Fluke PG7601-SYS-AF User Manual

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PG7601-SYS-AF™

Gas Operated Piston Gauge Pressure Calibration System

Operation and Maintenance Manual

NSN 6695-01-551-5125

Consists of Base System and Exchange Pack

PG7601-SYS-AF™ 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, a

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

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

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

DH Instruments, DH, DHI, PG7601-AF, PG7601, PPPC3, 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. 550152a-01 071001 Printed in the USA

AABBLLEE OOFF

OONNTTEENNTTS

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

TABLES................................................................................VII

FIGURES................................................................................IX

ABOUT THIS MANUAL............................................................. XI

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

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

1.1.1 OVERALL SYSTEM SPECIFICATIONS........................................................................................................1

1.1.1.1 PRESSURE MEASUREMENTS................................................................................................................2

1.1.2 PISTON GAUGE PLATFORM (PG7601-AF).................................................................................................2

1.1.2.1 EMBEDDED FEATURES...........................................................................................................................3

1.1.2.2 MEASUREMENT OF AMBIENT AND INSTRUMENT CONDITIONS........................................................4

1.1.3 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, -50, -200)............................................................5

1.1.4 MASS SET (MS-7001-35-AF)........................................................................................................................6

1.1.5 PRESSURE CONTROLLER (PPC3-7M-AF).................................................................................................7

1.1.6 REFERENCE VACUUM PUMP (D16B).........................................................................................................7

2. SYSTEM AND COMPONENT OVERVIEW AND DESCRIPTION .... 9

2.1 SYSTEM OVERVIEW (PG7601-SYS-AF)................................................................................................9

2.2 PISTON GAUGE PLATFORM AND TERMINAL (PG7601-AF).............................................................12

2.2.1 PLATFORM..................................................................................................................................................13

2.2.2 PG TERMINAL.............................................................................................................................................14

2.3 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, -50, -200)...............................................15

2.4 MASS SET (MS-7001-35-AF).................................................................................................................16

2.5 PRESSURE CONTROLLER (PPC3-7M-AF).........................................................................................16

2.6 REFERENCE VACUUM PUMP (D16B).................................................................................................18

3. INSTALLATION ................................................................ 19

3.1 UNPACKING AND INSPECTION...........................................................................................................19

3.1.1 UNPACKING AND INSPECTION OF PG7601-BAS-AF BASE SYSTEM...................................................19

3.1.1.1 PLATFORM, TERMINAL AND BELL JAR (PG7601-AF)........................................................19

3.1.1.2 PRESSURE CONTROLLER (PPC3-7M-AF)...........................................................................................20

3.1.1.3 REFERENCE VACUUM PUMP (D16B)...................................................................................................20

3.1.1.4 PRESSURE INTERCONNECTIONS KIT (PK-7601-P-AF) ......................................................20

3.1.1.5 VACUUM INTERCONNECTIONS KIT (PK-7601-V-AF)..........................................................................21

3.1.1.6 DOCUMENTATION AND ACCESSORIES..............................................................................................21

3.1.2 UNPACKING AND INSPECTION OF PG7601-EXC-AF EXCHANGE PACKAGE......................................21

3.1.2.1 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, PC-7100/7600-50, PC-7100/7600-200) AND

ACCESSORIES .......................................................................................................................................22

3.1.2.2 MASS SET (MS-7001-35-AF)..................................................................................................................22

3.1.2.3 DOCUMENTATION AND ACCESSORIES..............................................................................................23

3.2 SITE REQUIREMENTS..........................................................................................................................23

3.3 PHYSICAL SETUP.................................................................................................................................25

3.3.1 SETTING UP THE PLATFORM...................................................................................................................25

3.3.2 SETTING UP THE PRESSURE CONTROLLER.........................................................................................26

3.3.3 SYSTEM PRESSURE INTERCONNECTIONS............................................................................................26

3.3.4 SETTING UP THE MASS SET ....................................................................................................................27

3.3.5 INSTALLING A PISTON-CYLINDER MODULE INTO THE PLATFORM....................................................28

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

3.3.6 SETTING UP THE REFERENCE VACUUM PUMP AND VACUUM INTERCONNECTIONS.....................29

3.3.7 CONNECTING TEST GAS SUPPLY...........................................................................................................29

3.3.8 CONNECTING CONTROL VACUUM SUPPLY...........................................................................................30

3.4 POWER UP AND VERIFICATION .........................................................................................................30

3.4.1 POWER UP PLATFORM AND PRESSURE CONTROLLER......................................................................30

3.4.2 CHECK THAT ON-BOARD PISTON-CYLINDER MODULE AND MASS SET DIGITAL IDS ARE

CORRECT....................................................................................................................................................31

3.4.3 SET LOCAL GRAVITY VALUE ...................................................................................................................31

3.4.4 CHECK/SET SECURITY LEVEL.................................................................................................................31

3.4.5 CHECK PROPER OPERATION OF AMBIENT CONDITION MEASUREMENTS ......................................31

3.4.6 TURN ON AUTOGEN AND AUTOROTATE................................................................................................32

3.4.7 APPLY SUPPLY PRESSURE .....................................................................................................................32

3.4.8 APPLY CONTROL VACUUM......................................................................................................................32

3.4.9 APPLY REFERENCE VACUUM..................................................................................................................32

3.4.10 SET A GAUGE MODE PRESSURE, CHECK AUTOGEN AND AUTOROTATE FUNCTIONS..................32

3.4.11 CHECK PISTON BEHAVIOR MEASUREMENTS.......................................................................................34

3.4.12 CHECK REFERENCE VACUUM SYSTEM AND ABSOLUTE MODE OPERATION..................................34

3.5 ADDITIONAL PRECAUTIONS TO TAKE TO MAKE GOOD PRESSURE MEASUREMENTS.............36

4. GENERAL OPERATION ..................................................... 37

4.1 OPERATING PRINCIPLES....................................................................................................................37

4.1.1 FUNDAMENTAL OPERATING PRINCIPLE................................................................................................37

4.1.2 PRESSURE CONTROL, MANUAL AND AUTOMATED.............................................................................38

4.1.3 PRESSURE READY/NOT READY INDICATION........................................................................................39

4.1.3.1 PISTON POSITION READY/NOT READY ..............................................................................................39

4.1.3.2 PISTON ROTATION READY/NOT READY.............................................................................................40

4.1.3.3 VACUUM REFERENCE READY/NOT READY.......................................................................................40

4.1.4 PISTON POSITION......................................................................................................................................41

4.1.5 MASS LOADING PROTOCOL ....................................................................................................................42

4.2 USER INTERFACE................................................................................................................................45

4.2.1 PISTON GAUGE (SYSTEM INTERFACE)..................................................................................................45

4.2.1.1 KEYPAD LAYOUT AND PROTOCOL......................................................................................................45

4.2.1.2 MAIN RUN SCREEN................................................................................................................................46

4.2.1.3 GENERAL FUNCTION/MENU FLOW CHART........................................................................................48

4.2.1.4 SOUNDS..................................................................................................................................................48

4.2.2 PRESSURE CONTROLLER........................................................................................................................49

4.2.2.1 KEYPAD LAYOUT AND PROTOCOL......................................................................................................49

4.2.2.2 DIRECT PRESSURE CONTROL KEYS..................................................................................................50

4.2.2.3 MAIN RUN SCREEN................................................................................................................................51

4.2.2.4 SOUNDS..................................................................................................................................................52

4.3 DIRECT FUNCTION KEYS....................................................................................................................53

4.3.1 DIRECT FUNCTION KEYS SUMMARY......................................................................................................53

4.3.2 [P-C], VIEW AND SELECT PISTON-CYLINDER MODULES.....................................................................53

4.3.3 [UNIT], SELECT PRESSURE UNIT OF MEASURE....................................................................................55

4.3.4 [MODE], SELECT PRESSURE MEASUREMENT MODE...........................................................................56

4.3.5 [SYSTEM], VIEW SYSTEM CONDITIONS MEASUREMENT SCREENS..................................................57

4.3.5.1 FIRST SYSTEM RUN SCREEN ..............................................................................................................57

4.3.5.2 SECOND SYSTEM RUN SCREEN .........................................................................................................58

4.3.6 [AMBIENT], VIEW AMBIENT CONDITIONS MEASUREMENTS SCREEN ...............................................59

4.3.7 [HEAD], SET FLUID HEAD CORRECTION HEIGHT..................................................................................60

4.3.8 [ROTATE], MANAGE MOTORIZED PISTON ROTATION..........................................................................62

4.3.8.1 <2PRE-DECEL>.......................................................................................................................................64

4.3.9 [GEN], MANAGE AUTOMATED PRESSURE GENERATION....................................................................64

4.3.9.1 <2TARGET>.............................................................................................................................................66

4.3.9.2 <3RAISE> ................................................................................................................................................66

4.3.9.3 <4UL>.......................................................................................................................................................66

4.3.9.4 <5TOL>....................................................................................................................................................67

4.3.9.5 <6REFLOAT>...........................................................................................................................................67

4.3.9.6 VIEWING AND SETTING PPC3-7M-AF COM1 PORT SETTINGS.........................................................68

4.3.10 [RES], SET MASS LOADING RESOLUTION .............................................................................................68

4.3.11 [SET P], SET OR MEASURE A PRESSURE..............................................................................................69

4.3.11.1 [SET P] IN PRESSURE TO MASS MODE...............................................................................................71

4.3.11.2 [SET P] IN MASS TO PRESSURE MODE...............................................................................................72

4.3.11.3 COMMANDS FOR ZERO PRESSURE, ENDING A TEST......................................................................73

4.3.12 [P OR M], SET PRESSURE TO MASS OR MASS TO PRESSURE OPERATING MODE.........................73

4.3.13 [ ] AND [ ], [←], MANUAL CONTROL OF MOTORIZED ROTATION...............................................74

TABLE OF CONTENTS

4.4 [SETUP] MENU, MANAGE PRESSURE EQUATION VARIABLE SOURCES......................................75

4.4.1 <1SELECT>.................................................................................................................................................77

4.4.2 <2VIEW>......................................................................................................................................................77

4.4.3 <3EDIT>.......................................................................................................................................................78

4.5 [SPECIAL] MENU..................................................................................................................................81

4.5.1 <1PC/MS>, MANAGE METROLOGICAL ELEMENT DIGITAL IDS............................................................82

4.5.1.1 CREATE PISTON-CYLINDER MODULE.................................................................................................83

4.5.1.2 EDIT PISTON-CYLINDER MODULE.......................................................................................................86

4.5.1.3 VIEW PISTON-CYLINDER MODULE......................................................................................................86

4.5.1.4 DELETE PISTON-CYLINDER MODULE.................................................................................................87

4.5.1.5 SELECT THE ACTIVE PISTON-CYLINDER MODULE...........................................................................87

4.5.1.6 ADD MASS SET.......................................................................................................................................87

4.5.1.7 EDIT MASS SET......................................................................................................................................91

4.5.1.8 VIEW MASS SET.....................................................................................................................................91

4.5.1.9 DELETE MASS SET................................................................................................................................91

4.5.1.10 SELECT MASS SET................................................................................................................................92

4.5.1.11 ADD MASS LOADING BELL....................................................................................................................92

4.5.1.12 EDIT MASS LOADING BELL...................................................................................................................93

4.5.1.13 VIEW MASS LOADING BELL..................................................................................................................94

4.5.1.14 DELETE MASS LOADING BELL.............................................................................................................94

4.5.1.15 SELECT MASS LOADING BELL.............................................................................................................94

4.5.2 <2PRESU>, CUSTOMIZE UNIT FUNCTION SELECTIONS.......................................................................94

4.5.3 <3HEAD>, CUSTOMIZE FLUID HEAD FUNCTIONS .................................................................................96

4.5.3.1 <3HEAD>, <1FLUID>...............................................................................................................................97

4.5.3.2 <3HEAD>, <2UNIT>.................................................................................................................................97

4.5.3.3 <3HEAD>, <3ATM> .................................................................................................................................97

4.5.3.4 <3HEAD>, <4PISTON>............................................................................................................................98

4.5.4 <4PREFS>, SET USER PREFERENCES ...................................................................................................98

4.5.4.1 <4PREFS>, <1SCRSVR>........................................................................................................................98

4.5.4.2 <4PREFS>, <2SOUND>..........................................................................................................................99

4.5.4.3 <4PREFS>, <3TIME> ..............................................................................................................................99

4.5.4.4 <4PREFS>, <4ID> ...................................................................................................................................99

4.5.4.5 <4PREFS>, <5LEVEL>..........................................................................................................................100

4.5.5 <5REMOTE>, MANAGE REMOTE COMMUNICATION INTERFACES....................................................103

4.5.5.1 COM1, COM2 AND COM3 (RS232)......................................................................................................104

4.5.5.2 IEEE-488................................................................................................................................................104

4.5.5.3 RS232 SELF TEST................................................................................................................................105

4.5.5.4 EXTERNAL BAROMETER (RPM) COMMUNICATIONS (COM2).........................................................105

4.5.5.5 EXTERNAL VACUUM GAUGE COMMUNICATIONS (COM2) .............................................................107

4.5.6 <6GL>, SET VALUE OF LOCAL GRAVITY..............................................................................................110

4.5.7 <7CAL>, MANAGE INTERNAL MEASUREMENT SENSOR CALIBRATIONS........................................110

4.5.8 <8AMH>, OPERATE AUTOMATED MASS HANDLER (NOT INCLUDED)..............................................110

4.5.9 <9RESET>, USE SYSTEM RESETS.........................................................................................................111

4.5.9.1 <9RESET>, <1SETS> ...........................................................................................................................111

4.5.9.2 <9RESET>, <2UNITS>..........................................................................................................................112

4.5.9.3 <9RESET>, <3COM>.............................................................................................................................112

4.5.9.4 <9RESET>, <4CAL>..............................................................................................................................112

4.5.9.5 <9RESET>, <5SETUPS> ......................................................................................................................113

4.5.9.6 <9RESET>, <6ALL> ..............................................................................................................................113

5. REMOTE OPERATION ......................................................115

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

5.2 INTERFACING.....................................................................................................................................115

5.2.1 RS232 INTERFACE...................................................................................................................................115

5.2.1.1 COM1.....................................................................................................................................................116

5.2.1.2 COM2 AND COM3.................................................................................................................................116

5.2.2 IEEE-488 (GPIB)........................................................................................................................................117

5.3 COMMANDS........................................................................................................................................117

5.3.1 COMMAND SYNTAX.................................................................................................................................117

5.3.2 COMMAND SUMMARY.............................................................................................................................117

5.3.3 ERROR MESSAGES.................................................................................................................................120

5.3.4 COMMAND DESCRIPTIONS.....................................................................................................................121

5.3.4.1 IEEE STD. 488.2 COMMON AND STATUS COMMANDS.....................................................121

5.3.4.2 PG7601-AF COMMANDS......................................................................................................................123

5.4 STATUS SYSTEM................................................................................................................................148

5.4.1 STATUS REPORTING SYSTEM...............................................................................................................149

5.4.1.1 STATUS BYTE REGISTER ...................................................................................................................149

5.4.1.2 STANDARD EVENT REGISTER...........................................................................................................150

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

6. GENERAL MAINTENANCE AND ADJUSTMENTS ..................153

6.1 OVERVIEW..........................................................................................................................................153

6.2 ILLUSTRATED PARTS BREAKDOWN...............................................................................................154

6.3 PISTON-CYLINDER MODULES..........................................................................................................173

6.3.1 DISASSEMBLY AND REASSEMBLY.......................................................................................................173

6.3.1.1 PC-7100/7600-10-L (10 KPA/KG) DISASSEMBLY AND REASSEMBLY..............................................174

6.3.1.2 PC-7100/7600-10-L (10 KPA/KG) PISTON INSERTION TOOL............................................................178

6.3.1.3 PC-7100/7600-50 AND -200 (50 AND 200 KPA/KG) DISASSEMBLY AND REASSEMBLY ................180

6.3.2 CLEANING PISTON-CYLINDERS.............................................................................................................182

6.3.2.1 OVERVIEW............................................................................................................................................182

6.3.2.2 WATER/DETERGENT METHOD...........................................................................................................183

6.3.2.3 QUICK METHOD ...................................................................................................................................184

6.3.3 LUBRICATING PISTON-CYLINDER MODULES......................................................................................185

6.4 PLATFORM..........................................................................................................................................186

6.4.1 PISTON POSITION DETECTION ADJUSTMENT.....................................................................................186

6.4.2 DRIVE BELT REPLACEMENT..................................................................................................................187

6.4.3 DISASSEMBLY AND REASSEMBLY OF PG7601-AF.............................................................................187

6.4.3.1 PLATFORM............................................................................................................................................187

6.4.3.2 TERMINAL.............................................................................................................................................188

6.5 ADJUSTING PRESSURE CONTROLLER INTERNAL PRESSURE SENSOR...................................189

6.6 REFERENCE VACUUM PUMP............................................................................................................191

6.6.1 CHECK/TOP OFF OIL LEVEL...................................................................................................................191

6.6.2 DRAIN AND REFILL OIL...........................................................................................................................191

6.7 RELOADING EMBEDDED SOFTWARE INTO PLATFORM OR PRESSURE CONTROLLER FLASH

MEMORY.............................................................................................................................................192

6.8 STORAGE AND SHIPPING .................................................................................................................192

6.8.1 SHORT AND LONG TERM STORAGE.....................................................................................................192

6.8.2 PREPARATION FOR SHIPPING...............................................................................................................193

6.8.2.1 PISTON-CYLINDER MODULES............................................................................................................193

6.8.2.2 MASS SET.............................................................................................................................................193

6.8.2.3 PLATFORM............................................................................................................................................193

6.8.2.4 PRESSURE CONTROLLER..................................................................................................................194

6.8.2.5 VACUUM PUMP ....................................................................................................................................194

7. MAINTENANCE OF TRACEABILITY AND RECALIBRATION ...195

7.1 PRINCIPLES OF SYSTEM TRACEABILITY MAINTENANCE............................................................195

7.2 LOCAL METROLOGICAL MAINTENANCE BETWEEN RECALIBRATIONS.....................................195

7.2.1 OVERVIEW................................................................................................................................................195

7.2.2 PLATFORM, ADJUST ON-BOARD P, T, H SENSORS............................................................................195

7.2.2.1 BAROMETRIC PRESSURE SENSOR ..................................................................................................196

7.2.2.2 AMBIENT TEMPERATURE SENSOR...................................................................................................197

7.2.2.3 RELATIVE HUMIDITY SENSOR ...........................................................................................................198

7.3 RECALIBRATION................................................................................................................................198

7.3.1 OVERVIEW................................................................................................................................................198

7.3.2 CALIBRATION OF PISTON-CYLINDER MODULES................................................................................199

7.3.2.1 PREPARING FOR CALIBRATION.........................................................................................................199

7.3.2.2 U P D A T I N G P I S T O N- C Y L I N D E R M O D U L E D I G I T A L I D S ...................................................... 199

7.3.3 CALIBRATION OF MASS SET..................................................................................................................200

7.3.3.1 PREPARING FOR CALIBRATION.........................................................................................................200

7.3.3.2 UPDATING MASS SET DIGITAL ID......................................................................................................200

7.3.4 CALIBRATION OF PISTON-CYLINDER MODULE TEMPERATURE SENSOR......................................200

7.3.4.1 OVERVIEW............................................................................................................................................200

7.3.4.2 PROCEDURE ........................................................................................................................................201

7.3.4.3 CALCULATING AND UPDATING PISTON-CYLINDER TEMPERATURE SENSOR INFORMATION..201

7.3.5 CALIBRATION OF RESIDUAL VACUUM GAUGE...................................................................................202

7.3.5.1 OVERVIEW............................................................................................................................................202

7.3.5.2 PROCEDURE ........................................................................................................................................203

7.3.5.3 CALCULATING AND UPDATING VACUUM GAUGE CALIBRATION INFORMATION ........................204

TABLE OF CONTENTS

7.4 MANAGING METROLOGICAL ELEMENT DIGITAL IDS WITH CALTOOL™ FOR PG7000

SOFTWARE.........................................................................................................................................205

7.4.1 OVERVIEW................................................................................................................................................205

7.4.2 OPERATION..............................................................................................................................................205

7.4.2.1 GETTING STARTED..............................................................................................................................206

7.4.2.2 PROCESSING A NEW DIGITAL ID FILE (AFTER RECALIBRATION)...................................207

7.4.2.3 STORING DIGITAL IDS FROM THE PG7601-AF IN THE CALTOOL DATABASE OR TO *.DID FILE207

7.4.2.4 ARCHIVING DIGITAL IDS .....................................................................................................................208

8. TROUBLESHOOTING .......................................................209

8.1 OVERVIEW..........................................................................................................................................209

9. APPENDIX ......................................................................213

9.1 CONVERSION OF NUMERICAL VALUES..........................................................................................213

9.1.1 PRESSURE................................................................................................................................................213

9.2 DEFINED PRESSURE CALCULATIONS............................................................................................213

9.2.1 PG7601-AF ................................................................................................................................................215

9.2.2 FLUID HEADS ...........................................................................................................................................215

9.2.2.1 FLUID HEAD COMPONENTS...............................................................................................................215

9.2.2.2 OVERALL FLUID HEAD CORRECTION...............................................................................................217

9.3 GLOSSARY..........................................................................................................................................217

9.4 WARRANTY STATEMENT..................................................................................................................219

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

TABLES & FIGURES

AABBLLEES

Table 1. Base system, PG7601-BAS-AF, packing guide .......................................................................... 19

Table 2. Platform, PG7601-AF, packing list...............................................................................................20

Table 3. Pressure interconnections kit, PK-7601-P-AF, packing list.........................................................20

Table 4. Vacuum interconnections kit, PK-7601-V-AF, packing list ..........................................................21

Table 5. Base system accessories kit packing list.....................................................................................21

Table 6. Exchange pack, PG7601-EXC-AF, packing guide......................................................................22

Table 7. Piston-cylinder modules, PC-7100/7600-10-L, PC-7100/7600-50,

Table 8. Mass set, MS-7001-35-AF, packing list.......................................................................................23

Table 9. Exchange pack accessories packing list .....................................................................................23

Table 10. Summary of PG7601-AF PG Terminal direct function key operations...................................... 53

Table 11. SETUP file choices, factory preferred choice and normal value...............................................76

Table 12. Piston-cylinder module digital ID fields......................................................................................84

Table 13. Mass set digital ID fields............................................................................................................88

Table 14. Mass loading bell digital ID fields...............................................................................................92

Table 15. Pressure units of measure available..........................................................................................95

Table 16. Security levels - functions NOT executed per function/level ...................................................102

Table 17. COM1, COM2 and COM3 available settings...........................................................................104

Table 18. COM1 DB-9F pin designation..................................................................................................116

Table 19. COM2 and COM3 DB-9M pin designation ..............................................................................116

Table 20. Command summary.................................................................................................................118

Table 21. Error messages........................................................................................................................120

Table 22. Status byte register..................................................................................................................149

Table 23. Standard event register............................................................................................................150

Table 24. Mechanical maintenance procedures......................................................................................153

Table 25. Top Level Illustrated Parts Breakdown (see Figure 23) .........................................................154

Table 26. PG7601 Illustrated Parts Breakdown for Mass Set, Cases, and Covers (see Figure 24)......156

Table 27. PG7601 Illustrated Parts Breakdown for Piston Cylinders (see Figure 25) ...........................157

Table 28. PG7601 Illustrated Parts Breakdown for Piston Cylinder Cases (see Figure 26)..................157

Table 29. PG7601 Illustrated Parts Breakdown for PG Main Board (see Figure 27).............................159

Table 30. PG7601 Illustrated Parts Breakdown for PG Base Underside (see Figure 28)......................160

Table 31. PG7601 Illustrated Parts Breakdown for PG Base Outside (see Figure 29)..........................162

Table 32. PG7601 Illustrated Parts Breakdown for PG Terminal Outside (see Figure 30)....................163

Table 33. PG7601 Illustrated Parts Breakdown for PG Terminal Inside (see Figure 31).......................164

Table 34. PG7601 Illustrated Parts Breakdown for PPC3 Outside (see Figure 32)...............................165

Table 35. PG7601 Illustrated Parts Breakdown for PPC3 Pneumatic Module (see Figure 33).............167

