Fluke PPC3 User Manual

PPC3™

Pressure Controller/Calibrator

Operation and Maintenance Manual

High pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases

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

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

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

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

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

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

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

AutoRange, AutoZ, DH Instruments, DH, DHI, COMPASS, PPC, PPC3, QDUT, Q-RPT, RPM, RPM4, SDS and SPLT are trademarks, registered and otherwise, of DH Instruments, a Fluke Company.

Document No. 550128b-02 050815 Printed in the USA.

AABBLLEE

OONNTTEENNTTS

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

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

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

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

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

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

1.2 SPECIFICATIONS ...................................................................................................................................1

1.2.1 GENERAL SPECIFICATIONS.......................................................................................................................1

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

1.2.2.1 QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT)................................................................2

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

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

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

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

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

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

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

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

2.3 SETUP .....................................................................................................................................................6

2.3.1 PREPARING FOR OPERATION...................................................................................................................6

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

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

2.3.2.2 REAR PANEL.............................................................................................................................................7

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

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

2.3.5 CONNECTING TO A PRESSURE SUPPLY (SUPPLY PORT).....................................................................8

2.3.6 CONNECTING A VACUUM PUMP (EXHAUST PORT) ................................................................................8

2.3.7 CONNECTING EXTERNAL Q-RPTS IN RPM4 REFERENCE PRESSURE MONITORS.............................9

2.3.8 CONNECTING TO THE DEVICE UNDER TEST (TEST(+) AND TEST(-) PORTS)....................................10

2.3.8.1 INSTALLING A SELF PURGING LIQUID TRAP (SPLT) .........................................................................11

2.3.8.2 INSTALLING A DUAL VOLUME UNIT (DVU), G15K AND BG15K Q-RPTS...........................................12

2.3.9 THE VENT PORT.........................................................................................................................................12

2.3.10 CHECK/SET SECURITY LEVEL.................................................................................................................12

2.3.11 TURN OFF ABSOLUTE AND NEGATIVE GAUGE MODE (AXXX RPT)....................................................12

2.4 POWER-UP AND VERIFICATION.........................................................................................................13

2.4.1 SWITCH POWER ON ..................................................................................................................................13

2.4.2 CHECK PRESSURE MEASUREMENT OPERATION.................................................................................13

2.4.2.1 CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT.............................................................13

2.4.2.2 CHECKING GAUGE MODE PRESSURE MEASUREMENT...................................................................13

2.4.3 LEAK CHECK..............................................................................................................................................14

2.4.4 PURGE.........................................................................................................................................................14

2.4.5 CHECK PRESSURE CONTROL OPERATION...........................................................................................14

2.5 SHORT TERM STORAGE.....................................................................................................................14

3. OPERATION..................................................................... 15

3.1 USER INTERFACE................................................................................................................................15

3.1.1 MAIN RUN SCREEN....................................................................................................................................15

3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL.........................................................................17

3.1.3 DIRECT PRESSURE CONTROL KEYS......................................................................................................18

PPC3™ OPERATION AND MAINTENANCE MANUAL

3.1.4 REMOTE [ENT/SET P] FOOTSWITCH.......................................................................................................18

3.1.5 SOUNDS......................................................................................................................................................19

3.2 GENERAL OPERATING PRINCIPLES .................................................................................................19

3.2.1 AUTOMATED PRESSURE CONTROL.......................................................................................................19

3.2.2 PRESSURE READY/NOT READY..............................................................................................................21

3.2.3 GAUGE AND NEGATIVE GAUGE MODES WITH AN AXXX (ABSOLUTE) Q-RPT, DYNAMIC

COMPENSATION FOR ATMOSPHERIC PRESSURE ...............................................................................

3.2.4 MULTIPLE INTERNAL AND EXTERNAL Q-RPTS.....................................................................................23

3.2.5 MULTIPE RANGES (Q-RPTS, AUTORANGE AND INFINITE RANGING).................................................24

3.2.6 OPERATION WITH A PG7000 PISTON GAUGE........................................................................................25

3.2.7 DIRECT FUNCTION KEYS SUMMARY......................................................................................................25

3.3 DIRECT FUNCTION KEYS....................................................................................................................26

3.3.1 [RANGE]......................................................................................................................................................26

3.3.2 [UNIT]...........................................................................................................................................................28

3.3.3 [MODE] ........................................................................................................................................................29

3.3.4 [AUTORANGE]............................................................................................................................................30

3.3.5 [RPT]............................................................................................................................................................33

3.3.6 [AUTOTEST]................................................................................................................................................34

3.3.6.1 QUICK AUTOTEST..................................................................................................................................35

3.3.6.2 QDUT AUTOTEST...................................................................................................................................38

3.3.7 [HEAD].........................................................................................................................................................42

3.3.8 [PURGE] ......................................................................................................................................................43

3.3.9 [LEAK CK]...................................................................................................................................................45

3.3.10 [ENT/SET P] (SET PRESSURE AUTOMATICALLY)..................................................................................47

3.3.10.1 INTERRUPTING AUTOMATED PRESSURE CONTROL........................................................................48

3.3.10.2 AU T OM A T E D P R E S S U R E C O M M A N D S F O R Z E R O P R E S S U R E.................................................... 48

3.4 [SETUP].................................................................................................................................................49

3.4.1 <1RANGE> ..................................................................................................................................................49

3.4.1.1 SAVING AN AUTORANGE RANGE........................................................................................................50

3.4.1.2 DELETING AUTORANGE RANGES........................................................................................................50

3.4.2 <2RES> (RESOLUTION).............................................................................................................................50

3.4.3 <3JOG>........................................................................................................................................................51

3.4.4 <4UL> (UPPER LIMIT) ................................................................................................................................52

3.4.4.1 OVER PRESSURE FUNCTION...............................................................................................................53

3.4.5 <5ATEST>....................................................................................................................................................54

3.4.6 <6CONTROL>..............................................................................................................................................55

3.4.6.1 <LIMITS> (CUSTOM CONTROL PARAMETERS)..................................................................................56

3.4.6.2 TURNING-OFF CUSTOM CONTROL PARAMETERS............................................................................57

3.4.7 <7DRV> (DRIVERS) ....................................................................................................................................57

3.5 [SPECIAL] .............................................................................................................................................58

3.5.1 <1AUTOZ>...................................................................................................................................................58

3.5.1.1 EDIT AUTOZ............................................................................................................................................62

3.5.1.2 RUN AUTOZ.............................................................................................................................................62

3.5.2 <2REMOTE>................................................................................................................................................63

3.5.2.1 <1COM1> AND <2COM2>.......................................................................................................................64

3.5.2.2 <3IEEE-488>............................................................................................................................................64

3.5.2.3 <4FORMAT>............................................................................................................................................64

3.5.2.4 <5RS232 SELF-TEST>............................................................................................................................65

3.5.3 <3HEAD>.....................................................................................................................................................65

3.5.4 <4RESET> ...................................................................................................................................................66

3.5.4.1 <1SET>....................................................................................................................................................66

3.5.4.2 <2UNITS...................................................................................................................................................67

3.5.4.3 <3ATEST>................................................................................................................................................67

3.5.4.4 <4CAL>....................................................................................................................................................67

3.5.4.5 <5ALL>.....................................................................................................................................................68

3.5.5 <5PREFS> ...................................................................................................................................................68

3.5.5.1 <1SCRSVR>............................................................................................................................................69

3.5.5.2 <2SOUND>..............................................................................................................................................69

3.5.5.3 <3TIME>...................................................................................................................................................69

