GE Druck DPI610 Series Service Manual
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GE Druck DPI610 Series Service Manual

GE Druck DPI610 Series Service Manual

Portable pressure calibrator
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GE
DIGITAL SOLUTIONS
Druck DPI610/615 Series
Portable Pressure Calibrator
Service Manual 117M5877

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Summary of Contents for GE Druck DPI610 Series

  • Page 1 DIGITAL SOLUTIONS Druck DPI610/615 Series Portable Pressure Calibrator Service Manual 117M5877...
  • Page 2 © 2016 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.

  • Page 3: Safety Overview

    Use suitably qualified personnel and good engineering practice for all procedures used in this publication. Personnel servicing at depot level must have been on the associated GE Druck training course to ensure that they have the full knowledge required for this level.
  • Page 4 DPI615 series. Before commencing any activities on the DPI610_615 Series products take time to become familiar with the user manuals provided and have the current revision of product service manual by consulting GE or by visiting the GE product support website.
  • Page 5 DPI610 / DPI615 Series Service Manual Terminology The terminology used in this manual is specific and individual interpretation must not be introduced. The terms are defined as follows: Adjust: To bring to a more satisfactory state; to manipulate controls, levers, linkages, etc... to return equipment from an out-of-tolerance condition to an in-tolerance condition.
  • Page 6 DPI610 / DPI615 Series Service Manual TABLE OF CONTENTS PRELIMINARY PAGES Safety Overview Terminology & Abbreviation Contents CHAPTER ASSEMBLY DESCRIPTION INTRODUCTION General TOOLING TROUBLE SHOOTING GUIDE Power-up Transducer Temperature Sensor Printed Circuit Board Pressure Electrical PNEUMATICS VERSION Exploded View Exploded View Parts DPI610 Spare Parts DPI615 Spare Parts KEYPAD AND GASKET...
  • Page 7 DPI610 / DPI615 Series Service Manual Table of Contents Continued CHAPTER ASSEMBLY DESCRIPTION PNEUMATICS ASSEMBLY Disassembly Reassembly LOW PRESSURE RELIEF VALVE ASSEMBLY Disassembly Reassembly Tests to be performed after reassembly Pneumatics and Low Pressure Relief Valve Spares PRINTED CIRCUIT BOARD 10.1 Disassembly 10.2...
  • Page 8 DPI610 / DPI615 Series Service Manual Table of Contents Continued CHAPTER ASSEMBLY DESCRIPTION AERONAUTICAL VERSION 14.1 Aeronautical Assembly 14.2 Aeronautical Spares Aeronautical Pneumatics Assembly 14.3 14.3.1 Disassembly 14.3.2 Reassembly 14.4 Tests to be performed after reassembly PNEUMATICS SEALS 15.1 Pneumatics Seal Assembly 15.1.1 Pneumatics Seal Exploded View Parts 15.2...
  • Page 9 DPI610 / DPI615 Series Service Manual Table of Contents Continued CHAPTER ASSEMBLY DESCRIPTION PROCEDURES 20.1 Leak Test 20.2 Aeronautical - Ascent/Descent Settings 20.3 New PCA Configuration 20.4 Software Guide 20.4.1 Software Upgrade Table 20.4.2 Software Download Procedure 20.5 DPI610 & DPI615 Pin Numbers CONTACT DETAILS 117M5877 Revision -...
  • Page 10 DPI610 / DPI615 Series Service Manual THIS PAGE IS INTENTIONALLY LEFT BLANK 117M5877 Revision -...
  • Page 11 DPI610 / DPI615 Series Service Manual INTRODUCTION GENERAL This service manual is designed to assist with the service/repair/maintenance of the instrument. The versions of the DPI 610 and DPI 615 instruments are: pneumatic indicator, pneumatic calibrator, hydraulic calibrator and low pressure pneumatic calibrator. All instruments measure and display pneumatic and hydraulic pressure applied to the test port or to an externally connected pressure sensor.
  • Page 12 DPI610 / DPI615 Series Service Manual THIS PAGE IS INTENTIONALLY LEFT BLANK 117M5877 Revision -...
  • Page 13 DPI610 / DPI615 Series Service Manual TOOLING Supplier Supplier Part Number Description F-A4-0434 C Spanner for PV nut 181-474 Allen 3 mm T Shape Long Arm Alloy Steel Hex Key 288-7843 Pozidriv PZ2 Screwdriver 438-4324 Flat Terminal Screw Driver 449-9369 RS Pro 150 mm Screwdriver, Flat 6.5 mm Tip 459-4256 RS Pro 75 mm Screwdriver, Pozidriv PZ1 Tip...
  • Page 14 DPI610 / DPI615 Series Service Manual THIS PAGE IS INTENTIONALLY LEFT BLANK 117M5877 Revision -...

