DH Instruments PPC2 AF User manual

PPC2 AF™
Operation and Maintenance Manual

© 1998 DH Instruments, Inc.
© 1998,2002 DH Instruments, Inc. 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, Inc.
4765 East Beautiful Lane, Phoenix AZ 85044-5318, USA.
DH Instruments makes sincere efforts to ensure 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, PPC, PPC2 and PPC2 AF are trademarks, registered and otherwise, of DH Instruments, Inc.
Document No. 550090C-01
980812, 021025
Printed in the USA.

TABLE OF CONTENTS
Page I © 1998 DH Instruments, Inc.
T
TA
AB BL LE E O
OF
F C
CO
ON NT TE EN NT TS S
TABLE OF CONTENTS ............................................................. I
1. INTRODUCTION .................................................................1
1.1 PRODUCT OVERVIEW ...........................................................................................................................1
1.2 SUBASSEMBLY DESCRIPTION AND LOCATION ................................................................................1
1.2.1 FRONT PANEL ASSEMBLY ..................................................................................................................... 1
1.2.2 REAR PANEL ASSEMBLY ....................................................................................................................... 2
1.2.3 POWER SUPPLIES................................................................................................................................... 3
1.2.4 MICRO CARD............................................................................................................................................ 3
1.2.5 DRIVER BOARD ....................................................................................................................................... 4
1.2.6 BAROMETER BOARD .............................................................................................................................. 4
1.2.7 PNEUMATIC MODULE ............................................................................................................................. 5
1.2.8 TRANSDUCER SELECTION MODULE.....................................................................................................6
1.2.9 REFERENCE PRESSURE TRANSDUCERS............................................................................................. 6
1.2.9.1 HIGH (PRIMARY) PRESSURE REFERENCE TRANSDUCER.............................................................. 7
1.2.9.2 LOW (SECONDARY) PRESSURE REFERENCE TRANSDUCER ........................................................ 7
1.2.10 SOURCE PRESSURE RELIEF VALVE..................................................................................................... 7
1.2.11 SELF PURGING LIQUID TRAP (SPLT) .................................................................................................... 8
1.3 SPECIFICATIONS ...................................................................................................................................9
1.3.1 GENERAL SPECIFICATIONS ................................................................................................................... 9
1.3.2 PRESSURE MEASUREMENT SPECIFICATIONS .................................................................................... 9
1.3.2.1 HIGH PRESSURE REFERENCE TRANSDUCER (HI REF) .................................................................. 9
1.3.2.2 LOW PRESSURE REFERENCE TRANSDUCER (LO REF).................................................................. 9
1.3.2.3 BAROMETER ...................................................................................................................................... 10
1.3.3 PRESSURE CONTROL SPECIFICATIONS ............................................................................................ 10
1.3.3.1 STATIC PRESSURE CONTROL .........................................................................................................10
1.3.3.2 DYNAMIC PRESSURE CONTROL...................................................................................................... 10
2. INSTALLATION AND SHORT TERM STORAGE ..................... 11
2.1 UNPACKING AND INSPECTION ..........................................................................................................11
2.1.1 REMOVING FROM PACKAGING............................................................................................................ 11
2.1.2 INSPECTING CONTENTS....................................................................................................................... 11
2.2 SITE REQUIREMENTS..........................................................................................................................11
2.3 INITIAL SETUP......................................................................................................................................12
2.3.1 PREPARING FOR OPERATION.............................................................................................................. 12
2.3.2 POWER CONNECTION .......................................................................................................................... 12
2.3.3 CONNECTING TO A PRESSURE SUPPLY (SUPPLY PORT) ................................................................ 12
2.3.4 CONNECTING A VACUUM PUMP (EXHAUST PORT) ........................................................................... 12
2.3.5 CONNECTING TO THE DEVICE UNDER TEST (TEST PORT)................................................ 13
2.3.5.1 INSTALLING THE SPLT ...................................................................................................................... 13
2.3.6 THE VENT CONNECTION (VENT PORT) ............................................................................................... 14
2.3.7 THE AUTOZERO CONNECTION (AUTOZERO PORT)........................................................................... 14
2.4 POWER UP AND VERIFICATION .........................................................................................................14
2.4.1 SWITCH POWER ON.............................................................................................................................. 14
2.4.2 SET THE USER LEVEL (INITIAL START UP ONLY).............................................................................. 15
2.4.3 CHECK PROPER PRESSURE MEASUREMENT OPERATION ............................................................. 15
2.4.3.1 CHECKING ABSOLUTE PRESSURE MEASUREMENT ..................................................................... 15
2.4.3.2 CHECKING GAUGE PRESSURE MEASUREMENT ........................................................................... 15
2.4.4 LEAK CHECK.......................................................................................................................................... 15
2.4.5 PURGE .................................................................................................................................................... 15
2.4.6 CHECK PROPER PRESSURE CONTROL OPERATION........................................................................ 16
2.5 SHORT TERM STORAGE .....................................................................................................................16

