WIKA MENSOR CPC 2000 User manual

Operating Instructions
Betriebsanleitung
Mode d'emploi
Manual de Instrucciones
GB
D
F
E
Portable low-pressure controller, model CPC2000
Portabler Niederdruckcontroller, Typ CPC2000
Contrôleur basse pression portable, type CPC2000
Controlador portátil de bajas presiones, modelo CPC2000
Portable low-pressure controller model CPC2000

2
11155094.02 07/2012 GB/D/F/E
WIKA operating instructions, model CPC2000
GB
D
F
E
© 2012 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA® is a registered trademark in various countries.
WIKA® ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!
Lire le mode d‘emploi avant de commencer toute opération !
A conserver pour une utilisation ultérieure !
¡Leer el manual de instrucciones antes de comenzar cualquier trabajo!
¡Guardar el manual para una eventual consulta!
Operating instructions model CPC2000 Page 3 - 34
Betriebsanleitung Typ CPC2000 Seite 35 - 66
Mode d'emploi type CPC2000 Page 67 - 98
Manual de instrucciones modelo CPC2000 Página 99 - 130

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Contents
1. General information 4
2. Safety 5
2.1 Intended use 6
2.2 Personnel qualication 6
2.3 Special hazards 7
2.4 Labelling/Safety marks 8
3. Specications 9
4. Design and function 12
4.1 Short description 12
4.2 Scope of delivery 12
4.3 Electrical connections on the rear 12
4.4 Voltage supply 13
4.5 Front display of the CPC2000 13
4.6 Pressure connections 15
4.7 Overpressure protection 15
5. Transport, packaging and storage 16
6. Commissioning, operation 17
6.1 Operating mode 'Control' (CTRL) 17
6.2 Operating mode 'Measure' (MEAS) 18
6.3 Operating mode 'AUTO' 20
6.4 Leakage (LEAK) 22
6.5 SETUP settings (SETUP) 23
7. Interface 25
7.1 USB interface 25
7.2 RS-232 Interface 25
7.3 Interface conguration 25
7.4 Commands for serial interface 26
7.5 Driver 28
8. Maintenance, cleaning and service (recalibration) 29
9. Faults 30
10. Dismounting, return and disposal 30
11. Accessories 32
Appendix 1: EC Declaration of Conformity for model CPC2000 33
Declarations of conformity can be found online at www.wika.com.
Contents

4 WIKA operating instructions, model CPC2000
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1. General information
1. General information
■
The low-pressure controller described in the operating instructions has been designed
and manufactured using state-of-the-art technology.
All components are subject to stringent quality and environmental criteria during
production. Our management systems are certied to ISO 9001 and ISO 14001.
■
These operating instructions contain important information on handling the instrument.
Working safely requires that all safety instructions and work instructions are observed.
■
Observe the relevant local accident prevention regulations and general safety regula-
tions for the instrument’s range of use.
■
The operating instructions are part of the product and must be kept in the immediate
vicinity of the instrument and readily accessible to skilled personnel at any time.
■
Skilled personnel must have carefully read and understood the operating instructions
prior to beginning any work.
■
The manufacturer’s liability is void in the case of any damage caused by using the
product contrary to its intended use, non-compliance with these operating instructions,
assignment of insuciently qualied skilled personnel or unauthorised modications to
the instrument.
■
The general terms and conditions contained in the sales documentation shall apply.
■
Subject to technical modications.
■
Factory calibrations / DKD/DAkkS calibrations are carried out in accordance with
international standards.
■
Further information:
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: CT 27.51
- Application consultant: Tel.: [phone]
Fax: [phone]
E-mail: [email protected]

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1. General information / 2. Safety
Explanation of symbols
DANGER!
... indicates a directly dangerous situation resulting in serious injury or
death, if not avoided.
WARNING!
... indicates a potentially dangerous situation that can result in serious
injury or death, if not avoided.
CAUTION!
... indicates a potentially dangerous situation that can result in light injuries
or damage to equipment or the environment, if not avoided.
Information
... points out useful tips, recommendations and information for ecient and
trouble-free operation.
DANGER!
...identies hazards caused by electric power. Should the safety instruc-
tions not be observed, there is a risk of serious or fatal injury.
2. Safety
WARNING!
Before installation, commissioning and operation, ensure that the appropri-
ate portable low-pressure controller has been selected in terms of measur-
ing range, design and specic measuring conditions.
Non-observance can result in serious injury and/or damage to the equip-
ment.
Further important safety instructions can be found in the individual
chapters of these operating instructions.

