DH Instruments PPCH Operation And Maintenance Manual Download Page 1

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PPCH™

Hydraulic Pressure Controller/Calibrator

Ver. 1.01f and higher

Operation and Maintenance Manual

Summary of Contents for PPCH

Page 1: ...2009 DH Instruments a Fluke Company PPCH Hydraulic Pressure Controller Calibrator Ver 1 01f and higher Operation and Maintenance Manual...

Page 2: ...ssed or implied is provided DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described i...

Page 3: ...ITCH 8 2 3 5 CONNECTING PNEUMATIC POWER DRIVE PORT 9 2 3 6 SETTING UP AND FILLING THE FLUID RESERVOIR 9 2 3 6 1 INTERNAL RESERVOIR 9 2 3 6 2 EXTERNAL RESERVOIR 11 2 3 7 RESERVOIR RETURN SETTINGS 12 2...

Page 4: ...CTION KEYS 39 3 3 1 RANGE 39 3 3 2 UNIT 40 3 3 3 MODE 41 3 3 4 AUTORANGE 42 3 3 5 RPT 44 3 3 6 AUTOTEST 46 3 3 6 1 QUICK AUTOTEST 47 3 3 6 2 QDUT AUTOTEST 49 3 3 7 HEAD 52 3 3 8 PRIME 54 3 3 8 1 1PRIM...

Page 5: ...QUEUE 128 4 5 2 STATUS BYTE REGISTER 128 4 5 3 STANDARD EVENT REGISTER 130 4 5 4 READY STATUS REGISTER 130 4 6 IEEE STD 488 2 COMMON AND STATUS PROGRAM MESSAGES 131 4 6 1 PROGRAM MESSAGE DESCRIPTIONS...

Page 6: ...CONTROL VALVE SERVICE 166 5 13 RELOADING EMBEDDED SOFTWARE INTO FLASH MEMORY 166 5 14 SUBASSEMBLY DESCRIPTION AND LOCATION 167 5 14 1 ELECTRONIC MODULE 167 5 14 1 1 POWER ENTRY AND FUSE 167 5 14 1 2...

Page 7: ...oZ ON and OFF 76 Table 12 Reset Sets 83 Table 13 Reset Cal 84 Table 14 Reset All 84 Table 15 Security levels 88 Table 16 UNIT function available units of measure 90 Table 17 COM1 pin designations and...

Page 8: ...e control operation 29 Figure 11 Ready Not Ready in dynamic pressure control mode 30 Figure 12 Static pressure control operation 30 Figure 13 Ready Not Ready in static control mode 31 Figure 14 Monoto...

Page 9: ...ntenance and calibration information Section 6 is a quick troubleshooting guide Use it to troubleshoot unexpected PPCH behavior based on the symptom of that behavior Certain words and expressions have...

Page 10: ...PPCH OPERATION AND MAINTENANCE MANUAL 2009 DH Instruments a Fluke Company Page VIII N NO OT TE ES S...

Page 11: ...ainty Up to four external Q RPTs in one or two external Reference Pressure Monitors RPM4s can also be integrated into a PPCH system A barometer is also included for atmospheric pressure compensation o...

Page 12: ...perator 2A 250 V UV 440 2 power supply 3 15A 250 V NFS40 7612 power supply Pressure Ranges Four controller models from 70 MPa 10 000 psi max to 200 MPa 30 000 psi max Low uncertainty measurement provi...

Page 13: ...0 000 A40M 40 6 000 A20M 20 3 000 Warm Up Time 30 minute temperature stabilization recommended for best performance from cold power up Resolution To 1 ppm user adjustable Compensated Temperature Range...

Page 14: ...an 0 1 of span 1 2 2 3 ON BOARD BAROMETER The on board barometer is used only to measure changes in atmospheric pressure to provide dynamic compensation of the Q RPT s atmospheric pressure offset when...

Page 15: ...eration and Maintenance Manual 550132 1 ea Calibration Report 550100 1 ea Test Report 550200 1 ea Power Cord 7 5 ft 100770 100770 CE 1 ea Reservoir fill tube assembly 402039 1 ea Reservoir fill tube b...

Page 16: ...onnections to the device or system into which pressure is to be controlled see Section 2 3 9 4 Support facilities required include An electrical power source of 85 to 264 VAC 50 60 Hz A pneumatic powe...

Page 17: ...connections Remove the protective plastic sheet from the front panel display Familiarize yourself briefly with the front and rear panel see Section 2 3 2 Then proceed with Sections 2 3 3 to 2 3 11 2 3...

Page 18: ...OW port 17 RESERVOIR RETURN valve 18 DRIVE IN air supply port 19 Mechanical module pull out handles 20 TEST port Figure 2 Rear panel 2 3 3 POWER CONNECTION Check that the PPCH power switch is OFF Conn...

Page 19: ...H has an internal reservoir with a capacity of 300 cc that is filled from and whose level can be viewed on the rear panel of the instrument If greater capacity and or remote reservoir filling and leve...