PPC2 AF OPERATION AND MAINTENANCE MANUAL
© 1998 DH Instruments, Inc. Page II
3. OPERATION .................................................................... 17
3.1 GENERAL/MANUAL OPERATION .......................................................................................................17
3.1.1 THE MAIN RUN SCREEN ....................................................................................................................... 17
3.1.2 GENERAL OPERATING PRINCIPLES ................................................................................................... 18
3.1.2.1 MAIN KEYPAD LAYOUT AND PROTOCOL ........................................................................................ 18
3.1.2.2 DIRECT PRESSURE CONTROL KEYS .............................................................................................. 18
3.1.2.3 AUTOMATED PRESSURE CONTROL................................................................................................ 19
3.1.2.4 PRESSURE READY/NOT READY INDICATION ................................................................................. 21
3.1.2.5 MULTIPLE PRESSURE RANGES....................................................................................................... 22
3.2 DIRECT FUNCTION KEYS....................................................................................................................23
3.2.1 RANGE .................................................................................................................................................... 23
3.2.2 UNIT ........................................................................................................................................................ 24
3.2.3 CONTROL ............................................................................................................................................... 25
3.2.3.1 EXECUTING AUTOMATED PRESSURE CONTROL COMMANDS..................................................... 26
3.2.4 UPPER LIMIT .......................................................................................................................................... 28
3.2.5 SEQ ......................................................................................................................................................... 29
3.2.5.1 SETTING UP/EDITING A QUICK SEQUENCE.................................................................................... 29
3.2.5.2 SETTING UP/EDITING A FILE SEQUENCE ....................................................................................... 31
3.2.5.3 RUNNING A SEQUENCE .................................................................................................................... 31
3.2.6 CUSTOM CONTROL............................................................................................................................... 33
3.2.6.1 TURNING-OFF CUSTOM CONTROL PARAMETERS......................................................................... 34
3.2.7 HEAD....................................................................................................................................................... 34
3.2.8 LEAK CHECK/PURGE ............................................................................................................................ 36
3.2.8.1 LEAK CHECK/PURGE MENU AND FUNCTIONS FLOW CHART................................................ 37
3.2.8.2 LEAK CHECK SCREEN FUNCTION ................................................................................................... 37
3.2.8.3 PURGE FUNCTION............................................................................................................................. 38
3.2.8.4 SETTING PRESSURES FOR LEAK CHECK/PURGE FUNCTION............................................... 39
3.2.8.5 TYPICAL USE OF THE LEAK CHECK/PURGE FUNCTION................................................................ 39
3.2.9 ANALOG.................................................................................................................................................. 40
3.3 SETUP MENU KEY ...............................................................................................................................40
3.3.1 CONTROLREF ........................................................................................................................................ 41
3.3.2 RESLTN .................................................................................................................................................. 41
3.3.3 SEQUENCE............................................................................................................................................. 42
3.3.4 DRIVERS................................................................................................................................................. 45
3.4 SPECIAL MENU KEY ............................................................................................................................45
3.4.1 PRESU .................................................................................................................................................... 46
3.4.2 HEAD....................................................................................................................................................... 47
3.4.3 CONFIG................................................................................................................................................... 47
3.4.4 INTERNAL............................................................................................................................................... 47
3.4.4.1 AUTOZ................................................................................................................................................. 47
3.4.4.2 CAL...................................................................................................................................................... 48
3.4.4.3 REMOTE ............................................................................................................................................. 48
3.4.4.4 DATE ................................................................................................................................................... 48
3.4.4.5 RESET................................................................................................................................................. 49
3.4.4.6 LEVEL.................................................................................................................................................. 50
3.4.4.7 ATM ..................................................................................................................................................... 52
3.4.4.8 MAINT.................................................................................................................................................. 53
3.4.5 DIAG........................................................................................................................................................ 53
4. REMOTE OPERATION....................................................... 55
4.1 OVERVIEW ............................................................................................................................................55
4.2 INTERFACING.......................................................................................................................................55
4.2.1 RS232 INTERFACE................................................................................................................................. 55
4.2.1.1 COM1 .................................................................................................................................................. 55
4.2.1.2 COM2 .................................................................................................................................................. 56
4.3 COMMANDS..........................................................................................................................................57
4.3.1 COMMAND LIST ..................................................................................................................................... 57
4.3.2 ERROR MESSAGES............................................................................................................................... 58
4.3.3 COMMAND SUMMARY........................................................................................................................... 59

