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DH Instruments PPC3 Operation And Maintenance Manual

Pressure controller/calibrator
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PPC3™
Pressure Controller/Calibrator
Operation and Maintenance Manual
© 2002-2007 DH Instruments, a Fluke Company

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Summary of Contents for DH Instruments PPC3

  • Page 1 PPC3™ Pressure Controller/Calibrator Operation and Maintenance Manual © 2002-2007 DH Instruments, a Fluke Company...
  • Page 2 Products described in this manual are manufactured under international patents and one or more of the following U.S. patents: 5,142,483; 5,257,640; 5,331,838; 5,445,035. Other U.S. and international patents pending. AutoRange, AutoZ, DH Instruments, DH, DHI, COMPASS, PPC, PPC3, QDUT, Q-RPT, RPM, RPM4, SDS and SPLT are trademarks, registered and otherwise, of DH Instruments, a Fluke Company.

  • Page 3: Table Of Contents

    O P E R A T I O N ..............1 5 USER INTERFACE ..........................15 3.1.1 MAIN RUN SCREEN............................15 3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL.................17 3.1.3 DIRECT PRESSURE CONTROL KEYS......................18 Page I © 2002-2007 DH Instruments, a Fluke Company...
  • Page 4 3.5.5.4 <4ID>................................70 3.5.5.5 <5LEVEL> (SECURITY)...........................70 3.5.6 <6PUNIT>..............................73 3.5.7 <7INTERNAL> .............................75 3.5.7.1 <1CONFIG> .............................75 3.5.7.2 <2CONTROL REF>..........................75 3.5.7.3 <3BARO> ..............................76 3.5.7.4 <4PURGE> ..............................77 3.5.7.5 <5LO VNT> ..............................77 3.5.8 <8CAL> ................................79 3.5.9 <9LOG>................................79 © 2002-2007 DH Instruments, a Fluke Company Page II...

  • Page 5: Table Of Contents

    ON-BOARD BAROMETER........................136 5.8.5 VACUUM SENSOR............................136 5.8.6 PRESSURE CONTROL MODULE ......................137 5.8.7 DISPLAY ..............................137 5.8.8 DRIVER BOARD ............................137 PNEUMATIC SCHEMATICS........................ 137 5.9.1 PRESSURE CONTROL MODULE ......................137 5.9.2 Q-RPT MODULE CONFIGURATIONS (PRESSURE MEASUREMENT) ..........138 Page III © 2002-2007 DH Instruments, a Fluke Company...
  • Page 6 G L O S S A R Y ..............1 4 9 © 2002-2007 DH Instruments, a Fluke Company...

  • Page 7: Tables

    Table 1. Reference Pressure Transducer (Q-RPT) Designations and Ranges .......... 2 Table 2. PPC3 Packing List ......................... 5 Table 3. Position Designators of Q-RPTs in a PPC3 System ..............24 Table 4. Settings and What They Are Specific To (Range, Measurement Mode, Q-RPT, System) ..25 Table 5.
  • Page 8 Figure 12. Pressure Control Module Schematic ..................137 Figure 13. Q-RPT Module Schematics for Various Configurations ............139 Figure 14. Drivers Connector Schematic....................145 Figure 15. Remote [ENT/SET P] Connector Schematic ................146 © 2002-2007 DH Instruments, a Fluke Company Page VI...

  • Page 9: A B O U T T H I S M A N U Al

    Before using the manual, take a moment to familiarize yourself with the Table of Contents structure: Sections 1, 2 and 3 should be read by all first time PPC3 users. Section 3 is most important for those using the local front panel interface but should be read over by all users to familiarize themselves with general PPC3 operating principles.
  • Page 10 PPC3™ OPERATION AND MAINTENANCE MANUAL © 2002-2007 DH Instruments, a Fluke Company Page VIII...

  • Page 11: 1. Introduction

    ASCII character command strings over an RS232 or IEEE-488.2 interface. PPC3 models are available to measure and control pressure in ranges from as low as - 3 to 3 kPa (0.4 psi) to as high as 0 to 10 MPa (0 to 1 500 psi) in absolute, gauge and compound gauge measurement modes.

  • Page 12: Pressure Measurement Specifications

    PPC3 internal valves and logic handle switching between the two Q-RPTs as needed. Q-RPTs are available with two different performance levels, STANDARD class and PREMIUM class. See the product label on the PPC3 rear panel, the label on the Q-RPT module on the rear panel and/or the product calibration reports to determine the class of the Q-RPTs installed in PPC3.
  • Page 13 (k=2) following the ISO “Guide to the Expression of Uncertainty in Measurement.” 4. Maximum deviation of the PPC3 controlled pressure from the true value including measurement uncertainty and dynamic control hold limit.

  • Page 14: Utility Sensor

    PPC3™ OPERATION AND MAINTENANCE MANUAL 1.2.2.2 UTILITY SENSOR Base PPC3 pressure controllers include a utility sensor. If a Hi Q-RPT (see Section 3.2.4) is installed, there is no utility sensor. Utility sensors are used for pressure control, system monitoring and safety functions.

  • Page 15: I N S T A L L A T I On

    UNPACKING AND INSPECTION 2.1.1 REMOVING FROM PACKAGING PPC3 is delivered in a corrugated container with high density polyethylene inserts to hold it in place; or in the optional molded, medium density polyethylene shipping case with a custom foam insert. Remove the PPC3 and its accessories from the shipping container and remove each element from its protective plastic bag.

  • Page 16: Site Requirements

    The PPC3 can be installed on any flat, stable surface at a convenient height. The front feet can be extended so that the unit can be inclined slightly for easier viewing. The PPC3 can also be mounted in a standard 19 in. rack using the optional rack mount kit.

  • Page 17: Front And Rear Panels

    11. Pressure Connection, TEST(+) 5. COM1 Connector 12. Pressure Connection, TEST(-) 6. Drivers (12 V) Connector 13. Pressure Connection, EXHAUST 7. Power Switch 14. Pressure Connection, SUPPLY Figure 2. Rear Panel Page 7 © 2002-2007 DH Instruments, a Fluke Company...

