DH Instruments PPCH - V1.01, PPCH Operation And Maintenance Manual

PPCH™

Hydraulic Pressure Controller/Calibrator

Ver. 1.01f and higher

Operation and Maintenance Manual

High pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases can be released unexpectedly and with extreme force. High pressure systems should be assembled and operated only by personnel who have been instructed in proper safety practices.

This instrument is not to be operated in any other manner than that specified by the manufacturer.

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 AZ 85044-5318, USA.

DH Instruments makes sincere efforts to ensure 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.

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

AutoRange, AutoZ, DH Instruments, DH, DHI, COMPASS, PPC, PPCH, PPCK+, QDUT, Q-RPT, RPM, RPM4 and SDS are trademarks, registered and otherwise, of DH Instruments, a Fluke Company.

Loctite is a trademark of Loctite Corporation Teflon is a registered trademark of the Dupon de Nemours Company.

Document No. 550132h 090210 Printed in the USA.

TABLE OF CONTENTS

AABBLLEE

OONNTTEENNTTS

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

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

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

ABOUT THIS MANUAL ............................................................VII

1. INTRODUCTION

1.1 PRODUCT OVERVIEW ...........................................................................................................................1

1.2 SPECIFICATIONS ...................................................................................................................................2

1.2.1 GENERAL SPECIFICATIONS....................................................................................................................... 2

1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS........................................................................................3

1.2.2.1 QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT)................................................................3

1.2.2.2 UTILITY SENSOR......................................................................................................................................4

1.2.2.3 ON-BOARD BAROMETER ........................................................................................................................4

1.2.3 PRESSURE CONTROL SPECIFICATIONS..................................................................................................4

................................................................. 1

2. INSTALLATION .................................................................. 5

2.1 UNPACKING AND INSPECTION ............................................................................................................5

2.1.1 REMOVING FROM PACKAGING..................................................................................................................5

2.1.2 INSPECTING CONTENTS.............................................................................................................................5

2.2 SITE REQUIREMENTS............................................................................................................................6

2.2.1 INSTALLATION IN A 19 IN. RACK MOUNT .................................................................................................6

2.3 INITIAL SETUP ........................................................................................................................................7

2.3.1 PREPARING FOR OPERATION ...................................................................................................................7

2.3.2 FRONT AND REAR PANELS ........................................................................................................................ 7

2.3.2.1 FRONT PANEL ..........................................................................................................................................7

2.3.2.2 REAR PANEL.............................................................................................................................................8

2.3.3 POWER CONNECTION................................................................................................................................. 8

2.3.4 REMOTE [ENTER/SET P] CONNECTION (FOOTSWITCH OR OTHER SWITCH) .....................................8

2.3.5 CONNECTING PNEUMATIC POWER (DRIVE PORT) .................................................................................9

2.3.6 SETTING UP AND FILLING THE FLUID RESERVOIR ................................................................................9

2.3.6.1 INTERNAL RESERVOIR............................................................................................................................9

2.3.6.2 EXTERNAL RESERVOIR ........................................................................................................................11

2.3.7 RESERVOIR RETURN SETTINGS .............................................................................................................12

2.3.8 INSTALLING PUMP DRIVE OUT GAS EXHAUST FILTER ........................................................................13

2.3.9 CONNECTING TO OTHER DEVICES .........................................................................................................14

2.3.9.1 INSTALLING A LINE FILTER TO PROTECT THE PPCH .......................................................................14

2.3.9.2 CONNECTING TO AN RPM4 TO BE USED AS AN EXTERNAL REFERENCE DEVICE......................14

2.3.9.3 CONNECTING TO A PG7302 PISTON GAUGE .....................................................................................16

2.3.9.4 CONNECTING TO A DEVICE UNDER TEST (TEST PORT)..................................................................17

2.3.10 CHECK/SET SECURITY LEVEL.................................................................................................................17

2.3.11 TURN OFF ABSOLUTE MEASUREMENT MODE ......................................................................................18

2.4 POWER-UP AND VERIFICATION.........................................................................................................18

2.4.1 SWITCH POWER ON ..................................................................................................................................18

2.4.2 APPLY PNEUMATIC POWER (DRIVE AIR) ...............................................................................................18

2.4.3 CHECK PRESSURE MEASUREMENT OPERATION.................................................................................18

2.4.3.1 CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT.............................................................18

2.4.3.2 CHECKING GAUGE MODE PRESSURE MEASUREMENT...................................................................19

2.4.4 PRIME AND PURGE TEST SYSTEM..........................................................................................................19

2.4.5 LEAK CHECK ..............................................................................................................................................19

2.4.6 CHECK PRESSURE CONTROL OPERATION...........................................................................................19

2.5 STORAGE AND SHIPPING ...................................................................................................................20

2.5.1 SHORT TERM STORAGE ...........................................................................................................................20

2.5.2 LONG TERM STORAGE .............................................................................................................................20

PPCH™ OPERATION AND MAINTENANCE MANUAL

2.5.3 PREPARATION FOR SHIPPING.................................................................................................................20

3. OPERATION..................................................................... 21

3.1 USER INTERFACE ................................................................................................................................21

3.1.1 MAIN RUN SCREEN....................................................................................................................................21

3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL.........................................................................23

3.1.3 DIRECT PRESSURE CONTROL KEYS......................................................................................................24

3.1.4 REMOTE [ENT/SET P] (FOOT)SWITCH.....................................................................................................25

3.1.5 SOUNDS ......................................................................................................................................................25

3.2 GENERAL OPERATING PRINCIPLES .................................................................................................25

3.2.1 PRESSURE CONTROL PRINCIPLES ........................................................................................................25

3.2.2 AUTOMATED PRESSURE CONTROL .......................................................................................................28

3.2.2.1 IDLE, NO AUTOMATED CONTROL (MEASURE MODE).......................................................................28

3.2.2.2 DYNAMIC CONTROL ..............................................................................................................................29

3.2.2.3 STATIC CONTROL..................................................................................................................................30

3.2.2.4 MONOTONIC CONTROL.........................................................................................................................31

3.2.2.5 RAMP CONTROL.....................................................................................................................................32

3.2.3 PRESSURE READY/NOT READY ..............................................................................................................34

3.2.4 GAUGE MEASUREMENT MODE, DYNAMIC COMPENSATION FOR ATMOSPHERIC PRESSURE......34

3.2.5 MULTIPLE INTERNAL AND EXTERNAL Q-RPTS .....................................................................................35

3.2.6 MULTIPE RANGES (Q-RPTS, AUTORANGE AND INFINITE RANGING) .................................................36

3.2.7 FLUID RESERVOIR LOW LEVEL WARNING ............................................................................................37

3.2.8 OPERATION WITH A PG7000 PISTON GAUGE ........................................................................................38

3.2.9 DIRECT FUNCTION KEYS SUMMARY ......................................................................................................38

3.3 DIRECT FUNCTION KEYS ....................................................................................................................39

3.3.1 [RANGE] ......................................................................................................................................................39

3.3.2 [UNIT]........................................................................................................................................................... 40

3.3.3 [MODE] ........................................................................................................................................................41

3.3.4 [AUTORANGE] ............................................................................................................................................42

3.3.5 [RPT] ............................................................................................................................................................44

3.3.6 [AUTOTEST]................................................................................................................................................ 46

3.3.6.1 QUICK AUTOTEST..................................................................................................................................47

3.3.6.2 QDUT AUTOTEST...................................................................................................................................49

3.3.7 [HEAD] .........................................................................................................................................................52

3.3.8 [PRIME]........................................................................................................................................................54

3.3.8.1 <1PRIME>................................................................................................................................................55

3.3.8.2 <2PURGE> ..............................................................................................................................................56

3.3.9 [LEAK CK] ...................................................................................................................................................56

3.3.10 [ENT/SET P] (SET PRESSURE AUTOMATICALLY)..................................................................................58

3.3.10.1 DYNAMIC CONTROL MODE, [ENT/SET P]............................................................................................58

3.3.10.2 STATIC CONTROL MODE, [ENT/SET P]................................................................................................59

3.3.10.3 MONOTONIC CONTROL MODE, [ENT/SET P]......................................................................................61

3.3.10.4 RAMP CONTROL MODE, [ENT/SET P]..................................................................................................62

3.3.10.5 INTERRUPTING AUTOMATED PRESSURE CONTROL........................................................................63

3.3.10.6 AU T OM A T E D P R E S S U R E C O M M A N D S F O R Z E R O P R E S S U R E.................................................... 63

3.4 [SETUP] .................................................................................................................................................64

3.4.1 <1RANGE> ..................................................................................................................................................64

3.4.1.1 SAVING AN AUTORANGE RANGE ........................................................................................................64

3.4.1.2 DELETING AUTORANGE RANGES........................................................................................................65

3.4.2 <2RES> (RESOLUTION) .............................................................................................................................65

3.4.3 <3JOG>........................................................................................................................................................66

3.4.4 <4UL> (UPPER LIMIT) ................................................................................................................................67

3.4.4.1 OVER PRESSURE FUNCTION...............................................................................................................68

3.4.5 <5ATEST>....................................................................................................................................................68

3.4.6 <6CONTROL>..............................................................................................................................................69

3.4.6.1 <1LIMITS> (CUSTOM CONTROL PARAMETERS) ................................................................................70

3.4.6.2 <2MODE> ................................................................................................................................................72

3.4.6.3 TURNING-OFF CUSTOM CONTROL PARAMETERS............................................................................73

3.4.7 <7DRV> (DRIVERS) ....................................................................................................................................73

3.5 [SPECIAL] .............................................................................................................................................74

3.5.1 <1AUTOZ> ...................................................................................................................................................74

3.5.1.1 EDIT AUTOZ............................................................................................................................................77

3.5.1.2 RUN AUTOZ.............................................................................................................................................78

3.5.2 <2REMOTE> ................................................................................................................................................79

3.5.2.1 <1COM1, 2COM2>...................................................................................................................................80

3.5.2.2 <3IEEE-488>............................................................................................................................................80

3.5.2.3 <4FORMAT>............................................................................................................................................80

3.5.2.4 <5RS232 SELF-TEST>............................................................................................................................81

3.5.3 <3HEAD> .....................................................................................................................................................81

3.5.4 <4RESET> ...................................................................................................................................................82

TABLE OF CONTENTS

3.5.4.1 <1SETS>..................................................................................................................................................82

3.5.4.2 <2UNITS> ................................................................................................................................................83

3.5.4.3 <3ATEST>................................................................................................................................................83

3.5.4.4 <4CAL> ....................................................................................................................................................83

3.5.4.5 <5ALL>.....................................................................................................................................................84

3.5.5 <5PREF>......................................................................................................................................................84

3.5.5.1 <1SCRSVR> ............................................................................................................................................85

3.5.5.2 <2SOUND> ..............................................................................................................................................85

3.5.5.3 <3TIME>...................................................................................................................................................86

3.5.5.4 <4ID>........................................................................................................................................................86

3.5.5.5 <5LEVEL> (SECURITY)...........................................................................................................................87

3.5.6 <6PUNIT>.....................................................................................................................................................89

3.5.7 <7INTERNAL> .............................................................................................................................................91

3.5.7.1 <1CONFIG> .............................................................................................................................................91

3.5.7.2 <2BARO>.................................................................................................................................................91

3.5.7.3 <3PUMP>.................................................................................................................................................92

3.5.8 <8CAL> ........................................................................................................................................................94

3.5.9 <9LOG>........................................................................................................................................................94

4. REMOTE OPERATION

....................................................... 97

4.1 OVERVIEW ............................................................................................................................................97

4.2 INTERFACING .......................................................................................................................................97

4.2.1 RS232 INTERFACE .....................................................................................................................................97

4.2.1.1 COM1.......................................................................................................................................................97

4.2.1.2 IEEE-488..................................................................................................................................................98

4.2.1.3 COM2.......................................................................................................................................................98

4.3 PROGRAMMING FORMATS................................................................................................................. 98

4.3.1 CLASSIC PROGRAM MESSAGE FORMAT ............................................................................................... 99

4.3.2 ENHANCED PROGRAM MESSAGE FORMAT ..........................................................................................99

4.3.2.1 USING COMMAND TYPE COMMANDS .................................................................................................99

4.3.2.2 USIN G Q U E R Y T Y P E C O M M A N D S.................................................................................................100

4.4 COMMANDS ........................................................................................................................................101

4.4.1 PROGRAMMING MESSAGES ..................................................................................................................101

4.4.2 ERROR MESSAGES .................................................................................................................................102

4.4.3 PROGRAM MESSAGE DESCRIPTION OVERVIEW................................................................................103

4.4.4 PROGRAM MESSAGE DESCRIPTIONS..................................................................................................104

4.5 STATUS REPORTING SYSTEM .........................................................................................................128

4.5.1 ERROR QUEUE......................................................................................................................................... 128

4.5.2 STATUS BYTE REGISTER ....................................................................................................................... 128

4.5.3 STANDARD EVENT REGISTER ...............................................................................................................130

4.5.4 READY STATUS REGISTER .................................................................................................................... 130

4.6 IEEE STD. 488.2 COMMON AND STATUS PROGRAM MESSAGES................................................ 131

4.6.1 PROGRAM MESSAGE DESCRIPTIONS..................................................................................................131

5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION....................135

5.1 OVERVIEW ..........................................................................................................................................135

5.2 PREVENTIVE MAINTENANCE ...........................................................................................................135

5.3 CALIBRATION OF QUARTZ REFERENCE PRESSURE TRANSDUCERS (Q-RPTS) ...................... 137

5.3.1 PRINCIPLE ................................................................................................................................................137

5.3.1.1 PA AND PM COEFFICIENTS ................................................................................................................137

5.3.1.2 AS RECEIVED AND AS LEFT DATA ....................................................................................................138

5.3.2 EQUIPMENT REQUIRED .......................................................................................................................... 139

5.3.3 SET UP AND PREPARATION ...................................................................................................................139

5.3.4 RECOMMENDED CALIBRATION POINT SEQUENCE............................................................................139

5.3.5 TURNING OFF ABSOLUTE MEASUREMENT MODE FOR A Q-RPT .....................................................140

5.3.6 Q-RPT CALIBRATION USING CALTOOL FOR RPTS SOFTWARE........................................................ 141

5.3.7 EDITING AND VIEWING Q-RPT CALIBRATION INFORMATION............................................................141

5.3.8 Q-RPT CALIBRATION/ADJUSTMENT WITHOUT CALTOOL FOR RPTS SOFTWARE.........................143

5.4 ADJUSTMENT OF ON-BOARD BAROMETER...................................................................................144

5.5 ADJUSTMENT OF UTILITY SENSOR ................................................................................................144

5.6 FILLING AND DRAINING THE FLUID RESERVOIR ..........................................................................145

5.6.1 INTERNAL RESERVOIR ........................................................................................................................... 145

5.6.1.1 FILLING THE INTERNAL RESERVOIR.................................................................................................145

5.6.1.2 DRAINING THE INTERNAL RESERVOIR.............................................................................................146

5.6.2 EXTERNAL RESERVOIR ..........................................................................................................................146

PPCH™ OPERATION AND MAINTENANCE MANUAL

5.6.2.1 FILLING THE EXTERNAL RESERVOIR................................................................................................146

5.6.2.2 DRAINING THE EXTERNAL RESERVOIR............................................................................................147

5.6.3 PURGING CONTAMINATED FLUID FROM THE PPCH...........................................................................148

5.7 VOLUME CONFIGURATION ...............................................................................................................148

5.8 VALVE OPENING POINT CONFIGURATION.....................................................................................150

5.9 ACCESSING PPCH MECHANICAL MODULE....................................................................................151

5.10 HYDROPNEUMATIC PUMP................................................................................................................152

5.10.1 PRIMING THE PUMP.................................................................................................................................152

5.10.1.1 PRIMING THE PUMP CHECK VALVE ..................................................................................................153

5.10.2 PUMP REPLACEMENT .............................................................................................................................154

5.10.3 PUMP SPOOL VALVE INSPECTION OR REPAIR...................................................................................156

5.10.4 PUMP INLET FILTER (LIQUID) REPLACEMENT ....................................................................................158

5.11 LEAK CHECKING................................................................................................................................159

5.11.1 PRESSURE DECAY LEAK TESTING METHOD ......................................................................................159

5.11.2 LOCALIZING A LEAK WITHIN THE PPCH...............................................................................................160

5.11.2.1 HIGH PRESSURE VENT VALVE LEAK ................................................................................................161

5.11.2.2 LOW PRESSURE ISOLATION VALVE LEAK .......................................................................................163

5.11.2.3 LOW PRESSURE VENT VALVE LEAK.................................................................................................163

5.12 VALVE REPLACEMENT OR REPAIR................................................................................................. 165

5.12.1 SHUTOFF VALVE REPLACEMENT .........................................................................................................165

5.12.2 CONTROL VALVE SERVICE ....................................................................................................................166

5.13 RELOADING EMBEDDED SOFTWARE INTO FLASH MEMORY......................................................166

5.14 SUBASSEMBLY DESCRIPTION AND LOCATION ............................................................................167

5.14.1 ELECTRONIC MODULE............................................................................................................................167

5.14.1.1 POWER ENTRY AND FUSE..................................................................................................................167

5.14.1.2 POWER SUPPLIES ...............................................................................................................................167

5.14.1.3 DRIVER BOARD....................................................................................................................................168

5.14.1.4 MINI MICRO BOARD.............................................................................................................................168

5.14.1.5 ON-BOARD BAROMETER ....................................................................................................................168

5.14.2 MECHANICAL MODULE ...........................................................................................................................169

5.14.2.1 PUMP DRIVE AIR PRESSURE TRANSDUCER ...................................................................................169

5.14.2.2 HI Q-RPT OR UTILITY SENSOR...........................................................................................................169

5.14.2.3 TEST VENT VALVE...............................................................................................................................170

5.14.2.4 LO Q-RPT SHUTOFF VALVE................................................................................................................170

5.14.2.5 LO Q-RPT...............................................................................................................................................170

5.14.2.6 LO Q-RPT VENT VALVE .......................................................................................................................170

5.14.2.7 PUMP ACCUMULATOR ........................................................................................................................170

5.14.2.8 FRONT PANEL ......................................................................................................................................170

5.14.2.9 ELECTRICAL CABLE TRACK ...............................................................................................................170

5.14.2.10 HYDROPNEUMATIC PUMP..................................................................................................................170

5.14.2.11 INLET CONTROL VALVE ......................................................................................................................170

5.14.2.12 OUTLET CONTROL VALVE ..................................................................................................................171

5.14.2.13 FLUID RESERVOIR...............................................................................................................................171

5.14.2.14 RESERVOIR OVERFLOW/EXTERNAL RESERVOIR RETURN TUBE................................................171

5.14.2.15 THERMAL PRESSURE CONTROL UNIT (TPCU) ................................................................................171

5.14.2.16 DRIVE PRESSURE REGULATOR ........................................................................................................171

6. TROUBLESHOOTING .......................................................173

7. APPENDIX ......................................................................177

7.1 DRIVERS .............................................................................................................................................177

7.2 UNIT CONVERSION ............................................................................................................................ 178

7.2.1 PRESSURE................................................................................................................................................178

7.3 REMOTE [ENT] ...................................................................................................................................178

8. WARRANTY

....................................................................179

8.1 OVERVIEW ..........................................................................................................................................179

9. GLOSSARY.....................................................................181

TABLES & FIGURES

AABBLLEES

Table 1. Reference pressure transducer (Q-RPT) designations and ranges..............................................3

Table 2. PPCH packing list ..........................................................................................................................5

Table 3. Drive air requirements....................................................................................................................9

Table 4. Reservoir return settings for internal or external reservoir ..........................................................13

Table 5. MAIN RUN screen display fields..................................................................................................22

Table 6. Position designators of Q-RPTs in a PPCH system....................................................................36

Table 7. Settings and to what they are specific (range, measurement mode, Q-RPT, system) ...............37

Table 8. Summary of PPCH function key operation..................................................................................38

Table 9. Settings made by AutoRange......................................................................................................43

Table 10. Default pressure control parameters .........................................................................................70

Table 11. AutoZ ON and OFF....................................................................................................................76

Table 12. Reset – Sets...............................................................................................................................83

Table 13. Reset – Cal ................................................................................................................................84

Table 14. Reset – All..................................................................................................................................84

Table 15. Security levels............................................................................................................................88

Table 16. UNIT function - available units of measure................................................................................90

Table 17. COM1 pin designations and connections..................................................................................97

Table 18. COM2 DB-9F pin designations..................................................................................................98

Table 19. Program message list..............................................................................................................101

Table 20. Error numbers (#) and descriptions.........................................................................................102

Table 21. 8 Bit status byte register ..........................................................................................................128

Table 22. 8 bit standard event register ....................................................................................................130

Table 23. 8 bit ready status register.........................................................................................................130

Table 24. Program message list..............................................................................................................131

Table 25. PPCH maintenance parts ........................................................................................................136

Table 26. Calibration point sequence, standard class, Q-RPTs..............................................................140

Table 27. Troubleshooting guide .............................................................................................................173

Table 28. External drivers current output.................................................................................................177

Table 29. External drivers pin outs ..........................................................................................................177

Table 30. Pressure unit of measure conversion coefficients...................................................................178

Table 31. DHI Authorized Service Providers ...........................................................................................179

PPCH™ OPERATION AND MAINTENANCE MANUAL

IIGGUURREES

Figure 1. Front panel.................................................................................................................................... 7

Figure 2. Rear panel .................................................................................................................................... 8

Figure 3. Internal reservoir setup...............................................................................................................11

Figure 4. External reservoir setup..............................................................................................................12

Figure 5. Installing the exhaust filter/muffler..............................................................................................13

Figure 6. Connecting PPCH to an RPM4 or PG7302 using the standard

Figure 7. Keypad layout.............................................................................................................................23

Figure 8. Direct pressure control keys.......................................................................................................24

Figure 9. Pressure control system schematic............................................................................................27

Figure 10. Dynamic pressure control operation......................................................................................... 29

Figure 11. Ready/Not Ready in dynamic pressure control mode..............................................................30

Figure 12. Static pressure control operation..............................................................................................30

Figure 13. Ready/Not Ready in static control mode..................................................................................31

Figure 14. Monotonic pressure control operation......................................................................................32

Figure 15. Ready/Not Ready in monotonic pressure control mode...........................................................32

Figure 16. Ramp pressure control operation.............................................................................................33

Figure 17. Ready/Not Ready in ramp pressure control mode...................................................................33

Figure 18. Status register schematic .......................................................................................................129

Figure 19. Internal reservoir schematic ...................................................................................................146

Figure 20. External reservoir schematic ..................................................................................................147

Figure 21. Electronic module, internal view.............................................................................................167

Figure 22. Mechanical module, internal view...........................................................................................169

Figure 23. Drivers connector schematic..................................................................................................177

Figure 24. Remote [ENT/SET P] connector schematic ........................................................................... 178

PPCH interconnection accessories.........................................................................................16

ABOUT THIS MANUAL

BBOOUUTT

This manual is intended to provide the user with the basic information necessary to operate a PPCH pressure controller/calibrator. It also includes a great deal of additional information provided to allow you to optimize PPCH use and take full advantage of its many features and functions.

Before using the manual, take a moment to familiarize yourself with the Table of Contents structure: Sections 1, 2 and 3 should be read by all first time PPCH users. Section 3 is most important for those using the local front panel interface but should be read over general PPCH operating principles. Section 4 is for remote operation from an external computer. Section 5 provides maintenance and calibration information. Section 6 is a quick troubleshooting guide. Use it to troubleshoot unexpected PPCH behavior based on the symptom of that behavior. expressions have specific meaning as they pertain to PPCH. The Glossary, Section 9, is useful as a quick reference for exact definition of specific words and expressions as they are used in the manual.

For those of you who “don’t read manuals”, go directly to Section 2.3 to set up your PPCH and then go to Section 2.4 for power-up and verification. This will get you up and running quickly with a minimal risk of causing damage to yourself or your new PPCH. THEN… when you have questions or start to wonder about all the great features you might be missing, get into the manual!

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

HHIISS

AANNUUAAL

by all users to familiarize themselves with

Certain words and

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

[ ] indicates direct function keys (e.g., [RANGE]).

< > indicates PPCH screen displays (e.g., <1yes>).

PPCH™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

1. INTRODUCTION

11..

NNTTRROODDUUCCTTIIOON

1.1 PRODUCT OVERVIEW

PPCH is a stand-alone, pressure controller intended to precisely generate, adjust and control hydraulic pressure into a closed volume as is commonly needed for the calibration and testing of pressure measuring instruments. It has been designed to provide very high performance combined with maximum versatility and ease of use.

PPCH can be equipped with a low cost utility sensor for pressure monitoring or one or two Quartz Reference Pressure Transducers (Q-RPTs) to allow it to set and measure pressure with higher precision and very low measurement uncertainty. Up to four external Q-RPTs in one or two external Reference Pressure Monitors (RPM4s), can also be integrated into a PPCH system. A barometer is also included for atmospheric pressure compensation of gauge mode measurements and as a reference for AutoZero in absolute measurement mode.

PPCH generates high liquid pressure internally using a hydropneumatic pump driven by a drive air supply. Pressure control is achieved by servo-motor controlled, high pressure needle valves and a thermal pressure control system.

