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Fluke 6270A Service Manual

Fluke 6270A Service Manual

Pressure controller/calibrator
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See also: Operator's Manual
6270A
Pressure Controller/Calibrator
Service Manual
August 2016 Rev. 1, 6/17
© 2016-2017 Fluke Corporation. All rights reserved. Specifications are subject to change without notice.
All product names are trademarks of their respective companies.

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Summary of Contents for Fluke 6270A

  • Page 1 6270A Pressure Controller/Calibrator Service Manual August 2016 Rev. 1, 6/17 © 2016-2017 Fluke Corporation. All rights reserved. Specifications are subject to change without notice. All product names are trademarks of their respective companies.
  • Page 2 Fluke authorized resellers shall extend this warranty on new and unused products to end-user customers only but have no authority to extend a greater or different warranty on behalf of Fluke. Warranty support is available only if product is purchased through a Fluke authorized sales outlet or Buyer has paid the applicable international price.

  • Page 3: Table Of Contents

    Table of Contents Title Page Introduction .................... 1 Contact Fluke Calibration ..............2 Safety Information ................. 2 Symbols ....................3 The Product Manual Set ................ 4 Specifications ..................4 Control Specifications ................6 Pressure Measurement Specifications ..........6 PM200 Modules ................. 7 PM600 Modules .................
  • Page 4 6270A Service Manual G- and B-Series Valves ..............39 Remove and Inspect the B-Series Valves ........40 Install the B-Series Valves ............. 43 Remove and Inspect the G-Series Valves ........44 Install the G-Series Valves ............44 Power Supply and Fan ................45 Remove the Power Supply ..............
  • Page 5 Contents (continued) Inspect and Replace the CPS valves ..........122 Replacement Parts ................124 Screw Torque ..................136...
  • Page 6 6270A Service Manual...

  • Page 7: Introduction

    Note Repairs detailed in this manual are to the Modular-level only. Return the Product to Fluke Calibration or take the Product to a local Fluke Calibration Service Center for deeper-level repair.

  • Page 8: Contact Fluke Calibration

    6270A Service Manual Contact Fluke Calibration To contact Fluke Calibration, call one of the following telephone numbers: • Technical Support USA: 1-877-355-3225 • Calibration/Repair USA: 1-877-355-3225 • Canada: 1-800-36-FLUKE (1-800-363-5853) • Europe: +31-40-2675-200 • Japan: +81-3-6714-3114 • Singapore: +65-6799-5566 •...

  • Page 9: Symbols

    Do not disable safety interlocks or pressure-relief devices. Symbols The symbols shown in Table 1 are used in this manual or on the Product. Note The CE marking below does not apply to the 6270A-NPT-NA, PM600-A10M-NA, or PM600-A14M-NA. Table 1. Symbols Symbol...

  • Page 10: The Product Manual Set

    6270A Remote Programmers Guide (available on the Fluke Calibration website) • 6270A Service Manual (available on the Fluke Calibration website) To order, contact a Fluke Calibration sales representative. See Contact Fluke Calibration. Specifications General Specifications Power Requirements ......100 V ac to 240 V ac, 47 Hz to 63 Hz Fuse ............
  • Page 11 Pressure Controller/Calibrator Specifications Electromagnetic Compatibility (EMC) IEC 61326-1 (Controlled EM environment) ....IEC 61326-2-1; CISPR 11: Group 1, Class A Group 1 equipment has intentionally generated and/or use conductively coupled radio-frequency energy which is necessary for the internal functioning of the equipment itself.

  • Page 12: Control Specifications

    6270A Service Manual Interface / Communications Primary remote Interfaces ....IEEE, Ethernet, RS232, USB System Connection ......Supports interconnection of 2 or 3 systems Switch Test Connection ...... Standard 4 mm Jack: Nominal 24 V dc isolated drive Maximum 30 V dc w.r.t. chassis ground Aux Drivers .........

  • Page 13: Pm200 Modules

    Pressure Controller/Calibrator Control Specifications PM200 Modules 1-Year Model Range (SI Units) Range (Imperial Units) Measurement Mode Specification (%FS) PM200-BG2.5K -2.5 kPa to 2.5 kPa gauge 0.20 % -10 inH₂0 to 10 inH₂0 PM200-BG35K -35 kPa to 35 kPa -5 psi to 5 psi gauge 0.05 % PM200-BG40K...

  • Page 14: Pm600 Modules

    6270A Service Manual PM600 Modules The product specifications describe the Absolute Instrumental Uncertainty of the Product. The product specifications include linearity, hysteresis, repeatability, resolution, reference standard measurement uncertainty, 1 year stability, and temperature effects from 15 to 35 °C. The product specifications are provided at a 95 %, k=2, normally distributed, level of confidence.

  • Page 15: Theory Of Operation

    Pressure Controller/Calibrator Theory of Operation Theory of Operation This section provides a block diagram discussion of the Product pneumatic, mechanical, electrical, and communication design. Note In many of the procedures in this manual, the Product is referred to as the Unit Under Test (UUT). Overview Main Chassis - includes the main processor with chassis interface, front-panel processor, GUI interface, module interfaces, solenoid drivers, and distribution of...
  • Page 16 6270A Service Manual 6270A CONTROLLER – Pneumatic Diagram Pressure sensor – various ranges Solenoid Valve naming: Slot n Test Solenoid valve – 3000 psi Slot n Reference Control Supply Solenoid valve – 200 psi Control Exhaust Control Fine Supply Isolation Test...

