will open. Operators will quickly
become accustomed to the particular characteristics of the frequently used keys.
Tabs: Tabs are analogous to tabs in a notebook that allow switching quickly between related
screens. Tabs are keys that allow the operator to switch between a group of screens that have a
similar purpose, for example the tabs allow the operator to quickly switch between
four screens used to enter the setpoint.
Check Boxes: Check Boxes allow for the inclusion or exclusion of specific elements or
conditions.
Labels and Graphics: Labels and Graphics are text, or graphics that display information, but
do not respond to being touched (examples: ). They indicate choices
that have been made in the setup menus or indicate existing conditions as pressure is controlled or
measured.
SETUP menu
Stability indication
Current pressure value
Bar graph
Pressure Units
and Mode
Jog key pad selection tab
User defined jog key pad selection tab
Step key pad selection tab
Numeric key pad selection tab
Numeric keypad
Delete selected set point
Delete last entered digit
Accept selected set point
User defined control range limits
(configurable via SETUP-CONTROL)
Operating Mode
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC3000 17
3.6 Front panel navigation and variations
Screen Hierarchy: Navigation within the CPC3000 is similar to a computer file system or a web
page. Keys or tabs activate sub-menus. Within the sub-menus there may be related sub-menus
or selections. To return back through the hierarchy of screens the [BACK] key is provided.
Throughout this manual screen hierarchy will be designated using the following convention: "main-
>sub-menu->selection" or "main->sub-menu->tab->selection". Sometimes, a reference to a key will
be made in the context of a specific screen by simply giving the key name in bold square brackets
[KEY NAME] or by using the key name along with the actual graphic icon. The Hierarchical menu
structure is very intuitive and will become more obvious after reviewing following examples.
Bar Graph: The bar graph shows the relative indication of the range of the internal sensor, the
user defined limits on the internal sensor, the unused portion of the internal pressure sensor
range, the setpoint and the magnitude of the actual controlled pressure. The user defined control
limits can be selected in the Main->Setup->Control screen and can be set to correspond to the
range of the device under test. It is important to note that when the STEP keypad is active in
-
nal sensor. This is useful when calibrating or testing various range devices. Figure - "Bar Graph"
shows the bar graph when the CPC3000 is in vent mode with a setpoint of 2.5 psig. The user
defined range is 0 to 4 and there is an unused portion of the internal sensor.
Figure - Bar Graph
3.6.1 Operating mode (press to select mode):
MEASURE
In MEASURE mode, the instrument measures the pressure connected to the measure port (on
changing from CONTROL mode: the last controlled pressure will be held/sealed in the connect-
ed test assembly).
CONTROL
In CONTROL mode the instrument provides a very precise pressure at the measure port.
VENT
VENT opens measure port to atmospheric pressure.
Bar graph shows relative indication of:
• Range of the Internal sensor
• User defined limits
• Unused portion of the internal
sensor range
• Setpoint
• Current pressure reading
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC300018
Optional elements can be chosen in the Main->Setup->Display screen explained in section 7.8.1 of
this manual. Each optional element is displayed in the area below the pressure units.
Figure - Optional Display elements
Navigation to the SETUP screens is achieved pressing the Icon. Setup Figure - "Main Setup
Screen" shows the setup screen with the display tab activated. Other tabs at the bottom are used
to navigate to additional setup screens. Setup screens will be discussed in detail in section 7.8 of
this manual.
Figure - Main Setup Screen
Area for optional elements
Communication status Optional barometric
reference display
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC3000 19
3.7 Main menu setpoint entry options
There are four different ways to enter the setpoint in the CPC3000. Each setpoint entry method is
explained in detail in section 7.3 Setpoint Entry.
Pressure setpoint entry options are chosen using the tab keys . Pressing each tab
will open the respective screen for setpoint entry.
Figure - Numeric Keypad
Figure - "Numeric Keypad" shows the main menu with the numeric keypad selected.
Figure - Step Keypad
Figure - "Step Keypad" shows the main menu with the step keypad selected.
High-Speed Pneumatic Pressure Controller
CPC3000
Operating Instructions - CPC300020
Figure - User Defined Jog Keypad
Figure - "User Defined Jog Keypad" shows the main menu with the user defined jog keypad
selected
Figure - Jog Keypad
Figure - "Jog Keypad" shows the main menu with the jog keypad selected.
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