DH Instruments ADCS-601-AF Operation And Maintenance Manual

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ADCS-601-AF™

Air Data Calibration Standard

Operation and Maintenance Manual

NSN 6695-01-534-6087

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

Pressurized gases are potentially hazardous. Energy stored in these gases can be released

unexpectedly and with extreme force. Pressurized systems should be assembled and operated only by personnel who have been instructed in proper safety practices.

Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments, a

Fluke Company 4765 East Beautiful Lane Phoenix Arizona 85044-5318 USA.

DH Instruments makes sincere efforts to ensure the accuracy and quality of its published materials; however, no warranty,

expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the English version and other language versions, the English version predominates.

DH Instruments, DH, DHI, ADCS-601-AF, ADCS Tools, AMH, COMPASS, FPG8601, PG7601, PPC3 and RPM4 and are trademarks, registered and otherwise, of DH Instruments, a Fluke Company.

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Products described in this manual are manufactured under international patents and one or more of the following U.S. patents: 6,701,791, 5,142,483, 5,257,640, 5,331,838, 5,445,035. Other U.S. and international patents pending.

Document No. 550140d 051222 Printed in the USA

TABLE OF CONTENTS

AABBLLEE OOFF

OONNTTEENNTTS

TABLE OF CONTENTS ...............................................................I

TABLES..................................................................................V

FIGURES................................................................................VI

ABOUT THIS MANUAL.............................................................IX

1. INTRODUCTION ................................................................. 1

1.1 SPECIFICATIONS....................................................................................................................................1

1.1.1 ADCS SYSTEM GENERAL SPECIFICATIONS............................................................................................1

1.1.2 PG7601 PISTON GAUGE SPECIFICATIONS...............................................................................................2

1.1.2.1 AMBIENT AND PISTON-CYLINDER CONDITION MEASUREMENTS ....................................................2

1.1.2.2 PISTON-CYLINDER MODULE..................................................................................................................2

1.1.2.3 MASS SET.................................................................................................................................................3

1.1.3 FPG8601 GENERAL SPECIFICATIONS.......................................................................................................3

1.1.3.1 AMBIENT AND PISTON-CYLINDER CONDITION MEASUREMENTS ....................................................3

1.1.4 PRESSURE MEASUREMENT AND CONTROL SPECIFICATIONS............................................................3

1.1.4.1 10 TO 380 KPA, PG7601 AND PPC3-700K ..............................................................................................3

1.1.4.2 1 TO 15 KPA, FPG8601 AND PPC3-100K................................................................................................4

2. SYSTEM OVERVIEW ........................................................... 5

2.1 ADCS-601-AF SYSTEM...........................................................................................................................5

2.1.1 REFERENCE BENCH..................................................................................................................................12

2.1.2 CONTROL CABINET...................................................................................................................................13

2.1.3 GAS SUPPLY PANEL.................................................................................................................................15

2.2 PRESSURE STANDARDS.....................................................................................................................16

2.2.1 PG7601 PISTON GAUGE............................................................................................................................16

2.2.1.1 PG7601 PLATFORM................................................................................................................................17

2.2.1.2 PG7601 TERMINAL.................................................................................................................................17

2.2.1.3 PG7601 10 KPA/KG PISTON-CYLINDER MODULE...............................................................................18

2.2.1.4 AMH-38 AUTOMATED MASS HANDLER...............................................................................................19

2.2.1.5 AMH-38 MASS SET.................................................................................................................................21

2.2.2 FPG8601 FORCE BALANCED PISTON GAUGE .......................................................................................21

2.2.2.1 FPG8601 PLATFORM .............................................................................................................................23

2.2.3 PPC3 PRESSURE CONTROLLERS...........................................................................................................23

2.2.4 RPM4 A116K REFERENCE PRESSURE MONITOR..................................................................................25

2.3 VACUUM PUMPS..................................................................................................................................27

3. INSTALLATION ................................................................ 29

3.1 UNPACKING AND INSPECTION........................................................................................................... 29

3.1.1 ADCS CONTROL CABINET........................................................................................................................30

3.1.2 ADCS REFERENCE BENCH AND ACCESSORIES...................................................................................30

3.1.3 PG7601 PLATFORM AND BELL JAR ........................................................................................................32

3.1.4 PG7601 PISTON-CYLINDER MODULE (PC-7100/7600-10,TC) ................................................................32

3.1.5 PG7601 MASS SET (MS-AMH-38)..............................................................................................................33

3.1.6 PG7601 AUTOMATED MASS HANDLER (AMH-38)..................................................................................34

3.1.7 FPG8601 PLATFORM, PISTON-CYLINDER AND ACCESSORIES...........................................................34

3.1.8 FPG8601 MASS SET (MS-8601-2)..............................................................................................................35

3.1.9 SCROLL VACUUM PUMPS........................................................................................................................35

3.1.10 TURBO MOLECULAR VACUUM PUMP.....................................................................................................35

3.1.11 SYSTEM CONTROLLER.............................................................................................................................35

3.1.12 SYSTEM CONTROLLER STAND................................................................................................................36

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

3.2 SITE REQUIREMENTS..........................................................................................................................36

3.3 SETUP....................................................................................................................................................38

3.3.1 POSITION THE REFERENCE BENCH.......................................................................................................38

3.3.2 INSTALL REFERENCE TURBO VACUUM AND ROUGHING PUMPS......................................................39

3.3.3 POSITION THE PG7601 AND FPG8601 PLATFORMS ON THE REFERENCE BENCH..........................40

3.3.4 PREPARE FPG8601....................................................................................................................................40

3.3.5 MAKE PNEUMATIC INTERCONNECTIONS ON THE REFERENCE BENCH...........................................41

3.3.6 POSITION CONTROL CABINET AND MAKE PNEUMATIC, COMMUNICATIONS AND ELECTRICAL

CONNECTIONS TO REFERENCE BENCH................................................................................................42

3.3.7 CONNECT PRESSURE SUPPLIES TO CONTROL CABINET...................................................................43

3.3.8 APPLY SUPPLY PRESSURES AND CHECK GAS SUPPLY PANEL SETTINGS ....................................43

3.3.9 SET UP THE PG7601..................................................................................................................................44

3.3.9.1 PREPARE THE PLATFORM AND INSTALL THE PISTON-CYLINDER MODULE.................................44

3.3.9.2 INSTALL THE AMH-38 MASS SET.........................................................................................................44

3.3.9.3 INSTALL THE AMH-38 MASS HANDLER...............................................................................................45

3.3.9.4 INSTALL THE REFERENCE VACUUM CDG ASSEMBLY .....................................................................46

3.3.10 COMPLETE FPG8601 SETUP....................................................................................................................47

3.3.10.1 INSTALL THE PISTON-CYLINDER.........................................................................................................47

3.3.10.2 CONNECT THE MANIFOLD AND VALVE 9............................................................................................47

3.3.10.3 INSTALL THE REFERENCE VACUUM CDG ASSEMBLY.....................................................................48

3.3.11 COMPLETE REFERENCE VACUUM INTERCONNECTIONS ...................................................................49

3.3.12 INSTALL THE UTILITY VACUUM PUMP....................................................................................................49

3.3.13 SET UP THE SYSTEM CONTROLLER (PC)..............................................................................................49

3.4 POWER UP, INITIALIZATION, VERIFICATION....................................................................................50

3.4.1 MAIN POWER SWITCHES..........................................................................................................................50

3.4.2 SET OR VERIFY DEVICE COMMUNICATION PORT AND OTHER SETTINGS.......................................50

3.4.2.1 COMMUNICATION PORTS.....................................................................................................................50

3.4.2.2 PG7601 EXTERNAL VACUUM GAUGE COMMUNICATION .................................................................50

3.4.2.3 EDIT AND SELECT PG7601 SETUP FILE..............................................................................................51

3.4.3 PG7601 ........................................................................................................................................................51

3.4.3.1 POWER UP..............................................................................................................................................51

3.4.3.2 INITIALIZATION.......................................................................................................................................51

3.4.4 FPG8601......................................................................................................................................................52

3.4.4.1 POWER UP..............................................................................................................................................52

3.4.5 START UP SYSTEM CONTROLLER AND SOFTWARE............................................................................52

3.4.6 VERIFY SYSTEM OPERATION ..................................................................................................................53

3.5 ENTER VALUE OF LOCAL GRAVITY ..................................................................................................54

3.6 SPECIFY TEST GAS SPECIES.............................................................................................................55

3.7 ADDITIONAL PRECAUTIONS TO TAKE BEFORE MAKING PRESSURE MEASUREMENTS...........55

3.8 SHUT DOWN AND RESTART...............................................................................................................55

3.8.1 RESTART.....................................................................................................................................................55

3.8.2 SHUT DOWN ...............................................................................................................................................56

3.8.2.1 SHORT TERM SHUT DOWN ..................................................................................................................56

3.8.2.2 LONG TERM SHUT DOWN.....................................................................................................................56

4. OPERATION..................................................................... 57

4.1 GENERAL OPERATING PRINCIPLES..................................................................................................57

4.1.1 SYSTEM CONFIGURATION........................................................................................................................57

4.1.2 READY/NOT READY INDICATIONS...........................................................................................................57

4.1.2.1 OVERVIEW..............................................................................................................................................57

4.1.2.2 READY/NOT READY WHEN USING THE PG7601 PISTON GAUGE....................................................57

4.1.2.3 READY/NOT READY WHEN USING THE FPG8601 FORCE BALANCED PISTON GAUGE................58

4.1.3 TRANSITION BETWEEN STANDARDS, ACTIVE AND INACTIVE STANDARD.......................................58

4.1.4 DIFFERENCE BETWEEN REQUESTED AND ACTUAL SET PRESSURE...............................................59

4.1.5 ASOLUTE AND GAUGE MEASUREMENT MODES ..................................................................................60

4.2 FREQUENTLY USED FUNCTIONS.......................................................................................................60

4.2.1 CONNECTING A DEVICE UNDER TEST (DUT).........................................................................................61

4.2.2 CHANGING PRESSURE UNIT OF MEASURE...........................................................................................61

4.2.3 CHANGING MEASUREMENT MODE (ABSOLUTE, GAUGE)...................................................................62

4.2.4 SETTING PRESSURES...............................................................................................................................62

4.2.4.1 SETTING ZERO PRESSURE..................................................................................................................63

4.2.4.2 SETTING IDLE STATUS..........................................................................................................................63

4.2.5 PRESSURE EXERCISING THE DEVICE UNDER TEST............................................................................63

4.2.6 SETTING A HEAD CORRECTION..............................................................................................................64

4.2.7 STOPPING PRESSURE CONTROL, ABORTING FUNCTION EXECUTION.............................................64

4.2.8 SECURITY, USER RIGHTS.........................................................................................................................65

4.2.8.1 SETTING UP USERS AND MANAGING USER RIGHTS........................................................................65

TABLE OF CONTENTS

4.2.8.2 CHANGING ACTIVE USER.....................................................................................................................66

4.2.9 PRESSURE LEAK TEST.............................................................................................................................66

4.3 LOCAL OPERATION, ADCS TOOLS....................................................................................................67

4.3.1 OVERVIEW..................................................................................................................................................67

4.3.2 MAIN MENU.................................................................................................................................................69

4.3.3 ADCS MAIN TOOLBARS ............................................................................................................................70

4.3.4 ADCS STATUS BAR....................................................................................................................................74

4.3.5 ADCS RUN SCREEN...................................................................................................................................74

4.3.5.1 ADCS RUN SCREEN CONTROL PANEL...............................................................................................75

4.3.5.2 ADCS SYSTEM DISPLAY .......................................................................................................................76

4.3.5.3 ADCS RUN SCREEN TOOLBAR ............................................................................................................78

4.3.6 OTHER DEVICE RUN SCREENS ...............................................................................................................79

4.3.6.1 PG7601 PRESSURE STANDARD...........................................................................................................79

4.3.6.2 FPG8601 PRESSURE STANDARD ........................................................................................................80

4.3.6.3 PPC3 (FPG’S PRESSURE CONTROLLER)............................................................................................80

4.3.6.4 RPM4 REFERENCE PRESSURE MONITOR .........................................................................................81

4.4 AUTOMATED TESTING ........................................................................................................................82

4.4.1 SETTING UP TO RUN AUTOMATED TESTS.............................................................................................82

4.4.1.1 SETTING UP DEVICE UNDER TEST (DUT)...........................................................................................82

4.4.1.2 SETTING UP TEST DEFINITIONS..........................................................................................................84

4.4.1.3 SETTING UP SUPPORT DEVICES.........................................................................................................85

4.4.1.4 TEST OPTIONS (DATA OPTIONS).........................................................................................................85

4.4.2 RUNNING AUTOMATED TESTS ................................................................................................................86

4.4.2.1 RUNNING A MANUAL TEST...................................................................................................................87

4.4.2.2 RUNNING A TEST DEFINITION..............................................................................................................87

4.4.3 TEST RUN SCREENS.................................................................................................................................88

4.4.3.1 DATA PLOT RUN SCREEN.....................................................................................................................89

4.4.3.2 DATA GRID RUN SCREEN.....................................................................................................................89

4.4.3.3 DUT/REFERENCE COMPARISON RUN SCREEN ................................................................................90

4.4.4 TEST DATA..................................................................................................................................................91

4.4.5 REPORT EDITOR........................................................................................................................................91

4.4.6 RUNNING A MODEL 3682 AIR DATA CALIBRATOR................................................................................92

4.4.6.1 RUNNING A VALIDATION (CALIBRATION) ...........................................................................................92

4.4.6.2 RUNNING A STANDARDIZATION..........................................................................................................97

5. REMOTE OPERATION ......................................................103

6. GENERAL MAINTENANCE AND ADJUSTMENTS ..................105

6.1 SUMMARY...........................................................................................................................................105

6.2 FPG8601, CHECK BUBBLER AND ADD WATER IF NECESSARY...................................................106

6.3 FPG8601, REMOVE CLEAN AND REINSTALL THE PISTON-CYLINDER........................................107

6.3.1 OVERVIEW................................................................................................................................................107

6.3.2 REMOVING THE PISTON-CYLINDER FROM THE MOUNTING POST...................................................109

6.3.3 REMOVING THE PISTON FROM THE CYLINDER ..................................................................................111

6.3.4 CLEANING THE PISTON AND CYLINDER..............................................................................................112

6.3.5 PUTTING THE PISTON INTO THE CYLINDER........................................................................................113

6.3.6 INST AL L I N G T H E P I S T O N -C Y L I N D E R I N T H E M O U N T I N G P O S T .................................................114

6.3.7 RESTORING PISTON-CYLINDER LUBRICATION AND MOBILITY........................................................115

6.3.7.1 OVERVIEW............................................................................................................................................115

6.3.7.2 PISTON CENTERING AND LUBRICATING METHODS.......................................................................115

6.4 PG7601, DISASSEMBLE PLATFORM AND REMOVE MOUNTING POST PRT................................117

6.5 PG7601, REMOVE AND REINSTALL THE AUTOMATED MASS HANDLER AND MASS SET ........118

6.5.1 THE MASS HANDLER (AMH)...................................................................................................................118

6.5.2 THE MASS SET.........................................................................................................................................121

6.6 PG7601, REMOVE, CLEAN AND REINSTALL THE PISTON-CYLINDER MODULE.........................122

6.6.1 REMOVING THE PISTON-CYLINDER MODULE .....................................................................................122

6.6.2 INSTALLING THE PISTON-CYLINDER MODULE ...................................................................................123

6.6.3 DISASSEMBLING THE MODULE AND CLEANING THE PISTON-CYLINDER ASSEMBLY..................124

6.6.3.1 OVERVIEW............................................................................................................................................124

6.6.3.2 DISASSEMBLING AND REASSEMBLING THE MODULE ...................................................................124

6.6.3.3 LUBRICATING THE PISTON-CYLINDER MODULE.............................................................................127

6.6.3.4 CLEANING THE PISTON-CYLINDER...................................................................................................128

6.7 PG7601, PISTON POSITION DETECTION ADJUSTMENT................................................................130

6.8 PG7601, REPLACE PISTON ROTATION DRIVE BELTS...................................................................131

6.9 PG7601, ADJUST INTERNAL VACUUM GAUGE...............................................................................131

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

6.10 PG7601/FPG8601, ADJUST PPC3 PRESSURE CONTROLLERS.....................................................132

6.11 CONTROL CABINET, INTERRUPTING PRESSURE SUPPLY TO THE TEST

GAS SUPPLY PORT ...........................................................................................................................133

6.12 CONTROL CABINET, DRAIN DRIVE AIR TRAPS..............................................................................133

6.13 CONTROL CABINET, CHECK GAS SUPPLY PANEL SETTINGS.....................................................133

7. MAINTENANCE OF TRACEABILITY AND RECALIBRATION ...135

7.1 PRINCIPLES OF ADCS-601-AF TRACEABILITY MAINTENANCE....................................................135

7.2 LOCAL METROLOGY MAINTENANCE BETWEEN RECALIBRATIONS ..........................................135

7.2.1 OVERVIEW................................................................................................................................................135

7.2.2 FPG8601, ZERO AND ADJUST SPAN OF LOAD CELL..........................................................................136

7.2.2.1 AUTOMATICALLY INITIATED LOAD CELL ZERO AND SPAN ADJUSTMENT...................................136

7.2.2.2 OPERATOR INITIATED LOAD CELL ZERO AND SPAN ADJUSTMENT ............................................137

7.2.3 FPG8601, VALIDATE WITH PG7601........................................................................................................137

7.2.3.1 OVERVIEW............................................................................................................................................137

7.2.3.2 RUNNING VALIDATION........................................................................................................................138

7.2.3.3 VIEWING FPG VALIDATION DATA ......................................................................................................141

7.2.4 FPG8601, CHECK ON-BOARD P, T, H MEASUREMENTS.....................................................................141

7.2.5 FPG8601, VALIDATE LOAD CELL LINEARITY.......................................................................................141

7.2.5.1 OVERVIEW............................................................................................................................................141

7.2.5.2 LINEARITY VERIFICATION PROCEDURE...........................................................................................142

7.2.5.3 EVALUATING LINEARITY VERIFICATION DATA................................................................................142

7.2.6 FPG8601 AND PG7601, ZERO REFERENCE VACUUM CDGS..............................................................143

7.2.7 PG7601, ADJUST ON-BOARD P, T, H SENSORS...................................................................................146

7.3 RECALIBRATION................................................................................................................................147

7.3.1 OVERVIEW................................................................................................................................................147

7.3.2 PG7601, CALIBRATION OF PISTON-CYLINDER MODULE...................................................................148

7.3.2.1 PREPARING FOR CALIBRATION.........................................................................................................148

7.3.2.2 UPDATING PISTON-CYLINDER CALIBRATION INFORMATION........................................................148

7.3.3 PG7601, CALIBRATION OF MASS SET...................................................................................................149

7.3.3.1 PREPARING FOR CALIBRATION.........................................................................................................149

7.3.3.2 UPDATING MASS SET CALIBRATION INFORMATION ......................................................................150

7.3.4 PG7601, CALIBRATION OF PISTON-CYLINDER MODULE TEMPERATURE SENSOR.......................151

7.3.4.1 OVERVIEW............................................................................................................................................151

7.3.4.2 PROCEDURE ........................................................................................................................................152

7.3.4.3 CALCULATING AND UPDATING PISTON-CYLINDER TEMPERATURE SENSOR INFORMATION..152

7.3.5 PG7601, CALIBRATION OF REFERENCE VACUUM CDG.....................................................................154

7.3.5.1 OVERVIEW............................................................................................................................................154

7.3.5.2 REMOVING THE CDG ASSEMBLY......................................................................................................154

8. TROUBLESHOOTING .......................................................157

8.1 OVERVIEW..........................................................................................................................................157

9. APPENDIX ......................................................................159

9.1 CONVERSION OF NUMERICAL VALUES..........................................................................................159

9.1.1 PRESSURE................................................................................................................................................159

9.2 GLOSSARY..........................................................................................................................................160

9.3 WARRANTY STATEMENT..................................................................................................................161

TABLES & FIGURES

AABBLLEES

Table 1. ADCS-601-AF packing list...........................................................................................................29

Table 2. Reference Bench parts list...........................................................................................................30

Table 3. Interconnections kit parts list .......................................................................................................31

Table 4. ADCS accessory kit parts list.......................................................................................................31

Table 5. PG7601 Platform parts list...........................................................................................................32

Table 6. PC-7100/7600-10, TC piston-cylinder module parts list..............................................................33

Table 7. MS-AMH-38 mass set parts list ...................................................................................................33

Table 8. AHM-38 automated mass handler parts list ................................................................................34

Table 9. FPG8601 Platform parts list.........................................................................................................34

Table 10. MS-8601-2 mass set parts list...................................................................................................35

Table 11. Valve states................................................................................................................................59

Table 12. User rights user access areas ...................................................................................................65

Table 13. ADCS Tools Main Menu and sub-menus summary ..................................................................69

Table 14. ADCS Main Toolbar buttons.......................................................................................................70

Table 15. ADCS Run Screen Control Panel features................................................................................75

Table 16. ADCS System Display symbols.................................................................................................77

Table 17. ADCS Run Screen Toolbar........................................................................................................78

Table 18. Mechanical maintenance procedures......................................................................................105

Table 19. PG7601 mounting post wire colors, description and location..................................................117

Table 20. Gas Supply Panel pressure settings........................................................................................133

Table 21. Metrological maintenance procedures.....................................................................................136

Table 22. FPG8601 P, T, H limits............................................................................................................141

Table 23. Recalibration requirements......................................................................................................147

Table 24. Troubleshooting checklist ........................................................................................................157

Table 25. Pressure unit of measure conversions ....................................................................................159

Table 26. DHI Authorized Service Providers ...........................................................................................161

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

IIGGUURREES

Figure 1. ADCS-601-AF overall, front view.................................................................................................. 6

Figure 2. ADCS-601-AF system pneumatic schematic ...............................................................................

Figure 3. ADCS-601-AF simplified operational schematic ..........................................................................8

Figure 4. ADCS-601-AF system electrical schematic.................................................................................. 9

Figure 5. ADCS-601-AF system communications schematic....................................................................10

Figure 6. ADCS-601-AF software, communications and control flow chart ..............................................11

Figure 7. Reference Bench,

Figure 8. Pneumatic Interconnections Box, bulkhead ...............................................................................13

Figure 9. Control Cabinet, front and rear views......................................................................................... 14

Figure 10. Gas Supply Panel..................................................................................................................... 15

Figure 11. Piston gauge operating principle..............................................................................................16

Figure 12. PG7601 Platform rear panel.....................................................................................................17

Figure 13. PG7000 Terminal front panel ...................................................................................................17

Figure 14. PG7000 Terminal rear panel ....................................................................................................18

Figure 15. PG7601 10 kPa/kg piston-cylinder module .............................................................................. 18

Figure 16. AMH-38 automated mass handler............................................................................................19

Figure 17. AMH-38 operating principle schematic...............................................................................

