Instrutech Busy Bee PCM301 User manual

p/n 002663-100
InstruTech®
Pirani Capacitance Combination Vacuum Gauge
PCM301 Module
The Busy Bee™
User Manual
InstruTech
1475 S. Fordham St.
Longmont, CO 80503
USA
Phone: [phone]
Fax: [phone]
E-mail [email protected]
www.instrutechinc.com

Instruction Manual PCM301 Busy Bee
InstruTech Page 1
Important User Information There are operational characteristic differences between solid state equipment and
electromechanical equipment. Because of these differences, and because there are a variety of uses for solid state equipment, all
persons that apply this equipment must take every precaution and satisfy themselves that the intended application of this equipment is
safe and used in an acceptable manner.
In no event will InstruTech be responsible or liable for indirect or consequential damages that result from the use or application of this
equipment.
Any examples or diagrams included in this manual are provided solely for illustrative purposes. Because of the many variables and
requirements imposed on any particular installation, InstruTech cannot assume responsibility or liability for any actual use based on the
examples and diagrams.
No patent liability is assumed by InstruTech with respect to use of information circuits, equipment, or software described in this manual.
Throughout this manual we use notes, notices and apply internationally recognized symbols and safety messages to make you aware of
safety considerations.
Identifies information about practices or circumstances that can cause electrical or physical hazards which, if precautions are not taken,
could result in death or serious injury, property damage, or economic loss.
Identifies information about practices or circumstances that can cause electrical or physical hazards which, if precautions are not taken,
could result in minor or moderate injury, property damage, or economic loss.
Identifies information that is critical for successful application and understanding of the product.
Labels may be located on or inside the device to alert people that dangerous voltages may be present.
CAUTION
CccWARNING
WARNING
NOTICE
SHOCK HAZARD
CccWARNING
WARNING

p/n 002663-100
Copyright © 2016 by InstruTech
All rights reserved. No part of this work may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying and recording, or by any information storage or retrieval system, except as may be expressly permitted in
writing by InstruTech.
Printed in the United States of America
Conflat® is a registered trademark of Varian, Inc. / Agilent Technologies, Lexington, MA

Instruction Manual PCM301 Busy Bee
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Table of Contents
1 Introduction / General Information....................................................................................................................3
1.1 Description .................................................................................................................................................3
1.2 Specifications .............................................................................................................................................3
1.3 Dimensions.................................................................................................................................................4
1.4 Part Numbers .............................................................................................................................................5
1.5 Options & Accessories................................................................................................................................6
2 Important Safety Information.............................................................................................................................7
2.1 Safety Precautions - General......................................................................................................................7
2.2 Safety Precautions - Service and operation ...............................................................................................8
2.3 Electrical Conditions...................................................................................................................................8
2.3.1 Proper Equipment Grounding............................................................................................................8
2.3.2 Electrical Interface and Control..........................................................................................................9
2.4 Overpressure and use with hazardous gases.............................................................................................9
2.5 Gas Dependency.......................................................................................................................................10
3 Installation ........................................................................................................................................................10
3.1 Mechanical Installation............................................................................................................................10
3.2 Electrical Installation................................................................................................................................11
3.2.1 Grounding.........................................................................................................................................11
3.2.2 Connector.........................................................................................................................................12
3.2.3 Connector pin-out............................................................................................................................12
4 Setup and Operation.........................................................................................................................................13
4.1 Gauge start up and operation..................................................................................................................13
4.2 Gauge Status LEDs....................................................................................................................................13
4.3 Gauge Display...........................................................................................................................................14
4.4 Programming & configuration .................................................................................................................17
4.4.1 Relay setpoint characteristics (setpoint assigned to vacuum system pressure) .............................18
4.4.2 Programming the SP1 & SP2 setpoints with button on the gauge ..................................................20
4.4.3 Relay setpoint characteristics (atmospheric pressure (ATM) setpoint)...........................................21
4.4.4 Zero adjustment...............................................................................................................................22

