DH Instruments PPCH-G Operation And Maintenance Manual
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DH Instruments PPCH-G Operation And Maintenance Manual

High gas pressure controller/calibrator
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PPCH-G™
High Gas Pressure
Controller/Calibrator
Operation and Maintenance Manual
© 2007 DH Instruments, a Fluke Company

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Summary of Contents for DH Instruments PPCH-G

  • Page 1 PPCH-G™ High Gas Pressure Controller/Calibrator Operation and Maintenance Manual © 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, PPCH-G-G, QDUT, Q-RPT, RPM, RPM4 and SDS are trademarks, registered and otherwise, of DH Instruments, a Fluke Company.

  • Page 3: Table Of Contents

    CHECKING GAUGE MODE PRESSURE MEASUREMENT ..............14 2.4.5 LEAK CHECK ..............................15 2.4.6 CHECK PRESSURE CONTROL OPERATION ...................15 STORAGE AND SHIPPING ........................16 2.5.1 SHORT TERM STORAGE ...........................16 2.5.2 LONG TERM STORAGE ..........................16 2.5.3 PREPARATION FOR SHIPPING.........................16 Page I © 2007 DH Instruments, a Fluke Company...
  • Page 4 3.5.1.2 RUN AUTOZ.............................71 3.5.2 <2REMOTE> ..............................73 3.5.2.1 <1COM1, 2COM2>...........................73 3.5.2.2 <3IEEE-488> ............................74 3.5.2.3 <4FORMAT> ............................74 3.5.2.4 <5RS232 SELF-TEST> ..........................74 3.5.3 <3HEAD> ..............................75 3.5.4 <4RESET> ..............................75 3.5.4.1 <1SETS> ..............................76 3.5.4.2 <2UNITS> ..............................76 © 2007 DH Instruments, a Fluke Company Page II...

  • Page 5: Table Of Contents

    ADJUSTMENT OF UTILITY SENSOR ....................131 THERMAL PRESSURE CONTROL UNIT (TPCU) CONFIGURATION ..........132 VALVE OPENING POINT CONFIGURATION ..................133 OVERHAUL ............................134 RELOADING EMBEDDED SOFTWARE INTO FLASH MEMORY............135 SUBASSEMBLY DESCRIPTION AND LOCATION ................136 5.9.1 ELECTRONIC MODULE..........................136 Page III © 2007 DH Instruments, a Fluke Company...
  • Page 6 G L O S S A R Y ..............1 4 9 © 2007 DH Instruments, a Fluke Company...

  • Page 7: Tables

    Table 2. PPCH-G packing list ........................5 Table 3. MAIN RUN screen display fields....................18 Table 4. Position designators of Q-RPTs in a PPCH-G system ..............31 Table 5. Settings and to what they are specific (range, measurement mode, Q-RPT, system) ....32 Table 6.
  • Page 8 PPCH-G™ OPERATION AND MAINTENANCE MANUAL Figure 1. Front panel............................ 7 Figure 2. Rear panel ............................ 8 Figure 3. Connecting PPCH-G to an RPM4 or PG7202 using the standard PPCH-G interconnection accessories..................11 Figure 4. Keypad layout ..........................19 Figure 5. Direct pressure control keys ....................... 20 Figure 6.

  • 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 PPCH-G 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 PPCH-G operating principles.
  • Page 10 PPCH-G™ OPERATION AND MAINTENANCE MANUAL © 2007 DH Instruments, a Fluke Company Page VIII...

  • Page 11: I N T R O D U C T I O N

    ASCII character command strings over an RS232 or IEEE-488.2 interface. PPCH-G models are available to measure and control pressure in ranges from as low as 10 MPa (1 500 psi) to 100 MPa (15 000 psi) in absolute and gauge measurement modes.

  • Page 12: Pressure Measurement Specifications

    Quartz reference pressure transducers (Q-RPTs) can be installed in PPCH-G to obtain high precision and low uncertainty pressure measurement. One or two Q-RPTs can be included in the PPCH-G and/or additional Q-RPTs can be used externally mounted in a DHI RPM4 Reference Pressure Monitor (see Section 3.2.5).
  • Page 13 (k=2) following the ISO “Guide to the Expression of Uncertainty in Measurement.” 4. Maximum deviation of the PPCH-G controlled pressure from the true value including measurement uncertainty and dynamic control hold limit.

  • Page 14: Utility Sensor

    Warm Up Time None required Range PPCH-G-100M: 100 MPa (15 000 psi) absolute and gauge PPCH-G-70M: 70 MPa (10 000 psi) absolute and gauge PPCH-G-40M: 40 MPa (6 000 psi) absolute and gauge PPCH-G-20M: 20 MPa (3 000 psi) absolute and gauge Resolution 0.001 % of span...

  • Page 15: I N S T A L L A T I On

    2.1.1 REMOVING FROM PACKAGING PPCH-G is delivered in a wooden crate with high density polyethylene inserts to hold it in place. A molded transit case is available. Remove the PPCH-G and its accessories from the shipping container and remove each element from its protective plastic bag.