3.5.5.4 <4ID>........................................................................................................................................................70

3.5.5.5 <5LEVEL> (SECURITY)...........................................................................................................................70

3.5.6 <6PUNIT>.....................................................................................................................................................73

3.5.7 <7INTERNAL>.............................................................................................................................................75

3.5.7.1 <1CONFIG>.............................................................................................................................................75

3.5.7.2 <2CONTROL REF>..................................................................................................................................75

3.5.7.3 <3BARO>.................................................................................................................................................76

3.5.7.4 <4PURGE> ..............................................................................................................................................77

3.5.7.5 <5LO VNT>..............................................................................................................................................77

3.5.8 <8CAL>........................................................................................................................................................79

3.5.9 <9LOG>........................................................................................................................................................79

TABLE OF CONTENTS

4. REMOTE OPERATION ....................................................... 81

4.1 OVERVIEW............................................................................................................................................81

4.2 INTERFACING.......................................................................................................................................81

4.2.1 RS232 INTERFACE.....................................................................................................................................81

4.2.1.1 COM1.......................................................................................................................................................81

4.2.1.2 IEEE-488..................................................................................................................................................82

4.2.1.3 COM2.......................................................................................................................................................82

4.3 PROGRAMMING FORMATS.................................................................................................................82

4.3.1 CLASSIC PROGRAM MESSAGE FORMAT...............................................................................................83

4.3.2 ENHANCED PROGRAM MESSAGE FORMAT ..........................................................................................83

4.3.2.1 USING COMMAND TYPE COMMANDS.................................................................................................83

4.3.2.2 USIN G Q U E R Y T Y P E C O M M A N D S...................................................................................................84

4.4 COMMANDS..........................................................................................................................................85

4.4.1 PROGRAMMING MESSAGES....................................................................................................................85

4.4.2 ERROR MESSAGES...................................................................................................................................86

4.4.3 PROGRAM MESSAGE DESCRIPTION OVERVIEW..................................................................................87

4.4.4 PROGRAM MESSAGE DESCRIPTIONS....................................................................................................88

4.5 STATUS REPORTING SYSTEM.........................................................................................................114

4.5.1 ERROR QUEUE.........................................................................................................................................114

4.5.2 STATUS BYTE REGISTER.......................................................................................................................114

4.5.3 STANDARD EVENT REGISTER...............................................................................................................115

4.5.4 READY STATUS REGISTER....................................................................................................................116

4.6 IEEE STD. 488.2 COMMON AND STATUS PROGRAM MESSAGES................................................117

4.6.1 PROGRAM MESSAGE DESCRIPTIONS..................................................................................................117

5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION ...........121

5.1 OVERVIEW..........................................................................................................................................121

5.2 CALIBRATION OF QUARTZ REFERENCE PRESSURE TRANSDUCERS (Q-RPTS)......................121

5.2.1 PRINCIPLE ................................................................................................................................................121

5.2.1.1 PA AND PM COEFFICIENTS................................................................................................................122

5.2.1.2 AS RECEIVED AND AS LEFT DATA ....................................................................................................122

5.2.2 EQUIPMENT REQUIRED..........................................................................................................................123

5.2.3 SET-UP AND PREPARATION...................................................................................................................124

5.2.4 RECOMMENDED CALIBRATION POINT SEQUENCE............................................................................124

5.2.4.1 STANDARD CLASS Q-RPTS................................................................................................................125

5.2.4.2 PREMIUM CLASS Q-RPTS...................................................................................................................126

5.2.5 TURNING OFF ABSOLUTE AND NEGATIVE GAUGE MEASUREMENT MODES FOR AXXX

( AB S O L U T E ) Q - R P T S .........................................................................................................................

5.2.6 Q-RPT CALIBRATION USING CALTOOL FOR RPTS SOFTWARE........................................................128

5.2.7 EDITING AND VIEWING Q-RPT CALIBRATION INFORMATION............................................................128

5.2.8 Q-RPT CALIBRATION/ADJUSTMENT WITHOUT CALTOOL FOR RPTS SOFTWARE.........................130

5.3 ADJUSTMENT OF ON-BOARD BAROMETER...................................................................................131

5.4 ADJUSTMENT OF UTILITY SENSOR ................................................................................................131

5.5 PNEUMATIC CONTROL MODULE CONFIGURATION (<CONFIG>) ................................................132

5.6 OVERHAUL .........................................................................................................................................133

5.7 RELOADING EMBEDDED SOFTWARE INTO FLASH MEMORY......................................................134

5.8 SUBASSEMBLY DESCRIPTION AND LOCATION ............................................................................135

5.8.1 POWER SUPPLY MODULE......................................................................................................................135

5.8.2 MINI MICRO BOARD.................................................................................................................................135

5.8.3 Q-RPT MODULE........................................................................................................................................136

5.8.3.1 HI Q-RPT OR UTILITY SENSOR...........................................................................................................136

5.8.3.2 LO Q-RPT...............................................................................................................................................136

5.8.4 ON-BOARD BAROMETER........................................................................................................................136

5.8.5 VACUUM SENSOR....................................................................................................................................136

5.8.6 PRESSURE CONTROL MODULE ............................................................................................................137

5.8.7 DISPLAY....................................................................................................................................................137

5.8.8 DRIVER BOARD........................................................................................................................................137

5.9 PNEUMATIC SCHEMATICS................................................................................................................137

5.9.1 PRESSURE CONTROL MODULE ............................................................................................................137

5.9.2 Q-RPT MODULE CONFIGURATIONS (PRESSURE MEASUREMENT)..................................................138

127

PPC3™ OPERATION AND MAINTENANCE MANUAL

6. TROUBLESHOOTING .......................................................141

7. APPENDIX ......................................................................145

7.1 DRIVERS .............................................................................................................................................145

7.2 UNIT CONVERSION............................................................................................................................146

7.2.1 PRESSURE................................................................................................................................................146

7.3 REMOTE [ENT] ...................................................................................................................................146

8. WARRANTY ....................................................................147

8.1 OVERVIEW..........................................................................................................................................147

9. GLOSSARY .....................................................................149

TABLES & FIGURES

AABBLLEES

Table 1. Reference Pressure Transducer (Q-RPT) Designations and Ranges..........................................2

Table 2. PPC3 Packing List .........................................................................................................................5

Table 3. Position Designators of Q-RPTs in a PPC3 System ...................................................................24

Table 4. Settings and What They Are Specific To (Range, Measurement Mode, Q-RPT, System).........25

Table 5. Summary of PPC3 Function Key Operation................................................................................26

Table 6. Settings Made by AutoRange......................................................................................................31

Table 7. Default Pressure Control Parameters..........................................................................................55

Table 8. AutoZ ON and OFF......................................................................................................................60

Table 9. Reset – Sets.................................................................................................................................67

Table 10. Reset – Cal ................................................................................................................................68

Table 11. Reset – All..................................................................................................................................68

Table 12. Security Levels........................................................................................................................... 72

Table 13. UNIT Function - Available Units of Measure .............................................................................74

Table 14. COM1 Pin Designations and Connections ................................................................................81

Table 15. COM2 DB-9F Pin Designations................................................................................................. 82

Table 16. Program Message List...............................................................................................................85

Table 17. Error #s and Descriptions ..........................................................................................................86

Table 18. 8 Bit Status Byte Register........................................................................................................114

Table 19. 8 Bit Standard Event Register..................................................................................................115

Table 20. 8 Bit Ready Status Register.....................................................................................................116

Table 21. Program Message List.............................................................................................................117