  • Page 15: Troubleshooting Guide

    DPI610 / DPI615 Series Service Manual TROUBLE SHOOTING GUIDE Follow the trouble shooting charts and table for fault diagnoses and repair. Flowchart procedures are shown in this chapter as independent charts for hardware faults. Tables are only a guide for pressure and electrical problems The following conventions are used throughout this manual.
  • Page 16 DPI610 / DPI615 Series Service Manual POWER-UP 3.2 - P OWER UP DIAGNOSIS CHART 117M5877 Revision -...
  • Page 17 DPI610 / DPI615 Series Service Manual TRANSDUCER 3.3 - T RANSDUCER DIAGNOSIS CHART 117M5877 Revision -...

  • Page 18: Temperature Sensor

    DPI610 / DPI615 Series Service Manual TEMPERATURE SENSOR 3.4 - T EMPERATURE SENSOR DIAGNOSIS CHART 117M5877 Revision -...

  • Page 19: Print Circuit Board

    DPI610 / DPI615 Series Service Manual PRINT CIRCUIT BOARD 3.5 - PCA DIAGNOSIS CHART 117M5877 Revision -...
  • Page 20 DPI610 / DPI615 Series Service Manual PRESSURE NOTE: Disconnect all external connections from the instrument, use a known good leak free blanking plug for blanking off pressure port. Problem Action Chapter Pressure unstable Check transducer calibration K0415 Check transducer cable Chapter 7 Replace transducer Chapter 7...
  • Page 21 DPI610 / DPI615 Series Service Manual ELECTRICAL Problem Action Chapter RS232 Communication Ensure computer is compatible K0415 Check computer connections and settings Check RS232 Cable assembly Check COMMS setting Chapter 19.3.2 Replace PCA Chapter 10 Input voltage/current reading out of Calibrate K0415 specification...

  • Page 22: Exploded View

    DPI610 / DPI615 Series Service Manual PNEUMATICS VERSION EXPLODED VIEW TOP CASE SECTION MANIFOLD SECTION BASE UNIT SECTION 4.1 - E XPLODED VIEW OF NEUMATIC ERSION 117M5877 Revision -...

  • Page 23: Item Description

    MAIN PCA ASSEMBLY PLATE LOAD/HAND HANDLE BRACKET VENT VALVE ASSEMBLY - (TORQUED TO 0.25Nm) MANIFOLD SECTION PNEUMATICS ASSEMBLY LOW PRESSURE RELIEF VALVE ASSEMBLY GE INTERNAL PRESSURE TRANSDUCER BASE UNIT SECTION BASE CASE BASE CASE FEET KIT BATTERY COVER GASKET BATTERY COVER...
  • Page 24 VENT VALVE ASSEMBLY PRIMING VALVE ASSEMBLY 12.2 IS610-3 LOW PRESSURE RELIEF VALVE ASSEMBLY INSTALLED IN UNITS WITH PRESSURE RANGES 1BAR OR LESS I0610B-2 GE REMOTE PRESSURE TRANSDUCER CABLE ASSEMBLY IS610-4 CASE TOP ASSEMBLY TOP CASE KEYPAD KEYPAD GASKET IS610-5 BASE UNIT ASSEMBLY...

