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PG7000™ OPERATION AND MAINTENANCE MANUAL

© 1998-2008 DH Instruments, a Fluke Company

Page 182

5.3

PISTON-CYLINDER MODULES

5.3.1

DISASSEMBLY, CLEANING AND MAINTENANCE

PURPOSE

To disassemble and reassemble piston-cylinder modules and clean the piston-cylinder
elements when necessary.

PRINCIPLE

PG7000 piston-cylinders are high precision metrological assemblies. The annular gap
between the piston and the cylinder is adjusted to be less than 1 micron, and in some cases,
less than 0.5 micron. In normal operation, this space is lubricated by the pressurized medium
(except PC-7200 in which the piston-cylinder modules are gas operated but the space is
lubricated with a liquid). If the space becomes contaminated, usually due to foreign matter
carried by the pressurized medium, PG7000 performance can be affected. Symptoms of
contamination of the space (a

dirty

piston-cylinder) include:

•

Difficulty rotating piston:

The motorized rotation system (if present) is unable to start

piston rotation.

•

Decay in rotation rate is more rapid than normal:

Piston rotation slows down too

quickly, especially at low mass loads.

•

Poor sensitivity:

Very small mass changes do not have usual effect.

•

Noisy pressure:

The pressure defined when the piston is floating is not a stable as it

usually is.

If any of these symptoms are present, they

may

be caused by a

dirty

piston-cylinder.

The piston-cylinder module should be disassembled and the piston-cylinder cleaned. See
Section 5.3.2.1 for instructions and disassembly and cleaning of gas operated, gas lubricated
piston-cylinders (PC-7100 and PC-7600), Section 5.3.2.2 for gas operated, liquid lubricated
piston-cylinders (PC-7200) and Section 5.3.2.3 for oil operated piston-cylinders (PC-7300).

Gas lubricated piston-cylinders (PC-7100 and PC-7600) are highly sensitive to

contamination, much more so than liquid lubricated piston-cylinders (PC-7200 and PC-7300). When
using gas lubricated piston-cylinders, if symptoms of contamination develop rapidly with
operation after cleaning, there is almost certainly a source of contamination within the PG7000
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) or it is the return from unclean gas operated DUTs that are connected
to the PG7000 system.

Gas operated, liquid lubricated piston-cylinders (PC-7200) can exhibit behavior similar to

that of a dirty piston-cylinder when they are operated without lubricating liquid in the piston-
cylinder module reservoir. Before disassembling a PC-7200 piston-cylinder module for cleaning
due to poor performance, try filling the lubricating liquid reservoir (see Section 5.3.3).

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Summary of Contents for PG7000

Page 1: ... 1998 2008 DH Instruments a Fluke Company PG7000 PISTON GAUGES PG7102 PG7202 PG7302 PG7601 Ver 2 07a through 2 07g Operation and Maintenance Manual ...

Page 2: ...truments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described in it Mention of any product or brand does not constitute an endorsement by DH Instruments of that product or brand This manual was originally composed in English and was subsequently translated into other languages The fidelity of the...

Page 3: ...RMINAL REAR PANEL 12 1 3 2 PLATFORM REAR PANELS 12 2 INSTALLATION 13 2 1 UNPACKING AND INSPECTION 13 2 1 1 REMOVING FROM PACKAGING 13 2 1 1 1 PLATFORM 13 2 1 1 2 MASS SET 13 2 1 1 3 PISTON CYLINDER MODULE S 14 2 1 1 4 AUTOMATED MASS HANDLER 14 2 1 2 INSPECTING CONTENTS 14 2 1 2 1 PLATFORM 14 2 1 2 2 MASS SET 19 2 1 2 3 PISTON CYLINDER MODULE S 21 2 2 SITE REQUIREMENTS 22 2 3 SETUP 23 2 3 1 PREPARI...

Page 4: ...EN 45 3 8 GENERAL FUNCTION MENU FLOW CHART 46 3 9 DIRECT FUNCTION KEYS 47 3 9 1 DIRECT FUNCTION KEYS SUMMARY 47 3 9 2 P C 48 3 9 3 UNIT 49 3 9 3 1 CUSTOMIZING PRESSURE UNITS AVAILABLE UNDER THE UNIT FUNCTION 50 3 9 4 MODE 52 3 9 4 1 DIFFERENTIAL MEASUREMENT MODE PG7601 ONLY 53 3 9 4 2 HIGH LINE DIFFERENTIAL MEASUREMENT MODE PG7102 PG7302 AND PG7202 ONLY 60 3 9 5 SYSTEM 72 3 9 5 1 FIRST SYSTEM RUN ...

Page 5: ...125 3 11 8 1 2CONTROL 1UP DOWN 126 3 11 8 2 2CONTROL 2DISCREET 126 3 11 8 3 2CONTROL 3LOADALL 127 3 11 8 4 2CONTROL 4UNLOADALL 127 3 11 9 9RESET 127 3 11 9 1 9RESET 1SETS 128 3 11 9 2 9RESET 2UNITS 128 3 11 9 3 9RESET 3COM 129 3 11 9 4 9RESET 4CAL 129 3 11 9 5 9RESET 5SETUPS 130 3 11 9 6 9RESET 6ALL 130 4 REMOTE OPERATION 131 4 1 OVERVIEW 131 4 2 INTERFACING 131 4 2 1 RS232 INTERFACE 131 4 2 1 1 C...

Page 6: ... 5 3 2 2 DISASSEMBLY AND REASSEMBLY OF GAS OPERATED LIQUID LUBRICATED PISTON CYLINDER MODULES PC 7200 187 5 3 2 3 DISASSEMBLY AND REASSEMBLY OF OIL OPERATED OIL LUBRICATED PISTON CYLINDER MODULES PC 7300 189 5 3 3 FILLING OR EMPTYING GAS OPERATED LIQUID LUBRICATED PISTON CYLINDER MODULE RESERVOIR WITH LIQUID 191 5 3 4 CLEANING PISTON CYLINDERS 192 5 3 5 LUBRICATING PISTON CYLINDER MODULES 194 5 3 ...

Page 7: ...ure Available 51 Table 16 Valve Settings for Setting Differential Mode Static Pressure 56 Table 17 Valve Settings to Apply PG7000 Pressure to the RPM for Differential Mode Offsetting 57 Table 18 Valve Settings for Operating in Differential Mode 59 Table 19 SETUP File Choices Factory Preferred Choice and Normal Value 92 Table 20 Security Levels Functions NOT Executed Per Function Level 117 Table 21...

Page 8: ... 63 Figure 12 Status Byte Register 166 Figure 13 PG7202 Mounting Post Drain 181 Figure 14 10 and 20 kPa kg Gas Piston Cylinder Module Expanded View 184 Figure 15 10 kPa kg Piston Insertion Tool 185 Figure 16 Gas Piston Cylinder Module Sleeve Nut Tool 185 Figure 17 50 100 and 200 kPa kg Gas Piston Cylinder Modules Expanded View 186 Figure 18 Gas Operated Liquid Lubricated Piston Cylinder Module Exp...

Page 9: ...ion of general PG7000 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 PG7000 behavior based on the symptoms of that behavior Certain words and expressions have specific meaning as they pertain to PG700...

Page 10: ...PG7000 OPERATION AND MAINTENANCE MANUAL 1998 2008 DH Instruments a Fluke Company Page VIII N NO OT TE ES S ...

Page 11: ... PC 7100 7600 modules Maximum pressure is 11 MPa 1 600 psi Does not support definition of pressure against a vacuum reference PG7202 Gas operated liquid lubricated piston cylinder modules PC 7200 modules Oil operated piston cylinder modules PC 7300 modules Maximum pressure is 110 MPa 16 000 psi when operated with a PC 7200 module Maximum pressure is 200 MPa 30 000 psi when operated with a PC 7300 ...

Page 12: ... COM3 Automated pressure generator controller Host computer Overall Pressure Ranges Actual range depends on piston cylinder and mass set selection PG7102 Gauge 5 kPa to 11 MPa 0 7 to 1 600 psi Absolute 105 kPa to 11 MPa 15 to 1 600 psi Differential DP static pressure 11 MPa 1 600 psi PG7202 Gauge gas 100 kPa to 110 MPa 15 to 16 000 psi Absolute gas 200 kPa to 110 MPa 30 to 16 000 psi Gauge oil PG7...

Page 13: ... 20 vacuum fluorescent display and 4 x 4 function driven keypad Real time 1 second update rate display and measurement of ambient pressure temperature humidity and instrument piston cylinder temperature piston position piston drop rate piston rotation rate piston rotation decay rate reference vacuum conditions Real time 1 second update rate mass to pressure and pressure to mass calculations taking...

Page 14: ...mmands to set and read all instrument functions 1 2 1 2 AMBIENT AND INSTRUMENT CONDITION MEASUREMENTS Temperature Range Resolution Measurement Uncertainty Ambient Piston Cylinder Module 0 to 40 o C 0 to 40 o C 0 1 0 01 1 0 1 Barometric Pressure with Internal Sensor Range Resolution Measurement Uncertainty 70 to 110 kPa 10 Pa 140 Pa Barometric pressure can also be read automatically with any RS232 ...

Page 15: ...on Material Cylinder Material Nominal Diameter Nominal Area Mounting System Gas operated gas lubricated Tungsten carbide Tungsten carbide 25 mm 500 mm 2 Simple free deformation PC 7100 7600 50 Operation Piston Material Cylinder Material Nominal Diameter Nominal Area Mounting system Gas operated gas lubricated Tungsten carbide Tungsten carbide 16 mm 200 mm 2 Negative free deformation PC 7100 7600 1...

Page 16: ...Nominal Area Mounting System Gas operated liquid lubricated Synturion 6 Krytox optional Tungsten carbide 7 9 mm 49 0 mm 2 Negative free deformation PC 7200 500 Operation Lubricating Liquid Piston and Cylinder Material Nominal Diameter Nominal Area Mounting System Gas operated liquid lubricated Di 2 ethylhexyl Sebacate Krytox optional Tungsten carbide 5 0 mm 19 6 mm 2 Negative free deformation PC 7...

Page 17: ...ubricated Tungsten carbide 7 9 mm 49 0 mm 2 Simple free deformation PC 7300 500 Operation Piston and Cylinder Material Nominal Diameter Nominal Area Mounting System Oil operated oil lubricated Tungsten carbide 5 0 mm 19 6 mm 2 Simple free deformation PC 7300 1 Operation Piston and Cylinder Material Nominal Diameter Nominal Area Mounting System Oil operated oil lubricated Tungsten carbide 3 5 mm 9 ...

Page 18: ...ainty in piston cylinder effective area and typical measurement uncertainty in pressure defined by the piston gauge see the piston cylinder calibration report and current revision of DHI Technical Note 7920TN01 PC 7100 7600 10 PC 7100 7600 10 L Sensitivity 1 Reproducibility 2 Typical Drop Rate 35 kg 0 02 Pa 0 5 ppm 2 ppm 0 2 mm min PC 7100 7600 20 Sensitivity 1 Reproducibility 2 Typical Drop Rate ...

