DH Instruments FPG8601 User manual

© 2007 DH Instruments, a Fluke Company
FPG8601™/VLPC™
Operation and Maintenance Manual

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company
High pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases
can be released unexpectedly and with extreme force. High pressure systems should be assembled and
operated only by personnel who have been instructed in proper safety practices.
©2007 DH Instruments, a Fluke Company All rights reserved.
Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any
form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments, a
Fluke Company 4765 East Beautiful Lane Phoenix Arizona 85044-5318 USA.
DH Instruments makes sincere efforts to ensure the accuracy and quality of its’ published materials; however, no warranty,
expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages
resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not
constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was
subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the
English version and other language versions, the English version predominates.
DH Instruments, DH, DHI, PG7000 and CalTool are trademarks, registered and otherwise, of DH Instruments, a Fluke Company.
Swagelok is a registered trademark of the Swagelok Company
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Document No. 550122e
060105
Printed in the USA

TABLES AND FIGURES
Page III © 2007 DH Instruments, a Fluke Company
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TABLE OF CONTENTS.............................................................III
TABLES................................................................................VII
FIGURES..............................................................................VIII
ABOUT THIS MANUAL .............................................................XI
1. INTRODUCTION .................................................................1
1.1 OVERVIEW ..............................................................................................................................................1
1.2 REQUIREMENTS.....................................................................................................................................2
1.3 SPECIFICATIONS....................................................................................................................................2
1.3.1 GENERAL SPECIFICATIONS.......................................................................................................................2
1.3.1.1 FPG8601 GENERAL SPECIFICATIONS...................................................................................................2
1.3.1.2 AMBIENT AND INSTRUMENT CONDITION MEASUREMENTS..............................................................3
1.3.1.3 PISTON-CYLINDER...................................................................................................................................3
1.3.1.4 PRESSURE MEASUREMENT...................................................................................................................3
1.3.2 VLPC GENERAL SPECIFICATIONS............................................................................................................4
1.4 FPG PLATFORM FRONT AND REAR PANELS AND VLPC FRONT AND REAR PANELS.................5
1.4.1 TERMINAL FRONT AND REAR PANELS....................................................................................................5
1.4.1.1 FPG TERMINAL FRONT PANEL...............................................................................................................5
1.4.1.2 FPG TERMINAL REAR PANEL .................................................................................................................6
1.4.2 FPG PLATFORM FRONT VIEW ...................................................................................................................7
1.4.3 FPG PLATFORM BACK VIEW .....................................................................................................................8
1.4.3.1 VLPC REAR PANEL ASSEMBLY..............................................................................................................9
2. FPG THEORY OF OPERATION ........................................... 11
2.1 OVERVIEW ............................................................................................................................................11
2.2 PISTON-CYLINDER...............................................................................................................................11
2.3 LOAD CELL...........................................................................................................................................13
2.4 LUBRICATION PRESSURE ..................................................................................................................14
2.5 VACUUM REFERENCE PRESSURE....................................................................................................14
2.6 SIMPLIFIED FORMULA FOR CALCULATING DIFFERENTIAL PRESSURE......................................15
2.6.1 REFERENCE LEVEL...................................................................................................................................16
2.7 CORRECTIONS.....................................................................................................................................16
2.7.1 δN1...............................................................................................................................................................16
2.7.2 δN2...............................................................................................................................................................16
2.7.3 δN3...............................................................................................................................................................17
2.8 COMPLETE DIFFERENTIAL PRESSURE EQUATION ........................................................................18
3. VLPC THEORY OF OPERATION.......................................... 19
3.1 OVERVIEW ............................................................................................................................................19
3.2 SUPPLY AND REGULATION................................................................................................................20
3.3 FLOW CONTROL ..................................................................................................................................20
3.4 RANGE RESTRICTIONS.......................................................................................................................21
3.5 CONTROL..............................................................................................................................................21
3.6 READY/NOT READY.............................................................................................................................22