  • Page 17: Pneumatic Interfaces

    Pressure Controller/Calibrator Theory of Operation Pneumatic Interfaces All PMMs use the same pneumatic interface. See Figure 2. PMM Pneumatic Interface PCM Pneumatic Interface hxn028.eps Reference port Supply port   Test port Guide bushing, threaded rods   Alignment bushing Test port ...
  • Page 18 6270A Service Manual When the module bay door is opened, the system vents and releases the supply pressure. There may be a small residual pressure retained between solenoids IS and CS, see Figure 1. This pressure could be up to150 psi after the supply is removed.

  • Page 19: Electrical

    Pressure Controller/Calibrator Theory of Operation Electrical Figure 3 shows the electrical power distribution inside the Product chassis. 24 V dc power is the primary power distributed inside the chassis. Each module uses the 24 V dc power to create the specific voltage supplies required. Each module is isolated or filtered to provide appropriate power for the module requirements.

  • Page 20: Module Connector

    6270A Service Manual Module Connector All modules have the same electrical connector and pinout. The location of the connector and the module mechanical shape are the same for all PMMs. The PCM has unique physical dimensions. See Figure 4. hxn030.eps...

  • Page 21: Pca Overview

    Pressure Controller/Calibrator Theory of Operation PCA Overview Main PCA - This PCA manages system functions, contains all external communication ports, all system configuration settings, and is the central PCA for internal chassis communications. The main PCA is powered by 24 V dc from the main power supply.

  • Page 22: Communications / Firmware

    6270A Service Manual PCM PCA - This PCA is located inside the PCM and monitors internal PCM sensors and pulses the control solenoids. The PCA contains the control algorithm, monitors the primary pressure directly from the selected PMM, and interfaces with the main PCA.

  • Page 23: System Boot

    Software Upgrades To upgrade the software for the mainframe and interface: 1. Go to the Fluke Calibration website and download the latest 6270A firmware. 2. Connect a PC directly to the rear panel USB port. Note When the Product is connected to a PC with the USB connection, the Product appears as a flash drive, usually assigned to the E: drive.

  • Page 24: Maintenance

    6270A Service Manual Caution A power cycle during the PCM upgrade can erase the control coefficients. The process must be allowed to complete and the screen must disappear. Maintenance This section explains routine operator maintenance necessary to keep the Product in optimal condition.

  • Page 25: Pmm And Pcm Removal

    Pressure Controller/Calibrator Maintenance PMM and PCM Removal To remove the PMMs, see Figure 7: Caution To prevent damage to the sensors inside the modules, do not drop the modules. 1. Open the module bay  as described in Access the Module Bay. 2.
  • Page 26 6270A Service Manual hxn212.eps Figure 7. PMM and PCM Removal...

  • Page 27: Clean The Exterior

    Pressure Controller/Calibrator Maintenance Clean the Exterior To clean the Product, wipe it with a cloth that is lightly dampened with water or mild detergent. To clean the display, use a soft cloth lightly dampened with alcohol. Caution Do not use aromatic hydrocarbons or chlorinated solvents for cleaning.

  • Page 28: Fuse Replacement

    3. Pull out the fuse holder. 4. If necessary, replace the fuse. 5. Reinsert the fuse holder and snap it shut. Table 3. Replacement Fuses Fuse Description Fluke Part Number  Fuse 5x20MM, 2 AMP 1297149 Fuse Holder 4220903 huo027.eps...

  • Page 29: Manifold Replacement

    Pressure Controller/Calibrator Maintenance Manifold Replacement  Warning To prevent possible electrical shock, fire, or personal injury, turn off the Product and disconnect the mains power cord prior to the removal procedure. Shut off the supply pressure and vent the system before you remove the manifold, valve, or associated parts.
  • Page 30 6270A Service Manual hxn205.eps Figure 9. Manifold Installation...

  • Page 31: Repair And Replacement

    Pressure Controller/Calibrator Repair and Replacement Repair and Replacement The subsequent procedures explain how to disassemble parts of the Product. To reinstall the parts, reverse the steps unless otherwise specified. Feet and Tilt Stands To remove or replace the feet and tilt stands, see Figure 10: 1.
  • Page 32 6270A Service Manual hxn202.eps Figure 10. Remove Feet and Tilt Stands...

  • Page 33: Remove And Replace Handles

    Pressure Controller/Calibrator Repair and Replacement Remove and Replace Handles To remove or replace the Product handles, see Figure 11: 1. Use a 2.5 mm hex wrench to remove the three M4 x 8 socket cap screws on the side of each handle . 2.
  • Page 34 6270A Service Manual  Static Awareness  Semiconductors and integrated circuits can be damaged by electrostatic  discharge during handling. This notice explains how to minimize damage to these components. 1. Understand the problem. 2. Learn the guidelines for proper handling.

  • Page 35: Top Panel

    Pressure Controller/Calibrator Repair and Replacement Top Panel  Warning To prevent possible electrical shock, fire or personal injury, turn off the Product and disconnect the mains power cord prior to the removal procedure. Shut off the supply pressure and vent the system before you remove the manifold, valve, or associated parts.

