Calibration Test Stand Manual DL8601 (1)

7/21/2019 Calibration Test Stand Manual DL8601 (1)

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Manual: DL8601 Revision: Rev D 12/12

DataLoggerCalibration TestStand

OperatorsManual


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Thank you for purchasing this McElroy product.

The DataLogger Calibration Test Stand is used to calibrateand certify a DataLogger device. The calibration is done toensure accuracy of the device. For assistance with the teststand, please contact McElroy Manufacturing, Inc.

TX02830-11-12-08

World Class Training

This manual is intended as a guide only and does nottake the place of proper training by qualified instructors.The information in this manual is not all inclusive andcan not encompass all possible situations that can beencountered during various operations.

McElroy Manufacturing, Inc., offers advanced trainingclasses to enhance efficiency, productivity, safety andquality. Training is available at our facility or onsite at

your location. Call (918) 8368611

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2

Introduction


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Warranty

LIMITED WARRANTY

McElroy Manufacturing, Inc. (McElroy) warrants allproducts manufactured, sold and repaired by it to befree from defects in materials and workmanship, its

obligation under this warranty being limited to repairingor replacing at its factory and new products, within3 yearsafter shipment, with the exception of purchaseditems (such as electronic devices, pumps, switches, etc.),in which case that manufacturers warranty applies.Warranty applies when returned freight is prepaid andwhich, upon examination, shall disclose to have beendefective. This warranty does not apply to any productor component which has been repaired or altered byanyone other than McElroy or has become damageddue to misuse, negligence or casualty, or has not beenoperated or maintained according to McElroys printedinstructions and warnings. This warranty is expresslyin lieu of all other warranties expressed or implied.The remedies of the Buyer are the exclusive and soleremedies available and Buyer shall not be entitled toreceive any incidental or consequential damages. Buyerwaives the benefit of any rule that disclaimer of warrantyshall be construed against McElroy and agrees that suchdisclaimers herein shall be construed liberally in favor ofMcElroy.

RETURN OF GOODSBuyer agrees not to return goods for any reason exceptupon the written consent of McElroy obtained in advance

of such return, which consent, if given, shall specify theterms and conditions and charges upon which any suchreturn may be made. Materials returned to McElroy, forwarranty work, repair, etc., must have a Return MaterialAuthorization (RMA) number, and be so noted on thepackage at time of shipment. For assistance, inquiry shallbe directed to:

McElroy Manufacturing, Inc.P.O. Box 580550833 North Fulton Street Tulsa, Oklahoma 74158-0550

PHONE: (918) 8368611, FAX: (918) 8319285.EMAIL: [email protected]

Note: Certain repairs, warranty work, and inquiries maybe directed, at McElroys discretion, to an authorizedservice center or distributor.

TX02486-04-06-05

DISCLAIMER OF LIABILITY

McElroy accepts no responsibility of liability for fusionjoints. Operation and maintenance of the product is theresponsibility of others. We recommend qualified joining

procedures be followed when using McElroy fusionequipment.

McElroy makes no other warranty of any kind whatever,express or implied; and all implied warranties ofmerchantability and fitness for a particular purposewhich exceed the aforestated obligation are herebydisclaimed by McElroy.

PRODUCT IMPROVEMENT

McElroy reserves the right to make any changes in orimprovements on its products without incurring anyliability or obligation to update or change previously sold

machines and/or the accessories thereto.

INFORMATION DISCLOSED

No information of knowledge heretofore or hereafterdisclosed to McElroy in the performance of or inconnection with the terms hereof, shall be deemedto be confidential or proprietary, unless otherwiseexpressly agreed to in writing by McElroy and any suchinformation or knowledge shall be free from restrictions,other than a claim for patent infringement, is part of theconsideration hereof.

PROPRIETARY RIGHTSAll proprietary rights pertaining to the equipment orthe components of the equipment to be delivered byMcElroy hereunder, and all patent rights therein, arisingprior to, or in the course of, or as a result of the designor fabrication of the said product, are exclusively theproperty of McElroy.

LAW APPLICABLEAll sales shall be governed by the Uniform CommercialCode of Oklahoma, U.S.A.

Register your product online to activate yourwarranty:www.McElroy.com/fusion

(Copy information listed on the machine nameplate herefor your records).

Model No.

Serial No.