  • Page 16: Site Requirements

    PPCH-G™ OPERATION AND MAINTENANCE MANUAL SITE REQUIREMENTS PPCH-G weighs more than 50 kg (110 lb). Be sure that the location in which its installed is adequate to support the load. The PPCH-G can be installed on any flat, stable surface at a convenient height. The PPCH-G can also be mounted in a standard 19 in.

  • Page 17: Initial Setup

    PREPARING FOR OPERATION To prepare PPCH-G for check out and operation: Remove the plastic caps from the PPCH-G rear panel pressure connections. Remove the protective plastic sheet from the front panel display. Familiarize yourself briefly with the front and rear panel (see Section 2.3.2).

  • Page 18: Rear Panel

    2.3.3 POWER CONNECTION Check that the PPCH-G power switch is OFF. Connect the supplied power cable to the rear panel power input module. Connect the other end of the power cable to an electrical supply of 85 to 264 VAC, 50/60 Hz.

  • Page 19: Connecting Drive Air (Drive Port)

    Ensure that the PPCH-G is powered down, or if power is ON, it is in a vented condition (VENT LED ON). Do not apply the supply pressure before reading Sections 2.4.1 and 2.4.3.

  • Page 20: Connecting To Other Devices

    Q-RPT increase, the possibility of difficulty with pressure control when using the external Q-RPT increases. To connect a PPCH-G to an RPM4 to be used as part of the PPCH-G system proceed as follows: Set up the RPM4 for use as a PPCH-G external device following the instructions in the RRPM4 Operation and Maintenance Manual, Using RPM4 With a PPC3 Controller/Calibrator Section.

  • Page 21: Figure 3. Connecting Ppch-G To An Rpm4 Or Pg7202 Using The Standard Ppch-G Interconnection Accessories

    When external Q-RPTs are used with PPCH-G, the maximum set pressure is the maximum pressure of the PPCH-G controller/calibrator. The maximum pressure of the PPCH-G is determined by the PPCH-G controller model or the Hi Q-RPT if one is installed (see Section 1.2.1).

  • Page 22: Connecting To A Pg7202 Piston Gauge

    PG7202 TEST port to the PPCH-G TEST port (see Figure 3 for instructions on making this connection using the standard interconnections accessories supplied with the PPCH-G). The third leg of the tee is for the connection to the device or system under test.

  • Page 23: Check/Set Security Level

    Hi Q-RPT is more than 1 MPa (150 psi) away from standard atmospheric pressure. If the PPCH-G fails to reach the MAIN RUN screen, service is required. Record the sequence of operations and displays observed. Contact a DHI Authorized Service Provider (see Table 28).

  • Page 24: Apply Drive Air (Drive Port)

    Ensure that the PPCH-G is powered down, or if power is ON, it is in a vented condition (vent LED ON). Do not apply the supply pressure before reading Sections 2.4.1 and 2.4.3.

  • Page 25: Leak Check

    CUSTOM CONTROL (see Section 3.4.6.1) or use HI VOLUME DYNAMIC CONTROL (see Section 3.2.2.2). Use [LEAK CHECK] to perform a leak check of the PPCH-G and the system to which it is connected.

  • Page 26: Storage And Shipping

    The following procedure is recommended to prepare PPCH-G for shipment: Complete the long term storage procedure (see Section 2.5.2). Pack PPCH-G carefully being sure to use packing materials appropriate for shipment of a delicate instrument weighing approximately 50 kg (110 lb.). If available, use the original packing materials.

  • Page 27: O P E R A T I O

    Table 3 summarizes the PPCH-G MAIN RUN screen fields and their functions. PPCH-G 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 28: Table 3. Main Run Screen Display Fields

    <R>: Rate control limits are in use <P>: Piston gauge <C> is appended to the control character if control limits are custom Control character(s) flash when PPCH-G is actively controlling © 2007 DH Instruments, a Fluke Company Page 18...

  • Page 29: Function / Data Keypad Layout And Protocol

    3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL The PPCH-G 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 30: Direct Pressure Control Keys

    The jog keys are also used to adjust the target pressure during active dynamic pressure control. Pressing the [VENT] key aborts automated pressure control if active and causes PPCH-G to control pressure to near atmospheric pressure and then open the system vent valve (see Figure 6).

  • Page 31: Remote [Ent/Set P] (Foot)Switch

    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 PPCH-G 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 32: Figure 6. Pressure Control System Schematic

    This routine is initiated automatically when needed. If the PPCH-G includes a second, Lo Q-RPT(13), valves are included to isolate and vent the Lo Q-RPT when it is not being used. The valves are operated automatically to connect the Lo Q-RPT when it is selected for use or to isolate it and vent it when it is not being used.

  • Page 33: Automated Pressure Control

    PPCH-G range when the range is selected or AutoRange is used (see Section 3.3.4). Control parameters can be customized using the [SETUP], <6control> function (see Section 3.4.6.1).

  • Page 34: Dynamic Control

    Ready condition once achieved (see Section 3.4.6.2). Hi volume dynamic control may be necessary when the test volume connected to the PPCH-G is greater than 100 cc and/or if there are excessive leaks in the system into which pressure is being conrolled. The difference between standard and hi volume dynamic pressure control is in the use of the thermal pressure controller (TPCU).

