Instruction Manual Wally Box 65-2000-II Digital - Pneumatic - Calibrator IM.650.226DE (WIKA) IM.650.226DE (Issue 1-07/02) 25.07.01 1
Safety Information:! Operate the instrument with the plug-in power supply (AAC1417) only.! The instrument does not include any parts that can be replaced or repaired by the customer (except fuse of the current input, T100 ma). The housing must therefore not be opened. Changing the instrument beyond what is described in this manual is not permitted.! Only suitably qualified personnel, who has read and understood the instruction manual, should install, operate and maintain the equipment. We accept no liability for damage resulting from not following the instructions.! Pressure lines and couplings must be conform to the pressures used.! The instrument must be used with dry gases only that are not dangerous to health. In case of queries Please indicate the order and serial number of this instrument (refer to the type label inside the cover). Address for return of the unit: WIKA Instruments Corp. 1000 Wiegand Boulevard Lawrenceville, GA 30043 1-888-945-2872 Electromagnetic compatibility Concerning the electromagnetic compatibility the following standards have been applied: EN 55022: 1994 + change: 1997 / Al: 1995 + A2: 1997 Class B EN 50082-1: 1997 (EN 61000-4-2: 1995 + Al: 1998; EN 61000-4-3: 1996 + Al: 1998; EN 61000-4-4: 1995; EN 61000-4-6: 1996; ENV 50204:199 The instrument corresponds to the substantial safety requirements, fixed in the rules of the council for the assimilation of jurisdiction of the member states concerning the electromagnetic compatibility (89/336/EWG) as well as the low voltage directive (73/23/EWG). IM.650.226DE (Issue 1-07/02) 25.07.01 2
CONTENTS Safety information Page 2 1. GENERAL DESCRIPTION 1.1 Operating scheme 1.2 Functioning 1.3 Technical Data 2 OPERATION 2.1 Front panel 2.2 Display and keypads 2.3 Menu structure 3. TESTING 4. PNEUMATIC INPUTS AND OUTPUTS 5. PNEUMATIC CONNECTIONS TO THE TEST EQUIPMENT 5.1 Calibrate pressure gauges, displays or recorders 5.2 Calibrate differential pressure transformers 5.3 Calibrate pressure transformers 6. ELECTRICAL WIRING OF THE TEST EQUIPMENT 7. MAINTENANCE 7.1 Change the filter 7.2 Spare parts 8. RS232 INTERFACE 8.1 Socket layout ANNEX: TRANSMISSION PROTOCOL ADDRESS REFERENCE LIST IM.650.226DE (Issue 1-07/02) 25.07.01 3
1. GENERAL DESCRIPTION This instruction manual provides information for operation, start-up and handling of the Digital Pneumatic Calibrator "Wally Box 65-2000-II". The Digital Pneumatic Calibrator 65-2000-II is a universal calibration instrument with menu guided operation and measuring inputs for current (ma) and voltage (V). The instrument is mainly used for the maintenance and installation of pneumatic measuring and control instruments, especially for the calibration of various pressure transducers. It offers not only high precision pressure measurements, but also the exact measuring and display of transducer outputs in the form of current or voltage signals. The calibrator series 65-2000-II includes a rigid plastic carrying case with a venting valve and an aluminum front panel. The panel carries the reference pressure gauge, one precision pressure controller, a pressure selector valve, one hand pump with precise volume controller and vent valve, and the corresponding pneumatic and electric connections. IM.650.226DE (Issue 1-07/02) 25.07.02 4
1.1 Operating scheme 1.2 Functioning To simulate the pressure with the built-in pressure controller, an external air supply is necessary, e.g. from a pressurized air network or a air cylinder (max.. inlet pressure 100 PSI, approx. 7 bar). The inlet "AIR SUPPLY" leads to an air filter and further to the precision pressure controller. The controller enables continuous adjusting of increasing and falling pressure. The. controller is connected to output P1. The input P2 is connected to the reference pressure gauge. The calibrator series 65-2000-11 can operate independently from external pressure supply. The built-in hand pump (with the precise volume controller and the vent valve) applies precise pressure to the pressure outlet P3. IM.650.226DE (Issue 1-07/02) 25.07.02 5
The pressure selector valve directly connects the outputs P1, P2 or the input P3 to the reference pressure gauge. A further switching position vents the system. The input S directly leads to the S (secondary) input of the built-in pressure sensor (maximum static load 7 bar / 100 PSI). This input is used for the reference pressure when measuring differential pressure or reference vacuum when measuring absolute pressure. When measuring absolute pressure, the reference vacuum must be maintained steady to S. NOTE: The carrying case of the calibrator closes almost tight. After a transport by air it is possible that the cover of the case cannot be opened, caused by a vacuum inside the case. Open the vent valve to let air flow into the case. IM.650.226DE (Issue 1-07/02) 25.07.02 6
