DH Instruments PPCH - V1.01 User manual

© 2009 DH Instruments, a Fluke Company
PPCH™
Hydraulic Pressure Controller/Calibrator
Ver. 1.01f and higher
Operation and Maintenance Manual

© 2009 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.
© 2009 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, PPCK+, QDUT, Q-RPT, RPM, RPM4 and SDS are
trademarks, registered and otherwise, of DH Instruments, a Fluke Company.
Loctite is a trademark of Loctite Corporation
Teflon is a registered trademark of the Dupon de Nemours Company.
Document No. 550132h
090210
Printed in the USA.

TABLE OF CONTENTS
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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 ...................................................................................................................................2
1.2.1 GENERAL SPECIFICATIONS .......................................................................................................................2
1.2.2 PRESSURE MEASUREMENT SPECIFICATIONS........................................................................................3
1.2.2.1 QUARTZ REFERENCE PRESSURE TRANSDUCER (Q-RPT)................................................................3
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 PNEUMATIC POWER (DRIVE PORT) .................................................................................9
2.3.6 SETTING UP AND FILLING THE FLUID RESERVOIR ................................................................................9
2.3.6.1 INTERNAL RESERVOIR............................................................................................................................9
2.3.6.2 EXTERNAL RESERVOIR ........................................................................................................................11
2.3.7 RESERVOIR RETURN SETTINGS .............................................................................................................12
2.3.8 INSTALLING PUMP DRIVE OUT GAS EXHAUST FILTER........................................................................13
2.3.9 CONNECTING TO OTHER DEVICES .........................................................................................................14
2.3.9.1 INSTALLING A LINE FILTER TO PROTECT THE PPCH .......................................................................14
2.3.9.2 CONNECTING TO AN RPM4 TO BE USED AS AN EXTERNAL REFERENCE DEVICE......................14
2.3.9.3 CONNECTING TO A PG7302 PISTON GAUGE .....................................................................................16
2.3.9.4 CONNECTING TO A DEVICE UNDER TEST (TEST PORT)..................................................................17
2.3.10 CHECK/SET SECURITY LEVEL .................................................................................................................17
2.3.11 TURN OFF ABSOLUTE MEASUREMENT MODE......................................................................................18
2.4 POWER-UP AND VERIFICATION.........................................................................................................18
2.4.1 SWITCH POWER ON ..................................................................................................................................18
2.4.2 APPLY PNEUMATIC POWER (DRIVE AIR) ...............................................................................................18
2.4.3 CHECK PRESSURE MEASUREMENT OPERATION.................................................................................18
2.4.3.1 CHECKING ABSOLUTE MODE PRESSURE MEASUREMENT.............................................................18
2.4.3.2 CHECKING GAUGE MODE PRESSURE MEASUREMENT...................................................................19
2.4.4 PRIME AND PURGE TEST SYSTEM..........................................................................................................19
2.4.5 LEAK CHECK ..............................................................................................................................................19
2.4.6 CHECK PRESSURE CONTROL OPERATION ...........................................................................................19
2.5 STORAGE AND SHIPPING ...................................................................................................................20
2.5.1 SHORT TERM STORAGE ...........................................................................................................................20
2.5.2 LONG TERM STORAGE .............................................................................................................................20