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2. Safety
2.1 Intended use
The model CPC2000 low-pressure controller is used for testing and calibrating pressure
sensors.
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The technical specications contained in these operating instructions must be observed.
Improper handling or operation of the instrument outside of its technical specications
requires the instrument to be taken out of service immediately and inspected by an
authorised WIKA service engineer.
Handle electronic precision measuring instruments with the required care (protect from
humidity, impacts, strong magnetic elds, static electricity and extreme temperatures,
do not insert any objects into the instrument or its openings). Plugs and sockets must be
protected from contamination.
If the instrument is transported from a cold into a warm environment, the formation of
condensation may result in instrument malfunction. Before putting it back into operation,
wait for the instrument temperature and the room temperature to equalise.
The manufacturer shall not be liable for claims of any type based on operation contrary to
the intended use.
2.2 Personnel qualication
WARNING!
Risk of injury should qualication be insucient!
Improper handling can result in considerable injury and damage to
equipment.
■
The activities described in these operating instructions may only
be carried out by skilled personnel who have the qualications
described below.
■
Keep unqualied personnel away from hazardous areas.
Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical training,
knowledge of measurement and control technology and on their experience and knowl-
edge of country-specic regulations, current standards and directives, are capable of
carrying out the work described and independently recognising potential hazards.

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2. Safety
Special operating conditions require further appropriate knowledge, e.g. of aggressive
media.
2.3 Special hazards
WARNING!
Protection from electrostatic discharge (ESD) required.
The proper use of grounded work surfaces and personal wrist straps is
required when working with exposed circuitry (printed circuit boards),
in order to prevent static discharge from damaging sensitive electronic
components.
To ensure safe working on the instrument, the operating company must
ensure
■
that suitable rst-aid equipment is available and aid is provided
whenever required.
■
that the operating personnel are regularly instructed in all topics
regarding work safety, rst aid and environmental protection and
knows the operating instructions and, in particular, the safety instruc-
tions contained therein.
DANGER!
Danger of death caused by electric current
Upon contact with live parts, there is a direct danger of death.
Operation using a defective power supply unit (e.g. short circuit from the
mains voltage to the output voltage) can result in life-threatening voltag-
es at the instrument!
WARNING!
Residual media on the dismounted low-pressure controller can result
in a risk to persons, the environment and the equipment. Take sucient
precautionary measures.
Do not use this instrument in safety or Emergency Stop devices. Incor-
rect use of the instrument can result in injury.
Should a failure occur, aggressive media with extremely high tempera-
ture and under high pressure or vacuum may be present at the instru-
ment.
Pmax = 1 bar atmospheric pressure

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2. Safety
2.4.2 Explanation of symbols
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
CE, Communauté Européenne
Instruments bearing this mark comply with the relevant European
directives.
This marking on the instruments indicates that they must not be disposed
of in domestic waste. The disposal is carried out by return to the manufac-
turer or by the corresponding municipal authorities (see directive 2002/96/
EC).
2.4 Labelling/Safety marks
2.4.1 Product label
For an explanation of symbols,
see below
Power supply
Pressure medium
Operating temperature
Pressure range
Accuracy
Year of manufacture

