For OEM engineers, maintenance technicians, and vacuum system integrators, replacing a Pirani vacuum gauge can seem overwhelming. Different manufacturers use different analog output scaling methods, input power requirements, unique connectors, and proprietary wiring schemes. This can turn what could be a simple replacement into a time-consuming engineering project.

The Teledyne Hastings Instruments HVG-PR Pirani Vacuum Gauge was designed specifically to address these challenges. With two possible analog output curves, an industry-friendly RJ45 connection with standardized power / analog signal pinouts, and a compact size, the HVG-PR makes gauge replacement faster, easier, and more cost-effective than traditional alternatives.

Does My New Gauge Have the Correct Analog Output Signal?

A common issue encountered during vacuum gauge replacement is analog output incompatibility. Pirani vacuum gauges use manufacturer-specific voltage-versus-pressure relationships.

When a replacement gauge uses a different output signal than the original device, the consequences can include:

• PLC program modifications
• HMI software updates
• Recalculation of pressure conversion formulas
• Revalidation of automated pressure control sequences
• Extended equipment downtime

In many cases, the engineering effort required to accommodate a new gauge can cost far more than the gauge itself.

However, most major pirani vacuum gauge manufacturers use one of two basic logarithmic output signal scales: 1.0 V/decade or 1.286 V/decade. Fortunately, the HVG-PR supports both! The end-user can easily select which analog output signal they need.

Output Mode Options:

By selecting the output mode that matches the existing installation, the HVG-PR can often replace the original Pirani gauge without requiring any changes to the control software or pressure conversion algorithms already running in the system.

Do I Need to Rewire...And Can I Use my Existing Power Source?

Another challenge in vacuum equipment design is wiring. Large vacuum systems can contain multiple gauges, and each can require dedicated cables and specialized connectors. This increases assembly time, cable complexity, and material costs.

Most major pirani gauge manufacturers either offer or standardize on the RJ45 connector. Also, most major pirani vacuum gauge manufacturers standardize on the four most essential pins for this connection: Power, Power Common, Analog Output Signal, and Analog Common. If your vacuum equipment only uses the Analog Output Signal from the pirani vacuum gauge (and it uses RJ45), you probably will not have to rewire. Check your gauge RJ45 pinout for pins 1, 2, 3, and 5 as seen in the pinout chart. If they are the same, you don’t need to rewire.

Also, the most common DC Power Source for vacuum instrumentation is 24 VDC. The HVG-PR is flexible and will work with any power source from 12 to 36 VDC.

If your RJ45 pinout does not match or if you are using something other than the RJ45 connector, you are still in luck. The HVG-PR uses a standard RJ45 connector for power, analog output signal, and RS485. Technicians can quickly create custom cable lengths using readily available cable, RJ45 connector, and a standard RJ45 crimping tool. RJ45 connectors and crimping tools are sold everywhere. There is no need to order expensive custom cable assemblies.

Will the HVG-PR Physically Fit in my Application?

The HVG-PR offers a compact design which is ideal for OEM enclosures and other tight spaces. Two mechanical connections are offered: KF-16 and 1/8” male NPT.

A Simple Four-Step Replacement Process

Step 1: Identify the interface requirements for the existing vacuum gauge.

Determine whether the original gauge uses a 1.0 V/decade or 1.286 V/decade output curve. This information is typically found in the vacuum gauge manual or the PLC scaling equations.

Verify that your power source is between 12 and 36 VDC.

Confirm that your vacuum connection is compatible with either KF-16 or 1/8” NPT. Make sure to order the correct one.

Step 2: Connect the Gauge

Install the HVG-PR and connect the electrical interface. If you are only using the analog output signal for your system and currently use an RJ45 with the same connections on pins 1, 2, 3, and 5, you can plug and go. Otherwise, the use of a standard RJ45 connector allows for a quick connector conversion.

Step 3: Configure the HVG-PR output signal

Please see the HVG-PR product manual instructions to quickly select the output signal you require. 1.0 V/decade is the default, so you only need to make a change if you are using 1.286 V/decade.

Step 4: Resume Operation

Since the output curve matches the existing control logic, the system can often return to service without rewriting pressure conversion equations, modifying PLC code, or reconfiguring HMI displays.

