Fluke PPCH User Manual

PPCH™

Hydraulic Pressure Controller/Calibrator

Ver. 1.01f and higher

Operation and Maintenance Manual

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

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

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

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

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

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

Loctite is a trademark of Loctite Corporation

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

Document No. 550132h 090210

Printed in the USA.

TABLE OF CONTENTS

TABLE OF CONTENTS ...............................................................				I
TABLES ..................................................................................				V
FIGURES ................................................................................				VI
ABOUT THIS MANUAL ............................................................				VII
1.	INTRODUCTION .................................................................			1
	1.1	PRODUCT OVERVIEW ...........................................................................................................................		1
	1.2	SPECIFICATIONS ...................................................................................................................................		2
		1.2.1	GENERAL SPECIFICATIONS .......................................................................................................................	2
		1.2.2	PRESSURE MEASUREMENT SPECIFICATIONS........................................................................................	3
		1.2.2.1	QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT) ................................................................	3
		1.2.2.2	UTILITY SENSOR ......................................................................................................................................	4
		1.2.2.3	ON-BOARD BAROMETER ........................................................................................................................	4
		1.2.3	PRESSURE CONTROL SPECIFICATIONS..................................................................................................	4
2.	INSTALLATION ..................................................................			5
	2.1	UNPACKING AND INSPECTION ............................................................................................................		5
		2.1.1	REMOVING FROM PACKAGING..................................................................................................................	5
		2.1.2	INSPECTING CONTENTS.............................................................................................................................	5
	2.2	SITE REQUIREMENTS............................................................................................................................		6
		2.2.1	INSTALLATION IN A 19 IN. RACK MOUNT .................................................................................................	6
	2.3	INITIAL SETUP........................................................................................................................................		7
		2.3.1	PREPARING FOR OPERATION ...................................................................................................................	7
		2.3.2	FRONT AND REAR PANELS........................................................................................................................	7
		2.3.2.1	FRONT PANEL ..........................................................................................................................................	7
		2.3.2.2	REAR PANEL.............................................................................................................................................	8
		2.3.3	POWER CONNECTION.................................................................................................................................	8
		2.3.4	REMOTE [ENTER/SET P] CONNECTION (FOOTSWITCH OR OTHER SWITCH) .....................................	8
		2.3.5	CONNECTING PNEUMATIC POWER (DRIVE PORT) .................................................................................	9
		2.3.6	SETTING UP AND FILLING THE FLUID RESERVOIR ................................................................................	9
		2.3.6.1	INTERNAL RESERVOIR............................................................................................................................	9
		2.3.6.2	EXTERNAL RESERVOIR ........................................................................................................................	11
		2.3.7	RESERVOIR RETURN SETTINGS .............................................................................................................	12
		2.3.8	INSTALLING PUMP DRIVE OUT GAS EXHAUST FILTER........................................................................	13
		2.3.9	CONNECTING TO OTHER DEVICES .........................................................................................................	14
		2.3.9.1	INSTALLING A LINE FILTER TO PROTECT THE PPCH .......................................................................	14
		2.3.9.2	CONNECTING TO AN RPM4 TO BE USED AS AN EXTERNAL REFERENCE DEVICE ......................	14
		2.3.9.3	CONNECTING TO A PG7302 PISTON GAUGE .....................................................................................	16
		2.3.9.4	CONNECTING TO A DEVICE UNDER TEST (TEST PORT) ..................................................................	17
		2.3.10	CHECK/SET SECURITY LEVEL.................................................................................................................	17
		2.3.11	TURN OFF ABSOLUTE MEASUREMENT MODE......................................................................................	18
	2.4	POWER-UP AND VERIFICATION.........................................................................................................		18
		2.4.1	SWITCH POWER ON ..................................................................................................................................	18
		2.4.2	APPLY PNEUMATIC POWER (DRIVE AIR) ...............................................................................................	18
		2.4.3	CHECK PRESSURE MEASUREMENT OPERATION.................................................................................	18
		2.4.3.1	CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT.............................................................	18
		2.4.3.2	CHECKING GAUGE MODE PRESSURE MEASUREMENT...................................................................	19
		2.4.4	PRIME AND PURGE TEST SYSTEM..........................................................................................................	19
		2.4.5	LEAK CHECK ..............................................................................................................................................	19
		2.4.6	CHECK PRESSURE CONTROL OPERATION ...........................................................................................	19
	2.5	STORAGE AND SHIPPING ...................................................................................................................		20
		2.5.1	SHORT TERM STORAGE ...........................................................................................................................	20
		2.5.2	LONG TERM STORAGE .............................................................................................................................	20