Page 19: ...ical Note 7920TN01 PC 7200 100 Sensitivity 1 Reproducibility 2 Typical Drop Rate 50 kg 2 Pa 1 ppm 5 ppm 0 10 mm min PC 7200 200 Sensitivity 1 Reproducibility 2 Typical Drop Rate 50 kg 4 Pa 1 ppm 5 ppm 0 15 mm min PC 7200 500 Sensitivity 1 Reproducibility 2 Typical Drop Rate 50 kg 10 Pa 1 ppm 5 ppm 0 20 mm min PC 7200 1 Sensitivity 1 Reproducibility 2 Typical Drop Rate 50 kg 20 Pa 1 ppm 5 ppm 0 25 ...

Page 20: ...00 Sensitivity 1 Reproducibility 2 Typical Drop Rate 50 kg 4 Pa 1 ppm 5 ppm 0 04 mm min PC 7300 500 Sensitivity 1 Reproducibility 2 Typical Drop Rate 50 kg 10 Pa 1 ppm 5 ppm 0 10 mm min PC 7300 1 Sensitivity 1 Reproducibility 2 Typical Drop Rate 50 kg 20 Pa 1 ppm 5 ppm 0 20 mm min PC 7300 2 Sensitivity 1 Reproducibility 2 Typical Drop Rate 50 kg 40 Pa 1 ppm 5 ppm 0 40 mm min PC 7300 5 Sensitivity ...

Page 21: ... TERMINAL FRONT AND REAR PANELS 1 3 1 1 PG TERMINAL FRONT PANEL The front panel assembly 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 PG7000 models 1 Fluorescent display 2 Keypad Figure 1 PG Terminal Front Panel ...

Page 22: ...l remote communication connections and pressure connection ports The rear panels of all PG7000 models are identical except for the pressure connections see Figure 3 7 1 COM2 RS232 External Barometer External Vacuum Gauge PG7601 only and Pass Through Communications 2 COM3 RS232 Automated Pressure Generation Control Component AMH Automated Mass Handler 3 COM1 RS232 Remote Host Communications 4 Ambie...

Page 23: ...upper packing insert Inspect and inventory the accessories see Section 2 1 2 Remove the upper packing insert Carefully lift the PG7000 Platform from its position in the lower packing insert Note the orientation so that the same orientation will be used when PG7000 is repacked Reinstall the upper packing insert into the shipping and storage case and store in a safe place 2 1 1 2 MASS SET The stabil...

Page 24: ...dule in its bullet case be sure to empty out any liquid that may have collected in the hole in the bottom of the case Excess liquid will not compress making it difficult to fully close the case and could result in damaging it 2 1 1 4 AUTOMATED MASS HANDLER See the AMH 38 AMH 100 Operation and Maintenance Manual 2 1 2 INSPECTING CONTENTS Check that all items are present and have NO visible signs of...

Page 25: ...227 CE Power Cable 100770 Black 100770 CE Gray Accessory Kit 401560 NIP SS DH200 2 75 in 100204 ADPT SS DH200 F x 1 8 in NPT F 100299 O ring Buna 2 242 2 ea 101976 Storage Cover 7600 Type 102132 Allen Wrench 2 5 mm 102257 Allen Wrench 3 mm 102168 Allen Wrench 5 mm 102262 Spanner Wrench Metrological 122568 Krytox GPL205 6 0 5 oz 102496 Gift Kit with Gloves 400511 ADPT DH200 M x 1 8 in swage 400518 ...

Page 26: ... meters 102227 CE DB25M DB25F 1 5 meters 102227 CE Power Cable 100770 Black 100770 CE Gray Accessory Kit 401134 DH500 M x 1 8 in NPT F 103610 O ring Buna 2 242 2 ea 101976 Storage Cover 7600 Type 102132 Allen Wrench 2 5 mm 102257 Allen Wrench 3 mm 102168 Allen Wrench 5 mm 102262 Wrench 5 8 in 103044 Collar SS DH500 101201 Krytox GPL205 6 0 5 oz 102496 Gift Kit with Gloves 400511 Documentation Cali...

Page 27: ...102227 CE DB25M DB25F 1 5 meters 102227 CE Power Cable 100770 Black 100770 CE Gray Accessory Kit 401134 DH500 M x 1 8 in NPT F 103610 O ring Buna 2 242 2 ea 101976 Storage Cover 7600 Type 102132 Allen Wrench 2 5 mm 102257 Allen Wrench 3 mm 102168 Allen Wrench 5 mm 102262 Wrench 5 8 in 103044 Collar SS DH500 101201 Krytox GPL205 6 0 5 oz 102496 Gift Kit with Gloves 400511 Documentation Calibration ...

Page 28: ...a 2 242 2 ea 101976 Storage Cover 7600 Type 102132 Allen Wrench 2 5 mm 102257 Allen Wrench 3 mm 102168 Allen Wrench 5 mm 102262 Spanner Wrench Metrological 122568 Krytox GPL205 6 5 oz 102496 Gift Kit with Gloves 400511 ADPT DH200 M x 1 8 in swage 400518 Valve Vacuum Relief 401050 Union SS 4P 101984 Valve Toggle 4T OGS2 103733 ADPT SS 4P x 1 8 in NPT F 103734 Screen Vent SS 1 8 in NPT M 103735 Inst...

Page 29: ...t 80 and 100 kg DESCRIPTION PART NO Mass Set Refer to Table 9 Reusable Molded Transit Case with Foam Inserts 80 kg set 100 kg set 122577 1 ea 1 ea 123035 2 ea 3 ea Mass Set Tray and Spindle 123051 and 123536 Dust Covers 102814 and 102846 Calibration Report 550100 Table 7 AMH 38 Mass Set Parts List DESCRIPTION PART NO Mass Set Refer to Table 9 Reusable Molded Transit Case with Foam Inserts 13 kg se...

Page 30: ...1 1 1 MS AMH 38 402063 38 5 1 1 1 1 1 1 1 MS AMH 40 402089 40 3 1 1 1 1 1 1 1 1 MS AMH 60 402088 60 5 1 1 1 1 1 1 1 1 MS AMH 80 402087 80 7 1 1 1 1 1 1 1 1 MS AMH 100 402064 100 9 1 1 1 1 1 1 1 1 All mass sets also include a trim mass set of 50 g to 0 01 g total 100 g Table 10 Mass Set Compatibility 1 These mass sets on certain piston cylinder sizes can cause the maximum working pressure of the PG...

Page 31: ... 402431 401243 402131 401242 402142 401242 O rings 101918 102380 101918 102380 101918 102380 101921 102380 101921 102380 101921 102380 Insertion Tool 402371 402394 N A N A N A N A Calibration Report 550100 550100 550100 550100 550100 550100 Table 12 PC 7200 Piston Cylinder Modules Parts List 100 kPa PC 7200 100 200 kPa PC 7200 200 500 kPa PC 7200 500 1 MPa PC 7200 1 2 MPa PC 7200 2 Piston Cylinder...

Page 32: ...xcessive high frequency vibration for example from a vacuum pump on the same table as the PG7000 may affect piston sensitivity Bench stability Up to 100 kg may be loaded and unloaded onto the PG7000 Platform The bench on which the PG7000 sits should not deflect significantly under the mass load changes This can be verified by setting the PG7000 Platform on the bench leveling it loading and unloadi...

Page 33: ...pin cable supplied Connect electrical power 85 to 264 VAC 50 60 Hz to the PG7000 Terminal using the power cable supplied Any grounded power cable with a standard IEC320 313 connection may be used PG7601 Only Install the vacuum vent valve kit on the vacuum vent port on the rear of the PG7000 Platform Refer to the instruction sheet provided with the vent valve assembly Connect the reference vacuum s...

Page 34: ... 2 3 3 PG7302 DH500 DH500 is equivalent to AE F250C HIP HF4 etc If using a standard interconnections kit such as PK 7600 PPC MPC P N 400985 PK 7600 PPC MPC DIF P N 401581 or PK 7100 MPCD DIF P N 401645 see the instruction sheet provided with the kit for installation instructions If an OPG1 or GPC1 generator controller is being used pressure interconnecting hardware is included with it See its Oper...

Page 35: ...a 9 kg mass if the main masses are 10 kg It is 4 or 4 5 kg if the main masses are 5 kg The make up mass is placed on top of the main mass stack It is always the top of the stack Install the fractionary masses The fractionary masses are all the masses of lower value than the main masses and makeup mass These are masses of 5 kg and under for mass sets with 10 kg main masses They are masses of 2 kg a...

Page 36: ...If installing the piston cylinder module into a PG7302 or a PG7202 to be operated with oil first use the oil generation control component to fill the counter bore in the mounting post with oil until it just starts to overflow Purge the air from under the piston cylinder module PC 7300 modules only in PG7302 or PG7202 Rotate the piston cylinder module clockwise until all threads are engaged and the...

Page 37: ...dent gas operated and oil operated piston gauges When switching PC 7200 module between oil and gas and oil operation see Section 5 3 3 for information on emptying excess oil from the module Switching a PG7202 from gas to oil operation Only the high pressure PC 7300 oil modules may be used in the PG7202 platform PC 7300 1 2 5 Disconnect the gas generation control system from the TEST port Disconnec...

Page 38: ... torque DH500 glands to 15 Nm 12 ft lb Prepurge the oil from the PG7202 mounting post Hold a paper towel lightly over the DRAIN port opening Leaving the drain port open use the gas generation control component to flow enough gas through the mounting post to just lift the piston Purge the PG7202 mounting post Purge the PG7202 mouting post using the standard purging procedure see Section 5 2 4 and f...

Page 39: ...4 4 SETUP PRESSURE EQUATION VARIABLE INPUT SOURCES PG7000 uses many variables in calculating defined pressures The sources of the variables are determined by the current SETUP file SETUP files are viewed created edited and selected using the SETUP function accessed by pressing SETUP see Section 3 10 A factory SETUP file is available and already selected on a new PG7000 but the operator may desire ...

Page 40: ...approximately equal to the piston mass to pressure conversion factor multiplied by the mass load in kg The piston cylinder conversion factor is marked on the top of the piston cap and is in either kPa or MPa per kilogram kPa kg or MPa kg If the piston cannot be floated because it immediately sinks down from a float position there is a leak in the pressure system Identify and eliminate leaks until ...

Page 41: ...and measuring a vacuum reference To verify the vacuum reference capability n Install a piston cylinder module see Section 2 3 2 o Install the bell jar on the PG7601 Platform the bell jar aligns on the PG7601 vacuum plate and seals itself If using AMH 38 automated mass handling install the AMH 38 mass handler see the AMH 38 AMH 100 Operation and Maintenance Manual p Apply a vacuum through the refer...