Table 36. PG7601 Illustrated Parts Breakdown for PPC3 Inside (see Figure 34) .................................169

Table 37. PG7601 Illustrated Parts Breakdown for PPC3 Manifold detail (see Figure 35)....................170

Table 38. PG7601 Illustrated Parts Breakdown for PK-7601-P-AF (see Figure 36).............................. 171

Table 39. PG7601 Illustrated Parts Breakdown for Accessories Kit (see Figure 37).............................172

PC-7100/7600-200, packing list..............................................................................................22

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Table 40. PG7601-AF mounting post wire colors, description and location............................................188

Table 41. Metrological maintenance procedures.....................................................................................195

Table 42. Recalibration requirements......................................................................................................199

Table 43. Troubleshooting checklist ........................................................................................................209

Table 44. Pressure unit of measure conversions ....................................................................................213

Table 45. Defined pressure calculation variables....................................................................................214

Table 46. DHI Authorized Service Providers ...........................................................................................219

ABOUT THIS MANUAL

IIGGUURREES

Figure 1. System, PG7601-SYS-AF, standard installation........................................................................10

Figure 2. System, PG7601-SYS-AF, pneumatic schematic ......................................................................11

Figure 3. System, PG7601-SYS-AF, communications schematic.............................................................11

Figure 4. Piston gauge operating principle................................................................................................12

Figure 5. Platform, PG7601-AF, rear view.................................................................................................13

Figure 6. PG Terminal front panel..............................................................................................................14

Figure 7. PG Terminal rear panel ..............................................................................................................14

Figure 8. Piston-cylinder modules, PC-7100/7600-10-L, -50, -200........................................................... 15

Figure 9. Mass set, MS-7100-35-AF.......................................................................................................... 16

Figure 10. Pressure controller, PPC3-7M-AF, front panel.........................................................................17

Figure 11. Pressure controller, PPC3-7M-AF, rear panel..........................................................................17

Figure 12. Reference vacuum pump, D16B, front and side views ............................................................18

Figure 13. Piston-cylinder module installation...........................................................................................28

Figure 14. Piston gauge operating principle..............................................................................................37

Figure 15. Piston stroke and zones ...........................................................................................................42

Figure 16. PG Terminal keypad layout ......................................................................................................45

Figure 17. Platform MAIN run screen display fields...................................................................................47

Figure 18. RUN screen flow chart..............................................................................................................48

Figure 19. Pressure controller keypad layout............................................................................................49

Figure 20. Pressure controller direct pressure control keys......................................................................50

Figure 21. Pressure controller MAIN run screen display fields..................................................................52

Figure 22. Status byte register.................................................................................................................149

Figure 23. Top Level Illustrated Parts Breakdown for PG7601-SYS-AF..................................................155

Figure 24. PG7601 Illustrated Parts Breakdown for Mass Sets, Cases, and Covers..............................156

Figure 25. PG7601 Illustrated Parts Breakdown for Piston Cylinders......................................................158

Figure 26. PG7601 Illustrated Parts Breakdown for Piston Cylinder Cases ............................................158

Figure 27. PG7601 Illustrated Parts Breakdown for PG Main Board .......................................................159

Figure 28. PG7601 Illustrated Parts Breakdown for PG Base Underside................................................161

Figure 29. PG7601 Illustrated Parts Breakdown for PG Base Outside....................................................162

Figure 30. PG7601 Illustrated Parts Breakdown for PG Terminal Outside..............................................163

Figure 31. PG7601 Illustrated Parts Breakdown for PG Terminal Inside.................................................164

Figure 32. PG7601 Illustrated Parts Breakdown for PPC3 Outside......................................................... 166

Figure 33. PG7601 Illustrated Parts Breakdown for PPC3 Pneumatic Module........................................168

Figure 34. PG7601 Illustrated Parts Breakdown for PPC3 Inside............................................................169

Figure 35. PG7601 Illustrated Parts Breakdown for PPC3 Manifold detail..............................................170

Figure 36. PG7601 Illustrated Parts Breakdown for PK-7601-P-AF ........................................................171

Figure 37. PG7601 Illustrated Parts Breakdown for Accessories Kit.......................................................172

Figure 38. 10 kPa/kg piston-cylinder module (expanded view)...............................................................177

Figure 39. Gas piston-cylinder module sleeve nut tool............................................................................177

Figure 40. 10 kPa/kg piston insertion tool................................................................................................178

Figure 41. 50, 200 kPa/kg gas piston-cylinder modules (expanded view)..............................................182

Figure 42. Piston-cylinder module lubrication chart..................................................................................186

Figure 43. Vacuum gauge calibration setup.............................................................................................204

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

ABOUT THIS MANUAL

BBOOUUTT

This manual provides the user with the information necessary to operate and maintain a PG7601-SYS-AF gas operated piston gauge system.

Before using the manual, take a moment to familiarize yourself with the Table of Contents structure. All first time PG7601-AF users should read Section 2 and 4. Section 5 covers remote communication with an external computer. Sections 6 and 7 provide maintenance and calibration information. Section 1 is a quick troubleshooting guide. Use the information in Section 1 to troubleshoot unexpected PG7601AF behavior based on the symptoms of that behavior.

Certain words and expressions have specific meaning as they pertain to PG7601-AFs. The (see Section 9.3) they are used in this manual.

The PG7601-SYS-AF system includes a PPC3-7M-AF pressure controller. This manual covers the pressure controller to the extent necessary for normal operation of the PG7601-AF system. The PPC3-7M-AF has a complete, independent manual that is included on the PG7601-SYS-AF Support Disc.

FOR THOSE OF YOU WHO “DON’T READ MANUALS”, GO DIRECTLY TO SECTION 3.3 TO SET UP YOUR PG7601-AF. THEN GO TO SECTION 3.5. THIS WILL GET YOU RUNNING QUICKLY WITH MINIMAL RISK OF CAUSING DAMAGE TO YOURSELF OR YOUR PG7601-AF. THEN… WHEN YOU HAVE QUESTIONS OR START TO WONDER ABOUT ALL THE GREAT FEATURES YOU MIGHT BE MISSING, GET INTO THE MANUAL!

HHIISS

is useful as a quick reference for the definition of specific words and expressions as

AANNUUAAL

Glossary

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., [UNIT]).

< > indicates PG7601-AF screen displays (e.g., <1yes>)

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

1. INTRODUCTION

11..

PG7601-SYS-AF is a very high performance pressure calibration system for the validation and calibration of pressure measuring devices using gas as the pressurized medium. It operates 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.

PG7601-SYS-AF covers the pressure range of 7 to 7000 kPa (1 to 1 000 psi) in absolute and gauge modes with semi-automated operation and state of the art measurement uncertainty.

A PG7601-SYS-AF is made up of:

PG7601-BAS-AF, p/n 402351, the “base” system, including the piston gauge platform, pressure controller, vacuum pump and interconnecting hardware (everything except the piston-cylinder modules and masses).

PG7601-EXC-AF, p/n 402350, the “exchange package”, including the piston gauge’s three different size piston-cylinder modules and the mass set.

NNTTRROODDUUCCTTIIOON

1.1 SPECIFICATIONS

1.1.1 OVERALL SYSTEM SPECIFICATIONS

Power requirements

Instruments

Reference vacuum pump (D16B)

Operating temperature range

Storage temperature range

Operating humidity range

Storage humidity range

Dimensions

Bench space needed for installation

Weight (shipping)

PG7601-AF platform in case

PG7601-AF vacuum bell jar

PPC3-7M-AF pressure controller

D16B vacuum pump

Base system accessories

35 kg mass set, main masses case

35 kg mass set, fractional masses case

(3) piston-cylinder modules in case

Exchange pack accessories

System external communication ports

Overall pressure ranges

Actual range depends on piston-cylinder installed

Operating media

85 to 264 VAC, 50/60 Hz, 52 VA max. consumption

100 to 120 VAC, 50/60 Hz, 1430 VA max. consumption, full load 9.4 to 13 A

15 to 35 °C

5 to 90 °C (vacuum pump), -40 to 100 °C (other components)

5 to 95% R.H., non-condensing

65 cm x 56 cm (65 in. x 22 in.)

36 kg (79 lb)

5 kg (11 lb)

18 kg (40 lb)

40 kg (88 lb)

12 kg (26 lb)

35 kg (77 lb)

20 kg (44 lb)

10 kg (22 lb)

6 kg (13 lb)

RS 232 (COM1), IEEE-488

7 kPa to 7 MPa (1 to 1000 psi), gauge and absolute

air, helium, nitrogen

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Pressure connections

Device under test (DUT)

Test pressure supply (PPC3)

Control vacuum supply

1.1.1.1 PRESSURE MEASUREMENTS

The pressure measurement specifications of the PG7601-AF depend upon the piston-cylinder module used.

PC-7100/7600-10-L (10 kPa/kg)

PC-7100/7600-50 (50 kPa/kg)

PC-7100/7600-200 (200 kPa/kg)

1. Sensitivity: The smallest variation in input detectable in output.

2. Reproducibility: Combined long term stability of piston-cylinder effective area and masses predicted for 30 months.

3. Measurement uncertainty:

gauge and absolute measurement modes, at the PG7601-AF reference level including precision, predicted 30 month stability, temperature effect and calibration uncertainty, combined and expanded (k=2) following the ISO “Guide to the Expression of Uncertainty in Measurement. Assumes the PG7601-AF platform sensors are properly adjusted, use of MS-7001-35-AF mass set with measurement uncertainty of ± 5 ppm, uncertainty of not more than ± 2 ppm in the value of local acceleration due to gravity entered into the PG7601-AF Terminal.

Swagelok stems of 1/4 in. NPT F, 1/8 in. NPT F, AN4 M, 1/4 in. Swage

1/8 in. NPT F 1/8 in. NPT F

Sensitivity

Reproducibility

Measurement uncertainty

Sensitivity

Reproducibility

Measurement uncertainty

Sensitivity

Reproducibility

Measurement uncertainty

Maximum deviation of the PG7601-AF indicatied pressure from the true value of pressure, in

SS-QC4-B1-400 quick connector with quick connector

0.02 Pa + 0.5 ppm

± 4 ppm

± (0.2 Pa + 15 ppm)

0.1 Pa + 0.5 ppm

± 4 ppm

± (0.5 Pa + 20 ppm)

0.4 Pa + 0.5 ppm

± 6 ppm

± (2 Pa + 25 ppm)

1.1.2 PISTON GAUGE PLATFORM (PG7601-AF)

Power requirements Operating temperature range Weight

Instrument platform

PG Terminal

Dimensions

Instrument platform

PG Terminal

Microprocessors

Instrument platform

PG Terminal

Communication ports

RS232

IEEE-488

85 to 264 VAC, 50/60 Hz, 22 VA max. consumption. 15 to 25 °C

17 kg (37 lb)

1.4 kg (3 lb)

36 cm H (top of bell jar) x 40 cm W x 35 cm D (14.5 in. x 15.8 in. x

13.8 in.) 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 communications COM2: Not used (may be used for optional external barometer or vacuum gauge) COM3: PPC3 pressure controller communications

Host comptuer

1. INTRODUCTION

Overall pressure range

Operating media Mass load range Pressure connections

TEST port

Bell jar vent (VACUUM) port

Refe r e n c e v a c u u m pump down port

CE Conformance

7 kPa to 7 MPa (1 to 1000 psi), gauge and absolute (actual range depends on piston-cylinder selected)

air, helium, nitrogen

0.7 to 36.2 kg

DH200 (for 1/4 in. OD tube, equivalent to AE SF250C, HIP LF4) DH200 KF25 Available, must be specified.

1.1.2.1 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 (optional).

• Interfacing and automatic exploitation of optional external barometer via

RS232 (optional).

• Interfacing and automatic exploitation of external vacuum gauge via RS232 (optional).

• Storage and one step activation of metrological data digital IDs 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 PPC3-7M-AF pressure controller.

• Full RS232 and IEEE-488 communications with multi-level commands to set

and read all instrument functions.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

1.1.2.2 MEASUREMENT OF AMBIENT AND INSTRUMENT

CONDITIONS

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 15 to 25

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 (not included in PG7601-SYS-AF).

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 15 to 25 oC

Vacuum

Range

Resolution

Measurement uncertainty

0 to 20 Pa

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

1. INTRODUCTION

1.1.3 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, -50, -200)

The PG7601-SYS-AF piston-cylinders are integrated modules including mounting hardware delivered in individual shipping and storage bullet cases.

PC-7100/7600-10-L

Range

Operation

Piston material

Nominal mass of piston assembly

Cylinder material

Nominal diameter

Nominal area

Mounting system

Typical drop rate (35 kg load)

Nominal mass to pressure 10 kPa/kg (1.5 psi/kg)

7 to 350 kPa (1 to 50 psi) Gas operated, gas lubricated Tungsten carbide

0.4 kg Tungsten carbide 35 mm 1 000 mm Simple free deformation

0.1 mm/min

PC-7100/7600-50

Range

Operation

Piston Material

Nominal mass of piston assembly

Cylinder Material

Nominal Diameter

Nominal Area

Mounting system

Typical drop rate (35 kg load)

PC-7100/7600-200

Range

Operation

Piston Material

Nominal mass of piston assembly

Cylinder Material

Nominal Diameter

Nominal Area

Mounting System

Typical drop rate (35 kg load)

Nominal mass to pressure 50 kPa/kg (7.5 psi/kg)

25 to 1750 kPa (3.6 to 254 psi) Gas operated, gas lubricated Tungsten carbide

0.2 kg Tungsten carbide 16 mm

200 mm Negative free deformation

0.5 mm/min

Nominal mass to pressure 200 kPa/kg (14.5 psi/kg)

100 to 7000 kPa (14.5 to 1015 psi) Gas operated, gas lubricated Tungsten carbide

0.2 kg Tungsten carbide 8 mm 50 mm Negative free deformation

1.0 mm/min

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

1.1.4 MASS SET (MS-7001-35-AF)

Set composition

Mass discs and pucks

Material

Finish

Adjustment tolerance

Uncertainty in measured values

Mass loading bell

Material

Finish

Adjustment tolerance

Uncertainty in measured value

Trim masses < 50g

Adjustment tolerance

Uncertainty in measured value

1 x 4.5 kg disc(makeup mass) 5 x 5 kg disc 2 x 2 kg disc 1 x 1 kg disc 1 x 0.5 kg puck 2 x 0.2 kg puck 1 x 0.1 kg puck 1 x 0.3 kg mass loading bell Trim mass set of 50 g to 0.01 g (total 100 g)

304L non-magnetic stainless steel Electropolished

± 20 ppm of nominal value ± 5 ppm

6AL-4V titanium (bell and hanger), 304L stainless steel (adjustment ring), nickel plated 1018 steel (speed ring)

Mechanically polished

± 20 ppm of nominal value ± 8 mg

Adjusted to nominal value ± 1 mg

1. INTRODUCTION

1.1.5 PRESSURE CONTROLLER (PPC3-7M-AF)

Power requirements

Operating temperature range

Weight

Microprocessors

Communication ports

Fuses

Pressure range

Operating medium

Pressure connections

Test pressure supply

Control vacuum supply

Pressure limits

Maximum working pressure

Maximum supply pressure

On-board utility sensor

Resolution 0.001 % of span

Precision 0.1 % of span

85 to 264 VAC, 50/60 Hz, 30 VA max consumption 15 to 35 °C

12.7 kg (28.2 lb) approx Motorola 68302, 16 MHz RS232 (COM1), RS232 (COM2), IEEE-488.2 1 A, 250 VAC fuse, 5 x 20 mm, time lag type fuse Internal power supply fuse not replaceable by operator: 2A, 250 V (UV 440-2

power supply), 3.15A, 250 V (NFS40-7612 power supply) 7 kPa to 7 MPa (1 to 1000 psi), gauge and absolute Any clean, dry, non-corrosive gas SUPPLY: 1/8 in. NPT F

TEST(+): 1/8 in. NPT F TEST(-): 1/8 in. NPT F ATM (Vent):10-32 UNF EXHAUST:1/4 in. NPT F

7.7 MPa (1100 psi) Ultimate pressure lower than 2 kPa (0.3 psia); capacity 85 slm (3 cfm) min

7.03 MPa (1020 psi)

9.6 MPa (1 400 psi)

The pressure measurements made by the PPC3-7M-AF utility sensor are used only for pressure control and indication. They have no metrological function therefore they do not require traceable calibration. Adjustment of the PPC3 utility sensor is performed only for operational reasons (see Section 6.5).

1.1.6 REFERENCE VACUUM PUMP (D16B)

Power requirements

Operating temperature range

Weight

Oil capacity

Nominal pumping speed

Pumping speed

Ultimate total pressure

Pressure connections (intake

and exhauts)

100 to 120 VAC, 50/60 Hz, 1430 W max consumption, full load 9.4 to 13 A 12 to 40 °C 26 kg (57 lb) approx

0.5 l (1 qt)

/h (11.1 cfm)

18.9 m

16.5 m3/h (9.7 cfm)

0.2 Pa (1.5 mTorr) KF25

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

2. SYSTEM AND COMPONENT OVERVIEW AND DESCRIPTION

22.

YYSSTTEEMM AANNDD

OOMMPPOONNEENNTT

VVEERRVVIIEEWW AANNDD

2.1 SYSTEM OVERVIEW (PG7601-SYS-AF)

PG7601-SYS-AF is a very high performance pressure calibration system for the validation and calibration of pressure measuring devices using gas as the pressurized medium in the range of 7 to 7000 kPa (1 to 1 000 psi).

A PG7601-SYS-AF is made up of:

PG7601-BAS-AF, the “base system”. The base system is the operational piston gauge system, not including the piston-cylinder modules and mass set. The base system includes:

- PG7601-AF piston gauge platform with PG Terminal and vacuum bell jar

- PPC3-7M-AF pressure controller

- D16B reference vacuum pump

- Pressure and vacuum interconnecting hardware packages

PG7601-EXC-AF, the “exchange package”. The exchange package is the system’s metrological elements: the piston-cylinder modules and mass set. The exchange package includes:

EESSCCRRIIPPTTIIOON

- (3) piston-cylinder modules, PC-7100/7600-10-L, -50 and -200.

- MS-7001-35-AF 35 kg mass set The following figures in this section describe the PG7601-SYS-AF system: Figure 1. System, PG7601-SYS-AF, standard installation Figure 2. System, PG7601-SYS-AF, system pneumatic schematic Figure 3. System, PG7601-SYS-AF, electrical and communications schematic

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

1. DUT quick connector on stand

2. Tube, DUT connector to tee

3. Trim mass set

4. Vacuum vent valve

5. Tee

6. Platform shutoff valve assembly

7. Tube, pressure controller to tee

8. RS232 cable, pressure controller to platform

9. PPC3-7M-AF pressure controller

10. PG Terminal to platform cable

11. PG Terminal

12. D16B reference vacuum pump

13. Vacuum pump smoke eliminator

14. PG7601-AF platform

15. Vacuum shutoff valve

16. KF25 hose

17. KF25 elbow

18. Main mass stack

19. Fractional mass tray

Figure 1. System, PG7601-SYS-AF, standard installation

2. SYSTEM AND COMPONENT OVERVIEW AND DESCRIPTION

1. Test pressure supply

2. Pressure controller connection

3. Reference vacuum pump

4. Vacuum shutoff valve

5. Piston-cylinder module

6. Reference vacuum bell jar (removed in gauge measurement mode)

7. DUT connection

8. Vacuum vent valve

9. Platform shutoff valve

10. Control vacuum supply

Figure 2. System, PG7601-SYS-AF, pneumatic schematic

1. Electrical power cords

2. PG Terminal to PG7601-AF platform data and power connection

3. PG7601-AF platform to PPC3-7M-AF pressure controller connection (RS232)

4. PG7601-SYS-AF system remote communications (RS232)

5. PG7601-SYS-AF system remote communications (IEEE-488)

Figure 3. System, PG7601-SYS-AF, communications schematic

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

2.2 PISTON GAUGE PLATFORM AND TERMINAL (PG7601-AF)

The heart of the PG7601-SYS-AF is the PG7601-AF gas operated piston gauge and its piston-cylinder modules and mass set.

The PG7601-AF operates on the principle of the piston gauge in which pressure is defined by balancing it against a known force on a known area (see Figure 4). The known area is defined by a vertically mounted piston rotating in a cylinder and the known force is applied mass subjected to acceleration due to gravity. When the force applied by the pressure and the force appl ied by t he ma ss 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 4. The pressurized gas under the piston also lubricates the gap between the piston and the cylinder. floating, the piston must be rotating to keep it well centered in the cylinder and perfectly mobile.

The system includes three piston cylinder modules and a 35 kg mass set. The combination provides three ranges of 7 to 350 kPa (1 to 50 psi), 25 to 1750 kPa (3.6 to 260 psi) and 100 to 7 000 kPa (14.5 to 1000 psi). The PG7601-AF platform includes a bell jar that can be evacuated using the supplied reference vacuum pump so that pressure can be defined against vacuum (absolute mode) or atmosphere (gauge mode). The PPC3-7M-AF pressure controller adjusts pressure automatically or manually to float the piston (see Section 4.1.2).

to the piston by loading it with known

When

Figure 4. Piston gauge operating principle

2. SYSTEM AND COMPONENT OVERVIEW AND DESCRIPTION

2.2.1 PLATFORM

The PG7601-AF platform is the instrument base into which the piston-cylinder modules are mounted and onto which the masses are loaded. The platform also includes the electronic measurement system.

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

1. COM2 (RS232) for external barometer (optional), external vacuum gauge (optional), pass through communications

2. COM3 (RS232) – for PPC3-7M-AF pressure controller, AMH-38 automated mass handler (optional)

3. COM1 (RS232) - remote host communications

4. Ambient temperature sensor

Figure 5. Platform, PG7601-AF, rear view

5. IEEE-488 (GPIB) - remote host communications

6. Ambient relative humidity sensor

7. VACUUM port, for vacuum vent valve

8. TEST port, for connection to test system

9. PG Terminal port

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

2.2.2 PG TERMINAL

The PG Terminal houses the PG platform power supplies and provides the local user interface for interaction with the PG7601-SYS-AF system.

The front panel assembly provides a 2 x 20 vacuum fluorescent display and a 4 x 4 membrane keypad for local user interface.

1. Vacuum fluorescent display

2. Keypad

Figure 6. PG Terminal front panel

The PG Terminal rear panel assembly provides the communications connection to the PG7601-AF platform and the power connection module.

1. Power switch

2. Fuse (25-pin)

3. Power receptacle

Figure 7. PG Terminal rear panel

4. Connector for cable to PG7000 platform

5. Cooling fan

2. SYSTEM AND COMPONENT OVERVIEW AND DESCRIPTION

2.3 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, -50, -200)

The piston-cylinder module is mounted in the PG7601-AF platform. The piston-cylinder precisely converts pressure to a proportional force (see Section 4.1.1). There are three piston-cylinder modules for three different pressure ranges.

Figure 8. Piston-cylinder modules, PC-7100/7600-10-L, -50, -200

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

2.4 MASS SET (MS-7001-35-AF)

Combinations of masses from the 35 kg mass set are loaded onto in the piston-cylinder, as needed, to result in the set pressure desired.

The mass set is made up of (1) mass loading bell of 0.3 kg, (1) 4.5 kg makeup mass disc, (5) 5 kg mass discs, (2) 2 kg discs, (1) 1 kg disc, (1) 0.5 kg puck, (2) 0.2 kg puck, (1) 0.1 kg puck, 50 g to 0.01 g trim mass set in 1-2-2-1 progression.

Figure 9. Mass set, MS-7100-35-AF

2.5 PRESSURE CONTROLLER (PPC3-7M-AF)

The PPC3-7M-AF pressure controller is used to set and adjust pressure in the PG7601-SYS-AF system. Its operation can be fully automated to float the PG7601-AF’s piston under control of the PG7601-AF platform’s AutoGen function (see Section 4.1.2). It can also be used manually under direct operator control using its front panel direct pressure control keys.

The PPC3-7M-AF pressure controller is a component of the PG7601-SYS-AF system. It can also act as a stand alone component. For information on use of PPC3-7M-AF outside of the PG7601-SYS-AF system, see the PPC3 Operation and Maintenance Manual.