Date Received

Distributor


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Table of Contents

Equipment Safety Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Read and Understand . . . . . . . . . . . . . . . . . . . . . . . . 1-1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . 1-2 Units With Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Heater is Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Calibrating the Heater Stand Calibrating the Heater Stand . . . . . . . . . . . . . . . . . . . 2-1

Calibration DL3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Update Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Calibration Software . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Calibration Data File . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Calibration Certificate . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Calibration DL4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Connecting the Digital Pressure Sender to Your PC . . . . 4-1 Calibrating the Digital Pressure Sender . . . . . . . . . . . . 4-2 Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Specifications

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

COPYRIGHT 2011,2012

McElroy Manufacturing, Inc.

Tulsa, Oklahoma, USA

All rights reserved

All product names or trademarks are property of their respective owners .All information,illustrations and specifications in this manual are based on the latest information available at the

time of publication. The right is reserved to make changes at any time without notice.

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Equipment Safety

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Safety Alerts

This hazard alert sign appears in this manual.When you see this sign, carefully read what it says.YOUR SAFETY IS AT STAKE.

You will see the hazard alert sign with these words:DANGER, WARNING, and CAUTION.

Indicates an imminently hazardoussituation which, if not avoided, willresult in death or serious injury.

Indicates a potentially hazardoussituation which, if not avoided, couldresult in death or serious injury.

Indicates a hazardous situation which,if not avoided, may result in minor ormoderate injury.

In this manual you should look for two other words:NOTICEand IMPORTANT.

NOTICE: can keep you from doing something that mightdamage the machine or someone's property. It may alsobe used to alert against unsafe practices.

IMPORTANT: can help you do a better job or makeyour job easier in some way.

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P LIGRO

Read and Understand

Do not operate this equipment until you have carefully read,and understand all the sections of this manual, and all otherequipment manuals that will be used with it.

Your safety and the safety of others depends upon care andjudgment in the operation of this equipment.

Follow all applicable federal, state, local, and industry specificregulations.

McElroy Manufacturing, Inc. cannot anticipate every possiblecircumstance that might involve a potential hazard. Thewarnings in this manual and on the machine are therefore not allinclusive. You must satisfy yourself that a procedure, tool, workmethod, or operating technique is safe for you and others. Youshould also ensure that the machine will not be damaged ormade unsafe by the method of operation or maintenance youchoose.

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Equipment Safety

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General Safety

Safety is important. Report anything unusual that you noticeduring set up or operation.

LISTEN for thumps, bumps, rattles, squeals, air leaks, or unusualsounds.

SMELL odors like burning insulation, hot metal, burning rubber,hot oil, or natural gas.

FEEL any changes in the way the equipment operates.

SEE problems with wiring and cables, hydraulic connections, orother equipment.

REPORT anything you see, feel, smell, or hear that is differentfrom what you expect, or that you think may be unsafe.

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S A F E 1 S T 1 2 2 2 9 2

Wear Safety Equipment

Wear a hard hat, safety shoes, safety glasses, and otherapplicable personal protective equipment.

Remove jewelry and rings, and do not wear loose fitting clothingor long hair that could catch on controls or moving machinery.

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Equipment is Not Explosion Proof

DataLoggerTest Stand and equipment is notexplosion proof. Operation of equipment in ahazardous environment may result in explosionand death.

Do not operate this equipment in a hazardous environment.

W R 0 0 0 3 4 1 1 3 0 9 2

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Units With Hydraulics

Although the hydraulic pressures in this machine are low compared tosome hydraulically operated equipment, it is important to rememberthat a sudden hydraulic oil leak can cause serious injury, or even befatal if the pressure is high enough.

Escaping fluid under pressure can penetrate the skincausing serious injury. Keep hands and body awayfrom pinholes which eject fluid under pressure. Usea piece of cardboard or paper to search for leaks. Ifany fluid is injected into the skin, it must be immediatelyremoved by a doctor familiar with this type of injury.

NOTICE:Wear safety glasses, and keep face clear of area whenbleeding air from hydraulic system to avoid spraying oil into eyes.

Heater Is HotThe heater is hot and will burn clothing and skin.Keep the heater in its insulated heater shroud whennot in use, and use care when heating the pipe.

NOTICE:Use only a clean non-synthetic cloth to clean the heaterplates.

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Equipment Safety

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Electrical SafetyAlways ensure power cords are properlygrounded. It is important to remember that youare working in a wet environment with electricaldevices. Proper ground connections help tominimize the chances of an electric shock.

Frequently inspect electrical cords and unit for damage. Havedamaged components replaced and service performed by aqualified electrician.

Do not carry electrical devices by the cord.

NOTICE: Always connect units to the proper power source aslisted on the unit, or in the owner's manual. On units with twopower cords, plug each cord into separate power circuits. Do notplug into both outlets of one duplex receptacle.