  • Page 25: Base Unit Assembly

    DPI610 / DPI615 Series Service Manual DPI615 SPARE PARTS GE PART No: PART DESCRIPTION AND CONTENTS CHAPTERS IS615-1 PNEUMATIC ASSEMBLY IS615-3 LOW PRESSURE VALVE ASSEMBLY IS615-4 CASE TOP ASSEMBLY TOP CASE KEYPAD KEYPAD GASKET IS615-5 BASE UNIT ASSEMBLY BASE CASE...
  • Page 26 DPI610 / DPI615 Series Service Manual KEYPAD AND GASKET Disassembly .5.1 START TO REMOVE KEYPAD FROM ONE CORNER ITEM DESCRIPTION REFER TO FIF5.1 & 5.2 KEYPAD GASKET - UNDERSIDE FILM GASKET - STUCK DOWN WITH TOP FILM STILL ATTACHED Steps 1.Carefully start to peel keypad and Gasket from one corner (1) as shown in Fig.5.1 2.Fully remove keypad and Gasket.
  • Page 27 Test for reassembly Refer to chapter 19.3 for applicable tests. Final acceptance test Refer to chapter 19.8 for final acceptance test Keypad and Gasket Spares GE PART No SPARE PART DESCRIPTION AND CONTENTS IS610-6 KEYPAD & GASKET KEYPAD KEYPAD GASKET...
  • Page 28 DPI610 / DPI615 Series Service Manual TEMPERATURE SENSOR EXPLODED VIEW OF TEMPERATURE SENSOR INSTALLATION TEMPERATURE SENSOR HOUSING SECTION VIEW OF BASE .6.1 - R EMOVAL OF TEMPERATURE SENSOR ITEM DESCRIPTION TEMPERATURE SENSOR TEMPERATURE SENSOR CABLE TOP CASE ASSEMBLY BASE UNIT TEMPERATURE SENSOR HOUSING O RING SEAL CIRCLIP...
  • Page 29 DPI610 / DPI615 Series Service Manual Disassembly Steps 1.Unplug cable connector PL5 2.Remove circlip (7) and O ring seal (6) 3.Remove complete assembly from base unit. 4.Ensure TSH area from base unit is free from adhesive and dirt. 6..2 Reassembly Step 1.Feed Temperature assembly (PL5 end) from the outer base case (1).
  • Page 30 DPI610 / DPI615 Series Service Manual INTERNAL TRANSDUCER AND CABLE ASSEMBLY .7.1 T RANSDUCER AND CABLE ARRANGEMENT ITEM DESCRIPTION TOP CASE CABLE GROMET TRANSDUCER CABLE PCA TRANSDUCER CABLE CONNECTOR INTERNAL TRANSDUCER Take ESD precaution 7..1 Disassembly Steps 1.Cable assembly - unplug connectors (2) & (3) 2.Remove cable assembly through (4) 3.Use spanner to unscrew sensor (1) &...
  • Page 31 DPI610 / DPI615 Series Service Manual Tests to be performed after reassembly The following tests must be performed to validate the functionality of the part reassembled and that reassembly has not affected the overall instrument functionality Test for reassembly Refer to chapter 19.3 for applicable tests. Final acceptance test Refer to chapter 19.8 for final acceptance test Internal Transducer and Cable Assembly Spares...
  • Page 32 DPI610 / DPI615 Series Service Manual BASE CASE .8.1 REMOVAL OF BASE UNIT ITEM DESCRIPTION BASE UNIT HEX SCREW AND SHAKEPROOF WASHER BASE UNIT BANJO CONNECTOR TEMPERATURE SENSOR CABLE BATTERY POWER CABLE f battery compartment is contaminated replace complete base unit. Take ESD precautions 117M5877 Revision -...

