DH Instruments PPCH-G User manual

© 2007 DH Instruments, a Fluke Company
PPCH-G™
High Gas Pressure
Controller/Calibrator
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.
This instrument is not to be operated in any other manner than that specified by the manufacturer.
© 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 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.
Products described in this manual are manufactured under international patents and one or more of the following U.S. patents:
5,142,483; 5,257,640; 5,331,838; 5,445,035. Other U.S. and international patents pending.
AutoRange, AutoZ, DH Instruments,DH,DHI, COMPASS, PPC, PPCH-G-G, QDUT, Q-RPT, RPM, RPM4 and SDS are
trademarks, registered and otherwise, of DH Instruments, a Fluke Company.
Teflon is a registered trademark of 3M Corporation.
Document No. 550150-02
060522
Printed in the USA.

TABLE OF CONTENTS
Page I © 2007 DH Instruments, a Fluke Company
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TABLE OF CONTENTS ...............................................................I
TABLES ..................................................................................V
FIGURES................................................................................VI
ABOUT THIS MANUAL ............................................................VII
1. INTRODUCTION ................................................................. 1
1.1 PRODUCT OVERVIEW ...........................................................................................................................1
1.2 SPECIFICATIONS ...................................................................................................................................1
1.2.1 GENERAL SPECIFICATIONS .......................................................................................................................1
1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS........................................................................................2
1.2.2.1 QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT)................................................................2
1.2.2.2 UTILITY SENSOR......................................................................................................................................4
1.2.2.3 ON-BOARD BAROMETER ........................................................................................................................4
1.2.3 PRESSURE CONTROL SPECIFICATIONS ..................................................................................................4
2. INSTALLATION .................................................................. 5
2.1 UNPACKING AND INSPECTION ............................................................................................................5
2.1.1 REMOVING FROM PACKAGING..................................................................................................................5
2.1.2 INSPECTING CONTENTS.............................................................................................................................5
2.2 SITE REQUIREMENTS............................................................................................................................6
2.2.1 INSTALLATION IN A 19 IN. RACK MOUNT .................................................................................................6
2.3 INITIAL SETUP........................................................................................................................................7
2.3.1 PREPARING FOR OPERATION ...................................................................................................................7
2.3.2 FRONT AND REAR PANELS........................................................................................................................7
2.3.2.1 FRONT PANEL ..........................................................................................................................................7
2.3.2.2 REAR PANEL.............................................................................................................................................8
2.3.3 POWER CONNECTION.................................................................................................................................8
2.3.4 REMOTE [ENTER/SET P] CONNECTION (FOOTSWITCH OR OTHER SWITCH) .....................................8
2.3.5 CONNECTING DRIVE AIR (DRIVE PORT)...................................................................................................9
2.3.6 CONNECTING HIGH PRESSURE GAS SUPPLY (SUPPLY PORT)............................................................9
2.3.7 CONNECTING TO OTHER DEVICES .........................................................................................................10
2.3.7.1 CONNECTING TO AN RPM4 TO BE USED AS AN EXTERNAL REFERENCE DEVICE......................10
2.3.7.2 CONNECTING TO A PG7202 PISTON GAUGE .....................................................................................12
2.3.7.3 CONNECTING TO A DEVICE UNDER TEST (TEST PORT)..................................................................12
2.3.8 CHECK/SET SECURITY LEVEL .................................................................................................................13
2.3.9 TURN OFF ABSOLUTE MEASUREMENT MODE......................................................................................13
2.4 POWER-UP AND VERIFICATION.........................................................................................................13
2.4.1 SWITCH POWER ON ..................................................................................................................................13
2.4.2 APPLY DRIVE AIR (DRIVE PORT) .............................................................................................................14
2.4.3 APPLY HIGH PRESSURE GAS SUPPLY (SUPPLY PORT)......................................................................14
2.4.4 CHECK PRESSURE MEASUREMENT OPERATION.................................................................................14
2.4.4.1 CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT.............................................................14
2.4.4.2 CHECKING GAUGE MODE PRESSURE MEASUREMENT...................................................................14
2.4.5 LEAK CHECK ..............................................................................................................................................15
2.4.6 CHECK PRESSURE CONTROL OPERATION ...........................................................................................15
2.5 STORAGE AND SHIPPING ...................................................................................................................16
2.5.1 SHORT TERM STORAGE ...........................................................................................................................16
2.5.2 LONG TERM STORAGE .............................................................................................................................16
2.5.3 PREPARATION FOR SHIPPING.................................................................................................................16