Page I

PPCH™ OPERATION AND MAINTENANCE MANUAL

	2.5.3	PREPARATION FOR SHIPPING.................................................................................................................		20
3. OPERATION ... . ... . ... . . .. . . .. . . ..			. . ... . ... . ... . . .. . . .. . . .. . . ... . ... . ... . . .. . . ..	21
3.1	USER INTERFACE ................................................................................................................................			21
	3.1.1	MAIN RUN SCREEN....................................................................................................................................		21
	3.1.2	FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL.........................................................................		23
	3.1.3	DIRECT PRESSURE CONTROL KEYS......................................................................................................		24
	3.1.4	REMOTE [ENT/SET P] (FOOT)SWITCH.....................................................................................................		25
	3.1.5	SOUNDS ......................................................................................................................................................		25
3.2	GENERAL OPERATING PRINCIPLES .................................................................................................			25
	3.2.1	PRESSURE CONTROL PRINCIPLES ........................................................................................................		25
	3.2.2	AUTOMATED PRESSURE CONTROL .......................................................................................................		28
	3.2.2.1		IDLE, NO AUTOMATED CONTROL (MEASURE MODE) .......................................................................	28
	3.2.2.2			29
	3.2.2.3			30
	3.2.2.4			31
	3.2.2.5			32
	3.2.3	PRESSURE READY/NOT READY ..............................................................................................................		34
	3.2.4	GAUGE MEASUREMENT MODE, DYNAMIC COMPENSATION FOR ATMOSPHERIC PRESSURE......		34
	3.2.5	MULTIPLE INTERNAL AND EXTERNAL Q-RPTS .....................................................................................		35
	3.2.6	MULTIPE RANGES (Q-RPTS, AUTORANGE AND INFINITE RANGING) .................................................		36
	3.2.7	FLUID RESERVOIR LOW LEVEL WARNING ............................................................................................		37
	3.2.8	OPERATION WITH A PG7000 PISTON GAUGE ........................................................................................		38
	3.2.9	DIRECT FUNCTION KEYS SUMMARY ......................................................................................................		38
3.3	DIRECT FUNCTION KEYS....................................................................................................................			39
	3.3.1	[RANGE] ......................................................................................................................................................		39
	3.3.2	[UNIT]...........................................................................................................................................................		40
	3.3.3	[MODE] ........................................................................................................................................................		41
	3.3.4	[AUTORANGE] ............................................................................................................................................		42
	3.3.5	[RPT]............................................................................................................................................................		44
	3.3.6	[AUTOTEST]................................................................................................................................................		46
	3.3.6.1			47
	3.3.6.2			49
	3.3.7	[HEAD] .........................................................................................................................................................		52
	3.3.8	[PRIME]........................................................................................................................................................		54
	3.3.8.1			55
	3.3.8.2			56
	3.3.9	[LEAK CK] ...................................................................................................................................................		56
	3.3.10	[ENT/SET P] (SET PRESSURE AUTOMATICALLY)..................................................................................		58
	3.3.10.1		DYNAMIC CONTROL MODE, [ENT/SET P] ............................................................................................	58
	3.3.10.2		STATIC CONTROL MODE, [ENT/SET P] ................................................................................................	59
	3.3.10.3		MONOTONIC CONTROL MODE, [ENT/SET P] ......................................................................................	61
	3.3.10.4		RAMP CONTROL MODE, [ENT/SET P] ..................................................................................................	62
	3.3.10.5		INTERRUPTING AUTOMATED PRESSURE CONTROL ........................................................................	63
	3.3.10.6		AUTOMATED PRESSURE COMMANDS FOR ZERO PRESSURE ....................................................	63
3.4	[SETUP]			64
	3.4.1	<1RANGE> ..................................................................................................................................................		64
	3.4.1.1	........................................................................................................	SAVING AN AUTORANGE RANGE	64
	3.4.1.2	........................................................................................................	DELETING AUTORANGE RANGES	65
	3.4.2	<2RES> .............................................................................................................................(RESOLUTION)		65
	3.4.3	<3JOG>........................................................................................................................................................		66
	3.4.4	<4UL> ................................................................................................................................(UPPER LIMIT)		67
	3.4.4.1	...............................................................................................................		68
	3.4.5	<5ATEST>....................................................................................................................................................		68
	3.4.6	<6CONTROL>..............................................................................................................................................		69
	3.4.6.1	................................................................................	<1LIMITS> (CUSTOM CONTROL PARAMETERS)	70
	3.4.6.2	................................................................................................................................................		72
	3.4.6.3	............................................................................	TURNING - OFF CUSTOM CONTROL PARAMETERS	73
	3.4.7	<7DRV> ....................................................................................................................................(DRIVERS)		73
3.5	[SPECIAL] .............................................................................................................................................			74
	3.5.1	<1AUTOZ> ...................................................................................................................................................		74
	3.5.1.1	............................................................................................................................................		77
	3.5.1.2	.............................................................................................................................................		78
	3.5.2	<2REMOTE>................................................................................................................................................		79
	3.5.2.1	...................................................................................................................................		80
	3.5.2.2	............................................................................................................................................		80
	3.5.2.3	............................................................................................................................................		80
	3.5.2.4	............................................................................................................................		81
	3.5.3	<3HEAD> .....................................................................................................................................................		81
	3.5.4	<4RESET> ...................................................................................................................................................		82

© 2009 DH Instruments, a Fluke Company			Page II

		TABLE OF CONTENTS

3.5.4.1	<1SETS>..................................................................................................................................................	82
3.5.4.2	<2UNITS> ................................................................................................................................................	83
3.5.4.3	<3ATEST>................................................................................................................................................	83
3.5.4.4	<4CAL> ....................................................................................................................................................	83
3.5.4.5	<5ALL>.....................................................................................................................................................	84
3.5.5	<5PREF>......................................................................................................................................................	84
3.5.5.1	<1SCRSVR> ............................................................................................................................................	85
3.5.5.2	<2SOUND> ..............................................................................................................................................	85
3.5.5.3	<3TIME>...................................................................................................................................................	86
3.5.5.4	<4ID>........................................................................................................................................................	86
3.5.5.5	<5LEVEL> (SECURITY)...........................................................................................................................	87
3.5.6	<6PUNIT>.....................................................................................................................................................	89
3.5.7	<7INTERNAL> .............................................................................................................................................	91
3.5.7.1	<1CONFIG> .............................................................................................................................................	91
3.5.7.2	<2BARO> .................................................................................................................................................	91
3.5.7.3	<3PUMP>.................................................................................................................................................	92
3.5.8	<8CAL> ........................................................................................................................................................	94
3.5.9	<9LOG>........................................................................................................................................................	94

4. REMOTE OPERATION .......................................................			97
4.1	OVERVIEW ............................................................................................................................................		97
4.2	INTERFACING.......................................................................................................................................		97
	4.2.1	RS232 INTERFACE .....................................................................................................................................	97
	4.2.1.1	COM1 .......................................................................................................................................................	97
	4.2.1.2	IEEE-488 ..................................................................................................................................................	98
	4.2.1.3	COM2 .......................................................................................................................................................	98
4.3	PROGRAMMING FORMATS.................................................................................................................		98
	4.3.1 CLASSIC PROGRAM MESSAGE FORMAT ...............................................................................................		99
	4.3.2 ENHANCED PROGRAM MESSAGE FORMAT ..........................................................................................		99
	4.3.2.1	USING COMMAND TYPE COMMANDS .................................................................................................	99
	4.3.2.2 USING QUERY TYPE COMMANDS .................................................................................................		100
4.4	COMMANDS........................................................................................................................................		101
	4.4.1	PROGRAMMING MESSAGES ..................................................................................................................	101
	4.4.2	ERROR MESSAGES .................................................................................................................................	102
	4.4.3 PROGRAM MESSAGE DESCRIPTION OVERVIEW ................................................................................		103
	4.4.4	PROGRAM MESSAGE DESCRIPTIONS ..................................................................................................	104
4.5	STATUS REPORTING SYSTEM .........................................................................................................		128
	4.5.1	ERROR QUEUE.........................................................................................................................................	128
	4.5.2	STATUS BYTE REGISTER .......................................................................................................................	128
	4.5.3	STANDARD EVENT REGISTER ...............................................................................................................	130
	4.5.4	READY STATUS REGISTER ....................................................................................................................	130
4.6	IEEE STD. 488.2 COMMON AND STATUS PROGRAM MESSAGES................................................		131
	4.6.1	PROGRAM MESSAGE DESCRIPTIONS ..................................................................................................	131

