DH Instruments PPCK PLUS, PPCK+ Operation And Maintenance Manual

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PPCK+™

High Pressure Controller/Calibrator

Operation and Maintenance Manual

PPCK+™ 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.

transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments, Inc. 4765 E. 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 does not constitute an endorsement by DH Instruments of that product. This manual was originally composed in English and was subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the English version and other language versions, the English version predominates.

DH Instruments, DH, DHI, AutoZ, PPC, PPC2+, PPCK+, Thermal Pressure Control (TPC) and AutoZ are trademarks, registered and otherwise of DH Instruments, Inc.

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.

Document No. 550118a-01 20011213

Printed in the USA

PPCK+™ Operation and Maintenance Manual

AABBLLEE

TABLE OF CONTENTS................................................................................ i

TABLES................................................................................................... iv

FIGURES .................................................................................................. v

ABOUT THIS MANUAL .............................................................................. vi

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

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

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

2. INSTALLATION ..................................................................................... 7

2.1 UNPACKING AND INSPECTION..............................................................................................................7

2.2 SITE REQUIREMENTS..............................................................................................................................8

2.3 INITIAL SETUP..........................................................................................................................................8

2.4 POWER-UP AND VERIFICATION...........................................................................................................14

2.5 SHORT TERM STORAGE.......................................................................................................................15

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

1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS............................................................................................2

1.2.2.1 REFERENCE PRESSURE TRANSDUCER (RPT) SPECIFICATIONS.............................................3

1.2.2.2 ON-BOARD BAROMETER................................................................................................................4

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

2.1.1 REMOVING FROM PACKAGING......................................................................................................................7

2.1.2 INSPECTING CONTENTS.................................................................................................................................7

2.3.1 PREPARING FOR OPERATION........................................................................................................................8

2.3.2 FRONT AND REAR PANELS............................................................................................................................9

2.3.2.1 FRONT PANEL..................................................................................................................................9

2.3.2.2 REAR PANEL ASSEMBLY..............................................................................................................10

2.3.3 POWER CONNECTION...................................................................................................................................10

2.3.4 CONNECTING THE HIGH PRESSURE SUPPLY (SUPPLY PORT) ..............................................................11

2.3.5 CONNECTING TO THE DEVICE UNDER TEST (TEST PORT)......................................................................11

2.3.6 CONNECTING THE DRIVE PRESSURE SUPPLY (DRIVE IN PORT) ...........................................................12

2.3.7 DRIVE OUT PORT...........................................................................................................................................12

2.3.8 VENT PORT.....................................................................................................................................................13

2.3.9 THE DRAIN PORT...........................................................................................................................................13

2.3.10 THE ATM PORT (BAROMETER) ....................................................................................................................13

2.4.1 SWITCH POWER ON.......................................................................................................................................14

2.4.2 CHECK PROPER PRESSURE MEASUREMENT OPERATION.....................................................................14

2.4.2.1 CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT ....................................................14

2.4.2.2 CHECKING GAUGE MODE PRESSURE MEASUREMENT...........................................................14

2.4.3 LEAK CHECK..................................................................................................................................................15

2.4.4 CHECK PROPER PRESSURE CONTROL OPERATION...............................................................................15

NTTEE

NTTSS

PPCK+™ Operation and Maintenance Manual

3. OPERATION ....................................................................................... 17

3.1 GENERAL/MANUAL OPERATION .........................................................................................................17

3.2 DIRECT FUNCTION KEYS......................................................................................................................28

3.3 SETUP MENU KEY .................................................................................................................................46

3.4 SPECIAL MENU KEY..............................................................................................................................47

3.1.1 MAIN RUN SCREEN........................................................................................................................................17

3.1.2 GENERAL OPERATING PRINCIPLES ...........................................................................................................18

3.1.2.1 KEYPAD LAYOUT AND PROTOCOL..............................................................................................18

3.1.2.2 MANUAL PRESSURE CONTROL KEYS........................................................................................19

3.1.2.3 PRESSURE CONTROL OPERATING PRINCIPLES ......................................................................20

3.1.2.4 AUTOMATED PRESSURE CONTROL MODES.............................................................................22

3.1.2.5 PRESSURE READY /NOT READY.................................................................................................25

3.1.2.6 MULTIPLE PRESSURE RANGES...................................................................................................27

3.1.2.7 DIRECT FUNCTION KEYS SUMMARY ..........................................................................................28

3.2.1 [RANGE]...........................................................................................................................................................28

3.2.1.1 RANGE SPECIFIC FUNCTIONS AND SETTINGS .........................................................................30

3.2.2 [UNIT]...............................................................................................................................................................31

3.2.3 [CONTROL]......................................................................................................................................................32

3.2.3.1 SYSTEM DEFAULT CONTROL PARAMETERS.............................................................................34

3.2.3.2 EXECUTING AUTOMATED PRESSURE CONTROL COMMANDS...............................................34

3.2.4 [UL] (UPPER LIMIT) ........................................................................................................................................34

3.2.4.1 OVERPRESSURE FUNCTION........................................................................................................35

3.2.5 [SEQ] SEQUENCE...........................................................................................................................................35

3.2.6 [CUSTOM CONTROL].....................................................................................................................................36

3.2.6.1 TURNING-OFF CUSTOM CONTROL PARAMETERS....................................................................37

3.2.7 [HEAD].............................................................................................................................................................38

3.2.8 [LEAK CHECK]................................................................................................................................................39

3.2.9 [RES] (RESOLUTION).....................................................................................................................................41

3.2.10 [SET P] (SETTING PRESSURE AUTOMATICALLY)......................................................................................42

3.2.10.1 AUTOMATED PRESSURE COMMANDS FOR ZERO PRESSURE...............................................44

3.2.11 [←] AND [→] (JOG PRESSURE SET POINT) ................................................................................................45

3.3.1 SEQUENCE......................................................................................................................................................46

3.3.2 DRIVERS..........................................................................................................................................................46

3.4.1 AUTOZ..............................................................................................................................................................47

3.4.1.1 VIEW AUTOZ...................................................................................................................................50

3.4.1.2 EDIT AUTOZ....................................................................................................................................51

3.4.1.3 RUN AUTOZ....................................................................................................................................51

3.4.2 HEAD................................................................................................................................................................54

3.4.3 PresU ...............................................................................................................................................................55

3.4.4 INTERNAL........................................................................................................................................................56

3.4.4.1 CONFIG...........................................................................................................................................57

3.4.4.2 CAL..................................................................................................................................................58

3.4.4.3 REMOTE..........................................................................................................................................59

3.4.4.4 TIME.................................................................................................................................................60

3.4.4.5 RESET.............................................................................................................................................61

3.4.4.6 LEVEL..............................................................................................................................................63

3.4.4.7 ATM..................................................................................................................................................66

3.4.4.8 SCRSAV ..........................................................................................................................................67

3.4.4.9 LOG..................................................................................................................................................67

4. REMOTE OPERATION ......................................................................... 69

4.1 OVERVIEW..............................................................................................................................................69

4.2 INTERFACING.........................................................................................................................................69

4.2.1 RS232 INTERFACE.........................................................................................................................................69

4.2.1.1 COM1...............................................................................................................................................69

4.2.1.2 IEEE-488..........................................................................................................................................70

4.2.1.3 COM2...............................................................................................................................................70

PPCK+™ Operation and Maintenance Manual

4.3 PROGRAMMING FORMATS...................................................................................................................71

4.3.1 CLASSIC PROGRAM MESSAGE FORMAT...................................................................................................71

4.3.2 ENHANCED PROGRAM MESSAGE FORMAT...............................................................................................71

4.3.2.1 ENHANCED PROGRAM MESSAGE USING THE COMMAND TYPE............................................72

4.3.2.2 ENHANCED PROGRAM MESSAGE USING THE QUERY TYPE..................................................72

4.4 COMMANDS............................................................................................................................................73

4.4.1 PROGRAM MESSAGES..................................................................................................................................73

4.4.2 ERROR MESSAGES .......................................................................................................................................75

4.4.3 PROGRAM MESSAGE DESCRIPTION OVERVIEW......................................................................................76

4.4.4 PROGRAM MESSAGE DESCRIPTIONS........................................................................................................77

4.5 STATUS REPORTING SYSTEM...........................................................................................................107

4.5.1 ERROR QUEUE.............................................................................................................................................107

4.5.2 STATUS BYTE REGISTER............................................................................................................................108

4.5.3 STANDARD EVENT REGISTER...................................................................................................................110

4.5.4 READY STATUS REGISTER.........................................................................................................................111

4.6 IEEE STD. 488.2 COMMON AND STATUS PROGRAM MESSAGES..................................................111

4.6.1 PROGRAM MESSAGE DESCRIPTIONS......................................................................................................112

5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION ...........................115

5.1 OVERVIEW............................................................................................................................................115

5.2 CALIBRATION OF REFERENCE PRESSURE TRANSDUCERS.........................................................116

5.2.1 PRINCIPLE.....................................................................................................................................................116

5.2.1.1 PA AND PM COEFFICIENTS........................................................................................................117

5.2.1.2 SETTING ZNATERR......................................................................................................................117

5.2.1.3 ORDER OF OPERATIONS............................................................................................................118

5.2.1.4 AS RECEIVED/AS LEFT DATA.....................................................................................................118

5.2.2 EQUIPMENT REQUIRED ..............................................................................................................................119

5.2.3 SET-UP AND PREPARATION.......................................................................................................................120

5.2.4 RPT CALIBRATION USING CALTOOL FOR RPTs SOFTWARE................................................................120

5.2.5 EDITING AND VIEWING RPT CALIBRATION INFORMATION....................................................................120

5.2.6 SETTING ZNATERR......................................................................................................................................122

5.2.7 RPT CALIBRATION/ADJUSTMENT WITHOUT CALTOOL FOR RPTs SOFTWARE.................................122

5.3 ADJUSTMENT OF ON-BOARD BAROMETER.....................................................................................124

5.4 DRAIN PURGE ......................................................................................................................................124

5.5 RELOADING EMBEDDED SOFTWARE INTO FLASH MEMORY........................................................125

5.6 SUBASSEMBLY DESCRIPTION AND LOCATION ..............................................................................126

5.6.1 LOW PRESSURE PNEUMATIC MODULE....................................................................................................126

5.6.2 HIGH PRESSURE PNEUMATIC MODULE...................................................................................................126

5.6.3 DRIVER BOARD............................................................................................................................................127

5.6.4 POWER SUPPLIES .......................................................................................................................................128

5.6.5 ON-BOARD BAROMETER............................................................................................................................128

5.6.6 MICRO CARD.................................................................................................................................................128

5.6.7 THERMAL PRESSURE CONTROL UNIT (TPCU)........................................................................................128

5.6.8 REFERENCE PRESSURE TRANSDUCER (RPT)........................................................................................128

6. TROUBLESHOOTING .........................................................................129

7. APPENDIX .........................................................................................135

7.1 DRIVERS ...............................................................................................................................................135

7.2 UNIT CONVERSION..............................................................................................................................137

7.2.1 PRESSURE....................................................................................................................................................137

7.3 GLOSSARY...........................................................................................................................................138

7.4 WARRANTY STATEMENT....................................................................................................................140

PPCK+™ Operation and Maintenance Manual

AABBLLEES

Table 1. Model Designations and Ranges

Table 2. Default Pressure Control Parameters .......................................................................................5

Table 3. PPCK+ Packing List .................................................................................................................. 7

Table 4. Static and Dynamic Pressure Control Modes Summary.........................................................22

Table 5. PPCK+ Range Identification Summary...................................................................................27

Table 6. Summary of PPCK+ Direct Function Key Operation...............................................................29

Table 7. Default Pressure Control Parameters .....................................................................................34

Table 8. UNIT Function - Available Units..............................................................................................55

Table 9. Security Levels........................................................................................................................65

Table 10. Pin Designations and Connections .........................................................................................70

Table 11. List of PPCK+ COM2 DB-9M Pin Designations......................................................................70

Table 12. Program Message List.............................................................................................................73

Table 13. Error #’s and Descriptions.......................................................................................................75

Table 14. 8 Bit Status Byte Register......................................................................................................108

Table 15. 8 Bit Standard Event Register...............................................................................................110

Table 16. 8 Bit Ready Status Register..................................................................................................111

Table 17. Program Message List...........................................................................................................111

Table 18. Troubleshooting Guide..........................................................................................................129

Table 19. Driver Output .........................................................................................................................135

Table 20. External Drivers.....................................................................................................................136

Table 21. Conversion Coefficients ........................................................................................................137

Table 22. DHI Authorized Service Providers.........................................................................................141

..............................................................................................3

PPCK+™ Operation and Maintenance Manual

Figure 1. Front Panel................................................................................................................................9

Figure 2. Rear Panel Assembly..............................................................................................................10

Figure 3. Keypad Layout.........................................................................................................................18

Figure 4. Manual Pressure Control Keys................................................................................................19

Figure 5. Pneumatic Schematic..............................................................................................................21

Figure 6. Static Pressure Control Operation...........................................................................................23

Figure 7. Dynamic Pressure Control Operation .....................................................................................24

Figure 8. Ready/Not Ready in Static Control Mode..............................................................................26

Figure 9. Ready/Not Ready in Dynamic Control Mode.........................................................................26

Figure 10. Status Register Schematic....................................................................................................108

Figure 11. Internal View..........................................................................................................................126

Figure 12. Pneumatic Module, High and Low.........................................................................................127

Figure 13. Driver Cable Schematic.........................................................................................................136

IIG

URREESS

PPCK+™ Operation and Maintenance Manual

This manual is intended to provide the user with the basic information necessary to operate a PPCK+ pressure controller/calibrator. It also includes a great deal of additional information provided to allow you to optimize its 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 PPCK+ users. Section 3 is most important for those using the local front panel interface but should be read over by all users to familiarize themselves with general PPCK+ 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 PPCK+ behavior based on the symptom of that behavior.

For those of you who “don’t read manuals”, go directly to Section 2.3 to set up your PPCK+ and then

Section 2.4 for power-up and verification. This will get you running quickly with a minimal risk of causing damage to yourself or your new PPCK+. THEN… when you have questions or start to wonder about all the great features you might be missing, get into the manual!

Certain words and expressions have specific meaning as they pertain to PPCK+. The Glossary Section (Section 7.3) is useful as a quick reference for exact definition of specific words and expressions as they are used in the manual.

BBO

UTT

HIISS

Manual Conventions

AAN

UAALL

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

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

explanations.

[ ] indicates direct function keys (e.g., [RANGE]). < > indicates PPCK+ screen displays (e.g., <1yes>).

PPCK+™ Operation and Maintenance Manual

1. INTRODUCTION

1.1 PRODUCT OVERVIEW

PPCK+ is a stand-alone, microprocessor driven, pressure controller/calibrator intended to precisely measure and control precise gas pressure as needed for the calibration and testing of pressure measuring instruments. PPCK+ offers very high performance combined with maximum versatility and ease of use. PPCK+ is designed to cover very high gas pressures, especially ranges above 7 MPa (1 000 psi). PPCK+ measures and controls pressure in ranges from 0 to 1 000 psi (7 MPa) up to 0 to 10 000 psi (70 MPa), in both gauge and absolute measurement modes. For pressure ranges of 7 MPa (1 000 psi) and below, see DHI’s PPCK+ pressure controller/calibrator.

PPCK+ measures pressure using a high precision reference pressure transducer (RPT) and an on-board barometer. Pressure control is achieved by pneumatically actuated high pressure valves and a patented thermal pressure control (TPC) system for very fine adjustment.

PPCK+ can be controlled locally by the operator through the front panel display, keypad and special function keys or remotely over an RS232 or IEEE-488 interface using ASCII character command strings.

PPCK+™ Operation and Maintenance Manual

1.2 SPECIFICATIONS

1.2.1 GENERAL SPECIFICATIONS

Power Requirements: 85 to 264 VAC, 47 to 440 Hz, 60 VA max. consumption

Operating Temperature Range: 15 to 35 °C

Storage Temperature Range: -20 to 70 °C

Vibration: Meets MIL-T-28800D

Weight: 15.4 kg (34 lb)

Dimensions: 18 cm H x 32 cm W x 40 cm D (7.1 in. H x 12.6 in. W x 15.8 in. D)

Microprocessor: Motorola 68302, 16 MHz

Communication Ports: RS232 (COM1), RS232 (COM2), IEEE-488.2

Pressure Ranges: Each PPCK+ has three ranges (H1, H2, H3). Ranges are from 0 to

1 000 psi (7 MPa) to 0 to 10 000 psi (70 MPa). (See Table 1.)