Table 22. Calibration Point Sequence, Standard Class, Axxx and Gxxx Q-RPTs..................................125

Table 23. Calibration Point Sequence, Standard Class, BGxxx Q-RPTs................................................125

Table 24. Calibration Point Sequence, Standard Class, BA100K Q-RPT...............................................126

Table 25. Calibration Point Sequence, Premium Class, Axxx and Gxxx Q-RPTs ..................................126

Table 26. Calibration Point Sequence, Premium Class, BGxxx Q-RPTs................................................127

Table 27. Troubleshooting Guide.............................................................................................................141

Table 28. External Drivers Current Output ..............................................................................................145

Table 29. External Drivers Pin Outs.........................................................................................................145

Table 30. Pressure Unit of Measure Conversion Coefficients.................................................................146

Table 31. DHI Authorized Service Providers ...........................................................................................147

PPC3™ OPERATION AND MAINTENANCE MANUAL

IIGGUURREES

Figure 1. Front Panel ...................................................................................................................................7

Figure 2. Rear Panel....................................................................................................................................7

Figure 3. MAIN RUN Screen Display Fields..............................................................................................16

Figure 4. Keypad Layout............................................................................................................................17

Figure 5. Direct Pressure Control Keys .....................................................................................................18

Figure 6. Dynamic Pressure Control Operation.........................................................................................20

Figure 7. Static Pressure Control Operation..............................................................................................20

Figure 8. Ready/Not Ready in Dynamic Pressure Control Mode..............................................................21

Figure 9. Ready/Not Ready in Static Control Mode...................................................................................22

Figure 10. Status Register Schematic .....................................................................................................114

Figure 11. Internal View...........................................................................................................................135

Figure 12. Pressure Control Module Schematic......................................................................................137

Figure 13. Q-RPT Module Schematics for Various Configurations.........................................................139

Figure 14. Drivers Connector Schematic.................................................................................................145

Figure 15. Remote [ENT/SET P] Connector Schematic..........................................................................146

ABOUT THIS MANUAL

BBOOUUTT

This manual is intended to provide the user with the basic information necessary to operate a PPC3 pressure controller/calibrator. It also includes a great deal of additional information provided to allow you to optimize PPC3 use and take full advantage of its many features and functions.

Before using the manual, take a moment to familiarize yourself with the Table of Contents structure: Sections 1, 2 and 3 should be read by all first time PPC3 users. Section 3 is most important for those using the local front panel interface but should be read over by all users to familiarize themselves with general PPC3 operating principles. Section 4 is for remote operation from an external computer. Section 5 provides maintenance and calibration information. Section 6 is a quick troubleshooting guide. Use it to troubleshoot unexpected PPC3 behavior based on the symptom of that behavior. Certain words and expressions have specific meaning as they pertain to PPC3. The Glossary, Section 6, is useful as a quick reference for exact definition of specific words and expressions as they are used in the manual.

For those of you who “don’t read manuals”, go directly to Section 2.3 to set up your PPC3 and then go

to Section 2.4 for power-up and verification. This will get you up and running quickly with a minimal risk of causing damage to yourself or your new PPC3. THEN… when you have questions or start to wonder about all the great features you might be missing, get into the manual!

HHIISS

AANNUUAAL

Manual Conventions

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

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

additional explanations.

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

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

PPC3™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

1. INTRODUCTION

11.

NNTTRROODDUUCCTTIIOON

1.1 PRODUCT OVERVIEW

PPC3 is a stand-alone, pressure controller intended to precisely set and control gas pressure into a closed volume as is commonly needed for the calibration and testing of pressure measuring instruments. It has been designed to provide very high performance combined with maximum versatility and ease of use.

PPC3 can be equipped with a low cost utility sensor for pressure monitoring or one or two Quartz Reference Pressure Transducers (Q-RPTs) to allow it to set and measure pressure with very low measurement uncertainty. Up to four external Q-RPTs in one or two external Reference Pressure Monitors (RPM4s), can also be integrated into a PPC3 system. In some cases, a barometer is also included.

Pressure control is achieved by a patented pneumatic module based on digitally controlled solenoid valves and differential pressure regulators.

PPC3 is controlled locally by the operator using a front panel display, keypad and function keys or remotely by a computer using ASCII character command strings over an RS232 or IEEE-488.2 interface.

PPC3 models are available to measure and control pressure in ranges from as low as - 3 to 3 kPa (0.4 psi) to as high as 0 to 10 MPa (0 to 1 500 psi) in absolute, gauge and compound gauge measurement modes.

1.2 SPECIFICATIONS

1.2.1 GENERAL SPECIFICATIONS

Power Requirements

Operating Temperature Range

Storage Temperature Range

Vibration

Weight

Dimensions

Ventilation

Microprocessors

Communication Ports

Fuses

Pressure Ranges

Operating Medium

Pressure Connections

Pressure Limits

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

- 20 to 70 °C Meets MIL-T-28800D

12.7 kg (28.2 lb) approx 18 cm H x 32 cm W x 40 cm D (7.1 in. x 12.6 in. x 15.8 in.) To prevent product overheating, provide proper ventilation. Allow 10 cm

(4 in.) clearance from rear panel cooling fan. 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) Six controller models from 200 kPa (30 psi) max to 10 MPa (1 500 psi) max.

Low uncertainty measurement provided by selection of quartz reference pressure transducer(s) (Q-RPTs)

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

Maximum Working:Pressure: Controlle r or Hi Q-RPT maximum Maximum Test Pressure:w/out Damage: 110 % controller or Hi Q-RPT

Recommended Supply: Pressure: Maximum control pressure + 10 % Maximum Supply Pressure: w/out Damage:

PPC3 -7M: 9.6 MPa (1 400 psi) PPC3-2M, -700K, -200K: 3.5 MPa (500 psi)

maximum

PPC3-10M: 14 MPa (2 000 psi)

PPC3™ OPERATION AND MAINTENANCE MANUAL

1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS

1.2.2.1 QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT)

Quartz reference pressure transducers (Q-RPTs) can be installed in PPC3 to obtain low uncertainty pressure measurement. One or two Q-RPTs can be included in the PPC3 and/or additional Q-RPTs can be used externally mounted in DHI RPM4 Reference Pressure Monitors (see Section 3.2.4).

The type (Axxx, Gxxx, BGxxx, BAxxx) and range of the Q-RPT module(s) determines the PPC3 measurement specifications.

All Q-RPTs whose maximum pressure is over 200 kPa (30 psi) are of the absolute pressure type (Axxx) using an evacuated, permanently sealed reference. Axxx Q-RPTs can measure absolute, gauge and negative gauge pressure. Gauge pressure with an Axxx (absolute) Q-RPT is obtained by offsetting atmospheric pressure and applying dynamic compensation for atmospheric changes using the on-board barometer (see Section 3.2.3). Gxxx (gauge) Q-RPTs can measure positive gauge pressure only. BGxxx (bi-directional gauge) Q-RPTs can measure gauge and negative gauge pr essure. See Se cti on 3.3. 3, P RIN CIP LE, for additional information on absolute, gauge and negative gauge measurement modes.

PPC3s configured with two Q-RPT modules have only one TEST(+) and TEST(-) port. PPC3 internal valves and logic handle switching between the two Q-RPTs as needed.

Q-RPTs are available with two different performance levels, STANDARD class

and PREMIUM class. See the product label on the PPC3 rear panel, the label on the Q-RPT module on the rear panel and/or the product calibration reports to determine the class of the Q-RPTs installed in PPC3.