1.3 Technical Data Wally Box 65-2000-II (item no. AAC4465) Pressure measuring system: Accuracy: 0,02 % of reading ± 3 digits (including linearity, hysteresis and temperature error) Temperature compensation: compensation between 50 F and 104 F (error within the specified accuracy at max.. temperature change of 10 F/h) Resolution: max.. 44 000 digit (depending on the measuring range) Response time for 90 % of the measuring range: <1 s (measuring cycle: 16 conversions/s, with additional display filter 5 values/s) Pressure units selectable: mbar, bar, kpa, mmhg, PSI, IN.H 2 0 20, IN.Hg one programmable unit (default mh 2 0 20 ) Generation of the reference pressure: With external pressure supply and precision pressure controller; or with built-in hand pump, precision volume controller and vent valve; Measuring range: -10 to +100 PSI (approx.0,7 to 7 bar) Overload: Display: max. 150 PSI (approx. 10 bar) LCD 2x16 characters, 8 mm high, with backlight (selectable) Overload warning: optical warning at approx.5% overload of the nominal range (flashing display). Acoustic warning at 10% overload. IM.650.226DE (Issue 1-07/02) 25.07.02 7
Electrical measuring system: Voltage measurement: Range: 0...±32VDC Accuracy: 0.04 % FS ± 2 digit Resolution: 32 000 digits / 0.001 V Current measurement: Range: 0...± 32 ma DC Accuracy: 0.04% FS ± 2 digit Resolution: 32 000 digits/ 0.001 Temperature error: max. 0,002 %/K(current and voltage range) Input impedance: voltage measurement >_ 10 Mohm. current measurement <_ 1 Ohm Interface: RS232 serial interface (as a standard) Electric supply of the sample Voltage: 24 V DC ± 5% galvanically isolated 500 V DC Current: max. 30 ma Ambiance: Operating temperature: +50 F to 104 F (compensated range) Storage temperature: +14 F to 140 F Safety: refer to the EMC-compatibility (page 2) Protection: IP 67, NEMA 4X (with closed cover) resisting to fracture and pressure MIL-4150H Power supply: Plug-in power supply built-in Dimensions w - h - d Weight Pressure connections 100-240 VAC, 12 VDC, 2 A rechargeable NiMH battery: operation time approx. 18 h (without light, without interface operation) acoustic warning signal when the batteryis 90% discharged charging time approx.3 hours 13.2 in - 11.4 in 6 in. Approx. 11 lbs. Pneumatic connection with 1/8" NPT (internal thread) IM.650.226DE (Issue 1-07/02) 25.07.02 8
2. OPERATION 2.1 Front panel IM.650.226DE (Issue 1-07/02) 25.07.02 9
2.2 Display and keypads 2.2.1 Information in the display 2.2.2 Functions of the keys IM.650.226DE (Issue 1-07/02) 25.07.02 10
2.3 Menu structure IM.650.226DE (Issue 1-07/02) 25.07.02 11
3. TESTING The Digital Pneumatic Tester is operated with a builtin rechargeable NiMH-battery or with a separate universal plug-in power supply for 100...240 VAC mains. Operation time of the battery reaches up to approx.. 18 hours, depending on the functions executed. The present discharging state is displayed in the main menu. We recommend checking the state after each operating term (or daily during permanent operation) and recharge the battery if necessary by plugging-in the power supply (charging time approx.3 hours). The power supply may remain plugged-in without damage to the battery (processor controlled charging). 1. Press the ON/OFF key for 2 seconds to start the instrument. The display shows the start message: e.g.. AAC1075 (Nurnber of the software) FRG 49 Wally Box V.2.0 24.04.2001 (country) (software version) (software date) The instrument is ready for operation at once. After long periods of nonoperation, higher temperature differences (>10 F) or when the battery is completely discharged, the instrument should be switched-on for a acclimatization and warm-up time of approx.30 minutes. 2.The display shows the measured values for pressure and ma-/volt. 3. Before starting the tests: Check the zero point: Vent the test tube and press the "ZERO" key if the display does not show 0 PSI. Taring by the "ZERO" key is memorized and will be set again every time the "ZERO" key is pressed. ATTENTION: Before connecting the instrument, take all necessary precautions to prevent overloading the instrument or the test equipment. IM.650.226DE (Issue 1-07/02) 25.07.02 12