An Ideal Upgrade for OEMs and Maintenance Teams

The HVG-PR was designed with practical field requirements in mind. Rather than forcing users to adapt their equipment around the gauge, the gauge adapts to existing equipment through:

• Dual analog output compatibility
• Flexible input power requirements
• Standardized RJ45 connectivity
• Compact design with KF-16 or 1/8” Male NPT connections
• Simplified installation and maintenance procedures

For OEMs and system integrators looking to reduce assembly costs and maintenance departments seeking faster replacements, the HVG-PR offers a straightforward path to modernizing vacuum measurement systems without major redesign efforts.

Visit https://www.teledyne-hi.com/en-us/what-we-do/hvg-pr to learn more about the HVG-PR vacuum gauge.

Visit https://www.inforad.co.kr to learn more about Inforad’s complete sales, service, and design / build capabilities for Teledyne Hastings Instruments’ vacuum gauges, mass flow meters, and mass flow controllers in South Korea.

If you have questions about vacuum gauges or vacuum controllers, feel free to contact us by phone (+1-757-723-6531 or 1-800-950-2468), email Hastings_Instruments@Teledyne.com, or via Live Chat on our website www.teledyne-hi.com.

Happy Valentine’s Day 2021! Time for me to run out and order some freeze-dried flowers for my wife. What?... yes, it’s true! In case you have not heard of this, freeze-dried flowers can make a beautiful gift.

According to Flowers Forever – Bellabeads of Columbia SC, https://myflowersforeverjewelry.com/pages/freeze-dried-flowers, freeze-dried flowers will, “retain their beauty as if frozen in time as a lasting memento.” They can be placed in shadow boxes or frames and stored for many years.

So this is probably the best time to tell you about this fun application of vacuum technology. I recently worked with one of our vacuum customers who services freeze driers for florists, so this topic is “fresh” in my mind. Freeze drying is well-known for use in the manufacturing of food and drugs. Most likely, you have something in your house that has been processed with freeze-drying. So, let’s take a closer look.

Freeze drying, also known as lyophilization, is a process in which water molecules are removed from biological cells without damaging the cell structure. For starters, the product to be freeze-dried is chilled and the water inside is completely frozen (i.e. placed in the solid state). Next, the pressure is reduced using vacuum pumps and the water molecules sublimate – that is, water goes from the solid phase directly to the gas phase.

The gas load due to the water vapor is usually very high and requires condensers to trap the liberated water and stop it from overwhelming the pumping system. Commercial freeze driers (see image below) include a heat exchanger which serves two purposes: first, the heat exchanger is used to cool the product and later, it is used to gently heat the product to drive the water sublimation.

View inside commercial freeze-drier

Do you know of some other cool applications of vacuum technology, we would “love” to hear from you! Please visit Live chat with us at www.teledyne-hi.com or call 1-800-950-2468.

Special thanks to Flowers Forever – Bellabeads for the use of flower image from their beautiful website.

The use of Liquefied N₂ (LN₂) has revolutionized aluminum extrusion mold performance. CVS Corporation based in Gimpo, South Korea has developed a proprietary LN₂ cooling process that allows production output to more than double for some extrusion profiles. Production times vary based on the geometry of the extrusion profile. Ram speed test data can be found in Figure 1 below.

Figure 1: Extrusion Profile Table

The Aluminum Extrusion Mold Liquid Nitrogen Cooling System from CVS is designed to control the temperature of both the profile and the mold during the extrusion process. As the billet passes through the extrusion mold, the friction between the billet and the mold creates excess heat. This excess heat limits the extrusion ram speed and is the main cause of reduced productivity in the extrusion process. The CVS process maintains optimum profile and mold temperatures by using automated cryogenic proportional control valves to provide precision dosage of Liquefied N₂.

Figure 2: Aluminum Extrusion Mold Liquid Nitrogen Cooling System from CVS

Mr. Ko Hwa-Jin is the President of CVS Corporation and can be reached by email or website: www.ln2doser.com

Mr. Yoonk Min is the President of Inforad Corp. which is the distributor for Teledyne Hastings Instruments for South Korea. Mr. Min can be reached by email or website: www.inforad.co.kr

Wayne Lewey is the International Sales Manager at Teledyne Hastings Instruments and can be reached by email. 