  • Page 33: Battery Cover

    Test for reassembly Refer to chapter 19.3 for applicable tests Final acceptance test Refer to chapter 19.8 for final acceptance test Base Case Spare GE PART No PART DESCRIPTION AND CONTENTS IS610-5 BASE UNIT ASSEMBLY BASE CASE BASE CASE FEET KIT...
  • Page 34 DPI610 / DPI615 Series Service Manual PNEUMATICS ASSEMBLY . 9.1 E XPLODED VIEW OF PNEUMATICS ASSEMBLY ITEM DESCRIPTION PLUG INSERT M5 NUT M5 WASHER VOLUME ADJUSTER KNOB VOLUME ADJUSTER PISTON ROD LOCKING RING HAND PUMP KNOB PRESSURE/VACUUM KNOB PUMP PISTON ROD HAND PUMP LOCKING RING SENSOR ELECTRICAL CONNECTOR EARTH CONNECTION...
  • Page 35 DPI610 / DPI615 Series Service Manual ITEM DESCRIPTION HAND PUMP CYLINDER PRESSURE RELEASE VALVE TOP CASE Disassembly Steps 1.Use an adhesive tape to remove Plug insert (1) 2.Unscrew M5 nut (2) 3.Remove washer (3) 4.Remove valve adjust knob (4) 5.Grip and hold piston rod (9) tight and unscrew hand pump knob (7) 6.Remove pressure/vacuum knob (8) by unclipping at two positions 7.Remove 6mm tubing from push-in connector (13) 8.Remove 3mm tubes from Air intake banjo connector (14)
  • Page 36 DPI610 / DPI615 Series Service Manual LOW PRESSURE RELIEF VALVE ASSEMBLY NOTE: Low pressure relief valve is only fitted no pneumatics version with pressure ranges of 1Bar or less 9.2 - L OW PRESSURE RELIEF VALVE ASSEMBLY ITEM DESCRIPTION PNEUMATICS ASSEMBLY IN TOP CASE LOW PRESSURE RELAESE VALVE TUBING NOTE: Low pressure release valve is fitted between Release valve and manifold, tubing is cut square and push in...
  • Page 37 Test for reassembly Refer to chapter 19.3 for applicable tests. Final acceptance test Refer to chapter 19.8 for final acceptance test Pneumatics and Low Pressure Relief Valve Spares GE PART No PART DESCRIPTION AND CONTENTS IS610-1 PNEUMATICS ASSEMBLY IS615-1 IS610-3...

  • Page 38: Printed Circuit Board

    10-1 DPI610 / DPI615 Series Service Manual PRINTED CIRCUIT BOARD .10.1 PRINTED CIRCUIT BOARDS ASSEMBLY ITEM DESCRIPTION SCREW SELF-TAP No.4x5/6” & M3 WASHER PRINTED CIRCUIT BOARD ASSEMBLY SENSOR CABLE CONNECTOR PL1 TEMPERATURE CABLE CONNECTOR PL5 EARTHING CABLE CONNECTOR PL9 BATTERY CABLE CONNECTOR PL4 TOP CASE EXTERNAL CONNECTOR HOUSING EXTERNAL CONNECTOR HOUSING COVER...
  • Page 39 Refer to chapter 19.3 for applicable tests. Final acceptance test Refer to chapter 19.8 for final acceptance test 10.4 Printed Circuit Board Spare GE PART No PART DESCRIPTION AND CONTENTS IS610-7 Printed Circuit Boards NOTE: ON ORDERING STATE WHETHER IT IS FOR AERONAUTICAL VERSION...
  • Page 40 11-1 DPI610 / DPI615 Series Service Manual TOP CASE .11.1 TOP CASE ASSEMBLY FOR THIS PROCEDURE REFER TO OTHER SECTIONS AS STATED WITHIN EACH STEPS 11.1 Disassembly Steps 1.Remove Base unit refer to section 8 2.Remove - for the following configurations: a.
  • Page 41 Test for reassembly Refer to chapter 19.3 for applicable tests. Final acceptance test Refer to chapter 19.8 for final acceptance test 11.4 Top Case Spare GE PART No PART DESCRIPTION AND CONTENTS IS610-4 CASE TOP ASSEMBLY TOP CASE KEYPAD KEYPAD GASKET...
  • Page 42 DESCRIPTION TEST PORT HANDLE PRESSURE RELEASE VALVE ASSEMBLY TOP CASE MANIFOLD VOLUME ADJUSTER ASSEMBLY HAND PUMP ASSEMBLY 12.1.1 HYDRAULIC ASSEMBLY SPARES GE PART No: PART DESCRIPTION AND CONTENTS CHAPTERS IS610-2 HYDRAULIC ASSEMBLY TOP CASE VOLUME ADJUSTER/PUMP/RELEASE KNOBS HANDLE IS615-2 PLATE LOAD/HAND HANDLE BRACKET...
  • Page 43 DPI610 / DPI615 Series Service Manual 12-2 FOR THIS PROCEDURE REFER TO OTHER CHAPTERS AS STATED WITHIN EACH STEPS NOTE: BEFORE COMMENCING WITH ACTIVITIES DRAIN THE HYDRAULIC FLUID AS DESCRIBED IN USER MANUAL K0415 12.1.2Disassembly Steps 1.Remove Base unit refer to Chapter 8 2.Remove transducer and transducer cable assembly 3.Remove temperature sensor assembly 4.Remove Printed circuit board assembly refer to Chapter 10...
  • Page 44 12-3 DPI610 / DPI615 Series Service Manual 12.2.1 PRIMING VALVE SPARE PARTS GE PART No: PART DESCRIPTION AND CONTENTS CHAPTERS IS610-10 HYDRAULIC PRIMING VALVE ASSEMBLY 12.2 PRIMING VALVE ASSEMBLY CLEAR TUBING 4mm TY-WRAP IS615-10 INSTRUCTION GUIDE 12.3 INSTALL PRIMING VALVE TO HYRDRAULIC ASSEMBLY 12.3 - A...