PPCH is controlled locally by the operator using a front panel display, keypad and function keys or remotely by a computer using ASCII character command strings over an RS232 or IEEE-488.2 interface.

PPCH models are available to measure and control pressure in ranges from as low as 20 MPa (3 000 psi) to 200 MPa (30 000 psi) in absolute and gauge measurement modes.

PPCH™ OPERATION AND MAINTENANCE MANUAL

1.2 SPECIFICATIONS

1.2.1 GENERAL SPECIFICATIONS

Power Requirements

Operating Temperature Range

Storage Temperature Range

Vibration

Weight

Dimensions

Ventilation

Communication Ports

Fuses

Pressure Ranges

Operating Medium

Internal Reservoir Capacity

Pressure Connections

85 to 264 VAC, 50/60 Hz, 75 W max consumption 15 to 35 °C

- 20 to 70 °C Meets MIL-T-28800D 50 kg (110 lb) approx Without optional enclosure: 26 cm H x 44 cm W x 55.5 cm D (10.2 in. x 17.3

in. x 21.9 in.) Front panel is 19” wide X 6U high with mounting holes for standard 19 in. rack mount systems

With optional enclosure: 30 cm H x 52 cm W x 55.5 cm D (11.8 in. x 20.5 in. x 21.9 in.)

To prevent product overheating, provide proper ventilation. Allow 10 cm (4 in.) clearance from rear panel cooling fan.

RS232 (COM1), RS232 (COM2), IEEE-488.2 1 A, 250 VAC fuse, 5 x 20 mm, time lag type fuse Internal power supply fuse not replaceable by operator: 2A, 250 V (UV 440-2

power supply), 3.15A, 250 V (NFS40-7612 power supply) Four controller models from 70 MPa (10 000 psi max to 200 MPa (30 000 psi)

max. Low uncertainty measurement provided by selection of Quartz Reference Pressure transducer(s) (Q-RPTs)

Di-2-Ethyl Hexyl Sebacate (other fluids optional) 300 cc DRIVE: 1/8 in. NPT F

TEST: DH500 F

NOTE: DH500 is a gland and collar type fitting for ¼ in. (6.35 mm) coned and left hand threaded tube. DH500 is equivalent to

EXTERNAL: 1/8 in. NPT F

AE F250C, HIP HF4, etc.

OVERFLOW: 1/8 in. NPT F FILL/DRAIN: 1/4 in. swage M ATM: 10-32 UNF

Pressure Limits

Maximum Working: Test Pressure: Controller or Hi Q-RPT maximum

Maximum Test Pressure: without Damage: 115 % controller or Hi Q-RPT maximum

Required Drive Air Pressure:

Supply: H-100M: 700 kPa (100 psi) min, 850 kPa (120 psi) H-140M: 500 kPa (75 psi) min, 850 kPa (120 psi)

H-70M: 500 kPa (75 psi) min, 850 kPa (120 psi)

max; 330 l/m (10 cfm) max; 330 l/m (10 cfm) max; 450 l/m (15 cfm)

H-200M: 700 kPa (100 psi) min, 850 kPa (120 psi) max; 450 l/m (15 cfm)

1. INTRODUCTION

1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS

1.2.2.1 QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT)

Quartz reference pressure transducers (Q-RPTs) can be installed in PPCH to obtain high precision and low uncertainty pressure measurement. One or two Q-RPTs can be included in the PPCH and/or additional Q-RPTs can be used externally mounted in DHI RPM4 Reference Pressure Monitors (see Section 3.2.5).

ll PPCH Q-RPTs are of the absolute pressure type (Axxx) us ing an evacuated,

A permanently sealed reference. Axxx Q-RPTs used in PPCH can measure absolute and gauge pressure. Gauge pressure with an Axxx (absolute) Q-RPT is obtained by offsetting atmospheric pressure and applying dynamic compensation for atmospheric changes using the on-board barometer (see Section 3.2.4). See Section 3.3.3,  gauge measurement modes.

PPCHs configured with two Q-RPT modules have only one TEST port. PPCH internal valves and logic handle switching between the two Q-RPTs as needed.

Table 1. Reference pressure transducer (Q-RPT) designations and ranges

PRINCIPLE, for additional information on absolute and

RPT

DESIGNATION

A200M 200 30 000 A140M 140 20 000 A100M 100 15 000

A70M 70 10 000 A40M 40 6 000

Compensated Temperature Range

Measurement Uncertainty3

Delivered Pressure Uncertainty4

1. Combined linearity, hysteresis, repeatability.

2. Predicted Q-RPT measurement stability limit (k=2) over one year assuming regular use of AutoZero function. AutoZero occurs automatically in gauge mode whenever vented, by comparison with barometric reference in absolute mode. Absolute mode predicted one year stability without AutoZ is ± (0.005 % Q-RPT span + 0.005 % of reading).

3. Maximum deviation of the Q-RPT indication from the true value of applied pressure including precision, predicted one year stability limit, temperature effect and calibration uncertainty, combined and expanded (k=2) following the ISO “Guide to the Expression of Uncertainty in Measurement.”

4. Maximum deviation of the PPCH controlled pressure from the true value including measurement uncertainty and dynamic control hold limit.

5. % of reading applies to 30 to 100 % of Q-RPT span. Under 30 % of Q-RPT span, the value is a constant which is the % of reading value times 30 %.

A20M 20 3 000

Warm Up Time

Resolution

Acceleration Affect

Precision

Predicted Stability2

SI VERSION US VERSION

MAXIMUM PRESSURE

Absolute and Gauge [MPa]

30 minute temperature stabilization recommended for best performance from cold power up.

To 1 ppm, user adjustable 5 to 35 °C ± 0.008 % /g maximum, worst axis

Allows operation at ± 20° from reference plane without significant effect

<A200M A200M

± 0.012 % of reading5 ± 0.015 % of reading5 ± 0.005 % of reading5 ± 0.005 % of reading5 ± 0.013 % of reading5 ± 0.018 % of reading5 ± 0.015 % of reading5 ± 0.020 % of reading5

MAXIMUM PRESSURE

Absolute and Gauge [psi]

PPCH™ OPERATION AND MAINTENANCE MANUAL

1.2.2.2 UTILITY SENSOR

Base PPCH pressure controllers include a utility sensor. If a Hi Q-RPT (see Section 3.2.5) is installed, there is no utility sensor.

Utility sensors are used

for pressure control, system monitoring and safety functions. They are intended for indication only, not to provide reference pressure measurement. Q-RPTs (see Section 1.2.2.1) are used for reference measurement.

Warm Up Time

Range

Resolution

Precision

None required PPCH-70M: 70 MPa (10 000 psi) absolute and gauge

PPCH-100M: 100 MPa (15 000 psi) absolute and gauge PPCH-140M: 140 MPa (15 000 psi) absolute and gauge PPCH-200M: 200 MPa (30 000 psi) absolute and gauge

0.001 % of span

0.1 % of span

1.2.2.3 ON-BOARD BAROMETER

The on-board barometer is used only to measure changes in atmospheric pressure to provide dynamic compensation of the Q-RPT’s atmospheric pressure offset when operating in gauge measurement mode. If calibrated, it can also be used as an AutoZ reference for AutoZeroing in absolute measurement mode.

Warm Up Time

Range

Resolution

Precision

Predicted Stability

None required 70 to 110 kPa (10 to 16 psi)

0.001 % of span

0.1 % of span

0.05 kPa/yr (0.008 psi/yr)

1.2.3 PRESSURE CONTROL SPECIFICATIONS

Control Precision (Standard Dynamic Mode)

Default Dynamic Control Hold Limit

Lowest Controllable Pressure (absolute,

gauge modes)

Typical Control Ready Time (Dynamic Mode)

Slew Rate (0 to FS)

TEST Volume

0 to 100 cc, 50 cc optimum (operates in larger

volumes but pressure stabilizing time increases)

ALL MODELS

to ± 0.003 % of Q-RPT span

± 0.01 % of AutoRanged range

1 MPa (150 psi)

60 to 120 seconds.

60 seconds

2. INSTALLATION

22..

NNSSTTAALLLLAATTIIOON

2.1 UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

PPCH is delivered in a wooden crate with high density polyethylene inserts to hold it in place. Remove the PPCH and its accessories from the shipping container and remove each element from its protective plastic bag.

PPCH weighs more than 50 kg (110 lb). Take appropriate precautions to lift and place it safely.

2.1.2 INSPECTING CONTENTS

Check that all items are present and have no visible damage. A standard PPCH includes all items indicated in Table 2.

Table 2. PPCH packing list

DESCRIPTION PART #

1 ea. PPCH Pressure Controller/Calibrator FAM0010 1 ea. PPCH Enclosure (optional) 06-01

ACCESSORIES: 402038 (402038-CE)

1 ea. Operation and Maintenance Manual 550132 1 ea. Calibration Report 550100 1 ea. Test Report 550200 1 ea. Power Cord (7.5 ft.) 100770 (100770-CE) 1 ea. Reservoir fill tube assembly 402039 1 ea. Reservoir fill tube bracket 123832 2 ea. Bolts, SHC, M3 x 8 101010-Z 1 ea. Funnel 123959 1 ea. Filter/muffler, pump drive exhaust, 1/4. in. NPT M 103897 1 ea. Gland, DH200 100272 1 ea. Plug, DH200 100279

1 qt. Sebacate (synthetic oil). If PPCH is delivered filled with a fluid other than

Sebacate, this item is not included. 1 ea. Drivers Connector 401382 1 ea. General Accessories Disk (white CD) 102987

INTERCONNECTIONS KIT: 401536

2 ea. Nipple, 2.75 in., DH500 100207 1 ea. Nipple, 6 in., DH500 100208 2 ea. Nipple, 12 in., DH500 100209 1 ea. Union, DH500 100295 1 ea. Elbow, DH500 100168 1 ea. Tee, DH500 100291 2 ea. Gland, DH500 100271 3 ea. Plug, DH500 100285 5 ea. Collar, DH500 101201 1 ea. Nipple, 5 in. x 1/8 in., DH500 tips 123019 2 ea. Adaptor, DH500 F x 1/8 in. NPT M 102819 1 ea. Adaptor, DH500 F x 1/4 in. NPT F 102820

400503 or none

PPCH™ OPERATION AND MAINTENANCE MANUAL

2.2 SITE REQUIREMENTS

PPCH weighs more than 50 kg (110 lb). Be sure that the location in which it’s installed is adequate to

support the load.

The PPCH can be installed on any flat, stable surface at a convenient height. The PPCH can also be mounted in a standard 19 in. rack (see Section 2.2.1).

Minimizing the distance between

the PPCH and the device or system under test will enhance control

performance and reduce pressure setting times. Ready access to the PPCH rear panel should be considered to facilitate making and breaking

pressure connections. Also consider:

• Access to the internal reservoir FILL/DRAIN port if an external reservoir is not being used (see Section 2.3.6).

•

Location and connections to an external reservoir, if used (see Section 2.3.6.2). Hydraulic and RS-232 connections to an external RPM4 should be considered if RPM4 is to be

• used as an external reference pressure measurement device (see Section 2.3.9.1).

Location and connections to the device or system into which pressure is to be controlled (see

• Section 2.3.9.4).

Support facilities required include:

• An electrical pow

er source of 85 to 264 VAC, 50/60 Hz.

• A pneumatic power supply, of “drive air” to be connected to the PPCH DRIVE port. Required pressure varies with PPCH model (see Section 2.4.2).

ALWAYS use external tubing and fittings rated for pressures equal to or greater than the maximum

pressure PPCH will generate.

2.2.1 INSTALLATION IN A 19 IN. RACK MOUNT

PPCH is dimensioned to be ready for direct mounting in a standard 19 in. rack mount system. If PPCH was delivered in the optional enclosure, it must be removed from the enclosure prior

to rack mounting. The front panel is 6U (10.5 in.) high. Install PPCH into the rack mount system using heavy duty front panel bolts provided by the rack

vendor. Due to PPCH’s weight, it is imperative that a rail system also be used to support it along

the sides and/or rear. These are also supplied by the rack mount system vendor.

PPCH weighs more than 50 kg (110 lb). Take appropriate precautions to lift and place it safely. It is the user’s responsibility to support PPCH adequately on the sides and/or rear when installing it in a rack mount system.

2. INSTALLATION

2.3 INITIAL SETUP

2.3.1 PREPARING FOR OPERATION

To prepare PPCH for check out and operation:

Remove the plastic caps from the PPCH rear panel pressure connections.

Remove the protective plastic sheet from the front panel display. Familiarize yourself briefly with the front and rear panel (see Section 2.3.2).

Then proceed with Sections 2.3.3 to 2.3.11.

2.3.2 FRONT AND REAR PANELS

2.3.2.1 FRONT PANEL

1. Ready/Not Ready Indicator

2. Display

3. Remote activity indicator

Figure 1. Front panel

4. Cursor control keys

5. Multi-function keypad

6. Direct pressure control keys

PPCH™ OPERATION AND MAINTENANCE MANUAL

2.3.2.2 REAR PANEL

1. Electrical power connector (IEC-320C13) and fuse

2. Cooling fan

3. Remote [ENTER] connector

4. DRIVERS connector

5. RS-232 port, COM2

6. RS-232 port, COM1

7. Product label

8. IEEE-488 connector

9. ATM (barometer) port

10. Internal reservoir fill funnel

11. Internal reservoir level sight tube

12. Reservoir FILL/DRAIN port

13. PUMP DRIVE OUT gas exhaust port

14. Reservoir FILL/DRAIN valve

15. EXTERNAL reservoir return port

16. Reservoir OVERFLOW port

17. RESERVOIR RETURN valve

18. DRIVE IN air supply port

19. Mechanical module pull out handles

20. TEST port

Figure 2. Rear panel

2.3.3 POWER CONNECTION

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

2.3.4 REMOTE [ENTER/SET P] CONNECTION (FOOTSWITCH OR OTHER SWITCH)

Connect the optional remote ENTER footswitch, if available or a user supplied switch fitted to the optional cable (see Section 7.3). Connect the cable to the PPCH rear panel connection labeled REMOTE ENTER. Activating the switch is equivalent to key on the front panel (see Section 3.1.4).

pressing the [ENT/SET P]

2. INSTALLATION

2.3.5 CONNECTING PNEUMATIC POWER (DRIVE PORT)

Using a pressure connecting hose or tube of appropriate pressure rating, connect drive air supply to the DRIVE port on the rear panel of PPCH. It is important to proper PPCH pressure control that the supply connection not excessively restrict flow. The tube should have an ID of at least 3 mm (1/8 in.) and not be more than 2 m (6 ft) long. Generally, a 3 mm ID tube has OD of at least

6.35 mm (1/4 in.). The DRIVE port connection is 1/8 in. NPT female.

The drive air supply is regulated internally by PPCH. Drive air requirements for the different PPCH models are listed in Table 3.

Table 3. Drive air requirements

MODEL

PPCH-70M 500 kPa (75 psi) PPCH-100M 700 kPa (100 psi) PPCH-140M 500 kPa (75 psi) PPCH-200M 700 kPa (100 psi)

MINIMUM DRIVE AIR

PRESSURE

MAXIMUM DRIVE AIR

PRESSURE

850 kPa (120 psi)

MINIMUM

UNINTERRUPTED

FLOW

330 l/m (10 cfm)

450 l/m (15 cfm)

2.3.6 SETTING UP AND FILLING THE FLUID RESERVOIR

The PPCH fluid reservoir holds the fluid that supplies PPCH’s hydropneumatic pump and returns from its exhaust valve.

PPCH has an internal reservoir with a capacity of 300 cc that is filled from and whose level can be viewed on the rear panel of the instrument. If greater capacity and/or remote reservoir filling and level viewing are needed, external reservoir (part number 402102) may be installed.

See Section 2.3.6.1 to set up and fill the internal reservoir. See Section 2.3.6.2 to set up and fill an external reservoir.

Take care not to let the PPCH reservoir become empty. Operating PPCH with an empty reservoir will cause the hydropneumatic pump to draw air and lose its prime. A pump that has lost its prime must be reprimed using a special procedure (see Section 5.10.1). PPCH has a low

level warning displayed on the front panel that can be also checked by remote command (see

fluid Section 3.5.7.3).

The system connected to the TEST port is connected to the reservoir when the PPCH is vented ([VENT] LED ON). If there is an open point in the system below the fluid level in the reservoir, liquid will run from the reservoir and out of the open point.

2.3.6.1 INTERNAL RESERVOIR

The PPCH is shipped with its internal reservoir filled with PPCH’s working fluid. To operate without an external reservoir, the internal reservoir attachments must

be installed on the PPCH rear panel. These are included with the PPCH accessories (see Table 2).

PPCH™ OPERATION AND MAINTENANCE MANUAL

The internal reservoir attachments include:

- Reservoir fill tube bracket, p/n 123832 (grey painted bracket)

- (2) M3 x 8 bolts, p/n 101010-Z

- Reservoir fill tube assembly, p/n 402039 (1/2 in. PFA tube with fittings

attached)

To prevent draining the reservoir accidentally, leave the RESERVOIR FILL/DRAIN valve in the CLOSED position whenever the internal reservoir or external reservoir attachments are not installed. Opening the FILL/DRAIN valve opens the FILL/DRAIN port to the reservoir.

To set up to use the internal reservoir without an external reservoir, proceed as follows (numeric references refer to Figure 3):

Install the reservoir fill tube bracket(1) to the PPCH rear panel using 2 ea. M3

x 8 bolts(3).

- Funnel p/n 123959

Install the reservoir fill tube assembly(4) by connecting the 1/4 in. swage

female on the assembly to the 1/4 in. swage male FILL/DRAIN connection. Remove and retain the stainless steel cap that is installed on the connection as delivered. Orient the PFA tube vertically. Bend the tube slightly to extend through the reservoir fill bracket.

There is a red plug with a center pull tab in the end of the PFA tube. This

should be left in place when the funnel is not being used to prevent contamination and/or evaporation of the fluid. The funnel(2) can be stored in

the holder just behind the tube. Open the FILL/DRAIN valve(5). Fluid may enter the fill drain tube(4). Check that the EXTERNAL port(6) is plugged. It is plugged when delivered.

If it is not, use a 1/8 in. NPT M plug with Teflon® tape on the threads to plug

it. Not plugging the EXTERNAL port when using the internal reservoir only

will cause the fluid exhausted from the PPCH to leak out rather than

returning to the reservoir. Check that the OVERFLOW port(7) is open to atmosphere and

unobstructed. This assures the reservoir is open to atmosphere so proper

system venting and zeroing can occur.

Be sure the RESERVOIR RETURN valve(8) is on the INTERNAL position. Check the level of the fluid in the fill/drain tube. If the level is below the MAX

FILL position, top off the tank. See Section 5.6.1 for information on filling

and draining the PPCH internal reservoir.

The PFA reservoir fill tube is delivered with a red plug with a center pull tab installed. This plug can be used after the tube is installed to cover the opening and reduce evaporation of the fluid. The plug is vented.

2. INSTALLATION

1. Reservoir fill tube bracket

2. Reservoir fill funnel

3. M3 x 8 bolt

4. Reservoir fill tube assembly

Figure 3. Internal reservoir setup

5. Reservoir FILL/DRAIN valve

6. EXTERNAL Reservoir return port

7. Reservoir OVERFLOW port

8. RESERVOIR RETURN valve

2.3.6.2 EXTERNAL RESERVOIR

The PPCH is shipped with its internal reservoir filled with PPCH’s working fluid. An external reservoir, if desired, is connected in series to supply the internal

reservoir so that the internal reservoir’s features are still available. When using an external reservoir the internal reservoir attachments are NOT

installed. If they have been installed, remove them prior to setting up the external reservoir (see Section 2.3.6.1). Be sure to put the FILL/DRAIN valve in the CLOSED position before removing the fill/drain tube assembly.

To prevent draining the reservoir accidentally, leave the RESERVOIR FILL/DRAIN valve in the CLOSED position if the internal or external reservoir attachments are not installed. Opening the FILL/DRAIN valve opens the FILL/DRAIN port to the internal reservoir.

When installing an external reservoir, the bottom of the reservoir should be higher than the PPCH instrument. Avoid low points in the tubing between the PPCH and the external reservoir.

To set up to use an external reservoir, proceed as follows (numerical references refer to Figure 4):

With the reservoir FILL/DRAIN valve in the CLOSED position, connect a

tube coming from the bottom of the external reservoir to the FILL/DRAIN port(1). The FILL/DRAIN port is1/4 in. M swage.

Connect an external reservoir return tube from the EXTERNAL port(3) to the

inside of the reservoir. Remove and retain the 1/8 in. NPT plug installed in EXTERNAL port as shipped. The reservoir return tube returns fluid exhausted by PPCH to the external reservoir. The top of the tube should extend vertically to a level slightly higher than the top surface of the fluid in the reservoir. The top of the tube defines the fluid head applied to the PPCH Q-RPT when the PPCH is vented (see Section 5.6.2, Figure 20).

PPCH™ OPERATION AND MAINTENANCE MANUAL

Fill the external reservoir with fluid. This should be the same fluid that is in

the PPCH. PPCH will not operate properly with a fluid other than the liquid with which it was filled when delivered. The MAX FILL label on the rear of the PPCH does not apply when using an external reservoir.

Purge air from the internal reservoir and overflow circuit:

a. Prepare an 1/8 in. NPT plug (one was delivered installed in the

EXTERNAL port) by wrapping its threads with Teflon tape.

b. While watching the OVERFLOW port(4), slowly turn the

RESERVOIR FILL/DRAIN valve(2) to the OPEN position.

c. When air free fluid begins to flow from the OVERFLOW port, plug

the port with the 1/8 in. NPT plug.

Be sure the RESERVOIR RETURN valve(5) is in the EXTERNAL position. Be sure the external reservoir is open to atmosphere so proper system

venting and zeroing can occur.

Fill the reservoir return tube connected between the reservoir and the

EXTERNAL port with fluid. See Section 5.6.2 for additional information in

filling and draining an external reservoir.

When the PPCH is vented ([VENT] LED ON), the system connected to the TEST port is connected to the reservoir. If there is an open point in the system below the fluid level in the reservoir, liquid will run out of the reservoir through the open point.

2.3.7 RESERVOIR RETURN SETTINGS

The PPCH rear panel has a section labeled RESERVOIR RETURN. The settings and connections in this panel vary depending on whether the internal reservoir is being used alone or an external reservoir is being used.

Refer to Table 4 for correct reservoir return settings and other conditions when using the internal reservoir alone or an external reservoir. Also see Section 2.3.6 for internal and external reservoir setups.

1. Reservoir FILL/DRAIN port

2. PUMP DRIVE OUT gas exhaust port

3. Reservoir FILL/DRAIN valve

Figure 4. External reservoir setup

4. EXTERNAL Reservoir return port

5. Reservoir OVERFLOW port

6. RESERVOIR RETURN valve

2. INSTALLATION

Table 4. Reservoir return settings for internal or external reservoir

RESERVOIR

Internal only INTERNAL Open to

External EXTERNAL Plugged Connected to external

RETURN VALVE

POSITION

OVERFLOW

PORT EXTERNAL PORT

Plugged

atmosphere

reservoir return tube

See Section 5.6, Figure 19 and Figure 20 for schematics of the PPCH reservoir system.

Incorrect settings or port conditions in the RESERVOIR RETURN panel may lead to fluid

leaks and faulty measurements.

2.3.8 INSTALLING PUMP DRIVE OUT GAS EXHAUST FILTER/MUFFLER

A stainless steel filter (P/N 103897) is supplied in the PPCH accessory kit. The filter dampens the sound of supply gas being exhuasted from the hydro-pneumatic pump. To install the filter, first wrap 1 to 2 turns of teflon tape around the threads then insert the threaded end of the muffler into the Pump Drive Out port using a 9/16" wrench as shown in Figure 5. Do not overtighten.

It is important to use a wrench to install the filter instead of a screwdriver. The button head screw on the end of the filter adjusts the conductance of the muffler. If the muffler is too restrictive then the hydropneumatic pump will stall and the PPCH may not be able to increase pressure.

The filter/muffler is adjusted for conductance at the factory. If the filter adjustment is altered it can be returned to the factory setting by using a screwdriver to turn the button head screw clockwise until it stops then turning it one and half turns counterclockwise.

Figure 5. Installing the exhaust filter/muffler

PPCH™ OPERATION AND MAINTENANCE MANUAL

2.3.9 CONNECTING TO OTHER DEVICES

ALWAYS use external tubing and fittings rated for pressure equal to or greater than the

maximum pressure PPCH will be used to generate.

The PPCH TEST port is a DH500 female fitting.

DH500 is a gland and collar type fitting for 1/4 in. (6.35 mm) coned and left hand threaded

tube. DH500 is equivalent to AE F250C, HIP HF4, etc.

DH500 fittings are rated for working pressure up to 500 MPa (72 500 psi). Be sure to use stainless steel tubing rated for your maximum operating pressure with the DH500 fittings.