Several months ago, I saw an interesting article about a cool museum called the Neon Museum which is located in Las Vegas.

https://www.neonmuseum.org/

According to the museum’s website, “the Neon Museum is a non-profit 501 (c) 3 organization dedicated to collecting, preserving, studying and exhibiting iconic Las Vegas signs for educational, historic, arts and cultural enrichment.” The museum holds over 250 neon signs. Tours are given both day and, of course, at night. The main collection in the “Bone Yard” includes signage from Caesar’s Palace, The Stardust Resort and Casino, and the recently added giant guitar from the now closed Hard Rock Café.

Some of the pieces are still operational and “live” shows are given nightly. Other signs are dormant and are lit up by flood lights.

(Photos Courtesy of the Neon Museum, Las Vegas, NV)

Production of neon light tubes requires vacuum pumps and, of course, reliable vacuum measurement. Typically, glass tubes are bent into shape and then pumped to around 1 Torr and energized using a glow discharge to clean up the tube. Next, the tube is evacuated to the mTorr region. Different gases are then backfilled to a few Torr which, when excited in a glow discharge, create various colors. Neon gives the classic neon red/orange glow while carbon dioxide produces white, helium gives yellow, and mercury can be blended with neon to produce blues. In some cases, coatings on the internal surface of the glass can be used to create additional colors. When using coatings, mercury is included in the gas to ensure that UV photons are created to activate the fluorescent coating.

A nice tutorial of glow discharge characteristics with some history is given starting on page 14 in the February 2020 issue of Vacuum Technology & Coating magazine.  https://digital.vtcmag.com/12727/26337/index.html

The new HVG-2020B from Teledyne Hastings is a great vacuum gauge for this application. The gauge uses two vacuum sensors: a piezoresistive sensor to measure pressures from atmosphere to 10 Torr and a thermal Pirani sensor to measure from 1 Torr to 0.1 mTorr. In between 1 and 10 Torr, the gauge uses a weighted average to ensure a smooth transition between the two sensors. The piezoresistive sensor is gas species independent, so no matter what gas is being backfilled, the piezoresistive sensor gives an accurate measurement. The Pirani sensor’s response is affected by the gas species, but the user can select a gas and the correction is made.

So, the next time you see a neon light, you can think about the vacuum gauge that was probably used to manufacture the gas tube. And if you’re ever in Vegas, check out the Neon Museum!

For more information about any of our vacuum gauges or our complete line of mass flow meters and controllers, we are here to help. You can contact us at hastings_instruments@teledyne.com , Live Chat on our website www.teledyne-hi.com , or call 757-723-6531 (800-950-2468). And to learn more about the HVG-2020B Vacuum Gauge, click the link below, “5 Reasons you need the HVG-2020B Vacuum Gauge.”

Last month, we passed our ISO 9001 surveillance audit.  It has been over twenty years since we first obtained ISO and we wanted to take a step back and review some significant accomplishments.  

Teledyne Hastings Instruments rich history and customer centric vision continues to support, influence and grow with those who depend on quality process control and automation.

That's why we wanted to take a moment and celebrate a milestone with our core clients and those considering a Teledyne Hastings Instruments Flow instrument or Vacuum Gauge for the first time.

Teledyne Hastings Instruments' has been providing quality thermal mass flow instruments and vacuum meters and controllers for applications ranging from academic research to space exploration for over 70 years.  Let us work with you to find the best solution for your process.

OEM, custom applications, lead time crunch, just curious:   

Understanding Piezoelectric Pressure Sensors and Piezo Pressure Vacuum Gauges

Piezoelectric pressure sensors use a specialized material to create a small voltage when mechanical stress is applied to it. In this blog we will explain the principles behind the Piezoelectric pressure sensor, review its specific attributes and then discuss how it is used in vacuum gauge technology and industry applications.