  • Page 35: Static Control

    See Table 8 for default hold limit values and Section 3.4.6 to customize the hold limit. Figure 9. Static pressure control operation Page 25 © 2007 DH Instruments, a Fluke Company...

  • Page 36: Monotonic Control

    (see Figure 11). Measured pressure data is taken from the PPCH-G and output from the device under test during the slow ramp near the target pressure. Monotonic mode is also used to float the piston of a piston gauge when PPCH-G is used as the automated pressure control component in a piston gauge system.

  • Page 37: Ramp Control

    (see Figure 13). This control mode can be used for a variety of calibration and testing functions. When setting a ramp, PPCH-G attempts to establish the target rate within the rate hold limit and then maintains the rate until a new command is given or the active pressure range “upper limit”...

  • Page 38: Pg Control

    With ramp pressure control active, a Ready condition occurs whenever: • PPCH-G is controlling rate at the target rate value within the rate hold limit. Figure 14 illustrates Ready/Not Ready operation in ramp control mode. Note: Target is a rate of change value (pressure/time), not a pressure value Figure 14.

  • Page 39: Pressure Ready/Not Ready

    (see Section 3.4.6). 3.2.4 GAUGE MEASUREMENT MODE, DYNAMIC COMPENSATION FOR ATMOSPHERIC PRESSURE PPCH-G utility sensors and Q-RPTs are intrinsically absolute but they are also used in gauge measurement mode (difference from atmosphere) (see Section 3.3.3, PRINCIPLE). Gauge...

  • Page 40: Multiple Internal And External Q-Rpts

    Before operating PPCH-G with an external Q-RPT, check carefully that the RPM4’s Q-RPT TEST(+) port is connected to the PPCH-G TEST port. If an external Q-RPT is NOT connected to the PPCH-G TEST port, it will NOT measure the pressure generated by PPCH-G and PPCH-G may reach a pressure higher than the target pressure before it recognizes that the external Q-RPT is not connected (see Section 3.4.4.1).

  • Page 41: Multipe Ranges (Q-Rpts, Autorange And Infinite Ranging)

    External 1, Lo maximum range in RPM4 connected to PPCH-G • The display symbol is included in the upper, right hand corner of most PPCH-G displays and menus as a convenient indicator of the active Q-RPT. 3.2.6 MULTIPE RANGES (Q-RPTS, AUTORANGE AND INFINITE RANGING) A PPCH-G range is defined as a pressure span and associated settings.

  • Page 42: Operation With A Pg7000 Piston Gauge

    3.2.8 DIRECT FUNCTION KEYS SUMMARY Local operation of PPCH-G is through the front panel keypad. To minimize menu layers, the keypad numerical keys also provide direct access to the most commonly used functions. The function accessed is labeled on the bottom half of the key. Direct function keys are active whenever PPCH-G is in its MAIN RUN screen.

  • Page 43: Direct Function Keys

    [RANGE] selects from existing ranges. [AutoRange] creates new ranges (see Section 3.3.4). PRINCIPLE A PPCH-G range is defined as a pressure span and associated settings (see Section 3.2.6). A PPCH-G may have multiple ranges. Each Q-RPT (and the utility sensor if present) available to the PPCH-G system has a default range which is its maximum full scale.
  • Page 44 PPCH-G must be vented for the range change to occur. necessary to complete the range change. When selecting a range, if the range’s Q-RPT is an external Q-RPT and the PPCH-G cannot communicate with it, PPCH-G displays <Cannot find range’s external Q-RPT (Xn)> (where <Xn>...

  • Page 45: Unit]

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

  • Page 46: Mode]

    The default pressure units of measure available under the UNIT function depend on whether the PPCH-G 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 47: Autorange]

    3.3.1). PRINCIPLE PPCH-G 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 measurement and control parameters appropriately for the range.
  • Page 48 3.4.3 OPERATION To use the AutoRange function, press [AutoRange] and respond to PPCH-G’s prompts. Select measurement mode: The screen is identical in appearance and function to the [MODE] screen (see Section 3.3.3). Absolute mode is not available if absolute mode is turned off on all available Q-RPTs (see Section 5.2.5).

  • Page 49: Rpt]

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

  • Page 50: Autotest]

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

  • Page 51: Quick Autotest

    PRINCIPLE The AutoTest function is intended to facilitate the execution of a series of pressure control target values such as is commonly needed when PPCH-G is used to run a calibration sequence on a device or system being tested. There are two types of sequences:...
  • Page 52 (see Section 3.4.4) or change to a higher range if available (see Section 3.3.1). To AutoRange the PPCH-G automatically for a specific sequence based on the characteristics of a DUT, use a QDUT Test (see Section 3.3.6.2).
  • Page 53 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, PPCH-G vents and operation returns to the main run screen.

  • Page 54: Qdut Autotest

    2static 3monotonic to be run (see Section 3.4.6). Select the pressure control mode that is to be used by the PPCH-G when running the test points.. The next display is the selection of the...
  • Page 55 (see Section 3.3.10.6). It is preferable to make the low point, a point that PPCH-G can set. Enter the test lowest pressure point and press [ENT]. The display is: DUT tolerance: 0.05 %FS (span)
  • Page 56 Pressing [ESC] twice returns to the MAIN RUN screen without sequence execution (this feature can be used to AutoRange the PPCH-G based on DUT characteristics without running a specific test sequence). Pressing [ENT] causes sequence execution to proceed.