Table 1. Reference Pressure Transducer (Q-RPT) Designations and Ranges

SI VERSION US VERSION

RPT

DESIGNATION

A10M1 10 000 10 000 1 500 1 500

A7M1 7 000 7 000 1 000 1 000

A3.5M1 3 500 3 500 500 500

A2M1 2 000 2 000 300 300

A1.4M1 1 400 1 400 200 200 A700K1 700 700 100 100 A350K1 350 250 50 35 A200K1 200 100 30 15 A160K 1 160 60 23 8 A100K1 110 10 16 1.5

BA100K4 110 - - 16 - -

G200K2 - - 200 - - 30 G100K2 - - 100 - - 15

G15K2 - - 15 - - 2.2

BG15K3 - - ±15 - - ±2.2

1. All AXXXX RPTs support absolute, gauge and compound (negative) gauge modes.

2. All GXXXX RPTs are positive gauge mode only.

3. BG15K is bi-directional gauge from - 15 to + 15 kPa (- 2.2 to + 2.2 psi).

4. BA100K is a barometric range whose low point is 70 kPa absolute (10 psi).

MAXIMUM

PRESSURE

Absolute

[kPa]

MAXIMUM

PRESSURE

Gauge

[kPa]

MAXIMUM

PRESSURE

Absolute

[psi]

MAXIMUM

PRESSURE

Gauge

[psi]

1. INTRODUCTION

Warm Up Time

Resolution Compensated Temperature Range Acceleration Affect

Allows operation at ± 20° from significant effect

Predicted One Year Stability

Precision

Measurement Uncertainty3

Delivered Pressure Uncertainty4

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

2. Combined linearity, hysteresis, repeatability. Add + 1 Pa (0.00015 psi) in gauge mode with an Axxx (absolute) Q-RPT for the resolution and short term stability of the on-board barometer.

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

4. Maximum deviation of the PPC3 controlled pressure from the true value including measurement uncertainty and dynamic control hold limit.

5. % of reading value times measured pressure from 100 to 30 % of Q-RPT span. Under 30 % of Q-RPT span, % of reading value times 30 % of Q-RPT span. For example, if the Q-RPT is a Standard A160K, the Measurement Uncertainty in pressure is 0.010% times the measured pressure to 48 kPa (160 kPa span x 30%) and 0.0048 kPa (160 kPa span x 30% x 0.01%) under 48 kPa.

6. % of reading value times measured pressure from 100 to 30 % of AutoRanged span. Under 30% of AutoRanged span, % of reading value times 30% of AutoRanged span. If AutoRanged span is less then 30% of maximum Q-RPT span, % of reading values times measured pressure, or % of reading times 9% of Q-RPT span, whichever is greater. For example, if the Q-RPT is a Premium A160K and AutoRanged span is 160 kPa, the Measurement Uncertainty in pressure is measured pressure x 0.008% to 48 kPa (160 kPa AutoRanged span x 30%) and 0.0038 kPa (160 kPa span x 30% x 0.008%) under 48 kPa. If the AutoRanged span is 100 kPa (greater than 30% of 160 kPa maximum Q-RPT span), the measurement uncertainty in pressure is measured pressure x 0.008% to 30 kPa (100 kPa AutoRanged span x 30%) and 0.0024 kPa (100 kPa span x 30% x 0.008%) under 30 kPa. If the AutoRanged span is 30 kPa (less than 30% of the 160 kPa maximum Q-RPT span), the measurement uncertainty in pressure is measured pressure x 0.008% to 14.4 kPa (160 kPa maximum Q-RPT span x 9%) and 0.0012 kPa (160 kPa maximum Q-RPT span x 9% x 0.008%) under 14.4 kPa.

None required, 30 minute temperature stabilization recommended for best performance from cold power up.

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

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

± 0.005% of reading

STANDARD CLASS PREMIUM CLASS

± 0.008% of reading or

0.0024% of Q-RPT span, whichever is greater

± 0.01% of reading or 0.0030%

of Q-RPT span, whichever is

greater

± 0.011 % of reading or

0.0033% of Q-RPT span, whichever is greater

± 0.005% of reading, 0.0015%

of AutoRanged span, or

0.0005% of Q-RPT span, whichever is greater

± 0.008 % of reading, 0.0024%

of AutoRanged span, or

0.0007% of Q-RPT span, whichever is greater

± 0.009 % of reading,

0.0027% of AutoRanged span, or 0.0008% of Q-RPT span,

whichever is greater

PPC3™ OPERATION AND MAINTENANCE MANUAL

1.2.2.2 UTILITY SENSOR

Base PPC3 pressure controllers include a utility sensor. If a Hi Q-RPT (see Section 3.2.4) is installed, there is no utility sensor.

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

Warm Up Time Range

Resolution Precision

1.2.2.3 ON-BOARD BAROMETER

The on-board barometer is used only to measure changes in atmospheric pressure to provide dynamic compensation of the Q-RPT’s atmospheric pressure offset when using an Axxx (absolute) Q-RPT to make gauge pressure measurements.

Warm Up Time

Resolution

Precision

Predicted Stability

Range

None required PPC3-10M: 10 MPa (1 500 psi) absolute and gauge

PPC3-7M: 7 MPa (1 000 psi) absolute and gauge PPC3-2M: 2 MPa (300 psi) absolute and gauge PPC3-700K: 700 kPa (100 psi) absolute and gauge PPC3-200K: 300 kPa (45 psi) absolute; 200 kPa (30 psi) gauge

0.001 % of span

0.1 % of span

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

0.001 % of span

0.1 % of span

0.05 kPa/yr (0.008 psi/yr)

The on-board barometer is only present in PPC3s that have an Axxx

(absolute) or BGxxx (bi-directional gauge) internal Q-RPT.

1.2.3 PRESSURE CONTROL SPECIFICATIONS

Control Precision

Lowest Controllable Pressure

(gauge mode)

Lowest Controllable Pressure

(absolute, negative gauge modes)

Ultimate Pressure

(absolute, negative gauge)

Typical Pressure Setting Ready Time

Optimum TEST Volume

Default Dynamic Control Hold Limit

* Control precision is reduced in absolute mode under 7 kPa (1 psi) absolute.

PPC3-200K PPC3-700K PPC3-2M PPC3-7M PPC3-10M

± 0.002 % of reading or of 2 % of controller span, whichever is greater.*

Q-RPT used must provide resolution higher than expected

Zero set by automated venting. Lowest point above or below zero

limited only by Q-RPT resolution and control precision.

1.5 kPa

(0.2 psia)

TEST(+) port is isolated and connected to vacuum

supply. Typically < 50 Pa (0.008 psia) depending on

vacuum source and test volume configuration.

500 cc 500 cc 500 cc 250 cc 250 cc

3 kPa

(0.4 psia)

control precision.

5 kPa

(0.75 psia)

15 to 30 seconds.

± 0.005 % of current range

5 kPa

(0.75 psia)

10 kPa

(1.5 psia)

5 kPa

(0.75 psia)

2. INSTALLATION

22.

NNSSTTAALLLLAATTIIOON

2.1 UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

PPC3 is delivered in a corrugated container with high density polyethylene inserts to hold it in place; or in the optional molded, medium density polyethylene shipping case with a custom foam insert.

Remove the PPC3 and its accessories from the shipping container and remove each element from its protective plastic bag.

2.1.2 INSPECTING CONTENTS

Check that all items are present and have no visible damage. A standard PPC3 includes all items indicated in Table 2.