  • Page 45: Prepare For Assembly

    DPI610 / DPI615 Series Service Manual 12-4 12.3.1 PREPARE FOR ASSEMBLY 12.4 - H YDRAULIC VERSION WITH PRIMING VALVE Steps 1.Remove tubing (2) connected between Legris connectors (1) and (3). Release tube by first pressing down on the connector collar and then pulling the tube out. 2.Remove tubing (4) connected between Legris connectors (5) and (6).
  • Page 46 12-5 DPI610 / DPI615 Series Service Manual 12.3.2 ASSEMBLE PRIMING VALVE Fig 12.5 - Hydraulic Tubing installation Steps 1.Place the priming valve assembly over the body of the screwpress (K) and secure it in place with the two tywraps (11) provided. Trim off the surplus ends of the tywraps. 2.Cut the ends of the tubing off square and ensure that the tube is pushed all the way into the connector.
  • Page 47 DPI610 / DPI615 Series Service Manual 12-6 12.4 Tests to be performed after reassembly The following tests must be performed to validate the functionality of the part reassembled and that reassembly has not affected the overall instrument functionality Test for reassembly Refer to chapter 19.3 for applicable tests.

  • Page 48: Blanking Plug

    13-1 DPI610 / DPI615 Series Service Manual LOW PRESSURE VERSION 13.1 LOW PRESSURE ASSEMBLY 13.1 - L RESSURE ARIANT ASSEMBLY ITEM ITEM DESCRIPTION SOLENOID DRIVER PCA MAIN PCA ASSEMBLY LOW PRESSURE TRANSDUCER TUBING TEE 3mm TOP CASE BLANKING PLUG VOLUME ADJUSTER ASSEMBLY SOLENOID VALVE ASSEMBLY PLATE SPREADER CLEAR TUBING 3mm...
  • Page 49 ITEM GE PART No: DESCRIPTION IA4219-1-V0 SOLENOID DRIVER PCA IS610-7 MAIN PCA - SELECT UNIT IS615-7 209- LP TRANSDUCER CONTACT GE SALES TEAM: FOR CORRECT PRESSURE RANGE TRANSDUCER 181-034 Tee 3mm 191-137 BLANK PLUG IA2828-1-V0 VOLUME ADJUSTER ASSEMBLY 176-084 SOLENOID...
  • Page 50 13-3 DPI610 / DPI615 Series Service Manual 13.4 SOLENOID DRIVER PCA Top view 13.2 - E PCA I XPLODED VIEW OF OLENOID RIVER NSTALLATION 13.4.1Disassembly Steps 1.Disconnect Battery power cable (base unit) from PL1 of Solenoid driver PCA (1) 2.Disconnect Solenoid cable (3) from solenoid PCA PL2 (4) 3.Disconnect Earth cable form main PCA PL9 (2) 4.Slowly un-clip PCB support spacers form solenoid driver PCA (11) in two places 5.Disconnect Solenoid PCA from main PCA.
  • Page 51 DPI610 / DPI615 Series Service Manual 13-4 13.5 VOLUME ADJUSTER ASSEMBLY 13.3 - VOLUME ADJUSTER 13.5.1Disassembly Steps 1.Disconnect tubing in three positions from Volume adjuster (1) 2.Remove handle assembly by removing grub screw from (2) and remove Inner piston knob 3.Remove nut located under the inner piston knob (3) 4.Remove handle 5.Remove Lock nut (4)
  • Page 52 13-5 DPI610 / DPI615 Series Service Manual 13.6 LOW PRESSURE TRANSDUCER 13.4 - L RESSURE RANSDUCER 13.6.1Disassembly Steps 1.Disconnect transducer cable assembly (6) from transducer (5) 2.Disconnect tubing (4) from transducer in two positions 3.Carefully remove solenoid cable and grommet (1) from top case slot 4.Remove screws and washers (3) from three position, one with Earth cable (2) 5.Carefully remove transducer 6.Remove both tube fittings (4)