PPCH-G™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page II
3. OPERATION..................................................................... 17
3.1 USER INTERFACE ................................................................................................................................17
3.1.1 MAIN RUN SCREEN....................................................................................................................................17
3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL.........................................................................19
3.1.3 DIRECT PRESSURE CONTROL KEYS......................................................................................................20
3.1.4 REMOTE [ENT/SET P] (FOOT)SWITCH.....................................................................................................21
3.1.5 SOUNDS ......................................................................................................................................................21
3.2 GENERAL OPERATING PRINCIPLES .................................................................................................21
3.2.1 PRESSURE CONTROL PRINCIPLES ........................................................................................................21
3.2.2 AUTOMATED PRESSURE CONTROL .......................................................................................................23
3.2.2.1 IDLE, NO AUTOMATED CONTROL (MEASURE MODE).......................................................................23
3.2.2.2 DYNAMIC CONTROL ..............................................................................................................................24
3.2.2.3 STATIC CONTROL..................................................................................................................................25
3.2.2.4 MONOTONIC CONTROL.........................................................................................................................26
3.2.2.5 RAMP CONTROL.....................................................................................................................................27
3.2.2.6 PG CONTROL..........................................................................................................................................28
3.2.3 PRESSURE READY/NOT READY ..............................................................................................................29
3.2.4 GAUGE MEASUREMENT MODE, DYNAMIC COMPENSATION FOR ATMOSPHERIC PRESSURE......29
3.2.5 MULTIPLE INTERNAL AND EXTERNAL Q-RPTS .....................................................................................30
3.2.6 MULTIPE RANGES (Q-RPTS, AUTORANGE AND INFINITE RANGING) .................................................31
3.2.7 OPERATION WITH A PG7000 PISTON GAUGE........................................................................................32
3.2.8 DIRECT FUNCTION KEYS SUMMARY ......................................................................................................32
3.3 DIRECT FUNCTION KEYS....................................................................................................................33
3.3.1 [RANGE] ......................................................................................................................................................33
3.3.2 [UNIT]...........................................................................................................................................................35
3.3.3 [MODE] ........................................................................................................................................................36
3.3.4 [AUTORANGE] ............................................................................................................................................37
3.3.5 [RPT] ............................................................................................................................................................39
3.3.6 [AUTOTEST]................................................................................................................................................40
3.3.6.1 QUICK AUTOTEST..................................................................................................................................41
3.3.6.2 QDUT AUTOTEST...................................................................................................................................44
3.3.7 [HEAD] .........................................................................................................................................................47
3.3.8 [PRIME] (CYCLE) ........................................................................................................................................48
3.3.9 [LEAK CK] ...................................................................................................................................................49
3.3.10 [ENT/SET P] (SET PRESSURE AUTOMATICALLY)..................................................................................51
3.3.10.1 DYNAMIC CONTROL MODE, [ENT/SET P]............................................................................................51
3.3.10.2 STATIC CONTROL MODE, [ENT/SET P]................................................................................................53
3.3.10.3 MONOTONIC CONTROL MODE, [ENT/SET P]......................................................................................54
3.3.10.4 RAMP CONTROL MODE, [ENT/SET P]..................................................................................................55
3.3.10.5 PG CONTROL MODE, [ENT/SET P] .......................................................................................................56
3.3.10.6 INTERRUPTING AUTOMATED PRESSURE CONTROL........................................................................56
3.3.10.7 AUTOMATED PRESSURE COMMANDS FOR ZERO PRESSURE....................................................57
3.4 [SETUP] .................................................................................................................................................57
3.4.1 <1RANGE> ..................................................................................................................................................57
3.4.1.1 SAVING AN AUTORANGE RANGE ........................................................................................................58
3.4.1.2 DELETING AUTORANGE RANGES........................................................................................................58
3.4.2 <2RES> (RESOLUTION) .............................................................................................................................58
3.4.3 <3JOG>........................................................................................................................................................59
3.4.4 <4UL> (UPPER LIMIT) ................................................................................................................................60
3.4.4.1 OVER PRESSURE FUNCTION...............................................................................................................61
3.4.5 <5ATEST>....................................................................................................................................................61
3.4.6 <6CONTROL>..............................................................................................................................................62
3.4.6.1 <1LIMITS> (CUSTOM CONTROL PARAMETERS) ................................................................................64
3.4.6.2 <2MODE> ................................................................................................................................................66
3.4.6.3 TURNING-OFF CUSTOM CONTROL PARAMETERS............................................................................66
3.4.7 <7DRV> (DRIVERS) ....................................................................................................................................67
3.5 [SPECIAL] .............................................................................................................................................67
3.5.1 <1AUTOZ> ...................................................................................................................................................68
3.5.1.1 EDIT AUTOZ............................................................................................................................................71
3.5.1.2 RUN AUTOZ.............................................................................................................................................71
3.5.2 <2REMOTE> ................................................................................................................................................73
3.5.2.1 <1COM1, 2COM2>...................................................................................................................................73
3.5.2.2 <3IEEE-488>............................................................................................................................................74
3.5.2.3 <4FORMAT>............................................................................................................................................74
3.5.2.4 <5RS232 SELF-TEST>............................................................................................................................74
3.5.3 <3HEAD> .....................................................................................................................................................75
3.5.4 <4RESET> ...................................................................................................................................................75
3.5.4.1 <1SETS>..................................................................................................................................................76
3.5.4.2 <2UNITS> ................................................................................................................................................76