NOTICE: Disconnect the machine from the power source beforeattempting any maintenance or adjustment.

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Calibrating the Heater Stand

Calibrating the Heater Stand

Turn on the calibration heaters on the DL8701 and DL8702 calibration stand and allow themto stabilize at their preset temperatures.

NOTICE:Avoid drafts, open doors, HVAC outlets, fans, etc. near the heater calibration stand.

Heater #4 is set to 550F and will take the longest to stabilize.

Beginning each day of calibrations, verify the accuracy of each heater by using the Flukedrywell temperature calibrator, turning each heater enable switch OFF as the RTD is removedfrom the heater butt plate and inserted into the Fluke tester. Turn on power to the Fluke DryWell and wait for it to indicate the process temperature. Press SET and use the and keys to select the desired preset. Press SET again, then press and hold EXIT until thedisplay goes blank. The drywell thermostat should be set to the desired temperature (400F,440F, 500F and 540F) and allowed to stabilize before checking the heater controllers.These heaters should be maintained as closely as possible to the default preset temperatures sothat the tolerance zone of the DataLogger is centered around the test heater reading.

If the reading from the Fluke drywell calibrator varies from the temperature controller, it may be

adjusted to match the controllers display by entering or changing the PVOF (process variableoffset) parameter value in the temperature controller being calibrated.

Changing the PVOF parameter value

Note the difference between the readings and which is greater, then press and hold thetemperature controller SEL button down for six seconds until P is displayed. Press thedown-arrow button until the PVOF parameter is displayed. Press SEL to display the valueof PVOF. Enter a negative value if the Fluke calibrator reading is less than the temperaturecontroller and a positive value if the Fluke calibrator reading is higher than the temperaturecontroller. Press SEL to enter the new value. Press and hold SEL again (approximately threeseconds until the SV set temperature is displayed, then release and press once again. Thisreturns the display to the PV (process variable), which should now closely match the Fluke

calibrator.Allow a few minutes to stabilize and repeat this procedure as necessary to match the readings.Adjust as required until the heater controller and the calibrator readings match after stabilizing.

EXAMPLE:If the temperature controller reading is 10F higher than the calibrator, enter a valueof (-10) to PVOF to correct for the error. This should be allowed to stabilize for several minutesand rechecked. If variance still exists, but the heater controller still displays 1F higher than theFluke calibrator, enter the PVOF parameter again and decrease the value by (-1), making thefinal value (-11). If necessary, repeat this process to further modify the PVOF setting until thereadings match consistently.

When the readings match satisfactorily, remove the RTD from the Fluke drywell calibrator

and replace it in it respective heater. Return the respective heater enable switch to the ONposition. Repeat this process for all four heaters and allow all heaters to stabilize at the newcalibrated settings before attempting to calibrate the DataLogger.

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Calibration DL3

Introduction

This software guide outlines procedure for calibrating McElroy DL3-series DataLogger. It is not intended to instructfusion operator on pipe fusing procedure. If necessary, please refer to the DataLogger manual for Bluetoothcommunication setup.

This document is to be kept confidential and only provided to McElroy authorized calibration centers and personnel.

Failure to comply with procedures outlined in this manual could cause data recording inaccuracy and invaliddocumentation.

Each McElroy authorized calibration center is required to assign a calibration technician to be trained by McElroyand certified to perform DL3 DataLogger calibration.

At the end of each calibration, the calibration technician is required to send a copy of the calibration data file toMcElroy at [email protected] for archive and documentation purposes.

McElroy reserves the right to conduct inspections of the calibration stand and calibration procedure performed bythe authorize calibration technician to ensure compliance and proficiency.TX02826-1-6-09

Update Firmware

If it has been determined prior to the calibration procedure that the firmware is obsolete, refer to Instruction SheetDL1210101 and perform the procedure to update.

Insert the batteries to power up the DataLogger and check for the red flashing LED. This is automatic after afirmware upgrade, but must be triggered with Calibration Plug DL9101 (DL6303 Wireless) or DL9102 (DL6304Wired) if not upgraded.

Remove the pressure transducer from the coiled cord and insert the proper plug in the cable connector. When thered LED flashes, remove the plug and proceed. It is recommended to leave the pressure transducer disconnectedfrom the DataLogger until the actual pressure calibration procedure begins.TX04312-6-28-11

Calibration Software

DL3-PPC software version 0.2.3 and newer include the calibrationfeature that enables each DL3 system (Recon and DataLoggerpair) to perform standalone calibration.