  • Page 57: Head]

    TEST port height and the pressure actually applied to the device under test which is at a different height. In this case, it may be useful to make a head correction to the pressure measured by the PPCH-G in order to predict the pressure actually applied at a DUT at a different height.

  • Page 58: Prime] (Cycle)

    When using external Q-RPTs in RPM4, it is recommended that the RPM4 head height be adjusted to the reference level of the PPCH-G before connecting the RPM4. Then, the normal PPCH-G reference level to DUT head corrections can be made for all the Q-RPTs, whether internal or external to PPCH-G.

  • Page 59: Leak Ck]

    PPCH-G Q-RPTs and pressure in other parts of the test system. A large leak can cause the PPCH-G to be unable to set and control pressures reliably. The LEAK CHECK function is provided as a means of checking and quantifying leaks that may be present in the system.
  • Page 60 If NO leak check data is stored (i.e., if the PPCH-G 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 61: Ent/Set P] (Set Pressure Automatically)

    3.3.10 [ENT/SET P] (SET PRESSURE AUTOMATICALLY) PURPOSE To enter and execute target pressure and ramp values for PPCH-G automated pressure control. See Section 3.2.2 for information on automated pressure control and the different control modes available with PPCH-G. OPERATION The operation of [ENT/Set P] depends on the active pressure control mode.
  • Page 62 PPCH-G continues maintaining pressure at the target value following dynamic control protocol (see Section 3.2.2.2) until automated pressure control is interrupted. If PPCH-G is unable to control pressure or appears to control pressure poorly, see Section 6 to troubleshoot. See Section 3.4.6 for information on customizing pressure control parameters.

  • Page 63: Static Control Mode, [Ent/Set P]

    3. OPERATION 3.3.10.2 STATIC CONTROL MODE, [ENT/SET P] If the PPCH-G is not set for static control, use SPECIAL, <6control>, <2mode> to select static control mode. For best results, wait 5 with the PPCH-G vented before controlling pressure when changing to or from standard dynamic control mode. This is to allow time for the PPCH-G thermal pressure control unit to respond and stabilize.

  • Page 64: Monotonic Control Mode, [Ent/Set P]

    ] direct pressure control keys can be used in static mode while the PPCH-G is waiting for pressure stability to jog the pressure by the pressure step value. (see Section 3.1.3). These keys also jog the target value when in the ENTER target value screen.

  • Page 65: Ramp Control Mode, [Ent/Set P]

    3. OPERATION If PPCH-G is unable to control pressure or appears to control pressure poorly, see Section 6 to troubleshoot. See Section 3.4.6 for information on customizing pressure control parameters. 3.3.10.4 RAMP CONTROL MODE, [ENT/SET P] If the PPCH-G is not set for ramp control, use SPECIAL, <6control>, <2mode>...

  • Page 66: Pg Control Mode, [Ent/Set P]

    PG control is not to be used for regular PPCH-G stand alone operation. It should only be used by a PG7202 piston gauge AutoGen function. PG control mode is not to be used for regular PPCH-G stand alone operation. It is used only by a PG7202 piston to automated pressure control using the AutoGen function (see PG7000 Operation and Maintenance Manual).

  • Page 67: Automated Pressure Commands For Zero Pressure

    [SETUP] PURPOSE [SETUP] accesses a menu of functions and features commonly used in setting up and using PPCH-G. OPERATION 1range 2res 3jog 4UL To access the SETUP menu, press [SETUP] from the MAIN RUN screen.

  • Page 68: 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. © 2007 DH Instruments, a Fluke Company Page 58...

  • Page 69: 3Jog

    3. OPERATION PRINCIPLE The resolution with which PPCH-G 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 70: 4Ul> (Upper Limit)

    (see Section 3.3.3, Automated pressure control targets greater than the upper limit are not accepted. When the pressure measured by PPCH-G exceeds the upper limit, automated or direct manual pressure control is aborted and an intermittent warning beep sounds.

  • Page 71: Over Pressure Function

    PPCH-G supports QDUTAutoTests (see Section 3.3.6.2). When a QDUT AutoTest is run, the PPCH-G pressure accepted by the operator, and <IN> or <OUT> condition, at each point is logged. The logged pressure and an identifying header are stored in a data file. The data file can be viewed immediately following the last point of the sequence by selecting <3data>.

  • Page 72: 6Control

    Following the data file header, each test point is recorded including the pressure setting of the PPCH-G with head, AutoZ and range status as well as an indication of whether the reading was in or out of tolerance and the test point number over the total number of test points in the QDUT sequence.

  • Page 73: Table 8. Default Pressure Control Parameters

    (see Table 8 for definition of PPCH-G default control parameters). The default control parameters are those best suited to operate within PPCH-G pressure control and measurement specifications for a given range of operation.