Table 2. PPC3 Packing List

DESCRIPTION PART #

1 ea. PPC3 Pressure Controller/Calibrator FAM007 1 ea. Calibration Report 550100 1 ea. Test Report 550200

ACCESSORIES: 401918 (401918-CE)

1 ea. Operation and Maintenance Manual 550128 1 ea. Power Cord (7.5 ft.) 100770 (100770-CE) 1 set (6) Rubber Feet Caps 400203 1 ea. Drivers Connector 401382 1 ea. General Accessories Disk (white CD) 102987

PPC3™ OPERATION AND MAINTENANCE MANUAL

2.2 SITE REQUIREMENTS

The PPC3 can be installed on any flat, stable surface at a convenient height. The front feet can be extended so that the unit can be inclined slightly for easier viewing. The PPC3 can also be mounted in a standard 19 in. rack using the optional rack mount kit.

Minimizing the distance between the PPC3 and the device or system under test will enhance control performance and reduce pressure setting times.

Ready access to the PPC3 rear panel should be considered to facilitate making and breaking pressure connections.

Pneumatic and RS-232 connections to RPM4s should be considered if RPM4s are to be used as external reference pressure measurement devices (see Section 2.3.7).

The Self Purging Liquid Trap (SPLT), if used, should be mounted vertically at the low point of the connection between the PPC3 TEST(+) port and the test (see Section 2.3.8.1).

If you are using a G15K or BG15K Q-RPT with a Dual Volume Unit (DVU), its location and connections should be considered (see Section 2.3.8.2).

Support facilities required include:

• An electrical power source of 85 to 264 VAC, 50 - 60 Hz.

• A continuous, regulated pressure supply of clean, dry, non-corrosive gas at PPC3 maximum

control pressure + 10 % (at least 70 kPa (10 psi) in the case of a BG15K Q-RPT) to be connected to the PPC3 SUPPLY port. Lower gas pressure supply can be used but should exceed the maximum desired test output pressure by 10 to 20 %.

• A vacuum source of less than 1 psia (7 kPa) and with displacement of at least 3 cfm (90 lm) if control of pressures under 3 psi (20 kPa) gauge is desired.

2.3 SETUP

2.3.1 PREPARING FOR OPERATION

To prepare PPC3 for check out and operation:

Remove the plastic caps from the PPC3 rear panel pressure connections. Remove the protective plastic sheet from the front panel display. Install the rubber feet caps onto the bottom case feet, if desired. Familiarize yourself briefly with the front and rear panel (see Section 2.3.2).

Then proceed with Sections 2.3.3 to 2.3.11

2. INSTALLATION

2.3.2 FRONT AND REAR PANELS

2.3.2.1 FRONT PANEL

1. Ready/Not Ready Indicator

2. Display

3. Remote Activity Indicator

Figure 1. Front Panel

4. Cursor Control Keys

5. Multi-Function Keypad

6. Direct Pressure Control Keys

2.3.2.2 REAR PANEL

1. Label, Product

2. VENT port

3. COM2 Connector

4. IEEE-488 Connector

5. COM1 Connector

6. Drivers (12 V) Connector

7. Power Switch

Figure 2. Rear Panel

8. Fuse

9. Electrical Power Connector (IEC-320-C13)

10. Remote [ENT] Connector

11. Pressure Connection, TEST(+)

12. Pressure Connection, TEST(-)

13. Pressure Connection, EXHAUST

14. Pressure Connection, SUPPLY

PPC3™ OPERATION AND MAINTENANCE MANUAL

2.3.3 POWER CONNECTION

Check that the PPC3 power switch is OFF. Connect the supplied power cable to the rear panel power module. Connect the other end of the power cable to an electrical supply of 85 to 264 VAC, 50/60 Hz.

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

Connect the optional remote ENTER footswitch, if available or a user supplied switch fitted to the optional cable (see Section 7.3). Connect the cable to the PPC3 rear panel connection labeled REMOTE ENTER. Activating the switch is equivalent to pressing the [ENT/SET P] key on the front panel (see Section 3.1.4).

2.3.5 CONNECTING TO A PRESSURE SUPPLY (SUPPLY PORT)

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. The PPC3 SUPPLY port connection is 1/8 in. NPT female.

The supply pressure should be equal to the maximum PPC3 control pressure + 10 % (or at least 70 kPa (10 psi) for a BG15K Q-RPT). Lower gas pressure sources can be used but should exceed the maximum desired test output pressure by 10 to 20 %.

Never connect a pressure supply greater than 20 % over the maximum control pressure of

the PPC3 model you are using (except models with a BG15K Q-RPT only). Be sure to connect the pressure supply to the SUPPLY port. Connecting to another port is likely to damage PPC3.

2.3.6 CONNECTING A VACUUM PUMP (EXHAUST PORT)

For PPC3 to set pressures 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.

Never connect a pressure supply to or plug the PPC3 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 SUPPLY port and the PPC3 is NOT in the vent ON condition, there may be a constant gas exhaust through the PPC3 EXHAUST port.

To assure optimum pressure control when changing the pressure applied to the EXHAUST

port from vacuum to atmosphere or vice-versa, be sure to change the control reference setting if the setting is NOT in AUTO mode (see Section 3.5.7.2).

2. INSTALLATION

2.3.7 CONNECTING EXTERNAL Q-RPTS IN RPM4 REFERENCE PRESSURE MONITORS

PPC3 can be connected pneumatically and by RS-232 to one or two RPM4 reference pressure monitors to use up to four external Q-RPTs (two in each RPM4) as external reference pressure measurement devices (see Section 3.2.4).

The PPC3 then manages communications and other RPM4 functions to integrate the RPM4 measurement capabilities into the PPC3 system. The RPM4 Q-RPT module’s Self Defense System (SDS) is used to shut-off RPM4 Q-RPTs from the pressurized system when they are not in use (see the RPM4 Operation and Maintenance Manual).

As a general rule, making the pneumatic connection between the PPC3 TEST port and the

remote Q-RPT as direct as possible favors good pressure control. As distance, volumes and restrictions between the PPC3 TEST port and the remote Q-RPT are added, the possibility of difficulty with pressure control when using the external Q-RPT increases.

To connect a PPC3 to an RPM4 to be used as part of the PPC3 system proceed as follows:

Set up the RPM4 for use as an external device to PPC3 following the instructions in

the RPM4 Operation and Maintenance Manual, Using RPM4 With a PPC3 Controller/Calibration Section.

Using tubing of appropriate pressure rating and a Tee, connect the RPM4 Q-RPT

TEST(+) port to the PPC3 TEST(+) port. The third leg of the Tee is for the connection to the device or system under test. If there are two RPM4s, Tee the second RPM4 in series with the first one. The order of the RPM4s on the test line is not relevant.

If an RPM4 Q-RPT will be used in a gauge pressure range of less than 100 kPa (15 psi),

consider connecting the RPM4 Q-RPT module TEST(-) port to the PPC3 TEST(-) port and to the “low” connection of the DUT if available. This will improve pressure control and stability when ambient pressure is unstable. If the Q-RPT is an Axxx designation Q-RPT, this connection should be made but also be left open to atmosphere.

When external Q-RPTs are used with PPC3, the maximum set pressure is the maximum

pressure of the PPC3 controller/calibrator. The maximum pressure of the PPC3 is determined by the PPC3 controller model or the Hi Q-RPT if one is installed (see Section 1.2.1).