PPCH™ OPERATION AND MAINTENANCE MANUAL
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2.5.3 PREPARATION FOR SHIPPING.................................................................................................................20
3. OPERATION..................................................................... 21
3.1 USER INTERFACE ................................................................................................................................21
3.1.1 MAIN RUN SCREEN....................................................................................................................................21
3.1.2 FUNCTION / DATA KEYPAD LAYOUT AND PROTOCOL.........................................................................23
3.1.3 DIRECT PRESSURE CONTROL KEYS......................................................................................................24
3.1.4 REMOTE [ENT/SET P] (FOOT)SWITCH.....................................................................................................25
3.1.5 SOUNDS ......................................................................................................................................................25
3.2 GENERAL OPERATING PRINCIPLES .................................................................................................25
3.2.1 PRESSURE CONTROL PRINCIPLES ........................................................................................................25
3.2.2 AUTOMATED PRESSURE CONTROL .......................................................................................................28
3.2.2.1 IDLE, NO AUTOMATED CONTROL (MEASURE MODE).......................................................................28
3.2.2.2 DYNAMIC CONTROL ..............................................................................................................................29
3.2.2.3 STATIC CONTROL..................................................................................................................................30
3.2.2.4 MONOTONIC CONTROL.........................................................................................................................31
3.2.2.5 RAMP CONTROL.....................................................................................................................................32
3.2.3 PRESSURE READY/NOT READY ..............................................................................................................34
3.2.4 GAUGE MEASUREMENT MODE, DYNAMIC COMPENSATION FOR ATMOSPHERIC PRESSURE......34
3.2.5 MULTIPLE INTERNAL AND EXTERNAL Q-RPTS .....................................................................................35
3.2.6 MULTIPE RANGES (Q-RPTS, AUTORANGE AND INFINITE RANGING) .................................................36
3.2.7 FLUID RESERVOIR LOW LEVEL WARNING ............................................................................................37
3.2.8 OPERATION WITH A PG7000 PISTON GAUGE ........................................................................................38
3.2.9 DIRECT FUNCTION KEYS SUMMARY ......................................................................................................38
3.3 DIRECT FUNCTION KEYS....................................................................................................................39
3.3.1 [RANGE] ......................................................................................................................................................39
3.3.2 [UNIT]...........................................................................................................................................................40
3.3.3 [MODE] ........................................................................................................................................................41
3.3.4 [AUTORANGE] ............................................................................................................................................42
3.3.5 [RPT] ............................................................................................................................................................44
3.3.6 [AUTOTEST]................................................................................................................................................46
3.3.6.1 QUICK AUTOTEST..................................................................................................................................47
3.3.6.2 QDUT AUTOTEST...................................................................................................................................49
3.3.7 [HEAD] .........................................................................................................................................................52
3.3.8 [PRIME]........................................................................................................................................................54
3.3.8.1 <1PRIME>................................................................................................................................................55
3.3.8.2 <2PURGE> ..............................................................................................................................................56
3.3.9 [LEAK CK] ...................................................................................................................................................56
3.3.10 [ENT/SET P] (SET PRESSURE AUTOMATICALLY)..................................................................................58
3.3.10.1 DYNAMIC CONTROL MODE, [ENT/SET P]............................................................................................58
3.3.10.2 STATIC CONTROL MODE, [ENT/SET P]................................................................................................59
3.3.10.3 MONOTONIC CONTROL MODE, [ENT/SET P]......................................................................................61
3.3.10.4 RAMP CONTROL MODE, [ENT/SET P]..................................................................................................62
3.3.10.5 INTERRUPTING AUTOMATED PRESSURE CONTROL........................................................................63
3.3.10.6 AUTOMATED PRESSURE COMMANDS FOR ZERO PRESSURE....................................................63
3.4 [SETUP] .................................................................................................................................................64
3.4.1 <1RANGE> ..................................................................................................................................................64
3.4.1.1 SAVING AN AUTORANGE RANGE ........................................................................................................64
3.4.1.2 DELETING AUTORANGE RANGES........................................................................................................65
3.4.2 <2RES> (RESOLUTION) .............................................................................................................................65
3.4.3 <3JOG>........................................................................................................................................................66
3.4.4 <4UL> (UPPER LIMIT) ................................................................................................................................67
3.4.4.1 OVER PRESSURE FUNCTION...............................................................................................................68
3.4.5 <5ATEST>....................................................................................................................................................68
3.4.6 <6CONTROL>..............................................................................................................................................69
3.4.6.1 <1LIMITS> (CUSTOM CONTROL PARAMETERS) ................................................................................70
3.4.6.2 <2MODE> ................................................................................................................................................72
3.4.6.3 TURNING-OFF CUSTOM CONTROL PARAMETERS............................................................................73
3.4.7 <7DRV> (DRIVERS) ....................................................................................................................................73
3.5 [SPECIAL] .............................................................................................................................................74
3.5.1 <1AUTOZ> ...................................................................................................................................................74
3.5.1.1 EDIT AUTOZ............................................................................................................................................77
3.5.1.2 RUN AUTOZ.............................................................................................................................................78
3.5.2 <2REMOTE> ................................................................................................................................................79
3.5.2.1 <1COM1, 2COM2>...................................................................................................................................80
3.5.2.2 <3IEEE-488>............................................................................................................................................80
3.5.2.3 <4FORMAT>............................................................................................................................................80
3.5.2.4 <5RS232 SELF-TEST>............................................................................................................................81
3.5.3 <3HEAD> .....................................................................................................................................................81
3.5.4 <4RESET> ...................................................................................................................................................82