Operating Medium:

Pressure Supplies:

Pressure Connections: High Pressure Supply: DH200 F

Pressure Limits: Maximum Working Pressure: Range H3 +10 %

Any clean, dry, non-corrosive gas SUPPLY port: Range H3 + 5 %, supply pressure must remain

DRIVE IN port: 700 - 850 kPa (100 - 120 psi), supply must remain

Test and Drain: DH200 F Vent: 1/8 in. NPT F Drive In: 1/8 in. NPT F Drive Out: 1/8 in. NPT F ATM (on-board barometer): 10-32 UNF Note: DH200 F is a gland and collar type fitting for coned and left hand threaded 1/4 in. (6 mm) OD tube, equivalent to AE SF250C, HIP LF4, etc.

Maximum Pressure without Damage: Range H3 +20 % Maximum Working Supply Pressure: Range H3 + 10 % Maximum Supply Pressure without Damage: Range H3 + 20 %

constant ± 1 % to meet control specifications constant ± 5 % to meet control specifications

1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS

Each PPCK+ has three ranges using one Reference Pressure Transducers (RPT) and a barometer. All three ranges operate in both gauge and absolute mode.

All RPTs are of the absolute pressure type using an evacuated, permanently sealed reference. Gauge pressures are defined by offsetting atmospheric pressure with dynamic compensation for atmospheric changes using the on-board barometer (see Section 3.4.1, Gauge Mode, Dynamic Compensation for Atmospheric Pressure

PPCK+™ Operation and Maintenance Manual

Table 1. Model Designations and Ranges

RPT

DESIGNATION RANGE1 (LO) RANGE2 (MID) RANGE3 (HI) RANGE1 (LO) RANGE2 (MID) RANGE3 (HI)

A10000

A6000

A3000

US UNITS VERSION (psi) SI UNITS VERSION (MPa)

3 000 6 000 10 000 20 40 70 2 000 4 000 6 000 13 25 40 1 000 2 000 3 000 6 12 20

Note: All ranges are both absolute and gauge and support all measurement units available. The “US” or “SI” distinction only affects the nominal range values and settings.

1.2.2.1 REFERENCE PRESSURE TRANSDUCER (RPT) SPECIFICATIONS

All values are ± FS of the active range unless otherwise indicated.

Warm Up Time: 30 minutes for best performance

Resolution: To 1 ppm, user settable by individual range

Temperature Effect: Fully compensated from 0 to 50 °C with active independent

temperature measurement

0.005 % maximum temperature effect in normal ambient 15 to 35° C operating range

Acceleration Effect:

Measurement Precision

Predicted Stability

Measurement Uncertainty3: 90 day 1 year

± 0.008 %/g maximum, worst axis Allows operation at ± 20° from reference plane without significant effect

± 0.01 %

: 90 day 1 year

Gauge Mode (w/Autozero): 0.003 % 0.009 % Absolute Mode (w/Autozero): 0.003 % 0.009 % Absolute Mode (w/out Autozero): 0.006 % 0.015 %

Gauge Mode (w/Autozero): 0.012 % 0.015 % Absolute Mode (w/Autozero): 0.012 % 0.015 % Absolute Mode (w/out Autozero): 0.015 % 0.020 %

1 Measurement Precision: Combined linearity, hysteresis, repeatability of measurements made

by the reference pressure transducer.

2 Predicted Stability: Maximum change in zero and span over specified time period for typical

RPT used under typical conditions. As stability can only be predicted and varies from RPT to RPT, stability for a specific RPT should be established from experience.

3 Measurement Uncertainty: Maximum deviation of the reference pressure transducer indication

from the true value of measured pressure including precision, stability, temperature effect and calibration standard uncertainty of ± 0.005 % of reading.

The influence of the dynamic compensation for atmospheric pressure in gauge mode

measurement is less than ± 2.5 Pa (0.00035 psi).

PPCK+™ Operation and Maintenance Manual

1.2.2.2 ON-BOARD BAROMETER

The on-board barometer is NOT used as a source of absolute accuracy. It is ONLY used to measure changes in atmospheric pressure between zeroing opportunities to provide dynamic compensation of the RPTs atmospheric pressure offset when making gauge pressure measurements.

1.2.3 PRESSURE CONTROL SPECIFICATIONS

All values are ± FS of the active range unless otherwise indicated.

Modes and Ready Indication: Static: Sets pressure within hold limit and maintains rate of

Pressure is Ready when within hold limit and rate of Dynamic: Sets pressure within hold limit and continuously adjusts Pressure is Ready when within hold limit

Control Parameters: Hold limit, stability limit (optimum values set by default, can be

customized independently for each measurement range)

Control Precision1: ± 0.003 %, ± 0.01 % default dynamic control hold limit

Normal Test Volume: PPCK+ A3000: 0 to 500 cc (100 cc optimal)

PPCK+ A6000: 0 to 200 cc (50 cc optimal) PPCK+ A10000: 0 to 200 cc (50 cc optimal) Note: Pressure control system will operate in larger volumes but

pressure setting times are increased.

change lower than stability limit change is less than stability limit as close as possible to target

Gas is a compressible fluid. The larger the pressurized

the volume, the larger the stored energy. The size of high pressure volumes should be minimized for safety

Control Speed: Slew Rate (0 to Controller FS)

in Optimal Volume with No Control: 60 to 120 seconds Pressure Setting (Typical Time To Ready Indication for a 10 % Increment in Dynamic Mode): 90 seconds (reduced by increasing hold limit)

Minimum Pressure: Gauge Mode: 0 (vented)

Absolute Mode: Atmospheric pressure (vented)

Minimum Controlled Pressure: No limit (greater than atmosphere)

Delivered Pressure Uncertainty

: 90 day 1 year

Gauge Mode: 0.016 % 0.018 % Absolute Mode (w/Autozero): 0.016 % 0.018 % Absolute Mode (w/out Autozero): 0.018 % 0.022 %

1 Control Precision: Minimum useable hold limit in dynamic control mode. 2 Delivered Pressure Uncertainty: Maximum deviation from the true value of pressure applied to the device under

test in dynamic control mode with default control limits and assuming measurement uncertainty as in Section 1.2.2.1. In static control mode, the control error can be eliminated making delivered pressure uncertainty equal to measurement uncertainty.

PPCK+™ Operation and Maintenance Manual

Table 2. Default Pressure Control Parameters

DYNAMIC CONTROL MODE STATIC CONTROL MODE

HOLD LIMIT STABILITY LIMIT HOLD LIMIT STABILITY LIMIT

± 0.01 % FS of active pressure range

± 0.005 % FS/sec of active pressure range

± 1% FS of active pressure range

± 0.005 % FS/sec of

active pressure range (used only when control is not active)

PPCK+™ Operation and Maintenance Manual

OOTTEES

PPCK+™ Operation and Maintenance Manual

2. INSTALLATION

2.1 UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

PPCK+ is delivered in a corrugated container with high density polyethylene inserts to hold it in place; or in the optional molded medium density polyethylene shipping case with a custom foam insert.

Remove the PPCK+ and its accessories from the shipping container and remove each element from its protective plastic bag.

2.1.2 INSPECTING CONTENTS

Check that all items are present and have NO visible damage. A standard PPCK+ includes all items indicated in Table 3.

Table 3. PPCK+ Packing List

DESCRIPTION PART NO.

PPCK+ Pressure Controller/Calibrator

PPCK+ A3000 PPCK+ A6000

PPCK+ A10000 Calibration Certificate 550100 Test Report 550120 Accessories: 401655 or 401655-CE

User’s Manual 550118

Power Cord (7.5 ft.) 100770 or 100770-CE

(6) Rubber Feet Caps 400203

General Accessories Disk (Important: Includes

system support software and documentation)

Nip, SS, DH200, 2.75 in. 100204

Gland, SS, DH200, 7/16-20 100272

Plug, SS, DH200, 4T 100279

Adpt, SS, DH200F x 2NPTF 100299

(2) Clr, SS, DH200 101200

FAM0006-01

102987

PPCK+™ Operation and Maintenance Manual

2.2 SITE REQUIREMENTS

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

Minimizing the length of tubing connecting the PPCK+ to the device or system to be tested

enhances control performance and reduce pressure setting times. Ready access to the PPCK+ rear panel should be considered to facilitate making and breaking

pressure connections when necessary. Support facilities required include:

• An electrical power source of 85 to 264 VAC, 47 to 440 Hz.

• A continuous regulated high pressure supply of clean, dry, non-corrosive gas at maximum

PPCK+ range (H3) + 5 % to be connected to the SUPPLY port. Supply pressures of less than range H3 + 5 % may cause out of tolerance pressure control. The SUPPLY source must remain stable ± 1 % while PPCK+ is controlling. If a gas booster is used to supply high pressure, an accumulator is required to dampen the pressure changes caused by the booster cycling. Consider using the DHI GB-K gas booster package.

• A continuous regulated drive air pressure supply of clean, dry non-corrosive gas at 700 to 850 kPa (100 to 120 psig). The drive air supply must remain stable ± 5 % during PPCK+ operation. This DRIVE pressure supplies the precision low pressure control system that actuates PPCK+’s high pressure valves. The flow and consumption requirements are extremely low. Use of instrument grade nitrogen or air from a compressed air bottle is recommended. If shop or factory air is used, a filter/dryer must be installed. The DHI GB-K gas booster package includes a DRIVE air regulator and connection.

2.3 INITIAL SETUP

2.3.1 PREPARING FOR OPERATION

To prepare PPCK+ for check out and operation:

n Remove the plastic caps from the PPCK+ rear panel pressure connections. o Remove the protective plastic sheet from the front panel display. p Install the rubber feet caps onto the bottom case feet, if desired. q Familiarize yourself briefly with the front and rear panel (see Section 2.3.2).

PPCK+™ Operation and Maintenance Manual

2.3.2 FRONT AND REAR PANELS

2.3.2.1 FRONT PANEL

The front panel assembly provides a 2 x 20 vacuum fluorescent display of PPCK+ operating status and a membrane keypad for local user control.

1. Display 3. Manual Pressure Control Keys

2. Multi-Function Keypad 4. Remote Indicator

Figure 1. Front Panel

PPCK+™ Operation and Maintenance Manual

2.3.2.2 REAR PANEL ASSEMBLY

The rear panel assembly provides pressure connections, communications interfaces, the power ON/OFF module and product labeling. Pressure fittings are internally secured to prevent loosening when making and breaking connections.

1. Label, Product 9. Pass Through, ATM REF (10-32 UNF)

2. COM2 Connector 10. DRAIN Port (DH200 F)

3. IEEE-488 Connector 11. TEST Port (DH200 F) 4 COM1 Connector 12. VENT Port (1/8 in. NPT F)

5. Fuse 13. DRIVE OUT Port (1/8 in. NPT F)

6. Power Switch 14. DRIVE IN Port (1/8 in. NPT F)

7. Power Plug (IEC320-C13) 15. SUPPLY Port (DH200 F)

8. Drivers Option Connector

Figure 2. Rear Panel Assembly

2.3.3 POWER CONNECTION

n Check that the PPCK+ power switch is OFF. o Connect the supplied power cable to the rear panel power module. p Connect the other end of the power cable to an electrical supply of 85 to 264 VAC,

47 to 440 Hz.

PPCK+™ Operation and Maintenance Manual

2.3.4 CONNECTING THE HIGH PRESSURE SUPPLY (SUPPLY PORT)

The SUPPLY port is for connection of the high pressure gas that PPCK+ controls. Using a pressure connecting hose or rigid tube of appropriate pressure rating, connect the

pressure supply to the SUPPLY port on the rear panel of PPCK+. The SUPPLY connection is DH200 F.

DH200 F is a gland and collar type fitting for coned and left hand threaded 1/4 in. (6 mm) OD

tube, equivalent to AE SF250C, HIP LF4, etc. DO NOT USE INCORRECT FITTINGS; DAMAGE TO THE FITTING AND DANGER TO THE OPERATOR COULD RESULT.

The supply pressure should be equal to the maximum PPCK+ range + 5 %. The supply pressure must be stable ± 1 % for PPCK+ pressure control to operate within specifications (see Section 1.2.3).

Never connect a pressure supply greater than 20 % over the maximum range (H3) of the

PPCK+ model you are using. Always use the correct fittings.

Take care NOT to connect the high pressure supply to a port other than the SUPPLY port.

CONNECTING THE HIGH PRESSURE SUPPLY TO ANY PORT OTHER THAN THE SUPPLY PORT MAY DAMAGE THE PPCK+ AND MAY CAUSE OPERATOR INJURY.

2.3.5 CONNECTING TO THE DEVICE UNDER TEST (TEST PORT)

The TEST port is for connection of the PPCK+ to the system into which it will measure and control high gas pressures.

Using a pressure connecting hose or hard tube of appropriate pressure rating, connect the device or system to be tested to the TEST port. The PPCK+ TEST connection is DH200 F.

DH200 F is a gland and collar type fitting for coned and left hand threaded 1/4 in. (6 mm)

OD tube, equivalent to AE SF250C, HIP LF4, etc. DO NOT USE INCORRECT FITTINGS; DAMAGE TO THE FITTING AND DANGER TO THE OPERATOR COULD RESULT.

Gas is a compressible fluid. The larger the pressurized volume, the larger the stored energy.

The size of high pressure volumes should be minimized for safety.

NEVER apply pressure to the TEST port greater than the PPCK+ maximum range (H3)

working pressure. Internal damage to the PPCK+ may result.

Operating the PPCK+ connected to a system with liquid contaminants without taking proper

precautions to purge the system and test line may cause contamination of the PPCK+ that will affect measurement and control performance and require non-warranty service.

PPCK+™ Operation and Maintenance Manual

Minimizing the length and complexity of the test connection tubing enhances control

performance and reduces pressure setting time. For optimum operation, the total volume of the device or system under test including connecting tubing should be less than 500 cc

(30 in

) up to 200 MPa (3 000 psi) and less than 200 cc (12 in3) over 200 MPa (3 000 psi).

PPCK+ pressure control will not operate properly if there are excessive leaks in the

test system. As a general rule, the maximum acceptable leak rate for optimal PPCK+ automated pressure control operation and to assure in tolerance measurements with default pressure control parameters is ± 0.01 % of active range FS/second. If working with larger leaks is unavoidable, consider using STATIC CONTROL mode (see Section 3.1.2.4).

2.3.6 CONNECTING THE DRIVE PRESSURE SUPPLY (DRIVE IN PORT)

PPCK+’s high pressure valves are actuated by a drive pressure. This drive pressure must be connected and properly set for PPCK+ to operate properly.

Using a pressure connecting hose of appropriate pressure rating, connect the drive pressure supply to the DRIVE IN connection on the rear panel of PPCK+. The DRIVE IN connection is 1/8 in. NPT F.

The drive pressure must be between 700 - 850 kPa (100 - 120 psi). The supply pressure must be stable ± 5 % for PPCK+ pressure control to operate within specifications (see Section 1.2.3).

Never connect a pressure supply to the DRIVE IN port that is greater than 1 MPa (150 psi).

Damage to PPCK+ could result.

2.3.7 DRIVE OUT PORT

The DRIVE OUT port is the exhaust point for drive air used by PPCK+’s high pressure valve drive system (see Figure 5). The DRIVE OUT port should be open to atmosphere and unobstructed to allow drive air to escape. The drive air consumption is very low so there is no significant flow through the DRIVE OUT port.

Though a pressure hose can be connected to the DRIVE OUT port to direct the exhausted gas flow, the flow is very low and a completely unobstructed connection to atmosphere must be maintained.

The PPCK+ DRIVE OUT port is 1/8 in. NPT female.

NEVER plug, obstruct or connect a supply pressure to the DRIVE OUT port.

PPCK+™ Operation and Maintenance Manual

2.3.8 VENT PORT

The PPCK+ VENT port is the test exhaust port as well as the vent to atmosphere point used to set zero gauge pressure. Though a pressure hose can be connected to the VENT port to direct the vented gas flow, a completely unobstructed connection to atmosphere must be maintained for PPCK+ reference pressure measurements to operate normally.

The PPCK+ VENT port is 1/8 in. NPT female.

NEVER plug, obstruct or connect a supply pressure to the PPCK+ VENT port.

2.3.9 THE DRAIN PORT

The DRAIN port connects to the low point in the PPCK+ thermal pressure control volume (see Figures 2, 12). The volume serves as a sump to trap small quantities of liquids that may return to PPCK+ from the system connected to the TEST port.