5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION ....................			135
5.1	OVERVIEW ..........................................................................................................................................		135
5.2	PREVENTIVE MAINTENANCE ...........................................................................................................		135
5.3	CALIBRATION OF QUARTZ REFERENCE PRESSURE TRANSDUCERS (Q-RPTS) ......................		137
	5.3.1	PRINCIPLE ................................................................................................................................................	137
	5.3.1.1	PA AND PM COEFFICIENTS ................................................................................................................	137
	5.3.1.2	AS RECEIVED AND AS LEFT DATA ....................................................................................................	138
	5.3.2	EQUIPMENT REQUIRED ..........................................................................................................................	139
	5.3.3 SET UP AND PREPARATION...................................................................................................................		139
	5.3.4 RECOMMENDED CALIBRATION POINT SEQUENCE............................................................................		139
	5.3.5 TURNING OFF ABSOLUTE MEASUREMENT MODE FOR A Q-RPT .....................................................		140
	5.3.6 Q-RPT CALIBRATION USING CALTOOL FOR RPTS SOFTWARE........................................................		141
	5.3.7 EDITING AND VIEWING Q-RPT CALIBRATION INFORMATION............................................................		141
	5.3.8 Q-RPT CALIBRATION/ADJUSTMENT WITHOUT CALTOOL FOR RPTS SOFTWARE.........................		143
5.4	ADJUSTMENT OF ON-BOARD BAROMETER...................................................................................		144
5.5	ADJUSTMENT OF UTILITY SENSOR ................................................................................................		144
5.6	FILLING AND DRAINING THE FLUID RESERVOIR ..........................................................................		145
	5.6.1	INTERNAL RESERVOIR ...........................................................................................................................	145
	5.6.1.1	FILLING THE INTERNAL RESERVOIR.................................................................................................	145
	5.6.1.2	DRAINING THE INTERNAL RESERVOIR.............................................................................................	146
	5.6.2	EXTERNAL RESERVOIR ..........................................................................................................................	146

Page III

PPCH™ OPERATION AND MAINTENANCE MANUAL

	5.6.2.1	FILLING THE EXTERNAL RESERVOIR................................................................................................	146
	5.6.2.2	DRAINING THE EXTERNAL RESERVOIR............................................................................................	147
	5.6.3	PURGING CONTAMINATED FLUID FROM THE PPCH...........................................................................	148
5.7	VOLUME CONFIGURATION...............................................................................................................		148
5.8 VALVE OPENING POINT CONFIGURATION.....................................................................................			150
5.9	ACCESSING PPCH MECHANICAL MODULE....................................................................................		151
5.10	HYDROPNEUMATIC PUMP................................................................................................................		152
	5.10.1	PRIMING THE PUMP.................................................................................................................................	152
	5.10.1.1	PRIMING THE PUMP CHECK VALVE ..................................................................................................	153
	5.10.2	PUMP REPLACEMENT.............................................................................................................................	154
	5.10.3 PUMP SPOOL VALVE INSPECTION OR REPAIR...................................................................................		156
	5.10.4 PUMP INLET FILTER (LIQUID) REPLACEMENT ....................................................................................		158
5.11	LEAK CHECKING................................................................................................................................		159
	5.11.1 PRESSURE DECAY LEAK TESTING METHOD ......................................................................................		159
	5.11.2 LOCALIZING A LEAK WITHIN THE PPCH...............................................................................................		160
	5.11.2.1	HIGH PRESSURE VENT VALVE LEAK ................................................................................................	161
	5.11.2.2	LOW PRESSURE ISOLATION VALVE LEAK .......................................................................................	163
	5.11.2.3	LOW PRESSURE VENT VALVE LEAK .................................................................................................	163
5.12 VALVE REPLACEMENT OR REPAIR.................................................................................................			165
	5.12.1	SHUTOFF VALVE REPLACEMENT .........................................................................................................	165
	5.12.2	CONTROL VALVE SERVICE ....................................................................................................................	166
5.13 RELOADING EMBEDDED SOFTWARE INTO FLASH MEMORY......................................................			166
5.14 SUBASSEMBLY DESCRIPTION AND LOCATION ............................................................................			167
	5.14.1	ELECTRONIC MODULE............................................................................................................................	167
	5.14.1.1	POWER ENTRY AND FUSE..................................................................................................................	167
	5.14.1.2	POWER SUPPLIES ...............................................................................................................................	167
	5.14.1.3	DRIVER BOARD ....................................................................................................................................	168
	5.14.1.4	MINI MICRO BOARD .............................................................................................................................	168
	5.14.1.5	ON-BOARD BAROMETER ....................................................................................................................	168
	5.14.2	MECHANICAL MODULE ...........................................................................................................................	169
	5.14.2.1	PUMP DRIVE AIR PRESSURE TRANSDUCER ...................................................................................	169
	5.14.2.2	HI Q-RPT OR UTILITY SENSOR...........................................................................................................	169
	5.14.2.3	TEST VENT VALVE ...............................................................................................................................	170
	5.14.2.4	LO Q-RPT SHUTOFF VALVE ................................................................................................................	170
	5.14.2.5	LO Q-RPT...............................................................................................................................................	170
	5.14.2.6	LO Q-RPT VENT VALVE .......................................................................................................................	170
	5.14.2.7	PUMP ACCUMULATOR ........................................................................................................................	170
	5.14.2.8	FRONT PANEL ......................................................................................................................................	170
	5.14.2.9	ELECTRICAL CABLE TRACK ...............................................................................................................	170
	5.14.2.10	HYDROPNEUMATIC PUMP ..................................................................................................................	170
	5.14.2.11	INLET CONTROL VALVE ......................................................................................................................	170
	5.14.2.12	OUTLET CONTROL VALVE ..................................................................................................................	171
	5.14.2.13	FLUID RESERVOIR...............................................................................................................................	171
	5.14.2.14	RESERVOIR OVERFLOW/EXTERNAL RESERVOIR RETURN TUBE ................................................	171
	5.14.2.15	THERMAL PRESSURE CONTROL UNIT (TPCU) ................................................................................	171
	5.14.2.16	DRIVE PRESSURE REGULATOR ........................................................................................................	171
6. TROUBLESHOO TING . . . ..... . . . ..... . . . . ..... . . . ..... . . . ..... . . . . ..... . . . ..			173
7. APPENDIX ... . ... . ... . . .. . . .. . . .. . . ... . ... . ... . . .. . . .. . . .. . . ... . ... . ... . . .. . . .. .			177
7.1	DRIVERS .............................................................................................................................................		177
7.2	UNIT CONVERSION............................................................................................................................		178
	7.2.1	PRESSURE................................................................................................................................................	178
7.3	REMOTE [ENT] ...................................................................................................................................		178
8. WARRANTY ... . ... . ... . . .. . . .. . . .. . . ... . ... . ... . . .. . . .. . . .. . . ... . ... . ... . . .. . . .			179
8.1	OVERVIEW ..........................................................................................................................................		179
9. GLOSSA R Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			181