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page IV
4. GETTING STARTED .......................................................... 23
4.1 OVERVIEW ............................................................................................................................................23
4.2 INSTALLING FPG TOOLS ....................................................................................................................23
4.3 SETTING UP FPG TOOLS ....................................................................................................................24
4.4 BASIC FPG HARDWARE SETUP.........................................................................................................25
4.5 SETTING UP THE PISTON-CYLINDER................................................................................................26
4.6 CONNECTING THE FPG MANIFOLD AND VALVES...........................................................................26
4.7 SETTING UP THE FPG FOR OPERATION...........................................................................................28
4.8 SETTING UP THE VLPC .......................................................................................................................29
4.9 INTRODUCING GAS TO THE FPG.......................................................................................................29
4.10 CONNECTING A DUT............................................................................................................................30
4.10.1 GAUGE MODE.............................................................................................................................................30
4.10.2 ABSOLUTE MODE......................................................................................................................................30
4.10.3 ABSOLUTE DIFFERENTIAL MODE...........................................................................................................31
4.11 CONNECTING THE DUT MANIFOLD...................................................................................................32
4.11.1 SETTING UP THE TURBO PUMP ..............................................................................................................33
4.11.2 CONNECTING THE ION GAUGE ...............................................................................................................33
4.12 CHANGING LUBRICATION GAS..........................................................................................................34
4.12.1 PURGING THE LUBRICATING VOLUME WITH A NEW GAS................................................34
4.12.2 PURGING THE TEST PORT .......................................................................................................................35
5. SYSTEM OPERATION........................................................ 37
5.1 OVERVIEW ............................................................................................................................................37
5.2 ZEROING THE FPG...............................................................................................................................37
5.2.1 ZERO CONDITION ......................................................................................................................................37
5.2.2 STABILITY TEST.........................................................................................................................................38
5.2.3 STORE ZERO DATA...................................................................................................................................38
5.3 INTERNAL CALIBRATION....................................................................................................................38
5.3.1 DETERMINING CALIBRATION MASS VALUE..........................................................................................38
5.3.2 ACTIVATING NEW CALIBRATION ............................................................................................................39
5.4 SETTING A MEASUREMENT MODE....................................................................................................41
5.5 USING A DUT WITH FPG TOOLS.........................................................................................................41
5.6 ZEROING THE DUT MANIFOLD...........................................................................................................42
5.7 CHANGING PRESSURE WITH THE VLPC...........................................................................................42
5.7.1 SETTING 0 PRESSURE..............................................................................................................................43
5.8 LOGGING DATA WITH THE FPG.........................................................................................................43
5.9 SHUTTING DOWN THE FPG ................................................................................................................44
6. FPG TOOLS ..................................................................... 45
6.1 OVERVIEW ............................................................................................................................................45
6.2 MAIN MENU...........................................................................................................................................46
6.3 MAIN DISPLAY......................................................................................................................................46
6.3.1 STATUS BAR ..............................................................................................................................................47
6.3.2 RUN DISPLAY.............................................................................................................................................47
6.3.3 TARE DISPLAY...........................................................................................................................................49
6.3.4 PLOT DISPLAY ...........................................................................................................................................50
6.3.4.1 CUSTOM PLOTS .....................................................................................................................................50
6.3.4.2 STRIP CHARTS .......................................................................................................................................51
6.3.5 LOGGED DATA...........................................................................................................................................52
6.3.6 VLPC CONTROL.........................................................................................................................................54
6.3.7 RUN DIAGNOSTICS....................................................................................................................................56
6.3.8 DUT MANIFOLD..........................................................................................................................................59
6.4 TOOLBARS ...........................................................................................................................................60
6.4.1 WINDOW DISPLAY TOOLBAR ..................................................................................................................60
6.4.2 FUNCTIONS TOOLBAR..............................................................................................................................61
6.4.3 VALVE CONTROL.......................................................................................................................................64