The PPCK+ is delivered with a plug installed in the DRAIN port and the port is left plugged during normal operation. The DRAIN port should occasionally be purged by slowly opening the fitting with approximately 700 kPa (100 psi) trapped in the PPCK+ (see Section 5.4).

The PPCK+ DRAIN connection is DH200 F.

DH200 F is a gland and collar type fitting for coned and left hand threaded 1/4 in. (6 mm)

OD tube, equivalent to AE SF250C, HIP LF4, etc. DO NOT USE INCORRECT FITTINGS; DAMAGE TO THE FITTING AND DANGER TO THE OPERATOR COULD RESULT.

2.3.10 THE ATM PORT (BAROMETER)

The ATM pass through is connected to the on-board barometer. The ATM pass through assures that the on-board barometer is exposed to atmospheric pressure rather than to the pressure inside the PPCK+ case which may be slightly different from atmospheric pressure.

For calibration or verification of the on-board barometer through the ATM port, a pressure reference may be connected. The ATM REF port connection is 10-32 UNF F.

Do not plug or obstruct the ATM REF pass through as this may adversely affect GAUGE

mode operation.

NEVER connect a pressure greater than 110 kPa ABSOLUTE (16.5 psia) to the ATM REF port

or damage to the on-board barometer may result.

PPCK+™ Operation and Maintenance Manual

2.4 POWER-UP AND VERIFICATION

2.4.1 SWITCH POWER ON

Actuate the power switch on the PPCK+ rear panel. Observe the front panel display as PPCK+ initializes, error checks and goes to the main run screen (see Section 3.1.1).

PPCK+ operating condition at power-up is all valves closed. Powering down PPCK+ also causes all valves to close.

If the PPCK+ fails to reach the main run screen, service is required. Record the sequence of operation and displays observed and contact a DHI Authorized Service Provider (see Table 22).

The pressure range that was active on power down is active on power up.

2.4.2 CHECK PROPER PRESSURE MEASUREMENT OPERATION

2.4.2.1 CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT

Check that the PPCK+ operates properly in absolute mode. If the PPCK+ is not vented, press the [VENT] manual pressure control key to vent

the PPCK+ (VENT LED ON) (see Section 3.1.2.2). Open the TEST port as well to be sure the RPT is exposed to atmospheric pressure.

Press the [UNIT] function key and select <absolute> measurement mode (see Section 3.2.2). Change the pressure unit if desired (see Section 3.2.2).

Observe the current value of atmospheric pressure displayed on the PPCK+ main run screen (see Section 3.1.1). Check that the value agrees with the local value of atmospheric pressure within measurement tolerances. Repeat this process for all three PPCK+ ranges. Check that the values of atmospheric pressure measured by the different ranges agree with each other within PPCK+ measurement tolerances (see Section 1.2.2). If the values do not agree within tolerances, PPCK+ may need calibration or repair.

2.4.2.2 CHECKING GAUGE MODE PRESSURE MEASUREMENT

If the PPCK+ is not vented, press the [VENT] manual pressure control key to vent the PPCK+ (VENT LED ON) (see Section 3.1.2.2). Open the TEST port as well to be sure the RPT is exposed to atmospheric pressure.

Press the [UNIT] function key and select <gauge> mode (see 3.2.2). Change the pressure unit if desired (see Section 3.2.2).

PPCK+™ Operation and Maintenance Manual

Observe that, within 60 seconds, the [VENT] LED flashes and zero is indicated. It is normal for PPCK+ to indicate a value other than zero for up to 60 seconds when first entering gauge mode.

Using the [RANGE] function key to change ranges, observe that zero is indicated for each range within 60 seconds. When gauge mode is first entered or ranges are changed, it is normal for PPCK+ to indicate a value other than zero when vented. After up to 60 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 3.4.1) and that the TEST port is truly exposed to atmospheric pressure. If the display will not zero, PPCK+ may need repair.

2.4.3 LEAK CHECK

If desired, perform a leak check of the test system (see Section 3.2.8).

2.4.4 CHECK PROPER PRESSURE CONTROL OPERATION

Select a pressure range using the [RANGE] key (see Section 3.2.1). Press the [CONTROL] function key and select <dynamic> (see Section 3.2.3). Press [ENTER]. Specify a target pressure within the active range and press [ENTER] again

(see Section 3.2.3). PPCK+ should set the target pressure and indicate Ready (see Section 3.1.2.5) continuously

within 45 to 150 seconds. If it does not, see Section 6 to troubleshoot pressure control. Remember that the correct pressure supplies must be connected to the SUPPLY pressure DRIVE IN pressure ports for pressure control to operate properly (see Sections

2.3.6, 3.1.2.3).

Before setting a pressure with PPCK+, assure that the test system connected to the PPCK+

TEST port is rated for the pressure that will be generated.

2.5 SHORT TERM STORAGE

The following is recommended for short term storage of PPCK+:

n Vent the PPCK+. o Turn power OFF using the rear panel power switch. p Shut OFF or disconnect the pressure supply. q Shut OFF or disconnect the drive air supply.

PPCK+™ Operation and Maintenance Manual

OOTTEES

PPCK+™ Operation and Maintenance Manual

3. OPERATION

3.1 GENERAL/MANUAL OPERATION

PPCK+ is designed to balance simple, intuitive operation and the availability of a wide variety of functions with a high level of operator discretion. The local operator interface is through a 2 x 20 display, 4 x 4 keypad and four manual pressure control keys on the front panel.

3.1.1 MAIN RUN SCREEN

The PPCK+ 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 PPCK+ to set and read pressures. It provides complete information on the system's current configuration and operating status.

1. Ready/Not Ready indication (see Section 3.1.2.5):

*PRESSURE1 UNITM hzSR TPRESSURE2 CC NN/NN

4. Pressure measurement mode: <g> gauge, <a> absolute (see Section 3.2.2).

5. Head correction indication: Indicates whether a head correction is applied. <h> if applied, < > (blank) if not (see Section 3.2.7).

6. Autozero indication: Indicates whether the autozero function is ON or OFF. <z> if ON; < > (blank) if OFF (see Section 3.4.1).

7. Range indicator: Indicates <H> for high RPT and <1> for low range, <2> for mid range, <3> for high range (see Section 3.2.1).

8. Sequence counter: Not used in PPCK+.

9. Control mode indicator: Pressure control mode (<S> for static, <D> for dynamic, <M> for manual) with a <C> appended if custom control settings are in use. Shows <VLV> when the inlet or exhaust valve is in its opening routine (see Sections 3.1.2.3, 3.1.2.4). The control mode indicator characters flash when the system is controlling pressure (see Sections 3.2.3, 3.2.6).

10. PRESSURE2: Numerical sign and value of either target pressure <T>, rate of change of pressure <R> or deviation from target <D>. Target value and deviation are in the current pressure unit of measure. Rate of change of pressure is in current unit per second (see Section 3.2.3).

<*> when Ready, <↑> or <↓> indicating direction of measured pressure evolution if Not Ready.

2. PRESSURE1: Numerical value and sign of pressure measured by active RPT and range.

3. UNIT: Current pressure unit of measure (see Section 3.2.2).

PPCK+™ Operation and Maintenance Manual

11. Indicates whether the number following is target pressure <T>, rate of change of pressure <R> or current deviation from target value <D>) (see Section 3.2.3).

Target pressure <T> is indicated when:

• Dynamic control is active and pressure is Not Ready.

• Static control is active and pressure is outside of the hold limit.

Deviation <D> is indicated when:

• Dynamic control is active and pressure is Ready.

Rate of change <R> is indicated when:

• No control is active (e.g., control is suspended or system is vented).

• Static control is active, and pressure is inside the hold limit.

PPCK+ 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 3.4.4.8).

3.1.2 GENERAL OPERATING PRINCIPLES

3.1.2.1 KEYPAD LAYOUT AND PROTOCOL

The PPCK+ has a 4 x 4 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. The name of the function is on the bottom half of the key (see Sections 3.1.2.7, 3.2). These keys enter numerical values when editing.

2. The Editing and Execution keys are for causing execution, suspending execution, backing up in menus and editing entries.

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 3.3). The SPECIAL menu is for functions that are not generally used as a part of day to day operation (see Section

3.4). These keys enter numerical values when editing.

Figure 3. Keypad Layout

PPCK+™ Operation and Maintenance Manual

Pressing [ENTER] within a menu or function generally causes execution or forward movement in the menu tree. Pressing [ENTER] from the main run screen allows an automated pressure control command to be given.

Pressing [ESCAPE] moves back in the menu tree and/or causes execution to cease or suspend. Pressing [ESCAPE] repeatedly eventually brings you back to the main run screen and from there will allow a momentary viewing of the PPCK+ introduction screen.

Pressing [+/-] changes a numerical sign when editing. It also toggles through multiple screens when available.

Pressing [←] or [→] allows reverse or forward cursor movement when editing data entry. These keys also allow the target pressure value to be jogged up and down while controlling or when editing the target value.

Some screens 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 [←] and [→] 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.

3.1.2.2 MANUAL PRESSURE CONTROL KEYS

The manual pressure control keys provide direct operator control of pressure increase, decrease and vent. They can be useful in adjusting pressure when automated pressure control to a target value is not needed.

The manual pressure control keys interrupt and override automated pressure control. Pressing the [VENT] key causes PPCK+ to execute its vent routine in which

pressure is controlled to near atmospheric pressure and then the exhaust valve is fully opened. A RED LED just above the [VENT] key indicates the PPCK+ is in vent mode. The vent valve will remain open until the [VENT] key is pressed again, another manual pressure control key is pressed, or an automated pressure control command is given.

Pressing [↑] or [↓] causes pressure to increase or decrease at the slow slew rate. These are momentary keys that are active only as long as they are pressed. Releasing the key stops the pressure increase or decrease.

Pressing and holding the [FAST] key while pressing the [↑] or [↓] causes the pressure increase or decrease speed to change from slow to fast.

Figure 4. Manual Pressure Control Keys

PPCK+™ Operation and Maintenance Manual

3.1.2.3 PRESSURE CONTROL OPERATING PRINCIPLES

Numerical references in this section refer to Figure 5. PPCK+ is designed to precisely measures and control gas pressures into a volume

connected to its TEST port (14). Pressure is measured by a Reference Pressure Transducer (RPT)(17).

Pressure is controlled in two stages. The first stage of pressure control is valve control. Valve control is used for all

aspects of pressure control except the final stage of dynamic pressure control in which pressure is maintained at the target value (see Section 3.1.2.4). Valve control is accomplished by high pressure inlet and exhaust valves (3, 11). The HP inlet valve (3) controls the admission of pressure from the SUPPLY port (1). The HP exhaust valve (11) controls the exhaust of pressure out of the VENT port (13). The HP inlet and HP exhaust valves are dome-loaded needle valves. The valve is normally closed by a Belleville spring. The valve is opened and its needle position is controlled by the application of drive pressure onto the dome in opposing force to the Belleville spring. The drive pressure is supplied from the DRIVE IN port (6) and controlled by the drive air solenoid valves (2, 4, 10, 12).

When a command is given to set a pressure, the high pressure inlet (3) or exhaust (11) valve must be opened to admit or exhaust pressure. The opening procedure takes 5 to 10 seconds during which PPCK+ may appear to be idle. To notify the operator that the valve opening procedure is in process, the main run screen pressure control characters FLASH <VLV> during the valve opening routine (see Section 3.1.1).

The second stage of pressure control is thermal pressure control (TPC). TPC is used in the final stage of dynamic pressure control when very fine control is needed to maintain pressure at the target value (see Section 3.1.2.4). TPC, uses a pressurized volume in which there is a heating element and around which there is a forced air cooling system (16). Heating and cooling the gas in the volume causes it to expand or contract, increasing or decreasing pressure. This patented, pressure control system allows extremely fine pressure control without hysteresis or wear of mechanical parts.

The TPC system response is dependent on the volume connected to the TEST port. Whenever TPC response indicates that the test volume has changed, PPCK+ runs an automated routine to determine the new test volume. This routine is initiated automatically when needed. The execution of the volume determination routine may occur occasionally while TPC is active in dynamic control mode. This normal behavior appears as a delay in pressure control during which the pressure may vary by up to 700 kPa (100 psi). The volume determination configuration can also be launched by the user (see Section 3.4.4.1).

PPCK+™ Operation and Maintenance Manual

1. SUPPLY Port (DH200 F) 11. High Pressure Exhaust Valve

2. HP Inlet Valve Dome Exhaust Valve 12. HP Exhaust Valve Dome Exhaust Valve

3. High Pressure Inlet Valve 13. VENT Port (1/8 in. NPT F) 4 HP Inlet Valve Dome Supply Valves 14. TEST Port (DH200 F)

5. Drive Air Lines 15. DRAIN Port (DH200 F)

6. DRIVE IN Port (1/8 in. NPT F) 16. Thermal Pressure Control Unit (TPCU)

7. Drive Air Filter 17. Reference Pressure Transducer (RPT)

8. Drive Air Regulator (factory adj.) 18. High Pressure Filter(s)

9. DRIVE OUT Port (1/8 in. NPT F) 19. High Pressure Lines

10. HP Exhaust Valve Dome Exhaust Valves

Figure 5. Pneumatic Schematic

PPCK+™ Operation and Maintenance Manual

3.1.2.4 AUTOMATED PRESSURE CONTROL MODES

PPCK+ automated pressure control provides automated adjustment and control of pressure to a user designated target value. This feature allows pressure values to be set precisely by simple numerical entry. Pressing [SET P] from the main run screen allows a pressure control target value to be entered and executed. Pressing [ESCAPE] or a manual pressure control key causes active pressure control to be interrupted (see Section 3.1.2.2).

PPCK+ supports two pressure control modes to meet different pressure setting and controlling requirements. The two control modes are designated static and dynamic. Pressure control parameters for each control mode are automatically set to optimal default values for each PPCK+ range when the control mode is selected in the active range (see Sections 3.2.1, 3.2.3). If desired, control parameters can be customized by the user using the CUSTOM CONTROL function (see Section 3.2.6).

Control parameters:

• Target Value: The pressure setpoint specified by the operator.

• Hold Limit: A symmetrical positive and negative limit around the target value

within which the controlled pressure is to be maintained.

• Stability Limit: A rate of change of pressure limit in units of pressure/second used as a criterion for the Ready/Not Ready condition in static control or when automated control is not active.

See STATIC CONTROL and DYNAMIC CONTROL in this section for a detailed explanation of each control mode and its advantages, the default control parameters and the Custom Control options. See Table 4 for a summary of the two control modes.

Table 4. Static and Dynamic Pressure Control Modes Summary

CONTROL

MODE

Static

Dynamic

• Control error can be completely eliminated.

• Minimizes pressure setting time (Ready to Ready).

• Provides maximum tolerance for leaks in test volume.

• Set pressure is equal to target pressure.

• When testing multiple DUTs, final pressure is the same for all DUTs at each set point.

ADVANTAGES

DISADVANTAGES

• May require averaging of DUT readings for best results.

• When testing multiple DUTs, final pressure is not exactly the same for each DUT at a set point.

• Set pressure is not equal to target pressure.

• Control error is added to measurement uncertainty.

• Increases pressure setting time (Ready to Ready).

• Limited tolerance of leaks in test volume.

BEST USED

• When data acquisition from the DUT is automated allowing averaging of the DUT readings.

• When minimizing uncertainty is a priority.

• When reducing pressure setting time is a priority.

• When DUT readings must be recorded manually.

• When it is imperative that the final pressure be equal to the set pressure requested.

PPCK+™ Operation and Maintenance Manual

Static Control Static control mode is designed to bring the pressure near the target value and then

set a very slow pressure ramp during which valid comparative measurements between the PPCK+ and the DUT can be made. Static control is not intended to set and maintain pressure at a specific value, but rather to establish a very low rate of change of pressure near a nominal target value. The advantage of static control mode is that pressure can be set and/or measured without the random interference that is typical of a dynamic pressure control system. This can allow pressure control errors to be completely eliminated from the measurements. In addition, static control mode is almost always faster than dynamic control mode because the “hunt” time required to zero in on a specific set value is eliminated.

In static control mode, test measurements are made when a Ready condition occurs. Ready occurs when the current pressure value is within the hold limit and the rate of change of pressure is less than the stability limit (see Sections 3.1.2.5, 3.2.6). When Ready occurs, the reference pressures applied to the test system is not the set pressure requested, it is the momentary pressure value read back from the PPCK+. Since the pressure is evolving very slowly (in a fixed ramp at less than the stability test rate), measurements between the PPCK+ and the DUT can be compared very precisely by averaging the two over short periods.