Piezoresistive Pressure Sensors

A Piezoelectric pressure sensor functions on the principle that when mechanical stress is applied to a piezoelectric crystal, an electric potential is generated which is directly proportional to the pressure applied. A vacuum gauge that uses a piezoelectric pressure sensor typically houses the sensor in the diaphragm. This provides good linearity for vacuum transducers as the output signal correlates to the applied pressure. This signal is then used to produce an output voltage that is converted to a pressure measurement. Piezoelectric sensors are rugged and often used for measuring dynamic pressure. Because Piezoelectric sensors have a high sensitivity to dynamic changes in pressure, they are well-suited to the measurement of small changes, even in very high-pressure environments. Although they have a high sensitivity to dynamic pressure that can also be used to measure static pressures. 

Piezoelectric pressure sensors are typically used for measuring atmospheric pressure but can be paired with additional vacuum, pressure sensor technologies to create a wide-range vacuum gauge capable of measurement from vacuum to atmosphere. In some cases, a wide-range vacuum gauge can be further expanded upon by adding a 3^rd technology to provide a compact solution capable of wide-range measurement from atmospheric pressure to ultra-high vacuum.

"Direct" and "Indirect" Vacuum Pressure Gauges

In vacuum technology, pressure measurement is accomplished using either  “Direct” or “Indirect” methods. Direct gauges are so-called because they directly measure the force imparted on a surface. Based on the formula: P = F /A (pressure (P) equals force (F) per unit area (A), the gauge directly measures the pressure. Some examples of direct gauges include: bourdon gauges, capacitance manometers and Piezoelectric gauges.

Bourdon Gauge

One of the primary benefits of a direct vacuum gauge is the ability to make accurate measurements regardless of gas type. For example, if the system has 20 Torr of argon, helium, methane, or air, a direct measurement gauge will read the same pressure. Because of this attribute, direct gauges are referred to as “gas composition independent”. These are helpful to see the operating pressure being used during the process. 

Indirect gauges do not “directly” measure the force associated with the gas in the chamber. Rather, these gauges measure a property associated with the gas. For example, thermocouple vacuum gauges measure the thermal conductivity of the gas, which is a function of the pressure. Another example of an indirect gauge is the pirani vacuum gauge which measures the pressure-dependent thermal conductivity of the gas in a vacuum using a heated element, such as a wire or thin-film membrane. The heated element is part of a resistance bridge. The temperature, and thus the resistance of the heated element in the vacuum, changes as the pressure changes. By measuring the electrical behavior of the bridge, the pressure in the vacuum can be determined. Consequently, thermocouple and Pirani vacuum gauges can both be called indirect gauges.

 Thermocouple Gauge                     Pirani Gauge

Application: Vacuum Pressure Impregnation (VPI) Systems

Teledyne Hastings uses piezo sensors for pressure measurements in our HVG-2020A and HVG-2020B vacuum gauges. The HVG-2020A vacuum gauge uses a Piezoelectric sensor that provides accurate pressure measurement throughout the rough vacuum region. The HVG-2020B is a dual-sensor vacuum gauge that uses a Piezoelectric sensor and a Pirani sensor to measure a wide range.

Because the HVG-2020A measures from 0.1 Torr to 1000 Torr, it is well-suited to vacuum pressure impregnation (VPI) applications. Vacuum pressure impregnation (VPI) is an important application for applying insulating materials, as well as producing void-free castings. A typical example is the encapsulation of windings in electric motors. If an insulating resin is simply “painted” on a winding, the result will be a network of uninsulated voids between the winding layers. Applying pressure may force some insulation into the voids, but the subsequent release of that pressure will cause the trapped gas to expand again, causing voids to reappear.

These voids in the insulation can lead to motor failure due to movement of the wiring during operation. Also, in high-voltage applications, these air-filled gaps can serve as sites for corona discharge formation, leading to losses in efficiency and resulting in further weakening of the dielectric.

The proper method to prepare windings, and other potted devices for impregnation, is to begin by applying vacuum.

1. The first step is to load the assembly into a vacuum/pressure chamber and apply vacuum to remove air from the voids between the windings. A suitable pressure for this step is 5 Torr.
2. The next step involves a two-part soak. While under vacuum, the insulating resin is introduced into the chamber from a storage vessel. The vacuum provides the additional benefit of removing any air bubbles that may be present in the resin. After a dwell period, the chamber is pressurized to 85-95 psig for another period of time. This pressurization forces the resin into the previously evacuated voids in the winding layers.
3. After another dwell period, the pressure is relieved and the surplus resin is returned to the storage vessel. With the chamber at atmospheric pressure, it is opened and the assembly is removed. This process results in void-free application of the insulating resin on the windings.