TABLES AND FIGURES
Page V © 2007 DH Instruments, a Fluke Company
6.5 [RUN] .....................................................................................................................................................65
6.5.1 RUN MODE INITIALIZATION......................................................................................................................65
6.5.2 [RUN MONITOR] .........................................................................................................................................66
6.5.3 [RUN W/POINT LOG]..................................................................................................................................66
6.5.4 [RUN TEST SEQUENCE]............................................................................................................................66
6.6 [CONFIG]...............................................................................................................................................68
6.6.1 [SETTINGS].................................................................................................................................................68
6.6.2 [SYSTEM SETUP] .......................................................................................................................................69
6.6.2.1 <SETUP> .................................................................................................................................................69
6.6.2.2 <OPTIONS> .............................................................................................................................................70
6.6.2.3 <DATA FILE> ...........................................................................................................................................72
6.6.3 [FPG CALIBRATION SETUP].....................................................................................................................73
6.6.4 [INTERNAL LIMITS]....................................................................................................................................75
6.6.4.1 <SETUP> .................................................................................................................................................75
6.6.4.2 <PRESSURE> .........................................................................................................................................76
6.6.4.3 <TEMPERATURE> ..................................................................................................................................77
6.6.4.4 <HUMIDITY>............................................................................................................................................78
6.6.4.5 <MASS> ...................................................................................................................................................79
6.6.4.6 <PURGE> ................................................................................................................................................80
6.6.4.7 <VLPC>....................................................................................................................................................81
6.6.5 [DUT SELECTION]......................................................................................................................................83
6.7 TEST SEQUENCE EDITOR...................................................................................................................84
6.7.1 TOOLBAR....................................................................................................................................................84
6.7.2 <POINTS> TABLE.......................................................................................................................................85
6.7.3 [POINTS] TAB .............................................................................................................................................87
6.7.4 <SEQUENCE> TAB.....................................................................................................................................88
6.7.5 <CONTROL> TAB.......................................................................................................................................89
6.7.6 <CYCLE> TAB.............................................................................................................................................90
6.8 DUT DEFINITION EDITOR ....................................................................................................................91
6.8.1 TOOLBAR....................................................................................................................................................91
6.8.2 DUT DEFINITION SELECTOR....................................................................................................................92
6.8.2.1 [HEADER] TAB ........................................................................................................................................93
6.8.2.2 [CORRECTION] TAB ...............................................................................................................................94
6.8.2.3 [RANGE] TAB...........................................................................................................................................95
6.8.2.4 [TOLERANCE] TAB .................................................................................................................................96
6.8.2.5 [READ] TAB .............................................................................................................................................97
6.8.2.6 REMOTE COMMAND EDITOR ...............................................................................................................99
6.9 [UNITS] ................................................................................................................................................102
6.9.1 [USER DEFINED UNITS] ..........................................................................................................................102
6.9.2 [ABSOLUTE MODE], [GAUGE MODE]....................................................................................................103
6.9.2.1 [GAUGE MODE].....................................................................................................................................103
6.9.2.2 [ABSOLUTE MODE] ..............................................................................................................................104
6.10 [CHANGE USER LEVEL]....................................................................................................................104
6.11 [TOOLS]...............................................................................................................................................105
6.11.1 [REMOTE COMMUNICATIONS]...............................................................................................................105
6.12 INTERNATIONAL ISSUES ..................................................................................................................105
7. PISTON-CYLINDER MAINTENANCE ...................................107
7.1 OVERVIEW ..........................................................................................................................................107
7.2 REMOVING THE PISTON-CYLINDER FROM THE MOUNTING POST .............................................109
7.3 REMOVING THE PISTON FROM THE CYLINDER.............................................................................111
7.4 CLEANING THE PISTON AND CYLINDER ........................................................................................112
7.5 PUTTING THE PISTON INTO THE CYLINDER...................................................................................113
7.6 INSTALLING THE PISTON-CYLINDER IN THE MOUNTING POST ............................................114
7.7 RESTORING PISTON-CYLINDER LUBRICATION AND MOBILITY..................................................115
7.7.1 OVERVIEW................................................................................................................................................115
7.7.2 PISTON CENTERING AND LUBRICATING METHODS ..........................................................................115
7.8 DETERMINING EFFECTIVE AREA.....................................................................................................117
7.8.1 SETTING UP THE SYSTEM......................................................................................................................117
7.8.2 GENERATING A PRESSURE...................................................................................................................118
7.8.3 ADJUSTING THE NEEDLE VALVE..........................................................................................................118
7.8.4 TAKING DATA (FOR EACH PRESSURE)................................................................................................119
7.8.5 CALCULATING THE EFFECTIVE AREA .................................................................................................119

