Fluke PG7102 V2.03, PG7202 V2.03, PG7601 V2.03, PG7302 V2.03 Operation and Maintenance Manual

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PG7000™ PISTON GAUGES

PG7102™, PG7202™,

PG7302™, PG7601™

(Ver. 3.0 and Higher)

Operation and Maintenance Manual

PG7000™ 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.

Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments 4765 East Beautiful Lane Phoenix Arizona 85044-5318 USA.

DH Instruments makes sincere efforts to ensure the accuracy and quality of its published materials; however, no warranty, expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the English version and other language versions, the English version predominates.

DH Instruments, DH, DHI, PG7000, PG7102, PG7202, PG7302, PG7601, CalTool and COMPASS are trademarks, registered and otherwise, of DH Instruments, a Fluke Company.

Swagelok is a registered trademark of the Swagelok Company. Krytox is a registered trademark of the Dupont de Nemours Company.

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

Document No. 3152117 090615 Printed in the USA

AABBLLEE OOFF

OONNTTEENNTTS

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

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

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

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

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

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

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

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

1.2.1.1 EMBEDDED FEATURES...........................................................................................................................3

1.2.1.2 AMBIENT AND INSTRUMENT CONDITION MEASUREMENTS..............................................................4

1.2.2 PISTON-CYLINDER MODULES....................................................................................................................5

1.2.2.1 PC-7100/7600............................................................................................................................................5

1.2.2.2 PC-7200.....................................................................................................................................................6

1.2.2.3 PC-7300.....................................................................................................................................................7

1.2.3 MASS SETS...................................................................................................................................................8

1.2.4 PRESSURE MEASUREMENTS....................................................................................................................8

1.2.4.1 PC-7100/7600............................................................................................................................................8

1.2.4.2 PC-7200.....................................................................................................................................................9

1.2.4.3 PC-7300...................................................................................................................................................10

1.3 TERMINAL AND PLATFORM FRONT AND REAR PANELS ...............................................................11

1.3.1 TERMINAL FRONT AND REAR PANELS ..................................................................................................11

1.3.1.1 PG TERMINAL FRONT PANEL...............................................................................................................11

1.3.1.2 PG TERMINAL REAR PANEL.................................................................................................................12

1.3.2 PLATFORM REAR PANELS.......................................................................................................................12

2. INSTALLATION ................................................................ 13

2.1 UNPACKING AND INSPECTION........................................................................................................... 13

2.1.1 REMOVING FROM PACKAGING................................................................................................................13

2.1.1.1 PLATFORM..............................................................................................................................................13

2.1.1.2 MASS SET...............................................................................................................................................13

2.1.1.3 PISTON-CYLINDER MODULE(S) ...........................................................................................................14

2.1.1.4 AUTOMATED MASS HANDLER .............................................................................................................14

2.1.2 INSPECTING CONTENTS...........................................................................................................................14

2.1.2.1 PLATFORM..............................................................................................................................................14

2.1.2.2 MASS SET...............................................................................................................................................19

2.1.2.3 PISTON-CYLINDER MODULE(S) ...........................................................................................................21

2.2 SITE REQUIREMENTS..........................................................................................................................22

2.3 SETUP....................................................................................................................................................23

2.3.1 PREPARING FOR OPERATION.................................................................................................................23

2.3.1.1 SETTING UP THE PLATFORM...............................................................................................................23

2.3.1.2 SYSTEM PRESSURE INTERCONNECTIONS .......................................................................................24

2.3.1.3 SETTING UP A MASS SET.....................................................................................................................24

2.3.2 INSTALLING A PISTON-CYLINDER MODULE INTO THE PLATFORM....................................................25

2.3.3 SWITCHING A PG7202 BETWEEN GAS OPERATION AND OIL OPERATION .......................................27

2.4 POWER UP AND VERIFICATION .........................................................................................................28

2.4.1 POWER UP..................................................................................................................................................28

2.4.2 CHECK THAT ON-BOARD PISTON-CYLINDER MODULE AND MASS SET INFORMATION ARE

CORRECT....................................................................................................................................................29

2.4.3 SET LOCAL GRAVITY VALUE ...................................................................................................................29

2.4.4 SETUP PRESSURE EQUATION VARIABLE INPUT SOURCES.....................................................29

PG7000™ OPERATION AND MAINTENANCE MANUAL

2.4.5 CHECK PROPER OPERATION OF AMBIENT CONDITION MEASUREMENTS ......................................29

2.4.6 APPLY PRESSURE TO THE PISTON-CYLINDER MODULE....................................................................30

2.4.7 CHECK PROPER BEHAVIOR OF MOTORIZED PISTON ROTATION......................................................30

2.4.8 CHECK PROPER OPERATION OF PISTON BEHAVIOR MEASUREMENTS...........................................31

2.4.8.1 VERIFY VACUUM REFERENCE (PG7601 ONLY).................................................................................31

2.4.9 CHECK AUTOMATED PRESSURE GENERATION (IF PRESENT) ....................................................32

2.4.10 CHECK/SET SECURITY LEVEL.................................................................................................................32

2.4.11 ADDITIONAL PRECAUTIONS TO TAKE BEFORE MAKING PRESSURE MEASUREMENTS................32

2.5 SHORT TERM STORAGE.....................................................................................................................33

3. GENERAL OPERATION

..................................................... 35

3.1 FUNDAMENTAL OPERATING PRINCIPLES........................................................................................35

3.1.1 GAS OPERATED, LIQUID LUBRICATED PISTON-CYLINDER OPERATING PRINCIPLE

(PG7202) ....................................................................................................................................................36

3.2 KEYPAD LAYOUT AND PROTOCOL...................................................................................................37

3.3 SOUNDS................................................................................................................................................38

3.4 PRESSURE READY/NOT READY INDICATION...................................................................................38

3.4.1 PISTON POSITION READY/NOT READY..................................................................................................39

3.4.2 PISTON ROTATION READY/NOT READY.................................................................................................39

3.4.3 VACUUM REFERENCE READY/NOT READY (PG7601 ONLY) .....................................................40

3.5 PISTON POSITION................................................................................................................................41

3.6 MASS LOADING PROTOCOL...............................................................................................................42

3.7 MAIN RUN SCREEN..............................................................................................................................45

3.8 GENERAL FUNCTION/MENU FLOW CHART ......................................................................................46

3.9 DIRECT FUNCTION KEYS....................................................................................................................47

3.9.1 DIRECT FUNCTION KEYS SUMMARY......................................................................................................47

3.9.2 [P-C].............................................................................................................................................................48

3.9.3 [UNIT]...........................................................................................................................................................49

3.9.3.1 CUSTOMIZING PRESSURE UNITS AVAILABLE UNDER THE UNIT FUNCTION................................50

3.9.4 [MODE] ........................................................................................................................................................52

3.9.4.1 DIFFERENTIAL MEASUREMENT MODE (PG7601 ONLY) ........................................................53

3.9.4.2 HIGH LINE DIFFERENTIAL MEASUREMENT MODE (PG7102, PG7302 AND PG7202 ONLY)...........60

3.9.5 [SYSTEM] ....................................................................................................................................................72

3.9.5.1 FIRST SYSTEM RUN SCREEN ..............................................................................................................73

3.9.5.2 SECOND SYSTEM RUN SCREEN .........................................................................................................73

3.9.6 [AMBIENT]...................................................................................................................................................74

3.9.7 [HEAD].........................................................................................................................................................75

3.9.8 [ROTATE].....................................................................................................................................................77

3.9.8.1 <2PRE-DECEL>.......................................................................................................................................79

3.9.9 [GEN] (OPTIONAL)......................................................................................................................................79

3.9.9.1 <2TARGET>.............................................................................................................................................81

3.9.9.2 <3RAISE> ................................................................................................................................................82

3.9.9.3 <4UL>.......................................................................................................................................................82

3.9.9.4 <5TOL>....................................................................................................................................................82

3.9.9.5 <6REFLOAT>...........................................................................................................................................83

3.9.9.6 <7VOL>....................................................................................................................................................83

3.9.10 [RES]............................................................................................................................................................84

3.9.11 [ENTER/SET P] FROM RUN SCREEN.......................................................................................................85

3.9.11.1 [ENTER/SET P] IN PRESSURE TO MASS MODE .................................................................................86

3.9.11.2 [ENTER/SET P] IN MASS TO PRESSURE MODE .................................................................................88

3.9.11.3 C O M M A N D S F O R Z E R O P R E S S U R E , E N D I N G A T E S T .....................................................89

3.9.12 [P OR M]......................................................................................................................................................89

3.9.13 [ ] AND [ ], [←]....................................................................................................................................90

3.10 [SETUP] MENU......................................................................................................................................91

3.10.1 <1SELECT>.................................................................................................................................................93

3.10.2 <2VIEW>......................................................................................................................................................93

3.10.3 <3EDIT>.......................................................................................................................................................94

3.11 [SPECIAL] MENU..................................................................................................................................96

3.11.1 <1PC/MS>....................................................................................................................................................97

3.11.1.1 CREATE PISTON-CYLINDER MODULE.................................................................................................99

3.11.1.2 EDIT PISTON-CYLINDER MODULE .....................................................................................................101

3.11.1.3 VIEW PISTON-CYLINDER MODULE ....................................................................................................102

3.11.1.4 DELETE PISTON-CYLINDER MODULE ...............................................................................................102

3.11.1.5 SELECT THE ACTIVE PISTON-CYLINDER MODULE .........................................................................102

3.11.1.6 ADD MASS SET.....................................................................................................................................103

TABLE OF CONTENTS

3.11.1.7 EDIT MASS SET....................................................................................................................................107

3.11.1.8 VIEW MASS SET...................................................................................................................................107

3.11.1.9 DELETE MASS SET ..............................................................................................................................108

3.11.1.10 SELECT MASS SET..............................................................................................................................108

3.11.1.11 ADD MASS LOADING BELL..................................................................................................................109

3.11.1.12 EDIT MASS LOADING BELL.................................................................................................................110

3.11.1.13 VIEW MASS LOADING BELL................................................................................................................110

3.11.1.14 DELETE MASS LOADING BELL...........................................................................................................110

3.11.1.15 SELECT MASS LOADING BELL...........................................................................................................111

3.11.2 <2PRESU>.................................................................................................................................................111

3.11.3 <3HEAD>...................................................................................................................................................111

3.11.3.1 <3HEAD>, <1FLUID>.............................................................................................................................112

3.11.3.2 <3HEAD>, <2UNIT>...............................................................................................................................112

3.11.3.3 <3HEAD>, <3ATM> ...............................................................................................................................113

3.11.3.4 <3HEAD>, <4PISTON>..........................................................................................................................113

3.11.4 <4PREFS>.................................................................................................................................................114

3.11.4.1 <4PREFS>, <1SCRSVR>......................................................................................................................114

3.11.4.2 <4PREFS>, <2SOUND>........................................................................................................................114

3.11.4.3 <4PREFS>, <3TIME> ............................................................................................................................115

3.11.4.4 <4PREFS>, <4ID> .................................................................................................................................115

3.11.4.5 <4PREFS>, <5LEVEL>..........................................................................................................................116

3.11.5 <5REMOTE>..............................................................................................................................................118

3.11.5.1 COM1, COM2 AND COM3 (RS232) ......................................................................................................119

3.11.5.2 IEEE-488................................................................................................................................................119

3.11.5.3 RS232 SELF TEST ................................................................................................................................120

3.11.5.4 EXTERNAL BAROMETER (RPM) COMMUNICATIONS (COM2).........................................................120

3.11.5.5 EXTERNAL VACUUM GAUGE COMMUNICATIONS (COM2) (PG7601 ONLY) ..................................122

3.11.6 <6GL>........................................................................................................................................................124

3.11.7 <7CAL>......................................................................................................................................................125

3.11.8 <8AMH>.....................................................................................................................................................125

3.11.8.1 <2CONTROL>, <1UP/DOWN> ..............................................................................................................126

3.11.8.2 <2CONTROL>, <2DISCREET> .............................................................................................................126

3.11.8.3 <2CONTROL>, <3LOADALL> ...............................................................................................................127

3.11.8.4 <2CONTROL>, <4UNLOADALL> ..........................................................................................................127

3.11.9 <9RESET>.................................................................................................................................................127

3.11.9.1 <9RESET>, <1SETS> ...........................................................................................................................128

3.11.9.2 <9RESET>, <2UNITS> ..........................................................................................................................128

3.11.9.3 <9RESET>, <3COM>.............................................................................................................................129

3.11.9.4 <9RESET>, <4CAL>..............................................................................................................................129

3.11.9.5 <9RESET>, <5SETUPS> ......................................................................................................................130

3.11.9.6 <9RESET>, <6ALL> ..............................................................................................................................130

4. REMOTE OPERATION ......................................................131

4.1 OVERVIEW..........................................................................................................................................131

4.2 INTERFACING.....................................................................................................................................131

4.2.1 RS232 INTERFACE...................................................................................................................................131

4.2.1.1 COM1.....................................................................................................................................................132

4.2.1.2 COM2 AND COM3.................................................................................................................................132

4.2.2 IEEE-488 (GPIB)........................................................................................................................................133

4.3 COMMANDS........................................................................................................................................133

4.3.1 COMMAND SYNTAX.................................................................................................................................133

4.3.2 COMMAND SUMMARY.............................................................................................................................134

4.3.3 ERROR MESSAGES.................................................................................................................................136

4.3.3.1 AMH ERRORS.......................................................................................................................................137

4.3.4 COMMAND DESCRIPTIONS.....................................................................................................................137

4.3.4.1 IEEE STD. 488.2 COMMON AND STATUS COMMANDS .....................................................137

4.3.4.2 PG7000 COMMANDS............................................................................................................................139

4.4 STATUS SYSTEM................................................................................................................................166

4.4.1 STATUS REPORTING SYSTEM...............................................................................................................166

4.4.1.1 STATUS BYTE REGISTER ...................................................................................................................166

4.4.1.2 STANDARD EVENT REGISTER...........................................................................................................167

4.5 HIGH LINE DIFFERENTIAL MODE PROGRAMMING EXAMPLES....................................................168

4.5.1 RECOMMENDED SEQUENCE FOR A HOST PROGRAM TO REMOTELY SET A NEW HIGH LINE

PRESSURE AND ENABLE HIGH LINE DIFFERENTIAL MODE..............................................................168

4.5.2 RECOMMENDED SEQUENCE FOR A HOST PROGRAM TO REMOTELY ENABLE HIGH LINE

DIFFERENTIAL MODE USING THE LAST LINE PRESSURE SETTING.................................................171

PG7000™ OPERATION AND MAINTENANCE MANUAL

5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION ...........173

5.1 INTRODUCTION..................................................................................................................................173

5.2 PLATFORM..........................................................................................................................................174

5.2.1 CALIBRATION/ADJUSTMENT OF ON-BOARD MEASUREMENT FUNCTIONS....................................174

5.2.1.1 PRINCIPLES..........................................................................................................................................174

5.2.1.2 BAROMETRIC PRESSURE SENSOR ..................................................................................................174

5.2.1.3 AMBIENT TEMPERATURE SENSOR...................................................................................................175

5.2.1.4 RELATIVE HUMIDITY SENSOR ...........................................................................................................176

5.2.1.5 P I S T O N - C YL I N D E R M O D U L E T E M P E R A T U R E S E N S O R ..................................................... 176

5.2.1.6 REFERENCE VACUUM GAUGE (PG7601 ONLY)...............................................................................178

5.2.2 PISTON POSITION DETECTION ADJUSTMENT.....................................................................................179

5.2.3 EMPTYING OIL RUN-OFF TRAY (PG7202 AND PG7302 ONLY).................................................180

5.2.4 PURGE MOUNTING POST LIQUID RUN OFF (PG7202 ONLY) ..............................................180

5.2.5 DRIVE BELT REPLACEMENT..................................................................................................................181

5.3 PISTON-CYLINDER MODULES..........................................................................................................182

5.3.1 DISASSEMBLY, CLEANING AND MAINTENANCE.................................................................................182

5.3.2 DISASSEMBLY AND REASSEMBLY.......................................................................................................183

5.3.2.1 DISASSEMBLY AND REASSEMBLY OF GAS OPERATED, GAS LUBRICATED

PISTON-CYLINDER MODULES (PC-7100/7600) .......................................................................183

5.3.2.2 DISASSEMBLY AND REASSEMBLY OF GAS OPERATED, LIQUID LUBRICATED

PISTON-CYLINDER MODULES (PC-7200)..........................................................................................187