Page IV

	TABLES & FIGURES
TABLES
Table 1.	Reference pressure transducer (Q-RPT) designations and ranges..............................................	3
Table 2.	PPCH packing list ..........................................................................................................................	5
Table 3.	Drive air requirements....................................................................................................................	9
Table 4.	Reservoir return settings for internal or external reservoir ..........................................................	13
Table 5. MAIN RUN screen display fields..................................................................................................		22
Table 6. Position designators of Q-RPTs in a PPCH system ....................................................................		36
Table 7.	Settings and to what they are specific (range, measurement mode, Q-RPT, system) ...............	37
Table 8. Summary of PPCH function key operation ..................................................................................		38
Table 9. Settings made by AutoRange ......................................................................................................		43
Table 10.	Default pressure control parameters .........................................................................................	70
Table 11. AutoZ ON and OFF....................................................................................................................		76
Table 12. Reset – Sets...............................................................................................................................		83
Table 13. Reset – Cal ................................................................................................................................		84
Table 14.	Reset – All..................................................................................................................................	84
Table 15.	Security levels............................................................................................................................	88
Table 16.	UNIT function - available units of measure................................................................................	90
Table 17. COM1 pin designations and connections ..................................................................................		97
Table 18. COM2 DB-9F pin designations ..................................................................................................		98
Table 19. Program message list ..............................................................................................................		101
Table 20.	Error numbers (#) and descriptions .........................................................................................	102
Table 21.	8 Bit status byte register ..........................................................................................................	128
Table 22.	8 bit standard event register ....................................................................................................	130
Table 23.	8 bit ready status register.........................................................................................................	130
Table 24. Program message list ..............................................................................................................		131
Table 25. PPCH maintenance parts ........................................................................................................		136
Table 26.	Calibration point sequence, standard class, Q-RPTs..............................................................	140
Table 27.	Troubleshooting guide .............................................................................................................	173
Table 28.	External drivers current output.................................................................................................	177
Table 29.	External drivers pin outs ..........................................................................................................	177
Table 30.	Pressure unit of measure conversion coefficients ...................................................................	178
Table 31.	DHI Authorized Service Providers ...........................................................................................	179

Page V

PPCH™ OPERATION AND MAINTENANCE MANUAL

FIGURES
Figure 1.	Front panel....................................................................................................................................	7
Figure 2.	Rear panel ....................................................................................................................................	8
Figure 3.	Internal reservoir setup...............................................................................................................	11
Figure 4.	External reservoir setup..............................................................................................................	12
Figure 5.	Installing the exhaust filter/muffler ..............................................................................................	13
Figure 6. Connecting PPCH to an RPM4 or PG7302 using the standard
	PPCH interconnection accessories.........................................................................................	16
Figure 7.	Keypad layout .............................................................................................................................	23
Figure 8.	Direct pressure control keys .......................................................................................................	24
Figure 9.	Pressure control system schematic............................................................................................	27
Figure 10.	Dynamic pressure control operation.........................................................................................	29
Figure 11.	Ready/Not Ready in dynamic pressure control mode..............................................................	30
Figure 12.	Static pressure control operation..............................................................................................	30
Figure 13.	Ready/Not Ready in static control mode ..................................................................................	31
Figure 14.	Monotonic pressure control operation ......................................................................................	32
Figure 15.	Ready/Not Ready in monotonic pressure control mode...........................................................	32
Figure 16.	Ramp pressure control operation .............................................................................................	33
Figure 17.	Ready/Not Ready in ramp pressure control mode ...................................................................	33
Figure 18.	Status register schematic .......................................................................................................	129
Figure 19.	Internal reservoir schematic ...................................................................................................	146
Figure 20.	External reservoir schematic ..................................................................................................	147
Figure 21.	Electronic module, internal view .............................................................................................	167
Figure 22.	Mechanical module, internal view...........................................................................................	169
Figure 23.	Drivers connector schematic ..................................................................................................	177
Figure 24. Remote [ENT/SET P] connector schematic ...........................................................................		178

Page VI

ABOUT THIS MANUAL

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

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

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

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

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

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

Page VII

PPCH™ OPERATION AND MAINTENANCE MANUAL

NOTES

Page VIII

1. INTRODUCTION

1.INTRODUCTION

1.1PRODUCT OVERVIEW

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

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

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

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

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

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PPCH™ OPERATION AND MAINTENANCE MANUAL

1.2	SPECIFICATIONS
	1.2.1	GENERAL SPECIFICATIONS
		Power Requirements	85 to 264 VAC, 50/60 Hz, 75 W max consumption
	Operating Temperature Range		15 to 35 °C
	Storage Temperature Range		- 20 to 70 °C
		Vibration	Meets MIL-T-28800D
		Weight	50 kg (110 lb) approx
		Dimensions	Without optional enclosure: 26 cm H x 44 cm W x 55.5 cm D (10.2 in. x 17.3
			in. x 21.9 in.) Front panel is 19” wide X 6U high with mounting holes for
			standard
			19 in. rack mount systems
			With optional enclosure: 30 cm H x 52 cm W x 55.5 cm D
			(11.8 in. x 20.5 in. x 21.9 in.)
		Ventilation	To prevent product overheating, provide proper ventilation. Allow 10 cm
			(4 in.) clearance from rear panel cooling fan.
		Communication Ports	RS232 (COM1), RS232 (COM2), IEEE-488.2
		Fuses	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)
		Pressure Ranges	Four controller models from 70 MPa (10 000 psi max to 200 MPa (30 000 psi)
			max.
			Low uncertainty measurement provided by selection of Quartz Reference
			Pressure transducer(s) (Q-RPTs)
		Operating Medium	Di-2-Ethyl Hexyl Sebacate (other fluids optional)
	Internal Reservoir Capacity		300 cc
		Pressure Connections	DRIVE: 1/8 in. NPT F
			TEST: DH500 F
			NOTE: DH500 is a gland and collar type
			fitting for ¼ in. (6.35 mm) coned and left
			hand threaded tube. DH500 is equivalent to
			AE F250C, HIP HF4, etc.
			EXTERNAL: 1/8 in. NPT F
			OVERFLOW: 1/8 in. NPT F
			FILL/DRAIN: 1/4 in. swage M
			ATM: 10-32 UNF
		Pressure Limits	Maximum Working
			Test Pressure: Controller or Hi Q-RPT maximum