  • Page 18: Power Connection

    OFF. This is because when a supply pressure is applied to the PPC3 SUPPLY port and the PPC3 is NOT in the vent ON condition, there may be a constant gas exhaust through the PPC3 EXHAUST port.

  • Page 19: Connecting External Q-Rpts In Rpm4 Reference Pressure Monitors

    Q-RPT increases. To connect a PPC3 to an RPM4 to be used as part of the PPC3 system proceed as follows: Set up the RPM4 for use as an external device to PPC3 following the instructions in the RPM4 Operation and Maintenance Manual, Using RPM4 With a PPC3 Controller/Calibration Section.

  • Page 20: Connecting To The Device Under Test (Test(+) And Test(-) Ports)

    If you are using a self purging liquid trap (SPLT), see Section 2.3.8.1 before proceeding to connect the device under test. If the PPC3 has a G15K or BG15K Q-RPT, a dual volume unit (DVU) should be installed for very low pressure control. See Section 2.3.8.2 before proceeding to connect to the device under test.

  • Page 21: Installing A Self Purging Liquid Trap (Splt)

    Minimizing the length of the test connection tubing and restrictions in connections will enhance control performance and reduce pressure setting time. PPC3 pressure control will not operate properly if there are excessive leaks in the test system. In general, the maximum acceptable leak rate for optimal PPC3 automated pressure control operation and to assure in tolerance measurements with default pressure control parameters is ±...

  • Page 22: Installing A Dual Volume Unit (Dvu), G15K And Bg15K Q-Rpts

    2.3.9 THE VENT PORT The PPC3 VENT port is the system vent to atmosphere point used to set zero gauge pressure as well as to obtain Q-RPT measurements of atmospheric pressure. The PPC3 on-board barometer, if present is connected to the VENT port. Though a pressure hose can be...

  • Page 23: Power-Up And Verification

    2.4.1 SWITCH POWER ON Actuate the power switch on the PPC3 rear panel. Observe the front panel display as PPC3 initializes, error checks and goes to the MAIN RUN screen (see Section 3.1.1). PPC3 power-up condition is Internal, Hi Q-RPT or utility sensor active, VENT ON unless the pressure measured by the Hi Q-RPT is more than 20 kPa (3 psi) away from standard atmospheric pressure.

  • Page 24: Leak Check

    Shut OFF or disconnect the pressure supply. Shut OFF or disconnect the vacuum supply. Be sure the pressure supply is disconnected or the vacuum pump is bypassed from the PPC3 EXHAUST port before turning OFF the vacuum pump. © 2002-2007 DH Instruments, a Fluke Company...

  • Page 25: User Interface

    Figure 3 and its legend table summarize the PPC3 MAIN RUN screen fields and their functions. PPC3 has a screen saver function which causes the display to dim if no key is pressed for 10 minutes. Pressing a key restores full power to the display. The screen saver time can be changed or screen saving can be completely suppressed (see Section 3.5.5.1).

  • Page 26: Figure 3. Main Run Screen Display Fields

    PPC3 function. pressure unit/second Leading character <T>: Pressure control identifies the value. target <D>: Deviation from the pressure control target Figure 3. MAIN RUN Screen Display Fields © 2002-2007 DH Instruments, a Fluke Company Page 16...

  • Page 27: Function / Data Keypad Layout And Protocol

    3. OPERATION 3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL The PPC3 has a function/data keypad for local operator access to direct functions, function menus and for data entry. 1. The Function/Data keys allow very commonly 3. The Menu/Data keys provide access to...

  • Page 28: Direct Pressure Control Keys

    The optional remote ENTER function is a switch that duplicates the function of the front panel [ENT] key. The remote ENTER function is serviced by a connector on the PPC3 rear panel labeled REMOTE ENTER. An optional footswitch is available to activate remote entry hands free or a user supplied switch may be used.

  • Page 29: Sounds

    Pressure control parameters for each control mode are automatically set to optimal default values for the operating PPC3 range when the range is selected or AutoRange is used (see Section 3.3.4). Control parameters can be customized using the [SETUP], <6control>...

  • Page 30: Figure 6. Dynamic Pressure Control Operation

    Not Ready condition occurs (see Section 3.2.2) and pressure is readjusted to the target value (see Tables 6 and 7 and Section 3.3.6 for setting the hold and stability limits to user defined values). Figure 7. Static Pressure Control Operation © 2002-2007 DH Instruments, a Fluke Company Page 20...

  • Page 31: Pressure Ready/Not Ready

    3.2.2 PRESSURE READY/NOT READY There is a Ready/Not Ready indication LED on the PPC3 front panel. This indication is intended to provide the user with a clear and objective criterion for determining when a valid pressure measurement can be made.

  • Page 32: Gauge And Negative Gauge Modes With An Axxx (Absolute) Q-Rpt, Dynamic Compensation For Atmospheric Pressure

    AutoZ routine that measures P , is run offset,G automatically whenever the PPC3 is in the vented condition. This assures the continuous automated updating of the P value corresponding to atmospheric pressure. Gauge offset,G pressure is the measured absolute pressure, P , minus the atmospheric offset.

  • Page 33: Multiple Internal And External Q-Rpts

    Pressure Transducers (Q-RPT). Up to six Q-RPTs can be included in a PPC3 pressure controller/calibrator system. One or two Q-RPTs can be built into the PPC3, up to four may be located outside the PPC3 enclosure, in RPM4 reference pressure monitors (one or two per RPM4).

  • Page 34: Multipe Ranges (Q-Rpts, Autorange And Infinite Ranging)

    2 RPM4 on the PC3/RPM4 communications daisy chain * The display symbol is included in the upper, right hand corner of most PPC3 displays and menus as a convenient indicator of the active Q-RPT. 3.2.5 MULTIPE RANGES (Q-RPTS, AUTORANGE AND INFINITE RANGING) A PPC3 range is defined as a pressure span and associated settings.