TABLE OF CONTENTS
Page III © 2007 DH Instruments, a Fluke Company
3.5.4.3 <3ATEST>................................................................................................................................................77
3.5.4.4 <4CAL> ....................................................................................................................................................77
3.5.4.5 <5ALL>.....................................................................................................................................................77
3.5.5 <5PREF>......................................................................................................................................................78
3.5.5.1 <1SCRSVR> ............................................................................................................................................78
3.5.5.2 <2SOUND> ..............................................................................................................................................79
3.5.5.3 <3TIME>...................................................................................................................................................79
3.5.5.4 <4ID>........................................................................................................................................................79
3.5.5.5 <5LEVEL> (SECURITY)...........................................................................................................................80
3.5.6 <6PUNIT>.....................................................................................................................................................82
3.5.7 <7INTERNAL> .............................................................................................................................................84
3.5.7.1 <1CONFIG> .............................................................................................................................................84
3.5.7.2 <2BARO>.................................................................................................................................................84
3.5.7.3 <3SUPPLY>.............................................................................................................................................85
3.5.8 <8CAL> ........................................................................................................................................................85
3.5.9 <9LOG>........................................................................................................................................................85
4. REMOTE OPERATION ....................................................... 87
4.1 OVERVIEW ............................................................................................................................................87
4.2 INTERFACING.......................................................................................................................................87
4.2.1 RS232 INTERFACE .....................................................................................................................................87
4.2.1.1 COM1.......................................................................................................................................................87
4.2.1.2 IEEE-488..................................................................................................................................................88
4.2.1.3 COM2.......................................................................................................................................................88
4.3 PROGRAMMING FORMATS.................................................................................................................88
4.3.1 CLASSIC PROGRAM MESSAGE FORMAT ...............................................................................................89
4.3.2 ENHANCED PROGRAM MESSAGE FORMAT ..........................................................................................89
4.3.2.1 USING COMMAND TYPE COMMANDS .................................................................................................89
4.3.2.2 USING QUERY TYPE COMMANDS...................................................................................................90
4.4 COMMANDS..........................................................................................................................................91
4.4.1 PROGRAMMING MESSAGES ....................................................................................................................91
4.4.2 ERROR MESSAGES ...................................................................................................................................92
4.4.3 PROGRAM MESSAGE DESCRIPTION OVERVIEW ..................................................................................93
4.4.4 PROGRAM MESSAGE DESCRIPTIONS ....................................................................................................94
4.5 STATUS REPORTING SYSTEM .........................................................................................................117
4.5.1 ERROR QUEUE.........................................................................................................................................117
4.5.2 STATUS BYTE REGISTER .......................................................................................................................117
4.5.3 STANDARD EVENT REGISTER ...............................................................................................................119
4.5.4 READY STATUS REGISTER ....................................................................................................................119
4.6 IEEE STD. 488.2 COMMON AND STATUS PROGRAM MESSAGES................................................120
4.6.1 PROGRAM MESSAGE DESCRIPTIONS ..................................................................................................121
5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION....................123
5.1 OVERVIEW ..........................................................................................................................................123
5.2 CALIBRATION OF QUARTZ REFERENCE PRESSURE TRANSDUCERS (Q-RPTS) ......................123
5.2.1 PRINCIPLE ................................................................................................................................................123
5.2.1.1 PA AND PM COEFFICIENTS ................................................................................................................124
5.2.1.2 AS RECEIVED AND AS LEFT DATA ....................................................................................................125
5.2.2 EQUIPMENT REQUIRED ..........................................................................................................................125
5.2.3 SET-UP AND PREPARATION...................................................................................................................126
5.2.4 RECOMMENDED CALIBRATION POINT SEQUENCE............................................................................126
5.2.5 TURNING OFF ABSOLUTE ME AS UREME NT MOD E FOR A Q-RPT ...........................................127
5.2.6 Q-RPT CALIBRATION USING CALTOOL FOR RPTS SOFTWARE........................................................128
5.2.7 EDITING AND VIEWING Q-RPT CALIBRATION INFORMATION............................................................128
5.2.8 Q-RPT CALIBRATION/ADJUSTMENT WITHOUT CALTOOL FOR RPTS SOFTWARE.........................130
5.3 ADJUSTMENT OF ON-BOARD BAROMETER...................................................................................131
5.4 ADJUSTMENT OF UTILITY SENSOR ................................................................................................131
5.5 THERMAL PRESSURE CONTROL UNIT (TPCU) CONFIGURATION ...............................................132
5.6 VALVE OPENING POINT CONFIGURATION.....................................................................................133
5.7 OVERHAUL .........................................................................................................................................134
5.8 RELOADING EMBEDDED SOFTWARE INTO FLASH MEMORY......................................................135
5.9 SUBASSEMBLY DESCRIPTION AND LOCATION ............................................................................136
5.9.1 ELECTRONIC MODULE............................................................................................................................136

PPCH-G™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page IV
5.9.1.1 POWER ENTRY AND FUSE..................................................................................................................136
5.9.1.2 POWER SUPPLIES ...............................................................................................................................137
5.9.1.3 DRIVER BOARD....................................................................................................................................137
5.9.1.4 MINI MICRO BOARD.............................................................................................................................137
5.9.1.5 ON-BOARD BAROMETER ....................................................................................................................137
5.9.2 MECHANICAL MODULE ...........................................................................................................................138
5.9.2.1 SUPPLY PRESSURE TRANSDUCER...................................................................................................138
5.9.2.2 HI Q-RPT OR UTILITY SENSOR...........................................................................................................139
5.9.2.3 TEST VENT VALVE...............................................................................................................................139
5.9.2.4 SUPPLY ISOLATION VAVLE.................................................................................................................139
5.9.2.5 LO Q-RPT, ISOLATION VALVE, VENT VALVE (OPTIONAL)...............................................................139
5.9.2.6 SUPPLY ACCUMULATOR.....................................................................................................................139
5.9.2.7 FRONT PANEL ......................................................................................................................................139
5.9.2.8 ELECTRICAL CABLE TRACK ...............................................................................................................139
5.9.2.9 INLET CONTROL VALVE......................................................................................................................140
5.9.2.10 OUTLET CONTROL VALVE..................................................................................................................140
5.9.2.11 THERMAL PRESSURE CONTROL UNIT (TPCU) ................................................................................140
6. TROUBLESHOOTING .......................................................141
7. APPENDIX ......................................................................145
7.1 DRIVERS .............................................................................................................................................145
7.2 UNIT CONVERSION............................................................................................................................146
7.2.1 PRESSURE................................................................................................................................................146
7.3 REMOTE [ENT] ...................................................................................................................................146
8. WARRANTY ....................................................................147
8.1 OVERVIEW ..........................................................................................................................................147
9. GLOSSARY.....................................................................149