TABLE OF CONTENTS
Page III © 1998 DH Instruments, Inc.
5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION ............ 75
5.1 MAINTENANCE .....................................................................................................................................75
5.1.1 PNEUMATIC CONTROL MODULE CONFIGURATION........................................................................... 75
5.1.2 REPAIRS ................................................................................................................................................. 76
5.1.2.1 FUSE REMOVAL AND REPLACEMENT ............................................................................................. 76
5.1.2.2 FRONT PANEL REMOVAL AND REPLACEMENT.............................................................................. 77
5.1.2.3 DISPLAY REMOVAL AND REPLACEMENT........................................................................................ 77
5.1.2.4 REAR FITTING REMOVAL AND REPLACEMENT .............................................................................. 78
5.1.2.5 POWER SUPPLY REMOVAL.............................................................................................................. 78
5.1.2.6 BAROMETER BOARD REPLACEMENT ............................................................................................. 79
5.1.2.7 COOLING FAN REMOVAL AND REPLACEMENT .............................................................................. 79
5.1.2.8 SUPPLY PRESSURE RELIEF VALVE REMOVAL AND REPLACEMENT .......................................... 80
5.1.2.9 RELOADING EMBEDDED SOFTWARE INTO FLASH MEMORY ....................................................... 80
5.1.3 OVERHAUL............................................................................................................................................. 80
5.1.4 SELF PURGING LIQUID TRAP (SPLT) .................................................................................................. 81
5.1.4.1 MAINTENANCE ................................................................................................................................... 81
5.1.4.2 REPAIR ............................................................................................................................................... 81
5.1.4.3 OVERHAUL ......................................................................................................................................... 81
5.1.5 ILLUSTRATED PARTS BREAKDOWN ................................................................................................... 82
5.1.5.1 PARTS LISTS ...................................................................................................................................... 82
5.1.5.2 FIGURES............................................................................................................................................. 87
5.2 AUTOZERO OF REFERENCE TRANSDUCERS ..................................................................................99
5.2.1 HI REF (BY COMP AT ATM) ..................................................................................................................100
5.2.2 LO REF (BY VACUUM) ..........................................................................................................................102
5.2.3 VIEWING AND EDITING AUTOZERO VALUES.....................................................................................105
5.3 ADJUSTMENT OF BAROMETER .......................................................................................................106
5.4 CALIBRATION OF REFERENCE TRANSDUCERS............................................................................107
5.4.1 PRINCIPLE.............................................................................................................................................107
5.4.2 EQUIPMENT REQUIRED.......................................................................................................................109
5.4.3 SET-UP AND PREPARATION................................................................................................................109
5.4.4 ON-BOARD REFERENCE TRANSDUCER CALIBRATION FUNCTION ................................................110
5.4.4.1 OVERVIEW ........................................................................................................................................110
5.4.4.2 SELECTION OF REFERENCE TRANSDUCER (HI, LO) TO CALIBRATE .........................................111
5.4.4.3 SELECTION OF RANGE TO CALIBRATE AND ASSIGNMENT OF PA/PM .......................................111
5.4.4.4 RUNNING THE CALIBRATION OF A RANGE....................................................................................112
5.4.4.5 SETTING PA(Z)TARE.........................................................................................................................114
5.4.4.6 PREVIEWING CALIBRATION DATA..................................................................................................114
5.4.4.7 ACTIVATING CALIBRATION RESULTS.............................................................................................115
5.4.5 THE REFERENCE PRESSURE TRANSDUCERS CAN BE CALIBRATED WITHOUT USING THE ON-
BOARD CALIBRATION FUNCTION. THIS REQUIRES: .......................................................................115
5.4.6 VIEWING REFERENCE TRANSDUCER CALIBRATION INFORMATION .............................................116
5.5 DIAGNOSTIC FUNCTION ...................................................................................................................117
5.5.1 MODE.....................................................................................................................................................117
5.5.2 CALIB.....................................................................................................................................................119
5.5.2.1 DUCER ...............................................................................................................................................119
5.5.2.2 TBASE ................................................................................................................................................119
5.5.2.3 TEMP..................................................................................................................................................119
5.5.3 DISP .......................................................................................................................................................119
5.5.4 RELAY....................................................................................................................................................120
5.5.4.1 AMBIENT............................................................................................................................................120
5.5.4.2 ANALOGOPT......................................................................................................................................120
5.5.5 VALVE....................................................................................................................................................120
5.5.6 TEST.......................................................................................................................................................120
5.5.7 LOG........................................................................................................................................................120
6. TROUBLESHOOTING...................................................... 121
7. PREPARTION FOR SHIPMENT OR LONG TERM STORAGE . 125