During static pressure control, the hold limit is active. If the current pressure goes outside of the hold limit, a Not Ready condition occurs (see Section 3.1.2.5) and pressure is readjusted to be inside the hold limit. The hold limit is used to establish the maximum distance from the nominal set point at which data can be taken. The wider the hold limit, the lower the likelihood of an interruption of the Ready condition to readjust pressure. (see Section 3.2.3 for default hold and stability limit values and Section 3.2.6 for setting the hold and stability limits to user defined values).

Figure 6. Static Pressure Control Operation

PPCK+™ Operation and Maintenance Manual

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, as close to the target value as possible. The advantage of this dynamic control mode is that the final pressure achieved is the same as the target value. However, unlike static control, in dynamic control a control error must be included in the uncertainty on the final pressure applied. The maximum value of the control error is equal to the current hold limit. The typical value of the control error is generally well inside the hold limit.

In dynamic control mode, test measurements are made when a Ready condition occurs. Ready occurs when the set pressure is within the hold limit. The reference pressure value applied to the test system is assumed to be equal to the nominal pressure set value when Ready occurs.

During dynamic pressure control, the hold limit is active. If the pressure goes outside of the hold limit, a Not Ready condition will occur (see Section 3.1.2.5). See Sections 3.1.2.4 and 3.2.3 for default hold limit values. See Section 3.2.6 for setting the hold limit to a user defined value. During active dynamic pressure control, the stability limit is not used. The stability limit is used as the Ready/Not Ready criterion when control is suspended.

r e s s u

r e

Target Pressure

Pressure Continuously

Adjusted to the Target Value

Figure 7. Dynamic Pressure Control Operation

Time

PPCK+™ Operation and Maintenance Manual

3.1.2.5 PRESSURE READY /NOT READY

PPCK+ provides a Ready/Not Ready indication. This indication is intended to provide the user with a clear and objective criterion for determining when a valid pressure measurement can be made. On the main run screen, the far left character of the top display lines indicates Ready/Not Ready. In remote command responses,

Ready/Not Ready is indicated by “R” or “NR” in the response string. Ready/Not Ready front panel display indications are:

• <*>: Pressure Ready.

• <↓>: Pressure Not Ready and decreasing.

• <↑>: Pressure Not Ready and increasing.

When pressure control is NOT active: 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 (see Section 3.2.6).

When pressure control is active: The criteria for determining the Ready/Not Ready condition depend on whether the current control mode is static or dynamic.

Pressure Ready/Not Ready parameters are set by default when a control mode is selected. The parameters can be customized if desired (see Sections 3.2.3 and 3.2.6).

The Ready condition is handled specially when responding to an automated pressure

command of zero (see Section 3.2.10.1).

PPCK+™ Operation and Maintenance Manual

Ready/Not Ready In Static Control Mode When static pressure control mode is active a Ready condition occurs whenever:

• The current measured pressure is inside the hold limit.

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

r e s s u

r e

Target Pressure

Figure 8. Ready/Not Ready in Static Control Mode

Ready/Not Ready In Dynamic Control Mode

When dynamic pressure control mode is active, a Ready condition occurs whenever:

• The current measured pressure is inside the hold limit.

Not Ready:

Pressure out of

hold limit

Pressure inside of hold limit

Ready:

Time

Figure 9. Ready/Not Ready in Dynamic Control Mode

PPCK+™ Operation and Maintenance Manual

Ready/Not Ready When Pressure Control Is Not Active

When automated pressure control is NOT active, Ready is indicated whenever the rate of change of pressure is less than the current stability limit.

3.1.2.6 MULTIPLE PRESSURE RANGES

PPCK+ has one reference pressure transducer (RPT) which has three ranges. The multi-ranging feature allows measurement uncertainty to be optimized for the range of pressure in which you are working. Generally, the best range to select (see Section 3.2.1) is that whose full scale is closest to, but greater than, the maximum pressure of the device or system under test.

Ranges available can be viewed at any time, but a range change can only be executed when PPCK+ is vented (see Section 3.1.2.2).

When a range is changed, the upper limit (UL) is automatically changed to the default for that range or to the last upper limit that was set for that range (see Section

3.2.4). In addition, most other functions and settings are range specific (see Section

3.2.1.1).

Each PPCK+ has three ranges. In general, user settings and operational adjustments

are specific to the range currently in use, as if you had three instruments rather than one.

Ranges And Identification

The active reference transducer and range is continuously displayed in the upper right hand corner of the main run screen and most other screens. See Table 1 for a complete listing of the RPTs available and their ranges.

Hi RPT: The RPT in a PPCK+ is referred to as the Hi RPT. Range 1, 2 or 3: The three ranges of the RPT are referred to as 1 = lo range,

2 = mid range, 3 = hi range.

Table 5. PPCK+ Range Identification Summary

REFERENCE PRESSURE

TRANSDUCER AND RANGE

Hi RPT, Lo range Hi, 1 H1

Hi RPT, Mid range Hi, 2 H2

Hi RPT, Hi range Hi, 3 H3

* The display symbol is included in the upper, right hand corner of most PPCK+

menu displays as a convenient indicator of active range.

DESIGNATION DISPLAY SYMBOL *

PPCK+™ Operation and Maintenance Manual

3.1.2.7 DIRECT FUNCTION KEYS SUMMARY

Local operation of PPCK+ is through the 4 x 4 pressure sensitive keypad. To minimize the use of multi-layered menu structure, the 4 x 4 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 PPCK+ is in its main run screen. Table 6 summarizes the operation of the direct function keys.

Table 6 provides a brief summary of direct function key operation. It may be useful to

keep a copy of this summary near the PPCK+, especially when first becoming acquainted with its operation.

3.2 DIRECT FUNCTION KEYS

3.2.1 [RANGE]

 PURPOSE

To view and/or change the pressure measurement range.

 PRINCIPLE

Each PPCK+ has three ranges (see Section 3.1.2.6). Pressing the [RANGE] function key allows the ranges to be viewed and selected. PPCK+ functions and settings such as pressure unit of measure, control mode and upper

limit are range specific. Changes made while in one range apply to that range only and do not affect settings in other ranges. Only the HEAD function is not range specific (see Section 3.2.7).

 OPERATION

Pressing the [RANGE] function key activates the range viewing and selecting function. Pressing the [+/-] key or the [RANGE] key again while in the RANGE functions steps through displays of available ranges, Lo to Hi. Pressing [ENTER] while in the RANGE viewing function, if the PPCK+ is vented, causes the currently displayed range to become the active range. Pressing [ESCAPE] while in the range function returns to the main run screen with no range.

PPCK+™ Operation and Maintenance Manual

Table 6. Summary of PPCK+ Direct Function Key Operation

Direct Function Keys are active from the MAIN run screen

See corresponding manual sections for full detail

SPECIAL

MENU OF COMMONLY USED SETUP FEATURES INCLUDING

Menu of less frequently used internal functions and settings.

HEAD

Adjust height of fluid head correction. Set to zero to defeat head correction.

LEAK

CHECK

RES

Runs an automated leak check at the current pressure.

Adjust display resolution of measured pressure and other indications and settings.

UPPER

LIMIT

SEQ

CUSTOM

CONTROL

Set the upper limit pressure alarm for the active range.

Not used in PPCK+.

Set custom pressure control parameters (hold limit, stability limit) for the current control mode.

RANGE

Shows active range and then toggles through available ranges. [ENTER] on a range activates it.

UNIT

Change pressure measurement unit and/or measurement mode (gauge/absolute). Choice of units can be customized.

CONTROL

Change pressure control mode (static/dynamic). Set control parameters to default by selecting the control mode.

ENTER

SET P

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

Jog the pressure control set point by the amount of the hold limit while controlling or when entering a set point.

PPCK+™ Operation and Maintenance Manual

When the [RANGE] function key is first pressed, the active reference pressure transducer (RPT) and range are displayed. For example:

1. Identifies RPT currently in use (<Hi>).

Current Hi,Rng3 H3 psi 6000g/6000a

2. Identifies current range (<1>, <2> or <3>) of the RPT.

3. Range designator.

4. Full scale pressure value in the current units for the RPT and range number when used in gauge <g> or absolute <a> mode.

5. Units of measure (the units of measure currently active for this range).

Pressing the [+/-] key or pressing the [RANGE] key again causes the screen to step through the other available ranges in sequence: Lo to Hi and back to Lo. For example:

Select Hi, Rng1 H1 psi 2000g/2000a

2. Identifies range of the RPT (<1>, <2> or <3>).

3. Range designator.

4. Full scale pressure value in the active units of measure for the RPT and range number when used in gauge <g> or absolute <a> mode.

1. Identifies RPT (<Hi>).

5. Units of measure (the units of measure currently active for the range).

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

range. Use [UNIT] to change pressure units if desired (see Section 3.2.1).

The active range can only be changed when the system is vented. If [ENTER] is pressed

while in the RANGE function when PPCK+ is NOT vented, the display indicates <Vent system fully to change range>. Pressing the [VENT] key causes PPCK+ to vent and return to the RANGE function when the VENT is complete.

3.2.1.1 RANGE SPECIFIC FUNCTIONS AND SETTINGS

PPCK+ functions and settings are range specific. They are set and stored for each range so that changing them when in one range does not change them in the other ranges. When you return to a range, you will find the settings you left.

Functions and settings that are NOT range specific are:

• Functions: HEAD

• Setup Menu: <2Drivers>

PPCK+™ Operation and Maintenance Manual

3.2.2 [UNIT]

 PURPOSE

To specify the pressure unit of measure and measurement mode in which PPCK+ displays pressure values.

See also Section 3.4.3.

 PRINCIPLE

PPCK+ allows the pressure measurement unit and mode to be changed. Internally, PPCK+ 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).

PPCK+ RPTs intrinsically measure absolute pressure relative to an evacuated and sealed reference. They are also used to measure in gauge mode by the subtraction of atmospheric pressure. PPCK+ supports extensive on-board logic and measurements to assure the precise atmospheric compensation of absolute RPTs to deliver achieve gauge pressure (see Section 3.4.1, Gauge Mode, Dynamic Compensation For Atmospheric Pressure). This allows simple, one step switching between gauge and absolute measurement modes by the operator without special procedures or hardware.

 OPERATION

To change the pressure unit and/or the measurement mode, press the [UNIT] function key.

Measurement: H1 1unit 2mode

The display is: Select <1unit> to change pressure units or <2mode> to change measurement mode. If <2mode> is selected, the next screen offers the choice between <1gauge>

and <2absolute>. Making a selection returns to the main run screen with the selected measurement mode active.

If <1unit> is selected from the measurement screen, the units screen is presented. The cursor is on the number corresponding to the

active unit for the active range. To change the pressure unit for the active range, select the

1psi 2MPa 3kPa 4bar 5kcm2

desired unit. Pressing [ENTER] activates the unit and returns to the main run screen.

If the pressure unit selected is inWa, the reference temperature for water density must be specified. When inWa is selected as the unit, the next

Select inWa ref temp

4°C 20°C 60°F

display is:

PPCK+™ Operation and Maintenance Manual

Select the desired reference temperature for water density using the [←] or [→] key to move the cursor. Pressing [ENTER] returns to the main run screen with inWa based on water density at the selected reference temperature as the pressure unit. The current inWa reference temperature can be viewed by observing the position of the cursor in the reference temperature screen.

There are two possible default pressure unit screens (one US and one SI) depending on

whether the PPCK+ has been factory set as US or SI. Whether the PPCK+ is set up as US or SI is indicated by the right two characters on the top line of the PPCK+ introduction screen which can be viewed by pressing [ESCAPE] from the main run screen or when powering up PPCK+. For a US PPCK+ the default units are <1psi>, <2MPa>, <3kPa>, <4bar>, <5kcm2>. For an SI PPCK+, the default units are: <1MPa>, <2kPa>, <3bar>, <4psi>, <5kcm2>.

No reference temperature selection is necessary for the unit mmWa as the only reference

temperature commonly used for mmWa is 4 ºC.

The pressure measurement unit selected is range specific. When in a given range, all

functions and setting values are represented in the current measurement unit for that range. However, certain internal and/or metrological functions (e.g., RPT calibration coefficients) are always represented in Pa regardless of the current range unit.

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

The choice of six units available under the UNIT function can be modified from a wider

selection by the user (see Section 3.4.3). The units available under the UNIT function can be reset to default by pressing [SPECIAL] and selecting <4Internal>, <5Reset>, <2units> (see Section 3.4.4.5).

3.2.3 [CONTROL]

 PURPOSE

To set the automated pressure control mode for the active range and activate default control parameters.

PPCK+™ Operation and Maintenance Manual

 PRINCIPLE

The CONTROL function allows the active control mode for the current range to be set to either static control or dynamic control (see Section 3.1.2.4). The control mode is specific to the active range and is maintained with the range when ranges are changed.

When the control mode is selected using the CONTROL function, CONTROL parameters are set to system default parameters. The default control parameters have been determined to be those most suitable for the typical user to operate within PPCK+ pressure control and measurement specifications (see Section 3.2.3.1). If desired, control mode parameters can be customized using the CUSTOM CONTROL function (see Section 3.2.6).

For a complete description of the operation and purpose of static and dynamic control modes see Section 3.1.2.4.

 OPERATION

To select the control mode for the active range and set control parameters to the default control parameters, press the [CONTROL] function key from the main run screen. The display is:

Control mode: H3 1dynamic 2static

Selecting <1static> or <2dynamic> causes the selected pressure control mode to be activated with default control parameters and returns to the main run screen.

The control mode setting is range specific. A change in control mode made while in one

PPCK+ range does NOT affect the control mode setting in other ranges (see Section 3.2.1.1).

The current control mode is indicated by two characters in the middle of the bottom line

of the main run screen (<S> for static, <D> for dynamic, <M> for manual, with <C> appended if custom control settings are in use). (See Section 3.1.1.)

In dynamic control mode, whenever the pressure is Ready (inside the hold limit), the

display of measured pressure is equal to the target pressure. This is because in dynamic control mode, when the pressure is Ready, it is assumed that the measured pressure equals the target pressure. This is not true when setting zero in absolute measure mode (see Section 3.2.10.1).

PPCK+™ Operation and Maintenance Manual

3.2.3.1 SYSTEM DEFAULT CONTROL PARAMETERS

Default control parameters for the control mode are automatically set whenever the control mode is selected.

Table 7. Default Pressure Control Parameters

DYNAMIC CONTROL MODE STATIC CONTROL MODE

HOLD LIMIT STABILITY LIMIT HOLD LIMIT STABILITY LIMIT

± 0.01 % FS of active pressure range

± 0.005 % FS/sec of active pressure range

± 1 % FS of active pressure range

3.2.3.2 EXECUTING AUTOMATED PRESSURE CONTROL COMMANDS

 PURPOSE

To use the automated pressure control functions of PPCK+ to set target pressure values.

 OPERATION

See Section 3.2.10.

3.2.4 [UL] (UPPER LIMIT)

 PURPOSE

To set the upper limit pressure value for a pressure range and measurement mode.

 PRINCIPLE

± 0.005 % FS/sec of active pressure range

The UPPER LIMIT function allows the setting of a maximum pressure not to be exceeded when using a specific range and measurement mode. Automated pressure control target values above the upper limit will not be accepted and manual pressure control keys will abort off when the upper limit is reached.

Upper limit settings are specific to each range (H1, H2, H3) and measurement mode (gauge or absolute).

The UPPER LIMIT function is most often used to protect the device or system connected to the PPCK+ TEST port from accidental overpressure.

If no upper limit value is entered by the user, the upper limit for each range and

measurement mode is set by default to 105 % of each range and measurement mode for ranges H3 and to 115 % of each range for all other ranges.

PPCK+™ Operation and Maintenance Manual

 OPERATION

When the [UPPER LIMIT] function key is pressed from the main run screen the display is:

Upper Limit: H3 6300 psi a

Enter the desired upper limit value and PPCK+ returns to the main run screen with a new upper limit value active.

When the UPPER LIMIT has been exceeded, the display of current pressure flashes and an intermittent beep sounds. To return to normal operation, reduce pressure using manual 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 4 000 psi as the upper limit in absolute mode, the upper limit will not be (4 000 psia - atmospheric pressure) in gauge mode. The gauge mode upper limit for that range will still be the default limit or another limit that has been set in gauge mode.

Upper limits are always specified and displayed in the current pressure unit.