2. SYSTEM AND COMPONENT OVERVIEW AND DESCRIPTION

1. Ready/Not Ready indicator

2. Display

3. Remote activity indicator

4. Cursor control keys

5. Multi-function keypad

6. Direct pressure control keys

Figure 10. Pressure controller, PPC3-7M-AF, front panel

1. Label, product

2. VENT port

3. COM2 connector

4. IEEE-488 connector

5. COM1 connector (PG7601-AF communications)

6. Drivers (12 V) connector

7. Power switch

8. Fuse

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

10. Remote [ENTER] connector

11. Pressure connection, TEST(+)

12. Pressure connection, TEST(-)

13. Pressure connection, EXHAUST

14. Pressure connection, SUPPLY

Figure 11. Pressure controller, PPC3-7M-AF, rear panel

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

2.6 REFERENCE VACUUM PUMP (D16B)

The reference vacuum pump is connected to the PG7601-AF platform reference vacuum port using the PK-7601-V-AF vacuum interconnections kit. It is used to establish a vacuum under the platform’s vacuum bell jar when operating in absolute measurement mode against a vacuum.

1. Smoke eliminator

2. Exhaust flange

3. Intake flange

4. Handle 5 Power switch

6. Oil fill plug

Figure 12. Reference vacuum pump, D16B, front and side views

7. Maximum oil fill line

8. Minimum oil fill line

9. Oil drain plug

10. Oil level sight glass

11. Gas ballast valve

3. INSTALLATION

33.

NNSSTTAALLLLAATTIIOON

3.1 UNPACKING AND INSPECTION

3.1.1 UNPACKING AND INSPECTION OF PG7601-BAS-AF BASE SYSTEM

The PG7601-BAS-AF is the PG7601-SYS-AF gas piston gauge base system. It includes the system operational components but not the piston-cylinder modules and mass sets which are in the PG7601-EXC-AF exchange pack.

Check that all items included in the PG7601-BAS-AF base system are present and have NO visible signs of damage.

Table 1 provides a parts list of the base system major components and how they are Unpack and inspect the items following the instructions in Sections 3.1.1.1 to 3.1.1.6 and detailed packing lists in Table 2 to Table 5.

Table 1. Base system, PG7601-BAS-AF, packing guide

COMPONENT SHIPPED IN SECTION

PG7601-AF platform and Terminal molded transit case 3.1.1.1 Table 2

PG7601-AF vacuum bell jar corrugated container 3.1.1.1 Table 2

PPC3-7M-AF pressure controller corrugated container 3.1.1.2 None

D16B reference vacuum pump corrugated container 3.1.1.3 None

Vacuum pump smoke eliminator 3.1.1.3 None

PK-7601-P-AF pressure

interconnections kit

PK-7601-V-AF vacuum

interconnections kit

PG7601-BAS-AF documentation and

accessories

corrugated container

3.1.1.4 Table 3

3.1.1.5 Table 4

3.1.1.6 Table 5

DETAIL

TABLE

packed.

3.1.1.1 PLATFORM, TERMINAL AND BELL JAR (PG7601-AF)

The PG7601-AF platform is shipped in a molded transit case with the PG7601AF Terminal and connecting cable. The vacuum bell jar is packed in a separate double corrugated container.

To unpack proceed as follows:

Open the PG7601-AF shipping and storage case. Remove the PG Terminal and its cable from the upper packing insert. Remove the upper packing insert. Carefully lift the PG7601-AF platform from its position in the lower packing

insert. Note the orientation so that the same orientation is used when PG7601-AF is repacked.

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

safe place.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Carefully unpack the vacuum bell jar from its double packed corrugated

container. The bell jar is fragile. Set it aside where it is safe from damage.

Table 2. Platform, PG7601-AF, packing list

DESCRIPTION PART NO.

1 ea. PG7601-AF platform including: 402367 1 ea.

1 ea. PG7601-AF Terminal 401284 1 ea. Cable, DB25M x DB25F, PG Terminal to platform 102227 1 ea. Molded transit case (in which the platform is shipped) 122576

Bell jar and seal (in separate double corrugated container)

3.1.1.2 PRESSURE CONTROLLER (PPC3-7M-AF)

The PPC3-7M-AF pressure controller P/N 402014 is delivered in a corrugated container with high density polyethylene inserts to hold it in place.

Remove the PPC3-7M-AF from the shipping container and remove it from its protective plastic bag. There are no other items packed with the PPC3-7M-AF.

Remove the protective caps from the pressure controller rear panel and the sheet of protective film from the front panel display. Install the rubber feet caps included the accessories if desired (see Section 3.1.1.6)

122106 (bell jar)

101546 (seal)

3.1.1.3 REFERENCE VACUUM PUMP (D16B)

The D16B vacuum pump P/N 402058 is delivered in a corrugated container, held in position by “foam in place”. The smoke eliminator for the vacuum pump is packed with the accessories and interconnections kit (see Section 3.1.1.6).

3.1.1.4 PRESSURE INTERCONNECTIONS KIT (PK-7601-P-AF)

The PK-7601-P-AF pressure interconnections kit is delivered in a corrugated container. Inventory all items following Table 3.

Table 3. Pressure interconnections kit, PK-7601-P-AF, packing list

DESCRIPTION P/N 402364

1 ea Valve assembly, platform shutoff (PG7601-AF TEST to

PG7601-AF tee)

1 ea. Custom 1/4 in. ss tube, 76 cm (30 in.) (PPC3-7M-AF to

PG7601-AF tee)

1 ea. Custom 1/4 in. ss tube, 53 cm (21 in.) (DUT connection to

PG7601-AF tee)

1 ea. Tee, 1/4 in. Swage (DUT connection to PPC3-7M-AF to

PG7601-AF TEST) 1 ea. Adaptor, 1/8 in. NPT M x 1/4 in. Swage 102033 1 ea. Quick connector on stand (DUT connection) 401459 1 ea. Quick connector stem, 1/4 in. NPT F 102117 1 ea. Quick connector stem, 1/8 in. NPT F 102116 1 ea. Quick connector stem, AN4 M 102115 1 ea. Quick connector stem, 1/4 in. Swage 101977

402361

402362

402363

102939

3. INSTALLATION

3.1.1.5 VACUUM INTERCONNECTIONS KIT (PK-7601-V-AF)

The PK-7601-V-AF vacuum interconnections kit is delivered in a corrugated container. Inventory all items following Table 4.

Table 4. Vacuum interconnections kit, PK-7601-V-AF, packing list

DESCRIPTION P/N 402365

1 ea. Valve, vacuum shutoff, KF25 102763 1 ea. Elbow, KF25 103736 1 ea. Vacuum hose, KF25, 48 in. 103737 2 ea. Clamp, KF25 102121 2 ea. Centering ring, KF25 101542

3.1.1.6 DOCUMENTATION AND ACCESSORIES

The PK-7601-BAS-AF accessories are delivered in a corrugated container. Inventory all items following Table 5.

Table 5. Base system accessories kit packing list

DESCRIPTION P/N 402366

2 ea. Power cord, 7.5 ft. 100770 1 ea. Cable, null modem 402114 1 ea. Cable, RS232, 9 pin, 2m (PG7601-AF to PPC3-7M-AF) 100847 2 ea. O-ring, Buna 2-242 (PG7601-AF drive belts) 101976 1 ea. Dust cover, 7601 Type 102132 1 ea. Gloves, pair 101398 1 ea. 1 ea. Allen wrench, 2.5 mm 102257 1 ea. Allen wrench, 3 mm 102168 1 ea. Allen wrench, 5 mm 102262 1 ea. Piston insertion tool (10 kPa/kg) 402371 1 ea. Spanner wrench (piston-cylinder) 122568 1 ea. Mounting post PRT insertion plug 402389 1 ea. Valve assembly, vacuum relief, PG7601-AF platform with

1 set (6) Rubber feet caps (PPC3-7M-AF pressure controller) 400203 1 set Documentation

Krytox® GPL205/6 .5 oz.

instruction sheet

PG7601-AF Technical Data

PG7601-AF platform Calibration Report

PG7601-SYS-AF Operation and Maintenance Manual

PPC3-7M-AF Test Report

PG7601-SYS-AF Support Disc

102496

401050

550101 550100 550152 550161 402275

3.1.2 UNPACKING AND INSPECTION OF PG7601-EXC-AF EXCHANGE PACKAGE

The PG7601-EXC-AF is the PG7601-SYS-AF gas piston gauge system’s metrological elements. It includes the piston-cylinder modules and mass set.

Check that all items included in the PG7601-EXC-AF exchange package are present and have NO visible signs of damage.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Table 6 provides a parts list of the exchange package major components and how they are packed. Unpack and inspect the items following the instructions in Sections 3.1.2.1 to 3.1.2.3 and detailed packing lists in Table 7 to Table 9.

Table 6. Exchange pack, PG7601-EXC-AF, packing guide

COMPONENT SHIPPED IN SECTION

PC-7100/7600-10-L, -50 and 200 piston-cylinder modules and accessories

MS-7001-35-AF mass set (2) molded transit

PG7601-EXC-AF documentation and accessories

(3) bullet cases inside a single molded transit case

cases Corrugated

container

3.1.2.1 Table 7

3.1.2.2 Table 8

3.1.2.3 Table 9

DETAIL

TABLE

3.1.2.1 PISTON-CYLINDER MODULES (PC-7100/7600-10-L,

PC-7100/7600-50, PC-7100/7600-200) AND ACCESSORIES

The piston-cylinder modules are shipped in PVC bullet cases that are packed in a reusable transit case with foam inserts. The piston-cylinder module accessories are packed in a recess in the transit case.

Open the transit case and remove the piston-cylinder module bullet cases and accessories.

The bullet cases screw open by turning the lid counterclockwise.

Table 7. Piston-cylinder modules, PC-7100/7600-10-L, PC-7100/7600-50,

PC-7100/7600-200, packing list

DESCRIPTION P/N

1 ea. PC-7100/7600-10-L piston-cylinder module in bullet case 402184 1 ea. PC-7100/7600-50 piston-cylinder module in bullet case 401563 1 ea PC-7100/7600-200 piston-cylinder module in bullet case 401564 3 ea. Piston-cylinder module bullet case 401642 1 ea. Molded transit case for three piston –cylinder modules 402368 1 ea. O-ring, Viton, brown, 2-122 101918 2 ea. O-ring, Vitron, brown, 2-120 101921 3 ea. O-ring, Viton, brown, 2-130 102380

3.1.2.2 MASS SET (MS-7001-35-AF)

The stability over time of PG7601-AF 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 mass set accessory kit.

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

To unpack: Carefully remove each mass from the transit case. Do not remove masses from their plastic bags until ready to install them (see Section 3.3.4).

3. INSTALLATION

Table 8 details the the MS-7001-35-AF mass set.

Table 8. Mass set, MS-7001-35-AF, packing list

DESCRIPTION P/N 402259

1 ea. 4.5 kg make up mass disk 123334 5 ea. 5 kg mass disk 123213 2 ea 2 kg mass disk 121922 1 ea. 1 kg mass disc 121936 1 ea. 0.5 kg mass puck 123500 2 ea. 0.2 kg mass puck 123498 1 ea. 0.1 kg mass puck 123496 1 ea. 0.3 kg mass loading bell 402135 1 ea. Trim mass set (50 to 0.01 g) in case 402403 1 ea. Main mass molded transit case with inserts 123057 1 ea. Fractional mass modled transit case with inserts 122577

3.1.2.3 DOCUMENTATION AND ACCESSORIES

The PG7601-EXC-AF exchange pack accessories and documentation are shipped in a separate corrugated container. Open the corrugated container and inspect and inventory the contents.

Table 9 details the PG7601-EXC-AF exchange pack accessories and documentation.

Table 9. Exchange pack accessories packing list

DESCRIPTION P/N (PART OF 402259)

1 ea. Fractional mass tray 123051 1 ea. Main mass spindle 123536 1 ea. Fractional mass tray dust cover 102814 1 ea. Main mass stack dust cover 102847 1 ea. Gloves, pair 101398 4 ea. Calibration report (mass set and (3) piston-cylinder

modules)

4 ea. Metrology Support Disk 550300

550100

3.2 SITE REQUIREMENTS

See Section 2.1, Figure 1 for an illustration of the PG7601-SYS-AF standard installation.

When selecting and preparing a site to set up the PG7601-SYS-AF 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.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

♦ Air Currents: Do not install the PG7601-AF 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 PG7601-AF (vibration affects the floating piston). Excessive high frequency vibration, for example from a vacuum pump on the same table as the PG7601-AF, may affect piston sensitivity.

• Bench space: The recommended standard setup for the PG7601-SYS-AF system requires a bench space of at least 165 cm x 56 cm (65 in. x 22 in.) (see Section 2.1, Figure 1).

• Bench stability

: Up to 36 kg (79 lb) may be loaded and unloaded onto the PG7601-AF

platform. The bench on which the PG7601-AF sits should not deflect significantly under the mass load changes. This can be verified by setting the platform on the bench, leveling it using its bubble level, and 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 PG7601-SYS-AF system including the PG Terminal, mass set, pressure controller, reference vacuum connection and pump location and test instrument connection. There is a recommended standard setup for the system (see Section 2.1, Figure 1). This setup may be used or the setup may be customized.

If customizing the physical set up of the PG7601-SYS-AF system, follow these recommendation:

- The pressure connection between the test connection (to DUT) and the PG7601-AF platform

should be direct, with no components in between. The pressure controller

should NOT be connected between the PG7601-AF platform and the test connection.

- Minimize tubing lengths between the components.

- Do no use fittings, adaptors or components that will restrict flow in the system more than the components provided with the PK-7601-P-AF interconnections kit.

- Avoid low points or potential liquid traps between the PG7601-AF platform and the DUT connection.

- Be sure the surface on which the PG7601-AF platform is installed is isolated from the D16B vacuum pump vibration.

- Consider drilling a 4 in. hole in the bench to run the KF25 vacuum connection straight down through the bench to the vacuum pump.

• Electrical supply: Plan the supply of electrical power to the PG Terminal and to the pressure controller.

• Test gas supply: Plan the supply of test gas to the pressure controller. The test gas supply must be clean and dry (instrument grade minimum, high purity preferred) to avoid contaminating the pistoncylinder gap (see Section 3.3.7).

• Control v

acuum supply

: Plan the supply of control vacuum to the pressure control. The control

vacuum supply must be separate from the reference vacuum supply (see Section 3.3.8).

• Reference vacuum supply

: Plan for the vacuum connection to the platform and the location of the

reference vacuum pump. There is a recommended standard setup for the system (see Section 2.1, Figure 1). This setup may be used or the setup may be customized.

• Bell jar placement: Plan a location for the bell jar when it is

removed from the platform to load and unload masses or when operating in gauge mode. The bell jar may be placed on top of the pressure controller.

3. INSTALLATION

3.3 PHYSICAL SETUP

Before setting up the PG7601-AF system, see Section 2.1, Figure 1 for an illustration of the PG7601-

SYS-AF standard installation and Section 3.2 for information on site requirements.

To set up the PG7601-SYS-AF components for operation proceed as follows in the specified order:

Set up the PG7601-AF platform (see Section 3.3.1). Set up the PPC3-7M-AF pressure controller (see Section 3.3.2). Make the system pressure interconnections (see Section 3.3.3).

Set up the MS-7001-35-AF mass set (see Section 3.3.4) Install a piston-cylinder module into the platform (see Section 3.3.5). Set up the D16B vacuum pump and make the system vacuum interconnections (see Section 3.3.6).

Connect test gas supply (see Section 3.3.7). Connect control vacuum supply (see Section 3.3.8).

3.3.1 SETTING UP THE PLATFORM

Before setting up the PG7601-AF system, see Section 2.1, Figure 1 for an illustration of the

PG7601-SYS-AF standard installation and Section 3.2 for information on site requirements.

To set up the PG7601-AF platform proceed as follows:

Place the PG7601-AF platform on the site table in the desired orientation and location

(see Section 2.1, Figure 1). Though the rear panel is usually in the back, any orientation

can be used. Place the PG7601-AF Terminal at the desired location. Connect the PG7601-AF Terminal to the PG7601-AF platform using the 25 pin cable

supplied. Connect electrical power (85 to 264 VAC, 50/60 Hz) to the PG7601-AF Terminal using

the power cable supplied. Any grounded power cable with a standard IEC320-313

connection may be used. Install the vacuum vent valve on the vacuum vent port on the rear of the PG7601-AF

platform. Refer to the instruction sheet provided with the vent valve assembly. Level the platform using the PG7601-AF platform’s two front leveling feet and the bubble

level mounted on the front of the platform.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

3.3.2 SETTING UP THE PRESSURE CONTROLLER

Refer to Section 2.1, Figure 1 for an illustration of the PG7601-SYS-AF standard

installation and Section 3.2 for information on site requirements.

To set up the PPC3-7M-AF pressure controller proceed as follows:

Install the rubber feet caps on the PPC3-7M-AF if desired. Place the pressure controller at the desired location. Connect electrical power (85 to 264 VAC, 50/60 Hz) to the pressure controller using the

power cable supplied. Any grounded power cable with a standard IEC320-313

connection may be used. Connect and secure the 9 pin, RS232 cabl e supplied between the PPC3-7M-AF COM1

port and the PG7601-AF platform COM3 port.

3.3.3 SYSTEM PRESSURE INTERCONNECTIONS

This section assumes that the PG7601-AF system will be setup using the PK-7601-P-AF interconnections kit following the standard installation described in Section 2.1, Figure 1. Custom installations are also possible. Before considering a customer installation, see Section 3.2 for setup cautions and recommendations.

Use the PK-7601-P-AF interconnection kit (see Section 3.1.1.4) to interconnect the PG7601-SYS-AF system components as follows. Refer to Section 2.1, Figure 1.

Install the platform shutoff valve assembly onto the PG7601-AF TEST port. Use the

gland and collar that are delivered installed in the TEST port. Set aside the orange plug and install the gland and collar onto the DH200M end of the assembly. Be sure the collar is fully threaded (left hand thread). Then install the assembly into the TEST port by

tightening the gland. Install the 1/4 in. Swage tee onto the platform shutoff valve assembly. Finger tighten only. Install the 1/8 in. NPT M x 1/4 in. Swage adaptor into the TEST(+) port of the

PPC3-7M-AF. Use Teflon

tape or other thread sealer on the 1/8 in. NPT M threads.

Connect the “PPC3-7M-AF to tee” 1/4 in. stainless steel tube to the Swage tee. Finger

tighten only. Connect the “PPC3-7M-AF to tee” 1/4 in. stainless steel tube to the adaptor on the

PPC3-7M-AF TEST(+) port. Tighten firmly. Connect the “DUT quick connector on stand to tee” 1/4 in. stainless steel tube to the DUT

quick connector. Tighten firmly. Connect the “DUT quick connector on stand to tee” 1/4 in. stainless steel tube to the

Swage tee.

Tighten all three nuts on the Swage tee firmly.

Secure DUT quick connector stand to bench top if desired (screws not provided).

3. INSTALLATION

3.3.4 SETTING UP THE MASS SET

Place the mass loading tray and mass spindle (provided with the mass set accessories) at the desired location (see Section 2.1, Figure 1). Then follow the steps below:

It is VERY IMPORTANT that the individual masses be installed on the mass loading tray in proper sequence. This will ensure that PG7601-AF mass loading instructions are executed properly (carefully follow the instructions provided in this Section).

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

PG7601-AF masses are shipped in reusable, molded shipping and storage cases. One

of the cases contains a 4.5 kg mass and the masses of 2 kg and under. The other case contains the main masses of 5 kg each. Each mass is packed in a sealed plastic bag and then placed in a protective shipping insert.

If the masses have not yet been inventoried, open the shipping cases and identify the masses (see Section 3.1.2.2). Remove each mass from its

plastic

bag as you install it on

the spindle or tray.

Install the main masses: The main masses are a series of 5 kg masses numbered 1 to 5.

Pile the main masses onto the main mass spindle. Put mass number 5 at the bottom of the stack. Then pile in descending order: 5, 4, 3, 2, 1, bottom to top. Be careful NOT to confuse the 4.5 kg makeup mass with a 5 kg mass (refer to next step with main mass 1).

Install the make up mass: The ma ke up mass is a single 4.5 kg mass numbered 1. It

has the same diameter as the main masses.

The make up mass is installed vertically in the corresponding slot on the mass loading tray.

Install the fractional masses: The fractional masses are all the masses of 2 kg and

under. Fractional masses of 2 and 1 kg are discs with a central hole. Fractional masses of 100 to 500 g are solid, small diameter pucks. Fractional masses of 50 g and under are trim masses packed and stored in their own separate case.

Fractional mass discs and pucks are installed vertically in the corresponding slots in th e mass

loading tray. Note that there are (2) 2 kg masses numbered 1 and 2. When used, these

are always loaded first 1, then 2. The trim mass case can be placed near the mass tray as desired. Install the mass set dust covers (included in mass set accessories) if desired.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

3.3.5 INSTALLING A PISTON-CYLINDER MODULE INTO THE PLATFORM

To operate the PG7601-AF system, a piston-cylinder module must be installed in the platform’s mounting post. To install a piston-cylinder module in the PG7601-AF platform, proceed as follows:

Remove the PG7601-AF platform mounting post plug. Unscrew the ORANGE plastic

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

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.

Place the piston-cylinder module in the PG7601-AF platform mounting post. Place the

piston-cylinder module (thread down) into the platform mounting post (see Figure 13 below).

Screw the piston-cylinder module into the PG7601-AF platform mounting post.

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. Slight resistance will be encountered in the second half of travel as the piston-cylinder module O-rings seat in the mounting post.

Make the installed piston-cylinder active in the PG7601-AF platform. Use [P-C] to

select the piston-cylinder that was installed in the steps above (see Section 4.3.2). If no piston-cylinder module

digital ID has yet been created in PG7601-AF platform memory, it is not possible to select one and [P-C] results in an error message. In this case, see Section 4.5.1.1 to create or install a piston-cylinder digital ID.

To remove a piston-cylinder module from the platform, simply unthread it (counter

clockwise)

from the mounting post and return it to its bullet case.

Figure 13. Piston-cylinder module installation

Low torque manual rotation is all that should be required to fully seat the piston-cylinder module into the PG7601-AF mounting post. Never force the piston-cylinder module into the mounting post.

3. INSTALLATION

3.3.6 SETTING UP THE REFERENCE VACUUM PUMP AND

VACUUM INTERCONNECTIONS

Refer to Section 2.1, Figure 1 for an illustration of the PG7601-SYS-AF standard installation and identification of components. See Section 2.6 for detail on the D16B vacuum pump. See Section 3.2 for information on site requirements.

To set up the D16B reference vacuum pump and connect it to the PG7601-AF platform proceed as follows:

Install the smoke eliminator on the D16B vacuum pump. Orient the D16B vacuum

pump exhaust connection vertically. Remove the four capscrews, rotate the exhaust flange and reinstall the cap screws.

Remove the KF25 clamp, centering ring and rubber cover from the exhaust connection. Use the clamp and centering ring to install the smoke eliminator (the smoke eliminator is delivered with the PG7601-BAS-AF accessories).

Place the D16B vacuum pump in the desired location. The vacuum pump needs to

able to be reached by the 48 in. KF25 vacuum hose provided in the vacuum interconnections. The pump should not be installed on the same surface as the PG7601AF platform to avoid vibration of the operating pump affecting the platform.

Connect the pump’s electrical cord to a power supply (85 to 264 VAC, 50/60 Hz). Note

that pump has 1430 VA max. consumption that peaks on start up. A dedicated, “industrial rated” (slow blow) breaker may be needed to avoid an overload at start up.

Connect the vacuum shutoff valve to the PG7601-AF platform. Remove the KF25

vacuum clamp, centering ring and plug from the PG7601-AF platform’s KF25 vacuum connection. Use the KF25 clamp and centering ring to install the valve onto the platform’s vacuum port. Orient the valve so that it can be operated conveniently.

Connect the vacuum elbow to the vacuum shutoff valve. Use a KF25 clamp and

centering ring to connect the 90° KF25 elbow to the vacuum shutoff valve installed in step

. Orient the elbow so that it can be connected to the 48 in. vacuum hose that

connects to the vacuum pump.