The software is written to guide the technician step-by-step.

Follow these steps to perform the calibration:

1. Tap Menu

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Calibration DL3

Calibration Software (continued)

2. Tap Settings...

3. Tap the word Portat least 4 times until the next screen appears.

4. Tap the thin grey line just below the heading "Check DataLogger"to gain access to the next screen.

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Calibration DL3


5. Bring up the keyboard to enter the access code calib1and tap OKtoaccess the "Calibration Parameters" screen

6. In the "Calibration Parameter" screen, enter name of technician doingthe calibration.

Enter company who owns the calibration stand and employ's thecalibration stand.

Check to make sure time and date are correct. If not, follow the onscreen instructions to adjust date and time.

NOTICE:It is very important to ensure correct date and time in order togenerate an accurate calibration certificate.

7. Scroll down and enter each of the data field associated with thepyrometer used as the temperature calibration standard.

Information required includes the model number, serial number,certificate number and the expiration date of the NIST certifiedinstrument used as the temperature calibration standard.

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Calibration DL3


8. Scroll down and enter each of the data field associated with thepressure calibrator.

Information required includes the model number, serial number,certificate number and expiration date of the NIST certified instrumentused as the pressure calibration standard.

9. Scroll down for the Pressure transducer serial number. This field is onlyrequired for McElroy factory calibration and kept for inventory andrepair records. It is not required for subsequent calibrations.

10. These instructions refer to the buttons at the bottom of the page.

If for any reason the technician does not want to proceed withcalibration, data entered can be saved.

P H 0 3 6 9 3

- 1 1 - 1 0 - 0 8

P H 0 3 6 9 4 - 1 1 - 1 0 - 0 8

P H 0 3 6 9 5 - 1 1 - 1 0 - 0 8


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Calibration DL3


11. Scroll down for calibration instructions.

The DataLogger and Recon Bluetooth radio must have been pairedbefore proceeding. Please refer to the DataLogger manual forinstructions on pairing information.

Follow the on screen instructions to activate calibration mode on theDataLogger.

Check and enter the serial number engraved on the side of theDataLogger.

NOTICE:It is very important to ensure the correct serial number is entered.

12. Scroll down for the final step in the calibration parameter entry screen.

13. At this point, the Recon becomes the user interface for the DataLogger.The DataLogger sends messages and instructions to guide thecalibration technician.

To begin the calibration process, press the multifunction button on theDataLogger and follow the prompts on the screen.

The calibration procedure must be follow in full in order to generate a

complete and valid calibration certificate. At the end of a properly executed calibration, a summary will be

presented, and the Recon sends an EXIT command to turn off theDataLogger.

You may scroll up and down the screen to review the calibration stepsand prompts.

Tap the Exitbutton to end the session.

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Calibration DL3


14. TapYesto exit calibration or tap Noto continue reviewing calibrationdata.

This concludes the calibration session, and the program goes back tothe "Settings" screen.

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Calibration DL3

Calibration Data File

Each calibration, complete or incomplete, produces a calibration data file.

The data file name starts with the DataLogger serial number, date and time of the calibration, and ends with a.mdc file extension.

File name example: MDL3-0085 2008-10-09 at 09-27-36.mdc

Calibration data files are stored in the \My Documents\Calibrationfolder, and can be viewed on the Recon.

Follow these steps to view calibration data files:

1. Tap Menu

2. Tap Settings...

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Calibration DL3

Calibration Data File (continued)

3. Tap the word Portat least 4 times until the next screen appears.

4. Tap onView Calibration Data.

5. Click on the data file name of interest.

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P H 0 3 7 0 0 1 1 1 0 0 8

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Calibration DL3

Calibration Data File (continued)

6. Use the scroll bars to scroll through the contents of the summary andsession log.

Tap Exitwhen done.

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Calibration Certificate

Calibration certificates can be printed using the DL3-XP software onWindows desktop and notebook PC. This is the same software used to viewand print joint reports.

Retrieving Calibration certificate requires the installation of MicroSoft Active-Sync on the desk PC or laptop. Post calibration test should be performedby connecting the PPC to the DataLogger and comparing temperatureand pressure readings to the preset heaters and pressure calibration gauge.

Perform a faux joint report by entering data necessary to trigger alogging function and track a range of pressures by raising the pressure in thepressure calibrator in steps to determine that the DataLogger is reading andtracking temperature and pressure properly.