Page 42: ... See Section 3 11 4 5 for information on the security system As part of the PG7000 startup set your desired security level and a password PG7000 is delivered with the security level set to low to avoid inadvertent altering of critical internal settings but with access to changing security levels unrestricted It is recommended that the low security level be maintained at all times and password prot...

Page 43: ...3 Verify that there are NO leaks in the pressure system 2 5 SHORT TERM STORAGE The following is recommended for short term storage of PG7000 Remove all masses from the PG7000 Platform manual mass set only Vent all circuits to atmosphere Turn OFF power using the power switch on the rear of the PG7000 Terminal Cover the PG7000 Platform and mass set with the dust covers included in the platform and m...

Page 44: ...PG7000 OPERATION AND MAINTENANCE MANUAL 1998 2008 DH Instruments a Fluke Company Page 34 N NO OT TE ES S ...

Page 45: ...on and allow masses to be loaded on top of the piston There are different PG7000 models depending upon whether the pressure medium is oil or gas and whether a vacuum reference is needed The measurement uncertainty in the pressure defined by the piston gauge depends on the uncertainty in the effective area of the piston cylinder and the force applied by the mass accelerated by gravity PG7000 stores...

Page 46: ...gap between the piston and the cylinder through lateral holes near the bottom of the cylinder allowing liquid from the reservoir to enter the gap The pressure of the liquid in the gap Pl is equal to the gas pressure Pg plus the liquid head h Therefore the liquid pressure in the gap is always higher than the gas pressure by the amount of the liquid head regardless of the gas pressure value Since h ...

Page 47: ...in menus and editing entries 3 The Menu Data keys provide access to function menus from the main run screen The menu name is on the bottom half of the key The SETUP menu is for more frequently used functions The SPECIAL menu is for functions that are NOT generally used as a part of day to day operation These keys enter numerical values when editing Figure 7 PG7000 Keypad Layout Key press confirmat...

Page 48: ...Section 3 11 4 2 Sounds are used for the following indications Valid key press Brief high frequency beep Invalid key press Three rapid low frequency beeps Piston left end of stroke high or low Three rapid valid key press beeps Piston was at low stop or high stop and just entered spring zone see Section 3 5 3 4 PRESSURE READY NOT READY INDICATION The three characters on the top line far left of the...

Page 49: ...its specified in the current SETUP file see Section 3 10 The flashes if the piston is not at the top stop position to alert the user that this indicator is Not Ready Piston position not known current specified mass load is less than the load of the piston bell The bell must be installed for PG7000 piston position measurement to operate correctly so piston position values shown are not valid when t...

Page 50: ... only PG7000 model with vacuum reference capability It is only active when operating in absolute by vacuum mode see Section 3 9 4 The vacuum reference Ready Not Ready character indicates Ready or Not Ready based on the value of reference vacuum when making measurements in absolute by vacuum mode This ensures that definitions of absolute pressure with a vacuum reference will be made with the vacuum...

Page 51: ...ressure applied to the piston is within the equivalent of 2 kg of the pressure corresponding to the mass loaded on the piston The high and low spring zones indicate the piston is about to float The spring zone positions are fixed High and low measurement zones The piston is within the zone in which a Ready measurement can be made see Section 3 4 1 The pressure applied to the piston is the pressure...

Page 52: ... are different in pressure to mass mode see Section 3 9 12 the actual mass value loaded on the piston will be different from the mass loading instruction In the same manner in mass to pressure mode the nominal value of the mass load that the operator enters is different from the actual mass loaded on the piston The mass value shown in the MAIN run screen see Section 3 7 is always the actual mass v...

Page 53: ...nd then the makeup mass if possible kkk k is made up of the largest masses possible rather than a combination of smaller masses EXAMPLE To load 5 kg on a PG7601 USE the piston 0 2 kg the mass loading bell 0 3 kg the 4 5 kg makeup mass DO NOT USE the piston the mass loading bell 2 kg 1 2 kg 2 0 5 kg 1 When several masses of the same nominal value are included in kkk k they are loaded in numerical s...

Page 54: ...e pressure value to assure that adequate masses remain to set the desired differential pressure For example if the line pressure requires loading 10 6 kg the 0 5 and 0 1 kg masses will be used to set the line pressure and will not be available if they are needed to set the differential pressure If this situation occurs consider adjusting the line pressure so that it is set using a whole number of ...

Page 55: ...ble or out of range Flashes if condition is Not Ready and piston is floating see Section 3 4 2 v Vacuum Reference Ready Not Ready PG7601 only when Ready v if Not Ready due to vacuum not below ready limit Flashes if condition is Not Ready and piston is floating see Section 3 4 3 2 PRESSURE1 Numerical value and sign of the pressure defined by PG7000 with current mass loaded on current piston when al...

Page 56: ...and mass load 2 SYSTEM run screens Display piston position rotation temperature and reference vacuum PG7601 only AMBIENT run screen Displays ambient pressure temperature relative humidity and local gravity The flow chart below outlines the operating protocol of the run screens and associated key presses INTRO SCREEN MAIN RUN SCREEN SYSTEM 1 RUN SCREEN SYSTEM 2 RUN SCREEN AMBIENT RUN SCREEN POWER U...

Page 57: ...0 1 kg Edit and select files that determine the sources of the values for the variables PG7000 uses in calculations of reference pressures Access SYSTEM run screens 2 which display current measurements of piston behavior piston cylinder temperature and reference vacuum if present Toggles between the two screens Select pressure to mass or mass to pressure operation Access AMBIENT run screen which d...

Page 58: ...ese files can be added deleted viewed and edited by pressing SPECIAL 1pc ms see Section 3 11 1 The P C function provides rapid access from any run screen to viewing the piston cylinder modules available and selecting one to be active OPERATION Pressing P C activates the piston cylinder module viewing and selecting function Pressing the P C key again or while in the P C function steps through displ...

Page 59: ...sure in which the range offered by the piston cylinder module using the active mass set is displayed can be changed by pressing UNIT see Section 3 9 3 When the current pressure unit of measure is an altitude unit piston cylinder module range is expressed in kPa if the altitude unit is meters m or psi if the altitude unit is feet ft 3 9 3 UNIT PURPOSE To specify the unit of measure in which defined...

Page 60: ...PG7202 and PG7302 1MPa 2kPa 3bar 4psi 5kcm2 To restore the default UNIT function settings use the Unit Reset see Section 3 11 9 2 Certain internal and or metrological functions e g vacuum reference pressure are always represented in Pascal Pa regardless of the active pressure unit of measure When the current pressure unit of measure is an altitude unit atmospheric pressure in the AMBIENT run scree...

Page 61: ...nHg 4inWa 5kcm2 6Torr 7mTor 8none 1m 2ft 1user 3altitude PG7601 in absolute by vacuum mode only Not available in PG7102 PG7202 and PG7302 4user User defined unit As there are no altitude units on PG7102 PG7202 and PG7302 user is 3user The UNIT function display is not required to display six units To delete the current unit from the UNIT screen and show no unit select 2other 6none for that unit num...

Page 62: ...ll PG7000 models The barometer can be PG7000 s on board sensor or a remote RS232 barometer The uncertainty on the value of atmospheric pressure measured by the barometer must be considered but this value can become relatively small as pressure goes up For example if using a 0 01 barometer the added uncertainty at 1 MPa 150 psi is 10 ppm This mode is more convenient and less costly than absolute by...

Page 63: ...2 PG7202 and PG7302 selecting 3HLdif accesses high line differential mode see PRINCIPLE above and Section 3 9 4 2 For PG7601 selecting 2avac accesses absolute by vacuum mode Selecting 3aatm accesses absolute by ATM mode Selecting 4dif accesses differential mode see PRINCIPLE above and Section 3 9 4 1 Making a measurement mode selection returns to the previous run screen with the selected mode acti...

Page 64: ...determined by applying the static pressure as defined by the PG7601 following RPMoffset PGRPMstart RPMindicate Where PGRPMstart Pressure applied by PG7601 to RPM nominally equal to RPMstart RPMindicate RPM reading when PGRPMstart is applied to RPM test port Once the RPM offset has been determined differential pressures are defined by subtracting the static pressure measured by the RPM from an abso...

Page 65: ...tion on differential mode principles and includes a complete uncertainty analysis Consult DHI or visit www dhinstruments com OPERATION To select differential mode operation and access differential mode functions press MODE and select 4dif Differential mode operation includes Selecting differential mode setting static pressure and finding the RPM offset see Section 3 9 4 1 Selecting Differential Mo...

Page 66: ...uent determinations is 0 1 Pa then less frequent offset determinations may be considered Select 2yes to proceed with a new determination of the RPM offset see Section 3 9 4 1 PRINCIPAL The display is 1 Current pressure reading of the RPM in the current units of Set RPM P ENT 96 57785 kPa a Table 16 Valve Settings for Setting Differential Mode Static Pressure VALVE VALVE SETTING Control Selection S...

Page 67: ...truction is always given with 0 01 g resolution regardless of the current mass loading resolution setting see Section 3 9 10 Load the mass value following PG7000 mass loading protocol see Section 3 6 If an AMH 38 automated mass handler is being used the mass is loaded automatically and default mass loading reasolution of 0 1 kg is used Set the PG7000 Differential Mode Controller see Figure 9 to ap...

Page 68: ...eflected as zero drift of the differential pressures defined during the test To quantify this value perform the RPM offset procedure at the beginning and at the end of a test and evaluate the difference between the starting and ending RPM offset values Operating in Differential Mode Differential mode is often used to calibrate DUTs with very low differential pressure ranges These can easily be ove...

Page 69: ...fferential Mode Controller PG SHUTOFF valve in CLOSED position If desired read DUT output at zero differential pressure with TEST BYPASS valve open Put TEST BYPASS valve in CLOSED position If desired put CONTROL valve in STATIC P position and use system control component to adjust static pressure to starting value Press ENTER and enter a pressure or mass value Load mass as instructed on PG7000 Ins...

Page 70: ...e two different conditions to correct for the defect in the RPM offset Viewing Static Pressure and RPM Offset 2view To view the current RPM offset and the static pressure value at which the offset was recorded press MODE and select 4dif 2view This display is 1 RPM offset value that is currently active 2 PG7000 pressure at which RPM offset was recorded Offset 6 33 Pa 99 8755 kPa a Press ESCAPE to r...

Page 71: ...sure The crossfloating procedure consists of making mass adjustments on the tare PG7000 so that both pistons when connected together at the line pressure fall at their natural drop rate PG7000 s embedded piston fall rate measurements and calculations capabilities are used to assist the operator in performing the crossfloat The PG7000 that is used only to maintain the line pressure on the low side ...