4. PNEUMATIC INPUTS AND OUTPUTS For gauge pressure: Connect the teat equipment to P1 or P3. The differential input S remains open to atmosphere. For differential pressure: Connect the teat equipment input P (higher pressure) to P1 or P3. Connect the teat equipment input S (lower pressure) to S. For absolute pressure: Connect the teat equipment to P1 or P3. Connect the differential input S to external vacuum. For vacuum: P1 reap. P3 remains open to atmosphere. Connect the teat equipment to S. For gauge pressure and vacuum: Connect the teat equipment to P1 or P2. The differential input S remains open to atmosphere. IM.650.226DE (Issue 1-07/02) 25.07.02 13
5. PNEUMATIC CONNECTIONS TO THE TEST EQUIPMENT (EXAMPLES) IM.650.226DE (Issue 1-07/02) 25.07.02 14
IM.650.226DE (Issue 1-07/02) 25.07.02 15
5.3 Calibrate pressure transformers IM.650.226DE (Issue 1-07/02) 25.07.02 16
6. ELECTRICAL WIRING OF THE TEST EQUIPMENT (EXAMPLES) IM.650.226DE (Issue 1-07/02) 25.07.02 17
7. MAINTENANCE 7.1 Change the filter To change the filter 1. Remove the pressure lines and cables. 2. Unscrew the four screws from the front panel and remove the panel. 3. Unscrew and replace the filter. 4. Mount the front panel. IM.650.226DE (Issue 1-07/02) 25.07.02 18
7.2 Spare parts: Plug-in power supply 100-240 V / 12 V DC / 2 A EURO-version AAB3556 USA version AAC1417 Precision pressure controller 100 PSI. approx. 7 bar UXC-18713 Pressure selector valve U-20030 Air filter (P1) P-40166 Fuse T100 ma UXD-92568 Battery (NiMH) 7,2 V, 1300 mah AAB7894 Hand pump 100 PSI, approx. 7 bar AAC4480 Precision volume controller AAC4489 Pneumatic valve UXB-94428 IM.650.226DE (Issue 1-07/02) 25.07.02 19
8. RS232 INTERFACE 8.1 Socket layout IM.650.226DE (Issue 1-07/02) 25.07.02 20
ANNEX 1. Specification of the RS232 interface: 1. Synchronization mode: Asynchronous 2. Transmission rate: 19200 Baud 3. Data format (asynchronous): - Start bit: 1 Bit - Data bit: 8 Bit - Parity bit: even - Stop bit: 1 Bit 4. Signal polarity: RS-232 standard 5. Handshake: no handshake because of request control with fixed blocks 6. Transmission code: W&T-Protocol (master-slave) point to point communication, max. 1 user 7. Potentially not isolated 2. Transmission protocol For the communication between master (active user, e.g.. computer) and slave (passive user), two different kinds of frames are used: - Request.- Frame - Set - Frame The slave answers to these frames with the following frames: - Answer frame - Positive confirmation - Negative confirmation The bytes of these frames always have the same formats: - 1 Start bit (always "0") - 8 Data bits - 1 Parity bit (even) - 1 Stop bit (always "I") IM.650.226DE (Issue 1-07/02) 25.07.02 21
2.1 Description of the bytes of the frames Synchronization bytes (SYN): The synchronization bytes are used for the synchronization of the user units to the others. Start byte (SB): Marks the begin of a frame. The value depends on the type of the frame: - Request frame 10H - Set frame 68H - Answer frame 68H - Positive confirmation ASH - Negative confirmation DCH Slave address (SA): To every module in the RS485 bus a special bus address is allocated (slave address). The address can be a number between 0 and 31 Dec. Destination address (ZA) The destination address determines the transmission variable in the address reference list, that is to be read or written. Check byte The check byte determines which information is to be read from the slave. Also the data format is defined. Data format of the check byte (Bit 0...3): Bit (3S10) Dec. Format: 0000 0 Default (to address reference list) 0001 1 Default (to address reference list) 0010 2 Boolean 0011 3 Boolean 0100 4 unsigned Character 0101 5 signed Character 0110 6 unsigned Integer 0111 7 signed Integer 1000 8 unsigned long Integer 1001 9 signed long Integer 1010 10 Floating Point 1011 11 Floating Point 1100 12 ASCII 1101 13 ASCII 1110 14 Mixed data format 1111 15 Mixed data format IM.650.226DE (Issue 1-07/02) 25.07.02 22
Special case: With negative confirmation, the check byte includes an additional information about the error occurred. With positive confirmation, the check byte is set to 00Hex. Value: Function: 01H End of address table 0SH Wrong data format 04H Additional information not available 08H Variable to set not within min and max limits 1011 reading access not permitted S0H reading access permitted but wrong password 40H writing access not permitted 80H writing access permitted but wrong password C0H writing access not permitted (e.g.. wrong operation mode) Number byte (AB) The number byte defines the number of bytes to read or to write. Frame Check (FC) The check sum of the control bytes of a frame is stored in the frame check. FC = (unsigned char) SB + SA + ZA + KB + AB Data unit (DU) The data unit includes the data information to be sent by the slave or by the master. Data check (DC) The check sum of the data bytes of a frame is stored in the data check. CD = (unsigned char) sum of DU End byte (EB) The end byte marks the end of a frame. Value is always 16Hex. IM.650.226DE (Issue 1-07/02) 25.07.02 23