  • Page 74: 1Limits> (Custom Control Parameters)

    View/edit field of hold limit value in active pressure unit of measure. Shows active hold Hold limit: limit. 0.010 MPa Active control mode (<D> for standard dynamic, <d> for hi volume dynamic, <S> for static). © 2007 DH Instruments, a Fluke Company Page 64...
  • Page 75 Edit the ramp rate hold limit value if desired and press [ENT] to return to the main run screen with the edited values active. See Section 3.4.6, Table 8 for default control limits. Page 65 © 2007 DH Instruments, a Fluke Company...

  • Page 76: 2Mode

    [SETUP], <6control>, <2mode> (see Section 3.4.6). Selecting the mode automatically activates its default control parameters. This is a convenient way to put the PPCH-G into a known condition after trying custom control settings. © 2007 DH Instruments, a Fluke Company...

  • Page 77: 7Drv> (Drivers)

    <1momentary> or <2toggle>. [SPECIAL] PURPOSE [SPECIAL] accesses a menu of PPCH-G settings, adjustment and features that are less commonly used or not normally used in regular operation. OPERATION 1AutoZ 2remote 3head...

  • Page 78: 1Autoz

    Q-RPT zero between full recalibrations. PRINCIPLE AutoZ Purpose and Principle The main component of the change over time of the PPCH-G Q-RPTs is change in zero or offset, independent of span. Offsetting or “rezeroing” PPCH-G Q-RPTs relative to a reference between recalibrations allows measurement uncertainty specifications to be maintained with less frequent full calibrations.

  • Page 79: Table 9. Autoz On And Off

    ), is initiated by the operator. offset,A AutoZ in gauge measurement mode, dynamic compensation for atmospheric pressure PPCH-G Q-RPTs are intrinsically absolute but they can also be used in gauge measurement mode (difference from atmosphere) (see Section 3.3.3, PRINCIPLE). Gauge measurement mode is achieved by subtracting the value of atmospheric pressure from the Q-RPT’s absolute reading using AutoZ and by dynamically compensating for changes in...
  • Page 80 The AutoZ function and values are Q-RPT AND measurement mode (absolute, gauge) specific. When AutoZ is run for an external Q-RPT in an RPM4, the PPCH-G 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 PPCH-G.

  • Page 81: Edit Autoz

    3.5.1.2 RUN AUTOZ Run AutoZ applies only to PPCH-G Q-RPTs or utility sensors in absolute measurement mode. In gauge measurement modes, AutoZ is run automatically whenever the PPCH-G is in the VENT condition. Run AutoZ is the function by which the current RPT reading is compared to a...
  • Page 82 PPCH-G™ OPERATION AND MAINTENANCE MANUAL Allow the PPCH-G Q-RPT to stabilize at atmospheric pressure and ambient temperature for 10 to 15 minutes before running AutoZ. The stabilization period is not necessary for a utility sensor. To access run AutoZ, press [SPECIAL], <1AutoZ>, <4run>.

  • Page 83: 2Remote

    COM1 and COM2 communications. To select remote programming communications format. PRINCIPLE The PPCH-G 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 1), and COM2 is reserved for communicating with an external device (i.e.

  • Page 84: 3Ieee-488

    The receiving terminating character must be a line feed and EOI. Carriage returns are ignored if received. The PPCH-G 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 85: 3Head

    PPCH-G stores its user definable settings in non-volatile memory. The reset menu allows the user to selectively or completely reset these settings to factory defaults. This clears out any settings that the user has made, and should be used only to restore the PPCH-G to a known state.

  • Page 86: 1Sets

    PURPOSE Sets the six pressure units available under the UNIT function to the SI or US default selections depending on whether the PPCH-G 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 87: 3Atest

    The Reset - Cal function will reset Q-RPT, utility sensor and barometer calibration coefficients and settings and reset AutoZ values to zero. This will change the PPCH-G calibration and could cause it to make out of tolerance measurements. Clears all user values affecting the calibration of Q-RPTs, utility sensor and the on-board barometer.

  • Page 88: 5Pref

    To adjust the idle time after which PPCH-G’s SCREEN SAVER activates. PRINCIPLE PPCH-G 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 89: 2Sound

    DATE functions to set your local time and date. 3.5.5.4 <4ID> PURPOSE To view or edit the PPCH-G user ID and to view the PPCH-G serial number. OPERATION To access the ID function press [SPECIAL] and select <5pref>, <2ID>. Select <1view> to view the current ID.

  • Page 90: 5Level> (Security)

    For these reasons, depending upon the application in which PPCH-G 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 91: Table 13. Security Levels

    3. OPERATION PPCH-G is delivered with the security level set at low to avoid inadvertent altering of critical internal settings but with access to changing security levels unrestricted. It is recommended that the low security level be maintained at all times.

  • Page 92: 6Punit

    The [UNIT] function key makes available a choice of six default pressure units (US or SI units depending on whether the PPCH-G has been factory set as US or SI) (see Section 3.3.2). PPCH-G also supports many commonly used units other than those included in the default set ©...

  • Page 93: Table 14. Unit Function - Available Units Of Measure

    These units can be made available for active selection by customizing the UNIT function using [SPECIAL], <6PresU>. This allows PPCH-G 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 94: 7Internal

    (see Sections 5.5, 5.6). 3.5.7.2 <2BARO> PURPOSE To view the value of atmospheric pressure as measured by the PPCH-G on- board barometer. PRINCIPLE PPCH-G is equipped with an on-board barometer. The atmospheric pressure...