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4.4.5 Adjusting the Atmospheric Pressure Sensor....................................................................................22
5 Using the gauge with different gases ...............................................................................................................23
6 Analog Output...................................................................................................................................................24
7 Service...............................................................................................................................................................26
7.1 Calibration................................................................................................................................................26
7.2 Maintenance ............................................................................................................................................26
7.3 Contamination..........................................................................................................................................26
7.4 Removing the gauge from service............................................................................................................26
7.4.1 Separating the sensor from electronics ...........................................................................................27
7.4.2 Inspecting the sensor (Pirani Filament)............................................................................................28
7.5 Troubleshooting.......................................................................................................................................29
8 Factory Service and Support.............................................................................................................................30
9 Warranty...........................................................................................................................................................30

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1 Introduction / General Information
1.1 Description
The PCM301 Busy Bee™ vacuum gauge module combines pirani technology with a ceramic capacitance
diaphragm sensor to provide repeatable and accurate readings. Above 7.6 Torr, the measurement is not gas
dependent which allows for safe venting of any gas mixture. The Capacitance Diaphragm is a gas type
independent absolute pressure sensor. It provides excellent long term stability and performance. The
capacitance diaphragm sensor assembly is constructed of a compact ceramic and metal design resulting in a
simple yet rugged sensor suitable for numerous industrial applications. The corrosion resistant sensor material
provides excellent temperature compensation capability, thus enhancing the reliability of the pressure
measurements. The pirani sensor measures pressure indirectly by sensing the loss of heat from a sensor to the
surrounding gases. The higher the pressure of the surrounding gas, the more heat is conducted away from the
sensor. Pirani thermal conductivity gauges maintain a sensor (usually a wire) at some constant temperature,
and measure the current or power required to maintain that temperature.
The PCM301 provides the basic signal conditioning required to turn the sensor into a complete vacuum pressure
measurement instrument. The built-in controller provides a display with a log-linear analog output and two
setpoint relays. The capacitance diaphragm sensor is used for pressure measurements from 7.6 to 1,125 Torr.
The measurement range from 7.6 to 7.6 x 10-1 Torr is considered the crossover range where signals from both
the pirani and the capacitance sensors are used proportionally. Below 7.6 x 10-1 the pirani sensor is strictly used
to measure the pressure. The entire measurement range for the PCM301 Pirani Capacitance combination gauge
is 3.8 x 10-5 to 1,125 Torr.
1.2 Specifications
measurement range
3.8 x 10-5 to 1,125 Torr / 5 x 10-5 to 1,500 mbar / 5 x 10-3 Pa to 150 kPa
measurement principal
3.8 x 10-5 to 7.6 x 10-1 Torr
7.6 x 10-1 to 7.6 Torr
7.6 to 1,125 Torr
pirani
crossover range
capacitance diaphragm
accuracy - N2 (typical)
3.8 x 10-4 to 7.6 x 10-4 Torr: ± 50% of reading
7.6 x 10-4 to 75 Torr: ± 15% of reading
75 to 715 Torr: ± 5% of reading
715 to 790 Torr: ± 2.5% of reading
repeatability - (typical)
7.6 x 10-4 to 825 Torr: ± 2% of reading
materials exposed to gases
W, Ni, NiFe, AI2O3, SnAg, stainless steel, glass
internal gauge volume
1/8 in. NPT: 0.32 in3 (5.2 cm3), KF16: 0.29 in3 (4.7 cm3), KF25 & 4 VCR: 0.34 in3 (5.5 cm3)
1.33 in. Mini-CF: 0.49 in3 (8 cm3), 8 VCR: 0.43 in3 (7 cm3)
16KF long tube: 0.88 in3 (14.5 cm3), 1.33 in. Mini-CF long tube: 0.85 in3 (14 cm3)
admissible pressure
≤ 72.5 psi (5 bar) absolute
burst pressure
145 psi (10 bar) absolute
temperature
operating: + 10 to + 50 oC storage: -20 to + 65 oC
relative humidity
annual average: 0 to 65% during 60 days: 0 to 85% , non-condensing
bakeout temperature
≤ 80 oC at flange ≤ 250 oC at flange with the long tube option
weight
4 to 4.5 oz. (115 to 130 g)
housing (electronics)
aluminum extrusion
use
indoor only