  • Page 36: Module Guide Rails

    6270A Service Manual Module Guide Rails To replace the module guide rails, see Figure 13: 1. Open and slide out the module bay  as described in Access the Module Bay. 2. Remove the modules as described in PMM and PCM Removal.
  • Page 37 Pressure Controller/Calibrator Module Guide Rails hxn209.eps Figure 13. Remove Module Guide Rails...

  • Page 38: Communications Tray

    6270A Service Manual Communications Tray  Warning To prevent possible electrical shock, fire or personal injury, turn off the Product and disconnect the mains power cord prior to the removal procedure. Shut off the supply pressure and vent the system before you remove the manifold, valve, or associated parts.

  • Page 39: The Cpu

    Pressure Controller/Calibrator Module Guide Rails 8. Use a #2 Phillips screwdriver to remove the two M3 x 6 screws  from the COMM tray  and remove the tray from the chassis. hxn207.eps Figure 15. Remove the Communications Tray The CPU To remove the CPU, see Figure 16: 1.
  • Page 40 6270A Service Manual hxn208.eps Figure 16. Remove the CPU...

  • Page 41: Pmm Dock Assembly

    Pressure Controller/Calibrator Module Guide Rails PMM Dock Assembly Use the PMM dock assembly to mount the PM600 and PM200 transducer modules.  Warning To prevent possible electrical shock, fire or personal injury, turn off the Product and disconnect the mains power cord prior to the removal procedure.
  • Page 42 6270A Service Manual hxn218.eps Figure 17. PMM Dock Assembly 10. Use a 3 mm T-handle hex to remove all eight M4 x 30 screws  from both the PCM and PMM dock assemblies as shown in Figure 18. 11. Remove both dock assemblies from the chassis.
  • Page 43 Pressure Controller/Calibrator Module Guide Rails hxn219.eps Figure 18. Dock Assembly...
  • Page 44 6270A Service Manual 14. Remove and inspect the manifold connectors , O-rings , and backup rings  as shown in Figure 19. hxn220.eps Figure 19. Dock Assembly Components...

  • Page 45: G- And B-Series Valves

    Pressure Controller/Calibrator Module Guide Rails G- and B-Series Valves Use the procedure below to repair, replace, or clean the G- or B-series valves or associated parts. The G- and B-series valves are listed in Table 4. Note Valves can be replaced without removing the entire dock assembly. However, instructions for complete removal are included here.

  • Page 46: Remove And Inspect The B-Series Valves

    4. Inspect the seal  for contamination or excessive wear. 5. Inspect the O-ring , and base orifice . If any parts are damaged, remove the base  with a #2 Phillips screwdriver and replace the entire valve. The entire valve can be ordered from Fluke Calibration.
  • Page 47 Pressure Controller/Calibrator Module Guide Rails hxn215.eps Figure 21. Remove B-Series Valve...
  • Page 48 6270A Service Manual 6. See Figure 22. If you remove the base  there is a guide pin  to ensure base orientation is correct. Ensure both O-rings  on the bottom are present. hxn214.eps Figure 22. B-Series Valve Base...

  • Page 49: Install The B-Series Valves

    Pressure Controller/Calibrator Module Guide Rails Install the B-Series Valves 1. Use a #2 Phillips screwdriver and 4 screws  to install the base  into the manifold (use guide hole on base for orientation). Torque to 8 in/lbs. See Figure 23. 2.

  • Page 50: Remove And Inspect The G-Series Valves

    6270A Service Manual Remove and Inspect the G-Series Valves To remove the G-series valve, see Figure 24. 1. Use a small flat-head screwdriver to remove the c-clip . 2. Remove the coil  and washer  from the valve shaft . Note the orientation of the washer, the chamfered side faces the coil bottom (flat side faces the base).

  • Page 51: Power Supply And Fan

    Pressure Controller/Calibrator Power Supply and Fan hxn227.eps Figure 24. Remove the G-Series Valve Power Supply and Fan To replace the power supply, fan, or associated parts, use the subsequent instructions and Figures 25 and 26. The power supply and fan parts are listed in Table 49.

  • Page 52: Remove The Power Supply

    5. Disconnect the power entry module cables from CN1 , GND , and the power cable from CN2 . 6. Use a Phillips #2 screwdriver to remove the four M3.5 x 6 screws  and remove the power supply. Fluke Calibration recommends a minimum 6 inches (20 cm) length screwdriver for access.
  • Page 53 Pressure Controller/Calibrator Power Supply and Fan hxn221.eps Figure 25. Remove Power Supply...

  • Page 54: Remove The Fan

    6270A Service Manual Remove the Fan To remove the fan, see Figure 26: 1. Use a 5.5 mm nut driver to remove the 2 nuts  and washers  from the fan . 2. Lift out the fan. To replace the fan, do this procedure in reverse.

  • Page 55: Remove The Power Entry Module

    Pressure Controller/Calibrator Power Supply and Fan Remove the Power Entry Module To remove the power entry module, see Figure 27. 1. Use needle nose pliers to remove the brown , blue , and green  wires from the power entry module on the back of the Product. 2.

  • Page 56: Front Panel And Display Assembly

    6270A Service Manual Front Panel and Display Assembly Warning To prevent injury and electrical shock, disconnect the mains power cable prior to the removal procedure, shut off the supply pressure and vent the system before removing any manifold, valve or associated parts.
  • Page 57 Pressure Controller/Calibrator Front Panel and Display Assembly hxn213.eps Figure 28. Remove Front-Panel Assembly...