Page 20: ...eservoir fill bracket There is a red plug with a center pull tab in the end of the PFA tube This should be left in place when the funnel is not being used to prevent contamination and or evaporation o...

Page 21: ...in the CLOSED position if the internal or external reservoir attachments are not installed Opening the FILL DRAIN valve opens the FILL DRAIN port to the internal reservoir When installing an external...

Page 22: ...ng can occur Fill the reservoir return tube connected between the reservoir and the EXTERNAL port with fluid See Section 5 6 2 for additional information in filling and draining an external reservoir...

Page 23: ...of supply gas being exhuasted from the hydro pneumatic pump To install the filter first wrap 1 to 2 turns of teflon tape around the threads then insert the threaded end of the muffler into the Pump D...

Page 24: ...sure The filter should not be smaller then 40 micron DHI recommends high pressure filter kit p n 402376 2 3 9 2 CONNECTING TO AN RPM4 TO BE USED AS AN EXTERNAL REFERENCE DEVICE ALWAYS use external tub...

Page 25: ...nstalled see Section 1 2 1 Using a standard pin to pin DB 9M to DB 9F RS232 cable connect COM2 of the PPCH to COM1 of the RPM4 see Section 4 2 1 3 Turn ON the RPM4 and the PPCH Press RPT on the PPCH k...

Page 26: ...ystem proceed as follows Using tubing of appropriate pressure rating and a tee fitting connect the PG7302 TEST port to the PPCH TEST port see Figure 6 for instructions on making this connection using...

Page 27: ...in tolerance measurements with default pressure control parameters is 0 005 of reading second In DYNAMIC CONTROL mode to handle higher test system leak rates increase the hold limit using CUSTOM CONTR...

Page 28: ...APPLY PNEUMATIC POWER DRIVE AIR Apply pneumatic power of the appropriate pressure and flow rate to the PPCH DRIVE port see Section 2 3 5 It is normal for the hydropneumatic pump to cycle a few times w...

Page 29: ...seconds 2 4 4 PRIME AND PURGE TEST SYSTEM For PPCH pressure control to operate properly it is important to minimize the amount of gas present in the system connected to the TEST port The prime and pu...

Page 30: ...ENT LED ON the liquid contained in the reservoir may leak out through the opening Turn the power OFF using the rear panel power switch Shut OFF or disconnect the drive air pressure supply 2 5 2 LONG T...

Page 31: ...mote communication 3 1 1 MAIN RUN SCREEN The PPCH MAIN RUN screen is its home display that is reached on power up and from which other functions and menus are accessed It is the very top level of all...

Page 32: ...ator Indicates whether the AutoZero function is ON or OFF z AutoZ is ON blank AutoZ is OFF 3 5 1 6 RRH Active Q RPT position indicator Indicates the position in the PPCH system of the active Q RPT or...

Page 33: ...n cursor control in menus and editing entries 3 The Menu Data keys provide access to function menus when pressed from the MAIN RUN screen The menu name is on the bottom half of the key The SETUP menu...

Page 34: ...er direct pressure control key is pressed or an automated pressure control command is given Removing electrical power also closes the vent valve Pressing the and direct pressure control keys aborts au...

Page 35: ...see Section tolerance reading 3 3 6 Reservoir level low Ten brief beeps see Section 3 5 7 3 2 3 2 GENERAL OPERATING PRINCIPLES 3 2 1 PRESSURE CONTROL PRINCIPLES Numerical references in this section r...

Page 36: ...ontrol TPC TPC uses a pressurized volume in which there is a heating element and around which there is a forced air cooling system 14 Heating and cooling the fluid in the volume causes it to expand or...

Page 37: ...Reservoir return valve 10 EXTERNAL return port 11 Outlet valve servo controlled 12 Vent valve pneumatically controlled 13 TEST port 14 Thermal pressure control unit TPCU 15 Hi Q RPT 16 High pressure f...

Page 38: ...ive and negative control limit around a target value within which the controlled pressure or rate is maintained dynamic static ramp modes Rate Limit A rate of change of pressure limit in the same sign...

Page 39: ...me and or cannot maintain the Ready condition once achieved Hi volume dynamic control may be necessary when the test volume connected to the PPCH is greater than 100 cc The difference between standard...

Page 40: ...the stability with which the pressure control system can actively control pressure Using static control to control pressure near the desired set point and then measuring back the stabilized pressure...

Page 41: ...ressure approach see Figure 14 Measured pressure data is taken from the PPCH and output from the device under test during the slow ramp near the target pressure The advantage of this control mode is t...

Page 42: ...control mode Figure 15 Ready Not Ready in monotonic pressure control mode 3 2 2 5 RAMP CONTROL Ramp control is designed to set a pressure ramp at a target rate and maintain the rate within a rate hol...

Page 43: ...tes when current pressure control requirements have been met see Section 3 2 3 With ramp pressure control active a Ready condition occurs whenever PPCH is controlling rate at the target rate value wit...

