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ADCS-601™ OPERATION AND MAINTENANCE MANUAL

© 2005 DH Instruments, Inc.

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two chambers closed, the net force resulting from the difference in pressure between the two
chambers is transmitted to the load cell through the coupling. The value of the pressure is
calculated from the effective area of the piston-cylinder and the net force value measured by
the load cell. The 10 kPa/kg piston-cylinder combined with 1.5 kg net measurement span of
the load cell give the FPG8601 a pressure range of 0 to 15 kPa (4.5 inHg).

The FPG8601 Platform is interfaced with the system controller (PC) running FPG Tools
software that calculates pressure and controls the FPG8601 functions.

The PPC3 pressure controller is used to automate pressure control to set the pressure
measured by the FPG8601.

MASS

COMPARATOR

P

lub

P

hi

P

ref

LUBRICATING

FLOW

REG

SUPPLY

Figure 19.

Force balanced piston gauge operating principle

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Summary of Contents for ADCS-601

Page 1: ... 2005 DH Instruments Inc ADCS 601 Air Data Calibration Standard Operation and Maintenance Manual ...

Page 2: ...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 Eng...

Page 3: ...GAS SUPPLY PANEL 15 2 2 PRESSURE STANDARDS 16 2 2 1 PG7601 PISTON GAUGE 16 2 2 1 1 PG7601 PLATFORM 17 2 2 1 2 PG7601 TERMINAL 17 2 2 1 3 PG7601 10 KPA KG PISTON CYLINDER MODULE 18 2 2 1 4 AMH 38 AUTOMATED MASS HANDLER 19 2 2 1 5 AMH 38 MASS SET 21 2 2 2 FPG8601 FORCE BALANCED PISTON GAUGE 21 2 2 2 1 FPG8601 PLATFORM 23 2 2 3 PPC3 PRESSURE CONTROLLERS 23 2 2 4 RPM4 A116K REFERENCE PRESSURE MONITOR ...

Page 4: ...UM GAUGE COMMUNICATION 50 3 4 2 3 EDIT AND SELECT PG7601 SETUP FILE 51 3 4 3 PG7601 51 3 4 3 1 POWER UP 51 3 4 3 2 INITIALIZATION 51 3 4 4 FPG8601 52 3 4 4 1 POWER UP 52 3 4 5 START UP SYSTEM CONTROLLER AND SOFTWARE 52 3 4 6 VERIFY SYSTEM OPERATION 53 3 5 ENTER VALUE OF LOCAL GRAVITY 54 3 6 SPECIFY TEST GAS SPECIES 55 3 7 ADDITIONAL PRECAUTIONS TO TAKE BEFORE MAKING PRESSURE MEASUREMENTS 55 3 8 SH...

Page 5: ...NCE AND ADJUSTMENTS 105 6 1 SUMMARY 105 6 2 FPG8601 CHECK BUBBLER AND ADD WATER IF NECESSARY 106 6 3 FPG8601 REMOVE CLEAN AND REINSTALL THE PISTON CYLINDER 107 6 3 1 OVERVIEW 107 6 3 2 REMOVING THE PISTON CYLINDER FROM THE MOUNTING POST 109 6 3 3 REMOVING THE PISTON FROM THE CYLINDER 111 6 3 4 CLEANING THE PISTON AND CYLINDER 112 6 3 5 PUTTING THE PISTON INTO THE CYLINDER 113 6 3 6 INSTALLING THE ...

Page 6: ... LOAD CELL LINEARITY 141 7 2 5 1 OVERVIEW 141 7 2 5 2 LINEARITY VERIFICATION PROCEDURE 142 7 2 5 3 EVALUATING LINEARITY VERIFICATION DATA 142 7 2 6 FPG8601 AND PG7601 ZERO REFERENCE VACUUM CDGS 143 7 2 7 PG7601 ADJUST ON BOARD P T H SENSORS 146 7 3 RECALIBRATION 147 7 3 1 OVERVIEW 147 7 3 2 PG7601 CALIBRATION OF PISTON CYLINDER MODULE 148 7 3 2 1 PREPARING FOR CALIBRATION 148 7 3 2 2 UPDATING PIST...

Page 7: ...11 Valve states 59 Table 12 User rights user access areas 65 Table 13 ADCS Tools Main Menu and sub menus summary 69 Table 14 ADCS Main Toolbar buttons 70 Table 15 ADCS Run Screen Control Panel features 75 Table 16 ADCS System Display symbols 77 Table 17 ADCS Run Screen Toolbar 78 Table 18 Mechanical maintenance procedures 105 Table 19 PG7601 mounting post wire colors description and location 117 T...

Page 8: ...auge operating principle 22 Figure 20 FPG8601 front and rear views 23 Figure 21 PPC3 front panel 24 Figure 22 PPC3 rear panel 25 Figure 23 RPM4 front panel 26 Figure 24 RPM4 rear panel 26 Figure 25 Turbo pump local interface panel local control not used in regular ADCS 601 operation 28 Figure 26 Typical layout of overall ADCS 601 system at site of use 37 Figure 27 Piston cylinder module installati...

Page 9: ...iew 125 Figure 54 10 kPa kg piston insertion tool 126 Figure 55 10 kPa kg gas piston cylinder module sleeve nut tool 126 Figure 56 10 kPa kg piston cylinder module lubrication chart 128 Figure 57 PG7601 piston stroke and zones 131 Figure 58 ADCS Tools FPG Run Screen 137 Figure 59 ADCS Tools FPG Validation Setup Form 140 Figure 60 ADCS Tools FPG Validation Results Form 140 Figure 61 ADCS Tools CDG ...

Page 10: ...ADCS 601 OPERATION AND MAINTENANCE MANUAL 2005 DH Instruments Inc Page VIII N NO OT TE ES S ...

Page 11: ...attempted without using Section 3 All first time ADCS 601 users should read Section 2 Section 8 is a quick troubleshooting guide Use the information in Section 8 to troubleshoot unexpected ADCS 601 behavior based on the symptoms of that behavior Certain words and expressions have specific meaning as they pertain to ADCS 601 and its instruments The Glossary see Section 9 2 is useful as a quick refe...

Page 12: ...ADCS 601 OPERATION AND MAINTENANCE MANUAL 2005 DH Instruments Inc Page X N NO OT TE ES S ...

Page 13: ... balanced piston gauge with automated pressure control 1 1 SPECIFICATIONS 1 1 1 ADCS SYSTEM GENERAL SPECIFICATIONS Power Requirements Instruments AC1 Reference vacuum pumps AC2 Utility pump AC3 100 to 240 VAC 50 60 Hz 240 W max consumption Fuse 250VT 10A 110 V version 100 120V 50 60 Hz 1100 W max consumption Fuse 250VT 10A 220 V version 200 240V 50 60 Hz 1100 W max consumption Fuse 250VT 10A 110 V...

Page 14: ...4 5 mm 0 1 mm 0 2 mm Piston Rotation Rate and deceleration Range Resolution 2 to 99 rpm 1 rpm Reference Vacuum with on board gauge Range Resolution Measurement Uncertainty with external capacitance diaphragm gauge Range Resolution Measurement Uncertainty 0 to 20 Pa 0 01 Pa 0 1 Pa or 10 of reading whichever is greater 0 to 13 3 Pa 100 mTorr 0 001 Pa 0 01 mTorr 0 05 Pa 0 38 mTorr 1 1 2 2 PISTON CYLI...

Page 15: ...r Range Resolution Accuracy 200 kPa 1 Pa 0 1 kPa 1 1 4 PRESSURE MEASUREMENT AND CONTROL SPECIFICATIONS 1 1 4 1 10 TO 380 KPA PG7601 AND PPC3 700K Sensitivity 1 Precision 2 Measurement uncertainty 3 Control set point increments Stability of set pressure Typical control set point time 0 02 Pa 0 5 ppm 0 01 Pa 2 ppm see the piston cylinder calibration report and current revision of DHI Technical Note ...