  • Page 95: 3Supply

    Pmax! of an internal PPCH-G 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 PPCH-G. 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 96 PPCH-G™ OPERATION AND MAINTENANCE MANUAL © 2007 DH Instruments, a Fluke Company Page 86...

  • Page 97: Overview

    Sending a program message to the PPCH-G places it into remote mode. The remote indicator to the right of the display window lights when the PPCH-G 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 The [ESC] key returns the PPCH-G to local operation unless the <REMOTE>...

  • Page 98: Com2

    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 PPCH-G. 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 99: Classic Program Message Format

    PPCH-G in the form of comma delimited arguments. This data is usually a setting of some sort that is stored in the PPCH-G. 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 100: Using Query Type Commands

    You must wait for a reply with a query. If you send any type of program message to the PPCH-G 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 101: Commands

    4. REMOTE OPERATION COMMANDS 4.4.1 PROGRAMMING MESSAGES Table 17. Program Message List Send a command string out of the PPCH-G COM2 port. ABORT Stop pressure generation. ARANGE Read or set a new AutoRange to use. Read the current atmospheric pressure (on-board barometer).

  • Page 102: Error Messages

    ERR# 39 “Data verify error” ERR# 43 “Incorrect mode” ERR# 45 “Argument not allowed” ERR #46 “Argument cannot be negative” ERR #52 “Command obsolete” ERR #53 “Not Available” ERR# 54 “Not ready” © 2007 DH Instruments, a Fluke Company Page 92...

  • Page 103: Program Message Description Overview

    If the program message can be used to set data inside the PPCH-G, then this section describes the arguments and their limits. Default If the program message can be used to set data inside the PPCH-G, then this line shows (using the enhanced format) the default setting from the factory. Remarks This field has the details and remarks about the command.

  • Page 104: Program Message Descriptions

    The PPCH-G COM2 port can be used to communicate to another RS232 device (such as another PPCH-G). This allows the user to use one COM port or IEEE-488 port on the host computer to communicate with the PPCH-G and another device. A carriage return and a line feed (<CR><LF>) are added to the string.
  • Page 105 “X2L”: Second external RPM4, Lo Q-RPT Remarks The ARANGE command is used to define a PPCH-G range by specifying a desired unit of measure, measurement mode and maximum pressure. The PPCH-G then picks the best available Q-RPT and makes operational adjustments to optimize that range. Available Q-RPTs may be determined by the use of the “RPT”...
  • Page 106 The COM1 port is used to communicate to the PPCH-G. When the COM1 port configuration of the PPCH-G is changed, the program message reply (COM1 use only) is sent at the old COM1 settings, but all subsequent communications are accomplished at the new COM1 settings.
  • Page 107 COM2 is generally used to connect DHI RPM4 external measurement devices. The COM2 Remarks port can also be used to allow the host computer to communicate through the PPCH-G to an additional device connected to COM2. This can be useful if the host computer does not have 2 serial ports available.
  • Page 108 The down control valve will be used to decrease the pressure the requested amount at a rate of 0.2 % FS/sec. The PPCH-G controls pressure up to the target and then stops, so the change in pressure will be approximate.
  • Page 109 The fluid type. This must be “N2”, “Air”, “He”, “Oil”, “H2O”, or “User”. Remarks The PPCH-G 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 PPCH-G.
  • Page 110 An alphanumeric string up to 12 characters long. Remarks The user defined ID label can be used to allow the user to “tag” the PPCH-G with a unique identifier. This ID is stored in non-volatile memory and cannot be erased by a power failure,...
  • Page 111 The up control valve will be used to increase the pressure the requested amount at a rate of 0.2 % FS/sec. The PPCH-G controls pressure up to the target and then stops, so the change in pressure will be approximate.
  • Page 112 ‘3’ for “rate” control. Remarks The method which the PPCH-G controls pressure is selected with the “MODE” program message. When the control mode is set, control parameters are set to default parameters for that range. The control mode setting is range dependent.
  • Page 113 The Query format is used to check the PPCH-G 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 114 The pressure value and pressure unit of measure are right justified in this field. After receiving this program message, the PPCH-G replies back with the data after a new pressure measurement cycle is complete. This can take up to 1.5 seconds.
  • Page 115 The “PR?”, “PRR?”, “STAT?”, or “SR?” program message queries can be used to monitor the progress of the pressure setting routine. If the optional “v” argument is used, the PPCH-G does not attempt to perform its test volume determination routine at the beginning of the pressure setting procedure, but instead uses the volume specified for the pressure control.
  • Page 116 The target pressure in the current pressure unit. Remarks The PPCH-G sets the given target pressure using a rate of 2 % FS/sec, and stops controlling as the pressure approaches the given target. The system does not attempt to maintain the target pressure.
  • Page 117 “RPT” command or function key before the can be selected. The reply indicates the active range in psi if the PPCH-G is a “US” version or in kPa if the PPCH-G is an “SI” version.
  • Page 118 The next available pressure rate of change in the current pressure unit per second is returned. After receiving this program message, the PPCH-G replies back with the data once a new pressure measurement cycle is complete. This can take up to 1.5 seconds.
  • Page 119 “RESET” Remarks The PPCH-G 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 120 The second external RPM4, Lo RPT Remarks Up to six RPTs can be available for use in one PPCH-G system. Two of these can be internal, and the other four are external. These RPTs must be identified and initialized before they can be used by the PPCH-G.
  • Page 121 The “PR?”, “PRR?”, “STAT?”, or “SR?” program message queries can be used to monitor the progress of the pressure setting routine. If the optional “v” argument is used, the PPCH-G does not attempt to perform its test volume determination routine at the beginning of the pressure setting procedure, but instead uses the volume specified for the pressure control.
  • Page 122 These limits are part of the ready criteria. The “stability” limit applies to “static” and “dynamic” control modes only. The “rate” limit applied to “monotonic” control mode only. If this program message is used to set the stability or rate limit, the PPCH-G will then use CUSTOM control settings.
  • Page 123 The pressure or rate control cycle status can be checked using this program message. It returns a ‘1’ if the PPCH-G is actively controlling a pressure, a rate, is venting, or is holding a pressure. It returns a ‘0’ if it is idle or completely vented..
  • Page 124 “TPCVOL 10” Remarks This current volume that the PPCH-G believes is connected to its TEST port can be read back or overridden using this command. The volume should be set only in automated conditions, where the test volume is constant and the configuration does not change. This volume is only an approximate value that may be adjusted empirically for correct operation.
  • Page 125 The upper limit pressure in the current pressure unit and measurement mode. Remarks The PPCH-G 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 126 “VER?” Classic “VER” Remarks The software version of the PPCH-G can be read. This is useful for checking for the presence of the PPCH-G and for reference purposes. It indicates the internal RPT(s) and software version. Example Query sent: “VER?”...