2.3.9.1 INSTALLING A LINE FILTER TO PROTECT THE PPCH

PPCH uses pressure shutoff valves that are needle valves that close by the metal to metal contact of the needle in its seat. These valves can be damaged by hard particles. If the test system to which PPCH will be connected may contain hard particles, such as metal shavings from a production process, a line filter should be installed on the PPCH test port to prevent the particles from entering the PPCH when reducing pressure. The filter should not be smaller then 40 micron. DHI recommends high pressure filter kit p/n 402376.

2.3.9.2 CONNECTING TO AN RPM4 TO BE USED AS AN EXTERNAL REFERENCE DEVICE

ALWAYS use external tubing and fittings rated for pressure equal to or

greater than the maximum pressure PPCH will be used to generate.

PPCH can be connected hydraulically and by RS-232 to one or two RPM4 reference pressure monitors to use up to four external Q-RPTs (two in each RPM4) as external reference pressure measurement devices (see Section 3.2.5).

The PPCH then manages communications and other integrate the RPM4 measurement capabilities into the PPCH system. The user

is responsible for setting up hardware and following procedures to isolate lower pressure Q-RPTs from possible overpressure if pressures higher

than the Q-RPT maximum are generated.. PPCH and RPM4 do not have hardware provisions for isolating external Q-RPTs from the TEST circuit.

As a general rule, making the hydraulic connection between the PPCH TEST port and the remote Q-RPT as direct as possible favors good pressure control. As distance, volumes and restrictions between the PPCH TEST port and the remote QRPT increase, the possibility of difficulty with pressure control when using the external Q-RPT increases.

RPM4 functions to

2. INSTALLATION

To connect a PPCH to an RPM4 to be used as part of the PPCH system proceed as follows:

Set up the RPM4 for use as a PPCH external device following the instructions in the RRPM4 Operation and Maintenance Manual, Using RPM4 With a PPC3 Controller/Calibrator Section.

Using tubing of appropriate pressure rating and a tee fitting, connect the

RPM4 Q-RPT TEST(+) port to the PPCH TEST port (see Figure 6 for instructions

on making this connection using the standard interconnection accessories supplied with the PPCH). The third leg of the tee is for the connection to the device or system under test.

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

Using a standard pin-to-pin DB-9M to DB-9F RS232 cable, connect COM2 of

the PPCH to COM1 of the RPM4 (see Section 4.2.1.3).

Turn ON the RPM4 and the PPCH. Press [RPT] on the PPCH key pad. This causes PPCH to execute the

Q-RPT search function (see Section 3.3.5). Following the search, Q-RPTs with whom communication is established

are shown on the PPCH display,

identified by their position (see Table 6).

For PPCH to identify external RPM4s, the RPM4 COM port settings

must be:

Baud rate: between 1200 and 19200 Parity: Even Data bits: 7 Stop bits: 1

If PPCH is not able to establish communications with an RPM4 and its Q-RPTs, check that the RPM4 COM1 port settings conform to the requirements above. If the COM1 port settings are correct, check that the correct communications cable is being used (standard pin-to-pin DB-9M to DB-9F RS232) and is connected to the correct communications ports.

PPCH COM2 > 1st RPM4 COM1; 1st RPM4 COM2 > 2nd RPM4 COM1

See the RPM4 Operation and Maintenance Manual for additional information on RPM4 RS232 communications and COM port settings.

PPCH™ OPERATION AND MAINTENANCE MANUAL

1. PPCH

2. 2.75 in. (70 mm) DH 500 nipple

3. DH500 tee

4. 12 in. (305 mm) DH500 nipple

5. DH500 tee (RPM4) or union (PG7000)

6. 6 in. (152 mm) DH500 nipple

Figure 6. Connecting PPCH to an RPM4 or PG7302 using the standard

PPCH interconnection accessories

2.3.9.3 CONNECTING TO A PG7302 PISTON GAUGE

7. DH500 union (RPM4) or tee (PG7000)

8. 5 in. (127 mm) DH500 x 1/8 in. tube weld nipple (slightly flexible) 9a. RPM4 or RPM3 9b. PG7000

ALWAYS use external tubing and fittings rated for pressure equal to or

greater than the maximum pressure PPCH will be used to generate.

PPCH is frequently used as the automated pressure generation and control component in a PG7302 oil operated piston gauge system. To do so, it must be connected hydraulically and by RS-232 to the PG7302.

The PG7302 puts the PPCH into remote mode and manages its operation. To connect a PPCH to a PG7302 to be used as an automated pressure

generation and control component in the PG7302 system, proceed as follows:

Using tubing of appropriate pressure rating and a tee fitting, connect the

PG7302 TEST port to the PPCH TEST port (see Figure 6 for instructions on making this connection using the standard interconnections

accessories supplied with the PPCH). The third leg of the tee is for the connection to the device or system under test.

Using a standard pin-to-pin DB-9M to DB-9F RS232 cable, connect COM1 of

the PPCH to COM3 of the PG7302.

See the PG7000 Operation and Maintenance Manual for information on

operating the PG7302 with an automated pressure controlling device.

For PPCH to be identified by a PG7302 platform, the PPCH-COM1 port settings must be the same as the PG7302 COM3 settings (baud rate, parity, data bits, stop bits). If the PG7000 is not able to establish communications with PPCH, check that the PPCH COM1 port settings are the same as the PG7302 COM3 settings. If the COM port settings are correct, check that the correct communications cable is being used (standard pin-to-pin DB-9M to DB-9F RS232) and is connected to the correct communications ports.

See the PG7302 Operation and Maintenance Manual for additional information on PG7302 RS232 communications and COM port settings.

2. INSTALLATION

2.3.9.4 CONNECTING TO A DEVICE UNDER TEST (TEST PORT)

ALWAYS use external tubing and fittings rated for pressure equal to or

greater than the maximum pressure PPCH will be used to generate.

Using a pressure connecting hose or tube of appropriate pressure rating, connect the device or system to be tested to the PPCH TEST port. The PPCH TEST connection is DH500 female.

DH500 is a gland and collar type fitting for 1/4 in. (6.35 mm) coned and left hand threaded tube. DH500 is equivalent to AE F250C, HIP HF4, etc.

Minimizing the length of the test connection tubing will enhance control performance and reduce pressure setting time. For normal operation, the optimum total volume of the device or system under test including connecting tubing is 50 cc

) and should be less than 100 cc (6 in3).

(3 in

PPCH pressure control will not operate properly if there are excessive leaks in the system connected to its TEST port. In general, the maximum acceptable leak rate for optimal PPCH automated pressure control operation and to assure in tolerance measurements with default pressure control parameters is 0.005 % of reading/second. In DYNAMIC CONTROL mode, to handle higher test system leak rates, increase the hold limit using CUSTOM CONTROL (see Section 3.4.6.1) or use HI VOLUME DYNAMIC CONTROL (see Section 3.2.2.2).

2.3.10 CHECK/SET SECURITY LEVEL

PPCH has a security system based on user levels. By default, the security system is set to “low”, which includes certain access restrictions, and there is no password required to change the security level. See Section 3.5.5.5 for information on the security level system. As part of the PPCH startup, determine the security level that is appropriate for the PPCH and set a password if desired.

PPCH is delivered with the security level set to “low” to avoid inadvertent altering of critical internal settings but with access to changing security levels unrestricted. It is recommended that the low security level be maintained at all times and password protection be implemented if control over setting of security levels is desired.

PPCH™ OPERATION AND MAINTENANCE MANUAL

2.3.11 TURN OFF ABSOLUTE MEASUREMENT MODE

PPCH Q-RPTs can operate in both absolute and gauge measurement modes (see Section

3.3.3). If the PPCH will only be used in gauge mode, absolute measurement mode may be turned off for its Q-RPT(s) so it is no accidental use of the wrong measurement mode. See Section 5.3.5 for complete information on turning off absolute measurement mode.

longer accessible. This can avoid confusion and/or

2.4 POWER-UP AND VERIFICATION

2.4.1 SWITCH POWER ON

Actuate the power switch on the PPCH rear panel. Observe the front panel display as PPCH initializes, error checks and goes to the MAIN RUN screen (see Section 3.1.1).

PPCH pressure measured by the Hi Q-RPT is more than 100 kPa (15 psi) away from standard atmospheric pressure.

If the PPCH fails to reach the MAIN RUN screen, service is required. Record the sequence of operations and displays observed. Contact a DHI Authorized Service Provider (see Table 31).

power-up condition is Internal, Hi Q-RPT or utility sensor active, VENT ON unless the

2.4.2 APPLY PNEUMATIC POWER (DRIVE AIR)

Apply pneumatic power of the appropriate pressure and flow rate to the PPCH DRIVE port (see Section 2.3.5). It is normal for the hydropneumatic drive air is applied.

pump to cycle a few times when

2.4.3 CHECK PRESSURE MEASUREMENT OPERATION

2.4.3.1 CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT

Check that the PPCH operates properly in absolute mode. If the PPCH is not vented (VENT LED ON), press the [VENT] direct pressure

control key (see Section 3.1.3). Use the [RANGE]

Q-RPT’s DF range (see Section 3.3.1). Press the [MODE] function key and select

<absolute> (see Section 3.3.3). Use [UNIT] to change the pressure unit if

desired (see Section 3.3.2).

function key to change ranges if necessary and select the

Observe the current value of atmospheric pressure. with the local value of atmospheric pressure. Repeat this process for all the QRPTs and or the utility sensor in the PPCH system. Check that the values of atmospheric pressure measured by the different devices agree with each other within PPCH or RPM4 measurement tolerances as applicable (see Section

1.2.2.1, 1.2.2.2). Remember to consider that head pressures can be with liquids (see Section 3.3.7). If the Q-RPTs do not agree within tolerances, the PPCH or RPM4 Q-RPT may need calibration or repair.

Check that the value agrees

significant

2. INSTALLATION

2.4.3.2 CHECKING GAUGE MODE PRESSURE MEASUREMENT

If the PPCH is not vented (VENT LED ON), press the [VENT] direct pressure control key to vent it (see Section 3.1.3).

Use the [RANGE]

function key to change ranges if necessary and select the Q-RPT’s DF range (see Section 3.3.1). Press the [MODE] function key and select

<gauge> mode (see Section 3.3.3). Use [UNIT]

to change the pressure

unit if desired (see Section 3.3.2).

t is normal for PPCH to indicate a value other than zero for up to thirty seconds

I when first entering gauge mode. After ten to thirty seconds, the VENT LED should flash and zero should be indicated. If this does not occur, check that the AUTOZERO function is ON (see Section 3.5.1). If AUTOZERO is ON and the displayed

pressure will not zero when vented in gauge or bi-directional gauge

measurement mode, PPCH may need repair.

If a non-zero head correction value is active, PPCH will not indicate zero when

vented in gauge mode. Use [HEAD] to set the head height to zero (see Section 3.3.7).

Using the [RANGE] function key to change ranges, observe that zero is indicated for each Q-RPT within 10 to 30 seconds.

2.4.4 PRIME AND PURGE TEST SYSTEM

For PPCH pressure control to operate properly, it is important to minimize the amount of gas present in the system connected to the TEST port. The prime and purge functions are intended to assist in removing gas from the test system before starting a test.

Prior to controlling pressure with PPCH, it is recommended that a priming and/or purging procedure be completed (see Section 3.3.8).

2.4.5 LEAK CHECK

PPCH cannot control pressure properly if the system connected to the TEST port has excessive leaks. See Section 3.3.9 or information on the PPCH leak

test function.

For PPCH to operate properly, the leak rate in the test system after stabilization should not exceed 0.005% of reading/second.

Verify the maximum pressure rating of the system connected to the PPCH TEST port before entering a purge pressure value. Do not enter a purge pressure greater than the pressure rating of the system or instruments connected to the PPCH TEST port.

2.4.6 CHECK PRESSURE CONTROL OPERATION

Select a pressure range using [RANGE] (see Section 3.3.1). Press [SETUP], <6control>, <2mode>, <1dynamic>, <1standard>) (see Section 3.4.6). If

PCH was not already set to dynamic control mode, wait 5 minutes for the thermal pressure controller to stabilize.

ress [ENT]. Key in a target pressure within the active range and press [ENT] again

(see Section 3.3.10).

PPCH™ OPERATION AND MAINTENANCE MANUAL

Verify the maximum pressure rating of the system connected to the PPCH TEST port before entering a target pressure. Do not enter a target pressure greater than the pressure rating of the system or instruments connected to the PPCH TEST port.

PPCH should set the target pressure and indicate Ready (see Section 3.2.3) continuously in 60 to 120 seconds. If it does not, see Section 6 to troubleshoot.

2.5 STORAGE AND SHIPPING

2.5.1 SHORT TERM STORAGE

The following procedure is recommended for short term storage of PPCH:

Vent the PPCH test pressure.

If the PPCH TEST port is open to a point lower than the reservoir, when PPCH is vented

([VENT] LED ON), the liquid contained in the reservoir may leak out through the opening.

Turn the power OFF using the rear panel power switch. Shut OFF or disconnect the drive air pressure supply.

2.5.2 LONG TERM STORAGE

The following procedure is recommended for long term storage of PPCH:

Complete the short term storage procedure (see Section 2.5.1).

Plug the TEST port with a DH500 steel plug. Set the RESERVOIR FILL/DRAIN valve to CLOSED and the RESERVOIR RETURN

valve to INTERNAL.

2.5.3 PREPARATION FOR SHIPPING

The following procedure is recommended to prepare PPCH for shipment:

Complete the long term storage procedure (see Section 2.5.2).

Remove the internal reservoir accessories if they have been installed (see Section 2.3.6.1). Pack PPCH carefully being sure to use packing materials appropriate for shipment of a

delicate instrument weighing approximately 50 kg (110 lb.). If available, use the original packing materials.

3. OPERATION

33..

PPEERRAATTIIOON

3.1 USER INTERFACE

PPCH is designed to offer a practical balance between simple, straight forward operation and the availability of a wide variety of advanced functions with a high level of operator discretion. The local operator interface is through a 2 x 20 display, a function/data keypad, a cursor control pad and direct pressure control keys.

Remote communication is by RS232 (COM1) or IEEE-488. See Section 4 for information on remote communication.

3.1.1 MAIN RUN SCREEN

The PPCH MAIN RUN screen is its home display that is reached on power-up and from which other functions and menus are accessed. It is the very top level of all menu structures.

The MAIN RUN screen is where the operator works with PPCH to set and read pressures. It provides complete information on the system’s current configuration and operating status.

Table 5 summarizes the PPCH MAIN RUN screen fields and their functions.

PPCH has a screen saver function which causes the display to dim if no key is pressed for 10 minutes. Pressing a key restores full power to the display. The screen saver time can be changed or screen saving can be completely suppressed (see Section 3.5.5.1).

PPCH™ OPERATION AND MAINTENANCE MANUAL

Table 5. MAIN RUN screen display fields

PRESSURE1UNITM hzRRH

TPRESSURE2 CC NN/NN

DISPLAY FIELD NAME PURPOSE CONTENTS SECTION

1. PRESSURE1 Measured

2. UNIT Unit of

3. M Measurement

4. h Head

5. z AutoZero

6. RRH Active Q-

7. NN/NN Sequence

8. CC Pressure

Displays pressure

pressure

measured by active Q-RPT or utility sensor

Identifies unit of

measure

measure in which PRESSURE1 and PRESSURE2 are displayed

Identifies

mode

measurement mode of displayed pressure

Indicates whether a pressure indicator

fluid head correction

is applied to

PRESSURE1

Indicates whether indicator

the AutoZero

function is ON or

OFF

Indicates the position RPT position indicator

in the PPCH system

of the active Q-RPT

or utility sensor

Indicates progress of progress indicator

an ATest sequence,

during test execution

Indicates type of control indicator

pressure control,

whether control is

currently active and

whether custom

control limits are in use

Numerical pressure value and sign

1.2.2.1

1.2.2.2

3.3.10

Pressure unit of

3.3.2

measure abbreviation

<a>: absolute

3.3.3

<g>: gauge <h>: the fluid head

3.3.7

is not zero <blank>: fluid head is

zero <z>: AutoZ is ON

3.5.1

<blank>: AutoZ is OFF

<IH>: Internal Hi

3.2.5 <IuH>: Internal Hi (utility sensor)

<IL>: Internal Lo <X1H>: External 1 Hi <X1L>: External 1 Lo <X2H>: External 2 Hi <X2L>: External 2 Lo

<NN/NN>: Number of

3.3.6 this point over total number of points in the sequence

<D>: Control mode is standard dynamic <d>: Control mode is

3.2.1

3.4.6 hi volume dynamic

<S>: Control mode is static <M>: Control mode is monotonic <R>: Control mode is rate <C> is appended to the control character if control limits are custom

Control character(s) flash when PPCH is actively controlling

3. OPERATION

DISPLAY FIELD NAME PURPOSE CONTENTS SECTION

9. TPRESSURE2 Pressure information indicator

Pressure indication depending on current PPCH function. Leading character identifies the value.

<R>: Pressure rate of change in current pressure unit/second <T>: Pressure control target <D>: Deviation from the pressure control target

<Reservoir level low>: Indicates that the reservoir needs to be filled urgently.

3.3.10

3.5.7.3.2

3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL

The PPCH has a function/data keypad for local operator access to direct functions, function menus and for data entry.

1. The Function/Data keys allow very commonly used functions to be accessed directly by a single keystroke when pressed from the MAIN RUN screen (see Section 3.1.1). The name

of the function is on the bottom half of the key. These keys enter numerical value s when editing.

2. The Editing and Execution keys are for starting and suspending command execution, cursor control in menus and editing entries.

Figure 7. Keypad layout

3. The Menu/Data keys provide access to function menus when pressed from the MAIN RUN screen. The menu name is on the bottom half of the key. The SETUP menu is for more frequently used functions (see Section 3.4). The SPECIAL menu is for functions that are not generally a part of day to day operation (see Section 3.5). These keys enter numerical values w

hen editing.

used as

Pressing the [ENT/SET P] key generally causes execution or forward movement in the menu tree. Pressing [ENT/SET P] from the MAIN RUN screen allows an automated pressure control command to be given.

Pressing the [ESC] key moves back in the menu tree and/or causes execution to cease or suspend. Pressing [ESC] repeatedly eventually returns to the MAIN RUN screen and, from there, allows momentary viewing of the PPCH introduction screen.

Pressing the [+/-] key changes a numerical sign when editing. It also toggles through multiple screens when available and is a shortcut to a momentary display of the active RANGE from the MAIN RUN screen.

Pressing the [

], [ ], [ ] and [ ] keys allows reverse, forward and up, down cursor

movement when editing data entry or moving in menus.

PPCH™ OPERATION AND MAINTENANCE MANUAL

Some screens go beyond the two lines provided by the display. This is indicated by a flashing down arrow in the second line of the display. Press the cursor control keys to move the cursor to access the lines that are not visible or directly enter the number of the hidden menu choice if you know it.

3.1.3 DIRECT PRESSURE CONTROL KEYS

Figure 8. Direct pressure control keys

The direct pressure control keys provide direct manual control of pressure increase, decrease, jog and vent. They can be useful in adjusting pressure when automated pressure control to a target pressure or rate is not needed. The jog keys are also used to adjust the target pressure during active dynamic pressure control.

Pressing the [VENT] key aborts automated pressure control if active and causes PPCH to control pressure to near atmospheric pressure and then open the system vent valve (see Figure 9). On-going execution of

the vent function is indicated by lighting a RED LED just above the [VENT] key. Completion of the vent process is indicated by the Ready/Not Ready indicator light becoming GREEN with the vent RED vent LED still lighted. The vent valve remains open until the [VENT] key is pressed again, another direct pressure control key is pressed, or an automated pressure control command is given. Removing electrical power also closes the vent valve.

Pressing the [

] and [ ] direct pressure control keys aborts automated pressure control if

active and causes pressure to increase or decrease at the slow slew rate. Holding the

[FAST] key pressed while pressing the [

] or [ ] key causes the pressure increase or

decrease speed to change from slow to fast. Pressing the [

] and [ ] direct pressure control keys has a different effect depending on

the PPCH’s current activity:

• Pressure control idle: Causes the pressure to jog or step by a fixed amount which is

set automatically depending on the range (see Section 3.4.6, Table 10). The amount can be adjusted u

sing [SETUP], <3jog> or by pressing both the up and down jog keys

simultaneously (see Section 3.4.3).

• Dy

namic pressure control active: Causes the target pressure to be changed by a fixed

amount which is set automatically depending on the range. One press causes one step. The step value can be adjusted using [SETUP], <3jog> or by pressing both the up and down jog keys simultaneously (see Section 3.4.3).

• Static pressure control activ

e: No effect while pressure is actively controlled, changes

pressure by jog amount when pressure is in hold limit waiting for stability.

• Monotonic pressure control active: No effect.

• Ramp control active: No effect.

Pressing the up and down pressure jog keys ([ ] and [ ])simultaneously is a shortcut

to the jog step size adjustment menu.

3. OPERATION

3.1.4 REMOTE [ENT/SET P] (FOOT)SWITCH

The optional remote ENTER function is a switch that duplicates the function of the front panel [ENT] key. The remote ENTER function is serviced by a connector on the PPCH rear panel labeled REMOTE ENTER. An optional footswitch is available to activate remote entry hands free or a user supplied switch may be used. See Section 7.3 for information on remote

NTER switch wiring.

E The remote ENTER feature can be particularly convenient when running AutoTests

(see Section 3.3.6) in which using a footswitch to [ENT] allows hands free operation.

3.1.5 SOUNDS

PPCH is equipped with a variable frequency tone device to provide audible feedback and alarms. The beeper is used for the following indications.

Valid key press Brief beep. Choice between three frequencies

or NO sound is available (see Section 3.5.5.2).

alid key press Descending two tone “blurp”.

Inv

Leak check completed Three two second beeps (see Section 3.3.9). Purge routine completed Three two second beeps (see Section 3.3.8.2). Upper limit exceeded Intermittent one second beeps (see Section 3.4.4)

Activ

e external device not connected Eight second high frequency beep (see Section

3.2.5)

Pmax! (ov

AutoTest reading in tolerance/out of Ascending triad/descending triad (see Section tolerance reading 3.3.6).

Reserv

erpressure limit) exceeded Eight second high frequency beep (see Section

3.4.4.1).

oir level low Ten brief beeps (see Section 3.5.7.3.2).

3.2 GENERAL OPERATING PRINCIPLES

3.2.1 PRESSURE CONTROL PRINCIPLES

Numerical references in this section refer to Figure 9. PPCH is designed to precisely generate, measure and control liquid pressure into a volume

connected to its TEST port (13). Pressure is measured by a utility sensor or one or two Quartz Reference Pressure Transducers (Q-RPT)(15, 18).

Pressure is generated internally using a hydropneumatic pump(19). The hydropneumatic pump uses the ratio of two pistons to transform low pressure drive air into high pressure liquid output. The drive air pressure is controlled by an internal pressure regulator(3).

The liquid supply to the pump is from an internal or external reservoir. Liquid returned from the test system when reducing pressure is returned to the internal or external reservoir via a return tube that provides a constant fluid level when the system is vented. Provision is made for filling, draining, returning liquid to and viewing the level of the internal or external reservoir (6, 7,8,9,10) (see Section 5.6). Should the system be run with the reservoir empty causing the pump to draw air and lose the pump(4, 5) (see Section 5.10.1).

The hydropneumatic pump high pressure output supplies The inlet valve is a pressure balanced needle valve whose needle position is controller by a stepper motor and belt drive. The inlet valve provides very high precision control of the liquid

its prime, the internal reservoir can be pressurized to reprime

a servo-controlled inlet valve(17).

PPCH™ OPERATION AND MAINTENANCE MANUAL

admitted to the test system from the hydropneumatic pump to the test system. An outlet valve(11) of the same type as the inlet valve precisely controls liquid exhaust.

The inlet and exhaust valve can adjust and maintain pressure rates of change very precisely. When conditions are appropriate, a second stage of pressure control is used to maintain a

target pressure value within very narrow hold limits in dynamic control mode. The second stage is thermal pressure control (TPC). TPC, uses a pressurized volume in which there is a heating element and around which there is a forced air cooling system(14). Heating and cooling the fluid in the volume causes it to expand or contract, increasing or decreasing pressure. This pressure control system allows extremely fine pressure control without hysteresis or wear of mechanical parts.

The TPC system response is dependent on the operating liquid and the volume connected to the TEST port. It is minimally effective when there are leaks in the test system or the test volume is large. PPCH automatically determines whether conditions are appropriate to use TPC and runs an automated routine to determine the test volume. This routine is initiated automatically when needed.

3. OPERATION

1. DRIVE air port 2a. Drive air supply filter 2b. Pump inlet filter (liquid)

3. Drive air regulator

4. Drive air control manifold

5. Three-way reservoir pressure valve

6. OVERFLOW port

7. Reservoir fill/drain valve

8. Reservoir fill/drain/level tube

9. Reservoir return valve

10. EXTERNAL return port

11. Outlet valve, servo-controlled

12. Vent valve, pneumatically controlled

13. TEST port

14. Thermal pressure control unit (TPCU)

15. Hi Q-RPT

16. High pressure filter(s)

17. Inlet valve, servo-controlled

18. Lo Q-RPT, shutoff valve, vent valve, pneumatically controlled

19. Hydropneumatic pump

20. Pump drive out vent port and filter/muffler

21. Two-way hydropneumatic pump cutoff valve

22. Pump drive air pressure transducer

Figure 9. Pressure control system schematic

PPCH™ OPERATION AND MAINTENANCE MANUAL

3.2.2 AUTOMATED PRESSURE CONTROL

PPCH automated pressure control provides automated generation and control of pressure to a user designated target value or ramp rate.