Connect the 48 in. vacuum hose between the elbow and the vacuum pump. Use a

KF25 clamp and centering ring to connect the 48 in. vacuum hose to the 90° KF25 elbow that was installed in step

Remove the vacuum clamp, centering ring and plastic cover from the DB16B vacuum pump inlet port. Leave the protective screen in place. Use the clamp and centering ring to attach the 48 in. vacuum hose to the vacuum pump.

3.3.7 CONNECTING TEST GAS SUPPLY

Using a pressure connecting hose or tube of appropriate pressure rating, connect the pressure supply to the SUPPLY port on the rear panel of PPC3-7M-AF. The PPC3 SUPPLY port connection is 1/8 in. NPT female.

The PPC3 SUPPLY port is aluminum. When installing the 1/8 in. NPT M adaptor (not

included), take care not to cross thread it and damage the port threads.

The supply pressure should be equal to the maximum PPC3-7M-AF control pressure + 10 %. This is normally 7.7 MPa (1100 psi). A lower gas pressure supply can be used but should exceed the maximum desired test output pressure by 10 to 20 %. The supplied gas must be

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

clean, dry (instrument grade) nitrogen, air or helium. Using an unclean or moist gas supply will increase piston-cylinder cleaning frequency.

Never connect a pressure supply greater than 8.4 MPa (1200 psi). Be sure to connect the

pressure supply to the SUPPLY port. Connecting to another port is likely to damage PPC3-7M-AF.

3.3.8 CONNECTING CONTROL VACUUM SUPPLY

For the PPC3-7M-AF to set pressure under atmosphere and/or to reliably set pressure under 20 kPa (3 psi) gauge (other than zero gauge), a vacuum supply must be connected to the EXHAUST port.

The control vacuum supply is not included in the PG7601-AF system. For full PG7601-AF system operation, the control vacuum must be provided by a vacuum source with an ultimate pressure lower than 2 kPa (0.3 psia) and flow of at least 85 slm (3 cfm). The control vacuum supply should be separate from the PG7601-AF reference vacuum supply. Do not tee off the D16B reference vacuum pump to supply vacuum to the PPC3-7M-AF EXHAUST port. The flow through the EXHAUST port will have an adverse effect on the reference vacuum.

Using a vacuum hose or tube, connect the pressure supply to the EXHAUST port on the rear panel of PPC3-7M-AF. The PPC3 EXHAUST port connection is 1/4 in. NPT female.

Never connect a pressure supply to or plug the PPC3-7M-AF EXHAUST port.

To avoid building up pressure on the EXHAUST port or on a vacuum pump connected to the EXHAUST port, the vacuum source should either be continuously ON or the EXHAUST port should be bypassed to atmosphere when the vacuum source is OFF. This is because when a supply pressure is applied to the PPC3-7M-AF SUPPLY port and the PPC3 is NOT in the vent ON condition, there may be a constant gas exhaust through the PPC3 EXHAUST port.

3.4 POWER UP AND VERIFICATION

This section assumes that the physical setup of the PG7601-SYS-AF system has been completed (see Section 3.3).

3.4.1 POWER UP PLATFORM AND PRESSURE CONTROLLER

Turn the PG7601-AF 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 PG7601-AF platform, initializes, error checks and goes to the MAIN run screen (see Section 4.2.1.2).

…

.Searching…..> displays for more than 10 seconds, communication between the

If < platform and the PG Terminal is failing. Check that the platform to PG Terminal cable is properly installed.

Turn the PPC3-7M-AF power ON by pressing the power ON/OFF switch on its rear panel. Observe the front panel display as PPC3-7M-AF initializes, error checks and goes to the MAIN run screen (see Section 4.2.1.2).

If either product 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.

3. INSTALLATION

3.4.2 CHECK THAT ON-BOARD PISTON-CYLINDER MODULE

AND MASS SET DIGITAL ID

PG7601-AF uses stored piston-cylinder and mass set metrological information to calculate the reference pressures it defines (see Section 4.1.1). This information is stored in digital identification records (digital IDs) (see the stored metrological information of the piston-cylinder, mass set and mass loading bell must be correct. Before using the PG7601-AF system, the validity of the should be verified. Verification consists of comparing the piston-cylinder, mass set and mass loading bell information stored in the PG7601-AF platform to the information in the current piston-cylinder, mass set and mass loading bell calibration reports.

To verify the PG7601-AF 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 4.5.1). Compare all the information contained in the PG7601-AF

mass

piston-cylinder, cylinder, mass set and mass loading bell calibration reports delivered with the system.

If piston-cylinder or mass set information is incorrect or missing, it can be entered manually (see Section 4.5.1) or loaded remotely from a personal computer using the digital ID files supplied on the element’s Metrology Support Disk (see Section 7.4).

set and mass loading bell digital IDs to the information on the piston-

Section 4.5.1). For the pressure values to be correct,

S ARE CORRECT

stored information

(*.did)

3.4.3 SET LOCAL GRAVITY VALUE

PG7601-AF uses the value of local acceleration due to gravity (gl) in its calculation of the reference pressure it defines (see Section 4.1.1). The correct value of local acceleration due to gravity at the site of use must be entered. This is accomplished by pressing [SPECIAL], <6gl (see Section 4.5.6) and editing the value of local gravity. To access and edit the value of <6gl is first necessary for the PG7601-AF platform security level [SPECIAL], <4prefs>, <5level>, <1set user level> (see Section 4.5.4.5). After changing the

user level <none> t

access <6gl>, be sure to set it the user level back to <low>.

to be set to <none> using

> it

3.4.4 CHECK/SET SECURITY LEVEL

PG7601-AF has a security system based on user levels. By default, the security system is set to “low”, which includes certain access restrictions, and there is no password required to change the security level. See Section 4.5.4.5 for information on the security level system. As part of the system startup, determine the security level that is password if desired.

The PG7601-AF platform 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.

appropriate

and set a

3.4.5 CHECK PROPER OPERATION OF AMBIENT CONDITION

MEASUREMENTS

PG7601-AF automatically measures ambient conditions and uses the values in its pressure calculations.

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

• Display current ambient condition readings: Press [AMBIENT] on the PG7601-AF

Terminal. The ambient conditions run screen is displayed (see Section 4.3.6).

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

• 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 1.1.2.2).

The unit of measure in which ambient pressure is displayed is the same as the unit selected by pressing [UNIT] (see Section 4.3.3). Units of measure in which other ambient condition values are expressed cannot be changed.

PG7601-AF allows the source of ambient condition values used in reference pressure calculations to be specified. The source may be PG7601-AF’s on-board measurements, default values or operator entered values. See Section 4.4 for information on specifying the source of ambient condition values used by PG7601-AF in reference pressure calculations.

3.4.6 TURN ON AUTOGEN AND AUTOROTATE

In most cases, PG7601-AF is operated with the AutoRotate and AutoGen functions ON so that the piston is automatically rotated when necessary and the pressure is automatically adjusted to float the piston.

Press [ROTATE], <1on> (see Section 4.3.8). Press [GEN], <1on> (see Section

with the PPC3-7M-AF for the AutoGen function to complete initialization and be ON. initialization completes, <Turning ON automated generation> is displayed momentarily, automated control is turned ON and the display returns to the MAIN run screen. If communication cannot be established <P control timeout, autogen off> is displayed momentarily (see Section 4.3.9). When the PG7601-AF initializes the PPC3-7M-AF pressure controller, it automatically makes the necessary settings for it to operate in the system (pressure unit, measurement mode, control mode, hold limit, etc.).

4.3.9). The PG7601-AF must establish communication If

3.4.7 APPLY SUPPLY PRESSURE

If the supply pressure was not applied to the PPC3-7M-AF during setup (see Section 3.3.7), apply the regulated supply pressure to the SUPPLY port.

3.4.8 APPLY CONTROL VACUUM

If the supply vacuum was not applied to the PPC3-7M-AF during setup (see Section 3.3.8), apply the control vacuum to the EXHAUST port.

3.4.9 APPLY REFERENCE VACUUM

The D16B reference vacuum pump was installed and connected during the system setup (see Section 3.3.6).

Check that the vacuum shutoff valve on the PG7601-AF platform is closed. The knob should be rotated clockwise until it stops.

With the vacuum shutoff valve closed, turn ON the vacuum pump using its power switch.

3.4.10 SET A GAUGE MODE PRESSURE, CHECK AUTOGEN AND

UTOROTATE FUNCTIONS

This section assumes that the PG7601-AF system has already been set up, including

pressure interconnection (see Section 3.3).

3. INSTALLATION

Before applying pressure to the PG7601-AF system, be sure that all pressure vessels and connections connected to it are rated for the pressure levels that will be applied and that all connections have been properly tightened.

Check automated pressure generation and piston rotation while setting a gauge pressure. Proceed as follows:

Level the PG7601-AF platform using it’s bubble level and leveling feet.

Use [MODE] on the PG Terminal to set gauge measurement mode (see Section 4.3.4). Use [P-C] to check that the piston-cylinder selected is the one that is actually mounted in

the PG7601-AF platform (see Section 4.3.2). Be sure that the platform shutoff valve on the PG7601-AF TEST port is open (The

knob

should be rotated counter clockwise until it stops).

Press [P OR M], <1pressure> to select pressure entry mode (see Section 4.3.12).

Press [RES] and adjust mass loading resolution to 0.1 kg (see Section 4.3.10) Press [ENTER/SET P] and enter a pressure value to be generated. Follow the mass loading instruction (see Section 4.1.5) and press [ENTER].

The PG Terminal display returns to the MAIN run screen (see Section 4.2.1.2). The

PPC3-7M-AF pressure controller increases pressure and floats the piston. Piston

position is indicated in the bottom left hand corner of the display. If the PPC3-7M-AF does not increase the pressure or if the piston floats but drops very quickly:

- check that [GEN] is ON (see Section 4.3.9).

- confirm that a pressure supply is connected to the PPC3-7M-AF SUPPLY port (see Section 3.4.7).

- be sure a large leak is not present in

the test pressure circuit. Once floated, the piston fall rate should be less than the nominal fall rate given in the specifications of the piston-cylinder module being used (see Section 1.1.3).

Once the piston has started to float (piston position > -2.5 mm), the motorized piston

rotation system engages to rotate the piston (see Section 4.3.8). If the motorized rotation system does not engage check that:

- [ROTATE] is ON (see Section 4.3.8).

Motorized piston rotation may also be activated manually. Turn [ROTATE] OFF. Then press [ ] to engage motorized rotation manually (see Section 4.3.13). To stop rotation, hold [

] and then press [←]. Current rotation rate can be observed in the SYSTEM

SCREEN ([SYSTEM]) (see Section 4.3.5). Never stop piston rotation by running the rotating piston against the upper or lower stop.

Press [ENTER/SET P] and enter <0> to vent the system (see Section 4.3.11.3). If

automated rotation is not ON, be sure to stop the rotation of the piston manually by

holding [

] and then pressing [←]before pressing [ENTER].

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

3.4.11 CHECK PISTON BEHAVIOR MEASUREMENTS

Float the piston and rotate it (see Section 3.4.10). 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 4.3.5). The piston position reading system may be calibrated using an on-board procedure if necessary (see

recommended when installing a new

Section 6.4.1). Calibration of piston position reading is

PG7601-AF.

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 4.3.5).

3.4.12 CHECK REFERENCE VACUUM SYSTEM AND ABSOLUTE MODE OPERATION

This section assumes that the PG7601-AF system has already been set up, including

pressure interconnection (see Section 3.3).

Check the operation of the reference vacuum system and vacuum measurement and set an absolute pressure. Proceed as follows:

Level the PG7601-AF platform using it’s bubble level and leveling feet.

Close the vacuum shutoff valve on the PG7601-AF KF25 vacuum reference connection.

Turn on the D16B reference vacuum pump and allow it to warm up for 30 minutes.

Be sure that the platform shutoff valve on the PG7601-AF TEST port is open (The knob should be rotated counter clockwise until it stops).

Use [MODE] on the PG Terminal to set absolute measurement mode (see Section

4.3.4). Use [P-C] to check that the piston-cylinder selected is the one that is actually mounted in

the PG7601-AF platform (see Section 4.3.2).

Press [P OR M], <1pressure> to select pressure entry mode (see Section 4.3.12).

Press [ENTER/SET P] and enter a pressure value to be generated.

Follow the mass loading instruction (see Section 4.1.5)

Install the vacuum bell jar on the PG7601-AF platform. Close the vacuum vent valve on the back of the PG7601-AF platform. Open the KF25 vacuum shutoff valve. This connects the vacuum pump to the bell jar and

the pressure under the bell jar begins to pull down. Press [ENTER]. The PG Terminal display returns to the MAIN run screen (see Section

4.2.1.2). Press [SYSTEM] twice to observe the value of vac

uum read by the PG7601-AF’s’s builtin vacuum gauge. The indication is < >20 Pa> (0.0029 psi) until the pressure under the bell jar is less than 20 Pa (the value of reference vacuum can only be indicated in Pa; 1 Pa = 0.0075 Torr = 0.000145 psi).

On initial vacuum pull down, with the pump fully warmed up, the vacuum should reach the default Ready limit (see Section 4.1.3.3) of 5 Pa (0.000725 psi) in less than 3 min 30

sec. Subsequent pull down should be on the order of 1 minute.

3. INSTALLATION

If this performance is NOT achieved:

- check the connections between the vacuum pump and the PG7601-AF platform KF25 vacuum port.

- check that the vacuum vent valve on the back of the PG7601-AF platform is properly connected and is closed (handle down).

Once the reference vacuum level has reached the Ready limit (see Section 4.1.3.3), the

PPC3-7M-AF pressure controller increases or decreases pressure and floats the piston.

Piston position is indicated in the bottom left hand corner of the display.

If the PPC3-7M-AF does not increase or decrease the pressure or if the piston floats but drops

or rises very quickly after floating:

- check that [GEN] is ON (see Section 4.3.9).

- confirm that a pressure supply is connected to the PPC3-7M-AF SUPPLY port (see Section 3.3.7).

- confirm that a control vacuum supply is connected to

the PPC3-7M-AF EXHAUST

port (see Section 3.3.8).

- be sure a large leak is not present in

the test pressure circuit. Once floated, the piston fall rate should be less than the nominal fall rate given in the specifications of the piston-cylinder module being used (see Section 1.1.3).

Pressure may be controlled manually or automatically (see Section 4.1.2). To control pressure manually, turn [GEN] OFF or press [ESCAPE] on the PG Terminal after entering a mass load and use the direct pressure control keys under the PPC3-7M-AF display. When using PPC3-7M-AF directly, do not make any other changes or adjustments. Do not change units of measure ([UNIT]) or measurement mode ([MODE]).

Once the piston has started to float (piston position > -2.5 mm), the motorized piston

rotation system engages to rotate the piston (see Section 4.3 .8 ) . If the motorized rotation system does not engage check that:

- [ROTATE] is ON (see Section 4.3.8).

Motorized piston rotation may also be activated manually. Turn [ROTATE] OFF and press [ ] to engage motorized rotation manually (see Section 4.3.13). To stop rotation, hold [ ] and then press [←]. Current rotation rate can be observed in the SYSTEM SCREEN ([SYSTEM]) (see Section 4.3.5).

To set the next pressure or vent the system, press [ENT/SET P]. To vent the system enter a

pressure of <0> (see Section 4.3.11.3). If automated rotation is not ON, be sure to stop the rotation of the piston manually before pressing [ENTER].

Close the KF25 vacuum reference shutoff valve on the PG7601-AF platform vacuum

reference port. Open vacuum vent valve on the back of the PG7601-AF platform. Wait for pressure under bell jar to return to ambient. This takes about 40 seconds. Remove bell jar.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

3.5 ADDITIONAL PRECAUTIONS TO TAKE TO MAKE GOOD PRESSURE MEASUREMENTS

Before using PG7601-AF to perform calibrations, consider the following:

• Select/activate the correct piston-cylinder module, mass set and mass loading bell (see Sections 0,

4.5.1.10, 4.5.1.15).

• Set the pressure controller’s upper limit (UL)

• Enter the correct value of local grav

• Consider head corrections (see Sections 4.3.7).

• Level the PG7601-AF platform properly and check the level often (see Section 3.3.1).

• Select the correct pressure unit of measure and measurement mode (see Sections 4.3.3, 4.3.4).

• Verify that the settings for the

reference pressures are those desired (see Section 4.4).

• Verify that the piston-cylinder module is correctly cleaned and operating properly (see Section 6.3.2).

• Verify that there are NO leaks in t

• Always stop piston rotation before changing the pressure. Avoid stopping piston rotation by running

the rotating piston against the top or bottom end of stroke stop (see Section 4.3.8).

• Be

sure that the platform shutoff valve on the PG7601-AF TEST port is open (The knob should be

rotated counter clockwise until it stops).

ity at the site of use (see Section 4.5.6).

sources of variables to be used by PG7601-AF in its calculations of

he pressure system.

to avoid accidental overpressure (see Section 4.3.9.3).

4. GENERAL OPERATION

44.

EENNEERRAALL

PPEERRAATTIIOON

4.1 OPERATING PRINCIPLES

4.1.1 FUNDAMENTAL OPERATING PRINCIPLE

PG7601-AF operates on the principle of the piston gauge in which pressure is defined by balancing it against a known force on a known area (see Figure 14). The known area is defined by a vertically mounted piston rotating in a cylinder and the known force is applied to

the

the piston by loading it with known mass subjected to acceleration due to gravity. force applied by the pressure and the force applied by the mass accelerated by gravity are in equilibrium, the piston floats. The floating piston must be rotated to keep it centered in the cylinder and perfectly mobile. The floating piston moves up and down in its stroke, adjusting the pressurized volume, maintaining the force equilibrium and maintaining the pressure constant. The pressure can be calculated following the equation in Figure 14 (see also Section 9.2). The pressurized gas under the piston also lubricates the gap between the piston and the cylinder.

When

Figure 14. Piston gauge operating principle

The PG7601-AF platform holds the piston-cylinder module and allows mass to be loaded on top of the piston and pressure to be applied under the piston. Three piston-cylinder modules with different piston diameters provide three ranges using a single mass set. The masses can be at atmospheric pressure for gauge mode or absolute by addition of atmosphere measurements. The bell jar can be placed over the masses and evacuated for absolute with a vacuum reference operation (see Section 4.3.4).

The PPC3-7M-AF pressure controller is used to adjust the pressure in the system to float piston. The pressure controller automatically under the control of the PG7601-AF platform.

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. PG7601-AF stores the calibrated values of the piston-cylinders and masses it uses in digital IDs (see Section 4.5.1). To determine the effective area of the piston-cylinder and the force applied by number of influences on these values must be quantified and taken into consideration. For this reason, PG7601-AF includes extensive features to monitor the behavior and conditions of the piston-cylinder as well as ambient conditions that affect pressure definition.

can be operated manually from its front panel or

the masses under actual operating conditions, a

the

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

PG7601-AF 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. The source of each value used by PG7601-AF in its calculations can be selected by the user between PG7601-AF’s internal measurements, default values or user entered values. These sources are defined in SETUP files (see Section 4.4).

Once PG7601-SYS-AF system has been set up, it is define pressures applied to a In typical operation, the operator:

Selects the desired pressure unit of measure (see Section 4.3.3). Selects the appropriate piston-cylinder to cover the pressure range (see Section 4.3.2). Selects the desired pressure measurement mode (gauge, absolute) (see Section 4.3.4). Sets the head difference between the PG7601-AF reference level and the device under

test (see Section 4.3.7). Selects mass to pressure or pressure to mass operating mode (see Section 4.3.12). Enters a pressure to define or a mass value to be loaded (see Section 4.3.11.1,

4.3.11.2). Loads the specified mass total. If operating in absolute with vacuum reference mode (see Section 4.3.4), installs the bell

jar and opens the vacuum shutoff valve.

PPC3-7M-AF pressure controller adjusts pressure to float the piston (see Section 4.3.9)

and the PG7601-AF rotates the piston. Once the piston is floating and rotating (and vacuum

indicators indicate Ready (see Section 4.1.3) and a measurement can be made.

has reached a low enough level in absolute by vacuum mode), all Ready

device or system under test or to measure a stable pressure.

used in day-to-day operation either to

4.1.2 PRESSURE CONTROL, MANUAL AND AUTOMATED

Pressure control in the PG7601-SYS-AF system is provided by the PPC3-7M-AF pressure controller. The pressure controller uses internal on/off solenoid valves to admit and exhaust pressure as needed to set the desired pressure and float the PG7601-AF’s piston. When it is idle (not controlling pressure), all its valves are shut and it does not affect the pressurized test system. Once the pressure controller has floated the piston, it is put into the idle state so that the pressure is controlled only the by the floating piston.

The pressure controller may be operated manually or automatically. Normal operation of the PG7601-SYS-AF system is using automated pressure control.

Automated pressure control relieves the operator of the chore of setting and adjusting pressure. It has the advantages of setting pressure in a consistent manner and minimizing the risk of accidental overpressure. In automated pressure control, the PG7601-AF AutoGen function controls the pressure controller over an RS232 communications connection (see Section 3.3.2). Use [GEN] to turn AutoGen ON (s

If desired, the operator can use the PPC3-7M-AF as a manual pressure controller. For manual pressure control, use [GEN] to turn AutoGen OFF so that the PG7601-AF platform does not communicate with the pressure controller (see Section 4.3.9). Then the direct pressure control keys on the pressure controller front panel (see used to position of the floating piston.

Automated and manual pressure control can also be combined. For example, with AutoGen ON, the PPC3-7M-AF can be used to float the piston automatically, then [ESCAPE] on the PG7601-AF Terminal can be used to interrupt the AutoGen function so the operator can

increase and decrease pressure, including making small pressure steps to adjust the

ee Sec

tion 4.3.9).

Section 4.2.2.2) can be

4. GENERAL OPERATION

adjust piston position manually using direct pressure control keys on the pressure controller front panel.

It is not necessary to turn GEN off to interrupt automated pressure control. Pressing [ESCAPE] from the main run screen while automated pressure control is active suspends automated pressure control allowing manual pressure controller operation. Automated pressure control will resume the next time [ENTER/SET P] is used.

When using PPC3-7M-AF for direct pressure control after interrupting automated pressure control, do not make any other changes or adjustments. Do not change units of measure ([UNIT]) or measurement mode ([MODE]).

4.1.3 PRESSURE READY/NOT READY INDICATION

The PG7601-AF Terminal MAIN run screen (see Section 4.2.1.2) provides a pressure Ready/Not Ready indication. This indication is intended to give the user a clear and objective indication of when PG7601-AF 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 Ready/Not Ready.

2. Piston rotation Ready/Not Ready.

3. Reference vacuum (absolute by vacuum measurement mode only) Ready/Not Ready.

*** 100.4755 kPa g h + 0.1 mm 10.00564 kg

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

See Sections 4.1.3.1, 4.1.3.2 and 4.1.3.3 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 4.1.3.1, 4.1.3.2 and 4.1.3.3).

4.1.3.1 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 4.1.3.1).

is ensures that pressure measurements are made with the piston not more than

Th a certain distance from mid-float position and that measurements are not made while pressure is being adjusted.

The piston position Ready/Not Ready character is the first character from the left on the top line of the MAIN run screen (see Section 4.2.1.2).

The piston position Ready/Not Ready

criterion is determined by the current

SETUP file and can be customized by the user (see Section 4.4). Piston position Ready/Not Ready character indications include: <*> Piston position Ready

SETUP file) (see Section

(within the position

4.4).

limits specified in the current

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

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

current SETUP file, see Section 4.4) or AutoGen is adjusting piston position. 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 4.4) or AutoGen is adjusting piston position. The <↑> flashes if the piston is

not

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 PG7601-AF piston position measurement to operate correctly so piston position values shown are not valid when the bell is not installed.

Piston position always indicates Not Ready if automated pressure generation is

adjusting pressure, regardless of actual piston position.

4.1.3.2 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.

at the top stop position to alert the user that

The piston rotation Ready/Not Ready character is the second character from the left on the top line of the MAIN run screen (see Section 4.2.1.2).

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

4.5.1.1). Piston rotation rate Ready/Not Ready character indications include:

<*> Rotation

rate Ready: Rotation rate is higher than the minimum rotation

rate limit specified in the current piston-cylinder module digital ID (see Section 4.5.1.1).