TABLE OF CONTENTS
Page III © 2009 DH Instruments, a Fluke Company
3.5.4.1 <1SETS>..................................................................................................................................................82
3.5.4.2 <2UNITS> ................................................................................................................................................83
3.5.4.3 <3ATEST>................................................................................................................................................83
3.5.4.4 <4CAL> ....................................................................................................................................................83
3.5.4.5 <5ALL>.....................................................................................................................................................84
3.5.5 <5PREF>......................................................................................................................................................84
3.5.5.1 <1SCRSVR> ............................................................................................................................................85
3.5.5.2 <2SOUND> ..............................................................................................................................................85
3.5.5.3 <3TIME>...................................................................................................................................................86
3.5.5.4 <4ID>........................................................................................................................................................86
3.5.5.5 <5LEVEL> (SECURITY)...........................................................................................................................87
3.5.6 <6PUNIT>.....................................................................................................................................................89
3.5.7 <7INTERNAL> .............................................................................................................................................91
3.5.7.1 <1CONFIG> .............................................................................................................................................91
3.5.7.2 <2BARO>.................................................................................................................................................91
3.5.7.3 <3PUMP>.................................................................................................................................................92
3.5.8 <8CAL> ........................................................................................................................................................94
3.5.9 <9LOG>........................................................................................................................................................94
4. REMOTE OPERATION ....................................................... 97
4.1 OVERVIEW ............................................................................................................................................97
4.2 INTERFACING.......................................................................................................................................97
4.2.1 RS232 INTERFACE .....................................................................................................................................97
4.2.1.1 COM1.......................................................................................................................................................97
4.2.1.2 IEEE-488..................................................................................................................................................98
4.2.1.3 COM2.......................................................................................................................................................98
4.3 PROGRAMMING FORMATS.................................................................................................................98
4.3.1 CLASSIC PROGRAM MESSAGE FORMAT ...............................................................................................99
4.3.2 ENHANCED PROGRAM MESSAGE FORMAT ..........................................................................................99
4.3.2.1 USING COMMAND TYPE COMMANDS .................................................................................................99
4.3.2.2 USING QUERY TYPE COMMANDS.................................................................................................100
4.4 COMMANDS........................................................................................................................................101
4.4.1 PROGRAMMING MESSAGES ..................................................................................................................101
4.4.2 ERROR MESSAGES .................................................................................................................................102
4.4.3 PROGRAM MESSAGE DESCRIPTION OVERVIEW ................................................................................103
4.4.4 PROGRAM MESSAGE DESCRIPTIONS ..................................................................................................104
4.5 STATUS REPORTING SYSTEM .........................................................................................................128
4.5.1 ERROR QUEUE.........................................................................................................................................128
4.5.2 STATUS BYTE REGISTER .......................................................................................................................128
4.5.3 STANDARD EVENT REGISTER ...............................................................................................................130
4.5.4 READY STATUS REGISTER ....................................................................................................................130
4.6 IEEE STD. 488.2 COMMON AND STATUS PROGRAM MESSAGES................................................131
4.6.1 PROGRAM MESSAGE DESCRIPTIONS ..................................................................................................131
5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION....................135
5.1 OVERVIEW ..........................................................................................................................................135
5.2 PREVENTIVE MAINTENANCE ...........................................................................................................135
5.3 CALIBRATION OF QUARTZ REFERENCE PRESSURE TRANSDUCERS (Q-RPTS) ......................137
5.3.1 PRINCIPLE ................................................................................................................................................137
5.3.1.1 PA AND PM COEFFICIENTS ................................................................................................................137
5.3.1.2 AS RECEIVED AND AS LEFT DATA ....................................................................................................138
5.3.2 EQUIPMENT REQUIRED ..........................................................................................................................139
5.3.3 SET UP AND PREPARATION...................................................................................................................139
5.3.4 RECOMMENDED CALIBRATION POINT SEQUENCE............................................................................139
5.3.5 TURNING OFF ABSOLUTE MEASUREMENT MODE FOR A Q-RPT .....................................................140
5.3.6 Q-RPT CALIBRATION USING CALTOOL FOR RPTS SOFTWARE........................................................141
5.3.7 EDITING AND VIEWING Q-RPT CALIBRATION INFORMATION............................................................141
5.3.8 Q-RPT CALIBRATION/ADJUSTMENT WITHOUT CALTOOL FOR RPTS SOFTWARE.........................143
5.4 ADJUSTMENT OF ON-BOARD BAROMETER...................................................................................144
5.5 ADJUSTMENT OF UTILITY SENSOR ................................................................................................144
5.6 FILLING AND DRAINING THE FLUID RESERVOIR ..........................................................................145
5.6.1 INTERNAL RESERVOIR ...........................................................................................................................145
5.6.1.1 FILLING THE INTERNAL RESERVOIR.................................................................................................145
5.6.1.2 DRAINING THE INTERNAL RESERVOIR.............................................................................................146
5.6.2 EXTERNAL RESERVOIR ..........................................................................................................................146