  • Page 35: Operation With A Pg7000 Piston Gauge

    PG7000 when it is in “AutoGen” mode (see the PG7000 Operation and Maintenance Manual). The PPC3 may also be operated manually using its direct pressure control keys (see Section 3.1.3). 3.2.7 DIRECT FUNCTION KEYS SUMMARY Local operation of PPC3 is through the front panel keypad.

  • Page 36: Direct Function Keys

    PPC3™ OPERATION AND MAINTENANCE MANUAL whenever PPC3 is in its MAIN RUN screen. Table 5 summarizes the operation of the direct function keys and Sections 3.3.1 through 3.3.10 detail their operation. Table 5 provides a brief summary of direct function key operation. It may be useful to keep a copy of this summary near the PPC3, especially when first becoming acquainted with its operation.
  • Page 37 PPC3 must be vented for the range change to occur. Press [VENT] if necessary to complete the range change. When selecting a range, if the range’s Q-RPT is an external Q-RPT and the PPC3 cannot communicate with it, PPC3 displays <Cannot find range’s external Q-RPT (Xn)>.

  • Page 38: Unit]

    TEST(+) port is connected to the PPC3 TEST(+) port. If the external Q-RPT is NOT connected to the PPC3 TEST(+) port, it will not measure the pressure generated by PPC3 and PPC3 may reach a pressure higher than the target pressure before its watchdog function recognizes that the external Q-RPT is not connected.

  • Page 39: Mode]

    The default pressure units of measure available under the UNIT function depend on whether the PPC3 has been set up as an SI or US version (indicated by SI or US at bottom right of introduction screen). The choice of six units available under the UNIT function can be customized from a wider selection by the user (see Section 3.5.6).

  • Page 40: Autorange]

    (see Section 3.3.1). PRINCIPLE PPC3 is designed to support the calibration and test of a very wide variety of test ranges in various measurement modes with a single pressure controller system. The AutoRange function simplifies the task of selecting the Q-RPT best suited to cover a specific test range and setting controller parameters appropriately for the range.

  • Page 41: Table 6. Settings Made By Autorange

    100 ppm of AutoRange span 3.3.3 Q-RPT turn down Turn down Q-RPT See Premium Q-RPT pressure 1.2.2.1 (Premium class Q-RPTs only) characterization to improve measurement specifications measurement uncertainty when span is reduced Page 31 © 2002-2007 DH Instruments, a Fluke Company...
  • Page 42 Before operating PPC3 with external Q-RPTs, check carefully that the Q-RPT TEST(+) port is connected to the PPC3 TEST(+) port. If the external Q-RPT is NOT connected to the PPC3 TEST(+) port, it will not measure the pressure generated by PPC3 and PPC3 may reach a pressure higher than the target pressure before its watchdog function recognizes that the external RPT is not connected.

  • Page 43: Rpt]

    Also, pressing [RPT] initiates the Q-RPT search and allows the Q-RPTs that are available to PPC3 to be viewed. Use [RPT] to keep the PPC3 system configuration current if you connect and disconnect Q-RPTs without turning PPC3 power OFF and ON.

  • Page 44: Autotest]

    <PPC3 EXT DEV: ACTIVE> (if RPM4 is initialized by PPC3 and is currently in use) After using an RPM4 as an external device for a PPC3, cycle power to return to the previous RPM4 settings, restore front keypad capability and return to the normal MAIN RUN screen.

  • Page 45: Quick Autotest

    (see Section 3.4.4) or change to a higher range if available (see Section 3.3.1). To AutoRange the PPC3 automatically for a specific sequence based on the characteristics of a DUT, use a QDUT Test (see Section 3.3.6.2).
  • Page 46 <1up> causes the sequence to run from the low pressure to the FS pressure through zero and <2down> causes the sequence to run from FS to the low pressure through zero. © 2002-2007 DH Instruments, a Fluke Company Page 36...
  • Page 47 If the sequence was set up with <Next increment on ENTER>. Press [ENT] to continue to the next increment. After the last point of the test sequence has been executed, PPC3 vents and operation returns to the main run screen.

  • Page 48: Qdut Autotest

    1dynamic 2static to be run (see Section 3.4.6). Select the pressure control mode that is to be used by the PPC3 when running the test points.. The next display is the selection of the...
  • Page 49 This entry determines the maximum pressure of the QDUT Test sequence. Enter the maximum pressure and press [ENT]. Sequence full scale must be achievable by a QRPT available to PPC3 or an error will occur when PPC3 attempts to AutoRange to the specified full scale.
  • Page 50 The cursor keys or the [RPT] key can be used to toggle through other Q-RPTs available to cover the QDUT specified range and measurement mode. When the desired Q-RPT is displayed, press [ENT] to accept the proposed AutoRange. © 2002-2007 DH Instruments, a Fluke Company Page 40...
  • Page 51 Pressing [ESC] twice returns to the MAIN RUN screen without sequence execution (this feature can be used to AutoRange the PPC3 based on DUT characteristics without running a specific test sequence. Pressing [ENT] causes sequence execution to proceed.

  • Page 52: Head]

    PPC3 in order to predict the pressure actually applied at a different height. PPC3 can calculate head pressures for nitrogen, helium and air as the test gas over its working pressure range. The HEAD function allows the height difference to be specified and causes the resulting head pressure to be added to the pressure measured at the TEST port.

  • Page 53: Purge]

    Pressure control stops and a 5 second wait occurs. SPLT exhaust valve is opened. PPC3 waits until pressure is less than 20 kPa (3 psi) gauge or 110 kPa (16 psi) absolute. Page 43 © 2002-2007 DH Instruments, a Fluke Company...
  • Page 54 PPC3 internal vent valve is opened with the SPLT exhaust valve left open. The PURGE function makes use of the PPC3 valve driver option. Valve driver number 8 is used to actuate the SPLT exhaust valve. When making use of valve drivers, note that if the PURGE function is enabled, valve driver number 8 will be actuated independently of valve driver commands.