TABLES & FIGURES
Page V © 2007 DH Instruments, a Fluke Company
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Table 1. Quartz Reference Pressure Transducer (Q-RPT) designations and range..................................2
Table 2. PPCH-G packing list......................................................................................................................5
Table 3. MAIN RUN screen display fields..................................................................................................18
Table 4. Position designators of Q-RPTs in a PPCH-G system................................................................31
Table 5. Settings and to what they are specific (range, measurement mode, Q-RPT, system) ...............32
Table 6. Summary of PPCH-G function key operation..............................................................................33
Table 7. Settings made by AutoRange......................................................................................................37
Table 8. Default pressure control parameters ...........................................................................................63
Table 9. AutoZ ON and OFF......................................................................................................................69
Table 10. Reset – Sets...............................................................................................................................76
Table 11. Reset – Cal ................................................................................................................................77
Table 12. Reset – All..................................................................................................................................78
Table 13. Security levels............................................................................................................................81
Table 14. UNIT function - available units of measure................................................................................83
Table 15. COM1 pin designations and connections..................................................................................87
Table 16. COM2 DB-9F pin designations..................................................................................................88
Table 17. Program Message List...............................................................................................................91
Table 18. Error #s and descriptions...........................................................................................................92
Table 19. 8 Bit status byte register ..........................................................................................................117
Table 20. 8 bit standard event register ....................................................................................................119
Table 21. 8 bit ready status register.........................................................................................................119
Table 22. Program message list..............................................................................................................120
Table 23. Calibration point sequence, PPCH-G Q-RPTs........................................................................127
Table 24. Troubleshooting Guide.............................................................................................................141
Table 25. External drivers current output.................................................................................................145
Table 26. External drivers pin outs ..........................................................................................................145
Table 27. Pressure unit of measure conversion coefficients...................................................................146
Table 28. DHI Authorized Service Providers...........................................................................................147

PPCH-G™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page VI
F
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IG GU UR RE ES S
Figure 1. Front panel....................................................................................................................................7
Figure 2. Rear panel ....................................................................................................................................8
Figure 3. Connecting PPCH-G to an RPM4 or PG7202 using the standard
PPCH-G interconnection accessories.....................................................................................11
Figure 4. Keypad layout..............................................................................................................................19
Figure 5. Direct pressure control keys.......................................................................................................20
Figure 6. Pressure control system schematic............................................................................................22
Figure 7. Dynamic pressure control operation...........................................................................................24
Figure 8. Ready/Not Ready in dynamic pressure control mode................................................................25
Figure 9. Static pressure control operation................................................................................................25
Figure 10. Ready/Not Ready in static control mode..................................................................................26
Figure 11. Monotonic pressure control operation......................................................................................27
Figure 12. Ready/Not Ready in monotonic pressure control mode...........................................................27
Figure 13. Ramp pressure control operation.............................................................................................28
Figure 14. Ready/Not Ready in ramp pressure control mode...................................................................28
Figure 15. Status register schematic .......................................................................................................118
Figure 16. Electronic module, internal view.............................................................................................136
Figure 17. Mechanical module, internal view...........................................................................................138
Figure 18. Drivers connector schematic..................................................................................................145
Figure 19. Remote [ENT/SET P] connector schematic ...........................................................................146

ABOUT THIS MANUAL
Page VII © 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 is intended to provide the user with the basic information necessary to operate a PPCH-G
pressure controller/calibrator. It also includes a great deal of additional information provided to allow you
to optimize PPCH-G use and take full advantage of its many features and functions.
Before using the manual, take a moment to familiarize yourself with the Table of Contents structure:
Sections 1, 2 and 3 should be read by all first time PPCH-G users. Section 3 is most important for those
using the local front panel interface but should be read over by all users to familiarize themselves with
general PPCH-G operating principles. Section 1 is for remote operation from an external computer. Section
5 provides maintenance and calibration information. Section 6 is a quick troubleshooting guide. Use it to
troubleshoot unexpected PPCH-G behavior based on the symptom of that behavior. Certain words and
expressions have specific meaning as they pertain to PPCH-G. The Glossary, Section 9, is useful as a
quick reference for exact definition of specific words and expressions as they are used in the manual.
For those of you who “don’t read manuals”, go directly to Section 2.3 to set up your PPCH-G and then
go to Section 2.4 for power-up and verification. This will get you up and running quickly with a minimal risk of
causing damage to yourself or your new PPCH-G. THEN… when you have questions or start to wonder about
all the great features you might be missing, get into the manual!
(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 (e.g., [RANGE]).
< > indicates PPCH-G screen displays (e.g., <1yes>).