PPC2 AF OPERATION AND MAINTENANCE MANUAL
© 1998 DH Instruments, Inc. Page IV
8. MENU TREE .................................................................. 127
8.1 FUNCTION KEYS ................................................................................................................................127
8.2 SETUP MENU......................................................................................................................................128
8.3 VIEW/EDIT SEQUENCE MENU ..........................................................................................................129
8.4 EDIT SEQUENCE MENU.....................................................................................................................130
8.5 SPECIAL MENU ..................................................................................................................................131
8.6 AUTOZERO MENU..............................................................................................................................132
8.7 INTERNAL MENU................................................................................................................................133
8.8 CALIBRATION MENU .........................................................................................................................134
8.9 RUN CALIBRATION MENU.................................................................................................................135
8.10 RUN PA(Z) TARE MENU.....................................................................................................................136
8.11 DIAGNOSTICS MENU .........................................................................................................................137
9. APPENDIX .................................................................... 139
9.1 DRIVERS .............................................................................................................................................139
9.2 SPLT CABLE AND CONNECTIONS...................................................................................................140
9.3 UNIT CONVERSION............................................................................................................................141
9.3.1 PRESSURE ............................................................................................................................................141
9.4 WARRANTY STATEMENT (FOR DELIVERIES UNDER F33660-96-C7004).....................................142

1. INTRODUCTION
Page 1 © 1998 DH Instruments, Inc.
1
1. . I IN
NT TR RO OD DU UC CT TI IO ON N
1.1 PRODUCT OVERVIEW
PPC2 AF is a high precision pressure controller/calibrator intended to apply and measure accurate values
of gas pressure for the calibration and testing of pressure measuring instruments.
PPC2 AF measures and controls pressures in the range of 0 to 1 000 psi (0 to 7 MPa) in both gauge and
absolute mode. Six pressure measuring ranges are available using two high accuracy reference
transducers and an on-board barometer. Internal valving chooses the appropriate transducer for the
desired range and protects the lower pressure transducer when working at high pressures. Pressures are
controlled by a pneumatic module consisting of fast and slow inlet and exhaust solenoid valves and
differential pressure regulators.
PPC2 AF can be controlled locally by the operator using a front panel display, keypad and special function
keys or remotely by a computer using ASCII character command strings over an RS232 interface.
A Self Purging Liquid Trap (SPLT) can be used to protect PPC2 AF from liquid contaminants in the device
or system being tested.
1.2 SUBASSEMBLY DESCRIPTION AND LOCATION
1.2.1 FRONT PANEL ASSEMBLY
1. Display
2. Multi-Function Keypad
3. Direct Pressure Control Keys
4. Remote Indicator
Front Panel
The front panel assembly provides a 2 X 20 vacuum fluorescent display of PPC2 AF
operating status and a membrane keypad for local user control.

PPC2 AF OPERATION AND MAINTENANCE MANUAL
© 1998 DH Instruments, Inc. Page 2
1.2.2 REAR PANEL ASSEMBLY
1. Label, Product
2. Label, Warranty
3. Pressure Connection, EXHAUST
4. Pressure Connection, SUPPLY
5. COM1 Port
6. Fuse
7. Power Switch
8. Fitting, AUTOZERO
9. Fitting, TEST
10. Fitting, VENT
Rear Panel
The rear panel assembly provides pressure connections, the host communications interface
and the power on/off module, and product and warranty labeling. Pressure fittings are
internally secured to prevent loosening when making and breaking connections.