Figure 18. AMH-38 mass

Figure 19. Force balanced piston gauge operating principle.....................................................................22

Figure 20. FPG8601 front and rear views

Figure 21. PPC3 front panel ......................................................................................................................24

Figure 22. PPC3 rear panel.......................................................................................................................25

Figure 23. RPM4 front panel......................................................................................................................26

Figure 24. RPM4 rear panel.......................................................................................................................26

Figure 25. Turbo pump local interface panel

Figure 26. Typical layout of overall ADCS-601-AF system at site of use..................................................37

Figure 27. Piston-cylinder module installation...........................................................................................44

Figure 28. Local gravity and pressure medium fields in ADCS Tools .......................................................54

Figure 29. ADCS-601-AF simplified operational schematic ......................................................................59

Figure 30. ADCS Tools pressure exercis Figure 31. ADCS Tools pressure leak tes

Figure 32. ADCS-601-AF software, communications and control flow chart ............................................68

Figure 33. ADCS-601-AF program window...............................................................................................68

Figure 34. ADCS Main Toolbar..................................................................................................................70

Figure 35. ADCS Status Bar

Figure 36. ADCS Run Screen....................................................................................................................74

Figure 37. ADCS System Dis

Figure 38. PG7601 Run Screen.................................................................................................................79

Figure 39. FPG8601 Run Screen ..............................................................................................................80

Figure 40. PPC3 Run Screen ....................................................................................................................81

Figure 41. RPM4 Run Screen....................................................................................................................81

Figure 42. Data Plot Run Screen Figure 43. Data Grid Run Screen Figure 44. DUT/Reference Comparison Run Sc

top view.........................................................................................................12

......20

set.....................................................................................................................21

..................................................................................................23

(local control not used in regular ADCS-601-AF operation)....................................................28

e definition form..........................................................................64

t results form .............................................................................67

......................................................................................................................74

play..............................................................................................................78

...............................................................................................................89

..............................................................................................................90

reen................................................................................90

TABLES & FIGURES

Figure 45. FPG8601 bubbler and filter ....................................................................................................106

Figure 46. FPG8601 piston-cylinder assembly in mounting post............................................................108

Figure 47. Removing the FPG8601 mounting post .................................................................................110

Figure 48. Removing the FPG8601 piston-cyli

nder.................................................................................110

Figure 49. Alignment of the FPG8601 piston in the cylinder...................................................................113

Figure 50. AMH insta Figure 51. AMH mass

llation on PG7000 Platform....................................................................................119

set ........................................................................................................................122

Figure 52. PG7601 piston-cylinder module installation ...........................................................................123

Figure 53. 10 kPa/kg gas pist Figure 54. 10 k

Pa/kg pist

on-cylinder module, expanded view .........................................................125

on insertion tool................................................................................................126

Figure 55. 10 kPa/kg gas piston-cylinder module sleeve nut tool ...........................................................126

Figure 56. 10 kPa/kg piston-cylinder module lubric Figure 57. PG7601 pist Figure 58. ADCS Tools FPG Run Sc

on stroke and zones ...........................................................................................131

reen ...............................................................................................137

ation chart.................................................................128

Figure 59. ADCS Tools FPG Validation Setup Form...............................................................................140

Figure 60. ADCS Tools Figure 61. ADCS Tools CDG Zero Syst

FPG Validation Resu

em Display.................................................................................146

lts Form............................................................................140

Figure 62. PG7601 Ambient Sensors Adjust Form..................................................................................147

Figure 63. ADCS Tools PG7601 Piston-Cylinder Calibration Form ........................................................149

Figure 64. ADCS Tools PG7601 AMH-38 Mass Set Ca

libration Form ...................................................151

Figure 65. ADCS Tools PG7601 Piston-Cylinder Calibration Form ........................................................154

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

ABOUT THIS MANUAL

BBOOUUTT

This manual provides the information necessary to operate an ADCS-601-AF Air Data Calibration Standard. The ADCS-601-AF is a system made up of several standard instruments. This manual describes the individual instruments and their operation to the extent necessary for normal operation and maintenance of the ADCS-601-AF system. More detailed information on individual instruments and software is contained in each instrument or program’s specific operation and maintenance manual.

Before using the manual, take a moment to familiarize yourself with the Table of Contents structure. Set up of an ADCS-601-AF system should not be attempted without using Section 3. All first time ADCS-601AF users should read Section 4. Section 8 is a quick troubleshooting guide. Use the information in Section 8 to troubleshoot unexpected ADCS-601-AF behavior based on the symptoms of that behavior.

Certain words and expressions have specific meaning instruments. The Glossary (see Section 9.2) is useful as a quick reference for the definition of specific words and expressions as they are used in this manual.

HHIISS

AANNUUAAL

they pertain to ADCS-601-AF and its

Manual Conventions

(CAUTION) is used throughout the manual to identify user warnings and cautions.

(NOTE) is used throughout the manual to identify operating and applications advice and

additional explanations.

[ ] indicates direct function keys or objects (e.g., [RANGE]) on an instrument front panel keypad or in a software user interface.

< > indicates instrument front panel screen displays or labels in a software user interface (e.g., <1yes>)

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

1. INTRODUCTION

11.

ADCS-601-AF is a fully automated reference level Air Data Calibration Standard for the verification and calibration of air data range instruments, in particular Air Data Test Sets (ADTS). ADCS-601-AF’s intended function is the static pressure calibration of Pt and Ps range pressure transducers with very low measurement uncertainty. ADCS-601-AF is not intended to duplicate the functions of an ADTS in calibrating and testing onboard aircraft instruments.

ADCS-601-AF covers the pressure range of 1 to 380 kPa (0.3 to 120 inHg) in absolute and gauge modes with fully automated operation and state of the art uncertainty.

ADCS-601-AF is an integrated system made up of several instruments that work together under the control of ADCS Tools software running on a personal computer. Operator interaction with ADCS-601-AF is accomplished through the keyboard, pointing device and display of the system controller (personal computer).

The heart of the system is a fully automated PG7601 piston gauge or pressure balance that covers the range of 15 to 380 kPa (4.5 to 120 inHg). The PG7601 range is extended down to 1 kPa (0.3 inHg) by an FPG8601 force balanced piston gauge with automated pressure control.

NNTTRROODDUUCCTTIIOON

1.1 SPECIFICATIONS

1.1.1 ADCS SYSTEM GENERAL SPECIFICATIONS

Power Requirements

Instruments (AC1)

Reference vacuum pumps (AC2)

Utility pump (AC3)

Pressure Supply Requirements

Operating Temperature Range Weight

Reference bench

Utility and roughing vacuum pumps

Dimensions

Pressure Ranges Overall

PG7601 FPG8601

Operating Medium Pressure Connections

CE Conformance

Control cabinet

Reference bench

Control cabinet

TEST(+) port

TEST(-) port

100 to 240 VAC, 50/60 Hz, 240 W max. consumption Fuse: 250VT 10A 110 V version: 100 – 120V, 50/60 Hz, 1100 W max. consumption Fuse: 250VT 10A 220 V version: 200 – 240V, 50/60 Hz, 1100 W max. consumption Fuse: 250VT 10A 110 V version: 100 – 120V, 50/60 Hz, 800 W max. consumption Fuse: 250VT 10A 220 V version: 200 – 240V, 50/60 Hz, 800 W max. consumption Fuse: 250VT 10A

Drive air: 0.7 to 1 MPa (100 to 150 psi) Test gas: Nitrogen or air, 0.45 to 1 MPa (65 to 150 psi), clean and dry (instrument grade minimum, high purity preferred)

20 to 26 ºC

173 kg (380 lb) approx. (with turbo pump and controller installed) 105 kg (230 lb) approx. 19 kg (42 lb) each

145 cm H x 122 cm W x 76 cm D (57 in. x 48 in. x 30 in.) 124 cm H x 56 cm W x 66 cm D (49 in. x 22 in. x 26 in.)

1 to 380 kPa (0.3 to 120 inHg) 10 to 380 kPa (3 to 120 inHg) 1 to 15 kPa (0.2 to 4.5 inHg)

Nitrogen or air

Quick connector (1/4 in. NUPRO Quick connector (1/4 in. NUPRO

Available, must be specified.

SS-QC4-B1-400)

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

1.1.2 PG7601 PISTON GAUGE SPECIFICATIONS

1.1.2.1 AMBIENT AND PISTON-CYLINDER CONDITION MEASUREMENTS

Temperature

Range

Resolution

Measurement Uncertainty

Barometric Pressure

Range

Resolution

Measurement Uncertainty

Relative Humidity

Range

Resolution

Measurement Uncertainty

Piston Position

Range

Resolution

Measurement Uncertainty

Piston Rotation

(Rate and deceleration)

Range

Resolution

Reference Vacuum

(with on-board gauge)

Range

Resolution

Measurement Uncertainty

(with external capacitance diaphragm gauge)

Range

Resolution

Measurement Uncertainty

Ambient 0 to 40

0.1 0.01 ± 1 ± 0.1

70 to 110 kPa 10 Pa ± 140 Pa

5 to 95 % RH 1 % RH

± 10 % RH

± 4.5 mm

0.1 mm ± 0.2 mm

2 to 99 rpm 1 rpm

0 to 20 Pa

0.01 Pa ± 0.1 Pa or 10 % of reading, whichever is greater

0 to 13.3 Pa (100 mTorr)

0.001 Pa (0.01 mTorr) ± 0.05 Pa (0.38 mTorr)

Piston Cylinder Module

C 0 to 40 oC

1.1.2.2 PISTON-CYLINDER MODULE

PC-7100/7600-10

Nominal pressure to mass

Piston assembly nominal mass

Operation

Piston material

Cylinder material

Nominal diameter

Nominal area

Mounting system

Typtical drop rate

10 kPa/kg Gas operated, gas lubricated Tungsten carbide Tungsten carbide 35 mm 1 000 mm Positive free deformation

0.2 mm/min

0.5 kg

1. INTRODUCTION

1.1.2.3 MASS SET

Masses > 50g

Material

Finish

Uncertainty in

measured values

304L non-magnetic stainless steel Electropolished ± 5 ppm or 1 mg, whichever is greater

1.1.3 FPG8601 GENERAL SPECIFICATIONS

1.1.3.1 AMBIENT AND PISTON-CYLINDER CONDITION MEASUREMENTS

Temperature:

Range

Resolution

Accuracy

Relative Humidity:

Range

Resolution

Accuracy

Vacuum:

Range

Resolution

Accuracy

Ambient and Lubrication

Pressure Sensor:

Range

Resolution

Accuracy

Lubrication Gas [°C] [°C] 0 to 40 0 to 40

0.1 0.01 ± 0.2 ± 0.1

5 to 95 %RH 1 %RH ± 10 %RH

13.3 Pa (100 mTorr)

0.001 Pa (0.01 mTorr) ± 0.06 Pa (0.45 mTorr)

200 kPa 1 Pa ± 0.1 kPa

Piston-Cylinder

1.1.4 PRESSURE MEASUREMENT AND CONTROL SPECIFICATIONS

1.1.4.1 10 TO 380 KPA, PG7601 AND PPC3-700K

Sensitivity1

Precision

Measurement uncertainty

Control set point increments

Stability of set pressure

Typical control set point time

1 Sensitivity: The smallest variation in input detectable in output. 2 Precision: Combined linearity, hysteresis, repeatability. 3 Measurement uncertainty:

including all sources of uncertainty combined and expanded (k=2) following the ISO “Guide to the Expression of Uncertainty in Measurement.”

Maximum deviation of the indicated pressure from the true value of applied pressure

0.02 Pa + 0.5 ppm

± (0.01 Pa + 2 ppm)

see the piston-cylinder calibration report and current revision of DHI Technical Note 7920TN01.

1 kPa ± 1 Pa 60 to 180 seconds

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

1.1.4.2 1 TO 15 KPA, FPG8601 AND PPC3-100K

Resolution1

Precision

Measurement uncertainty

0.01 Pa

± (2 ppm + 50 mPa)

± 0.008% of reading or 0.3 Pa (0.0001 inHg) , whichever is larger

Control set point increments

Stability of set pressure

Typical control set point time

1 Resolution: Minimum display increment. 2 Precision: Combined linearity, hysteresis, repeatability. 3 Measurement uncertainty:

including all sources of uncertainty combined and expanded (k=2) following the ISO “Guide to the Expression of Uncertainty in Measurement.” Note: The uncertainty assigned to the FPG8601 used in an ADCS-601-AF system is expanded relative to the standard FPG8601 instrument. to allow validation by the PG7601 and an indefinite recalibration interval. See Section 7.2.3 and DHI Technical Note 2090TN05.

Maximum deviation of the indicated pressure from the true value of applied pressure

1 Pa ± 1 Pa (0.0003 inHg) 60 to 180 seconds

2. SYSTEM OVERVIEW

22.

YYSSTTEEMM

VVEERRVVIIEEW

2.1 ADCS-601-AF SYSTEM

ADCS-601-AF is a fully automated reference level Air Data Calibration Standard for the verification and calibration of air data range instruments, in particular Air Data Test Sets (ADTS). ADCS-601-AF’s intended function is the static pressure calibration of Pt and Ps range pressure transducers. To this end, the system automatically sets pressure values with very low measurement uncertainty in the range of 1 to 380 kPa (0.3 to 120 inHg) in absolute and gauge modes. ADCS-601-AF is not intended to duplicate the functions of an ADTS.

The ADCS-601-AF system is made up of two automated pressure standards with overlapping ranges to cover the full pressure range. An automated PG7601 piston gauge covers the range of 15 to 380 kPa (4.5 to 120 inHg) (see Section 2.2.1). The PG7601 range is extended down to 1 kPa (0.3 inHg) by an FPG8601 force balanced piston gauge with automated pressure control (see Section 2.2.2). The system also includes vacuum pumps and vacuum measurement instruments to support absolute mode operation.

in performing a comparison of the FPG8601

An RPM4 Reference Pressure Monitor is included to and PG7601 pressure standards.

assist

Physically, the ADCS-601-AF system is divided into two major components (see Figure 1). The Reference Bench (see Section 2.1.1) is a laboratory table onto which are installed the PG7601 and FPG8601 pressure standards, pneumatic control switching hardware and the reference vacuum pumping systems. The Control Cabinet (see Section 2.1.2) contains the PPC3 automated pressure controllers, RPM4 (personal computer) is connected to the system by a USB interface hub (See Figure 5).

The ADCS-601-AF system Section 4.3.1). ADCS Tools manages the entire system, communicating with other software programs and system instruments. ADCS Tools computers display, keyboard and pointing device.

See the following figures in this section describing the overall ADCS-601-AF system: Figure 1. ADCS-601-AF overall, front view Figure 2 ADCS-601-AF system pneumatic schematic Figure 3. ADCS-601-AF simplified operational schematic Figure 4. ADCS-601-AF system electrical schematic Figure 5. ADCS-601-AF system communications schematic Figure 6. ADCS-601-AF software and communications, flow chart

Reference Pressure Monitor and Gas Supply Panel (see Section 2.1.3). The system controller

is controlled by ADCS Tools software running on a personal computer (see

also

provides the overall system interface through the personal

Figure 7. Reference Bench, top view

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

1. Control cabinet

2. Reference bench

3. Turbo pump controller and reference turbo pump (behind controller)

Figure 1. ADCS-601-AF overall, front view

4. Reference roughing vacuum pump

5. Utility vacuum pump Note: System controller (PC), display and

keypad not shown

2. SYSTEM OVERVIEW

Figure 2. ADCS-601-AF system pneumatic schematic

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

Figure 3. ADCS-601-AF simplified operational schematic

2. SYSTEM OVERVIEW

Figure 4. ADCS-601-AF system electrical schematic

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

Figure 5. ADCS-601-AF system communications schematic

2. SYSTEM OVERVIEW

Figure 6. ADCS-601-AF software, communications and control flow chart

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

2.1.1 REFERENCE BENCH

The ADCS-601-AF Reference Bench is a wooden topped laboratory work bench onto which are installed the PG7601 and FPG8601 pressure standards. Also included on the bench is a pneumatic interconnections box (see Figure 8), the system connections to the device under test (DUT) and the pumping system for the reference vacuum against which absolute pressure is defined.

1. Pneumatic interconnections box

2. PG7601 piston gauge

3. FPG8601 force balanced piston gauge

4. FPG Terminal

5. FPG reference vacuum CDG

6. Reference vacuum manifold

7. PG Terminal

8. Reference turbo pump and controller, reference roughing vacuum pump, utility vacuum pump

Figure 7. Reference Bench, top view

9. AMH-38 automated mass handler

10. Reference vacuum vent valve

11. PG reference vacuum CDG

12. Pressure Connection, TEST (+) (connect absolute pressure tests and “high” side of differential pressure tests)

13. Pressure Connection, TEST (-) (connect low side of differential pressure tests)

14. Reference connection to atmosphere for gauge mode operation

2. SYSTEM OVERVIEW

1. Connection to FPG8601’s PPC3 pressure controller TEST(+) port in control cabinet, 1/4 in. SWG

2. Connection to FPG8601’s PPC3 pressure controller TEST(-) port in control cabinet, 1/4 in. SWG

3. Connection to valve driver manifold in control cabinet, (8) channel pneumatic

4. Connection to RPM4 TEST(+) port in control cabinet, 1/4 in. SWG

5. Connection to utility vacuum source, 1/4 in. SWG

6. Connection to PG7601’s PPC3 pressure controller TEST(+) port in control cabinet, 1/4 in. SWG

Figure 8. Pneumatic Interconnections Box, bulkhead

2.1.2 CONTROL CABINET

The ADCS-601-AF Control Cabinet is a 19 inch rack mount enclosure into which are mounted the PPC3 pressure controllers that provide automated pressure control for the PG7601 and FPG8601 pressure standards and an RPM4 Reference Pressure Monitor used to perform the validation comparison of the PG7601 and FPG8601 (see Figure 9). Also included in the control cabinet are electrical

power

Section 2.1.3) which sets and indicates gas pressure supplies to various parts of the system.

connections and a Gas Supply Panel (see

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

1. Main power switch for utility vacuum pump (AC3)

2. Main power switch for reference vacuum roughing pump, turbo pump and turbo pump controller (AC2)

3. Main power switch for all instruments (AC1)

4. RPM4 used in comparison to validate FPG8601 with PG7601

5. Connections for remote communication with device under test (RS232, USB, IEEE-488)

6. PPC3 pressure controller for PG7601 system

7. PPC3 pressure controller for FPG8601 system

8. Access door to Gas Supply Panel

1. Power sockets for system components

2. Utility vacuum supply connection (1/4 in. NPT F)

3. Control Cabinet connections pass through and storage

4. Power cable holder for stress relief

5. Drive air supply connection (1/4 in. NPT F)

6. Test gas supply connection (1/4 in. NPT F)

7. Power supply connections (IEC-320-C13)

Figure 9. Control Cabinet, front and rear views

2. SYSTEM OVERVIEW

2.1.3 GAS SUPPLY PANEL

The Gas Supply Panel is in the ADCS-601-AF Control. It is accessed by a door in the lower part of the front of the Control Cabinet (see Figure 9).

The Gas Supply Panel is used to set and indicate gas pressure supplies ADCS-601-AF systems and components (see Figure 10).

to various

1. Regulator and gauge to set PG7601’s AMH (automated mass handler) drive air pressure.

2. Regulator and gauge to set drive pressure for system pneumatically actuated vavles.

3. Regulator and gauge to set FPG8601 piston-cylinder purge pressure supply

4. Regulator and gauge to set pressure supply to the PG7601 system’s PPC3 pressure controller

5. Regulator and gauge to set pressure supply to the FPG8601 system’s PPC3 pressure controller

6. Gas supply panel gauges and regulators

7. Drive air supply 5 micron filter trap

8. Drive air supply coalescing filter trap

*See Section 6.13 for regulator set values

Figure 10. Gas Supply Panel

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

2.2 PRESSURE STANDARDS

2.2.1 PG7601 PISTON GAUGE

The heart of the ADCS-601-AF Air Data Calibration Standard is a PG7601 gas operated piston gauge. The PG7601 piston gauge system includes:

- PG7601 piston gauge platform with terminal (on reference bench)

- PC-7600/7100-10, TC 10 kPa/kg piston-cylinder module (mounted in platform)

- MS-AMH-38, 38 kg mass set (installed on platform)

- AMH-38-VAC, automated mass handler (installed on platform)

- CDG-VAC-REF, capacitance diaphragm gauge with display and isolation valve for

measurement of PG7601 reference vacuum in absolute mode (installed on platform)

- PPC3-700K pressure controller to automate PG7601 system pressure control (in

The PG7601 piston gauge, AMH-38 automated mass handler and PPC3-pressure

control cabinet).

controller are stand alone products for which separate Operation and Maintenance manuals are available with much more complete information than is included in this manual. Copies of these manuals are provided on the ADCS-601-AF Support CD and are available at www.dhinstruments.com.

The PG7601 operates on the principle of the piston gauge in which pressure is defined by balancing it against a known force on a known area (see Figure 11). The known area is defined by a vertically mounted piston rotating in a cylinder and the known force is applied to

the

the piston by loading it with known mass subjected to acceleration due to gravity.

When force applied by the pressure and the force applied by the mass accelerated by gravity are in equilibrium, the piston floats and the pressure under the piston remains constant. The pressur e can be calculated following the equation in Figure 11. The pressurized fluid under the piston also

lubricates

the gap between the piston and the cylinder. When floating, the piston must be

rotating to keep it well centered in the cylinder. The PG7601 is equipped with a 10 kPa/kg piston-cylinder module and 38 kg mass set, giving

it a range of 10 to 380 kPa (3 to 120 inHg). The PG7601 Platform includes a bell jar that can be evacuated with a vacuum pump so that pressure can be defined against vacuum (absolute mode) or atmosphere (gauge mode). The AMH-38 mass handler allows the mass load to be changed automatically. The PPC3 pressure controller adjusts pressure automatically to float the piston (see Section 2.2.3).

Figure 11. Piston gauge operating principle

2. SYSTEM OVERVIEW

2.2.1.1 PG7601 PLATFORM

The PG7601 Platform is the instrument base into which the piston-cylinder onto which the masses are loaded is mounted. The platform also includes the PG7601’s electronic measurement system.

The PG7601 Platform rear panel provides the connection to the PG Terminal, remote communication connections and pressure connection ports.