See Section 3.3.10 for information on using [ENT/SET P] to set pressure automatically and

abort automated pressure control.

PPCH supports four pressure control modes to meet different pressure setting and controlling requirements: dynamic, static, monotonic and ramp. Pressure control parameters for each control mode are automatically set to optimal default values for the operating PPCH range when the range is selected or AutoRange is used (see Section 3.3.4). Control parameters can be customized using the [SETUP], <6control> function (see Section 3.4.6.1).

Control parameters: Target Value

The pressure set point or ramp rate specified by the operator (dynamic, static, monotonic, ramp modes).

Target Limit Setting short of the target value (monotonic mode). Hold Limit A symmetrical positive and negative control limit around a target value

within which the controlled pressure or rate is maintained (dynamic, static, ramp modes).

Rate Limit A rate of change of pressure limit in the same sign as the direction in

which pressure is controlled in units of pressure/second (monotonic mode).

Stability Limit An absolute value rate of change of pressure limit in units of

pressure/second (static mode and control not active).

See this Section 3.2.2 and Sections 3.2.2.1 to 3.2.2.5 for a detailed explanation of each control mode and its advantages, the default control parameters and the control customization options.

3.2.2.1 IDLE, NO AUTOMATED CONTROL (MEASURE MODE)

In any control mode, PPCH pressure control can be interrupted so that no control occurs. Control inactive is indicated by the pressure control indicator characters on the MAIN RUN screen NOT flashing. The control character(s) is/are the two characters in the center of the bottom line of the display (see Section 3.1.1).

To abort control when control or [

When control is idle (measure mode), a Ready condition occurs any time the pressure stability test is met (see Section 3.2.3).

is active press [ENT/Set P], [ESC], [VENT], [

]. [ENT/Set P] does NOT abort control in monotonic mode.

]

3. OPERATION

3.2.2.2 DYNAMIC CONTROL

Dynamic control mode is designed to set the pressure to the target value and

control continuously to keep pressure within the hold limit and as close to the target value as possible (see Figure 10).

advantage of this control mode is that the final pressure achieved is the

The same as the target value. The maximum value of the control error is equal to the hold limit. The average value of the control error is generally much smaller than the hold limit.

During dynamic pressure control, the hold limit is active. If the pressure goes outside of the hold limit, a Not Ready condition occurs. See Table 10 for default hold limit values and Section 3.4.6 to customize the hold limit.

There are two types of dynamic control. Standard dynamic control is the default type of dynamic control also available for situations in which standard dynamic control cannot achieve a

Ready condition in a reasonable amount of time and/or cannot maintain the Ready condition once achieved. Hi volume dynamic control may be necessary

when the test volume connected to the PPCH is greater than 100 cc. The difference between standard and hi volume dynamic pressure control is in the use of the thermal pressure controller (TPCU). In standard dynamic control, control transitions from the control valves to the TPCU before Ready occurs and the target pressure is reached. In hi volume dynamic control, control is by the valves only unless they valves are unable to maintain the Ready condition.

used in most situations. Hi volume dynamic control is

PPCH includes a Ready/Not Ready feature that indicates when current pressure control requirements have been met (see Section 3.2.3).

With dynamic pressure control active, a Ready condition occurs whenever:

The current measured pressure is inside the hold limit.

• Figure 11 illustrates Ready/Not Ready operation in dynamic control mode.

In dynamic control mode, normal procedure is to assume that when a Ready condition occurs (pressure inside the control hold limit), the measured pressure equals the target pressure. For this reason, when the pressure is Ready in dynamic control mode, the measured pressure display is equal to the target pressure.

Figure 10. Dynamic pressure control operation

PPCH™ OPERATION AND MAINTENANCE MANUAL

Figure 11. Ready/Not Ready in dynamic pressure control mode

3.2.2.3 STATIC CONTROL

Static control mode is designed to set the pressure near the target value and

then interrupt active control to allow pressure to stabilize naturally within the hold limit (Figure 12).

advantage of this control mode is that pressure can be set and/or measured

The within a defined limit of a target without interference from the pressure control system. In a system without excessive leaks, the pressure stability achieved may be greater than the stability with which the pressure control system can actively control pressure. Using static control to control pressure near the desired set point and then measuring back the stabilized pressure without interference of the control function can allow control errors to be completely eliminated. However, the final pressure achieved is not equal to the target value and the time required to achieve sufficiently stable pressure is dependent on the characteristics of the test volume and may be longer than in other modes. During static pressure control, the hold limit is active. If the pressure goes outside of the hold limit, pressure is readjusted to the target value. Se e Table 10 for default hold limit values and Section 3.4.6 to customize the hold limit.

Figure 12. Static pressure control operation

3. OPERATION

PPCH includes a Ready/Not Ready feature that indicates when current pressure control requirements have been met (see Section 3.2.3).

With static pressure control active a Ready condition occurs whenever:

•

NO control valve is operating.

• The current measured pressure is at the target value within the hold limit.

• The rate of change of pressure is less than the current stability limit.

Figure 13. Ready/Not Ready in static control mode

3.2.2.4 MONOTONIC CONTROL

Monotonic control mode is designed to set pressure increments and take data

from a device under test while assuring the evolution of pressure is always in the same direction (ascending for ascending increments, descending for descending increments). In monotonic control mode the pressure is set near the target value and then controlled at a low rate of change in the same direction as the target pressure approach (see Figure 14). Measured pressure data is taken from the

Figure 13 illustrates Ready/Not Ready operation in Static control mode.

PPCH target pressure.

and output from the device under test during the slow ramp near the

The advantage of this control mode is that in a sequence of pressures, ascending or descending increments are set without overshoot or oscillation as is desirable when determining the hysteresis of a device under test (DUT). This method also tends to achieve a ready condition more quickly than dynamic or static control. However, the final pressure achieved is not equal to the target value and for best results it is necessary to average alternating PPCH and DUT readings to compensate for possible timing differences in the readings.

When setting a monotonic pressure point, PPCH attempts to set a ramp rate less than the rate limit at the near end of the pressure target limit and then maintains the ramp rate until a new pressure target value is entered or the range “upper limit” (UL) is reached (see Section 3.4.4). If the ramp rate exceeds the specified target rate or changes default pressure and ramp rate target limit the limits.

sign, a Not Ready condition occurs. See Table 10 for

values and Section 3.4.6 to customize

PPCH™ OPERATION AND MAINTENANCE MANUAL

Figure 14. Monotonic pressure control operation

PPCH includes a Ready/Not Ready feature that indicates when current pressure control requirements have been met (see Section 3.2.3).

With monotonic pressure control active, a Ready condition occurs whenever:

•

PPCH has reached the target pressure has passed the target limit and is controlling ramp rate at less than the rate limit.

Figure 15 illustrates Ready/Not Ready operation in monotonic control mode.

Figure 15. Ready/Not Ready in monotonic pressure control mode

3.2.2.5 RAMP CONTROL

Ramp control is designed to set a pressure ramp at a target rate and maintain

the rate within a rate hold limit (see Figure 16). This control mode can be used for a variety of calibration and testing functions.

When setting a ramp, PPCH attempts to establish the target rate within the rate hold limit as quickly as possible and then maintains the rate until a command is given or the active range “upper limit” is reached (see Section

3.4.4). If the rate is outside of the rate hold limit, a Not Ready condition occurs. See Table 10 for default target rate and hold limit values and Section 3.4.6 to customize the hold limit.

new

3. OPERATION

Figure 16. Ramp pressure control operation

*Note that Figure 15 plots rate of change of pressure, not pressure.

PPCH includes a Ready/Not Ready feature that indicates when current pressure control requirements have been met (see Section 3.2.3).

With ramp pressure control active, a Ready condition occurs whenever:

•

PPCH is controlling rate at the target rate value within the rate hold limit.

Figure 17 illustrates Ready/Not Ready operation in ramp control mode.

Figure 17. Ready/Not Ready in ramp pressure control mode

*Note that Figure 16 plots rate of change of pressure, not pressure.

PPCH™ OPERATION AND MAINTENANCE MANUAL

3.2.3 PRESSURE READY/NOT READY

There is a Ready/Not Ready indication LED on the PPCH front panel. Ready/Not Ready status is also available remotely. This indication is intended to provide the operator with a clear and objective criterion for determining when a valid pressure measurement can be made.

The Ready/Not Ready LED indications are: <Green, no flash> Pressure Ready, control idle. PPCH is NOT actively controlling the

pressure. This indicates no control is occurring and the pressure stability is within the stability limit.

<Green, slow flash> Pressure Ready, control active. PPCH is actively controlling the

pressure and the criteria for a Ready condition to occur in the active control mode have been met.

<Red > Pressure Not Ready. Either PPCH is idle and pressure does not meet

the stability limit or PPCH is actively controlling the pressure and Ready conditions have not yet been met. The control characters in the middle of the second line of the MAIN RUN screen flash if control is active (see Section 3.1.1).

When automated pressure control is idle (measure mode): A

Ready condition occurs any time the pressure rate of change is inside the stability limit. The stability limit is defined in terms of rate of change of pressure in current pressure units per second. The stability limit is set by default (see Table 10) and can be customized (see Section 3.4.6).

When pressure control is activ

e: The criteria for determining the Ready/Not Ready

condition depend on whether the current control mode is static, dynamic, monotonic or ramp (see Sections 3.2.2.2, 3.2.2.3, 3.2.2.4, 3.2.2.5). Pressure Ready/Not Ready parameters are

by default when AutoRange is used, or a control mode is selected (see Table 10).

set The parameters can be customized if desired (see Section 3.4.6).

3.2.4 GAUGE MEASUREMENT MODE, DYNAMIC

COMPENSATION FOR ATMOSPHERIC PRESSURE

PPCH utility sensors and Q-RPTs are intrinsically absolute but they are also used in gauge measurement mode (difference from atmosphere) (see Section 3.3.3,  P measurement mode is achieved by subtracting the value of atmospheric pressure, P the Q-RPT’s absolute reading using AutoZ (see Section 3.5.1). In gauge measurement mode,

the AutoZ routine that measures P

, is run automatically whenever the PPCH is in

offset,G

the vented condition. This assures the continuous automated updating of the P corresponding to atmospheric pressure. Gauge pressure is the mea sure d abs olut e pre ssur e,

, minus the atmospheric offset.

gauge

= Pu - P

offset,G

However, atmospheric pressure can change between opportunities to run AutoZ and update the value of P

, for example when running an extended test without venting. PPCH uses

offset,G

dynamic compensation for atmospheric pressure to correct for these changes in atmospheric pressure. When AutoZ executes, and P PPCH’s on board barometer, P change in atmospheric pressure, ΔP the current barometer reading, P execution, P

atm,0

, is also recorded. Later, when no longer vented, the

atm,0

, since P

atm

, and the barometer reading at the time of AutoZ

atm

ΔP

= P

atm

was updated, is the difference between

offset,G

- P

atm,0

Dynamic compensation for atmospheric pressure uses ΔP

is determined, the reading of

offset,G

to correct the value of P

atm

thus always compensating real time for changes in atmospheric pressure:

RINCIPLE). Gauge

, from

offset,G

value

offset,G

gauge

= Pu - P

offset,G

- ΔP

atm

3. OPERATION

PPCH Q-RPTs allow instantaneous switching between gauge and absolute measurements modes. Any additional uncertainty in gauge measurement mode due to the dynamic compensation for atmospheric pressure technique is a function of the resolution and short term stability of the on-board barometer, not its absolute measurement uncertainty. This additional uncertainty, ± 1 Pa (0.00015 psi), is insignificant in the pressure ranges covered by PPCH.

3.2.5 MULTIPLE INTERNAL AND EXTERNAL Q-RPTS

A base PPCH pressure controller includes a high precision, utility pressure sensor whose range is equal to the controller’s range. The utility sensor is not intended to serve as a pressure reference for low uncertainty measurement. It is for indication, pressure control, system safety and maintenance functions only.

To obtain low uncertainty, traceable pressure measurement, PPCH uses Quartz Reference Pressure Transducers (Q-RPT). Up to six Q-RPTs can be included in a PPCH pressure controller/calibrator system. One or two Q-RPTs can be built into the PPCH, up to two may be located outside the PPCH enclosure in RPM4 reference pressure monitors (one or two per RPM4). Once the Q-RPTs available to a PPCH system have been set up and identified, communication with them is managed by PPCH transparently to the operator. However, setting up hardware and following procedures to protect lower pressure Q-RPTs from overpressure when higher pressure Q-RPTs are used is the responsibility of the user.

Take precautions not to overpressure external Q-RPTs when using them with a PPCH. When using external Q-RPTs in RPM4s as reference pressure measurement devices with a PPCH, the user is responsible to setting up hardware and following procedures to protect lower range QRPTs from overpressure. Only the Lo Q-RPT (IL) built-into the PPCH is protected automatically.

Communication between RPM4s and a PPCH controller is by daisy chained RS232 connections from PPCH’s COM2 port.

The PPCH RPT function (see Section 3.3.5) is used to identify Q-RPTs available to the PPCH.

The PPCH then manages communication with the internal and external Q-RPTs transparently to the operator, selecting the appropriate Q-RPT for the range of operation and configuring it as specified.

Each Q-RPT has a default range, which is its maximum range. It can also be downranged using PPCH’s AutoRange function.

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

external Q-RPT and the PPCH Hi utility sensor or Q-RPT (watchdog). If the difference becomes excessive, control is aborted, an audible warning sounds and a warning is displayed.

If this occurs, make sure the PPCH and RPM4 Q-RPT TEST(+) ports are connected together and try again.

Position Identification of Q-RPTs In a PPCH System

Position identification of the currently active Q-RPT or utility sensor in the PPCH system is continuously displayed in the upper right hand corner of the PPCH’s MAIN RUN screen and most other screens (see Section 3.1.1). See Table 6 for position designation prot ocol f or th e Q-RPTs available in a PPCH system.

PPCH™ OPERATION AND MAINTENANCE MANUAL

See Table 1 for a complete listing of Q-RPTs available and their default ranges.

Table 6. Position designators of Q-RPTs in a PPCH system

Q-RPT POSITION IDENTIFICATION DISPLAY SYMBOL*

Internal to PPCH, utility sensor, if present Internal Utility, Hi IuH Internal to PPCH, Q-RPT of maximum

range Internal to PPCH, Q-RPT with lower

maximum range in PPCH with two QRPTs or a utility sensor and Q-RPT.

External to PPCH, Q-RPT of higher maximum range in 1st RPM4 on PPCH/RPM4 communications daisy chain

External to PPCH, Q-RPT with lower maximum range in dual Q-RPT RPM4 that is the 1 communications daisy chain

External to PPCH, Q-RPT of higher maximum range in 2nd RPM4 on PPCH/RPM4 communications daisy chain

External to PPCH, Q-RPT with lower maximum range in dual Q-RPT RPM4 that is the 2 communications daisy chain

• The display symbol is included in the upper, right hand corner of most PPCH displays and menus as a convenient indicator of the active Q-RPT.

RPM4 on the PPCH/RPM4

RPM4 on the PC3/RPM4

Internal, Hi IH

Internal, Lo IL

External 1, Hi X1H

External 1, Lo X1L

External 2, Hi X2H

External 2, Lo X2L

3.2.6 MULTIPE RANGES (Q-RPTS, AUTORANGE AND INFINITE RANGING)

A PPCH range is defined as a pressure span and associated settings. A PPCH may have multiple ranges. Each Q-RPT (and the utility sensor, if present) available to the

PPCH system has a default range which is its maximum span. Additional ranges, lower than the QRPT’s maximum span, may be created using AutoRange (see Section 3.3.4). Ranges created using AutoRange may be saved with all their settings for reactivation later (see Section 3.4.1).

PPCH range is identified by a range screen showing the Q-RPT used by the range, its current

A unit of measure and its full scale pressure in gauge and absolute (if available) measurement modes. The range screen is viewed by pressing [RANGE] or [+/-] from the MAIN RUN screen.

1. Q-RPT or utility sensor designator.

2. Type of range. <DF> for the Q-RPT’s default range; <AR> for a range created by AutoRange.

3. Q-RPT or utility sensor position designator.

4. Current pressure unit of measure.

5. Full scale pressure in current unit of measure in gauge and/or absolute measurement mode depending on the measurement modes available.

Most settings made in a PPCH range, such as unit of measure, measurement mode, display resolution, control mode and control parameters are specific to the range. The range specific settings are stored with the range and recalled whenever the range is made active. This makes setting up and saving ranges a convenient way to store and recall frequently used operating configurations. See Table 7 for a listing of PPCH adjustments and settings and whether they are range, Q-RPT o

r system specific.

Active A100M DF IH psi 15000g/15000a

3. OPERATION

The ranges available on a PPCH system are accessed using [RANGE] (see Section 3.3.1) and/or created using [AutoRange] (see Section 3.3.4). External Q-RPTs connected to the PPCH (see Section 3.2.5) are initialized using [RPT] (see Section 3.3.5).

Table 7. Settings and to what they are specific (range, measurement mode, Q-RPT, system)

SETTING PURPOSE SPECIFIC TO SECTION

Unit Set pressure unit of measure Range 3.3.2 Mode Set pressure measurement mode

Resolution Set pressure display resolution Range 3.4.2 Jog Set jog step size Range 3.4.3 Control Set pressure control mode and

Upper Limit Set upper limit alarm Range and measurement mode 3.4.4 AutoZ Run AutoZ, ON/OFF, set and view value Range and measurement mode 3.5.1 Screen

Saver, Sound, Time, ID, Level

Head Set fluid head correction height, fluid, unit

Valve Drivers

Cal Various Q-RPT and utility sensor

(absolute, gauge)

parameters

Set system user preferences System 3.5.5

of measure Set status of external valve drivers System 3.4.7

calibration functions

Range 3.3.3

Range 3.4.6

System 3.3.7

3.5.3

Q-RPT, utility sensor or barometer 3.5.8

3.2.7 FLUID RESERVOIR LOW LEVEL WARNING

If PPCH’s fluid reservoir is allowed to become empty, air may be drawn into the hydropneumatic pump (see Figure 9) causing it to lose its prime. If this occurs, operation is interrupted until the pump is reprimed using an on-board pump priming routine (see Section

5.10.1). To prevent against allowing the reservoir to become empty, PPCH’s internal reservoir

equipped with a float switch to provide a warning when the level is low. The warning system is active when using the internal reservoir or the external reservoir if it is connected as recommended in Section 2.3.6.2.

A low fluid level condition is indicated by:

•

Ten rapid beeps when the low level is first observed during operation or on power up.

• Intermittent display of <Reservoir level low> on the bottom left of the MAIN RUN screen.

By default, when a low level condition is determined, PPCH pressure generation capability is stopped. This is to avoid running the PPCH internal hydropneumatic pump dry for extended periods if the reservoir becomes empty without an operator present. It is also possible to set the PPCH so that operation will not stop when a low level condition is determined (see Section 3.5.7.3.2).

The status of the

reservoir low level warning may also be viewed using [SPECIAL],

<7internal>, <3pump>, <2level> (see Section 3.5.7.3.2). The status of the reservoir low level warning can be determined by remote command over

the IEEE-488 or RS232 interface (see Section 4.4.3).

PPCH™ OPERATION AND MAINTENANCE MANUAL

3.2.8 OPERATION WITH A PG7000 PISTON GAUGE

PPCH can act as a pressure control component for automatically setting pressure and floating the piston of a PG7302 oil operated piston gauge.

For automated operation, the PPCH communicates with the PG7000 through an RS232 connection from the PG7000 COM3 port to the PPCH COM1 port. Pressure control commands are sent from the PG7000 when it is in “AutoGen” mode (see the PG7000 Operation and Maintenance Manual).

The PPCH may also be operated manually using its direct pressure control keys (see Section

3.1.3).

3.2.9 DIRECT FUNCTION KEYS SUMMARY

Local operation of PPCH is through the front panel keypad. To minimize menu layers, the keypad numerical keys also provide direct access to the most commonly used functions. The function accessed is labeled on the bottom half of the key. Direct function keys are active whenever PPCH is in its MAIN RUN screen. Table 8 summarizes the operation of the direct function keys and Sections 3.3.1 through 3.3.10 detail their operation.

Table 8 provides a brief summary of direct function key operation. It may be useful to keep a copy of this summary near the PPCH, especially when first becoming acquainted with the instrument’s operation.

Table 8. Summary of PPCH function key operation

DIRECT FUNCTION KEYS ARE ACTIVE FROM THE MAIN RUN SCREEN

See corresponding manual Sections 3.3.1 through 3.3.10 for full detail.

Adjust DUT fluid head height. Set to zero for no fluid head correction.

Run automated test system prime and/or purge routine.

Run an automated leak check at the current pressure.

Set up and optimize all aspects of PPCH measurement, control and displays for a specific operating range and measurement mode.

Search for and initialize internal and external Q-RPTs available to the PPCH system.

View active range and toggle through available ranges. [ENT] on a range activates it.

Select pressure unit of measure for the active range. Choice of units available in this menu can be customized.

Select the pressure measurement mode for the active range (absolute, gauge).

Menu of less commonly used internal functions and settings.

Menu of commonly used setup features including save/delete AutoRange ranges, set display resolution, adjust jog step size, set upper/lower limit, view AutoTest data, select pressure control mode and adjust control limits, set status of external 12V drivers

Set up and run automated test sequences.

Input a pressure control set point command from the run screen. ENTER values when editing.

3. OPERATION

3.3 DIRECT FUNCTION KEYS

3.3.1 [RANGE]

 PURPOSE

[RANGE] selects from existing ranges. [AutoRange] creates new ranges (see Section 3.3.4).

To view and/or change the active pressure measurement range and associated settings.

 PRINCIPLE

A PPCH range is defined as a pressure span and associated settings (see Section 3.2.6). A PPCH may have multiple ranges. Each Q-RPT (and the utility sensor if present)

available to the PPCH system has a default range which is its maximum full scale. Additional ranges, lower than the Q-RPT’s full scale, may also be created using AutoRange (see Section 3.3.4). Ranges created using AutoRange may be saved with all their settings

for reactivation (see

Section 3.4.1). The [RANGE]

function key allows the active PPCH range and available ranges to be viewed

and selected.

 OPERATION

Pressing the [RANGE] function key activates the range viewing and selecting function. When the [RANGE] function key is first pressed, the range identification screen for the active range is displayed. For example:

1. Q-RPT or utility sensor designator.

2. Type of range. <DF> for the Q-RPT’s default range; <AR> for a range created by AutoRange.

3. Q-RPT or utility sensor position designator.

4. Current pressure unit of measure.

5. Full scale pressure in current unit of measure in gauge and/or absolute measurement mode depending on the measurement modes available.

Active A70M DF IH MPa 70g/70a

Pressing the [+/-] key or the [RANGE] key again while in the RANGE function toggles through displays of the other available ranges, from lowest range to highest range.

To select a range to become the active range, press [ENT] while the desired range is displayed. PPCH must be vented for the range change to occur. Press [VENT] if necessary to complete the range change.

When selecting a range, if the range’s Q-RPT is an external Q-RPT and the PPCH cannot communicate with it, PPCH displays <Cannot find range’s external Q-RPT (Xn)> (where <Xn> is the Q-RPT position designator). Use [ENT] or [ESC] to return to the range selection screen. For information on setting up and communicating with external Q-RPTs see Section

2.3.9.1. Pressing [ESC]

while in the RANGE function returns to the MAIN RUN screen with no range

change having been made.

Range full scale limits are given in the pressure unit that is currently active for

that range. Change the active unit (see Section 3.3.1) to display the range limits in a different unit.

PPCH™ OPERATION AND MAINTENANCE MANUAL

Pressing [+/-] from the MAIN RUN screen provides a shortcut to a momentary view of the

range identification screen for the active range.

PPCH saved AutoRange ranges that use Q-RPTs in external RPM4s are available for selection from the [RANGE] key. AutoRange ranges saved locally on the RPM4, are not available on the PPCH [RANGE] key.

Many PPCH settings and functions are range specific. See Table 7 for identification of range specific settings.

To protect against overpressure situations and for maximum measurement performance, the active range can only be changed when the system is vented. If [ENT] is pressed while in the RANGE function when PPCH is NOT vented, the display indicates <Vent system fully to change range>. Pressing the [VENT] key causes PPCH to vent and complete the range change.

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

Take care not to overpressure external Q-RPTs when using them with a PPCH. When using external Q-RPTs in RPM4s as reference pressure measurement devices with a PPCH, the user is responsible to setting up hardware and following procedures to protect lower range Q-RPTs from overpressure. Only the Lo Q-RPT (IL) built-into the PPCH is protected automatically.

3.3.2 [UNIT]

 PURPOSE

To select the unit of pressure in which PPCH displays pressure values.

For information on selecting the measurement mode (absolute, gauge), see Section 3.3.3.

 PRINCIPLE

PPCH allows the unit of measure in which pressure values are displayed to be changed. PPCH supports 15 different pressure units of measure as well as user defined units.