  • Page 127: Status Reporting System

    STATUS REPORTING SYSTEM The PPCH-G status reporting system is used to track and report system status and errors. It follows the model of the IEEE Std 488.2 and works for the COM1 and the IEEE-488 port with slight differences. The PPCH-G can be programmed to respond to various status conditions by asserting the SRQ of the IEEE- 488 interface.

  • Page 128: Figure 15. Status Register Schematic

    Indicates that the SRQ line of the IEEE-488 interface has been asserted by the PPCH-G. This bit is cleared when a serial poll is performed on the PPCH-G, 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 129: Standard Event Register

    ESB bit. The description of these bits are given as: Power On (Bit 7) Indicates that the PPCH-G power has been cycled since the last time this bit was read or cleared. User Request (Bit 6) Indicates that the PPCH-G was set to local operation manually from the front panel by the user (pressing the [ESC] key).

  • Page 130: Ieee Std. 488.2 Common And Status Program Messages

    IEEE STD. 488.2 COMMON AND STATUS PROGRAM MESSAGES The PPCH-G 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 131: Program Message Descriptions

    “∗OPC” Query “∗OPC?” Remarks This Command enables the PPCH-G to set the OPC bit in the Standard Event Status Register when it has completed all pending functions. The Query replies with a “1” when all functions are complete. Example Sent: “∗OPC”...
  • Page 132 (as if the “∗RST” program message was executed), and the ∗TST query will return a non zero value. If the PPCH-G passed the test on power-up OR if the ∗TST query was used at least once since the PPCH-G was powered up the reply will be a ‘0’.

  • Page 133: Maintenance, Adjustments A N D C A L I B R A T I O

    For rapid assistance in specific situations use the troubleshooting guide in Section 6. PPCH-G 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 134: Pa And Pm Coefficients

    (see Section 3.5.5.5). Incorrect editing of PA and PM values can cause out of tolerance measurements. A new PPCH-G is delivered with PA and PM values set to zero and 1 for all ranges. This does not mean that the PPCH-G 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 135: As Received And As Left Data

    PA, PM and P offset A new PPCH-G is delivered with PA and PM values set to zero and 1 for all ranges. This does not mean that the PPCH-G 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 136: Set-Up And Preparation

    To set-up and prepare the PPCH-G for calibration of an internal Q-RPT: Set the PPCH-G 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 137: Turning Off Absolute Measurement Mode For A Q-Rpt

    In absolute mode, a point at or near atmospheric pressure. Zero (vented) in gauge mode. PPCH-G Q-RPTs that will NOT be used in absolute measurement mode may be calibrated in gauge measurement mode with a gauge pressure standard. PPCH-G 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).

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

    A user level security system is available to control access (see Section 3.5.5.5). A new PPCH-G is delivered with PA and PM values set to zero and 1 for all ranges. This does not mean that the PPCH-G 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 139 The value of PA is always in Pascal (Pa). The value of PM is dimensionless. PPCH-G 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 PPCH-G (see the RPM4 Operation and Maintenance Manual).

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

    RPTs software, Sections 5.2.1, 5.2.2 and 5.2.3 should be reviewed thoroughly. PPCH-G must be in a pressure control mode OTHER THAN piston gauge mode when it is calibrated. The control character in the middle of the bottom line of the display must be other than <P>...

  • Page 141: Adjustment Of On-Board Barometer

    The on-board barometer is a low accuracy sensor used only for measuring changes in atmospheric pressure over short periods of time (see Section 3.2.4). PPCH-G measurement uncertainty does not depend on the measurement uncertainty of the on-board barometer unless it is used as a source of P...