Page 44: ...or ramp see Sections 3 2 2 2 3 2 2 3 3 2 2 4 3 2 2 5 Pressure Ready Not Ready parameters are set by default when AutoRange is used or a control mode is selected see Table 10 The parameters can be cus...

Page 45: ...asurement devices with a PPCH the user is responsible to setting up hardware and following procedures to protect lower range Q RPTs from overpressure Only the Lo Q RPT IL built into the PPCH is protec...

Page 46: ...ettings A PPCH may have multiple ranges Each Q RPT and the utility sensor if present available to the PPCH system has a default range which is its maximum span Additional ranges lower than the Q RPT s...

Page 47: ...allowed to become empty air may be drawn into the hydropneumatic pump see Figure 9 causing it to lose its prime If this occurs operation is interrupted until the pump is reprimed using an on board pum...

Page 48: ...p a copy of this summary near the PPCH especially when first becoming acquainted with the instrument s operation Table 8 Summary of PPCH function key operation DIRECT FUNCTION KEYS ARE ACTIVE FROM THE...

Page 49: ...or the Q RPT s default range AR for a range created by AutoRange 3 Q RPT or utility sensor position designator 4 Current pressure unit of measure 5 Full scale pressure in current unit of measure in ga...

Page 50: ...ted to the PPCH TEST port it will not measure the pressure generated by PPCH and PPCH may reach a pressure higher than the target pressure before its watchdog function recognizes that the external Q R...

Page 51: ...ge unit of measure See Section 7 2 1 for tables of the conversion factors used by PPCH If the pressure unit selected is inWa inches of water the reference temperature for water density must we specifi...

Page 52: ...ted Gauge mode only abs mode OFF is displayed when MODE is pressed 3 3 4 AUTORANGE PURPOSE To automatically set up PPCH to optimize its measurement and control characteristics and other features to co...

Page 53: ...e Table 10 3 2 2 3 4 6 1 Jog step Set jog step size 100 ppm of AutoRange span 3 4 3 OPERATION To use the AutoRange function press AutoRange and respond to PPCH s prompts Select measurement mode The sc...

Page 54: ...function recognizes that the external RPT is not connected Take care not to overpressure external Q RPTs when using them with a PPCH When using external Q RPTs in RPM4s as reference pressure measurem...

Page 55: ...dentification of RPTs in External 2 second RPM4 Hi and Lo positions IH A200Mu L none X1H A200M L A70M X2H A40M L none The cursor is on the position designator of the active Q RPT or utility sensor Use...

Page 56: ...trol target values such as is commonly needed when PPCH is used to run a calibration sequence on a device or system being tested There are two types of sequences Quick Test Allows quick definition and...

Page 57: ...crease the upper limit before running the sequence see Section 3 4 4 or change to a higher range if available see Section 3 3 1 To AutoRange the PPCH automatically for a specific sequence based on the...

Page 58: ...minimum 1 maximum 999 After making the next increment on selection the display is 1 Indication of minimum and maximum pressure included in the sequence which is about to run ENTER to run MPa g 0 000...

Page 59: ...est See Section 3 4 5 for information on QDUT AutoTest data files To run a QDUT Test press AutoTest and select 2QDUT The display is Run current QDUT AutoTest 1yes 2no This selection provides the choic...

Page 60: ...also be defined The display is 1 Entry field for minimum pressure of the QDUT Test sequence Recalls last value entered DUT low point 2000 psi a This entry determines the lowest pressure of the QDUT s...

Page 61: ...t AutoRange has selected to cover the QDUT full scale and measurement mode 3 Pressure unit of measure specified in QDUT setup 4 AutoRange full scale pressure in gauge mode and absolute mode if availab...

Page 62: ...ssure increment press ENT The display is 1 Final target pressure at which DUT indicated cardinal value of the pressure point 2 IN or OUT depending on whether DUT was in or out of tolerance DUT is IN i...

Page 63: ...reference level marked on the rear panel This assures that a consistent head height is applied to the system connected to the PPCH TEST port when the system is vented by the VENT function of PPCH and...

Page 64: ...Q RPT When a head correction is being applied it is indicated by h in the top line of the MAIN RUN screen see Section 3 1 1 When the head correction is zero the h is not shown To change units of head...

Page 65: ...e system is closed by tightening the fitting Priming aborts automatically when the pressure reaches 0 5 MPa 75 psi OPERATION The PRIME function interrupts automatically when pressure of 0 5 MPa 75 psi...

Page 66: ...the actual pressure The second line alternates between a display of the target purge pressure or Venting and a display of the current cycle and total number of cycles to be executed 1 005 MPa g IH Pur...

Page 67: ...tion 3 4 6 2 To access the LEAK CHECK function press LEAK CHECK from the MAIN RUN screen Select 1run to run a leak test The display is 1 Edit field for the time over which the leak check pressure chan...

Page 68: ...s shows the results of the last leak check run regardless of the range that is now active The results screen includes the range indicator to indicate the range in which the leak check was run 3 3 10 E...