To simplify operation, quick access to six unit choices is made available under the [UNIT] key. The default units available depend on whether the PPCH was originally configured as an SI or US version. The [UNIT] key contents can be customized by the user to any configuration of six units (see Section 3.5.6).

3. OPERATION

Internally, PPCH always operates in Pascal (Pa), the SI unit of pressure. Values of pressure are represented in other units by the application of conversion factors to convert from Pa (see Section 7.2.1).

 OPERATION

To change the pressure unit of measure for the active range, press [UNIT] from the MAIN RUN screen while the range is active. The display is:

1MPa 2kPa 3hPa 4bar 5mbar 6psi

The cursor is on the number corresponding to the pressure unit of measure active for the current range. To change the pressure unit of measure, select the desired unit. Making the selection

returns to the MAIN RUN screen with the selected unit active.

The pressure measurement unit selected is range specific. When in a given range, all functions and settings are represented in the current measurement unit for that range. However, certain internal and/or metrological functions (e.g., Q-RPT calibration coefficients) are always represented in Pa regardless of the active range unit of measure.

See Section 7.2.1 for tables of the conversion factors used by PPCH.

If the pressure unit selected is inWa (inches of water), the reference temperature for water density must we specified in a separate menu (choices are 4ºC, 20ºC 60ºF). No reference temperature selection is necessary for the unit mmWa as the only reference temperature commonly used for mmWa is 4 ºC.

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

an be reset to default by reset (see Section 3.5.4.2).

3.3.3 [MODE]

 PURPOSE

To set the measurement mode (absolute or gauge) for the active range.

For information on selecting the unit of measure, see Section 3.3.2.

 PRINCIPLE

PPCH supports simple, one-step switching between two measurement modes: Absolute Measures pressure relative to vacuum (zero is hard vacuum). Range is

from zero absolute to full scale. Minimum set pressure is atmospheric pressure (vented).

PPCH™ OPERATION AND MAINTENANCE MANUAL

Gauge Measures pressure relative to atmosphere (zero is ambient pressure)

using PPCH’s automated offsetting of atmospheric pressure with dynamic compensation for atmospheric pressure changes (see Section 3.2.4).

Range is from zero gauge to full scale. The maximum pressure of each Q-RPT is the same in absolute and gauge measurement modes. If the Q-RPT will not be used in absolute mode, absolute mode can be turned off to avoid

using it unintentionally (see Section 5.3.5).

 OPERATION

To change the active measurement mode for press [MODE] from the MAIN RUN screen while the range is active. The display is:

a range,

Measurement mode:

1abs 2gage

Only gauge mode is available if absolute mode is OFF (see Section 5.3.5).

Certain PPCH settings, including AutoZ ON/OFF (see Section 3.5.1) are range AND

measurement mode specific. See Table 7 for a listing of settings and what they are specific to.

Absolute mode on an PPCH Q-RPT can be turned OFF in the calibration function (see Section 5.3.5). When absolute mode is turned OFF, only gauge mode can be activated. <Gauge mode only, abs mode OFF> is displayed when [MODE] is pressed.

3.3.4 [AUTORANGE]

 PURPOSE

To automatically set up PPCH to optimize its measurement and control characteristics and other features to cover a specific pressure range.

[AutoRange] creates new ranges. See [Range] to select from existing ranges (see Section

3.3.1).

 PRINCIPLE

PPCH is designed to support the calibration and test of a very wide variety of test ranges in various measurement modes with a single pressure controller system.

The AutoRange function simplifies the task of selecting the Q-RPT best suited to cover a specific test range and setting measurement and control parameters appropriately for the range. These are set automatically based on operator entry of desired measurement mode, pressure unit of measure and range full scale. The selections and settings made by AutoRange are summarized in Table 9.

range set up using AutoRange and all its range specific settings, may be saved for later

A recall using [SETUP], <1range> (see Section 3.4.1). Saved ranges are available for selection using [RANGE] (see Section 3.3.1). If a range created by AutoRange is not saved,

t is o verwritten by the next AutoRange or erased when another range is selected or PPCH

i power is turned OFF.

Use [AutoTest], <1QDUT> to AutoRange PPCH based on DUT tolerance (see Section

3.3.6.2).

3. OPERATION

Table 9. Settings made by AutoRange

SETTING/SELECTION PURPOSE SET TO SECTION

Unit Set pressure unit of measure Operator specified during

Mode Set pressure measurement mode

Full scale Establish span maximum Operator specified during

Q-RPT Select most appropriate Q-RPT

Upper limit

Resolution Set pressure display resolution 10 ppm of AutoRange span or

Control mode Select dynamic, static,

Control parameters Set dynamic, static, monotonic

Jog step Set jog step size 100 ppm of AutoRange span 3.4.3

(absolute, gauge)

to cover range NOTE: User is

responsible for connecting and disconnecting external QRPTs, including protecting them from overpressure when

using a higher range

Set maximum pressure control limit

monotonic or ramp pressure control

and ramp control mode control limits

AutoRange Operator specified during

AutoRange

AutoRange Q-PRT with lowest default full

scale that is greater than the AutoRange full scale

Upper limit: 105 % of AutoRange range or 102% of QRPT default range, whichever is lower

1 ppm of default Q-RPT range, whichever is larger.

Standard dynamic control 3.2.2

See Table 10 3.2.2

3.3.2

3.3.3

None

3.2.5

3.4.4

3.4.2

3.4.6.1

 OPERATION

To use the AutoRange function, press [AutoRange] and respond to PPCH’s prompts.

Select measurement mode: The screen is identical in appearance and function to the

[MODE] screen (see Section 3.3.3). Absolute mode is not available if absolute mode is turned off on all available Q-RPTs (see Section 5.3.5).

Select pressure unit of measure: The screen is identical in appearance and function

to the [UNIT] screen (see Section 3.3.2).

Enter the AutoRange full scale pressure: Enter the desired full scale pressure

value in the <------> entry field and press [ENT]. If the full scale pressure entered cannot be covered by any of the Q-RPTs available, an error message is displayed. If the full scale pressure can be covered by an available Q-RPT, AutoRange proceeds to the range display.

View proposed AutoRange range: The proposed AutoRange range screen is:

1. Indication that this is a screen of the proposed AutoRange range.

2. Designator and position of the Q-RPT that AutoRange has selected to cover the AutoRange full scale and measurement mode.

3. Pressure unit of measure specified in AutoRange.

4. AutoRange full scale pressure in gauge mode and absolute mode if available. Shows gauge mode if absolute is OFF for the Q-RPT.

AutoRange A140M X1H MPa 100g/100a

PPCH™ OPERATION AND MAINTENANCE MANUAL

If an external Q-RPT that should be available is not being selected by AutoRange, use [RPT] to search for Q-RPTs and determine whether external Q-RPTs have been properly connected and initialized (see Section 3.3.5). The PPCH utility sensor (IuH) cannot be AutoRanged.

Accept proposed AutoRange: To accept the proposed AutoRange and go the MAIN

RUN screen with the AutoRanged range active, press [ENT] or [AutoRange]. To modify the AutoRange full scale, measurement mode or pressure unit of measure, use [ESC] to back up through the AutoRange screens and make changes.

If you would like to use a Q-RPT other than the one selected by AutoRange, use [RPT] or the cursor control keys to toggle through the choices available. Only Q-RPTs that can cover the specified full scale and measurement mode are offered. Press [ENT] or [AutoRange] when the desired Q-RPT is displayed.

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

To verify or confirm the active range from the MAIN RUN screen, use [+/-] or [RANGE] to

view the active range description (see Section 3.3.1).

See Table 9 for a listing of all selections and settings affected by AutoRange and their

default values.

3.3.5 [RPT]

 PURPOSE

Search for, initialize and display internal and external Q-RPTs available to the PPCH system.

 PRINCIPLE

Up to six Q-RPTs can be included in a PPCH pressure controller/calibrator system, two internal and four external (see Section 3.2.5). PPCH communicates with external Q-RPTs by RS232 over its

COM2 port.

To be available for use by the PPCH system, external Q-RPTs must be identified and initialized. A Q-RPT search function occurs automatically each time PPCH power is cycled. Also, pressing [RPT] initiates the Q-RPT search and allows the Q-RPTs that are available to PPCH to be viewed. Use [RPT] to update the PPCH system con fig ur ati on if yo u c onnect and disconnect Q-RPTs without cycling PPCH power.

See Section 2.3.9.1 for information on hooking up external Q-RPTs to a PPCH system.

3. OPERATION

 OPERATION To run the Q-RPT and utility sensor search and initialize function, press [RPT]. PPCH

displays <Searching for RPTs…> while it runs the search function. When the RPT search is complete, the Q-RPTs identification screen is displayed.

1. IH, and L: Identification of RPTs in Internal (PPCH), Hi and Lo positions.

2. X1H and L: Identification of RPTs in External 1 (first RPM4), Hi and Lo positions.

3. X2H and L: Identification of RPTs in External 2 (second RPM4), Hi and Lo positions.

IH:A200Mu L:none X1H:A200M L:A70M X2H:A40M L:none

The cursor is on the position designator of the active Q-RPT or utility sensor. Use the cursor control keys to move the cursor to other positions and to view the third line if present. Press [ENT] to make the selected Q-RPT or utility sensor active in its default range (see Section

3.2.6). Press [RPT] again to cause the Q-RPT search to run again. Press [ESC]

to return to the

MAIN RUN screen without making any changes.

See Table 1 for a listing of Q-RPT designators and their corresponding default ranges and

Table 6 for information on Q-RPT system position identification designators.

For PPCH to successfully identify and initialize external RPM4s, the RPM4 COM1 port

settings must be:

Baud rate: between 1200 and 19200 Parity: Even Date bits: 7 Stop bits: 1

If PPCH is not able to establish communications with RPM4s and their Q-RPTs, check that the RPM4 COM1 port setting conform to the requirements above. If the COM1 port settings are correct, check that the correct communications cable is being used (standard pin-to-pin DB-9M to DB-9F RS232) and is connected to the correct communications ports.

PPCH COM2 > 1

RPM4 COM1; 1st RPM4 COM2 > 2nd RPM4 COM1

See the RPM4 Operation and Maintenance Manual for additional information on RPM4 RS232 communications and COM port settings.

PPCH™ OPERATION AND MAINTENANCE MANUAL

When an RPM4 is initialized as an external device to a PPCH pressure controller, the RPM4

front panel keypad is locked out and the second line of the display becomes:

<PPCH EXT DEV: IDLE> (if RPM4 is initialized by PPCH but not currently in use)

<PPCH EXT DEV: ACTIVE> (if RPM4 is initialized by PPCH and is currently in use)

After using an RPM4 as an external device for a PPCH, cycle power to return to the previous RPM4 settings, restore front keypad capability and return to the normal MAIN RUN screen.

Some screens, such as the RPT identification screen, go beyond the two lines provided by the display. Press the cursor control keys to move the cursor to access the lines that are not visible or directly enter the number of the hidden menu choice if you know it.

The third line is not included if no 2

(X2) RPM4 is detected.

3.3.6 [AUTOTEST]

 PURPOSE

To execute a programmed sequence of automated pressure control target values and/or to AutoRange the PPCH based on the full scale and tolerance of the device under test.

 PRINCIPLE

The AutoTest function is intended to facilitate the execution of a series of pressure control target values such as is commonly needed when PPCH is used to run a calibration sequence on a device or system being tested.

There are two types of sequences:

Quick Test Allows quick definition and execution of a sequence in

the current range and using all of the current

settings (pressure unit of measure, measurement

mode, control mode, control settings, display resolution).

Quick DUT Test (QDUT) AutoRanges PPCH based on the full scale and

tolerance of a device under test, prompts the user

through the increments of a calibration sequence and logs calibration data. The first portion of the QDUT function can be used alone to automatically set PPCH range and operating characteristics appropriately for the device under test. The sequence function assumes that the pressure at each target point will be adjusted so that the device under test reads a cardinal target pressure point. This is particularly useful when calibrating analog gauges.

Test sequences are defined by the minimum pressure, maximum pressure and test increment in % of full scale. For tests, in gauge mode, the minimum pressure is always zero. For tests in absolute mode, the minimum pressure is defined by the user.

 OPERATION

To run an AutoTest press [AutoTest] from the MAIN RUN screen.

The display is:

Select the test type desired. See Section 3.3.6.1 for Quick Test or Section 3.3.6.2 for QDUT Test.

Run an AutoTest: IH

1Quick 2QDUT

3. OPERATION

3.3.6.1 QUICK AUTOTEST

 OPERATION To run a Quick Test, press [AutoTest] and select <1Quick>.

The display is:

This selection provides the choice between running the last Quick Test or setting up a new Quick Test definition. Select <1yes> to rerun the last Quick Test. Select <2no> to define a new Quick Test.

When <2no> is selected from the Run current QuickTest menu, the set-up/edit routine is accessed. The first display is:

1. Entry field for maximum pressure of the Quick Test sequence. Recalls value last entered.

un current IH

uickTest 1yes 2no

Quick Test FS: IH

50 MPa g

This entry determines the maximum pressure of the Quick Test sequence. Enter the maximum pressure and press [ENT].

Sequence FS must be less than the pressure upper limit of the active pressure range or an error will occur when the test begins to run. To set up and run a sequence including a pressure greater than the current upper limit, increase the upper limit before running the sequence (see Section 3.4.4) or change to a higher range if available (see Section 3.3.1). To AutoRange the PPCH automatically for a specific sequence based on the characteristics of a DUT, use a QDUT Test (see Section 3.3.6.2).

If the active measurement mode is absolute (see Section 3.3.3), the lowest pressure must also be defined. The next display is:

Quick Test low P IH

1. Entry field for minimum pressure of the Quick Test sequence. Recalls last value entered.

10 MPa a

This entry determines the lowest pressure of the Quick Test sequence for tests in absolute measurement mode. Note that PPCH vents in response to a command for zero absolute pressure and cannot set pressure under atmospheric pressure (see Section 3.3.10.6). Enter the test lowest pressure point and press [ENT].

The display is:

1. Entry field for sequence pressure increment in

This selection determines the size of the pressure increment in terms of % of the span of the test. The pressure sequence will run in pressure steps of (span x increment %) ending with the uneven increment if applicable.

% of full scale. Recalls last value entered.

Test increment

20.0%FS

PPCH™ OPERATION AND MAINTENANCE MANUAL

Enter the desired pressure increment and press [ENT].

The display is:

This selection determines the order in which the test sequence increments will execute. Selecting <1up> causes the sequence to execute starting at the low point and going to the full scale value.

Selecting <2down> causes the sequence to run starting at the full scale value and going to the low point.

Selecting <3u&d> causes the sequence to run from low point to full scale and back to low point.

Selecting <4d&u> causes the sequence to run from full scale to low point and back to full scale.

Test point sequence

1up 2down 3u&d 4d&u

After making the increment order selection the display is:

Next point on:

1ENTER 2Timer

This selection determines how the sequence will proceed from point to point when the test is run.

If <1ENTER> is selected, the sequence proceeds to the next target value whenever, and only whenever, [ENT] is pressed.

If <2Timer> is selected, a timer is started at each point when a pressure Ready condition is achieved (see Section 3.2.3). The sequence continues to the next pressure point without operator intervention once the timer has

expired. After selecting <2Timer>, an additional screen is presented for entry of the timer value in seconds (minimum 1, maximum 999).

After making the next increment on selection, the display is:

ENTER to run MPa g

1. Indication of minimum and maximum pressure included in the sequence which is about to run.

0.000 to 50.000

This screen is offered for the user to check, prior to execution, that the correct sequence is defined and that it does not exceed the range of the device or system being tested. Pressing [ESC] returns to theAutoTest selection screen without sequence execution. Pressing [ENT] causes sequence execution to proceed.

Pressure control begins to set the first target value of the sequence (or vent execut es if the fir st increme nt is zero ). The displa y is the MAIN RUN Screen with indication of the sequence progress:

1. Indication of sequence increment that is currently being executed / total increments in sequence. Changes to ENTER or countdown time remaining once Ready condition has been reached at target value.

Except for the bottom right hand corner, the sequence run display is identical to the normal MAIN RUN screen (see Section 3.1.1). The bottom right corner provides sequence increment is completed.

If the sequence was set up with <Next increment on timed delay>, execution proceeds automatically each time a Ready condition has occurred at the increment and the countdown timer has expired. If the sequence was set up with <Next increment on ENTER>. Press [ENT] to continue to the next increment.

8.232 MPa g IH

T 10.000 D 2/11

information on sequence execution. This information updates as each

3. OPERATION

After the last point of the test sequence has been executed, PPCH vents and operation returns to the main run screen.

Regardless of whether the sequence was set up for next increment on time delay or on ENTER, pressing [ENT] always causes the sequence to proceed to the next increment. This feature can be used to skip one or several increments if desired.

To interrupt the sequence at any time, press [ESC]. Pressure control ceases immediately and the display goes to:

Abort Quick AutoTest

1no 2yes

Select <2yes> to cause the sequence to abort and return to the MAIN RUN screen. Select <1no> to cause the sequence to resume where it left off.

All Quick Sequences end with a VENT command after the last point. To avoid the VENT, press [ESC] rather than [ENT] after the last point.

3.3.6.2 QDUT AUTOTEST

 OPERATION The QDUT AutoTest AutoRanges the PPCH (see Section 3.3.4) based on the

span and tolerance of a DUT before

running a test sequence. QDUT AutoTest also calculates DUT in or out of tolerance conditions and collects data while running the test. See Section 3.4.5 for information on QDUT AutoTest data files.

To run a QDUT Test, press [AutoTest] and select <2QDUT>.

The display is:

un current QDUT

AutoTest: 1yes 2no

This selection provides the choice between running the last QDUT Test, including AutoRanging the PPCH based on the previously entered DUT characteristics or setting up a new QDUT Test definition. Select <1yes> to rerun the last QDUT Test (see below in this Section). Select <2no> to define a new QDUT Test.

When <2no> is selected from the Run Current QDUT Test menu, the set-up/edit routine is accessed. The information needed to AutoRange PPCH based on the DUT characteristics is then collected (see Section 3.3.4).

first display is the selection of the

The pressure control mode in which the test is to be run (see Section 3.4.6).

Control: 1dynamic

2static 3monotonic

Select the pressure control mode that is to be used by the PPCH when running the test points.

The next display is the selection of the measurement mode of the DUT (see Section 3.3.3). If only gauge mode is available, this display is skipped.

Select the measurement mode of the DUT that is being tested. If the desired measurement mode is not available, the QRPTs available to PPCH do not support the measurement mode or it is turned off.

DUT measurement mode

1abs 2gage

PPCH™ OPERATION AND MAINTENANCE MANUAL

The next display is to specify the unit of measure. Select the unit of measure in which the test is to be run. The choice of units available can be customized (see Section 3.5.6).

The next display is to specify the full scale (maximum pressure) of the DUT or test.

1. Entry field for maximum pressure of the QDUT Test sequence.

1kPa 2Pa 3MPa 4hPa 5bar 6mbar

DUT full scale:

12000 psi g

Thi s entry det e r m i n e s the maxim u m p r e s s u r e of t h e Q D U T Test sequence. Enter the maximum pressure and press [ENT].

Sequence full scale must be achievable by a QRPT available to PPCH or an error will

occur when PPCH attempts to AutoRange to the specified full scale (see Section 3.3.4).

If the measurement mode selected is absolute, the lowest pressure must also be defined. The display is:

DUT low point:

1. Entry field for minimum pressure of the QDUT Test sequence. Recalls last value entered.

2000 psi a

This entry determines the lowest pressure of the QDUT sequence for tests in absolute measurement mode. Note that PPCH vents in response to a command for zero absolute pressure and cannot set pressure under atmospheric pressure (see Section 3.3.10.6). It is preferable to make the low point, a point that PPCH can set. Enter the test lowest pressure point and press [ENT].

The display is:

DUT tolerance:

1. Entry field for tolerance of the DUT that is being tested in % of the DUT’s span.

0.05 %FS (span)

This entry determines the in and out of tolerance limits for the DUT when the test is run. It is also used to determine appropriate PPCH resolution and control limit settings for the resulting AutoRange range.

Enter the DUT tolerance and press [ENT]. The display is:

1. Entry field for sequence pressure increment in % of full scale. Recalls last value entered.

Test increment:

20.0%FS

3. OPERATION

This selection determines the size of the pressure increment for the test in terms of % of the full scale (FS) value entered in the DUT Full Scale screen. The pressure sequence will run in pressure steps of (full scale x increment %) ending with the uneven increment if applicable.

Enter the desired pressure increment and press [ENT].

The display is:

Test point sequence

1up 2down 3u&d 4d&u

This selection determines the order in which the test sequence increments will execute. Sele ctin g <1up> causes the sequence to execute starting at low point and going to the full scale value.

Selecting <2down> causes the sequence to run starting at the full scale value and going to low point.

Selecting <3u&d> causes the sequence to run from low point to full scale and back to low point.

Selecting <3d&u> causes the sequence to run from full scale to low point and back to full scale.

The next display is the proposed AutoRange range to run the QDUT test (see Section 3.3.4 for additional information on AutoRange).

1. Indication that this is a screen of the proposed AutoRange range.

2. Designator and position of the Q-RPT that AutoRange has selected to cover the QDUT full scale and measurement mode.

3. Pressure unit of measure specified in QDUT setup.

4. AutoRange full scale pressure in gauge mode and absolute mode if available.

AutoRange A140M X1H psi 12000g/12000a

The cursor keys or the [RPT] key can be used to toggle through other Q-RPTs available to cover the QDUT specified range and measurement mode. When the desired Q-RPT is displayed, press [ENT] to accept the proposed AutoRange.

The QDUT AutoTest can now be run. The display is:

ENTER to run psi g

1. Indication of minimum and maximum pressure included in the sequence which is about to run.

0.0 to 10000.0

This screen is offered for the user to check, prior to execution, that the correct sequence is defined and that it does not exceed the range of the device or system being tested.

Pressing [ESC] twice returns to the MAIN RUN screen without sequence execution (this feature can be used to AutoRange the PPCH based on DUT characteristics without running a specific test sequence). Pressing [ENT] causes sequence execution to proceed.

The display is:

0.000 psi g IH

Prep & ENTER 0/11

Perform any operations that are needed before running the test such as making connections or exercising the DUT. The PPCH direct pressure control keys are active to allow pressure adjustment (see Section 3.1.3 ). When ready to begin the

t, press [ENT].

tes

PPCH™ OPERATION AND MAINTENANCE MANUAL

Pressure control begins to set the first target value of the sequence using the pressure control mode specified when setting up the sequence (or vent executes if the first increment is zero). The display is:

1. Indication of sequence increment that is currently being executed / total increments in sequence. Changes to ENTER once Ready condition has been achieved at target value.

Except for the bottom right hand corner, the sequence run display is identical to the normal MAIN RUN screen (see Section 3.1.1). The bottom right corner provides

information on sequence execution. This information updates as each

sequence increment is executed. Once a Ready condition has been achieved (see Section 3.2.3), use the direct

manual pressure control keys PPCH until the DUT reads the cardinal value of the pressure increment.

Once the DUT indicates the cardinal value of the pressure increment, press [ENT]. The display is:

1. Final target pressure at which DUT indicated cardinal value of the pressure point.

2. <IN> or <OUT> depending on whether DUT was in or out of tolerance. DUT is <IN> if cardinal point – PPCH pressure < DUT tolerance * DUT span.

Press [ENTER] to accept this test point and proceed to the next test point or [←] to repeat the point.

48.335 psi g IH

T60.000 D 2/11

] and [ ]) to adjust the pressure set by

([

60.010 psi g IH

T60.012 IN 2/11

Repeat set pressure, take reading and accept data at each point until all points in the sequence have been accepted.

All QDUT tests end with a VENT command after the last point. To avoid the

VENT, press [ESC] after the last point.

After the last point in the sequence has been completed, the display is:

AutoTest complete

1exit 2repeat 3data

Select <1exit> to go the MAIN run screen retaining the AutoRange that was setup by QDUT.

Select <2repeat> to start the same test again at <Prep & [ENT]>. Select <3data> to view the data collected in the QDUT AutoTest that was just

completed (see Section 3.4.5).

3.3.7 [HEAD]

 PURPOSE

To cause a pressure fluid head correction to be added to or subtracted from the pressure measured by the PPCH reference pressure transducer in order to predict the pressure at a height other than the PPCH’s reference level.

3. OPERATION

 PRINCIPLE

PPCH is calibrated at the reference level marked on the instrument rear panel. Frequently, when performing a calibration or test, the device or system under test is at a different height than the PPCH’s TEST port. This difference in height, commonly called head, can cause a significant difference between the pressure measured by the PPCH at its TEST port height and the pressure actually applied to the device under test which is at a different height. In this case, it may be useful to make a head correction to the pressure measured by the PPCH in order to predict the pressure actually applied at a DUT at a different height.

PPCH can calculate head pressure over its working pressure range for oil, water or a user defined liquid as well as a variety of gasses. The HEAD fun ction allo ws th e heig ht di ffere nce to be spe cif ied and causes the resulting head pressure to be added to the pressure measured at the TEST port.

The [HEAD] function key is used to specify the height difference between the PPCH reference level and another height. Entering a height of zero turns the function off. The height units and the test fluid are specified by pressing [SPECIAL], <3Head> (see Section 3.5.3).