1. Entry field to enter desired upper limit value.

3.2.4.1 OVERPRESSURE FUNCTION

In addition to the UL function, PPCK+ has an overpressure function. This function executes when the maximum RPT range is exceeded by 25 %. The function causes all pressure control to be interrupted and disabled, changes the range to H3 and causes the display to flash. The overpressure function also logs the time and date of the overpressure condition to assist in incident diagnosis. To recover from an overpressure condition, cycle PPCK+ power.

3.2.5 [SEQ] SEQUENCE

 PURPOSE

Not supported in PPCK+.

PPCK+™ Operation and Maintenance Manual

3.2.6 [CUSTOM CONTROL]

 PURPOSE

To customize the control parameters of the current pressure control mode for the current range.

See Sections 3.1.2.4, 3.2.3 for information on setting pressures automatically.

 PRINCIPLE

Automated pressure control and the associated pressure Ready/Not Ready condition are characterized by hold limit and stability limit parameters which determine how PPCK+ controls and under what conditions a Ready indication will occur (see Sections 3.1.2.4 and 3.1.2.5).

PPCK+ provides system default values for the hold limit and stability limit parameters for each range. The default values are those most suitable for the typical user to operate within PPCK+ specifications. The default parameters are automatically set each time the control mode is selected using the [CONTROL] function key (see Table 6).

 PRINCIPLE

The CUSTOM CONTROL function allows the hold and stability limit parameters to be customized by the user. This can be used to increase control speed (time to Ready), usually by decreasing control precision, or to increase precision which usually decreases control speed (see Section 3.1.2.5). For example, changing the dynamic pressure control hold limit from its default value of ± 0.01 % FS of the current range to ± 0.02 % will decrease the time required to set a pressure (achieve a Ready condition) since the limit in which the pressure must be set has increased by a factor of two but it will also increase by a factor of two the maximum possible control error included when Ready is indicated.

Adjusting default control parameters using the CUSTOM CONTROL function may result in

control parameters that the PPCK+ is unable to meet so that a Ready condition never occurs. This does not indicate a PPCK+ malfunction, just that the control parameters need to be relaxed or set back to default parameters.

Default Pressure Control Parameters

DYNAMIC CONTROL MODE STATIC CONTROL MODE

HOLD LIMIT STABILITY LIMIT HOLD LIMIT STABILITY LIMIT

± 0.01 % FS of active pressure range

± 0.005 % FS/sec of active pressure range

± 1 % FS of active pressure range

± 0.005 % FS/sec of active pressure range

PPCK+™ Operation and Maintenance Manual

 OPERATION

To set custom control parameters, press the [CUSTOM CONTROL] key from the main run screen. The display is:

Hold limit: H3

0.30 psi D

Enter the desired hold limit. The next display is:

Stability limit: H3

0.30 psi D

1. Current reference transducer (<H> for high) and range (<1>, <2> or <3>).

2. Current control mode setting for this range (<S> for static, <D> for dynamic).

3. Entry field for setting the desired hold limit. Recalls the default hold limit or the last custom hold limit set for the currently active range.

1. Current reference transducer (<H> for high, <L> for Lo) and range (<1>, <2> or <3>).

2. Current control mode (<S> for static, <D> for dynamic).

3. Entry field for setting the desired stability limit. Recalls the default stability limit or the last custom stability limit for the currently active range.

Enter the desired stability limit. The display returns to the main run screen with the custom control parameters active.

To reset default control parameters for a range and control mode, select the control

mode using the CONTROL function while in that range.

Custom control parameters are range and control mode specific. Changes made in one

range and control mode are stored for that range and control mode and will be recalled when that range and control mode is returned to. Changes made in one range and control mode do not affect any other range control mode setting.

When custom control parameters are active, a <C> is appended to the control mode

indicating character (<S> for static, <D> for dynamic) in the middle of the bottom line of the main run screen (see Section 3.1.1).

3.2.6.1 TURNING-OFF CUSTOM CONTROL PARAMETERS

To return to default pressure control parameters for the active range and control mode, select the control mode using the CONTROL function (see Section 3.2.3). Making a control mode selection automatically sets the control parameters to default values.

PPCK+™ Operation and Maintenance Manual

3.2.7 [HEAD]

 PURPOSE

To cause a pressure value representing a difference in height to be added to the pressure measured by the PPCK+ reference pressure transducer.

 PRINCIPLE

PPCK+'s reference pressure transducers measure gauge or absolute pressure at the height of the rear panel TEST port. Frequently, when performing a calibration or test, the device or system under test is at a different height than the PPCK+’s TEST port. This difference in height, frequently called head, can cause a significant difference between the pressure measured by the PPCK+ 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 is useful to make a head correction to the pressure measured by the PPCK+ RPT at its test port in order to accurately predict the pressure actually applied at a different height.

PPCK+ can accurately calculate head pressures for nitrogen, helium and air as the test gas over its working pressure range. The HEAD function allows the height difference to be specified and causes the resulting head pressure to be added to the pressure measured at the TEST port.

The [HEAD] function key is used to turn the head correction function ON and OFF and to specify the height difference between the PPCK+ TEST port and another height. The height unit of measure and the te st gas are specified by pressing [SPECIAL] and selecting <2Head> (see Section 3.4.2).

 OPERATION

To access the HEAD function, press the [HEAD] function key. The display is:

Edit head height: 95 cm N2

In PPCK+’s measurement ranges with gas as the test medium, specifying the head height

within ± 30 cm (12 in.) is adequate to assure that, even in the worst case, the uncertainty on the head correction will be insignificant relative to the tolerance on the measurement.

1. Test gas currently specified for the head correction.

2. Entry field for head height.

PPCK+™ Operation and Maintenance Manual

Entering a value of zero turns the HEAD function OFF. Entering a value other than zero turns the HEAD function ON using the height entered. Pressing [ESCAPE] returns to the main run screen with no change to the current head setting.

The HEAD function is NOT range specific. The HEAD setting remains the same as ranges

are changed. Edits made to the head specifications are independent of range.

When the HEAD function is ON (head height not 0), the ON condition is indicated by an

<h> in the top line, right side of the main run screen (see Section 3.1.1). When the HEAD function is OFF (head height 0), the <h> is not shown.

To change units of head height between inches and centimeters and to change the test

gas species, press [SPECIAL] and select <2Head> (see Section 3.4.2).

The reference height of the PPCK+ pressure

measurement is the middle of the PPCK+ TEST port. The head height should be entered as a positive value if the device or system under test is higher than the PPCK+ and negative if it is lower.

3.2.8 [LEAK CHECK]

 PURPOSE

To run an automated leak check routine using PPCK+’s measurement capability to measure the total pressure change and average rate of change over a period of time; to edit the leak check time.

 PRINCIPLE

The Leak Check function is provided to assist in using PPCK+ to measure leaks by measuring pressure changes.

The principle of the Leak Check function is the measurement of pressure increase or decrease. 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.

Changing the pressure in a test system causes adiabatic temperature changes in the gas

that need to have dissipated before a valid leak measurement can be made. In general, a 2 to 5 minute wait before running a leak check is adequate to allow the adiabatic temperature change to dissipate sufficiently for valid leak measurements to be made. However, stabilization time may be much longer as volumes and pressures increase.

PPCK+™ Operation and Maintenance Manual

 OPERATION

Use automated (see Section 3.2.10) or manual (see Section 3.1.2.2) pressure control to set the pressure at which the leak check is to be conducted. Once the pressure has been set, abort pressure control and wait three minutes for pressure stabilization.

To access the LEAK function press [SETUP], <5Leak>. The display is:

Leak Check H3 1run 2view

Press <2view> to view the results of the last leak check executed. The results screen displays <Data NOT available> briefly and returns to main run screen if NO leak check data is stored (i.e., if the PPCK+ has never run a leak test or a reset has cleared previous leak test results). Pressing [ENTER] or [ESCAPE] returns to the main run screen.

In both dynamic and static pressure control mode, abort control and wait at least three

minutes before conducting a leak check.

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.

Press <1run> to run a leak check and/or to edit the leak check time. The display is:

Set leak check time:

1. Edit field for leak check time in seconds (1 min, 999 max).

Edit the leak check time if desired. Press [ENTER] to run leak test. The display is:

5458.55 psi a zH3 Leak testing 13 s

Pressing [ESCAPE] during the countdown offers a leak check abort option to return to the main run screen or continue leak test. Pressing [ENTER] during the leak check countdown causes the countdown to restart.

1. Standard main run screen first line.

2. Indication that leak test is running and countdown of time[s] remaining.

PPCK+™ Operation and Maintenance Manual

Once the leak check countdown has completed, the results screen is displayed:

Δ P -0.02 psi H3 Rate -0.026/sec

Pressing [ENTER] from the leak check results screen following execution of a leak check starts a new leak check routine directly without having to go through the leak check menu. Pressing [ESCAPE] returns to the main run screen.

Pressing [ENTER] while counting down a leak check or when in leak check results screen

starts a new leak check sequence.

3.2.9 [RES] (RESOLUTION)

 PURPOSE

To set the resolution with which measured pressures and other indications and settings are displayed.

 PRINCIPLE

1. Net change in pressure over the leak check time period.

2. Indicator of range in which leak check was run.

3. Average rate of change of pressure over the leak check time period.

The resolution with which the pressure measured by PPCK+ is displayed can be adjusted. This feature can be used to reduce the resolution when lower precision measurements are being made and additional digits might confuse or distract the operator.

The resolution setting determines the number of digits with which pressure is displayed. The desired resolution is calculated based on the full scale of the range and then rounded to the furthest digit to the right.

 OPERATION

To access the resolution function, press [RES]. The display is:

Use the [←] and [→] keys to select the desired level of resolution. Press [ENTER] to set the resolution and return to the main run screen.

The default resolution setting is 0.001 %. The maximum resolution setting is 0.0001 %.

Measure resltn: H3

0.0010% FS < and >

The resolution setting affects the display of the measured pressure as well as other

indications and settings.

The resolution setting is range specific. A resolution setting made in one range does NOT

affect other ranges.

PPCK+™ Operation and Maintenance Manual

3.2.10 [SET P] (SETTING PRESSURE AUTOMATICALLY)

 PURPOSE

To set a pressure automatically.

See Sections 3.2.3, 3.1.2.4 for information on setting the control mode (Static

or Dynamic).

 PRINCIPLE

PPCK+ automatically sets and holds pressure to a user designated target value. This feature allows pressure values to be set easily and precisely by simple numerical entry from the front panel or by remote command (see Sections 3.1.2.3, 3.1.2.4).

Automatic pressure setting is controlled from the main run screen using [ENTER] and [SET P] from the main run screen. [SET P] causes the pressure target entry screen to be displayed and then launches automated pressure control. [ESCAPE] aborts automated pressure control.

PPCK+ supports two pressure control modes to meet different pressure setting and controlling requirements: static and dynamic (see Section 3.1.2.4). Control initiated using [SET P] executes in the current control mode. Use [CONTROL] to change control modes (see Section 3.2.3).

Manual pressure control keys are also available to adjust pressure directly without a target value (see Section 3.1.2.2). Pressures set manually are not controlled after the setting process.

 OPERATION

To set a pressure, press [SET P] from the main run screen. The display is:

* 2000.00 psi g H3 Target: 3000.00

Use the numerical keys and editing keys to enter the target pressure value desired (see Section 3.2.10.1 for information on zero pressure commands). Also, the [←] and [→] keys can be pressed to jog the current target pressure value displayed down or up by the current pressure control hold limit.

For information on PPCK+’s pressure control technology see Section 3.1.2.3.

1. Ready/Not Ready indication, current pressure, units, measurement mode, range (regular first line of main run screen).

2. Entry field for target value of pressure to be set automatically. Comes up with last entry or zero if pressure measurement units have been changed, range

has been changed, or system has been vented.

PPCK+™ Operation and Maintenance Manual

Press [ENTER] to start pressure control to the target pressure, in the current control mode (see Section 3.2.3) and return to the main run screen. The main run screen is:

↑ 2547.95 psi a H3 T 3000.00 DC

Observe the Ready/Not Ready indication to determine when Ready conditions have been satisfied (see Section 3.1.2.5). PPCK+ will continue controlling following static or dynamic control operation protocol (see Section 3.1.2.4) until automated pressure control is interrupted.

Automated pressure control is interrupted by:

• Pressing [ESCAPE]: Suspends control and remains in main run screen.

1. Ready/Not Ready indication, current pressure, units, measurement mode, range (regular first line of main run screen).

2. Current control mode indicator: Flashes when automated pressure control is ON. <D> for dynamic control, <S> for static control with <C> added if custom control parameters are in use. <VLV> when opening a control valve (see Sections 3.2.3, 3.1.2.3).

3. <T>, target pressure value when controlling and in Not Ready condition. <R>, pressure rate of change when in static control inside the hold limit. <D>, deviation from the target value when in dynamic control mode and in Ready condition.

• Pressing any manual pressure control key (see Section 3.1.2.2): Suspends control and executes direct pressure control.

• Pressing any function key: Suspends control and goes to the selected function.

• Pressing [ENTER/SET P]: Suspends control and goes to ENTER target pressure

value screen. To resume automated pressure control, press [SET P] and ENTER a target

pressure value.

Pressure control status is indicated by the pressure control characters of the main

run screen. These are located in the middle of the bottom line of the display. The control character indications are as follows:

- <D> dynamic control mode with default control parameters

- <S> static control mode with default control parameters

- <DC> dynamic control mode with custom control parameters

- <SC> static control mode with custom control parameters

- <VLV> static or dynamic control mode and a control valve is in the opening process

- <M> manual control mode

- FLASHING character: System is actively controlling pressure

- NON FLASHING character: Control is idle

PPCK+™ Operation and Maintenance Manual

In dynamic control mode, whenever the pressure is Ready (inside the hold limit), the

A target pressure entry that exceeds the current upper limit (see Section 3.2.4) or

that is out of range will not be accepted as the target value when [ENTER] is pressed and the buzzer will sound. The minimum and maximum in range target will be set.

See Section 6 if PPCK+ is unable to control pressure or appears to control

pressure poorly.

Pressing the [←] and [→] editing keys on the 4 x 4 keypad can be used while

controlling to jog the pressure control target value down or up by the current hold limit. These keys also jog the target value when in the [SET P] screen (see Section 3.2.11).

3.2.10.1 AUTOMATED PRESSURE COMMANDS FOR ZERO PRESSURE

Zero in gauge mode:

Zero in absolute mode:

Due to the manner in which PPCK+ handles an automated pressure command for

zero in absolute pressure measurement mode, a Ready condition will occur at an atmospheric pressure, not zero. When setting zero in absolute measurement mode, the Ready condition should not be interpreted to mean that the pressure is zero within the hold limit. Ready is an indication that the PPCK+ TEST port is open to atmospheric pressure and the rate of change of pressure has reached the current stability limit. The current displayed pressure should be used as the measured value of pressure applied to the device or system under test.

A command for automated pressure control to a target value of zero when in gauge pressure measurement mode is interpreted in the same manner as if the [VENT] manual pressure control key had been pressed (see Section 3.1.2.2). A Ready condition occurs when the vent valve has been opened and the pressure meets the current stability test.

Since PPCK+ has no provision for setting pressure lower than atmosphere, a command for automated pressure control to a target value of zero when absolute pressure measurement

mode is interpreted in the same way as a command for zero in gauge measurement mode. PPCK+ executes the [VENT]

function (see Section 3.1.2.2) and a Ready condition occurs when the vent valve has been opened and the pressure meets the current stability test. The vented condition (atmospheric pressure) is the lowest pressure that PPCK+ can set.

PPCK+™ Operation and Maintenance Manual

3.2.11 [←] AND [→] (JOG PRESSURE SET POINT)

 PURPOSE

To jog the pressure target value in small increments around the set point.

See Section 3.2.10 for information on setting pressure automatically.

 PRINCIPLE

PPCK+ sets and adjusts pressure automatically to a user designated target value. In some cases, it can be useful to slightly adjust the target value, for example to set the DUT to read a specific value as commonly done when verifying or calibrating an analog gauge.

The PPCK+ jog function makes it easy to adjust the target pressure slightly. Pressing the [←] and [→] keys of the 4 x 4 keypad while controlling pressure in the main run screen or when displaying the target pressure in the set pressure screen, causes the target value to increase or decrease by the amount of the current hold limit (see Section

3.2.3).

For information on setting pressure automatically with PPCK+ see Sections 3.2.10,

3.1.2.3, 3.1.2.4).

 OPERATION

The target pressure value can be jogged:

• In dynamic control mode while controlling pressure in the main run screen.

• In dynamic control mode in the set target screen.

To jog the target pressure value, press [←] to increase the target value or [→] to decrease the target value.