Page 72: ...manages the data acquisition and handling necessary to support differential mode operation Differential mode operation requires setting the line pressure including crossfloating the two PG7000 piston gauges and then setting differential pressures at the line pressure These two independent operations are supported under MODE 3HLdif 1run High line differential mode relies upon the very high sensitiv...

Page 73: ...on high line differential mode principles using PG7102 and PG7601 piston gauges and includes a complete uncertainty analysis Consult DHI or visit our website www dhinstruments com to obtain a copy OPERATION High line differential mode does not support operation with AMH automated mass handler s To select high line differential mode operation and access differential mode functions press MODE 3HLdif...

Page 74: ...ifferential mode the reference PG7000 tests for these conditions and provides error messages as follows Cannot find PG7000 on COM2 COM2 of the reference PG7000 must be connected to COM1 of the tare PG7000 using a valid RS232 cable and both interfaces must be properly set so that communications between the two PG7000s can occur see Sections 3 11 5 1 3 11 5 4 If the reference is unable to communicat...

Page 75: ...return to the previous run screen in high line differential measurement mode see Section 3 9 4 2 Setting Differential Pressures at a High Line Pressure Select 2yes to set a new line pressure value or repeat the line pressure setting procedure at the current line pressure value see Section 3 9 4 2 Setting a Line Pressure MODE 3HLdif 1run 2yes The line pressure setting procedure must be executed eac...

Page 76: ...ding instruction display of pressure to mass mode see Section 3 9 11 1 The mass loading instruction is always given with 0 1 kg resolution regardless of the current mass loading resolution setting see Section 3 9 10 Load the indicated mass on both the tare and reference PG7000s following PG7000 mass loading protocol using main and fractional masses only do not use trim masses see Section 3 6 Press...

Page 77: ...unt down while the measurements are made Be sure not to interfere with the free movement of the piston cylinders during the countdown After the countdown completes the results are displayed 1 Average fall rate of the taring piston 2 Average fall rate of the reference piston 3 Difference between the reference and taring piston fall rates R T This is the natural fall rate difference T 0 9 mm min R 1...

Page 78: ...ium fall rate of zero This process can be repeated as many times as desired If a standard piston cylinder and mass set rather than a tare piston cylinder and mass set is being used in the tare PG7000 the tare piston may be the heavy one at the start of the crossfloat see Section 3 9 4 2 PRINCIPLE In this case rather than reduce mass on the tare PG7000 add a small amount of mass to the reference PG...

Page 79: ...pressure mode and set differential pressures at this line pressure see Section 3 9 4 2 Setting Differential Pressures at a High Line Pressure The value of the average equilibrium fall rate measured by the crossfloat should typically be inside of 5 mm min and or the suggested mass adjustment should be inside of 50 mg The device under test DUT can often be used to evaluate the quality of the equilib...

Page 80: ...ing instructions follow conventional PG7000 mass loading protocol see Section 3 6 but the differential mass loading instructions are on top of the line pressure mass load The mass load corresponding to the line pressure on the tare and reference PG7000s must remain exactly the same throughout the differential measurements While in high line differential mode the piston position and piston rotation...

Page 81: ...e differential pressure indicated on the top line of the reference display For best results log DUT readings and average them over time while the PG7000 pistons fall through the 0 0 mm point Averaging for 10 to 30 seconds allows the random pressure noise from piston rotation to be integrated and eliminated Repeat Steps through for each desired differential pressure point If the last differential p...

Page 82: ...ton crossfloat procedure should be performed at the beginning of each sequence of differential pressure definitions To return to the HLDif mode menu press ESCAPE To return to the previous run screen press ENTER 3 9 5 SYSTEM PURPOSE To access the two SYSTEM run screens which display current values of PG7000 piston behavior piston cylinder temperature and vacuum reference PG7601 only measurements OP...

Page 83: ...millimeters mm away from mid stroke position and cannot be changed Indicates HSTOP when the piston is at the high stop all the way up and LSTOP when the piston is at the low stop all the way down Flashes when Not Ready and piston is floating see Section 3 4 1 Indicates when information is unavailable or out of range Pressing ESCAPE in the first SYSTEM run screen returns operation to the MAIN run s...

Page 84: ...fault or user depending on current SETUP selection Flashes when Not Ready and piston is floating see Section 3 4 3 The unit of measure is Pascal Pa and cannot be changed Indicates 20 Pa if current SETUP selection is internal or external and current measurement is out of range or greater than 20 Pascal Blank if PG7000 model is not PG7601 Pressing ESCAPE in the second SYSTEM run screen returns opera...

Page 85: ...ve humidity RH and cannot be changed Indicates if current SETUP selection is internal and current measurement is unavailable or out of range Pressing ESCAPE in the AMBIENT run screen returns operation to the MAIN run screen All function keys are active from the AMBIENT run screen and operation returns to that screen when leaving functions that were accessed from it The current selection in SETUP d...

Page 86: ... liquids To determine when and how precisely a head correction for liquids must be made 0 03 psi inch 90 Pa cm may be used as an estimation of the liquid head value Regardless of the head function s setting corrections are automatically applied to the calculated reference pressure to compensate for the deviation between the current piston position and the mid stroke position see Section 3 11 3 4 T...

Page 87: ... between the current piston position and mid stroke see Section 3 11 3 4 This PISTON head can be turned ON and OFF see Section 3 11 3 4 3 9 8 ROTATE PURPOSE To turn automatic control of motorized piston rotation acceleration and brake ON and OFF See Section 3 9 13 for information on manual control of motorized piston rotation Motorized rotation is optional in PG7102 PG7202 and PG7302 PRINCIPLE Mot...

Page 88: ...or Pressing accelerates rotation or followed by stops rotation see Section 3 9 13 Automatic motorized rotation is generally left ON for normal operation It is turned OFF in situations where rotation system actuation independent of operator initiative is undesired e g when performing a crossfloat intercomparison with another piston gauge OPERATION To access the AutoRotate functions press ROTATE The...

Page 89: ...tion is probably not desired and it is not beneficial for piston deceleration to initiate it when ENTER SET P is pressed For this reason the function to start piston deceleration when ENTER SET P is pressed can be turned ON and OFF If pre deceleration is ON and AutoRotate is ON piston rotation deceleration always initiates immediately when ENTER SET P is pressed If pre deceleration is OFF and Auto...

Page 90: ... automated pressure generation control component idle and does not attempt to use it If an automated pressure control component is included in the PG7000 system automated pressure generation control is generally left ON for normal operation It is turned OFF in situations where pressure control independent of operator initiative is undesired e g when performing a crossfloat intercomparison with ano...

Page 91: ...7 Proper operation of the automated pressure generation control function is dependent on PG7000 s measurements of piston position When using AutoGen be sure that the piston position indication system is properly adjusted see Section 5 2 2 Proper operation of the automated pressure generation control function is dependent on PG7000 s measurements of piston position and rotation rate These measureme...

Page 92: ...essure generation function see Section 3 9 9 and the generation component s Operation and Maintenance Manual UL section OPERATION To view or set the UPPER LIMIT of the automated pressure control component used by AutoGen press GEN 4UL If AutoGen is not currently ON the control component UPPER LIMIT cannot be accessed and an error message is displayed If AutoGen is ON the current UPPER LIMIT of the...

Page 93: ...ess than the worse case agreement between the pressure controller pressure measurement and the pressure indicated by the PG7000 when its piston is floating 3 9 9 5 6REFLOAT PURPOSE To turn ON and OFF a function that causes the automated generation component see Section 3 9 9 to refloat the piston to the target piston position after a new pressure or mass target is entered even if the piston is alr...

Page 94: ...t there is a whole number nominal relationship between mass loaded on the piston in kilograms kg and the pressure at which the piston will float in kilo Pascal kPa or Mega Pascal MPa This relationship is called the pressure to mass conversion coefficient and is expressed as kPa kg or MPa kg The pressure to mass conversion coefficient is marked on the cap of each piston PG7000 mass sets are made up...

Page 95: ...tive the AMH loads the required mass value wit 0 1 kg resolution and the operator is prompted with an instruction to load the trim mass under 0 1 kg For fully automated operation the mass loading resolution should always be set to 0 1 kg OPERATION To access the resolution function press RES The display is Mass loading rsltn 0 01 g and Press the and keys to select the desired level of resolution de...

Page 96: ...ing at the pressure indicated on the top line of PG7000 display Repeat Steps through for each desired pressure value Typical Absolute by Vacuum Mode Operational Sequence PG7601 Only Press MODE and absolute by vacumm avac mode see Section 3 9 4 Press P OR M and select pressure to mass or mass to pressure mode see Section 3 9 12 Press ENTER SET P and enter a pressure or mass value If AutoRoate is ON...

Page 97: ...ion proceeds to the mass loading instruction screen The display is 1 Mass to load using trim masses 2 Nominal mass to load using main and fractional masses Load nominal mass 10 0 kg and 3 17 g If an AMH automated mass handling system is active and mass loading resolution is set to 0 1 kg the AMH loads the mass automatically As it does the steps of its operation are displayed If resolution is set t...

Page 98: ...re generation to be suspended if ON see Section 3 9 9 and AutoRotate to stop piston rotation if ON see Section 3 9 8 When ENTER is pressed to confirm mass entry automated pressure generation and or motorized rotation resume The display is 1 Edit field for total trim mass currently loaded 2 Edit field for nominal mass of main and fractional masses currently loaded Load nominal mass 10 0 kg and 3 17...

Page 99: ... be installed 2 Unknown pressure except in absolute by atmosphere measurement mode in which the current value of atmospheric pressure is displayed This is the value of absolute by atmospheric pressure when the system is vented 3 Unknown meaningless mass load 4 Unknown meaningless piston position psi a mm kg 3 9 12 P OR M PURPOSE To select between PG7000 pressure to mass or mass to pressure operati...

Page 100: ...on is floating and stop rotation before changing the pressure or mass load see Section 3 9 8 Motorized rotation can also be engaged manually to accelerate or brake piston rotation at any time under direct operator control is used for momentary acceleration of piston rotation followed by is used to start a function that stops piston rotation OPERATION To momentarily engage the motorized piston rota...

Page 101: ...rmination PRINCIPLE PG7000 piston gauges perform continuous real time calculations of the pressure defined by the floating piston under current conditions see Section 7 2 for the details on the calculations applied The calculations are used to determine the defined pressure displayed in the MAIN run screen and to arrive at the mass to load value when a target pressure is entered in pressure to mas...

Page 102: ...e see Section 3 10 1 Table 19 SETUP File Choices Factory Preferred Choice and Normal Value VARIABLE SOURCE CHOICES FACTORY DEFAULT CHOICE NORMAL VALUE Atmospheric pressure 1 Internal 2 Normal 3 User 4 COM2 1 Internal 101 325 kPa 14 6959 psi Ambient temperature 1 Internal 2 Normal 3 User 1 Internal 20 C Ambient relative humidity 1 Internal 2 Normal 3 User 1 Internal 45 RH Piston cylinder temperatur...