5.3.2.3 DISASSEMBLY AND REASSEMBLY OF OIL OPERATED, OIL LUBRICATED

PISTON-CYLINDER MODULES (PC-7300)..........................................................................................189

5.3.3 FILLING OR EMPTYING GAS OPERATED, LIQUID LUBRICATED PISTON-CYLINDER MODULE

RESERVOIR WITH LIQUID.......................................................................................................................191

5.3.4 CLEANING PISTON-CYLINDERS.............................................................................................................192

5.3.5 LUBRICATING PISTON-CYLINDER MODULES......................................................................................194

5.3.6 RECALIBRATION......................................................................................................................................198

5.3.6.1 UPDATING PISTON-CYLINDER MODULE FILES................................................................................198

5.4 MASS SETS.........................................................................................................................................198

5.4.1 CLEANING.................................................................................................................................................198

5.4.2 RECALIBRATION......................................................................................................................................198

5.4.2.1 UPDATING MASS SET FILES...............................................................................................................198

5.5 RELOADING EMBEDDED SOFTWARE INTO PG7000 FLASH MEMORY........................................199

5.6 DISASSEMBLY AND REASSEMBLY OF PG7000 .............................................................................199

5.6.1 PLATFORM................................................................................................................................................199

5.6.2 TERMINAL.................................................................................................................................................199

5.6.3 AMH AUTOMATED MASS HANDLER REMOVAL...................................................................................199

6. TROUBLESHOOTING .......................................................201

6.1 OVERVIEW..........................................................................................................................................201

7. APPENDIX ......................................................................205

7.1 CONVERSION OF NUMERICAL VALUES..........................................................................................205

7.1.1 PRESSURE................................................................................................................................................205

7.2 DEFINED PRESSURE CALCULATIONS............................................................................................205

7.2.1 PG7102, PG7202 AND PG7302................................................................................................................207

7.2.2 PG7601 ......................................................................................................................................................208

7.2.3 FLUID HEADS ...........................................................................................................................................209

7.2.3.1 FLUID HEAD COMPONENTS...............................................................................................................209

7.2.3.2 OVERALL FLUID HEAD CORRECTION...............................................................................................210

7.3 GLOSSARY..........................................................................................................................................211

7.4 WARRANTY STATEMENT..................................................................................................................213

TABLES AND FIGURES

AABBLLEES

Table 1. PG7102 Parts List........................................................................................................................15

Table 2. PG7202 Parts List........................................................................................................................16

Table 3. PG7302 Parts List........................................................................................................................17

Table 4. PG7601 Parts List........................................................................................................................18

Table 5. Manual Mass Set Parts List (excluding 80 and 100 kg) ..............................................................19

Table 6. Manual Mass Set Parts List (80 and 100 kg)............................................................................... 19

Table 7. AMH-38 Mass Set Parts List........................................................................................................19

Table 8. AMH-100 Mass Set Parts List......................................................................................................19

Table 9. Mass Set Compositions............................................................................................................... 20

Table 10. Mass Set Compatibility ..............................................................................................................20

Table 11. PC-7100/7600 Piston-Cylinder Modules Parts List ...................................................................21

Table 12. PC-7200 Piston-Cylinder Modules Parts List ............................................................................21

Table 13. PC-7300 Piston-Cylinder Modules Parts List ...........................................................................22

Table 14. Summary of PG7000 Direct Function Key Operations..............................................................47

Table 15. Pressure Units of Measure Available.........................................................................................51

Table 16. Valve Settings for Setting Differential Mode Static Pressure.....................................................56

Table 17. Valve Settings to Apply PG7000 Pressure to the RPM for Differential Mode Offsetting...........57

Table 18. Valve Settings for Operating in Differential Mode......................................................................59

Table 19. SETUP File Choices, Factory Preferred Choice and Normal Value..........................................92

Table 20. Security Levels - Functions NOT Executed Per Function/Level..............................................117

Table 21. COM1, COM2 and COM3 Available Settings..........................................................................119

Table 22. COM1 DB-9F Pin Designation.................................................................................................132

Table 23. COM2 and COM3 DB-9M Pin Designation .............................................................................132

Table 24. Command Summary................................................................................................................134

Table 25. Error Messages........................................................................................................................136

Table 26. Status Byte Register ................................................................................................................166

Table 27. Standard Event Register..........................................................................................................167

Table 28. Mounting Post Wire Colors, Description and Location............................................................178

Table 29. PG7000 Troubleshooting Checklist.........................................................................................201

Table 30. Pressure Unit of Measure Conversions...................................................................................205

Table 31. PG7000 Defined Pressure Calculation Variables....................................................................206

Table 32. DHI Authorized Service Providers ...........................................................................................213

PG7000™ OPERATION AND MAINTENANCE MANUAL

IIGGUURREES

Figure 1. PG Terminal Front Panel............................................................................................................11

Figure 2. PG Terminal Rear Panel.............................................................................................................12

Figure 3. PG Platform Rear Panel.............................................................................................................12

Figure 4. Piston-Cylinder Module Installation............................................................................................ 26

Figure 5. Piston Gauge Operating Principle.............................................................................................. 35

Figure 6. Gas Operated, Liquid Lubricated Piston-Cylinder (PC-7200) Operating Principle ...................37

Figure 7. PG7000 Keypad Layout..............................................................................................................37

Figure 8. Piston Stroke and Zones ............................................................................................................41

Figure 9. Run Screen Flow Chart ..............................................................................................................46

Figure 10. Differential Mode Controller Schematic....................................................................................55

Figure 11. High Line Differential Mode Schematic ....................................................................................63

Figure 12. Status Byte Register...............................................................................................................166

Figure 13. PG7202 Mounting Post Drain.................................................................................................181

Figure 14. 10 and 20 kPa/kg Gas Piston-Cylinder Module (Expanded View)......................................... 184

Figure 15. 10 kPa/kg Piston Insertion Tool..............................................................................................185

Figure 16. Gas Piston-Cylinder Module Sleeve Nut Tool........................................................................185

Figure 17. 50, 100 and 200 kPa/kg Gas Piston-Cylinder Modules (Expanded View).............................186

Figure 18. Gas Operated, Liquid Lubricated Piston-Cylinder Module (Expanded View) .......................188

Figure 19. Oil Piston-Cylinder Module (Expanded View) ........................................................................190

Figure 20. Filling Gas Operated, Liquid Lubricated Piston-Cylinder Module Reservoir (PC-7200)....... 192

Figure 21. Gas Operated, Gas Lubricated Piston-Cylinder Module Lubrication Chart ............................195

Figure 22. Gas Operated, Liquid Lubricated Piston-Cylinder Module Lubrication Chart ........................196

Figure 23. Oil Operated Piston-Cylinder Module Lubrication Chart ........................................................197

ABOUT THIS MANUAL

BBOOUUTT

This manual provides the user with the information necessary to operate various PG7000 Piston Gauges. It also includes a great deal of additional information provided to help you optimize PG7000 use and take full advantage of its many features and functions.

This manual covers four PG7000 models: PG7102, PG7202, PG7302 and PG7601. The four models have many features and characteristics in common as well as individual differences. When discussing features that are common to all four models, they are referred to collectively as PG7000. When providing information pertaining to a specific model, that model is referred to by its specific model number.

Before using the manual, take a moment to familiarize yourself with the Table of Contents structure. All first time PG7000 users should read Sections 1 and 2. Section 3 provides a comprehensive description of general PG7000 operating principles. Section 4 covers remote communication with an external computer. Section 5 provides maintenance and calibration information. Section 6 is a quick troubleshooting guide. Use the information in Section 6 to troubleshoot unexpected PG7000 behavior based on the symptoms of that behavior.

Certain words and expressions have specific meaning as they pertain to PG7000s. The Glossary (see Section 7) is useful as a quick reference for the definition of specific words and expressions as they are used in this manual.

FOR THOSE OF YOU WHO “DON’T READ MANUALS”, GO DIRECTLY TO SECTION 2.3 TO SET UP YOUR PG7000. THEN GO TO SECTION 2.4. THIS WILL GET YOU RUNNING QUICKLY WITH MINIMAL RISK OF CAUSING DAMAGE TO YOURSELF OR YOUR PG7000. THEN… WHEN YOU HAVE QUESTIONS OR START TO WONDER ABOUT ALL THE GREAT FEATURES YOU MIGHT BE MISSING, GET INTO THE MANUAL!

HHIISS

AANNUUAAL

Manual Conventions

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

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

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

< > indicates PG7000 screen displays (e.g., <1yes>)

PG7000™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

1. INTRODUCTION

11.

NNTTRROODDUUCCTTIIOON

1.1 PRODUCT OVERVIEW

PG7000 Piston Gauges are reference level pressure standards that operate on the piston gauge principle. Pressure is defined by balancing it against the force exerted by a known mass accelerated by gravity on the effective area of a piston-cylinder.

A PG7000 piston gauge consists of the PG7000 Platform, one or several piston-cylinder modules, a mass set. An automated mass handling system is available. A PG7000 system normally also includes the means to generate and adjust pressures and to interconnect the system components and a device being calibrated or tested. The pressure generation component can be manual or automated. COMPASS Pressure software may also be included to assist in executing test sequences, acquiring test data and producing test reports.

There are four PG7000 Platforms: PG7102, PG7202, PG7302 and PG7601. These have a common PG7000 presentation and features. They are distinguished by their normal operating medium (oil and/or gas) and the capability to define pressures relative to a vacuum reference.

for

• PG7102 - Gas operated with gas lubricated piston-cylinder modules (PC-7100/7600 modules)

- Maximum pressure is 11 MPa (1 600 psi)

- Does not support definition of pressure against a vacuum reference

• PG7202 - Gas operated, liquid lubricated piston-cylinder modules (PC-7200 modules)

- Oil operated piston-cylinder modules (PC-7300 modules)

- Maximum pressure is 110 MPa (16 000 psi) when operated with a PC-7200 module

- Maximum pressure is 200 MPa (30 000 psi) when operated with a PC-7300 module

- Does not support definition of pressure against a vacuum reference

• PG7302 - Oil operated (PC-7300 modules)

- Maximum pressure is 500 MPa (72 500 psi)

• PG7601 - Gas operated, gas lubricated piston-cylinder modules (PC-7100/7600 modules)

- Maximum pressure is 7 MPa (1 000 psi)

- Supports definition of pressure against a vacuum reference PG7000 platforms, piston-cylinder modules, mass sets and mass handling systems are designed to

maximize metrological performance and ease of operation. They include many features that enhance the fundamental precision and stability of pressure measurements as well as simplifying use and reducing operator influence on the measurements. Extensive monitoring and controlling capability and advanced local and remote user interfaces are integrated into PG7000 Platforms.

Operator interaction with PG7000 and its extensive capabilities and peripherals is accomplished through a single display and keypad on the PG Terminal or from a computer via a single standard RS232 or IEEE-488 interface.

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.2 SPECIFICATIONS

1.2.1 GENERAL SPECIFICATIONS

Power Requirements Operating Temperature Range Operating Humidity Range Weight

Instrument platform with no mass loaded.

PG7102 PG7202 PG7302 PG7601

PG Terminal

Dimensions

Instrument Platform

PG Terminal

Microprocessors

Instrument Platform

PG Terminal

Communication Ports

RS232

IEEE-488

Overall Pressure Ranges

Actual range depends on piston-cylinder and mass set selection

PG7102 Gauge: 5 kPa to 11 MPa (0.7 to 1 600 psi)

PG7202 Gauge (gas): 100 kPa to 110 MPa (15 to 16 000 psi)

85 to 264 VAC, 50/60 Hz, 22 VA max. consumption. 15 to 35 °C 5 to 95% R.H., non-condensing

13 kg (29 lb) 13 kg (29 lb) 13 kg (29 lb) 17 kg (37 lb)

1.4 kg (3 lb)

36 cm H x 40 cm W x 35 cm D (14.5 in. x 15.8 in. x 13.8 in.) (Height: Top of mounting post with piston-cylinder module installed

for PG7102/PG7202/PG7302; top of bell jar for PG7601.) 12 cm H x 15 cm W x 20 cm D (4.7 in. H x 5.9 in. W x 7.9 in. D)

Motorola 68302 Hitachi 64180

COM1: Host computer COM2: External barometer or vacuum gauge (PG7601) and pass through communications COM3: Automated pressure generator/controller

Host computer

Absolute: 105 kPa to 11 MPa (15 to 1 600 psi) Differential: DP + static pressure < 11 MPa (1 600 psi)

Absolute (gas): 200 kPa to 110 MPa (30 to 16 000 psi) Gauge (oil): (PG7302 module): 1 to 200 MPa (150 to 30 000 psi) Absolute (oil): (PG7302 module) 1.1 to 200 MPa (165 to 30 000 psi) Differential: DP + static pressure < 110 MPa (16 000 psi)

PC-7200 can be operated in oil up to 200 MPa (30 000 psi)

when used with PC-7300 oil operated piston-cylinders.

PG7302 Gauge: 20 kPa to 500 MPa (3 to 75 000 psi)

PG7601 Gauge: 4 kPa to 7 MPa (0.6 to 1 000 psi)

Operating Media

PG7102 PG7202

PG7302 PG7601

Absolute: 120 kPa to 500 MPa (20 to 75 000 psi)

Absolute: 7 kPa to 7 MPa (0.7 to 1 000 psi) Differential: - 90 to 350 kPa (-13 to 50 psi) at 15 to 200 kPaa (2 to 30 psia) static pressure

Gas: air, helium, nitrogen Gas: any non-corrosive

Oil: Di2-EthylHexyl Sebacate (synthetic oil) Oil: Di2-EthylHexyl Sebacate (synthetic oil) Gas: air, helium, nitrogen

1. INTRODUCTION

Maximum Mass Load

PG7102 PG7202

PG7302 PG7601

Pressure Connections

PG7102 PG7202

PG7302 PG7601

CE Conformance

100 kg, while not exceeding 11 MPa (1 600 psi) 100 kg, while not exceeding 110 MPa (16 000 psi) when operated

with PC-7200 piston-cylinder modules or 200 MPa (30 000 psi) when operated with PC-7300 piston-cylinder modules

100 kg 38 kg

Test port: DH200 Test port: DH500

Drain port: DH500 Test port: DH500 Test port: DH200

Bell Jar Vent Port: DH200

Vacuum Reference Pump Down Port: KF25 (KF40 available on optional AMH automated mass handler)

External Vacuum Port: Optional KF25 on bell jar (KF40 available on optional AMH automated mass handler)

DH200 and DH500 are gland and collar type fittings for

1/4 in. (6.35 mm) coned and left hand threaded tubes.

DH200 is equivalent to AE SF250C, HIP LF4, etc.

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

Available, must be specified.

1.2.1.1 EMBEDDED FEATURES

• Local control with 2 x 20 vacuum fluorescent display and 4 x 4 function driven keypad.

• Real time (1 second update rate) display and measurement of ambient (pressure, temperature, humidity) and instrument (piston-cylinder temperature, piston position, piston drop rate, piston rotation rate, piston rotation decay rate, reference vacuum) conditions.

• Real time (1 second update rate) mass-to-pressure and pressure-to-mass calculations taking into consideration all environmental and operational variables.

• Full gas and liquid fluid head corrections including DUT head correction and piston position head correction.

• Adjustable mass loading resolution (0.01 g to 0.1 kg).

• Audible prompts of instrument status (piston movement, Ready/Not Ready indication)

with override capability.

• Integrated automated mass handling option (AMH-38 or AMH-100).

• Interfacing and automatic exploitation of external barometer via RS232.

• Interfacing and automatic exploitation of any external vacuum gauge via

RS232 (PG7601 only).

• Automated differential mode to define low differential pressures at various static pressures between vacuum and two atmospheres.

• Automated high line differential mode to define differential pressure at high line pressure.

PG7000™ OPERATION AND MAINTENANCE MANUAL

• Storage and one step activation of metrological data on up to 18 piston-cylinder modules, (3) mass sets and (3) mass loading bells.

• Continuous pressure Ready/Not Ready indication based on measured conditions.

• Motorized, intelligent piston drive system based measured rotation rate with operator alert and manual override.

• Integrated automated pressure control with standard DHI pressure controllers.

• Full RS232 and IEEE-488 communications with multi-level commands to set and read all instrument functions.