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3. Specications
3. Specications
Reference pressure sensors
Pressure range mbar 1 10 50 100 500 1,000
Accuracy % FS 0.3 0.1 0.1 0.1 0.1 0.1
Type of pressure Positive or negative gauge pressure or dierential pressure
Pressure units Pa, kPa, hPa, bar, mbar, psi, inH2O, inHg, mmHg, Torr
Base instrument
Instrument
Instrument version desktop instrument with carry handle
Dimensions 102.6 x 257 x 271 mm without carry handle
Weight 4.6 kg
Ingress protection IP 20
Pressure generation internal, electric pump
Display
Screen backlit, multiline graphic display
Resolution 5 (4 digits for 50/500 mbar measuring range)
Keyboard Membrane keypad
Menu language German, English, Spanish and French
Connections
Pressure connections 6.6 x 11 (hose diameter, D = 6 mm)
Wetted parts Ni, Al, CuBe, PU
Voltage supply
Power supply DC 24 V, 1 A
Power consumption 24 VA
Battery type Li-Ion
Battery life approx. 8 h
Permissible ambient conditions
Media Ambient air
Operating temperature 10 ... 40 °C
Storage temperature -10 ... +70 °C
Relative humidity 30 ... 80 % r. h. (non-condensing)

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3. Specications
Base instrument
Control parameter
Control steps 0 ... 50 % individually adjustable or 100 %
Control rate approx. 5 s (dependent upon test volume)
Communication
Interface RS-232 and USB
Response time 1 value/s
Zero point adjustment automatic (at denable time intervals)
manual (ZERO button)
Approvals and certicates
CE conformity
EMC directive 2004/108/EC, EN 61000-6-3, emissions for residential, commer-
cial and light-industrial environments and EN 61000-6-2, interfer-
ence immunity for industrial environments
Certicate
Calibration 1) incl. 3.1 calibration certicate per EN 10204
1) Calibration in a horizontal position.
For further specications see WIKA data sheet CT 27.51 and the order documentation.

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3. Specications
Dimensions in mm
Front view
Side view

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4. Design and function
4. Design and function
4.1 Short description
The microprocessor controlled CPC2000 low-pressure controller is used for the
■
simple generation of positive and negative reference pressures.
■
pressure measurement of positive and negative pressures.
■
dierential pressure measurement.
■
identication of leaks in test samples.
4.2 Scope of delivery
■
Model CPC2000 portable low-pressure controller
■
Power supply unit
■
Operating instructions
■
3.1 calibration certicate per DIN EN 10204 (optional DKD/DAkkS certicate)
Cross-check scope of delivery with delivery note.
4.3 Electrical connections on the rear
-
+
Actual pressure
value
Pressure value
Controller Pump
Measuring
pressure
USB Interface
RS-232 Interface
Connection for power supply unit
Microprocessor Set-actual value
comparison Valves
pos. pressure
neg. pressure
RS-232 PC interface
USB interface
Display

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4. Design and function
4.4 Voltage supply
The low-pressure controller is factory set for connection to a voltage supply of DC 24 V.
The power supply connector is located on the rear panel.
DANGER!
Electric shock hazard! Before removing the fuse, the power supply must
be removed from the plug.
Operation using a defective power supply unit (e.g. short circuit from the
mains voltage to the output voltage) can result in life-threatening voltag-
es at the instrument!
Only the original power supply unit included in initial delivery (Mascot
model 9926) should be used.
1. Design the wiring particularly carefully when connecting to other devices. Under
certain circumstances, internal connections in third-party devices (e.g. GND connect-
ed to the ground) can lead to impermissible voltages that could compromise or even
destroy the function of the device itself or a device connected to it.
2. The mains plug must always be plugged in to a mains socket and be accessible, so
that one can always remove it from the mains socket without diculty.
4.5 Front display of the CPC2000
Pressure
connec-
tions
ON/OFF
button
Increase set point to 100 %
Increase set point by x %
decrease set point by x %
Set set point to 0 %
Zero point adjustment
During the control process → Vent
otherwise, selects SETUP
In control mode: Starts the leak meas-
urement, otherwise without function