  • Page 53: Solenoid Valve Assembly

    DPI610 / DPI615 Series Service Manual 13-6 13.7 SOLENOID VALVE ASSEMBLY 13.5 - S OLENOID ALVE SSEMBLY 13.7.1Disassembly Steps 1.Remove low pressure transducer as explained in section 6 of this chapter 2.Disconnect solenoid cable from solenoid driver PCA as explained in section 1 of this chapter 3.Disconnect clear tubing from (7) 4.Remove both nuts and washers (3&5) 5.Remove complete solenoid valve assembly (1,2,6&7) from plate spreader (4)
  • Page 54 ERONAUTICAL SSEMBLY VIEW ITEM DESCRIPTION PNEUMATIC ASSEMBLY TUBE ADAPTOR 1/16” ADAPTOR G1/4 TO G1/8 & SEALS NEEDLE VALVE ADAPTOR TEE TUBING 1/16” BULKHEAD ASSEMBLY M5x8 SCREW WITH FESTO SEAL GE PRESSURE TRANSDUCER TOP CASE ADAPTOR SWIVEL ELBOW 117M5877 Revision -...

  • Page 55: Spare Parts

    DPI610 / DPI615 Series Service Manual 14-2 AERONAUTICAL 14.2 SPARE PARTS ITEM GE PART No: DESCRIPTION IS610-1 PNEUMATICS ASSEMBLY 182-118 ADAPTOR 182-148 ADPATOR G1/4 TO G1/8 204-008 SEAL G1/8 204-053 SEAL G1/4 176-081 NEEDLE VALVE 182-117 ADAPTOR TEE 179-025 TUBING 1/16”...
  • Page 56 14-3 DPI610 / DPI615 Series Service Manual 14.3 AERONAUTICAL PNEUMATICS ASSEMBLY 14.1 - A ERONAUTICAL NEUMATICS ARTS 14.3.1Disassembly Steps 1.Disconnect Tube fitting (1) from base unit to manifold as per Chapter 8 section 8.1 2.Disconnect tubing from both bulkheads (5) 3.Cut Ty-wraps (6) 4.Disconnect Transducer cable (4) 5.Refer to Chapter 9 section 9.1 for removal of complete Pneumatics Assembly...
  • Page 57 DPI610 / DPI615 Series Service Manual 14-4 14.4 Tests to be performed after reassembly The following tests must be performed to validate the functionality of the part reassembled and that reassembly has not affected the overall instrument functionality. Test for reassembly Refer to chapter 19.3 for applicable tests.
  • Page 58 15-1 DPI610 / DPI615 Series Service Manual PNEUMATIC SEALS 15.1 PNEUMATICS SEAL ASSEMBLY OLD VERSION BOSS 15.1 - E XPLODED VIEW OF NEUMATICS SEAL PLACEMENT 117M5877 Revision -...
  • Page 59 DPI610 / DPI615 Series Service Manual 15-2 15.1.1 PNEUMATICS SEAL EXPLODED VIEW PARTS ITEM DESCRIPTION O RING 200-019-4470 O RING 200-006-4470 SCREW M3x12 PN HD POZI ST ST BRASS PUMP VALVE CAP O RING 8x1mm O RING 200-003-9775 PUMP SHUTTLE SPRING 15.3mm SPRING 7.5mm BRASS PUMP END CAP...
  • Page 60 15-3 DPI610 / DPI615 Series Service Manual 15.2 DISASSEMBLY FOR REPLACING SEALS 15.2.1Hand Pump Assembly Steps 1.Carefully remove manifold (11) screw (19) this screw has screw lock 222 applied 2.Carefully remove cylinder section (13) from manifold (11) 3.Carefully remove BOSS, adhesive 648 has been applied 4.Pull out piston rod (17) and piston (16) from cylinder (13) - Note : seals are attached to piston (14 &...
  • Page 61 REFER TO FIG 15.1 WHERE TO FIT SEALS 15.2 - P NEUMATICS 15.4.1 PNEUMATICS SEAL KIT CONTENTS PNEUMATICS SEAL KIT - GE PART Number: IS610-8 or IS615-8 ITEM - REFER TO Fig 15.1 & 15.2 DESCRIPTION O RING 200-019-4470 O RING 200-006-4470...