Using a standard pin-to-pin DB-9M to DB-9F RS232 cable, connect COM2 of the PPC3

to COM1 of the RPM4 (see Section 4.2.1.3). If there are two RPM4s, connect COM2 of the first RPM4 to COM1 of the second RPM4. The order of the RPM4 daisy chain is not

relevant. Turn ON the PPC3 and RPM4(s). Press [RPT] on the PPC3 key pad. This causes PPC3 to execute the Q-RPT search

function (see Section 3.3.5). Q-RPTs with whom communication is established will be

shown on the PPC3 display identified by their position (see Table 3).

PPC3™ OPERATION AND MAINTENANCE MANUAL

For PPC3 to identify external RPM4s, the RPM4 COM1 port settings must be:

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

If PPC3 is not able to establish communications with RPM4s and their Q-RPTs, check that the RPM4 COM1 port setting conform to the requirements above. If the COM1 port settings are correct, check that the correct communications cable is being used (standard pin-to-pin DB-9M to DB-9F RS232) and is connected to the correct communications ports.

PPC3 COM2 > 1

See the RPM4 Operation and Maintenance Manual for additional information on RPM4

RS232 communications and COM port settings.

2.3.8 CONNECTING TO THE DEVICE UNDER TEST (TEST(+) AND TEST(-) PORTS)

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

If you are using a self purging liquid trap (SPLT), see Section 2.3.8.1 before proceeding to connect the device under test.

If the PPC3 has a G15K or BG15K Q-RPT, a dual volume unit (DVU) should be installed for very low pressure control. See Section 2.3.8.2 before proceeding to connect to the device under test.

Using a pressure connecting hose or tube of appropriate pressure rating, connect the device or system to be tested to the PPC3 TEST(+) port. The PPC3 TEST(+) connection is 1/8 in. NPT female.

PPC3 TEST(+) AND TEST(-) PORTS All PPC3s have a TEST(+) and a TEST(-) port. See Figure 13 for PPC3 internal Q-RPT

TEST port configurations.

The TEST(+) port is connected to Axxx (absolute) Q-RPTs and to the high side of Gxxx or BGxxx (gauge, bi-directional gauge) Q-RPTs.

The TEST(-) port is connected to PPC3s internal barometer, if present, and to the low side of Gxxx or BGxxx (gauge, bi-directional gauge) Q-RPTs.

• When operating in absolute mode: The TEST(-) port is left open to atmosphere.

• When operating in gauge or negative gauge mode with a range greater than 50 kPa

(7.5 psi): The TEST(-) port is normally left open to atmosphere. A possible exception is when the device or system under test is in an ambient pressure that may differ significantly from the ambient pressure around the PPC3. For example, if the PPC3 is controlling pressure into DUTs in an environmental chamber, the pressure in the environmental chamber may be different from ambient pressure around the PPC3. In this case, connecting a tube from the TEST(-) port to the inside of the chamber may improve measurement results. If the Q-RPT in use is an Axxx Q-RPT, this tube must be left open to the environment so t hat the pressure inside cannot deviate too far from ambient. When using an Axxx Q-RPT, if this tube is connected to t he lo w o r re f er en c e si d e of DU Ts , b e s ur e to open to the local environment as well.

• When operating in gauge or negative gauge mode with a range less than 50 kPa (7.5 psi):

As a general rule, it is preferable to connect the PPC3 TEST(-) port(s) directly to the low or reference side of the device under test to assure that these are at the same pressure. When using an Axxx Q-RPT, this connection must also be open to atmosphere. When using a Gxxx or BGxxx Q-RPT, it is preferable that this connection not be open to atmosphere.

2. INSTALLATION

Do not apply pressure to the TEST(+) port without having a pressure supply equal to or

greater than the applied pressure connected to the SUPPLY port. When controlling pressure to the TEST(+) port externally, do not cause the pressure to change at a very rapid rate. For example, do not vent suddenly by opening an external valve. Internal damage to the PPC3 may result.

Do not connect a pressure supply to the TEST(-) port. The pressure applied to this port

should be maintained at atmospheric pressure (between 70 and 110 kPa (10 and 16 psia)). Exceeding these limits may damage a Gxxx or BGxxx Q-RPT and/or the PPC3’s on-board barometer.

Operating the PPC3 connected to a system with liquid contaminants without taking

proper precautions to purge the system and test line may cause contamination of the PPC3 that will require non-warranty service.

Minimizing the length of the test connection tubing will enhance control performance and

reduce pressure setting time. For normal operation, the total volume of the device or system under test including connecting tubing should be less than 1 000 cc (60 in

)

up to 2 000 kPa (300 psi) and less than 500 cc (30 in3) above 2 000 kPa (300 psi).

Minimizing the length of the test connection tubing and restrictions in connections will

enhance control performance and reduce pressure setting time.

PPC3 pressure control will not operate properly if there are excessive leaks in the test

system. In general, the maximum acceptable leak rate for optimal PPC3 automated pressure control operation and to assure in tolerance measurements with default pressure control parameters is ± 0.5 % of set pressure/minute. In DYNAMIC CONTROL mode, to handle higher test system leak rates, increase the hold limit using CUSTOM CONTROL (see Section 3.4.6.1).

PPC3 pressure control may be adversely affected if the test connection tubing is too

restrictive. For optimum results, the inner diameter of the connecting hose should be > 1.75 mm (0.07 in.), or more.

2.3.8.1 INSTALLING A SELF PURGING LIQUID TRAP (SPLT)

The SPLT (optional) is intended to collect and exhaust liquid or other contaminants that may be present in the device or system under test so that they do not return to contaminate the PPC3.

The SPLT is installed in the TEST(+) connection line at a low point between PPC3 and the device or system under test. If the PPC3 system includes external Q-RPTs in RPM4(s), the RPM4s should be connected on the PPC3 side of the SPLT.

See the SPLT Operation and Maintenance manual for more complete instructions on SPLT installation.

PPC3™ OPERATION AND MAINTENANCE MANUAL

2.3.8.2 INSTALLING A DUAL VOLUME UNIT (DVU), G15K AND

BG15K Q-RPTS

To achieve in tolerance pressure control with the very low range of the G15K and BG15KQ-RPTs, a PK-PPC-BG-DVU dual volume units should be installed in-line on the TEST(+) and TEST(-) ports. The DVU includes two thermally isolated volumes installed in the test line to improve control stability.

See the PK-PPC-BG-DVU instruction sheet for additional information on its installation.

2.3.9 THE VENT PORT

The PPC3 VENT port is the system vent to atmosphere point used to set zero gauge pressure as well as to obtain Q-RPT measurements of atmospheric pressure. The PPC3 on-board barometer, if present is connected to the VENT port. Though a pressure hose can be connected to the VENT port to direct the vented gas flow, a completely unobstructed connection to atmosphere must be maintained for PPC3 reference pressure measurements to operate normally.

The PPC3 VENT port fitting is 10-32 UNF.

NEVER plug, obstruct or connect a supply pressure to the PPC3 VENT port. This may

adversely affect GAUGE mode operation and AutoZeroing functions.

2.3.10 CHECK/SET SECURITY LEVEL

PPC3 has a security system based on user levels. By default, the security system is set to “low”, which includes certain access restrictions, and there is no password required to change the security level. See Section 3.5.5.5 for information on the security level system. As part of the PPC3 startup, determine the security level that is appropriate for the PPC3 and set a password if desired.

PPC3 is delivered with the security level set to “low” to avoid inadvertent altering of critical

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

2.3.11 TURN OFF ABSOLUTE AND NEGATIVE GAUGE MODE (AXXX RPT)

If your PPC3 has an Axxx (absolute) Q-RPT, it is able to operate in gauge, negative gauge and absolute measurement modes (see Section 3.3.3). If the PPC3 will be used only in gauge mode, the other measurement modes can be turned off so they are no longer accessible. This can avoid confusion and/or accidental use of the wrong measurement mode. See Section 5.2.5 for complete information on turning off absolute and negative gauge measurement modes.