Page 16: ...ion Minimum display increment 2 Precision Combined linearity hysteresis repeatability 3 Measurement uncertainty Maximum deviation of the indicated pressure from the true value of applied pressure including all sources of uncertainty combined and expanded k 2 following the ISO Guide to the Expression of Uncertainty in Measurement Note The uncertainty assigned to the FPG8601 used in an ADCS 601 syst...

Page 17: ...to assist in performing a comparison of the FPG8601 and PG7601 pressure standards Physically the ADCS 601 system is divided into two major components see Figure 1 The Reference Bench see Section 2 1 1 is a laboratory table onto which are installed the PG7601 and FPG8601 pressure standards pneumatic control switching hardware and the reference vacuum pumping systems The Control Cabinet see Section ...

Page 18: ...s Inc Page 6 1 Control cabinet 2 Reference bench 3 Turbo pump controller and reference turbo pump behind controller 4 Reference roughing vacuum pump 5 Utility vacuum pump Note System controller PC display and keypad not shown Figure 1 ADCS 601 overall front view ...

Page 19: ...2 SYSTEM OVERVIEW Page 7 2005 DH Instruments Inc Figure 2 ADCS 601 system pneumatic schematic ...

Page 20: ...ADCS 601 OPERATION AND MAINTENANCE MANUAL 2005 DH Instruments Inc Page 8 Figure 3 ADCS 601 simplified operational schematic ...

Page 21: ...2 SYSTEM OVERVIEW Page 9 2005 DH Instruments Inc Figure 4 ADCS 601 system electrical schematic ...

Page 22: ...ADCS 601 OPERATION AND MAINTENANCE MANUAL 2005 DH Instruments Inc Page 10 Figure 5 ADCS 601 system communications schematic ...

Page 23: ...2 SYSTEM OVERVIEW Page 11 2005 DH Instruments Inc Figure 6 ADCS 601 software communications and control flow chart ...

Page 24: ...rchased separately 1 Pneumatic interconnections box 2 PG7601 piston gauge 3 FPG8601 force balanced piston gauge 4 FPG Terminal 5 FPG reference vacuum CDG 6 Reference vacuum manifold 7 PG Terminal 8 Reference turbo pump and controller reference roughing vacuum pump utility vacuum pump may be purchased separately 9 AMH 38 automated mass handler 10 Reference vacuum vent valve 11 PG reference vacuum C...

Page 25: ...PPC3 pressure controller TEST port in control cabinet 1 4 in SWG Figure 8 Pneumatic Interconnections Box bulkhead 2 1 2 CONTROL CABINET The ADCS 601 Control Cabinet is a 19 inch rack mount enclosure into which are mounted the PPC3 pressure controllers that provide automated pressure control for the PG7601 and FPG8601 pressure standards and an RPM4 Reference Pressure Monitor used to perform the val...

Page 26: ... remote communication with device under test RS232 USB IEEE 488 6 PPC3 pressure controller for PG7601 system 7 PPC3 pressure controller for FPG8601 system 8 Access door to Gas Supply Panel 1 Power sockets for system components 2 Utility vacuum supply connection 1 4 in NPT F 3 Control Cabinet connections pass through and storage 4 Power cable holder for stress relief 5 Drive air supply connection 1...

Page 27: ...H automated mass handler drive air pressure 2 Regulator and gauge to set drive pressure for system pneumatically actuated vavles 3 Regulator and gauge to set FPG8601 piston cylinder purge pressure supply 4 Regulator and gauge to set pressure supply to the PG7601 system s PPC3 pressure controller 5 Regulator and gauge to set pressure supply to the FPG8601 system s PPC3 pressure controller 6 Gas sup...

Page 28: ...he PG7601 operates on the principle of the piston gauge in which pressure is defined by balancing it against a known force on a known area see Figure 11 The known area is defined by a vertically mounted piston rotating in a cylinder and the known force is applied to the piston by loading it with known mass subjected to acceleration due to gravity When the force applied by the pressure and the forc...

Page 29: ...d mass handler 3 COM1 RS232 System controller PC communications 4 Ambient temperature sensor 5 IEEE 488 host communications not used 6 Ambient relative humidity sensor 7 Pressure ports TEST port DH200 VACUUM vent port DH200 not used 8 PG7000 Terminal port Figure 12 PG7601 Platform rear panel 2 2 1 2 PG7601 TERMINAL The PG7000 Terminal contains the PG7601 power supplies It also provides a local use...

Page 30: ...he power connection module 1 Power switch 2 Fuse 3 Power receptacle 4 Connector for cable to PG7000 25 pin 5 Cooling fan Figure 14 PG7000 Terminal rear panel 2 2 1 3 PG7601 10 KPA KG PISTON CYLINDER MODULE The piston cylinder module is mounted in the PG7601 Platform see Section 2 2 1 1 and performs the pressure to force conversion Figure 15 PG7601 10 kPa kg piston cylinder module ...

Page 31: ...ch a separate Operation and Maintenance manual is available with much more complete information than is included in this manual A copy of the AMH manual is provided on the ADCS 601 Support CD and is available at www dhinstruments com 1 KF 40 vacuum connections 2 2 Lifting handles 2 3 Mass lifter and pneumatic actuation solenoid valves 4 Vacuum bell jar delivered with PG7601 Platform 5 AMH status i...

Page 32: ...mass selection pins 4 Flexible diaphragm 5 Mass lifting assembly 6 Lifting ledge on mass lifting shaft 7 Electronics and electrical controls 8 Mass lifter 9 Solenoid valve 10 Binary mass carrier 11 Main mass column rotation belt 12 Piston cap 13 Main mass column 14 Main masses Figure 17 AMH 38 operating principle schematic ...

Page 33: ...The FPG8601 force balanced piston gauge and PPC3 pressure controller are stand alone products for which separate Operation and Maintenance manuals are available with much more complete information than is included in this manual A copy of the FPG8601 manual is provided on the ADCS 601 Support CD and is available at www dhinstruments com The FPG8601 operates on the principle of the piston gauge see...

Page 34: ...red by the load cell The 10 kPa kg piston cylinder combined with 1 5 kg net measurement span of the load cell give the FPG8601 a pressure range of 0 to 15 kPa 4 5 inHg The FPG8601 Platform is interfaced with the system controller PC running FPG Tools software that calculates pressure and controls the FPG8601 functions The PPC3 pressure controller is used to automate pressure control to set the pre...

Page 35: ...F 7 Drive air supply 1 8 in NPTF 8 Coalescing filter 9 Drivers option connector Not Used 10 COM3 RS232 Not used 11 FPG Terminal port Figure 20 FPG8601 front and rear views 2 2 3 PPC3 PRESSURE CONTROLLERS The ADCS 601 system includes two PPC3 pressure controllers that are installed in the Control Cabinet see Section 2 1 2 One of the pressure controllers is used to automate pressure control for the ...

Page 36: ...sure controller uses on off solenoid valves and internal high precision pressure transducers to adjust and stabilize pressure precisely in response to remote commands The PPC3 front panel provides a local user interface and display for the PPC3 Pressure Controller Local commands to PPC3s are not used in normal ADCS 601 operation See the PPC3 Operation and Maintenance manual for details on local op...

Page 37: ...surements when validating the FPG8601 see Section 7 2 3 The RPM4 is an RPM4 A116Ks The RPM4 pressure controller is a stand alone product for which a separate Operation and Maintenance manual is available with much more complete information than is included in this manual A copy of the RPM4 manual is provided on the ADCS 601 Support CD and is available at www dhinstruments com The RPM4 Reference Pr...

Page 38: ... keys 5 Multi function keypad Figure 23 RPM4 front panel 1 12VDC power supply connection 2 Remote ENT connector 3 IEEE 488 connector 4 COM2 connector 5 COM1 connector 6 Power switch 7 Fuse 8 Electrical power connector IEC 320 C13 9 Fan 10 Product label bottom of case 11 TEST pressure port 12 TEST pressure port 13 ATM pressure port Figure 24 RPM4 rear panel ...