Head influences in gauge and absolute mode with a liquid as the test fluid can be confusing, particularly when using an external reservoir.

Follow the recommendations below for

consistent results in various setups and measurement modes.

Head Effect Considerations when Using the Internal Reservoir

When the PPCH is vented, it is open to the return tube in the internal reservoir. The top of this tube is intentionally above the normal surface of the liquid in the reservoir and is aligned with the Q-RPT reference level marked on the rear panel. This assures that a consistent head height is applied to the system connected to the PPCH TEST port when the system is vented by the VENT function of PPCH and that its height is the same as the reference level of the Q-RPT.

• In both gauge and absolute measurement modes, enter the difference between the PPCH reference level (marked on the rear panel of PPCH) and the DUT height as the head height in [HEAD]. In gauge measurement mode, if you “zero” the device under test (DUT) with the PPCH vented before the test, always enter the head height in [HEAD] as zero.

• In gauge measurement mode, be sure AutoZ is ON for the active Q-RPT (see Section

3.5.1). Allow PPCH to AutoZero when vented before running a test. Note that if the

head height entered in [HEAD] is not zero, it is normal for PPCH to display a non-

DUT zero value of pressure after AutoZeroing.

Head Effect Considerations when Using an External Reservoir

The external reservoir is normally mounted at a level higher than the PPCH internal reservoir (see Section 2.3.6.2).

• The reference lev

el is not the same in gauge and absolute measurement modes.

• In gauge measurement mode, enter the difference between the top of the return tube or liquid level in the external reservoir (not the level marked on the back of PPCH) and the DUT height as the head height in [HEAD]. But, in gauge measurement mode, if you “zero” the device under test (DUT) with the PPCH vented before the test, always enter the head height in [HEAD] as zero.

• In gauge measurement mode, be sure AutoZ is ON for the active Q-RPT (see Section

3.5.1). Allow PPCH to AutoZero when vented before running a test. Note that if the DUT head height entered under [HEAD] non-zero value of pressure after AutoZeroing.

• In absolute measurement mode, enter the difference between the PPCH reference level (marked on the rear panel of the PPCH) and the DUT height as the head height in [HEAD].

is not zero, it is normal for PPCH to display a

PPCH™ OPERATION AND MAINTENANCE MANUAL

 OPERATION

To access the HEAD function, press the [HEAD] function key. The display is:

1. Test fluid currently specified for the head correction.

2. Entry field for head height.

Edit head height:

+ 25 cm oil

Edit the head height to the desired value (positive if the DUT is above the reference level, negative if below). Press [ENT] to return to the MAIN RUN screen with the new head correction active. Press [ESC] to return with no changes.

The reference height of the PPCH pressure measurement is the reference level marked on the PPCH rear panel. In gauge measurement mode, when using an external reservoir, the reference level is the top of the reservoir return tube or the liquid in the reservoir if no return tube is installed.

The HEAD function is NOT range specific. The HEAD ON or OFF status remains the same as ranges are changed. Edits made to the head settings are independent of active range or Q-RPT.

When a head correction is being applied, it is indicated by <h> in the top line of the MAIN RUN screen (see Section 3.1.1). When the head correction is zero, the <h> is not shown.

To change units of head height between inches and centimeters and to change the test fluid, use [SPECIAL], <3head> (see Section 3.5.3).

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

3.3.8 [PRIME]

 PURPOSE

To execute the PPCH test system PRIME and/or PURGE function. PRIME is intended to fill a test volume with liquid up to a low pressure. PURGE is intended to cycle between a vented condition and high pressure to remove gas from the test system and/or exercise a DUT prior to testing it.

 PRINCIPLE PPCH is designed to generate and precisely control liquid pressure. It operates much more

effectively in a gas free system. Ideally, devices are filled with liquid prior to be being connected to PPCH. The PRIME and PURGE routines are both intended to assist in safely

3. OPERATION

and efficiently removing any gas that may remain in the test system before using PPCH to control pressure precisely.

Normally, PRIME is used first to fill the system, chasing out gas and priming it to a low pressure. If there is still a possibility of gas being trapped in the system, PURGE is then used to rapidly cycle between vent and a high pressure. At the high pressure, gas mixes with the oil and is drawn out in the vent process.

 OPERATION

To reach the PRIME and/or PURGE function, press [PRIME] from the MAIN RUN screen.

3.3.8.1 <1PRIME>

 PURPOSE

To run an automated routine that fills the system under test with liquid supplied by the PPCH to drive out as much gas as possible. The routine assumes that the user has opened one or more fittings from which gas can escape at the end of the system connected to the PPCH TEST port.

The normal procedure is to start the priming routine from a vented condition while observing an open point (preferably the highest point), such as a loosened fitting, in the test system. PPCH pumps liquid into the system chasing gas out of the test opening. When gas free liquid runs out of the open point, the system is closed by tightening the fitting. Priming aborts automatically when the pressure reaches 0.5 MPa (75 psi).

The PRIME function interrupts automatically when pressure of 0.5 MPa (75 psi) is sensed. However, the pressure applied to the TEST port may momentarily spike as high as 7 MPa (1 000 psi).

 OPERATION

Prior to running the PRIME routine, connect a system or device to be pressurized to the PPCH TEST port. Leave a point open in the system that can be closed by tightening a fitting or closing a valve. Preferably, the open point is at a location in the system to which gas will tend to travel as the system is filled with liquid. Usually, this is a high point.

Vent PPCH by pressing [VENT]. Wait for vent to complete as indicated by a green Ready indication.

To run the PRIME routine, press [PRIME], <1prime>. The display is: To begin priming, press [PRIME].

PPCH supplies liquid to its TEST port until [PRIME], [ESC] or [ENT] is pressed or the pressure reaches 0.5 MPa (75 psi).

0.000 MPa g IH

[PRIME] to prime

0.441 MPa g IH

******Priming*******

If [PRIME], [ESC] or [ENT] is pressed during priming, the routine interrupts and returns to the <[PRIME] to prime> display. Press [PRIME] again to continue priming. If the pressure reaches 0.5 MPa (75 psi), the priming routine ends and <Prime completed> is displayed

To leave the priming routine press [ESC] or [ENT] from the <Prime completed> screen.

Consider purging after priming (see Section 3.3.8.2).

PPCH™ OPERATION AND MAINTENANCE MANUAL

3.3.8.2 <2PURGE>

 PURPOSE

To run an automated routine that cycles the pressure rapidly to remove gas from the test system and/or exercise a DUT.

 OPERATION

Executing the PURGE function will generate high pressure. The default purge pressure is 50% of the active range. Take appropriate safety precautions before using this function.

Prior to running the PURGE routine, the system connected to the PPCH TEST port should be primed if it contains gas (see Section 3.3.8.1). It may also be leak tested (see Section 3.3.9). To run the purge function, press [PRIME], <2purge>. The display is:

1. Edit field for the number of times to cycle the pressure. Default is 1.

2. Edit field for cycle high pressure. Default is 50 % of active range. Maximum is 100 % of active range.

Edit the number of cycles and the cycle pressure as desired. Check carefully that the pressure value entered is acceptable for all the hardware that is connected to the TEST port. Press [ENT] to begin cycling. The display is:

The top line is the regular run screen displaying the actual pressure. The second line alternates between a display of the target purge pressure (or <Venting>) and a display of the current cycle and total number of cycles to be executed.

To interrupt the purge routine and return to the prime/purge menu, press [ENT] or [ESC]. When all cycles of the purge routine have completed, PPCH beeps three times and displays <Purging complete>. Press [ESC] to go to the MAIN RUN screen or [ENT] repeat the purge process.

3.3.9 [LEAK CK]

 PURPOSE

Cycle 1 times to

20 MPa approx

1.005 MPa g IH

Purging to 20.000

Cycle 1 of 3

To run an automated pressure decay based leak check routine to determine the leak rate of the system connected to the PPCH TEST port.

 PRINCIPLE

Leaks in the system connected to PPCH’s TEST port can cause differences between the pressure measured by the PPCH Q-RPTs and pressure in other parts of the test system. A large leak can cause the PPCH to be unable to set and control pressures reliably. The LEAK CHECK function is provided as a means of checking and quantifying leaks that may be present in the system.

The principle of the LEAK CHECK function is the measurement of the decrease or increase in pressure in a fixed volume over time. The LEAK CHECK function allows a leak check time to be set. The total pressure change and the average rate of change over the leak check time are calculated and displayed.

3. OPERATION

Changing the pressure in a test system causes adiabatic temperature change in the pressurized liquid that need to have dissipated before a valid leak measurement can be made. In general, a 2 to 3 minute wait before running a leak check is adequate to allow the adiabatic temperature change to dissipate and valid leak measurements to be made. However, stabilization time may be much longer with liquid test media, as volume and/or pressure increases.

 OPERATION

To run a leak check, first set the pressure to the desired leak check pressure using the direct pressure control keys (see Section 3.1.3) or automated pressure control (see Section 3.3.10).

The effect of the thermal pressure control unit (TPCU) can make it difficult to run a reliable leak test when the PPCH is in dynamic control mode. Before leak testing, change the control mode to a mode other than dynamic and wait at least 5 minutes for the TPCU to cool down and stabilize (see Section 3.4.6.2).

To access the LEAK CHECK function, press [LEAK CHECK] from the MAIN RUN screen. Select <1run> to run a leak test. The display is:

Set leak check time:

1. Edit field for the time over which the leak check pressure change will be measured, in seconds.

15 s

Edit the leak check time if desired (minimum 1, maximum 999) and press [ENT]. Press [ENT] again when ready to start the leak test. The leak test display is:

1. Standard MAIN RUN screen first line showing measured pressure.

2. Active RPT position indicator

3. Indication that leak test is running and countdown of time remaining.

70.089 MPa a HI

Leak testing 13 s

[ESC] can be used to abort the running leak test. [ENT] while the leak test is running restarts the leak check timer. When the leak check timer countdown has completed PPCH beeps three times and the leak check results screen is displayed:

1. Total pressure change from start to finish of leak check time.

2. Indicator of RPT used to run leak check.

3. Average rate of change of pressure over the leak check time period.

∆P 0.61 MPa HI

Rate 0.04 MPa/sec

From the leak check results screen, press [ENT] to repeat the leak test. Press [ESC] to return to leak check main menu and exit to the MAIN RUN screen.

PPCH™ OPERATION AND MAINTENANCE MANUAL

As a general rule, the maximum acceptable leak rate for optimal PPCH automated pressure

control operation and to assure in tolerance measurements with default pressure control parameters is

0.005 % of reading/second. In dynamic control mode, to handle higher test system leak rates, try using hi volume dynamic control (see Section 3.4.6.2) and/or increase the hold limit using [SPECIAL], <6control>, <1limits> (see Section 3.4.6.1).

To view the results of the most recently completed leak check, press <2view>. Press [ENTER] or [ESC] to return to the MAIN RUN screen. If NO leak check data is stored (i.e., if the PPCH has never run a leak test or a reset has cleared previous leak test results), the results screen displays <Data NOT available> briefly and returns to MAIN RUN screen.

Leak check is range specific in the sense that leak check is run using the active range. However, only one set of leak check results is maintained in memory and each leak test completed overwrites the memory. View leak check always shows the results of the last leak check run regardless of the range that is now active. The results screen includes the range indicator to indicate the range in which the leak check was run.

3.3.10 [ENT/SET P] (SET PRESSURE AUTOMATICALLY)

 PURPOSE

To enter and execute target pressure and ramp values for PPCH automated pressure control.

See Section 3.2.2 for information on automated pressure control and the different control modes available with PPCH.

 OPERATION The operation of [ENT/Set P] depends on the active pressure control mode.

Dynamic mode: See Section 3.3.10.1. Static mode: See Section 3.3.10.2. Monotonic mode: See Section 3.3.10.3.

amp mode: See Section 3.3.10.4. Interrupting automated pressure control: See Section 3.3.10.5. Automated commands for zero pressure: See Section 3.3.10.6.

The active range pressure control mode and parameters can be viewed and edited using

[SPECIAL], <6control> (see Section 3.4.6).

3.3.10.1 DYNAMIC CONTROL MODE, [ENT/SET P]

If the PPCH is not set for dynamic control, use SPECIAL, <6control>, <2mode>

to select dynamic control mode.

For best results, wait 5 minutes with the PPCH vented before controlling pressure when changing to or from dynamic control mode. This is to allow time for the PPCH thermal pressure control unit to respond and stabilize.

3. OPERATION

Press [ENT/SET P] from the MAIN RUN screen. The display is:

1. Standard MAIN RUN screen first line showing measured pressure and active Q-RPT.

2. Edit field for the pressure control target pressure in current pressure unit of measure.

20.007 MPa g HI

Target:40.000

Edit the target pressure value as desired.

A target pressure entry that exceeds the current upper limit (see Section

3.4.4) is not accepted. Negative values are not accepted. See Section 3.3.10.6 for information on zero target value.

Press [ENT/SET P] to start pressure control to the target pressure and return to the MAIN RUN screen. The MAIN RUN screen when pressure control is active is:

1. Standard MAIN RUN screen first line showing measured pressure and active Q-RPT. Shows target pressure value when condition is Ready.

2. Current control mode indicator. Flashes when automated pressure control is active. Character is <D> for standard or <d> for hi volume dynamic control. <C> is appended if custom control parameters are in use.

3. Target pressure value (<T>) when controlling and condition is Not Ready. Current deviation from the target pressure (<D>) when in dynamic control mode and condition is Ready.

40.000 kPa a HI

D 0.002 D

Observe the Ready/Not Ready indicator LED (see Section 3.2.3) for indication of when the controlled pressure has reached the target and stabilized

inside the hold limit. PPCH continues maintaining pressure at the target value following dynamic control protocol (see Section 3.2.2.2) until automated pressure control is interrupted.

If PPCH is unable to control pressure or appears to control pressure poorly, see Section 6 to troubleshoot. Note that there are two types of dynamic control, standard and hi volume, to accommodate different test situations (see Section 3.2.2.2)

See Section 3.4.6 for information on customizing pressure control parameters.

The [ ] and [ ] direct pressure control keys can be used while controlling to jog the pressure control target value up or down by the jog step value (see Section

3.1.3). These keys also jog the target value when in the ENTER target value screen.

3.3.10.2 STATIC CONTROL MODE, [ENT/SET P]

If the PPCH is not set for static control, use SPECIAL, <6control>, <2mode> to select static control mode.

PPCH™ OPERATION AND MAINTENANCE MANUAL

For best results, wait 5 with the PPCH vented before controlling pressure when changing to or from dynamic control mode. This is to allow time for the PPCH thermal pressure control unit to respond and stabilize.

Press [ENT/SET P] from the MAIN RUN screen. The display is:

1. Standard MAIN RUN screen first line showing measured pressure and active Q-RPT.

2. Edit field for the pressure control target pressure in current pressure unit of measure.

20.007 MPa g HI

Target:40.0

Edit the target pressure value as desired.

A target pressure entry that exceeds the current upper limit (see Section

3.4.4) is not accepted. Negative values are not accepted. See Section 3.3.10.6 for information on zero target value.

Press [ENT/SET P] to start pressure control to the target pressure and return to the MAIN RUN screen. The MAIN RUN screen when pressure control is active is:

1. Standard MAIN RUN screen first line showing measured pressure and active Q-RPT.

2. Current control mode indicator. Flashes when automated pressure control is active. Character is <S> for static control. <C> is appended if custom control parameters are in use.

3. Target pressure value (<T>) when controlling and condition is Not Ready. Pressure rate of change <R> when within hold limit and waiting for pressure stability.

38.979 MPa a HI

R 0.002/s S

Observe the Ready/Not Ready indicator LED (see Section 3.2.3) for indication of when the controlled pressure is within the hold limit and stable. controlling following static pressure control protocol (see Section 3.2.2.3) until automated pressure control is interrupted.

If PPCH is unable to control pressure or appears to control pressure poorly,

see Section 6 to troubleshoot.

See Section 3.4.6 for information on customizing pressure control

parameters.

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

PPCH continues

3. OPERATION

3.3.10.3 MONOTONIC CONTROL MODE, [ENT/SET P]

If the PPCH is not set for monotonic control, use SPECIAL, <6control>, <2mode> to select monotonic control mode.

Use monotonic control with caution. Once pressure is set to the target, an ascending monotonic ramp will continue increasing pressure until stopped by a new pressure command, aborting control or reaching the active range upper limit pressure (see Section 3.4.4).

Press [ENT/SET P] from the MAIN RUN screen. The display is:

1. Standard MAIN RUN screen first line showing measured pressure and active Q-RPT.

2. Edit field for the pressure control target pressure in current pressure unit of measure.

20.007 MPa g HI

Target:40.0

Edit the target pressure value as desired.

A target pressure entry that exceeds the current upper limit (see Section

3.4.4) is not accepted. Negative values are not accepted. See Section 3.3.10.6 for information on zero target commands.

Press [ENT/SET P] to start pressure control to the target pressure and return to the MAIN RUN screen. The MAIN RUN screen when pressure control is active is:

1. Standard MAIN RUN screen first line showing measured pressure and active Q-RPT. Always shows measured pressure.

2. Current control mode indicator. Flashes when automated pressure control is active. Character is <M> for monotonic control. <C> is appended if custom control parameters are in use.

3. Target pressure value (<T>) at all times.

99.998 MPa a HI

T 100.000 M

Observe the Ready/Not Ready indicator LED (see Section 3.2.3) for indication of when ramp rate target. PPCH continues controlling following monotonic pressure control protocol (see Section 3.2.2.4) until automated pressure control is interrupted.

If PPCH is unable to control pressure or appears to control pressure poorly,

see Section 6 to troubleshoot.

the controlled pressure is at the target pressure and under the monotonic

PPCH™ OPERATION AND MAINTENANCE MANUAL

See Section 3.4.6 for information on customizing pressure control

parameters.

3.3.10.4 RAMP CONTROL MODE, [ENT/SET P]

If the PPCH is not set for ramp control, use SPECIAL, <6control>, <2mode> to select ramp control mode.

Use ramp control with caution. An ascending ramp will not stop increasing pressure until stopped by a new pressure command, aborting control or reaching the active range upper limit pressure (see Section 3.4.4).

Press [ENT/SET P] from the MAIN RUN screen. The display is:

1. Standard MAIN RUN screen first line showing measured pressure and active Q-RPT.

2. Edit field for the target ramp rate in current pressure unit of measure per second.

20.007 MPa g HI

Target rate:1.0000/s

Edit the target ramp value as desired. Enter a negative value for a descending rate.

A rate entry of 0 is not accepted.

Press [ENT/SET P] to start pressure control to the target ramp rate and return to the MAIN RUN screen. The MAIN RUN screen when pressure control is active is:

1. Standard MAIN RUN screen first line showing measured pressure and active Q-RPT. Always shows measured pressure.

2. Actual pressure rate of change (<R>) at all times.

3. Current control mode indicator. Flashes when automated pressure control is active. Character is <R> for ramp control. <C> is appended if custom control parameters are in use.

25.377 MPa a HI

R 1.015/s R

Observe the Ready/Not Ready indicator LED (see Section 3.2.3) for indication of

the target rate has been established within the rate hold limit. PPCH

when continues controlling following ramp pressure control protocol (see Section

3.2.2.5) until automated pressure control is interrupted.

If PPCH is unable to control pressure or appears to control pressure poorly,

see Section 6 to troubleshoot.

3. OPERATION

See Section 3.4.6 for information on customizing pressure control

parameters.

3.3.10.5 INTERRUPTING AUTOMATED PRESSURE CONTROL

Automated pressure control is interrupted by:

• Pressing [ESC]: Suspends control and remains in MAIN RUN screen. Does not vent pressure. PPCH passively measures the pressure applied to its TEST port. Pressure may take some time to stabilize if control mode is dynamic as thermal pressure control unit stabilizes.

• Pressing any direct pressure control key other than the jog keys (see Section 3.1.3): Suspends control and executes direct pressure control.

• Pressing function. Does not vent pressure. PPCH passively measures the pressure.

• Pressing [ENT/SET P]: In dynamic, static and ramp modes, suspends control and goes to ENTER target screen. Does not vent pressure. PPCH passively measures the pressure. In monotonic mode, [ENT/SET P] suspends control only if the pressure has not yet reached the target limit. [ENT/SET P] does not suspend control during the slow ramp after the target pressure has been reached. This is to avoid suspending control when setting the next pressure increment as that could cause the direction of pressure evolution to reverse, violating the monotonic excursion.

any function key: Suspends control and goes to the selected

• Sending any remote command when in local mode interrupts pressure control.

To resume automated pressure control, press [ENT/SET P] and ENTER a target pressure value.

3.3.10.6 AUTOMATED PRESSURE COMMANDS FOR ZERO PRESSURE

A command for automated pressure control to a target value of zero when in gauge or absolute measurement mode is interpreted in the same manner as if the [VENT] direct pressure control key had been pressed (see Section 3.1.3). A Ready running AutoZ, if applicable (see Section 3.5.1). Zero is not an accepted entry in ramp control mode.

command for zero pressure in absolute measurement mode results in setting atmospheric pressure by opening the TEST port to atmosphere. This is the lowest absolute pressure PPCH can set. When zero absolute is given as a pressure target, the pressure actually measured by the PPCH after the ready condition occurs must be read back rather than assuming a specific pressure value has been set.

condition occurs when the vent sequence has completed, including

PPCH cannot set pressure under atmosphere. An automated pressure control

PPCH™ OPERATION AND MAINTENANCE MANUAL

3.4 [SETUP]

 PURPOSE

[SETUP] accesses a menu of functions and features commonly used in setting up and using PPCH.

 OPERATION

To access the SETUP menu, press [SETUP] from the MAIN RUN screen. The display is:

SETUP menu choices include:

1range 2res 3jog 4UL

5ATest 6control 7drv

<1range> Save and delete ranges created by AutoRange (see Section 3.4.1). <2res> Adjust the resolution of pressure displays (see Section 3.4.2). <3jog> <4UL> <5ATest> <6control>

> Set and view status of external 12V drivers (see Section 3.4.7).

<7drv

Adjust the jog function pressure step value (see Section 3.4.3). Adjust the upper pressure limit (see Section 3.4.4). View data files resulting from running QDUT AutoTests (see Section 3.4.5). Select pressure control mode and view/adjust control limits (see section 3.4.6).

3.4.1 <1RANGE>

 PURPOSE

Save AutoRange ranges and associated settings for recall. Delete previously saved AutoRange ranges.

 PRINCIPLE

The PPCH AutoRange function creates a range and automatically sets various operating parameters proportionally to the range (see Section 3.3.4). Operating settings can then be changed by the user. Many operating settings are specific to the current range (see Table 7).

[SPECIAL], <1range> allows the AutoRange range and associated settings to

be saved for later recall using the [RANGE] key (see Section 3.3.1). This can save the user from having to recreate frequently used ranges and custom settings.

[SPECIAL], <1range> is also used to delete ranges that have been saved but are no longer needed.

3.4.1.1 SAVING AN AUTORANGE RANGE

 OPERATION

To save a range created by AutoRange, the range must be the active range. Use AutoRange to create the range (see Section 3.3.4) and then make any desired feature and setting adjustments.

Once

the AutoRange range is set up as desired, press [SETUP], <1range> and

select <1save>. The display is:

1. Indication that this is an AutoRange range to be saved.

2. Designator and position of the Q-RPT used by the range to be saved.

3. Pressure unit of measure of the range to be saved.

4. Full scale pressure of the range to be saved in

gauge mode and absolute mode if available.

Save range A100M IH

MPa 80g/80a

3. OPERATION

Press [ENT] to save the range or [ESC] to return to the MAIN RUN scr een without saving the range.

Default (DF) Q-RPT ranges cannot be saved. They are permanent.

Duplicate AutoRange ranges cannot be saved. A duplicate AutoRange range is a range that has the same measurement mode and full scale and uses the same Q-RPT as a range that has already been saved.

3.4.1.2 DELETING AUTORANGE RANGES

 OPERATION

To delete a single saved AutoRange range, press [SETUP], <1range>, <2delete>. If there are any saved ranges available to delete, the display is:

1. Indication that the cursor control keys may be

used to toggle through the saved ranges to select the one to be deleted.

2. Designator and position of the Q-RPT used by

the range to be deleted.

3. Pressure unit of measure of the range to be

deleted.

4. Full scale pressure of the range to be deleted

in gauge mode and absolute mode if available.

< and > A200M X1H

MPa 170g/170a

Use the cursor control keys to toggle through the ranges available to be deleted. When the desired range to be deleted is displayed, press [ENT]. If you are sure you want to delete this range, press [ENT] again in response to the <Delete?> query. Press [ESC] to return to the <AutoRange:> screen without deleting a range.

To delete all of the saved AutoRange ranges, press [SETUP], <1range>, <3delete all>. If you are sure you want to delete all the ranges, respond <1yes> to the <Delete all saved ranges?> query. If not, respond <2no>.

3.4.2 <2RES> (RESOLUTION)

 PURPOSE

To set the resolution with which measured pressures and other pressure indications and settings are displayed.

 PRINCIPLE

The resolution with which PPCH displays pressure values can be adjusted. This feature can be used to reduce the resolution when lower precision measurements are being made and excess resolution might confuse or distract the operator.