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page VI
8. GENERAL MAINTENANCE ................................................121
8.1 OVERVIEW ..........................................................................................................................................121
8.2 REFILLING THE BUBBLER ON THE FPG .........................................................................................121
8.3 ZEROING THE VACUUM SENSOR ....................................................................................................122
8.3.1 SET – UP....................................................................................................................................................123
8.3.2 WARM-UP..................................................................................................................................................123
8.3.3 TEST THE ZERO OF THE VACUUM SENSOR........................................................................................123
8.4 CALIBRATING THE INTERNAL CALIBRATION MASS.....................................................................125
8.4.1 INITIAL PREPARATIONS .........................................................................................................................125
8.4.2 REMOVE THE LOAD CELL COVER ........................................................................................................125
8.4.3 REMOVE THE CALIBRATION MASS AND DRIVE..................................................................................126
8.4.4 DETERMINE THE TRUE MASS VALUE OF THE INTERNAL CALIBRATION MASS............................126
8.4.5 PUT THE MASS BACK INTO THE DRIVE ASSEMBLY ..........................................................................127
8.4.6 REATTACH THE LOAD CELL COVER....................................................................................................127
8.4.7 FINAL STEPS............................................................................................................................................127
8.5 MOUNTING POST PRT CALIBRATION..............................................................................................128
8.5.1 REMOVE THE PRTS.................................................................................................................................128
8.5.2 CREATE THE PRT CABLE ADAPTER ....................................................................................................128
8.5.3 DETERMINE THE RO VALUE ..................................................................................................................129
8.5.4 ENTER THE RO VALUE INTO THE FPG TERMINAL..............................................................................129
8.5.5 REATTACH THE PRTS TO THE FPG ......................................................................................................130
8.6 PREPARING FOR STORAGE / SHIPMENT........................................................................................130
8.6.1 FPG8601....................................................................................................................................................130
8.6.2 VLPC..........................................................................................................................................................130
8.6.3 3-DUT MANIFOLD.....................................................................................................................................131
9. DATA FILES ...................................................................133
9.1 OVERVIEW ..........................................................................................................................................133
9.2 POINT LOG DATA FILE (*.DAT).........................................................................................................133
9.2.1 NAMING AND STORING DATA FILES ....................................................................................................133
9.2.2 FILE FORMAT ...........................................................................................................................................133
9.3 INTERNAL CALIBRATION LOG FILE ................................................................................................133
9.4 SYSTEM ZERO LOG FILE ..................................................................................................................134
9.5 ERROR LOG FILE...............................................................................................................................134
10. TROUBLESHOOTING .......................................................135
10.1 OVERVIEW ..........................................................................................................................................135
11. APPENDIX......................................................................137
11.1 INTERNAL VALVES............................................................................................................................137
11.2 UNIT CONVERSIONS..........................................................................................................................139
11.3 FPG8601 PRESSURE CALCULATIONS ............................................................................................140
11.3.1 COMPENSATED PRESSURES ................................................................................................................140
11.3.2 DIFFERENTIAL PRESSURES ..................................................................................................................140
11.3.3 CORRECTION TERMS..............................................................................................................................140
11.3.4 THERMAL TRANSPIRATION CORRECTION..........................................................................................141
11.3.5 SAMPLE CALCULATIONS.......................................................................................................................144
11.3.5.1 GAUGE PRESSURE..............................................................................................................................144
11.3.5.2 ABSOLUTE PRESSURE .......................................................................................................................145
11.3.5.3 ABSOLUTE DIFFERENTIAL PRESSURE.............................................................................................146
11.3.5.4 INTERNAL CALIBRATION (KCAL)........................................................................................................147
11.4 DECLARATION OF CONFORMITY.....................................................................................................147
11.5 GROUNDING / ELECTRICAL SCHEMATICS.....................................................................................147
11.5.1 SYSTEM LEVEL GROUNDING.................................................................................................................148
11.5.2 FPG GROUND DIAGRAM.........................................................................................................................149
11.5.3 VLPC POWER DIAGRAM.........................................................................................................................150
12. WARRANTY STATEMENT .................................................151
13. GLOSSARY.....................................................................153

TABLES AND FIGURES
Page VII © 2007 DH Instruments, a Fluke Company
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Table 1. Nominal VLPC Ranges ................................................................................................................ 19
Table 2. Nominal VLPC Ranges, 15 kPa Unit ........................................................................................... 21
Table 3. Equipment for Basic FPG Hardware Setup ................................................................................ 25
Table 4. Internal Calibration Results Options ............................................................................................ 40
Table 5. <Run Display> Labels.................................................................................................................. 48
Table 6. <Tare Display> Labels ................................................................................................................. 49
Table 7. <Custom Plot Properties> Tab Fields .......................................................................................... 51
Table 8. <Logged Points> Labels .............................................................................................................. 53
Table 9. <VLPC Interface> Options ........................................................................................................... 55
Table 10. <Diagnostics Display> Options .................................................................................................. 56
Table 11. <DUT Manifold> Color Scheme ................................................................................................. 59
Table 12. <DUT Manifold> Display ............................................................................................................ 60
Table 13. Window Display Toolbar Options............................................................................................... 61
Table 14. Functions Toolbar Option........................................................................................................... 61
Table 15. System Settings ......................................................................................................................... 68
Table 16. <System Setup><Setup> Options ............................................................................................. 69
Table 17. <System Setup><Options> Options .......................................................................................... 71
Table 18. <Options>, <Data File> Tab Fields ............................................................................................ 72
Table 19. <FPG8601 Calibration Setup> Options ..................................................................................... 74
Table 20. <Internal Limits> <Setup> Options ............................................................................................ 75
Table 21. <Internal Limits> <Pressure> Options ....................................................................................... 77
Table 22. <Internal Limits> <Temperature> Options ................................................................................. 78
Table 23. <Internal Limits> <Humidity> Options........................................................................................ 79
Table 24. <Internal Limits> <Mass> Options ............................................................................................. 80
Table 25. <Internal Limits> <Purge> Options ............................................................................................ 81
Table 26. <Internal Limits> <VLPC> Options ............................................................................................ 82
Table 27. <DUT Selection & I/O Setup> Options....................................................................................... 83
Table 28. Test Sequence Editor, <Toolbar> Options ................................................................................ 84
Table 29. Test Sequence Editor, <Points> Options................................................................................... 86
Table 30. Test Sequence Editor, <Points> Tab Fields .............................................................................. 87
Table 31. Test Sequence Editor, <Sequence> Tab Fields ........................................................................ 88
Table 32. Test Sequence Editor, <Control> Tab Fields............................................................................. 89
Table 33. Test Sequence Editor, <Cycle> Tab Fields ............................................................................... 90
Table 34. DUT Definition Editor, <Toolbar> Features ............................................................................... 91
Table 35. DUT Definition Editor, [Header] Tab Fields ............................................................................... 93
Table 36. DUT Definition Editor, [Correction] Tab Fields........................................................................... 94
Table 37. DUT Definition Editor, [Range] Tab Fields................................................................................. 95
Table 38. DUT Definition Editor, [Tolerance] Tab Fields ........................................................................... 97
Table 39. DUT Definition Editor, [Read] Tab Fields................................................................................... 98
Table 40. Piston-Cylinder Maintenance Equipment................................................................................. 107
Table 41. Effective Area Calculation Variables........................................................................................ 119
Table 42. Sample Effective Area Spread Sheet ...................................................................................... 120
Table 43. Bubbler Maintenance Equipment............................................................................................. 121
Table 44. Vacuum Reference Zeroing Equipment List ............................................................................ 122
Table 45. Vacuum Reference Zeroing Equipment List ............................................................................ 125
Table 46. Effective Area Calculation Variables........................................................................................ 127
Table 47. PRT Calibration Cable Connections ........................................................................................ 128
Table 48. Effective Area Calculation Variables........................................................................................ 129