Page 39: ...control pressure under atmospheric pressure The utility vacuum source is a dry scroll pump that is normally located under the Reference Bench and has single connection to the Control Cabinet rear panel Reference vacuum source The reference vacuum source provides vacuum to the reference circuit of the PG7601 and FPG8601 pressure standards for operation in absolute mode The reference vacuum source c...

Page 40: ...ents Inc Page 28 1 Local power switch 2 Display 3 Turbo pump life button 4 Turbo pump conditions button 5 Turbo pump START STOP button 6 Turbo pump LO SPEED button Figure 25 Turbo pump local interface panel local control not used in regular ADCS 601 operation ...

Page 41: ...sories molded transit case in corrugated outer carton 3 1 3 Table 5 PG7601 bell jar double corrugated container 3 1 3 N A PG7601 piston cylinder module and accessories PC 7100 7600 10 TC corrugated container with foam insert PVC bullet case 3 1 4 Table 6 PG7601 mass set MS AMH 38 2 molded transit cases in corrugated outer carton 3 1 5 Table 7 PG7601 automated mass handler AMH 38 corrugated contain...

Page 42: ...acuum CDG assembly in a corrugated container ADCS accessories kit in plastic bags FPG8601 piston insertion tool in a corrugated container 2 scroll vacuum pumps if ordered from DHI with the ADCS 601 system turbo molecular pump if ordered from DHI with the ADCS 601 system To unpack Remove top and at least two sides from the wood crate Remove corrugated containers from under the bench taking care not...

Page 43: ...llar 101016 Z 100918 Z 4 ea Screw and washer 1 4 20 vacuum tube mounting bracket to bench 103846 103435 Z 102620 Z 4 ea Centering ring KF16 101544 4 ea Clamp KF16 102975 1 ea Tee KF16 103696 1 ea Adaptor KF25 x KF16 103237 5 ea Centering ring KF25 101542 5 ea Clamp KF25 102121 1 ea Hose KF25 with flanges PVC 103720 3 ea Centering ring KF40 103245 1 ea Screen with KF40 centering ring 103633 4 ea Cl...

Page 44: ...ts position in the lower packing insert Note the orientation so that the same orientation is used when PG7601 is repacked Reinstall the upper packing insert into the shipping and storage case and store in a safe place Table 5 PG7601 Platform parts list DESCRIPTION PART 1 ea PG7601 platform including 402216 1 ea Bell jar and seal in separate double corrugated container 122106 and 101546 1 ea PG7000...

Page 45: ...tective gloves are provided in the accessory kit of the PG7601 Platform The PG7601 mass set is shipped in 2 molded transit cases The PG7601 masses should be removed from their shipping cases and inventoried when actually setting up the PG7601 system To unpack Do not unpack the masses until you are ready to install them on the PG7601 Platform see Section 3 3 9 2 Wear protective gloves when handling...

Page 46: ...ate corrugated container To unpack proceed as follows Open the FPG8601 shipping and storage case The top of the case removes completely Remove the FPG Terminal piston cylinder manifold vacuum reference CDG assembly and accessories from the upper packing insert Inspect and inventory see Table 9 Remove the upper packing insert Carefully lift the FPG8601 Platform from its position in the lower packin...

Page 47: ...with the FPG8601 mass set Table 10 MS 8601 2 mass set parts list DESCRIPTION PART 401672 1 ea CLB hanger 401789 1 ea Molded case with insert 402072 3 ea 0 5 kg mass 123500 2 ea 0 2 kg mass 123498 1 ea 0 1 kg mass 123496 3 1 9 SCROLL VACUUM PUMPS Two identical scroll vacuum pumps required to operate the ADCS 601 system One is the roughing pump for the reference vacuum turbo pump The other is the ut...

Page 48: ... of change of ambient temperature Vibration Minimize local vibration Excessive vibration will reduce the stability of the pressures defined by PG7601 and the FPG8601 vibration affects the floating piston Overall footprint The ADCS 601 Control Cabinet and Reference Bench must be disposed as shown in Figure 1 Select a location where adequate space is available also consider the location of the syste...

Page 49: ...3 INSTALLATION Page 37 2005 DH Instruments Inc Figure 26 Typical layout of overall ADCS 601 system at site of use ...

Page 50: ...n Section 3 1 Then follow the set up instructions in Sections 3 3 1 to 3 3 13 sequentially Once the system is set up power it up initialize it and verify it following the instructions in Section 3 4 Note all fittings adaptors and parts mentioned in the setup instructions are included with the ADCS 601 unless specifically stated otherwise See the parts lists in Section 3 1 to locate all parts When ...

Page 51: ...er to the turbo pump Install PFA vent bleed tube between the adaptor and the valve attached to the turbo pump controller bracket Install a KF16 tee onto the turbo pump KF16 fitting Orient the tee so that the common port is connected to the turbo pump and the legs are pependicular to the pump body Install a KF16 x KF25 adapator on the right side looking from rear of the KF16 vacuum tee Position vac...

Page 52: ... plastic tube included with valve 11 between valve 11 and the V11 port on the FPG platform Install a KF16 blank off cap on the FPG8601 low test port Install 1 8 in NPT M x 1 8 in Legris adaptors into the DRIVE IN and LUBRICATION SUPPLY ports on the rear of the FPG8601 Platform see Figure 20 Install a 1 8 NPT M x 1 4 in Swage adaptor into the VACUUM port on the rear of the FPG8601 Platform see Figu...

Page 53: ...he 1 4 in stainless steel tube labeled FPG TEST to the 1 4 in Swage open port on valve 2 in the interconnections box Before tightening orient the tube so that the KF16 connection to the FPG8601 high test port can be made see Section 3 3 4 Make the connection to the FPG high test port Tighten the 1 4 in Swage connection There is a 1 4 in stainless steel tube with a 1 4 in Swage by DH200 M adaptor i...

Page 54: ...oned extend the feet under each corner of the cabinet to level the cabinet in a fixed position Unwind the large bundle of pneumatic tubes and electrical connections that originate from the rear opening of the cabinet Connect the large grey 8 port connector from the Control Cabinet to the VALVE CONTROL connection on the Reference Bench interconnections box bulkhead Connect the 1 4 in PFA tube label...

Page 55: ...reference pressure monitor will power up and go to their main run screens Do NOT operate either of the PUMP AC2 AC3 power switches 3 3 7 CONNECT PRESSURE SUPPLIES TO CONTROL CABINET Connect a drive air supply to the DRIVE AIR SUPPLY port on the rear of the Control Cabinet The fitting is a 1 4 in NPT F The connecting tube and adaptor are not supplied See Section 1 1 1 for drive air supply requireme...

Page 56: ... knurled area and rotate it counterclockwise Place the piston cylinder module thread down into the PG7601 mounting post see Figure 27 Rotate the piston cylinder module clockwise until all threads are engaged and there is NO gap between the piston cylinder module and the PG7601 mounting post Slight resistance will be encountered in the second half of travel as the piston cylinder module O rings sea...

Page 57: ...nother convenient location near the PG7601 Platform Connect the AMH 38 15V power supply to the rear of the AMH 38 and plug it into the power strip under the Reference Bench Connect the 9 pin D sub cable labeled AMH COM1 to the COM1 port on the rear of the AMH 38 Connect the 1 8 in pneumatic line labeled 8 RED from the Reference Bench interconnections box to the drive air port on the back of the AM...

Page 58: ...e binary mass tray Be sure to use the T handled 3 mm allen wrench to tighten the shaft to the end of the threads applying sufficient torque to cause the mass load to rotate Failure to fully screw in the shaft will cause misalignment between the mass handler and the mass load that may cause damage to the AMH 38 mass handler when operated Install the AMH 38 mass lifting shaft Slip the threaded end o...

Page 59: ...on cylinder with one hand and turn the piston cylinder lower section of the bullet case upside down supporting the piston cylinder with the cupped hand Lift the lower section of the bullet case off of the piston cylinder Place the piston cylinder on to a stable soft surface lint free towels Take care that the piston does not slide out of the cylinder Remove the FPG8601 lower mounting post Loosen t...