1. COM2 (RS232) - External vacuum gauge (Reference vacuum CDG)

2. COM3 (RS232) – PPC3 pressure controller, AMH automated mass handler

3. COM1 (RS232) – System controller (PC) communications

4. Ambient temperature sensor

5. IEEE-488 - host communications (not used)

6. Ambient relative humidity sensor

7. Pressure ports: TEST port (DH200), VACUUM vent port (DH200, not used)

8. PG7000 Terminal port

Figure 12. PG7601 Platform rear panel

2.2.1.2 PG7601 TERMINAL

The PG7000 Terminal contains the PG7601 power supplies. It also provides a local user interface through a 2 x 20 vacuum fluorescent display and 4 x 4 membrane keypad. Local commands to PG7601 are not used in normal ADCS-601-AF operation. See the PG7000 Operation and Maintenance manual for details on local operation of PG7000.

1. Fluorescent display

2. Keypad

Figure 13. PG7000 Terminal front panel

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

The PG7000 Terminal rear panel assembly provides the communications connection to the PG7000 Platform and the power connection module.

Figure 14. PG7000 Terminal rear panel

2.2.1.3 PG7601 10 KPA/KG PISTON-CYLINDER MODULE

The piston-cylinder module is mounted in the PG7601 Platform (see Section

2.2.1.1) and performs the pressure to force conversion.

1. Power switch

2. Fuse

3. Power receptacle

4. Connector for cable to PG7000 (25-pin)

5. Cooling fan

Figure 15. PG7601 10 kPa/kg piston-cylinder module

2. SYSTEM OVERVIEW

2.2.1.4 AMH-38 AUTOMATED MASS HANDLER

The AMH-38 automated mass handler is mounted on the PG7601 Platform (see Section 2.2.1.1) and serves to automatically change the mass load on the pistoncylinder to set different values of pressure.

The AMH-38 automated mass handler is a stand alone product for which a

separate Operation and Maintenance manual is available with much more complete information than is included in this manual. A copy of the AMH manual is provided on the ADCS-601-AF Support CD and is available at www.dhinstruments.com

1. KF-40 vacuum connections (2)

2. Lifting handles (2)

3. Mass lifter and pneumatic actuation solenoid valves

4. Vacuum bell jar (delivered with PG7601 Platform)

Figure 16. AMH-38 automated mass handler

5. AMH status indication LED

6. RS232 Port, COM1

7. DC power connection

8. Drive air pressure connection

9. Drive vacuum connection

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

1. Mass loading bell

2. Binary mass tubes

3. Binary mass selection pins

4. Flexible diaphragm

5. Mass lifting assembly

6. Lifting ledge on mass lifting shaft

7. Electronics and electrical controls

8. Mass lifter

9. Solenoid valve

10. Binary mass carrier

11. Main mass column rotation belt

12. Piston cap

13. Main mass column

14. Main masses

Figure 17. AMH-38 operating principle schematic

2. SYSTEM OVERVIEW

2.2.1.5 AMH-38 MASS SET

The masses of the 38 kg mass set are loaded onto in the piston-cylinder as required to apply a force corresponding the the set pressure desired. The AMH-38 mass handler (see Section 2.2.1.4) loads and unloads the masses automatically.

Figure 18. AMH-38 mass set

2.2.2 FPG8601 FORCE BALANCED PISTON GAUGE

The ADCS-601-AF Air Data Calibration Standard includes an FPG8601 force balanced piston gauge to cover the air data pressure range below the range of the PG7601 gas operated piston gauge. The FPG8601 system includes:

- FPG8601 piston gauge platform with terminal and 10 kPa/kg piston-cylinder (installed on Reference Bench).

- Capacitance diaphragm gauge with display and isolation valve for measurement of FPG8601 reference vacuum in absolute mode (mounted on platform).

- PPC3-100K A116Ks/BG15Ks, pressure controller to automate FPG8601 system pressure control (see Section 2.2.3) (in control cabinet).

- MS-8601-2, 2 kg mass set with

(accessory used separately in metrological maintenance (see Section 7.2.5)).

The FPG8601 force balanced piston gauge and PPC3 pressure controller are stand alone

products for which separate Operation and Maintenance manuals are available with much more complete information than is included in this manual. A copy of the FPG8601 manual is provided on the ADCS-601-AF Support CD and is available at www.dhinstruments.com.

The FPG8601 operates on the principle of the piston gauge (see Section 2.2.1); however, the force resulting from a difference in pressure across the piston is measured by a force balanced, load cell rather than balanced directly against masses subjected to the acceleration due to gravity (see Figure 11). The piston-cylinder is suspended from the load cell. Rather than rotating the piston in the cylinder, the piston-cylinder gap is conical and gas flow through the gap is used to center the piston. The force across the piston is to the load cell through a coupling system. There are two independent chambers at either end

of the piston-cylinder. The lower chamber is held at atmosphere or vacuum while the pressure to be measured is applied to the upper chamber. The load cell is zeroed with a pressure difference of zero across the piston (bypass open), taring out the weight of the piston and coupling and other parasitic forces. Then, with the pressure bypass between the

hanger for validation of FPG8601 load cell linearity.

transmitted

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

two chambers closed, the net force resulting from the difference in pressure between the two chambers is transmitted to the load cell through the coupling. The value of the pressure is calculated from the effective area of the piston-cylinder and the net force value measured by the load cell. The 10 kPa/kg piston-cylinder combined with 1.5 kg net measurement span of the load cell give the FPG8601 a pressure range of 0 to 15 kPa (4.5 inHg).

The FPG8601 Platform is interfaced with the system controller (PC) running FPG Tools software that calculates pressure and controls the FPG8601 functions.

The PPC3 pressure controller is used to automate pressure control to set the pressure measured by the FPG8601.

SUPPLY

REG

LUBRICATING

FLOW

MASS

COMPARATOR

lub

ref

Figure 19. Force balanced piston gauge operating principle

2. SYSTEM OVERVIEW

2.2.2.1 FPG8601 PLATFORM

1. Upper mounting post

2. TEST(+) port, KF-16

3. Mounting post temperature sensor (PRT) connector

4. TEST(-) port, KF-16

5. Lower mounting post

2.2.3 PPC3 PRESSURE CONTROLLERS

The ADCS-601-AF system includes two PPC3 pressure controllers that are installed in the Control Cabinet (see Section 2.1.2). One of the pressure controllers is used to automate pressure control for the PG7601 piston gauge system (see to automate pressure control of the FPG8601 force balanced piston gauge system.

The two pressure controllers are:

6. Vacuum reference port, KF-25

7. Mounting post reference

8. Reference vacuum CDG connector

9. CDG port, KF-16

10. Instrument reference level

1. COM2 (RS232) - Not used

2. COM1 (RS232) – remote host communications

3. IEEE-488 – remote host communications – Not used

4. Utility vacuum port, 1/8 in. NPTF

5. Bubbler

6. Lubrication pressure supply port, 1/8 in. NPTF

7. Drive air supply, 1/8 in. NPTF

8. Coalescing filter

9. Drivers option connector

– Not Used

10. COM3 (RS232) – Not used

11. FPG Terminal port

Figure 20. FPG8601 front and rear views

Section 2.2.1). The other is used

PPC3-700K – for the PG7601 piston gauge system. PPC3-100K A116Ks/BG15Ks with special very low pressure control option for

the FPG8601 force balanced piston gauge system.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

The PPC3 pressure controllers are stand alone products for which a separate Operation

and Maintenance manual is available with much more complete information than is included in this manual. A copy of the PPC3 manual is provided on the ADCS-601-AF Support CD and is available at www.dhinstruments.com.

The PPC3 pressure controller uses on/off solenoid valves and internal high precision pressure transducers to adjust and stabilize pressure precisely in response to remote commands.

The PPC3 front panel provides a local user interface and display for the PPC3 Pressure Contro ller. Local commands to PPC3s are not used in normal ADCS-601-AF operation. See the PPC3 Operation and Maintenance manual for details on local operation of PPC3.

1. Ready/Not ready indicator

2. Display

3. Remote activity indicator

Figure 21. PPC3 front panel

4. Cursor control keys

5. Multi-function keypad

6. Direct pressure control keys

2. SYSTEM OVERVIEW

1. Label, product

2. VENT port

3. COM2 connector

4. IEEE-488 connector

5. COM1 connector

6. Drivers (12 V) connector

7. Power switch

8. Fuse

9. Electrical power connector (IEC-320-C13)

10. Remote [ENT] connector

11. Pressure connection, TEST(+)

12. Pressure connection, TEST(-)

13. Pressure connection, EXHAUST

14. Pressure connection, SUPPLY

Figure 22. PPC3 rear panel

2.2.4 RPM4 A116K REFERENCE PRESSURE MONITOR

The ADCS-601-AF system includes an RPM4 Reference Pressure Monitor that is installed in the Control Cabinet (see Section 2.1.2). The RPM4 is used as a precise pressure comparator in the process of compar validating the FPG8601 (see Section 7.2.3).

The RPM4 is an RPM4 A116Ks.

The RPM4 pressure controller is a stand alone product for which a separate Operation

and Maintenance manual is available with much more complete information than is included in this manual. A copy of the RPM4 manual is provided on the ADCS-601-AF Support CD and is available at www.dhinstruments.com.

The RPM4 Reference Pressure Monitor includes a very high precision pressure transducer (Q-RPT) and the necessary hardware to connect the transducer to the ADCS-601-AF TEST (+) port when it is needed or isolate and vent it when it is not.

The RPM4 front panel provides a local user interface and display for the RPM4 Reference Pressure Monitor. Local commands to RPM4 are not used in normal ADCS-601-AF operation. See the RPM4 Operation and Maintenance manual for details on local operation of RPM4.

ing the PG7601 and FPG8601 measurements when

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

1. Ready/Not Ready indicator

2. Display

3. Remote activity indicator

4. Cursor control keys

5. Multi-function keypad

Figure 23. RPM4 front panel

1. 12VDC power supply connection

2. Remote [ENT] connector

3. IEEE-488 connector

4. COM2 connector

5. COM1 connector

6. Power switch

7. Fuse

8. Electrical power connector (IEC-320-C13)

9. Fan

10. Product label (bottom of case)

11. TEST(+) pressure port

12. TEST(-) pressure port

13. ATM pressure port

Figure 24. RPM4 rear panel

2. SYSTEM OVERVIEW

2.3 VACUUM PUMPS

The ADCS-601-AF vacuum pumps are stand alone products for which separate Operation and

Maintenance manuals are available with much more complete information than is included in this manual. A copy of the manual is provided on the ADCS-601-AF Support CD.

There are two vacuum sources in the ADCS-601-AF system.

- Utility vacuum source: The utility vacuum source provides vacuum to the pressure controllers so that they can control pressure under atmospheric pressure. The utility vacuum source is a dry, scroll pump that is normally located under the Reference Bench and has single connection to the Control Cabinet rear panel.

- Reference vacuum source: The reference vacuum source provides vacuum to the reference circuit of the PG7601 and FPG8601 pressure standards for operation in absolute mode. The reference vacuum source consists of a roughing pump and a turbo molecular pump. The roughing pump is a dry, scroll pump located under the Reference Bench. The turbo molecular pump is mounted to the bottom surface of the Reference Bench and includes a Controller mounted in a bracket under the Reference Bench.

See the original manufacturer Operation and Maintenance Manuals for additional information on the turbo molecular pump and turbo pump controller.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

1. Local power switch

2. Display

3. Turbo pump life button

4. Turbo pump conditions button

5. Turbo pump START/STOP button.

6. Turbo pump LO SPEED button

Figure 25. Turbo pump local interface panel (local control not used in regular ADCS-601-AF operation)

3. INSTALLATION

33.

NNSSTTAALLLLAATTIIOON

3.1 UNPACKING AND INSPECTION

Check that all items included in the ADCS-601-AF system are present and have NO visible signs of damage. A parts list of the major components supplied and how they are packed is provided in Table 1. Unpack and inspect the items following the instructions in Sections 3.1.1 to 3.1.12 and detailed parts list Table 1 to Table 10.

Table 1. ADCS-601-AF packing list

COMPONENT SHIPPED IN SECTION

Control Cabinet wood crate 3.1.1 N/A Reference Bench wood crate 3.1.2 Table 2 ADCS-601-AF interconnections kit corrugated container in

ADCS-601-AF accessories kit corrugated container in

Reference vacuum CDG assembly for PG7601

PG7601 Platform, PG7000 Terminal and accessories

PG7601 bell jar double corrugated

PG7601 piston-cylinder module and accessories (PC-7100/7600-10, TC)

PG7601 mass set (MS-AMH-38) (2) molded transit

PG7601 automated mass handler (AMH-38)

FPG8601 Platform, FPG8000 Terminal, piston-cylinder and accessories

FPG piston insertion tool corrugated container in

FPG8601 mass set (MS-FPG-2) molded transit case in

(2) scroll vacuum pumps corrugated containers

Turbo molecular vacuum pump corrugated container

System controller (personal computer with display, keypad and pointing device)

System controller stand corrugated container 3.1.12 N/A

Reference Bench wood crate

corrugated container in Reference Bench wood crate

molded transit case in corrugated outer carton

container corrugated container

with foam insert , PVC bullet case

cases in corrugated outer carton

corrugated container with foam inserts

molded transit case in corrugated outer carton

Reference Bench wood crate

corrugated outer carton

with inserts in Reference Bench wood crate

(2) corrugated containers

3.1.2 Table 3

3.1.2 Table 4

3.1.2 N/A

3.1.3 Table 5

3.1.3 N/A

3.1.4 Table 6

3.1.5 Table 7

3.1.6 Table 8

3.1.7 Table 9

3.1.2 N/A

3.1.8 Table 10

3.1.2 N/A

3.1.11 N/A

DETAIL

TABLE

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

3.1.1 ADCS CONTROL CABINET

The ADCS Control Cabinet weighs more than 100 kg (220 lb.). Do not attempt to remove

it from the crate with less than two personnel qualified to handle heavy items.

The Control Cabinet (p/n 402198) is shipped in a large, wooden crate. To unpack: Remove the top and at least two sides of the crate. Remove the packing bag from

the cabinet. Lift and roll the cabinet out of the crate. This requires more than one person. There are no accessories or items other than the Control Cabinet itself packed in the Control

Cabinet crate.

3.1.2 ADCS REFERENCE BENCH AND ACCESSORIES

The Reference Bench is shipped assembled in a wooden crate. Tubing and accessories, a power strip and the vacuum turbo pump controller are mounted on the bench.

Also packed in the Reference Bench wooden crate are:

- ADCS interconnections kit in a corrugated container

- PG7601 reference vacuum CDG assembly in a corrugated container

- ADCS accessories kit in plastic bags

- FPG8601 piston insertion tool in a corrugated container

- (2) scroll vacuum pumps

- turbo molecular pump

To unpack: Remove top and at least two sides from the wood crate. Remove corrugated containers from under the bench taking care not to damage the vacuum pump controller and bracket mounted on the front of the bench. Remove the bench from the pallet.

Table 2 to Table 4 detail all items included with the Reference Bench and packed in the reference bench wooden crate.

Table 2. Reference Bench parts list

DESCRIPTION PART #

1 ea. Reference bench with wood top (145 cm H x 122 cm W x 76 cm D (57 in. x 48 in.

x 30 in.)) 1 ea. Pneumatic interconnections and switching box (mounted on top of bench) 402214 1 ea. TEST port bracket (mounted on top of bench) 402230

1 set. Interconnecting tubing (mounted on top of bench) in 402230,

1 ea. Turbo pump controller in bracket with power cord installed (mounted on bench) 402212 1 ea. Power strip (mounted under bench) in 402210

402211

402210

402214

3. INSTALLATION

Table 3. Interconnections kit parts list

DESCRIPTION PART #

402213

1 ea. Tube, turbo pump vent (1/8 in. PFA) 402237 1 ea. Tube assembly, interconnections box to FPG TEST (1/4 in. s.s. with 1/4 in.

402234

Swage x KF16 adaptor) (not in corrugated container, secured to top of bench) 1 ea. Tube, interconnections box to FPG CONTROL (1/4 in. s.s.) (not in corrugated

402235

container, secured to top of bench) 1 ea. Tube assembly, turbo pump to FPG VACUUM port (1/4 in. PFA. with 1/4 in.

402236

Swage x KF16 adaptor) 1 ea. Tube assembly, utility vacuum pump to Control Cabinet (3/8 in. PFA with 3/8 in.

402238

Swage x KF25 adaptor) 1 ea. Adapter, 3/8 in. Swage x 1/4 in. NPT M 101806 1 ea. Adapter, 1/8 in. Swage x 10-32 O-seal 124436 2 ea. Mounting bracket (main vertical vacuum tube) 123911 2 ea. Screw and washer, M4, vacuum tube mounting bracket collar 101016-Z,

100918-Z

4 ea. Screw and washer, 1/4-20., vacuum tube mounting bracket to bench 103846,

103435-Z,

102620-Z 4 ea. Centering ring, KF16 101544 4 ea. Clamp, KF16 102975 1 ea. Tee, KF16 103696 1 ea. Adaptor, KF25 x KF16 103237 5 ea. Centering ring, KF25 101542 5 ea. Clamp, KF25 102121 1 ea. Hose, KF25 with flanges (PVC) 103720 3 ea. Centering ring, KF40 103245 1 ea. Screen, with KF40 centering ring 103633 4 ea. Clamp, KF40 103246 1 ea. Blank-off cap, KF40 103310 1 ea. Cross, KF40 103649 1 ea. Nipple, KF40 103651 1 ea. Adaptor, KF40 x KF25 (bellows) 124098 1 ea. Plug, DH200 M 100279 1 ea. Adaptor, 1/4 in. Swage x 1/8 in. NPT M 102033 2 ea. Adaptor, 1/8 in. Swage x 1/8 in. Legris 103425

Table 4. ADCS accessory kit parts list

4 ea. Power cord (14 AWG,15 Amp) (AC1, AC2, AC3, turbo pump controller bracket) 103690 3 ea. Fuse, 250VT 10A 103697 2 ea. Quick connect stem, 1/8 in. NPT F 102116 2 ea. Quick connect stem, 1/4 in. NPT F 102117 2 ea. Quick connect stem, AN4 M 102115 1 ea. Adaptor, KF40 x KF16 103650 1 ea. ADCS-601-AF Operation and Maintenance Manual (hard copy) 550140

DESCRIPTION PART #

402224

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

DESCRIPTION PART #

9 ea. Calibration report:

- PG7601 Platform

- PG7601 10 kPa/kg piston-cylinder module

- PG7601 AMH mass set

- PG7601 reference vacuum CDG

- FPG8601 platform with FPG8601 piston-cylinder

- FPG8601 reference vacuum CDG

- FPG8601 2 kg mass set

- RPM4 A116Ks

- PPC3-100K A116Ks/BG15Ks 1 ea. ADCS-601-AF Test Report 550141 1 ea. ADCS-601-AF Support CD 402215 1 ea. DHI General Accessory CD 102987

402224

550100

3.1.3 PG7601 PLATFORM AND BELL JAR

The PG7601 Platform is shipped in a molded transit case. The PG7601 Platform accessories are also included in the case. The PG7601 bell jar is packed in a separate double corrugated container.

To unpack proceed as follows:

Open the PG7601 shipping and storage case. Remove the PG Terminal and accessories from the upper packing insert. Inspect and

inventory the accessories (see Table 5).

Remove the upper packing insert. Carefully lift the PG7601 Platform from its position in the lower packing insert. Note the

orientation so that the same orientation is used when PG7601 is repacked.

Reinstall the upper packing insert into the shipping and storage case and store in a safe place.

Table 5. PG7601 Platform parts list

DESCRIPTION PART #

1 ea. PG7601 platform including: 402216 1 ea.

1 ea. PG7000 Terminal 401284 1 ea. Power cord, 7.5 ft 100770 1 ea. Cable, PG Terminal to Platform 102227 1 ea. Molded transit case (in which the Platform is shipped) 122576

Accessory kit including: 402217

2 ea. O-ring, Buna 2-242 101976 1 ea. Tool, 3 mm hex wrench (with T handle) 103473 1 ea. Cable, null modem 402114 1 ea. Allen wrench, 5 mm 102262 1 ea. Spanner wrench (metrological) 122568 1 ea. 1 ea. Gift kit with gloves 400511

Bell jar and seal (in separate double corrugated container)

Krytox® GPL205/6 .5 oz.

122106 and

101546

102496

3.1.4 PG7601 PISTON-CYLINDER MODULE (PC-7100/7600-10,TC)

The piston-cylinder module is shipped in a PVC bullet case packed in a corrugated container with custom foam inserts. The piston-cylinder module accessories are also in the corrugated container.

Open the corrugated container and remove the piston-cylinder module and accessories.

3. INSTALLATION

The bullet case screws open by turning the lid counterclockwise. Table 6 details all items included with the PG7601 piston-cylinder module.

Table 6. PC-7100/7600-10, TC piston-cylinder module parts list

DESCRIPTION PART #

1 ea. PC-7100/7600-10, TC piston-cylinder module 401418 1 ea. PVC bullet case 401642

Accessory kit including: 401243

1 ea. O-ring, Viton 2-222 101918 1 ea. O-ring, Viton 2-130 102380 1 ea. Piston insertion tool 122186

401562

3.1.5 PG7601 MASS SET (MS-AMH-38)

The stability over time of PG7601 pressure measurements is a function of the stability of

the masses loaded on the piston. Precautions should be taken in handling the masses to minimize influences that may change their mass. This includes always wearing protective gloves when handling the masses to avoid contaminating them with body oils and perspiration. Protective gloves are provided in the accessory kit of the PG7601 Platform.

The PG7601 mass set is shipped in (2) molded transit cases. The PG7601 masses should be removed from their shipping cases and inventoried when actually setting up the PG7601 system.

To unpack: Do not unpack the masses until you are ready to install them on the PG7601 Platform (see Section 3.3.9.2). Wear protective gloves when handling the masses. Carefully remove each mass from the transit case and take it out of its sealed plastic bag.

Table 7 details all items included with the MS-AMH-38 mass set.

Table 7. MS-AMH-38 mass set parts list

DESCRIPTION PART #

1 ea. Molded transit case 402096 1 ea. Molded transit case 123949

38 kg mass set including: 402233

1 ea. Mass loading bell 402090 1 ea. Binary mass carrier 123855 1 ea. Mass lifting shaft/trim mass tray 402113 1 ea. 0.1 kg tubular mass 123850-01 1 ea. 0.2 kg tubular mass 123850-02 1 ea. 0.4 kg tubular mass 123850-03 1 ea. 0.8 kg tubular mass 123850-04 1 ea. 1.6 kg tubular mass 123850-05 1 ea. 3.2 kg tubular mass 123850-07 5 ea. 6.4 kg mass disc 123851

402219

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

3.1.6 PG7601 AUTOMATED MASS HANDLER (AMH-38)

The AMH-38 automated mass handler is delivered in a corrugated container with foam inserts. The AMH-38 accessories are included in the same corrugated container.