  • Page 58: Remove Keypad Pca And Knob From The Front-Panel Assembly

    6270A Service Manual Remove Keypad PCA and Knob from the Front-Panel Assembly To remove the keypad PCA and knob from the front panel, see Figure 29: 1. Shut off supply pressure and vent the system. 2. Remove all pressure lines and fittings from the manifold.
  • Page 59 Pressure Controller/Calibrator Front Panel and Display Assembly hxn217.eps Figure 29. Remove Keypad PCA and Knob from Front Assembly...

  • Page 60: Remove Display Components From The Display Panel Shell

    6270A Service Manual Remove Display Components from the Display Panel Shell To remove the display components from the display-panel shell, see Figure 30: 1. Shut off supply pressure and vent the system. 2. Remove all pressure lines and fittings from the manifold.
  • Page 61 Pressure Controller/Calibrator Front Panel and Display Assembly hxn224.eps Figure 30. Remove Display Components from the Display Panel Shell...
  • Page 62 6270A Service Manual 14. Use a #2 Phillips screwdriver to remove the four M3 x 6 screws  that secure the display to the display PCA cover, see Figure 31. 15. Feed the display  cables , , and through the holes in the display PCA cover.

  • Page 63: Remove The Module Bay Latch Assembly

    Pressure Controller/Calibrator Front Panel and Display Assembly Remove the Module Bay Latch Assembly To remove the module bay latch assembly from the display-panel shell, see Figure 32: 1. Shut off the supply pressure and vent the system. 2. Remove all pressure lines and fittings from the manifold. 3.
  • Page 64 6270A Service Manual hxn210.eps Figure 32. Remove Latch Assembly...

  • Page 65: Pcm Assembly

    Pressure Controller/Calibrator PCM Assembly PCM Assembly Warning To prevent injury and electrical shock, disconnect the mains power cable prior to the removal procedure, shut off the supply pressure, and vent the system before removing any manifold, valve or associated parts. For this procedure, see Figure 33: 1.
  • Page 66 6270A Service Manual hxn401.eps Figure 33. Module Disassembly 13. Remove the retaining rings  from the clamp screws  and remove the clamp screws from the PCM with a pair of short needle-nose pliers. See Figure 34.
  • Page 67 Pressure Controller/Calibrator PCM Assembly hxn401.eps Figure 34. Module Components...

  • Page 68: Replace The Control Valves

    6270A Service Manual Replace the Control Valves Each valve and the blank have specific orientation which is referenced by a guide pin in the manifold. Make sure the apply and release valves are not reversed. When the valves are reversed, control performance is impacted and control tuning is required.
  • Page 69 Pressure Controller/Calibrator PCM Assembly hxn404.eps Figure 36. Replace Control Valves (B) 6. Remove and install the control valves.

  • Page 70: Inspect The Control Valves

    6270A Service Manual Note Make sure to not interchange the coils or valves between apply/release valves. a. Use a 3/4 inch wrench and remove the coil-retaining nut  from the control valve (apply) coil  or (release) coil . This should only be hand tight or very loosely tightened with a 3/4 inch wrench.
  • Page 71 Pressure Controller/Calibrator PCM Assembly See Figure 38 for examples of what to inspect for. •  make sure there is a good valve indentation on the body surface where it has made continuous contacted with the orifice. •  look for specks on the surface of the indentation. This can cause the valve to leak.

  • Page 72: Pcm Supply, Test, Exhaust Sensor Alignment

    6270A Service Manual PCM Supply, Test, Exhaust Sensor Alignment 1. Read the current sensor coefficient values with a remote command terminal (for example, Hyperterminal or COMPASS for Pressure Direct Remote Terminal) and send the commands below to read the current coefficients for the PCM sensors: a.

  • Page 73: Calibrate The Sensors

    Test port (ATM and 3,000 psi). See Figure 40. Note Fluke Calibration does not recommend to do this adjustment at a maximum pressure <1500 psi to ensure best sensor alignment. If you do not have a 3000 psi module, use the highest-rated module that you have.

  • Page 74: Supply Port (Atm And 3,000 Psi)

    6270A Service Manual Regulator Max 6000 psi Input 3300 psi Out Pump 3300 6000 Supply Bottle CGA Fitting Ball Valve 6270A High Range Module ≥ 1500 psi hxn301.eps Figure 40. Calibrating Sensors Supply Port (ATM and 3,000 psi) Note There is an isolation valve between the supply port on the manifold and the supply port of the PCM.
  • Page 75 1 bar BURST PRESSURE 45 PSIG V mA ZERO LOOP V mA MEAS SOURCE ° ° Supply Bottle STORE 100% SETUP RECALL CGA Fitting Ball Valve 6270A High Range Module ≥ 1500 psi hxn302.eps Figure 41. Calibrate the Supply Port...

  • Page 76: Exhaust Port (Hard Vacuum Then Atm)

    6270A Service Manual Exhaust Port (Hard Vacuum then ATM) 1. Install the highest range PMM that you have and make it the fixed range. 2. Set the PMM measurement mode to Absolute. 3. Install a shutoff valve on the test port.
  • Page 77 Pressure Controller/Calibrator Calibration Sled and PMM hxn409.eps Figure 42. Disassembly Kit The new assembly has a M4x12 SCH screw with the ground connections and star washers already assembled and zip tied into place. Remove the zip tie  before installation.