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mounting orientation
any
analog output
log-linear 0 to 8 Vdc, 1 V/decade
output impedance
2 × 4.7 , short-circuit proof
load impedance
≥10 k, short-circuit proof
error signal
analog output switches to 0 V
response time
< 30 ms
input power (1)
15 to 30 Vdc, ≤ 2.5 W protected against power reversal
fuse required
1 AT
supply voltage ripple
<1 p-p
setpoint relays
2 Solid State, normally open, potential free, <30 V (ac) / (dc), ≤0.3 A resistive
setpoint relay hysteresis (2)
10% of threshold
setpoint relay range (N2)
3.8 x 10-5 to 1,125 Torr
setpoint switching time
<30 msec
connector
9-pin D-sub male
diagnostics port
3-pin, 2.5 mm Jack connector
CE compliance
EMC (EN61000-6-2, EN61000-6-3, EN61010)
environmental
RoHS compliant
(1)WARNING! The gauge may only be connected to power supplies, instruments, or control devices that conform to the
requirements of a grounded protective extra-low voltage (SELV) and limited power source (LPS), Class 2. The connection to the gauge has
to be fused.
(2)The hysteresis and the switching characteristics can be programmed via the diagnostic port.
1.3 Dimensions
in. (mm)
Fitting dimension A
1/8 in. NPT 1.41 in. (36 mm)
NW16KF 0.57 in. (14.5 mm)
NW25KF 0.85 in. (21.5 mm)
1 1/3 in. Mini-CF 1.22 in. (30.9 mm)
1/4 in. Cajon 4VCR 1.68 in. (42.7 mm)
1/2 in. Cajon 8VCR 1.82 in. (46.3 mm)
NW16KF w. Long Tube 5.15 in. (130.8 mm)
1 1/3 in. Mini-CF w. Long Tube 5.13 in. (130.2 mm)

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1.4 Part Numbers
Sensor Material
T = Tungsten
PCM301 T U T # # A
Display Units of Measure
T = Torr
Fitting / Flanges
A = 1/8 in. NPT Male
B = NW16KF
C = NW25KF
E = 1 1/3 in. Mini-CF (NW16CF)
G = 4VCR Female
H = 8VCR Female
I = 16KFwith Long Tube
J = 1 1/3 in. Mini-CF with Long Tube
Electronics
C = 2 set-point relays (absolute P.)
D = 2 setpoint relays ( 1 for absolute
press. and 1 for atmospheric switch)
Electrical Connector
A = 9-pin D-sub male
Example: PCM301TUTBCA (PCM301 tungsten pirani sensor, Torr display, NW16KF fitting, two setpoint relays, 9-pin D-Sub Connector)
Spare Parts
PCM301 Spare Sensor, 1/8 in. NPT Male
PCM301 Spare Sensor, NW16KF
PCM301 Spare Sensor, NW25KF
PC3A
PC3B
PC3C
PCM301 Spare Sensor, 1 1/3 in. Mini-CF
PCM301 Spare Sensor, 4 VCR Female
PCM301 Spare Sensor, 8 VCR Female
PC3E
PC3G
PC3H
PCM301 Spare Sensor, 16KF Long Tube
PC3BL
PCM301 Spare Sensor, 1 1/3 in. Mini-CF Long Tube
Centering ring with fine filter, NW16 KF
PC3EL
002628

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1.5 Options & Accessories
Part Number
Optional Wall Mount AC-DC
PS401 Power Supply
Input: 100 - 240 Vac
Output: 24 Vdc @ 750 mA (18 W)
Various AC plugs, 6 ft. cable length
with North American AC Plug
PS401-A
with Universal European AC Plug
PS401-EU
with UK AC Plug
PS401-UK
with China AC Plug
PS401-C
with Australian AC Plug
PS401-SP
PS401-UX For Use With User
Supplied AC Power Cord
This variation of the PS401 power supply may
be used when an AC plug that is not listed
above is required. The conventional
IEC60320 AC power entry receptacle allows
use with any user supplied AC mains power
cord set available worldwide.
Input: 100 - 240 Vac
Output: 24 Vdc @ 2.5 A (60 W)
Cable Length: 6 ft.
PS401-UX