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

rotation rate limit specified in the current piston-cylinder module digital ID (see Section 4.5.1.1) or motorized rotation system is currently engaged. Note that the low rotation limit is automatically reduced to

the mass loaded on the piston is less than 3 kg. The <

5 rpm when

<> 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 ) . T h e b e l l m u st b e i n st a l l e d f o r P G 7601-AF piston rota tion rate me a sureme nt to operate correctly so piston rotation rate cannot be measured when the bell is not installed.

Under 3 kg mass load, the low rotation rate Ready limit automatically

goes to 5 rpm.

4.1.3.3 VACUUM REFERENCE READY/NOT READY

The vacuum reference Ready/Not Ready character is only active when operating in absolute by vacuum mode (see Section 4.3.4).

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 measurements of absolute

4. GENERAL OPERATION

pressure with a vacuum reference will be made with the vacuum under the PG7601-AF 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 (see Section 4.2.1.2).

The vacuum reference Ready/Not Ready criterion is determined by the current SETUP file and can be customized by the user (see Section 4.4). The vacuum reference criterion is a fixed vacuum reference selection in the SETUP file is internal (the default is 5 Pa (0.00075 psi). 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. 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 4.4).

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

is internal and vacuum value is above the

4.4). The < indicator is Not Ready.

>> flashes if the piston is floating to alert the user that this

value that can be customized by the user when the

limit

specified (see Section

4.1.4 PISTON POSITION

When operating a PG7601-AF 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

4.2.1.2) and in the first SYSTEM run screen (see Section 4.3.5). Piston position is used as a criterion for the Ready/Not Ready indication as valid measurements can only be made when the piston is within the correct position limits (see Section 4.1.3.1).

4.5

The full piston stroke is ± different positions and zones as illustrated in Figure 15. These zones are:

• High and low stops: 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 a 2 kg load 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 4.1.3.1). The pressure applied to the piston is the pressure corresponding to the mass loaded on the piston. The default value

high and low measurement zones is ± 2.5 mm around midstroke position. This value can be adjusted in the SETUP file (see Section 4.4).

mm from the midstroke position. The stroke is divided into

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

the

• Piston float target: Applies only when AutoGen automated pressure control is ON Section 4.3.9). The float target is the positi

piston before control is stopped and a Ready condition can occur.

on to which the PPC3-7M-AF must

(see

set the

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

• Midstroke: The piston is at the middle of its stroke. The bottom of the piston (or its equivalent for the hollow 10 kPa/kg and 50 kPa/kg pistons) is at the reference level marked on the mounting post (see Section 4.3.7). There is equal stroke available from midstroke 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, PG7601-AF displays < ---- > 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 15. Piston stroke and zones

4.1.5 MASS LOADING PROTOCOL

 PURPOSE

To provide the operator with mass loading instructions and allow mass entry in convenient nominal values which PG7601-AF can accurately convert to measured mass values to determine the actual mass load.

 PRINCIPLE

All PG7601-AF manual mass set masses of 0.1 kg and above, including 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 with lower uncertainty than ± 20 ppm and reported in the mass set, mass loading bell or piston-cylinder module calibration report. These measured actual values are used by PG7601-AF 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 PG7601-AF to describe the mass to load or the mass that is loaded. Following simple mass loading rules allows PG7601-AF to correctly 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 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

mass v

lue 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 4.2.1.2) is always the actual mass v

4.3.12) the actual

lue. The

4. GENERAL OPERATION

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 PG7601-AF 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 low uncertainty 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 4.3.13).

PG7601-AF 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.

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: mm.m kg and tt.tt g

Nominal mass load: mm.m kg and tt.tt g

mm.m and tt.tt must be expressed and loaded following the mass loading rules below:

Mass Loading Rules

See Section 3.3.4 and Section 4.1.5, PRINCIPLE for PG7601-AF mass set principles and protocol information. Refer to display examples immediately above to identify

mm.m and tt.tt.

See EXAMPLES: Mass Loading below for mass loading examples. PG7601-AF mass loading entries and instructions are always formatted: mm.m kg and tt.tt g

• The mass set being used must be properly set up (see Section 3.3.4) and must be

selected as the active mass set (see Section 4.5.1.10).

•

mm.m

is made up of the piston, the mass loading bell and mass set masses of 0.1 kg

and greater.

• mm.m always includes the mass loading bell and then the makeup mass, if possible.

• mm.m is made up of the largest masses possible rather than a combination of smaller

masses.

• When loading masses of which there are more than one (e.g. 5 kg, 2 kg, 0.2 kg), they are

always loaded in sequential order (1, 2, 3…).

• tt.tt is always made up of gram masses of 50 g and under from the trim mass set. These

masses can be loaded in any combination and any order to reach the total gram value.

EXAMPLE: To load 5 kg on the 50 kPa/kg piston: 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.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

EXAMPLE: When loading (3) 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 3.3.4.

EXAMPLE: Load 15.2 kg and 14.63 g on the 200 kPa/kg piston

Load:

piston (0.2 kg)  bell (0.3 kg) 

4.5 kg #1 (makeup mass)  5 kg #1, #2

0.2 kg #1

14.63 g trim mass

Total:

00.2 kg, 00.00 g

00.5 kg, 00.00 g

05.0 kg, 00.00 g

15.0 kg, 00.00 g

15.2 kg, 00.00 g

15.2 kg, 14.630 g

EXAMPLE: Load 35.0 kg and 00.00 g on the 10 kPa/kg piston

Load:

piston (0.4 kg)  bell (0.3 kg) 

4.5 kg #1 (makeup mass)  5 kg #1, #2, #3, #4, #5

Total:

00.4 kg, 00.00 g

00.7 kg, 00.00 g

05.2 kg, 00.00 g

30.2 kg, 00.00 g

2 kg #1, #2

0.5 kg #1

0.2 kg #1

0.1 kg #1

EXAMPLE: Load 3.4 kg and 00.00 g on the 10 kPa/kg piston

Load:

Total:

piston (0.4 kg)  bell (0.3 kg)  2 kg #1

0.5 kg #1

0.2 kg #1

34.2 kg, 00.00 g

34.7 kg, 00.00 g

34.9 kg, 00.00 g

35.0kg, 00.00 g

00.4 kg, 00.00 g

00.7 kg, 00.00 g

02.7 kg, 00.00 g

03.2 kg, 00.00 g

03.4 kg, 00.00 g

When PG7601-AF 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 3.3.4).

For PG7601-AF mass loading protocol

operate properly, the mass set in use must be EXACTLY

the mass set that is defined by the active mass set digital ID (see Section 4.5.1.10).

4. GENERAL OPERATION

4.2 USER INTERFACE

The local user interface of the PG7601-SYS-AF system is the PG7601-AF’s PG Terminal keypad and display. In normal operation, the PPC3-7M-AF pressure controller operates automatically under the control of the PG7601-AF platform and the PPC3-7M-AF front panel is not used. The exception is when the pressure controller is used manually and controlled by the operator through its front panel direct pressure control keys (see Section 4.2.2.2).

The PG7601-AF system may also be operated using commands from an external PG7601-AF platform’s RS232 (COM1) or IEEE-488 interfaces (see Section 5).

4.2.1 PISTON GAUGE (SYSTEM INTERFACE)

4.2.1.1 KEYPAD LAYOUT AND PROTOCOL

The PG7601-AF’s PG Terminal is the local user interface to the PG7601-SYS-AF system.

The PG Terminal 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 4.3). These key 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.

enter numerical values when

computer

over the

Figure 16. PG Terminal keypad layout

Key press confirmation is provided by both tactile and audible feedback. A single beep confirms a valid entry. A de sc ending two note tone signals an invalid entry. The valid entry audible feedback can be suppressed or modified using [SPECIAL], <5prefs>, <2sound> (see Section 4.5.4.2).

Pressing [ENTER/SET P] generally causes execution or

forward

movement in the

menu tree. [ENTER/SET P] is also used to enter a command to set a pressure. Pressing [ESCAPE] generally causes 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 and holding [ESCAPE] allows momentary viewing of the PG7601-AF identification screen.

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

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Pressing [←] and [→] 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.

4.2.1.2 MAIN RUN SCREEN

The PG7601-AF MAIN run screen is its home display that is reached on power up and from which other functions and menus are accessed. It is the top level of all menu structures.

The MAIN run screen is where PG7601-AF is left in normal operation. It displays the pressure defined by PG7601-AF, the Ready/Not Ready condition and a variety of other information. See Figure 17 for MAIN run screen details.

The screen described below is called the MAIN run screen. The SYSTEM and AMBIENT screens (see Sections 4.3.5 and 4.3.6) are also run screens in the sense that all the other functions may be accessed directly from them and pressure or

entries may be made from them. See Section 4.2.1.3 for a description of

mass PG7601-AF’s main menu/function structure.

prvPRESSURE1 unit mGh +N.N mm NN.NNNNN kg

DISPLAY FIELD NAME PURPOSE CONTENTS SECTION

1. prv Ready/Not Ready indicators

1a. p Piston position

Ready/Not Ready indicator

Indicates status of measurement Ready/Not Ready criteria

Indicates status of piston position Ready/Not Ready criterion

<*>: Ready <not *>: Not Ready

<*>: Ready <↑>: Not Ready , piston too high <↓>: Not Ready, piston too low <?>: Piston position not available

Flashes if condition Not Ready and piston is floating

4.1.3

4.1.3.1

4. GENERAL OPERATION

DISPLAY FIELD NAME PURPOSE CONTENTS SECTION

1b. r Piston rotation

Ready/Not Ready indicator

1c: v Reference

vacuum

Ready/Not Ready indicator

2. PRESSURE1 Defined pressure Pressure defined by PG7601-AF

3. UNIT Unit of measure Identifies pressure unit of

4. m Measurement mode

5. G AutoGen indicator

6. h Head correction indicator

7. NN.NNNNN kg Mass load Indicates current true mass load

8. +N.N mm Piston position Indicates the current piston position

Indicates status of piston rotation Ready/Not Ready criterion

Indicates status of reference vacuum level Ready/Not Ready criterion

when piston is floating with indicated mass load and all conditions are Ready

measure in which PRESSURE1 is displayed

Identifies measurement mode of displayed pressure

Indicates status of automated pressure generation

Indicates whether a fluid head correction is applied to PRESSURE1

(assuming mass loading instructions and protocol have been followed)

relative to midstroke in mm

<*>: Ready < < >: Not Ready, rotation rate too

low or motorized rotation

engaged <?>: Rotation rate not available Flashes if condition Not Ready and

piston is floating < >: Blank, vacuum reference

Ready/Not Ready not in use

(gauge mode)

<*>: Ready < > >: Not Ready, vacuum level too

high Flashes if condition Not Ready and

piston is floating Numerical pressure value and sign 4.1.1

Pressure unit of measure abbreviation

<a>: absolute <g>: gauge

< >: blank, AutoGen is OFF <G>: AutoGen is ON

Flashes if AutoGen is ON and currently actively controlling

<h>: the fluid head is not zero

<blank>: fluid head is zero

numerical mass value 4.1.5

numerical value of piston position Blank if piston position not available

4.1.3.2

4.1.3.3.

4.3.3

4.3.4

4.3.9

4.3.7

4.1.4

Figure 17. Platform MAIN run screen display fields

When a number is too large to display in the allocated screen space, PG7601-AF displays <********>

or <OVERFLOW>.

The PG Terminal 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 4.5.4.1).

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

4.2.1.3 GENERAL FUNCTION/MENU FLOW CHART

The local operator interface with PG7601-AF system is provided by the PG Terminal keypad and display. Normal PG7601-AF 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.

• 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

RUN SCREEN

+/-

ESC

TO PREVIOUS RUN SCREEN

ESC

SYSTEM 2

RUN SCREEN

Figure 18. RUN screen flow chart

4.2.1.4 SOUNDS

MAIN RUN SCREEN

SYSTEM

SYSTEM 1

SYSTEM

P-C UNIT MODE SYSTEM

RES

ENT SPECIAL SETUP

AMBIENT

RUN SCREEN

OTHER FUNCTION KEYS

HEAD

ROTATE

ESCESC

AMBIENT

GEN

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 4.5.4.2). 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. Descending, two tone blurp. Three rapid valid key press beeps. Piston was at low

stop or high stop and just entered spring zone (see Section 4.1.4).

4. GENERAL OPERATION

4.2.2 PRESSURE CONTROLLER

The normal user interface to the system is the PG7601-AF Platform’s PG Terminal (see Section 4.2.1).

PPC3-7M-AF is the pressure controlling component of the PG7601-SYS-AF system. In normal operation, the PPC3-7M-AF pressure controller operates automatically under the control of the PG7601-AF platform and the pressure controller front panel is not used. exception is when the pressure controller is used manually and controlled by the operator through its front panel direct pressure control keys.

4.2.2.1 KEYPAD LAYOUT AND PROTOCOL

In typical PG7601-SYS-AF system operation, the PPC3-7M-AF pressure controller keypad is not used. Occasionally, when using manual pressure control (see Section 4.1.2), [ENT/SET P] may be used to set a pressure.

The

The PPC3 has a function/data keypad for local operator access to direct functions, function menus and for data entry.

1. The Function/Data keys allow very commonly used functions to be accessed directly by a single keystroke when pressed from the MAIN run screen (see PPC3 Operation and Maintenance Manual). The name of the function is on the bottom half of the key. These keys enter numerical values when editing.

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

3. The Menu/Data keys provide access to function menus when pressed from the MAIN run screen. The menu name is on the bottom half of the key. The SETUP menu is for more frequently used functions. 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 19. Pressure controller keypad layout

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

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Pressing [ESC] moves back in the menu tree and/or causes execution to cease or suspend. Pressing [ESC] repeatedly eventually returns to the MAIN run screen and, from there, allows momentary viewing of the PPC3 introduction screen.

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

Pressing [

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

movement when editing data entry or moving in menus.

4.2.2.2 DIRECT PRESSURE CONTROL KEYS

Figure 20. Pressure controller direct pressure control keys

The [ENT/SET P] key of the PPC3-7M-AF main keypad can be used to set a target pressure that PPC3-7M-AF will automatically set and maintain. Once the target pressure has been reached, control at the target pressure value continues until [ESC] or another function key is pressed.

The PPC3-7M-AF direct pressure control keys (Figure 20) provide direct manual control of pressure increase, decrease, jog and vent. They can be used to adjust pressure manually directly under operator control rather

than under control of the PG7601-AF AutoGen

automated pressure control function (see Section 4.3.9). Pressing the [

decrease at the slow slew rate. Holding [FAST] pressed while pressing [

] or [ ] direct pressure control keys causes pressure to increase or

] or [ ] causes

the pressure increase or decrease speed to change from slow to fast. Pressing [VENT] causes PPC3-7M-AF to control pressure to near atmospheric pressure and

then open its internal vent valve. On-going execution of the vent function is indicated by lighting a RED LED just above the [VENT] key. Completion of the vent process is indicated by the PPC3-7M-AF’s Ready/Not Ready indicator light becoming GREEN with the vent RED LED still lighted. The vent valve remains open until [VENT] is pressed again, another direct pressure control key is pressed, or an automated pressure control command is given from the PPC3-7M-AF front panel or by the PG7601-AF AutoGen function.

Pressing the [

] and [ ] direct pressure control keys causes the pressure to jog or step by a fixed amount. During active pressure control, they cause the target pressure to be changed by the fixed amount. One press causes one step. The approximate value of the step is set automatically depending on the current active PPC3 range. The value can be adjusted using

[SETUP], <3jog> or pressing both the up and down jog keys simultaneously. The [

] and [ ]

keys are not normally used when PPC3-7M-AF is part of a PG7601-SYS-AF system.

4. GENERAL OPERATION

Before using the PPC3-7M-AF pressure controller direct pressure control keys, be sure that the PG7601-AF platform AutoGen function is OFF or not active. The AutoGen function can be made inactive by pressing [ESCAPE] on the PG Terminal.

When using PPC3-7M-AF for direct pressure control, do not make any other changes or adjustments. Do not change units of measure ([UNIT]) or measurement mode ([MODE]).

4.2.2.3 MAIN RUN SCREEN

The PPC3-7M-AF pressure controller MAIN run screen is its home display that is reached on power-up and from which other functions and menus are accessed. It is the very top level of all menu structures.

The MAIN run screen is where the operator works with PPC3-7M-AF pressure controller to set and read pressures. It provides complete information on the system’s current configuration and operating status.

Figure 21 and its legend table summarize the PPC3 MAIN run screen fields and their functions.

PPC3 has a screen saver function which causes the display to dim if no key is pressed for 10 minutes. Pressing a key restores full power to the display. The screen saver time can be changed or screen saving can be completely suppressed (use [SPECIAL], <5prefs>, <1ScrSav> from the PPC3-7M-AF front panel).

PRESSURE1UNITm hzRRH TPRESSURE2 CC NN/NN

DISPLAY FIELD NAME PURPOSE CONTENTS

1. PRESSURE1 Measured

2. UNIT Unit of

3. m Measurement

pressure

measure

mode

Displays pressure measured by PPC3-7MAF internal utility sensor

Identifies pressure unit of measure in which PRESSURE1 and PRESSURE2 are displayed

Identifies measurement mode of displayed pressure

Numerical pressure value and sign

Pressure unit of measure abbreviation

<a>: absolute <g>: gauge

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

DISPLAY FIELD NAME PURPOSE CONTENTS

4. h Head

5. z AutoZero

6. RRH Active RPT

7. NN/NN (not used in normal

PG7601-SYS-AF operation)

8. CC Pressure

9. TPRESSURE2 Pressure

pressure indicator

indicator

position indicator

Sequence progress indicator

control indicator

information indicatior

Indicates whether a fluid head correction is applied to PRESSURE1

Indicates whether the AutoZero function is ON or OFF

Indicates the position of the active utility sensor. Normally <IuH> when used in PG7601-SYS-AF

Indicates progress of an ATest sequence, during test execution

Indicates type of pressure control, whether control is currently active and whether custom contr ol limits are in use. Normally <D> when used in PG7601SYS-AF

Pressure indication depending on current PPC3 function. Leading character identifies the value.

<h>: the fluid head is not zero

<blank>: fluid head is zero

<z>: AutoZ is ON <blank>: AutoZ is OFF

<IH>: Internal Hi <IuH>: Internal Hi

(utility sensor)

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

<NN/NN>: Number of this

point over total number of points in the sequence

<D>: Control mode is dynamic <S>: Control mode is static

<C> is appended to the <D> or <S> if control limits are custom

Control character(s) flash if PPC3 is actively controlling

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

Figure 21. Pressure controller MAIN run screen display fields

4.2.2.4 SOUNDS

PPC3 is equipped with a variable frequency tone device to provide audible feedback and alarms. The beeper is used for the following indications.

Valid key press Brief beep. Choice between three

Invalid key press Descending two tone “blurp”. Leak check completed Three two second beeps. Upper or lower limit exceeded Intermittent one second beeps. Pmax! (overpressure limit) exceeded Eight second high frequency beep.

frequencies or NO sound is available.

4. GENERAL OPERATION

4.3 DIRECT FUNCTION KEYS

4.3.1 DIRECT FUNCTION KEYS SUMMARY

Local operator interface with the PG7601-SYS-AF system is provided by the 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 PG7601-AF is in a run screen (MAIN, SYSTEM or AMBIENT). Table 10 summarizes the operation of the direct function keys. Section 4.2.1.3 provides a flow chart of PG Terminal general operation. See corresponding manual Sections to 4.3.2 to 4.3.13.

It may be useful to keep a copy of Table 10 near the PG7601-AF, especially when first

becoming acquainted with its operation.

Table 10. Summary of PG7601-AF PG Terminal 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 PG7601-AF uses in calculations of reference pressures.

Select pressure to mass or mass to pressure operation.

(main, ambient, system).

Activate motorized piston rotation acceleration and deceleration manually.

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

Turn automatic activation of motorized rotation ON/OFF.

Set the resolution of PG7601-AF 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.

View available piston-cylinder modules (range) and select active one.

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

Turn automated pressure generation/control ON/OFF, adjust control parameters, set upper limit for automated pressure control.

Set pressure measurement mode (gauge, absolute).

4.3.2 [P-C], VIEW AND SELECT PISTON-CYLINDER MODULES

 PURPOSE

To view and/or change the active piston-cylinder module. Changing the piston-cylinder

module is equivalent to changing the range.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

[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], <1PC/MS> (see Section 4.5.1).

The active mass set and mass loading bell are selected by pressing [SPECIAL], <1PC/MS> (see Section 4.5.1).

 PRINCIPLE

To make valid pressure and mass load calculations, PG7601-AF must know the exact characteristics of the piston-cylinder module that is currently in use. See Section 9.2.1 for detailed information on PG7601-AF pressure and mass calculations.

Most PG7601-AFs are used with more than one piston-cylinder module. Detailed characteristics on up to 18 piston-cylinder modules can be stored in digital identification records (digital IDs). Digital IDs can be added, viewed, edited and deleted locally using [SPECIAL], <1pc/ms> (see Section 4.5.1) or remotely using CalTool for

PG7000 s

ftware.

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

Pres [P-C] to activate the piston-cylinder module viewing and selecting function. Press [P-C] again or [+/-] while in the P-C function to step 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 always in kPa/kg.

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

1.02 to 51.8 psi

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/kg.

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.

Pressing [ENTER] while in the P-C function causes PG7601-AF to select the currently displayed piston-cylinder module as the active piston-cylinder module.

Select 200kPa/kg 382 14 to 1000 psi

4. GENERAL OPERATION

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 4.3.3).

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).

4.3.3 [UNIT], SELECT PRESSURE UNIT OF MEASURE

 PURPOSE

To specify the unit of measure in which pressure defined by the PG7601-AF and other pressure values are expressed.

 PRINCIPLE

PG7601-AF supports a wide variety of pressure units of measure. Internally, PG7601-AF 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 9.1.1 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). See Section 4.3.4 for information on changing the measurement mode.

 OPERATION

To change [UNIT] function key from any run screen. The display is:

the pressure unit of measure, press the

1psi 2kPa 3inHg 4mmHg 5inWa 6ft

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

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 60°F

Select the desired reference temperature for water density using [←] or [→] 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 9.1 for tables of the pressure unit of measure conversion factors used by

PG7601-AF.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

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 4.5.2). The default units are:

1psi 2kPa 3inHg 4mmHgr 5inWa 6ft

To restore the default UNIT function settings, use the Unit Reset (see Section 4.5.9.2).

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).

4.3.4 [MODE], SELECT PRESSURE MEASUREMENT MODE

 PURPOSE

To specify the measurement mode (gauge, absolute) in which PG7601-AF defines reference pressures.

Pressure measurement mode and unit of measure is not the same thing. See Section 4.3.3 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. PG7601-AF can define absolute and gauge pressure. These are referred to as

measurement modes. The specific PG7601-AF measurement modes are as follows:

• gauge: Defines gauge pressure by leaving the PG7601-AF mass load open to atmosphere. 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 vacuum (absolute by vac): 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.

• 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. The barometer can be PG7601-AF’s on-board sensor or a remote RS232 barometer (not included in standard PG7601-SYS-AF system). 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 than absolute by vacuum since no vacuum reference needs to be established. However, it does not allow absolute pressures under

4. GENERAL OPERATION

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.

 OPERATION

To change the pressure measurement mode, press [MODE] from any run screen.

Measurement mode:

The display is:

1g 2avac 3aatm

The cursor is on the number corresponding to the current measurement mode. Selecting <1g> accesses gauge mode.

Selecting <2avac> accesses absolute by vacuum mode. Selecting <3aatm> accesses absolute by ATM mode. Making a measurement mode selection returns to the previous run screen with the selected

mode active.

4.3.5 [SYSTEM], VIEW SYSTEM CONDITIONS MEASUREMENT SCREENS

 PURPOSE

To access the two SYSTEM run screens which display current values of PG7601-AF piston behavior, piston-cylinder temperature and vacuum reference measurements.

 OPERATION

To access the SYSTEM run screens, press [SYSTEM] from any other run screen. There are two SYSTEM run screens. Pressing [SYSTEM] or [±] when in a SYSTEM screen toggles between the first and second SYSTEM screens.

See Sections 4.3.5.1 and 4.3.5.2 for detailed information on second SYSTEM run screens.

contents of the first and

the

The SYSTEM screens are run screens. This means that other functions can be accessed from the SYSTEM screens and the active SYSTEM screen will be returned to when leaving functions. The MAIN screen and AMBIENT screen are also run screens (see Section 4.2.1.3).