Remove all parts from the shipping container. Be sure not to lose or discard the accessories. Table 8 details all items included with the AMH-38 automated mass handler.

Table 8. AHM-38 automated mass handler parts list

DESCRIPTION PART #

1 ea. AHM-38 Automated Mass Handler 402100

Accessory kit including: 402218

1 ea. 15 VDC power supply 103986 1 ea. Power cord 100770 4 ea. Cable tie, hook and loop 103485 1 ea. O-ring, Viton, 2-273 103493

3.1.7 FPG8601 PLATFORM, PISTON-CYLINDER AND ACCESSORIES

The FPG8601 Platform is shipped in a molded transit case. The FPG8601 Platform accessories are also included in the case.

The FPG8601 piston insertion tool is packed in a separate corrugated container.

To unpack proceed as follows:

Open the FPG8601 shipping and storage case. The top of the case removes completely. Remove the FPG Terminal, piston-cylinder, manifold, vacuum reference CDG assembly

and accessories from the upper packing insert. Inspect and inventory (see Table 9).

Remove the upper packing insert. Carefully lift the FPG8601 Platform from its position in the lower packing insert.

Reinstall the upper packing insert into the shipping and storage case and store in a safe place.

Table 9 details all items included with the FPG8601 Platform.

Table 9. FPG8601 Platform parts list

DESCRIPTION PART #

1 ea. FPG8601 Platform including: 402207 1 ea. FPG8000 Terminal 401671 1 ea. Cable, FPG Terminal to Platform 102227 1 ea. Power cord 100770 1 ea. Bypass manifold 402209 2 ea. Piston-cylinder O-ring carriers (taped to front of FPG Platform) in 402207 1 ea. Valve, FPG CONTROL, tube pneumatically actuated (Valve 11) in 402209 1 ea. CDG, reference vacuum assembly with valve 402227 1 ea. Cable, CDG connection 402228 1 ea. Piston-cylinder assembly in PVC bullet case 401662 1 ea. Molded transit case (in which the Platform is shipped) 123346

3. INSTALLATION

Accessory/interconnect kit including: 402226

4 ea. KF16 clamps 102975

DESCRIPTION PART #

4 ea. KF16 centering rings 101544 1 ea. Blank-off cap, KF16 103238 1 ea. O-ring, silicone, 2-128 103621 1 ea. O-ring, Vitonr brown, 2-128 103692 1 ea. O-ring, silicone, 2-151 103004 1 ea. Bottle, 125 ml, distilled water 402229 1 ea. Piston insertion tool (in separate corrugated carton in Reference Bench

wood crate)

402231

3.1.8 FPG8601 MASS SET (MS-8601-2)

Precautions should be taken in handling the masses to minimize influences that may

change their mass. This includes always wearing protective gloves when handling the masses to avoid contaminating them with body oils and perspiration. Protective gloves are provided in the accessory kit of the PG7601 Platform.

The FPG8601 mass set is shipped in a black, molded plastic case in a corrugated liner. The FPG8601 mass set is not used in day to day ADCS-601-AF operation (see Section 7.2.5). Table 10 details all items included with the FPG8601 mass set.

Table 10. MS-8601-2 mass set parts list

DESCRIPTION PART #

1 ea. CLB hanger 401789 1 ea. Molded case with insert 402072 3 ea. 0.5 kg mass 123500 2 ea. 0.2 kg mass 123498 1 ea. 0.1 kg mass 123496

401672

3.1.9 SCROLL VACUUM PUMPS

Two identical scroll vacuum pumps are included in the ADCS-601-AF system. One is the roughing pump for the reference vacuum turbo pump. The other is the utility vacuum pump.

The pumps are delivered with their power cord in corrugated containers with foam inserts. The part number of the scroll pump is 103630 or 103717.

3.1.10 TURBO MOLECULAR VACUUM PUMP

The turbo molecular vacuum pump is delivered in a corrugated container with foam inserts. The part number of the turbo molecular pump is 103631

3.1.11 SYSTEM CONTROLLER

The system controller consists of a personal computer, flat panel display, keyboard and pointing device (“mouse”). These are packed in (2) to (4) corrugated containers, depending on configuration.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

The system controller is delivered with all necessary ADCS-601-AF system software preloaded including:

- ADCS Tools-AF™

- FPG Tools™

- COMPASS for Pressure™

- USB hub driver

The part number of the system controller is 103388.

3.1.12 SYSTEM CONTROLLER STAND

The system controller stand is packed in a corrugated container with assembly instructions. For most users, the stand is a temporary solution for mounting the system controller at the time of initial system installation and start up.

The part number of the system controller stand is 103695.

3.2 SITE REQUIREMENTS

The environment required to operate an ADCS-601-AF Air Data Calibration Standard within its estimated measurement uncertainty limits is generally that of a high level, physical metrology laboratory.

When selecting and preparing a site to set up the ADCS-601-AF system, the following should be considered:

• Ambient conditions: To achieve optimum metrological performance, ambient conditions should be controlled and maintained within the following limits:

• Temperature: 19 to 23 °C, minimize rate of change of temperature.

• Relative Humidity: 10 to 60 %RH (non-condensing).

• Ambient Pressure: Minimize external influences that will cause barometric instability.

• Air Currents: Do not install the ADCS-601-AF Reference Bench under a source of vertical air currents

such as an overhead air conditioning or heating ducts. These can exaggerate rate of change of ambient temperature.

• Vibration: Minimize local vibration. Excessive vibration will reduce the stability of the pressures

defined by PG7601 and the FPG8601 (vibration affects the floating piston).

• Overall footprint: The ADCS-601-AF Control Cabinet and Reference Bench must be disposed as shown in Figure 1. Select a location where adequate space is available, also consider the location of the system controller (PC) and connection of a ADCS-601-AF system layout at site of use.

• Access to rear of Control Cabinet and Reference Bench: To perform maintenance functions troubleshoot the ADCS-601-AF system, it is necessary to have access to the rear of the Control Cabinet and Reference Bench. Be sure the ADCS-601-AF is installed so that 360 degree access to areas of the system is available.

• Electrical power supply: Plan the supply of electrical power to the Control Cabinet. See Section

1.1.1 for electrical power requirements. Note that the vacuum pumps draw a particularly when starting up.

device under test (DUT). See Figure 26 for typical

and

high

amount of power,

• Pressure supplies: Plan the pneumatic pressure supplies to the rear panel of the Control Cabinet. Two separate supplies are required (see Section 1.1.1). The Test Gas Supply must be very clean

dry. This gas supplies the PG and FPG piston-cylinders. Cleaner gas will reduce maintenance

and by reducing the necessary piston-cylinder cleaning frequency.

• Bell jar and AMH placement: Plan a location for the PG7601 bell jar and automated mass handler when they are removed from the platform.

3. INSTALLATION

Figure 26. Typical layout of overall ADCS-601-AF system at site of use

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

3.3 SETUP

Before setting up the ADCS-601-AF system, see Section 3.2 for information on site requirements.

ADCS-601-AF is a complex system made up of several sub-systems. Setting up and verifying the

complete system is an extensive, step by step, process in which the sequence of operations is important. Always follow the instructions in Sections 3.3.1 to 3.4.6 in sequential order when setting up and verifying the system. Allow a minimum of three hours to complete the process.

To set up the ADCS-601-AF system, first unpack it following the instructions in Section 3.1. Then follow the set up instructions in Sections 3.3.1 to 3.3.13 sequentially. Once the system is set up, power it up, initialize it and verify it following the instructions in Section 3.4.

Note all fittings, adaptors and parts mentioned in the setup instructions are included with the ADCS-601-AF

lis

unless specifically stated otherwise. See the parts

When assembling, use Teflon® tape or other appropriate thread sealer on all NPT thread fittings.

ts in Section 3.1 to locate all parts.

3.3.1 POSITION THE REFERENCE BENCH

Refer to the Site Requirements section of this manual and then position the bench and table where you want them (See Section 3.2). Consider positioning of everything including gas supplies, pumps, access to rear of system, DUT and computer.

Move the Control Cabinet out of the way until it is needed.

3. INSTALLATION

3.3.2 INSTALL REFERENCE TURBO VACUUM AND ROUGHING PUMPS

Attach the turbo pump to the

vacuum tube that extends down through the bench using a KF40 flange and a the KF40 centering ring with a screen. Orient the pump so that its lateral KF16 flange is facing towards the rear of the bench.

Attach turbo pump controller

cable (on turbo pump controller) to the turbo pump.

Install PFA vent bleed tube

between the adaptor and the valve attached to the turbo pump controller bracket.

Install a KF16 tee onto the

turbo pump KF16 fitting. Orient the tee so that the common port is connected to the turbo pump and the legs are pependicular to the pump body.

Install a KF16 x KF25

adapator on the right side (looking from rear) of the KF16 vacuum tee.

Position vacuum roughing

pump under the bench (the two scroll vacuum pumps provided are identical, so either one may be used here).

Connect turbo pump KF25 connection to roughing pump using KF25 plastic hose.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

3.3.3 POSITION THE PG7601 AND FPG8601 PLATFORMS ON THE REFERENCE BENCH

Place the PG7601 and FPG8601 Platforms and their Terminals in their approximate positions on the bench (see Figure 7).

3.3.4 PREPARE FPG8601

Attach the FPG manifold to the

KF16 FPG8601 high control port. Do not make the low control port connection. Connect the 1/8 in. plastic tube included with the manifold between valve 10 on the manifold and the V10 port on the FPG platform.

Attach FPG valve 11 to the 1/4

Swage fitting on the top of the FPG manifold. Orient the valve so that the flow arrow points away from the manifold (up). Connect the 1/8 in. plastic tube included with valve 11 between valve 11 and the

V11 port on the FPG platform.

Install a KF16 blank-off cap on

the FPG8601 low test port.

Install 1/8 in. NPT M x 1/8 in. Legris adaptors into the DRIVE IN and LUBRICATION

SUPPLY ports on the rear of the FPG8601 Platform (see Figure 20).

Install a 1/8 NPT M x 1/4 in. Swage adaptor into the VACUUM port on the rear of the

FPG8601 Platform (see Figure 20).

Connect the FPG vacuum tube assembly (1/4 in. PFA with 1/4 in. Swage x KF16

adaptor installed) between the FPG VACUUM port and the KF16 tee previously installed on the turbo pump under the bench.

Connect the FPG8000 Terminal to the rear of the FPG8601 platform rear with the 25 pin

cable.

Connect the FPG8601 power cord (16 AWG) from the FPG8000 Terminal to the power

strip underneath the bench. Do not power up the FPG8601.

Fill the FPG8601 bubbler bowl with distilled water (see Section 6.2).

3. INSTALLATION

3.3.5 MAKE PNEUMATIC INTERCONNECTIONS ON THE REFERENCE BENCH

Remove and set aside the cover from

the Reference Bench pneumatic interconnections box by removing the four screws that hold it (see Figure 7).

Unwind the (4) 1/8 in. pneumatic lines

coming out of the interconnections box.

Connect the 1/4 in. stainless steel tube

labeled FPG CNTL to the inside of the FPG CONTROL port on the interconnections box bulkhead. Before tightening, orient the tube so that the connection to the top port of valve 11 on the FPG8601 can be made (see Section

3.3.4). Make the connection to valve 11. Tighten both fittings.

Connect the 1/4 in. stainless steel tube labeled FPG TEST to the 1/4 in. Swage open

port on valve 2 in the interconnections box. Before tightening, orient the tube so that the KF16 connection to the FPG8601 high test port can be made(see Section 3.3.4). Make the connection to the FPG high test port. Tighten the 1/4 in. Swage connection.

There is a 1/4 in. stainless steel tube

with a 1/4 in. Swage by DH200 M adaptor installed coming out of the interconnections box. Connect the DH200 M end of the adaptor to the TEST port on the rear of the PG7601 platform. The gland and collar for the DH200M adaptor are delivered in the TEST port. Be sure both the Swage and swage DH200 M nuts are tight.

Install a DH200 stainless steel plug in

the VACUUM port on the rear of the PG7601 platform. The gland for the DH200M plug is delivered in the TEST port. No collar us used with a plug.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

Make the PG7601 platform lateral

KF25 vacuum port connection to the Reference Bench tubing using a KF25 clamp and centering ring.

Ensure that the 1/8 in. pneumatic line

labeled 4 is connected between the interconnections box and the valve labeled V4 at the PG7601 lateral KF25 vacuum port.

Connect the 1/8 in. pneumatic line

labeled 7 from the interconnections box to the DRIVE IN port on the rear of the FPG8601 platform.

Ensure that the 1/8 in. pneumatic line

labeled 6 runs from the interconnections box down through the reference vacuum tube hole in the bench and connects to the valve labeled V6 on the back of the turbo pump controller bracket.

Reinstall the Reference Bench pneumatic interconnections box cover that was removed in .

3.3.6 POSITION CONTROL CABINET AND MAKE PNEUMATIC, COMMUNICATIONS AND ELECTRICAL CONNECTIONS TO REFERENCE BENCH

Position the Control Cabinet next to the Reference Bench (see Figure 26). Once the

Cabinet is positioned, extend the feet under each corner of the cabinet to level the cabinet in a fixed position.

Unwind the large bundle of pneumatic tubes and electrical connections that originate

from the rear opening of the cabinet.

Connect the large, grey, (8) port connector from the Control Cabinet to the VALVE

CONTROL connection on the Reference Bench interconnections box bulkhead.

Connect the 1/4 in. PFA tube labeled MONITOR to the MONITOR connection on the

Reference Bench interconnections box bulkhead.

Connect the 1/4 in. PFA tube labeled PG CNTL(+) to the PG CONTROL(+) connection

on the Reference Bench interconnections box bulkhead.

Connect the 1/4 in. PFA tube labeled UTIL VAC to the UTILITY VACUUM connection on

the Reference Bench interconnections box bulkhead.

Connect the 1/4 in. PFA tube labeled FPG CNTL(-) to the FPG CONTROL(-) connection

on the Reference Bench interconnections box bulkhead.

Connect the 1/4 in. PFA tube labeled FPG CNTL(+) to the FPG CONTROL(+)

connection on the Reference Bench interconnections box bulkhead.

Connect the 1/8 in. PFA tube labeled FPG LUB SUP to the LUBRICATION SUPPLY

port on the rear of the FPG8601 platform.

Connect the 9 pin D-sub cable labeled PG COM1 to the COM1 port on the rear of the

PG7601 Platform.

3. INSTALLATION

Connect the 9 pin D-sub cable labeled PG COM2 to the COM2 port on the rear of the

PG7601 Platform.

Connect the 9 pin D-sub cable labeled PG COM3 to the COM3 port on the rear of the

PG7601 Platform.

Connect the 9 pin D-sub cable labeled FPG COM1 to the COM1 port on the rear of the

FPG8601 Platform.

Connect a 14 AWG/20 A power cord from the rear of the turbo pump controller enclosure

to the AC2 REFERENCE ROUGHING PUMP CONTROLLER socket on the rear of the Control Cabinet. Do NOT connect it to the AC2 REFERENCE TURBO PUMP CONTROLLER socket.

Connect the reference vacuum roughing pump cord to one of the two power sockets on

the rear of the turbo pump controller enclosure.

Connect the power cord from the power strip under the Reference Bench to the AC1

BENCH INSTRUMENTS socket on the rear of the Control Cabinet.

Connect 14 AWG/20 A power cords from the AC1, AC2 and AC3 IEC connectors on the

rear of the Control Cabinet to a 110 V, 60 Hz power supply.

Power up the Control Cabinet by operating the REFERENCE BENCH (AC1) power

switch on the front, top, left of the cabinet. The two PPC3 pressure controllers and the RPM4 reference pressure monitor will power up and go to their main run screens. Do NOT operate either of the PUMP (AC2, AC3) power switches.

3.3.7 CONNECT PRESSURE SUPPLIES TO CONTROL CABINET

Connect a drive air supply to the DRIVE AIR SUPPLY port on the rear of the Control

Cabinet. The fitting is a 1/4 in. NPT F. The connecting tube and adaptor are not supplied. See Section 1.1.1 for drive air supply requirements.

Connect an instrument gas supply to the TEST GAS SUPPLY port on the rear of the

Control Cabinet. The fitting is a 1/4 in. NPT F. The connecting tube and adaptor are not supplied. See Section 1.1.1 for test gas supply requirements.

3.3.8 APPLY SUPPLY PRESSURES AND CHECK GAS SUPPLY PANEL SETTINGS

Once the TEST GAS SUPPLY has been applied, do not interrupt it without following the

procedure described in Section 6.11.

Open the door on the front of a Control Cabinet to access the Control Panel. Key to the

door lock is stored inside the door. Verify that the AMH DRIVE and FPG LUBRICATION regulators on the Control Panel are off (regulator set fully counter clockwise).

Apply the supply pressure to the SUPPLY ports on the rear of the Control Cabinet (see

Section 3.3.7, Steps 1, 2).

Leave the AMH DRIVE and FPG LUBRICATION regulators set to zero. Check and

adjust the other Control Panel regulator settings as necessary. See Section 6.13 for definition of correct settings.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

3.3.9 SET UP THE PG7601

3.3.9.1 PREPARE THE PLATFORM AND INSTALL THE PISTON-

CYLINDER MODULE

Connect the PG7601 Terminal to the PG7601 platform rear with 25 pin cable. Connect the PG7601 power cord from the PG7000 Terminal to the power

strip underneath the bench. Do not power up the PG7601.

Remove the PG7000 Platform mounting post plug. Unscrew the ORANGE

plastic mounting post plug that is installed in the PG7000 Platform mounting post. Rotate counterclockwise to remove.

Remove the PC-7100/7600-10, TC piston-cylinder module from its bullet

case. Open the bullet case by rotating its lid counterclockwise. Remove the piston-cylinder module from the bullet case base by unthreading it from the case. Hold the piston-cylinder module body by the knurled area and rotate it counterclockwise.

Place the piston-cylinder module (thread down) into the PG7601 mounting

post (see Figure 27). Rotate the piston-cylinder module clockwise until all threads are engaged and there is NO gap module and the PG7601 mounting post. Slight resistance will be encountered in the second half of travel as the piston-cylinder module Orings seat in the mounting post.

between the piston-cylinder

3.3.9.2 INSTALL THE AMH-38 MASS SET

The stability over time of PG7601 pressure measurements is a function of

See Section 2.2.1.5 to identify the different elements of the 38 kg mass set.

Figure 27. Piston-cylinder module installation

the stability of the masses loaded on the piston. Precautions should be taken in handling the masses to minimize influences that may change their mass. This includes always wearing protective gloves when handling the masses to avoid contaminating them with body oils and perspiration. Protective gloves are provided in the accessory kit of the PG7601 Platform.

3. INSTALLATION

Open the mass set molded, transit cases and remove all the masses and

mass set elements from their plastic bags.

Place the pyramidal shaped binary mass carrier on top of the piston cap. Slip the mass loading bell over the binary mass carrier and slide it down until

the inside top of the bell sits on the binary mass carrier.

Install the main mass discs (6.4 kg each with AMH-38) onto the mass bell

starting with mass #1 and loading up in sequential order. Mass #1

should be at the bottom of the stack and mass #5 at the top. The mass sequence numbers are laser marked on the top surface of each mass. Pass the mass disc over and down the mass loading bell and center it on the ledge at the bottom of the bell. Load the rest of the main masses, sequentially, onto the bottom mass.

Install the binary mass tubes concentrically from the largest to smallest,

outside to inside. The largest, long tubes slip down between the main mass stack and the bell and rest on the ledge at the bottom of the mass bell. The smaller masses load onto the pyramidal steps of the binary mass carrier.

This phase of mass set installation is complete. The mass lifting shaft assembly

is not yet installed. It will be installed after the AMH autmomated mass handler is installed over the masses on the platform (see Section 3.3.9.3).

3.3.9.3 INSTALL THE AMH-38 MASS HANDLER

Place the AMH-38 mass handler on top of the Control Cabinet or at another

convenient location near the PG7601 Platform.

Connect the AMH-38 15V power supply to the rear of the AMH-38 and plug it

into the power strip under the Reference Bench.

Connect the 9 pin D-sub cable labeled AMH COM1 to the COM1 port on the

rear of the AMH-38.

Connect the 1/8 in. pneumatic line labeled 8 RED from the Reference Bench

interconnections box to the drive air port on the back of the AMH-38. The drive air port is the top port of the two quick connectors with a red band. Press the quick connect stem into the connector firmly until it clicks into place.

Open the door on the front of a Control Cabinet to access the Control Panel.

Set the AMH DRIVE regulator on the Control Panel as specified in Section 6.13.

Insert the mass lifting shaft into the hole in the center of the AMH mass lifter and

slide it down until the trim mass tray sits on the top of the lifter. This arrangement trips the AMH’s internal proximity sensor allowing the AMH system to be operated off of the PG7000 Platform without an actual mass load.

Set the COM1 and COM2 ports of the PPC3-700K pressure controller and

the COM3 port of the PG7601 (see Section 3.4.2).

Power up the PG7601 Platform using the power switch on the rear of the

PG7000 Terminal. If the PG7601 is already powered up, use [SPECIAL], <8AMH>, <2control>, <3loadall> from the PG7000 Terminal front panel. The AMH-38 trim mass tray should rise approximately 2.5 cm (1 in.) above the top of the lifter; followed by the sound of the main mass selection columns rotating. Then the trim mass tray should be lowered back down. The steps of this procedure are commented on the PG Terminal display as they execute. See Section 6.5 for additional information on installing and removing AMH-38 from the PG7601 Platform.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

Visually inspect the condition of the AMH-38 mass handler by carefully

tipping it to look inside. The main mass selection columns should have all their flat surfaces (no ledges) oriented towards the center and all binary mass selection pins should be retracted. If these conditions are present the AMH-38 is ready to install on the PG7601 Platform.

Install the AMH-38 mass handler onto the PG7601 Platform (see Section

6.5.1, Figure 50). Verify that the O-ring is installed on the bottom circumference of the AMH-38 vacuum chamber. Using the handles on the

the AMH-38 vacuum chamber, lift the AMH-38 above the PG7601

side platform and masses. Center it over the mass load and gently lower it down until the bottom circumference of the AMH-38 vacuum chamber reaches the PG7601 vacuum plate. Check that the vacuum chamber is well aligned on the vacuum plate.