Page 69: ...are in use 3 Target pressure value T when controlling and condition is Not Ready Current deviation from the target pressure D when in dynamic control mode and condition is Ready 40 000 kPa a HI D 0 00...

Page 70: ...MAIN RUN screen first line showing measured pressure and active Q RPT 2 Current control mode indicator Flashes when automated pressure control is active Character is S for static control C is appended...

Page 71: ...et pressure value as desired A target pressure entry that exceeds the current upper limit see Section 3 4 4 is not accepted Negative values are not accepted See Section 3 3 10 6 for information on zer...

Page 72: ...rent pressure unit of measure per second 20 007 MPa g HI Target rate 1 0000 s Edit the target ramp value as desired Enter a negative value for a descending rate A rate entry of 0 is not accepted Press...

Page 73: ...r the target pressure has been reached This is to avoid suspending control when setting the next pressure increment as that could cause the direction of pressure evolution to reverse violating the mon...

Page 74: ...function creates a range and automatically sets various operating parameters proportionally to the range see Section 3 3 4 Operating settings can then be changed by the user Many operating settings a...

Page 75: ...When the desired range to be deleted is displayed press ENT If you are sure you want to delete this range press ENT again in response to the Delete query Press ESC to return to the AutoRange screen wi...

Page 76: ...ntrol keys and increase or decrease pressure by a nominal amount each time they are pressed If pressure control is NOT active pressing the jog key causes an up or down pressure step If dynamic pressur...

Page 77: ...r is lower The upper limit is very useful in assuring that the pressure ramps of monotonic or ramp pressure control modes do not result in an accidental overpressure OPERATION To view or edit the uppe...

Page 78: ...e both the PPCH and the RPM4 may execute overpressure routines in response to an overpressure condition of the RPM4 See the RPM4 Operation and Maintenance Manual for information on the RPM4 overpressu...

Page 79: ...ile header is between the first point and the last point Press ESC to exit the data file Confirmation is required to exit the data view function 3 4 6 6CONTROL PURPOSE To set the automated pressure co...

Page 80: ...hichever is greater Not applicable Not applicable Note of range limits are of default or AutoRanged range OPERATION To access the CONTROL function press SETUP 6control The display is Dynamic standard...

Page 81: ...namic d for hi volume dynamic S for static Hold limit IH 0 010 MPa D Edit the hold limit value if desired and press ENT to view the stability limit The next display is 1 Active Q RPT designator 2 View...

Page 82: ...en with the edited values active See Section 3 4 6 Table 10 for default control limits 3 4 6 2 2MODE PURPOSE To select the active automated pressure control mode PRINCIPLE See Section 3 4 6 PRINCIPLE...

Page 83: ...control 2mode see Section 3 4 6 Selecting the mode automatically activates its default control parameters This is a convenient way to put the PPCH into a known condition after trying custom control se...

Page 84: ...ime keypad sound frequency unit ID number time date security protection level see Section 3 5 5 6Punit Customize the UNIT key pressure unit of selections See section 3 5 6 7intern Access internal func...

Page 85: ...te pressure nominally atmospheric pressure with uncertainty significantly better than that of the Q RPT that is being AutoZeroed Given the high range of PPCH Q RPTs this is easily accomplished with a...

Page 86: ...stability over time of PPCH internal and external Q RPTs and maximizing the recalibration interval by compensating for change in zero between full recalibrations The following simple recommendations...

Page 87: ...is new or has just been calibrated Poffset should be roughly equal to atmospheric pressure for a PPCH Q RPT in gauge mode Select 3edit to edit the value of Poffset for the active Q RPT and measurement...

Page 88: ...ossible change in zero see Section 3 5 1 PRINCIPLE Allow the PPCH Q RPT to stabilize at atmospheric pressure and ambient temperature for 10 to 15 minutes before running AutoZ The stabilization period...

Page 89: ...lt selection is 1baro With this selection when AutoZ is ON the PPCH on board barometer see Section 3 5 7 2 is used as the AutoZ reference Pstd 0 and AutoZ runs automatically whenever PPCH is vented Th...

Page 90: ...eived command but responds with both and ASCII 13 carriage return and an ASCII 10 line feed There are no other options 3 5 2 2 3IEEE 488 The IEEE 488 port s primary address can be set from 1 to 31 in...

Page 91: ...a test fails Execution is suspended until ENT is pressed The PPCH RS232 test can fail for three reasons 1 The RS232 cable being used is incorrect see Section 4 2 1 1 for information on the correct cab...

Page 92: ...e transducers Q RPTs Reset functions should only be used by qualified personnel with knowledge of reset consequences Reset functions should not be used experimentally OPERATION To access the RESET men...

Page 93: ...3 5 5 2 Volume Determination Return to default 3 5 7 1 3 5 4 2 2UNITS PURPOSE Sets the six pressure units available under the UNIT function to the SI or US default selections depending on whether the...

Page 94: ...global reset command that clears the entire user section of non volatile memory returning PPCH to the as delivered condition except the ID function see Section 3 5 5 4 and the security level password...