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page VIII
Table 49. Troubleshooting Tips ............................................................................................................... 135
Table 50. Internal Valve Descriptions ...................................................................................................... 138
Table 51. Unit Conversion Factors .......................................................................................................... 139
Table 52. FPG Defined Pressure Calculation Variables.......................................................................... 142
Table 53. DHI Authorized Service Providers ........................................................................................... 151
F
FI
IG GU UR RE ES S
Figure 1. FPG8601 Terminal Front Panel.................................................................................................... 5
Figure 2. FPG8601 Terminal Rear Panel .................................................................................................... 6
Figure 3. FPG Platform Front View.............................................................................................................. 7
Figure 4. FPG Platform Back View .............................................................................................................. 8
Figure 5. VLPC Rear Panel.......................................................................................................................... 9
Figure 6. Piston-cylinder Lubricating Flow ................................................................................................. 12
Figure 7. Internal Calibration Mass Alignment ........................................................................................... 13
Figure 8. FPG Forces................................................................................................................................. 17
Figure 9. Gauge Mode VLPC Block Diagram ............................................................................................ 20
Figure 10. Absolute Mode VLPC Block Diagram....................................................................................... 20
Figure 11. VLPC Ready Criterion .............................................................................................................. 22
Figure 12. FPG8601 System Schematic.................................................................................................... 23
Figure 13. FPG8601 Manifold Connection................................................................................................. 27
Figure 14. Internal Calibration Results Window......................................................................................... 39
Figure 15. FPG Tools(Factory Mode) ....................................................................................................... 46
Figure 16. <Status Bar> ............................................................................................................................. 47
Figure 17. <Run Display> .......................................................................................................................... 47
Figure 18. <Tare Display>.......................................................................................................................... 49
Figure 19. <Plot Data> ............................................................................................................................... 50
Figure 20. <Custom Plot Properties>......................................................................................................... 51
Figure 21. <Logged Points> Display.......................................................................................................... 52
Figure 22. <VLPC Interface> ..................................................................................................................... 55
Figure 23. <Select VLPC Range>.............................................................................................................. 55
Figure 24. <Diagnostics Display> .............................................................................................................. 56
Figure 25. Window Display Toolbar ........................................................................................................... 59
Figure 26. Window Display Toolbar ........................................................................................................... 60
Figure 27. Manual Valve Control Toolbar .................................................................................................. 65
Figure 28. <Settings>................................................................................................................................. 68
Figure 29. <System Setup><Setup> Tab .................................................................................................. 69
Figure 30. <System Setup><Interface> ..................................................................................................... 71
Figure 31. <System Setup>, <Data File> Tab ........................................................................................... 72
Figure 32. <FPG8601 Calibration Setup>.................................................................................................. 74
Figure 33. <Internal Limits> <Setup>......................................................................................................... 75
Figure 34. <Internal Limits> <Pressure>.................................................................................................... 76
Figure 35. <Internal Limits> <Temperature> ............................................................................................. 78
Figure 36. <Internal Limits> <Humidity> .................................................................................................... 79
Figure 37. <Internal Limits> <Mass> ......................................................................................................... 80
Figure 38. <Internal Limits> <Purge> ........................................................................................................ 81
Figure 39. <Internal Limits> <VLPC>......................................................................................................... 82
Figure 40. <DUT Selection & I/O Setup>................................................................................................... 83
Figure 41. Test Sequence Editor, <Toolbar>............................................................................................. 84
Figure 42. Test Sequence Editor, <Test Points> Table............................................................................. 85
Figure 43. Test Sequence Editor, <Points> Tab........................................................................................ 87
Figure 44. Test Definition Editor, <Control> Tab ....................................................................................... 89