Maximum Test Pressure

without Damage: 115 % controller or Hi Q-RPT maximum Required Drive Air Pressure

Supply: H-70M: 500 kPa (75 psi) min, 850 kPa (120 psi) max; 330 l/m (10 cfm)

H-100M: 700 kPa (100 psi) min, 850 kPa (120 psi) max; 330 l/m (10 cfm)

H-140M: 500 kPa (75 psi) min, 850 kPa (120 psi) max; 450 l/m (15 cfm)

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

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1. INTRODUCTION

1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS

1.2.2.1QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT)

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

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

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

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

RPT		SI VERSION		US VERSION
RPT		MAXIMUM PRESSURE		MAXIMUM PRESSURE
DESIGNATION		MAXIMUM PRESSURE		MAXIMUM PRESSURE
DESIGNATION		Absolute and Gauge [MPa]		Absolute and Gauge [psi]
		Absolute and Gauge [MPa]		Absolute and Gauge [psi]

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

A70M		70		10 000
A40M	40		6 000

A20M		20		3 000

Warm Up Time

Resolution

Compensated Temperature Range

Acceleration Affect

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

To 1 ppm, user adjustable 5 to 35 °C

± 0.008 % /g maximum, worst axis

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

	<A200M	A200M
Precision1	± 0.012 % of reading5	± 0.015 % of reading5
Predicted Stability2	± 0.005 % of reading5	± 0.005 % of reading5
Measurement Uncertainty3	± 0.013 % of reading5	± 0.018 % of reading5
Delivered Pressure Uncertainty4	± 0.015 % of reading5	± 0.020 % of reading5

1.Combined linearity, hysteresis, repeatability.

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

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

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

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

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PPCH™ OPERATION AND MAINTENANCE MANUAL

1.2.2.2UTILITY SENSOR

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

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

Warm Up Time

Range

Resolution

Precision

None required

PPCH-70M: 70 MPa (10 000 psi) absolute and gauge PPCH-100M: 100 MPa (15 000 psi) absolute and gauge PPCH-140M: 140 MPa (15 000 psi) absolute and gauge PPCH-200M: 200 MPa (30 000 psi) absolute and gauge

0.001 % of span

0.1 % of span

1.2.2.3ON-BOARD BAROMETER

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

	Warm Up Time	None required
	Range 70 to 110 kPa (10 to 16 psi)
	Resolution 0.001 % of span
	Precision	0.1 % of span
	Predicted Stability	0.05 kPa/yr (0.008 psi/yr)
	Predicted Stability
1.2.3	PRESSURE CONTROL SPECIFICATIONS

		ALL MODELS
Control Precision (Standard Dynamic Mode)		to ± 0.003 % of Q-RPT span

	Default Dynamic Control Hold Limit	± 0.01 % of AutoRanged range
Lowest Controllable Pressure (absolute,		1 MPa (150 psi)
	gauge modes)	1 MPa (150 psi)
	gauge modes)

Typical Control Ready Time (Dynamic Mode)		60 to 120 seconds.
	Slew Rate (0 to FS)	60 seconds

	TEST Volume	0 to 100 cc, 50 cc optimum (operates in larger
	TEST Volume	volumes but pressure stabilizing time increases)
		volumes but pressure stabilizing time increases)

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2. INSTALLATION

2.INSTALLATION

2.1UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

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

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

2.1.2 INSPECTING CONTENTS

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

Table 2. PPCH packing list

	DESCRIPTION	PART #
1 ea.	PPCH Pressure Controller/Calibrator	FAM0010
1 ea.	PPCH Enclosure (optional)	06-01
ACCESSORIES:		402038 (402038-CE)
1 ea.	Operation and Maintenance Manual	550132
1 ea.	Calibration Report	550100
1 ea.	Test Report	550200
1 ea.	Power Cord (7.5 ft.)	100770 (100770-CE)
1 ea.	Reservoir fill tube assembly	402039
1 ea.	Reservoir fill tube bracket	123832
2 ea.	Bolts, SHC, M3 x 8	101010-Z
1 ea.	Funnel	123959
1 ea.	Filter/muffler, pump drive exhaust, 1/4. in. NPT M	103897
1 ea.	Gland, DH200	100272
1 ea.	Plug, DH200	100279
1 qt.	Sebacate (synthetic oil). If PPCH is delivered filled with a fluid other than	400503
	Sebacate, this item is not included.	or none
1 ea.	Drivers Connector	401382
1 ea.	General Accessories Disk (white CD)	102987
INTERCONNECTIONS KIT:		401536
2 ea.	Nipple, 2.75 in., DH500	100207
1 ea.	Nipple, 6 in., DH500	100208
2 ea.	Nipple, 12 in., DH500	100209
1 ea.	Union, DH500	100295
1 ea.	Elbow, DH500	100168
1 ea.	Tee, DH500	100291
2 ea.	Gland, DH500	100271
3 ea.	Plug, DH500	100285
5 ea.	Collar, DH500	101201
1 ea.	Nipple, 5 in. x 1/8 in., DH500 tips	123019
2 ea.	Adaptor, DH500 F x 1/8 in. NPT M	102819
1 ea.	Adaptor, DH500 F x 1/4 in. NPT F	102820

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PPCH™ OPERATION AND MAINTENANCE MANUAL

2.2SITE REQUIREMENTS

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

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

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

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

Also consider:

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

•Location and connections to an external reservoir, if used (see Section 2.3.6.2).

•Hydraulic and RS-232 connections to an external RPM4 should be considered if RPM4 is to be used as an external reference pressure measurement device (see Section 2.3.9.1).

•Location and connections to the device or system into which pressure is to be controlled (see Section 2.3.9.4).