Page 95: ...een saver time to zero eliminates the SCREEN SAVER function so that the display permanently remains at full brightness OPERATION To access the SCREEN SAVER function press SPECIAL 5pref 1ScrSav Edit in...

Page 96: ...nt ID Select 2edit to edit the ID The ID has twelve characters When the edit screen is opened the cursor is on the first character Numerical values can be entered directly from the keypad In addition...

Page 97: ...lows access and editing in all areas including critical metrological information Low Low security is designed to protect the specific metrological information and SYSTEM DIAGNOSTIC AND MAINTENANCE fun...

Page 98: ...utoZ 1on 1off SPECIAL 1AutoZ 3edit SPECIAL 2remote SPECIAL 2remote make changes SPECIAL 3head SPECIAL 4reset SPECIAL 4reset 4cal SPECIAL 4reset 5all SPECIAL 5pref 1ScrSvr SPECIAL 5pref 2sound SPECIAL...

Page 99: ...is entered the password is made inactive and the user will not be required to enter a password to access the user level menu This condition with a security level of 2low is the factory default If ther...

Page 100: ...ich unit position 1 6 of the UNIT function key menu is to be changed Set up unit 6 Enter the number of the unit position that you would like to change The display becomes Unit 6 1SI 2other 3user Selec...

Page 101: ...PPCH is connected PRINCIPLE AND OPERATION These functions are considered part of PPCH maintenance and are therefore covered in the maintenance section of this manual see Sections 5 7 5 8 3 5 7 2 2BARO...

Page 102: ...tic pump has been in operation and to reset the timer if desired see Section 3 5 7 3 4 3 5 7 3 1 1PRIME PURPOSE To run an automated routine to prime the PPCH s on board hydropneumatic pump when it has...

Page 103: ...ould always be set to the 1abort default condition 3 5 7 3 3 3PRESSURE PURPOSE To view the pressure measured by the pump drive pressure transducer and the calculated pump fluid output pressure PRINCIP...

Page 104: ...perator Normally the time is reset to zero when the pump is serviced or replaced see Section 5 10 OPERATION To view the pump timer press SPECIAL 7internal 3pump 4hours The hours of pump operation pump...

Page 105: ...CIAL 9Log Use and to move back and forth between older and newer log entries Each log entry has two screens one with the event description and one with the even time and date Use and to toggle between...

Page 106: ...PPCH OPERATION AND MAINTENANCE MANUAL 2009 DH Instruments a Fluke Company Page 96 N NO OT TE ES S...

Page 107: ...from remote to local or from local to remote aborts any active generation 4 2 1 RS232 INTERFACE 4 2 1 1 COM1 The PPCH COM1 RS232 interface is located on the back of the unit It is a 9 pin male DB 9F c...

Page 108: ...al pin to pin DB 9M to DB 9F RS232 cable to be used to connect to a DCE device Handshaking is not required or supported Table 18 COM2 DB 9F pin designations PIN FUNCTION DESCRIPTION 2 RxD This pin tra...

Page 109: ...is put into an Error Queue and the ERR query program message can be used to get a text description of the most recent error If you are using the IEEE 488 port the service request line can be setup to...

Page 110: ...operator CLS Clear the error queue No reply UNIT KPA MMODE A PS 100 Three commands at once No reply ERR Wait for reply User should use ERR query following a series of non query commands to check for e...

Page 111: ...ration information obsolete format PR Read the next PPCH pressure PRR Read the next PPCH pressure rate and ATM PS Set a new target pressure and start automated pressure control PSF Set a new target pr...

Page 112: ...roper command argument s ERR 8 External device time out error ERR 9 Unknown command ERR 10 Missing or invalid command suffix ERR 11 Command missing argument ERR 12 System overpressured or overpressure...

Page 113: ...re are multiple arguments then commas must separate them The PPCH will always reply to a Classic program message You must wait for this reply before issuing another program message If this field is no...

Page 114: ...set up to communicate with the device on COM2 Refer to the COM2 program message If the PPCH is using an external RPM4 as the active RPT then this command should not be used to interfere with the RPM4...

Page 115: ...nt range data including the RptLabel used for the range Example enhanced Cmd sent Reply ARANGE read the current range in the current units 1000 0 psi A IH Example classic Cmd sent Reply ARANGE read th...

Page 116: ...ta stop COM1 Classic COM1 baud parity data stop COM1 Arguments Baud The baud rate This may be 300 600 1200 2400 4800 9600 or 19200 Parity The data parity This may be O for odd E for even or N for none...

Page 117: ...gram message argument s See Also PASSTHRU 3 5 2 1 4 2 1 3 DATE Purpose Read or set the PPCH date Command Query DATE date DATE Classic DATE date DATE Arguments date The date in the numerical only forma...

Page 118: ...e enhanced Cmd sent Reply DRV2 1 1 Example classic Sent Reply DRV1 1 DRV1 1 Errors ERR 6 The n or x arguments are not within given limits See Also 3 4 7 DS Purpose Decrease the pressure slowly Command...