The resolution setting determines the number of digits with which pressure is displayed. The resolution is calculated based on the full scale of the range and then rounded to the furthest digit to the right. For example, resolution of 0.001 % on a range of 150 MPa is 150 X 0.001 % = 0.0015 which is rounded down to 0.001 MPa.

Default resolution is 10 ppm of active range span. Resolution is set automatically by

AutoRange (see Section 3.3.4).

PPCH™ OPERATION AND MAINTENANCE MANUAL

 OPERATION

To access the resolution function, press [SETUP], <2res>. The display is:

Display resltn: IH

0.0010 %FS < and >

Use the cursor control keys to set the desired level of resolution. Press [ENT] to return to the MAIN RUN screen with the new resolution setting active or [ESC] to make no changes.

The resolution setting is range specific. A resolution setting made in one range does NOT

affect other ranges.

The maximum resolution setting is limited in AutoRange ranges that are less than 10 % of

the Q-RPT default full scale.

The maximum resolution setting when using a utility sensor is 0.001 % of utility sensor

span.

3.4.3 <3JOG>

 PURPOSE

Adjust the nominal change in pressure caused by using the jog direct pressure control keys ([

] and [ ]).

 PRINCIPLE

The jog direct pressure control keys, [

] and [ ], increase or decrease pressure by a nominal amount each time they are pressed. If pressure control is NOT active, pressing the jog key causes an up or down pressure step. If dynamic pressure control is active, the jog key causes the pressure control target value to be changed by the amount of the jog step. [SETUP], <3jog> allows the nominal value of the jog step to be adjusted.

The default jog step is 0.02% of active range span. The maximum jog step is 5 % of active

range span. Jog step value is set automatically by AutoRange (see Section 3.3.4).

See Section 3.1.3 for information on the jog key effect while control is active in various

control modes.

 OPERATION

To access the jog step adjustment function, press [SETUP], <3jog>. The display is:

Jog step size: IH

0.010 MPa

Edit the value of the jog step as desired. Press [ENT] to return to the MAIN RUN screen with the new jog step size active. Press [ESC] to return to the MAIN RUN screen with no change to the jog step size.

Pressing [ ] and [ ] simultaneously is a short cut to the <Jog step size:> menu.

3. OPERATION

The jog step setting is range specific. A jog step setting made in one range does NOT

affect other ranges.

3.4.4 <4UL> (UPPER LIMIT)

 PURPOSE

To set the upper limit pressure value for a pressure range and measurement mode.

 PRINCIPLE

The UPPER LIMIT function allows the setting of a maximum pressure not to be exceeded when using a specific range and measurement mode. Absolute and gauge measurement modes (see Section 3.3.3,  PRINCIPLE) have their own, specific limits.

Automated pressure control targets greater than the upper limit a

re not accepted. When the pressure measured by PPCH exceeds the upper limit, automated or direct manual pressure control is aborted and an intermittent warning beep sounds.

The UPPER LIMIT function is most often used to protect the device or system connected to the PPCH TEST port from accidental overpressure.

The default upper limit is 105 % of AutoRange span or 102 % of Q-RPT default (maximum)

full scale, whichever is lower.

The upper limit is very useful in assuring that the pressure ramps of monotonic or ramp

pressure control modes do not result in an accidental overpressure.

 OPERATION

To view or edit the upper limit press [SETUP], <4UL>. The display is:

Upper limit: IH

1. Entry field for upper limit value in active pressure unit of measure and measurement mode.

204.000 MPa a

Edit the upper limit value as desired. The maximum upper limit is 105 % of AutoRange range or 102 % of default QRPT range, whichever is lower. Press [ENT] to return to the MAIN RUN screen with the new upper limit active. Press [ESC] to return to the MAIN RUN screen with no change to the upper limit.

When the upper limit has been exceeded, the display of current pressure flashes and a buzzer sounds at 2 second intervals. To return to normal operation, reduce pressure using direct pressure control keys or an automated pressure command.

Upper limit values are specific to each range and measurement mode. Be careful not to assume that the upper limit set in one measurement mode will apply to the other. For example, if you set 100 MPa as the upper limit in gauge mode, the upper limit will not be 100 MPa in absolute mode of the same range.

PPCH™ OPERATION AND MAINTENANCE MANUAL

Upper limits are always specified and displayed in the current pressure unit of measure.

3.4.4.1 OVER PRESSURE FUNCTION

In addition to the UL function, PPCH has an over pressure function. The over pressure function executes when a Q-RPT measures a pressure that is

104 % of its default span or a utility sensor measures a pressure that is 110 % of its default span.

When PPCH is using an external Q-RPT in an RPM4, the PPCH utility sensor or Hi Q-RPT acts as a watchdog. If the watchdog measures a pressure greater than the maximum pressure of the active external Q-RPT, PPCH executes the overpressure function.

The o v er pressure f unction causes al l pressure control t o be interrupted, changes the active range to the default range of the Internal, Hi (IH) Q-RPT or u tility sensor and causes the measured pressure display to flash. The overpressure function also logs the time and date of the overpressure condition in both user and factory logs to assist in incident diagnosis (see Section 3.5.9).

To recover from an overpressure,

correct the overpressure condition and cycle PPCH power. Be sure to correct the condition that caused the overpressure before cycling power.

RPM4 has its own, independent overpressure function. When a Q-RPT on an RPM4 is active, both the PPCH and the RPM4 may execute overpressure routines in response to an overpressure condition of the RPM4. See the RPM4 Operation and Maintenance Manual for information on the RPM4 overpressure function.

3.4.5 <5ATEST>

 PURPOSE

To view the data files that are created when QDUT AutoTests are run (see Section 3.3.6).

 PRINCIPLE

PPCH supports QDUTAutoTests (see Section 3.3.6.2). When a QDUT AutoTest is run, the PPCH pressure accepted by the operator, and <IN> logged. The logged pressure and an identifying header are stored in a data file. The data file can be viewed immediately following the last point of the sequence by selecting <3data>. In addition, the up to ten previous data files recorded can be viewed anytime using [SETUP],

<5ATest>.

Data File Protocol

or <OUT> condition, at each point is

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

Data files are identified by a header whose first line is the full scale of the DUT and the number of test points in the QDUT AutoTest sequence. The second line is the date (YYYYMMDD) and time (HH:MM:SS) at which the last point of the sequence was accepted.

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

3. OPERATION

 OPERATION

To access the QDUT AutoTest data file viewing function press [SETUP], <5ATest>. The first display is the data file header which can be used to toggle through data files:

1. Full scale of the QDUT AutoTest sequence with pressure unit of measure and measurement mode.

2. Number of test points completed / total number of test points in the sequence definition.

3. Date (YYYYMMDD) and time the last point was completed.

6000.0 psi g 11/11

20021105 10:15 am

Use the forward and backward cursor control keys to scroll through the headers of the other QDUT AutoTest data files available. PPCH stores up to ten data files in order of execution with a new data file pushing all the files back and deleting the oldest one. When the header of the data file you would like to view appears, press [ENT] or the down cursor control key to view the first point of the identified sequence.

The display is:

1. PPCH pressure logged for the test point.

2. Head, AutoZ and active Q-RPT indicator (same as in the PPCH MAIN RUN screen).

3. Indication that this point was out of tolerance. Indicates <IN> if point was in tolerance. Definition of out of tolerance is (Nominal point – PPC pressure > DUT tolerance * DUT FS).

4. Number of this test point / total number of points in the sequence.

6000.5 psi g hzX1H

View data OUT 2/11

Press [ENT] to move to the next data point or use the up and down cursor control keys to scroll backwards and forwards through the test points. The data file header is between the first point and the last point.

Press [ESC] to exit the data file. Confirmation is required to exit the data view function.

3.4.6 <6CONTROL>

 PURPOSE

To set the automated pressure control mode for the active range, customize control parameters for the active control mode, activate default control parameters.

 PRINCIPLE

The CONTROL function allows the active control mode for the current range to be set to dynamic (standard or hi volume), static, monotonic or ramp. The control mode set is specific to the active range and is saved with that range when ranges are changed. For a complete description of the operation and purpose of the different control modes see Section 3.2.2.

When a control mode is selected using the CONTROL function, CONTROL parameters automatically set to default values for that control mode in the active range (see Table 10 for definition of PPCH

default control parameters). The default control parameters are those best suited to operate within PPCH pressure control and measurement specifications for a given range of operation.

Control mode parameters can be viewed and customized in the CONTROL function (see Section 3.4.6.). Customizing the

control parameters changes the conditions required for a Ready condition to occur (see Section 3.2.3). This can be used to increase control speed (reduce time

to Ready), usually by decreasing control precision, or to increase precision which usually decreases control speed. For example, changing the dynamic pres sure control hold limit from its default value of ± 0.01 % of the active range to ± 0.05 % of the active range decreases the time required to set a pressure since the limit within which the pressure must

are

PPCH™ OPERATION AND MAINTENANCE MANUAL

be set has increased. However, it will also increase the maxim um po s si bl e co nt r ol er r or w hen Ready is indicated.

Table 10. Default pressure control parameters

HOLD LIMIT

DYNAMIC

MODE

(standard and

hi volume)

STATIC MODE

MONOTONIC

MODE

RAMP MODE

CONTROL

IDLE

*Note: % of range limits are of default or AutoRanged range.

± 0.01 % of active range, or 0.003 % of Q-RPT maximum span, whichever is greater

± 1 % of active range ± 0.005 % of active

Not applicable Not applicable 1 % of Q-RPT

± 25 % of target rate Not applicable Not applicable Not applicable Not applicable ± 0.005 % of active

PRESSURE

STABILITY LIMIT

Not applicable Not applicable Not applicable

range or 2 ppm of Q-RPT maximum span/second, whichever is greater

range or 2 ppm of Q-RPT maximum range/second, whichever is greater

PRESSURE

TARGET LIMIT RATE LIMIT

Not applicable Not applicable

maximum span

Not applicable Not applicable

0.05 % of Q-RPT maximum span/second

 OPERATION

To access the CONTROL function, press [SETUP], <6control>. The display is:

Dynamic,standard IH

1limits 2mode

Select <1limits> to view or edit the active control limits for the active control mode (see Section 3.4.6.1).

t <2mode> to change the active control mode (see Section 3.4.6.2).

Selec

3.4.6.1 <1LIMITS> (CUSTOM CONTROL PARAMETERS)

 PURPOSE

To view active pressure control parameters and/or set custom control parameters.

 PRINCIPLE

See Section 3.4.6,  PRINCIPLE.

 OPERATION

[SETUP], <6control>, <1limits> views and/or sets limits for the active control mode only. To set limits for a control mode other than the active control mode, select that control mode first using [SETUP], <6control>, <2mode>.

To view active control parameters and/or set custom control parameters, press [SETUP], <6control>, <1limits> from the MAIN RUN screen. The display is depends upon the active control mode.

To reset default control parameters for a range and control mode, select the control mode using [SETUP], 6control, 2mode.

3. OPERATION

Custom control parameters are range specific. Changes made in one range are stored for that range and are recalled when that range is made active. Changes made in one range do not affect any other range.

When custom control parameters are active, a <C> is appended to the control mode indicating character (<D> for standard dynamic, <d> for hi volume dynamic, <S> for static, <M> for monotonic, <R> for rate) in the middle of the bottom line of the MAIN RUN screen.

Dynamic (standard and hi volume) and Static Control Modes

When dynamic or static control mode is active, the [SETUP], <6control>, <1limits> display is:

1. Active Q-RPT designator.

2. View/edit field of hold limit value in active pressure unit of measure. Shows active hold limit.

3. Active control mode (<D> for standard dynamic, <d> for hi volume dynamic, <S> for static).

Hold limit: IH

0.010 MPa D

Edit the hold limit value if desired and press [ENT] to view the stability limit. The next display is:

1. Active Q-RPT designator.

2. View/edit field of stability limit value in active pressure unit of measure. Shows active stability limit.

3. Active control mode (<D> for standard dynamic, <d> for hi volume dynamic, <S> for static).

Stability limit: IH

0.010 kPa/s D

Edit the stability limit value if desired and press [ENT] to return to the main run screen with the edited values active.

See Section 3.4.6, Table 10 for default control limits.

Monotonic Control Mode

When monotonic control mode is active, the [SETUP], <6control>, <1limits> display is:

1. Active Q-RPT designator.

2. View/edit field of pressure target limit value in active pressure unit of measure. Shows active target limit.

3. Active control mode (<M> for monotonic).

Target limit: IH

1.000 MPa M

Edit the target limit value if desired and press [ENT] to view the monotonic ramp rate limit. The next display is:

PPCH™ OPERATION AND MAINTENANCE MANUAL

1. Active Q-RPT designator.

2. View/edit field of monotonic ramp rate limit in active pressure unit of measure per second. Shows active rate limit.

3. Active control mode (<M> for monotonic).

Rate limit: IH

0.050 MPa/s M

Edit the target ramp rate if desired and press [ENT] to return to the main run screen with the edited values active.

See Section 3.4.6, Table 10 for default control limits.

Ramp Control Mode

When ramp control mode is active, the [SETUP], <6control>, <1limits> display is:

1. Active Q-RPT designator.

2. View/edit field of pressure ramp rate hold limit value in active pressure unit of measure per second.

3. Active control mode (<R> for ramp).

Rate hold limit: X1H

0.100 MPa/s R

Edit the ramp rate hold limit value if desired and press [ENT] to return to the main run screen with the edited values active.

See Section 3.4.6, Table 10 for default control limits.

3.4.6.2 <2MODE>

 PURPOSE

To select the active automated pressure control mode.

 PRINCIPLE

See Section 3.4.6,  PRINCIPLE.

 OPERATION

The control mode selection display is:

The cursor is on the active control mode. Making a control mode selection activates the control mode, sets default control parameters for that control mode (see Section 3.4.6, Table 10) and returns to the main run screen. To set custom control parameters, press [SETUP], <6control>, < screen (see Section 3.4.6.1).

namic control mode selection, standard or hi volume

When <1dynamic> is selected, the type of dynamic control (standard or hi volume) must be specified (see Section 3.2.2.2).

fter selecting <1dynamic>, display is:

Select the desired dynamic control mode type. The default is <1standard>. Making a control mode selection activates the control mode, sets default control parameters for that control mode.

1dynamic 2static X1H

3monotonic 4ramp

1limits> from the MAIN RUN

Dynamic control X1H

1standard 2hi volume

3. OPERATION

Control mode setting is range specific. A change in control mode made while in one PPCH range does NOT affect the control mode setting in other ranges.

The current control mode is indicated by two characters in the middle of the bottom line of the MAIN RUN screen (<D> for standard dynamic, <d> for hi volume dynamic, <S> for static, <M> for monotonic, <R> for ramp, with <C> appended if custom control settings are in use). (See Section 3.1.1)

3.4.6.3 TURNING-OFF CUSTOM CONTROL PARAMETERS

To return to default pressure control parameters for the active range and control mode, select the control mode using [SETUP], <6control>, <2mode> (see Section 3.4.6). Selecting the mode automatically activates its default control parameters. This is a convenient way to after trying custom control settings.

put the PPCH into a known condition

3.4.7 <7DRV> (DRIVERS)

 PURPOSE

To control the output signals of PPCH’s 8 channel, 12 V external drivers.

 PRINCIPLE

PPCH external drivers are available to drive peripheral equipment in a PPCH system, for example, solenoid valves. The driver electrical connections are available from a rear panel connector.

See Section 7.1 for driver specifications and connector pin-outs.

 OPERATION

To access the driver control function press [SETUP], <7drv>. The display is:

External drivers: 1

2 3 4 5 6 7 8

Pressing the keypad numerical key driver number turns that driver ON and OFF with either a momentary or a toggled response. An active driver is indicated by <*> immediately following the driver number.

Pressing [ENT] while in the external drivers menu causes a menu to appear that allows selection of whether the driver actuation by selecting the driver number will be <1momentary> or <2toggle>.

PPCH™ OPERATION AND MAINTENANCE MANUAL

3.5 [SPECIAL]

 PURPOSE

[SPECIAL] accesses a menu of PPCH settings, adjustment and features that are less commonly used or

not normally used in regular operation.

 OPERATION

1AutoZ 2remote 3head

Press [SPECIAL] from the MAIN RUN screen to access the SPECIAL menu. The display is:

Some screens, such as the SPECIAL menu, go beyond the two lines provided by the display. This is indicated by a flashing arrow in the second line of the display. Press the cursor control keys to move the cursor to access the lines that are not visible or directly enter the number of the hidden menu choice if you know it.

SPECIAL menu choices include:

4reset 5pref 6Punit

7internal 8cal 9log

<1AutoZ> Manage AutoZero function for the active Q-RPT or utility sensor (see Section 3.5.1).

<2rem

ote> View and edit PPCH COM port (RS-232) and IEEE-488 interface settings (see Section 3.5.2). <3head> <4reset> <5pref>

Set HEAD function fluid and height unit of measure (see Section 3.5.3). Access PPCH’s various reset functions (see Section 3.5.4). View and set screen saver time, keypad sound frequency, unit ID number, time/date,

security protection level (see Section 3.5.5).

<6Punit> Customize

ntern> Access internal functions including control configurations, on-board barometer viewing,

<7i

the [UNIT] key pressure unit of selections (See section 3.5.6).

pump and reservoir functions (see Section 3.5.7).

<8cal>

View and adjust RPM3 utility sensor, Q-RPT and barometer calibration coefficients (see Sections 3.5.8 and 5.2).

<9log>

View the PPCH incident log (see Section 3.5.9).

3.5.1 <1AUTOZ>

 PURPOSE

To offset the PPCH system Q-RPTs relative to a reference value in order to compensate for possible changes in Q-RPT zero between full recalibrations.

 PRINCIPLE

AutoZ Purpose and Principle

The main component of the change over time of the PPCH Q-RPTs is change in zero or offset, independent of span. Offsetting or “rezeroing” PPCH Q-RPTs relative to a reference between recalibrations allows measurement uncertainty specifications to be maintained with less frequent full calibrations. The PPCH AutoZero function (AutoZ) provides full on-board support for the rezeroing process to simplify its application by the user.

The AutoZero function uses three values:

1. P

: The pressure value indicated by the AutoZ reference, the device that is acting as

std,0

the reference relative to which to offset the Q-RPT.

3. OPERATION

In absolute measurement mode, the pressure at which AutoZ is performed is normally atmospheric pressure and the P

In gauge measurement mode

value can be supplied by manual entry.

std,0

, P

is always zero (atmospheric pressure) which is

std,0

supplied by definition when the Q-RPT is vented to atmosphere.

2. P

: The pressure reading of the Q-RPT, with no AutoZ offset, at the time AutoZ is

u,0

performed.

3. P offset (P measurement mode (

The AutoZ function manages the determination, storage and application of P

and P

offset,G

) and the indication of the AutoZ reference (P

u,0

represents the change in zero of the Q-RPT relative to the AutoZ standard (P

offset

: The difference between the reading of the Q-RPT with no AutoZ

offset,A

) for gauge (G) or absolute

std,0

offset

= P

u,0

- P

std,0

offset

std,0

for

PPCH system Q-RPTs in absolute and gauge measurement modes.

When the Q-RPT is calibrated, P intervals using the AutoZ function. The most recent value of P

is set to zero. P

offset

is then redetermined at regular

offset

is applied to the Q-RPT

offset

reading to correct for change in zero over time. The AutoZ function can be turned ON and OFF. Table 11 summarizes the effect of AutoZ

ON and OFF for PPCH Q-RPTs in different measurement modes.

AutoZ in absolute measurement mode

Q-RPTs with the designation Axxx are intrinsically absolute. They have an evacuated and sealed reference. Axxx Q-RPTs can measure absolute pressure (difference fr om vacuum). All PPCH Q-RPTs are of the Axxx type.

In absolute measurement mode, the source of P

must be an absolute pressure, nominally

std,0

atmospheric pressure, with uncertainty significantly better than that of the Q-RPT that is being AutoZeroed. Given the high range of PPCH Q-RPTs, this is easily accomplished with a variety of digital barometers, including PPCH’s on-board barometer (see Section 3.5.7.2).

When using an Axxx (absolute) Q-RPT in

absolute measurement mode, with AutoZ ON,

absolute pressure is calculated as:

= Pu - P

abs

offset,A

In absolute measurement mode, execution of the AutoZ function to update the AutoZ value (P

AutoZ in gauge measurement mode, dynamic compensation for atmospheric pressure

), is initiated by the operator.

offset,A

PPCH Q-RPTs are intrinsically absolute but they can also be used in gauge measurement mode (difference from atmosphere) (see Section 3.3.3,  PRINCIPLE). Gauge measurement mode is achieved by subtracting the value of atmospheric pressure from the Q-RPT’s absolute reading using AutoZ and by dynamically compensating for changes in atmospheric pressure between opportunities for AutoZ to execute (see Section 3.2.4).

In gauge measurement mode, the value of P

is always zero gauge pressure. Zero gauge

std,0

pressure, by definition, is applied to the Q-RPT when it is vented to atmosphere. In gauge measurement mode, the AutoZ routine is run automatically whenever the PPCH is in the vented condition. This assures regular automated updating of the P

offset,G

value

corresponding to atmospheric pressure. Gauge pressure is the measured absolute pressure,

, minus P

offset,G

gauge

= Pu - P

offset,G

When AutoZ is ON, dynamic compensation for atmospheric pressure is also applied to compensate for changes in atmospheric pressure between AutoZ updates (see Section 3.2.4). The measured gauge pressure is calculated using ΔP

= Pu - P

gauge

offset.G

to correct the value of P

atm

- ΔP

atm

offset.G

PPCH™ OPERATION AND MAINTENANCE MANUAL

In gauge measurement mode, execution of the AutoZ function to update the value of P occurs automatically whenever PPCH is vented. Updating ΔP

occurs automatically

atm

atm,0

continuously during unvented operation.

Take care to consider fluid heads in gauge mode operation. The fluid head when vented may

be different from the fluid head at other pressures due to the height of the reservoir to which the Q-RPT is connected when vented (see Section 3.3.7,  PRINCIPLE).

AutoZ ON/OFF

The AutoZ function can be turned ON and OFF, separately for gauge and absolute measurement modes. Table 11 summarizes the effect of AutoZ ON and OFF for PPCH Q-RPTs in absolute and gauge measurement modes.

Table 11. AutoZ ON and OFF

MEASUREMENT

MODE

Absolute

Gauge

AutoZ

STATUS

ON YES

OFF NO

ON YES

OFF

offset

APPLIED

YES

ΔP

atm

APPLIED

Not Applicable

AutoZ

ROUTINE

RUNS

When initiated

by operator Not available Automatically

when PPCH in

VENT condition

Recommendations for the Use of the AutoZ Function

The AutoZ function provides a powerful and easy to use tool for improving the stability over time of PPCH internal and external Q-RPTs and maximizing the recalibration interval by compensating for change in zero between full recalibrations. The following simple recommendations will help assure that you use this feature to best advantage.

In gauge measurement mode: Always leave AutoZ ON when operating. In absolute measurement mode: Always leave AutoZ ON when operating if the AutoZ routine

has been run regularly using a valid Z

reference.

offset

In absolute measurement mode: Run AutoZ at least every 30 days or when RPM4 has been

exposed to temperature changes exceeding 15 ºC (36 ºF).

In absolute measurement mode: Run AutoZ only when a reference whose measurement

uncertainty is known to be significantly better than that of the Q-RPT to be AutoZeroed is available. Keep range ratios in mind when comparing uncertainty. A ± 0.1 % FS barometer is roughly 100 times better than a ± 0.01 % 100 MPa (15 000 psi) Q-RPT because the QRPT/barometer pressure range ratio is 1000:1.

In absolute measurement mode: Allow the PPCH to stabilize at atmospheric pressure and

ambient temperature for 10 to 15 minutes before running AutoZ.

In absolute measurement mode: Take care to properly consider fluid heads on the

Q-RPTs and the AutoZ reference.

 OPERATION

The AutoZ function and values are Q-RPT AND measurement mode (absolute, gauge)

specific.

3. OPERATION

When AutoZ is run for an external Q-RPT in an RPM4, the PPCH causes the RPM4 to run its own AutoZero routine. The RPM4 Q-RPT is then AutoZeroed as if it had been AutoZeroed independently of the PPCH.

To access the PPCH AutoZ function menu press [SPECIAL], <1AutoZ>. The display is:

1. Active Q-RPT designator.

2. Indication of active measurement mode (<abs> for absolute, <gage> for gauge).

3. Indication of whether AutoZ is currently ON or OFF for this Q-RPT and measurement mode.

1off 2view IH

3edit 4run abs ON

Select <1off> (or <1on>) to change the AutoZ status for the current Q-RPT and measurement mode from ON to OFF or vice versa.

AutoZ ON is indicated by a <z> in the MAIN RUN screen, top line, fourth character from the

right. When AutoZ is OFF, the character is blank.

Select <2view> to view the current value of P

for the active Q-RPT and measurement

offset

mode.

offset

Select <3edit> to edit the value of P

should be zero for Axxx Q-RPTs when the PPCH is new or has just been calibrated.

offset

should be roughly equal to atmospheric pressure for a PPCH Q-RPT in gauge mode.

for the active Q-RPT and measurement mode

offset

(see Section 3.5.1.1).