PPCH-G™ OPERATION AND MAINTENANCE MANUAL
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N
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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 PRODUCT OVERVIEW
PPCH-G is a pressure controller intended to precisely set and control high pneumatic pressure into a
closed volume as is commonly needed for the calibration and testing of pressure measuring instruments.
It has been designed to provide very high performance combined with maximum versatility and ease of
use. Four different control modes are available for different applications.
PPCH-G can be equipped with a low cost utility sensor for pressure monitoring or one or two Quartz
Reference Pressure Transducers (Q-RPTs) to allow it to set and measure pressure with higher precision
and very low measurement uncertainty. Up to two external Q-RPTs in an external Reference Pressure
Monitors (RPM4), can also be integrated into a PPCH-G system. A on-board barometer is included for
atmospheric pressure compensation of gauge mode measurements and as a reference for AutoZero in
absolute measurement mode.
PPCH-G requires a constant gas pressure supply greater than the maximum pressure to be controlled. This
can be supplied by a DHI GB-H-152-70M or GB-H-100M gas booster package. Pressure control is achieved
by servo-motor controlled, high pressure needle valves and a thermal pressure control system.
PPCH-G is controlled locally by the operator using a front panel display, keypad and function keys or
remotely by a computer using ASCII character command strings over an RS232 or IEEE-488.2 interface.
PPCH-G models are available to measure and control pressure in ranges from as low as 10 MPa (1 500 psi)
to 100 MPa (15 000 psi) in absolute and gauge measurement modes.
PPCH-G is the standard automated pressure control component for automated pressure control in
ranges greater than 10 MPa (1 500 psi) in PG7202 high pressure gas piston gauge systems.
1.2 SPECIFICATIONS
1.2.1 GENERAL SPECIFICATIONS
Power Requirements 85 to 264 VAC, 50/60 Hz, 75 W max consumption
Operating Temperature Range 15 to 35 °C
Storage Temperature Range - 20 to 70 °C
Vibration Meets MIL-T-28800D
Weight With Hi Q-RPT or utility sensor only: 30 kg (66 lb)
With Hi Q-RPT or utility sensor and Lo Q-RPT: 33 kg (73 lb)
Enclosure: add 10 kg (22 lb)
Dimensions Without optional enclosure: 26 cm H x 44 cm W x 55 cm D
(10.2 in. x 17.3 in. x 21.7 in.) Front panel is 19” wide X 6U high with mounting
holes for standard 19 in. rack mount systems
With optional enclosure: 30 cm H x 52 cm W x 55 cm D
(11.8 in. x 20.5 in. x 21.7 in.)
Ventilation To prevent product overheating, provide proper ventilation. Allow 10 cm
(4 in.) clearance from rear panel cooling fan.
Communication Ports
Fuses
RS232 (COM1), RS232 (COM2), IEEE-488.2
Fuses 1 A, 250 VAC fuse, 5 x 20 mm, time lag type fuse
Internal power supply fuse not replaceable by operator: 2A, 250 V (UV 440-2
power supply), 3.15A, 250 V (NFS40-7612 power supply)

PPCH-G™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 2
Pressure Ranges Four controller models from 20 MPa (3 000 psi) max to 100 MPa (15 000 psi)max.
Low uncertainty measurement provided by selection of Quartz Reference
Pressure transducer(s) (Q-RPTs)
Operating Media Nitrogen, air, consult factory regarding other non-corrosive gases
Pressure Supplies Test pressure supply: Greater than maximum pressure to be controlled by at
least 5% of controller range, but not more than 15%
greater than controller range, minimum 70% of
controller range. Must remain stable ± 1 % and flow
must be adequate to maintain stable supply while
slewing. into test volume.
Drive air supply: 500 to 800 kPa (75 to 120 psi)
Pressure Connections DRIVE: 1/8 in. NPT F
TEST: DH500F
SUPPLY: DH500F
NOTE: DH500 is a gland and collar type fitting for ¼
in. (6.35 mm) coned and left hand threaded tube.
DH500 is equivalent to AE F250C, HIP HF4, etc.
ATM: 10-32 UNF
Pressure Limits Maximum working
T test pressure: Controller or Hi Q-RPT maximum
Maximum test
pressure without
damage: 115 % controller or Hi Q-RPT maximum
1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS
1.2.2.1 QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT)
Quartz reference pressure transducers (Q-RPTs) can be installed in PPCH-G to
obtain high precision and low uncertainty pressure measurement. One or two
Q-RPTs can be included in the PPCH-G and/or additional Q-RPTs can be used
externally mounted in a DHI RPM4 Reference Pressure Monitor (see Section 3.2.5).
All PPCH-G Q-RPTs are of the absolute pressure type (Axxx) using an evacuated,
permanently sealed reference. Axxx Q-RPTs used in PPCH-G can measure
absolute and gauge pressure. Gauge pressure is obtained by offsetting atmospheric
pressure and applying dynamic compensation for atmospheric changes using the
on-board barometer (see Section 3.2.4). See Section 3.3.3, PRINCIPLE, for
additional information on absolute and gauge measurement modes.
PPCH-G models configured with two Q-RPT modules have only one TEST port.
PPCH-G internal valves and logic handle switching between the two Q-RPTs as
needed.
Table 1. Quartz Reference Pressure Transducer (Q-RPT) designations and range
SI VERSION US VERSION
RPT
DESIGNATION MAXIMUM PRESSURE
Absolute and Gauge [MPa]
MAXIMUM PRESSURE
Absolute and Gauge [psi]
A100M 100 15 000
A70M 70 10 000
A40M 40 6 000
A20M 20 3 000
A14M 14 2 000
A10M 10 1 500
A7M 7 1 000