  • Page 78: Pm200 And Pm600 Modules

    222 (or equivalent) 1. The PM200 and PM600 modules are calibrated with tamper-proof seals and any parts inside the module must be repaired at a Fluke Calibration authorized service provider. See Figure 43. 2. Remove the guide rail spring .

  • Page 79: Pm600 Digital Barometer Optimization

    (CAL_DATE2) to align. Alignment is not required and is only used for dynamic compensation of barometric pressure while in gauge mode. Fluke Calibration recommends to only align the on-board barometer only if calibrating the PM600 module in gauge mode with atypical results.
  • Page 80 6270A Service Manual Supply Pressure Port - 115% FS or FS+15 psi whichever is greater Measured Pressure (Test Port) Test Supply PPC4 PRESSURE CONTROLLER/CALIBRATOR A700K/A160K ENTER PUSH TO ENTER SELECT SET P VENT REMOTE hxn310.eps Figure 44. PM600 Barometer Optimization Setup The UUT is set up with a minimum pressure of 75 kPa and maximum of 103 kPa.

  • Page 81: Return To Service - Safety Validation Recommendations

    Product after maintenance or repair, read the following sections. Electrical If service work is done to the ac power entry, ac power wiring, ac/dc supply, grounding, or components in the near vicinity, then Fluke Calibration recommends Hypot and Ground Bond testing per IEC 61010-1 Annex F. Pressure...

  • Page 82: Calibration Adjustment

    PMM. The references given here are the preferred from an overall uncertainty and calibration interval viewpoint. Other types of references, such as a Fluke Calibration 7250 Pressure Controller/Calibrator, can potentially be used when the standard is maintained on a shorter calibration interval.

  • Page 83: Pm600

    Pressure Controller/Calibrator Calibration Adjustment PM600 Reference Dwell Averaging PM600 Range Piston Cylinder Reference Mode Pressure Pressure System Time Time ------------ [kPa] [kPa] ------------- ------------- ------------- 200 kPa, 500 kPa, 1 MPa, 2 A20M 20 000 PG7202 Absolute by ATM MPa /kg P-C 200 kPa, 500 kPa, 1 MPa, 2 A14M 14 000...

  • Page 84: Calibration And Adjustment Procedures

    6270A Service Manual Calibration and Adjustment Procedures This procedure describes calibration and performance verification to the specifications, As Found data collection procedures, adjustment, and as left verification procedures for the Product. The procedure is meant to bring the Product into specification after repair or when the UUT fails the performance tests.
  • Page 85 Pressure Controller/Calibrator Calibration and Adjustment Procedures Minimum Use Item Equipment Notes Specifications Must interface with Piston Barometric Range: 70 KPa to Barometric range RPM3 Gauge or COMPASS for Reference 110 kPa or RPM4 Pressure Instrument manuals, work instructions, specifications, and other documentation for any associated...

  • Page 86: Preliminary Operations

    6270A Service Manual • If a 2400 DWG is used: o Calibrated and approved temperature probe to measure piston-cylinder temperature. o Calibrated and approved vacuum sensor if the 2400 DWG is used in absolute by vacuum mode. o Calibrated and approved piston gauge monitor.

  • Page 87: Setup

    Pressure Controller/Calibrator Calibration and Adjustment Procedures Setup 1. Inspect the UUT for any defects, potential issues, or problems. 2. Check UUT test port for contamination. 3. Install the UUT sensor(s) in the appropriate calibration fixture or Product chassis. 4. Make all necessary connections to the UUT (power, RS232 communication, pressure).
  • Page 88 6270A Service Manual Supply Pressure Port - 115% FS or FS+15 psi whichever is greater Control Vacuum Source (Exhaust Port) Measured Pressure (Test Port) AMH Drive Pressure 40 psi AMH38 Exhaust Supply Test 7601,7 Cal Sled PPC4 PRESSURE CONTROLLER/CALIBRATOR A700K/A160K...
  • Page 89 Pressure Controller/Calibrator Calibration and Adjustment Procedures Measured Pressure (Test +) Supply Pressure - 10% above Test Pressure Barometer AMH/PPCH Drive Pressure -- 100 psi -- connect to PPCH-G UUT RPM4 REFERENCE PRESSURE MONITOR + / - RANGE UNIT MODE • SETUP AutoRange AutoTest...

  • Page 90: Module Calibration

    6270A Service Manual Module Calibration For the procedures in the subsequent sections, environmental conditions must be within the correct limits for the type of laboratory. Make sure to exercise the UUT range before calibration and do As Found measurements before C0 or C1 adjustments, repairs, or upgrades are made to an operational instrument.

  • Page 91: Calibration Of Modules In Calibration Sled

    Pressure Controller/Calibrator Module Calibration c. Read zOffset of slot • CAL:PRES(n):ZERO:VAL? • Run As Found data for pressures defined in the calibration matrices at the end of this manual. • Run the calibration routine found in the 2-point calibration (zero/span) menu.
  • Page 92 6270A Service Manual 5. Read zOffset (value always in psi), enter UCOEF_SET[0]? Run As Found data for pressures defined in the calibration matrices in Calibration Tables. 1. The As Found data determines the new C0 and C1 calibration coefficients and calibration date.
  • Page 93 Pressure Controller/Calibrator Module Calibration Note Do this in an Excel spreadsheet where C1_Corrected = known_y’s and reference pressure data = known_x’s. Write the new calibration date, C0, C1 to the module and clear the zOffset. 1. Write new calibration date to module, enter CAL_DATE mm/dd/yy 2.