Page 103: ...OPERATION To select a SETUP file number to make it the active SETUP file press SETUP and select 1select In the following screen enter the number of the desired SETUP file and press ENTER If a valid SETUP file number has been entered operation returns to the previous run screen with the selected SETUP file number displayed and active Entering an invalid SETUP file number causes an error message to ...

Page 104: ...is displayed in RH Select 4PCT to view the piston cylinder temperature variable source choice and the current value The value is displayed in degrees Centigrade C Select 5g to view the gravity variable source choice and the current value The value is displayed in meters per second squared m s2 Select 6READY to view the values of Ready Not Ready status criteria see Section 3 4 These include 1Pposit...

Page 105: ... value If 3user is selected the user value must be entered in the current pressure unit of measure see Section 3 9 3 4COM2 Use real time readings from the device connected by RS232 to PG7000 s COM2 port The external barometer must be properly set up to communicate with PG7000 see Section 3 11 5 4 for information on setting up to read an external barometer For differential mode operation see Sectio...

Page 106: ...sure when operating in absolute by vacuum mode Edit the value in Pascal Pa under which the reference vacuum must be for a vacuum Ready condition to occur see Section 3 4 3 Select 7vac to specify the reference vacuum variable source for the value used for the pressure under the bell jar when calculating the absolute pressure defined in absolute by vacuum mode Pressing 7vac offers the reference vacu...

Page 107: ... output of and adjust PG7000 internal sensors and measurement systems see Section 3 11 7 8AMH View the status of and directly control an AMH automated mass handler see Section 3 11 8 9reset Access and execute various reset options see Section 3 11 9 3 11 1 1PC MS PURPOSE To perform the following piston cylinder module and mass set metrological functions View and edit piston cylinder module metrolo...

Page 108: ...et and mass bell functions as follows Create a new piston cylinder module see Section 3 11 1 1 Edit piston cylinder module information see Section 3 11 1 2 View piston cylinder module information see Section 3 11 1 3 Delete a piston cylinder module see Section 3 11 1 4 Select the active piston cylinder module see Section 3 11 1 5 Create a new mass set see Section 3 11 1 6 Edit mass set information...

Page 109: ...m k P kg mm min Calibration report number nnnnnnnnn Calibration report date yyyymmdd OPERATION Adding or editing a piston cylinder module requires the user to specify a large number of variables in a series of data entry screens described below For a summary of the piston cylinder module data requirements in the order they are edited see PRINCIPLE in this section PG7000 can store up to 18 piston c...

Page 110: ...re operated with oil as the test medium Reference level offset Edit the value of the reference level offset which corrects the piston cylinder reference level for hollow pistons 5 kPa kg 10 kPa kg 20 kPa kg and 50 kPa kg gas lubricated piston cylinder modules only to the reference level marked on the mounting post see Section 3 9 7 The value must be entered in millimeters mm This value is reported...

Page 111: ...art of the PG7000 calibration or recalibration process See Section 3 11 1 1 describing adding a new piston cylinder module The principles and procedures to add or edit a piston cylinder module are identical except for the identification of the piston cylinder module to be edited To edit information on an existing piston cylinder module press SPECIAL 1PC MS and select 1PC 2edit The display identifi...

Page 112: ...rently active piston cylinder module Press ENTER to delete the currently active piston cylinder module or press P C to toggle through the other piston cylinder modules available see Section 3 9 2 When the desired piston cylinder module is identified press ENTER to proceed with deleting the piston cylinder module information Confirmation to delete is required Select 2yes to delete the piston cylind...

Page 113: ...5 kg if the mass set main masses are 5 kg The purpose of this mass is to arrive at a whole number nominal mass load equal to the sets main masses 10 kg or 5 kg when added to the piston and mass loading bell 2 10 kg masses The main masses in a standard 80 or 100 kg mass set Sequentially numbered from 1 up to the total number of 10 kg masses Mass sets of 80 kg do not normally include 10 kg masses 3 ...

Page 114: ...luded in the definition of a mass set Also one PG7000 system may be used with several piston cylinder modules mass loading bells and mass sets Therefore the piston mass and mass loading bell mass information are not part of the mass set Piston mass information is defined and stored in the piston cylinder module file see Section 3 11 1 1 and mass loading bell information is defined and stored in a ...

Page 115: ...MH for an automated mass handler mass set Mass set type 1manual 2AMH Edit the calibration report number up to nine digits to the the number of the current calibration report of the mass set that is being added and press ENTER The display is Cal report number 1 Edit the calibration report date to the date of the current calibration report of the mass set that is being added format must be YYYYMMDD ...

Page 116: ...3 6 PRINCIPLE It is imperative that the make up mass be defined and entered in the MKUP group Operation within each mass group is identical for example select 5 00 The display is 1 Edit field for number of masses in the mass group of masses in group 0 deletes grp 1 Edit the number of masses in group to reflect the number of masses of that nominal value there are in the group and press ENTER The di...

Page 117: ...e mass set data after a recalibration or if a mass set configuration changes PRINCIPLE OPERATION Mass set information is element specific metrological data Uninformed or accidental altering of this information may lead to out of tolerance measurements Mass set information should only be edited by qualified personnel as part of the PG7000 calibration or recalibration process See Section 3 11 1 6 de...

Page 118: ... set is selected operation returns to the MAIN run screen If an AMH automated mass handler mass set is selected the PG7000 platform attempts to establish communication with the AMH and initialize it If the communication cannot be established with the AMH an error is displayed If communication with the AMH mass set is established the AMH is initialized and all masses are loaded If the AMH is unable...

Page 119: ...ading bell and press ENTER The value defaults to the default density for the typical mass loading bell for the PG7000 model The display is Mass density 5058 kg m3 The AMH automated mass handler mass bell includes the bell the binary mass carrier and the mass lifting shaft Edit the calibration report number up to nine digits to the the number of the current calibration report of the mass loading be...

Page 120: ...s loading bell to edit is selected from the existing mass loading bell screen 3 11 1 13 VIEW MASS LOADING BELL PURPOSE To view information contained in an existing mass loading bell file OPERATION To view information contained in an existing mass loading bell file press SPECIAL and select 1PC MS 3mass bell 1view The viewing function is identical to the add function see Section 3 11 1 11 3 11 1 14 ...

Page 121: ...ame height as the piston reference level and if so a head correction is needed to determine atmospheric pressure at the piston reference level This head correction is referred to as ATM head The ATM head height can be edited by pressing SPECIAL and selecting 3head 3atm The ATM head is only applied to internal or external barometer readings It is not applied to normal or user values of atmospheric ...

Page 122: ... of three gasses Making a gas selection returns to the previous run screen with that gas active for the DUT head function The display is Gas type 1N2 2He 3Air If 2liquid is selected the display offers the choice of oil water or a user defined liquid If the user defined liquid is selected its density must be specified Making a liquid selection returns to the previous run screen with that liquid act...

Page 123: ...ection function ON so that a head correction for piston position IS automatically applied Select 2off to turn the PISTON head correction function OFF so that a head correction for piston position IS NOT applied The PISTON head is automatically turned OFF has no effect in gauge or differential measurement mode when the set pressure is zero system vented or bypassed When the system is vented or bypa...

Page 124: ...e screen saver function PRINCIPLE PG7000 has a SCREEN SAVER function which causes the display to dim after a front panel key is NOT pressed for a certain amount of time The default time activates the screen saver after 10 minutes The time can be adjusted by the user or screen saving can be disabled OPERATION To access the SCREEN SAVER function press SPECIAL and select 4prefs 1ScrSav Edit the time ...

Page 125: ... screen PG7000 also allows the user to store one unique twelve character alpha numeric ID number This feature is frequently used to assign an organizational control ID such as an asset number tool number standard number etc The ID function allows the ID number to be viewed and edited It also displays the PG7000 factory serial number OPERATION To access the ID function press SPECIAL and select 4pre...

Page 126: ...e This level is intended for use only by the system manager and or calibration facility It allows access and editing in all areas including critical metrological information and other settings that affect measurement integrity Low Low security is designed to protect the specific metrological information and system diagnostic and maintenance functions of the system against accidental alteration It ...

Page 127: ...ew SPECIAL 1PC MS any selection 2edit SPECIAL 1PC MS any selection 3add SPECIAL 1PC MS any selection 4delete SPECIAL 1PC MS 1PC 5select SPECIAL 1PC MS 2mass set 5select SPECIAL 1PC MS 2mass bell 5select SPECIAL 2presU SPECIAL 3head SPECIAL 4prefs SPECIAL 4prefs 3time make changes SPECIAL 4prefs 4ID 2edit SPECIAL 6remote access SPECIAL 6remote make changes SPECIAL 5prefs 3time make changes SPECIAL ...

Page 128: ...and a password will NOT be required to access the User Level menu This is the factory default with a security level of 2low Once a password has been entered the User Level cannot be changed without reentering the password If there is an active password the PG7000 password entry screen appears PG7000 NS nnn xx Password pppppp The user must enter the user defined password or the factory secondary pa...

Page 129: ...er communications as well as the port s communications settings Select 1settings to view and edit COM2 communications settings Select 2baro to view and edit external barometer communications settings see Section 3 11 5 4 To access the RS232 self test press SPECIAL 5remote 5RS232test 3 11 5 1 COM1 COM2 AND COM3 RS232 The COMx ports can be set for the specific settings required by the user The setti...

Page 130: ...r COM3 COM1 passes PASSED is displayed briefly followed by the conclusion PG7000 RS232 test has PASSED If a test fails Execution is suspended until ENTER is pressed The PG7000 RS232 test can fail for three reasons 1 The RS232 cable being used is incorrect see Section 4 2 1 for information on the correct cable 2 COM1 and COM2 or COM3 do NOT have the same serial communications settings and therefore...

Page 131: ... terminators Supplies CR or CR LF terminators Request to send string must be printable alphanumeric no control modes or nulls After pressing SPECIAL and selecting 5remote 2COM2 2baro 2user the display is COM2 meas req string The string value is entered on the second line It may have up to 20 characters When the string screen is opened the cursor is on the first character Numerical values can be en...

Page 132: ... ambient pressure indicated by the PG7000 to not be identical see Section 3 11 3 3 For communications with an external barometer on COM2 to be established properly the inquiry string to send to the barometer must be defined following this section and the PG7000 COM2 port and barometer COM port must have the same communications settings Press SPECIAL and select 5remote 2COM2 1settings to set up PG7...

Page 133: ...gs on PG7601 COM2 or a DHI RPM s COM2 the following requirements apply to the remote vacuum gauge s communications Replies to a request to send string within 2 seconds Accepts CR LF terminators Supplies CR or CR LF terminators Request to send string must be printable alphanumeric no control modes or nulls After pressing SPECIAL and selecting 5remote 2COM2 3vac 2user the display is COM2 meas req st...