1.2.1.2 AMBIENT AND INSTRUMENT CONDITION

MEASUREMENTS

Temperature

Range

Resolution

Measurement Uncertainty

Barometric Pressure with Internal Sensor

Range

Resolution

Measurement Uncertainty

Relative Humidity

Range

Resolution

Measurement Uncertainty

Piston Position

Range

Resolution

Measurement Uncertainty

Piston Rotation

(Rate and deceleration)

Range

Resolution

Ambient 0 to 40

0.1 0.01 ± 1 ± 0.1

70 to 110 kPa 10 Pa ± 140 Pa Barometric pressure can also be read automatically with any

RS232 device such as a DHI RPM.

5 to 95 % RH 1 % RH

± 10 % RH

± 4.5 mm

0.1 mm ± 0.2 mm

2 to 99 rpm 1 rpm

Piston Cylinder Module

C 0 to 40 oC

Vacuum

(PG7601 only)

Range

Resolution

Measurement Uncertainty

0 to 20 Pa

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

1. INTRODUCTION

1.2.2 PISTON-CYLINDER MODULES

All piston-cylinders are integrated modules including mounting hardware delivered in individual shipping and storage bullet cases.

1.2.2.1 PC-7100/7600

Gas operated, gas lubricated piston-cylinder characteristics. Used in PG7102 and PG7601 platforms.

PC-7100/7600-10, TC PC-7100/7600-10-L

Operation

Piston Material

Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

Gas operated, gas lubricated Tungsten carbide Tungsten carbide 35 mm 1 000 mm Simple free deformation

PC-7100/7600-20

Piston Material

Cylinder Material

Nominal Diameter

Mounting System

PC-7100/7600-50

Piston Material

Cylinder Material

Nominal Diameter

Mounting system

PC-7100/7600-100

Piston Material

Cylinder Material

Nominal Diameter

Mounting System

PC-7100/7600-200

Piston Material

Cylinder Material

Nominal Diameter

Mounting System

Operation

Nominal Area

Operation

Nominal Area

Operation

Nominal Area

Operation

Nominal Area

Gas operated, gas lubricated Tungsten carbide Tungsten carbide 25 mm

500 mm Simple free deformation

Gas operated, gas lubricated Tungsten carbide Tungsten carbide 16 mm 200 mm Negative free deformation

Gas operated, gas lubricated Tungsten carbide Tungsten carbide 11 mm 98 mm Negative free deformation

Gas operated, gas lubricated Tungsten carbide Tungsten carbide 8 mm 50 mm Negative free deformation

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.2.2.2 PC-7200

Gas operated, liquid lubricated piston-cylinder module characteristics. Used in PG7202 platform.

Though not recommended for day-to-day operation, PC-7200 modules can also be filled completely with oil and operated with oil as the test medium (see Section 2.3.3).

PC-7200-100

Operation

Lubricating Liquid

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

PC-7200-200

Operation

Lubricating Liquid

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

PC-7200-500

Operation

Lubricating Liquid

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

PC-7200-1

Operation

Lubricating Liquid

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

PC-7200-2

Operation

Lubricating Liquid

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

Gas operated, liquid lubricated Synturion 6 (Krytox

optional)

Tungsten carbide

11.2 mm

98.1 mm

Negative free deformation

Gas operated, liquid lubricated Synturion 6 (Krytox

optional)

Tungsten carbide

7.9 mm

49.0 mm

Negative free deformation

Gas operated, liquid lubricated Di-2-ethylhexyl Sebacate (Krytox Tungsten carbide

5.0 mm

19.6 mm

Negative free deformation

Gas operated, liquid lubricated Di-2-ethylhexyl Sebacate (Krytox Tungsten carbide

3.5 mm

9.8 mm Negative free deformation

Gas operated, liquid lubricated Di-2-ethylhexyl Sebacate (Krytox Tungsten carbide

2.5 mm

4.9 mm Negative free deformation

optional)

1. INTRODUCTION

1.2.2.3 PC-7300

Oil operated, oil lubricated piston-cylinder module characteristics. Used in PG7302 and PG7202 platforms (1 MPa/kg and higher only in PG7202).

PC-7300 modules PC-7300-1, -2 and -5 may also be used in a PG7202 platform.

PC-7300-100

Operation

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

PC-7300-200

Operation

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

PC-7300-500

Operation

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

PC-7300-1

Operation

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

PC-7300-2

Operation

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

PC-7300-5

Operation

Piston and Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

Oil operated, oil lubricated Tungsten carbide

11.2 mm

98.1 mm

Simple free deformation

Oil operated, oil lubricated Tungsten carbide

7.9 mm

49.0 mm

Simple free deformation

Oil operated, oil lubricated Tungsten carbide

5.0 mm

19.6 mm

Simple free deformation

Oil operated, oil lubricated Tungsten carbide

3.5 mm

9.8 mm Simple free deformation

Oil operated, oil lubricated Tungsten carbide

2.5 mm

4.9 mm Simple free deformation

Oil operated, oil lubricated Tungsten carbide

1.6 mm

2.0 mm Simple free deformation

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.2.3 MASS SETS

Masses > 50g

Material

Finish

Adjustment Tolerance

304L non-magnetic stainless steel Electropolished ± 20 ppm of nominal value (manual mass sets, AMH

automated mass handler mass sets do not have fixed adjustment tolerances)

Uncertainty of Measured Values

Masses < 50g

± 5 ppm or 1 mg, whichever is greater ± 1 mg

Masses designated “tare” are delivered without reported measured values and are intended

only for use on the “tare” PG7000 in high line differential pressure measurement mode.

1.2.4 PRESSURE MEASUREMENTS

1.2.4.1 PC-7100/7600

For uncertainty in piston-cylinder effective area and typical measurement uncertainty in pressure defined by the piston gauge, see the piston-cylinder calibration report and current revision of DHI Technical Note 7920TN01.

All masses are delivered in molded, reusable, transit cases with custom inserts.

PC-7100/7600-10 PC-7100/7600-10-L

Sensitivity

Reproducibility

Typical Drop Rate (35 kg)

PC-7100/7600-20

Sensitivity

Reproducibility

Typical Drop Rate (35 kg)

PC-7100/7600-50

Sensitivity

Reproducibility

Typical Drop Rate (35 kg)

PC-7100/7600-100

Sensitivity

Reproducibility

Typical Drop Rate (35 kg)

PC-7100/7600-200

Sensitivity

Reproducibility

Typical Drop Rate (35 kg)

1 Sensitivity: The smallest variation in input detectable in output. 2 Reproducibility: Combined long term stability of piston-cylinder effective area and masses.

0.02 Pa + 0.5 ppm

± 2 ppm

0.2 mm/min

0.04 Pa + 0.5 ppm

± 2 ppm

0.3 mm/min

0.1 Pa + 0.5 ppm

± 2 ppm

0.5 mm/min

0.2 Pa + 0.5 ppm

± 3 ppm

0.7 mm/min

0.4 Pa + 0.5 ppm

± 3 ppm

1.0 mm/min

1. INTRODUCTION

Piston-cylinder modules designated “tare” are delivered without reported values and are intended only for use on the “tare” PG7000 in high line differential pressure measurement mode.

1.2.4.2 PC-7200

PC-7200-100

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

2 Pa + 1 ppm

± 5 ppm

0.10 mm/min

PC-7200-200

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

PC-7200-500

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

PC-7200-1

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

PC-7200-2

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

1 Sensitivity: The smallest variation in input detectable in output. 2 Reproducibility: Combined long term stability of piston-cylinder effective area and masses.

4 Pa + 1 ppm

± 5 ppm

0.15 mm/min

10 Pa + 1 ppm

± 5 ppm

0.20 mm/min

20 Pa + 1 ppm

± 5 ppm

0.25 mm/min

40 Pa + 1 ppm

± 5 ppm

0.50 mm/min

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.2.4.3 PC-7300

PC-7300-100

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

2 Pa + 1 ppm

± 5 ppm

0.02 mm/min

PC-7300-200

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

PC-7300-500

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

PC-7300-1

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

PC-7300-2

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

PC-7300-5

Sensitivity

Reproducibility

Typical Drop Rate (50 kg)

1 Sensitivity: The smallest variation in input detectable in output. 2 Reproducibility: Combined long term stability of piston-cylinder effective area and masses.

4 Pa + 1 ppm

± 5 ppm

0.04 mm/min

10 Pa + 1 ppm

± 5 ppm

0.10 mm/min

20 Pa + 1 ppm

± 5 ppm

0.20 mm/min

40 Pa + 1 ppm

± 5 ppm

0.40 mm/min

100 Pa + 1 ppm

± 5 ppm

1.00 mm/min

1. INTRODUCTION

1.3 TERMINAL AND PLATFORM FRONT AND REAR PANELS

1.3.1 TERMINAL FRONT AND REAR PANELS

1.3.1.1 PG TERMINAL FRONT PANEL

The front panel assembly provides a 2 x 20 vacuum fluorescent display and a 4 x 4 membrane keypad for local user interface. The terminal front panel assembly is the same for all PG7000 models.

1. Fluorescent display

2. Keypad

Figure 1. PG Terminal Front Panel

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.3.1.2 PG TERMINAL REAR PANEL

The rear panel assembly provides the communications connection to the PG7000 Platform and the power connection module. The terminal rear panel assembly is the same for all PG7000 models.

1. Power switch

2. Fuse

3. Power receptacle

Figure 2. PG Terminal Rear Panel

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

5. Cooling fan

1.3.2 PLATFORM REAR PANELS

The PG7000 Platform rear panels provide the connection to the PG Terminal, remote communication connections and pressure connection ports. The rear panels of all PG7000 models are identical except for the pressure connections (see Figure 3, # 7).

1. COM2 (RS232) - External Barometer, External Vacuum Gauge (PG7601 only) and Pass Through Communications

2. COM3 (RS232) - Automated Pressure Generation/Control Component

3. COM1 (RS232) - Remote Host Communications

4. Temperature - Humidity Probe

5. IEEE-488 - Remote Host Communications

6. AMH Connection

7. Pressure Ports:

PG7102 - TEST port: DH200

PG7202 - TEST and DRAIN

ports: DH500

PG7302 - TEST port: DH500 PG7601 - TEST and VACUUM vent

ports: DH200

Vacuum pull down port on front

left side: KF25

8. PG7000 Terminal Port

Figure 3. PG Platform Rear Panel

2. INSTALLATION

22.

NNSSTTAALLLLAATTIIOON

2.1 UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

A typical PG7000 system includes the PG7000 Platform (see Section 2.1.1.1), a mass set, (see Section 2.1.1.2), one or more piston-cylinder modules (see Section 2.1.1.3) and other accessories such as an AMH automated mass handler and/or pressure generation and control components (see the accessory Operation and Maintenance Manual or Instruction Sheet).

2.1.1.1 PLATFORM

The mass loading bell is a metrological element that is part of the mass set. Like all of the masses, it is preferable not to handle it with bare hands. Protective gloves are provided in the accessory kit of each PG7000 Platform.

The PG7000 Platform is shipped in a reusable, molded shipping and storage case.  Open the PG7000 shipping and storage case (it is the large, 66 cm x 53 cm

x 47 cm case).

 Remove the PG Terminal and accessories from upper packing insert.

Inspect and inventory the accessories (see Section 2.1.2).

 Remove the upper packing insert.  Carefully lift the PG7000 Platform from its position in the lower packing

insert. Note the orientation so that the same orientation will be used when PG7000 is repacked.

 Reinstall the upper packing insert into the shipping and storage case and

store in a safe place.

2.1.1.2 MASS SET

The stability over time of PG7000 pressure measurements is a function of the stability of the masses loaded on the piston. Precautions should be taken in handling the masses to minimize influences that may change their mass. This includes always wearing protective gloves when handling the masses to avoid contaminating them with body oils and perspiration. Protective gloves are provided in the accessory kits of PG7000 Platforms.

The mass set accessories are shipped in a separate corrugated container. Open the corrugated container and inspect and inventory the accessories.

The PG7000 masses are shipped in reusable, molded shipping and storage cases. The PG7000 masses should be removed from their shipping cases and inventoried when actually setting up the PG7000 system.

PG7000™ OPERATION AND MAINTENANCE MANUAL

2.1.1.3 PISTON-CYLINDER MODULE(S)

The piston-cylinder modules are shipped in Acetal bullet cases that are packed in corrugated containers with custom foam inserts.

Open the corrugated containers and remove the piston-cylinder modules and accessories.

The bullet cases screw open by turning the lid counterclockwise.

When reinstalling an oil (PC-7300) or liquid lubricated (PC-7200) piston-cylinder module in its bullet case, be sure to empty out any liquid that may have collected in the hole in the bottom of the case. Excess liquid will not compress, making it difficult to fully close the case and could result in damaging it.

2.1.1.4 AUTOMATED MASS HANDLER

See the AMH-38/AMH-100 Operation and Maintenance Manual.

2.1.2 INSPECTING CONTENTS

Check that all items are present and have NO visible signs of damage. A parts list of items supplied is provided in Section 2.1.2.1 for PG7000, Section 2.1.2.2 for mass sets, and Section 2.1.2.3 for piston-cylinder modules.

2.1.2.1 PLATFORM

Each PG7000 Platform is delivered complete with accessories as listed by part number in Tables 1 through 4.

2. INSTALLATION

Table 1. PG7102 Parts List

PG7102

DESCRIPTION

Platform 3117734 3117752 Manual Mass Bell 3071537 Terminal 3069735 PG Terminal to Platform Cable Non-CE (DB25M - DB25F,

≈ 1.8 meters) CE (DB25M - DB25F,

≈ 1.5 meters) Power Cable 3133781 (Black) 3153005 (Gray) TH Probe Assembly 3446036 Accessory Kit 3117741 Cable, Null Modem 3077370 NIP, SS, DH200, 2.75 in. 3068377 ADPT, SS, DH200 F x 1/8 in. NPT F 3068547 O-ring, Buna 2-242 (2 ea.) 3135041 Storage Cover, 7600 Type 3135594 Allen Wrench, 2.5 mm 3136044 Allen Wrench, 3 mm 3135703 Allen Wrench, 5 mm 3136098 Spanner Wrench (Metrological) 3068940 Krytox® GPL205/6 0.5 oz. Gift Kit with Gloves 3123777 ADPT, DH200 M x 1/8 in. swage 3069062

Documentation Calibration Report (PG Platform) Calibration Report (Mass Bell) Technical Data PG7000 Operation & Maintenance Manual Documentation CD

P/N 3069572

NON-CE

3068724

3072235

2493420

3152121 3152121 3152139

3152117 3139043

PG7102

P/N 3072317

PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 2. PG7202 Parts List

PG7202

DESCRIPTION

Platform 3119996 3120027 Manual Mass Bell 3071537 Terminal 3069735 PG Terminal to Platform Cable Non-CE (DB25M - DB25F,

≈ 1.8 meters) CE (DB25M - DB25F,

≈ 1.5 meters) Power Cable 3133781 (Black) 3153005 (Gray) TH Probe Assembly 3446036 Accessory Kit 3120011 Cable, Null Modem 3077370 DH500 M x 1/8 in. NPT F 3142684 O-ring, Buna 2-242 (2 ea.) 3135041 Storage Cover, 7600 Type 3135594 Allen Wrench, 2.5 mm 3136044 Allen Wrench, 3 mm 3135703 Allen Wrench, 5 mm 3136098 Wrench, 5/8 in. 3139417 Collar, SS, DH500 3068607 Krytox® GPL205/6 0.5 oz. Gift Kit with Gloves 3123777 Documentation

Calibration Report (PG) Calibration Report (Mass Bell) Technical Data PG7000 Operation & Maintenance Manual Documentation CD

#3070404

NON-CE

3068724

3072235

2493420

3152121 3152121 3152139

3152117 3139043

PG7202

#3072395

2. INSTALLATION

Table 3. PG7302 Parts List

PG7302

DESCRIPTION

P/N 3069747

NON-CE

Platform 3118073 3118086 Manual Mass Bell 3071537 Terminal 3069735 PG Terminal to Platform Cable Non-CE (DB25M - DB25F,

≈ 1.8 meters) CE (DB25M - DB25F,

Calibration Report (PG) Calibration Report (Mass Bell) Technical Data PG7000 Operation & Maintenance Manual Documentation CD

3068724

3072235

2493420

3152121 3152121 3152139

3152117 3139043

PG7302

P/N 3072339

PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 4. PG7601 Parts List

PG7601

DESCRIPTION

Platform 3117525 3117540 Manual Mass Bell 3071603 Bell Jar and Seal 3068933 and 3068634 Terminal 3069735 PG Terminal to Platform Cable Non-CE (DB25M - DB25F,

≈ 1.8 meters) CE (DB25M - DB25F,

≈ 1.5 meters) Power Cable 3133781 (Black) 3153005 (Gray) TH Probe Assembly 3446036 Accessory Kit 3117533 Cable, Null Modem 3077370 NIP, SS, DH200, 2.75 in. 3068377 ADPT, SS, DH200 F x 1/8 in. NPT F 3068547 O-ring, Buna 2-242 (2 ea.) 3135041 Storage Cover, 7600 Type 3135594 Allen Wrench, 2.5 mm 3136044 Allen Wrench, 3 mm 3135703 Allen Wrench, 5 mm 3136098 Spanner Wrench (Metrological) 3068940 Krytox® GPL205/6 .5 oz. Gift Kit with Gloves 3123777 ADPT, DH200 M x 1/8 in. swage 3069062 Valve, Vacuum Relief 3124573 Documentation

Calibration Report (PG) Calibration Report (Mass Bell) Technical Data PG7000 Operation & Maintenance Manual Documentation CD

P/N 3069028

NON-CE

3068724

3072235

2493420

3152121 3152121 3152139

3152117 3139043

PG7601

P/N 3072258

2. INSTALLATION

2.1.2.2 MASS SET

PG7000 mass sets are composed of different combinations of individual masses and accessories depending on the specific mass set ordered (see Tables 5 - 9).