  • Page 55: Leak Ck]

    Do not plug the SPLT exhaust valve. The purge routine can not be completed with the SPLT exhaust valve plugged and the SPLT’s protective function will not be effective. If the SPLT is electrically connected to the PPC3, its exhaust valve will always be open when the PPC3 vent valve is open.
  • Page 56 To view the results of the most recently completed leak check, press <2view>. If NO leak check data is stored (i.e., if the PPC3 has never run a leak test or a reset has cleared previous leak test results), the results screen displays <Data NOT available> briefly and returns to MAIN RUN screen.

  • Page 57: Ent/Set P] (Set Pressure Automatically)

    A target pressure entry that exceeds the current upper limit (see Section 3.4.4) or that is out of range will not be accepted as the target value. If PPC3 is unable to control pressure or appears to control pressure poorly, see Section 6 to troubleshoot.

  • Page 58: Interrupting Automated Pressure Control

    How low the pressure in the PPC3 and the system connected to the PPC3 TEST(+) will go is a function of the quality of the vacuum pump used, the characteristics of the volume connected to the TEST(+) port and PPC3’s internal restrictions.

  • Page 59: Setup]

    NOT be interpreted as meaning that the pressure is zero within the hold limit. Ready is an indication that the rate of change of pressure inside PPC3 has reached the current stability limit. The current pressure measured by PPC3, not zero, should be used as the value of pressure applied to the device or system under test.

  • Page 60: Saving An Autorange Range

    <Delete all saved ranges?> query. If not, respond <2no>. 3.4.2 <2RES> (RESOLUTION) PURPOSE To set the resolution with which measured pressures and other pressure indications and settings are displayed. © 2002-2007 DH Instruments, a Fluke Company Page 50...

  • Page 61: 3Jog

    3. OPERATION PRINCIPLE The resolution with which PPC3 displays pressure values can be adjusted. This feature can be used to reduce the resolution when lower precision measurements are being made and excess resolution might confuse or distract the operator. The resolution setting determines the number of digits with which pressure is displayed.

  • Page 62: 4Ul> (Upper Limit)

    Automated pressure control targets greater than the upper limit or lower than the lower limit are not accepted. When the pressure measured by PPC3 exceeds the upper limit or lower limit, automated or direct manual pressure control is aborted and an intermittent warning beep sounds.

  • Page 63: Over Pressure Function

    The BG15K Q-RPT negative over pressure limit is - 17.5 kPa (- 2.3 psi). When PPC3 is using an external Q-RPT in an RPM4, the PPC3 utility sensor or Hi Q-RPT acts as a watchdog. If the watchdog measures a pressure greater than the maximum pressure of the active external Q-RPT, PPC3 executes the overpressure function.

  • Page 64: 5Atest

    Data File Protocol Up to ten QDUT AutoTest data files are buffered, ten at a time, in PPC3 memory. When a new test is completed, its data file goes to the front of the queue and the oldest data file is deleted.

  • Page 65: 6Control

    When a control mode is selected using the CONTROL function, CONTROL parameters are automatically set to default values for the active range (see Table 7 for definition of PPC3 default control parameters). The default control parameters have been determined to be most suitable for the typical user to operate within PPC3 pressure control and measurement specifications.

  • Page 66: Limits> (Custom Control Parameters)

    [SETUP], <6control>, <1limits> from the MAIN RUN screen (see Section 3.4.6.1). Control mode setting is range specific. A change in control mode made while in one PPC3 range does NOT affect the control mode setting in other ranges.

  • Page 67: Turning-Off Custom Control Parameters

    <1momentary> or <2toggle>. The PPC3 PURGE function makes use of the valve driver option. Valve driver number 8 is used to actuate the SPLT exhaust valve. The SPLT exhaust valve Is actuated when performing the PURGE function and in the background every time the PPC3 VENT function is used.

  • Page 68: Special]

    PRINCIPLE AutoZ Purpose and Principle The main component of the change over time of the PPC3 Q-RPTs is change in zero or offset, independent of span. Offsetting or “rezeroing” PPC3 Q-RPTs relative to a reference between recalibrations allows measurement uncertainty specifications to be maintained with less frequent full calibrations.
  • Page 69 AutoZeroed. For higher range Q-RPTs, this is easily accomplished with a variety of digital barometers or with a lower range Q-RPT in the PPC3 system. For lower range Q-RPTs, a piston gauge or other standard may be required to provide P with low enough uncertainty.

  • Page 70: Table 8. Autoz On And Off

    P reference. offset • In absolute measurement mode: Run AutoZ at least every 30 days or when PPC3 has been exposed to temperature changes exceeding 15 ºC (36 ºF). © 2002-2007 DH Instruments, a Fluke Company Page 60...
  • Page 71 The AutoZ function and values are Q-RPT AND measurement mode (gauge/negative gauge or absolute) specific. When AutoZ is run for an external Q-RPT in an RPM4, the PPC3 causes the RPM4 to run its own AutoZero routine. The RPM4 Q-RPT is then AutoZeroed as if it had been AutoZeroed independently of the PPC3.

  • Page 72: Edit Autoz

    (see Section 3.5.1.2). <4run> is only applicable to Axxx (absolute) Q-RPTs in std,0 absolute measurement mode. AutoZ is run automatically without operator intervention in gauge and negative gauge measurement modes whenever PPC3 is in the VENT condition (see Section 3.2.3, PRINCIPLE).

  • Page 73: 2Remote

    COM1 and COM2 communications. To select remote programming communications format. PRINCIPLE The PPC3 has two RS-232 communications ports referred to as COM1 and COM2 and a single IEEE-488 (GPIB) port. COM1 or the IEEE-488 port is for communicating with a host computer (see Section 4), and COM2 is reserved for communicating with an external device (i.e.

  • Page 74: 1Com1> And <2Com2

    The receiving terminating character must be a line feed and EOI. Carriage returns are ignored if received. The PPC3 sends a line feed and asserts the EOI line to terminate a reply. These settings are fixed to agree with IEEE Std. 488.2. If you change the address, the IEEE interface will reset (PON) and become idle.

  • Page 75: 5Rs232 Self-Test

    From the MAIN RUN screen, pressure [SPECIAL], <3Head>. Select the desired height unit of measure and press [ENT]. Select the type of gas that is being supplied to PPC3 and press [ENT]. The characteristics of the gas selected will be used by PPC3 in calculating head pressures.