1. INTRODUCTION
Page 3 © 2007 DH Instruments, a Fluke Company
Warm Up Time 30 minute temperature stabilization recommended for
best performance from cold power up.
Resolution To 1 ppm, user adjustable
Compensated Temperature Range 15 to 35 °C
Acceleration Affect ± 0.008 % /g maximum, worst axis
Allows operation at ± 20° from reference plane without
significant effect
Predicted one year stability1± 0.005% of reading
Q-RPTs A7M, A10M (1000 and 1500 psi)
STANDARD CLASS PREMIUM CLASS
Precision2± 0.008% of reading or
0.0024% of Q-RPT span,
whichever is greater5
± 0.005% of reading,
0.0015% of AutoRanged
span, or 0.0005% of
Q-RPT span, whichever is
greater6
Measurement Uncertainty3± 0.01% of reading or
0.0030% of Q-RPT span,
whichever is greater5
± 0.008 % of reading,
0.0024% of AutoRanged
span, or 0.0007% of
Q-RPT span, whichever is
greater6
Delivered Pressure Uncertainty4± 0.014% of reading or
0.004% of Q-RPT span,
whichever is greater5
± 0.013 % of reading,
0.014% of AutoRanged
span, or 0.003% of
Q-RPT span, whichever is
greater6
Q-RPTs A14M to A100M (2000 to 15000 psi)
Precision2± 0.012% of reading or 0.0036% of span,
whichever is greater5
Measurement Uncertainty3± 0.013% of reading or 0.004 % of span,
whichever is greater5
Delivered Pressure Uncertainty4± 0.016 % of reading or 0.005% of span,
whichever is greater5
1. Predicted Q-RPT measurement stability limit (k=2) over one year assuming regular use of AutoZero function. AutoZero
occurs automatically in gauge mode whenever vented, by comparison with barometric reference in absolute mode.
Absolute mode predicted one year stability without AutoZ is ± (0.005 % Q-RPT span + 0.005 % of reading).
2. Combined linearity, hysteresis, repeatability.
3. Maximum deviation of the Q-RPT indication from the true value of applied pressure including precision, predicted one year
stability limit, temperature effect and calibration uncertainty, combined and expanded (k=2) following the ISO “Guide to the
Expression of Uncertainty in Measurement.”
4. Maximum deviation of the PPCH-G controlled pressure from the true value including measurement uncertainty and
dynamic control hold limit.
5. % of reading value times measured pressure from 100 to 30 % of Q-RPT span. Under 30 % of Q-RPT span, % of reading
value times 30 % of Q-RPT span. For example, if the Q-RPT is a an A40M, the Measurement Uncertainty in pressure is
0.013% times the measured pressure to 12 MPa (40 MPa span x 30%) and 0.00156 MPa (40 MPa span x 30% x 0.013%)
under 12 MPa.
6. % of reading value times measured pressure from 100 to 30% of AutoRanged span. Under 30% of AutoRanged span, % of
reading value times 30% of AutoRanged span. If AutoRanged span is less then 30% of maximum Q-RPT span, % of reading
values times measured pressure, or % of reading times 9% of Q-RPT span, whichever is greater. For example, if the Q-RPT is a
Premium A7M and AutoRanged span is 7 MPa, the Measurement Uncertainty in pressure is measured pressure x 0.008% to 2.1
MPa (7 MPa AutoRanged span x 30%) and 0.168 kPa (7 MPa span x 30% x 0.008%) under 2.1 MPa. If the AutoRanged span is
5 MPa (greater than 30% of 7 MPa maximum Q-RPT span), the Measurement Uncertainty in pressure is measured pressure x
0.008% to 1.5 MPa (7 MPa AutoRanged span x 30%) and 0.012 kPa (5 MPa span x 30% x 0.008%) under 1.5 MPa. If the
AutoRanged span is 2 MPa (less than 30% of the 7 MPa maximum Q-RPT span), the Measurement Uncertainty in pressure is
measured pressure x 0.008% to 0.63 MPa (7 MPa maximum Q-RPT span x 9%) and 0.05 kPa (7 MPa maximum Q-RPT span x
9% x 0.008%) under 0.63 MPa.

PPCH-G™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 4
1.2.2.2 UTILITY SENSOR
Base PPCH-G pressure controllers include a utility sensor. If a Hi Q-RPT
(see Section 3.2.5) is installed, there is no utility sensor.
Utility sensors are used for pressure control, system monitoring and safety
functions.They are intended for indication only, not to provide reference pressure
measurement. Q-RPTs (see Section 1.2.2.1) are used for reference measurement.
Warm Up Time None required
Range PPCH-G-100M: 100 MPa (15 000 psi) absolute and gauge
PPCH-G-70M:70 MPa (10 000 psi) absolute and gauge
PPCH-G-40M:40 MPa (6 000 psi) absolute and gauge
PPCH-G-20M:20 MPa (3 000 psi) absolute and gauge
Resolution 0.001 % of span
Precision 0.1% of span
1.2.2.3 ON-BOARD BAROMETER
The on-board barometer is used only to measure changes in atmospheric pressure
to provide dynamic compensation of the Q-RPT’s atmospheric pressure offset when
operating in gauge measurement mode. If calibrated, it can also be used as an
AutoZ reference for AutoZeroing in absolute measurement mode.
Warm Up Time None required
Range 70 to 110 kPa (10 to 16 psi)
Resolution 0.001 % of span
Precision 0.1 % of span
Predicted Stability 0.05 kPa/yr (0.008 psi/yr)
1.2.3 PRESSURE CONTROL SPECIFICATIONS
Lowest controllable pressure
(absolute, gauge modes) 0.7 Mpa (100 psi)
Typical control ready time (dynamic
mode)
90 to 150 seconds (assuming no supply limitation)
Typical maximum slew rate (0 to FS,
50 cc test)
60 seconds
Default dynamic control hold limit ± 0.01 % of active range, or 0.003 % of Q-RPT maximum
span, whichever is greater
Control precision to ± 0.001 % of Q-RPT span
TEST volume Standard dynamic control: 0 to 100 cc
Other control modes: 0 to 500 cc
Highly pressurized gas is inherently
dangerous due to the high energy stored. The
energy stored increases with volume.