Page 60: ... VACUUM CDG ASSEMBLY The PG7601 and FPG8601 reference vacuum CDGs are delivered with an isolation valve connected to them This valve is normally closed and serves to maintain vacuum on the CDG at all times as exposing the CDG to atmospheric pressure will cause zero shifts New CDGs are shipped with vacuum behind the isolation valve Do not break the valve fittings or operate the valve without establ...

Page 61: ...3 3 12 INSTALL THE UTILITY VACUUM PUMP Position the utility vacuum pump under the bench The two scroll vacuum pumps provided are identical so either one may be used here Install a 3 8 in Swage x 1 4 in NPT M adaptor on the Control Cabinet UTILITY VACUUM port Connect the utility pump inlet to the Control Cabinet UTILITY VACUUM port using the 3 8 in PFA with 3 8 Swage x KF25 adaptor installed tube a...

Page 62: ...art up as ADCS Tools controls a relay on the circuit so that these pumps power up only when absolute measurement mode is set 3 4 2 SET OR VERIFY DEVICE COMMUNICATION PORT AND OTHER SETTINGS 3 4 2 1 COMMUNICATION PORTS On the RPM4 A116K front panel use SPECIAL 2remote 1COM1 to set the COM1 port On the PPC3 200K A116K BG15K front panel use SPECIAL 2remote 1COM1 and 2COM2 to set the COM1 and COM2 RS2...

Page 63: ...g Check that the PG7601 to PG Terminal cable is properly installed If PG7601 fails to reach the main run screen service may be required Record the sequence of operations and displays observed and contact a DHI Authorized Service Provider see Table 26 3 4 3 2 INITIALIZATION VERIFY THE PISTON CYLINDER MODULE MASS SET AND MASS LOADING BELL PG7601 uses stored piston cylinder and mass set metrological ...

Page 64: ...F switch on the rear panel of the FPG8000 Terminal Observe the display as the terminal connects with the FPG8000 Platform tests initializes and goes to the main run screen If Searching displays for more than 5 seconds the communications between the FPG8601 and the FPG Terminal are failing Check that the FPG8601 to FPG Terminal cable is properly installed If the FPG Terminal fails to reach the main...

Page 65: ... than 0 2 mm min indicates a possible leak Set a target pressure of 20 kPa 6 inHg The PG7601 should change the mass load use the PG7601 PPC3 pressure controller to decrease pressure and float its piston rotate its piston and indicate Ready Set a target pressure of 10 kPa 3 inHg The ADCS 601 will transition from the PG7601 to the FPG8601 standard The FPG8601 pressure controller should descend press...

Page 66: ...ments at very low absolute pressure Run an FPG validation in absolute mode see Section 7 2 3 3 5 ENTER VALUE OF LOCAL GRAVITY To correctly calculate the pressure defined by its PG7601 and FPG8601 pressure standards local value of acceleration due to gravity must be known and entered into ADCS Tools To enter the local value of acceleration due to gravity into ADCS Tools press Maintenance on the mai...

Page 67: ...Assure that adequate metrological maintenance has been performed see Section 7 3 8 SHUT DOWN AND RESTART 3 8 1 RESTART To restart an assembled ADCS 601 follow the steps below If the ADCS 601 has been shut down for an extended period consider performing the maintenance functions see Section 6 If they have been disconnected connect and apply required pressure supplies to the Control Cabinet rear pan...

Page 68: ...3 8 2 1 SHORT TERM SHUT DOWN To reduce consumption of power and preserve vacuum pump life the following conditions may be implemented when the ADCS 601 is not in use for example over the weekend In this state ADCS 601 is in gauge measurement mode with the utility vacuum pump turned off Put system into gauge measurement mode by pressing the Measurement Mode button on the ADCS Run Screen Toolbar see...

Page 69: ... and conditions are appropriate for the ADCS 601 pressure definition to be within the estimated measurement uncertainty budget ADCS 601 provides a go no go Ready Not Ready indication The Ready Not Ready indication is provided by the ADCS Tools software that manages the overall system see Section 4 3 The indication is by a circle to the left of the current pressure reading which is RED when the pre...

Page 70: ... in the FPG8601 when ambient conditions have significantly changed since the last FPG8601 zero A feature in the Maintenance FPG Cal Options menu is provided to decouple the FPG8601 internal limits and the Ready Not Ready status of the ADCS 601 when the FPG8601 is the active reference see Section 7 2 When Regulation see Section 4 1 4 is OFF the ADCS 601 Ready Not Ready condition when using the FPG8...

Page 71: ...trollers to set the same pressure on either side of the isolation valve Once this transition pressure has been set and stabilized the valves are operated The default transition pressure is 15 kPa in absolute mode and 14 kPa in gauge mode The value can be changed in ADCS Tools Setup Configuration Limits but this is not recommended The transition between standards is initiated automatically when a p...

Page 72: ...4 5 inHg it is possible to set exactly the requested pressure by using Regulation mode In Regulation mode the PPC3 pressure target is iteratively adjusted by the difference between the PPC3 pressure transducer reading and the FPG8601 reading to cause the FPG8601 to read the requested value of pressure within the FPG8601 pressure hold limit See Section 4 1 2 3 for information on pressure Ready Not ...

Page 73: ...ugh the quick connectors are self sealing they may leak To access the test port it must be vented to atmosphere In gauge measurement mode the TEST port is always vented To vent the TEST port press the VENT button on the ADCS Run Screen Toolbar see Section 4 3 5 3 and wait for the vent process to complete indicated Pressure is 0 000 and Ready The TEST port can then be accessed safely without damage...

Page 74: ...down arrow next to the MEASUREMENT MODE button on the ADCS Main Run Screen Toolbar see Section 4 3 5 3 The ADCS Main Run Screen Pressure field displays Measurement Mode Transition while the ADCS 601 system makes the changes necessary to change measurement modes Do not attempt any other operations until the measurement mode transition is complete as indicated by the Pressure field no longer indicat...

Page 75: ...tting If the Vent using the FPG in gauge measurement mode option IS selected the active pressure standard is transitioned to FPG8601 if it is not already active and the FPG8601 s PPC3 controller vents to atmosphere setting zero gauge pressure The ADCS Control Panel Pressure field indicates the reading of the FPG8601 4 2 4 2 SETTING IDLE STATUS This section describes the ADCS 601 idle condition The...

Page 76: ...rence in height between the ADCS 601 reference level and the DUT reference level is entered in the ADCS Control Panel Head Correction field The value is positive if the DUT reference level is higher than the ADCS reference level and negative if the DUT is lower than the ADCS The value is always entered in centimeters cm 4 2 7 STOPPING PRESSURE CONTROL ABORTING FUNCTION EXECUTION To abort current p...

Page 77: ...may be viewed but no changes additions or deletions to DUT definitions can be made Edit Plots The option to edit plots is available on the Plot Form but no changes can be saved Program Options Tools Test Options may be viewed but no changes can be saved Support Device Setup Support Device may be viewed but no changes additions or deletions to support device definitions can be made Test Setup Test ...

Page 78: ...easurement mode This change in pressure can cause the leak test to fail There are three parts to the leak test PG7601 drop rate test residual vacuum test and FPG lubrication flow test If any part of the leak test fails the overall leak test fails The PG7601 drop rate portion of the leak test sets a high and low pressure with the PG7601 After stability is achieved the change in piston position over...

Page 79: ...re 1 Main Menu see Section 4 3 2 The Main Menu is a bar across the top of the ADCS Tools program window Each main menu selection leads to a drop down menu 2 ADCS Main Toolbar see Section 4 3 3 The Main Toolbar is across the top of the screen just under the Main Menu The toolbar is made up of buttons that are shortcuts to ADCS menu items and functions 3 ADCS Status Bar see Section 4 3 4 The Status ...

Page 80: ...ADCS 601 OPERATION AND MAINTENANCE MANUAL 2005 DH Instruments Inc Page 68 Figure 32 ADCS 601 software communications and control flow chart Figure 33 ADCS 601 program window ...