4.3.5.1 FIRST SYSTEM RUN SCREEN

 OPERATION

The first SYSTEM run screen provides real time display of piston rotation rate, decay in piston rotation rate, piston position and piston fall rate.

To access the first SYSTEM run screen, press [SYSTEM] from any other run screen.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

The first SYSTEM run screen displays:

1. <nnn rpm>: Numerical value of current piston rate of rotation. The unit of measure is rotations per minute [rpm] and cannot be changed. Flashes when Not Ready and piston is floating (see Section 4.1.3.2). Indicates < ---- unavailable or out of range. Message indicating piston rotation is being accelerated or decelerated is displayed to the right when motorized rotation is engaged.

2. <±nn/min>: Numerical value of current decay in piston rotation rate (deceleration). The unit of measure is rotations per minute [rpm/min] and cannot be changed. < ---- > when information is unavailable or out of range. Message indicating piston rotation is being accelerated or decelerated is displayed here when motorized rotation is engaged.

3. <±n.nn/min>: Sign and numerical value of current piston vertical rate of displacement. A negative value indicates piston falling. A positive value indicates piston rising. The unit of measure is millimeters per minute [mm/min] and cannot be changed. Indicates < ---- > when information is unavailable or out of range.

4. <±n.nn mm>: Sign and numerical value of current position of the piston within the piston stroke (see Section 4.1.4) relative to the mid-stroke position. The unit of millimeters [mm] and cannot be changed. Indicates <HSTOP> when the piston is at the high stop (all the way up) and <LSTOP> when the piston is at the low stop (all the way down). Flashes when Not Ready and piston is floating (see Section 4.1.3.1). Indicates < ---- > when information is unavailable or out of range.

hen information is

> w

nnn rpm ±nn/min ±n.nn mm ±n.nn/min

measure

Pressing [ESCAPE] in the first SYSTEM run screen returns operation to the MAIN run screen. Pressing [SYSTEM] or [±] toggles between the first and second run screen. All function keys are active from the first SYSTEM run screen and operation returns to that screen when leaving functions the were accessed from it.

The measurement systems for piston behavior indications rely on movement of the mass loading bell. Piston behavior indications (piston position, piston rotation rate) are not valid when the mass bell is not loaded on the piston.

See Section 4.1.4 for information on the piston stroke and measurement zone.

4.3.5.2 SECOND SYSTEM RUN SCREEN

 OPERATION

The second SYSTEM run screen displays the values of piston-cylinder temperature and temperature rate of change. Vacuum and vacuum rate of change are also displayed. If internal or external measurement is specified for the vacuum values in SETUP (see Section 4.4), the second SYSTEM run screen provides a real time display of the values measured.

To access SYSTEM run screen. To access the first SYSTEM run screen, press [SYSTEM] from any run screen.

the second SYSTEM run screen, press [SYSTEM] or [±] from the first

4. GENERAL OPERATION

The second SYSTEM run screen displays:

1. <n.nn°C>: Current piston-cylinder temperature. Source of value can be internal measurement, default or user depending on current SETUP selection (see Section 4.4). The unit of measure is degrees

[±°C] and cannot be changed. Indicates > when information is unavailable or out of

range.

2. <+n.nn/min>: Sign and numerical value of current rate of change of temperature. A negative value indicates temperature decreasing. A positive value indicates temperature increasing. The unit of measure is degrees Centigrade per minute

[°C/min] and cannot be changed. Indicates < --

-- > when information is unavailable or out of

range. Indicates < ---- > when “user” or “default” is the current SETUP selection for piston-cylinder temperature source (see Section 4.4).

3. <+nnn.n/min>: Sign and numerical value of current rate of change of the vacuum reference pressure. A negative value indicates pressure decreasing. A positive value indicates pressure increasing. The unit of measure is Pascal per minute [Pa/min] and cannot be changed. Indicates < ---- > when information is unavailable or out of range. <Blank> if the PG7601-AF model is not PG7601-AF or if user or default is the current SETUP selection for reference vacuum (see Section 4.4).

4. <nnn.n Pa>: Current vacuum reference value. measurement, default or user depending on current SETUP selection. Flashes when Not Ready and piston is floating (see Section 4.1.3.3). The unit of measure is Pascal [Pa] and cannot be changed. Indicates < >20 Pa > if current SETUP selection is internal or external and current measurement is out of range or greater than 20 Pascal. is not PG7601.

Centigrade

< ----

n.nn°C ±n.nn/min nnn.n Pa ±nnn.n/min

Can be internal measurement, external

<Blank> if PG7601-AF model

Pressing [ESCAPE] in the second SYSTEM run screen returns operation to the MAIN run screen. Pressing [SYSTEM] or [±] toggles between the first and second SYSTEM run screen. All function keys are active from the second SYSTEM run screen and operation returns to that screen when leaving functions that were accessed from it.

The current selection in SETUP determines the source of the values used by PG7601-AF for piston-cylinder temperature and vacuum reference values (see Section 4.4). If the SETUP setting is user or default, the SYSTEM screen displays the user or default value, not PG7601-AF’s on-board measurement(s).

4.3.6 [AMBIENT], VIEW AMBIENT CONDITIONS MEASUREMENTS SCREEN

 PURPOSE

Access the AMBIENT run screen which displays the current ambient condition values being used by PG7601-AF for calculations of reference pressure.

 PRINCIPLE

PG7601-AF uses ambient condition values to calculate the reference pressures that it defines (see 9.2.1). The source of the ambient condition values is specified in the current SETUP file (see Section 4.4). The AMBIENT run screen displays the current ambient condition values. If the SETUP selection for t then the AMBIENT run screen provides a real time display of the measurement by PG7601-AF’s on-board sensor for that variable.

he ambient condition is internal measurement,

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

 OPERATION

To access the AMBIENT run screen, press [AMBIENT] from any other run screen (MAIN or SYSTEM).

The AMBIENT screen is a run screen. This means that other functions can be accessed from the AMBIENT screen and the active AMBIENT screen will be returned to when leaving functions. The MAIN screen and SYSTEM screens are also run screens (see Sections 4.2.1.2 and 4.3.5)

The AMBIENT run screen displays:

1. <nnnnnnn uuuu>: Current numerical value and pressure unit of atmospheric pressure. Source of value can be internal measurement, remote barometer, default or user depending on current SETUP selection (see Section 4.4). The unit of measure is determined by Section 4.3.3). ATM head is applied to internal or external barometer reading to correct atmospheric pressure PG7601-AF reference level (see Section 9.2.2.1). Indicates <

---- > when information is unavailable or Indicates <TIMEOUT> if the current SETUP selection is a remote barometer and PG7601-AF communication with the barometer times out.

2. <n.nn°C>: Current ambient temperature. Source of value can be internal measurement, default or user depending on current SETUP selection (see Section 4.4). The unit of measure is degrees Centigrade [ºC] and cannot be changed. Indicates < ---- > when information is unavailable or out of range.

3. <n.nnnnnnm/s2>: Value of local acceleration due to gravity selection (see Section 4.4). The unit of measure is meters per second squared [m/s2] and cannot be changed.

4. <nn%RH>: current SETUP selection (see Section 4.4). The unit of measure is percent relative humidity [%RH] and cannot be changed. Indicates < -- > if current SETUP selection is internal and current unavailable or out of range.

Current ambient relative humidity. Can be internal measurement, default or user depending on

the UNIT function setting (see

out of range.

nnnnnnn uuuu nn.n°C

the

. Can be default or user depending on current SETUP

nn%RH n.nnnnnn/s2

measurement

Pressing [ESCAPE] in the AMBIENT run screen returns operation to the MAIN run screen. All function keys are active from the AMBIENT run screen and operation returns to that screen when leaving functions that were accessed from it.

The current selection in SETUP determines the source of the values used by PG7601-AF for atmospheric pressure, ambient temperature and relative humidity. If the SETUP setting for these values is user or default, the AMBIENT screen displays the user or default value, not PG7601-AF’s on-board measurement(s).

To change the ambient pressure unit of measure, see Section 4.3.3. 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).

4.3.7 [HEAD], SET FLUID HEAD CORRECTION HEIGHT

 PURPOSE

To cause a pressure value, representing the fluid head resulting from a difference in height, to be added to the pressure defined by PG7601-AF at its reference level. To set the height of the DUT head.

 PRINCIPLE

The pressure defined by the PG7601-AF’s floating piston is the pressure at the bottom of the piston. This is referred to as the PG7601-AF reference level. The height of the bottom of the piston with the piston in mid-stroke position is marked reference level on the PG7601-AF piston-cylinder module mounting post. Frequently, when performing a calibration or test, the

4. GENERAL OPERATION

device or system under test is at a different height than the PG7601-AF reference level. This difference in height (referred to as DUT head) can cause a significant difference between the pressure defined by the PG7601-AF at its reference level and the pressure actually applied to the device under test located at a different height. In this case, it is useful to make a head correction to the pressure defined by the PG7601-AF at its reference level in order to accurately predict the pressure actually applied at a different height. The HEAD function allows this head correction to be applied automatically based on operator entry of the height difference. The fluid used and the HEAD function unit of measure are set using [SPECIAL], <3head> (see Section 4.5.3).

PG7601-AF can accurately determine head pressures for gases (nitrogen, helium and air) and

quids (Di-2 ethylhexyl Sebacate oil, water and a user defined liquid) as the pressurized

l medium. A liquid head might be useful if the PG7601-AF is used with a gas/liquid interface.

When gas is the test fluid, use of the HEAD function is most important at low absolute pressures. In this case, specifying the head height within ± 0.2 in. (5 mm) is adequate to ensure that, even in the worst case, the uncertainty on the head correction will be insignificant relative to the tolerance on the PG7601-AF measurement. Use of the HEAD function to ensure in tolerance measurements is particularly critical when a liquid is the test fluid, due to the high density of liquids. To determine when and how precisely a head correction for liquids must be made, 0.03 psi/inch (90 Pa/cm) may be used as an estimation of the liquid head value.

Regardless of the DUT head function’s setting, corrections are automatically applied to the calculated reference pressure to compensate for the deviation between the current piston position and the mid-stroke position (see Section 4.5.3).

The pistons of the 10 kPa/kg and 50 kPa/kg piston-cylinder modules are hollow. Therefore, the natural reference level is not at the bottom of the piston. So that, in practice, the actual reference level is the same for all piston-cylinder modules, a reference level offset is applied when a hollow piston is used. The reference level offset is included in the piston-cylinder digital ID (see Section 4.5.1.1) and corrects the reference level back to the reference point marked on the mounting post.

 OPERATION

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

Edit DUT head height

1. Test fluid currently specified for the head correction.

2. Entry field for head height (1 to 999 cm or in.).

95 cm N2

Entering a value of zero turns the HEAD function OFF. Entering a value other than zero turns the HEAD function ON using the height entered. Pressing [ESCAPE] returns to the MAIN run screen with NO change to the current head setting. A separate function in [SPECIAL] is used to change the head fluid or height unit (see Section 4.5.3).

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Reference

Line

(+)

REFERENCE LEVEL

(-)

The reference height of PG7601-AF pressure definition is the bottom of the piston in midstroke float position. This position is marked on the piston-cylinder module mounting post. The DUT head height should be entered as a positive value if the device or system under test is higher than the PG7601-AF reference level and negative if it is lower.

To change units of DUT head height between inches and centimeters and to change the test fluid, use [SPECIAL], <3Head> (see Section 4.5.3).

When the HEAD function is ON (DUT head value different from 0), the application of a head correction is indicated by <h> in the right side of the top line of the MAIN run screen (see

<h>

Section 4.2.1.2). When the HEAD function is OFF, the

is NOT shown. PG7601-AF also has a separate head correction to compensate for the deviation between the current piston position and mid-stroke (see Section 4.5.3). This PISTON head can be turned ON and OFF.

4.3.8 [ROTATE], MANAGE MOTORIZED PISTON ROTATION

 PURPOSE

To turn automatic control of motorized piston rotation (acceleration and deceleration) ON and OFF.

See Section 4.3.13 for information on manual control of motorized piston rotation.

 PRINCIPLE

The motorized piston rotation system is used to start or increase piston rotation rate when the piston is floating. It is also used to stop piston rotation when necessary, for example before manipulating mass to set a new pressure moving the piston to the end of its stroke. The system operates by engaging a motor driven belt around the bottom of the mass loading bell to accelerate or brake the rotation rate of the mass bell and piston it is loaded on. The motorized rotation system can engage with the piston at any position in its stroke and at any rotation speed with minimal impact on piston position and the defined pressure. When the motorized rotation system disengages, the piston is completely free.

With automatic motorized rotation ON, the motorized rotation system engages and disengages automatically as needed when the piston is floating to maintain the piston rotation rate above the minimum rate Ready limit (see Section 4.1.3.2). Th e rot atio n rat e is

the

measured by PG7601-AF on board sensors and the rotation rate limits are set in

digital ID of the active piston cylinder (see Section 4.5.1.1). Whenever the piston is floating, the motorized rotation system will attempt to maintain the piston rotation rate within limits (except under the cutoff mass load of 3 kg where the low rotation limit becomes 5 rpm).

the Ready

The piston rotation Ready/Not Ready indication character indicates Not Ready to alert the

4. GENERAL OPERATION

operator when the motorized rotation system is about to engage. The rotation system will not engage when the current mass load is less than the mass of the piston + mass loading bell.

The motorized rotation system is also used to decelerate and stop rotation when starting a new pressure point. If the piston is floating and rotating when [ENTER/SET P] is pressed, the motorized rotation system engages at a speed near the rotation rate of the piston and then brakes it to a stop. Piston rotation is stopped to avoid loading and unloading masses on the rotating piston and to avoid stopping rotation by friction between the piston and the piston end of stroke stops.

With automatic motorized rotation OFF, the motorized rotation system engages only when actuated by the operator. Pressing [

] accelerate rotation or [ ] followed by [←] stops rotation (see Section 4.3.13). Rotation should always be stopped before the piston is moved up or down against the end of stroke stop.

Automatic motorized rotation is generally left

ON for normal operation. It is turned OFF in situations where rotation system actuation independent of operator initiative is undesired (e.g. when performing a crossfloat intercomparison with another piston gauge).

 OPERATION

Piston rotation should always be stopped by the motorized rotation system or manually before the pressure is changed. Piston rotation should not be stopped by friction of the rotating piston against the upper or lower end of stroke stop.

To access the AutoRotate functions, press [ROTATE]. The display is:

AutoRotate OFF 1on 2pre-decel

<AutoRotate ON> or <AutoRotate OFF> indicates the current state of AutoRotate. Use <1on> or <1off> to change the state.

When automated rotation is OFF, the PG7601-AF motorized rotation system will only engage if the operator presses [

] or [ ] followed by [←] (see Section 4.3.13).

When automated rotation is ON, the automated rotation system engages automatically. When the piston is floating, it engages as needed to maintain the piston rotation rate within the rotation rate Ready limits (see Section 4.1.3.2). When [ENTER/SET P] is pressed, it engages to stop rotation before masses are loaded and/or the function can be turned ON and OFF, see Section 4.3.8.1). Manual control using [

] followed by [←] is also still active.

[

pressure is adjusted (this

] and

Automatic motorized piston rotation is dependent on PG7601-AF’s measurements of piston position and rotation rate. These measurements are only available when the mass loading bell is installed on the piston. Automatic piston rotation is suspended when the current PG7601AF mass load does not include the mass loading bell.

Proper operation of the rotation system is dependent on PG7601-AF’s measurements of piston position. Be sure that the piston position indication system is properly adjusted (see Section 6.4.1).

When PG7601-AF is operating in absolute by vacuum mode using the internal vacuum sensor to measure reference vacuum, automatic motorized piston rotation will not engage until the reference vacuum value is within the Ready limit (see Section 4.1.3.3).

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

4.3.8.1 <2PRE-DECEL>

 PURPOSE

To turn ON and OFF a function that causes the automated rotation system to begin the piston rotation deceleration when [ENTER/SET P] is pressed rather than at the time mass is to be loaded.

On a PG7601-AF platform equipped with motorized rotation, when AutoRotate is on, the piston rotation deceleration function is used to stop rotation before masses are loaded or pressure is adjusted. As the deceleration function can take up to one minute to execute, it can be initiated the moment that [ENTER/SET P] is pressed to enter a new pressure or mass target. The deceleration function then runs while the new target value is being entered. However, when the next target does not require changing main masses, it may not be necessary to stop piston rotation. In these cases, running the deceleration function is probably not desired and it is not beneficial for piston deceleration to initiate when [ENTER/SET P] is pressed. For this reason, the function to start piston deceleratoin when [ENTER/SET P] is pressed can be turned ON and OFF.

If pre-deceleration is ON and AutoRotate is ON, piston rotation deceleration always initiates immediately when [ENTER/SET P] is pressed.

If pre-deceleratoin is OFF and AutoRotate is ON, piston rotation deceleration occurs after entry of the pressure or mass target value and only if the new target requires changing main masses.

 OPERATION

To turn ON and OFF the function that causes stopping piston rotation to initiate when [ENTER/SET P] is pressed, press [ROTATE], <2pre-decel> . The cursor is on the choice corresponding to the current state. Select <2on> for piston rotation deceleration to initiate when [ENTER/SET P] is pressed. Select <1off> for deceleration to initiate only after entry of a new pressure or mass target and only if main masses need to be moved. The default is <2on>.

4.3.9 [GEN], MANAGE AUTOMATED PRESSURE GENERATION

 PURPOSE

To turn ON and OFF automated pressure control and view and edit automated pressure control settings. Requires that an automated pressure control component be included in the PG7601-AF system and properly configured.

 PRINCIPLE

A PG7601-SYS-AF system includes a PPC3-7M-AF automated pressure controller. The controller, when properly configured and interfaced with PG7601-AF, is controlled by PG7601-AF to automatically set and adjust pressure to float the piston. The PPC3-7M-AF controller is interfaced via PG7601-AF’s COM3 RS232 port (see Section 3.3.2).

With the PPC3-7M-AF properly configured and interfaced with PG7601-AF, the functions under [GEN] are used to turn automated pressure generation/control ON and operating parameters associated with automated pressure control.

OFF and to set

With automated pressure generation/control ON, PG7601-AF uses the automated control component to float and refloat its piston when a pressure or mass value is entered. [ENTER/SET P] is pressed to initiate a new command. The automated control function is suspended when any function key is pressed, when entering remote mode or if automated pressure control is turned OFF.

After a target pressure or mass has been entered (locally or remotely) and the required mass has been loaded, the GEN function controls the pressure control component as needed to

4. GENERAL OPERATION

float the PG7601-AF piston at the piston float target (see Section 4.3.9.1). When the target value has been exceeded, pressure control stops so that the pressure is controlled only by the floating piston without interference from the pressure controller. When the piston moves beyond the high or low piston position ready limit (see Section 4.1.3.1), the GEN function refloats it to the piston float target. The piston float target and piston position ready limits are

adjustable. See Section 4.1.4, Figure 15 for a description piston position stroke zones

user and limits.

With automated pressure generation/control OFF, PG7601-AF leaves the automated pressure generation/control component idle and does not attempt to use it.

In this case

pressure can be controlled manually by the operator from the PPC3-7M-AF front panel. For normal operation, automated pressure control is generally left ON. It is turned OFF in

situations where pressure control independent of operator initiative is undesired (e.g. when performing a crossfloat intercomparison with another piston gauge).

The [GEN] menu also includes the adjustable piston float target that defines the position to which the piston is set when floated (see Section 4.3.9.1); viewing and setting the UPPER LIMIT of the automated pressure generation component to avoid accidental overpressure (see Section 4.3.9.3), viewing and setting the assumed pressure controller tolerance used to determine

pressure

setting limits when floating the PG7601-AF piston (see Section 4.3.9.4), a choice to not readjust piston position if the piston is already floating within the Ready limit after a new target is executed (see Section 4.3.9.5).

 OPERATION

AutoGen OFF 1on

To access the GEN functions, press [GEN]. The display is:

2target 3raise 4UL  5tol 6refloat

<AutoGen ON> or <AutoGen OFF> indicates the current state of AutoGen. Use <1on> or <1off> to change the state.

If automated pressure control is OFF, when <1on> is pressed, PG7601-AF attempts to initialize automated pressure control. To do so, communication must be established with the PPC3-7M-AF pressure controller (see Section 4.5.5.1). If PG7601-AF is unable to establish communication with a valid pressure control component, <P control timeout, autogen off> is displayed

momentarily.

Correct the communications error with the pressure control component and try again. If PG7601-AF is able to establish communications with a valid automated pressure control component, <Turning ON automated generation> is displayed momentarily and automated control is turned ON. When initializing automated pressure control, PG7601-AF automatically makes the settings on the pressure control component to set it up to operate in the system (pressure unit, measurement mode, control mode, hold limit, etc.).

The PG7601-AF automated control function will attempt to float the piston within the piston

position ready limits (see Section 4.1.3.1) after any m

ss to pressure or pressure to mass

command once mass loading has been confirmed. It will continue to attempt to float its piston until [ENTER/SET P] is pressed to initiate a new command, a function key is pressed to interrupt AugoGen, or automated pressure control is turned OFF using [GEN].

If automated pressure control is ON and <1off> is pressed, <Turning OFF automated generation> is displayed momentarily and automated control is turned OFF. The PG7601-AF automated control function is inactive.

It is not necessary to turn GEN off to interrupt automated pressure control. Pressing [ESCAPE] from the main run screen while automated pressure control is active suspends automated pressure control allow manual operation. Automated pressure control will resume the next time [ENTER/SET P] is used.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Automated pressure generation/control ON is indicated by a <G> in the right of the top line of the PG Terminal MAIN run screen. The <G> flashes when automated generation is active (see Section 4.2.1.2).

Proper operation of the automated pressure control function is dependent on PG7601-AF’s measurements of piston position and rotation rate. These measurements are only available when the mass loading bell is installed on the piston. Automated pressure control is automatically turned off when the PG7601-AF entered pressure or mass load does not include the mass loading bell.

Proper operation of the automated pressure control function is dependent on PG7601-AF’s measurements of piston position. When using AutoGen, be sure that the piston position indication system is properly adjusted (see Section 6.4.1).

To help protect against accidental overpressure, when using automated pressure generation/control, set the upper limit (UL) of the pressure control system using [GEN], <4UL> (see Section 4.3.9.3).

4.3.9.1 <2TARGET>

 PURPOSE

To adjust the position to which the piston must be set before the automated generation function considers the piston floating process complete (see Sections

4.3.9, 4.1.4).

 OPERATION

To adjust the AutoGen piston float target press [GEN], <2target>. Edit the value of the target as desired. The default is + 1 mm. The entry should not exceed + 2.5 mm.

4.3.9.2 <3RAISE>

 PURPOSE

This function is only used with an AMH-38 automated mass handling system. Automated mass handling is not included in the PG7601-SYS-AF system.

4.3.9.3 <4UL>

 PURPOSE

To read and/or set the UPPER LIMIT (UL) of the PPC3-7M-AF pressure controller. This function is used to protect against accidental overpressure when using the PG7601-AF automated pressure generation function (see Section 4.3.9 and the PPC3 Operation and Maintenance Manual, UL section).

 OPERATION

To view or se

t the UPPER LIMIT of the PPC3-7M-AF pressure controller used by

AutoGen, press [GEN], <4UL>. If AutoGen is not ON, the control component UPPER LIMIT cannot be accessed

and <AutoGen OFF no UL> is displayed. If AutoGen is ON, the current UPPER LIMIT of the pressure conroller is

displayed and can be edited.

4. GENERAL OPERATION

The pressure controller will abort pressure generation and beep repeatedly if its UPPER LIMIT is exceeded.

4.3.9.4 <5TOL>

 PURPOSE

To read and/or set the pressure measuring tolerance of the pressure controller used by AutoGen to automate pressure control.

The control tolerance function can be used to reduce the time required to set pressure and float the PG7601-AF piston when the pressure controller used is significantly more accurate than the default tolerance value. The tolerance can also be described as the degree of agreement between the pressure control’s pressure measurement and the pressure value set by the PG7601-AF when its piston is floating. In general, making the tolerance smaller reduces the time required to float the piston and making the tolerance wider increases the time. However, if the tolerance is set too small so that it does not correctly reflect the degree of agreement between the pressure controller pressure measurement and the PG7601-AF’s floating piston, overshoot of the piston float point or inability to float the piston will result.