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2 Important Safety Information
InstruTech has designed and tested this product to provide safe and reliable service, provided it is installed and
operated within the strict safety guidelines provided in this manual.Please read and follow all warnings and
instructions.
To avoid serious injury or death, follow the safety information in this document. Failure to comply with these
safety procedures could result in serious bodily harm, including death, and or property damage.
Failure to comply with these warnings violates the safety standards of installation and intended use of this
instrument. InstruTech disclaims all liability for the customer’s failure to comply with these instructions.
Although every attempt has been made to consider most possible installations, InstruTech cannot anticipate
every contingency that arises from various installations, operation, or maintenance of the module. If you have
any questions about the safe installation and use of this product, please contact InstruTech.
2.1 Safety Precautions - General
The product should never be operated with the electronics cover removed.
WARNING! Do not modify this product or substitute any parts without authorization of qualified
InstruTech service trained personnel. Return the product to an InstruTech qualified service and repair center to
ensure that all safety features are maintained. Do not use this product if unauthorized modifications have been
made.
WARNING! Source power must be removed from the product prior to performing any servicing.
WARNING! The gauge may only be connected to power supplies, instruments, or control devices that
conform to the requirements of a grounded protective extra-low voltage (SELV) and limited power source (LPS),
Class 2. The connection to the gauge has to be fused.
After servicing this product, ensure that all safety checks are made by a qualified service person. When
replacement parts are required, ensure that the parts are specified by InstruTech. Substitutions of non-
qualified parts may result in fire, electric shock or other hazards. Use of unauthorized parts or modifications
made to this product will void the warranty.
To reduce the risk of fire or electric shock, do not expose this product to rain or moisture. These products are
not waterproof and careful attention must be paid to not spill any type of liquid onto these products. Do not
use these products if they have been damaged. Immediately contact InstruTech to arrange return of the
product if it is damaged.
WARNING
WARNING
WARNING

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Due to the possibility of corrosion when used in certain environmental conditions, it is possible that the
product’s safety could be compromised over time. It is important that the product be periodically inspected for
sound electrical connections and equipment grounding. Do not use if the equipment grounding or electrical
insulation has been compromised.
2.2 Safety Precautions - Service and operation
Ensure that the vacuum port on which the PCM301 is mounted is electrically grounded.
Use an appropriate power source of 15 to 30 Vdc, 2.5 W minimum.
Turn off power to the unit before attempting to service the module.
Turn off power to the unit before detaching the electronics from the sensor for sensor replacement, sensor
cleaning or bakeout purposes.
Turn off power to the unit if a cable or plug is damaged or the product is not operating normally according to
this instruction manual. Contact qualified InstruTech service personnel for any service or troubleshooting
condition that may not be covered by this instruction manual.
Do not use if the unit has been dropped or the enclosure has been damaged. Contact InstruTech for return
authorization and instructions for returning the product to InstruTech for evaluation.
Gauge failures due to contamination or wear and tear are not covered by the warranty. We recommend
checking the zero at regular intervals.
2.3 Electrical Conditions
WARNING! When high voltage is present in any vacuum system, a life threatening electrical shock hazard
may exist unless all exposed electrical conductors are maintained at earth ground potential. This applies to all
products that come in contact with the gas contained in vacuum chambers. An electrical discharge within a
gaseous environment may couple dangerous high voltage directly to any ungrounded conductor of electricity. A
person could be seriously injured or killed by coming in contact with an exposed, ungrounded electrical
conductor at high voltage potential. This condition applies to all products that may come in contact with the gas
inside the vacuum chamber (vacuum/pressure containment vessel).
2.3.1 Proper Equipment Grounding
WARNING! Hazardous voltages that could seriously injure or cause death are present in many vacuum
processes. Verify that the vacuum connection port on which the gauge is mounted is electrically grounded.
Consult a qualified Electrician if you are in doubt about your equipment grounding. Proper grounding of your
equipment is essential for safety as well as intended operation of the equipment.