Page 119: ...Oil H2O or User Remarks The PPCH can make a fluid head correction to allow it to display the pressure at the level of the device under test instead of at the level of the PPCH Example enhanced Cmd se...

Page 120: ...ID string ID Classic ID string ID Arguments String An alphanumeric string up to 12 characters long Remarks The user defined ID label can be used to allow the user to tag the PPCH with a unique identi...

Page 121: ...eply IS 1 1 no reply if IEEE 488 Example enhanced Cmd sent Reply IS 1 1 Example classic Sent Reply IS 1 IS 1 Errors ERR 6 ERR 55 The n argument is a 0 or a 1 Hardware malfunction fluid reservoir is lo...

Page 122: ...dard dynamic control 1 1 for hi volume dynamic control 2 for monotonic control 3 for rate control Remarks The method which the PPCH controls pressure is selected with the MODE program message When the...

Page 123: ...is used for communication with DHI RPM4s used as PPCH external measurement devices The COM2 port can alternatively be used to communicate to another RS232 device such as another PPCH This allows the...

Page 124: ...owed to operate in gauge mode Changes made using this program message take effect immediately The calibration information of DHI RPM4s connected to PPCH must be adjusted directly on the RPM4 The infor...

Page 125: ...be executed omitting the automated control configuration routine Command PS n v Classic PS n v Arguments n v The target pressure in the current pressure units The volume of the system connected to the...

Page 126: ...en target pressure using a rate of 0 2 FS sec and stops controlling when the pressure has reached or passed the given target The system does not attempt to maintain the target pressure The PR PRR STAT...

Page 127: ...lso PR PRR SR 3 1 1 3 5 7 2 RANGE Purpose Change the active range to one of the available internal or external default Q RPT ranges Read the active range full scale pressure unit and measurement mode...

Page 128: ...ed since the ready check flag was set Example enhanced Cmd sent Reply READYCK 1 1 no reply if GPIB 488 Example enhanced Cmd sent Reply READYCK 1 Example enhanced Cmd sent Reply READYCK 1 if PPCH condi...

Page 129: ...ld not take place during this period Example enhanced Cmd sent Reply RESET RESET no reply if IEEE 488 Example enhanced Cmd sent Reply RESET RESET Example classic Sent Reply RESET RESET See Also 3 5 4...

Page 130: ...2 ERR 18 ERR 55 The target pressure is out of range Active external RPM4 timeout Pressure has exceeded maximum limits This command not valid in rate control mode Hardware malfunction reservoir low See...

Page 131: ...ocator Serial RngGa RngAbs RptMode RngLabe RPT type label This label identifies the RPT type and range This is the same label used on the PPCH front panel screen RptLocator Text field identifying the...

Page 132: ...volume is constant and the configuration does not change This argument is only an approximation value and it may be adjusted empirically for correct operation A higher v setting speeds up the generati...

Page 133: ...ad and set as a percent of the full scale range of the RPT range These limits are part of the ready criteria The stability limit applies to static and dynamic control modes only The rate limit applied...

Page 134: ...current pressure unit of measure Example enhanced Query sent Reply TP 10 000 MPa a Example classic Sent Reply TP 10 000 MPa a See Also PS 3 3 10 TPCCFG planned command as of PPCH Ver 1 01f Purpose Sta...

Page 135: ...ply TPCVOL 50 50 Errors ERR 6 The volume was invalid See Also 5 7 UCOEF Purpose To convert 1 Pascal to the current pressure units Query UCOEF Classic UCOEF Remarks The PPCH handles all pressure values...

Page 136: ...unitg ref UNIT unita ref UNIT Arguments unit ref The text corresponding to the pressure unit of measure The optional unit reference temperature only if the unit is InWa Remarks This program message de...

Page 137: ...s It indicates the internal RPT s and software version Example enhanced Query sent Reply VER DH INSTRUMENTS A FLUKE COMPANY PPCH us A100M A20M Ver1 00 US version Example classic Query sent Reply VER D...

Page 138: ...e PPCH status reporting system is used to track and report system status and errors It follows the model of the IEEE Std 488 2 and works for the COM1 and the IEEE 488 port with slight differences The...

Page 139: ...register to 20 14 hex an SRQ will occur if the MAV or the ERROR bit are set The description of these bits are given as OPER N A Bit 7 128 RQS Requested Service Bit 6 64 Indicates that the SRQ line of...

Page 140: ...ccurred A command error is typically a syntax error in the use of a correct program message EXE Execution Error Bit 4 Indicates if a remote program message cannot be processed due to device related co...

Page 141: ...mands These commands also cover the status reporting commands See Section 4 5 for details on the status registers mentioned in these commands Table 24 Program message list CLS Clear all of the status...

Page 142: ...anufacture the model the serial number and the software version Each is separated by a comma Example enhanced Sent IDN Reply DH INSTRUMENTS INC PPCH 1 35785 0 Ver1 00 kkbj OPC Purpose Sets the operati...