Page 81: ...ers Set up ADCS 601 system users and manage their passwords and rights 4 2 8 Setup Change Current User Change the current ADCS 601 user 4 2 8 2 Test Options Set up options relating to managing data collected when running a test and how tests end 4 4 1 4 Remote Communications Send and receive remote commands manually using the Direct Remote Communication tool N A Tools Unit of measure Converter Run...

Page 82: ...ion toolbar see Section 4 4 2 2 Figure 34 ADCS Main Toolbar Table 14 ADCS Main Toolbar buttons BUTTON DESCRIPTION SEE SECTION Rotating DHI logo or ON button Located at far left of the Toolbar Shows a rotating DHI logo when the ADCS Tools program is running normally Stops rotating if the system software has been paused or the computer has experienced a fatal fault Shows an ON button when the ADCS T...

Page 83: ...s the characteristics of the running test to be viewed When not running a test is a shortcut to the Test Definition Editor 4 4 1 2 ADCS Run Screen Opens the ADCS Run Screen 4 3 5 PG7601 Run Screen Opens the PG7601 Run Screen 4 3 6 1 FPG Run Screen Opens the FPG8601 Run Screen 4 3 6 2 PPC3 Pressure Controller Run Screen Opens the FPG8601 s PPC3 Pressure Controller Run Screen 4 3 6 3 RPM4 Pressure M...

Page 84: ... is identical to averaging data during a test Both automatic and manual averages can be used to average the data The drop down arrow displays a menu that lists the automatic and manual averaging options The option with an preceding it is the active averaging mode To change the automatic averaging time select it in the menu and enter the desired averaging time in the input box that follows Data can...

Page 85: ...Run Screen When a test is running opens the DUT Reference Comparison Run Screen This display provides convenient real time error information calculated for each DUT compared to the ADCS 601 4 4 3 3 Device Run Screen When running an automated test generates a popup menu to allow the selection of the desired Device Run Screen to display The selected Device Run Screen automatically displays in the ma...

Page 86: ...ent of an instrument front panel It is the front panel of the ADCS 601 system The run screen is the interface through which ADCS functions are controlled and readings are observed see Figure 36 The ADCS Run Screen is opened by pressing the ADCS Run Screen button on the ADCS Main Toolbar The screen can be resized and repositioned The run screen has three main sections 1 Control Panel see Section 4 ...

Page 87: ...layed Target Pressure Enter display a target pressure and the unit of measure Double click the displayed value to highlight and edit the complete number Enter a desired target pressure and press ENTER for the ADCS 601 to set a pressure automatically Regulate Target and s Appear only when FPG8601 is the active pressure standard Checking the Regulate Target box causes the FPG8601 system to regulate ...

Page 88: ...n active standard Displays the current pressure and unit of meaure or the status of the FPG8601 pressure standard The circular indicator is a Ready Not Ready indicator see Section 4 1 1 Upper Limit The maximum allowable target pressure for the ADCS 601 This limit is imposed for all test and manually entered target pressures Change the limit by entering a new maximum pressure value in the current A...

Page 89: ...is represented graphically and digitally in the bell jar area and the mass rotation is represented in the AMH vacuum chamber area Bell jar light blue ADCS 601 is in gauge measurement mdoe atmospheric pressure is under the bell jar Bell jar black ADCS 601 is in absolute measurement mode vacuum is under the bell jar PG7601 masses PG7601 masses White vertical line movement approximates mass rotation ...

Page 90: ...the FPG8601 Always vent or set a new target pressure after aborting pressure control when the FPG8601 is the active pressure standard Failure to do so will eventually result in an FPG8601 overpressure condition ADCS Tools automatically vents all system pressure after an FPG8601 overpressure Change Pressure Unit of Measure Changes pressure unit of measure for all ADCS 601 pressure values other than...

Page 91: ...mode only 4 3 6 OTHER DEVICE RUN SCREENS 4 3 6 1 PG7601 PRESSURE STANDARD The PG7601 Run Screen provides more detailed information on PG7601 status and a Toolbar to control it directly Use the PG7601 Run Screen button on the ADCS Tools Main Toolbar to open the screen The screen may be resized and relocated The PG7601 Run Screen should only be used to view PG7601 status Use of the Toolbar on this r...

Page 92: ...or for advanced trouble shooting by qualified personnel Figure 39 FPG8601 Run Screen 4 3 6 3 PPC3 FPG S PRESSURE CONTROLLER The PPC3 Run Screen provides more detailed information on the FPG8601 system s pressure controller and a Toolbar to control it directly Use the PPC3 Run Screen button on the ADCS Tools Main Toolbar to open the screen The screen may be resized and relocated The PPC3 Run Screen...

Page 93: ...o control it directly Use the RPM4 Run Screen button on the ADCS Tools Main Toolbar to open the screen The screen may be resized and relocated The RPM4 Run Screen should only be used to view RPM4 status Use of the Toolbar on this run screen may conflict with other ADCS 601 Tools functions The RPM4 Run Screen Toolbar should only be used for advanced trouble shooting by qualified personnel Figure 41...

Page 94: ...S Tools is preconfigured to support automated validation calibration and standardization of the King Nutronics 3682 Air Data Calibrator see Section 4 4 6 4 4 1 SETTING UP TO RUN AUTOMATED TESTS To run an automated test a DUT Definition must be setup to identify the device under test see Section 4 4 1 1 To run a multipoint test following a scripted test scenario a Test Definition must also be set u...

Page 95: ...low one DUT Definition to represent any number of like Model devices from the same Manufacturer Select the Manufacturer and Model on the Header tab If the desired selections are in the drop down list press the Find Previous Setup button to search for previous setups or examples of the DUT If the Manufacturer and Model are not in the list enter them Enter relevant information on the Calibration tab...

Page 96: ...ayed While in the Editor use the Editor Toolbar options to create edit view and delete tests Sample tests are already included in the Test Definition database as examples The Test Editor uses the same editing concepts as the DUT Editor Only one Test Definition can be edited at a time The test scroll bar and the Test Selector are available to make new test selections A flashing indicator displays w...

Page 97: ...ected the last accessed Support Device Definition displays To edit an existing Support Device Definition use the Editor Toolbar buttons to select the desired definition Then simply edit the desired fields Press the Editor Toolbar Save button to save the changes Sample Support Devices are already included in the Support Device database as examples 4 4 1 4 TEST OPTIONS DATA OPTIONS ADCS Tools uses t...

Page 98: ...xed time delay and enter a time to allow stepping back for a fixed time after the test ends Check Prompt to repeat to have ADCS Tools query the operator at the end of a test check No repeat option to have the test complete without pausing Check Auto generate reports after complete test to have ADCS Tools automatically generate a test report using the last report template used when the test is comp...

Page 99: ... not a required part of a Manual Test During the test initialization process the last Manual Test selections display These selections can be changed if desired There are no requirements to use any specific combination of devices For example a Manual Test can be executed using a temperature controller only Manual Tests should be used for trouble shooting device final output setups and running speci...

Page 100: ...o running the test Run Test Sequence Runs leak test if included and pressure exercise if included followed by the test points taking data at each point based on the test data selections The test parameters are defined by the Test Definition see Section 4 4 1 2 End Test Presents the Test Notes screen to record test specific notes and the Test Complete screen with various test conclusion options Cer...

Page 101: ...e The Data Plot Run Screen can be opened by pressing the Data Plot button on the ADCS Tools Main Tool Bar see Section 4 3 3 Table 14 Each point taken during a test causes the graph to update with the current test point information The graph can be changed or printed without affecting test execution Use the Data Plot Tool Bar on the Data Plot Run Screen to select the plot type and customize the cur...

Page 102: ... additional information on this screen and its options The COMPASS for Pressure manual is an on line manual available by pressing the button when available in COMPASS features It can also be accessed on the ADCS 601 system controller in the COMPASS for Pressure program group reached using the Windows START button Programs The Reference DUT Comparison Run Screen is available any time a test is runn...

Page 103: ...d drop down plot type selector to modify the plot The data in a test Data File can also be stored in the Test Data Database The database is in the Microsoft Access format This common format enables easy manipulation and integration with other databases Users are welcome to add fields and customize the database as desired However if the fundamental structure of the database is altered the Database ...