The pressure controller tolerance determines, when applicable:

a) the distance from the actual pressure target that pressure is set before the

AutoGen function begins to seek movement of the piston.

b) the amount of pressure overshoot that must occur before “forced rotation” is

used to overcome possible friction between the piston and the cylinder.

 OPERATION

To view or set the pressure control tolerance, press [GEN], <5tol>. The current value of the pressure control tolerance is displayed. The value is in

% of full scale of the pressure controller. If the pressure controller is AutoRanged, the AutoRange maximum pressure is used as full scale (see the PPC3 Operation and Maintenance Manual).

The default tolerance value is 0.05% of full scale. This tolerance is appropriate for the PPC3-7M-AF pressure controller’s utility sensor assuming it is regularly adjusted (see Section 6.5).

the pressure tolerance less than

Edit the tolerance value if desired. Do not the worse case agreement between the pressure controller pressure measurement and the pressure indicated by the PG7601-AF when its piston is floating.

make

4.3.9.5 <6REFLOAT>

 PURPOSE

To turn ON and OFF a function that causes the automated generation component (see Section 4.3.9.) to refloat the piston to the target piston position after a new pressure or mass target is entered, even if the Ready limits. When REFLOAT is ON, the piston is always refloated to the target piston position after a new pressure or mass target command. This gives the full stroke of the piston to drop before refloat is necessary. When REFLOAT is OFF, the time required to activate the pressure control component and refloat the piston is eliminated if it is not needed. This can result in very rapid pressure setting when the piston is still floating after a mass load change.

piston is already floating within the piston position

 OPERATION

To turn ON and OFF the Refloat function, press [GEN], <6refloat>. The cursor is on the choice corresponding to the current state. Select <1no> for the piston NOT to be controlled to the target position after a pressure or mass command if the piston is

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

already in the Ready piston position limits. Select <2yes> for the piston to always to be controlled to the raise the piston. The default is <2yes>.

4.3.9.6 VIEWING AND SETTING PPC3-7M-AF COM1 PORT SETTINGS

 PURPOSE

To view and set the PPC3-7M-AF COM1 port for communication with the PG7601-AF platform.

 PRINCIPAL

For the PG7601-AF automated pressure control function to operate, the PG7601-AF platform must be able to communicate with the PPC3-7M-AF pressure controller. Communications are by RS232 between the PG7601-AF platform COM3 port and the PPC3-7M-AF pressure controller COM1 port. For the two components to communicate, their COM port settings must be identifical. The default settings for both COM ports are:

Baud rate 2 400 Parity EVEN Length 7 Stop Bit 1

To view and set the PG7601-AF COM3 port settings, see Section 4.5.5.1. To view and set the PPC3-7M-AF COM1 port settings, see OPERATION below.

 OPERATION

The

PPC3-7M-AF

COM1 port settings can be viewed and set from the PPC3-7M-AF

front panel. First, be sure the PPC3-7M-AF is ready for local operation. If the PG7601-AF

AutoGen function is on, suspend it by pressing [ESCAPE] on the PG Terminal keypad. Then press [ESCAPE] on the PPC3-7M-AF front panel. Press [SPECIAL], <2remote>, <1COM1>. Step through the settings, making the desired selections.

4.3.10 [RES], SET MASS LOADING RESOLUTION

 PURPOSE

To set the resolution with which PG7601-AF loads mass in response to pressure or mass commands (see Section 4.3.12).

 PRINCIPLE

PG7601-AF piston-cylinders are sized such that there is a whole number, nominal relationship between mass loaded on the piston in kilograms [kg] and the pressure at which the piston will float in kilo Pascal [kPa]. This relationship is called the pressure to mass

conversion coefficient and is expressed as kPa/kg. The pressure to mass conversion coefficient is marked on the cap of each piston.

The PG7601-AF mass set is made up of masses in multiples and submultiples of the kilogram making it simple to load mass values rounded to 0.01 g, 1 g, 10 g or 0.1 kg.

When using PG7601-AF to define pressure, the desired pressure value is entered (see Section

4.3.11) and PG7601-AF prompts the user with the mass value to be loaded. Due to the many variables that influence the exact pressure to mass relationship for a piston-cylinder (even there is nominally a whole number mass to pressure relationship) the mass value to load to reach

though

4. GENERAL OPERATION

exactly the pressure requested is always an odd value. Therefore, defining the exact pressure value requested always requires loading mass with 0.01 g resolution.

When it is acceptable for the pressure values defined to not be exactly the nominal pressure value, operation can be simplified and mass loading errors reduced by loading mass with a lower level of resolution and using the pressure that the lower level resolution mass load generates. For example, on a piston-cylinder with a nominal pressure to mass relationship of 10 kPa/kg, defining a pressure of exactly 100 kPa, nominally requires loading 10 kg of mass. However, once all the influences on the measurement are taken into consideration, the actual mass to load to define exactly 100 kPa will not be 10.00000 kg; it will be a value near 10 kg such as 9.99731 kg. This value is difficult to load, as it requires relatively complex mass accounting and the manipulation of very small sub-gram masses. To avoid handling a difficult, odd mass value, one might instead decide to load 10 kg and use whatever pressure results. In this example, loading 10 kg rather than 9.99731 kg would result in defining 100.0269 kPa rather than 100.0000 kPa. The pressure defined is only very slightly different from the nominal value and there is no additional uncertainty if that value is used. The savings in time and reduction of possible mass loading errors are significant.

The PG7601-AF RES function is to select the mass loading resolution that PG7601-AF uses, starting at 0.01 g and increasing in powers of 10 to 0.1 kg. This function is very useful to make operation more convenient and less error prone when it is not imperative that the pressure defined by PG7601-AF be exactly the nominal pressure of the test or calibration sequence.

 OPERATION

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

Mass loading rsltn:

0.01 g < and >

Press [←] and [→] to select the desired level of resolution. [←] decreases resolution and [→] increases resolution. Press [ENTER] to set the selected resolution and return to the

MAIN run screen. The resolution range is from 0.01 g to 0.1 kg.

The RES setting has no affect in mass to pressure mode. The RES setting only affects the resolution of the mass commands that result from pressure entries in pressure to mass mode (see Section 4.3.12).

4.3.11 [SET P], SET OR MEASURE A PRESSURE

 PURPOSE

To enter and execute pressure to mass or mass to pressure commands (see Section 4.3.12).

 PRINCIPLE

PG7601-AF can calculate and display the mass to be loaded to achieve an entered pressure value (pressure to mass mode), or the pressure resulting from an entered mass load (mass to pressure mode). The P mode (see Section 4.3.12).

OR M function is used to set pressure to mass or mass to pressure

Pressing [SET P] from any run screen (MAIN, SYSTEM or AMBIENT) accesses the pressure or mass entry screen which allows the command value

to be entered and proceeds through

the sequence to set or read the pressure defined by PG7601-AF.

 OPERATION

To access the pressure or mass entry screen, press [SET P] from any run screen. The sequence after [SET P] has been pressed varies between mass to pressure and pressure to mass mode. T he mode is selected by pressing [P

4.3.11.1 for details on [SET P] in pressure t

OR M] (see Section 4.3.12). See Section

o mass mode and Section 4.3.11.2 for mass to

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

pressure mode. See immediately below for typical operational sequences in gauge and absolute modes.

Typical gauge and absolute by ATM [SET P] operational sequence

Press [MODE] and select gauge or absolute by ATM (aatm) mode if not already in desired

moe (see Section 4.3.4).

Press [P OR M] and select pressure to mass or mass to pressure mode if not already in

desired mode (see Section 4.3.12).

Press [SET P] and enter a pressure or mass value. If the piston is floating and

AutoRotate is ON, the braking function engages to stop piston rotation (see Section

4.3.8). Otherwise, stop rotation using [

] followed by [←] (see Section 4.3.13). Load mass as instructed (see Section 4.1.5). Use the PPC3-7M-AF pressure controller to float the PG7601-AF piston. If the AutoGen

function is ON, the automated pressure control component floats the piston automatically (see Section 4.3.9). Otherwise, use the PPC-7M-AF direct pressure control keys (see Section 4.2.2.2).

When PG7601-AF indicates Ready on all Ready/Not Ready indicators (see Section 4.1.3),

take a DUT reading at the pressure indicated on the top line of PG7601-AF display. Repeat Steps through for each pressure value desired. Consider setting <0> as the last point or after last point to vent system and leave it in a

known state (see Section 4.3.11.3).

Typical Absolute by

Vacuum Mode Operational Sequence

Press [MODE] and select absolute by vacuum (avac) mode if not already in this mode (see

Section 4.3.4). Press [P OR M] and select pressure to mass or mass to pressure mode if not already in

desired mode (see Section 4.3.12).

Press [SET P] and enter a pressure or mass value. If AutoRoate is ON, the braking

function engages to stop piston rotation (see Section 4.3.8). Otherwise, stop rotation

using [

] followed by [←] (see Section 4.3.13). Load mass as instructed (see Section 4.1.5). Install bell jar on PG7601-AF, shut vacuum vent valve, open vacuum reference shutoff

valve (see Section 2.1). Wait for vacuum under bell jar to reach Ready condition (see

Section 4.1.3.3).

Use the PPC3-7M-AF pressure controller to float the PG7601-AF piston. If the AutoGen

function is ON, the automated pressure control component floats the piston automatically (see Section 4.3.9) (automated pressure control does not start until reference vacuum is

use

under Ready limit). Otherwise,

the PPC-7M-AF direct pressure control keys (see

Section 4.2.2.2)

When PG7601-AF indicates Ready on all Ready/Not Ready indicators (see Section 4.1.3),

take a DUT reading at absolute pressure indicated on the top line of the PG7601-AF display.

Shut vacuum reference shutoff valve, open vacuum vent valve. Wait for pressure under

bell jar to return to ambient. Remove bell jar. Repeat Steps through for each desired pressure point. Consider setting <0> as the last point or after last point to vent system and leave it in a

known state (see Section 4.3.11.3).

4. GENERAL OPERATION

4.3.11.1 [SET P] IN PRESSURE TO MASS MODE

 PURPOSE

To enter and execute a pressure to mass command in pressure to mass mode (see Section 4.3.12).

 OPERATION

Use [P

OR M] to put the PG7601-AF in pressure to mass operation mode (see

Section 4.3.12), then press [SET P] in any run screen. If automated rotation is on, the <D

ECELERATING> screen shows until piston deceleration is complete.

Pressing [ENTER/SET P] in the run screen causes automated pressure generation to be suspended if ON (see Section 4.3.9) and AutoRotate to stop piston rotation if ON (see Section 4.3.8). When [ENTER/SET P] is pressed to confirm mass entry, automated pressure generation and/or motorized rotation resume.

The display is:

1. Current measurement mode.

2. Current pressure unit of measure.

3. Entry field for the target value of pressure to be set.

Target pressure:

100.0000 kPa a

Use the numerical and editing keys to enter the target pressure value desired. Press [ENTER/SET P] to process the target pressure value. If the pressure

value entered cannot be executed, an explanatory error message is displayed momentarily and operation returns to the target pressure entry screen with the previous target pressure value displayed. If the target pressure value entered is valid, the value is processed and operation proceeds to the mass loading instruction screen. The display is:

Load nominal mass:

1. Mass to load using trim masses.

2. Nominal mass to load using main and fractional masses.

10.0 kg and 3.17 g

With PG7601-AF in absolute by vacuum measurement mode (see Section 4.3.4), the instruction is <Load mass & vac:> indicating that the mass should be loaded and then the bell jar should be installed and vacuum established under the bell jar.

Load the nominal mass value following the protocol described in Section 4.1.5 and press [SET P]. When [SET P] is

pressed confirming that the nominal mass value has been loaded, operation returns to the previous run screen with the new pressure target and mass value active.

To make in tolerance measurements, it is imperative that all mass loading instructions be executed following the protocol describe in Section 4.1.5. This ensures that the actual mass value resulting from a nominal mass loading command will be correct. Failure to load masses following the PG7601-AF mass loading protocol is likely to result in out of tolerance mass load determinations and pressure definitions.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

The resolution with which the pressure to mass mode mass loading instruction is given depends on the resolution set in the RES function. The RES function makes it possible to avoid loading high resolution mass values when it is not imperative that the pressure defined be exactly the nominal pressure requested (see Section 4.3.9.6).

The pressure to mass loading instruction is given in nominal mass while the MAIN run screen displays the true mass loaded (see Section 4.1.5). For this reason, the nominal mass loading instruction and the true mass displayed in the MAIN run screen are slightly different values. This is normal operation.

4.3.11.2 [SET P] IN MASS TO PRESSURE MODE

 PURPOSE

To enter and execute a mass to pressure command in mass to pressure mode (see Section 4.3.12).

 OPERATION

Use [P

OR M] to put the PG7601-AF in mass to pressure operation mode (see

Section 4.3.12), then press [SET P] in any run screen. If automated rotation is on, the <D

ECELERATING> screen shows until piston deceleration is complete.

Pressing [SET P] in the run screen causes automated pressure generation to be suspended if ON (see Section 4.3.9) and AutoRotate to stop piston rotation if ON (see Section 4.3.13). When [SET P] is pressed to confirm mass entry, automated pressure generation and/or motorized rotation resume.

The display is:

Load nominal mass:

1. Edit field for total trim mass currently loaded.

2. Edit field for nominal mass of main and fractional masses currently loaded.

10.0 kg and 3.17 g

Use the numerical and editing keys to enter the nominal mass loaded on the piston following the mass loading protocol described in Section 4.1.5. Press [SET P] to process the mass value. If the mass value entered cannot be executed, an explanatory error message is displayed momentarily and operation returns

to the mass entry screen with the previous nominal mass value displayed. If the mass value entered is valid, the value is processed and operation proceeds to the previous run screen with the new mass value active.

To make in tolerance measurements, it is imperative that the value of mass loaded on the piston be the NOMINAL mass following the protocol described in Section 4.1.5. This ensures that PG7601-AF will correctly determine the true mass value loaded. Failure to enter nominal mass values following the PG7601-AF mass loading

protocol

is likely to result in out of tolerance mass load determination and

pressure definitions.

4. GENERAL OPERATION

The setting of the RES function has no effect on the resolution of mass load entries in mass to pressure mode (see Section 4.3.9.6).

The mass to pressure mass entry is expressed in nominal mass while the MAIN run screen displays the true mass loaded (see Section 4.1.5). For this reason, the nominal mass loading instruction and the true mass displayed in the MAIN run screen are slightly different values. This is normal operation.

4.3.11.3 COMMANDS FOR ZERO PRESSURE, ENDING A

TEST

Entering a value of zero as the target presure is a convenient way to end a test and vent the automated pressure control component when AutoGen is ON.

Entering a value of zero in pressure to mass mode causes the following sequence to occur:

Stop piston rotation if AutoRotate is ON. Vent pressure control component if AutoGen is ON or prompt operator to vent. A special run screen displays reflecting that the PG7601-AF is at rest and the

mass loading bell may not be installed.

The display following execution of a 0 command is:

1. <?> in Ready/Not Ready indicator positions since status of piston is unknown since mass loading bell may not be installed.

2. Unknown pressure except in absolute by atmosphere measurement mode in which the current value of atmospheric pressure is displayed. This is the value of absolute by atmospheric pressure when the system is vented.

3. Unknown/meaningless mass load.

4. Unknown/meaningless piston position as bell may not be loaded.

???----- psi a

--- mm --------kg

4.3.12 [P OR M], SET PRESSURE TO MASS OR MASS TO PRESSURE OPERATING MODE

 PURPOSE

To select between PG7601-AF pressure to mass or mass to pressure operation mode.

 PRINCIPLE

Piston gauges are generally used either to define desired pressure set points (e.g. when applying reference pressures to a device to be calibrated) or to measure a static pressure (e.g. when performing a crossfloat intercomparison with another piston gauge). PG7601-AF supports these two typical situations with two operating modes: pressure to mass and mass to pressure.

In pressure to mass operating mode, the operator enters target pressure values and the PG7601-AF provides instructions of the mass to load to achieve the desired target pressure.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

In mass to pressure operating mode, the operator enters the mass currently loaded and the PG7601-AF determines the pressure resulting from the current mass load. Mass to pressure mode is also useful to determine the true mass resulting from a nominal mass load (see Section 4.1.5), since the true mass resulting from an nominal mass load is displayed in the MAIN run screen.

The P

OR M function is used to set the PG7601-AF operating mode to either pressure to

mass or mass to pressure.

 OPERATION

For details on pressure to mass and mass to pressure operation, see Section 4.3.11.

To access the P OR M function, press [P OR M]. the display is:

Select entry mode: 1pressure 2mass

Selecting <1pressure> activates pressure to mass mode and returns to the previous run screen. Selecting <2mass> activates mass to pressure mode and returns to the previous run screen.

4.3.13 [ ] AND [ ], [←], MANUAL CONTROL OF MOTORIZED ROTATION

 PURPOSE

For the operator to engage motorized piston rotation acceleration or deceleration.  PRINCIPLE

Motorized piston rotation is a standard feature on PG7601-AF. Motorized rotation engages and disengages to rotate or stop the rotation of the PG7601-AF piston.

Motorized rotation can be set to engage and disengage automatically to maintain the piston within Ready condition rotation rate limits when the piston is floating and stop rotation before changing the pressure or mass load (see Section 4.3.8). Motorized rotation can also be engaged manually

to accelerate or brake piston rotation at any time under direct operator

control.

] is used for momentary acceleration of piston rotation. [ ], held and followed by [←] is

[

used to start a function that stops piston rotation.  OPERATION To momentarily engage the motorized piston rotation system and accelerate the piston, press

[

] from any run screen. The motorized rotation system engages and remains engaged

until maximum rotation rate has been achieved or the key is released. The display is a modified version of the 1

SYSTEM run screen (see Section 4.3.5) to indicate that piston rotation is being accelerated while showing rotation rate and piston position:

4. GENERAL OPERATION

1. Current piston rotation rate.

2. Current rate of piston vertical displacement.

3. Current piston position.

12 rpm ACCELERATING + 2.05 mm 0.1/min

To start the piston braking function press and hold [

], then press [←]. The motorized

rotation system engages and stays engaged until the piston rotation is stopped. Once the braking function starts the keys may be released and the function will complete unless [ESCAPE] is pressed.

The display is a modified version of the 1

SYSTEM run screen (see Section 4.3.5) to indicate that piston rotation is being decelerated while showing rotation rate and position:

1. Current piston rotation rate.

2. Current rate of piston vertical displacement.

3. Current piston position.

48 rpm DECELERATING + 2.05 mm 0.1/min

To interrupt the piston rotation braking routine, press [ESCAPE].

The motorized rotation system can be set to operate automatically based on current

piston position and rotation rate. See Section 4.3.8 for information.

4.4 [SETUP] MENU, MANAGE PRESSURE EQUATION VARIABLE SOURCES

 PURPOSE To select, view and edit the SETUP files that determine the source of the values that PG7601-AF uses in

its calculation of defined pressure and as criteria for Ready/Not Ready condition determination.

The factory default SETUP file #1 is the file normally used for PG7601-AF operation.

 PRINCIPLE The PG7601-AF piston gauge perform continuous, real time calculations of the pressure defined by the

floating piston under current conditions (see Section 9.2.1 for the details on the calculations applied). The calculations are used to determine the defined pressure displayed in the MAIN run screen, and to arrive at the mass to load value when a target pressure is entered in pressure to mass mode.

The equations that PG7601-AF uses to calculate variables. PG7601-AF allows the source of the value used for each variable to be specified. For example, the value of barometric pressure used to calculate current air density and to add to gauge pressure to define absolute pressure in absolute by atmosphere mode could come either from PG7601-AF’s internal sensor, an external barometer (optional) connected to PG7601-AF’s COM2 port, a

pressure include many instrument and ambient

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

user entered value or be set to standard atmospheric pressure. The PG7601-AF SETUP function allows the source (and in some cases the value) of the variables used in the pressure equation to be specified. In order to allow various combinations of sources and/or values to be setup and recalled, SETUP files can be created, stored, edited and recalled. The SETUP files also include certain variables used to determine PG7601-AF Ready/Not Ready status. Table 11 identifies the variables included in the SETUP file, the factory source setting for each variable and the default value for each variable.

Variable source and value selections are recorded in SETUP files. These files can be stored and recalled so that specific combinations of variable sources and/or values can be conveniently recalled. There 10 SETUP files available. File #1 is a factory SETUP

file that cannot be edited. It includes the factory

are

default variable choices and values. PG7601-AF is normally used with SETUP file #1 selected.

SETUP files, USER values and PG7601-AF’s calculation capabilities can be used to calculate defined

pressure in specific conditions independent of actual PG7601-AF operation.

The SETUP function supports the following:

• View SETUP files (see Section 4.4.2);

• Create/edit SETUP files (see Section 4.4.3);

• Select active SETUP file (see Section 4.4.1).

Table 11. SETUP file choices, factory preferred choice and normal value

VARIABLE

Atmospheric pressure 1. Internal

Ambient temperature 1. Internal

Ambient relative humidity 1. Internal

Piston-cylinder temperature

Gravity 1. Local

Vacuum 1. Internal

Ready/Not Ready

Piston position

Ready/Not Ready

Maximum vacuum reference pressure in absolute by vacuum mode

SOURCE CHOICES

2. Normal

3. User

4. COM2

2. Normal

3. User

2. Normal

3. User

1. Internal

2. Normal

3. User

2. Normal

3. User

2. Normal

3. User

4. COM2

1. User None 1. User

NORMAL VALUE

101.325 kPa (14.6959 psi)

20 °C 1. Internal

45 %RH 1. Internal

20 °C 1. Internal

9.806650 m/s2 1. Local

0 Pa 1. Internal

FACTORY

DEFAULT CHOICE

(SETUP FILE #1)

1. Internal (measurement)

(measurement)

(fixed value, ± 2.5 mm default)

(fixed value, 5 Pa absolute default)

4. GENERAL OPERATION

The factory default SETUP choice is the SETUP choice setting for all variables in a new SETUP file.

SETUP file #1 is fixed to factory SETUP choices and cannot be altered.

 OPERATION

To access the SETUP menu, press [SETUP] from the MAIN run screen. The display is:

Current SETUP: #01 1select 2view 3edit

<#nn> in the upper right hand corner displays the number of the SETUP file that is currently active. Select <1select> to select a different SETUP file to be active (see Section 4.4.1). Select

<2view> to view the variable choices and values of the active SETUP file (see Section 4.4.2).

Select

<3edit> to create or edit a SETUP file (see Section 4.4.3).

4.4.1 <1SELECT>

 PURPOSE

To change the active SETUP file number.

PG7601-AF is normally operated with factory SETUP file #1. Changing the current SETUP file will change the source and in some cases the values of the variables used by PG7601-AF in calculating defined pressure. SETUP files should be selected and changed only by qualified personnel. Incorrect SETUP file selection may cause out of tolerance calculations and measurements. See Section 4.4,  PR

INCIPLE, for information on SETUP files and their use.

 OPERATION

To select a SETUP file number to make it the active SETUP file, use [SETUP], <1select>. Enter the number of the desired SETUP file and press [ENTER]. If a valid SETUP file number has been entered, operation returns to the previous run screen with the selected SETUP file number displayed and active.

Entering an invalid SETUP file number causes an error message to be displayed briefly and returns to the select SETUP file screen.

If the SETUP file selected specifies COM2 as the source of barometric pressure, PG7601-AF attempts to read a barometer on COM2 when initializing the new SETUP file. If PG7601-AF is unable to read a barometer on COM2, a communications time out message is displayed briefly and operation returns to the select SETUP file screen. See Section 4.5.5.4 for information on configuring COM2 to read an external barometer.

4.4.2 <2VIEW>

 PURPOSE

To view the contents of any SETUP file number.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Selecting <2view> SETUP allows any SETUP file to be selected and viewed. Selecting a file in <2view> does not make it active. To specify the active SETUP file, use [SETUP], <1select>.

 OPERATION

See Table 11 for a listing of the source choices for each SETUP file variable.