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4. Design and function
The front screen of the display, behind the membrane, is made from
glass. If there is any possibility of the window breaking during operation
(including damage to the front membrane), all personnel in the vicinity of
the instrument must wear eye protection before and during its use.
4.5.1 On/O button
Button to turn the instrument on and o.
4.5.2 Menu button
With this button the SETUP menu can be accessed, and there the
settings for each operating mode can be made. When the CTRL mode
is used, you will nd that the device is left in VENT mode on leaving the
SETUP menu.
The SETUP menu items are made up of six submenu items. For a detailed description of
these items, see chapter 6.5 „SETUP settings (SETUP)“.
4.5.3 LEAK button
With the LEAK button, a device connected to the controller can be
tested for leaks. (This feature is only available in CONTROL mode.)
4.5.4 ZERO button
Button for manually correcting the zero point of the integrated sensor.
External inuences such as temperature, pressure, mounting position or
surroundings, can alter the zero point of the instrument, i.e. the display
when the pressure ports are open. During zero adjustment, the device
automatically detects these changes and corrects them in the current
pressure display. The zero point adjustment requires a change of the
internal valves, which is not possible without loss of pressure.
(If this should interfere with the application, the automatic zero point
adjustment can be switched o.)

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4. Design and function
4.6 Pressure connections
■
Dierential pressure instruments are connected to the j and the i connections of the
instrument.
■
Relative pressure instruments are connected to the j connection (i connection is
open to atmosphere).
■
Instruments for negative gauge pressure are connected to the i connection
(j connection is open to atmosphere).
Only connect test and calibration installations once the system has been
depressurised!
Never perform functional tests with compressed or medical air. This can
damage instruments with low pressure ranges.
The connection to the low-pressure controller is made via a 6.6 x 11 mm pressure connec-
tion.
The hose diameter should be 6 mm.
4.7 Overpressure protection
The maximum permissible pressure must not be exceeded:
Pressure range Oberload
1 mbar 5 times overload
10 mbar 5 times overload
50 mbar 5 times overload
100 mbar 5 times overload
500 mbar 2 times overload
1,000 mbar 2 times overload

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5. Transport, packaging and storage
5. Transport, packaging and storage
5.1 Transport
Check low-pressure controller for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
5.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change in
installation site, sending for repair).
5.3 Storage
Permissible conditions at the place of storage:
■
Storage temperature: -10 ... +70 °C
■
Humidity: 30 ... 80 % r. h. (no condensation)
Avoid exposure to the following factors:
■
Direct sunlight or proximity to hot objects
■
Mechanical vibration, mechanical shock (putting it down hard)
■
Soot, vapour, dust and corrosive gases
■
Potentially explosive environments, ammable atmospheres
Store the low-pressure controller in its original packaging in a location that fulls the
conditions listed above. If the original packaging is not available, pack and store the
instrument as described below:
1. Wrap the instrument in an antistatic plastic lm.
2. Place the instrument, along with shock-absorbent material, in the packaging.
3. If stored for a prolonged period of time (more than 30 days), place a bag, containing a
desiccant, inside the packaging.
4. Do not storage the instrument with the pressure connections closed! Barometric
pressure changes can damage instruments with low pressure ranges.
WARNING!
Before storing the instrument (following operation), remove any residual
media. This is of particular importance if the medium is hazardous to
health, e.g. caustic, toxic, carcinogenic, radioactive, etc..

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6. Commissioning, operation
6. Commissioning, operation
Never perform functional tests with compressed or medical air. This can
damage instruments with low pressure ranges.
Protect the instrument from sunlight, as this can lead to measuring
errors.
6.1 Operating mode 'Control' (CTRL)
The CTRL mode is used for the calibration of pressure sensors and other pressure
instruments. In CTRL mode, the pump is active and regulates according to the desired
pressure. The internal sensor provides the current value on the display.
Setting
■
Press the MENU button. Conrm the menu point MODE with SELECT and press the
/ button until CTRL appears. Conrm with SELECT.
■
In the submenu RANGE the upper limits of the pressure range are dened
( / button and / buttons) and conrmed with SELECT
■
In the submenu UNIT the pressure units are dened ( / buttons) and conrmed
with SELECT .
■
In the submenu STEP the step sequence in % is dened ( / buttons and /
buttons), conrmed with SELECT.
■
With the MENU button, you can exit the submenu
Operation
The instrument will revert to VENT mode
on exiting the menus, meaning the
sensor of the calibrator will be vented. In
the top centre of the display, the set point
of the pressure range will be displayed.
In the bottom centre of the display, the
percentage value can be read. On exiting
the menus, this value will be 0 %. With
the SELECT button, one can switch
between the set pressure value and the
percentage value.
■
The percentage value can be altered with the / buttons (in the dened step
sizes) and altered with the / buttons.
Change set point by x %
Pressure change in % via / buttons
Change pressure to 100 % via button
Change pressure back to 0 % via button