Connect the 1/8 in. PFA tube labeled 5 (with blue band on quick connect

stem) from the Reference Bench interconnections box to the vacuum port on the back of the AMH-38. The vacuum port is the bottom port of the two quick connectors with a blue band. Press the quick connect stem into the connector firmly until it clicks into place.

It is imperative that the mass loading shaft be fully threaded into the binary

mass tray. Be sure to use the T handled 3 mm allen wrench to tighten the shaft to the end of the threads applying sufficient torque to cause the mass load to rotate. Failure to fully screw in the shaft will cause misalignment between the mass handler and the mass load that may cause damage to the AMH-38 mass handler when operated.

Install the AMH-38 mass lifting shaft. Slip the threaded end of the shaft

down through hole in the center of the mass lifter (see Section 6.5.1, Figure

Thread the shaft into the binary mass carrier by holding and rotating the

50). trim mass tray. NOTE THAT SHAFT HAS A LEFT HAND THREAD SO IT MUST BE ROTATED COUNTER-CLOCKWISE TO TIGHTEN IT. Use the T handled, 3 mm allen wrench supplied in the AMH-38 accessories to tighten the assembly. Tighten until you feel the mass start to rotate.

Level the PG7601 Platform using its two leveling feet and the level mounted

on the top of the AMH-38 mass handling system.

3.3.9.4 INSTALL THE REFERENCE VACUUM CDG ASSEMBLY

The PG7601 and FPG8601 reference vacuum CDGs are delivered with an

isolation valve connected to them. This valve is normally closed and serves to maintain vacuum on the CDG at all times as exposing the CDG to atmospheric pressure will cause zero shifts. New CDGs are shipped with vacuum behind the isolation valve. Do not break the valve fittings or operate the valve without establishing vacuum first.

Connect the PG7601 reference vacuum CDG assembly (CDG, valve, KF16 x

KF40 adaptor) to the KF40 port on the left (viewed from front) of the AMH-38 vacuum chamber. Use a KF40 centering ring and clamp. Install so that the CDG body is in the vertical position.

Connect the 15 pin cable labeled PG CDG from the Control Cabinet to the

top of the CDG.

3. INSTALLATION

Connect the 1/8 drive air tube labeled 3 from the Reference Bench

interconnections box to the valve labeled V3 on the PG7601 CDG assembly.

3.3.10 COMPLETE FPG8601 SETUP

3.3.10.1 INSTALL THE PISTON-CYLINDER

NEVER touch the lapped surfaces (polished appearance) of the piston or

cylinder with your bare hands. Body oils and acids can permanently etch the surfaces.

The FPG8601 10 kPa/kg piston-cylinder is shipped in a PVC bullet case.

Open the piston-cylinder bullet case by rotating its lid counterclockwise (if

necessary, remove the 2.5 mm countersunk screw on the lower (flat) section of the bullet case to vent the inside of the case).

Remove the upper section of the bullet case. Put on gloves to protect the piston-cylinder from contamination before

handling it.

Cup the exposed piston-cylinder with one hand and turn the piston-cylinder

lower section of the bullet case upside down supporting the piston-cylinder

with the cupped hand. Lift the lower section of the bullet case off of the piston-cylinder. Place the piston-cylinder on to a stable soft surface (lint-free towels). Take

care that the piston does not slide out of the cylinder. Remove the FPG8601 lower mounting post. Loosen the nut at the center of

mounting post while applying slight upward pressure with one hand under

the lower mounting post. The upward pressure is necessary to relieve the

threads of the mounting post while turning the nut. Remove the shipping insert from the mounting post by removing the indexing

pin and piston retaining nuts. Install the piston-cylinder in the mounting post following the instructions in

Section 6.3.6.

3.3.10.2 CONNECT THE MANIFOLD AND VALVE 9

The bypass/control manifold is connected to the right side (viewed from the front) of the FPG8601 Platform. The manifold itself was already connected to the FPG8601 (see Section 3.3.4) and the piston-cylinder has already been installed (see Section 3.3.10.1).

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

Connect the lower KF16

manifold tube to the KF16

low control port on the

FPG8601 mounting post. Connect the FPG8601

vacuum isolation valve

(valve 9) to the bottom of

the lower mounting post at

the KF25 connection.

Mount the valve so that

main body is vertical and

the lateral KF25 port is to

the left (viewed from the

front). Connect the 1/8 in.

pneumatic line labeled 9

from the FPG8601

vacuum isolation valve

(valve 9) to the V9 port on

the front of the FPG8601. Level the FPG8601 using

the bubble level on the top of the platform and the back two leveling feet.

3.3.10.3 INSTALL THE REFERENCE VACUUM CDG ASSEMBLY

The PG7601 and FPG8601 reference vacuum CDGs are delivered with an

Connect the FPG8601 reference vacuum CDG assembly (CDG, KF16

clamp/o-ring, KF16 pneumatic valve) to the KF16 port on the front of the

mounting post. Install so that the CDG body is in the vertical position. Connect the CDG electrical cable to the VACUUM SENSOR electrical

connector on the front of the FPG8601 platform. Connect the 1/8 in. pneumatic line labeled 12 from the CDG isolation valve

(valve 12) to the V12 port on the front of the FPG8601.

3. INSTALLATION

3.3.11 COMPLETE REFERENCE VACUUM INTERCONNECTIONS

Connect the KF40 cross to the AMH-

38 right side (viewed from front) KF40 fitting.

Connect the KF40 cross to the

vertical vacuum tube (that comes up through the bench). Adjust the position of the vertical tube if necessary by loosening and retightening the holding collar on the vertical tube brackets (under the bench).

Connect the KF40 cross to the

bellows adaptor KF40 connection.

Connect the KF25 port on the bellows

adaptor to the FPG8601 valve 9 KF25 port. It may be necessary to move the FPG slightly.

Connect the KF40 blank-off cap to the top port of the KF40 cross.

Verify the bubble level on top of the FPG8601 platform and re-level if necessary.

3.3.12 INSTALL THE UTILITY VACUUM PUMP

Position the utility vacuum pump under the bench. The two scroll vacuum pumps

provided are identical, so either one may be used here.

Install a 3/8 in. Swage x 1/4 in. NPT M adaptor on the Control Cabinet UTILITY VACUUM port. Connect the utility pump inlet to the Control Cabinet UTILITY VACUUM port using the

3/8 in. PFA with 3/8 Swage x KF25 adaptor installed tube assembly.

Connect the utility pump power cord to the AC2 UTILITY PUMP socket on the rear of the

control cabinet.

3.3.13 SET UP THE SYSTEM CONTROLLER (PC)

The system controller is a standard personal computer with flat screen display, keyboard and pointing device. These may be installed on the computer stand supplied or at any other convenient location.

Connect the USB cable labeled PC USB that comes out of the back of the Control Cabinet to a USB port on the back of the system controller (PC).

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

3.4 POWER UP, INITIALIZATION, VERIFICATION

3.4.1 MAIN POWER SWITCHES

Turn ON the INSTRUMENTS power switch on the front, top, left of the Control Cabinet.

The (2) PP3 pressure controllers and the RPM4 reference pressure monitor in the Control Cabinet should initialize and go their main run screens. If they do not power up, check from the rear of the Control Cabinet that their power cords are properly connected and/or that the power switch on the power strip inside the Control Cabinet is ON.

Turn ON the UTILITY PUMP power switch on the front, top, left of the Control Cabinet. If

the utility pump does not power up, check the power switch on the pump and turn it ON if necessary.

If ADCS Tools software is currently ON, be sure the current measurement mode is

gauge. Turn ON the REFERENCE PUMPS power switch on the front, top, left of the Control Cabinet. The reference turbo and roughing pumps should NOT start up as ADCS Tools controls a relay on the circuit so that these pumps power up only when absolute measurement mode is set.

3.4.2 SET OR VERIFY DEVICE COMMUNICATION PORT AND OTHER SETTINGS

3.4.2.1 COMMUNICATION PORTS

On the RPM4 A116K front panel use [SPECIAL], <2remote>, <1COM1> to set the COM1 port.

On the PPC3-200K A116K/BG15K front panel use [SPECIAL], <2remote>, <1COM1> and <2COM2> to set the COM1 and COM2 RS232 ports.

On the PPC3-700K front panel use [SPECIAL], <2remote>, <1COM1> and <2COM2> to set the COM1 and COM2 RS232 ports.

On the PG7601 Terminal front panel, use [SPECIAL], <5remote>, <1COM1>, <2COM2> (after COM2 select <1settings>) and <3COM3>, <to set the COM1, COM2 and COM3 RS232 ports.

The correct settings for all RS232 (COM) ports are.

Baud 9 600 Parity NONE Length 8 Stop Bit 1 Terminators <CR><LF> (PG7601 only)

3.4.2.2 PG7601 EXTERNAL VACUUM GAUGE COMMUNICATION

On the PG7601 Terminal front panel, select [SPECIAL], <5remote>, <2COM2>, <3vac>, <2user>.

When <COM2 meas req string> is displayed, use the [→] key to scroll through characters until a <p> is displayed. Then press [ENT] followed by [ESC]. Choose <2yes> in response to the <Save edits> prompt.

When <Reply conv coef> is displayed, press [ENT] to accept the value of <1.00 Pa/unit>.

3. INSTALLATION

When <Leading characters to strip> is displayed, press [ENT] to accept the value of <0>.

3.4.2.3 EDIT AND SELECT PG7601 SETUP FILE

On the PG7601 Terminal front panel, select [SETUP], <3edit>. When <Edit SETUP file:> is displayed, press [ENT] to accept <#2 >. Then select <7vac>, <4COM2>. Press [ESC] and in response to <Save as

SETUP file:> press [ENT] to accept <#2 > . This returns operation to the MAIN RUN screen.

Select [SETUP], <1select>. When <Use SETUP file:> is displayed, enter <2>. <Initializing extern vac sensor> should be displayed briefly. If a failure

message is displayed, check COM ports (see Section 3.4.2.1)

3.4.3 PG7601

3.4.3.1 POWER UP

In normal ADCS-601-AF operation, the PG7601 is controlled remotely by ADCS Tools software. For power up and initialization, the PG7601’s PG7000 Terminal

keypad and display are used. Turn the PG7601 power ON by pressing the power ON/OFF switch on the rear

panel of the PG7000 Terminal. Observe the display as the terminal connects with the PG7601 Platform, tests, initializes and goes to the main run screen.

If <….Searching…..> displays for more than 5 seconds, the communications between the PG7000 and the PG Terminal are failing. Check that the PG7601 to PG Terminal cable is properly installed.

If PG7601 fails to reach the main run screen, service may be required. Record the sequence of operations and displays observed and contact a DHI Authorized Service Provider (see Table 26).

3.4.3.2 INITIALIZATION

VERIFY THE PISTON-CYLINDER MODULE, MASS SET AND MASS LOADING BELL

PG7601 uses stored piston-cylinder and mass set metrological information to calculate the reference pressures it defines (see the PG7000 Operation and Maintenance Manual for more detail). For the pressure values to be correct, the stored metrological information on the piston-cylinder and mass set must be correct. Before using PG7601 for accurate pressure definition, the validity of the stored information should be verified. This consists of comparing the pistoncylinder and mass set information stored in PG7601 to the information in the current piston-cylinder and mass set calibration reports.

With a new ADCS-601-AF system, the piston-cylinder module and mass set information have already been loaded into the PG7601.

To verify the PG7601 piston-cylinder and mass set information, use the viewing capabilities accessed by pressing [SPECIAL], <1PC/MS> on the PG7000 Terminal. Compare the information contained in the PG7601 piston-cylinder and mass set files to the information on the piston-cylinder and mass set calibration reports.

VERIFY SETUP FILE

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

PG7601 uses many variables in calculating defined pressures. The sources of the variables are determined by the current SETUP file. SETUP files are viewed, created, edited and selected using the SETUP function accessed by pressing

[SETUP] on the PG7000 Terminal. ADCS-601-AF systems use SETUP file #2. VERIFY/SELECT AUTOGEN ON Press [AutoGen] on the PG7000 Terminal. AutoGen should be ON. VERIFY/SELECT AUTOROTATE ON Press [Rotate] on the PG7000 Terminal. AutoRotate should be ON. VERIFY AMBIENT CONDITION MEASUREMENTS

PG7000 automatically measures ambient conditions and uses these conditions in its pressure calculations.

To verify that the ambient condition measurements are operating properly proceed as follows:

• Display current ambient condition readings: Press [AMBIENT] on the

PG7000 Terminal. The ambient conditions run screen is displayed.

• Verify proper ambient condition readings: Compare the ambient condition

values displayed to the actual values of ambient conditions. Refer to the PG7601 ambient condition measurement specifications when evaluating the ambient readings (see Section 1.1.2.1).

3.4.4 FPG8601

3.4.4.1 POWER UP

Turn the FPG8601 power ON by pressing the power ON/OFF switch on the rear panel of the FPG8000 Terminal. Observe the display as the terminal connects with the FPG8000 Platform, tests, initializes and goes to the main run screen.

If <….Searching…..> displays for more than 5 seconds, the communications between the FPG8601 and the FPG Terminal are failing. Check that the FPG8601 to FPG Terminal cable is properly installed.

If the FPG Terminal fails to reach the main run screen, service may be required. Record the sequence of operations and displays observed and contact a DHI Authorized Service Provider (see Table 26).

3.4.5 START UP SYSTEM CONTROLLER AND SOFTWARE

To start up the system controller proceed as follows:

Turn ON the system controller using its power switch and wait for it to complete booting

to the normal desktop.

Run the FPG Tools program using the icon on the desktop. Once the FPG Tool

program has completed booting, select [Run], [Run Monitor]. During initialization select

<Gauge> measurement mode. Wait for initialization to complete.

Run the ADCS Tools program using the icon on the desktop. Select the [ON] button on

the main ADCS Toolbar (see Section 4.3.3). ADCS Tools initializes the complete ADCS-601-AF system. Warnings that the system calibration has changed may appear. This is normal as ADCS Tools is writing to its database for the first time. Select [OK] in response to these warnings.

Set system local gravity and test gas species in ADCS Tools following the instructions in

Sections 3.5 and 3.6.

3. INSTALLATION

It is imperative that local gravity and test gas species be set correctly prior to ADCS-

601-AF operation or out of tolerance measurement are likely.

Run manual FPG8601 internal calibration:

- Access the ADCS Tools FPG Run Screen (see Section 4.3.6.2).

- Press the FPG8601 internal calibration button.

This button is identified by a wrench

icon.

- When the results windows appears, press <Active the calibration>.

ADCS-601-AF is now ready to operate. See Section 3.4.6 to verify operation before

regular use.

3.4.6 VERIFY SYSTEM OPERATION

Once the ADCS-601-AF is fully assembled and powered up (see Section 3.3), the following steps may be used to verify operation:

Check gauge mode operation of the PG7601 and FPG8601 systems:

Plug the ADCS-601-AF TEST(+) port with the plug quick connector stem provided.

- Set operation to gauge mode in FPG Tools (see Section 4.2.3). Set a target pressure of 380 kPa (112 inHg) (see Section 4.2.4). The PG7601 should

- automatically load mass, use the PG7601 PPC3 pressure controller to increase pressure and float the PG7601 piston, rotate its piston and

indicate Ready. Onc Ready is indicated and about 30 seconds have been allowed for pressure stabilization, the drop rate of the PG7601 should not exceed –0.2 mm/min. A faster drop rate value than –0.2 mm/min indicates a possible leak.

- Set a target pressure of 20 kPa (6 inHg). The PG7601 should change the mass load, use the PG7601 PPC3 pressure controller to decrease pressure and float its piston, rotate its piston and indicate Ready.

- Set a target pressure of 10 kPa (3 inHg). The ADCS-601-AF will transition from the PG7601 to the FPG8601 standard. The FPG8601 pressure controller should descend pressure and set a stable pressure near the target pressure value and indicate Ready.

- Set a target pressure of 1 kPa (0.2 inHg). The FPG8601 pressure controller should descend pressure and set a stable pressure near the target pressure and indicate Ready.

Check absolute mode operation.

- Set ADCS-601-AF operation to absolute mode (see Section 4.2.3). Wait for the mode transition to complete. The reference Pa (11 mTorr) within 20 to 30 minutes.

- Set a target pressure of 80 kPa (24 inHg) (see Section 4.2.4). The PG7601 should automatically load mass, use the PG7601 PPC3 pressure controller to decrease pressure and float its piston, rotate its piston and indicate Ready. Onc indicated and about 30 seconds have been allowed for pressure stabilization, the drop rate of the PG7601 should not be positive. A positive value indicates a possible leak.

- Set a target pressure of 30 kPa (9 inHg). The PG7601 should automatically load mass, use the PG7601 PPC3 pressure controller to decrease pressure and float its piston, rotate its piston and indicate Ready.

vacuum value should descend to less than 1.5

Ready is

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

- Set a target pressure of 1 kPa (0.2 inHg). The FPG8601 pressure controller should descend pressure and set a stable pressure near the target pressure and indicate Ready. Note: It may take up to 3.5 to 4 minutes to obtain a ready condition for descending increments at very low absolute pressure.

Run an FPG validation in absolute mode (see Section 7.2.3).

3.5 ENTER VALUE OF LOCAL GRAVITY

To correctly calculate the pressure defined by its PG7601 and FPG8601 pressure standards, local value of acceleration due to gravity must be known and entered into ADCS Tools.

To enter the local value of acceleration due to gravity into ADCS Tools, press [Maintenance] on the main menu and select [Calibration]. Edit the value of local gravity to enter gravity at the site of use of the ADCS-601-AF System (see Figure 28).

See the PG7000 and FPG8601 Operation and Maintenance Manuals for additional

information on how acceleration due to gravity is used in the calculation of defined pressure.

Figure 28. Local gravity and pressure medium fields in ADCS Tools

3. INSTALLATION

3.6 SPECIFY TEST GAS SPECIES

The ADCS-601-AF system, and especially the FPG8601 pressure standard, are dependent upon the species of the test gas used.

The test gas used must be correctly specified in ADCS Tools. To enter the test gas species into ADCS Tools, press [Maintenance] on the main menu and

select [Calibration]. Select the test gas that is supplied to the ADCS-601-AF Control Cabinet TEST GAS SUPPLY port (see Figure 28). The gas choices are limited to Nitrogen and Air.

3.7 ADDITIONAL PRECAUTIONS TO TAKE BEFORE MAKING PRESSURE MEASUREMENTS

Before using ADCS-601-AF, consider the following:

• Enter the correct value of local gravity at the site of use in ADCS Tools (see Section 3.4.5).

• Consider head corrections (see Section 4.2.6).

• Level the PG7601 and FPG8601 Platforms properly using their bubble levels.

•

Verify that the PG7601 piston-cylinder module is correctly cleaned and operating properly (see Section 6.6).

• Verify that there are NO leaks in the system connected to the test port.

Assure that adequate metrological maintenance has been performed (see Section 7).

•

3.8 SHUT DOWN AND RESTART

3.8.1 RESTART

To restart an assembled ADCS-601-AF, follow the steps below. If the ADCS-601-AF has been shut down for an extended period, consider performing the maintenance functions (see Section 6).

If they have been disconnected, connect and apply required pressure supplies to the

Control Cabinet rear panel (see Section 1.1.1).

Connect AC1, AC2, AC3 power cords from Control Cabinet to power supplies. Turn ON

main power switches (INSTRUMENTS, REFERENCE PUMPS and UTILITY PUMP) on front of Control Cabinet. The utility vacuum pump should start up, if not check its local power switch.

Run the FPG Tools program on the system controller by selecting the FPG Tools icon

on the desktop. Once the program has opened, select [Run], [Run Monitor] to initialize the FPG8601. Wait for initialization to complete.

Run the ADCS Tools program on the system controller by selecting the ADCS Tools

icon on the desktop. Once the program has opened, press the [ON] button. Follow the prompts to complete the ADCS-601-AF initialization process. Select the desired measurement mode when the prompt appears.

ADCS-601-AF should ready for regular operation (see Section 4).

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

3.8.2 SHUT DOWN

Pressure must always be supplied to the TEST GAS SUPPLY port on the rear of the

Control Cabinet unless the FPG8601 has been shut down following the long term shut down instructions in Section 3.8.2.2. Failure to supply pressure to the FPG8601 lubrication gas circuit will cause damage to the instrument.

There are two different standard ADCS-601-AF shut down conditions.

1) Short term shut down: Short term shut down is intended to limit power consumption and preserve vacuum pump life when the system is not used for limited periods of time such as overnight or over a weekend (see Section 3.8.2.1). Short term shut down may down if support facilities allow it.

2) Long term shut down: Long term shut down is intended to completely shut down the ADCS-601-AF system when it will not be used for extended periods of time or before it will be disassembled. Long term shut down should be avoided to the extent possible as restarting from long term shut down is more likely to require maintenance procedures before normal operation is restored.

also be used for extended periods and is preferable to long term shut

3.8.2.1 SHORT TERM SHUT DOWN

To reduce consumption of power and preserve vacuum pump life, the following conditions may be implemented when the ADCS-601-AF is not in use, for example over the weekend. In this state, ADCS-601-AF is in gauge measurement mode with the utility vacuum pump turned off.

Put system into gauge measurement mode by pressing the [Measurement

Mode] button on the ADCS Run Screen Toolbar (see Section 4.3.5.3). If necessary, wait for the mode transition to complete.

Turn OFF the UTILITY PUMP power switch on the front of the Control Cabinet.

DO NOT disconnect pressure supplies. Pressure supplies must be maintained.

Utility vacuum must be supplied to the ADCS-601-AF for it to operate

normally, even in gauge mode. Be sure to reestablish utility vacuum after a short term shut down. Failure to do so will prevent ADCS-601-AF from functioning properly.

3.8.2.2 LONG TERM SHUT DOWN

If the ADCS-601-AF will not be used for an extended period, or to shut it down completely for disassembly, proceed as follows.

Complete the short term shut down (see Section 3.8.2.1).

Use the ADCS Tools [FPG] button to display the FPG run screen. In the

ADCS Tools FPG Run Screen, press the [Shutdown] (OFF) button.

Wait for the FPG8601 to indicate Ready and the measured pressure to indicate

< -- SHUTDOWN -- > indicating the FPG is shut down.

Disconnect pressure supplies and turn OFF power using main switches on

front of Control Cabinet.

4. OPERATION

44.

PPEERRAATTIIOON

4.1 GENERAL OPERATING PRINCIPLES

4.1.1 SYSTEM CONFIGURATION

The ADCS-601-AF system is completely configured from a hardware and software standpoint when it is delivered. All necessary operating values are entered into individual components and all interfaces are set for internal consistency and to communicate with ADCS Tools software.