Page 143: ...user settings units resolution generation settings and retains them when the unit if OFF On power up this memory is checked If this memory is corrupted all user settings are reset to default as if th...

Page 144: ...PPCH OPERATION AND MAINTENANCE MANUAL 2009 DH Instruments a Fluke Company Page 134 N NO OT TE ES S...

Page 145: ...Priming the hydropneumatic pump see Section 5 10 1 Certain operational problems or failures can be diagnosed and corrected locally To troubleshoot PPCH operation based on behavioral symptoms and iden...

Page 146: ...cessary Leak test the PPCH see Section 5 11 1 Leak rate after stabilization should not exceed 0 002 of reading second If leak check fails replace isolation or vent valve s if needed see Section 5 11 2...

Page 147: ...orts the calibration process of PPCH Q RPTs CalTool and its documentation are provided on a General Accessories Disk with the new PPCH Most users should use CalTool software to assist in the calibrati...

Page 148: ...ed As left data is also calculated and presented At any time a reference pressures applied b associated Q RPT readings c PA PM and Poffset values can be used to calculate as received and as left value...

Page 149: ...ressure points in the range to be calibrated See Section 5 3 4 for information on the recommended calibration point sequence for PPCH Q RPTs 5 3 3 SET UP AND PREPARATION To set up and prepare the PPCH...

Page 150: ...URPOSE To prevent selection of absolute measurement mode for a Q RPT PRINCIPLE PPCH Q RPTs are intrinsically absolute Axxx type but are frequently used in gauge measurement mode only see Section 3 3 3...

Page 151: ...ormation fields including The calibration date This field is normally used to record the date on which the Q RPT is calibrated The value of absolute mode AutoZero Poffset See Section 3 5 1 for complet...

Page 152: ...f PA 2 Position designator of the Q RPT being viewed 3 Value of PM PA 0 0 Pa IH PM 1 000000 If in edit mode the calibration fields can be edited Pressing ENT in the PM field goes to the next calibrati...

Page 153: ...e Section 3 5 1 If calibrating in absolute measurement mode turn AutoZ ON if it is left ON in normal PPCH operation If calibrating in gauge measurement mode always turn AutoZ ON Use SPECIAL 8cal 1Hi R...

Page 154: ...surement mode see Section 3 5 1 OPERATION To edit the values of PA and PM for the barometer press SPECIAL 8cal 2barometer Pressing ENT steps through displays of the calibration date YYYYMMDD and PA an...

Page 155: ...ondition is indicated by an audible alarm and intermittent display of Reservoir level low on the display bottom line see Section 3 5 7 3 To fill the internal reservoir proceed as follows see illustrat...

Page 156: ...ILL DRAIN tube assembly downward to a vertical position in which fluid runs out the tube The reservoir should drain fully in a few moments If you have drained the reservoir because the test fluid has...

Page 157: ...eave RESERVOIR FILL DRAIN valve set to OPEN PPCH will not operate correctly with valve set to CLOSE position Figure 20 External reservoir schematic 5 6 2 2 DRAINING THE EXTERNAL RESERVOIR To drain the...

Page 158: ...To run an automated routine that determines the volume of the system into which the PPCH is controlling pressure to optimize the performance of PPCH pressure control PRINCIPLE PPCH pressure control is...

Page 159: ...ase or decrease by up to 1 4 MPa 200 psi from the starting point The volume configuration routine may be run at any pressure greater than 1 MPa 150 psi Dynamic pressure control mode must be active The...

Page 160: ...mple leaks restrictions in test lines air in test volume low drive pressure supply In addition the VALVE CONFIG function allows valve opening point tables to be returned to original factory values Thi...

Page 161: ...access the PPCH mechanical module the chassis is opened from the rear and the module slides out on rails PROCEDURE To access the PPCH mechanical module proceed as follows Vent the PPCH and disconnect...

Page 162: ...will operate normally again This requires forcing oil into the pump The PPCH pump priming routine uses the drive air supply to pressurize the reservoir forcing oil into the pump This makes recovery f...

Page 163: ...ine flashes Priming complete Press ESC or ENT to vent and return operation to the main run screen 5 10 1 1 PRIMING THE PUMP CHECK VALVE PRINCIPLE If the pump fails to prime using the standard procedur...

Page 164: ...ser A failed or failing pump may be indicated by failure to generate pressure inability to reach maximum pressure oil mist coming from pump air exhaust see Troubleshooting Section 6 To avoid pump fail...

Page 165: ...unit Install the new pump in the reverse order see Section 5 1 Table 25 to identify the correct pump to installed Apply Loctite 242 or equivalent non permanent thread locker to the pump mount threads...

Page 166: ...ling action PROCEDURE To inspect and or repair the pump spool valve proceed as follows Vent the PPCH and disconnect electrical power and drive air supply Open PPCH chassis to gain access to the mechan...

Page 167: ...o ring Place plug back into spool valve body Seat the retaining clip back into the spool valve body Note that a good deal of force is required to properly seat the retaining clip Make certain that th...