Page 104: ...vents if the procedures below are followed as instructed The model 3682 validation procedure automatically runs the model 3682 through the required pressure sequence and records actual and test pressure at each point If the Ps transducer is being run the Offset Check Point can be executed before the pressure sequence When the sequence is complete the results of the test are stored in a test data f...

Page 105: ...fields provided at the top of the display Do not change to IEEE Address Also verify that the range is correct then press Next Select the King 3682 Ps Validation or King 3682 Pt Validation test from the list and press Finish There are no further initialization steps The test will complete initialization and start to run The status bar updates during initialization to display the current system oper...

Page 106: ...essary to run an offset Check Point when running a test that will determine as received error or when trying to evaluate the DUT In this case press No and skip to Step At the next prompt do NOT press OK before having set the model 3682 to Calibration Manual mode To set Calibration Manual mode on the front panel of the model 3682 Press Advance Press Calibration Manual Press Advance Select Calibrati...

Page 107: ...ng the actual pressure set by ADCS 601 On the front panel of the model 3682 perform the following operations Press MEASURE The ACTUAL field begins to blink Enter the ADCS601 Pressure displayed on the ADCS Tools popup using the numeric keys at the bottom of the model 3682 display Verify that the information is entered correctly and press Enter The model 3682 prints the calibration offset value Ente...

Page 108: ...mmunications After all steps on the 3682 are complete and its display is the IEEE address selection screen press OK on the ADCS Tools popup It is imperative that the model 3682 be in the correct mode of operation when the test begins ADCS Tools sets up the the model 3682 remote interface for automatic calibration Ten to twenty seconds after OK is pressed the model 3682 prints out the current mode ...

Page 109: ... the 3682 that will cause it to vent pressure unless the ADCS 601 is vented first Causing pressure on the ADCS 601 TEST port to vent when the ADCS 601 is not vented may cause damage to the ADCS 601 NOTE The ADCS 601 is always vented before the model 3682 vents if the procedures below are followed as instructed The model 3682 standardization procedure steps the operator through the model 3682 requi...

Page 110: ...DE button on the ADCS Tools Main Run Screen Vent the ADCS 601 using the VENT button on the ADCS Tools Main Run Screen Enter the appropriate Upper Limit value on the ADCS Run Screen Enter 32 inHg when calibrating the Ps transducer and 110 inHg when calibrating the Pt transducer Connect the ADCS 601 TEST port to the 3682 Ps or Pt port Select Run Run Test Definition in ADCS Tools Select inHg as the u...

Page 111: ... updates during initialization to display the current system operation ADCS Tools automatically opens the Data Plot Run Screen see Section 4 4 3 1 when running a test but there is no relevant data to plot when running a validation test To close the Data Plot Run Screen simply click on the x in the upper right hand corner of the Run Screen ADCS Tools sets the test pressure dwells for 60 seconds det...

Page 112: ... The dialog box notifies the operator that the sequence for the last point is different from the other points OK must be pressed BEFORE ADVANCE is pressed on the model 3682 On the last test point of the standardization DO NOT press ADVANCE on the model 3682 before OK has been pressed on the ADCS Tools dialog box and the second dialog box indicating it is safe to proceed appears Pressing ADVANCE on...

Page 113: ...nts Inc When the test is complete the Test Complete form displays Press Exit Test to close the dialog box and return to the ADCS Main Run Screen On the model 3682 press ADVANCE and follow its prompts to complete the standardization process ...

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Page 115: ... computer and the ADCS 601 system computer is not available at the time of publication of this manual Individual ADCS 601 components such as the PG7601 and the PPC3 pressure controllers can be addressed individually on their RS232 and or IEEE 488 interfaces but this is not a normal part of ADCS 601 operation See the Operation and Maintenance Manual for the individual component for additional infor...

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Page 117: ...down and up positions 6 months if pressure control to float PG7601 piston does not operate correctly if pressure is not stable when piston is floating 6 7 PG7601 Replace piston rotation drive belts Disassemble PG7601 rotation plate replace belts and reassemble If piston rotation system no longer operates reliably 6 8 PG7601 Adjust on board vacuum gauge Run an automated function from ADCS Tools tha...

Page 118: ...se permanent damage to essential parts of the FPG For the FPG8601 s load cell to operate properly it must be surrounded by gas with the appropriate level of humidity 40 to 70 RH To assure the appropriate level of humidity the FPG lubrication gas passes through a water filled bubbler and then a pressure reduction before it enters the load cell enclosure The bubbler s water supply is consumed over t...

Page 119: ...should now be ready to resume normal operation 6 3 FPG8601 REMOVE CLEAN AND REINSTALL THE PISTON CYLINDER 6 3 1 OVERVIEW Read this section completely before electing to remove clean and reinstall the FPG8601 piston cylinder assembly Consider restoring piston cylinder mobility procedures see Section 6 3 7 before undertaking piston cylinder cleaning In normal operation the FPG8601 piston cylinder sh...

Page 120: ...ston is perfectly mobile When FPG8601 pressure readings are noisy unless very obvious signs of contamination are present always try piston cylinder manipulation to establish normal behavior before disassembling and cleaning the piston cylinder See Section 6 3 7 for the procedure to reestablish piston mobility Failure to follow each of the FPG8601 piston cylinder disassembly assembly steps can caus...

Page 121: ...n the CDG at all times as exposing the CDG to atmospheric pressure will cause zero shifts Do not break the valve fittings or operate the valve without establishing vacuum first Remove the vacuum isolation valve valve 9 on the bottom of the lower mounting post and remove the vacuum reference CDG and valve see Sections 3 3 10 2 7 2 6 Detach the bottom mounting post PRT by unscrewing the knurled nut ...

Page 122: ... the lapped surfaces polished appearance of the piston or cylinder with your bare hands Body oils and acids can permanently etch the surfaces Remove one of the piston retaining nuts Figure 48 Removing the FPG8601 piston cylinder With one hand supporting the piston to maintain its current position slowly remove the remaining piston retaining nut ...

Page 123: ...parts with a gap as small as one micron a special tool and procedure is required to remove one from the other without risk of the piston cocking in the cylinder and binding as it leaves the cylinder When removing the FPG8601 piston from its cylinder proceed as follows Remove the cup from the spindle of the FPG8601 insertion tool and place both on a flat stable surface Lift the piston cylinder by t...

Page 124: ...n lint free towels on a flat surface Discard misted lint free towels Transfer the piston to the two clean lint free towels Using gloves fold two new lint free towels three times over Buff the piston while rolling it on the flat surface Repeat Step twice This step is critical if any glass cleaner is left on the piston the piston will not be mobile when it is reassembled and the FPG8601 pressure out...

Page 125: ...into the cylinder before the piston cylinder can be reinstalled in the FPG8601 Platform Figure 49 Alignment of the FPG8601 piston in the cylinder The piston must be installed in the cylinder with the correct end at the top and the correct rotational orientation Installing the piston incorrectly in the cylinder may result in poor FPG8601 performance and or out of tolerance measurements Place the cy...

Page 126: ...nder see Section 6 3 5 place the silicon O ring carrier assembly on the upper portion of the cylinder lip up The silicon O ring is orange and more soft than the Viton O ring do not confuse the two Place the Viton O ring carrier inside the lower mounting post lip down The Viton O ring is a brownish color and is firm relative to the silicon O ring Carefully slide the piston cylinder assembly into th...

Page 127: ...w of lubricating gas from the center of the piston cylinder through its upper and lower conical gaps see Section 2 2 2 While the lubricating gas flow can maintain the piston centered in the cylinder for its action to be effective the piston must first be well lubricated with gas and centered in the cylinder A piston cylinder that has just been installed in the FPG8601 mounting post may not be well...

Page 128: ...s METHOD 1 CYLINDER MANIPULATION Hold the cylinder Gently move it up and down while rotating it The movement is very limited Do not force it METHOD 2 LIFT AND DROP Put a finger under each of the piston retaining nuts Gently lift the piston compressing the load limiting springs on the piston connecting rods The movement is very limited Do not force the piston up Once the piston is up let it drop do...