Teledyne Hastings: HVG-2020A Vacuum Gauge

The Teledyne Hastings’ HVG-2020A vacuum gauge is a media-isolated, gas composition independent, piezoresistive instrument that provides accurate pressure measurement throughout the rough vacuum region. 

The HVG-2020A is easy to install, can be configured with an optional touchscreen display to offer a choice of data views, and provides both analog and digital output for process control integration.

• With a wide variety of linear analog output signals to select from, the HVG-2020A is an excellent choice to replace more expensive capacitance manometers.
• Digital output options include RS232 and RS485 via a connection on the top of the gauge.  A USB connection is also available on many models to make connection and operation simple.
• Monitor and view data remotely using our free, Microsoft® Windows®-based software and log data to Microsoft® Excel® for comprehensive diagnostics that record how the vacuum behaves over time.

Analog I/O: The HVG-2020A has a 9-pin D-sub connection on top of the gauge that allows an analog output signal to be measured amongst other features.  The selected linear analog output signal is proportional to the full-scale range of the sensor (1000 Torr).

• Available outputs include: 0-1 VDC, 0-5 VDC, 0-10 VDC, 0-20 mA, and 4-20 mA.  The vacuum gauge is factory-configured with one of these outputs “active”, but can be easily changed using the touchscreen interface (if installed), or using digital communication when not configured with a touchscreen. Digital communication with the HVG-2020A will be discussed in greater depth in the next section.  
• The 9-pin D-sub connection has Hi and Lo setpoints which are activated when the pressure is above or below the respective setpoint. Additionally, the 9-pin D-sub has a pin for input power and can accept 12-36 VDC.  For installations without 12-36 VDC, power can be supplied using a bayonet-style connector at the 24 VDC input connection.

Digital I/O:  As mentioned earlier, the HVG-2020A offers a variety of digital communication options in addition to the previously discussed analog choices.

• The micro-USB connection is the simplest method to interface the vacuum gauge and allows it to be directly connected to a PC without the need for adapters or extra wiring. 
• The 4-conductor TRRS connection can be used to “daisy-chain” multiple gauges together using RS485 or a standard RS232 communication connection. 
• The 9-pin D-sub connection has two pins designated for TTL serial communication.
• LabVIEW™ Drivers

All of these digital communication options (with the exception of TTL) enable PC connection and allow monitoring and viewing of data remotely using our free Microsoft® Windows®-based software.  This software has many useful features including data logging and  customization / configuration of the vacuum gauge.  Digital communication is also used to change the analog output, adjust Hi and Lo setpoint values, stream pressure readings, or change pressure units (among many other functions), when the HVG-2020A is not configured with the optional display.

Touchscreen Display:  The most powerful feature of the HVG-2020A is the optional touchscreen display which allows monitoring of pressure measurements in a variety of combinations and graphic representations while operating. The display is powered off the vacuum gauge power supply (no additional power supply needed) and is especially useful for installations in which a remote display would be inconvenient. Five different display modes (shown left to right below) include: Pressure, Pressure and Temperature, Setpoint, Bar Graph, and Pressure over Time.  Note that the pressure measurement is always displayed in each mode. 

The touchscreen’s Menu Button allows the user to cycle through a selection of submenus to change the screen orientation (should the gauge be mounted in a position other than vertical), zero the gauge (only performed if the system pressure is known to be well below 0.1 Torr), view device information (serial number and firmware level), change the analog output, select RS232 or RS485 and a number of baud rates, and restore the vacuum gauge’s configuration to factory default settings.  The straight-forward arrangement of measurements and easy to read display, lets you “see clearly”, similar to 20/20 vision!

Applications and Industries

• Rough Vacuum Monitoring

• Semiconductor
• Laser Systems
• Chemical Research
• Air Sampling
• Central Vacuum Monitoring
• Oil Reprocessing
• Medical Research