  • Page 76: 4Reset

    This clears out any settings that the user has made, and should be used only to restore the PPC3 to a known state. PPC3 goes through its power up sequence after any type of reset is executed.

  • Page 77: 2Units

    PURPOSE Sets the six pressure units available under the UNIT function to the SI or US default selections depending on whether the PPC3 has been factory set for SI or US (see Section 3.3.2). Sets the user defined unit to 1.000/Pa (see Section 3.5.6).

  • Page 78: 5All

    Combines all resets in one global reset command that clears the entire user section of non-volatile memory returning PPC3 to the “as delivered” condition except the ID function (see Section 3.5.5.4) and the security level password (see Section 3.5.5.5).

  • Page 79: 1Scrsvr

    To adjust the idle time after which PPC3’s SCREEN SAVER activates. PRINCIPLE PPC3 has a SCREEN SAVER function which causes the display to dim after a front panel key is NOT pressed for a certain amount of time. The default screen saver time activates the screen saver after 10 minutes.

  • Page 80: 4Id

    TIME and DATE functions to set your local time and date. 3.5.5.4 <4ID> PURPOSE To view or edit the PPC3 user ID and to view the PPC3 serial number. OPERATION To access the ID function press [SPECIAL] and select <5prefs>, <2ID>. Select <1view> to view the current ID.
  • Page 81 For these reasons, depending upon the application in which PPC3 is being used, it may be desirable to restrict access to certain functions for certain users. The user level function provides a means of restricting access to certain functions.

  • Page 82: Table 12. Security Levels

    [SPECIAL], <8cal>, <2edit> under any selection • • • [SPECIAL], <9log>, view • [SPECIAL], <9log>, clear log • • • Remote communications disabled • “•” indicates the function/menu is NOT accessible. © 2002-2007 DH Instruments, a Fluke Company Page 72...

  • Page 83: 6Punit

    3. OPERATION OPERATION PPC3 is delivered with no active password and access to the User Level menu is open. The user level is set to <1Low>. User levels can be changed freely until a password has been created. access LEVEL...

  • Page 84: Table 13. Unit Function - Available Units Of Measure

    PPC3™ OPERATION AND MAINTENANCE MANUAL using [SPECIAL], <6PresU>. This allows PPC3 to offer a very wide selection of units while simplifying day to day operation. The typical user customizes the [UNIT] function key to support his/her six most commonly used units.

  • Page 85: 7Internal

    EXHAUST port condition. PRINCIPLE The PPC3 exhaust (down) control valves and the output of the exhaust pressure regulator are connected to the PPC3 EXHAUST port (see Figure 12). The response of the pressure control module, particularly when controlling pressure near and under atmospheric pressure, changes depending on whether the EXHAUST port is connected to a vacuum source or left open to atmosphere.

  • Page 86: 3Baro

    It also allows viewing of the current status of the EXHAUST port. The normal condition of the ControlRef function is <1auto>. In this condition, the operator need not be concerned with informing the PPC3 of EXHAUST port pressure conditions as PPC3 determines the existing condition automatically.

  • Page 87: 4Purge

    PPC3 measurement uncertainty does not depend on the measurement uncertainty of the on-board barometer. OPERATION PPC3’s that have only Gxxx Q-RPTs (no Axxx or BGxxx) are NOT equipped with an on-board barometer. To view the current reading of the on-board barometer press [SPECIAL], <7internal>, <3baro>.
  • Page 88 In normal RPM4 operation as an external device to a PPC3, the TEST(- ) valve is normally closed. It is only opened when PPC3 is controlling with coarse pressure control.

  • Page 89: 8Cal

    Pmax! of an internal PPC3 Q-RPT or utility sensor is exceeded (see Section 3.4.4.1). • A memory fault occurs. Over pressure events on external Q-RPTs are not logged on the PPC3. They are logged in the RPM4’s log (see the RPM4 Operation and Maintenance Manual). OPERATION To view the event log press [SPECIAL], <9Log>.
  • Page 90 PPC3™ OPERATION AND MAINTENANCE MANUAL © 2002-2007 DH Instruments, a Fluke Company Page 80...

  • Page 91: Overview

    Sending a program message to the PPC3 places it into remote mode. The remote indicator to the right of the display window lights when the PPC3 is in remote mode. It will also flicker when a program message is received. The menus usually accessed from the front panel are locked out while in remote.

  • Page 92: Ieee-488

    The main difference between the two formats is that when using the IEEE-488 interface, a “?” must be included in an enhanced command for there to be a response from the PPC3. In all other cases (classic or enhanced), every command has a response. In addition, the enhanced message format supports IEEE Std 488.2 syntax, format and status reporting.

  • Page 93: Classic Program Message Format

    PPC3 in the form of comma delimited arguments. This data is usually a setting of some sort that is stored in the PPC3. If data is specified, it must be preceded by at least one white space from the program message header and be within the range and format described in the program message description.

  • Page 94: Using Query Type Commands

    You must wait for a reply with a query. If you send any type of program message to the PPC3 after a query before receiving a reply, the program message will be discarded and an error will be generated. Errors are reporting using the IEEE Std.

  • Page 95: Commands

    Read the last PPC3 pressure, rate and ATM. RANGE Read or set the active range (PPC2+ legacy command). RANGE Read or set and Q-RPT or utility sensor default range (PPC3 command). RATE Read the next available rate of change of pressure. READYCK Read or set a flag that is cleared by a Not Ready condition.

  • Page 96: Error Messages

    Read or set the exhaust reference status flag. VENT Read, execute or abort a vent process. Read the PPC3 software version. PPC2+ legacy command. No function in PPC3. ZNATERRn:HI PPC2+ legacy command. No function in PPC3. ZNATERRn:LO Read or set the AutoZero P for the specified Q-RPT.

  • Page 97: Program Message Description Overview

    Classic This is the Classic program message syntax to send data to the PPC3, to execute a PPC3 function, or to query for data. The PPC3 must be set to use the classic format (see Section 3.5.2.3). The command may be followed by a ‘(=)’ and additional argument characters to show that argument(s) can be passed.