Page 129: ...ad screws 3 mm around the perimeter of the platform Lift the base cover plate gently and carefully disconnect the sensor leads at their board connections noting their locations Remove the cover plate and electronic board attached to it Loosen but do not remove the four socket head screws 3 mm located on the PRT cable pass through plate The plate is located on the inside of the base Slide the PRT o...

Page 130: ...AMH 2control 3loadall on the PG7000 Terminal to load all the masses of the AMH mass set This assures that no masses are retained in the AMH so it will be able to be lifted off the platform freely Remove the PG7601 bell jar and disconnect the vacuum connection from the AMH vacuum chamber Remove the Pyrex bell jar and set aside Remove the flange from the KF 40 connection on the right side of the AMH...

Page 131: ...internal proximity sensor allowing the AMH system to be operated off of the PG7000 Platform without an actual mass load Clear the AMH and test its operation On the PG7000 Terminal press SPECIAL 8AMH 2control 3loadall The trim mass tray should rise approximately 2 5 cm 1 in above the top of the lifter Then the trim mass tray should be lowered back down The steps of this procedure are commented on t...

Page 132: ...le in the center of the mass lifter Thread the shaft into the binary mass carrier by holding and rotating the trim mass tray NOTE THAT SHAFT HAS A LEFT HAND THREAD SO IT MUST BE ROTATED COUNTER CLOCKWISE TO TIGHTEN IT Use the 3 mm allen wrench supplied in the AMH 38 accessories to tighten the assembly until you feel the mass start to rotate It is imperative that the mass loading shaft be fully thr...

Page 133: ...all the piston cylinder module in the PG7601 Platform See Section 6 6 2 Install the binary mass carrier Place the pyramidal shaped carrier on top of the piston cap Install the mass loading bell Slip the mass loading bell over the binary mass carrier and slide it down until the inside top of the bell sits on the binary mass carrier Install the main mass discs Load the main mass discs 6 4 kg each on...

Page 134: ...NCLUDED Figure 51 AMH mass set 6 6 PG7601 REMOVE CLEAN AND REINSTALL THE PISTON CYLINDER MODULE It may be necessary to remove the piston cylinder module from the PG7601 Platform to clean the piston cylinder or have it recalibrated For instructions on removing the piston cylinder module disassembling cleaning and reinstalling it see Sections 6 6 1 to 6 6 3 4 6 6 1 REMOVING THE PISTON CYLINDER MODUL...

Page 135: ...GE plastic mounting post plug that is installed in the PG7601 Platform mounting post Rotate counterclockwise to remove Remove the piston cylinder module from its bullet case Open the piston cylinder module bullet case by rotating its lid counterclockwise Remove the piston cylinder module from the bullet case base by unthreading it from the case Hold the piston cylinder module body by the knurled a...

Page 136: ...ylinder cleaned If symptoms of contamination develop rapidly with operation after cleaning the piston cylinder module there is almost certainly a source of contamination within the ADCS 601 system This source must be identified and eliminated to reduce piston cylinder cleaning frequency Very often the source of contamination is the test gas supply itself which contains humidity or lubricating oil ...

Page 137: ... to loosen the socket head cap retaining screw 1 The cap retaining screw will not fully disengage from the piston cap due to the adjustment mass 3 Gently remove the cap and screw from the assembly When installing the piston cap during reassembly remember to reinstall the adjustment mass 3 Remove the main module housing 4 by sliding it upward leaving the piston cylinder assembly behind Reinstall th...

Page 138: ...ADCS 601 OPERATION AND MAINTENANCE MANUAL 2005 DH Instruments Inc Page 126 Figure 54 10 kPa kg piston insertion tool Figure 55 10 kPa kg gas piston cylinder module sleeve nut tool ...

Page 139: ...ng O Rings O rings identified for lubrication should be lubricated prior to installation During service O rings may be left in place and a thin film of vacuum grease applied to the outside diameter Vacuum grease may be applied by placing a drop 3 4mm diameter approximately 15 30mg of grease between the thumb and forefinger and then rolling the O ring between the thumb and forefinger to apply a thi...

Page 140: ...ston cylinder module disassembly without familiarizing yourself with Section 6 6 3 2 of this manual Incorrect disassembly may damage or destroy the piston cylinder element There are two recommended piston cylinder cleaning methods Use the one with which you have most success Water Detergent Method Of the two cleaning methods the water detergent method is more time consuming but it is also more tho...

Page 141: ...ted by contact with the operator s hands Do not buff the assembly Just dry it thoroughly Reassemble the metrological assembly in reverse order If the assembly temperature was elevated during cleaning it may be necessary to wait to allow the temperature of the assembly to return to ambient temperature before the assembly will operate normally Glass Cleaner Method Of the two cleaning methods the gla...

Page 142: ...xt to each value Enter 0 for Main Then press ENT to cause all the binary masses to load Run the PG7601 piston position calibration function Press ESC on the PG7000 Terminal until operation returns to the main run screen Press SPECIAL 7cal 5Pposition 2cal When the prompt Hold piston at max down stop appears press ENT The piston is already at the down stop because the pressure under the piston is ve...

Page 143: ... Allen tool remove the three screws on the outer diameter of the circular black pulley plate that is at the bottom of the platform mounting post Do not remove the screws on the inner diameter Remove the two drive belts and replace them with the new ones Realign the notched pulley with the pins on the drive motor Replace the pulley plate and three screws Engage the drive system to ensure proper ope...

Page 144: ...complete Press Maintenance on the ADCS Tools Main Menu and select Run PG PPC3 Adjust or Run FPG PPC3 Adjust View the PPC Adjustment Setup form This form is identical to the FPG Validation Setup form see Section 7 2 3 2 Edit if desired Recommended default values are the same as FPG validation but the recommended pressure points are For the A116K transducer of the FPG PPC3 1 7 11 15 kPa or their equ...

Page 145: ...rted again by pressing the ON button on the ADCS Tools FPG Run Screen 6 12 CONTROL CABINET DRAIN DRIVE AIR TRAPS The ADCS 601 Control Cabinet contains two traps to clean the drive air that is supplied to the ADCS 601 system see Figure 10 These should be emptied regularly The traps can be emptied without removing pressure To empty the traps proceed as follows Open the door on the front of the ADCS ...

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Page 147: ...d the value of the masses that are loaded on the piston cylinder see Section 2 2 1 The FPG8601 measurement uncertainty is predominantly dependent upon the effective area of its piston cylinder the value of its internal calibration mass and the linearity and repeatability of its force balanced load cell see Section 2 2 2 In the air data range of 1 to 15 kPa 0 3 to 4 5 inHg that is covered by the FP...

Page 148: ...rm ambient pressure temperature and humidity sensor readings relative to a standard and adjust if necessary 6 months increase to 1 year when justified by experience 7 2 7 7 2 2 FPG8601 ZERO AND ADJUST SPAN OF LOAD CELL The FPG8601 uses a precision load cell to measure the force resulting from the pressure across its piston cylinder The load cell zero may drift with time and ambient condition chang...

Page 149: ...validation process is performed automatically by ADCS Tools The validation can be run in absoloute or gauge measurement mode The absolute mode validates the complete system including the reference vacuum CDGs Gauge mode validation can also be used to check gauge mode only if desired The validation routine compares the PG7601 and FPG8601 at pressures across their overlapping ranges and logs the res...

Page 150: ...3 3 Check the FPG8601 bubbler water supply see Section 6 2 Zero the PG7601 and FPG8601 reference vacuum CDGs see Section 7 2 6 Validate load cell linearity with the FPG8601 mass set see Section 7 2 5 If the FPG Validation test is not able to result in a PASS condition after all corrective actions the FPG8601 and or other components of the ADCS 601 system require service and DHI Authorized Service ...

Page 151: ...the Averaging Time An average is taken for the number of Readings Per Point specified The RPM4 Monitor is then connected to the FPG8601 system and the process is repeated The comparison of the PG7601 and FPG8601 is calculated following FPG8601 RPM4 PG7601 RPM4 After the last pressure has completed the system remains in current conditios and the FPG Validation Results Form is presented View results...