  • Page 94: Calibration Tables

    PMM. The references given here are the preferred from an overall uncertainty and calibration interval viewpoint. Other types of references, such as a Fluke Calibration 7250 Pressure Controller/Calibrator, can potentially be used when the standard is maintained on a shorter calibration interval.

  • Page 95: Pm600 Calibration Definition

    Pressure Controller/Calibrator Calibration Tables PM600 Calibration Definition Table 8. PM600 Calibration Definition PM600 Reference Reference Averaging Piston-Cylinder Dwell Time Range Pressure Pressure System Mode Time ----------- [kPa] [kPa] ------------- ------------- ------------- 200 kPa, 500 kPa, 1 Absolute by A20M 20 000 PG7202 MPa, 2 MPa /kg P-C...

  • Page 96: Pm200 Test Definition Matrices

    6270A Service Manual • 2465 The Piston-Cylinder selected must be able to cover the range of 75 kPa to 103 kPa absolute pressure. PM200 Test Definition Matrices Table 9. PM200-BG2.5K Pressure Point MatrixPM200-BG2.5K As Found / As Left Points Set Pressure...
  • Page 97 Pressure Controller/Calibrator Calibration Tables Table 10. PM200-BG35K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points Descending Points 1. UUT is zeroed before setting pressure. Table 11. PM200-BG40K Pressure Point Matrix As Found / As Left Points Calibration Segment Pressure No.
  • Page 98 6270A Service Manual Table 12. PM200-BG60K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points Descending Points 1. UUT is zeroed before setting pressure. Table 13. PM200-A100K Pressure Point Matrix...
  • Page 99 Pressure Controller/Calibrator Calibration Tables Table 14. PM200-BG100K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points Descending Points 1. UUT is zeroed before setting pressure. Table 15. PM200-BG100K Pressure Point Matrix: Negative Pressure As Found / As Left Points Set Pressure Averaging Time...
  • Page 100 6270A Service Manual Table 16. PM200-A200K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points Descending Points Table 17. PM200-BG200K Pressure Point Matrix As Found / As Left Points...
  • Page 101 Pressure Controller/Calibrator Calibration Tables Table 18. PM200-BG200K Pressure Point Matrix: Negative Pressure As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points -100 Descending Points UUT is zeroed before setting pressure. Pressure point is limited by minimum pressure of reference and ATM pressure.
  • Page 102 6270A Service Manual Table 20. PM200-BG250K Pressure Point Matrix: Negative Pressure As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points -100 Descending Points 1. UUT is zeroed before setting pressure.
  • Page 103 Pressure Controller/Calibrator Calibration Tables Table 22. PM200-G700K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points Descending Points 1. UUT is zeroed before setting pressure. Table 23. PM200-G1M Pressure Point Matrix As Found / As Left Points Set Pressure Calibration Segment...
  • Page 104 6270A Service Manual Table 24. PM200-G1.4M Pressure Point Matrix As Found / As Left Points Set Pressure Dwell Time Averaging Calibration Segment Pressure No. [kPa] Time [s] Ascending Points 1120 1400 1120 Descending Points 1. UUT is zeroed before setting pressure.
  • Page 105 Pressure Controller/Calibrator Calibration Tables Table 26. PM200-G2.5M Pressure Point Matrix As Found / As Left Points Set Pressure Dwell Time Averaging Calibration Segment Pressure No. [kPa] Time [s] 1000 Ascending Points 1500 2000 2500 2000 1500 Descending Points 1000 1. UUT is zeroed before setting pressure. Table 27.
  • Page 106 6270A Service Manual Table 28. PM200-G4M Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] 1600 Ascending Points 2400 3200 4000 3200 2400 Descending Points 1600 1. UUT is zeroed before setting pressure.
  • Page 107 Pressure Controller/Calibrator Calibration Tables Table 30. PM200-G10M Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] 2000 4000 Ascending Points 6000 8000 10 000 8000 6000 Descending Points 4000 2000 1.

  • Page 108: Pm600 Test Definition Matrices

    6270A Service Manual Table 32. PM200-G20M Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] 4000 8000 Ascending Points 12 000 16 000 20 000 16 000 12 000...
  • Page 109 Pressure Controller/Calibrator Calibration Tables Table 34. PM600-G100K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points Descending Points 1. UUT is zeroed before setting pressure. Table 35. PM600-A100K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time...
  • Page 110 6270A Service Manual Table 36. PM600-G200K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points Descending Points 1. UUT is zeroed before setting pressure. Table 37. PM600-A200K Pressure Point Matrix...
  • Page 111 Pressure Controller/Calibrator Calibration Tables Table 38. PM600- A350K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] 87.5 Ascending Points 262.5 262.5 Descending Points 87.5 Table 39. PM600- A700K Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time...
  • Page 112 6270A Service Manual Table 40. PM600- A1.4M Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Calibration Segment Pressure No. Dwell Time [s] [kPa] Time [s] Ascending Points 1050 1400 1050 Descending Points Table 41. PM600- A2M Pressure Point Matrix...
  • Page 113 Pressure Controller/Calibrator Calibration Tables Table 42. PM600- A3.5M Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] Ascending Points 1750 2625 3500 2625 1750 Descending Points Table 43. PM600- A7M Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time...
  • Page 114 6270A Service Manual Table 44. PM600- A10M Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Time Calibration Segment Pressure No. Dwell Time [s] [kPa] 2500 Ascending Points 5000 7500 10000 7500 5000 Descending Points 2500 1. ATM: atmospheric pressure from laboratory barometer via PG system.
  • Page 115 Pressure Controller/Calibrator Calibration Tables Table 46. PM600- A20M Pressure Point Matrix As Found / As Left Points Set Pressure Averaging Calibration Segment Pressure No. Dwell Time [s] [kPa] Time [s] 5000 Ascending Points 10 000 15 000 20 000 15 000 10 000 Descending Points 5000...