Table 5. Manual Mass Set Parts List (excluding 80 and 100 kg)

DESCRIPTION PART NO.

Mass Set Refer to Table 9 Reusable Molded Transit Case with Foam Inserts

35 kg set 40 kg set 45 kg set 55 kg set

Mass Set Tray and Spindle 3147461 and 3148764 Dust Covers 3138017 and 3138130 Calibration Report 3152121

Table 6. Manual Mass Set Parts List (80 and 100 kg)

DESCRIPTION PART NO.

Mass Set Refer to Table 9 Reusable Molded Transit Case with Foam Inserts

80 kg set 100 kg set

Mass Set Tray and Spindle 3147461 and 3148764 Dust Covers 3138017 and 3138127 Calibration Report 3152121

Table 7. AMH-38 Mass Set Parts List

3068969

1 ea. 1 ea. 1 ea. 1 ea.

3068969

1 ea. 1 ea.

3068991

1 ea. 1 ea. 1 ea. 2 ea.

3068984

2 ea. 3 ea.

DESCRIPTION PART NO.

Mass Set Refer to Table 9 Reusable Molded Transit Case with Foam Inserts

13 kg set (MS-AMH-13) 25 kg set (MS-AMH-25) 39 kg set (MS-AMH-38)

Calibration Report 3152121

3123990

1 ea. 1 ea. 1 ea.

3069004

1 ea. 1 ea. 1 ea.

Table 8. AMH-100 Mass Set Parts List

DESCRIPTION PART NO.

Mass Set Refer to Table 9 Reusable Molded Transit Case with Foam Inserts

40 kg set (MS-AMH-40) 60 kg set (MS-AMH-60) 80 kg set (MS-AMH-80) 100 kg set (MS-AMH-100)

Calibration Report 3152121

3123990

1 ea. 1 ea. 1 ea. 1 ea.

3068984

1 ea. 2 ea. 2 ea. 3 ea.

PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 9. Mass Set Compositions

DESIGNATION PART #

MS-7001-35 3069850 35 - 5 2 1 1 2 1 1 (4.5) MS-7002-35 3069861 35 - 5 2 1 1 2 1 1 (4) MS-7002-40 3070021 40 - 6 2 1 1 2 1 1 (4) MS-7002-45 3069980 45 - 7 2 1 1 2 1 1 (4) MS-7002-55 3069877 55 - 9 2 1 1 2 1 1 (4) MS-7002-80 3070000 80 6 1 2 1 1 2 1 1 (9) -

MS-7002-100 3070017 100 8 1 2 1 1 2 1 1 (9) -

TOTAL

MASS (kg)

kg 2kg 1kg

NOMINAL

MASS SET COMPOSITION

MASS SET COMPOSITION DESIGNATION PART # NOMINAL

TOTAL

MASS (kg)

MS-AMH-13 3071491 13 - - 1 1 1 1 1 1 1 1 MS-AMH-25 3071484 25 - - 3 1 1 1 1 1 1 1 MS-AMH-38 3071433 38 - - 5 1 1 1 1 1 1 1 MS-AMH-40 3071528 40 3 1 - 1 1 1 1 1 1 1 MS-AMH-60 3071519 60 5 1 - 1 1 1 1 1 1 1 MS-AMH-80 3071504 80 7 1 - 1 1 1 1 1 1 1

MS-AMH-100 3071440 100 9 1 - 1 1 1 1 1 1 1

All mass sets also include a trim mass set of 50 g to 0.01 g (total 100 g)

10 kg

6.4 kg

6.2 kg

3.2 kg

Table 10. Mass Set Compatibility

DESIGNATOR

MS-7001-35 35 MS-7002-35 35 MS-7002-40 40 MS-7002-45 45 MS-7002-55 55 MS-7002-80 80 •1

MS-7002-100 100 •1

MS-AMH-13 13 MS-AMH-25 25 MS-AMH-38 38 MS-AMH-40 40 MS-AMH-60 60 •1

MS-AMH-80 80 •1

MS-AMH-100 100 •1

These mass sets, on certain piston-cylinder sizes, can cause the maximum working pressure of the PG Platform to be

exceeded. Do not exceed the following maximum working pressures:

PG7201: 11 MPa (1 600 psi) PG7202: When using PC-7200 piston-cylinder modules: 110 MPa (16 000 psi)

When using PC-7300 piston-cylinder modules: 200 MPa (30 000 psi) PG7302:500 MPa (72 500 psi)

NOMINAL

TOTAL MASS (kg)

PG7102 PG7202 PG7302 PG7601

• • •

•1

• • •

•1

0.5 kg

1.6 kg

0.2 kg

0.8 kg

0.1 kg

0.4 kg

MAKE-UP

MASS

(kg)

0.2 kg

•

0.1 kg

BELL, SHAFT,

BINARY MASS

CARRIER

(3 PARTS)

•

2. INSTALLATION

The mass loading bell and piston make up part of the total mass load. The mass loading bell for loading manual mass sets is delivered with the PG7000 platform. The mass loading bell for AMH mass sets is delivered with the mass set. Piston-cylinder modules are purchased and delivered separately.

2.1.2.3 PISTON-CYLINDER MODULE(S)

Table 11. PC-7100/7600 Piston-Cylinder Modules Parts List

10 kPa

PC-7100/

7600-10-L

Piston-Cylinder Kit 3171975 3070095 3071581 3070109 3071615 3070111 Piston-Cylinder

Module Hermetic Acetal

Bullet Case Accessory Kit 3125242 3122928 3122229 3124345 3124345 3124345

O-rings

Insertion Tool 3071793 3071841 N/A N/A N/A N/A

Calibration Report 3152121 3152121 3152121 3152121 3152121 3152121

3125106 3122937 3122116 3124088 3122234 3124194

3070203 3070203 3070203 3070203 3070203 3070203

3134867 3136458

10 kPa

PC-7100/

7600-10 TC

3134867 3136458

20 kPa

PC-7100/

7600-20

3134867 3136458

50 kPa

PC-7100/

7600-50

3134880 3136458

100 kPa

PC-7100/ 7600-100

3134880 3136458

200 kPa

PC-7100/ 7600-200

3134880 3136458

Table 12. PC-7200 Piston-Cylinder Modules Parts List

Piston-Cylinder Kit 3070419 3070428 3070437 3070443 3070455 Piston-Cylinder Module 3120245 3120250 3120292 3120303 3120326 Hermetic Acetal

Bullet Case Accessory Kit 3120277 3120277 3120315 3120315 3120315

O-rings

Anti-Extrusion Ring N/A N/A 3148417 3148417 3148417 Syringe 3139439 3139439 3139439 3139439 3139439 Syringe tips (3) 3139421 (3) 3139421 (3) 3139421 (3) 3139421 (3) 3139421 Synturion 6 fluid 3120289 3120289 - - Sebacate fluid - - 3120590 3120590 3120590 Calibration Report 3152121 3152121 3152121 3152121 3152121

100 kPa

PC-7200-100

3071852 3071852 3071852 3071852 3071852

(2) 3134158

2721018 2644003

200 kPa

PC-7200-200

(2) 3134158

2721018 2644003

500 kPa

PC-7200-500

(2) 3134158

2721018 2644003

1 MPa

PC-7200-1

(2) 3134158

2721018 2644003

2 MPa

PC-7200-2

(2) 3134158

2721018 2644003

PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 13. PC-7300 Piston-Cylinder Modules Parts List

100 kPa

PC-7300-100

Piston-Cylinder Kit 3070039 3070042 3070056 3070063 3070074 3070088 Piston-Cylinder

Module Hermetic Acetal

Bullet Case Accessory Kit 3119102 3119102 3119102 3119366 3119366 3119366

O-rings

Calibration Reports

3118918 3118976 3119032 3119116 3119178 3119229

3071865 3071865 3071865 3071865 3071865 3071865

2527053 3134022

3152121 3152121 3152121 3152121 3152121 3152121

200 kPa

PC-7300-200

2527053 3134022

500 kPa

PC-7300-500

2527053 3134022

1 MPa

PC-7300-1

1785497

(5) 927863

2 MPa

PC-7300-2

1785497

(5) 927863

5 MPa

PC-7300-5

1785497

(5) 927863

2.2 SITE REQUIREMENTS

The exact PG7000 system installation is affected by the elements other than the PG7000 Platform that make up the PG7000 system.

When selecting and preparing a site to set up the PG7000 system, the following should be considered:

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

♦ Temperature: 19 to 23 °C, minimize rate of change of temperature. ♦ Relative Humidity: 10 to 60 %RH (non-condensing). ♦ Ambient Pressure: Minimize external influences that will cause barometric instability. ♦ Air Currents: Do not install the PG7000 Platform under a source of vertical air currents such as an

overhead air conditioning duct. These can blow on the mass load and add unquantified forces.

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

defined by PG7000 (vibration affects the floating piston). Excessive high frequency vibration, for example from a vacuum pump on the same table as the PG7000, may affect piston sensitivity.

• Bench stability: Up to 100 kg may be loaded and unloaded onto the PG7000 Platform. The bench on which the PG7000 sits should not deflect significantly under the mass load changes. This can be verified by setting the PG7000 Platform on the bench, leveling it, loading and unloading the complete mass set while observing whether the level setting changes.

• Location of other components: Plan the space required and a convenient layout for the complete PG7000 system including the PG Terminal, mass set, pressure generation/control component(s), test instrument connection and computer (if present). If using a DHI PPC, MPC, GPC or OPG to generate/control pressure, see its Operation and Maintenance Manual for information on installing it. If a DHI interconnections kit is being used to interconnect the components, see its instruction sheet.

• Electrical and pressure supplies: Plan the supply of electrical power to the PG Terminal and to the pressure generation/control component(s), if needed. If using a DHI PPC, MPC, GPC or OPG to generate/control pressure, see its Operation and Maintenance Manual for information on the pressures source(s) it needs and how to connect them. Gas supplied to a PC-7100/7600 piston-cylinder module must be clean and dry (instrument grade minimum, high purity preferred) to avoid contaminating the piston-cylinder gap.

• Reference vacuum supply (PG7601 only): Plan for the vacuum connection to the platform or the optional AMH automated mass handler and the location of the reference vacuum pump.

• Bell jar placement (PG7601 only): Plan a location for the bell jar when it is removed from the platform to load and unload masses. A small shelf is often used for this purpose.

2. INSTALLATION

• AMH automated mass handler (optional) placement: If an AMH is being used, plan electrical and pneumatic connections to it as well as a location to place it when it is removed from the platform (see the AMH-38/AMH-100 Operation and Maintenance Manual).

2.3 SETUP

2.3.1 PREPARING FOR OPERATION

Before setting up the PG7000 system, see Section 2.2 for information on site

requirements.

To prepare PG7000 for check out and operation:

 Set up the PG7000 Platform (see Section 2.3.1.1).  If an optional AMH-100 mass set is being used, set it up with its mass set (see the AMH-

38/AMH-100 Operation and Maintenance Manual).

 Make the system pressure interconnections (see Section 2.3.1.2).  If a manual mass set is being used, set up the manual mass set (see Section 2.3.1.3).

2.3.1.1 SETTING UP THE PLATFORM

To set up the PG7000 Platform proceed as follows:  Place the PG7000 Platform on the site table in the desired orientation.

Though the rear panel is usually in the back, any orientation can be used.

 Place the PG7000 Terminal at the desired location.  Connect the PG7000 Terminal to the PG7000 Platform using the 25-pin

cable supplied.

 Connect the PG7000 Temperature - Humidity Probe per Figure 3.  Connect electrical power (85 to 264 VAC, 50/60 Hz) to the PG7000 Terminal

using the power cable supplied. Any grounded power cable with a standard IEC320-313 connection may be used.

 (PG7601 Only) - Install the vacuum vent valve kit on the vacuum vent port

on the rear of the PG7000 Platform. Refer to the instruction sheet provided with the vent valve assembly.

Connect the reference vacuum source and shutoff valve to the reference

vacuum port. Take measures to assure that vacuum oil cannot return to the PG7601. If an optional AMH-38 automated mass handler is being used, the reference vacuum may be connected to the larger KF40 vacuum connection on the AMH-38 vacuum chamber.

 If an external barometer and/or vacuum gauge is/are being used, establish

communications between the barometer/vacuum gauge and the PG7000 Platform by connecting the external device RS232 port to the PG7000 Platform Com2 port and setting up PG7000 to read and use an external barometer and/or vacuum gauge (see Section 3.11.5.4, 3.11.5.5). Set the external barometer head height (see Section 3.11.3.3).

 If an automated pressure generation/control component is being used,

establish communications between the automated pressure generation/control component and the PG7000 Platform by connecting the

PG7000™ OPERATION AND MAINTENANCE MANUAL

generation/control component RS232 port to the PG7000 Platform COM3 port and setting up PG7000 to use an automated pressure generation/control component (see Section 3.9.9).

 If an AMH automated mass handling system is being used, set up the AMH

mass set and the AMH mass handler following the instructions in the AMH38/AMH-100 Operation and Maintenance Manual.

Level the platform using the PG7000 Platform’s two leveling feet and the

level mounted on the front of the platform. (Or on the optional AMH mass handling system.)

2.3.1.2 SYSTEM PRESSURE INTERCONNECTIONS

Interconnect the PG7000 Platform, pressure generation/control components and a test connection.

The pressure connection on the PG7000 TEST port is:

• PG7102/PG7601: DH200 (DH200 is equivalent to AE SF250C,HIP LF4, etc.). Adapters to convert the DH200 connection to 1/8 in. NPT female and 1/8 in. swage are provided with PG7102 and PG7601 Platform accessories.

• PG7202: DH500 (DH500 is equivalent to AE F250C, HIP HF4, etc.). Connect the gas test medium pressure control/generation component to the TEST port. If the PG7202 is to be operated in oil, connect the oil pressure control/generation component to the DRAIN port (the gas or oil component is disconnected when not in use, see Section 2.3.3).

If using a standard interconnections kit such as PK-7600-PPC/MPC P/N 3069508, PK-7600-PPC/MPC-DIF P/N 3070127 or PK-7100-MPCD-DIF P/N 3070226, see the instruction sheet provided with the kit for installation instructions. If an OPG1 or GPC1 generator/controller is being used, pressure interconnecting hardware is included with it. See its Operation and Maintenance Manual for connection instructions.

• PG7302: DH500 (DH500 is equivalent to AE F250C, HIP HF4, etc.).

2.3.1.3 SETTING UP A MASS SET

If installing an MS-AMH-xxx mass set for use with an AMH automated mass handling system, see the AMH-38/AMH-100 Operation and Maintenance Manual.

To install a PG7000 manual mass set, place the mass loading tray (provided with the mass set accessories) at the desired location then install the individual masses on the mass loading tray. See the AMH-38/AMH-100 Operation and Maintenance Manual for instructions on installation of an AMH mass set for automated mass handling.