Support facilities required include:

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

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

ALWAYS use external tubing and fittings rated for pressures equal to or greater than the maximum pressure PPCH will generate.

2.2.1 INSTALLATION IN A 19 IN. RACK MOUNT

PPCH is dimensioned to be ready for direct mounting in a standard 19 in. rack mount system.

If PPCH was delivered in the optional enclosure, it must be removed from the enclosure prior to rack mounting.

The front panel is 6U (10.5 in.) high.

Install PPCH into the rack mount system using heavy duty front panel bolts provided by the rack vendor. Due to PPCH’s weight, it is imperative that a rail system also be used to support it along the sides and/or rear. These are also supplied by the rack mount system vendor.

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

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2. INSTALLATION

2.3INITIAL SETUP

2.3.1 PREPARING FOR OPERATION

To prepare PPCH for check out and operation:

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

Remove the protective plastic sheet from the front panel display. Familiarize yourself briefly with the front and rear panel (see Section 2.3.2). Then proceed with Sections 2.3.3 to 2.3.11.

2.3.2 FRONT AND REAR PANELS

2.3.2.1FRONT PANEL

1.	Ready/Not Ready Indicator	4.	Cursor control keys
2.	Display	5.	Multi-function keypad
3.	Remote activity indicator	6.	Direct pressure control keys

Figure 1. Front panel

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PPCH™ OPERATION AND MAINTENANCE MANUAL

2.3.2.2REAR PANEL

1.	Electrical power connector (IEC-320-	11.	Internal reservoir level sight tube
	C13) and fuse	12.	Reservoir FILL/DRAIN port
2.	Cooling fan	13.	PUMP DRIVE OUT gas exhaust port
3.	Remote [ENTER] connector	14.	Reservoir FILL/DRAIN valve
4.	DRIVERS connector	15.	EXTERNAL reservoir return port
5.	RS-232 port, COM2	16.	Reservoir OVERFLOW port
6.	RS-232 port, COM1	17.	RESERVOIR RETURN valve
7.	Product label	18.	DRIVE IN air supply port
8.	IEEE-488 connector	19.	Mechanical module pull out handles
9.	ATM (barometer) port	20.	TEST port
10.	Internal reservoir fill funnel

Figure 2. Rear panel

2.3.3 POWER CONNECTION

Check that the PPCH power switch is OFF.

Connect the supplied power cable to the rear panel power input module.

Connect the other end of the power cable to an electrical supply of 85 to 264 VAC, 50/60 Hz.

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

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

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2. INSTALLATION

2.3.5 CONNECTING PNEUMATIC POWER (DRIVE PORT)

Using a pressure connecting hose or tube of appropriate pressure rating, connect drive air supply to the DRIVE port on the rear panel of PPCH. It is important to proper PPCH pressure control that the supply connection not excessively restrict flow. The tube should have an ID of at least 3 mm (1/8 in.) and not be more than 2 m (6 ft) long. Generally, a 3 mm ID tube has OD of at least 6.35 mm (1/4 in.). The DRIVE port connection is 1/8 in. NPT female.

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

Table 3. Drive air requirements

			MINIMUM
	MINIMUM DRIVE AIR	MAXIMUM DRIVE AIR	UNINTERRUPTED
MODEL	PRESSURE	PRESSURE	FLOW
PPCH-70M	500 kPa (75 psi)		330 l/m (10 cfm)

PPCH-100M	700 kPa (100 psi)	850 kPa (120 psi)
PPCH-100M	700 kPa (100 psi)

PPCH-140M	500 kPa (75 psi)		450 l/m (15 cfm)
PPCH-140M	500 kPa (75 psi)

PPCH-200M	700 kPa (100 psi)
PPCH-200M	700 kPa (100 psi)

2.3.6 SETTING UP AND FILLING THE FLUID RESERVOIR

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

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

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

Take care not to let the PPCH reservoir become empty. Operating PPCH with an empty reservoir will cause the hydropneumatic pump to draw air and lose its prime. A pump that has lost its prime must be reprimed using a special procedure (see Section 5.10.1). PPCH has a low fluid level warning displayed on the front panel that can be also checked by remote command (see Section 3.5.7.3).

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

2.3.6.1INTERNAL RESERVOIR

The PPCH is shipped with its internal reservoir filled with PPCH’s working fluid.

To operate without an external reservoir, the internal reservoir attachments must be installed on the PPCH rear panel. These are included with the PPCH accessories (see Table 2).

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PPCH™ OPERATION AND MAINTENANCE MANUAL

The internal reservoir attachments include:

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

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

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

-Funnel p/n 123959

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

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

Install the reservoir fill tube bracket(1) to the PPCH rear panel using 2 ea. M3 x 8 bolts(3).

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

There is a red plug with a center pull tab in the end of the PFA tube. This should be left in place when the funnel is not being used to prevent contamination and/or evaporation of the fluid. The funnel(2) can be stored in the holder just behind the tube.

Open the FILL/DRAIN valve(5). Fluid may enter the fill drain tube(4).

Check that the EXTERNAL port(6) is plugged. It is plugged when delivered. If it is not, use a 1/8 in. NPT M plug with Teflon® tape on the threads to plug it. Not plugging the EXTERNAL port when using the internal reservoir only will cause the fluid exhausted from the PPCH to leak out rather than returning to the reservoir.

Check that the OVERFLOW port(7) is open to atmosphere and unobstructed. This assures the reservoir is open to atmosphere so proper system venting and zeroing can occur.

Be sure the RESERVOIR RETURN valve(8) is on the INTERNAL position.

Check the level of the fluid in the fill/drain tube. If the level is below the MAX FILL position, top off the tank. See Section 5.6.1 for information on filling and draining the PPCH internal reservoir.

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

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2. INSTALLATION

1.	Reservoir fill tube bracket	5.	Reservoir FILL/DRAIN valve
2.	Reservoir fill funnel	6.	EXTERNAL Reservoir return port
3.	M3 x 8 bolt	7.	Reservoir OVERFLOW port
4.	Reservoir fill tube assembly	8.	RESERVOIR RETURN valve

Figure 3. Internal reservoir setup

2.3.6.2EXTERNAL RESERVOIR

The PPCH is shipped with its internal reservoir filled with PPCH’s working fluid.

An external reservoir, if desired, is connected in series to supply the internal reservoir so that the internal reservoir’s features are still available.