  • Page 116: Calibration With Compass For Pressure

    6270A Service Manual Calibration with COMPASS for Pressure See the other guidelines for calibration at the start of this main section. In addition: • Use the As Found data file to determine the new C0 and C1 calibration coefficients and calibration date.

  • Page 117: Troubleshooting

    The default location is C:\dhi\COMPASS for Pressure\Data. Troubleshooting Table 48 explains minor troubleshooting issues. For issues outside of the scope of this section, the Product may require service. See Contact Fluke Calibration. Table 48. Troubleshooting Problem Probable Cause...
  • Page 118 Door not closed Make sure the front panel is closed. Internal door-close Check the sensor. Send the Product to Fluke Calibration sensor failed for repair. System in remote operation mode Verify front panel is closed, verify the USB connection to...

  • Page 119: Reset Controller Settings

    Pressure Controller/Calibrator Troubleshooting Table 48. Troubleshooting (cont.) Problem Probable Cause Action Pressure Generation or Indication Problems Blocked exhaust port Remove shipping plugs or excessive restriction. Product does Setpoint applied below not control Connect vacuum pump. atmosphere down Slew Rate set to zero Increase slew rate.

  • Page 120: System

    6270A Service Manual System The system diagnostics menu supplies information on these system components: • Door Switch – This is a mechanical-electrical switch near the front panel that senses when the panel is open. When open, the system vents and the module information screen shows.

  • Page 121: Control

    Pressure Controller/Calibrator Troubleshooting Control The Control diagnostics menu shows information about the PCM: • Port Pressure – This menu shows the pressure measurement at the test, supply, and exhaust ports. • Control Module – This menu shows the PCM model number, serial number, and firmware version.

  • Page 122: Remote Interface

    6270A Service Manual Remote Interface The Remote Interface diagnostics menu provides information on remote communication by monitoring the input and output communication. The menu contains independent diagnostics for RS-232, USB, Ethernet, GPIB, and the system bus communications. RS-232 – Shows the Receive and Transmit data for this interface.
  • Page 123 Pressure Controller/Calibrator Contamination Prevention System (CPS) hxn029.eps Figure 48. CPS Cleaning and Inspection 5. To disassemble the filter assembly (see Figure 49), turn the screen retainer  counter clockwise to remove it from the filter manifold . 6. Pull the filter and retainer from filter manifold while rocking side to side carefully to remove the coalescing filter ...
  • Page 124 6270A Service Manual 8. The screen  can be removed from the screen retainer. 9. Inspect all of the parts and replace as necessary. Coat the O-rings lightly with vacuum grease. hxn031.eps Figure 49. CPS Filter Disassembly...
  • Page 125 Pressure Controller/Calibrator Contamination Prevention System (CPS) 10. Inspect to make sure all O-rings are in the correct place prior to re-assembly (see Figure 50). • The filter retainer has an O-ring on each end. • The filter manifold has 3 O-rings. •...

  • Page 126: Separate The Lower And Upper Housing

    6270A Service Manual Separate the Lower and Upper Housing To separate the lower and upper housing, see Figures 51 and 52: 1. Vent the controller to remove all pressure to the CPS. 2. Remove the hose from the quick connect .
  • Page 127 Pressure Controller/Calibrator Contamination Prevention System (CPS) hxn033.eps Figure 51. CPS Disassembly...

  • Page 128: Inspect And Replace The Cps Valves

    6270A Service Manual Purge Vent hxn034.eps Figure 52. CPS Assembly Inspect and Replace the CPS valves To inspect and replace the CPS valves, see Figure 53: 1. Separate the lower and upper housing from the chassis as described previously. 2. Vent the controller to remove all pressure to the CPS.
  • Page 129 Pressure Controller/Calibrator Shim (included in Vent Valve only) hxn035.eps Figure 53. CPS Valve Replacement 8. Reassemble in reverse order. Note When the lower and upper housing is mounted to the chassis, lift the assembly up and install one screw and leave it slightly loose to allow orientation.