Page 134: ...COM2 under Vac see Section 3 10 and verify that communications with the external vacuum gauge are achieved Then view current vacuum readings in the AMBIENT run screen see Section 3 9 6 and verify that the readings are correct For communications with an external vacuum gauge on COM2 to be established properly the inquiry string to send to the vacuum gauge must be defined following this section and ...

Page 135: ...d part of PG7000 maintenance and are covered in the maintenance section of this manual see Section 5 3 11 8 8AMH PURPOSE Control optional AMH automated mass handling system directly and view its status see the AMH 38 AMH 100 Operation and Maintenance Manual for information PRINCIPLE An optional automated mass handling system is available for PG7000 Platforms AMH 38 is used with PG7601 and AMH 100 ...

Page 136: ...anything else under the AMH trim mass tray When the mass load is lowered it will pinch or crush anything under it 3 11 8 2 2CONTROL 2DISCREET PURPOSE To load and unload specifc AMH masses OPERATION To load and unload specific AMH masses press SPECIAL 8AMH 2control 2discreet The display is 64 is present only with AMH 100 1 2 4 8 16 32 64 Main 1 The 1 2 4 8 16 32 and 64 indicate the 0 1 0 2 0 4 0 8 ...

Page 137: ... loaded on the piston Do not put your fingers or anything else under the AMH trim mass tray When the mass load is lowered it will pinch or crush anything under it 3 11 9 9RESET PURPOSE To reset various PG7000 settings to default or factory values PG7000 stores its user definable settings in non volatile memory The reset menu allows the user to selectively or completely reset these settings to fact...

Page 138: ... to 0 01 g see Section 3 9 10 Automatic rotation off see Section 3 9 8 Automatic rotation pre decel on see Section 3 9 8 1 Automatic pressure generation off see Section 3 9 9 Automatic pressure generation controller raise function to OFF see Section 3 9 9 2 Automatic pressure generation controller tolerance to 0 05 of full scale see Section 3 9 9 4 Automatic pressure generation controller refloat ...

Page 139: ...ecial caution with this reset as critical calibration data may be altered To access Reset Cal press SPECIAL and select 1reset 4cal Reset Cal DOES NOT reset piston cylinder module mass set and mass bell files There is no user available reset for them Reset Cal clears and sets to default the user calibration coefficients for PG7000 on board sensors see Section 5 2 1 This includes Barometric Sensor A...

Page 140: ... 5setups Reset Setups deletes all SETUP files and selects SETUP file 1 as the active SETUP file see Section 3 10 3 11 9 6 9RESET 6ALL OPERATION PURPOSE To return PG7000 to the original as delivered factory condition To access Reset All press SPECIAL and select 1reset 6all Performs the functions of the Sets Units Cal and Com resets see Sections 3 11 9 1 to 3 11 9 5 User security level to low but do...

Page 141: ...OM2 and or COM3 ports and can take up to 5 seconds to reply MASS possible communications with an external AMH mass handler PGEN requires communications with an external pressure controller SETUP possible communications with external barometer or vacuum gage You must wait for this reply before issuing another command to PG7000 This ensures that PG7000 has completed the command An exception is the u...

Page 142: ...The PG7000 COM2 and COM3 RS232 interfaces are located on the PG7000 Platform rear panel They are 9 pin male DB 9M connectors configured as a DTE device Data is transmitted out of PG7000 using pin 3 and is received on pin 2 This allows a standard pin to pin DB 9F to DB 9M RS232 cable to be used to connect to a DCE slave Handshaking is NOT required or supported COM2 and COM3 are used by the PG7000 P...

Page 143: ...ble to have old replies in this buffer while you are expecting new replies from a just issued command Address Terminating Characters 10 CR and LF with EOI asserted with LF IEEE Local Functions Supported SH1 AH1 T4 L2 RL2 DC2 Parallel poll mode is not supported Physical Interface IEEE 488 2 with tri state bus drivers IEEE 488 To establish IEEE 488 communications the host computer must have an IEEE ...

Page 144: ... offset value DIFSETUP Prepare PG7601 to determine the differential mode RPM offset DUTHEIGHT Set or read the DUT head height ESE Read or set the Event Status Enable Register ERR Read the last error message ESR Read the Event Status Register HLDFALL Read the results of the last natural fall rate measurement step completed in high line differential mode HLDLINEP Set a new line pressure in high line...

Page 145: ...ESUME mode Set the resume mode which determines whether a pressure setting process initiated by remote command will pause after target entry and require the RESUME comand to continue RPM x Send a command to an external DHI RPM connected to COM2 RST Reset user settings to factory defaults SETUP Set or read the setup to use SN Read the PG7000 serial number SPEED Read the piston rotation speed SRE Re...

Page 146: ... ERR 8 Eighth argument missing or out of range ERR 9 Unknown command ERR 10 Motorized rotation recovering from overload ERR 11 Command missing argument ERR 12 System overpressured ERR 13 External RPM or PG7000 not detected ERR 14 User unit not defined ERR 15 Range jumper setting invalid ERR 16 Element not defined ERR 17 UDD not defined ERR 18 Command not yet available ERR 19 Not available with gau...

Page 147: ...4 4 for details on the status registers mentioned in these commands Query forms of these commands must be followed by a question mark and IEEE 488 2 Common Commands always start with an asterisk Unlike the other PG7000 commands they must have a space instead of an equals sign between the command and any arguments Also unlike the other PG7000 commands if you are using the IEEE 488 port the query fo...

Page 148: ...ommand Reply OPC 1 OPT Purpose Reads the list of installed molbloc RFM options Syntax OPT Remarks This Query returns any registered option s installed in the PG Each option is separated by a comma Query Reply A comma delimited text field of the installed options Example Command Reply Reply OPT NONE no options installed auto rotation auto rotation option RST Purpose Resets the PG7000 settings to fa...

Page 149: ...ample Command Reply TST 1 See Also 3 11 9 1 4 3 4 2 PG7000 COMMANDS Purpose To send a command through PG7000 to an external device on COM2 Syntax ddddd Default N A Argument N A Remarks If PG7000 receives a command from the serial port COM1 with a as the leading character the character is stripped off and the command is sent out the secondary serial port COM2 Any data received from the secondary se...

Page 150: ...1 to 21 See the SETUP command Setup 21 is reserved for remote communication use only Source The measurement source This can be INTERNAL DEFAULT normal USER RPM or the user defined barometer label Meas The current measurement used is kPaa This can only be set if the source argument is USER If specified the limit for this argument is 70 to 110 kPaa Remarks PG7000 has an internal atmospheric pressure...

Page 151: ...nd cannot be changed The meas argument is used to allow the user to define a fixed value if the source is set to USER The reply will always include the source and the meas fields Example Typical command Typical reply AMBT2 USER 22 00 USER 22 0 dC Typical command Typical reply AMBT9 INTERNAL INTERNAL 23 2 dC Error See 9 3 2 Error Messages ERR 1 ERR 2 ERR 3 The setup number x is invalid The source a...

Page 152: ...s handling system can load and unload masses on the PG7000 piston cylinder automatically The masses can all be loaded onto the piston or unloaded and held in the mass handling by a single command Setting 1 causes the AMH to operate to load all the masses Setting 0 causes the AMH to operate to unload all the masses This command can only be executed when the an AMH mass set is selected and the AMH i...

Page 153: ...eply ATMHEIGHT 20 20 00 cm Error See 9 3 2 Error Messages ERR 1 The argument was 1000 or 1000 See Also 3 9 7 PRINCIPLE 3 11 3 3 BELL Purpose Read or select the mass loading bell to use Syntax BELL x BELL Default 1 Argument x The mass bell number 1 2 or 3 Remarks You may define up to three different loading mass bells to use with PG7000 using the BELLx command You can then use the BELL x command to...

Page 154: ...7 1 Argument x 1 for COM1 port 2 for COM2 port 3 for COM3 port The arguments must be separated by commas Remarks The available parameters are listed below Once the port is configured the configuration is stored in permanent memory and becomes active on power up When the configuration of the primary port COM1 is changed the returned reply is sent at the original COM1 settings but all subsequent rep...

Page 155: ...Pressure 0 Pa 101325 0 Paa Argument Offset NEW Saves the current calculation of RPM offset if PG7601 is currently in the offset determination mode else set the differential offset value in Pa Pressure The PG7601 defined pressure when the previously determined differential offset was saved or if Offset is NEW this argument is ignored and should not be used Remarks The DIFOFFSET commands have two ty...

Page 156: ...g 9 7 g 28 05 g Error See the DIFLOAD and DIFOFFSET commands ERR 1 The barometer measurement resulted in an invalid mass load ERR 23 ERR 28 Vacuum reference not supported by this PG7000 An external measurement device has not been SETUP See Also 3 9 4 1 DIFLOAD DIFOSSET DUTHEIGHT Purpose To set or read the height of an external Device Under Test DUT relative to the reference level on the PG7000 mou...

Page 157: ...7102 will also configure itself and the tare PG7000 to set a new line pressure A tare PG7000 must be connected to the reference PG7102 s COM2 port and communications setting of the tare PG7000 s COM1 port must match the reference PG7102 s COM2 port After this command is successfully executed you can use the MR command to get the mass value needed to set the line pressure NEXT Executes the next ste...

Page 158: ...e mm s The tare piston natural fall rate mm s The natural fall rate difference Example Typical command Typical reply HLDVIEW 2000 0 kPa 23 4 23 2 0 3 0 4 0 21 See Also 3 9 4 2 3 11 5 4 5 MODE ABORT HLDVIEW HLDPPOS HLDFALL HLDXFLT HLDXFLT Purpose Get the results of the last crossfloat fall rate measurement step while executing the line pressure sequence in high line differential mode Syntax HLDXFLT...

Page 159: ...handler was not detected See Also 3 11 1 10 3 11 1 PRINCIPLE MASSx Purpose Read or set a mass set s general information Syntax Massx Sn Dens extra1 extra2 extra3 Cert CalDate EditDate AMH Massx Default N A Argument x The mass set number 1 2 or 3 Sn The mass set serial number 4 digits max Dens The main mass density extra1 2 3 These are placeholders for data fields that are obsolete and are always 0...

Page 160: ...mand Use the MASSx command to create a new mass set prior to using the MASSSETx command to add masses to the set To define the mass set contents send the MASSSETx nominal true AMHType command to specify the mass set 1 2 or 3 and to set the nominal and true mass values for the first mass in the set This erases the current mass set and opens the mass set for writing Then send MASSSET nominal true on...

Page 161: ...wer up a memory test is run to check the integrity of the internal data RAM If the memory has been corrupted then FATAL MEMORY LOSS will be displayed to alert the user The status memory can be read from a remote computer Typical causes of memory fault Upgrade of PG7000 software Connection of a cable to PG7000 when PG7000 is on Failure of internal memory Return string MEM 1 System is OK MEM 0 Syste...