When using an external reservoir the internal reservoir attachments are NOT installed. If they have been installed, remove them prior to setting up the external reservoir (see Section 2.3.6.1). Be sure to put the FILL/DRAIN valve in the CLOSED position before removing the fill/drain tube assembly.

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

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

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

With the reservoir FILL/DRAIN valve in the CLOSED position, connect a tube coming from the bottom of the external reservoir to the FILL/DRAIN port(1). The FILL/DRAIN port is1/4 in. M swage.

Connect an external reservoir return tube from the EXTERNAL port(3) to the inside of the reservoir. Remove and retain the 1/8 in. NPT plug installed in EXTERNAL port as shipped. The reservoir return tube returns fluid exhausted by PPCH to the external reservoir. The top of the tube should extend vertically to a level slightly higher than the top surface of the fluid in the reservoir. The top of the tube defines the fluid head applied to the PPCH Q-RPT when the PPCH is vented (see Section 5.6.2, Figure 20).

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PPCH™ OPERATION AND MAINTENANCE MANUAL

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

Purge air from the internal reservoir and overflow circuit:

a.Prepare an 1/8 in. NPT plug (one was delivered installed in the EXTERNAL port) by wrapping its threads with Teflon tape.

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

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

c.When air free fluid begins to flow from the OVERFLOW port, plug the port with the 1/8 in. NPT plug.

Be sure the RESERVOIR RETURN valve(5) is in the EXTERNAL position.

Be sure the external reservoir is open to atmosphere so proper system venting and zeroing can occur.

Fill the reservoir return tube connected between the reservoir and the EXTERNAL port with fluid. See Section 5.6.2 for additional information in filling and draining an external reservoir.

1.	Reservoir FILL/DRAIN port	4.	EXTERNAL Reservoir return port
2.	PUMP DRIVE OUT gas exhaust port	5.	Reservoir OVERFLOW port
3.	Reservoir FILL/DRAIN valve	6.	RESERVOIR RETURN valve

Figure 4. External reservoir setup

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

2.3.7 RESERVOIR RETURN SETTINGS

The PPCH rear panel has a section labeled connections in this panel vary depending on alone or an external reservoir is being used.

RESERVOIR RETURN. The settings and whether the internal reservoir is being used

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

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2. INSTALLATION

Table 4. Reservoir return settings for internal or external reservoir

	RESERVOIR
	RETURN VALVE	OVERFLOW
RESERVOIR	POSITION	PORT	EXTERNAL PORT
Internal only	INTERNAL	Open to	Plugged
		atmosphere

External	EXTERNAL	Plugged	Connected to external
			reservoir return tube

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

Incorrect settings or port conditions in the RESERVOIR RETURN panel may lead to fluid leaks and faulty measurements.

2.3.8INSTALLING PUMP DRIVE OUT GAS EXHAUST FILTER/MUFFLER

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

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

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

Figure 5. Installing the exhaust filter/muffler

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PPCH™ OPERATION AND MAINTENANCE MANUAL

2.3.9 CONNECTING TO OTHER DEVICES

ALWAYS use external tubing and fittings rated for pressure equal to or greater than the maximum pressure PPCH will be used to generate.

The PPCH TEST port is a DH500 female fitting.

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

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

2.3.9.1INSTALLING A LINE FILTER TO PROTECT THE PPCH

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

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

ALWAYS use external tubing and fittings rated for pressure equal to or greater than the maximum pressure PPCH will be used to generate.

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

The PPCH then manages communications and other RPM4 functions to integrate the RPM4 measurement capabilities into the PPCH system. The user is responsible for setting up hardware and following procedures to isolate lower pressure Q-RPTs from possible overpressure if pressures higher than the Q-RPT maximum are generated.. PPCH and RPM4 do not have hardware provisions for isolating external Q-RPTs from the TEST circuit.

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

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2. INSTALLATION

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

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

Using tubing of appropriate pressure rating and a tee fitting, connect the RPM4 Q-RPT TEST(+) port to the PPCH TEST port (see Figure 6 for instructions on making this connection using the standard interconnection accessories supplied with the PPCH). The third leg of the tee is for the connection to the device or system under test.

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

Using a standard pin-to-pin DB-9M to DB-9F RS232 cable, connect COM2 of the PPCH to COM1 of the RPM4 (see Section 4.2.1.3).

Turn ON the RPM4 and the PPCH.

Press [RPT] on the PPCH key pad. This causes PPCH to execute the Q-RPT search function (see Section 3.3.5). Following the search, Q-RPTs with whom communication is established are shown on the PPCH display, identified by their position (see Table 6).

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

Baud rate: between 1200 and 19200 Parity: Even

Data bits: 7 Stop bits: 1

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

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

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

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PPCH™ OPERATION AND MAINTENANCE MANUAL

1.PPCH

2.2.75 in. (70 mm) DH 500 nipple

3.DH500 tee

4.12 in. (305 mm) DH500 nipple

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

6.6 in. (152 mm) DH500 nipple

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

8.5 in. (127 mm) DH500 x 1/8 in. tube weld nipple (slightly flexible)

9a. RPM4 or RPM3

9b. PG7000

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

2.3.9.3CONNECTING TO A PG7302 PISTON GAUGE

ALWAYS use external tubing and fittings rated for pressure equal to or greater than the maximum pressure PPCH will be used to generate.

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

The PG7302 puts the PPCH into remote mode and manages its operation.

To connect a PPCH to a PG7302 to be used as an automated pressure generation and control component in the PG7302 system, proceed as follows:

Using tubing of appropriate pressure rating and a tee fitting, connect the PG7302 TEST port to the PPCH TEST port (see Figure 6 for instructions on making this connection using the standard interconnections accessories supplied with the PPCH). The third leg of the tee is for the connection to the device or system under test.

Using a standard pin-to-pin DB-9M to DB-9F RS232 cable, connect COM1 of the PPCH to COM3 of the PG7302.

See the PG7000 Operation and Maintenance Manual for information on operating the PG7302 with an automated pressure controlling device.

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

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

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2.3.9.4CONNECTING TO A DEVICE UNDER TEST (TEST PORT)

ALWAYS use external tubing and fittings rated for pressure equal to or greater than the maximum pressure PPCH will be used to generate.

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

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

Minimizing the length of the test connection tubing will enhance control performance and reduce pressure setting time. For normal operation, the optimum total volume of the device or system under test including connecting tubing is 50 cc (3 in3) and should be less than 100 cc (6 in3).