To view an existing SETUP file, press [SETUP], <2view>. The display is:

View SETUP file:

1. Entry field for number of SETUP file to be viewed. Defaults to SETUP file currently selected.

#02

Enter the desired SETUP file number and press [ENTER].

View #02 latmP 2ambT

If a valid SETUP file number is entered, the display is:

3%RH 4PCT 5g 6READY

7vac

Select <1atmP> to view the atmospheric pressure variable source choice and current value. The value is displayed in the current pressure unit of measure (see Section 4.3.3).

<2ambT> to view the ambient temperature variable source choice and the current

Selec value. The value is displayed in degrees Centigrade [°C].

Select <3%RH> to view the ambient relative humidity variable source choice and the current value. The value is displayed in %RH.

Select <4PCT> to view the piston-cylinder temperature variable source choice and the current value. The value is displayed in degrees Centigrade [°C].

Select <5g> to view the gravity variable source choice and the current value. The value is displayed in meters per second squared [m/s

Select <6READY> to view the values of Ready/Not Ready status criteria (see Section 4.1.3). These include:

<1Pposition>

Piston position Ready/Not Ready limits (see Section 4.1.3.1). The value is displayed as a band in

millimeters about mid-float

position [± mm] (see Section 4.1.4). The default is 2.5 mm.

<2v

Maximum reference vacuum pressure limit when operating

ac>

in absolute by vacuum mode. The value is displayed in Pascal [Pa]. The default is 5 Pa.

Select <7vac> : to view the reference vacuum variable source choice and the current value. The value is displayed in Pascal [Pa].

4.4.3 <3EDIT>

 PURPOSE

See Section 4.4, PRINCIPLE for information on SETUP files and their purpose.

To edit an existing SETUP file and/or to create a new SETUP file.

4. GENERAL OPERATION

SETUP file #1 is the factory preferred file and it cannot be edited.

 OPERATION

See Table 11 for a listing of the source choices for each variable.

To edit an existing SETUP file or create a new SETUP file, press [SETUP], <3edit>. The display is:

Edit SETUP file:

1. Entry field for number of SETUP file to be edited or created. Defaults to SETUP file currently selected, but not #1 since SETUP file #1 cannot be edited.

#02

Enter the desired SETUP file number and press [ENTER].

Edit #02 latmP 2ambT

If a valid SETUP file number is entered, the display is:

3%RH 4PCT 5g 6READY

7vac

Selecting an item leads to the variable source choices menu for that item. The cursor is on the source choice that is currently selected in that SETUP file number. Select the desired variable source. The selection causes the variable choice selection to be made and returns to the edit menu. From the variable source choice menus, pressing [ENTER] or [ESCAPE] returns to the edit selection menu. This allows easy, discreet movement between variable source choices when editing a SETUP file.

Select <1atmP> to specify the atmospheric pressure variable source for the pressure values that are used to calculate ambient air density and to add to gauge pressure measurements to calculate absolute pressure in absolute by addition of atmosphere mode. Selecting <1atmP> offers the atmospheric pressure variable source choices:

<1internal>

<2normal>

Use real time readings from PG7601-AF’s on-board barometer. Use a fixed value of 101.325 kPa (14.6959) psi.

<3user> Use a fixed user entered value. If <3user> is selected, the user

value must be entered, in the current pressure unit of measure.

<4COM2>

Use real time readings from the device connected by RS232 to PG7601-AF’s COM2 port. The external barometer (optional) must be properly set up to communicate with PG7601-AF (see Section

4.5.5.4 for information on setting up to read an external barometer).

<2ambT> to specify the ambient temperature variable source for the temperature

Selec values that are used to calculate ambient air density. Selecting <2ambT> offers the temperature variable source choices:

<1internal>

Use real time readings from PG7601-AF’s on-board ambient temperature platinum resistance thermometer (on the platform rear panel).

<2normal>

Use a fixed value of 20 °C.

<3user> Use a fixed user entered value. If <3user> is selected, the user

value must be entered, in degrees Centigrade [°C].

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Select <3%RH> to specify the relative humidity variable source for the relative humidity values that are used to calculate ambient air density. Selecting <3%RH> offers the relative humidity variable source choices:

<1internal>

Use real time readings from PG7601-AF’s on-board relative humidity sensor (on the platform rear panel).

<2normal>

Use a fixed value of 45 %RH.

<3user> Use a fixed user entered value. If <3user> is selected, the user

value must be entered, in percent relative humidity [%RH].

Select <4PCT> to specify the piston-cylinder temperature variable source for the temperature values that are used to compensate piston-cylinder effective area for temperature. Selecting

<4PCT> offers the temperature variable source choices:

<1internal>

Use real time readings from PG7601-AF’s on-board pistoncylinder temperature platinum resistance thermometer (embedded in the piston-cylinder module mounting post).

<2normal>

Use a fixed value of 20 °C.

<3user> Use a fixed user entered value. If <3user> is selected, the user

value must be entered, in degrees Centigrade [°C].

Select <5g> to specify the value of acceleration due to gravity that is used in calculating the force applied to the piston. Pressing <5g> offers the gravity variable source choices:

<1locall> Use the fixed value of local gravity stored under [SPECIAL],

<6gl> (see Section 4.5.6).

<2normal>

<3user>

Use a fixed value of 9.806650 m/s Use a fixed user entered value different from the current local

gravity value stored in the [SPECIAL], <6gl> menu option. If <3user> is selected, the user value must be entered, in meters per second squared [m/s

Select <6READY> to edit the values of Ready/Not Ready status criteria (see Section 4.1.3). These include:

<1position>: Piston position limits. Edit the fixed value, in millimeters [mm],

of the band around mid-float position within which the piston position is Ready (see Section 4.1.3.1). This also determines

limit

the

at which the piston is refloated by the GEN function

when GEN is ON (see Section 4.3.9).

<2v

ac>:

Maximum reference vacuum pressure when operating in absolute by vacuum mode. Edit the value, in Pascal [Pa], under which condition to occur (see Section 4.1.3.3).

the reference vacuum must be for a vacuum Ready

Select <7vac> to specify the reference vacuum variable source for the value used for the pressure under the bell jar when calculating the absolute pressure defined in absolute by

vacuum mode. Pressing <7vac> offers the reference vacuum variable source choices:

<1internal>:

Use real time readings from PG7601-AF’s on-board vacuum gauge (mounted directly in the vacuum plate, under the mass load).

<2normal>:

Use a fixed value of 0 Pa.

<3user>: Use a fixed user entered value. If <3user> is selected, the user

value must be entered, in Pascal [Pa].

4. GENERAL OPERATION

<4COM2>:

4.5 [SPECIAL] MENU

 PURPOSE

The [SPECIAL] key accesses a menu of PG7601-AF functions and settings that are less commonly or not normally used in regular operation.

 OPERATION

To access the SPECIAL menu, press [SPECIAL] from the MAIN run screen. This display is:

Some screens, such as the SPECIAL menu, go beyond the two lines provided by the display.

This is indicated by an 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.

Use real time readings from or through the device connected by RS232 to PG7601’s COM2 port. The external vacuum gauge must be properly set up to communicate with PG7601-AF (see Section 4.5.5.5 for information on setting up to read an external vacuum gauge).

1PC/MS 2presU 3head 4prefs 5remote 6gl  7cal 8AMH 9reset

Special menu choices include: <1PC/MS>: Creat, edit and view piston-cylinder module, mass set and mass loading bell

digital identifications (digital ID). Select mass set and mass loading bell to be used (see Section 4.5.1).

<2presU>:

<3head>: Change the height unit of measure and t he fluid used in

Customize the pressure unit of measure choices available under [UNIT] (see Section 4.5.2)

DUT head corrections; adjust the barometer head height; turn the automated piston position head correction ON and OFF (PG7302 only) (see Section 4.5.3).

<4prefs>:

To access a menu of internal PG7601-AF operational preferences and functions including screen saver, sounds, time/date, instrument ID and user level protection (see Section 4.5.4).

<5rem

te>: Set up/modify PG7601-AF RS232 (COM1, COM2, COM3) and IEEE-488

interfaces. Test RS232 ports. Set up external barometer communications (see Section 4.5.5).

<6gl

Set the value of local gravity used by PG7601-AF in reference pressure calculations when gl is specified as the gravity value in the active SETTINGS file (see Section 4.5.6).

<7cal>: View the output of and

adjust

PG7601-AF internal sensors and measurement

systems (see Section 4.5.7).

<8AMH>: View the status of and directly control an AMH automated mass handler (optional

accessory not included in PG7601-SYS-AF system) (see Section 4.5.8).

<9reset>: Access and execute various reset options (see Section 4.5.9).

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

4.5.1 <1PC/MS>, MANAGE METROLOGICAL ELEMENT DIGITAL ID

 PURPOSE

To create, edit and view piston-cylinder module, mass set and mass loading bell digital identifications (digital ID). Select mass set and mass loading bell to be used.

See Section 4.3.2 for information on using [P-C] for rapid access to piston-cylinder module

selection in regular day to day operation.

Piston-cylinder, mass set and mass bell digital IDs can also be managed using CalTool for PG7000 software (see Section 7.4). In normal operation, using CalTool for PG7000 remotely is preferable to using the PG Terminal front panel.

The piston-cylinder module and mass set information contained in the digital IDs accessed using <1PC/MS> is element specific metrological data. Uninformed or accidental altering of this information may lead to out of tolerance measurements. Piston-cylinder module and mass set information should only be edited by qualified personnel as part of the PG7601-AF calibration or recalibration process.

 PRINCIPLE To calculate the pressure defined by its floating piston, PG7601-AF must have available the

specific characteristics of the piston-cylinder module, mass set and mass loading bell that are being used. This information is stored in the PG7601-AF platform memory in digital identification records referred to as digital IDs. Digital IDs can be created, viewed and edited using functions under [SPECIAL], <1PC/MS>. This is also where the active mass and mass loading bell are selected.

The piston-cylinder module and mass set information required by PG7601-AF is reported in the Calibration Reports that are delivered with the metrological elements. When the PG7601-AF platform and metrological elements are delivered together, the digital IDs for the metrological element information have normally already been created in PG7601-AF memory. If the metrological elements are delivered separately from the platform or after a recalibration when new data is available, the information must be entered or edited by the user. This can be done using CalTool for PG7000 software for from the PG Terminal front panel using functions under [SPECIAL], <1PC/MS>. See Section 7.4 for information on using CalTool for PG7000 software to manage metrological element digital IDs.

 OPERATION

To access the piston-cylinder module, mass set and mass loading bell digital IDs, press [SPECIAL], <1PC/MS>. The display is:

1PC 2mass set 3mass bell

4. GENERAL OPERATION

Select the type of metrological element digital ID that you would like to view, edit, create or make active.

See Sections 4.5.1.1 to 4.5.1.15 for operation of specific piston-cylinder module, mass and mass bell functions as follows:

Piston-cylinder module

Create a new digital ID (see Section 4.5.1.1). Edit existing digital ID (see Section 4.5.1.2). View existing digital ID (see Section 4.5.1.3). Delete existing digital ID (see Section 4.5.1.4). Select a piston-cylinder module to be active (see Section 4.5.1.5).

Mass set

Create a new digital ID (see Section 4.5.1.6). Edit existing digital ID (see Section 4.5.1.7). View existing digital ID (see Section 4.5.1.8). Delete existing digital ID (see Section 4.5.1.9). Select a mass set to be active (see Section 4.5.1.10).

Mass loading bell

Create a new digital ID (see Section 4.5.1.11). Edit existing digital ID (see Section 4.5.1.12).

set

View existing digital ID (see Section 4.5.1.13). Delete existing digital ID (see Section 4.5.1.14). Select a mass loading bell to be active (see Section 4.5.1.15).

4.5.1.1 CREATE PISTON-CYLINDER MODULE

 PURPOSE

To create a new piston-cylinder module digital ID. The piston-cylinder module created is available for selection from the [P-C] function key.

If the piston-cylinder module and PG7601-AF platform were delivered together, the piston-cylinder module digital ID has normally already been created. Before creating a new piston-cylinder module, press [P-C] to check if it already exists (see Section 4.3.2).

 PRINCIPLE

The PG7601-AF functions to add and edit piston-cylinder module digital IDs allow piston-cylinder variable values to be defined and stored. These values are used by PG7601-AF in calculating defined pressure, piston-cylinder range and pressure to mass and mass to pressure values when the piston-cylinder module is made active by selecting pressing [P-C]. The information needed can be found in the calibration report for the piston-cylinder module.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

The values contained in a piston-cylinder module digital ID are listed in Table 12.

Table 12. Piston-cylinder module digital ID fields

FIELD DESCRIPTION UNIT OF MEASURE

Serial number (S/N) Factory assigned serial number.

Effective area (Ae) Piston-cylinder area at 0 pressure

Piston temperature coefficient Linear thermal expansivity of the

Cylinder temperature coefficient Linear thermal expansivity of the

Effective area pressure

coefficient

Piston-cylinder surface tension Force due to surface tension of

Reference level offset Offset to correct hollow 10 and 50

Piston assembly mass Mass of the piston, adjustment

Piston assembly average

density

Piston rotation rate limits Lower limit below which piston

k(P) Special variable for high line

Calibration report number Number of last calibration report

Calibration report date Date last calibartion report was

 OPERATION

Numeric only.

and 20°C

piston material

cylinder material Change in effective area with

pressure

fluid. Zero for gas operated pistoncylinders

kPa/kg piston-cylinder reference level to the standard PG7601-AF platform reference level

mass, cap and cap nut Average overall density of the

piston, adjustment mass, cap and cap nut

rotation rate is Not Ready. Upper limit which is target rate of automated rotation.

differential pressure mode. Not used (zero) in PG7601-AF.

issued for the piston-cylinder module

issued

nnnn

mm2

-6

x 10

° C-1

x 10-6 °C-1

x 10-6 MPa-1

N/m

kg/m

rpm

kg/mm/min

nnnnnnnnn

yyyymmdd

Adding or editing a piston-cylinder module digital ID from the PG Terminal front panel requires the user to specify a large number of variables in a series of data entry screens described below. For a summary of the piston-cylinder module data requirements see Table 12.

PG7601-AF can store up to 18 piston-cylinder module digital IDs. When <3add> is selected and all the digital ID records have already been used, a warning is displayed. A digital ID record must be deleted before one can be added.

Piston-cylinder module digital IDs can be viewed, edited, uploaded and downloaded from a personal computer using CalTool for PG7000 software (see Section 7.4). For most users, CalTool is more convenient for this function than the PG Terminal front panel.

4. GENERAL OPERATION

To create a new piston-cylinder module digital ID, press [SPECIAL] , <1PC/MS>, <1PC>, <3add>. A series of data entry screens will be presented. Edit each

menu to reflect the correct information on the piston-cylinder module being added. Press [ENTER] after each entry to proceed to the next screen. Pressing [ESCAPE] at any point offe rs an <Abandon edits?> query and then returns to the <1PC> menu without saving any of the edited data or [ENTER] returns to the add piston-cylinder module process.

The data entry screens to add or edit a piston-cylinder module are, in order:

Serial number (S/N): The serial number is four digits. The default is <1>.

The number is marked on the piston cap.

Effective area at 0 pressure and 20 °C: The value must be entered in

square millimeters [mm

]. The default is <0>. The value is reported in the

calibration report for the piston-cylinder module.

Piston temperature coefficient: The value must be entered as relative change

per degree centigrade [nn x 10

-6

/°C]. The 10-6 exponent is fixed. The default is

<00>. The value is reported in the calibration report for the piston-cylinder module.

Cylinder temperature coefficient: The value must be entered as relative

change per degree centigrade [nn x 10

-6

/°C]. The 10-6 exponent is fixed.

The default is <00>. The value is reported in the calibration report for the piston-cylinder module.

Effective area pressure coefficient: The value must be entered as relative

change per MegaPascal [n.nn x 10

-6

/MPa]. The 10

-6

exponent is fixed. The default is 0.00. The value is reported in the calibration report for the pistoncylinder module.

Piston-cylinder surface tension effect: This value is always 0.00 for

PG7601-AF piston-cylinders. The value is in Newton per meter [N/m]. The default is 0.00.

Reference level offset: The value must be entered in millimeters [mm].

The default is 0.00. The value is also reported in the calibration report for the piston-cylinders.

Piston assembly mass: The value must be entered in kilogram [kg]. The

default is 0.200000. The value is reported in the calibration report for the piston-cylinder module.

Piston assembly average density: The value must be entered in kilogram

per cubic meter [kg/m

]. The default is 0. The value is reported in the

calibration report for the piston-cylinder module.

Rotation rate limits [rpm]: The minimum Ready rotation rate and the target

maximum rate. The values must be entered in rotations per minute [rpm]. The value automatically defaults to the factory recommended value of 10 to 30 rpm. In most circumstances, the factory default values should be used.

k(P) coefficient [kg/mm/min]: Not used by PG7601-AF. The value is 0. Calibration report number: The calibration report number must be numeric

only and can be up to nine (9) digits long. The default is 1.

Calibration report date: The date must be expressed in yyyymmdd format.

The default is 19800101.

After pressing [ENTER] to accept the edited calibration report date, the option to save the edited piston-cylinder module information is presented. The display is:

Save PC S/N nnnn 1no 2yes

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL

Select <2yes> to save the piston-cylinder module information under serial number nnnn and return to the <1PC/MS> menu.

Select <1no> to discard all edits and return to the <1PC/MS> menu.

4.5.1.2 EDIT PISTON-CYLINDER MODULE

 PURPOSE

After a recalibration, a digital ID file (*.DID) is normally delivered with the calibration report. CalTool for PG7000 software can be used to load the new digital ID into the PG7601-AF platform and update the calibration information without having to use the PG Terminal front panel (see Section 7.4).

To edit information contained in an existing piston-cylinder digital ID.

 PRINCIPLE/OPERATION

A piston-cylinder module digital ID contains element specific metrological data. Uninformed or accidental altering of this information may lead to out of tolerance measurements. Piston-cylinder module information should only be edited by qualified personnel as part of the PG7601-AF calibration or recalibration process.

See Section 4.5.1.1 describing adding a new piston-cylinder module. The principles and procedures to add or edit a piston-cylinder module digital ID are identical except for the identification of the piston-cylinder module to be edited.

To edit information on an existing piston-cylinder module, press [SPECIAL] , <1PC/MS>, <1PC>, <2edit>.

The display identifies the currently active piston-cylinder module. Press [ENTER] to edit the currently active piston-cylinder module or press [P-C] to toggle through the other piston-cylinder modules available. When the desired piston-cylinder module is identified, press [ENTER] to proceed with editing piston-cylinder module information. Operation of the editing function is identical to the add new piston-cylinder module procedure (see Section 4.5.1.1, OPERATION).

4.5.1.3 VIEW PISTON-CYLINDER MODULE

 PURPOSE

To view the information contained in an existing piston-cylinder module digital ID.

 PRINCIPLE/OPERATION

See Section 4.5.1.1, PRINCIPLE. The piston-cylinder module viewing function allows the piston-cylinder module information to be viewed but not altered.

To view information on an <1PC/MS>, <1PC>, <3view>.

The display identifies the currently active piston-cylinder module. Press [ENTER] to view the currently active piston-cylinder module or press [P-C] to toggle through the other piston-cylinder modules available (see Section 4.3.2). When the desired piston-cylinder module is identified, press [ENTER] to proceed with viewing piston-cylinder module information. Successive [ENTER] steps through the piston-cylinder information screens in the same order as the add and edit functions.

existing piston-cylinder module, press

[SPECIAL] ,

pressing of

Fluke PG7601-SYS-AF User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

ABOUT THIS MANUAL

1. INTRODUCTION

1.1 SPECIFICATIONS

1.1.1 OVERALL SYSTEM SPECIFICATIONS

1.1.1.1 PRESSURE MEASUREMENTS

1.1.2 PISTON GAUGE PLATFORM (PG7601-AF)

1.1.2.1 EMBEDDED FEATURES

1.1.4 MASS SET (MS-7001-35-AF)

1.1.5 PRESSURE CONTROLLER (PPC3-7M-AF)

1.1.6 REFERENCE VACUUM PUMP (D16B)

2. SYSTEM AND COMPONENT OVERVIEW AND DESCRIPTION

2.1 SYSTEM OVERVIEW (PG7601-SYS-AF)

2.2 PISTON GAUGE PLATFORM AND TERMINAL (PG7601-AF)

2.2.1 PLATFORM

2.2.2 PG TERMINAL

2.3 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, -50, -200)

2.4 MASS SET (MS-7001-35-AF)

2.5 PRESSURE CONTROLLER (PPC3-7M-AF)

2.6 REFERENCE VACUUM PUMP (D16B)

3. INSTALLATION

3.1 UNPACKING AND INSPECTION

3.1.1 UNPACKING AND INSPECTION OF PG7601-BAS-AF BASE SYSTEM

3.1.1.1 PLATFORM, TERMINAL AND BELL JAR (PG7601-AF)

3.1.1.2 PRESSURE CONTROLLER (PPC3-7M-AF)

3.1.1.3 REFERENCE VACUUM PUMP (D16B)

3.1.1.4 PRESSURE INTERCONNECTIONS KIT (PK-7601-P-AF)

3.1.1.5 VACUUM INTERCONNECTIONS KIT (PK-7601-V-AF)

3.1.1.6 DOCUMENTATION AND ACCESSORIES

3.1.2 UNPACKING AND INSPECTION OF PG7601-EXC-AF EXCHANGE PACKAGE

3.1.2.2 MASS SET (MS-7001-35-AF)

3.1.2.3 DOCUMENTATION AND ACCESSORIES

3.2 SITE REQUIREMENTS

3.3 PHYSICAL SETUP

3.3.1 SETTING UP THE PLATFORM

3.3.2 SETTING UP THE PRESSURE CONTROLLER

3.3.3 SYSTEM PRESSURE INTERCONNECTIONS

3.3.4 SETTING UP THE MASS SET

3.3.5 INSTALLING A PISTON-CYLINDER MODULE INTO THE PLATFORM

3.3.7 CONNECTING TEST GAS SUPPLY

3.3.8 CONNECTING CONTROL VACUUM SUPPLY

3.4 POWER UP AND VERIFICATION

3.4.1 POWER UP PLATFORM AND PRESSURE CONTROLLER

3.4.3 SET LOCAL GRAVITY VALUE

3.4.4 CHECK/SET SECURITY LEVEL

3.4.6 TURN ON AUTOGEN AND AUTOROTATE

3.4.7 APPLY SUPPLY PRESSURE

3.4.8 APPLY CONTROL VACUUM

3.4.11 CHECK PISTON BEHAVIOR MEASUREMENTS

3.4.12 CHECK REFERENCE VACUUM SYSTEM AND ABSOLUTE MODE OPERATION

3.5 ADDITIONAL PRECAUTIONS TO TAKE TO MAKE GOOD PRESSURE MEASUREMENTS

4. GENERAL OPERATION

4.1 OPERATING PRINCIPLES

4.1.1 FUNDAMENTAL OPERATING PRINCIPLE

4.1.2 PRESSURE CONTROL, MANUAL AND AUTOMATED

4.1.3 PRESSURE READY/NOT READY INDICATION

4.1.3.1 PISTON POSITION READY/NOT READY

4.1.3.2 PISTON ROTATION READY/NOT READY

4.1.3.3 VACUUM REFERENCE READY/NOT READY

4.1.4 PISTON POSITION

4.1.5 MASS LOADING PROTOCOL

4.2 USER INTERFACE

4.2.1 PISTON GAUGE (SYSTEM INTERFACE)

4.2.1.1 KEYPAD LAYOUT AND PROTOCOL

4.2.1.2 MAIN RUN SCREEN

4.2.1.3 GENERAL FUNCTION/MENU FLOW CHART

4.2.1.4 SOUNDS

4.2.2 PRESSURE CONTROLLER

4.2.2.1 KEYPAD LAYOUT AND PROTOCOL

4.2.2.2 DIRECT PRESSURE CONTROL KEYS

4.2.2.3 MAIN RUN SCREEN

4.2.2.4 SOUNDS

4.3 DIRECT FUNCTION KEYS

4.3.1 DIRECT FUNCTION KEYS SUMMARY

4.3.2 [P-C], VIEW AND SELECT PISTON-CYLINDER MODULES

4.3.3 [UNIT], SELECT PRESSURE UNIT OF MEASURE