TABLES AND FIGURES
Page IX © 2007 DH Instruments, a Fluke Company
Figure 45. Test Definition Editor, <Cycle> Tab .......................................................................................... 90
Figure 46. DUT Definition Editor, <Toolbar>.............................................................................................. 91
Figure 47. <DUT Selection> Tool .............................................................................................................. 93
Figure 48. DUT Definition Editor, [Header Tab .......................................................................................... 93
Figure 49. DUT Definition Editor, [Correction] Tab .................................................................................... 94
Figure 50. DUT Definition Editor, [Range] Tab .......................................................................................... 95
Figure 51. DUT Definition Editor, [Tolerance] Tab..................................................................................... 96
Figure 52. DUT Definition Editor, [Read] Tab ............................................................................................ 97
Figure 53. <Insert Special Character> Panel............................................................................................. 99
Figure 54. <Initialization Commands Editor> Panel................................................................................. 100
Figure 55. <Read Commands Editor> Panel........................................................................................... 101
Figure 56. <RS232 Settings> Panel ........................................................................................................ 101
Figure 57. <User Defined Unit Setup>..................................................................................................... 102
Figure 58. <Remote Communications> ................................................................................................... 105
Figure 59. FPG8601 Piston Assembly in Mounting Post......................................................................... 108
Figure 60. Removing the Mounting Post.................................................................................................. 110
Figure 61. Removing the Piston............................................................................................................... 110
Figure 62. Alignment of the FPG piston in the cylinder ........................................................................... 113
Figure 63. FPG8601 and PG7000 Cross Float Setup ............................................................................. 117
Figure 64. FPG8601 Bubbling System .................................................................................................... 122
Figure 65. Calibration Mass Drive Assembly ........................................................................................... 126
Figure 66. PRT Calibration Cable Adaptor .............................................................................................. 128
Figure 67. FPG Internal Valve Configuration........................................................................................... 137

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
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ABOUT THIS MANUAL
Page XI © 2007 DH Instruments, a Fluke Company
A
AB
BO OU UT T T
TH
HI IS S M
MA
AN NU UA AL L
This manual provides the user with the information necessary to operate the FPG8601 system. It also
includes a great deal of additional information provided to help you optimize system use and take full
advantage of its many features and functions.
Realize that the numbers on the PC software screen captures and the VLPC range information are for
example purposes only. In some cases the information required to setup the FPG is installed with FPG
Tools. In other cases, the values must be entered into the FPG calibration setup (see Section 6.6.3).
Before using the manual, take a moment to familiarize yourself with the Table of Contents structure.
All first time FPG users should read Section 2 for a comprehensive description of general operating
principles. Section 8 provides maintenance and calibration information. Use the information in Section
10 to troubleshoot unexpected system behavior based on the symptoms of that behavior.
Certain words and expressions have specific meaning as they pertain to the FPG System. The Glossary
(see Section 13) is useful as a quick reference for exact definition of specific words and expressions as
they are used in this manual.
FOR THOSE OF YOU WHO “DON’T READ MANUALS”, GO DIRECTLY TO SECTION 4 TO SET UP YOUR
FPG SYSTEM. THEN GO TO SECTIONS 5 and 6. THIS WILL GET YOU RUNNING QUICKLY WITH
MINIMAL RISK OF CAUSING DAMAGE TO YOURSELF OR YOUR FPG. THEN… WHEN YOU HAVE
QUESTIONS OR START TO WONDER ABOUT ALL THE GREAT FEATURES YOU MIGHT BE MISSING, GET
INTO THE MANUAL!
Manual Conventions
(CAUTION) is used in throughout the manual to identify user warnings and cautions.
(NOTE) is used throughout the manual to identify operating and applications advice and additional
explanations.
[ ] indicates direct function keys or menu options (e.g., [Run]).
< > indicates FPG Tools screen displays (e.g., <FPG Pressure>).