The system hardware configuration can be viewed and edited using panels [Setup], [Configuration] form. Changes to the configuration should only be made when necessary by personnel with advanced knowledge of the system. Uninformed changes to the configuration are likely to cause ADCS-601-AF to no longer operate properly.

4.1.2 READY/NOT READY INDICATIONS

4.1.2.1 OVERVIEW

Typcial ADCS-601-AF operation consists of using the system to set values of pressure with very low measurement uncertainty. A variety of operations by the ADCS-601-AF system may be required to achieve the requested pressure and the time required to complete these may vary. In order to make it clear to the operator when a pressure setting request has been completed and conditions are appropriate for the ADCS-601-AF pressure definition to be within the estimated measurement uncertainty budget, ADCS-601-AF provides a “go/no go” Ready/Not Ready indication.

The Ready/Not Ready indication is provided by the ADCS Tools software that manages the overall system (see Section 4.3). The indication is by a circle to the

left Ready and Green when the pressure is Ready.

The conditions that must be met to reach a Ready condition vary depending upon whether the active pressure standard is the PG7601 piston gauge or the FPG8601 force balanced piston gauge. See Sections 4.1.2.2 and 4.1.2.3 for additional information on the Ready/Not Ready criteria for the two pressure standards.

4.1.2.2 READY/NOT READY WHEN USING THE PG7601 PISTON

the current pressure reading which is RED when the pressure is Not

GAUGE

ADCS-601-AF uses the Ready/Not Ready directly from the PG7601 to

determine the Ready/Not Ready condition. See the PG7000 Operation and Maintenance manual for a more detailed description of PG7000 Ready/Not Ready operation.

When the PG7601 is the active pressure standard ADCS-601-AF pressure Ready/Not Ready depends directly upon the PG7601 Ready/Not Ready condition.

The PG7601 Ready/Not Ready condition is dependent upon three criteria. For the PG7601 pressure to be considered Ready, all three crteria must be met.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

1. Piston position: For a Ready condition to exist, the PG7601’s piston must be floating within the position limits defined in the PG7601’s active SETUP file AND the PPC3 pressure controller is not controlling. The default PG7601 SETUP file is #2. The default piston position Ready limits are - 2.5 mm and + 2.5 mm of midstroke. The full stroke of the piston from top stop to bottom stop is + 4.5 to - 4.5 mm.

2. Piston rotation rate: For a Ready condition to exist, the PG7601’s piston must be rotating at a rate within the rotation rate limits defined in the pistoncylinder’s characteristics file. The default is 10 to 40 rpm. When the mass load on the PG7601 is < 3 kg (corresponds to pressure of < 30 kPa (9 inHg)) the maximum rate limit is removed.

3. Reference vacuum level in absolute mode: In absolute measurement mode, for a Ready condition to exist, the reference vacuum as measured by the reference vacuum capacitance diaphragm gauge must be lower than the vacuum limit specified in the PG7601’s active SETUP file. The SETUP file is #2. The default minimum reference vacuum value is < 5 Pa (38 mTorr).

4.1.2.3 READY/NOT READY WHEN USING THE FPG8601 FORCE

BALANCED PISTON GAUGE

When the FPG8601 is the active pressure standard, ADCS-601-AF pressure Ready/Not Ready depends upon the value and stability of the pressure measured by the FPG8601 and the internal limits within FPG Tools. FPG8601 internal limits will force a Not Ready condition in the FPG8601 when ambient conditions have significantly changed since the last FPG8601 zero. A feature in the [Maintenance],[FPG Cal Options] menu is provided to decouple the FPG8601 internal limits and the Ready/Not Ready status of the ADCS-601-AF when the FPG8601 is the active reference (see Section 7.2).

When Regulation (see Section 4.1.4) is OFF, the Ready condition when using the FPG8601 is dependent on:

FPG8601 pressure stability: For a Ready condition to exist, the FPG8601’s pressure rate of change must be less than the FPG8601 stability criterion. The default FPG8601 stability criterion is ± 0.5 Pa/s (0.00015 inHg/s).

When Regulation (see Section 4.1.4) is ON, the ADCS-601-AF Ready/Not Ready condition when using the FPG8601 depends upon:

1. FPG8601 pressure hold limit: For a Ready condition to exist, the pressure measured limit. The default hold limit is ± 1.0 Pa (0.0003 inHg).

2. FPG8601 pressure stability: The FPG8601 pressure stability criterion is not used to determine Ready when the ADCS-601-AF is actively controlling a pressure. When pressure control is aborted, a Ready condition will occur when the FPG8601’s pressure rate of change is less than the FPG8601 stability criterion.

by the FPG8601 must be inside of the FPG8601 pressure hold

ADCS-601-AF Ready/Not

4.1.3 TRANSITION BETWEEN STANDARDS, ACTIVE AND INACTIVE STANDARD

down to 1 kPa (0.3 inHg) pressure control (see Section 2.2.2).

an FPG8601 force balanced piston gauge with automated

4. OPERATION

In normal operation, the ADCS Tools software that manages the ADCS-601-AF system, determines which pressure standard system to use based on the pressure value to be set. ADCS Tools also handles the transition from one standard to the other when the requested pressure point requires changing the active pressure standard.

There is always an active pressure standard (see Table 11). Active is defined as connected to the ADCS-601-AF TEST(+)

port. Changing the active pressure standard requires

changing the states of the PG and FPG ISOLATION valves (valves 1 and 2) (see Figure 29)

without causing excessive perturbation to the pressure applied

the TEST(+) port and the device under test. This is accomplished by using the two PPC3 pressure controllers to set the same pressure on either side of the isolation valve. Once this transition pressure has been set and stabilized, the valves are operated. The default transition pressure is 15 kPa in absolute mode and 14 kPa in gauge mode. The value can be changed in ADCS Tools, [Setup], [Configuration], [Limits] but this is not recommended.

The transition between standards is initiated automatically when a pressure request is made that requires the standard that is not currently active. A transition can also be initiated using the [Standard Transition] button on the ADCS Run Screen Toolbar (see Section 4.3.5.3).

Table 11. Valve states

Meas. mode

absolute

gauge

Active

standard

1 2 4 6 9 10 11

PG7601 1 0 0 0 1 1 1 on

FPG8601 0 1 0 0 1 0 1 on

PG7601 1 0 1 1 1 1 1 off

FPG8601 0 1 1 1 1 0 1 off

Valve states

(1 = open, 0 = closed)

Reference

vacuum

pumps

Note: For valve references, see Figure 29, ADCS-601-AF simplified operational schematic.

4.1.4 DIFFERENCE BETWEEN REQUESTED AND ACTUAL SET

PRESSURE

ADCS-601-AF is not designed to set exactly the pressure that has been requested. Rather, it sets a value of pressure very close to the requested pressure and returns the exact pressure value it has set.

The majority of the ADCS-601-AF pressure range (15 kPa (4.5 inHg) and up) is covered by an automated PG7601 piston gauge (see Section 2.2.1). The automated mass handling system of the PG7601 can load mass in steps

Figure 29. ADCS-601-AF simplified operational schematic

of 0.1 kg. On the PG7601’s 10 kPa/kg piston-

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

cylinder, 0.1 kg corresponds to increments of 1 kPa (0.3 inHg). When a pressure is requested of the PG7601, it calculates the mass to load to reach the pressure. It then loads the mass as closely as possible using its 0.1 kg resolution, calculates the actual pressure achieved and displays that value. Therefore, when using the PG7601, the actual pressure set may be up to 0.5 kPa (0.15 inHg) different from the pressure requested.

The FPG8601 pressure standard used to handle pressure requests under 15 kPa (4.5 inHg) (see Section 2.2.2) is normally used in a similar manner. commanded to set and stabilize the requested pressure. Due to the possible difference between the PPC3’s pressure transducer and the FPG8601, the final pressure set by the PPC3 will not be exactly the requested pressure as read by the FPG8601. Since the FPG8601 is the pressure standard and has much lower measurement uncertainty than the PPC3’s transducer, the FPG8601’s reading is displayed as the ADCS-601-AF pressure value.

When using the FPG8601 (pressure points under 15 kPa (4.5 inHg), it is possible to set exactly the requested pressure by using Regulation mode. In Regulation mode, the PPC3 pressure target is iteratively adjusted by the difference between the PPC3 pressure transducer reading and the FPG8601 reading to cause the FPG8601 to read the requested value of pressure within the FPG8601 pressure hold limit. See Section 4.1.2.3 for information on pressure Ready/Not Ready criteria when using FPG8601 with Regulation mode can be turned ON and OFF in the ADCS

Tools Run Screen Control Panel when the FPG8601

is the active pressure standard (see Section 4.3.5.1).

4.1.5 ASOLUTE AND GAUGE MEASUREMENT MODES

The

FPG8601’s PPC3 pressure controller is

ON and OFF. Regulation mode

ADCS-601-AF can operate in two measurement modes. In absolute mode pressure is defined relative to a vacuum. Vacuum is provided by the

system reference vacuum pumps and is applied to the reference circuit of the pressure standards (see Figu re 29) . The residual vacuum level is ready by thePG7601 and FPG8601 reference vacuum CDGs.

In gauge mode pressure is defined relative to atmosphere. The reference vacuum pumps are turned O

FF or isolated and the reference circuit of the pressure standards is opened to atmosphere. The DUT may be connected to the reference circuit on the TEST(-) port to assure that the DUT and pressure standards are at a common reference pressure.

See Section 4.2.3 for additional information on changing measurement modes.

There is a well defined order of operation for transitioning the ADCS-601-AF system

between measurement modes. The order is controlled by the ADCS Tools software. Mode transitions should only be performed under ADCS Tools control. Vacuum pumps must always be left ON in absolute mode. Before turning OFF vacuum pumps or disconnecting vacuum supplies, transition to gauge mode. Once a measurement mode change is initiated, it should be allowed to complete uninterrupted.

4.2 FREQUENTLY USED FUNCTIONS

Regular ADCS-601-AF operations relating to connecting and disconnecting devices under test and setting pressures are performed from the ADCS Tools ADCS Run Screen (see Section 4.3.5).

How to perform common ADCS-601-AF functions is summarized in Sections 4.2.1 to 4.2.8).

4. OPERATION

4.2.1 CONNECTING A DEVICE UNDER TEST (DUT)

The ADCS-TEST(+) port should never be pneumatically accessed (make or break connection)

unless the ADCS is “vented” following the instructions below. Damage to the system and/or the DUT may result from opening the TEST(+) port in other than “vented” condition.

The device or devices under test (DUT) are connected to the TEST port(s) at the front of the ADCS-601-AF Reference Bench.

Absolute measurement mode devices are connected to the TEST(+) port only. For gauge or “differential” mode devices the high side is connected to the TEST(+) and the low side is connected to the TEST(-) port. The TEST(-) port is at atmospheric pressure when the ADCS-601-AF is in gauge mode.

The TEST port connections are self sealing quick connectors (with no quick connector stem installed, they are closed). To connect, use one of the quick connector stems supplied with the ADCS-601-AF accessories. For proper ADCS-601-AF operation it is important that the system connected to the TEST port(s) be leak free and the volume connected to the TEST (+) port not exceed 1 liter (61 in. the TEST (+) port, the quick connector plug supplied should always be used to seal it. Though the quick connectors are self sealing, they may leak.

). When operating ADCS-601-AF with nothing connected to

To access the test port, it must be vented to atmosphere. In gauge measurement mode: the TEST(-) port is always vented. To vent the TEST(+)

port, press the [VENT] button on the ADCS Run Screen Toolbar (see Section 4.3.5.3) and wait for the vent process to complete (indicated <Pressure> is <0.000> and Ready). The

port can then be accessed safely without damage to the DUT or the system.

TEST(+

)

In absolute measurement mode: The TEST(-) is not used and in an unknown state. To

vent the TEST(+) port, press the [VENT] button on the Run Screen Toolbar (see Section

4.3.5.3) and wait for the vent process to complete (indicated <Pressure> is < and Ready). The TEST(+

) port can then be accessed safely.

--- VENT--- >

4.2.2 CHANGING PRESSURE UNIT OF MEASURE

ADCS-601-AF supports a variety of pressure units of measure. To change the pressure unit for the ADCS pressure, press the [Unit of Measure] button on the ADCS Run Screen Toolbar (see Section 4.3.5.3) and select the desired unit. When the ADCS pressure unit of measure is changed, the unit of measure of the ADCS-601-AF components (RPM pressure monitor, PPC pressure controllers) is also changed, if the unit selected is supported by the

component. If the unit unit of measure change.

A shortcut to changing pressure unit of measure is to click on the pressure value. If the pressure unit shortcut is supported for that value, a pop menu gives the change unit option.

Note that the pressure unit of measure for the values of <ATM> (atmospheric pressure) and <Reference Vacuum> are set separately from the rest of the ADCS pressure value units.

not supported by the component, the component does not make a

For information on the pressure conversion calculations used by ADCS-601-AF, see

Section 9.1.1.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

4.2.3 CHANGING MEASUREMENT MODE (ABSOLUTE, GAUGE)

There is a well defined order of operation for transitioning the ADCS-601-AF system

The current ADCS-601-AF measurement mode is indicated by:

- <a> (absolute) or <g> (gauge> following the pressure unit of measure in the ADCS

Control Panel <Pressure> field (see Section 4.3.5.1).

he color of the pressure standard reference pressure circuit and PG

- T ADCS System Display. light blue = gauge mode (atmospheric reference), black = absolute mode (vacuum reference) (see Section 4.3.5.2).

- The value displayed in the ADCS Run Screen Control Panel <Reference Vacuum> field. <N/A>= gauge mode; numerical value = absolute mode (see Section 4.3.5.1).

The complete ADCS-601-AF system is always in either absolute or gauge measurement mode. Target pressure requests are interpreted and set in the active measurement mode. In absolute mode the ADCS-601-AF pressure standard reference pressure circuit is pulled down to vacuum by the reference vacuum system. In gauge mode, the reference pressure circuit is open to atmospheric pressure.

7601 bell jar in the

To change the ADCS-601-AF measurement mode from gauge to absolute or absolute to gauge,

press the down arrow next to the [MEASUREMENT MODE] button on the ADCS Main Run Screen Toolbar (see Section 4.3.5.3). The ADCS

Main Run Screen

<Pressure> field displays

< ---Measurement Mode Transition--- > while the ADCS-601-AF system makes the changes

necessary to change measurement modes. Do not attempt any other operations until the measurement mode transition is complete, as indicated by the <Pressure> field no longer indicating < ---Measurement Mode Transition--- > and the Status Bar (see Section 4.3.4) no longer indicating transition activities. This process may require several minutes to complete.

port) is

After a measurement mode change, the ADCS pressure (pressure on TEST(+

)

always vented to atmosphere. Pressing the [MEASUREMENT MODE] button itself, rather than the down arrow next to it, is

used to reset the current measurement mode.

4.2.4 SETTING PRESSURES

Before setting a pressure, be sure that the TEST(+) port is not open to atmosphere or

connected to a system with a very large leak. Execution of certain pressure requests could damage the ADCS-601-AF system if the TEST(+) port is open. If nothing is connected to the TEST(+) port, it must be plugged with the plug quick connect stem provided.

To set a pressure with ADCS-601-AF, first verify that ADCS-601-AF is in the desired measurement mode (gauge or absolute) (see Section 4.2.3) and that the TEST(+) open to atmosphere. If nothing is connected to the TEST(+) port, it should be plugged with the plug quick connector stem provided.

port is not

Enter the desired target pressure in the ADCS Control Panel <Target Pressure> field and press [ENTER] on the system controller (PC). Observe the ADCS Status Bar and System Display for information on progress in setting the requested pressure (see Section4.3.1). When

4. OPERATION

the requested pressure has been set and stabilized, a Ready indication is given (see Section

4.1.1) and the actual value of the set pressure is displayed in

the <Pressure> field. In most

cases, the final set pressure is not exactly equal to the target pressure (see Section 4.1.4).

4.2.4.1 SETTING ZERO PRESSURE

Setting zero in absolute measurement mode

In absolute measurement mode, entering a target pressure of zero transitions the active pressure standard to the FPG8601 if it is not already active, controls down using the FPG’s PPC3 pressure controller to the pressure defined in [Setup], [Configuration], [Limits] and then opens the FPG bypass valve (see Figure 29). This causes the pressure on the FPG8601 and at the ADCS-601-AF TEST(+ to be pulled down as low as possible directly by the reference vacuum pump system. The pressure achieved is indicated in the ADCS Control Panel <Pressure> field. Ready is indicated when the FPG8601 stability criterion is reached.

) port,

Setting zero in gauge measurement mode

The result of entering zero as the target pressure in gauge measurement mode depends upon a [Maintenance], [FPG Cal Options] selection (see Section 4.3.2).

If the <Vent using

the FPG in gauge measurement mode> option IS NOT selected, the active pressure standard is transitioned to PG7601 if it is not already active and the PG7601’s PPC3 controller vents to atmosphere setting zero gauge pressure. The ADCS Control Panel <Pressure> field is fixed to <0.000>. This is the default setting.

If the <Vent using the FPG in gauge measurement mode> option IS selected, the active pressure standard is transitioned to FPG8601 if it is not already active and the FPG8601’s PPC3 controller vents to atmosphere setting zero gauge pressure. The ADCS Control Panel <Pressure> field indicates the reading of the FPG8601.

4.2.4.2 SETTING IDLE STATUS

This section describes the ADCS-601-AF idle condition. The system can be

left in this condition indefinitely but the system must remain powered ON and supplied with pressure and vacuum. See Section 3.7 for information on ADCS-601-AF system short and long term shut down procedures.

In the normal idle (resting) condition of the ADCS-601-AF system, the pressure applied to the TEST(+) port is vented. This can be accomplished by pressing the ADCS Run Screen Toolbar [VENT] button (see Section 4.3.5.3) or setting a target pressure of zero in gauge measurement mode (see Section 4.2.4.1).

When vented in absolute mode, indicates < --- VENT --- > and the pressure is Ready. When vented in gauge mode, the <Pressure> field indicates <0.000> and the pressure is Ready.

4.2.5 PRESSURE EXERCISING THE DEVICE UNDER TEST

Many devices require pressure exercising prior to validation or calibration. Generally, their exercising can be performed quickly and without precise knowledge of the endpoint pressures. ADCS-601-AF supports a function to allow simple, rapid exercising of the DUT. The exercise function uses the PG7601’s pressure controller alone rather than the pressure standards.

To run an exercise routine, press the [Exercise Pressure] button on the ADCS Run Screen Toolbar (see Section 4.3.5.3). Then fill in the form to define the desired exercise routine (see Figure 30).

the ADCS Control Panel

<Pressure> field

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

The <Dwell> is a wait time at the maximum pressure for each cycle. The <Control Timeout> is the amount of time ADCS Tools will attempt to set a required pressure before

giving up and continuing if it is unsuccessful. After defining the exercise routine, press [OK] to proceed with the exercise routine. To

interrupt the routine, use the [Abort] button on the Main Toolbar (see Section 4.3.3) or the

[Abort Control] button on the ADCS Run Screen Toolbar (see Section 4.3.5.3).

Figure 30. ADCS Tools pressure exercise definition form

4.2.6 SETTING A HEAD CORRECTION

ADCS-601-AF can automatically correct for the difference in height between the ADCS-601AF reference level and the reference level of a device under test (DUT). The head correction, adds or subtracts the pressure corresponding to a difference in height by calculating the pressure head using the density of the test gas at the measured pressure.

The reference level of the ADCS-601-AF system is the reference level of the PG7601 piston gauge which is marked on the front of the AMH automated mass handler vacuum chamber.

The difference in height between the ADCS-601-AF reference level and the DUT reference level, is entered in the ADCS Control Panel <Head Correction> field. The value is positive if the DUT reference level is higher than the ADCS reference level and negative if the DUT is lower than the ADCS. The value is always entered in centimeters (cm).

4.2.7 STOPPING PRESSURE CONTROL, ABORTING FUNCTION EXECUTION

To abort current pressure control, press the [Abort Control] button on the ADCS Run Screen Toolbar (see Section 4.3.5.3). This causes the PPC3 pressure controller to stop actively controlling and shut off from the system. To resume, a new target pressure must be entered.

To abort execution of a function (e.g. pressure standard change, measurement mode change, FPG8601 validation, press the [Abort] on the ADCS Main Toolbar. This causes execution of the function to stop. Nothing further occurs until a new instruction is given. The ADCS Main Toolbar

[Abort]

button is only available when a function that can be aborted is running.

Aborting execution of a measurement mode change may leave the system in an <Unknown

Measurement Mode> state. If this occurs, set a measurement mode (see Section 4.2.3) before attempting any other operation.

The ADCS Main Toolbar has a [Pause] button. This button is to pause system operation. To resume operation after pressing [Pause], press [Pause] again.

4. OPERATION

4.2.8 SECURITY, USER RIGHTS

The ADCS Tools program that runs the ADCS-601-AF system includes provisions to protect against undesired editing and changes to program parameters. The protection system is based on user rights.

ADCS Tools always has an active user. User access can be password protected. User rights can be managed to prevent a user from being able to make changes in specific areas of ADCS Tools.

See Table 12 for a description of the User Access areas that can be limited by management of user rights.

The typical set up of ADCS Tools to

manager user rights is for the “Admin” user to be password controlled and only used by the system manager. The system manager can then set up and delete specific users with user passwords as desired.

Table 12. User rights user access areas

USER ACCESS AREA RIGHTS DENIED IF THIS AREA IS NOT ACCESSIBLE

Calibration

Configuration

FPG Options

ADCS PG Sensors

Edit Plots

Program Options

Support Device

Users

[Maintenance], [Calibration] may be viewed but no changes can be saved. [Setup], [Configuration] may be viewed but no changes can be saved. [Maintenance], [FPG Options] may be viewed but no changes can be saved. [Maintenance], [PG Sensors] may be viewed but no changes can be saved. [Setup], [DUT] may be viewed but no changes, additions or deletions to DUT definitions

DUT

can be made. The option to edit plots is available on the Plot Form but no changes can be saved.

[Tools],[Test Options] may be viewed but no changes can be saved. [Setup], [Support Device] may be viewed but no changes, additions or deletions to

support device definitions can be made.

[Setup], [Test] may be viewed but no changes, additions or deletions to test definitions

Test

can be made. Access to [Setup], [Setup Users] is not available.

4.2.8.1 SETTING UP USERS AND MANAGING USER RIGHTS

When ADCS Tools is first installed, two users are already set up.

1. User name: Admin Password: None User access: All

NOTE: This user cannot be deleted or edited. To prevent unintended use of

the Admin user, change its password.