Each time [←] or [→] is pressed, the target value is adjusted up or down by the current value of the hold limit each time the key is pressed. Use [CUSTOM CONTROL] to adjust the hold limit (see Section 3.2.6).

It will take several seconds after the pressure control target value has been adjusted for

PPCK+ to respond.

PPCK+™ Operation and Maintenance Manual

3.3 SETUP MENU KEY

 PURPOSE

The [SETUP] menu key accesses a menu of functions and features commonly used in setting up PPCK+ for use.

 OPERATION

Press the [SETUP] key from the main run screen to access the SETUP menu. The display is:

3.3.1 SEQUENCE

 PURPOSE

Not supported in PPCK+.

3.3.2 DRIVERS

 PURPOSE

To control the output signals of PPCK+'s 8 channel, 12 V external drivers.

 PRINCIPLE

PPCK+ external drivers are available to drive peripheral equipment, for example solenoid valves, in a system that includes PPCK+. The driver electrical connections are available from a rear panel connector.

See Section 7.1 for driver specifications and pin-outs.

 OPERATION

1Sequence 2Drivers

To access the driver control function press [SETUP] and select <4drivers>. The display is:

Pressing the keypad numerical key driver number turns that driver ON and OFF with either a momentary or a toggled response (see next paragraph). An active driver is indicated by <*> immediately following the driver number.

Pressing [ENTER] while in the <External drivers> menu causes a menu to appear that allows selection of whether the driver actuation will be <1momentary> or <2toggle>.

External drivers: 1 2 3 4 5 6 7 8

PPCK+™ Operation and Maintenance Manual

3.4 SPECIAL MENU KEY

The [SPECIAL] menu key accesses a menu of functions that are less commonly used or not normally used in regular operation.

Press the [SPECIAL] menu key to access the SPECIAL menu. The display is:

1AutoZ 2Head 3PresU 4Internal

Press <1AutoZ> to turn AutoZ ON/OFF and view AutoZ values (see Section 3.4.1). Press <2Head> to set head height units and change the head fluid (see Section 3.4.2). Press <3PresU> to customize the choice of pressure units of measure under [UNIT] (see

Section 3.4.3). Press <4Internal> to access internal settings and functions RPT calibration, remote interface

settings, time and date, resets, user levels and screen saver (see Sections 3.4.4.1 to 3.4.4.8).

3.4.1 AUTOZ

 PURPOSE

To change the offset (zero) of the reference pressure transducer (RPT) relative to a reference value in order to compensate for RPT zero drift between full recalibrations.

To assure operation within "with autozero" measurement uncertainty specifications

(see Section 1.2.2.1), it is recommended that AutoZ be run (the value of ZOFFSET updated) at least every 30 days or when PPCK+ has been exposed to temperature changes

exceeding ± 20 ºC (36 ºF).

 PRINCIPLE

How AutoZ Works

The main component of the change over time of the PPCK+ RPTs is zero drift or offset, independent of span. Rezeroing PPCK+ RPTs relative to a more stable reference between recalibrations allows lower measurement uncertainty specifications to be maintained with less frequent full calibrations. The PPCK+ autozero function (AutoZ) provides full on-board support for the rezeroing process to simplify its application by the user.

PPCK+™ Operation and Maintenance Manual

The autozeroing function uses four parameters:

1. ZSTD: The value of the autozero reference pressure as indicated by the reference autozero device.

In absolute measurement mode, the autozero pressure is usually a pressure value near atmospheric pressure and the ZSTD value can be supplied either: a) by manual entry; b) automatically from a DHI RPM connected to the PPCK+ COM2 port.

In gauge measurement mode, the autozero pressure is always zero (atmospheric pressure) which is supplied by definition when the RPT is vented to atmosphere.

2. ZCURERR: The difference between ZSTD and the RPT indication at the autozero pressure at some time after the calibration of the RPT (ZCURERR = RPT w/out ZOFFSET - ZSTD).

3. ZNATERR: The difference between ZSTD and the RPT indication at the autozero pressure just after the RPT has been calibrated. This is referred to as the natural error at the autozero pressure. Because no RPT is perfectly linear and ZSTD is not perfectly accurate, the disagreement between the RPT reading and ZSTD at the autozero pressure is unlikely to ever be zero.

4. ZOFFSET: ZCURERR corrected for ZNATERR, represents the drift of the RPT relative to the reference (ZOFFSET = ZCURERR - ZNATERR). The current RPT reading, adjusted by ZOFFSET, is the autozeroed RPT reading (e.g., the RPT reading corrected for zero drift since it was calibrated). In gauge mode, ZOFFSET also includes the value of atmospheric pressure that is being subtracted to arrive at gauge pressure.

The AutoZ function manages the determination, storage and application of ZNATERR and ZOFFSET individually for each PPCK+ range and measurement mode.

AutoZ ON/OFF

The AutoZ function can be turned ON and OFF. When AutoZ is ON, the ZOFFSET is always applied to the pressure measured by PPCK+. When AutoZ is OFF, ZOFFSET is not applied (except for an absolute RPT in gauge mode for which ZOFFSET is the current value of atmospheric pressure which is always subtracted to achieve gauge pressure).

PPCK+™ Operation and Maintenance Manual

Gauge Mode, Dynamic Compensation For Atmospheric Pressure

PPCK+ allows gauge pressure measurements with an absolute RPT by calculation, subtracting the value of atmosphere (tare) from the RPT's absolute measurement to arrive at a gauge value. The appropriate tare value changes with the natural evolution of atmospheric pressure at a given location. For this reason, the value of the tare is redetermined each time the RPT is known to be exposed to atmospheric pressure (e.g., the PPCK+ is vented and the pressure is stable). However, if atmospheric pressure changes significantly between opportunities to redetermine the tare, for example if running an extensive test that does not include returns to a vented condition, the changes in atmospheric pressure during that time will not be taken into account and a significant zero offset in the gauge pressure indications could result.

To minimize zero errors due to the evolution of atmospheric pressure between taring opportunities when using an absolute RPT in gauge measurement mode, PPCK+ dynamically compensates the atmospheric tare value. PPCK+'s on-board barometer measures atmospheric pressure independently from the RPT. Between opportunities to update the tare value (vented conditions), the difference between the on-board barometer reading at the time of the last tare value and the current on-board barometer reading is used to compensate the tare value. This value is called ATMOFFSET. This technique, which relies only on the resolution and short term stability of the on-board barometer, rather than its absolute measurement uncertainty, allows gauge measurements with an absolute RPT with an additional uncertainty due to possible changes in atmospheric pressure limited to ± 2.5 Pa (0.00035 psi).

Recommendations For The Use Of The AutoZ Function

The AutoZ function provides a powerful and easy to use tool for improving the measurement uncertainty specifications of a PPCK+ and reducing the calibration recall interval by compensating for zero drift between full recalibrations. The following simple recommendations will help assure that you use this feature to best advantage.

• Always leave AutoZ ON when operating in the gauge measurement mode unless the on-board barometer has malfunctioned (see Section 3.4.4.7).

• Always leave AutoZ ON when operating in the absolute measurement mode if ZNATERR was set properly at calibration and the AutoZ routine using a valid atmospheric reference has been run regularly.

• Execute the run AutoZ routine only when a reference whose measurement uncertainty is known to be significantly lower than that of the PPCK+ RPT is available. Keep range ratios in mind when comparing uncertainties. A ± 0.01 % FS barometer has roughly 200 times lower measurement uncertainty than a ± 0.02 % FS 2 000 psi (14 MPa) PPCK+ range because the RPT/barometer range ratio is 10:1.

• The best day to day reference for running AutoZ in absolute mode is a properly calibrated, barometric range, DHI PPCK+ interfaced directly to the PPCK+ COM2 port. The on-board barometer can also be used as a stable atmospheric pressure reference.

• Allow the PPCK+ to stabilize at atmospheric pressure and ambient temperature for 5 to 10 minutes before running AutoZ in gauge measurement mode.

PPCK+™ Operation and Maintenance Manual

 OPERATION

The AutoZ function and values are range AND mode (gauge or absolute) specific.

To access the PPCK+ AutoZ function press [SPECIAL] and select <1AutoZ>. The display is:

1off 2view H3 3edit 4run

Selecting <1off> (or <1on>) is for changing the AutoZ status for the current range and measurement mode from ON to OFF or vice versa. Selecting <1off> turns OFF the AutoZ function for the current range and mode (see AutoZ ON/OFF

of this Section).

AutoZ ON is indicated by a <z> in the main run screen, top line, third character from

the right. When AutoZ is OFF, the character is blank.

Selecting <2view> allows the current value of ZOFFSET for the current range and mode to be viewed.

Selecting <3edit> allows the value of ZOFFSET for the current range and measurement mode to be edited.

Selecting <4run> allows the routine for determination and activation of ZOFFSET by measurement of ZSTD to be executed.

3.4.1.1 VIEW AUTOZ

To view the current ZOFFSET for the current range and measurement mode press [SPECIAL] and select <1AutoZ>, <2view>. The display is:

ZOFFSET absolute H3

0.0 Pa

ZOFFSET should be zero when the PPCK+ is new or has just been calibrated.

ZOFFSET in absolute mode should be roughly equal to atmospheric pressure for an absolute RPT operating in gauge mode.

The value of ZOFFSET is always displayed and entered in Pascal (Pa) as PPCK+'s

internal operations are in Pa.

1. Current measurement mode.

2. Current range.

3. Display field of current value of ZOFFSET.

PPCK+™ Operation and Maintenance Manual

3.4.1.2 EDIT AUTOZ

The edit AutoZ function should be used with great caution as entering inappropriate

values and turning ON AutoZ may result in incorrect autozeroing and out of tolerance measurements. In normal operation, the value of ZOFFSET should be changed using the run AutoZ function (seen Section 3.4.1.3). The only expected use of edit AutoZ is to set ZOFFSET to zero after a calibration of PPCK+ RPTs. Before editing ZOFFSET, see Sections 3.4.1, PRINCIPLE and 5.2.6).

To edit the current ZOFFSET for the current range and measurement mode, press [SPECIAL] and select <1AutoZ>, <3edit>. The display is:

ZOFFSET absolute H3

0.0 Pa

The value of ZOFFSET is always displayed and entered in Pascal (Pa).

1. Current measurement mode.

2. Current range.

3. Edit field for value of ZOFFSET.

3.4.1.3 RUN AUTOZ

Run AutoZ is the function by which the current RPT reading is compared to ZSTD and a new value of ZOFFSET representing RPT zero drift is determined (see Section 3.4.1, PRINCIPLE, How AutoZ Works

To access run AutoZ, press [SPECIAL] and select <1AutoZ>, <4run>. If the measurement mode of the current range is gauge, run AutoZ occurs

transparently to the user whenever AutoZ is ON and the PPCK+ is in the vented condition. The display is:

Rng H3 is gauge, no manual AutoZ

1. Indication of current range.

PPCK+™ Operation and Maintenance Manual

If the measurement mode of the current range is absolute the display is:

AutoZ H3 abs by:

1Entry 2COM2

1. Current range.

2. Current measurement mode.

3. Selection of source of ZSTD for ZOFFSET determination.

Selecting <1Entry> allows the value of ZSTD to be entered from the front panel keypad.

Selecting <2COM2> allows the value of ZSTD to be read automatically from an RPM interfaced with PPCK+'s COM2 communications port.

Allow the PPCK+ to stabilize at atmospheric pressure and ambient temperature for

5 to 10 minutes before running AutoZ.

If running AutoZ results in values of ZOFFSET that are greater than ± 0.015 % FS of

the current PPCK+ measurement range, the PPCK+ and/or the source of ZSTD may be out of tolerance or the AutoZ process may have been faulty. Before activating a new ZOFFSET greater than ± 0.015 % FS of the current PPCK+ range, check to be sure that both the PPCK+ and the source of ZSTD were in good working order, properly vented to stable atmospheric pressure, at the same height, and reading in the same pressure units when AutoZ was run.

When the run AutoZ selection is made, if a HEAD correction is currently active

(see Section 3.2.7) the head correction will be disabled to avoid "autozeroing" the head value.

The value of ZOFFSET in absolute mode will not be exactly equal to the difference

between the current reading and ZSTD if ZNATERR is not zero (see Section 3.4.1, PRINCIPLE, How AutoZ Works

The value of ZOFFSET is always displayed and entered in Pascal (Pa).

PPCK+™ Operation and Maintenance Manual

Run Autoz By Entry (Absolute Mode Only)

AutoZ by entry allows the value of ZSTD (see Section 3.4.1, PRINCIPLE, How AutoZ Works) to be entered manually. This provides a simple way of autozeroing relative to an independent reference device such as a house barometer that does not interface directly with PPCK+.

To access run AutoZ by entry press [SPECIAL] and select <1AutoZ>, <4run>, <1Entry>. The display is:

1. Pressure reading, units and mode of the active

14.10 psi a H3 ZSTD: 0.0000

RPT range.

2. Active range indicator.

3. Entry field for the value of ZSTD.

Enter the value of ZSTD in the current units. The next display is:

Old ZOFFSET: 0.0 Pa New ZOFFSET: 978.5 Pa

The new ZOFFSET is the ZOFFSET calculated from this execution of run AutoZ. Press [ENTER] to activate the new ZOFFSET for the current range absolute

measurement mode and return to the main run screen. Press [ESCAPE] to maintain the old ZOFFSET and return to the main run screen.

The value of ZOFFSET is always displayed and entered in Pascal (Pa).

The value of ZSTD is entered in the current pressure units.

Run Autoz By Com2 (Absolute Mode Only)

AutoZ by COM2 allows the value of ZSTD (see Section 3.4.1, PRINCIPLE, How AutoZ Works) to be read automatically from a DHI RPM3 connected by RS232 interface to the PPCK+ COM2 port.

To access run AutoZ by COM2 press [SPECIAL] and select <1AutoZ>, <4run>, <2COM2>. The display is:

14.10 psi a H3 ZSTD: 14.07

1. Pressure reading, units and mode of the active RPT range.

2. Active range indicator.

3. Pressure reading of the RPM connected to PPCK+'s COM2 port.

PPCK+™ Operation and Maintenance Manual

When Ready, press [ENTER]. The next display is:

Old ZOFFSET: 0.0 Pa New ZOFFSET: 756.8 Pa

The new ZOFFSET is the ZOFFSET calculated from this execution of run AutoZ. Press [ENTER] to activate the new ZOFFSET and return to the main run screen.

For PPCK+ to communicate with an RPM connected to it's COM2 port, the PPCK+ and

the RPM RS232 interfaces must be set up properly (see Section 3.4.4.3). If the PPCK+ is unable to locate an RPM on COM2 when running AutoZ by COM2, after 6 seconds it will time out and display <RPM not detected>.

Press [ESCAPE] to maintain the old ZOFFSET and return to the main run screen.

The value of ZOFFSET is always displayed and entered in Pascal (Pa).

3.4.2 HEAD

 PURPOSE

To specify the configuration of the HEAD function (see Section 3.2.7) including the length unit of measure for head height entry and the test gas species for head pressure calculations.

 OPERATION

From the main run screen, press [SPECIAL] and select <2Head>. The display is:

Select the desired head height unit. The next display is:

Head height unit: 1in 2cm

Gas type: 1N2 2He 3Air

Select the type of gas that is being supplied to PPCK+. The characteristics of the gas selected will be used by PPCK+ in calculating head pressures.

PPCK+™ Operation and Maintenance Manual

3.4.3 PresU

 PURPOSE

To customize the selection of pressure units that are available for selection from the [UNIT] function key.

 PRINCIPLE

The [UNIT] function key makes available a choice of six default pressure units (US or SI units depending on whether the PPCK+ has been factory set as US or SI) (see Section 3.2.2). PPCK+ also supports many commonly used units other than those included in the default set up. These units can be made available for active selection by customizing the UNIT function using [SPECIAL], <3PresU>. This allows PPCK+ to offer a very wide selection of units while simplifying day to day operation. The typical user will customize 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] and select <3PresU>. The display is:

Set up user unit #6

1. Entry field to select which unit position (1 - 6) of the UNIT function key menu is to be changed.

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 available are listed in Table 8.

Table 8. UNIT Function - Available Units

<1SI> <2other> <3user>

<1Pa>

<2kPa>

<3MPa>

<4mbar>

<5bar>

<6mmHg>

<7mmWa>

<1psi>

<2psf> <3inHg> <4inWa>

<5kcm2>

*<6none>

The UNIT function display may include less than six units. To delete the current unit from the UNIT screen and show no unit, select <2other>, <6none> for that unit number.