  • Page 98: Program Message Descriptions

    The PPC3 COM2 port can be used to communicate to another RS232 device (such as another PPC3). This allows the user to use one COM port or IEEE-488 port on the host computer to communicate with the PPC3 and another device. A carriage return and a line feed (<CR><LF>) are added to the string.
  • Page 99 “X2L”: Second external RPM4, Lo Q-RPT Remarks The ARANGE command is used to define a PPC3 range by specifying a desired unit of measure, measurement mode and maximum pressure, and have the PPC3 pick the best available Q-RPT and make operational adjustments to optimize that range. Available Q-RPTs may be determined by the use of the “RPT”...
  • Page 100 ’1’ To enable AUTO mode. This will override the manual selection. Remarks At low pressures, PPC3 control is affected by whether the EXHAUST port is open to atmosphere or connected to vacuum. The PPC3 has an internal sensor that can be used to automatically determine if the EXHAUST port is open to atmosphere or to a vacuum.
  • Page 101 ’1’ Autozero ON Remarks The PPC3 AutoZ function can be turned ON and OFF. There is a separate AutoZ flag for the gauge and absolute modes for each RPT. This command sets the AutoZ status for the current mode of the active internal or external RPT only.
  • Page 102 COM2 is generally used to connect DHI RPM4 external measurement devices. The COM2 port can also be used to allow the host computer to communicate through the PPC3 to an additional device connected to COM2. This can be useful if the host computer does not have 2 serial ports available.
  • Page 103 The slow speed will be used for a calculated amount of time (up to 5 seconds) to create the desired change. The PPC3 will not attempt to control the pressure to a target, so the change in pressure will be approximate. This is the equivalent of using the step up direct pressure control key.
  • Page 104 The fluid type. This must be “N2”, “Air”, “He”, “Oil”, “H2O”, or “User”. Remarks The PPC3 can make a fluid head correction to allow it to display the pressure at the level of the device under test instead of at the level of the PPC3.
  • Page 105 An alphanumeric string up to 12 characters long. Remarks The user defined ID label can be used to allow the user to “tag” the PPC3 with a unique identifier. This ID is stored in non-volatile memory and cannot be erased by a power failure, system fault or...
  • Page 106 The slow speed will be used for a calculated amount of time (up to 5 seconds) to create the desired change. The PPC3 will not attempt to control the pressure to a target, so the change in pressure will be approximate. This is the equivalent of using the step down direct pressure control key.
  • Page 107 Value is always a negative value of gauge pressure. Remarks Negative gauge mode in PPC3 has a lower limit. New automated pressure control targets can not be less than this value. If the pressure exceeds the lower limit, the pressure display flashes, and pressure control is aborted.
  • Page 108 ’1’ for dynamic pressure control. Remarks The method which the PPC3 controls pressure is selected with the “MODE” program message. When the control mode is set, control parameters go to default parameters for that range. The control mode setting is range dependent.
  • Page 109 ‘AUTO’ for the PPC3 to automatically open and close the low vent valve. Remarks A PPC3 with at least one Gxxx or BGxxx Q-RPT has a low vent valve that is used to vent the TEST(-) port. This valve is normally controlled automatically depending on current PPC3 operation but it can be commanded to open or close using the “NVENT”...
  • Page 110 A carriage return and a line feed (<CR><LF>) are added to the string that is sent. The Query format is used to check the PPC3 COM2 receive buffer to see if a message has been received on COM2 from the device. The message received by the COM2 port must be terminated with a carriage return or a carriage return and a line feed.
  • Page 111 After receiving this program message, the PPC3 replies back with the data after a new pressure measurement cycle is complete. This can take up to 1.5 seconds.
  • Page 112 The PPC3 sets the specified target pressure using the current control settings and mode. Control continues until a new target pressure is set, the PPC3 goes into LOCAL mode, or an “ABORT” program message is executed. If the given target is ‘0’ and the pressure units are gauge, the PPC3 vents.
  • Page 113 The target pressure in the current pressure unit of measure. Remarks The PPC3 sets the given target pressure using just the fast speed, and stops controlling when the pressure has reached or passed the given target. The system does not attempt to maintain the target pressure.
  • Page 114 “RPT” command or function key before the can be selected The reply indicates the active range in psi if the PPC3 is a “US” version or in kPa if the PPC3 is an “SI” version.
  • Page 115 “READYCK” Remarks The internal ready check flag is cleared whenever the PPC3 reaches a Not Ready (NR) condition. The “READYCK” query returns the status of the flag. The flag is set by sending the “READYCK 1” program message while the PPC3 is in a Ready condition. The “READYCK”...
  • Page 116 “RESET” Remarks The PPC3 has user settings (units, resolution, control modes, etc.) that can be reset to factory defaults. System calibration coefficients and communications settings are not affected. The remote “RESET” program message corresponds to the front panel “Reset - Sets.” The reset cycle takes up to 3 seconds to complete.
  • Page 117 The second external RPM4, Lo Q-RPT Remarks Up to six Q-RPTs can be available for use in one PPC3 system. Two of these can be internal, and the other four are external. These Q-RPTs must be identified and initalized before the can be used by the PPC3.
  • Page 118 Remarks The stability limit can be read and set as a percent of the full scale range of the Q-RPT range. If this program message is used to set the stability limit, the PPC3 will then use CUSTOM control settings.
  • Page 119 The time in a 12 hour format using a colon delimiter ”am” or “pm” Remarks The PPC3 has an internal real time clock. It is used for date stamping calibrations and log data. Example Cmd sent: “TIME 12:52PM” (enhanced) Query reply: “12:52pm”...
  • Page 120 The upper limit pressure in the current pressure unit and measurement mode. Remarks The PPC3 has an upper limit for each range and for each measurement mode (gauge and absolute). New automated pressure control targets cannot be greater than this value. If the pressure does exceed the upper limit, the pressure display flashes, and pressure control stops.
  • Page 121 Remarks The PPC3 has an internal sensor that determines if the EXHAUST port is open to atmosphere or to vacuum. You can manually override it if desired. The query can also be used to see the sensor status (if auto is enabled). If the auto function is disabled, then the query returns the last VAC setting.
  • Page 122 “VER?” Classic “VER” Remarks The software version of the PPC3 can be read. This is useful for checking for the presence of the PPC3 and for reference purposes. It indicates the internal Q-RPT(s) and software version. Example Query sent: “VER?”...
  • Page 123 PPC3. There is a separate offset for gauge and absolute measurement modes. Using this program message will overwrite the current offset, so caution must be used. Changes made using this program message take effect immediately.