1. INTRODUCTION
Page 3 © 1998 DH Instruments, Inc.
1.2.3 POWER SUPPLIES
Internal Layout
PPC2 AF has two independent power supplies.
1. + 12 V DC (± 2 %) @ 3.3 Amps: for internal and external valve execution.
2. + 5 V DC (± 2 %) @ 3.0 Amps; + 15 V DC (± 10 % / - 3 %) @ 2.0 Amps; - 15 V DC
(± 5 %) @ 0.35 Amps: for the supply of the micro board and driver board electronics.
1.2.4 MICRO CARD
Internal Layout
The micro card supports a Motorola 68302 microcontroller; EPROM, EEPROM, NVRAM and
flash memories; RS-232 communications; the front panel keypad and display control; and a
two channel frequency counter for reading reference pressure transducers. An I/O port
controls other boards and devices in PPC2 AF.

PPC2 AF OPERATION AND MAINTENANCE MANUAL
© 1998 DH Instruments, Inc. Page 4
1.2.5 DRIVER BOARD
Internal Layout
The driver board is controlled by the micro card (see Section 1.2.4). It supports the
12 V drivers for the internal and external solenoid valve actuation and the barometer board
(see Section 1.2.6). It also supplies power to the cooling fan.
1.2.6 BAROMETER BOARD
Internal Layout
The barometer board supports a board mounted, barometric range, micromachined silicon
sensor and an ambient temperature sensor. The barometer readings are used for dynamic
atmospheric pressure compensation when measuring gauge pressure with an absolute
reference transducer.

1. INTRODUCTION
Page 5 © 1998 DH Instruments, Inc.
1.2.7 PNEUMATIC MODULE
Internal Layout
The pneumatic module is an integrated assembly that includes two inlet (fast and slow) and
two exhaust control valves and differential pressure regulators. The differential pressure
regulators use pressure feedback to maintain a constant differential pressure across the
control valves. The control valves are solenoid type actuated by 12 V.
Pneumatic Module

PPC2 AF OPERATION AND MAINTENANCE MANUAL
© 1998 DH Instruments, Inc. Page 6
1.2.8 TRANSDUCER SELECTION MODULE
Internal Layout
The transducer selection module includes solenoid valves to connect and disconnect the low
pressure (secondary) reference transducer from the test system and to independently vent
the low pressure reference transducer.
1.2.9 REFERENCE PRESSURE TRANSDUCERS
Internal Layout
There are two reference pressure transducers. Their basic sensing principle is the
measurement of the change in the natural oscillating frequency of a quartz tuning fork with
temperature and with mechanical stress resulting from the change in pressure applied to a
connecting bellows or bourdon tube. Two independent quartz elements are used: one subjected
to pressure related stress; the other is used only to monitor temperature.

1. INTRODUCTION
Page 7 © 1998 DH Instruments, Inc.
1.2.9.1 HIGH (PRIMARY) PRESSURE REFERENCE
TRANSDUCER
The high pressure reference transducer has a full scale range of 1 000 psi
(7 MPa) in gauge and absolute mode.
1.2.9.2 LOW (SECONDARY) PRESSURE REFERENCE
TRANSDUCER
The low pressure reference transducer has a full scale range of 35 psi (220 kPa)
in gauge mode and 50 psi (330 kPa) in absolute mode.
1.2.10 SOURCE PRESSURE RELIEF VALVE
Internal Layout
The source pressure relief valve is a factory set, adjustable, spring loaded pressure relief
valve with a brass body, Viton O-ring seal and stainless steel internal parts. The valve is set
to relieve at 1 200 psi (8.3 MPa).

PPC2 AF OPERATION AND MAINTENANCE MANUAL
© 1998 DH Instruments, Inc. Page 8
1.2.11 SELF PURGING LIQUID TRAP (SPLT)
1. Purge Tube
2. Exhaust
Valve
3. Pressure
Connections
4. Electrical
Connection
SPLT (Overall View)
The SPLT is a free standing accessory designed to protect the PPC2 AF from liquid
contamination returning form the system or device under test. It is made up of a stainless
steel body with an internal X-Type coalescing filter and a bottom drain port fitting with an
electrically actuated purge valve. The filter valve assembly is installed in a mounting stand.