Page 168: ...PT the filter can be accessed through the top of the PPCH chassis If the PPCH has a Lo Q RPT the PPCH must be placed on its side so that the bottom of the mechanical module is facing you Looking at th...

Page 169: ...CAY LEAK TESTING METHOD PROCEDURE To determine whether a leak is present in a system by measuring the rate of pressure decay a pressure is set allowed to stabilize and then the pressure change over ti...

Page 170: ...A LEAK WITHIN THE PPCH To determine if there is a leak in the PPCH first leak check the complete PPCH by running a pressure decay leak test with the PPCH TEST port plugged see Section 5 11 1 If there...

Page 171: ...ure vent valve proceed as follows If the PPCH TEST port is not already plugged plug it with a DH500 gland and plug If the PPCH has a Lo Q RPT use RANGE to make the Hi Q RPT or utility sensor active se...

Page 172: ...and and plug supplied with PPCH accessories in the open port of the TPCU Reapply drive air supply connect electrical power and power on the PPCH Perform a pressure decay based leak check see Section 5...

Page 173: ...nnections on the pressure tube between the isolation valve and the high pressure cross Slide back the valve assembly in the mounting slots to fully remove the loosened tube Install a DH200 gland and p...

Page 174: ...cal power and drive air supply Open the PPCH chassis to gain access to the mechanical module see Section 5 9 Loosen the low pressure vent valve bracket retaining hardware two button head bolts Disconn...

Page 175: ...to replace a PPCH shutoff valve is the same for all three valves To replace a shutoff valve proceed as follows Vent the PPCH and disconnect electrical power and drive air supply Open PPCH chassis to g...

Page 176: ...PPCH uses FLASH memory This allows the embedded software that controls PPCH operations and functions to be loaded into PPCH over its COM1 port from a computer with a simple FLASH loading utility progr...

Page 177: ...micro card 5 On board barometer Figure 21 Electronic module internal view 5 14 1 1 POWER ENTRY AND FUSE Electrical Power Connector IEC 320 C13 and main fuse Fuse 1 A 250 VAC fuse 5 x 20 mm time lag t...

Page 178: ...ion 5 14 2 15 Power to and control of servo valve stepping motors see Section 5 14 2 11 Fluid reservoir level detector Remote ENT Keypad and display Beeper 5 14 1 4 MINI MICRO BOARD The micro board su...

Page 179: ...e micromachined silicon sensor and an ambient temperature sensor The transducers readings are used to indicate the drive air pressure to the hydropneumatic pump see Section 5 14 2 10 The temperature s...

Page 180: ...essure stainless steel volume of approximately 40 cc 5 14 2 8 FRONT PANEL Sheet metal with inlaid overlay panel on which a membrane switch keypad and electro luminescent display are mounted 5 14 2 9 E...

Page 181: ...SERVOIR OVERFLOW EXTERNAL RESERVOIR RETURN TUBE 1 4 in PFA tube 5 14 2 15 THERMAL PRESSURE CONTROL UNIT TPCU High pressure volume containing a helicoidal heating element The TPCU is used for fine pres...

Page 182: ...PPCH OPERATION AND MAINTENANCE MANUAL 2009 DH Instruments a Fluke Company Page 172 N NO OT TE ES S...

Page 183: ...PCH is unable to find external RPM4 and Q RPT The RPM4 COM1 port settings are not correct Set RPM4 COM1 port to settings required for use with PPCH 2 3 9 1 RPM4 Operation and Maintenance Manual Measur...

Page 184: ...ve pressure supply not connected incorrectly connected or not adequate Correct pressure supply Observe pump drive air pressure 2 3 5 3 5 7 3 There is a very large leak in the test system or TEST port...

Page 185: ...n 5 14 2 15 Poor pressure control characterized by overshooting target The volume connected to the TEST port is too small Add volume to the system connected to the TEST port 1 2 3 A filter in the PPCH...

Page 186: ...depressurization Wait for Q RPT recovery Pressure indication is negative Control mode was changed from dynamic to another mode while not vented It is preferable to be vented when changing measurement...

Page 187: ...t of all the activated drivers cannot exceed one Amp Therefore refer to Table 28 if multiple drivers are being activated simultaneously Table 28 External drivers current output OF ACTIVE DRIVERS MAX C...

Page 188: ...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...

Page 189: ...h indirect damage includes but is not limited to loss of production profits revenue or goodwill even if DH Instruments a Fluke Company has been advised of the possibility thereof and regardless of whe...

Page 190: ...PPCH OPERATION AND MAINTENANCE MANUAL 2009 DH Instruments a Fluke Company Page 180 N NO OT TE ES S...

Page 191: ...or calibrate Dynamic Control Control mode in which the pressure is constantly adjusted to remain as close as possible to the target value External device or External Q RPT A Q RPT in an RPM4 external...

Page 192: ...ed in units of pressure per second e g kPa second The stability limit is used as the Ready Not Ready criterion Ready if rate of change is less than stability limit Not Ready if rate of change is great...

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DH Instruments PPCH, Operation And Maintenance Manual

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