It is VERY IMPORTANT that the individual masses be installed on the mass loading tray in proper sequence. This will ensure that PG7000 mass loading instructions are executed properly (carefully follow the instructions provided in Section 2.3.1.3, Installing Masses on the Mass Loading Tray

2. INSTALLATION

Installing Masses on the Mass Loading Tray (Manual Mass Set)

PG7000 masses are shipped in reusable, molded shipping and storage cases. One of the cases contains a 4.0, 4.5 or 5 kg mass and the masses of 2 kg and under, the other case(s) contain(s) the main masses of 10 or 5 kg each. Each mass is packed in a sealed plastic bag and then placed in a protective shipping insert.

To install the masses on the mass loading tray, proceed as follows:

 Open the shipping cases.  Install the main masses: The main masses (a series of 10 kg masses if the

mass set is > 55 kg, a series of 5 kg masses if the mass set is < 60 kg) are installed horizontally aligned on the mass loading spindle.

 The main masses are sequentially numbered starting with he number 1.

The main mass with the highest sequential number is installed first at the bottom of the stack (i.e., the first mass loaded on the tray). The rest of the

main masses should be stacked upwards in descending order ending with main mass sequential number 1. Be careful NOT to confuse the makeup mass (refer to next item) with main mass 1.

 Install the make up mass: The make up mass is a single mass

sequentially numbered 1. It has the same diameter as the main masses. It is a 9 kg mass if the main masses are 10 kg. It is 4 or 4.5 kg if the main masses are 5 kg.

The make up mass is placed on top of the main mass stack. It is always the

top of the stack.

 Install the fractionary masses: The fractionary masses are all the masses

of lower value than the main masses and makeup mass. These are masses of 5 kg and under for mass sets with 10 kg main masses. They are masses of 2 kg and under for mass sets with 5 kg main masses. Fractionary masses of 1 to 5 kg are discs with a central hole. Fractionary masses of 100 to 500 g are solid, small diameter pucks. Fractionary masses of 50 g and under are grams masses packed and stored in their own separate storage case.

Fractionary mass discs and pucks are installed vertically in the corresponding slots

in the mass loading tray. Use a consistent setup for the sequence number when there are two masses (e.g., always load sequential number 1 in the front).

2.3.2 INSTALLING A PISTON-CYLINDER MODULE INTO THE PLATFORM

To operate the PG7000 Platform, a piston-cylinder module must be installed in its mounting post. To install a piston-cylinder module in the PG7000 Platform, proceed as follows:

 Remove the PG7000 Platform mounting post plug. Unscrew the ORANGE plastic

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

PG7000™ OPERATION AND MAINTENANCE MANUAL

 Remove the piston-cylinder module from its bullet case. Select a piston-cylinder

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

PC-7200 gas operated, liquid lubricated piston-cylinder modules are delivered with their lubricating liquid reservoir drained. The reservoir must be filled prior to using the piston-cylinder module. If installing a PC-7200 gas operated, liquid lubricated piston-cylinder module, see Section 5.3.3 for instructions on how to fill the module’s liquid lubrication reservoir prior to installation, then continue the procedure from this point.

When reinstalling an oil or liquid lubricated gas piston-cylinder module in its bullet case, be sure to empty out any liquid that may have collected in the hole in the bottom of the case. The liquid will not compress, making it difficult to fully close the case and could result in damaging it.

 Place the piston-cylinder module in the PG7000 Platform mounting post. Place

the piston-cylinder module (thread down) into the PG7000 Platform mounting post (see Figure 4 below).

If installing the piston-cylinder module into a PG7302 or a PG7202 to be operated with oil, first use the oil generation control component to fill the counter bore in the mounting post with oil until it just starts to overflow.

 Purge the air from under the piston-cylinder module (PC-7300 modules only in

PG7302 or PG7202). Rotate the piston-cylinder module clockwise until all threads are

engaged and there is no gap between the piston-cylinder module and the mounting post. Back the piston-cylinder module off slightly by rotating it counterclockwise 3/4 turn. Slowly supply additional oil to the mounting post from the pressure generation/control component. Watch the oil run off tube on the bottom right of the platform. As soon as oil appears or can be seen flowing, stop the oil supply.

 Screw the piston-cylinder

module into the PG7000 Platform mounting post.

Rotate the piston-cylinder module clockwise until all threads are engaged and there is NO gap between the pistoncylinder module and the PG7000 mounting post. Slight resistance will be encountered in the second half of travel as the piston-cylinder module O-rings seat in the mounting post.

Figure 4. Piston-Cylinder Module Installation

2. INSTALLATION

Low torque manual rotation is all that should be required to fully seat the piston-cylinder module into the PG7000 mounting post. Never force the piston-cylinder module into the mounting post.

Always maintain PG7202 and PG7302 piston- cylinder modules vertical with the piston cap up. Do not invert the assembly, as this might allow liquid to run up into the piston head and into the adjustment mass and cap. Liquid contamination of the piston head and cap changes the mass of the piston assembly and could lead to out of tolerance pressure definitions at low mass loads. If liquid contaminates the adjustment mass and cap, disassemble the module and clean it (see Sections 5.3.1, 5.3.4, 5.3.2.2).

2.3.3 SWITCHING A PG7202 BETWEEN GAS OPERATION AND

OIL OPERATION

PG7202 can be operated with gas as the pressurized medium using PC-7200 gas operated, liquid lubricated modules or with oil as the pressurized medium using oil operated PC-7300 modules.

PC-7200 gas operated, liquid lubricated piston-cylinder modules can be operated in gas oil filled with oil and operated in oil. Oil operation of PC-7202 modules is not recommended for routine operation. It can be useful in very specific crossfloating circumstances, particularly when establishing a calibration link between independent gas operated and oil operated piston gauges. When switching PC-7200 module between oil and gas and oil operation, see Section 5.3.3 for information on emptying excess oil from the module.

Switching a PG7202 from gas to oil operation

Only the high pressure PC-7300 oil modules may be used in the PG7202 platform (PC-7300-1, -2, -5)

 Disconnect the gas generation/control system from the TEST port. Disconnect the

tube at the DH500 TEST port connection on the back of the PG7202. Loosely install a DH500 plug in the TEST port.

 Connect the oil generation/control system to the DRAIN port. Connect a tube from

the oil generation/control system to the PG7202 DRAIN port and tighten it (torque DH500 glands to 15 Nm (12 ft.lb)).

 Fill the PG7202 mounting post with oil. Hand tighten the DH500 plug in the TEST

port. Use the oil generation/control component to fill the PG7202 mounting post with oil. Fill to the edge of the second step in the mounting post. Place a paper towel under the TEST port plug and loosen the DH500 plug allowing oil to run out until it is at the level of the first step in the mounting post and there is no air in the run off oil. If there is still air in the run off, repeat the operation. After filling the mounting post, tighten the DH500 plug (torque DH500 glands to 15 Nm (12 ft.lb)).

 Install a PC-7300 oil operated piston-cylinder module in the PG7202 platform.

Install the module and purge the air from underneath it (see Section2.3.2).

 Operate with oil as the test medium. The PG7202 can now be operated with oil as the

test medium.

PG7000™ OPERATION AND MAINTENANCE MANUAL

The maximum working pressure of the PG7202 platform when used in oil with a PC-7300 module is 200 MPa (30 000 psi). The maximum pressure when using a PC-7200 module is 110 MPa (16 000 psi). Do not exceed this limit.

Switching a PG7202 from oil to gas operation

 Remove the piston-cylinder module. Disinstall the PC-7300 oil operated piston-cylinder

module for the PG7202 platform.

 Disconnect the oil generation/control system from the DRAIN port. Place a paper

towel under the DRAIN port and disconnect the tube to the oil generation/control system. Let all the oil run out of the PG7202 platform.

 Remove the DH500 plug from the TEST port. Place a paper towel under the TEST

port and remove the DH500 plug. Let all the oil run out of the PG7202 platform..

 Install a PC-7200 gas operated, liquid lubricated piston-cylinder module in the

PG7202 platform. Install the piston-cylinder module (see Section 2.3.2).

 Connect the gas generation/control system to the TEST port. Connect a tube from

the oil generation/control system to the PG7202 TEST port and tighten it (torque DH500 glands to 15 Nm (12 ft.lb)).

 Prepurge the oil from the PG7202 mounting post. Hold a paper towel lightly over the

DRAIN port opening. Leaving the drain port open, use the gas generation/control component to flow enough gas through the mounting post to just lift the piston.

 Purge the PG7202 mounting post. Purge the PG7202 mouting post using the standard

purging procedure (see Section 5.2.4) and finish by tightening the plug in the DRAIN port.

 Operate with gas as the test medium. The PG7202 can now be operated with gas as

the test medium.

The maximum working pressure of the PG7202 platform when used with a PC-7200 module is 110 MPa (16 000 psi). Do not exceed this limit.

2.4 POWER UP AND VERIFICATION

2.4.1 POWER UP

Turn the PG7000 power ON by pressing the power ON/OFF switch on the rear panel of the PG Terminal. Observe the PG terminal display as the terminal connects with the PG7000 Platform, tests, initializes and goes to the main run screen (see Section 3.7).

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

If PG7000 fails to reach the main run screen, service may be required. Record the sequence of operations and displays observed and contact a DHI Authorized Service Provider (see Table 32).

2. INSTALLATION

2.4.2 CHECK THAT ON-BOARD PISTON-CYLINDER MODULE

AND MASS SET INFORMATION ARE CORRECT

PG7000 uses stored piston-cylinder and mass set metrological information to calculate the reference pressures it defines (see Section 3.1). For the pressure values to be correct, the stored metrological information on the piston-cylinder, mass set and mass loading bell must be correct. Before using PG7000 for accurate pressure definition, the validity of the stored information should be verified. This consists of comparing the piston-cylinder, mass set and mass loading bell information stored in PG7000 to the information in the current piston-cylinder and mass set calibration reports.

To verify the PG7000 piston-cylinder, mass set and mass loading bell information, use the piston-cylinder and mass set viewing capabilities accessed by pressing [SPECIAL], <1PC/MS> (see Section 3.11.1). Compare all the information contained in the PG7000 piston-cylinder, mass set and mass loading bell files to the information on the current piston-cylinder, mass set and mass loading bell calibration reports.

2.4.3 SET LOCAL GRAVITY VALUE

PG7000 uses the value of local acceleration due to gravity (gl) in its calculation of the reference pressure it defines (see Section 3.1). The correct value of local acceleration due to gravity at the site of PG7000 use must be entered. This is accomplished by pressing [SPECIAL], <6gl> (see Section 3.11.6) and editing the value of local gravity.

2.4.4 SETUP PRESSURE EQUATION VARIABLE INPUT SOURCES

PG7000 uses many variables in calculating defined pressures. The sources of the variables are determined by the current SETUP file. SETUP files are viewed, created, edited and selected using the SETUP function accessed by pressing [SETUP] (see Section 3.10). A factory SETUP file is available and already selected on a new PG7000, but the operator may desire to customize it. The factory setup file assumes that PG7000’s internal measurement values will be used whenever possible.

2.4.5 CHECK PROPER OPERATION OF AMBIENT CONDITION

MEASUREMENTS

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

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

• Display current ambient condition readings: Press [AMBIENT]. The ambient

conditions run screen is displayed (see Section 3.9.6).

• Verify proper ambient condition readings: Compare the ambient condition values

displayed to the actual values of ambient conditions. Refer to the ambient condition measurement specifications when evaluating the ambient readings (see Section 1.2.1.2).

The unit of measure in which ambient pressure is displayed is the same as the unit selected by pressing [UNIT] (see Section 3.9.3). Units of measure in which other ambient condition values are expressed cannot be changed.

PG7000 allows the source of ambient condition values used in reference pressure calculations to be specified. The source may be PG7000’s on-board measurements, default values or operator entered values. See Section 3.10 for information on specifying the source of ambient condition values used by PG7000 in reference pressure calculations.

PG7000™ OPERATION AND MAINTENANCE MANUAL

2.4.6 APPLY PRESSURE TO THE PISTON-CYLINDER MODULE

This section assumes that the PG7000 system has already been set up, including pressure interconnection (see Section 2.3).

Before applying pressure to the PG7000 system, be sure that all pressure vessels and connections are rated for the pressure levels that will be applied and that all connections have been properly tightened.

Continuing with the PG7000 set up and check out requires applying pressure to the pistoncylinder module and floating the piston.

Proceed as follows:

 Turn OFF automated piston rotation (if present) and automated pressure

generation (if present). This will prevent the automated rotation and pressure

generation features (if present) from interfering during verification of these features (see Sections 3.9.8 and 3.9.9 for information on automated piston rotation and pressure generation).

 Load mass on the piston. Install the mass loading bell on the piston. Then load the

make up mass (9, 4.5 or 4 kg depending on the mass set) (see Section 2.3.1.3). If the PG7000 platform is equipped with AMH automated mass handling, press [ENTER] and enter a low value of pressure or mass to cause mass to be loaded onto the piston.

 Float the piston. Use the pressure generation/control component of the PG7000

system to apply pressure under the piston through the PG7000 Platform TEST port. The piston will float at a pressure approximately equal to the piston mass to pressure conversion factor multiplied by the mass load in kg. The piston-cylinder conversion factor is marked on the top of the piston cap and is in either kPa or MPa per kilogram [kPa/kg or MPa/kg].

If the piston cannot be floated because it immediately sinks down from a float position, there is a leak in the pressure system. Identify and eliminate leaks until the piston, once floated, falls at a rate less than the nominal fall rate given in the specifications of the piston-cylinder module being used (see Section 1.2.2).

2.4.7 CHECK PROPER BEHAVIOR OF MOTORIZED PISTON

ROTATION

The motorized rotation feature can be set to engage and disengage automatically as needed to maintain the floating piston rotating within a set rotation rate range when floating, and to stop rotation before mass manipulation to set a different pressure occurs (see Section 3.9.8). Motorized

piston rotation can also be activated manually by pressing [ activated by pressing and holding [

] and then pressing [←] (see Section 3.9.13).

Turn automated rotation OFF by pressing [ROTATE] and selecting <1off>. Load at least the mass bell on the piston, float the piston and press [

motorized rotation system should engage and cause the mass bell and piston to begin rotating. Within 5 to 30 seconds, depending on the mass load, the rotation rate should reach 80 rpm for PG7601 or about 50 rpm for PG7102 or PG7302. Current rotation rate can be observed by pressing [SYSTEM] (see Section 3.9.5).

]. Stopping piston rotation can be

]. When the piston is floating, the

2. INSTALLATION

2.4.8 CHECK PROPER OPERATION OF PISTON BEHAVIOR

MEASUREMENTS

Float the piston and rotate it (see Sections 2.4.6 and 2.4.7). Press [SYSTEM] once to reach the first SYSTEM run screen. Verify that the piston position,

piston fall/rise rate, piston rotation rate and piston rotation decay rate are indicating correctly (see Section 3.9.5). The piston position reading system may be calibrated using an on-board procedure if necessary (see Section 5.2.2). Calibration of piston position is recommended when installing a new PG7000 and regularly after installation.

Press [SYSTEM] again to reach the second SYSTEM run screen. Verify that the piston-cylinder temperature and temperature rate of change are indicating correctly (see Section 3.9.5). If checking a PG7601 Platform, verify that the vacuum reference measurement is operating correctly (see Section 2.4.8.1).

2.4.8.1 VERIFY VACUUM REFERENCE (PG7601 ONLY)

PG7601 includes provisions for establishing and measuring a vacuum reference. To verify the vacuum reference capability:

 Install a piston-cylinder module (see Section 2.3.2).  Install the bell jar on the PG7601 Platform (the bell jar aligns on the PG7601

vacuum plate and seals itself). If using AMH-38 automated mass handling, install the AMH-38 mass handler (see the AMH-38/AMH-100 Operation and Maintenance Manual).

 Apply a vacuum through the reference vacuum port (KF25 port on front left

side of platform or KF40 if using the optional AMH-38 automated mass handler).

 Press [SYSTEM] twice to observe the value of vacuum read by the

PG7601’s built-in vacuum gauge.

If a vacuum pump of adequate capacity has been correctly connected to the reference vacuum port, the vacuum read by the PG7601 built-in vacuum gauge should go to 4 Pascal [Pa] or lower in less than five minutes on the first pump down and two to three minutes on immediately subsequent pump downs.

If this performance is NOT achieved:

• The vacuum pump may be inadequate.

• The connection of the vacuum pump to the PG7601 platform of AMH-38 may

have leaks or excessive restrictions.

• The PG7601 built-in vacuum gauge or external vacuum gauge may be incorrect.