1. INTRODUCTION
Page 9 © 1998 DH Instruments, Inc.
1.3 SPECIFICATIONS
1.3.1 GENERAL SPECIFICATIONS
Power Requirements 85 to 264 VAC, 47 to 440 Hz, 30 VA max consumption.
Operating Temperature Range 15 to 35 °C
Storage Temperature Range - 20 to 70 °C
Vibration Meets MIL-T-28800D
Weight 12.8 kg (28.2 lb)
Dimensions 7.1" H X 12.6" W X 15.8" D (18 cm X 32 cm X 40 cm)
Microprocessor Motorola 68302, 16 MHz
Communication Port RS232 (COM1)
Pressure Ranges -15 to 1 000 psi (7 MPa) gauge/0 to 1 000 psi absolute in six ranges using two
reference pressure transducers and a barometer
Operating Medium Clean, dry, non-corrosive gas
Pressure Connections Supply: 1/8 in. NPT F
Test: 1/4 in. NPT F
Vent: 1/4 in. NPT F
Exhaust: 1/4 in. NPT F
AutoZero: 1/4 in. NPT F
1.3.2 PRESSURE MEASUREMENT SPECIFICATIONS
PPC2 AF measures pressures in gauge and absolute mode in six ranges using two reference
pressure transducers and a barometer.
The reference pressure transducers are of the absolute pressure type using an evacuated,
permanently sealed reference. They are used to measure gauge pressures by atmospheric
offset determined by direct measurement when the reference transducer is vented. The
atmospheric offset is dynamically compensated while operating in gauge mode using
measurements of the changes in atmosphere provided by a separate barometer.
1.3.2.1 HIGH PRESSURE REFERENCE TRANSDUCER (HI REF)
Ranges High (3): 0 to 1 000 psi (7 MPa) gauge/absolute
Mid (2): 0 to 600 psi (4 MPa) gauge/absolute
Low (1): 0 to 300 psi (2 MPa) gauge/absolute
Measurement Precision
(Combined Linearity, Hysteresis
and Repeatability)
± 0.01% F.S. of each range
Stability (6 Month with Use of
AutoZero Function)
± 0.005% F.S. of maximum range
Resolution 1 ppm of maximum range
1.3.2.2 LOW PRESSURE REFERENCE TRANSDUCER (LO REF)
Ranges High (3): - 15 to 35 psi (250 kPa) gauge
0 to 50 psi (350 kPa) absolute
Mid (2): - 15 to 15 psi (100 kPa) gauge
0 to 30 psi (200 kPa) absolute
Low (1): - 15 to 0 psi gauge
0 to 15 psi (100 kPa) absolute
Measurement Precision
(Combined Linearity, Hysteresis
and Repeatability)
± 0.01 % F.S. of each range
Stability (6 Month with Use of
AutoZero Function)
± 0.005 % F.S. of maximum range
Resolution 1 ppm of maximum range

PPC2 AF OPERATION AND MAINTENANCE MANUAL
© 1998 DH Instruments, Inc. Page 10
1.3.2.3 BAROMETER
The barometric sensor is not used to provide absolute accuracy, it is used only to
measure the changes in atmospheric pressure to provide dynamic compensation
of the reference pressure transducer atmospheric pressure offset measurements
when using a reference pressure transducer to make gauge pressure
measurements.
Range 11 to 16 psia (70 to 110 kPa)
Accuracy (Nominal) ± 0.5 % of reading
Resolution 0.001 psi (7 Pa)
1.3.3 PRESSURE CONTROL SPECIFICATIONS
Control Modes Available Static and dynamic
Control Volume 0 to 30 in3(500 cc), ideal 7 to 15 in3(125 to 250 cc)
Control Limits System defaults provided for each pressure measurement
range but can be customized by the user using the CUSTOM
CONTROL function.
1.3.3.1 STATIC PRESSURE CONTROL
Default Hold Limit ± 1 % of F.S. of the active pressure measurement range
Default Stability Limit ± 0.005 % of F.S./sec of the active pressure
measurement range
1.3.3.2 DYNAMIC PRESSURE CONTROL
Default Hold Limit ± 0.05 psi (138 Pa) for Hi Ref ranges (1 to 3)
± 0.0025 psi (7 Pa) for Lo Ref ranges (1 to 3)
Default Stability Limit ± 0.05 psi (350 Pa)/sec for Hi Ref ranges (1 to 3)
± 0.0025 psi (18 Pa)/sec for Lo Ref ranges (1 to 3)