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6. Commissioning, operation
■
The set pressure demand can only be changed with the / buttons. With the
/ buttons, you can jump to the location of the set pressure setting.
As soon as the controller display indicates a stable value, the data can be recorded:
In CTRL mode it is possible to adjust the zero point of the controller manually and to
check the connected instrument for leaks.
■
Manual zero point adjustment: Conrm using the ZERO button and the reference
measuring cell of the instrument will be adjusted.
■
Leak test: By pressing the LEAK button, the control process will be deactivated and
the system closed. It can be controlled via the display if the value is stable. By pressing
the LEAK button again, the mode will be stopped and the unit placed back in Control
mode.
6.2 Operating mode 'Measure' (MEAS)
The Measure mode is used to measure a dierential or gauge pressure. The pump is not
active in this operating mode. The pressure is measured directly from the internal refer-
ence sensor.
Setting
■
Press the MENU button. Conrm the menu point MODE with SELECT and press the
/ button until MEAS appears. Conrm with SELECT.
■
For the MEAS mode, the submenu points RANGE and STEPS are not relevant.
Operating mode
Battery status
Measured value
Set point in % of the full scale value
Pressure unit
Full scale value

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6. Commissioning, operation
■
In the menu, go to the UNIT item with the / button, select the pressure unit and
conrm with SELECT.
■
Press the MENU button in order to exit the menu.
■
SETTINGS submenu:
■
Go to the SETTINGS menu item with the / button, conrm with SELECT.
■
In the submenu, go to the zero point adjustment item and conrm with SELECT.
■
Under the point, AUTO-ZERO, the automatic zero point adjustment for the MEAS
mode can be activated or deactivated.
Operation
On leaving the menu, the zero point of the internal sensor is adjusted, dependent upon
the setting. The instrument then begins to measure the subsequent pressures.
Using the ZERO button in MEAS mode, the instrument‘s zero point can be compensated
at any time.
CAUTION!
If the connected pressure should exceed the permissible highest loading
(125 %), the internal sensor will be closed o using a magnetic valve.
The display will then show ERROR. Using the SELECT button, the
instrument can be closed o and opened up freely.
Operating mode
Battery status
Measured value
Set point in % of the full scale value
Pressure unit
Full scale value

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6. Commissioning, operation
6.3 Operating mode 'AUTO'
In
AUTO mode, a pressure prole can be stored. This is especially useful when multiple
pressure sensors or pressure switches are to be calibrated with the same values. The
mode also enables a dened prole to be traversed several times in succession.
Setting
■
Press the MENU button. Conrm the menu item MODE with the SELECT button and
press the / button until AUTO appears. Conrm with SELECT.
■
For the AUTO mode, the submenu points RANGE, UNIT and STEPS are not relevant.
■
Go to the SETTINGS menu item with the / buttons and conrm with the
SELECT button. The submenu item zero point adjustment is not relevant.
■
In the submenu, go to the AUTO mode item with the UP/DOWN buttons and conrm
with SELECT.
■
RANGE: Pressure range that will be covered
■
UNIT: Pressure unit
■
STEPS : The number of steps which will be taken to increase and decrease the
pressure. These increments are calculated by the controller itself.
In the submenu point, CONFIGURATION 1, further settings can be dened for the AUTO
mode.