2. User name: Test User Password: None User access: DUT, Edit Plots, Features, Program Options

To set up or delete users or to edit user rights or passwords, the active user must have acces to the <Users> access area. The “Admin” user always has this access.

To manage users and user rights select [Setup], [Setup Users] from the ADCS Tools main menu.

To create a new user, press the [Create] button. The red, flashing <Editing User> bar appears. Edit <User Name> and <Password> as desired. Use the checbox list under <User Access> to grant access to user areas (see Table 12). When editing is complete, press the [Save] botton to save the new user.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

To delete a user, select the user from the <Supported Users> list and then press the [DELETE] button.

To edit a user, select the user from the <Supported Users> list and then begin editing as desired. The red, flashing <Editing User> bar appears. When editing is complete, press the [Save] button to save the new user.

4.2.8.2 CHANGING ACTIVE USER

When ADCS Tools is started up a user must be specified in the [User Login] dialog box.

To change active users, press [Setup], [Change Current User] to cause the [User Login] dialog box to appear.

4.2.9 PRESSURE LEAK TEST

It is good practice to run a leak test on the ADCS-601-AF after performing a setup or maintenance operation that requires pressure fittings to be disconnected. The leak test can quickly determine if the ADCS-601-AF is performing properly. A report detailing the status of the individual portions of the leak test is provided upon test completion. The information in this report is used to isolate leaks in the ADCS-601-AF system (see Figure 31).

To run a pressure leak test, first put in the

ADCS-601-AF

in absolute measurement mode (see Section 4.2.3). After at least one hour in absolute mode, press the [Leak Test] button on the ADCS Run Screen Toolbar (see Section 4.3.5.3). User confirmation is required to ensure that there are no DUTs connected to t

he ADCS-601-AF that cannot support the leak test pressure. During the leak test, pressures of 375 kPa (110.7 inHg) and 15 kPa (4.4 inHg) are set.

Do not attempt to run a leak test until the ADCS-601-AF has been in absolute

measurement mode for at least 1 hour. The residual vacuum reference can change significantly during the first hour of absolute measurement mode operation after transitioning from gauge measurement mode. This change in pressure can cause the leak test to fail.

There are three parts to the leak test: PG7601 drop rate test, residual vacuum test and FPG lubrication flow test. If any part of the leak test fails, the overall leak test fails.

The PG7601 drop rate portion of the leak test sets a high and low pressure with the PG7601. After stability is achieved the change in piston position over a 30s interval is used to determine the drop rate of the piston-cylinder. The recorded drop rates are compared to factory defined drop rate limits to determine a PASS/FAIL status. A high piston drop rate indicates a leak in the pressure circuit that interconnects the TEST(+) port, the PG7601 and the PG7601 pressure controller.

The residual vacuum portion of the leak test records the FPG8601 and PG7601 vacuum reference sensor outputs when the FPG8601 bypass valve is closed. The residual vacuum test is executed during the high pressure portion of the PG7601 drop rate test. The recorded residual vacuum pressures and the difference between them must fall below factory determined limits to pass the residual vacuum portion of the leak test. The residual vacuum test fails when a leak into the vacuum reference circuit is present.

The FPG8601 lubrication flow portion of the leak test is executed while the PG7601 drop rate test is setting the high pressure. In this test, the FPG8601 bypass valve is closed to monitor the rate of increase in the FPG8601 pressure due to the lubrication flow. Without pressure control, the FPG8601 pressure increases as a result of the FPG8601 lubrication flow when the FPG8601 bypass valve is closed. The change in the indicated FPG8601 pressure is recorded over a 30s interval to determine the pressure rate of change caused by the lubrication flow. The recorded value must fall below factory defined limits to pass the

4. OPERATION

FPG8601 lubrication flow portion of the test. A failure indicates a leak in the pressure circuit which interconnects the upper FPG8601 mounting post, the FPG8601 pressure controller (PPC3), and the FPG8601 isolation valve (valve 2).

Figure 31. ADCS Tools pressure leak test results form

4.3 LOCAL OPERATION, ADCS TOOLS

4.3.1 OVERVIEW

ADCS Tools, running on a personal computer, is the software program that controls the overall ADCS-601-AF system (see Figure 32). ADCS Tools communicates with other software programs and system instruments, providing instructions and reading their responses to execute ADCS-601-AF system functions.

ADCS Tools also provides the local

user interface through the system controller’s display, keyboard and pointing device. Direct operator interaction with ADCS-601-AF system subprograms and individual system instruments is not required in normal operation.

Operator interaction with the ADCS Tools program is through four main program features that follow conventional Microsoft® Windows

protocol for file management, menu and

message formatting, graphics and editing. The ADCS Tools features are:

1. Main Menu (see Section 4.3.2): The Main Menu is a bar across the top of the ADCS

Tools program window. Each main menu selection leads to a drop down menu.

2. ADCS Main Toolbar (see Section 4.3.3): The Main Toolbar is across the top of the

screen just under the Main Menu.

The toolbar is made up of buttons that are shortcuts

to ADCS menu items and functions.

3. ADCS Status Bar (see Section 4.3.4): The Status Bar is across the bottom of the

ADCS Tools

program window. It continually displays current ADCS system activity at multiple levels. The ADCS Status Bar is the best source of information on what the ADCS-601-AF system is doing at any particular moment.

4. ADCS Run Screen (see Section 4.3.5): The Run Screen is the main operator interface for actually running the instrument

and includes real time ADCS-601-AF displays and controls. The ADCS Run

ADCS-601-AF system. It is equivalent to the front panel of an

Screen includes the ADCS Control Panel, ADCS System Display and ADCS Run Screen Toolbar.

5. Other Run Screens (see Section 4.3.6): system components with which ADCS Tools screens are also available to view data while tests are running.

To start up ADCS Tools, see Section 3.8.1.

Run screens are available for individual ADCS

communicates directly. Plot and Data Grid

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

Figure 32. ADCS-601-AF software, communications and control flow chart

Figure 33. ADCS-601-AF program window

4. OPERATION

4.3.2 MAIN MENU

The ADCS Main Menu is a bar across the top of the ADCS Tools program window. Each main menu selection leads to a drop down menu.

Table 13 summarizes the Main Menu and its sub-menus.

Table 13. ADCS Tools Main Menu and sub-menus summary

MAIN MENU

ITEM

Run

Setup

Tools

Data

Maintenance

SUB-MENU

ITEM

Start ADCS or S

top ADCS

Run Test Definition

Run Manual Test Start execution of a test with data logging but with no predefined

xit Program

Test Set up predefined test sequences for selection and execution

DUT Set up of DUTs to be tested. 4.4.1.1 Support Device Set up of instruments/devices to be used in running tests that

Configuration Set up ADCS-601-AF system instruments and adjust test

Users Set up ADCS-601-AF system users and manage their

ange Current

User Test Options Set up options relating to managing data collected when running

Remote Communications

nit of measure

U Converter

View Data File View data files created by running tests or FPG validations. 4.4.3.3 Plot Data File Plot the information in a data file. 4.4.3.3 Database Data

Viewer Write Data File

to Database

eport Editor Run the Report Editor to generate a report from a test Data File

FPG Cal Options FPG8601 zeroing and spanning run time options. 7.2.2 PG Sensors Display and adjust PG7601 ambient conditions sensors. 7.2.7 Calibration View and edit calibration values for active PG7601 piston-

un FPG

R Validation

tart ADCS] starts operation of the ADCS-601-AF system,

establishing communication with system components and initializing the system. System power must be ON, pressure sources must be applied and FPG Tools software must be running before [S

top ADCS] stops operation of ADCS-601-AF interrupting

communication between ADCS Tools and system components. Start execution of a predefined Test Definition sequence. 4.4.2.1

sequence. Shut down the ADCS Tools and exit the program. Do not use

this option without reading shut down procedure in Section 3.8.

using [Run], [Run Test Definition].

are not DUTs, for example a multimeter to read DUT output.

parameters.

passwords and rights. Change the current ADCS-601-AF user. 4.2.8.2

a test and how tests end. Send and receive remote commands manually using the Direct

Remote Communication tool. Run the Unit of Measure Converter. This tool not only acts as a

convenient unit converter, it also provides the ability to create custom pressure units.

Sort, plot and display stored test data. 4.4.3.3

Add an existing test Data File to the Test Data Database. This is a shortcut to the feature available in the Database Data Viewer.

or data stored in the Test Data Database.

cylinder and mass set. View and edit value of local gravity used by PG7601 and

FPG8601. View and edit species of test gas used in ADCS-601-AF system.

Run automated routine to validate FPG8601 with PG7601. 7.2.3

DESCRIPTION SEE

SECTION

3.4.5

tart ADCS] is selected.

4.4.2.2

3.8

4.4.1.2

4.4.1.3

4.1.1

4.2.8

4.4.1.4

N/A

4.4.3.3

4.4.5

7.3.2,

7.3.3, 3.5,

3.6

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

MAIN MENU

ITEM

Window Conventional Windows screen organization options. N/A Help Information about ADCS Tools. N/A

SUB-MENU

ITEM

Run CDG Zero Run a routine to zero the PG7601 and FP8601 reference

PG PPC Adjust Run a routine to adjust the PG7601’s PPC3 pressure controller

FPG PPC Adjust Run a routine to adjust the FPG8601’s PPC3 pressure controller

PG Internal Vacuum Zero

vacuum CDGs relative to a vacuum standard.

relative to the PG7601.

Q-RPTs relative to the FPG8601. Run a routine to adjust the PG7601’s internal vacuum gauge

relative to its external CDG

DESCRIPTION SEE

SECTION

7.2.6

6.10

6.9

4.3.3 ADCS MAIN TOOLBARS

The ADCS Main Toolbar is located across the top of the screen just under the Main Menu. The ADCS Main Toolbar contents vary for different operations. The three possible toolbar

configurations and the operation of their buttons are summarized in Table 14.

Manual operation toolbar

Running a manual test main toolbar (see Section 4.4.2.1)

Running a test definition toolbar (see Section 4.4.2.2)

Figure 34. ADCS Main Toolbar

Table 14. ADCS Main Toolbar buttons

BUTTON DESCRIPTION SEE

Rotating DHI logo

ON button

Run Test

Pause

Located at far left of the Toolbar. Shows a rotating DHI logo when the ADCS Tools program is running normally. Stops rotating if the system software

has been paused or the computer has experienced a fatal fault. Shows an ON button when the ADCS Tools program is NOT running. Press

the ON button to start ADCS Tools (see Section 3.8.1 before starting A Tools).

Shortcut to the [R Tools is running a test, this option is disabled.

Causes communications between ADCS Tools and system components to pause, suspending most operation. To restart, when paused, press pause again

When running a test, suspends test execution and pauses test timers.

un], [Run Test Definition] menu choice. When ADCS

DCS

SECTION

N/A

4.4.2.1

4.4.2

4. OPERATION

BUTTON DESCRIPTION SEE

Abort

Device Under Test

(DUT)

Support Device

ADCS Run Screen

PG7601 Run

Screen

Aborts sequential operations and functions such as changing measurement modes or transitioning pressure standards.

This feature can be used to cut short certain operations such as the FPG8601 Purge.

When running a test causts the <Abort Test> confirmation pop-up to appear. When running a test, allows the characteristics of the DUT to be viewed. When not running a test, is a shortcut to the DUT Editor.

When running a test, allows the characteristics of a support device to be viewed.

When not running a test, is a shortcut to the Support Device Editor.

When running a test, allows the characteristics of the running test to be

Test

viewed. When not running a test, is a shortcut to the Test Definition Editor.

Opens the ADCS Run Screen.

Opens the PG7601 Run Screen.

SECTION

N/A

4.4.1.1

4.4.1.3

4.4.1.2

4.3.5

4.3.6.1

FPG Run Screen

PPC3 Pressure

Controller Run

Screen

RPM4 Pressure

Monitor Run

Screen

Data Grid Run

Screen

Data Plot Run

Screen

Opens the FPG8601 Run Screen.

Opens the FPG8601’s PPC3 Pressure Controller Run Screen.

Opens the RPM4 Pressure Monitor Run Screen.

When a test is running, opens the Data Grid Run Screen.

When a test is running, opens the Data Plot Run Screen.

4.3.6.2

4.3.6.3

4.3.6.4

4.4.3.2

4.4.3.1

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

BUTTON DESCRIPTION SEE

Create Data File

When running a Manual Test, creates a new Data File. A standard windows filebox allows the selection of the Data File name and location. The choices in [Options], [Data File] determine the default file naming convention and file location. It also specifies whether or not to automatically name the file and avoid the filebox prompt.

A separate Data File is created for every active DUT. If there are no DUTs, only one Data File is created. However, no DUT information is logged.

Log a single data

point

When running a Manual Test, if a data file has been created, logs the instantaneous output of all devices to the Data File. This is identical in function to using a 0 averaging time in a test. All non-automated devices must have their outputs entered in the <Manual Data Entry > window.

Average and take 1

point

When running a Manual Test, if a data file has been created, averages all devices according to the active averaging method. This is identical to averaging data during a test. Both automatic and manual averages can be used to average the data. The drop down arrow displays a menu that lists the automatic and manual averaging options. The option with an “*” preceding it is the active averaging mode.

To change the automatic averaging time select it in the menu and enter the desired averaging time in the input box that follows. Data can be automatically averaged from 1 to 9999s.

SECTION

4.4.2.1,

4.4.3.3

4.4.2.1,

4.4.3.3

4.4.2.1,

4.4.3.3

Log 1 point at fixed

intervals

When running a Manual Test, if a data file has been created, logs an instantaneous data point at fixed time intervals. When the icon is pressed, an input box displays to allow entry of the time interval. A data point will automatically be logged when the option is pressed and data points will be logged repeatedly at the specified time interval until the [Abort Data Acquisition] button is pressed or the test is aborted. Taking data in this manner can be convenient when trying to monitor slowly evolving processes, e.g. the effect of temperature on a DUT.

The output of all manual entry devices must be entered for every data point

logged. This minimizes the automation provided by this function.

Taking data at short time intervals can quickly result in a very large Data

File.

4.4.2.1,

4.4.3.3

4. OPERATION

BUTTON DESCRIPTION SEE

SECTION

Average and log

points at fixed

intervals

When running a Manual Test, if a data file has been created, averages all device outputs and logs the results at fixed time intervals. When the icon is pressed the <Average Setup> window displays to allow entry of the averaging time and the interval between averages. After the entry, data automatically begins averaging. When the average is complete, the results are logged and the countdown to the next average begins. When the time specified as the <Timed Point Interval(s)> has been reached, another averaging cycle begins. This process is repeated until the [Abort Data Acquisition] button is pressed or the run mode is closed. Taking data in this way can be convenient when trying to mimic a test that includes multiple readings per point.

Taking data at short time intervals can quickly result in a very large Data

File.

Press the [Abort Data Acquisition] option to abort fixed interval data

acquisition.

Abort data

acquisition

When running a Manual Test that is logging date, press this icon to abort data acquisition at fixed intervals or a point currently being averaged.

4.4.2.1,

4.4.3.3

DUT/Reference

Comparison Run

Screen

When a test is running, opens the DUT/Reference Comparison Run Screen. This display provides convenient, real time, error information

calculated for each DUT compared to the ADCS-601-AF.

4.4.3.3

Device Run Screen

When running an automated test, generates a popup menu to allow the selection of the desired Device Run Screen to display. The selected Device Run Screen automatically displays in the main window.

4.4.2

Click outputs on the various run screens to get a list of options that apply

to the output. Display unit of measure and resolution can be changed for most outputs.

Step Back

When running a Test Definition automated test, causes the current test point to be interrupted and the test point sequence to step back to the most recent target output step. Subsequent clicks cause the test to step back one point for each click. This button is used to repeat points when needed.

Step Forward

When running a Test Definition autoamted test, causes the current test point to be interrupted and the test point sequence to step forward to the next step in the point sequence. This feature only moves forward up to the take data step of the highest point executed. The limitation is to ensure that data is logged at each point and points are not skipped entirely. Most often this button is used to skip through test dwell of an increment or to skip over previously executed points when the step back key has been used.

4.4.2.2

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

4.3.4 ADCS STATUS BAR

The ADCS Tools Status Bar is located across the bottom of the main screen (see Figure 33, Figure 35).

In all run modes, ADCS Tools flashes information related to the status of its current operations blue panel indicates the minor function, the text to the right indicates specific activity at a given moment.

on this display. The red panel on the left displays the current major function. The

Figure 35. ADCS Status Bar

4.3.5 ADCS RUN SCREEN

The ADCS Tools ADCS Run Screen should be considered the equivalent of an instrument front panel. It is the front panel of the ADCS-601-AF system. The run screen is the interface through which ADCS functions are controlled and readings are observed (see Figure 36).

The ADCS Run Screen is opened by pressing Main Toolbar. The screen can be resized and repositioned.

The run screen has three main sections:

1. Control Panel (see Section 4.3.5.1): The Control Panel the ADCS-601-AF system. It includes instrument displays.

2. Sy

3. Toolbar (see Section 4.3.5.3): The Toolbar buttons are for controlling ADCS-601-AF functions.

stem Display (see Section 4.3.5.2): The System Display

on system status. It is an animated operational schematic of the ADCS-601-AF system.

the [ADCS Run Screen]

is for reading and controlling

is to provide real time information

button on the ADCS

Figure 36. ADCS Run Screen

4. OPERATION

4.3.5.1 ADCS RUN SCREEN CONTROL PANEL

The features of the ADCS Run Screen Control Panel (see Figure 36) are summarized in Table 15.

Table 15. ADCS Run Screen Control Panel features

LABEL DESCRIPTION

Circular Ready/Not Ready Indicator and Ready timer

Pressure

Target Pressure

Regulate Target

Reference Vacuum

Green when the ADCS-601-AF pressure is Ready. Red when the pressure is Not Ready. When the FPG8601 is the active pressure standard, characters immediately below the circular indicator indicate whether the Not Ready condition is due to an FPG8601 operational limit being exceeded (see Section 4.1.1).

When Ready is achieved, a counter is display

the circular indicator. The counter accumulates time since the

of Ready condition occurred. This feature is convenient to assure a certain dwell time at pressure after the pressure has been set.

Displays pressure, pressure unit of measure and measurement mode (<a> absolute, <g> gauge). This is the pressure applied to ADCS-601-AF TEST(+) port by the active pressure standard.

When PG7601 is the active pressure standard, the pressure value shown is valid ONLY when the PG7601’s piston is floating and the pressure is Ready.

Provides a status message during functions in which the pressure is not known.

Right click on the value to produces a pop up menu in which the unit of measure can be changed (see Section 4.2.2), the resolution of the pressure value can be adjusted and a strip chart of over time can be displayed.

Enter/display a target pressure and the unit of measure. Double click the displayed value to highlight and edit the complete number.

Enter a desired target pressure and press [ENTER] for the ADCS-601-AF to set a pressure automatically.

Appear only when FPG8601 is the active pressure standard.

and

Checking the <Regulate Target> box causes the FPG8601 system

[ ] s

to regulate the pressure read by the FPG8601 to equal the target pressure value and changes the Rready/Not Ready criterion (see Sections 4.1.4, 4.1.2.3). This will cause the final set pressure to equal

the target pressure and w

a pressure. The <s> value is the frequency, in seconds, with which the

readjustment of pressure control to regulate to the target value occurs. Default is 30 s.

Displays atmospheric pressure value as read by the PG7601’s on-

ATM

board barometer. Right click on the value to produces a pop up menu in which the

unit of measure can be changed, the resolution of the pressure value can be adjusted and a strip chart of the value over time can be displayed. The <ATM> unit of measure is independent of other pressure display fields.

Displays current value of vacuum read by the CDG vacuum gauge of the active pressure standard when ADCS-601-AF is in absolute measurement mode.

Indicates “N/A” when ADCS-601-AF is in gauge mode. Right click on the value to produces a pop up menu in which the

unit of measure can be changed, the resolution of the pressure value can be adjusted and a strip chart of the value over time can be displayed. The <Reference Vacuum> unit of measure is independent of other pressure display fields.

ill increase the time required to set

ed to the upper right

the

value

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

LABEL DESCRIPTION

Ambient Temperature

Head Correction

PG Pressure

(=> when active standard)

FPG Pressure

(=> when active standard)

Upper Limit

Current value of ambient temperature read by the active pressure standard. Value is from the PG7601 on-board temperature sensor when the PG7601 is active; the FPG8601 mounting post sensor when the FPG8601 is active.

Right click on the value to produces a pop up menu in which the unit of measure can be changed, the resolution of the pressure value can be adjusted and a strip chart of the value over time can be displayed. Changing the <Ambient Temperature> unit of measure changes all ADCS Tools temperature displays.

Enter the difference in height between the reference level of the ADCS-601-AF system and the device under test, in centimeters [cm] (see Section 4.2.6). The value is positive if the DUT is above the ADCS reference level, negative if it is below

Displays the current pressure and unit of measure or the status of the PG7601 pressure standard. The circular indicator is a Ready/Not Ready indicator (see Section 4.1.1).

The pressure value show piston is floating and the pressure is Ready.

Displays the current pressure and unit of meaure or the status of the FPG8601 pressure standard. The circular indicator is a Ready/Not Ready indicator (see Section 4.1.1).

The maximum allowable target pressure for the ADCS-601-AF. This limit is imposed for all test and manually entered target pressures.

Change the limit by entering a new maximum pressure value in the current ADCS-601-AF unit of measure. The mimimum allowable entry value is 110 kPa (32.5 inHg). The maximum allowable entry value cannot exceed 384 kPa (113.4 inHg).

The PG7601 pressure controller Upper Limit setting is forced to 110% of the <Upper Limit> entry. Review the PPC3 Operation and Maintenance Manual for details on the Upper Limit setting of a PPC3.

Since the PG7601 can only set a target pressure within approximately 1 kPa (0.3 inHg) of the requested target, it is possible for an ADCS-601-AF pressure to exceed the <Upper Limit> entry by approximately 1 kPa (0.3 inHg).

n is valid ONLY when the PG7601’s

4.3.5.2 ADCS SYSTEM DISPLAY

The ADCS System Display is a simplified operational schematic of the ADCS-601-AF system that provides the operator with real time, quick visual indication of ADCS-601-AF system states (see Figure 37). The schematic represents the FPG8601 and PG7601 pressure standards, their pressure controllers valves

Table 16 summarizes the symbols used in the ADCS Sy

and the measured pressure and reference pressure circuits with

Display.

stem

4. OPERATION

Table 16. ADCS System Display symbols

FEATURE DESCRIPTION

Vacuum Pump

TEST(+) port

Pressure Controller

PG7601 Pressure

Standard

PG7601 masses

Represents the reference vacuum pumping system.