1. To open a calibration data file, click the folder icon or click FilethenOpen.

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Calibration DL3

Calibration Certificate (continued)

2. Calibration files are not displayed by default. Click the Files of Typearrow and selectAll Files (*.*)to revealdata files with the ".mdc" file extension:

3. Select a data file to generate certificate by double-clicking the file name.

P H 0 3 7 0 4 - 1 1 - 1 0 - 0 8

P H 0 3 7 0 5 - 1 1 - 1 0

- 0 8


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Calibration DL3

Calibration Certificate (continued)

4. Once opened, the certificate can be inspected and printed by clicking the Printer icon.

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Calibration DL4

Introduction

This software guide outlines the procedure for calibrating a McElroy DL4 series DataLogger. It is notintended to instruct a fusion operator on pipe fusing procedure.

This document is to be kept confidential and only provided to McElroy authorized calibration centers andpersonnel.

Failure to comply with the procedures outline in this manual could cause data recording inaccuracy andinvalid documentation.

Each McElroy authorized calibration center is required to assign a calibration technician to be trained byMcElroy and certified to perform DL4 DataLogger calibration.

At the end of each calibration, the calibration technician is required to send a copy of the calibration datafile to McElroy at [email protected] for archive and documentation purposes.

McElroy reserves the right to conduct inspections of the calibration stand and calibration procedureperformed by the authorized calibration technician to ensure compliance and proficiency.TX04542-12-13-12

Connecting the Digital Pressure Sender to Your PC

To calibrate or update the firmware of your digital pressure sender, you must first connect it to your PC through yourPC's built in serial port or a USB to serial port converter.

If you have neither a built-in serial port nor a USB to serial port converter, McElroy recommends MKH00146 - USBto serial port converter.

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Digital Pressure Sender

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Calibration DL4

Calibrating the Digital Pressure Sender

To calibrate your McElroy digital pressure sender, youmust first connect it to your PC see instructions in sectionConnecting the Digital Pressure Sender to Your PC.

Once your digital pressure sender is connected to your PC,start the McElroy DL4 Firmware Update and CalibrationProgram. This program can be found your Start menusMcElroy folder.

Select the serial port name that corresponds to the physical port to which the digital pressure sender is connected.If you have several serial ports, you may have to try each until the correct one is found. In the example below, USBSerial Port (COM6) is the correct serial port. Your serial port may be different.

Click the open button and you should see the Serial #,Calibration Date, Firmware Version, and other fieldspopulate with information about your pressure sender.

Click the calibration button.

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Calibration DL4

Calibrating the Digital Pressure Sender (continued)

Enter the information for all fields on theCalibration Setup page, and then follow theon-screen instructions.

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Firmware Update

To update your McElroy digital pressure senders firmware,you must first connect it to your PC see instructions insection Connecting the Digital Pressure Sender to YourPC.

Once your digital pressure sender is connected toyour PC, start the McElroy DL4 Firmware Update andCalibration Program. This program can be found yourStart menus McElroy folder.

Select the serial port name that corresponds to the physical port to which the digital pressure sender is connected.If you have several serial ports, you may have to try each until the correct one is found. In the example below,

USB Serial Port (COM6) is the correct serial port. Your serial port may be different.

Click the open button and you should see the Serial #, Calibration Date, Firmware Version, and other fieldspopulate with information about your pressure sender.

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P H 0 4 8 2 6 1 2 1 3 1 2


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Calibration DL4

Firmware Update (continued)

Firmware updates may be found at McElroys sofwaredownload page. Click the Update Firmware button andselect the desired firmware file (.dl4f file). A dialog box

may appear with important information regarding thisfirmware update. Some firmware updates may requirere-calibration.TX04544-12-13-12

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Specifications

Specifications

Size: 36" W x 24" D x 53" H (Rack Assembly)

Space Requirements: 2' x 3' Floor space

2' x 2' Bench top space, Adjacent to Rack Assembly (For Pressure Calibrator and

Fluke Temperature Calibration

Power Requirements: 2 x 15A Dedicated Circuits 110 - 125VAC (DL8701)

1 x 15A Dedicated Circuits 220 - 240VAC (DL8702)

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About this manual . . .McElroy Manufacturing continually strives to give customers the best quality productsavailable. This manual is printed with materials made for durable applications and harshenvironments.

This manual is waterproof, tear resistant, grease resistant, abrasion resistant and the bondingquality of the printing ensures a readable, durable product.

The material does not contain any cellulose based materials and does not contribute to theharvesting of our forests, or ozone-depleting constituents. This manual can be safely disposedof in a landfill and will not leach into ground water.

TX001660-8-19-99


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