  • Page 130: Replacement Parts

    6270A Service Manual Replacement Parts The Figures and Tables listed in this section show the part numbers of each replacement part or accessory for the Product. Table 49. Replaceable Parts Reference Part Description Quantity Designator Number Cable assembly,5 conductors,shielded,usb a-to-mini b, usb 4563003 2.0,0.8mtr...
  • Page 131 Pressure Controller/Calibrator Replacement Parts Table 49. Replaceable Parts (cont.) Reference Part Description Quantity Designator Number G-Series Valves 4392808 B-Series Valves 4392813 M4 X 16 Screws, Flat Head, Phillips 4386879 6270-4005,PCA, Chassis Solenoid Driver Extension, Module 4388106 Interface M3 X 6 Screw, Pan Head, Phillips #2, with Flat and Lock 4556816 Washer Cable Assembly, Module to Driver Board...
  • Page 132 6270A Service Manual Table 49. Replaceable Parts (cont.) Reference Part Description Quantity Designator Number Cable assembly, 24v Power Cable 4363224 Screw,M3 X 0.5,6mm,Flat,Phillips,Stainless 3153213 Fan Assembly, With Crimps And Conn 4588052 Washer,Flat,Stainless,Din125 M3,3.2mm,7.0mm, .5mm 3152972 Lock Nut W/ Nylon Insert,M3 - 0.5,Stainless Steel...
  • Page 133 Washer (4 Display To PCA Cover) (7 Display CPU To PCA Cover) Touchscreen Display PCAP 4397322 Cable Assembly, Touch Controller To Display 4408085 Screw, M3 X 10 mm (Touch Driver PCB) 4565518 6270A Safety Information 4454642 Y6270 Rack-Mount Kit Instruction Sheet 4456631...
  • Page 134 6270A Service Manual See Detail 4 / 5 / 6 (5x) See Detail (2x) (4x) (2x) hxn511.eps Figure 54. Main Chassis Replacement Parts...
  • Page 135 Pressure Controller/Calibrator Replacement Parts 65,66 (3x) (4x) (3x) 43,44 (3x) (2x) (2x) (2x) hxn511_a.eps Figure 55. Main Chassis Replacement Parts, Detail A and B...
  • Page 136 6270A Service Manual Table 49. Replaceable Parts (cont.) PCM Section Ref. Description PMM/PCM Shipping Box (not shown) 4530235 Shipping Foam Kit - PCM (not shown) 4561031 Control Valve, 0.5mm Seat, Full Round Face 4016411 Screw Flat Head Machine M4 X 7 X 20 Phillips...
  • Page 137 Pressure Controller/Calibrator Replacement Parts Table 49. Replaceable Parts (cont.) PMM-CAL-KIT Section Ref. Description 6270-2036,BASE, PMM-CAL-KIT 4571875 6270-2018,PMM GUIDE RAIL 4420072 103339-Z,FOOT,BLK NITRILE,DIA 13.6 3154424 SCREW,M4X0.7,12MM,FLAT,PHILLIPS,STAINLESS 2184957 STEEL,PASSIVATED,ROHS COMPL. 6270-2037,MANIFOLD, PMM CAL KIT 4560841 Connector Bracket 4560876 SCREW,M4-0.7 X 8MM L,SOCKET HEAD CAP SCREW,SS,W/ 4398423 NYLON PATCH 260402240,WASHER, M4 EXTERNAL STAR,STAINLESS...
  • Page 138 6270A Service Manual 9, 8 (2x) hxn509.eps Figure 56. PMM-CAL-KIT-20M Parts...
  • Page 139 Pressure Controller/Calibrator Replacement Parts Table 49. Replaceable Parts (cont.) CPS Assembly Reference Fluke Description Designator 6270-2024,HOUSING, UPPER, OMAHA CPS 4542476 ADPTR-102033,ADAPTOR, 1/8 IN NPTM X 1/4 IN SWGM 3068676 6270-2047,TUBE, BENT, CONTROLLER CONNECTION, CPS 4604550 SCREW, M4-0.7 X 12MM, SHCS...
  • Page 140 6270A Service Manual Table 49. Replaceable Parts (cont.) Reference Description Fluke PN Designator 6270-2030,RETAINER, SCREEN, CPS 4542532 FILTER SCREEN,SS CYLINDER,19MM ID,25.4MM L,165 X 800 4613942 WIRE FILTER MESH O-RING,20MM ID X 2MM 4581522 W,VITON/FLUOROELASTOMER,A75,BLACK 6270-2029,RETAINER, FILTER, CPS 4542526 O-RING,6MM ID X 3MM...
  • Page 141 Pressure Controller/Calibrator Replacement Parts (3x) P3000 HC20 36,35 34,35,4 (3x) (3x) 41, 42 (4x) 11 or 49 (2x) (2x) 6,19 5,13 16,17 (2x) (2x) hxn510.eps Figure 57. CPS Assembly Parts...

  • Page 142: Screw Torque

    6270A Service Manual Screw Torque The torque for the screws used in the Product are listed in Table 50. Table 50. Screw Torque Part Torque Group Description Function Number N-m (lb-in) SCREW, M3x0.5x25mm, 6-LOBE PLASTIC BEZEL TO FRONT PANEL Chassis 4637695 1.7 (15)
  • Page 143 Pressure Controller/Calibrator Screw Torque Part Torque Group Description Function Number N-m (lb-in) Chassis PCM DOCK TO CHASSIS 2.26 (20) SCREW, M5x0.8x75mm, SOCKET REAR PORT MANIFOLD TO Chassis HEAD CAP SST WITH NYLON 4560793 4.5 (40) CHASSIS PATCH SCREW, M4x0.7x16mm, FLAT SOLENOID VALVES TO MANIFOLD Chassis 4386879...
  • Page 144 6270A Service Manual Part Torque Group Description Function Number N-m (lb-in) SCREW, M4x0.7x30mm, SOCKET 4400701 COVER TO MODULE BASE (FRONT) 1.7 (15) CAP, SST WITH NYLON PATCH SCREW, M3x0.5x6mm, FLA, SENSOR BRACKET TO MODULE 3153213 0.57 (5) PHILLIPS, SS BASE (PM600 only) SCREW, M4x0.7x12mm, SOCKET...

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