Page 162: ...marks You may manually control the rotation of the PG7000 piston with bell installed instead of using the auto rotate function see the AROT command The PG7000 will only rotate the piston if the bell is installed and the piston position is not close or against the top or bottom of the piston travel You should not typically use this command when the auto rotate feature is enabled Example Typical com...

Page 163: ...sses are rotated when floating 6 The PG7000 achieves a Ready condition at the requested mass load This command replies before execution of the steps actually starts The PR command can be used to monitor the status of these events and determine when the PG7000 measurement is Ready The ABORT command or changing to local front panel operation using the ESC key the LOCAL command or a GPIB go to local ...

Page 164: ... fields Example Typical command Typical reply PRT2 USER 25 USER 25dC Typical command Typical reply PRT9 INTERNAL INTERNAL 21 34 dC Error See 9 3 2 Error Messages ERR 1 ERR 2 ERR 3 The setup number x is invalid The source argument is invalid The meas argument is invalid See Also 3 10 1 2 1 2 SETUP PGEN Purpose Set or read the piston float target for automatic piston floating using an external press...

Page 165: ...set The reference level offset from the mounting post reference mark k P The mass to fall rate coefficient for tare piston cylinders used in high line differential mode Remarks You may define up to seventeen different piston cylinder sets to use with PG7000 using the PISTONx and the PISTONVARx command is then used to edit the piston cylinder set physical information Example Typical command Typical...

Page 166: ...PC s auto generation functions Any reply from the component will be returned until another command is sent to the PG7000 Example Typical command Typical reply PPC PR R 561 0 psi a See Also 3 9 9 PGEN PPOS Purpose Read the current piston position rate of vertical movement Syntax PPOS Default N A Argument N A Remarks The PG7000 piston position has a total travel of 9 mm This piston position is repre...

Page 167: ... by the piston position rotation speed AMH automated mass handler status and the pressure generation status R for Ready NR for Not Ready x This 3 rd character indicates any ongoing activity by the PG7000 to reach a Ready condition Any character except a whitespace will keep the PG ready status Not Ready NR no activity A the auto rotate feature is accelerating mass rotation D the auto rotate featur...

Page 168: ...ation using the ESCAPE key the LOCAL command or a GPIB go to local function will stop the operation Example Typical command Typical reply PS 100 100 0000 kPa g Error See 9 3 2 Error Messages ERR 1 If target results in an invalid mass load See Also 3 9 12 3 9 10 3 9 11 3 9 3 MS PR UNIT RESUME READYx Purpose Set or read the ready criteria for a specific Setup Syntax READYx USER RdyBand RdyVac READYx...

Page 169: ... REMOTE command can only be canceled by a LOCAL command or by turning off PG7000 power then reapplying it Example Typical command Typical reply REMOTE REMOTE Error None See Also LOCAL RESET Purpose To reset all operating parameters to factory default settings Syntax RESET Default N A Argument N A Remarks The reset command can be given to return the PG7000 to a known state This command is the same ...

Page 170: ...me mode Syntax RESUME mode Default RESUME 1 Argument Mode 0 RESUME command is not needed to complete a remote pressure set operation 1 RESUME command is needed to complete any remote pressure set operation Remarks RESUME 1 is needed only if it is necessary for PG7000 operation to pause after a pressure target has been given to allow the operator to load mass This is the case when using a manual ma...

Page 171: ... piston rotation speed and rotation decay deceleration Syntax SPEED Default N A Argument N A Remarks The current piston rotation speed and decay rate are returned separated by a comma The decay rate is returned as 0 if there is not enough valid data to calculate the rate The speed will also be returned as 0 if the bell is not installed Example Typical command Typical reply SPEED 44 2 rpm 2 3 rpm m...

Page 172: ...communications settings After setting up the COM2 port and defining the device you must then use the AMBPx and SETUP commands to direct PG7000 to use the external barometer if you want this device to be used as the source of atmospheric pressure values Example Typical command Typical reply UDD DEV PR 4 1000 ext barometer is in kPa DEV PR 4 1000 000 Error See 9 3 2 Error Messages ERR 1 ERR 2 ERR 3 ...

Page 173: ...he source of values of vacuum in the PG7601 bell jar It is also possible to use both an external barometer and an external vacuum sensor using the PG COM2 port The barometer must be an RPM3 or RPM4 plugged into the PG COM2 port and selected as an active external barometer The vacuum sensor is then plugged into the RPM3 RPM4 s COM2 port The RPM3 RPM4 s COM2 port must be set to the same settings as ...

Page 174: ...SER RPM or the user defined vacuum label meas The current measurement used in Paa This can only be set if the source argument is USER If specified the limit for this argument is 0 to 99 Paa Remarks PG7601 has an internal vacuum pressure gauge that can be used as the source of values of reference vacuum under the bell jar used in pressure calculations You may also request that another source be use...

Page 175: ...ernal automated pressure generation control component test pressure will quickly decrease to atmospheric Example Typical command Typical reply VENT 1 VENT 1 Error See 9 3 2 Error Messages ERR 1 If n not set to 1 or 0 See Also 3 9 9 PPC PGEN VER Purpose Read the version number of the internal software Syntax VER Default N A Argument N A Remarks The software version of the EPROM can be read Example ...

Page 176: ...a sign bit on some computer systems 4 4 1 STATUS REPORTING SYSTEM The PG7000 status reporting system is used to track and report system status and errors The status subsystem is layered under and reports to the status reporting system It follows the model of the IEEE Std 488 2 and works for the COM1 and the IEEE 488 port with slight differences PG7000 can be programmed to respond to various status...

Page 177: ...This bit is cleared when a serial poll is performed on PG7000 and is a part of the status byte register when read using a serial poll This bit does not apply if the COM1 port is being used MSS Master Summary Status Bit 6 Indicates that an event or events occurred that caused PG7000 to request service from the Host much like the RQS bit Unlike the RQS bit it is READ ONLY and can be only cleared whe...

Page 178: ...such as a transducer time out QYE Query Error Bit 2 Indicates that an error has occurred in the protocol for program message communications This is typically caused by a program message being sent to PG7000 without reading a waiting reply RQC Request Control Bit 1 This bit is not supported as PG7000 cannot become the active controller in charge OPC Operation Complete Bit 0 Indicates that PG7000 ha...

Page 179: ...ng The status of the fall rate step can be monitored by sending the HLDLINEP command until the reply is no longer BUSY1 During this time the reference and tare piston positions should also be monitored So while using HDLPPOS to monitor piston occasionally send HLDLINEP looking for the response OK Send HLDPPOS Request the reference and tare PG piston positions Reply 0 4 0 5 0 1 Reference and tare p...

Page 180: ...nce and tare positions average crossfloat fall rate difference since the start of this function Send HLDLINEP Check if the step is completed Reply BUSY2 Step is still busy continue in this loop Reply OK Step is still complete go to next step The results of the crossfloat fall rate measurement step can now be obtained Send HLDXFLT Request the crossfloat results Reply 6 9 1 0 046 g Crossfloat fall r...

Page 181: ... line pressure is as expected Ensure that the reference PG7000 COM2 port is configured identically to the tare PG7000 COM1 port and that the two COM ports are connected properly Change the measured mode to high line differential Send UNIT UUUUD Request for unit UUUU and high line differential mode Reply UUUUD Unit and measurement mode set complete Or Send MMODE D Request for high line differential...

Page 182: ...PG7000 OPERATION AND MAINTENANCE MANUAL 1998 2008 DH Instruments a Fluke Company Page 172 N NO OT TE ES S ...

Page 183: ...Section 5 2 1 5 Calibration of reference vacuum sensor PG7601 only see Section 5 2 1 6 Calibration of piston cylinder modules and mass set see Sections 5 3 2 5 4 2 Drive belt replacement motorized rotation option only see Section 5 2 54 This section provides information on maintenance adjustment and calibration procedures and certain repair procedures Calibration maintenance and repair services fo...

Page 184: ...measurement uncertainty specification of the on board sensor should be taken into consideration when selecting a reference relative to which to adjust them see Section 1 2 1 2 The ambient pressure temperature and relative humidity sensors in particular do not require a high level reference The PG7000 CAL function supports a user defined adder and multiplier that are used to offset and if necessary...

Page 185: ...and Multipliers and their use in adjusting internal sensors 5 2 1 3 AMBIENT TEMPERATURE SENSOR PURPOSE To view and adjust the output of the on board ambient temperature sensor The ambient temperature sensor and piston cylinder module temperature sensor are of the same technology and read in the same manner However their recommended calibration procedures differ reflecting the different measurement...

Page 186: ...cal to access a screen in which the values of HA and HM can be edited From here press ESCAPE and select 3 RH 1view to view the relative humidity sensor reading with the edited calibration coefficients applied See Section 5 2 1 1 for an explanation of Adders and Multipliers and their use in adjusting internal sensors 5 2 1 5 PISTON CYLINDER MODULE TEMPERATURE SENSOR PURPOSE To view and adjust the o...

Page 187: ...is a piston cylinder module temperature display 3 Current value of the resistance slope relative to temperature 4 Current value of the offset at 0 C in ohm 19 951 C PCT RZ100 003 Ω S0 3896 To adjust the values of RZ and or S press SPECIAL and select 4PCT 2cal to access a screen in which the values of RZ and S can be edited From here press ESCAPE and select 4PCT 1view to view the piston cylinder mo...

Page 188: ...VDT P1 5 2 1 6 REFERENCE VACUUM GAUGE PG7601 ONLY PURPOSE To view and adjust the output of the on board reference vacuum gauge PG7601 only OPERATION To view the output of the reference vacuum gauge press SPECIAL and select 6vac 1view The display is 1 Current reading of the vacuum gauge in Pascal Reads 20 whenever the current reading is greater than 20 Pa 2 Indication that this is a vacuum display ...

Page 189: ...ure 8 If the PG7000 Platform is equipped with an AMH mass set be sure to see Special Considerations When Using an AMH Mass Set To automatically adjust the PG7000 piston position indication system load the mass bell only on the piston Then press SPECIAL 7cal 5Pposition 2cal The prompt Hold piston at max down stop appears Place the piston in the fully down position be sure to compress the springs so...

Page 190: ... both PG7202 and PG7302 very small quantities of oil leak out of the top of the gap between the piston and cylinder when pressure is applied Excess oil is collected and runs down the mounting post and out through a transparent tube on the right side of the PG7202 PG7302 Platform to an oil run off tray under the platform To empty the oil run off tray proceed as follows Using a paper towel or cloth ...

Page 191: ...unting Post Drain 5 2 5 DRIVE BELT REPLACEMENT Periodic replacement of the drive system belts may be necessary to retain maximum performance of the rotational engagement system Due to specific material properties of the drive belts it is important that only genuine DHI replacement parts be used A set of spare drive belts is included in the accessories delivered with the PG7000 Platform To remove t...