The value of P

operation, the value of P

is always displayed and entered in Pascal (Pa). Normally, in day to day

offset

is changed by running AutoZ (see Section 3.5.1.2), not direct editing.

offset

Select <4run> to run the AutoZ routine which determines and activates P (see Section 3.5.1.2). <4run> is only applicable to absolute measurement mode. AutoZ is run automatically without operator intervention in gauge measurement mode whenever PPCH is in the VENT condition (see Section 3.2.4).

3.5.1.1 EDIT AUTOZ

The edit AutoZ function should be used with great caution as entering inappropriate values and turning ON AutoZ may result in out of tolerance measurements. In normal day to day operation, the value of the AutoZ offset, P should be changed using the run AutoZ function (seen Section 3.5.1.2) in absolute measurement mode or automatically in gauge modes.

Before editing P

, see Section 3.5.1,  PRINCIPLE.

offset

relative to P

offset

std,0

offset

PPCH™ OPERATION AND MAINTENANCE MANUAL

To edit the current P

value for the active Q-RPT and measurement mode,

offset

press [SPECIAL], <1AutoZ>, <3edit>. The display is:

1. <Abs> for absolute, <Gage> for gauge.

2. Active Q-RPT for which P

3. Edit field for value of P

Edit P

as desired and press [ENT] to activate the new value. Press [ESC] to

offset

is being viewed.

offset

Poffset, Abs IH

8.4 Pa

abandon changes.

The value of P

is always displayed and entered in Pascal (Pa).

offset

3.5.1.2 RUN AUTOZ

Run AutoZ applies only to PPCH Q-RPTs in absolute measurement mode. In gauge measurement modes, AutoZ is run automatically whenever the PPCH is in the VENT condition.

Run AutoZ is the function by which the current RPT reading is compared to a reference, P The value of P

, at atmospheric pressure to determine a new value of P

std,0

is then used by AutoZ to automatically correct the RPT for

offset

possible change in zero (see Section 3.5.1,  PRINCIPLE).

offset

Allow the PPCH Q-RPT to stabilize at atmospheric pressure and ambient temperature for 10 to 15 minutes before running AutoZ. The stabilization period is not necessary for a utility sensor.

To access run AutoZ, press [SPECIAL], <1AutoZ>, <4run>. If the current measurement mode is gauge, a message indicating that AutoZ

cannot be run manually in gauge mode is displayed.

If the current measurement mode is absolute and a Q-RPT is active (not a

utility sensor), the display is:

1. Real time reading (without head correction), pressure unit of measure and measurement mode of the active Q-RPT.

2. Active Q-RPT position designator.

3. Entry field for the value of P pressure unit of measure.

. in the current

std,0

Enter the value of the AutoZ reference (P

std,0

0.0967 MPa a HI

Pstd,0:0.00000

) in the same unit of measure as the top line display and press [ENT]. PPCH logs the readings and calculates a new AutoZ P

Press [ENT] to activate the new value of

offset

new AutoZ reference (P

value. The next display is:

offset

or [ESC] to start over with entry of a

) value.

std,0

Old P

New P

offset

: 0.0 Pa

: 675 Pa

3. OPERATION

While the value of P

value of P

is always in Pascal (Pa). .

offset

If running AutoZ results in a value of P

is entered in the current pressure unit of measure, the

std,0

that is greater than ± 0.01 % FS of

offset

the span of the Q-RPT that is being AutoZeroed, the Q-RPT and/or the reference used as the source of Pstd,0 may be out of tolerance or the AutoZ process may have been faulty. Before activating a new P

greater than ± 0.01 % FS of the active Q-RPT,

offset

check to be sure that both the Q-RPT and the reference were in good working order, properly vented to stable atmospheric pressure, with the same fluid heads and reading in the same pressure units when AutoZ was run.

When running AutoZ, if a HEAD correction is currently active (see Section

3.3.7),it is momentarily disabled to avoid “zeroing out” the head value.

If the current measurement mode is absolute and a utility sensor is active

(not a Q-RPT), the display is:

1. ActiveRPT designator.

2. Current measurement mode (absolute).

3. Selection of source of P to AutoZ.

reference to which

std,0

AutoZ Hi abs by:

1baro 2entry

The default selection is <1baro>. With this selection, when AutoZ is ON, the PPCH on-board barometer (see Section 3.5.7.2) is used as the AutoZ reference

) and AutoZ runs automatically whenever PPCH is vented. The AutoZ

std,0

function should be ON with <1baro> selected unless there is a malfunction of the on-board barometer.

Select <2entry> to run AutoZ manually by entering the value of AutoZ reference

) as described in “If the current measurement mode is absolute and a

std,0

Q-RPT is active” above.

3.5.2 <2REMOTE>

 PURPOSE

To configure the PPCH COM1, COM2 and IEEE-488 (GPIB) communication ports. To test COM1 and COM2 communications. To select remote programming communications format.

 PRINCIPLE

The PPCH has two RS-232 communications ports referred to as COM1 and COM2 and a single IEEE-488 (GPIB) port. COM1 or the IEEE-488 port is for communicating with a host computer (see Section 4), and COM2 is reserved for communicating with an external device (i.e. an RPM4, a multimeter, etc.). [SPECIAL], <2remote>.

PPCH has two remote communications formats, classic and enhanced. Which of these is active can be selected.

These ports’ settings can be viewed and changed using

A self test is supplied for RS-232 communications. The self test allows verification that the PPCH RS232 ports (COM1 and COM2) are operating properly and that a valid interface cable is being used.

PPCH™ OPERATION AND MAINTENANCE MANUAL

 OPERATION

To access the communications settings, press [SPECIAL], <2Remote>. Choice include:

<1COM1> To view and edit COM1 settings (see Section 3.5.2.1.). <2COM2>

3IEEE> To view and edit IEEE-488 settings (see Section 3.5.2.2).

<4form

<5RS232test>

at> To select remote programming command format (see Section 3.5.2.3).

To view and edit COM2 settings (see Section 3.5.2.1.).

To run the COM1 and COM2 communications test (see Section 3.5.2.4).

3.5.2.1 <1COM1, 2COM2>

The COMx ports can be set for specific communications settings. The settings are baud rate, parity, data bits and stop bits. The available options are:

Baud 300, 600, 1 200, 2 400, 4 800, 9 600, 19 200, 28 800, 38 400 Parity NONE, ODD or EVEN Length 7 or 8 Stop Bit 1 or 2

The default is <2 400, E, 7,1> for both COM1 and COM2. The user can also specify one or two termination characters as well as define

these characters. These are referred to as “Term1” and “Term2”. These define the characters that mark the end of commands that are sent to the PPCH. The PPCH looks for an ASCII(13) (carriage return) to terminate a received command but responds with both and ASCII(13) (carriage return) and an ASCII(10) (line feed). There are no other options.

3.5.2.2 <3IEEE-488>

The IEEE-488 port’s primary address can be set from 1 to 31 in this screen. The factory default value is 10. Secondary addressing is not used or supported. This address must not conflict with the address of any other device on the same IEEE-488 bus.

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

3.5.2.3 <4FORMAT>

The PPCH has two different syntax formats available for the remote program commands. The classic format is compatible with previous PPC products and is the default format. The enhanced format follows the syntax, format, and status reporting features of IEEE Std 488.2. The details of each are covered in Section 4.3.

[SPECIAL], <2rem syntax to be selected. The cursor is on the active format. Select <1classic> to activate the classic command format or <2enhanced> for the enhanced format.

Selecting a format resets the IEEE-488 interface and puts it into an idle state.

ote>, <4format> allows the remote program command

3. OPERATION

3.5.2.4 <5RS232 SELF-TEST>

The RS232 self-test is provided to check the PPCH COM ports and the interface cable independently of an external device or computer.

If you are having difficulty communicating with PPCH from a host computer

using RS232, the RS232 self test can help establish that the PPCH COM1 port

you are trying to communicate with and the interface cable you are using are good. To run a self test of the RS232 ports (COM1 and COM2), press [SPECIAL],

<2remote>, <5RS232test>. The display prompts you to connect COM1 to COM2 using a standard pin-to-pin

DB-9F to DB-9M RS232 cable (see Section 4.2.1.1).

the cable has been installed, press [ENT] to run the self-test. The test is first

Once executed in the COM1→COM2 direction and then in the COM2→COM1 direction.

If the COM1→COM2 test passes: <PASSED> displays briefly and the test

proceeds to COM2→COM1.

If COM2→COM1 passes: <PASSED> is displayed briefly followed

by the conclusion, <The RS232 test

has PASSED>.

If a test fails: Execution is suspended until [ENT] is

pressed.

The PPCH RS232 test can fail for three reasons:

1. The RS232 cable being used is incorrect (see Section 4.2.1.1 for

information on the correct cable).

2. COM1 and COM2 do NOT have the same serial communications settings

and therefore cannot communicate together (see Section 3.5.2.1 to set the COM ports).

3. COM1 or COM2 is defective.

The reason for failed communications is almost always a cable or incorrect RS232 interface settings. Be sure that these are correct before concluding that a COM port is defective.

3.5.3 <3HEAD>

 PURPOSE

To view or change the properties of the HEAD function (see Section 3.3.7) including the unit of measure of length for head height entry and the test fluid type and species for calculations.

 OPERATION

From the MAIN RUN screen, pressure [SPECIAL], <3Head>. Select the desired height unit of measure and press [ENT].

density

Select <1gas> or <2liqud> depending on the pressurized medium between the PPCH and the height at which pressure is to be calculated. Select the gas or liquid species. The liquid selection <3User>, is to create a custom liquid with a user entered density.

Use [HEAD] to set a fluid head height if desired (see Section 3.3.7).

PPCH™ OPERATION AND MAINTENANCE MANUAL

3.5.4 <4RESET>

 PURPOSE

To reset various PPCH settings to default or factory values.

 PRINCIPLE

PPCH stores its user definable settings in non-volatile memory. The reset menu allows the user to selectively or completely reset these settings to factory defaults. This clears out any settings that the user has made, and should be used only to restore the PPCH to a known state. PPCH goes through its power up sequence after any type of reset is executed.

PPCH reset functions will change current settings to factory defaults. These may include settings vital to PPCH operation and affecting the calibration of the quartz reference pressure transducers (Q-RPTs). Reset functions should only be used by qualified personnel with knowledge of reset consequences. Reset functions should not be used experimentally.

 OPERATION

To access the RESET menu, press [SPECIAL], <4reset>. The display is:

1sets 2units 3ATest

4cal 5all

RESET menu choices include:

<1set> to reset general system operating parameters (see Section 3.5.4.1). <2units> <3ATest> <4cal>

to reset unit of measure functions (see Section 3.5.4.2). to reset AutoTest parameters and clear the AutoTest data log (see Section 3.5.4.3). to reset internal calibration coefficients and modes (see Section

3.5.4.4).

<5all> to reset all settings except ID and security password to factory default values

(see Section

3.5.4.5).

3.5.4.1 <1SETS>

 PURPOSE

Sets most general operating parameters back to default values. Does not affect calibration coefficients, remote interfaces or AutoRange ranges. The Reset – Sets resets are itemized in Table 12.

3. OPERATION

Table 12. Reset – Sets

RESET RESULT SEE SECTION

[UNIT] Returns pressure unit of measure to first of six

[MODE] Returns measurement mode to the natural Q-RPT

[RANGE] Hi Q-RPT or utility sensor default range. 3.3.1 [HEAD] 0 cm height and Nitrogen medium. 3.3.7 Control Mode Dynamic, standard 3.4.6 Control Limits Default values of Hi RPT default range. 3.4.6.1 Upper Limit Default value of Hi RPT default range. 3.4.4 Resolution 0.001% FS of Hi RPT default range. 3.4.2 AutoZ AutoZ ON. Z Leak Check 15 second run time 3.3.9 Screen Saver 10 minutes to activation. 3.5.5.1 Key Sounds Medium 3.5.5.2 Volume

Determination

available.

mode.

value not affected. 3.5.1

offset

Return to default 3.5.7.1

3.3.2

3.3.3

3.5.4.2 <2UNITS>

 PURPOSE

Sets the six pressure units available under the UNIT function to the SI or US default selections depending on whether the PPCH has been factory set for SI or US (see Section 3.3.2).

Sets the user defined unit to 1.000/Pa (see Section

3.5.6).

3.5.4.3 <3ATEST>

 PURPOSE

• Resets Quick Test and Q-DUT Tests to default (see Section 3.3.6).

•

Clears AutoTest data log (see Section 3.4.5).

3.5.4.4 <4CAL>

 PURPOSE

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

Clears all user values affecting the calibration of Q-RPTs, utility sensor and the on-board barometer. Does not clear factory coefficients. The Reset – Cal resets are itemized in Table 13.

PPCH™ OPERATION AND MAINTENANCE MANUAL

RESET RESULT SEE SECTION

All Q-RPT user calibration coefficients

Q-RPT absolute mode ON. 5.3.5 Utility Sensor calibration

coefficients On-board barometer

calibration coefficients Calibration date Set all dates to 19800101. 5.3.7, 5.5, 5.4 AutoZ values All P

AutoZ function ON, all Q-RPTs, all measurement modes. 3.5.1

3.5.4.5 <5ALL>

Table 13. Reset – Cal

PA to zero, PM to 1. 5.3.1.1, 5.3.7

PA to zero, PM to 1. 5.5

PA to zero, PM to 1. 5.4

values to zero for absolute mode and

offset

101325 Pa for gauge modes.

3.5.1

The reset - all function clears and deletes large amounts of user defined information including critical calibration data.

 PURPOSE

Combines all resets in one global reset command that clears the entire user section of non-volatile memory returning PPCH to the “as delivered” condition except the ID function (see Section Section

3.5.5.5). The Reset – All resets are itemized in Table 14.

RESET RESULT SEE SECTION

Reset – Sets All the resets of Reset – Sets 3.5.4.1 Reset – Units All the resets of Reset – Units 3.5.4.2 Reset – Atest All the resets of Reset – Atest 3.5.4.3 Reset – Cal All the resets of Reset – Cal 3.5.4.4 Remote Interfaces COM1, COM2 and IEEE-R88 interfaces to

default settings. Remote Communications Remote command format to Classic. 3.5.2.3 Level (Security) Low. 3.5.5.5 Valve Config Return to factory valve opening points to

factory values.

3.5.5.4) and the security level password (see

Table 14. Reset – All

3.5.2

3.5.7.1

3.5.5 <5PREF>

 PURPOSE

To access a menu of PPCH operational preferences and functions.

 OPERATION

To access the PREF menu press [SPECIAL], <5pref>. The display is:

1ScrSvr 2sound 3time

4ID 5level

3. OPERATION

The PREF menu includes:

<1ScrSvr> View and change the screen saver activation time (see Section <2sound> View and change the key press sounds (see Section

3.5.5.2).

<3time> View and edit the internal time and date settings (see Section

3.5.5.1).

3.5.5.3).

<4ID> View the RPM3 serial number (SN) and view or edit the ID number (see

Section

<5level> View and set user security level and password (see Section

3.5.5.4).

3.5.5.5).

3.5.5.1 <1SCRSVR>

 PURPOSE

To adjust the idle time after which PPCH’s SCREEN SAVER activates.

 PRINCIPLE

PPCH has a SCREEN SAVER function which causes the display to dim after a front panel key is NOT pressed for a certain amount of time. The default screen saver time activates the screen saver after 10 minutes. The screen saver activation time can be adjusted by the user or screen saving can be completely eliminated.

Setting screen saver time to zero eliminates the SCREEN SAVER function so

that the display permanently remains at full brightness.

 OPERATION

To access the SCREEN SAVER function, press [SPECIAL], <5pref>, <1ScrSav>. Edit, in minutes, the idle time after which screen saver will activate

to dim the screen. Set the time to zero to eliminate the SCREEN SAVER function.

3.5.5.2 <2SOUND>

 PURPOSE

To adjust or suppress the PPCH valid key press sound.

 PRINCIPLE

PPCH provides audible feedback by a brief “beep” when a valid key press is made. The tone frequency of this beep may be selected from three choices or it may be completely suppressed. Invalid key presses are indicated by a descending two tone “blurp” which cannot be suppressed.

 OPERATION

To access the keypad sound adjustment function press [SPECIAL], <5pref>, <2sound>. Select between <2lo>, <3mid> or <4hi> to adjust the valid key press tone frequency. Select <1none> to suppress the valid key press tone.

The sound function only affects the valid key press tone. The invalid key press and other tones cannot be suppressed. See Section 3.1.5 for a complete listing of PPCH sounds.

PPCH™ OPERATION AND MAINTENANCE MANUAL

3.5.5.3 <3TIME>

 PURPOSE

To view and edit the PPCH internal time and date settings.

 OPERATION

To access the TIME function press [SPECIAL], <5pref>, <3time>. The display is:

Edit: 1time 2date

08:32:11 am 20020925

Select <1time> to edit the time. Edit hours, then minutes, then am/pm by pressing [ENT] after each entry. Seconds go to zero when minutes are entered. This can be used to synchronize the time with a time standard.

Select <2date> to edit the date. The date must be specified in YYYYMMDD format.

The PPCH date and time are set to United States Mountain Standard Time in the final test and inspection process at the factory. If desired, use the TIME and DATE functions to set your local time and date.

3.5.5.4 <4ID>

 PURPOSE

To view or edit the PPCH user ID and to view the PPCH serial number.

 OPERATION

To access the ID function press [SPECIAL] and select <5pref>, <2ID>. Select <1view> to view the current ID.

Select <2edit> to edit the ID. The ID has twelve characters. When the edit screen is opened, the cursor is on

the first character. Numerical values can be entered directly from the keypad. In addition, the cursor control keys can be used to toggle through a list of available alpha numeric characters. Holding the key slews through the characters. Character order going up is: blank space, symbols, lower case letters, upper case letters, numbers. After selecting a character, press [ENT] to activate it and move to the next character field.

When a character is selected the cursor moves to the next character. To leave a blank character, press [ENT] with the field for that character blank. Use this for the trailing characters if the ID being entered is less than twelve characters.

After the last of the twelve characters has been entered, the <Save ID?> option is offered. Select <1no> to return to the ID edit screen. Select <2yes> to save the edited ID.

The ID can be set remotely from a computer which is quite a bit more convenient than entering characters from the keyboard (see Section 4.4, ID command). The ID is not cleared or reset by any RESET function (see Section

3.5.4).

3. OPERATION

3.5.5.5 <5LEVEL> (SECURITY)

 PURPOSE

To set user protection levels to restrict access to certain functions and to edit the password required for changing user levels.

 PRINCIPLE

PPCH’s front panel user interface provides the means to access all PPCH user defined data, settings and functions including calibration data. Inadvertent, uninformed or unauthorized altering or deleting of data, settings and functions could require extensive reconfiguration by the user and might cause invalid readings and behavior. For these reasons, depending upon the application in which PPCH is being used, it may be desirable to restrict access to certain functions for certain users. The user level function provides a means of restricting access to certain functions. Four different levels of security are available.

Access to changing security levels can be left open, or be protected by a password.

Security Levels

The security levels are structured to support typical operating environments as follows:

None This level is intended for use only by the system manager and/or

calibration facility. It allows access and editing in all areas including critical metrological information.

Low Low security is designed to protect the specific metrological

information and SYSTEM DIAGNOSTIC AND MAINTENANCE functions of the system against accidental alteration. It is intended for an advanced operator performing many different tasks. Low security is the default user level setting.

Medium Medium security is designed to protect specific metrological

information in the system and to assure that the PPCH is operated using consistent operational parameters.

High High security is designed to protect all operating parameters. It is

intended to minimize operator choices, for example to perform repeated identical calibrations under consistent conditions.

PPCH is delivered with the security level set at low to avoid inadvertent altering of critical internal settings but with access to changing security levels unrestricted. It is recommended that the low security level be maintained at all times. If there is a risk of unauthorized changing of the security level, changing authority should be password protected (see  OPERATION of this section).

The security levels are structured to support typical levels of operation as shown in Table 15. Specifically, the security levels prevent execution of the functions accessed by the key strokes marked by “•”:

PPCH™ OPERATION AND MAINTENANCE MANUAL

FUNCTION LOW MEDIUM HIGH

[RANGE]

[UNIT]

[MODE]

[AutoRange]

[RPT]

[AutoTest], <2QDUT>

[AutoTest], <1Quick>, <Run current Quick ATest: 2no>

[HEAD]

[PRIME]

[LEAK CK]

[SETUP]

[SETUP], <1range>

[SETUP], <2res>

[SETUP], <4UL>

[SETUP], <6control>

[SETUP], <7drv>

[SPECIAL]

[SPECIAL], <1AutoZ>

[SPECIAL], <1AutoZ>, <1on/1off>

[SPECIAL], <1AutoZ>, <3edit>

[SPECIAL], <2remote>

[SPECIAL], <2remote>, make changes

[SPECIAL], <3head>

[SPECIAL], <4reset>

[SPECIAL], <4reset>, <4cal>

[SPECIAL], <4reset>, <5all>

[SPECIAL], <5pref>, <1ScrSvr>

[SPECIAL], <5pref>, <2sound>

[SPECIAL], <5pref>, <3time>

[SPECIAL], <5pref>, <3time>, make changes

SPECIAL], <5pref>, <4ID>, <2edit>

[SPECIAL], <6Punit>

[SPECIAL], <7internal>

[SPECIAL], <7internal>, <1config>, <1volume>

[SPECIAL], <7internal>, <1config>, <2valve>

[SPECIAL], <8cal>

[SPECIAL], <8cal>, <2edit> under any selection

[SPECIAL], <9log>, view

[SPECIAL], <9log>, clear log

Remote communications disabled

“•” indicates the function/menu is NOT accessible.

Table 15. Security levels

•

• •

•

• •

•

• •

• • •

•

• •

• • •

• •

• • •

• •

•

• •

• • •

•

• • •

•

3. OPERATION

 OPERATION

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

To access the LEVEL function press [SPECIAL], <5pref>, <5level>. The display is:

Selecting <1change user level> brings up the restriction menu:

1change user level

2edit password

Restrictions: 1none

2low 3medium 4high

The cursor is on the current restriction level. Select a different level or or [ESC] back to the MAIN RUN screen.

If no password is active, selecting <2edit password> displays the user

password and allows it to be edited.

Password: pppppp

0 disables password

Once a password has been entered, the user level cannot be changed without reentering the password.

Passwords can be up to six numbers in length and cannot start with a zero. If <0> is entered, the password is made inactive and the user will not be required to enter a password to access the user level menu. This condition, with a security level of <2low>, is the factory default.

If there is an active password, the PPCH password entry screen appears. The user must enter the user defined password or the factory secondary

PPCH SNnnnn-xx

Password: pppppp

password to proceed further:

The first field, <nnnn>, is the serial number of the PPCH, followed by a second field, <xx>, that represents the number of times that a secondary password has been used. The second field, <xx>, increments each time a secondary password is used. The third field, <pppppp> is for user entry of the normal password.

The factory secondary password is available in case the user’s password has been misplaced or forgotten. It can be obtained by contacting a DHI Authorized Service Center (see Table 31). The factory secondary

password is different for all

PPCH’s and changes each time it is used.

3.5.6 <6PUNIT>

 PURPOSE

To customize the selection of pressure units of measure that are available in the [UNIT] key menu.

PPCH™ OPERATION AND MAINTENANCE MANUAL

 PRINCIPLE

The [UNIT] function key makes available a choice of six default pressure units (US or SI units depending on whether the PPCH has been factory set as US or SI) (see Section 3.3.2). PPCH also supports many commonly used units other than those included in the These units can be made available for active selection by customizing the UNIT function using [SPECIAL], <6PresU>. This allows PPCH to offer a very wide selection of units while simplifying day to day operation. The typical user customizes the [UNIT] function key to support his/her six most commonly used units.

 OPERATION

To customize the [UNIT] function key, from the MAIN RUN screen press [SPECIAL], <6PresU>. The display is:

default set up.

1. Entry field to specify which unit position (1 – 6) of the [UNIT] function key menu is to be changed.

Set up unit #6

Enter the number of the unit position that you would like to change. The display becomes:

Unit#6

1SI 2other 3user

Select the desired pressure unit category (SI units include units based on SI such as mmHg), then select the desired unit from the unit menu.

The units of measure available are listed in Table 16.

Table 16. UNIT function - available units of measure

<1SI> <2OTHER> <3USER>

<1Pa>

<2hPa>

<3kPa>

<4MPa>

<5mbar>

<6bar>

<7mmHg>

<8mmWa>

<1psi>

<2psf> <3inHg> <4inWa>

<5kcm2>

<6Torr>

<7mTor>

If <3user> is selected, the user unit must be defined. The display is:

Define user unit:

1. Entry field.

1.000000 unit/Pa

Enter the number of user units per Pascal (Pa) in the entry field. Pressing [ENT] defines the user unit and returns to the <Set up unit #n> screen.

The user defined unit label can be customized to any alphanumeric, four character label

using the remote command “UDU” (see Section 4.4).

See Section 7.2.1 for the pressure unit conversion factors used by PPCH.

DH Instruments PPCH - V1.01, PPCH Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual