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Fluke Calibration PG9000 Operation and Maintenance Manual

PG9000™
Piston Gauge
Operation and Maintenance Manual
© 1998-2010 Fluke Calibration
Warning
To prevent possible electrical shock, fire, or personal injury:
Read all safety Information before you use the product. Use the product only as specified, or the protection supplied by the
product can be compromised.
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.
Use only the main power cord and connector approved for the voltage and
plug configuration in your country and rated for the product.
Make sure the ground conductor in the main power cord is connected to a
protective earth ground. Disruption of the protective earth could put voltage on the chassis that could cause death.
Replace the main power cord if the insulation is damaged or if the
insulation shows signs of wear.
Do not put the product where access to the main power cord is blocked. Do not use and disable the product if it is damaged. Use this product indoors only.
© 1998 - 2010 Fluke Calibration All rights reserved. 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 p ermission of Fl uke Cali bratio n, 4 765 East Beautiful Lane, Phoenix, Arizona 85044-5318 USA.
Fluke Calibration makes sincere efforts to ensure the accuracy and quality of its published materials; however, no warranty, expressed or implied, is provided. Fluke Calibration 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 Fluke Calibration 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.
Fluke Calibration, DH, DHI, PG9000, PG9607, CalTool and COMPASS are trademarks, registered and otherwise, of Fluke Corporation.
Swagelok is a registered trademark of the Swagelok Company. Krytox is a registered trademark of the Dupont de Nemours Company.
Products described in this manual are manufactured unde r international patents and one or more of the following U.S. patents: 6,701,791, 5,142,483, 5,257,640, 5,331,838, 5,445,035. Other U.S. and international patents pending.
Document No. 3782240 100820 Printed in the USA

Table of Contents

Table of Contents ................................................................. III
Tables .................................................................................. V
Figures ................................................................................ VI
About This Manual ............................................................... VII
1. Introduction ..................................................................... 1
1.1 Product Overview ................................................................................................................................... 1
1.2 Specifications ......................................................................................................................................... 2
1.2.1 General Specifications ............................................................................................................................. 2
1.2.1.1 AMH Automated Mass Handler (Optional) .............................................................................................. 3
1.2.1.2 Embedded Features ............................................................................................................................... 3
1.2.1.3 Ambient and Instrument Condition Measurements ................................................................................. 4
1.2.2 Piston-Cylinder Assembly (PC-9607-5) ................................................................................................... 5
1.2.3 Mass Sets ................................................................................................................................................. 5
1.2.4 Pressure Measurements (PG9607) .......................................................................................................... 5
1.3 Front and Rear Panels ........................................................................................................................... 6
1.3.1 Terminal Front and Rear Panels .............................................................................................................. 6
1.3.1.1 PG Terminal Front Panel ........................................................................................................................ 6
1.3.1.2 PG Terminal Rear Panel ........................................................................................................................ 6
1.3.2 Remote Electronics Module Rear Panel ................................................................................................. 7
1.3.3 Base Rear Panel ....................................................................................................................................... 8
2. Installation ....................................................................... 9
2.1 Unpacking And Inspection .................................................................................................................... 9
2.1.1 Removing From Packaging ..................................................................................................................... 9
2.1.1.1 Platform ................................................................................................................................................. 9
2.1.1.2 Manual Mass Set ................................................................................................................................... 9
2.1.1.3 Piston-Cylinder Assembly (PG9607) .................................................................................................... 10
2.1.1.4 Vacuum Reference Hardware (Optional) .............................................................................................. 10
2.1.1.5 AMH Automated Mass Handler (Optional) ............................................................................................ 10
2.1.1.6 AMH Mass Set (Optional) ..................................................................................................................... 10
2.1.2 Inspecting Contents ............................................................................................................................... 11
2.1.2.1 Platform ............................................................................................................................................... 11
2.1.2.2 Mass Set .............................................................................................................................................. 12
2.1.2.3 Piston-cylinder Assembly ..................................................................................................................... 13
2.1.2.4 Vacuum Reference (Optional) .............................................................................................................. 14
2.1.2.5 Automated Mass Handler (Optional) ..................................................................................................... 15
2.2 Site Requirements ................................................................................................................................ 15
2.3 Setup ..................................................................................................................................................... 17
2.3.1 Preparing for Operation ......................................................................................................................... 17
2.3.1.1 Setting Up the Platform ........................................................................................................................ 17
2.3.1.2 System Pressure Interconnections ....................................................................................................... 17
2.3.1.3 Setting Up A Manual Mass Set ............................................................................................................. 18
2.3.1.4 Setting Up An AMH Automated Mass Handler (Optional) ..................................................................... 19
2.3.1.5 Setting Up an AMH Mass Set ............................................................................................................... 20
2.3.1.6 Setting Up Vacuum Reference Hardware (Optional) ............................................................................. 22
2.3.2 Installing and Removing a PG9607 Piston-Cylinder Assembly ........................................................... 23
2.4 Power Up And Verification .................................................................................................................. 26
2.4.1 Powe r Up ................................................................................................................................................ 26
2.4.2 Check That On-board Piston-Cylinder Module And Mass Set Information Are Correct .................... 26
2.4.3 Set Local Gravity Value ......................................................................................................................... 26
2.4.4 Setup Pressure Equation Variable Input Sources ................................................................................ 26
2.4.5 Check Proper Operation Of Ambient Condition Measurements ......................................................... 27
2.4.6 Apply Pressure To The Piston-Cylinder Module .................................................................................. 27
2.4.7 Check Proper Behavior Of Motorized Piston Rotation ........................................................................ 28
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TABLE OF CONTENTS
2.4.8 Check Proper Operation Of Piston Behavior Measurements .............................................................. 28
2.4.9 Verify Vacuum Reference ...................................................................................................................... 28
2.4.10 AMH Start Up/Verificati on ...................................................................................................................... 29
2.4.11 Check Automated Pressure Generation (If Present) ............................................................................ 30
2.4.12 Check/Set Security Level ....................................................................................................................... 30
2.4.13 Additional Precautions to Take Before Making Pressure Measurements .......................................... 31
2.5 Short Term Storage .............................................................................................................................. 31
3. General Operation ........................................................... 33
3.1 Fundamental Operating Principles ..................................................................................................... 33
3.2 Keypad Layout And Protocol .............................................................................................................. 34
3.3 Sounds .................................................................................................................................................. 35
3.4 Pressure Ready/Not Ready Indication ................................................................................................ 35
3.4.1 Piston Position Ready/Not Ready ......................................................................................................... 36
3.4.2 Piston Rotation Ready/Not Ready ......................................................................................................... 36
3.4.3 Vacuum Reference Ready/Not Ready ................................................................................................... 37
3.5 Piston Position ..................................................................................................................................... 37
3.6 Manual Mass Loading .......................................................................................................................... 38
3.7 AMH Mass Loading .............................................................................................................................. 40
3.7.1 Operating Principals .............................................................................................................................. 40
3.7.2 AMH Operation ....................................................................................................................................... 42
3.7.2.1 Installing an AMH Mass Handler on the PG9000 Platform .................................................................... 43
3.7.2.2 Removing a Mass Handler from the PG9000 Platform ......................................................................... 45
3.7.2.3 AMH Mass to Pressure or Pressure to Mass Operation ............................................................................ 45
3.7.2.4 Direct Control of AMH Functions .......................................................................................................... 46
3.7.2.5 Making and Breaking Reference Vacuum with AMH ............................................................................. 46
3.7.2.6 Accessing the PG9000 Piston-Cylinder Module with AMH .................................................................... 46
3.7.2.7 AMH Indicator LED .............................................................................................................................. 47
3.7.2.8 AMH Error Messages ........................................................................................................................... 47
3.8 Controlled Clearance Pressure (PG9607)........................................................................................... 49
3.9 Main Run Screen .................................................................................................................................. 50
3.10 General Function/Menu Flow Chart .................................................................................................... 51
3.11 Direct Function Keys............................................................................................................................ 51
3.11.1 Direct Function Keys Summary ............................................................................................................ 51
3.11.2 [P-C] ........................................................................................................................................................ 52
3.11.3 [UNIT] ...................................................................................................................................................... 53
3.11.3.1 Customizing Pressure Units Available Under the UNIT Function .......................................................... 54
3.11.4 [MODE] .................................................................................................................................................... 55
3.11.4.1 Differential Measurement Mode ............................................................................................................ 56
3.11.5 [SYSTEM] ................................................................................................................................................ 63
3.11.5.1 First System Run Screen...................................................................................................................... 64
3.11.5.2 Second System Run Screen ................................................................................................................ 64
3.11.5.3 Third System Run Screen .................................................................................................................... 65
3.11.6 [AMBIENT] .............................................................................................................................................. 66
3.11.7 [HEAD] .................................................................................................................................................... 67
3.11.8 [ROTATE] ................................................................................................................................................ 69
3.11.8.1 <2Pre-Decel> ....................................................................................................................................... 70
3.11.9 [GEN] (Optional) ..................................................................................................................................... 71
3.11.9.1 <2target>.............................................................................................................................................. 73
3.11.9.2 <3raise> ............................................................................................................................................... 73
3.11.9.3 <4UL> .................................................................................................................................................. 73
3.11.9.4 <5tol> ................................................................................................................................................... 73
3.11.9.5 <6refloat> ............................................................................................................................................. 74
3.11.10 [RES] ....................................................................................................................................................... 74
3.11.11 [ENTER/SET P] From Run Screen ......................................................................................................... 76
3.11.11.1 [ENTER/SET P] In Pressure To Mass Mode ........................................................................................ 77
3.11.11.2 [ENTER/SET P] In Mass To Pressure Mode ........................................................................................ 78
3.11.11.3 Commands for zero pressure, ending a test ......................................................................................... 79
3.11.12 [P OR M] ................................................................................................................................................... 79
3.11.13 [ ] and [ ], [←] .................................................................................................................................. 80
3.12 [SETUP] Menu ....................................................................................................................................... 81
3.12.1 <1select> ................................................................................................................................................ 82
3.12.2 <2view> ................................................................................................................................................... 83
3.12.3 <3edit> .................................................................................................................................................... 84
3.13 [SPECIAL] Menu ................................................................................................................................... 86
3.13.1 <1PC/MS> ............................................................................................................................................... 87
3.13.1.1 Create a Piston-Cylinder Module .......................................................................................................... 88
© 1998-2010 Fluke Calibration Page IV
TABLE OF CONTENTS
3.13.1.2 Edit a Piston-Cylinder Module .............................................................................................................. 90
3.13.1.3 View a Piston-Cylinder Module ............................................................................................................. 90
3.13.1.4 Delete a Piston-Cylinder Module .......................................................................................................... 91
3.13.1.5 Select The Active Piston-Cylinder Module ............................................................................................ 91
3.13.1.6 Add a Mass Set .................................................................................................................................... 92
3.13.1.7 Edit a Mass Set .................................................................................................................................... 96
3.13.1.8 View a Mass Set .................................................................................................................................. 96
3.13.1.9 Delete a Mass Set ................................................................................................................................ 96
3.13.1.10 Select Mass Set ................................................................................................................................... 96
3.13.1.11 Add a Mass Loading Bell ...................................................................................................................... 97
3.13.1.12 Edit a Mass Loading Bell ...................................................................................................................... 98
3.13.1.13 View a Mass Loading Bell .................................................................................................................... 98
3.13.1.14 Delete A Mass Loading Bell ................................................................................................................. 99
3.13.1.15 Select A Mass Loading Bell .................................................................................................................. 99
3.13.2 <2presU> ................................................................................................................................................ 99
3.13.3 <3head> .................................................................................................................................................. 99
3.13.3.1 <3head>, <1fluid> ...............................................................................................................................100
3.13.3.2 <3head>, <2unit> ................................................................................................................................101
3.13.3.3 <3head>, <3atm> ................................................................................................................................101
3.13.3.4 <3head>, <4piston> ............................................................................................................................101
3.13.4 <4prefs> .................................................................................................................................................102
3.13.4.1 <4prefs>, <1ScrSvr> ...........................................................................................................................102
3.13.4.2 <4prefs>, <2sound> ............................................................................................................................102
3.13.4.3 <4prefs>, <3time> ...............................................................................................................................103
3.13.4.4 <4prefs>, <4ID> ..................................................................................................................................103
3.13.4.5 <4prefs>, <5level> ..............................................................................................................................104
3.13.5 <5remote> ..............................................................................................................................................106
3.13.5.1 COM1, COM2, COM3 and COM4 (RS232) .........................................................................................107
3.13.5.2 IEEE-488.............................................................................................................................................107
3.13.5.3 RS232 Self Test ..................................................................................................................................108
3.13.5.4 External Barometer (RPM) Communications (COM2) ..........................................................................108
3.13.5.5 External Vacuum Gauge Communications (COM2) .............................................................................110
3.13.6 <6gl> ......................................................................................................................................................112
3.13.7 <7cal>.....................................................................................................................................................113
3.13.8 <8AMH> .................................................................................................................................................113
3.13.8.1 <2control>, <1up/down> ......................................................................................................................114
3.13.8.2 <2control>, <2discreet> .......................................................................................................................114
3.13.8.3 <2control>, <3loadall> .........................................................................................................................114
3.13.8.4 <2control>, <4unloadall> .....................................................................................................................115
3.13.9 <9reset> .................................................................................................................................................115
3.13.9.1 <9reset>, <1sets> ...............................................................................................................................115
3.13.9.2 <9reset>, <2units> ..............................................................................................................................116
3.13.9.3 <9reset>, <3com> ...............................................................................................................................116
3.13.9.4 <9reset>, <4cal> .................................................................................................................................116
3.13.9.5 <9reset>, <5setups> ...........................................................................................................................117
3.13.9.6 <9reset>, <6all> ..................................................................................................................................117
4. Remote Operation ......................................................... 119
4.1 Overview ............................................................................................................................................. 119
4.2 Interfacing ........................................................................................................................................... 119
4.2.1 RS232 interface .....................................................................................................................................119
4.2.1.1 COM1 .................................................................................................................................................119
4.2.1.2 COM2, COM3 and COM4 ...................................................................................................................120
4.2.2 IEEE-488 (GPIB) .....................................................................................................................................120
4.3 Commands .......................................................................................................................................... 121
4.3.1 Command Syntax ..................................................................................................................................121
4.3.2 Command Summary .............................................................................................................................121
4.3.3 Error Messages .....................................................................................................................................123
4.3.3.1 AMH Errors .........................................................................................................................................124
4.3.4 Command descriptions ........................................................................................................................124
4.3.4.1 IEEE Std. 488.2 Common And Status Commands ..............................................................................124
4.3.4.2 PG9000 Commands ............................................................................................................................126
4.4 Status System ..................................................................................................................................... 151
4.4.1 Status Reporting System ......................................................................................................................151
4.4.1.1 Status Byte Register............................................................................................................................151
4.4.1.2 Standard Event Register .....................................................................................................................153
Page III © 1998-2010 Fluke Calibration
TABLE OF CONTENTS
5. Maintenance, Adjustments And Calibration ..................... 155
5.1 Introduction ........................................................................................................................................ 155
5.2 Platform ............................................................................................................................................... 156
5.2.1 Calibration/Adjustment Of On-board Measurement Funct ions ..........................................................156
5.2.1.1 Principles ............................................................................................................................................156
5.2.1.2 Barometric Pressure Sensor ...............................................................................................................156
5.2.1.3 Ambient Temperature sensor ..............................................................................................................157
5.2.1.4 Relative Humidity Sensor ....................................................................................................................158
5.2.1.5 Piston-Cylinder Module Temperature Sensors ....................................................................................158
5.2.1.6 Reference Vacuum Sensor (Optional) .................................................................................................160
5.2.2 Piston Position Detection Adjustment .................................................................................................160
5.2.3 Drive Belt Replacement ........................................................................................................................161
5.3 Piston-Cylinder Disassembly, Cleaning And Maintenance ............................................................ 162
5.3.1 Disassembly Of The PG9607 Piston Retaining Assembly ..................................................................163
5.3.1.1 Disassembly Procedure ......................................................................................................................163
5.3.1.2 Reassembly Procedure .......................................................................................................................164
5.3.2 Cleaning (Other Than PG9607) .............................................................................................................165
5.3.3 Cleaning (PG9607) ................................................................................................................................166
5.3.4 Recalibration .........................................................................................................................................167
5.3.4.1 Updating Piston-Cylinder Module Files ................................................................................................167
5.4 Mass Sets ............................................................................................................................................ 167
5.4.1 Cleaning .................................................................................................................................................167
5.4.2 Recalibration .........................................................................................................................................167
5.5 Reloading Embedded Software Into PG9000 Flash Memory .......................................................... 167
5.6 Disassembly And Reassembly Of PG9000 ....................................................................................... 168
5.6.1 Platform .................................................................................................................................................168
5.6.2 Terminal .................................................................................................................................................168
5.6.3 AMH Automated Mass Handler Removal .............................................................................................168
6. Troubleshooting............................................................ 169
6.1 Overview ............................................................................................................................................. 169
7. Appendix ...................................................................... 173
7.1 Conversion Of Numerical Values ...................................................................................................... 173
7.1.1 Pressure ................................................................................................................................................173
7.2 Defined Pressure Calculations .......................................................................................................... 173
7.2.1 Calculations ...........................................................................................................................................175
7.2.2 Fluid Heads ............................................................................................................................................176
7.2.2.1 Fluid Head Components ......................................................................................................................176
7.2.2.2 Overall Fluid Head Correction .............................................................................................................177
7.3 Glossary .............................................................................................................................................. 178
7.4 Limited Warranty And Limitation Of Liability ................................................................................... 180
© 1998-2010 Fluke Calibration Page IV

Tables

Table 1. PG9607 Parts List ........................................................................................................................ 11
Table 2. Manual Mass Set Parts List (excluding 80 and 100 kg) ............................................................... 12
Table 3. Manual Mass Set Parts List (80 and 100 kg) ............................................................................... 12
Table 4. AMH-100 Mass Set Parts List ...................................................................................................... 12
Table 5. Mass Set Compositions ............................................................................................................... 13
Table 6. 50 mm Gas Piston-Cylinder Ass embly Parts List ........................................................................ 13
Table 7. PG9000 Vacuum Reference Hardware ....................................................................................... 14
Table 8. AHM-100-VAC Parts List ............................................................................................................. 15
Table 9. Drive Air Pressure Requirement by Mass Set ............................................................................. 16
Table 10. AMH Errors ................................................................................................................................ 48
Table 11. Summary of PG9000 Direct Function Key Operations .............................................................. 52
Table 12. Pressure Units of Measure Available ......................................................................................... 55
Table 13. Valve Settings for Setting Differential Mode Static Pressure ..................................................... 59
Table 14. Valve Settings to Apply PG9000 Pressure to the RPM for Differential Mode Offsetting ........... 60
Table 15. Valve Settings for Operating in Differential Mode ...................................................................... 62
Table 16. SETUP File Choices, Factory Preferred Choice and Normal Value .......................................... 82
Table 17. Security Levels - Functions NOT Executed Per Function/Level .............................................. 105
Table 18. COM1, COM2, COM3 and COM4 Available Settings.............................................................. 107
Table 19. COM1 DB-9F Pin Designation ................................................................................................. 120
Table 20. COM2, COM3 and COM4 DB-9M Pin Designation ................................................................. 120
Table 21. Command Summary ................................................................................................................ 121
Table 22. Error Messages ........................................................................................................................ 123
Table 23. Status Byte Register ................................................................................................................ 151
Table 24. Standard Event Register .......................................................................................................... 153
Table 25. PG9000 Troubleshooting Checklist ......................................................................................... 169
Table 26. Pressure Unit of Measure Conversions ................................................................................... 173
Table 27. PG9000 Defined Pressure Calculation Variables .................................................................... 174
Table 28. Fluke Calibration Authorized Service Providers ...................................................................... 181
Page V © 1998-2010 Fluke Calibration
PG9000™ OPERATION AND MAINTENANCE MANUAL

Figures

Figure 1. PG Terminal Front Panel .............................................................................................................. 6
Figure 2. PG Terminal Rear Panel ............................................................................................................... 7
Figure 3. PG9000 Remote Electronics Module Rear Panel ....................................................................... 7
Figure 4. PG9000 Base Rear Panel (PG9607 shown) ................................................................................ 8
Figure 5. AMH Mass Set ............................................................................................................................ 21
Figure 6. PG9607 Piston-Cylinder Installation ........................................................................................... 25
Figure 7. Piston Gauge Operating Principle .............................................................................................. 33
Figure 8. PG9000 Keypad Layout .............................................................................................................. 34
Figure 9. Piston Stroke and Zones ............................................................................................................ 38
Figure 10. AMH Schematic/Operati ng Pri nc ip le ........................................................................................ 42
Figure 11. AMH Installation on PG9000 Platf or m ...................................................................................... 43
Figure 12. AMH Indicator location .............................................................................................................. 47
Figure 13. Run Screen Flow Chart ............................................................................................................ 51
Figure 14. Differential Mode Controller Schematic .................................................................................... 58
Figure 15. PG9000 Platform Reference Level Location ............................................................................. 68
Figure 16. Status Byte Register ............................................................................................................... 151
Figure 17. Piston Retainer Assem bl y ....................................................................................................... 164
Figure 18. Gas Operated, Gas Lubricated Piston-Cylinder Module Lubrication Chart ............................. 165
© 1998-2010 Fluke Calibration Page VI

About This Manual

This manual provides the user with the information n ecessary to operate the PG9000 Piston Gauge. It also includes a great dea l of additional information provide d to help optimize PG9000 use and take f ull advantage of its many features and functions.
Before using the m anual, tak e a m om ent to become familiar with the T able of Co ntents s tructur e. All first time PG9000 users should read Sect ions 1 and 2. Section 3 provides a comprehensi ve description of general PG9000 operating principles. Section 4 covers remote communication with an external computer. Section 5 provides maintenance and calibration information. Section 6 is a quick troubleshooting guide. Use the information in Section 6 to troubleshoot unexpected PG9000 behavior based on the symptoms of that behavior.
Certain words and expressions have specific meaning as they pertain to PG9000s. The Glossary (see Section 7) is useful as a quick referenc e for the definition of specific words and ex pressions as the y are used in this manual.
Note
For those who “DON’T READ MANUALS”, go directly to section 2.3 to set up the PG9000. Then go to section 2.4. This will get you running quickly with minimal risk of causing damage to yourself or your PG9000. Then… when you have questions or start to wonder about all the great features you might be missing, get into the manual!
Manual Conventions
Caution
“Caution” is used in throughout the manual to identify conditions or actions that could cause harm to the PG9000 or to the devices that are connected to the PG9000.
Warning
“Warning” is used in throughout the manual to identify actions that could po se a hazard to the user of the PG9000.
Note
“Note” is used throughout the manual to identify operating and applications advice and additional explanations.
[ ] indicates direct function keys (e.g., [RANGE]).
< > indicates PG9607 screen displays (e.g., <1yes>)
Page VII © 1998-2010 Fluke Calibration
PG9000™ OPERATION AND MAINTENANCE MANUAL
Notes
© 1998-2010 Fluke Calibration Page VIII

1. Introduction

1.1 Product Overview

PG9000 Piston Gauges are reference level pressure standards that operate on the piston gauge principle. Pressure is defined by balancing it against the force exerted by a known mass accelerated by gravity on the effective area of a piston-cylinder.
A PG9000 piston gauge consists of the PG9000 Platform, a piston-cylinder module and a mass set. Optional hardware for vacuum reference operation is available. An optional automated m ass handling system is available as well. A PG9000 system typically also includes the m eans to generate and adjust pressures and to interconnect the system components and a device being calibrated or tested. The pressure generation component can be manual or autom ated. COMPASS also be included to assist in executing test sequences, acquiring test data and producing test reports.
The PG9000 Platform consists of the PG9000 Base, Term inal and Remote Elec tronics Module. Local user interface is through the keypad and display on the terminal. Remote communications and all on board (built in) sensors are located inside or are connected to the Remote Electronics Module.
PG9000 is a fam ily of piston gauges with common presentation and f eatures. The f irst production model of the PG9000 family is the PG9607.
®
for Pres sure software may
PG9607 operates up to a maximum pressure of 500 kPa and supports definition of pressure against
either atmosphere or vacuum reference using a gas operated, gas lubricated piston-cyli nder module (PC-9607-5).
PG9607 was design ed to exploit a unique 50 m m diameter piston-c ylinder. With this piston-cylinder, the piston is mounted in a fixed p osition in the m ounting post and the c ylinder f loats and is rotated. A controlled clearance pr essure can be introduced into the mounting post allowing the pis ton diameter and thus the gap between the piston and cylinder to be varied.
PG9607 is available o n a lim ited basis and, ge nerall y, is only of fered f or use in natio nal m easurement institutes or other laboratories performing fundamental research in pressure metrology.
PG9000 platform, piston-c ylinder module, mass set and optional automated mass handling s ystem are designed to max imize metr ological p erform ance and e ase of op eration. T he y include m any features that enhance the fundamental precision and stability of pressure measurements as well as simplifying use and reducing operator inf luence on the measurements. Ex tensive monitoring and controlling cap ability and advanced local and remote user interfaces are integrated into the PG9000 Platform.
Operator interaction with PG9000 and its extensive capab ilities and peripherals is accomplished through a single display and keypad on the PG Terminal or from a computer via a single standard RS232 or IEEE-488 interface.
Page 1 © 1998-2010 Fluke Calibration
PG9000™ OPERATION AND MAINTENANCE MANUAL
PEM Fuse: 1A, 250V, 5x20mm, Slow blow