2. INSTALLATION

2.4 POWER-UP AND VERIFICATION

2.4.1 SWITCH POWER ON

Actuate the power switch on the PPC3 rear panel. Observe the front panel display as PPC3 initializes, error checks and goes to the MAIN RUN screen (see Section 3.1.1).

PPC3 power-up condition is Internal, Hi Q-RPT or utility sensor active, VENT ON unless the pressure measured by the Hi Q-RPT is more than 20 kPa (3 psi) away from standard atmospheric pressure.

If the PPC3 fails to reach the MAIN RUN screen, service is required. Record the sequence of operations and displays observed.

2.4.2 CHECK PRESSURE MEASUREMENT OPERATION

2.4.2.1 CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT

If the PPC3 has an Axxx (absolute) Q-RPT or a utility sensor (IuH), check that it operates properly in absolute mode.

If the PPC3 is not vented (VENT LED OFF), press the [VENT] direct pressure control key to vent the PPC3 (VENT LED ON) (see Section 3.1.3).

Using the [RANGE] function key to change ranges if necessary and select the

Axxx (absolute) Q-RPT DF range (see Section 3.3.1). Press the [MODE] function key and select <absolute> mode (see Section 3.3.3). Use [UNIT] to change the pressure unit if desired (see Section 3.3.2).

Observe the current value of atmospheric pressure. Check that the value agrees with the local value of atmospheric pressure. Repeat this process for all the Axxx (absolute) Q-RPTs and or the utility sensor in the PPC3 system. Check that the values of atmospheric pressure measured by the different devices agree with each other within PPC3 or RPM4 measurement tolerances as applicable (see Section 1.2.2.1, 1.2.2.2). If they do not agree within tolerances, the PPC3 or RPM4 Q-RPT may need calibration or repair.

2.4.2.2 CHECKING GAUGE MODE PRESSURE MEASUREMENT

If the PPC3 is not vented, press the [VENT] direct pressure control key to vent it (see Section 3.1.3).

Press the [MODE] function key and select <gauge> mode. Change the pressure unit if desired (see Section 3.3.3).

Observe that, within ten seconds, zero is indicated. It is normal for PPC3 to indicate a value other than zero for up to ten seconds when first entering gauge mode.

Using the [RANGE] function key to change ranges, observe that zero is indicated for each Q-RPT within 10 seconds. It is normal for PPC3 to indicate a value other than zero when vented when gauge mode is first entered or ranges are changed. After about ten seconds, the VENT LED should flash and zero should be indicated. If this does not occur, check that the AUTOZERO function is O N (see Section 3.5.1). If AUTOZERO is ON and the displayed pressure will not zero when vented in gauge or bi-directional gauge measurement mode, PPC3 may need repair.

PPC3™ OPERATION AND MAINTENANCE MANUAL

2.4.3 LEAK CHECK

If desired, perform a leak check of the test system (see Section 3.3.9).

2.4.4 PURGE

If an SPLT is included and installed in the test line and the Device Under Test (DUT) may be contaminated with liquids, perform a purge of the DUT (see Section 3.3.8). The PURGE function must first be activated (see Section 3.5.7.4). This will rid the DUT of contaminating liquids.

Operating the PPC3 connected to a system with liquid contaminants without taking

proper precautions to purge the system and test line may cause contamination of the PPC3 that will require non-warranty service.

2.4.5 CHECK PRESSURE CONTROL OPERATION

Select a pressure range using [RANGE] (see Section 3.3.1). Press [SETUP], <6control>, <2dynamic> (see Section 3.4.6). Then [ESC] back to the

MAIN RUN screen. Press [ENT]. Key in a target pressure within the active range and press [ENT] again

(see Section 3.3.10).

Verify the maximum pressure rating of the system connected to the PPC3 TEST(+) port

before entering a target pressure. Do not enter a target pressure greater than the pressure rating of the system connected to the PPC3 TEST(+) port.

PPC3 should set the target pressure and indicate Ready (see Section 3.2.2) continuously in 15 to 60 seconds. If it does not, see Section 6 to troubleshoot.

2.5 SHORT TERM STORAGE

The following procedure is recommended for short term storage of PPC3:

Vent the PPC3 test pressure.

Turn the power OFF using the rear panel power switch. Shut OFF or disconnect the pressure supply. Shut OFF or disconnect the vacuum supply. Be sure the pressure supply is disconnected or the

vacuum pump is bypassed from the PPC3 EXHAUST port before turning OFF the vacuum pump.

3. OPERATION

33.

PPEERRAATTIIOON

3.1 USER INTERFACE

PPC3 is designed to offer a practical balance between simple, straight forward operation and the availability of a wide variety of advanced functions with a high level of operator discretion. The local operator interface is through a 2 x 20 display, a function/data keypad, a cursor control pad and direct pressure control keys.

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

3.1.1 MAIN RUN SCREEN

The PPC3 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 to set and read pressures. It provides complete information on the system’s current configuration and operating status.

Figure 3 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 (see Section 3.5.5.1).

PPC3™ OPERATION AND MAINTENANCE MANUAL

PRESSURE1UNITM hzRRH TPRESSURE2 CC NN/NN

DISPLAY FIELD NAME PURPOSE CONTENTS SECTION

1. PRESSURE1 Measured pressure

Displays pressure measured by active Q-RPT

Numerical pressure value and sign

1.2.2.1

1.2.2.2

3.3.10

2. UNIT Unit of measure

Identifies pressure unit of measure in

Pressure unit of measure abbreviation

3.3.2

which PRESSURE1 and PRESSURE2 are displayed

3. M Measurement mode

4. h Head pressure indicator

5. z AutoZero indicator

Identifies measurement mode of displayed pressure

Indicates whether a fluid head correction is applied to PRESSURE1

Indicates whether the AutoZero function is ON or

<a>: absolute <g>: gauge or

negative gauge <h>: the fluid head

is not zero <blank>: fluid head is

zero

<z>: AutoZ is ON <blank>: AutoZ is OFF

3.3.3

3.3.7

3.5.1

OFF

6. RRH Active QRPT position indicator

Indicates the position of the active utility sensor or Q-RPT in the PPC3 system

<IH>: Internal Hi

3.2.4 <IuH>: Internal Hi (utility sensor)

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

7. NN/NN Sequence progress indicator

Indicates progress of an ATest sequence, during test execution

<NN/NN>: Number of this point over total number of points in the

3.3.6

sequence

8. CC Pressure control indicator

Indicates type of pressure control, whether control is currently active and whether custom control limits are in use

<D>: Control mode is dynamic <S>: Control mode is static

<C> is appended to the <D> or <S> if control

3.2.1

3.4.6

limits are custom Control character(s)

flash if PPC3 is actively controlling

9. TPRESSURE2 Pressure information indicatior

Pressure indication depending on current PPC3 function. Leading character identifies the value.

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

3.3.10

<D>: Deviation from the pressure control target

Figure 3. MAIN RUN Screen Display Fields

3. OPERATION

3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL

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 Section 3.2.7). 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.

Figure 4. Keypad Layout

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

3.5). These keys enter numerical values when editing.

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

Pressing the [ESC] key moves back in the menu tree and/or causes execution to cease or suspend. Pressing [ESC] repeatedly eventually returns to the MAIN RUN screen and, from there, allows momentary viewing of the PPC3 introduction screen.