• There may be a leak in the PG7601.

PG7000™ OPERATION AND MAINTENANCE MANUAL

2.4.9 CHECK AUTOMATED PRESSURE GENERATION (IF PRESENT)

To check automated pressure generation/control:  Verify that the automated pressure generation/control component is properly connected

to the system (see Section 2.3.1.2).

 When operation has returned to the main run screen, turn ON automated pressure generation

control, if available, by pressing [GEN] and selecting <1on> (see Section 3.9.9).

 Press [P

OR M], <1pressure> to select pressure entry mode (see Section 3.9.12). Press

[ENTER] and enter a pressure value to be generated and follow the mass loading

instruction (see Section 3.6).

 Verify the pressure generation/control component properly generates pressure and floats

the PG7000 piston.

2.4.10 CHECK/SET SECURITY LEVEL

PG7000 has a security system based on User Levels. By default, the security system is set to low and NO password is required to change the security level. See Section 3.11.4.5 for information on the security system. As part of the PG7000 startup, set your desired security level and a password.

PG7000 is delivered with the security level set to low to avoid inadvertent altering of critical internal settings but with access to changing security levels unrestricted. It is recommended that the low security level be maintained at all times and password protection be implemented if control over setting of security levels is desired.

2.4.11 ADDITIONAL PRECAUTIONS TO TAKE BEFORE MAKING

PRESSURE MEASUREMENTS

Before using PG7000 to make accurate pressure measurements, consider the following:

• Select/activate the correct piston-cylinder module, mass set and mass loading bell

(see Sections 3.9.2, 3.11.1.10, 3.11.1.15).

• If using an automated pressure generation/control component with automated pressure

generation, set the pressure controller’s upper limit (UL) (see Section 3.9.9.3).

• Enter the correct value of local gravity at the site of use (see Section 3.11.6).

• Consider head corrections (see Sections 3.9.7 and 3.11.3).

• Level the PG7000 Platform properly (see Section 2.3.1.1).

• Select the correct pressure unit of measure and measurement mode (see Sections 3.9.3

and 3.9.5).

• Verify that the settings for the sources of variables to be used by PG7000 in its

calculations of reference pressures are those desired (see Section 3.10).

2. INSTALLATION

• Verify that the piston-cylinder module is correctly cleaned and operating properly

(see Section 5.3).

• PG7202 only: Ensure that the piston-cylinder module liquid reservoir is filled (see Section 5.3.3).

• Verify that there are NO leaks in the pressure system.

2.5 SHORT TERM STORAGE

The following is recommended for short term storage of PG7000.

 Remove all masses from the PG7000 Platform (manual mass set only).  Vent all circuits to atmosphere.  Turn OFF power using the power switch on the rear of the PG7000 Terminal.

Cover the PG7000 Platform and mass set with the dust covers included in the platform and mass set

accessories (not used with AMH mass handling system).

PG7000™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

3. GENERAL OPERATION

33.

EENNEERRAALL

PPEERRAATTIIOON

3.1 FUNDAMENTAL OPERATING PRINCIPLES

PG7000s operate on the principle of the piston gauge in which pressure is defined by balancing it against a known force on a known area (see Figure 5). The known area is defined by a vertically mounted piston rotating in a cylinder and the known force is applied to the piston by loading it with known mass subjected to acceleration due to gravity. When the force applied by the pressure and the force applied by the mass accelerated by gravity are in equilibrium, the piston floats and the pressure under the piston remains constant. The pressure can be calculated following the equation in Figure 5 (see also, Section 7.2). Generally, the pressurized fluid under the piston also lubricates the gap between the piston and the cylinder. PG7202 uses a unique gas operated, liquid lubricated piston-cylinder (see Section 3.1.1).

Figure 5. Piston Gauge Operating Principle

The PG7000 Platform is designed to mount a variety of piston-cylinder sizes, allow pressure to be applied under the piston and allow masses to be loaded on top of the piston. There are different PG7000 models depending upon whether the pressure medium is oil or gas and whether a vacuum reference is needed.

The measurement uncertainty in the pressure defined by the piston gauge depends on the uncertainty in the effective area of the piston-cylinder and the force applied by the mass accelerated by gravity. PG7000 stores the calibrated values of the piston-cylinders and masses it uses in on-board files (see Section 3.11.1). To determine the effective area of the piston-cylinder and the force applied by the masses under actual operating conditions, a number of influences on these values must be quantified and taken into consideration. For this reason, PG7000 includes extensive features to monitor the behavior and conditions of the piston-cylinder as well as ambient conditions that affect pressure definition (see Sections 3.9.5 and 3.9.6). PG7000 uses the piston-cylinder, mass and ambient condition information to calculate the pressure defined by a given mass load or the mass load needed to define a given pressure (see Section 7.2). The source of each value used by PG7000 in its calculations can be selected by the user between PG7000’s internal measurements, default values or user entered values. These sources are defined in SETUP files (see Section 3.10).

PG7000™ OPERATION AND MAINTENANCE MANUAL

Once PG7000 has been set up, it is used in day-to-day operation either to define pressures applied to a device or system under test or to measure a stable pressure. To interface with the PG Terminal, the operator:

 Selects the appropriate piston-cylinder to cover the pressure range (see Section 3.11.1.5).  Selects the desired pressure unit of measure (see Section 3.9.3).  Selects the desired pressure measurement mode (gauge, absolute, differential) (see Section 3.9.4).  Sets the head difference between the PG7000 and the device under test (see Section 3.9.7).  Selects mass to pressure or pressure to mass operating mode (see Section 3.9.12).  Enters a pressure to define or a current mass load to calculate (see Section 3.9.11.1 and 3.9.11.2).  Loads masses by hand or with optional AMH automated mass handler, floats piston and defines

pressure.

3.1.1 GAS OPERATED, LIQUID LUBRICATED PISTON-CYLINDER

OPERATING PRINCIPLE (PG7202)

PG7202 provides very high pressure gas pressure operation using a unique gas operated, liquid lubricated piston-cylinder system.

The principle of operation of the gas operated, liquid lubricated piston-cylinder is simple but very effective (see Figure 6). The measured gas pressure, Pg, is applied to the bottom of the piston and to the top of a liquid reservoir located around the cylinder. The reservoir is connected to the gap between the piston and the cylinder through lateral holes near the bottom of the cylinder, allowing liquid from the reservoir to enter the gap. The pressure of the liquid in the gap, Pl, is equal to the gas pressure Pg, plus the liquid head, h. Therefore, the liquid pressure in the gap is always higher than the gas pressure by the amount of the liquid head regardless of the gas pressure value. Since h is small and the space between the piston and cylinder is typically < 1 micron, the bleed of liquid from the bottom of the cylinder towa rds the gas pressure is extremely small. The mounting post of the 7202 piston gauge is configured so this minute amount of liquid drops directly into a sump that is deadened (see Section 5.2.4, 3.1.1) and not in the flow path of test gas into and out of the system. Though molecules of the liquid may migrate through the gas, no significant contamination of the test system occurs. Because the liquid reservoir is contained in the piston-cylinder module, piston-cylinders can be removed and installed in the PG7202 piston gauge platform with no loss of liquid from the reservoir. All PC-7200 piston-cylinder modules can be delivered using Krytox, a fluorinated synthetic fluid, to lubricate the piston-cylinder in applications where the system must remain perfectly free of hydrocarbons (e.g. when calibrating instrumentation for oxygen service).

3. GENERAL OPERATION

Figure 6. Gas Operated, Liquid Lubricated

Piston-Cylinder (PC-7200) Operating Principle

3.2 KEYPAD LAYOUT AND PROTOCOL

PG7000 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 from the main run screen by a single keystroke. The name of the function is on the bottom half of the key (see Section 3.9.1). These keys enter numerical values when editing.

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

3. The Menu/Data keys provide access to function menus 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. The SPECIAL menu is for functions that are NOT generally used as a part of day to day operation. These keys enter numerical values when editing.

Figure 7. PG7000 Keypad Layout

Key press confirmation is provided by both tactile and audible feedback. A single beep confirms a valid entry. A descending two note tone signals an invalid entry. The audible valid entry feedback can be suppressed or modified by pressing [SPECIAL] and selecting <5prefs>, <2sound> (see Section 3.11.4.2).

Pressing the [ENTER/SET P] key generally causes execution or forward movement in the menu tree. [ENTER/SET P] is also used to enter a command to set a pressure.

PG7000™ OPERATION AND MAINTENANCE MANUAL

Pressing the [ESCAPE] key generally allows movement back in the menu tree and/or causes execution to cease or suspend without changes being implemented. Pressing [ESCAPE] repeatedly eventually returns to the main run screen. From the main run screen, pressing [ESCAPE] allows momentary viewing of the PG7000 identification screen.

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

Pressing the [←] and [→] keys when editing allows reverse and forward cursor movement when editing data entry. These keys are also used to scroll through choices.

Menu selections can be made by pressing the number of the selection directly or by pressing [←] and [→] to place the cursor on the number of the desired selection and pressing [ENTER].

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 [←] and [→] 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.

3.3 SOUNDS

The PG Terminal is equipped with a variable frequency tone device to provide audible feedback and alarms. Some sounds can be modified and all sounds can be suppressed (see Section 3.11.4.2). Sounds are used for the following indications:

Valid key press

Invalid key press

Piston left end of stroke high

or low

Brief high frequency beep. Three rapid, low frequency beeps. Three rapid valid key press beeps. Piston was at low stop or high stop and

just entered spring zone (see Section 3.5).

3.4 PRESSURE READY/NOT READY INDICATION

The three characters on the top line, far left, of the main run screen provide a pressure Ready/Not Ready indication. This indication is intended to give the user a clear and objective indication of when PG7000 conditions are such that the value of pressure it is defining is valid and in tolerance. There are three Ready/Not Ready indication characters to indicate the status of the three main Ready/Not Ready criteria. The Ready/Not Ready indication characters are shown on the first line, top left hand side, of the main run screen.

1. Piston position and vertical movement.

2. Piston rotation.

3. Reference vacuum (PG7601 in absolute by vacuum measurement mode only).

For each Ready/Not Ready indication character, <*> indicates a Ready condition. Therefore, <***> or <** > indicates that all conditions necessary for an in tolerance pressure definition are present. Any indication other than <*> indicates Not Ready.

*** 100.4755 kPa g h

+ 0.1 mm 10.00564 kg

See Sections 3.4.1, 3.4.2 and 3.4.3 for details on each of the three Ready/Not Ready indicating characters.

The criteria used to distinguish between Ready and Not Ready conditions can be customized by the user

(see Sections 3.4.1, 3.4.2, 3.4.3).

3. GENERAL OPERATION

3.4.1 PISTON POSITION READY/NOT READY

The piston position Ready/Not Ready character indicates Ready or Not Ready based on the position of the piston in its vertical stroke (see Section 3.5) and an automated measure generation status (see Section 3.9.9). This ensures that pressure definitions will be made with the piston not more than a certain distance from mid-float position and that measurements will not be made while the action of an automated pressure controller may influence the pressure.

The piston position Ready/Not Ready character is the first character from the left on the top line of the main run screen.

The piston position Ready/Not Ready criterion is determined by the current SETUP file and can be customized by the user (see Section 3.10).

Piston position Ready/Not Ready character indications include: <*> Piston position Ready (within the position limits specified in the current SETUP file)

(see Section 3.5).

<↓> Piston position Not Ready, low (below the position limits specified in the current

SETUP file, see Section 3.10). The <↓> flashes if the piston is not at the bottom stop position to alert the user that this indicator is Not Ready.

<↑> Piston position Not Ready, high (above the position limits specified in the current

SETUP file) (see Section 3.10). The <↑> flashes if the piston is not at the top stop position to alert the user that this indicator is Not Ready.

<?> Piston position not known (current specified mass load is less than the load of the piston

+ bell). The bell must be installed for PG7000 piston position measurement to operate correctly so piston position values shown are not valid when the bell is not installed.

<T> Tare PG7000 is Not Ready (PG7102 and PG7202 only). Indicates that piston

position or rotation rate is Not Ready on the tare PG7000 in high line differential mode (see Section 3.9.4.2).

Piston position always indicates Not Ready if automated pressure generation is adjusting

pressure, regardless of actual piston position.

In PG7102 and PG7202 high line differential pressure mode (see Section 3.9.4.2), the piston position Ready/Not Ready indicator applies to the pistons of both the tare and the reference PG7000. For Ready to be indicated, both pistons must be within the ready limits for piston position.

3.4.2 PISTON ROTATION READY/NOT READY

The piston rotation Ready/Not Ready character indicates Ready or Not Ready based on the rotation rate of the piston.

The piston rotation Ready/Not Ready character is the second character from the left on the top line of the main run screen.

The piston rotation rate Ready/Not Ready criterion is specific to the currently active piston-cylinder module and can be edited by the user (see Sections 3.11.1.1).

PG7000™ OPERATION AND MAINTENANCE MANUAL

Piston rotation rate Ready/Not Ready character indications include: <*> Rotation rate Ready: Rotation rate is within the rotation rate limits specified in the

current piston-cylinder module file) (see Section 3.11.1.1).

<> Rotation rate Not Ready, low: Rotation rate is less than the lower rotation rate limit

specified in the current piston-cylinder module file (see Section 3.11.1.1) or motorized rotation system is currently engaged. Note that the low rotation limit is automatically reduced when the mass loaded on the piston is less than 3 kg. The

<> flashes if the piston is floating to alert the user that this indicator is Not Ready.

<?> Rotation rate not known: Current specified mass load is less than the load of the

(piston + bell). The bell must be installed for PG7000 piston rotation rate measurement to operate correctly so piston rotation rate cannot be measured when the bell is not installed.

At mass loads less then 3 kg the low rotation limit is automatically reduced to an operational minimum to maximize free rotation time.

In PG7102 and PG7202 high line differential pressure mode (see Section 3.9.4.2), the piston rotation rate Ready/Not Ready indicator applies to the pistons of both the tare and the reference PG7000. For Ready to be indicated, both pistons must be within the ready limits for piston rotation rate.

3.4.3 VACUUM REFERENCE READY/NOT READY (PG7601 ONLY)

The vacuum reference Ready/Not Ready character is only used with PG7601, as it is the only PG7000 model with vacuum reference capability. It is only active when operating in absolute by vacuum mode (see Section 3.9.4).

The vacuum reference Ready/Not Ready character indicates Ready or Not Ready based on the value of reference vacuum when making measurements in absolute by vacuum mode. This ensures that definitions of absolute pressure with a vacuum reference will be made with the vacuum under the PG7601 bell jar lower than a specified value. When the vacuum is not low enough, vacuum measurement errors may be excessive.

The vacuum reference Ready/Not Ready character is the third character from the left on the top line of the main run screen.

The vacuum reference Ready/Not Ready criterion is determined by the current SETUP file and can be customized by the user (see Section 3.10). The vacuum reference criterion is a fixed value that can be customized by the user when the vacuum reference selection in the SETUP file is internal. If the selection in the SETUP file is NOT internal, the vacuum reference Ready/Not Ready character always indicates Ready and the value cannot be customized.

Vacuum reference Ready/Not Ready character indications include: < > (Blank) Vacuum reference Ready/Not Ready is not in use. This is not a PG7601;

or if PG7601, current measurement mode is not absolute by vacuum.

<*> Vacuum reference Ready. Vacuum value is below limit specified in the current

SETUP file if source is internal OR source is default or user and the vacuum value is not a measured value (see Section 3.10).

< > > Vacuum reference Not Ready. Current SETUP file source for vacuum is internal

and vacuum value is above the limit specified (see Section 3.10). The < the piston is floating to alert the user that this indicator is Not Ready.

>> flashes if

3. GENERAL OPERATION

3.5 PISTON POSITION

When operating a PG7000 piston gauge, reference pressure values are defined by loading known mass values on the piston and adjusting the pressure to float the piston. Piston position is measured and displayed real time on the MAIN run screen (see Section 3.7) and in the first SYSTEM run screen (see Section 3.9.5). Piston position is used as a criterion for the Ready/Not Ready indication as valid measurements can only be made when the piston is in the correct position (see Section 3.4.1).

The full piston stroke is ± 4.5 mm from the midstroke position. The stroke is divided into different positions and zones as illustrated in Figure 8. These zones are:

• High and low

stops: The piston is at the minimum or maximum end of stroke. The pressure

applied to the piston is higher (at high stop) or lower (at low stop) than that corresponding to the mass loaded on the piston. The high and low stop positions are fixed.