  • Page 142: Thermal Pressure Control Unit (Tpcu) Configuration

    THERMAL PRESSURE CONTROL UNIT (TPCU) CONFIGURATION PURPOSE To run an automated routine that determines the volume of the system into which PPCH-G is controlling pressure to optimize the performance of thermal pressure control (TPC) used in standard dynamic control mode. PRINCIPLE PPCH-G uses thermal pressure control (TPC) for very fine pressure control around the target value in standard dynamic control mode (see Section 3.2.2.2).

  • Page 143: Valve Opening Point Configuration

    (see Section 6). PRINCIPLE PPCH-G uses servo-controlled needle valves to precisely admit and exhaust gas into and out of the test volume. Knowledge of the opening points of these valves is critical to pressure control performance.

  • Page 144: Overhaul

    The VALVE CONFIG routine will cause PPCH-G to set pressure of 95% of the controller’s maximum pressure. Be sure that any fittings or devices connected to the PPCH-G test port can safely be exposed to this pressure prior to running the routine.

  • Page 145: Reloading Embedded Software Into Flash Memory

    SOFTWARE. A FLASH loading utility and the latest release of PPCH-G 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 146: Subassembly Description And Location

    PPCH-G™ OPERATION AND MAINTENANCE MANUAL SUBASSEMBLY DESCRIPTION AND LOCATION PPCH-G consists of two modules. The electronic module is mounted on the top of the unit (see Section 5.9.1). The mechanical module (see Section 5.9.2) is beneath the electronic module. 5.9.1 ELECTRONIC MODULE 1.

  • Page 147: Power Supplies

    (see Section 3.2.4). The temperature sensor is used for temperature compensation of the barometric sensor. Page 137 © 2007 DH Instruments, a Fluke Company...

  • Page 148: Mechanical Module

    The range of the pressure transducer depends upon the range of the pressure controller. The transducers readings are used to indicate the pressure available at the PPCH-G SUPPLY port and the value of the supply pressure is used in the PPCH-G pressure control algorithm.

  • Page 149: Hi Q-Rpt Or Utility Sensor

    5.9.2.5 LO Q-RPT, ISOLATION VALVE, VENT VALVE (OPTIONAL) PPCH-G can be equipped with an optional Q-RPT of a lower range than the Hi Q-RPT or utilitiy sensor. The Lo Q-RPT is of the same technology as the Hi Q- RPT (see Section 5.9.2.2). The Lo Q-RPT isolation and vent valves are of the same technology as the test vent valve (see Section 5.9.2.3).

  • Page 150: Inlet Control Valve

    Used to precisely control the exhaust from the TEST port. 5.9.2.11 THERMAL PRESSURE CONTROL UNIT (TPCU) High pressure volume containing a helicoidal heating element. The TPCU is used for fine pressure control in standard dynamic control mode (see Section 3.2.2.2). © 2007 DH Instruments, a Fluke Company Page 140...

  • Page 151: Table 24. Troubleshooting Guide

    PPCH- G operation. This troubleshooting guide is intended as an aid in identifying the reason for PPCH-G behavior and determining whether the behavior is normal operation or an internal or external problem.
  • Page 152 There is a restriction in the test connection Remove the restriction to allow free flow Poor pressure control characterized between the PPCH-G and the test or the between the PPCH-G, the RPM4 (if by excessive overshooting/ PPCH-G, the RPM4 and the test.
  • Page 153 Add volume to the system connected to the TEST port. 1.2.3 by overshooting target. too small. A filter in the PPCH-G or an accessory is Replace the filter element. dirty and causing a restriction. Poor pressure control characterized Reduce test volume if slew rate is by very slow slew rate.
  • Page 154 PPCH-G™ OPERATION AND MAINTENANCE MANUAL © 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 PPCH-G accessories. Table 26 and Figure 18 should be referred to when building a cable to utilize the drivers port. Table 26. External drivers pin outs...

  • Page 156: Unit Conversion

    The PPCH-G remote ENTER function operates by detecting the open or closed status of the REMOTE ENTER switch. The normal status of the ENTER switch is OPEN. When PPCH-G detects a CLOSED condition held for 300 ms, it is interpreted as equivalent to a press of the [ENT/SET P] key.

  • Page 157: Overview

    The provisions of this warranty and limitation may not be modified in any respect except in writing signed by a duly authorized officer of DH Instruments, a Fluke Company. The above warranty and the obligations and liability of DH Instruments, a Fluke Company and its Authorized Service Providers exclude any other warranties or liabilities of any kind.
  • Page 158 PPCH-G™ OPERATION AND MAINTENANCE MANUAL © 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 PPCH-G that is the lower of the two if there is a second Q-RPT or utility sensor in the PPCH-G.
  • Page 160 Transducer) RPT PPCH-G, is referred to as the Hi Q-RPT. The lower pressure range Q-RPT in a dual Q-RPT PPCH-G is referred to as the Lo Q- RPT. PPCH-G Q-RPTs are designated by a leading A (absolute) followed by three numbers and a letter indicating the maximum range of the Q-RPT in MPa (nnnM).

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