  • Page 124: Status Reporting System

    4.5.1 ERROR QUEUE The PPC3 keeps track of remote errors by using an error queue. If an error occurs, it is pushed onto the Error Queue. If you are using the COM1 port, the error number is immediately replied in the form “ERR#nn where nn is the error code from 0 to 99. The “ERR?” (or “ERR”) query can then be used to pull the error from the Error Queue in it’s descriptive text format.

  • Page 125: Standard Event Register

    Indicates that the SRQ line of the IEEE-488 interface has been asserted by the PPC3. This bit is cleared when a serial poll is performed on the PPC3, and is a part of the Status Byte Register when read using a serial poll. This bit does not apply if the COM1 port is being used.

  • Page 126: Ready Status Register

    This is typically caused by a program message being sent to the PPC3 without reading a waiting reply. Request Control (Bit 1) This bit is not supported as the PPC3 cannot become the active controller in charge. Operation Complete (Bit 0) Indicates that the PPC3 has completed all requested functions.

  • Page 127: Ieee Std. 488.2 Common And Status Program Messages

    IEEE STD. 488.2 COMMON AND STATUS PROGRAM MESSAGES The PPC3 supports a set of commands that are common to all instruments conforming to IEEE Std. 488.2. These command make it easy to perform basic function for any device that supports these commands.
  • Page 128 (as if the “∗RST” program message was executed), and the ∗TST query will return a non zero value. If the PPC3 passed the test on power-up OR if the ∗TST query was used at least once since the PPC3 was powered up the reply will be a ‘0’.
  • Page 129 Read the Ready Status Register. Command “RSR?” Remarks The Ready Status Register contents are cleared after reading. The reply is in decimal numeric form. Example Sent: “RSR?” (enhanced) Reply: “6” (The MEAS and NRDY) Page 119 © 2002-2007 DH Instruments, a Fluke Company...
  • Page 130 PPC3™ OPERATION AND MAINTENANCE MANUAL © 2002-2007 DH Instruments, a Fluke Company Page 120...

  • Page 131: Overview

    Chapter 6. PPC3 is covered by a limited one (1) year warranty. Unauthorized service or repair during the warranty period is undertaken at the owner’s risk and may cause damage that is not covered under warranty and/or may void the warranty.

  • Page 132: Pa And Pm Coefficients

    PM values can cause out of tolerance measurements. A new PPC3 is delivered with PA and PM values set to zero and 1 for all ranges. This does not mean that the PPC3 has not been calibrated. In the original factory calibration, privileged factory coefficients are used for calibration with the user PA and PM set to zero and 1.

  • Page 133: Equipment Required

    (the readings that the transducer would have made with the old PA, PM and P offset A new PPC3 is delivered with PA and PM values set to zero and 1 for all ranges. This does not mean that the PPC3 has not been calibrated. In the original factory calibration, privileged factory coefficients are used for calibration with the user PA and PM set to zero and 1.

  • Page 134: Set-Up And Preparation

    To set-up and prepare the PPC3 for calibration of an internal Q-RPT: Set the PPC3 on a stable surface near the calibration standard at a height as close as possible to the calibration standard’s reference height. Consider the connections that may need to be made to the rear panel and access to the front panel display and keypad.

  • Page 135: Standard Class Q-Rpts

    (positive pressures) measurement mode only. Use the gauge mode (Gxxx) calibration point sequence (see Table 22). BGxxx Q- RPTs calibrated in gauge measurement mode only should not be used in negative gauge mode. Page 125 © 2002-2007 DH Instruments, a Fluke Company...

  • Page 136: Premium Class Q-Rpts

    Axxx (absolute) Q-RPTs calibrated in gauge measurement mode by applying gauge reference pressure values should be used in gauge mode only (see Section 5.2.5). © 2002-2007 DH Instruments, a Fluke Company Page 126...

  • Page 137: Turning Off Absolute And Negative Gauge Measurement Modes For Axxx (Absolute) Q-Rpts

    To access the Q-RPT calibration editing area press [SPECIAL], <8cal> and select the desired Q-RPT. Then select <1edit> to make changes. Page 127 © 2002-2007 DH Instruments, a Fluke Company...

  • Page 138: Q-Rpt Calibration Using Caltool For Rpts Software

    PPC3 may also use external Q-RPTs mounted in RPM4 Reference Pressure Monitors. Viewing and adjustment of RPM4 calibration information is performed locally on the RPM4, not through PPC3 (see the RPM4 Operation and Maintenance Manual). 5.2.6 Q-RPT CALIBRATION USING CALTOOL FOR RPTS SOFTWARE To calibrate PPC3 Q-RPTs using CalTool software, refer to Sections 5.2.1,...
  • Page 139 5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION A new PPC3 is delivered with PA and PM values set to zero and 1 for all ranges. This does not mean that the PPC3 has not been calibrated. In the original factory calibration, privileged factory coefficients are used for calibration with the user PA and PM set to zero and 1.

  • Page 140: Q-Rpt Calibration/Adjustment Without Caltool For Rpts Software

    Perform a linear regression to find the offset and slope that best fit the non-corrected PPC3 readings to the calibration standard pressures. The offset is the new value of PA, the slope is the new value of PM. Press [SPECIAL], <8Cal>, <1Q-RPT>, <2edit> and write the new calibration date and the new values of PA and PM for the Q-RPT and range calibrated.