2. INSTALLATION
Page 5 © 2007 DH Instruments, a Fluke Company
2
2. . I IN
NS ST TA AL LL LA AT TI IO ON N
2.1 UNPACKING AND INSPECTION
2.1.1 REMOVING FROM PACKAGING
PPCH-G is delivered in a wooden crate with high density polyethylene inserts to hold it in place.
A molded transit case is available.
Remove the PPCH-G and its accessories from the shipping container and remove each
element from its protective plastic bag.
PPCH-G weighs more than 50 kg (110 lb). Take appropriate precautions to lift and place it
safely.
2.1.2 INSPECTING CONTENTS
Check that all items are present and have no visible damage.
A standard PPCH-G includes all items indicated in Table 2.
Table 2. PPCH-G packing list
DESCRIPTION PART #
1 ea. PPCH-G Pressure Controller/Calibrator FAM0011
1 ea. PPCH-G Enclosure (optional) 06-01
ACCESSORIES: 402255 (402255-CE)
1 ea. Operation and Maintenance Manual 550150
1 ea. Calibration Report 550100
1 ea. Test Report 550200
1 ea. Power Cord (7.5 ft.) 100770 (100770-CE)
1 ea. Drivers Connector 401382
1 ea. General Accessories Disk (white CD) 102987
INTERCONNECTIONS KIT: 401536
2 ea. Nipple, 2.75 in., DH500 100207
1 ea. Nipple, 6 in., DH500 100208
2 ea. Nipple, 12 in., DH500 100209
1 ea. Union, DH500 100295
1 ea. Elbow, DH500 100168
1 ea. Tee, DH500 100291
2 ea. Gland, DH500 100271
3 ea. Plug, DH500 100285
5 ea. Collar, DH500 101201
1 ea. Nipple, 5 in. x 1/8 in., DH500 tips 123019
2 ea. Adaptor, DH500 F x 1/8 in. NPT M 102819
1 ea. Adaptor, DH500 F x 1/4 in. NPT F 102820

PPCH-G™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 6
2.2 SITE REQUIREMENTS
PPCH-G weighs more than 50 kg (110 lb). Be sure that the location in which its installed is adequate to
support the load.
The PPCH-G can be installed on any flat, stable surface at a convenient height. The PPCH-G can also
be mounted in a standard 19 in. rack (see Section 2.2.1).
Minimizing the distance between the PPCH-G and the device or system under test will enhance control
performance and reduce pressure setting times.
Ready access to the PPCH-G rear panel should be considered to facilitate making and breaking
pressure connections.
Also consider:
•High pressure gas source and connection of high pressure gas supply (see Section 2.3.6).
•Pressure and RS-232 connections to an external RPM4 should be considered if RPM4 is to be
used as an external reference pressure measurement device (see Section 2.3.7.1).
•Location and connections to the device or system into which pressure is to be controlled (see
Section 2.3.7.3).
Support facilities required include:
•An electrical power source of 85 to 264 VAC, 50/60 Hz.
•A pneumatic power supply, of “drive air” to be connected to the PPCH-G DRIVE port (see Section 2.3.5).
ALWAYS use external tubing and fittings rated for pressures equal to or greater than the maximum
pressure PPCH-G will set and control.
2.2.1 INSTALLATION IN A 19 IN. RACK MOUNT
PPCH-G is dimensioned to be ready for direct mounting in a standard 19 in. rack mount system.
If PPCH-G was delivered in the optional enclosure, it must be removed from the enclosure
prior to rack mounting.
The front panel is 6U (10.5 in.) high.
Install PPCH-G into the rack mount system using heavy duty front panel screws provided by the
rack vendor. Due to PPCH-G’s weight, it is imperative that a rail system also be used to support
it along the sides and/or rear. These are also supplied by the rack mount system vendor.
PPCH-G weighs more than 50 kg (110 lb). Take appropriate precautions to lift and place it
safely. It is the user’s responsibility to support PPCH-G adequately on the sides and/or rear when
installing it in a rack mount system.

2. INSTALLATION
Page 7 © 2007 DH Instruments, a Fluke Company
2.3 INITIAL SETUP
2.3.1 PREPARING FOR OPERATION
To prepare PPCH-G for check out and operation:
Remove the plastic caps from the PPCH-G rear panel pressure connections.
Remove the protective plastic sheet from the front panel display.
Familiarize yourself briefly with the front and rear panel (see Section 2.3.2).
Then proceed with Sections 2.3.3 to 2.3.9.
2.3.2 FRONT AND REAR PANELS
2.3.2.1 FRONT PANEL
1. Ready/Not Ready Indicator
2. Display
3. Remote Activity Indicator
4. Cursor Control Keys
5. Multi-Function Keypad
6. Direct Pressure Control Keys
Figure 1. Front panel

PPCH-G™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 8
2.3.2.2 REAR PANEL
1. Electrical power connector (IEC-320-C13)
and fuse
2. Cooling fan
3. Remote [ENTER] connector
4. DRIVERS connector
5. RS-232 port, COM2
6. RS-232 port, COM1
7. Product label
8. IEEE-488 connector
9. ATM (barometer) port
10. Test gas VENT port
11. DRIVE air supply port
12. Test gas SUPPLY port
13. Mechanical module pull out handles
14. TEST port
Figure 2. Rear panel
2.3.3 POWER CONNECTION
Check that the PPCH-G power switch is OFF.
Connect the supplied power cable to the rear panel power input module.
Connect the other end of the power cable to an electrical supply of 85 to 264 VAC, 50/60 Hz.
2.3.4 REMOTE [ENTER/SET P] CONNECTION (FOOTSWITCH
OR OTHER SWITCH)
Connect the optional remote ENTER footswitch, if available or a user supplied switch fitted to
the optional cable (see Section 7.3). Connect the cable to the PPCH-G rear panel
connection labeled REMOTE ENTER. Activating the switch is equivalent to pressing the
[ENT/SET P] key on the front panel (see Section 3.1.4).