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The PCM301 must be electrically connected to the grounded vacuum chamber. The connection must conform
to the requirements of a protective connection according to EN 61010:
➔VCR® connections fulfill this requirement.
➔For gauges with a KF connection, use a conductive metallic clamping ring.
WARNING! In order to protect personnel from electric shock and bodily harm, shield all conductors
which are subject to potential high voltage electrical discharges in or around the vacuum system.
2.3.2 Electrical Interface and Control
It is the user’s responsibility to ensure that the electrical signals from this product and any connections made to
external devices, for example, relays and solenoids, are used in a safe manner. Always double check the system
set-up before using any signals to automate your process. Perform a hazardous operation analysis of your
system design and ensure safeguards and personnel safety measures are taken to prevent injury and property
damage.
2.4 Overpressure and use with hazardous gases
WARNING! Install suitable protective devices that will limit the level of pressure inside your vacuum
chamber to less than what the vacuum chamber system components are capable of withstanding. For example,
a quick-connect, O-ring compression fitting may forcibly release a mounted device from the vacuum chamber
fitting with only a few psi over local uncorrected barometric (atmospheric) pressure.
In cases where an equipment failure could cause a hazardous condition, always implement fail-safe system
operation. For example, use a pressure relief device in an automatic backfill operation where a malfunction
could result in high internal pressures if the pressure relief device was not installed on the chamber.
WARNING! Overpressure in the vacuum system > 14.5 psia (1 bar)
Injury caused by released parts and harm caused by escaping process gases can result if clamps are opened
while the vacuum system is pressurized. Do not open any clamps while the vacuum system is pressurized. Use
the type of clamps which are suited to overpressure.
WARNING! Overpressure in the vacuum system > 29 psia (2.5 bar)
KF connections with elastomer seals (O-rings) cannot withstand such pressures. Process media can thus leak
and possibly damage your health. Use O-rings provided with an outer centering ring.
CAUTION! If the internal pressure of a vacuum measuring device is allowed to increase above local
uncorrected barometric pressure (atmospheric pressure side), vacuum fittings may release and possible
overpressure conditions may cause leaks that would allow the gas inside the tube to release into the
atmosphere of the surrounding environment. Toxic, pyrophoric and flammable gases are examples of
hazardous gases that if allowed to leak out of the vacuum/pressure containment vessel into the atmospheric

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environment, could cause bodily injury and possible damage to equipment. Never expose the vacuum
measuring device internal volume to pressure above local atmospheric pressure when using hazardous gases.
2.5 Gas Dependency
WARNING! The measurement value is gas dependent below 7.6 Torr. The pressure reading applies to dry
air, O2, CO and N2. For other gases, the measurements have to be corrected. Refer to section 5 titled “Using
the gauge with different gases” for more details.
3 Installation
3.1 Mechanical Installation
WARNING! Fragile components. The ceramic sensor may be damaged by impacts. Do not drop the
product and prevent shocks and impacts.
CAUTION! Dirt and damage can impair the function of the vacuum component. Take appropriate
measures to ensure cleanliness and prevent damage. Touching the product or parts with bare hands increases
the desorption rate. Always use clean, lint free gloves as well as clean tools when working with this product.
Mount the gauge so that no vibrations occur. Should gauge adjustments become necessary in the future, be
sure to install it so that the adjustment button can be accessed with a pin.
Mount the PCM301 as close as possible to the pressure you want to measure. Long or restricted, small diameter
tubing will create a pressure difference between your process chamber and the gauge. This may cause a delay
in response to pressure changes. Mounting the PCM301 too close to a gas source inlet may also cause
measurement and control instability.
The PCM301 can be mounted in any orientation, however, if possible, mount the gauge with port down to help
minimize the effect of any particles or condensation collecting in the gauge.
For electrical safety purposes the housing of the gauge must be grounded to the vacuum chamber. When using
KF flanges, metal clamps must be used to ensure proper grounding. Do not attempt to modify your flange in
order to use non-metallic-type flange clamps. Be aware that some vacuum fittings such as NPT connections
installed using Teflon tape may not allow for metal-to-metal contact between the vacuum gauge and the
vacuum chamber. If such is the case, use a 12 gauge or larger copper wire to connect the vacuum gauge to a
ground lug on your vacuum chamber.
Use all metal vacuum fittings with metal seals when operating pressures are expected to be below 1.00 x 10-7
Torr (1.33 x 10-7 mbar, 1.33 x 10-5 Pa).