PPCK+™ Operation and Maintenance Manual

If <3user> is selected, the user unit must be defined. The display is:

Define user unit:

1.0000000 Units/PA

1. Entry field.

Enter the number of user units per Pascal (Pa) in the entry field. Pressing [ENTER] defines the user unit and returns to the <Set up unit #> screen.

See Section 7.2 for the pressure unit conversion factors used by PPCK+.

3.4.4 INTERNAL

 PURPOSE

To view, set, adjust, and maintain various aspects of PPCK+'s internal operation including:

<1Config> to run the thermal pressure control volume determination routine (see Section 3.4.4.1).

<2Cal> to view and edit calibration coefficients for the PPCK+ RPT ranges and on-board barometer (see Section 3.4.4.2).

<3Remote> to view and edit RS232 (COM) port and IEEE-488 interface settings (see Section 3.4.4.3).

<4Time> to adjust the date and time (see Section 3.4.4.4). <5Reset> to access various system reset functions (see Section 3.4.4.5). <6Level> to set the user protection level and password (see Section 3.4.4.6). <7Atm> to view the on-board barometer reading (see Section 3.4.4.7). <8ScrSav> to adjust the activation time of the front panel display saver (see

Section 3.4.4.8). <9Log> to view and/or clear the PPCK+ event log.

 OPERATION

To access the internal selections press [SPECIAL] and select <4Internal>. The display is:

1Config 2Cal 3Remote 4Time 5Res et 6Level

7Atm 8ScrSav

PPCK+™ Operation and Maintenance Manual

Select the desired internal function. Select <2Cal> to view and edit calibration coefficients for the PPCK+ RPT ranges and

on-board barometer (see Section 3.4.4.2). Select <3Remote> to view and edit RS232 (COM) port and IEEE-488 interface settings

(see Section 3.4.4.3). Select <4Time> to adjust the date and time (see Section 3.4.4.4). Select <5Reset> to access various system reset functions (see Section 3.4.4.5). Select <6Level> to set the user protection level and password (see Section 3.4.4.6). Select <7Atm> to view the on-board barometer reading (see Section 3.4.4.7). Select <9ScrSav> to adjust the activation time of the front panel display saver (see

Section 3.4.4.8).

3.4.4.1 CONFIG

 PURPOSE

To run an automated routine that determines the volume of the system into which PPCK+ is controlling pressure to optimize the performance of thermal pressure control (TPC) used in dynamic control mode.

 PRINCIPLE

PPCK+ uses thermal pressure control (TPC) for very fine pressure control around the target value in dynamic control mode (see Section 3.1.2.3). For optimal TPC operation, PPCK+ must have a good estimation of the size of the volume connected to the PPCK+ TEST port. In normal dynamic control mode operation, if PPCK+’s estimation of the volume seems incorrect as evidenced by unexpected control response, PPCK+ runs a 0.5 to 2.5 minute routine to determine the test volume. The volume determination routine can also be initiated by the operator using [SPECIAL], 4Internal, 1Config.

The operator initiated volume determination routine can be useful after a test volume change to avoid the increased control time and reduced control precision that may exist until PPCK+ automatically determines the volume.

Thermal pressure control (TPC) is only used in dynamic control mode.

Therefore, the volume configuration routine only executes when dynamic control mode is active.

Due to the high compressibility of low pressure gas, the configuration routine

does not produce reliable results at when run at a starting pressure under 1 MPa (150 psi). Therefore, the volume configuration routine cannot be run under 1 MPa (150 psi).

PPCK+™ Operation and Maintenance Manual

 OPERATION

PPCK+ uses self diagnostics to determine when to run the TPC configuration

routine in dynamic control mode. Therefore, it is not normally necessary to run the configuration routine separately.

Running the Config routine may cause the set pressure to increase or decrease

by up to 1.4 MPa (200 psi).

The dynamic control mode volume determination routine may be run at any pressure greater than 1 MPa (150 psi). Dynamic pressure control mode must be active.

To run the volume determination routine, first set a pressure above 1 MPa (150 psi). Then press [SPECIAL] and select

Run config? 1Yes 2No

<4Internal>, <1Config>. The display is: Selecting <1Yes> causes the volume determination routine to run. While the

routine is running, <Running config…> flashes on the bottom line of the PPCK+ display. Completing the routine may take up to 2.5 minutes and cause the pressure to change by 0.7 to 1.4 kPa (100 to 200 psi).

When the volume determination is complete the display is:

Activate new config? 1Yes 2No

Select <1Yes> to activate the new volume determination. Select <2No> to retain the old volume determination and return to the main run screen.

The volume configuration routine cannot be run under 1 MPa (1 000 psi). An error

message is displayed if the volume configuration routine is initialized at a pressure under 1 MPa (150 psi).

3.4.4.2 CAL

 PURPOSE

To calibrate the PPCK+ reference pressure transducer (RPT) and adjust the on-board barometer. This function is considered part of PPCK+ maintenance and is therefore covered in the maintenance section of this manual (see Section 5.2).

 PRINCIPLE

See Sections 5.2, 5.3, and 5.4.

 OPERATION

See Sections 5.2, 5.3, and 5.4.

PPCK+™ Operation and Maintenance Manual

3.4.4.3 REMOTE

 PURPOSE

To configure the PPCK+ communication ports including COM1, COM2 and the IEEE-488 interface.

 PRINCIPLE

The PPCK+ has two RS232 communications ports referred to as COM1 and COM2 and an IEEE-488 (GPIB) interface. Communication with a host computer is accomplished using either COM1 or the IEEE-488 interface. COM2 is reserved for connecting an external device (e.g., a multimeter, RPM, etc.). The configuration of all the communication ports can be set up through the PPCK+ front panel.

 OPERATION

To access the port configurations and remote program command mode, select [SPECIAL], <4Internal>, <3Remote>. Select <COM1>, <COM2> or <IEEE> to view and edit that port’s settings. Select <format> to select the remote programming command format to use (see FORMAT of this Section).

COM1 And COM2

The COMx ports can be set for the specific settings required by the user. These settings are baud, parity, length and stop bit. The available options are:

• Baud: 300, 600, 1 200, 2 400, 4 800, 9 600

• Parity: NONE, ODD or EVEN

• Length: 7 or 8

• Stop Bit: 1 or 2

The default is <2400, E, 7,1> for 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 PPCK+. The PPCK+ 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.

PPCK+™ Operation and Maintenance Manual

IEEE-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 devices on the same IEEE-488 bus.

The receiving terminating character must be a line feed and EOI. Carriage returns are ignored if received. The PPCK+ sends a line feed and asserts the EOI line to terminate a reply. These settings are fixed to agree with IEEE Std. 488. If you change the address, the IEEE interface will reset (PON) and become idle.

Format

The PPCK+ 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. Selecting a format resets the IEEE interface and puts it into an idle state.

3.4.4.4 TIME

 PURPOSE

To view and edit the PPCK+ internal time and date settings.

 OPERATION

To access the time function press

[SPECIAL] and select <4Internal>, <4Time>. The display is:

Select <1time> to edit the time. Edit hours, then minutes, then am/pm by pressing ENTER at each entry. Seconds go to zero when minutes are entered.

Select <2date> to edit the date. The date must be specified in YYYYMMDD format.

The PPCK+ 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 date function to set your local time and date.

Edit: 1time 2date 08:32:11 am 20000115

PPCK+™ Operation and Maintenance Manual

3.4.4.5 RESET

 PURPOSE

To reset various PPCK+ settings to default or factory values. PPCK+ 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 set up, and should be used only to restore the PPCK+ to a known state. PPCK+ will go through its reboot sequence after any type of reset is executed.

PPCK+ reset functions change current settings to factory defaults. These may

include settings vital to PPCK+ operation and affecting the calibration of the reference pressure transducer. Reset functions should be used only by qualified personnel with knowledge of reset consequences. Reset functions should never be used “experimentally”.

 OPERATION

To access the reset function press

[SPECIAL] and select <4Internal>, <5Reset>. The display is:

Reset – Sets

1sets 2units 3seq 4cal 5all

 PURPOSE

Sets most general system operating parameters back to default values. Does not affect calibration coefficients or remote interfaces.

• Returns each range unit of measure to the first of six available under [UNIT] (see Section 3.2.2).

• Returns measurement mode to the absolute (see Section 3.2.2).

• Range to H3 (see Section 3.2.1).

• Head settings to 0 cm and Nitrogen (see Section 3.2.7).

• Automated pressure control parameters to defaults (see Section 3.2.3.1).

• All upper limit values to defaults (see Section 3.2.4).

• Pressure display resolution to 0.001 % FS (see Section 3.2.9).

• Control mode to dynamic (see Section 3.2.3).

PPCK+™ Operation and Maintenance Manual

• COM ports and IEEE-488 settings to default (see Section 3.4.4.3).

• Autozero enabled (see Section 3.4.1).

• Screen saver to 10 minutes (see Section 3.4.4.8).

Reset - Units

 PURPOSE

Sets the six pressure units available under the UNIT function to the SI or US default selections depending on whether the PPCK+ has been factory set for SI or US. See Sections 3.2.2 and 3.4.3.

Reset - Seq  PURPOSE

• The SEQUENCE function is not supported in PPCK+.

Reset - Cal  PURPOSE

The reset - cal function will delete RPT calibration coefficients changing the

PPCK+ calibration.

Clears all user values affecting the calibration of RPTs and the on-board barometer including:

• Sets all user RPT PA/PM values to 0 and 1 (see Section 5.2.1.1).

• Sets user on-board barometer PA/PM to 0 and 1 (see Section 5.3).

• Sets all ZNATERR values back to zero (see Section 5.2.6).

• Sets all ZOFFSET values back to zero (see Section 3.4.1).

PPCK+™ Operation and Maintenance Manual

Reset - All  PURPOSE

The reset - all function will clear and delete large amounts of user defined

information including critical calibration data.

Combines all resets in one global reset command that clears the entire user section of non-volatile memory. These include:

• Reset - sets

• Reset - units

• Reset - seq

• Reset - cal

• Reset - Com1, Com2 and IEEE-488 interface to defaults (see

Section 3.4.4.3)

None of the reset options affects the user level protection settings (see

Section 3.4.4.6).

3.4.4.6 LEVEL

 PURPOSE

To set user protection levels to restrict access to certain functions and to edit the password required for changing user levels.

 PRINCIPLE

PPCK+'s front panel user interface provides the means to access all PPCK+ 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 PPCK+ 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.

PPCK+™ Operation and Maintenance Manual

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 This level of security is designed to protect the specific metrological

information and system diagnostic and maintenance functions of the system. It is intended for an advanced operator performing many different tasks.

Medium This level of security is designed to protect specific metrological

information in the system and to assure that the PPCK+ is operated using consistent operational parameters.

High This level of 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.

PPCK+ 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 9.

Specifically, the security levels prevent execution of the X’d functions.

PPCK+™ Operation and Maintenance Manual

Table 9. Security Levels

FUNCTION LOW MEDIUM HIGH

[RANGE] key [UNIT] key [CONTROL] key [UPPER LIMIT] key [CUSTOM CONTROL] key [HEAD] key [LEAK CHECK] key [RES] key [SETUP] menu, <2Drivers> [SPECIAL] menu [SPECIAL] menu, <1AutoZ> [SPECIAL] menu, <1AutoZ>, edit [SPECIAL] menu, <2Head> [SPECIAL] menu, <3PresU> [SPECIAL] menu, <4Internal> [SPECIAL] menu, <1Config> [SPECIAL] menu, <4Internal>, <2Cal> [SPECIAL] menu, <4Internal>, <4Time>, edit [SPECIAL] menu, <4 Internal>, <5Reset>, <4cal> [SPECIAL] menu, <4Internal>, <5Reset>, <5all>

 OPERATION

•

• •

•

• •

•

• •

• • •

• •

• • •

PPCK+ is delivered with no active password and open access to the User Level menu. The user level is set to 1Low. User levels can be changed freely until a password has been created.

To access the User Level function, press

[SPECIAL] and select <4Internal>, <6Level>. If no password yet exists or if the

Password:

pppppp

0 disables password

correct password has been entered. The display is:

Selecting <1change> user level brings up the restriction menu:

Restriction: 1none 2low 3medium 4high

You can then select the current restriction level, or [ESC] back to the RUN screen.

PPCK+™ Operation and Maintenance Manual

The second selection <edit password> displays the user password and allows it to be edited. Passwords can be up to six

1change user level 2edit password

numbers in length and cannot start with a zero.

Once a password has been entered, the user level cannot be changed without

reentering the password.

If <0> is entered, then the password is made inactive and the user will not be required to enter a password to access the user level menu. This is the factory default with a security level of <2low>.

If there is an active password, the PPCK+ password entry screen will appear. The user must enter the user defined password

PPCK+ SN

nnnn-xx

Password:

pppppp

or the factory secondary password to proceed any further:

The first field <nnnn> is the serial number of the PPCK+, followed by a second field <xx> that represents the number of times that a secondary password has been used. This second field increments each time a secondary password is used. The third field is where the user enters the password.

The factory secondary password is available in case the user's password has

been misplaced or forgotten. It can be obtained by contacting DHI Customer Service. The factory secondary

password is different for all PPCK+'s

and changes each time it is used.

3.4.4.7 ATM

 PURPOSE

To view the value of atmospheric pressure as measured by the onboard barometer.

 PRINCIPLE

PPCK+ has an independent on-board barometer. The atmospheric pressure measurements made by the on-board barometer are used only for dynamic compensation of atmospheric pressure when using an absolute reference pressure transducer to make gauge pressure measurements (see Section 3.4.1, PRINCIPLE).

The on-board barometer is a low accuracy sensor used only for measuring

changes Section 3.4.1, PRINCIPLE). PPCK+ measurement uncertainty does not depend on the absolute uncertainty of the on-board barometer.

in atmospheric pressure over short periods of time (see

PPCK+™ Operation and Maintenance Manual

 OPERATION

To view the current reading of the on-board barometer press [SPECIAL] and select <4Internal>, <7Atm>. The display is in the pressure units of the current PPCK+ range.

3.4.4.8 SCRSAV

 PURPOSE

To adjust the PPCK+ screen saver function.

 PRINCIPLE

PPCK+ 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. This function is factory set to activate after 10 minutes of inactivity but can be adjusted by the user.

 OPERATION

To access the screen saver function press [SPECIAL] and select <4Internal>, <8ScrSav>. Edit the screen saver on time in minutes as desired.

Setting screen saver time to zero eliminates the screen saver function so that

the display will permanently remain at full brightness.

3.4.4.9 LOG

 PURPOSE

To view and/or clear the PPCK+ event log.

 PRINCIPLE

PPCK+ records to a log each time one of the following events occurs:

• The RPT is overpressure.

• A memory fault occurs.

 OPERATION

To view the event log press [SPECIAL] and select <4Internal>, <9Log>. The oldest logged event appears. Pressing [ENTER] steps through the logged events from the oldest to the most recent and ending with the option to clear the log, YES or NO.

If NO events have been logged, <End of log> displays.

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OOTTEES

PPCK+™ Operation and Maintenance Manual

4. REMOTE OPERATION

4.1 OVERVIEW

Most of the PPCK+ front panel functions can also be executed by commands from a remote computer. The host computer can communicate to the PPCK+ using the PPCK+ COM1 RS232 port or the IEEE-488 port.

Before writing code which makes use of PPCK+ remote commands, familiarize yourself with its operating principles by reading Sections 2 and 3 of this manual.

4.2 INTERFACING

Sending a program message to the PPCK+ will place it into remote mode. The remote indicator in the lower left hand corner of the PPCK+ front panel lights when the PPCK+ is in remote mode. It also flickers when a program message is received. The menus usually accessed from the front panel are locked out while in remote. The [ESCAPE] key returns the PPCK+ to local operation unless the “REMOTE” program message was sent to the unit, which locks out all keypad operation.

4.2.1 RS232 INTERFACE

4.2.1.1 COM1

The PPCK+ COM1 RS232 interface is located on the back of the unit. It is a 9-pin female DB-9F connector configured as a DCE device. Data is transmitted out of the unit using pin 2, and is received on pin 3. This allows a normal pin-to-pin DB-9M to DB-9F RS232 cable to be used to connect to a DTE host.

Handshaking is not required or supported. The COM1 receive buffer is 80 bytes deep. If you overflow the buffer by sending too much data, the data will be lost. Because of this, you must send a single program message at a time and you must wait for the PPCK+ to reply from the previous command before issuing another command.