1.2 Specifications

1.2.1 General Specifications

Power Requirements
Operating Temperature Range Operating Humidity Range
Weight
Instrument platform with no mass or piston-cylinder loaded.
PG9607 (without vacuum hardware)
Remote Electronics Module
PG Terminal
Optional Vacuum Reference Hardware
Dimensions
PG9607 Base (without vacuum hardware)
PG9607 Base (with optional vacuum bell
jar and vacuum gauge connected)
Remote Electronics Module
PG Terminal
Microprocessors
Instrument Platform
PG Terminal
Communication Ports
RS232
IEEE-488
Fuses
Overall Pressure Range
Operating Media Maximum Mass Load
50/60 Hz, 60 VA max. consumption. 100 to 240 VAC, operating altitude: <2000m 100 to 150 VAC, operating altitude: <5000m
15 to 35 °C 5 to 95% R.H., non-condensing
34 kg (74 lb)
1.9 kg (4 lb)
1.4 kg (3 lb) 16 kg (36 lb)
34.1 cm H x 54.3 cm W x 52.3 cm D (13.4 in x 21.4 in x 20.6 in) (Height: top of piston-cylinder assembly)
56 cm H x 54.3 cm W x 52.3 cm D (22 in x 21.4 in x 20.6 in) (Height: Top of bell jar)
10.2 cm H x 35.1 cm W x 19.6 cm D (4 in. 13.8 in. x 7.7 in.) 12 cm H x 15 cm W x 20 cm D (4.7 in. H x 5.9 in. W x 7.9 in. D)
Motorola 68302 Hitachi 64180
COM1: Host computer COM2: Residual vacuum sensor (external) COM3: Automated pressure generator/controller COM4: Unused/spare or pass through Host computer
Internal power supply Fuse: 3.15A, 250V Gauge: 10.5 kPa to 500 kPa (1.5 to 72.5 psi)
Absolute: 10.5 kPa to 500 kPa (1.5 to 72.5 psi) Differential: - 89.5 to 400 kPa (-13 to 58 psi) at
10.5 to 110 kPaa (1.5 to 16 psia) static pressure Gas: nitrogen, hel i um, dry air (dewpoint ≤ -40 °C)
100 kg1
1
MS-AMH-100 mass set contains approximately 104.5 kg of mass. Combined with the piston or cylinder and bell ass embly, total mass loads may be up to 106 kg resulting in pressures of up to 530 kPa. (76.9 psi)
Page 2 © 1998-2010 Fluke Calibration
1. INTRODUCTION
and are CE
Pressure Connections
Remote Electronics Module
CE Conformance
1.2.1.1 AMH Automated Mass Handler (Optional)
Power Requirements:
Operating Temperature:
Dimensions:
Power/Communications:
AMH Drive Air Supply:
AMH Vacuum Supply:
Pressure Connections:
CE conformance:
PG 9607 Base
AMH Drive
AMH Vent
Vacuum Bell Jar
Weight:
Available, must be specified
Pressure:
Vacuum:
Test port: : DH200 Controlled Clearance Pressure: DH200
Quick connector equivalent to Swagelok QM Series (QM2-B-200), Use with DESO (double end shut off) type stem
Quick connector equivalent to Swagelok QM Series (QM2-B-200), Use with SESO (single end shut off) type stem only.
Note
DH200 and DH500 are gland and collar t ype fittings for 1/4 in. (6.35 mm) coned and left hand threaded tubes. DH200 is equivalent to AE SF250C, HIP LF4, etc. DH500 is equivalent to AE F250C, HIP HF4, etc.
ATM port: 10-32 UNF 3x KF40, 1x KF50 (top)
All PG9000 models conform to CE requirements marked.
15 VDC @ 2 A, 30 W max. consumption
15 to 35 ºC 41 cm H x 41 cm W x 36 cm D (16.3 in. x 16.1 in. x 14.1 in.)
12 kg (25 lbs)
Custom 8 pin connector 550 kPa (80 psi), ± 10%, minimal flow At least 50 kPa (7.5 pi) under atmosphere, minimal flow
Quick connector DESO (double end shut off) type stem
Quick connector SESO (single end shut off) type stem
1.2.1.2 Embedded Features
• Local control with 2 x 20 vacuum fluorescent display and 4 x 4 function driven keypad.
• Real time (1 second upda te rate) display and measurem ent of ambient (pressure, temperature, humidity) and instrument (piston-cylinder temperature, piston posit ion, piston drop rate, pis ton rotation rate, pisto n rotation decay rate, reference vacuum) conditions.
• Real time (1 second update rate) mass-to-pressure and pressure-to- mass calculations taking into consideration all environmental and operational variables.
• Full gas and liquid f luid head corrections includ ing DUT head correctio n and piston position h ead co rr ection. Barom eter he ad c orrection included for atmosphere reference operation (gauge mode).
• Adjustable mass loading resolution (0.01 g to 0.1 kg).
• Audible prompts of instrument status (piston movement, Ready/Not
Ready indication) with override capability.
• Integrated automated mass handling option (AMH-100-VAC).
• Interfacing and automatic exploitation of external barometer via RS232.
• Interfacing and autom atic exploitation of an y external vacuum gauge via
RS232.
• Automated differential mode to define low differential pressures at various static pressures between vacuum and two atmospheres.
• Storage and one step activation of metrological data on up to 18 piston- cylinder modules, (3) mass sets and (3) mass loading bells.
Page 3 © 1998-2010 Fluke Calibration
PG9000™ OPERATION AND MAINTENANCE MANUAL
• Continuous pressure Ready/Not Ready indication based on measured conditions.
• Motorized, intelligent piston drive system based measur ed rotation rate with operator alert and manual override.
• Integrated autom ated pressure control with standard Fluke Calibration pressure controllers.
• Full RS232 and IEEE-488 c ommunications wit h multi-level com mands to set and read all instrument functions.
1.2.1.3 Ambient and Instrument Condition Measurements
Temperature
Range
Resolution
Measurement Uncertainty
Barometric Pressure with Internal Sensor
Range
Resolution
Measurement Uncertainty
Relative Humidity
Measurement Uncertainty
Piston Position
Measurement Uncertainty
Piston Rotation
(Rate and deceleration)
1
Range
Resolution
Range
Resolution
Range
Resolution
Ambient 0 to 40
0.1 ± 1
70 to 110 kPa 10 Pa ± 140 Pa Barometric pressure can also be read automatically with any
RS232 device such as a DH Intruments RPM.
5 to 95 % RH 1 % RH
± 10 % RH
± 4.5 mm
0.1 mm ± 0.2 mm
2 to 99 rpm 1 rpm
1
Piston Cylinder Module
o
C 0 to 40 oC
o
C 0.01 o C
o
C ± 0.1 o C
Vacuum (Optional)
Range
Resolution
Measurement Uncertainty
1
PG9000 uses a Fluke Hart Scientific 2626-S temperature and humidity probe specified and factory calibrated to deliver ±0.25 ˚ C uncertainty on temperature and ±3% on relative humidity. PG9000 performance requirements and factory calibration services require only the specifications listed above to meet stated product uncertainties.
© 1998-2010 Fluke Calibration Page 4
0 to 13 Pa
0.01 Pa ± 0.05 Pa + 0.5 % of reading
1. INTRODUCTION

1.2.2 Piston-Cylinder Assembly (PC-9607-5)

The piston is mounted in a fixed position on the mounting post. The cylinder floats and is rotated.
Piston Material:
Cylinder Material:
Nominal Diameter:
Nominal Area:
Mounting System:
Typical Drop Rate:
Tungsten carbide Tungsten carbide 50 mm 2 000 mm Free deformation with controlled clearance pres sure (CCP) available on
inside of piston. < 0.25 mm/min at 500 kPa (Full mass load)
2