Page 192: ...If any of these symptoms are present they may be caused by a dirty piston cylinder The piston cylinder module should be disassembled and the piston cylinder cleaned See Section 5 3 2 1 for instructions and disassembly and cleaning of gas operated gas lubricated piston cylinders PC 7100 and PC 7600 Section 5 3 2 2 for gas operated liquid lubricated piston cylinders PC 7200 and Section 5 3 2 3 for o...

Page 193: ...mum protection to the piston cylinder element assuring that it is protected during routine piston cylinder handling Cleaning the piston cylinder requires disassembly of the module and exposure of the piston cylinder to possible damage These risks include damage to the critical working surfaces for all piston cylinder sizes and chipping or breaking especially for small diameter piston cylinders Onl...

Page 194: ... behind Step 6 applies only to 20 kPa kg Reinstall the piston cap 2 directly onto the piston head 6 Using the cap as a handle slide the piston out of the cylinder Take care not to cock the piston in the cylinder at the point at which it leaves the cylinder Steps 7 8 and 9 apply only to 10 kPa kg Reinstall the piston cap 2 directly onto the piston head 5 Place the 10 kPa kg piston insertion tool se...

Page 195: ...5 MAINTENANCE ADJUSTMENTS AND CALIBRATION Page 185 1998 2008 DH Instruments a Fluke Company Figure 15 10 kPa kg Piston Insertion Tool Figure 16 Gas Piston Cylinder Module Sleeve Nut Tool ...

Page 196: ...nder sleeve 7 so that the sleeve nut 10 is facing up Using the sleeve nut tool see Figure 16 remove the sleeve nut 5 The sleeve nut tool is a spanner that fits into the two holes on the sleeve nut The 50 100 and 200 kPa kg sleeve nuts have a right hand thread so they are loosened by turning counter clockwise Holding the cylinder 9 in the open end of the cylinder sleeve 7 turn the cylinder sleeve o...

Page 197: ...er disassembly cleaning and reassembly The instructions and recommendations contained in this manual should be followed carefully throughout the operation NEVER touch the lapped surfaces polished appearance of the piston or cylinder with your bare hands Body oils and acids can permanently etch the surfaces In normal use always maintain PC 7200 gas operated liquid lubricated piston cylinder modules...

Page 198: ...ning screw will not fully disengage from the piston cap due to the adjustment mass 3 Gently remove the cap and screw from the assembly Take care to be sure the piston head is out of the cap so as NOT to apply torque to the piston 7 when removing the cap In reassembly when installing the piston cap be sure the adjustment mass 3 is still in place on the screw Take great care to slip piston cap 2 str...

Page 199: ...routine piston cylinder handling Cleaning the piston cylinder requires disassembly of the module and exposure of the piston cylinder to possible damage These risks include damage to the critical working surfaces and chipping or breaking especially for small diameter pistons in particular the PC 7300 5 MPa kg Only qualified personnel should undertake piston cylinder disassembly cleaning and reassem...

Page 200: ...screw the main module housing 4 from the bullet case leaving the piston cylinder and sleeve assembly behind in the bullet case base Carefully reinstall the piston cap 2 onto the piston head 6 taking care not to apply sideways torque on the piston 7 Using the cap as a handle slide the piston straight out of the cylinder NOTE Do not twist the piston or apply sideways force to it It can easily be sna...

Page 201: ...d are poor piston sensitivity excessive piston drop rate and or excessive rotation decay rate To avoid running out of lubricating liquid it is recommended that the piston cylinder module liquid reservoir be refilled approximately once a week when the module is being used extensively or if the module has not been used for an extended period of time The reservoir may also be emptied for shipping or ...

Page 202: ...mbly without familiarizing yourself with Section 5 3 1 of this manual Incorrect disassembly may damage or destroy the piston cylinder element Disassemble the piston cylinder module following the instructions given in Section 5 3 2 1 for PC 7100 7600 modules Section or Section 5 3 2 2 for PC 7200 modules or Section 5 3 2 3 for PC 7300 modules Reinsert the piston with cap installed into the cylinder...

Page 203: ...manding but it is less thorough DO NOT undertake piston cylinder module disassembly without familiarizing yourself with Section 5 3 1 of this manual Incorrect disassembly may damage or destroy the piston cylinder Disassemble the piston cylinder module following the instructions given in Section 5 3 2 1 for PC 7100 7600 modules Section or Section 5 3 2 2 for PC 7200 modules or Section 5 3 2 3 for P...

Page 204: ...grease Lubricating 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 forefinge...

Page 205: ...5 MAINTENANCE ADJUSTMENTS AND CALIBRATION Page 195 1998 2008 DH Instruments a Fluke Company Figure 21 Gas Operated Gas Lubricated Piston Cylinder Module Lubrication Chart ...

Page 206: ...PG7000 OPERATION AND MAINTENANCE MANUAL 1998 2008 DH Instruments a Fluke Company Page 196 Figure 22 Gas Operated Liquid Lubricated Piston Cylinder Module Lubrication Chart ...

Page 207: ...5 MAINTENANCE ADJUSTMENTS AND CALIBRATION Page 197 1998 2008 DH Instruments a Fluke Company Figure 23 Oil Operated Piston Cylinder Module Lubrication Chart ...

Page 208: ...o avoid contaminating them with liquids or particles They should never be handled with bare hands Over time or by an accidental incident masses may become soiled In these cases they can be cleaned Masses should be cleaned with a non abrasive general purpose cleaner such as glass cleaner and wiped dry with lint free paper towels 5 4 2 RECALIBRATION PRINCIPLE Piston cylinders and mass sets are recal...

Page 209: ...e PG7000 accessories It is a well known cable configuration available from most cable and computer product suppliers A straight through cable such as that used for standard RS232 communications will NOT communicate to allow flash memory writing The DHI flash software loading utility and PG7000 embedded software are available for download from the SOFTWARE section of DHI s worldwide web site at www...

Page 210: ...PG7000 OPERATION AND MAINTENANCE MANUAL 1998 2008 DH Instruments a Fluke Company Page 200 N NO OT TE ES S ...

Page 211: ...correct Use sounds function to set keypad sounds as desired 3 11 42 Cannot access certain functions Display shows ACCESS RESTRICTED User Level setting restricts access to those functions Change User Level or consult system manager 3 11 8 Cannot establish communication over interface Computer and or PG7000 interface not correctly configured incorrect or bad interface cable Check and correct interfa...

Page 212: ...is less than minimum Ready rotation rate Current mass load is under cutoff load of 3 kg Operation is normal 3 4 2 Motorized rotation unable to start piston rotation Piston cylinder dirty Clean piston cylinder 5 3 1 The piston deceleration function starts immediately when ENTER SET P is pressed Operation is normal but can be modified so that deceleration does not occur if it is not needed Turn off ...

Page 213: ...sure controller TOLERANCE function setting is too small or the volume setting PG7302 PG7307 only is incorrect Adjust the tolerance setting adjust the volume setting PG7302 PG7307 only 3 9 9 4 3 9 9 6 Piston position detection system is not properly calibrated and piston is not floating as expected Calibrate piston position indication system 5 2 2 Automated pressure control GEN is overshooting the ...

Page 214: ...PG7000 OPERATION AND MAINTENANCE MANUAL 1998 2008 DH Instruments a Fluke Company Page 204 N NO OT TE ES S ...

Page 215: ... 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 inch of water 4 014649 E 03 inWa 20 C inch of water 4 021732 E 03 inWa 60 F inch of water 4 018429 E 03 inHg 0 C inch of mercury 2 953 E 04 kcm ...

Page 216: ...G7601 and RPM at the static pressure of differential mode Pa Determined experimentally in PG7601 differential mode operation see Section 3 9 4 1 Selecting Differential Mode Setting Static Pressure Finding RPM Offset PRPM Current static pressure reading from reference pressure monitor Paa Read automatically from external atm P source specified by SETUP file Used in PG7601 differential mode only 3 1...

Page 217: ... ρ Mg P θ θ 2 1 nom C P P P A A λ α α θ θ 1 20 1 10 6 0 20 Absolute pressure by addition of atmosphere reference atm HA P P m a A P P A π A πΓ ρ ρ Mg P θ θ 2 1 nom C P P θ P λ α α θ A A 1 20 1 10 6 0 20 High line differential pressure ΗD T TX C P R RX C P L P P m a RX R HLD P α α P A ρ ρ g M M ΔP T T R R Δ θ θ θ θ α α θ 1 nom L C P R P P θ ΔP P λ α α θ A A R R 1 20 1 10 6 0 20 Δ RX ΗG P P m a G L ...

Page 218: ...m C P P θ P λ α α θ A A 1 20 1 10 6 0 20 Absolute pressure by adding atmospheric pressure atm HA P P m a A P P A π A πΓ ρ ρ Mg P θ θ 2 1 nom C P P θ P λ α α θ A A 1 20 1 10 6 0 20 Absolute pressure with vacuum reference vac HA P P A P P A π A πΓ Mg P θ θ 2 nom C P P θ P λ α α θ A A 1 20 1 10 6 0 20 Differential pressure differential mode offset RPM vac HA P P D P P P P A π A πΓ Mg P θ θ Δ 2 nom C ...

Page 219: ...essure temperature and relative humidity values as specified in the active SETUP file see Section 3 10 Assumed to be zero when operating in absolute with a vacuum reference mode Calculated using static pressure density measured by RPM in PG7601 differential mode g gravity m s2 acceleration due to gravity value as specified in the active SETUP file see Section 3 10 hD DUT height m Height of DUT abo...

Page 220: ...0 reference level 7 2 3 2 OVERALL FLUID HEAD CORRECTION The overall fluid head correction for each PG7000 mode results from combining the three head components In general overall head correction is given by P atm DUT H H H H P P P P Gauge mode P a f D a f HG gh gh P ρ ρ ρ ρ Absolute mode by adding atmospheric pressure Air density is zero for all components except for the ATM head which is used to ...

Page 221: ...ve to atmospheric pressure He Helium gas Head Fluid head a pressure difference due to a difference in height See also ATM head DUT head and PISTON head High Line Differential As in high line differential pressure measurement mode Pressure expressed relative to a line pressure greater than atmospheric pressure Defined by using two piston gauges HSTOP LSTOP High stop and low stop piston maximum end ...

Page 222: ...n specific criteria for each condition Reference Level Height at which pressures are defined PG7000 defines pressures at its reference level Fluid head corrections correct the pressure relative to the reference level Reference PG7000 The PG7000 used on the reference side high side in high line differential pressure mode see also Tare PG7000 SETUP file File specifying the source of values for the v...

Page 223: ... 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 at all are subject to an evaluation and shipping charge as well as applicable repair and or calibration costs The provisions of this warranty...

Page 224: ...PG7000 OPERATION AND MAINTENANCE MANUAL 1998 2008 DH Instruments a Fluke Company Page 214 N NO OT TE ES S ...

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