PPCK+™ Operation and Maintenance Manual

Table 10. Pin Designations and Connections

PPCK+ COM1 DB-9F PIN DESIGNATIONS

PIN # FUNCTION DESCRIPTION

2 TxD This pin transmits serial data from the PPCK+ to the host. 3 RxD This pin accepts serial data from the host computer. 5 Grn This pin is the common return for the TxD and RxD signals.

IBM PC/XT DB-9F CONNECTIONS

DB-25M DB-9F DB-9M DB-9F

2 3 3 3 3 2 2 2 7 5 5 5

IBM PC/XT DB-9M TO PPCK+ DB9F

CONNECTION

4.2.1.2 IEEE-488

The PPCK+ IEEE-488 interface is located on the back of the unit. The physical and electrical interface conforms to IEEE Std 488.1-1987 Subset E2 and IEEE Std.

488.2 1992. You should not attempt to communicate with the IEEE-488 interface while using the COM1 interface. The IEEE-488 receive buffer is 250 bytes deep. If you attempt to overflow the buffer, the PPCK+ will hold off release of the NRFD handshake line until it can service and empty the receive buffer. This keeps the buffer from overflowing.

4.2.1.3 COM2

The PPCK+ COM2 RS232 interface is located on the back of the unit. It can be used to allow the Host computer to communicate with another device through the PPCK+. This allows the user to use one Host COM port to communicate with the PPCK+ and an additional RS232 device. Refer to the ”PASSTHRU” remote program message for details.

COM2 is a 9-pin male DB-9M connector configured as a DTE device. Data is transmitted out of the unit using pin 3, and is received on pin 2. This allows a normal pin-to-pin DB-9M to DB-9F RS232 cable to be used to connect to a DCE device.

Handshaking is not required or supported.

Table 11. List of PPCK+ COM2 DB-9M Pin Designations

PIN # FUNCTION DESCRIPTION

3 TxD This pin transmits serial data from the PPCK+ to a device. 2 RxD This pin accepts serial data from the external device. 5 Grn This pin is the common return for the TxD and RxD signals. 4 DTR This pin is Data Terminal Ready (DTR) (held at +5 V).

PPCK+™ Operation and Maintenance Manual

4.3 PROGRAMMING FORMATS

The PPCK+ program message set is downward compatible with the previous PPCK program message set. It is identical to the PPC2+ program message set with the exception of a few commands that are not included for PPCK+ because they support PPC2+ functions that PPCK+ does not include. This message set includes an enhanced program message format to support IEEE Std

488.2 syntax, format, and status reporting. The user must select whether to use either the original “classic” program message format, or the new “enhanced” program message format. The enhanced format is recommended when possible, as the classic format is obsolete. Selection can be accomplished from the front panel (see Section 3.4.4.3) or remotely by using the “MSGFMT” program message. The default is the classic program message format to allow downward compatibility with existing host software. The basic commands are similar for both the classic and enhanced formats, but the usage, syntax, format and status reporting are different.

The PPCK+ enhanced program message format also includes additional common program messages that are required in every device that complies with the IEEE Std 488.2. These addition common program messages are covered separately in Section 4.6.1.

4.3.1 CLASSIC PROGRAM MESSAGE FORMAT

The classic program message format is downward compatible with the previous PPCK program message set. However, several PPCK functions are not supported by PPCK+ and neither are their corresponding commands (see CFG, DEVICE, DPG, ISO, PPC, HOLD, TOUT, TS, CONFIG). This format is recommended only if you need downward compatibility with older PPCK controllers. Each program message sent is also a query. You can only send one program message to the PPCK+ at time. After sending any program message, you must wait for the PPCK+ to reply before sending another program message. This reply will contain data, or a numeric error message if the program message was invalid. You must wait for this reply before issuing another program message to the PPCK+. This ensures that the PPCK+ has completed the program message. Most remote program messages will return a reply within 500 ms except:

PR, PRR, SR, ATM, RATE: Up to 2.0 seconds to allow a new measurement.

The syntax and format used for each program message in the classic mode is listed next to the keyword ‘Classic:’ in each program message summary in Section 4.4.4.

4.3.2 ENHANCED PROGRAM MESSAGE FORMAT

This enhanced program message format uses the IEEE Std. 488.2 format, syntax and status reporting and is recommended for new applications. Errors are reported using the IEEE Std.

488.2 status reporting model. If an error is reported, the error is put into an Error Queue and the “ERR?” query program message can be used to get a text description of the most recent error. If you are using the IEEE-488 port, the service request line can be setup to be asserted if this occurs (see Section 4.5.2). There are two possible program message types for every program message. Each of these two types starts with the same basic text referred to as the program message header.

PPCK+™ Operation and Maintenance Manual

4.3.2.1 ENHANCED PROGRAM MESSAGE USING THE COMMAND TYPE

The COMMAND type of program message executes a process and can additionally send data to the PPCK+ in the form of comma delimited arguments. This data is usually a setting of some sort that is stored in the PPCK+. If data is specified, it must be preceded by at least one white space from the program message header and be within the range and format described in the program message description. The keyword “Command:” will appear to the left of the required syntax in each program message description.

If you are using the IEEE-488 port, the Command type does not generate a reply so you do not need to wait for a reply. You also may send multiple program messages at once by separating each program message with a semicolon. The commands will be queued and executed in as received order.

If you are using the RS232 port COM1, the Command type will always generate a reply so you must wait for a reply before issuing another program message. Because of this, you can only send one Command program message at a time while using the COM1 port.

4.3.2.2 ENHANCED PROGRAM MESSAGE USING THE QUERY TYPE

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

488.2 status reporting model. A Query program message always ends with a question mark. Most queries will return a reply within 200 ms except:

PR?, PRR?, SR?, ATM?, RATE? Up to 2.0 seconds to allow a new measurement. The syntax for using a QUERY program message is listed next to the keyword

“Query:” in each program message summary in Section 4.4.4.

PPCK+™ Operation and Maintenance Manual

4.4 COMMANDS

4.4.1 PROGRAM MESSAGES

Shown are the basic program messages for the classic and the enhanced formats. There are also additional IEEE Std. 488.2 common commands (they start with an ‘*’) that are common in all IEEE-488.2 compatible devices. These commands and the enhanced format status reporting model are covered in Sections 4.5 and 4.6.

Table 12. Program Message List

# ABORT AINCAL AINR AINRNG ATM AUTOPURGE AUTOVAC AUTOZERO CALAMB COM1 COM2 CONFIG DATE DEVICE DF DP DPG DRV DS ERR GPIB HEAD HOLD HS HS% IF IP IS ISO LOCAL MEM MODE MSGFMT PASSTHRU PCALd,LO PCALd,HI PPC PR

Send a command string out of the PPCK+ COM2 port. Stop pressure generation. Obsolete PPC2+ command not supported by PPCK+. Obsolete PPC2+ command not supported by PPCK+. Obsolete PPC2+ command not supported by PPCK+. Read the current atmospheric pressure (on-board barometer). Command for PPC2+ feature not supported by PPCK+. Command for PPC2+ feature not supported by PPCK+. Read or set the status of the automatic zero function. Read or set the PPCK+ ambient sensor user calibration Read or set the configuration of the COM1 port. Read or set the configuration of the COM2 port. Run a TPC configuration routine. Read or set the current date. Obsolete PPC2 Command. Decrease the pressure quickly. Decrease the pressure a given amount. Obsolete PPC2 Command. Read or set the status of an the external valve drivers. Decrease pressure slowly. Read the last error message. Read or set the GPIB interface address. Read or set the head settings. Obsolete PPC2 Command. Read or set the current control hold limit in pressure. Read or set the current control hold limit in percent full scale. Increase the pressure quickly. Slowly increase the pressure a given amount. Increase the pressure slowly. Obsolete PPC2 Command. Returns control to the PPCK+ front panel. Read the power-up memory test status. Read or set the current pressure control mode. Read or set the type of program message format to use. Send a command string out of the PPCK+ COM2 port. Read or set the user Lo RPT calibration information. PPCK+ has no Lo RPT. Read or set the user Hi RPT calibration information for the specific range. Obsolete PPC2 Command. Read the next PPCK+ RPT pressure.

PPCK+™ Operation and Maintenance Manual

Table 12. Program Message List (Continued)

PRR PS PSF PSH PSS QPRR RANGE RANGEHI RATES RATE READY READYCK REMOTE RES RESET RETURN RPMS RS SCRSAV SETS SN SR SS SS% STAT TIME TOUT TP TS UCOEF UDD UDU UL UNIT VAC VENT VER ZNATERRd,HI ZNATERRd,LO ZOFFSETd,HI ZOFFSETd,LO

Read the next PPCK+ RPT pressure, rate, and ATM. Set a new target pressure and start automated pressure control. Set a new target pressure and use only the fast speed to reach the target. Obsolete PPC2 Command. Set a new target pressure and use only the slow speed to reach the target. Read the last PPCK+ RPT pressure, rate and ATM. Read or set the active range of the PPCK+. Read values of all three PPCK+ ranges. Read or set the rates that define the manual or remote fast and slow rates. Read the next available rate of change of pressure. Obsolete PPC2 Command. Read or set a flag that is cleared by a Not Ready condition. Enable remote local lockout operation. Read or set the pressure display resolution for the current RPT and range. Reset the PPCK+ to the default user parameters. Start a new automated pressure control set using the current target value. Obsolete PPC2 command. Start a fixed rate generation at the rate specified. Read or set the front panel screen saver period. Specify default or custom generation settings. Read the serial number of the PPCK+. Read the next available pressure status. Read or set the stability required for a Ready condition. Read or set the stability required for a Ready condition in % FS/ s. Read the pressure generation status. Read or set the current time of day. Obsolete PPC2 Command. Read the current target pressure. Obsolete PPC2 Command. Convert a pressure in Pascal to pressure in the current units. Obsolete PPC command. Read or set the user defined pressure unit. Read or set the upper limit for the current range. Read or set the pressure unit of measure for the current range. Command for PPC2+ feature not supported by PPCK+. Read, execute or abort a vent process. Read the PPCK+ software version. Read or set the autozero natural error for Hi RPT. Read or set the autozero natural error for Lo RPT. PPCK+ has no Lo RPT. Read or set the autozero offset for Hi RPT. Read or set the autozero offset for Lo RPT. PPCK+ has no Lo RPT.

PPCK+™ Operation and Maintenance Manual

4.4.2 ERROR MESSAGES

The PPCK+ always replies to a program message while using the classic format. If the program message is incorrect or contains invalid data, an error number will be returned in the form <ERR#n> where n is an integer number that represents a specific error. This allows for easy error trapping by the host computer.

In the enhanced format, each error is placed into the Error Queue as it occurs. The <ERR?> query can then be used to remove from the queue and reply the text description of each error that has occurred. If you are using the COM1 port, the Error Queue is cleared each time a program message (except <ERR>) is received. Section 4.5.1 explains the details of the Error Queue. Here is a list of the possible errors numbers and the error description for each.

Table 13. Error #’s and Descriptions

REPLY DESCRIPTION

ERR# 0 "OK" ERR# 2 "Text argument is too long" ERR# 3 "User defined coefficient cannot be 0" ERR# 4 "External device not detected" ERR# 5 "External device improperly configured" ERR# 6 "Numeric argument missing or out of range" ERR# 7 "Missing or improper command argument(s)" ERR# 8 "External device time-out error" ERR# 9 "Unknown command" ERR# 10 “Missing or invalid command suffix” or ”the pressure is

not greater than 1 MPa or PPCK+ is busy” ERR# 11 "Command missing argument" ERR# 12 "System overpressured" ERR# 13 "Text queue overflow" ERR# 14 "User unit not defined" ERR# 16 “Generation failure” ERR# 18 "Command not yet available" ERR# 19 "Not available with absolute units" ERR# 20 "Not available with gauge transducer” ERR# 21 "User device not defined" ERR# 22 "Pressure is not stable" or “Must be vented” ERR# 23 "Option not available or installed" ERR# 24 "Unit must be vented" ERR# 25 "Transducer out of calibration" ERR# 26 "COM port failed to initialize" ERR# 27 "Internal device#1 time-out error" ERR# 28 "Device failure" ERR# 30 "Must be on range H3" ERR# 31 "Upper limit is too low" ERR# 32 "Not stable enough" ERR# 33 "Failed to generate pressure" ERR# 44 “Entry already exists” ERR# 45 “Argument not allowed”

PPCK+™ Operation and Maintenance Manual

4.4.3 PROGRAM MESSAGE DESCRIPTION OVERVIEW

Each program message description is separated into the following sections:

Purpose A brief description of the programs message’s function. Command

Query This is the Enhanced program message syntax to request data from the PPCK+.

Classic This is the Classic program message syntax to send data to the PPCK+, to execute a

Arguments If the program message can be used to set data inside the PPCK+, then this section

Default If the program message can be used to set data inside the PPCK+, then this line

Remarks This field has the details and remarks about the command. Example Examples are given for the enhanced and classic methods.

Errors If the program message can report an argument error, the types of errors are listed.

See Also Indicates related program messages (“----“) and refers to manual Sections giving

This is the Enhanced program message syntax to send data to the PPCK+ or to execute a PPCK+ function. The PPCK+ must be set to use the enhanced format (see Section 4.3). It may be sent alone, or followed by at least one white space and additional argument(s) to show that arguments can be passed. If there are multiple arguments, then commas must separate them. If you are using the IEEE-488 port, multiple Command type program messages can be sent in one message if you separate them with a semicolon. There will be no reply from the PPCK+ using the IEEE-488 port. If you are using the COM1 port, the PPCK+ will reply and you must wait for this reply. If this field is not listed in the program message description, then the Command type is not supported when using the Enhanced format.

The PPCK+ must be set to use the enhanced format (see Section 4.3.2). The PPCK+ will always reply to a query. You must wait for this reply before issuing another program message. If this field (Query) is not listed in the program message description, then the Query type for the program message is not supported when using the Enhanced format.

PPCK+ function, or to query for data. This type of command is not recommended for new applications. The PPCK+ must be set to use the classic format (see Section 4.3). It may be followed by a ‘(=)’ and additional argument characters to show that argument(s) can be passed. If there are multiple arguments, then commas must separate them. The PPCK+ will always reply to a Classic program message. You must wait for this reply before issuing another program message. If this field is not listed in the program message description, then it is not supported when using the classic format.

describes the arguments and their limits.

shows (using the enhanced format) the default setting from the factory

Enhanced:

Classic:

If using the classic format or the COM1 port, the error message will be replied after receiving the program message. If using the enhanced format via the IEEE-488 port, the error condition will be handled by the status reporting model which will store the errors in an Error Queue and can be programmed to assert the IEEE-488 SRQ line to signal an error has occurred. In either case, the “ERR” or “ERR?” program message can be used to retrieve a text description of the error.

detail on PPCK+ operation corresponding to the program message.

An example of the use of an enhanced method program message to be sent to the PPCK+ is shown. The message sent to the PPCK+ appears after the “Cmd sent:” label. If only a Query type exists, the “Query sent:” label is shown instead. Directly under this label, “Query reply” shows a typical reply to a query type. “Reply:” shows that a query format does not exist. It may have a short description next to it.

An example of the use of a classic program message to be sent to the PPCK+ is shown. The command sent to the PPCK+ appears after the “Cmd sent:” label. The “Reply” label shows a typical reply to the “Sent” example. It may have a short description next to it.

PPCK+™ Operation and Maintenance Manual

4.4.4 PROGRAM MESSAGE DESCRIPTIONS

Purpose To allow the host PC to communicate with a device connected to the PPCK+

COM2 port. This program message is obsolete. You should instead use the “PASSTHRU” program message. This command is not available when using the

enhanced command format. Instead, use the “PASSTHRU” command. Classic “#xx” Arguments xx: The string to send out of the COM2 port. It must be less than

40 characters long.

Remarks The PPCK+ COM2 port can be used to communicate to another RS232 device (such

as another PPCK+). This allows the user to use one COM port or IEEE-488 port on

the host computer to communicate with the PPCK+ and another device. A carriage

return and a line feed (<CR><LF>) are added to the string.

After this program message is issued, the PPCK+ will reply back the first string

received by the PPCK+ COM2 port that is terminated with a carriage return.

Line feeds are discarded. This will discontinue when the next program message is

sent to the PPCK+.

There is no other reply from this program message. Prior to using this program

message, you must ensure that the PPCK+ COM2 port is correctly set up to

communicate with the device on COM2. Refer to the “COM2=“ program message. Example (classic) This example assumes that a second PPCK+’s COM1 port is connected to the

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Specifications and Main Features

Frequently Asked Questions

User Manual