2. INSTALLATION AND SHORT TERM STORAGE
Page 11 © 1998 DH Instruments, Inc.
2
2. . I IN
NS ST TA AL LL LA AT TI IO ON N A AN ND D S
SH
HO OR RT T
T
TE
ER RM M S
ST
TO OR RA AG GE E
2.1 UNPACKING AND INSPECTION
2.1.1 REMOVING FROM PACKAGING
PPC2 AF is delivered in a molded medium density polyethylene shipping case with a custom
foam insert for holding the PPC2 AF, SPLT if included, documentation and accessories.
Remove all PPC2 AF elements from the shipping case and remove each element from its
protective plastic bag.
2.1.2 INSPECTING CONTENTS
Check that all items are present and have no visible damage.
PPC2 AF includes:
DESCRIPTION PART NO.
PPC2 AF Pressure Controller/Calibrator 401270
Calibration Certificate 550200
Test Report 550102
ACCESSORIES: 401273
User’s Manual 550090
Power Cord (7.5 ft.) 100770
(4) Rubber Feet Caps 400202
1/4 in. NPT Male X KF 16 SS Vacuum Adaptor 102519
Male Electrical Connector for Drivers 102478
SPLT on Stand (with filter) * 401271
(1) Spare SPLT Filter Element * 102502
Shipping Case with Inserts 401272
* If supplied.
2.2 SITE REQUIREMENTS
The PPC2 AF can be installed on any flat, stable surface at a convenient height. The front feet can be
extended so that the unit can be inclined slightly for easier viewing. The PPC2 AF can also be mounted in
a standard 19" rack mount using the optional rack mount kit.
Minimizing the length of tubing between the PPC2 AF to the device or system to be tested will
enhance control performance and reduce pressure setting times.
Ready access to the PPC2 AF rear panel should be considered to facilitate making and breaking
pressure connections.
The SPLT, if used, needs to be mounted vertically at the low point of the pneumatic system.

PPC2 AF OPERATION AND MAINTENANCE MANUAL
© 1998 DH Instruments, Inc. Page 12
Support facilities required include:
• An electrical power source of 85 to 264 VAC, 47 to 440 Hz.
• A continuous regulated source pressure of 1 100 psi (8 MPa) clean, dry, non-corrosive gas
to connect to the pressure supply. Lower gas pressure sources can be used but should
exceed the maximum desired test output pressure by 10 to 20%.
• A vacuum source of less than 1 psia (7 kPa) and at least 3 cfm (90 lm) is needed to control
under 2 psi (14 kPa) gauge.
When supply pressure is applied to the PPC2 AF supply port, there is a constant gas exhaust through
the EXHAUST port of PPC2 AF to which the vacuum source will be connected. Therefore, the vacuum
source should either be continuously "on" or should bypass to atmosphere when the vacuum source is
"off" to avoid building up pressure on the EXHAUST port and/or the vacuum pump. To conserve gas,
vent the test volume and shut off the pressure supply when PPC2 AF is not in use.
2.3 INITIAL SETUP
2.3.1 PREPARING FOR OPERATION
To prepare PPC2 AF for check out and operation:
• Remove the plastic caps from the five (5) PPC2 AF rear panel pressure connections.
• Remove the protective plastic sheet from the front panel display.
• Install the rubber feet caps onto the bottom case feet, if desired.
2.3.2 POWER CONNECTION
• Check that the PPC2 AF power switch is off.
• Connect the supplied power cable to the rear panel power module.
• Connect the other end of the power cable to an electrical supply of 85 to 264 VAC, 47 to 440 Hz.
2.3.3 CONNECTING TO A PRESSURE SUPPLY (SUPPLY PORT)
Using a pressure connecting hose of appropriate pressure rating, connect the pressure supply
to the SUPPLY connection on the rear panel of PPC2 AF. The PPC2 AF SUPPLY connection
is 1/8 in. NPT female.
Never connect a pressure supply greater than 1 200 psi (8 MPa) to PPC2 AF.
2.3.4 CONNECTING A VACUUM PUMP (EXHAUST PORT)
For PPC2 AF to set pressures under atmosphere and/or to reliably set pressure under 2 psi (914 kPa)
gauge other than zero gauge, a vacuum pump must be connected to the exhaust port.
Never connect a pressure supply to or plug the PPC2 AF EXHAUST port.
When changing the pressure applied to the EXHAUST port from vacuum to atmosphere, be
sure to change the control reference setting (see Section 3.3.1).