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

2.3.10 CHECK/SET SECURITY LEVEL

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

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

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PPCH™ OPERATION AND MAINTENANCE MANUAL

2.3.11 TURN OFF ABSOLUTE MEASUREMENT MODE

PPCH Q-RPTs can operate in both absolute and gauge measurement modes (see Section 3.3.3). If the PPCH will only be used in gauge mode, absolute measurement mode may be turned off for its Q-RPT(s) so it is no longer accessible. This can avoid confusion and/or accidental use of the wrong measurement mode. See Section 5.3.5 for complete information on turning off absolute measurement mode.

2.4POWER-UP AND VERIFICATION

2.4.1 SWITCH POWER ON

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

PPCH 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 100 kPa (15 psi) away from standard atmospheric pressure.

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

2.4.2 APPLY PNEUMATIC POWER (DRIVE AIR)

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

2.4.3 CHECK PRESSURE MEASUREMENT OPERATION

2.4.3.1CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT

Check that the PPCH operates properly in absolute mode.

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

Use the [RANGE] function key to change ranges if necessary and select the Q-RPT’s DF range (see Section 3.3.1). Press the [MODE] function key and select <absolute> (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 Q- RPTs and or the utility sensor in the PPCH system. Check that the values of atmospheric pressure measured by the different devices agree with each other within PPCH or RPM4 measurement tolerances as applicable (see Section 1.2.2.1, 1.2.2.2). Remember to consider that head pressures can be significant with liquids (see Section 3.3.7). If the Q-RPTs do not agree within tolerances, the PPCH or RPM4 Q-RPT may need calibration or repair.

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2. INSTALLATION

2.4.3.2CHECKING GAUGE MODE PRESSURE MEASUREMENT

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

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

It is normal for PPCH to indicate a value other than zero for up to thirty seconds when first entering gauge mode. After ten to thirty seconds, the VENT LED should flash and zero should be indicated. If this does not occur, check that the AUTOZERO function is ON (see Section 3.5.1). If AUTOZERO is ON and the displayed pressure will not zero when vented in gauge or bi-directional gauge measurement mode, PPCH may need repair.

If a non-zero head correction value is active, PPCH will not indicate zero when vented in gauge mode. Use [HEAD] to set the head height to zero (see Section 3.3.7).

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

2.4.4 PRIME AND PURGE TEST SYSTEM

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

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

2.4.5 LEAK CHECK

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

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

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

2.4.6 CHECK PRESSURE CONTROL OPERATION

Select a pressure range using [RANGE] (see Section 3.3.1).

Press [SETUP], <6control>, <2mode>, <1dynamic>, <1standard>) (see Section 3.4.6). If PCH was not already set to dynamic control mode, wait 5 minutes for the thermal pressure controller to stabilize.

Press [ENT]. Key in a target pressure within the active range and press [ENT] again (see Section 3.3.10).

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PPCH™ OPERATION AND MAINTENANCE MANUAL

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

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

2.5STORAGE AND SHIPPING

2.5.1 SHORT TERM STORAGE

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

Vent the PPCH test pressure.

If the PPCH TEST port is open to a point lower than the reservoir, when PPCH is vented ([VENT] LED ON), the liquid contained in the reservoir may leak out through the opening.

Turn the power OFF using the rear panel power switch.

Shut OFF or disconnect the drive air pressure supply.

2.5.2 LONG TERM STORAGE

The following procedure is recommended for long term storage of PPCH: Complete the short term storage procedure (see Section 2.5.1).

Plug the TEST port with a DH500 steel plug.

Set the RESERVOIR FILL/DRAIN valve to CLOSED and the RESERVOIR RETURN valve to INTERNAL.

2.5.3 PREPARATION FOR SHIPPING

The following procedure is recommended to prepare PPCH for shipment: Complete the long term storage procedure (see Section 2.5.2).

Remove the internal reservoir accessories if they have been installed (see Section 2.3.6.1).

Pack PPCH carefully being sure to use packing materials appropriate for shipment of a delicate instrument weighing approximately 50 kg (110 lb.). If available, use the original packing materials.

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Fluke PPCH User Manual

TABLE OF CONTENTS

TABLES

FIGURES

ABOUT THIS MANUAL

1. INTRODUCTION

1.1PRODUCT OVERVIEW

SPECIFICATIONS

GENERAL SPECIFICATIONS

1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS

1.2.2.2UTILITY SENSOR

PRESSURE CONTROL SPECIFICATIONS

2. INSTALLATION

2.1UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

2.1.2 INSPECTING CONTENTS

2.2SITE REQUIREMENTS

2.2.1 INSTALLATION IN A 19 IN. RACK MOUNT

2.3INITIAL SETUP

2.3.1 PREPARING FOR OPERATION

2.3.2 FRONT AND REAR PANELS

2.3.2.1FRONT PANEL

2.3.2.2REAR PANEL

2.3.3 POWER CONNECTION

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

2.3.5 CONNECTING PNEUMATIC POWER (DRIVE PORT)

2.3.6 SETTING UP AND FILLING THE FLUID RESERVOIR

2.3.6.1INTERNAL RESERVOIR

2.3.6.2EXTERNAL RESERVOIR

2.3.7 RESERVOIR RETURN SETTINGS

2.3.8INSTALLING PUMP DRIVE OUT GAS EXHAUST FILTER/MUFFLER

2.3.9 CONNECTING TO OTHER DEVICES

2.3.9.1INSTALLING A LINE FILTER TO PROTECT THE PPCH

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

2.3.9.3CONNECTING TO A PG7302 PISTON GAUGE

2.3.9.4CONNECTING TO A DEVICE UNDER TEST (TEST PORT)

2.3.10 CHECK/SET SECURITY LEVEL

2.3.11 TURN OFF ABSOLUTE MEASUREMENT MODE

2.4.1 SWITCH POWER ON

2.4.2 APPLY PNEUMATIC POWER (DRIVE AIR)

2.4.3 CHECK PRESSURE MEASUREMENT OPERATION

2.4.3.1CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT

2.4.3.2CHECKING GAUGE MODE PRESSURE MEASUREMENT

2.4.4 PRIME AND PURGE TEST SYSTEM

2.4.5 LEAK CHECK

2.4.6 CHECK PRESSURE CONTROL OPERATION

2.5STORAGE AND SHIPPING

2.5.1 SHORT TERM STORAGE

2.5.2 LONG TERM STORAGE

2.5.3 PREPARATION FOR SHIPPING