  • Page 62: Hydraulic Seals

    16-1 DPI610 / DPI615 Series Service Manual HYDRAULIC SEALS NOTE: ENSURE PRE-CAUTIONS ARE TAKEN AS THERE WILL BE SOME AMOUNT OF OIL SPILLAGE CHECK OIL FLUID MSDS FOR FURTHER DETAILS 16.1 PRIMING PUMP ASSEMBLY 16.1 - P RIMING PUMP EXPLODED VIEW ITEM DESCIPTION PRIMER PUMP END CAP...
  • Page 63 DPI610 / DPI615 Series Service Manual 16-2 16.2 VOLUME ADJUSTER ASSEMBLY 16.2 - E XPLODED VIEW OF OLUME DJUSTER ITEM DESCRIPTION MANIFOLD O RING VITON SEAL COMPRESSOR BODY GLYDRING & VITON SEAL (THIS IS A TWO PART SEAL) COMPRESSOR PISTON COMPRESSOR SHAFT BOSS - SCREW SPRING COVER...
  • Page 64 REFER TO FIG 16.2 REFER TO FIG 16.1 16.3 - H YDRAULIC 16.3.1 HYDRAULIC SEAL KIT CONTENTS HYDRAULIC SEAL KIT GE PART No: IS610H-8 or IS615H-8 ITEM DESCRIPTION FOR PRIMING PUMP - REFER TO FIG16.1 O RING 200-017-4470 O RING 200-110-9775 FOR VOLUME ADJUSTER - REFER TO FIG 16.2...
  • Page 65 DPI610 / DPI615 Series Service Manual 16-4 16.4 Tests to be performed after reassembly The following tests must be performed to validate the functionality of the part reassembled and that reassembly has not affected the overall instrument functionality. Test for reassembly Refer to chapter 19.3 for applicable tests.

  • Page 66: Indicator Assembly

    NDICATOR ASSEMBLY VIEW ITEM DESCRIPTION GE TRANSDUCER TOP CASE BLANKING PLUG TOP CASE MANIFOLD SWAGELOCK PIPE FITTINGS VALVE ASSEMBLY 17.2 INDICATOR SPARES ITEM GE PART No: DESCRIPTION 191-137 TOP CASE BLANKING PLUG 176-063 MANIFOLD 176-021 VALVE ASSEMBLY 117M5877 Revision -...
  • Page 67 DPI610 / DPI615 Series Service Manual 17-2 17.3 DISASSEMBLY AND REASSEMBLY OF THE INDUCTOR VERSION ALL PARTS ARE INTERLINKED Manifold (4) is linked to pressure port bulkhead Valve assembly (6) s linked to volume adjuster knob section Both the manifold (4) and valve assembly (6) are linked by swagelock pipe assembly 17.4 Tests to be performed after reassembly The following tests must be performed to validate the functionality of the part reassembled and that reassembly has not affected the overall instrument functionality...
  • Page 68 18-1 DPI610 / DPI615 Series Service Manual DPI610 & DPI615 COMMON PARTS 18.1 SPARES GE PART No PARTS DESCRIPTION AND CONTENTS PDCR2200 INTERNAL TRANSUCER CONTACT SERVICE ADMIN TEAM IO610B-1 EXTERNAL TRANSDUCER - CONTACT SERVICE ADMIN TEAM IO610B-2 EXTERNAL TRANSDUCER CABLE ASSEMBLY SELECT LENGTH...

  • Page 69: Battery Charger

    DPI610 / DPI615 Series Service Manual 18-2 18.2 ACCESSORIES GE PART No PARTS DESCRIPTION AND CONTENTS 191-126 RE-CHARGEABLE BATTERY PACK (Ni-cad) 191-129 BATTERY CHARGER IO610-A RECHARGEABLE BATTERIES & CHARGER 191-A023 BATTERY CHARGER 110v IO610A-2 110V RECHARGEABLE BATTERIES & CHARGER IO620-IDT621...