- White <V> on black backgound = vacuum pump is ON and pulling a vacuum.

- Black <V> on white background = vacuum pump is OFF.

TEST(+) port on front of Reference Bench to which ADCS-601-AF

sets pressures and device under test is connected. Changes to <MONITOR> when running an FPG Validation.

PG7601 and FPG8601’s pressure controllers. To view the pressure measured by th econtroller’s internal transducer, see the controller component’s front panel (in the Control Cabinet).

PG7601 gas operated piston gauge (see Section 2.2.1). The PG7601 piston position is represented graphically

in the bell jar area and the mass rotation is represented in the AMH vacuum chamber area.

- Bell jar light blue = ADCS-601-AF is in gauge measurement mdoe; atmospheric pressure is under the bell jar.

- Bell jar black = ADCS-601-AF is in absolute measurement mode; vacuum is under the bell jar.

PG7601 masses. White vertical line movement approximates mass rotation rate.

and digitally

FPG8601 Pressure

Standard

Automated Valve

Pressure tubing

FPG8601 force balanced piston gauge (see Section 2.2.2).

Control valve.

- Vertical parallel lines = valve open

- Horizontal parallel lines = valve closed

- Black = valve not actuated/engergized

- Red = valve actuated/enegized

Tubes making up measured pressure, reference pressure and control pressure circuits.

- Light blue = at atmospheric pressure, vented (valid for all circuits).

- Dark blue = under control of active pressure standard system (PG7601 or FPG8601).

- Black = under reference vacuum.

- Grey = Unknown status.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

Figure 37. ADCS System Display

4.3.5.3 ADCS RUN SCREEN TOOLBAR

The ADCS Run Screen Toolbar is at the bottom of the ADCS Run Screen. Its buttons are summarized inTable 17.

Table 17. ADCS Run Screen Toolbar

BUTTON DESCRIPTION

Causes ADCS-601-AF to vent the TEST(+) port to atmosphere

Vent

(see Section 4.2.4.2). Alw

ys makes PG6701 the active pressure standard and vents

unless the <Use the FPG measurement when vented in gauge

mode> option is active (see Section 4.2.4.1).

Abort Control

Change Pressure Unit of

Measure

Change Active Pressure

Standard

Exercise

Aborts on-going pressure control. When the FPG8601 is the active pressure standard, the pressure will continue to increase until a new target pressure is set or the [Vent] button is pressed. The increase in pressure is a direct result of the lubrication flow in the FPG8601.

Always vent or set a new target pressure after aborting pressure

control when the FPG8601 is the active pressure standard. Failure to do so will eventually result in an FPG8601 overpressure condition. ADCS Tools automatically vents all system pressure after an FPG8601 overpressure.

Changes pressure unit of measure for all ADCS-601-AF pressure values other than atmospheric pressure and reference vacuum.

Click any displayed quantity on any ADCS-601-AF run screen to access a popup menu with a choice to change the unit of measure.

Transition active pressure standard from PG7601 to FPG8601 or vice-versa (see Section 4.1.3).

Since ADCS-601-AF automatically transitions pressure standards as

needed depending upon the target pressure request, this

function is not frequently used in normal operation.

Setup and run an automated routine to cycle pressure a given number of times between a mininimum and maximum value (see Section 4.2.5).

4. OPERATION

BUTTON DESCRIPTION

Change Unit of Measure

Leak Test

Change measurement mode (gauge to absolute and vice-versa) (see Section 4.2.3).

Press the dow button itself to reset the current measurement mode.

Run an ADCS-601-AF pressure leak test (see Section 4.2.9). The leak test can be used in absolute measurement mode only.

to change the measurement mode, press the

n arrow

4.3.6 OTHER DEVICE RUN SCREENS

4.3.6.1 PG7601 PRESSURE STANDARD

The PG7601 Run Screen provides more detailed information on PG7601 status and a Toolbar to control it directly. Use the [PG7601 Run Screen] button on the ADCS Tools Main Toolbar to open the screen. The screen may be resized and relocated.

The PG7601 Run Screen should only be used to view PG7601 status. Use of

the Toolbar on this run screen may conflict with other ADCS-601-AF Tools functions. The PG7601 Run Screen Toolbar should only be used for advanced trouble shooting by qualified personnel.

Figure 38. PG7601 Run Screen

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

4.3.6.2 FPG8601 PRESSURE STANDARD

The FPG8601 Run Screen provides more detailed information on FPG8601 status and a Toolbar to control it directly. Use the [FPG8601 Run Screen] button on the ADCS Tools Main Toolbar to open the screen. The screen may be resized and relocated.

The FPG8601 Run Screen should only be used to view FPG8601 status. Use

of the Toolbar on this run screen may conflict with other ADCS-601-AF Tools functions. The FPG8601 Run Screen Toolbar should only be used during ADCS-601-AF start up or for advanced trouble shooting by qualified personnel.

4.3.6.3 PPC3 (FPG’S PRESSURE CONTROLLER)

The PPC3 Run Screen provides more detailed information on the FPG8601 system’s pressure controller and a Toolbar to control it directly. Use the [PPC3 Run Screen] button on the ADCS Tools Main Toolbar to open the screen. The screen may be resized and relocated.

The PPC3 Run Screen should only be used to view PPC3 status. Use of the

There is no PPC3 Run Screen for the PG7601 system’s PPC3 pressure

Figure 39. FPG8601 Run Screen

Toolbar on this run screen may conflict with other ADCS-601-AF Tools functions. The PPC3 Run Screen Toolbar should only be used for advanced trouble shooting by qualified personnel.

controller because the PG7601 PPC3 is controlled by the PG7601, not by ADCS Tools.

4. OPERATION

Figure 40. PPC3 Run Screen

4.3.6.4 RPM4 REFERENCE PRESSURE MONITOR

The RPM4 Run Screen provides more detailed information on the RPM4’s pressure controller and a Toolbar to control it directly. Use the [RPM4 Run Screen] button on the ADCS Tools Main Toolbar to open the screen. The screen may be resized and relocated.

The RPM4 Run Screen should only be used to view RPM4 status. Use of the

Toolbar on this run screen may conflict with other ADCS-601-AF Tools functions. The RPM4 Run Screen Toolbar should only be used for advanced trouble shooting by qualified personnel.

Figure 41. RPM4 Run Screen

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

4.4 AUTOMATED TESTING

ADCS Tools uses the engine of COMPASS for Pressure® calibration software to manage

automated testing using ADCS-601-AF. Frequent reference is made to the COMPASS for Pressure User’s manual for detail on setting up and running automated tests that is beyond the scope of this manual. The COMPASS for Pressure manual is an on-line manual available by pressing the [?] button, when available, in COMPASS features. It can also be accessed on the ADCS-601-AF system controller in the COMPASS for Pressure program group reached using the Windows START button , Programs.

ADCS-601-AF has the capability to run automated tests. Automated tests are tests in which a device under test (DUT) is defined and test data is logged to a data file. If the DUT is able to be interfaced with ADCS-601-AF by an RS232, IEEE-488 or USB interface, readings can be acquired from it automatically during the test.

Two test run modes are available. [Run Manual Test] runs a point by point test controlled by the operator. [Run Test Definition] runs a multi-point test script on a device under test (DUT). Running a test definition with a DUT whose output can be interfaced with ADCS-601-AF allows a complete test sequence to be run unattended by an operator.

See Section 4.4.1 for information on setting up to run automated tests.

ADCS Tools is preconfigured to support automated validation (calibration) and

standardization of the King Nutronics 3682 Air Data Calibrator (see Section 4.4.6).

See Section 4.4.2 for information on running automated tests.

4.4.1 SETTING UP TO RUN AUTOMATED TESTS

To run an automated test, a DUT Definition must be setup to identify the device under test (see Section 4.4.1.1). To run a multipoint test following a scripted test scenario, Definition must also be set up (see Section 4.4.1.2). If support devices that are not part of the ADCS-601-AF such as a multimeter

or a temperature chamber are needed to run a test,

Support Device Definitions must be set up to define them (see Section 4.4.1.3).

4.4.1.1 SETTING UP DEVICE UNDER TEST (DUT)

ADCS Tools uses the engine of COMPASS for Pressure® calibration software

to manage automated testing using ADCS-601-AF. The DUT Editor is a COMPASS for Pressure Device Editor. See the COMPASS for Pressure User’s Manual for complete information on Device Editors and DUT Definitions. The COMPASS for Pressure manual is an on-line manual available by pressing the [?] button, when available, in COMPASS features. It can also be accessed on the ADCS-601-AF system controller in the COMPASS for Pressure program group reached using the Windows START button , Programs.

a Test

ADCS Tools automated testing is organized around the support, testing and maintenance of Devices Under Test (DUTs). DUT Definitions not only specify the relationship between raw device outputs and pressure; they determine how the output data will be acquired and maintain calibration and tracking information

4. OPERATION

for the device. A DUT can be setup to provide DUT pressure only or to include measurement of other variables.

The DUT Editor provides features to create, edit, view and remove DUT Definitions from the ADCS Tools database. Access the DUT Editor by pressing [Setup], [DUT] from the ADCS Tools main menu or pressing the [DUT Editor] button on the main toolbar. When selected, the last accessed DUT Definition displays. To edit an existing DUT, use the Editor Toolbar features to select the desired DUT. Then simply edit the desired fields. Press the Editor Toolbar, [Save] button to save the changes.

Sample DUTs are already included in the DUT Definition database as examples. Use the following steps to create a DUT Definition.

Select [Setup], [DUT]

Press the Editor Toolbar, [New] button. Enter a <Record Label> that allows users to quickly identify the defined DUT. Begin completing the DUT Definition starting with the [Header] tab. Select a

<DUT Type> and a <Record Type>.

DUTs can be defined as <Individual>, <Profile> and <Profile w/Range>. These

selections allow an explicit DUT to be created including specific range and serial number information; or, a profile DUT that is identified during the test initialization process. Profile DUTs allow one DUT Definition to represent any number of like <Model> devices from the same <Manufacturer>.

Select the <Manufacturer> and <Model> on the [Header] tab. If the

desired selections are in the drop down list, press the [Find Previous

Setup] button to search for previous setups or examples of the DUT. If the <Manufacturer> and <Model> are not in the list, enter them.

Enter relevant information on the [Calibration] tab. Select the appropriate <Data Acquisition Type> and corresponding settings

using the [Communications] tab.

If applicable, select the [Output] tab. Simple DUTs allow direct entry of all

relevant final output information. To create a final output for advanced DUTs, press the [Add] button and edit the information on the Output Relationship Editor. If the final output requires remote commands to read the <Raw Output>, press the [Edit Commands] button to launch the Remote Command Editor. Simple DUT remote commands are accessed on the [Communications] tab. Specify the commands required to interface with the device. Press the [Add] button to add as many final outputs as are supported by the DUT.

The [Set] tab is used when the DUT will be used as a controller. However,

the DUT cannot be used as a controller in ADCS Tools.

Press the Editor Toolbar, [Save] button to save all changes. Any errors in

the setup must be remedied before the DUT Definition can be saved.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

4.4.1.2 SETTING UP TEST DEFINITIONS

ADCS Tools uses the engine of COMPASS for Pressure® calibration software

to manage automated testing using ADCS-601-AF. The Test Editor is a COMPASS for Pressure feature. See the COMPASS for Pressure User’s Manual for complete information on Test Editor. The COMPASS for Pressure manual is an on-line manual available by pressing the [?] button, when available, in COMPASS features. It can also be accessed on the ADCS-601-AF system controller in the COMPASS for Pressure program group reached using the Windows START button , Programs.

Test Definitions are used to define a specific test procedure including the sequence of test points and a large number of operational details. DUT(s) to be tested and a Test Definition are selected during the initialization of ADCS Tools, [Run Test Definition] mode. A pointer to a default Test Definition for a DUT is included in the DUT Definition, [Calibration] tab.

Create, edit and remove Test Definitions using the Test Editor. Access this feature using the ADCS Tools [Setup], [Test] or the Main Toolbar, [Edit Test] button. When the Test Editor is opened, the last accessed Test Definition is displayed. While in the Editor, use the Editor Toolbar options to create, edit, view and delete tests.

Sample tests are already included in the Test Definition database as examples. The Test Editor uses the same editing concepts as the DUT Editor. Only one

Test Definition can be edited at a time. The test scroll bar and the Test Selector are available to make new test selections. A flashing indicator displays when a Test Definition is modified or a new definition is created.

Familiarity with test execution sequence is necessary for proper setup of a

Test Definition. Review Section 4.4.2.1 before setting up a Test Definition.

Tests can be edited whenever ADCS Tools is not in an active run mode. Select [Setup], [Test] to display the Test Editor. Simply changing information in the

Test Editor places the Editor in the edit mode. No specific option needs be selected to begin editing a Test Definition. Use the [Save] button to store the edits or press the [Restore] button to return the test to its original state.

Different types of Test Definitions are supported. The choices are:

• Simple Test – Basic test that defines a list of pressure points only. No macro or changes in reference device during the test are permitted.

• Advanced Test – Can include temperature points. In addition Test Macros can be used to test a device.

When setting up Test Definitions in ADCS Tools the pressure <Read> and

<Set> device is always <ADCS-601> and cannot be changed.

4. OPERATION

4.4.1.3 SETTING UP SUPPORT DEVICES

ADCS Tools uses the engine of COMPASS for Pressure® calibration software to

manage automated testing using ADCS-601-AF. The Support Device Editor is a COMPASS for Pressure Device Editor. See the COMPASS for Pressure User’s Manual for complete information on Device Editors and Support Device Definitions. The COMPASS for Pressure manual is an on-line manual available by pressing the [?] button, when available, in COMPASS features. It can also be accessed on the ADCS-601-AF system controller in the COMPASS for Pressure program group reached using the Windows START button, Programs.

All devices that are not specifically DUTs are considered support devices. Support devices are setup in Support Device Definitions using the Support Device Definition Editor. Device Definitions define support devices that measure and produce outputs as well as devices that control in response to target sets. A Support Device Definition can also allow the device to act as a DUT to allow it to be tested and calibrated without having to set it up separately as a DUT. A single support device can provide multiple final outputs and final sets.

The Support Device Editor provides features to create, edit, view and remove Support Device Definitions from the ADCS Tools database. Access the Support Device Editor by pressing [Setup], [Support Device] or the Main Toolbar [Device Definition Editor] button. When selected, the last accessed Support Device Definition displays. To edit an existing Support Device Definition, use the Editor Toolbar buttons to select the desired definition. Then simply edit the desired fields. Press the Editor Toolbar, [Save] button to save the changes.

Sample Support Devices are already included in the Support Device database as examples.

4.4.1.4 TEST OPTIONS (DATA OPTIONS)

ADCS Tools uses the engine of COMPASS for Pressure® calibration software

to manage automated testing using ADCS-601-AF. The Test Options supported by ADCS Tools are COMPASS for Pressure features. See the COMPASS for Pressure User’s Manual section on [Tools], [Options] for complete information on ADCS Tools Test Options tabs. The COMPASS for Pressure manual is an on-line manual available by pressing the [?] button, when available, in COMPASS features. It can also be accessed on the ADCS-601-AF system controller in the COMPASS for Pressure program group reached using the Windows START button , Programs.

ADCS Tools allows preferences to be set concerning how data is collected and displayed when running automated tests and operations that occur to conclude a test. These preferences are set using [Tools], [Test Options].

The [Test Options] form includes five tabs whose functions are describe below.

[Data Grid] Tab

The [Data Grid] tab is used to customize the Data Grid Run Screen that is available while running tests. The grid can be customized to display only the desired data field columns while suppressing other columns. The order of the columns can also be changed. Any test data item logged in the Data File can be included in any column of the Data Grid Run Screen by using the correct

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

combination of features. Press the [Default Settings] button to automatically display the ADCS Tools default data fields.

[Data File] Tab

The [Data File] tab is used to customize the selection of data fields that are actually logged in the test Data File. The selections do not affect the data displayed in the Data Grid Run Screen. Although a specific piece of data is not logged in a test Data File, it can still display in the Data Grid Run Screen.. Only data actually logged to the Data File can be imported into the Test Data Database. Press the [Default Settings] button to automatically log the ADCS

Tools default data fields. [Data Header] Tab

The [Data Header] tab is used to customize the data logged in the header portion of a test Data File. Header data includes detailed information on the specific devices used to measure test data. Although header data is the basis of report information, not all header data is desired. Few ADCS Tools setups will require all header data. Check the header options relevant to your typical setups.

[End Test] Tab

The [End Test] tab is used to user preferences affecting operations that occur to conclude a test sequence.

<Finish point of each cycle> allows the operator to use the ADCS Tools features to step back in a test to repeat points. Check <Enable repeat for fixed time delay> and enter a time to allow stepping back for a fixed time after the test ends. Check <Prompt to repeat> to have ADCS Tools query the operator at the end of a test. check <No repeat option> to have the test complete without pausing.

Check <Auto generate reports after complete test> to have ADCS Tools automatically generate a test report using the last report template used when the test is completed. The <Test Complete> options still display at the end of the test.

Check <Prompt for test notes at the end of complete tests> to have ADCS Tools prompt the operator to enter notes specific to the test once the test has completed.

4.4.2 RUNNING AUTOMATED TESTS

ADCS Tools uses the engine of COMPASS for Pressure® calibration software to manage

automated testing using ADCS-601-AF. The Run Test functions supported by ADCS Tools are COMPASS for Pressure features. See the COMPASS for Pressure User’s Manual Run Modes Section for complete information on running automated tests. The COMPASS for Pressure manual is an on-line manual available by pressing the [?] button, when available, in COMPASS features. It can also be accessed on the ADCS-601-AF system controller in the COMPASS for Pressure program group reached using the Windows START button , Programs.

ADCS Tools has two automated test run modes. In both run modes, a data file is created to collect data from the test.

Run Test Definition Activated by selecting [Run], [Run Test Definition] from the ADCS

Tools main run menu. This run mode is to run a Test Definition that

specifies a pre-defined test sequence and test parameters.

4. OPERATION

Run Manual Test Activated by selecting [Run], [Run Manual Test] from the ADCS Tools

main run menu. This run mode allows any combination of test hardware and DUTs to be specified. There is no pre-defined test sequence. Pressures can be set as desired and data can be taken at any time by pressing the appropriate data acquisition option on the Main Toolbar.

Before activating a run mode, make sure that all instruments that will be used to run are properly configured and remotely connected to the system controller (host PC). This will prevent interface time-outs that will interrupt the test initialization process.

4.4.2.1 RUNNING A MANUAL TEST

ADCS Tools uses the engine of COMPASS for Pressure® calibration

software to manage automated testing using ADCS-601-AF. The Run Manual Test function supported by ADCS Tools is a COMPASS for Pressure feature. See the COMPASS for Pressure User’s Manual Run Modes Section for complete information on running automated tests. The COMPASS for Pressure manual is an on-line manual available by pressing the [?] button, when available, in COMPASS features. It can also be accessed on the ADCS-601-AF system controller in the COMPASS for Pressure program group reached using the Windows START button , Programs.

Use this feature to manually select a DUT and support devices to include in a test and execute the test without predefined parameters in a Test Definition. This run mode is useful for running devices when there is no fixed sequence to be executed. Although, data acquisition is supported, it is not a required part of a Manual Test. During the test initialization process, the last Manual Test selections display. These selections can be changed if desired. There are no requirements to use any specific combination of devices. For example, a Manual Test can be executed using a temperature controller only. Manual Tests should be used for trouble shooting device final output setups and running specialized tests. Run a Manual Test, for example, to verify that a device is working properly with ADCS Tools or to log “drift” data of a device over time at one point.

To run a Manual Test select [Run], [Run Manual Test]. Test Initialization occurs in the same manner as when running a Test Definition but no Test Definition selection is required (see Section 4.4.2.2). After initialization, all remote devices are automatically polled and output information is displayed on their run screens. Use the features

on the Data Acquisition section of the Main

respective

Toolbar to create a Data File and log test points. Use features on the Test Conditions Run Screen as well as the individual run screens of the devices to change the state of the devices.

4.4.2.2 RUNNING A TEST DEFINITION

ADCS Tools uses the engine of COMPASS for Pressure® calibration

software to manage automated testing using ADCS-601-AF. The Run Test Definition function supported by ADCS Tools is a COMPASS for Pressure feature. See the COMPASS for Pressure User’s Manual Run Modes Section for complete information on running automated tests. The COMPASS for Pressure manual is an on-line manual available by pressing the [?] button, when available, in COMPASS features. It can also be accessed on the ADCS-601-AF system controller in the COMPASS for Pressure program group reached using the Windows START button , Programs.

ADCS-601-AF™ OPERATION AND MAINTENANCE MANUAL

A Test Definition test has the test parameters and pressure sequence predefined (see Section 4.4.1). To run a Test Definition test, a DUT Definition and Test Definition must have been created (see Section 4.4.1.1, 4.4.1.2).

To run a Test

Definition

select [Run], [Run Test Definition]. The run process

has three main steps:

Test Initialization: Steps through screens to:

- Select unit of measure. When running a Test Definition, the unit specified by the Test Definition is always used to log data.

- Specify user.

- Select DUT(s) to be tested. Double click DUTs in the grid to add them to the list of DUTs to be tested.

- Configure DUT(s). Specifies details specific to the DUT being tested.

- Select Test Definition to be run. By default, the Test Definition specified in the DUT Definition is selected. Double click the desired Test Definition.

- After the Test Definition has been selected, most ADCS-601-AF users can press [Finish] to skip remaining initialization steps and go directly to running the test.

Run Test Sequence: Runs leak test (if included) and pressure exercise (if

included) followed by the test points taking data at each point based on the test data selections. The test parameters are defined by the Test Definition (see Section 4.4.1.2).

End Test: Presents the Test Notes screen to record test specific notes and

the Test Complete screen with various test conclusion options. Certain aspects of the test conclusion can be customized using the [Tools], [Test Options], [End Test] tab (see Section 4.4.1.4).

4.4.3 TEST RUN SCREENS

Special run screens are available when running an automated test. The Data Plot and Data Grid Run Screens are available when running any automated test

for which there is a data file. These run screens visualize test results while the test is running.

The DUT/Reference Comparison Run Screen is available when running any automated test, regardless of whether there is a data file. This screen provides real time DUT and ADCS-601-AF readings and information on the agreement between them.

See Section 4.4.3.1 for information on the Data Plot Run Screen, Section 4.4.3.2 for information on the Data Grid Run Screen and Section 4.4.3.3 for information on the DUT/Reference Comparison Run Screen.

DH Instruments ADCS-601-AF Operation And Maintenance Manual

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User Manual