Page 152: ...ith a detailed log of the validation test data Generate Report opens the Report Editor to generate a report from the validation data file Re Run Validation re runs the validation test immediately Exit closes the FPG Validation Results Form Figure 59 ADCS Tools FPG Validation Setup Form Figure 60 ADCS Tools FPG Validation Results Form ...

Page 153: ...er for adequate water level see Section 6 2 Table 22 FPG8601 P T H limits MEASUREMENT VALUE AND LIMITS Lubrication gas pressure gauge mode 140 kPa abs 8 Lubrication gas pressure absolute mode 40 kPa abs 8 Lubrication gas relative humidity 40 to 70 RH Mounting post temperature 19 to 27 ºC 7 2 5 FPG8601 VALIDATE LOAD CELL LINEARITY 7 2 5 1 OVERVIEW The FPG8601 uses a precision load cell to measure t...

Page 154: ... to check more points in the low end of the span Evaluate the linearity verification data using the information in Section 7 2 5 3 Remove the masses and CLB from the FPG8601 Reinstall the piston cylinder and lower mounting post see Section 6 3 6 7 2 5 3 EVALUATING LINEARITY VERIFICATION DATA The objective of the linearity evaluation using the CLB and FPG8601 mass set is not to verify the absolute ...

Page 155: ... outputs 1 count Linearity tolerance 2 counts 2 ppm 454 863 3 counts Pass fail condition Pass If the any load cell linearity verification point results in an fail condition repeat the verification process including the initial zeroing of the load cell with the CLB and 500 g mass loaded Be sure the load cell output is stable at each point If the load cell linearity verification consistently has one...

Page 156: ...ss Push the KF40 bellows connection on the FPG8601 to provide clearance for the KF40 centering rings to clear the fittings Rotate the KF40 cross 90º and install it on the vertical tube coming up through the bench from the turbo pump Remove the CDGs from the PG7601 AMH 38 and the FPG8601 Keep them electrically and pneumatically connected CAUTION DO NOT BREAK THE CONNECTIONS AT THE CDG OR THE CDG WI...

Page 157: ...he pressure to pull down and stabilize Observe the level of vacuum as indicated by the vacuum reference Observe CDG readings on the ADCS Tools CDG Zero Run Screen Using the potentiometers on the top of the CDGs adjust the CDGs to cause their output as indicated on the ADCS Tools CDG Zero Run Screen to agree with the value indicated by the vacuum reference ion gauge Isolate the CDGs from the KF40 c...

Page 158: ...s sensors are verified and adjusted relative to a reference without being removed from the platform The measurement uncertainty specification of the on board sensor should be taken into consideration when selecting a reference relative to which to adjust them The sensors are adjusted using Maintenance PG Sensors in ADCS Tools see Figure 62 The PG Sensors Adjust form allows the current output of ea...

Page 159: ...w effective area value into system Yearly until decreased frequency justified by experience Recommended end of first and second years then every three years if no significant changes observed 7 3 2 PG7601 Calibration of mass set Determination of mass values of mass set and piston assembly and entry of new values into the system Yearly until decreased frequency justified by experience Recommended e...

Page 160: ... to pack it 7 3 2 2 UPDATING PISTON CYLINDER CALIBRATION INFORMATION Piston cylinder module information is element specific metrological data Uninformed or accidental altering of this information may lead to out of tolerance measurements Piston cylinder module information should only be edited by qualified personnel as part of the ADCS 601 calibration or recalibration process When a piston cylinde...

Page 161: ...es has been pressed Figure 63 ADCS Tools PG7601 Piston Cylinder Calibration Form 7 3 3 PG7601 CALIBRATION OF MASS SET 7 3 3 1 PREPARING FOR CALIBRATION Piston gauge mass sets are often calibrated in a facility other than that in which the ADCS 601 system is used so calibrating the mass set requires removing it from the PG7601 Platform and shipping it If the mass set and the piston cylinder module ...

Page 162: ... are always the ADCS 601 PG7601 s active mass bell and mass set Check that the correct bell and mass set are shown by verifying their serial numbers against the serial numbers shown in the panel labels To change the active mass bell and mass set use Setup Configuration PG To edit the mass bell value click on the value and enter the desired value Be sure to enter the value in kilogram The average d...

Page 163: ...ification is 0 1 C 0 02 Ω with a resolution of 0 01 C The ohmic measurement system in the PG7601 is self calibrated using on board 100 and 110 Ω reference resistors The normal calibration procedure of the PRT is to determine it s offset relative at ambient temperature relative to a reference This can be done without removing the RPT from the mounting post if a reference is available that can be in...

Page 164: ...vironment if the environment has a clear temperature cycle time Evaluate the results of the readings If total temperature change of either indication is greater than 0 05ºC the temperature instability is too great and the measurements should be repeated until total temperature change is less than 0 05ºC Resume normal ADCS 601 operation Press ESC on the PG7601 until its main run screen appears Pres...

Page 165: ... capability to to view or edit the value of the PG7601 s mounting post PRT offset and slope Use Maintenance Calibration Piston Cylinder see Figure 65 ADCS Tools must be ON for the Maintenance menu to be accessible The PRT calibration data is displayed and edited in the Mounting Post PRT panel Check that the correct PRT is shown by verifying its serial number against the serial number shown in the ...

Page 166: ...be removed from the ADCS 601 system See Section 7 3 5 2 for instructions on removing the PG7601 CDG assembly and readout The CDG and its power supply readout are completely autonomous elements whose calibration is independent of ADCS 601 The units should return from calibration adjusted to operate within manufacuturer s specifications No settings in ADCS 601 are required when the CDG and supply re...

Page 167: ...he CDG Disconnect the CDG isolation valve valve 3 1 8 in pneumatic actuation line V9 using the quick connector on the valve Disconnect the electrical cable on the top of the CDG Break the KF40 fitting on the AMH 38 vacuum chamber or the KF25 fitting on the adaptor DO NOT BREAK ANY FITTINGS ON THE CDG SIDE OF THE VALVE Remove the CDG supply readout Remove the Control Cabinet main rear panel to acce...

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Page 169: ...r to clear Record conditions leading up to the event including the numbers displayed when enter is pressed and report the information to a DHI Authorized Service Provider PG7601 displays TOUT or TIME OUT PG7601 is having a communications problem with an external device or pressure generation control component Check setup and communications with external vacuum gauge or pressure generation control ...

Page 170: ...n position indication needs to be adjusted Clean piston cylinder level PG7601 Platform remove sources of vibration calibrate piston position inidication 6 6 PG7601 piston position readings seem incorrect Piston position reading system needs to be adjusted Execute piston position detection adjustment procedure 6 7 FPG8601 pressure indication is unstable when the FPG8601 is bypassed vented Piston cy...

Page 171: ... corresponding values expressed in other units 9 1 1 PRESSURE Table 25 Pressure unit of measure conversions TO CONVERT FROM PA TO MULTIPLY BY Pa Pascal 1 0 mbar millibar 1 0 E 02 kPa kilo Pascal 1 0 E 03 bar Bar 1 0 E 05 mmWa 4 C millimeter of water 1 019716 E 01 mmHg 0 C millimeter of mercury 7 50063 E 03 psi pound per square inch 1 450377 E 04 psf pound per square foot 1 007206 E 06 inWa 4 C inc...

Page 172: ...mass set is a an AMH 38 mass set with a nominal total mass of 38 kg Mass Bell The combination of parts that is loaded onto the piston to carry the masses This includes the sleeve that is slid over the piston the binary mass tray and the lifting shaft Medium pressurized The pressurized fluid Multiplier A value by which internal sensor readings are multiplied to change their slope pressure multiplie...

Page 173: ...pose of this warranty such indirect damage includes but is not limited to loss of production profits revenue or goodwill even if DHI has been advised of the possibility thereof and regardless of whether such products are used individually or as components in other products Items returned to DHI under warranty claim but determined to not have a defect covered under warranty or to not have a defect ...

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