• High and low spring zones: The combination of pressure and the force of the high or low stop springs have caused the piston to leave the stop. The pressure applied to the piston is within the equivalent of 2 kg of the pressure corresponding to the mass loaded on the piston. The high and low spring zones indicate the piston is about to float. The spring zone positions are fixed.

• High and low measurement zones: The piston is within the zone in which a Ready measurement can be made (see Section 3.4.1). The pressure applied to the piston is the pressure corresponding to the mass loaded on the piston. The default value of the high and low measurement zones is ± 2.5 mm around midstroke position. This value can be adjusted in the SETUP file (see Section 3.10).

• Midstroke: The piston is at the middle of its stroke. The bottom

of the piston (or its equivalent for hollow pistons) is at the reference level marked on the mounting post (see Section 3.9.7). There is equal stroke available to the high and low stops.

The piston position monitoring system is driven by the internal ring in the base of the mass loading bell. When the bell is not installed, piston position cannot be measured. If the current mass load is less than the mass of the piston + bell, PG7000 will display < ---- > where piston position is normally displayed. If the current mass load is greater than the mass of the piston + bell but the bell is not actually installed, the piston position indication is not valid.

Figure 8. Piston Stroke and Zones

PG7000™ OPERATION AND MAINTENANCE MANUAL

3.6 MASS LOADING PROTOCOL

 PURPOSE

To provide the operator with mass loading instructions and allow mass entry in convenient nominal values which PG7000 can accurately convert to measured mass values to determine the actual mass load.

 PRINCIPLE

All PG7000 manual mass set masses of 0.1 kg and above, including those in the mass set, the mass loading bell and the piston assembly, are adjusted so that their true mass is within ± 20 ppm of their nominal value. The nominal value is marked on each mass. Each mass’s actual individual value is measured more accurately than ± 20 ppm and reported in the mass set, mass loading bell or pistoncylinder module calibration report. These measured actual values are used by PG7000 in all of its defined pressure calculations. The nominal mass values, and the sequential numbers of the nominal masses when there are several of the same value, are used by PG7000 to describe the mass to load or the mass that is loaded. Following a few simple mass loading rules allows PG7000 to accurately transform actual mass values into nominal mass values and vice-versa so that mass loading instructions to the operator and the operator mass entries can be made in simple nominal mass instructions while representing actual individual mass values.

Since the nominal mass values written on the masses and the actual values of the individual masses are different, in pressure to mass mode (see Section 3.9.12) the actual mass value loaded on the piston will be different from the mass loading instruction. In the same manner, in mass to pressure mode the nominal value of the mass load that the operator enters is different from the actual mass loaded on the piston. The mass value shown in the MAIN run screen (see Section 3.7) is always the actual mass value. The mass loading instruction given in pressure to mass mode and the mass value entered by the operator in mass to pressure mode is always the nominal mass value. If PG7000 mass loading protocol is followed, the conversion from nominal mass to actual mass occurs correctly allowing very simple nominal mass loading and accounting for the operator while using very accurate measured mass values for metrological calculations.

 OPERATION

To avoid wear to masses and to the piston-cylinder module end of stroke stops, the piston should not be rotating when masses are loaded or unloaded. Before loading masses, stop piston rotation by hand or using the motorized rotation system (see Section 3.9.13).

PG7000 instructions to the operator of mass to load, and operator entries of the mass that is loaded, are always expressed in terms of nominal mass within 0.1 kg and in terms of grams for values under 0.1 kg. This protocol is also followed when using the AMH automated mass handler.

In pressure to mass mode, the instruction of the mass to load to achieve the requested pressure is formatted:

In mass to pressure mode, the entry of the mass currently loaded on the piston is formatted:

Load nominal mass: kkk.k kg and gg.gg g

Nominal mass load: kkk.k kg and gg.gg g

3. GENERAL OPERATION

kkk.k and gg.gg must be expressed and loaded following the mass loading rules below:

Mass Loading Rules

See Sections 2.3.1.3, Installing Masses On The Mass Loading Tray

and 3.6. for PG7000 mass set principles and protocol information. Refer to display examples immediately above to identify kkk.k and gg.gg. See EXAMPLES: Mass Loading below for mass loading examples.

PG7000 mass loading entries and instructions are always formatted: kkk.k kg and nn.nn g

• The mass set being used must be selected as the active mass set (see Section 3.11.1.10) and must

be properly set up prior to use (see Section 3.11.1.6).

• kkk.k is made up of the piston, the mass loading bell and mass set masses of 0.1 kg and greater.

When using an AMH mass set, the binary mass carrier and mass lifting shaft are also included.

• kkk.k always includes the mass loading bell and then the makeup mass, if possible.

• kkk.k is made up of the largest masses possible rather than a combination of smaller masses.

EXAMPLE: To load 5 kg on a PG7601:

 USE the piston (0.2 kg) + the mass loading bell (0.3 kg) + the 4.5 kg makeup mass.  DO NOT USE the piston + the mass loading bell + 2 kg #1 + 2 kg #2 + 0.5 kg #1.

When several masses of the same nominal value are included in kkk.k, they are loaded in numerical sequence, low to high.

EXAMPLE: When loading three 5 kg masses:

 USE 5 kg mass #1, #2 and #3.  DO NOT USE 5 kg mass #4, #3, #1.

This rule will be followed automatically if masses are installed and used as described in Section 3.6.

• gg.gg is made up of mass from the gram trim mass set (masses of 50 g to 0.01 g). These masses

can be loaded in any order.

When PG7000 provides mass loading instructions and calculates the true mass of the mass currently loaded, it assumes that the mass set in use has been set up correctly (see Section 2.3.1.3). For PG7000 mass loading protocol to operate properly, the mass set in use must be EXACTLY the mass set that has been defined by the add and/or edit mass function (see Section 3.11.1.6).

PG7000™ OPERATION AND MAINTENANCE MANUAL

In PG7102 and PG7202 High Line Differential mode (see Section 3.9.4.2), there are two types of mass loading instructions: line pressure setting and differential pressure setting. Both follow conventional PG7000 mass loading protocol. The line pressure mass instructions are always given with 0.1 kg resolution. This is to preserve the smaller masses for setting the differential pressure. The differential pressure mass loading instructions follow conventional mass loading protocol using the masses that remain after the line pressure has been set. It may be necessary to adjust the line pressure value to assure that adequate masses remain to set the desired differential pressure. For example, if the line pressure requires loading 10.6 kg, the 0.5 and 0.1 kg masses will be used to set the line pressure and will not be available if they are needed to set the differential pressure. If this situation occurs, consider adjusting the line pressure so that it is set using a whole number of kilograms, in this example 10.0 or 11.0 kg.

EXAMPLES: Manual Mass Loading

• Mass loading instruction using a PG7601 and a

35 kg mass set:

12.3 kg and 32.33 g

Load:

 piston (0.2 kg)   bell (0.3 kg)   4.5 kg #1 (makeup mass)   5 kg #1  2 kg #1  0.2 kg #1  0.1 kg #1  32.33 g from trim mass set

• Mass loading instruction using PG7302 and an 80 kg mass set:

77.6 kg and 10.45 g

Load:

 piston (0.2 kg)  bell (0.8 kg)  9 kg #1 (makeup mass)  10 kg #1 through #6  5 kg #1  2 kg #1  0.5 kg #1  0.1 kg #1  10.45 g from trim mass set

3. GENERAL OPERATION

3.7 MAIN RUN SCREEN

The PG7000 main run screen is its home display that is reached upon powering up and from which other functions and menus are accessed. It is the top level of all menu structures.

The main run screen is where PG7000 is left in normal operation. It displays the pressure defined by PG7000, Ready/Not Ready condition and a variety of other information.

The screen described below is called the MAIN run screen. The SYSTEM and AMBIENT screens (see Sections 3.9.5 and 3.9.6) are also run screens in the sense that all the other functions may be accessed directly from them and pressure or mass entries may be made from them. See Section 3.8 for a description of PG7000’s main menu/function structure.

3. <unit>: Current pressure unit of measure (see Section

3.9.3).

prvPRESSURE1 unit aGh

+N.N mm NN.NNNNN kg

1. <prv>: Three Ready/Not Ready indication characters

2. <PRESSURE1>: Numerical value and sign of the

(from left to right: piston position, piston rotation, vacuum reference) (see Section 3.4). Each character indicates as follows:

<p>: Piston Position Ready/Not Ready. <*> when Ready, <↑> when Not Ready due to piston above measuring zone, <↓> when Not Ready due to piston below measuring zone, <?> if piston position not available or out of range. Flashes if condition is Not Ready and piston is floating (see Section 3.4.1). Indicates Not Ready when automated pressure generation is adjusting pressure.

<r>: Piston Rotation Ready/Not Ready. <*> when Ready, <<> when Not Ready due to piston rotation rate too low or motorized rotation engaged, <?> if piston position not available or out of range. Flashes if condition is Not Ready and piston is floating. (see Section 3.4.2).

<v>: Vacuum Reference Ready/Not Ready (PG7601 only). <*> when Ready, <v> if Not Ready due to vacuum not below ready limit. Flashes if condition is Not Ready and piston is floating (see Section 3.4.3).

pressure defined by PG7000 with current mass loaded on current piston when all Ready/Not Ready indication characters indicate Ready.

4. Current measurement mode. <a> for absolute, <g> for gauge, <d> for differential or high line differential (see Section 3.9.4).

5. Automated pressure generation status. <G> if automated pressure generation is ON. The <G> flashes if automated pressure generation is ON and active, blank if automated pressure generation is not ON (see Section 3.9.9).

6. DUT head correction status. <h> if a head correction is currently being applied, blank if head height is zero (see Section 3.9.7).

7. <NN.NNNNN kg>: Current mass load in actual mass (assuming mass loading instructions have been followed and/or mass loading entries are correct (see Section 3.6).

8. <± N.N mm>: Current piston position in millimeters from midstroke position. Positive values are above midstroke, negative values below. Indicates < ---- > if piston position not available or out of range (see Section 3.5).

When a number is too large to display in the allocated screen space, PG7000 displays <********> or <OVERFLOW>.

PG7000 has a screen saver function that 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 activation time can be changed or screen saving can be completely disabled (see Section 3.4.5.1).

PG7000™ OPERATION AND MAINTENANCE MANUAL

3.8 GENERAL FUNCTION/MENU FLOW CHART

Local operator interface with PG7000 is provided by PG Terminal keypad and display. Normal PG7000 operation is organized around run screens from which functions and menus are accessed. The run screens include:

• MAIN run screen: Displays Ready/Not Ready, defined pressure, piston position and mass load.

• (2) SYSTEM run screens: Display piston position, rotation, temperature and reference vacuum

(PG7601 only).

• AMBIENT run screen: Displays ambient pressure temperature, relative humidity and local gravity. The flow chart below outlines the operating protocol of the run screens and associated key presses.

POWER

RESET

INTRO SCREEN

5 SEC

≈

DELAY

ESC

TO PREVIOUS RUN SCREEN

ESC

MAIN RUN SCREEN

SYSTEM

SYSTEM 1

RUN SCREEN

+/-

SYSTEM

SYSTEM 2

RUN SCREEN

RES

ENT SPECIAL SETUP

P-C UNIT MODE SYSTEM

AMBIENT

RUN SCREEN

OTHER FUNCTION KEYS

Figure 9. Run Screen Flow Chart

HEAD

ROTATE

ESCESC

AMBIENT

GEN

3. GENERAL OPERATION

3.9 DIRECT FUNCTION KEYS

3.9.1 DIRECT FUNCTION KEYS SUMMARY

Local operator interface with PG7000 is provided by PG Terminal keypad and display. To minimize the use of multi-layered menu structures, the keypad’s numerical keys also provide direct access to the most commonly used functions. The function accessed is labeled on the bottom half of the each key. Direct function keys are active whenever PG7000 is in a run screen (MAIN, SYSTEM or AMBIENT). Table 14 summarizes the operation of the direct function keys. Section 3.8 provides a flow chart of PG Terminal general operation. See corresponding manual Sections to 3.9.1 to 3.11.9.

It may be useful to keep a copy of Table 14 near the PG7000, especially when first becoming

acquainted with its operation.

Table 14. Summary of PG7000 Direct Function Key Operations

DIRECT FUNCTION KEYS ARE ACTIVE FROM ANY RUN SCREEN

See corresponding manual sections for full detail.

Menu of less frequently used internal functions and settings including resets, user preferences, internal calibration and remote interface setup.

Edit and select files that determine the sources of the values for the variables PG7000 uses in calculations of reference pressures.

Select pressure to mass or mass to pressure operation.

(main, ambient, system).

Activate motorized control manually. Activates when pressed, deactivates when released.

From a run screen: Access mass or pressure setting commands. From other screens: Select menu choice, enter value, confirm selection.

Turn automatic activation of motorized rotation ON/OFF.

Turn automated pressure generation/control ON/OFF, adjust control parameters, set upper limit for automated pressure control. Has no effect if an automated pressure generation/control component is not part of the PG7000 system.

Set the resolution of PG7000 mass loading commands (0.01 g to 0.1 kg).

Access SYSTEM run screens (2) which display current measurements of piston behavior, piston-cylinder temperature and reference vacuum if present. Toggles between the two screens.

Access AMBIENT run screen which displays current values of barometric pressure, ambient temperature, ambient humidity and local gravity as specified in the active SETUP file.

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

Select active piston-cylinder module (range).

Set unit of measure in which pressures are defined. Choice of units available from this key can be customized.

Set pressure measurement mode (gauge, absolute, differential).

PG7000™ OPERATION AND MAINTENANCE MANUAL

3.9.2 [P-C]

 PURPOSE

To view and/or change the active piston-cylinder module. In most cases, changing the piston-cylinder module is equivalent to changing the range.

[P-C] is for selecting the active piston-cylinder module only. Piston-cylinder modules can be added and deleted and their characteristics can be edited by pressing [SPECIAL] and selecting <1PC/MS> (see Section 3.11.1).

The active mass set and mass loading bell are selected by pressing [SPECIAL] and selecting <1PC/MS> (see Section 3.11.1).

 PRINCIPLE

To make valid pressure and mass load calculations, PG7000 must know the exact characteristics of the piston-cylinder module that is currently in use. See Section 7.2 for detailed information on PG7000 pressure and mass calculations.

Most PG7000s are used with more than one piston-cylinder module. Detailed characteristics on up to 18 piston-cylinder modules are stored in files. These files can be added, deleted, viewed and edited by pressing [SPECIAL], 1pc/ms (see Section 3.11.1).

The P-C function provides rapid access, from any run screen, to viewing the piston-cylinder modules available and selecting one to be active.

 OPERATION

Pressing [P-C] activates the piston-cylinder module viewing and selecting function. Pressing the [P-C] key again or [+/-] while in the P-C function steps through displays of available piston-cylinder modules.

When [P-C] is first pressed, a summary of the characteristics of the active piston-cylinder module is displayed, for example:

1. Nominal pressure to mass conversion coefficient of the pistoncylinder module that is currently selected (active). This value is calculated from the effective area of the piston-cylinder and is in kPa (if < 1 MPa) or MPa. Upgraded Type 5000 pistoncylinders may be displayed in psi.

2. Serial number of the active piston-cylinder module.

3. Current pressure unit of measure.

4. Nominal pressure in current pressure units resulting from loading all the mass of the active mass set.

5. Nominal pressure in current pressure units resulting from loading the piston and mass bell only.

Active 10 kPa/kg 247

0.7 to 50 psi

3. GENERAL OPERATION

Pressing [P-C] again or [+/-] causes the screen to step through the other available pistoncylinder modules in the sequence that they were added.

1. Nominal pressure to mass conversion coefficient of the pistoncylinder module. This value is calculated from the effective area of the piston-cylinder and is always in kPa (if < MPa) or MPa.

2. Serial number of the piston-cylinder module.

3. Current pressure unit of measure.

4. Nominal maximum pressure using the piston-cylinder module. Pressure, in current pressure units, resulting from loading all the mass of the active mass set.

5. Nominal minimum pressure using the piston-cylinder module. Pressure, in current pressure units, resulting from loading the piston and mass bell only.

Select 200kPa/kg 382

14 to 1000 psi

Pressing [ENTER] while in the P-C function causes PG7000 to select the currently displayed piston-cylinder module as the active piston-cylinder module.

Pressing [ESCAPE] while in the P-C function returns to the main run screen without changing piston-cylinder modules.