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

Pressing the [

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

movement when editing data entry or moving in menus.

Some screens go beyond the two lines provided by the display. This is indicated by a

flashing down arrow in the second line of the display. Press the cursor control keys to move the cursor to access the lines that are not visible or directly enter the number of the hidden menu choice if you know it.

PPC3™ OPERATION AND MAINTENANCE MANUAL

3.1.3 DIRECT PRESSURE CONTROL KEYS

Figure 5. Direct Pressure Control Keys

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

The [

] and [ ] direct pressure control keys interrupt and override automated pressure

control. Pressing the [VENT] key causes PPC3 to control pressure to near atmospheric pressure and

then open the system vent valve (see Figures 12 and 13). On-going execution of the vent function is indicated by lighting a RED LED just above the [VENT] key. Completion of the vent process is indicated by the Ready/Not Ready indicator light becoming GREEN with the vent RED LED still lighted. The vent valve remains open until the [VENT] key is pressed again, another direct pressure control key is pressed, or an automated pressure control command is given.

Pressing the [ decrease at the slow slew rate. Holding the [FAST] key pressed while pressing the [

] key causes the pressure increase or decrease speed to change from slow to fast.

or [ Pressing the [

] and [ ] direct pressure control keys causes pressure to increase or

]

] 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 (see Section 3.4.3).

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

shortcut to the jog step size adjustment menu.

3.1.4 REMOTE [ENT/SET P] FOOTSWITCH

The optional remote ENTER function is a switch that duplicates the function of the front panel [ENT] key. The remote ENTER function is serviced by a connector on the PPC3 rear panel labeled REMOTE ENTER. An optional footswitch is available to activate remote entry hands free or a user supplied switch may be used. See Section 7.3 for information on remote ENTER switch wiring.

The remote ENTER feature can be particularly convenient when running AutoTests (see Section 3.3.6) in which using a footswitch to [ENT] allows hands free operation.

3. OPERATION

3.1.5 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 frequencies

or NO sound is available (see Section 3.5.5.2).

Invalid key press Descending two tone “blurp”. Leak check completed Three two second beeps (see Section 3.3.9). Upper or lower limit exceeded Intermittent one second beeps (see Section 3.4.4) External device not connected Eight second high frequency beep (see Section

2.3.7)

Pmax! (overpressure limit) exceeded Eight second high frequency beep (see Section

3.4.4.1).

AutoTest reading in tolerance/out of Ascending triad/descending triad (see Section tolerance reading 3.3.10).

3.2 GENERAL OPERATING PRINCIPLES

3.2.1 AUTOMATED PRESSURE CONTROL

PPC3 automated pressure control provides automated adjustment and control of pressure to a user designated target value. Pressing [ENT/SET P] from the MAIN RUN screen allows a pressure control target value to be entered and executed. Pressing [ESC], a direct pressure control key or a function key causes active pressure control to be interrupted. Sending a remote command when in local mode also interrupts pressure control.

PPC3 supports two pressure control modes to meet different pressure setting and controlling requirements: dynamic and static. Pressure control parameters for each control mode are automatically set to optimal default values for the operating PPC3 range when the range is selected or AutoRange is used (see Section 3.3.4). Control parameters can be customized using the [SETUP], <6control> function (see Section 3.4.6).

Control parameters:

Target Value The pressure setpoint specified by the operator. Hold Limit A symmetrical positive and negative limit around the target value within

which the controlled pressure is maintained.

Stability Limit A rate of change of pressure limit in units of pressure/second used as a

criterion for the Ready/Not Ready condition in static control or when

See this section, Dynamic Control and Static Control for a detailed explanation of each

control mode and its advantages, the default control parameters and the control customization options.

PPC3 is idle (control not active).

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

continuously to keep pressure within the hold limit and as close to the target value as possible (see Figure 6). The advantage of this control mode is that the final pressure achieved is the same as the target value. The maximum value of the control error is equal to the hold limit. The average value of the control error is generally much smaller than the hold limit.

PPC3™ OPERATION AND MAINTENANCE MANUAL

During dynamic pressure control, the hold limit is active. If the pressure goes outside of the hold limit, a Not Ready condition occurs. See Tables 6 and 7 for default hold limit values and Section 3.3.6 to customize the hold limit.

Figure 6. Dynamic Pressure Control Operation

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

active control to allow pressure to stabilize naturally within the hold limit. The advantage of this control mode is that pressure can be set and/or measured within a defined limit of a target without interference from the pressure control system. In a system without excessive leaks, the pressure stability achieved may be greater than the stability with which the pressure control system can actively control pressure. Using static control to control pressure near the desired set point and then measuring back the stabilized pressure without interference of the control function can allow control errors to be completely eliminated. However, the final pressure achieved is not equal to the target value. During static pressure control, the hold limit is active. If the pressure goes outside of the hold limit, a Not Ready condition occurs (see Section 3.2.2) and pressure is readjusted to the target value (see Tables 6 and 7 and Section 3.3.6 for setting the hold and stability limits to user defined values).

Figure 7. Static Pressure Control Operation

+ 130 hidden pages

Fluke PPC3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

ABOUT THIS MANUAL

1. INTRODUCTION

1.1 PRODUCT OVERVIEW

1.2 SPECIFICATIONS

1.2.1 GENERAL SPECIFICATIONS

1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS

1.2.2.1 QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT)

1.2.2.2 UTILITY SENSOR

1.2.2.3 ON-BOARD BAROMETER

1.2.3 PRESSURE CONTROL SPECIFICATIONS

2. INSTALLATION

2.1 UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

2.1.2 INSPECTING CONTENTS

2.2 SITE REQUIREMENTS

2.3 SETUP

2.3.1 PREPARING FOR OPERATION

2.3.2 FRONT AND REAR PANELS

2.3.2.1 FRONT PANEL

2.3.2.2 REAR PANEL

2.3.3 POWER CONNECTION

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

2.3.5 CONNECTING TO A PRESSURE SUPPLY (SUPPLY PORT)

2.3.6 CONNECTING A VACUUM PUMP (EXHAUST PORT)

2.3.7 CONNECTING EXTERNAL Q-RPTS IN RPM4 REFERENCE PRESSURE MONITORS

2.3.8 CONNECTING TO THE DEVICE UNDER TEST (TEST(+) AND TEST(-) PORTS)

2.3.8.1 INSTALLING A SELF PURGING LIQUID TRAP (SPLT)

2.3.9 THE VENT PORT

2.3.10 CHECK/SET SECURITY LEVEL

2.3.11 TURN OFF ABSOLUTE AND NEGATIVE GAUGE MODE (AXXX RPT)

2.4 POWER-UP AND VERIFICATION

2.4.1 SWITCH POWER ON

2.4.2 CHECK PRESSURE MEASUREMENT OPERATION

2.4.2.1 CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT

2.4.2.2 CHECKING GAUGE MODE PRESSURE MEASUREMENT

2.4.3 LEAK CHECK

2.4.4 PURGE

2.4.5 CHECK PRESSURE CONTROL OPERATION

2.5 SHORT TERM STORAGE

3. OPERATION

3.1 USER INTERFACE

3.1.1 MAIN RUN SCREEN

3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL

3.1.3 DIRECT PRESSURE CONTROL KEYS

3.1.4 REMOTE [ENT/SET P] FOOTSWITCH

3.1.5 SOUNDS

3.2 GENERAL OPERATING PRINCIPLES

3.2.1 AUTOMATED PRESSURE CONTROL