1.2.3 Mass Sets

Masses > 50g
Material
Finish
Adjustment Tolerance
Uncertainty of Measured Values
Masses < 50g
304L non-magnetic stainless steel Electropolished ± 20 ppm of nominal value (manual mass sets, AMH
automated mass handler mass sets do not have fixed adjustment tolerances)
± 5 ppm or 1 mg, whichever is greater
± 1 mg

1.2.4 Pressure Measurements (PG9607)

Note
For uncertainty in piston-cylind er effective area and typical measurem ent uncertainty in pressure defined by the piston gauge, see the piston­cylinder calibration report and current revision of Fluke Calibration Technical Note 0180TN12.
The piston is mounted in a fixed position on the mounting post. The cylinder floats and is rotated.
All masses are delivered in molded, reusable, transit cases with custom inserts.
Sensitivity1:
1
Sensitivity: The smallest variation in input detectable in output.
2
Reproducibility: The root sum square of the stability of effective area and stability of the
Reproducibility
AMH-100 mass set for 1 year. Refer to Fluke Calibration Technical Note 0180TN12
0.005 Pa + 0.5 ppm
2
:
± 2 ppm + 0.05 Pa
.
Page 5 © 1998-2010 Fluke Calibration
PG9000™ OPERATION AND MAINTENANCE MANUAL

1.3 Front and Rear Panels

1.3.1 Terminal Front and Rear Panels

1.3.1.1 PG Terminal Front Panel
The front panel ass embly provides a 2 x 20 vacuum fluorescent display and a 4 x 4 membrane keypad for local user interface. The terminal front panel assembly is the same for all PG9000 models.
Fluorescent display Keypad
Figure 1. PG Terminal Front Panel
1.3.1.2 PG Terminal Rear Panel
The rear panel assembly provides the communications connection to the PG9000 Remote Elec tronics Module. The terminal r ear panel assembly is the same for all PG9000 models.
© 1998-2010 Fluke Calibration Page 6
1. INTRODUCTION
Power switch
Connector for 25 pin cable to PG
COM 2 (RS232) – External
Component
PG DRIVER – 15 pin Cable to
COM 4 (RS232) – Pass Through
COM 1 (RS232) – Remote Host
TERMINAL
  Fuse Power receptacle
Figure 2. PG Terminal Rear Panel
Remote Electronics Module
Cooling fan

1.3.2 Remote Electronics Module Rear Panel

The PG9000 Remote Electronics Modu le houses all working electr onics (processor, sensor and communications) for the PG9000 in addition to sensors for ambient conditions (temperature, pressure and humidity).
Barometer, External Vacuum Gauge and Pass through Communication
COM 3 (RS232) – Automated
Pressure Generation/Control
PG BaseATM Connection (Barometer) Mounting Post PRT Connector to
PG Remote Electronics Module
TH Probe Connector
Figure 3. PG9000 Remote Electronics Module Rear Panel
Communications
IEEE-488 – Remote Host
Communications
AMH Connection Connector for 25 pin Cable to PG
Page 7 © 1998-2010 Fluke Calibration
PG9000™ OPERATION AND MAINTENANCE MANUAL

1.3.3 Base Rear Panel

The PG9000 Platform rear panel provides the communications connection to the PG Remote Electronics Module, test and controlled clearance pressure connections as well as (optional) AMH Automated Mass Handler connections.
PG Driver – to PG Remote
Electronics Module
 AMH Connection  AMH Vent Port  Controlled Clearance Pressure
Port – PG9607 Only
 TEST Pressure Port  AMH Drive Pressure Port  PRT Connector – to Remote
Electronics Module
Figure 4. PG9000 Base Rear Panel (PG9607 show n)
© 1998-2010 Fluke Calibration Page 8