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
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1. INTRODUCTION
Page 1 © 2007 DH Instruments, a Fluke Company
1
1. . I IN
NT TR RO OD DU UC CT TI IO ON N
1.1 OVERVIEW
The FPG8601 (Force-Balanced Piston Gauge), VLPC (Very Low Pressure Controller) and FPG Tools
(PC Based Software) are used in conjunction to act as a high precision pressure measurement and data
acquisition system. Operator interaction with the FPG/VLPC and its extensive capabilities is accomplished
through the PC based software from a computer via a standard RS232 port. FPG Tools also provides
features to define a test sequence, read DUT’s with a standard RS232 or IEEE-488 output, and log data
to a data file.
FPG pressure is defined by using a high precision load cell to measure the force exerted on the effective
area of a piston-cylinder (see Section 2). Instead of rotating the piston like other piston gauges, the FPG
provides sensitivity between the piston and cylinder by maintaining a constant flow through the annular
gap. This flow generates a centering force that prevents the piston from touching the cylinder during
normal operation. Noise normally associated with rotation is therefore not present.
FPG platforms are designed to maximize metrological performance and ease of operation in both gauge
and absolute modes. Many features are included to enhance the fundamental precision and stability of
pressure measurements as well as simplifying use and reducing the operator influence on the
measurements.
The VLPC generates low pressure in gauge and absolute modes (0 to 15 kPa). It is used to set and
stabilize pressure as read by the FPG so that the VLPC/FPG combination can be used to set user
specified target pressure values. The general operating principle of the VLPC is to generate a stable flow
through one of a number of restrictions depending on the range of pressure to be controlled (see Section
3.4). The pressure drop across the restriction is the controlled differential pressure. Feedback from the
FPG is used to dynamically readjust the flow to obtain the desired target pressure.
FPG Tools is the complete interface to both the FPG and the VLPC. An interface to all functional aspects
of both instruments is provided by the software. FPG Tools uses three basic modes of operation to
remotely interact with the FPG and VLPC: [Run Mode], [Run w/Point Logging], and [Run Test Sequence]
(see Section 6.5). These modes respectively allow simple monitoring of pressure, monitoring of pressure
with user dependant steps and data acquisition, and monitoring with defined test steps and data acquisition.
A DUT can be used in any run mode for real-time error determination and/or data acquisition.

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 2
1.2 REQUIREMENTS
FPG Tools is a PC based application designed for 32 bit versions of Windows. The PC requirements
stated below are necessary to maintain the minimum acceptable performance between the software and
related hardware components.
•Windows XP, 98, NT service pack 4 or greater
•500 MHz Pentium Processor or compatible
•32 Mb of Ram
•12 Mb free hard drive space
1.3 SPECIFICATIONS
1.3.1 GENERAL SPECIFICATIONS
1.3.1.1 FPG8601 GENERAL SPECIFICATIONS
Power Requirements: 85 to 264 VAC, 50 to 60 Hz, 60 VA consumption
Operating Temperature: 15 to 35 °C
Weight: Instrument platform
FPG Platform 31.2 kg (61 lb)
FPG Terminal 1.4 kg (3 lb)
Dimensions:
FPG Platform 53.4 cm H x 35.8 cm W x 35.5 cm D
(21 in. H x 14.1 in. W x 14 in. D)
FPG Terminal 12 cm H x 15 cm W x 20 cm D
(4.7 in. H x 5.9 in. W x 7.9 in. D)
Microprocessors:
Instrument Platform Motorola 68302
FPG Terminal Hitachi 64180
Communication Ports:
RS232 COM1: Host computer
COM2: VLPC
COM3: Not Used
IEEE-488.2 Not used
Maximum Pressure Ranges: 0 – 15 kPa Gauge and Absolute
Operating Media: Gas: air or Nitrogen (N2)
Pressure Supplies: Lubrication port: 700 - 850 kPa (100 - 120 psi), supply
must remain constant ±1 % to meet control specifications
Drive In Supply: 600 to 1000 kPa (90 to 150 psi) air
Maximum Overpressure Limit: +20 kPa to –10 kPa (+3 to – 1.5 psi)
Pressure Connections:
Lubrication Supply Port
Upper Test Port
Lower Test Port
Drive In Port
Vacuum Port
1/8 in. NPT
KF16
KF16
1/8 in. NPT
1/8 in. NPT
CE Conformance: Not available
Driver Port (Ext Valve): Not used