2. INSTALLATION
Page 9 © 2007 DH Instruments, a Fluke Company
2.3.5 CONNECTING DRIVE AIR (DRIVE PORT)
Using a pressure connecting hose or tube of appropriate pressure rating, connect drive air
supply to the DRIVE port on the rear panel of PPCH-G. The DRIVE port connection is 1/8 in.
NPT female. Use Teflon™tape or another thread sealant to minimize leakage.
If a DHI GB-H-152 is being used to supply pressure to the PPCH-G, the drive air may be
supplied from the GB-H-152 DRIVE OUT port.
Drive air pressure must be between 500 and 800 kpa (75 to 120 psi).
2.3.6 CONNECTING HIGH PRESSURE GAS SUPPLY (SUPPLY
PORT)
Highly pressurized gas can be extremely hazardous. Before applying pressure to PPGH-G
and/or the system connected to it, be sure that all pressure vessels and connections are rated
for the pressure levels that will be applied and that all connections have been properly tightened.
Ensure that the PPCH-G is powered down, or if power is ON, it is in a vented condition (VENT LED
ON). Do not apply the supply pressure before reading Sections 2.4.1 and 2.4.3.
The PPCH-G SUPPLY port is for connection of the high pressure gas that PPCH-G controls.
Before connecting a high pressure supply, be sure that the PPCH-G is powered off, or if it is
off, that it is in a vented condition (vent LED ON). Do not apply the supply pressure before
reading Sections 2.4.1 and 2.4.3.
If a DHI GB-H-152 gas booster is being used for the high pressure gas supply,
interconnections to connect the booster output to PPCH-G SUPPLY port are supplied with
the booster. See the booster Operation and Maintenance Manual for details on setting up
the connection.
Using a pressure tube of appropriate pressure rating, connect the pressure supply to the
SUPPLY port on the rear panel of PPCH-G. The SUPPLY connection is DH500 F.
DH500 is a gland and collar type fitting for 1/4 in. (6.35 mm) coned and left hand threaded
tube. DH500 is equivalent to AE F250C, HIP HF4, etc. DO NOT USE INCORRECT FITTINGS;
DAMAGE TO THE FITTING AND DANGER TO THE OPERATOR COULD RESULT.
The supply pressure should be at least 5% of the PPCH-G range greater than the
maximum PPH-G pressure to be controlled but not greater than 115% of the PPCH-G
controller range. The minimum supply pressure is 70% of the PPCH-G range. The
supply pressure must be stable ±1 % and assure adequate flow to remain stable while
PPCH-G is slewing pressure for PPCH-G pressure control to operate within specifications
(see Section 1.2.3).
Never connect a pressure supply greater than 15 % over the maximum range of the PPCH-G
model you are using. Always use the correct fittings.
Take care NOT to connect the high pressure supply to a port other than the SUPPLY port.
CONNECTING THE HIGH PRESSURE SUPPLY TO ANY PORT OTHER THAN THE SUPPLY PORT MAY
DAMAGE THE PPCH-G AND MAY CAUSE OPERATOR INJURY.

PPCH-G™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 10
2.3.7 CONNECTING TO OTHER DEVICES
ALWAYS use external tubing and fittings rated for pressure equal to or greater than the
maximum pressure PPCH-G will be used to control.
The PPCH-G TEST port is a DH500 female fitting.
DH500 is a gland and collar type fitting for 1/4 in. (6.35 mm) coned and left hand threaded
tube. DH500 is equivalent to AE F250C, HIP HF4, etc. DO NOT USE INCORRECT FITTINGS;
DAMAGE TO THE FITTING AND DANGER TO THE OPERATOR COULD RESULT.
DH500 fittings are rated for working pressure up to 500 MPa (72 500 psi). Be sure to use
stainless steel tubing rated for your maximum operating pressure with the DH500 fittings.
2.3.7.1 CONNECTING TO AN RPM4 TO BE USED AS AN EXTERNAL
REFERENCE DEVICE
ALWAYS use external tubing and fittings rated for pressure equal to or
greater than the maximum pressure PPCH-G will be used to control.
PPCH-G can be connected pneumatically and by RS-232 to an RPM4 reference
pressure monitor to use up to two external Q-RPTs as external reference pressure
measurement devices (see Section 3.2.5).
The PPCH-G then manages communications and other RPM4 functions to
integrate the RPM4 measurement capabilities into the PPCH-G system. The
user is responsible for setting up hardware and following procedures to
isolate lower pressure Q-RPTs from possible overpressure if pressures
higher than the Q-RPT maximum are generated.. PPCH-G and RPM4 do not
have hardware provisions for isolating external Q-RPTs from the TEST circuit.
As a general rule, making the pneumatic connection between the PPCH-G TEST
port and the remote Q-RPT as direct as possible favors good pressure control. As
distance, volumes and restrictions between the PPCH-G TEST port and the remote
Q-RPT increase, the possibility of difficulty with pressure control when using the
external Q-RPT increases.
To connect a PPCH-G to an RPM4 to be used as part of the PPCH-G system
proceed as follows:
Set up the RPM4 for use as a PPCH-G external device following the
instructions in the RRPM4 Operation and Maintenance Manual, Using RPM4 With a
PPC3 Controller/Calibrator Section.
Using tubing of appropriate pressure rating and a tee fitting, connect the
RPM4 Q-RPT TEST(+) port to the PPCH-G TEST port (see Figure 3 for
instructions on making this connection using the standard interconnection
accessories supplied with the PPCH-G). The third leg of the tee is for the
connection to the device or system under test.