2. Request frame The request frame is necessary to read data or additional information from a slave. Format of the request frame: Byte: 0-2 3 4 5 6 7 8 9 Name: SYN SB SA ZA KB AB FC EB occupied by: Synchronization bytes Start byte 10H Slave address destination address check byte number of bytes frame Check end byte 16H With the request frame, single words, values covering more addresses, or additional information of the destination address can be read. If the contents of a single destination address is requested, the number byte is set to 00Hex. In the answer frame the data format and the number of bytes is entered from the address reference list to the check byte and the number byte. A data format eventually entered in the request frame is ignored. If a number byte is set in the request frame (request covering more addresses) the data format in the answer frame is set to 04Hex (unsigned char). The number byte of the answer frame receives the value of the number byte of the request frame. A data format eventually entered in the request frame is ignored. If the additional information of a destination address is requested, the check byte must include the identification for this additional information. The data format and the number byte are ignored. The check byte and the answer byte are set according to the reference list. Valid, request frames are answered with an answer frame. Invalid request frames are answered with negative Confirmation IM.650.226DE (Issue 1-07/02) 25.07.02 24
3. Set frame The set frame is used for writing data to a slave. Byte: 0-2 3 4 5 6 7 8 9-X Y Z Name: SYN SB SA ZA KB AB FC DU DC EB Function: Synchronization bytes Start byte 68H Slave address Destination address Check byte number byte Frame Check Data bytes Data Check End byte 16H With the set frame, single words, values covering more addresses, or additional information can be written. If the contents of a single destination address is written, the number byte must correspond to the number byte of the address reference list. The data format must be set to default or to the data format from the address reference list. If more variables are to be set covering more addresses, the data format must be set to default. The number byte means the number of bytes to write, only whole variables have to be written. Valid set flames are answered with a positive confirmation. Invalid set frames are answered with negative confirmation. IM.650.226DE (Issue 1-07/02) 25.07.02 25
4. Answer frame The answer frame is transmitted by the slave because of a request frame of the master. Byte: 0-2 3 4 5 6 7 8 9-X Y Z Name: SYN SB SA ZA KB AB FC DU DC EB Function: Synchronization bytes Start byte 68H Slave address Destination address Check byte number byte Frame Check Data bytes Data Check End byte 16H If no data format and no number of bytes (AB) is set in the request frame in the check byte, the data format and the number of bytes are entered into the answer frame from the address list. IM.650.226DE (Issue 1-07/02) 25.07.02 26
5. Positive and negative confirmation The positive confirmation is transmitted y the slave, if a set frame of the master has been executed validly. A negative confirmation is transmitted by the slave, if a set frame or a request frame couldn't be executed validly. Byte Name Function 0-2 SYN Synchronizations bytes 3 SB Positive: Start byte A2H Negative: Start byte DCH 4 SA Slave Address 5 ZA Destination Address 6 KB Check byte 7 AB Number byte 8 FC Frame Check 9 EB End Byte 16H The check byte is occupied by 00Hex for positive confirmation and by an error code for negative confirmation. IM.650.226DE (Issue 1-07/02) 25.07.02 27
Abbreviations of the data formats: BOOL-boolean, UCHAR-unsigned char, SCHAR-signed char, USINT-unsigned integer, SIINT-signed integer, ULONG-unsigned long, SLONG-signed long, FLOAT- float, ASCII-ASCU-code, MIX-mixed data format Abbreviations of the status: L-read, S-write, LP-read with password, SP-write with password, SW-write with factory password Data structure 3, (Unit of the instrument) Byte 1-8: format of the unit (ASCII), Byte 9-18: unit (ASCII), Byte 19-22: factor (FLOAT) IM.650.226DE (Issue 1-07/02 25.07.02 28