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For potentially contaminating applications and to protect the measurement system against contamination,
installation of the optional seal with centering ring and filter is recommended. See section 1.4 for accessories
part numbers.
Remove the protective lid and install the product to the vacuum system following manufacturer’s
recommendations for different flanges and fittings. Keep the protective lid for future maintenance.
or
Clamp
Seal with centering ring
Seal with centering
ring and filter
Protective lid
3.2 Electrical Installation
3.2.1 Grounding
WARNING! Be sure the vacuum gauge and the rest of your vacuum system are properly grounded for
safety as well as intended operation of the equipment. When using KF flanges, metal clamps must be used to
ensure proper grounding.
WARNING! The gauge may only be connected to power supplies, instruments or control devices that
conform to the requirements of a grounded protective extra-low voltage (SELV) and limited power source (LPS),
Class 2. The connection to the gauge has to be fused.
Ground loops, differences of potential, or EMC problems may affect the measurement signal. For optimum
signal quality, please do observe the following:
•Use an overall metal braided shielded cable. The connector must have a metal case.
•Connect the cable shield to ground at one side via the connector case. Make sure the connector case has
direct contact to the cable's shield on its whole circumference. Do not connect the other side of the shield.
•Connect the supply common with protective ground directly at the power.
•Use differential measurement input (signal common and supply common conducted separately).
•Potential difference between supply common and housing ≤18 V (overvoltage protection).

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3.2.2 Connector
Good, recommended practice is to remove power from any cable prior to connecting or disconnecting it.
The PCM301 is provided with one 9-pin D-sub male connector used for the I/O interface. Fabricate a cable to
connect to the vacuum gauge as shown below:
3.2.3 Connector pin-out
9-pin D-sub (DE-9P) male connector (used for analog output and digital I/O)
PIN NUMBER
PIN DESCRIPTION
1
Relay 1 (SP1), Normally Open
2
Not assigned
3
Power Input (15 to 30 Vdc, 2.5 W) protected against power reversal and transient over-voltages
4
Power common GND
5
Analog output (Log-Linear 0 to 8 Vdc, 1 V/decade)
6
Relay 1 Common
7
Relay 2 Common
8
Analog output common
9
Relay 2 (SP2), Normally Open
Wiring Diagram
6
7
5
8
3
4
1
9+
–
+
–
+24V
SP2
SP1
10k
18V
4.7
4.7
Measurement
signal

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4 Setup and Operation
4.1 Gauge start up and operation
Read this user manual in its entirety before operating the instrument.
The signal output is available when power is applied to the gauge. Allow for a stabilizing time of approx. 10 min.
Once the gauge has been switched on, it can remain in operation continuously regardless of the pressure.
Connect power to the PCM301 using the designated pins 3 and 4 of the 9-pin D-sub connector. Alternatively,
you can power the device by connecting InstruTech’s PS401-A power supply to the gauge.
4.2 Gauge Status LEDs
SP1SP2 ADJ
ST
DIA Status
Light-emitting diodes (LEDs)
LED
State
Condition
<ST>
off
lit green
lit solid or blinking red
no supply voltage
measurement mode
error
<SP1>
lit green
off
SP1 Relay closed
SP1 Relay open
<SP2>
lit green
off
SP2 Relay closed
SP2 Relay open

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4.3 Gauge Display
Display Background
Condition
off
no supply voltage
lit green
measurement and programming mode
lit red
error
The display can be rotated by 180 ° via the diagnostic port.
A) Display Start up
When the supply voltage is applied the software version is briefly displayed as shown below.

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B) Normal Display Mode
The display normal pressure measurement screen is shown below:
No symbol displayed = within range

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C) Setpoint Parameter Mode
To view the setpoint relay 1 or setpoint relay 2 threshold (setpoint value) briefly press <SP1> or the <SP2>
button. The corresponding threshold is displayed and the corresponding relay flashes along with the status
symbol of the relay as to whether that relay is closed or open. The screen also displays the symbol for the
specific sensor principal currently performing the pressure measurement as well as the units of measure.
D) Error Messages

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4.4 Programming & configuration
Programming and configuration of the device is accomplished via the push buttons and the diagnostic port.
While limited number of parameters can be configured using the push buttons, the diagnostics port (marked
(DIA) can be used to program all parameters and settings for the gauge at the same time. Furthermore, the
diagnostic port <DIA> allows communications of the pressure readings and all status information to a PC.
Diagnostic Port
SP1SP2 ADJ
ST
DIA Status
Setpoint 2 & 1 push button
Zero adjustment
push button
A) Settings available via Push Buttons
•SP1 & SP2 - Programming the setpoint threshold (setpoint value)
•ADJ - Zero adjustment
B) Settings available via the Diagnostic Port
•SP1 & SP2 - setpoint threshold
•Setpoint relay switching characteristics
•Setpoint hysteresis