2. Installation

2.1 Unpacking And Inspection

2.1.1 Removing From Packaging

A typical PG9000 system includes the PG9000 Platform ( see Section 2.1.1.1), a mass set (see Section 2.1.1.2), a piston-cylinder assembly (see Section 2.1.1.3) and oth er access ories suc h as vacuum reference hardware (see Section 2.1.1.4), an AMH automated mass handler (see Section 2.1.1.5) and/or pressure generation and control components (see the accessory Operation and Maintenance Manual or Instruction Sheet).
2.1.1.1 Platform
The PG9000 Platform c onsists of the PG9000 Base, R emote Electronic s Module, Terminal and inter connect a ccessories . The Base is shipped in a custom woode n crate. The Platf orm compone nts are shipp ed in a reusab le, molded shi pping and storage case. The cables an d accessories ar e shipped i n a corrugated c ontainer with other PG9000 accessories including operating instructions and calibration reports.
Open the PG9000 Base shipping crate (71 cm x 71 cm x 56 cm). Carefully lift the PG9000 B ase from its position in the lower pack ing insert.
Note the orientation s o that the sam e orientation will b e used when PG90 00 is repacked.
Warning
The PG9000 Base has a mass of 34 kg (74 lb). It is recommended to remove it from the packaging with two people on opposite sides of the shipping container. Removing or lifting with only one person may cause injury.
Open the PG9000 molded, reusable recalibration transit case and the
accessories corrugated shipping container.
Remove the PG Terminal, Remote Electronics Module and Temperature-
Humidity Probe from the recalibration transit case and the Platform accessories from the shipping container. Inspect and inventory the accessories (see Section 2.1.2.1).
Reinstall the pack ing insert s into the s hippin g and s torage cas es and store in
a safe place.
2.1.1.2 Manual Mass Set
Caution
The stability over time of PG9000 pressure measurements is a function of the stability of the masses loaded on the cylinder. Precautions should be taken in handling the masses to minimize influences that may change their mass. This includes always wearing protective gloves when handling the masses to avoid contaminating them with body oils and perspiration. Protective gloves are provided in the accesso ry kits of PG9000 Platforms.
Page 9 © 1998-2010 Fluke Calibration
PG9000™ OPERATION AND MAINTENANCE MANUAL
The mass set accessories are shipped in a separate corrugated container. Open the corrugated container and inspect and inventory the accessories.
The PG9000 masses are shipped in reusable, molded shipping and storage cases. The PG9000 masses should be removed from their shipping cases and inventoried w hen setting up the PG9000 system (see Section 2.1.1.2 for mass set content detail).
The PG9000 manual mass bell ships in a separate corrugated container.
The mass loading bell is a metrological element that is part of the mass set. Like all of the masses, it is preferable not to handle it with bare hands. Protective gloves are provided in the accessory kit of each PG9000 Platform.
2.1.1.3 Piston-Cylinder Assembly (PG9607)
The PG9607 piston-cylinder assembly is shipped in a molded plastic case with custom pol yethylene ins erts that accom modates 2 Acetal bullet c ases. The p iston and the cylind er are separat e; each is packed i n its own bullet cas e. Do not handle either of t hese elements with bare hands. Use the gloves that are in the PG9000 accessory kit or use the lint free wipes. See Section 2.1.2.3 for details.
Never handle the piston or cylinder with bare hands. Oil and acids from bare skin can damage the crit ical surfa ces (polished appearance).
Caution
Caution
2.1.1.4 Vacuum Reference Hardware (Optional)
The optional PG9000 Vacuum Reference Hardware includes the vacuum Bell Jar, reference vacuum sensor with power supply and interconnect cables and fittings necessary for vacuum operation.
The PG9000 Bell Jar is pack ed in a large wooden crate (66 cm x 66cm x 71 cm ). The vacuum refer ence sensor, power supply and assoc iated fittings and cables are packed in a reusable molded Vacuum Measurement Kit transit case. Remaining fittings and adaptors are shipped in the PG9000 accessories corrugated container (see Section 2.1.2.4).
2.1.1.5 AMH Automated Mass Handler (Optional)
AMH-100-VAC is delivered in a corrugated container with foam cut outs to hold items in place. Accessories are bagged together and packaged in a separate corrugated container with other PG9000 system accessories.
Remove all parts from the shipping boxes. See Section 2.1.2.5 for more detail.
2.1.1.6 AMH Mass Set (Optional)
PG9000 AMH masses are shipped in reusable, molded shipping and storage cases. One of the cas es contains the binar y masses, binar y mass car rier, mass bell and lifting shaft/trim mass tra y. The other cases c ontain the m ain masses of 10 kg (see Section 0 for mass set content detail). Each mass is packed in a sealed plastic bag and then plac ed in a protective s hipping insert. The PG9000 AMH masses should be re moved from their shipping c as es and in ve ntori ed w he n setting up the PG9000 system (see Section 2.1.1.2 for mass set content detail).
© 1998-2010 Fluke Calibration Page 10
2. INSTALLATION
Caution
The stability over time of PG9000 pressu re meas urement s is a funct ion of the stability of the masses loaded on the piston. Precautions should be taken in handling the masses to minimize influences that may change their mass. This includes always wearing protectiv e gloves when handling the masses to avoid contaminating them with body oils and perspiration. Protective gloves are provid ed in the accessory kits of PG9000 Platforms.

2.1.2 Inspecting Contents

Inspect all parts for damage. If damage is noted, report it to your Shipping & Receiving Department and the delivering carrier for appropriate action.
Inspect for any miss ing components or access ories referring to Tables 1-8. S ho uld any items be missing, contact Fluke Calibration or your local Fluke Calibration representative.
A parts list of item s supplied is prov ided in Sectio n 2.1.2.1 for PG9000 Platform, Section 2.1.2.2 for mass sets, Section 2.1.2.3 for Piston-Cylinder Assemblies, Section 2.1.2.4 for (optional) vacuum reference hardware and Section 2.1.2.5 for (optional) Automat ed Ma ss Handl er .
2.1.2.1 Platform
Each PG9000 Platform is delivered complete with access ories as listed by part number in Table 1.
Table 1. PG9607 Parts List
PG9607
PLATFORM
3821488 Base Terminal Remote Electronics Module Transit case for recalibration items Accessory Kit 3841024
ADPT, DH200 M X 1/8 in. swage 3069062 (2) NIP, SS, DH200, 2.75" 3068377 (2) ADPT, SS, DH200 F X 1/8 in. NPT F 3068547 ADPT, SS, DH200 M X 1/4 in. swage 3069081 Tee, SS, 1/4 in. swage 3138683 Union, SS, 1/4 in. swage x 1/8 in. swage 3135076 ADPT, SS, 1/4 in. swage x 1/8 in. NPT F 3141914 ADPT, SS, 1/8 in. NPT M x 1/8 in swage 3068564 ADPT, 10-32UNF x 1/8 in. Swage 3141516 1/8” tubing, PFA, 2 m 3232357 (2) 1/4 in. tubing, SS, 10 cm 3853024 1/4 in. tubing, SS, 20 cm 3853036 1/4 in. tubing, SS, 50 cm 3853049 1/8 in. tubing, SS, 30 cm 3852995 1/8 in. tubing, SS, 150 cm 3853008 (2) O-ring, Viton, brown, 2-029 3144730 O-ring, Viton, brown, 2-019 3134945 (2) O-ring, Buna, 2-242 3135041 Allen wrench, 2.5 mm 3136044 Allen wrench, 3 mm 3135703 Allen wrench, 5 mm 3136098
3789373
3789710
3789425
3841097
Page 11 © 1998-2010 Fluke Calibration
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