  • Page 70: Test Information

    19-1 DPI610 / DPI615 Series Service Manual TEST INFORMATION 19.1 TEST EQUIPMENT REQUIRED EQUIPMENT SPECIFCATION / DESCRIPTION PRESSURE CALIBRATION AUTOMATIC TEST EQUIPMENT BESPOKE CALIBRATION RIG PRESSURE STANDARD CLASS A DEADWEIGHT WHERE POSSIBLE - (<0.025% FS) ELECTRICAL CALIBRATION DIGITAL VOLT METER FOR 5V ±30ppm ±1 digit FOR 50V...
  • Page 71 DPI610 / DPI615 Series Service Manual 19-2 19.3 TEST GUIDE TABLE TESTS GUIDE FOR EACH CHAPTERS REFER TO USER MANUAL K0415 LEAK TEST FINAL CHAPTERS REFER TO ACCEPTANCE CHAPTERS FOR EXTRA CALIBRATION CHAPTER TEST CHAPTER TEST GUIDE 20.1 19.8 TEMPERATURE PRESSURE ELECTRICAL 19.4...
  • Page 72 19-3 DPI610 / DPI615 Series Service Manual 19.6 CHAPTER 10 - PCA Configuring new PCA Power up unit - internal sensor will be sensed Wait for power-up routine Select “TASK” menu Select “ADVANCED” mode Select “SETUP” Select “SETTING” Select “CALIBRATION” Enter Pin number:1129 Select “SETUP”...
  • Page 73 DPI610 / DPI615 Series Service Manual 19-4 THIS PAGE IS INTENTIONALLY LEFT BLANK 117M5877 Revision -...
  • Page 74 20-1 DPI610 / DPI615 Series Service Manual PROCEDURES 20.1 LEAK TEST Note: Refer to user manual K0415 for operation. Leak testing should be performed in a stable temperature environment away from drafts. Gauge/Abs pneumatic UUT For pneumatic units ranged 1 to 20 bar: Apply full scale pressure. Using the leak test feature, set the wait and timing duration’s to 4 minutes and 1 minute respectively.
  • Page 75 DPI610 / DPI615 Series Service Manual 20-2 20.2 AERONAUTICAL - ASCENT/DESCENT SETTINGS Before proceeding, ensure the leak test has been performed as defined in section 20.1. Connect the UUT pressure port to a calibrated ROC meter. Open the vent valve on the UUT pressure port and perform a ‘zero’ operation. Close the vent valve together with the ascent and descent control needle valves inside the UUT.

  • Page 76: Software Guide

    20-3 DPI610 / DPI615 Series Service Manual 20.4 SOFTWARE GUIDE Note: Guide to determine if instrument requires an upgrade of software or PCA replacement 1st DK software 2nd DK Software (Main Code) Procedure 19.1 - S OFTWARE ROCEDURE 117M58777 Revision -...
  • Page 77 DPI610 / DPI615 Series Service Manual 20-4 20.4.1 SOFTWARE UPGRADE TABLE Product Main Code Version Action Required DK155 2.07 or Lower Replace PCA DPI610/615PC DK175 2.03 or Lower Up-grade software (Main Code) DK344 3.02 or Lower Up-grade software (Main Code) PNEUMATIC DK344 4.00...

  • Page 78: Software Download Procedure

    20-5 DPI610 / DPI615 Series Service Manual 20.4.2 SOFTWARE DOWNLOAD PROCEDURE Downloading new instrument software affects its functionality. Calibration and/ or other stored data may be rendered invalid. For compatibility with previous versions, refer to the release notes with the upgrade package. For connections refer to user manual K0415 Connect the DPl610 instrument to the PC via the RS232 serial link.

  • Page 79: Pin Number

    DPI610 / DPI615 Series Service Manual 20-6 20.5 DPI610 AND DPI615 PIN NUMBERS PIN NUMBER KEY PRESS DESCRIPTION FOR USE 4321 ENTER CALIBRATION 5487 ENTER SOFTWARE UPGRADE 1129 SETUP CONFIGURATION 6100 SETUP OVER-RIDE CUSTOMER PIN NUMBER 1359 SETUP GE SERVICE MENU 117M5877 Revision -...

  • Page 81: Contact Details

    CONTACT DETAILS GE Druck, Groby site offers comprehensive facilities for the repair and calibration of GE branded instruments. We offer first class service to ensure your product is returned as promptly as possible. This site has an ISO17025 accredited laboratory which is accredited by the United Kingdom...

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