2. INSTALLATION AND SHORT TERM STORAGE
Page 13 © 1998 DH Instruments, Inc.
2.3.5 CONNECTING TO THE DEVICE UNDER TEST (TEST PORT)
See Section 2.3.5.1 before proceeding to connect the device under test.
Using a pressure connecting hose of appropriate pressure rating, connect the device or system to
be tested to the TEST port of the PPC2 AF. The PPC2 AF TEST connection is ¼ in. NPT female.
Minimizing the length of the test connection hose will enhance control performance and
reduce pressure setting time. For normal operation, the total volume of the device of
system under test including connecting tubing should be less than 30 in3(500 cc).
PPC2 AF pressure control will not operate properly if there are excessive leaks in the test
system (see Section 3.2.8).
PPC2 AF pressure may be adversely affected if the test connection hose is too restrictive.
For optimum results, the inner diameter of the connecting hose should be > 0.07” (1.75 mm).
NEVER apply pressure to the TEST port without having a pressure supply equal to or great than
the applied pressure connected to the SUPPLY port. When controlling pressure externally, or
measuring external pressure through the SUPPLY port, NEVER cause the pressure to change at
a very rapid rate. For example, do not vent suddenly by opening an external valve. Internal
PPC2 AF damage may result.
2.3.5.1 INSTALLING THE SPLT
The SPLT (if provided) is intended to collect and exhaust liquid contaminants that may be
present in the device or system under test so that they do not return to the PPC2 AF.
The SPLT is installed in the test connection line at a low point between PPC2 AF and
the device or system under test. The SPLT pressure connections are 1/4 in. NPT female.
Teflon tape or another sealing material should be used to assure leak free
connection of adapters installed in the SPLT pressure connections.
Proper SPLT operation is dependent on the gas flowing through it in the correct
direction. Be sure to connect the SPLT to the device or system under test and
the PPC2 AF following the connector port labels on the SPLT.
Connect the SPLT electrically to the PPC2 AF rear panel DRIVER connection and to the
SPLT terminal blocs. See Appendix 9.2 for information on preparing the SPLT
electrical cable and connection to the SPLT terminal blocs.
The SPLT must be mounted vertically with the purge valve at the bottom to
perform properly. It must be at a lower point in the system than the PPC2 AF
and/or the device under test. In operation, liquid contaminants collected from the
device or system under test will be exhausted through the SPLT purge valve.
Liquid contaminants will be forcibly ejected from the SPLT purge tube. Provision
for collecting the purged liquids should be considered when installing the SPLT.
Excessively dirty or wet filter elements can adversely affect pressure control.

PPC2 AF OPERATION AND MAINTENANCE MANUAL
© 1998 DH Instruments, Inc. Page 14
PPC2 AF with SPLT and DUT
2.3.6 THE VENT CONNECTION (VENT PORT)
The PPC2 AF VENT connection is the system vent to atmosphere point used to set zero
gauge pressure and obtain reference pressure transducer measurements of atmospheric
pressure. Though a pressure hose can be connected to the VENT connection to direct the
vented gas flow, a completely unobstructed connection to atmosphere must be obtained for
PPC2 AF reference pressure measurements to operate normally.
The PPC2 AF VENT connection is 1/4 in. NPT female.
Never plug, obstruct or connect a supply pressure to the PPC2 AF vent connection.
2.3.7 THE AUTOZERO CONNECTION (AUTOZERO PORT)
The PPC2 AF AUTOZERO connection is used for the AutoZero by Vacuum function and is
not needed at start up. It should be left open to atmosphere.
2.4 POWER UP AND VERIFICATION
2.4.1 SWITCH POWER ON
Actuate the power switch on the PPC2 AF rear panel. Observe the front panel display as
PPC2 AF initializes, error checks and goes to the main run screen (see Section 3.1.1).
PPC2 AF operating condition at power up is VENT valve closed, Hi reference pressure
transducer active.
If the PPC2 AF fails to reach the main run screen, service is required. Record the sequences
of operation and displays observed.
If the active range on power down was a Hi reference transducer range, the same range will
be active on the next power up. If the active power down range was a Lo reference
transducer range, range H3 will be active on power up. This is to protect the Lo reference
transducer from accidental overpressure (see Section 3.1.2.5).