1. INTRODUCTION
Page 3 © 2007 DH Instruments, a Fluke Company
1.3.1.2 AMBIENT AND INSTRUMENT CONDITION MEASUREMENTS
Temperature:
Range
Resolution
Accuracy
Lubrication Pressure Piston-Cylinder
[°C] [°C]
0 to 40 0 to 40
0.1 0.01
±0.2 ±0.1
Relative Humidity:
Range
Resolution
Accuracy
5 to 95 %RH
1 %RH
±10 %RH
Vacuum:
Range
Resolution
Accuracy
13 Pa
1 mPa
±20 mPa
Ambient and Lubrication
Pressure Sensor:
Range
Resolution
Accuracy
200 kPa
1 Pa
±0.1 kPa
1.3.1.3 PISTON-CYLINDER
Cylinder Material: Tungsten carbide
Piston Material: Tungsten carbide
Nominal Diameter: 35 mm
Nominal Area: 980.5164 mm2
Mounting System: Non-rotative piston
1.3.1.4 PRESSURE MEASUREMENT
Resolution1: 10 mPa
Precision Reproducability2: ±20 mPa
Uncertainty3: Absolute: ±(25 mPa + 0.003 % of reading)
Standard Measurement: Gauge and absolute differential: ±(20 mPa + 0.003 %
of reading)
1. Resolution: The smallest variation in input detectable in output.
2. Reproducibility: Combined reproducibility of force measurement and long term stability of
piston-cylinder effective area.
3. Standard Measurement Uncertainty: All sources of uncertainty under typical operating
conditions are identified, quantified and combined following ISO/TAG4/WG3. The result is then
rounded upwards to provide conservative global figures for the typical user in typical conditions
of the maximum deviation from the true value of the pressure determined by the FPG8601 and
the pressure actually present at the test point.

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 4
1.3.2 VLPC GENERAL SPECIFICATIONS
Power Requirements: 85 to 264 VAC, 47 to 60 Hz, 70 VA max. consumption
Operating Temperature Range: 15 to 35 °C
Storage Temperature Range: - 20 to 70 °C
Weight: 41.6 kg (91.5 lb)
Dimensions: 30.5 cm H x 53.4 cm W x 50.5 cm D
(12 in. H x 21 in. W x 19.9 in. D)
Microprocessor: Motorola 68302, 16 MHz
Communication Ports:
RS232
IEEE-488.2
COM1: FPG
COM2:: Not Used
Not used
Control Specifications: ±0.02 Pa + 30 ppm of range selected
Operating Medium: Gas: air or Nitrogen (N2)
Pressure Supplies: SUPPLY port: 700 - 850 kPa (100 - 120 psi), supply must remain
constant ±1 % to meet control specifications
Drive Air Supply: 600 to 1000 kPa (90 to 150 psi) air
Pressure Connections: Test (Lo) 1/4 VCO
Test (Hi) 1/4 VCO
ATM 1/4 VCO
Vacuum 3/8 VCO
Supply 1/8 NPT F
Drive 1/8 NPT F

1. INTRODUCTION
Page 5 © 2007 DH Instruments, a Fluke Company
1.4 FPG PLATFORM FRONT AND REAR PANELS AND VLPC
FRONT AND REAR PANELS
1.4.1 TERMINAL FRONT AND REAR PANELS
1.4.1.1 FPG TERMINAL FRONT PANEL
The front panel assembly provides a 2 x 20 vacuum fluorescent display and a 4 x 4
membrane keypad for local user interface.
1. Display
2. Multi-Function Keypad
Figure 1. FPG8601 Terminal Front Panel

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 6
1.4.1.2 FPG TERMINAL REAR PANEL
The rear panel assembly provides the communications connection to the FPG
platform and the power connection module.
1. Power Switch
2. Fuse
3. Power Receptacle
4. Connector for Cable to
FPG (25 pin
5. Cooling Fan
Figure 2. FPG8601 Terminal Rear Panel

1. INTRODUCTION
Page 7 © 2007 DH Instruments, a Fluke Company
1.4.2 FPG PLATFORM FRONT VIEW
The front of the FPG provides the connections to the VLPC, DUT and vacuum sensor. It also
provides the electrical connection to the mounting post PRTs and vacuum sensor reading.
1. Upper Mounting Post
2. TEST+ (KF-16)
3. Mounting Post PRT Connector
4. TEST- (KF-16)
5. Lower Mounting Post
6. Vacuum Reference Port (KF-25)
7. Mounting Post Reference
8. Vacuum Sensor Connector
9. Vacuum Sensor Port
10. Reference Level
Figure 3. FPG Platform Front View

FPG8601™/VLPC™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 8
1.4.3 FPG PLATFORM BACK VIEW
The FPG platform rear panels provide the connection to the FPG Terminal, remote
communication connections and supply pressure connection ports.
1. COM2 (RS232) – VLPC
2. COM1 (RS232) – Remote Host
Communication
3. IEEE-488 – Not Used
4. Absolute Mode – Lubrication
Pressure Vacuum
5. Bubbler
6. Lubrication Supply
7. Drive In
8. Coalescing Filter
9. Drivers Option Connector -
Not Used
10. COM3 (RS232) – Not Used
11. FPG Terminal Port
Figure 4. FPG Platform Back View