  • Page 141: Adjustment Of On-Board Barometer

    PURPOSE To adjust the output of the on-board barometer (see Section 1.2.2.3). PPC3’s that have only Gxxx Q-RPTs (no Axxx or BGxxx) are NOT equipped with an on-board barometer. PRINCIPLE The on-board barometer output can be adjusted using PA and PM values in the same manner as Q-RPTs (see Section 5.2.1.1).

  • Page 142: Pneumatic Control Module Configuration ()

    Connect the normal supply pressure to the rear panel SUPPLY port and perform a leak check. If the PPC3 Hi Q-RPT or utility sensor is an A350K or lower, the configuration routine should be run twice, once with a vacuum source attached to the EXHAUST port and once without. If the PPC3 Hi Q-RPT or utility sensor is greater than A350K, the configuration routine can be run with or without a vacuum pump connected to the EXHAUST port (use your most common configuration).

  • Page 143: Overhaul

    If the PPC3 has a Hi Q-RPT less than or equal to A350K, repeat the configuration routine in the other operating mode (<1vac> or <2atm>). If you never use the PPC3 in one of the two conditions, it is not necessary to configure it in that condition.

  • Page 144: Reloading Embedded Software Into Flash Memory

    SOFTWARE located under SUPPORT. A FLASH loading utility and the latest PPC3 software are available for download at no charge. If you do not have access to the web or have difficulty downloading or loading software, contact your DHI representative or a DHI Authorized Service Provider for assistance.

  • Page 145: Subassembly Description And Location

    The micro board supports a Motorola 68302 micro-controller, EPROM, EEPROM, 128k x 16 bit NVRAM, 8 Mbit flash memory; RS-232 and IEEE-488.2 communications; keypad and display control. An I/O port controls other ports and devices in RPM4. Page 135 © 2002-2007 DH Instruments, a Fluke Company...

  • Page 146: Q-Rpt Module

    5.8.3.1 HI Q-RPT OR UTILITY SENSOR The higher range pressure transducer in a PPC3 may be a Q-RPT (quartz reference pressure transducer) or a utility sensor depending on the specified PPC3 configuration. A Q-RPT is intended to provide very high precision, low uncertainty, traceable pressure measurement.

  • Page 147: Pressure Control Module

    • Remote [ENT] • Keypad and display • Beeper PNEUMATIC SCHEMATICS 5.9.1 PRESSURE CONTROL MODULE The bypass vent valve is not included in model PPC3-10M. Figure 12. Pressure Control Module Schematic Page 137 © 2002-2007 DH Instruments, a Fluke Company...

  • Page 148: Q-Rpt Module Configurations (Pressure Measurement)

    Valve C is the TEST(-) vent valve. In normal operation with BGxxx or Gxxx Q-RPTs, this valve is closed during fine pressure control (see Section 3.5.7.5). Valve D is shown for reference. It is in the pressure control module. © 2002-2007 DH Instruments, a Fluke Company Page 138...

  • Page 149: Figure 13. Q-Rpt Module Schematics For Various Configurations

    Valve C is the TEST(-) vent valve. In normal operation with BGxxx or Gxxx Q-RPTs, this valve is closed during fine pressure control (see Section 3.5.7.5). Figure 13. Q-RPT Module Schematics for Various Configurations Page 139 © 2002-2007 DH Instruments, a Fluke Company...
  • Page 150 PPC3™ OPERATION AND MAINTENANCE MANUAL © 2002-2007 DH Instruments, a Fluke Company Page 140...

  • Page 151: Table 27. Troubleshooting Guide

    Before assuming that unexpected behavior is caused by a system defect or breakdown, the operator should use this manual and other training facilities to become thoroughly familiar with PPC3 operation. This troubleshooting guide is intended as an aid in identifying the reason for PPC3 behavior and determining whether the behavior is due to normal operation or an internal or external problem.
  • Page 152 Change UL and/or active range if beeper is sounding intermittently. has been exceeded. needed. 3.4.4, 3.4.4.1 Pressure display is flashing, no PPC3 and/or external RPM4 has been over- Correct the overpressure condition and beeper is sounding and direct pressured. cycle power ON and OFF. 3.4.4.1 pressure control keys are inactive.
  • Page 153 SOLUTION There is a restriction in the test connection Remove the restriction to allow free flow between the PPC3 and the test or the PPC3, between the PPC3, the RPM4 (if present) the RPM4 and the test. and the test. 2.3.8...
  • Page 154 PPC3™ OPERATION AND MAINTENANCE MANUAL © 2002-2007 DH Instruments, a Fluke Company Page 144...

  • Page 155: Drivers

    120 mA 100 mA The male connector (P/N 401382) for the DRIVERS port is delivered with the PPC3 accessories. Table 29 and Figure 14 should be referred to when building a cable to utilize the drivers port. Table 29. External Drivers Pin Outs...

  • Page 156: Unit Conversion

    Inches of Mercury for Values of Pressure Altitude, H, in Geopotential Feet.” MIL-STD-859A provides tables of pressure in inches of mercury as a function of altitude in feet. PPC3 uses a set of equations to model the pressure/altitude relationship. The worst case deviation between the MIL-STD-859A table and the calculated pressure is 0.0001 inches of mercury (0.3 Pa).

  • Page 157: Overview

    In no event shall DH Instruments, a Fluke Company be liable to purchaser for any unforeseeable or indirect damage, it being expressly stated that, for the purpose of this warranty, such indirect damage includes, but is not...
  • Page 158 PPC3™ OPERATION AND MAINTENANCE MANUAL © 2002-2007 DH Instruments, a Fluke Company Page 148...

  • Page 159: G L O S S Ar

    Internal, Lo. Refers to a Q-RPT internal to the PPC3 that is the lower of the two if there is a second Q-RPT or utility sensor in the PPC3.
  • Page 160 In negative gauge measurement mode there is also a lower limit. Utility Sensor The internal, high (IuH) transducer in a PPC3 if when there is no Q-RPT in the IH position. A utility sensor is a low accuracy pressure transducer used for pressure indication, safety and housekeeping functions, not for low uncertainty measurement.

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