The pressure unit of measure in which the range offered by the piston-cylinder module using

the active mass set is displayed can be changed by pressing [UNIT] (see Section 3.9.3).

When the current pressure unit of measure is an altitude unit, piston-cylinder module range

is expressed in kPa if the altitude unit is meters (m) or psi if the altitude unit is feet (ft).

3.9.3 [UNIT]

 PURPOSE

To specify the unit of measure in which defined pressures are expressed.

 PRINCIPLE

PG7000 supports a wide variety of pressure units of measure. Internally, PG7000 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 Pascal. See Section 7.1.1 for Unit of Measure Conversions.

The pressure unit of measure selection (e.g., psi, kPa, etc.) is separate from the pressure measurement mode selection (gauge, absolute or differential). See Section 3.9.4 for information on changing the measurement mode.

 OPERATION

To change the pressure unit of measure, press the [UNIT] function key from any run screen. The display is (default units depend on model):

1kPa 2Mpa 3Pa

4bar 5psi 6kcm2

The cursor is on the number corresponding to the active unit. To change the pressure unit, select the desired unit. The display returns to the previous run screen with the selected unit active.

PG7000™ OPERATION AND MAINTENANCE MANUAL

If the pressure unit selected is inWa, the reference

Select inWa ref temp

temperature for water density must be specified. When inWa is selected as the unit, the next display is:

4°C 20°C 20°F

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 active pressure unit. The current inWa reference temperature can be viewed by observing the position of the cursor in the reference temperature screen.

See Section 7.1 for tables of the pressure unit of measure conversion factors used by

PG7000.

The UNIT function provides rapid access to a choice of up to six units. The choice of units can be customized from a wider selection by the user (see Section 3.9.3.1). The default units of the UNIT function depend on the PG7000 model. The default units are:

PG7102 and PG7601: 1kPa 2MPa 3Pa 4bar 5psi 6kcm2

PG7202 and PG7302: 1MPa 2kPa 3bar 4psi 5kcm2

To restore the default UNIT function settings, use the Unit Reset (see Section 3.11.9.2).

Certain internal and/or metrological functions (e.g., vacuum reference pressure) are always represented in Pascal [Pa], regardless of the active pressure unit of measure.

When the current pressure unit of measure is an altitude unit, atmospheric pressure in the AMBIENT run screen is expressed in kPa if the altitude unit is meters (m) or psi if the altitude unit is feet (ft).

3.9.3.1 CUSTOMIZING PRESSURE UNITS AVAILABLE UNDER THE UNIT FUNCTION

 PURPOSE

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

 PRINCIPLE

The UNIT function provides a choice of different pressure units of measure depending on the PG7000 model. The units that are available by default are those indicated in the Note in Section 3.9.3. However, PG7000 supports many other pressure units of measure. Other units can be made available for selection and units can be deleted by customizing the UNIT function. This allows PG7000 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 the six most commonly used units.

3. GENERAL OPERATION

 OPERATION

To customize the [UNIT] function key, from the main run screen press [SETUP] and select <2PresU>. The display is:

1. The UNIT number in the [UNIT] menu that is to be changed.

Enter the number of the unit position that you would like to change. The display becomes:

Set up user unit #6

Unit #6 1SI 2other

3altitude 4user

Select the desired pressure unit category. SI units include units based on SI such as mmHg. Select the desired unit from the unit list (see Table 15).

Table 15. Pressure Units of Measure Available

<1SI> <2Other> <3altitude>* <4User>**

<1Pa> <2Kpa> <3MPa> <4mbar> <5bar> <6mmHg> <7mmWa>

* <3altitude>: PG7601 in absolute by vacuum mode only. Not available in PG7102, PG7202 and PG7302.

** <4user>: User defined unit. As there are no altitude units on PG7102, PG7202 and PG7302, user is <3user>.

<1psi> <2psf> <3inHg> <4inWa> <5kcm2> <6Torr> <7mTor> <8none>

<1m> <2ft>

<1user>

The UNIT function display is not required to display six units. To delete the current unit from the UNIT screen and show no unit, select <2other>, <6none> for that unit number.

If <4user> was selected, the user unit must be defined. The display is:

Define user unit:

1. Entry field.

1.000000 Units/Pa

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 7.1.1 for the pressure unit of measure conversion factors used

by PG7000.

The user defined unit can be assigned a user defined label using the UDU

remote command (see Section 4.3.4.2).

PG7000™ OPERATION AND MAINTENANCE MANUAL

3.9.4 [MODE]

 PURPOSE

To specify the measurement mode (gauge, absolute, differential) in which PG7000 defines reference pressures.

Pressure measurement mode and unit of measure are not the same thing.

See Section 3.9.3 for information on the pressure unit of measure.

 PRINCIPLE

Pressure defined relative to absolute zero or vacuum is generally referred to as absolute pressure.

Pressure defined relative to atmospheric pressure is generally referred to as gauge pressure, with pressure below atmosphere called negative gauge pressure.

Pressure defined relative to another pressure that may be, but is not necessarily atmospheric pressure, is generally referred to as differential pressure.

PG7000s (depending on the model) can define absolute, gauge, negative gauge and differential pressures. These are referred to as measurement modes.

The specific PG7000 measurement modes are as follows:

• gauge: Defines gauge pressure by leaving the PG7000 mass load open to atmosphere. This measurement mode is supported by all PG7000 models. It does not allow negative gauge pressures. The minimum gauge pressure is the pressure resulting from loading the combined mass of the piston and the bell on piston-cylinder effective area.

• absolute by adding atmospheric pressure (absolute by ATM): Defines absolute pressure by defining a pressure in the same manner as in gauge mode and adding the value of atmospheric pressure measured by a barometer. This measurement mode is supported by all PG7000 models. The barometer can be PG7000’s on-board sensor or a remote RS232 barometer. The uncertainty on the value of atmospheric pressure measured by the barometer must be considered but this value can become relatively small as pressure goes up. For example, if using a ± 0.01 % barometer, the added uncertainty at 1 MPa (150 psi) is 10 ppm.

This mode is more convenient and less costly than absolute by vacuum since no vacuum reference needs to be established. However, it does not allow absolute pressures under atmosphere and the minimum absolute pressure is atmospheric pressure plus the pressure resu lting from loading the combined mass of the piston and the bell on the piston-cylinder effective area.

• absolute by vacuum (absolute by vac) (PG7601 only): Defines absolute pressure by measuring relative to an evacuated bell jar. This mode is time consuming as the vacuum under the bell jar must be made and broken to adjust the mass load for each pressure to be set. This mode is required for setting absolute pressures under atmospheric pressure and for lowest uncertainty under about 1 MPa (150 psi).

• differential (dif) (PG7601 only): Defines differential pressures at an absolute static pressure between vacuum and two atmospheres by defining an absolute pressure relative to an evacuated bell jar and subtracting static pressure monitored by a digital pressure indicator. An offsetting technique ensures that only the digital indicator’s resolution and very short term repeatability influence the measurement results. Allows positive and negative differential pressure (including gauge pressures) with one common hardware setup. Covers pressures very near and at zero without limitations due to piston-cylinder size and mass loads (see Section 3.9.4.1).

3. GENERAL OPERATION

• high line differential (HLdif) (PG7102 and PG7202 only): Defines differential pressures and at gauge static pressure between the lowest gauge pressure supported by the piston-cylinder and the maximum gauge pressure supported by the piston-cylinder. Requires the use of a PG7202 or PG7102 as the “reference” and a second gas operated PG7000 as the “tare”. Differential pressures are defined by setting a common line pressure on both PG7000s and then adding the differential pressure to the reference PG7000 (see Section 3.9.4.2).

 OPERATION

To change the pressure measurement mode, press [MODE] from any run screen. The resulting display depends on the PG7000 Model:

Measurement mode:

PG7102, PG7202, PG7302 [MODE] Screen PG7601 [MODE] Screen

1gauge 2abs 3HLdif

Measurement mode:

1g 2avac 3aatm 4dif

For PG7102, PG7202 and PG7302, selecting <2abs> accesses absolute by ATM mode (see PRINCIPLE above).

For PG7102, PG7202 and PG7302 selecting <3HLdif> accesses high line differential mode (see PRINCIPLE above and Section 3.9.4.2).

For PG7601, selecting <2avac> accesses absolute by vacuum mode. Selecting <3aatm> accesses absolute by ATM mode. Selecting <4dif> accesses differential mode (see PRINCIPLE above and Section 3.9.4.1).

Making a measurement mode selection returns to the previous run screen with the selected mode active.

The cursor is on the number corresponding to the current measurement mode.

When using an AMH automated mass handler, be sure to apply drive vacuum to the AMH when switching operation to absolute by vacuum mode (see the AMH-38/AMH-100 Operation and Maintenance Manual).

3.9.4.1 DIFFERENTIAL MEASUREMENT MODE (PG7601 ONLY)

 PURPOSE

To define gauge pressures near and under atmospheric pressure that cannot be covered in conventional gauge mode; to define pressures at a static pressure near atmospheric pressure but other than atmospheric pressure.

Differential mode operation is only supported by PG7601. Differential mode operation requires that the PG7601 SETUP AtmP selection be for an external barometer connected to COM2 (see Section 3.10, 3.11.5.4). Differential mode operation also requires the PG7000 Differential Mode Interconnections Kit P/N 3070127, which includes the Differential Mode Controller.

PG7000™ OPERATION AND MAINTENANCE MANUAL

 PRINCIPLE

Differential mode is designed to allow PG7601 to define pressures which piston gauges have typically not covered or for which they have been difficult to use. This includes positive and negative gauge pressures right around zero, for example ± 2.5 kPa (10 in. H2O); as well as low differential pressures at low absolute static pressures, for example 0 to 2.5 kPa (20 Torr) at 15 kPa absolute (2.2 psia) static pressure.

The principal of differential mode is to define a differential pressure as the difference between an absolute pressure relative to vacuum and a second absolute pressure (the static pressure) measured by a precision Reference Pressure Monitor (RPM). An offsetting procedure “tares” the RPM so that the uncertainty contributed to the differential pressure by the RPM’s measurement is a function of the RPM resolution and short term repeatability rather than its absolute accuracy and long term stability.

For differential mode operation, the static pressure is set to the desired value as measured by the RPM (atmospheric pressure for gauge pressure measurements). Then RPM offset at the static pressure is determined by applying the static pressure as defined by the PG7601 following:

RPM

Where:

PGRPMstart

RPMindicate

= Pressure applied by PG7601 to RPM

Once the RPM offset has been determined, differential pressures are defined by subtracting the static pressure measured by the RPM from an absolute pressure defined by the PG7601 following:

offset = PGRPMstart - RPMindicate

(nominally equal to RPM RPM reading when PGRPMstart is applied

to RPM test port

start)

dif = PGabs - RPMcurrent - RPMoffset

Where:

Pgdif

abs

Pg RPM RPM

current offset

= Differential pressure defined by PG7601 = Absolute pressure defined by PG7601 = Current RPM indication of static pressure

= Disagreement between PG7601 and RPM at

the operating static pressure

For differential mode operation, the PG7000 Differential Mode Interconnections Kit should be used to provide the DUT high and low test connections and support the RPM offsetting procedure (see Figure 9 and Section 3.9.4.1). A precision Reference Pressure Monitor, such as a DHI RPM, must be selected for the AtmP source in SETUP (see Section 3.10, 3.11.5.4).

PG7601 differential measurement mode manages the data acquisition and handling to support differential mode operation without operator effort. Differential mode operation requires setting the static pressure at which differential measurements are to be made and regular determination of the RPM offset. These functions are supported under [MODE], <4dif>.

3. GENERAL OPERATION

1. PG/STATIC P CONTROL Port

2. PG Port

3. TEST HIGH Port (Quick Connection)

4. TEST LOW Port (Quick Connection)

5. 1/8 in. NPT F or 4T Quick Connector

6. STATIC P Port

7. STATIC P SUPPLY Port

8. CONTROL SELECTION Valve

9. PG SHUTOFF Valve

10. TEST BYPASS Valve

11. Reference Pressure Monitor (RPM) (Optional)

12. STATIC P SELECTION Valve

13. Static Pressure Exhaust (Internal)

Figure 10. Differential Mode Controller Schematic

DHI Technical Note 9940TN02 provides more detailed information on differential mode principles and includes a complete uncertainty analysis. Consult DHI or visit www.dhinstruments.com.

 OPERATION

To select differential mode operation and access differential mode functions press [MODE] and select <4dif>.

Differential mode operation includes:

• Selecting differential mode, setting static pressure and finding the RPM offset

(see Section 3.9.4.1, Selecting Differential Mode, Setting Static Pressure, Finding RPM Offset (<1run>).

• Operating in differential mode (see Section 3.9.4.1, Operating In

Differential Mode).

• Viewing differential mode static pressure and RPM offset (see

Section 3.9.4.1, Viewing Static Pressure and RPM Offset (<2view>)

• Selecting Differential Mode, Setting Static Pressure, Finding RPM

Offset (<1run>)

Fluke PG7102 V2.03, PG7202 V2.03, PG7601 V2.03, PG7302 V2.03 Operation and Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

ABOUT THIS MANUAL

1. INTRODUCTION

1.1 PRODUCT OVERVIEW

1.2 SPECIFICATIONS

1.2.1 GENERAL SPECIFICATIONS

1.2.1.1 EMBEDDED FEATURES

1.2.2 PISTON-CYLINDER MODULES

1.2.2.1 PC-7100/7600

1.2.2.2 PC-7200

1.2.2.3 PC-7300

1.2.3 MASS SETS

1.2.4 PRESSURE MEASUREMENTS

1.2.4.1 PC-7100/7600

1.2.4.2 PC-7200

1.2.4.3 PC-7300

1.3 TERMINAL AND PLATFORM FRONT AND REAR PANELS

1.3.1 TERMINAL FRONT AND REAR PANELS

1.3.1.1 PG TERMINAL FRONT PANEL

1.3.1.2 PG TERMINAL REAR PANEL

1.3.2 PLATFORM REAR PANELS

2. INSTALLATION

2.1 UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

2.1.1.1 PLATFORM

2.1.1.2 MASS SET

2.1.1.3 PISTON-CYLINDER MODULE(S)

2.1.1.4 AUTOMATED MASS HANDLER

2.1.2 INSPECTING CONTENTS

2.1.2.1 PLATFORM

2.1.2.2 MASS SET

2.1.2.3 PISTON-CYLINDER MODULE(S)

2.2 SITE REQUIREMENTS

2.3 SETUP

2.3.1 PREPARING FOR OPERATION

2.3.1.1 SETTING UP THE PLATFORM

2.3.1.2 SYSTEM PRESSURE INTERCONNECTIONS

2.3.1.3 SETTING UP A MASS SET

2.3.2 INSTALLING A PISTON-CYLINDER MODULE INTO THE PLATFORM

2.4 POWER UP AND VERIFICATION

2.4.1 POWER UP

2.4.3 SET LOCAL GRAVITY VALUE

2.4.4 SETUP PRESSURE EQUATION VARIABLE INPUT SOURCES

2.4.6 APPLY PRESSURE TO THE PISTON-CYLINDER MODULE

2.4.8.1 VERIFY VACUUM REFERENCE (PG7601 ONLY)

2.4.9 CHECK AUTOMATED PRESSURE GENERATION (IF PRESENT)

2.5 SHORT TERM STORAGE

3. GENERAL OPERATION

3.1 FUNDAMENTAL OPERATING PRINCIPLES

3.2 KEYPAD LAYOUT AND PROTOCOL

3.3 SOUNDS

3.4 PRESSURE READY/NOT READY INDICATION

3.4.1 PISTON POSITION READY/NOT READY

3.4.2 PISTON ROTATION READY/NOT READY

3.4.3 VACUUM REFERENCE READY/NOT READY (PG7601 ONLY)

3.5 PISTON POSITION

3.6 MASS LOADING PROTOCOL

3.7 MAIN RUN SCREEN

3.8 GENERAL FUNCTION/MENU FLOW CHART

3.9 DIRECT FUNCTION KEYS

3.9.1 DIRECT FUNCTION KEYS SUMMARY

3.9.2 [P-C]

3.9.3 [UNIT]

3.9.3.1 CUSTOMIZING PRESSURE UNITS AVAILABLE UNDER THE UNIT FUNCTION

3.9.4 [MODE]

3.9.4.1 DIFFERENTIAL MEASUREMENT MODE (PG7601 ONLY)