PPCH™ OPERATION AND MAINTENANCE MANUAL
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5.6.2.1 FILLING THE EXTERNAL RESERVOIR................................................................................................146
5.6.2.2 DRAINING THE EXTERNAL RESERVOIR............................................................................................147
5.6.3 PURGING CONTAMINATED FLUID FROM THE PPCH...........................................................................148
5.7 VOLUME CONFIGURATION...............................................................................................................148
5.8 VALVE OPENING POINT CONFIGURATION .....................................................................................150
5.9 ACCESSING PPCH MECHANICAL MODULE ....................................................................................151
5.10 HYDROPNEUMATIC PUMP................................................................................................................152
5.10.1 PRIMING THE PUMP.................................................................................................................................152
5.10.1.1 PRIMING THE PUMP CHECK VALVE ..................................................................................................153
5.10.2 PUMP REPLACEMENT.............................................................................................................................154
5.10.3 PUMP SPOOL VALVE INSPECTION OR REPAIR...................................................................................156
5.10.4 PUMP INLET FILTER (LIQUID) REPLACEMENT ....................................................................................158
5.11 LEAK CHECKING................................................................................................................................159
5.11.1 PRESSURE DECAY LEAK TESTING METHOD ......................................................................................159
5.11.2 LOCALIZING A LEAK WITHIN THE PPCH...............................................................................................160
5.11.2.1 HIGH PRESSURE VENT VALVE LEAK ................................................................................................161
5.11.2.2 LOW PRESSURE ISOLATION VALVE LEAK .......................................................................................163
5.11.2.3 LOW PRESSURE VENT VALVE LEAK.................................................................................................163
5.12 VALVE REPLACEMENT OR REPAIR.................................................................................................165
5.12.1 SHUTOFF VALVE REPLACEMENT .........................................................................................................165
5.12.2 CONTROL VALVE SERVICE ....................................................................................................................166
5.13 RELOADING EMBEDDED SOFTWARE INTO FLASH MEMORY......................................................166
5.14 SUBASSEMBLY DESCRIPTION AND LOCATION ............................................................................167
5.14.1 ELECTRONIC MODULE............................................................................................................................167
5.14.1.1 POWER ENTRY AND FUSE..................................................................................................................167
5.14.1.2 POWER SUPPLIES ...............................................................................................................................167
5.14.1.3 DRIVER BOARD....................................................................................................................................168
5.14.1.4 MINI MICRO BOARD.............................................................................................................................168
5.14.1.5 ON-BOARD BAROMETER ....................................................................................................................168
5.14.2 MECHANICAL MODULE ...........................................................................................................................169
5.14.2.1 PUMP DRIVE AIR PRESSURE TRANSDUCER ...................................................................................169
5.14.2.2 HI Q-RPT OR UTILITY SENSOR...........................................................................................................169
5.14.2.3 TEST VENT VALVE...............................................................................................................................170
5.14.2.4 LO Q-RPT SHUTOFF VALVE................................................................................................................170
5.14.2.5 LO Q-RPT...............................................................................................................................................170
5.14.2.6 LO Q-RPT VENT VALVE .......................................................................................................................170
5.14.2.7 PUMP ACCUMULATOR ........................................................................................................................170
5.14.2.8 FRONT PANEL ......................................................................................................................................170
5.14.2.9 ELECTRICAL CABLE TRACK ...............................................................................................................170
5.14.2.10 HYDROPNEUMATIC PUMP..................................................................................................................170
5.14.2.11 INLET CONTROL VALVE......................................................................................................................170
5.14.2.12 OUTLET CONTROL VALVE..................................................................................................................171
5.14.2.13 FLUID RESERVOIR...............................................................................................................................171
5.14.2.14 RESERVOIR OVERFLOW/EXTERNAL RESERVOIR RETURN TUBE................................................171
5.14.2.15 THERMAL PRESSURE CONTROL UNIT (TPCU) ................................................................................171
5.14.2.16 DRIVE PRESSURE REGULATOR ........................................................................................................171
6. TROUBLESHOOTING .......................................................173
7. APPENDIX ......................................................................177
7.1 DRIVERS .............................................................................................................................................177
7.2 UNIT CONVERSION............................................................................................................................178
7.2.1 PRESSURE................................................................................................................................................178
7.3 REMOTE [ENT] ...................................................................................................................................178
8. WARRANTY....................................................................179
8.1 OVERVIEW ..........................................................................................................................................179
9. GLOSSARY.....................................................................181

TABLES & FIGURES
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Table 1. Reference pressure transducer (Q-RPT) designations and ranges..............................................3
Table 2. PPCH packing list..........................................................................................................................5
Table 3. Drive air requirements....................................................................................................................9
Table 4. Reservoir return settings for internal or external reservoir ..........................................................13
Table 5. MAIN RUN screen display fields..................................................................................................22
Table 6. Position designators of Q-RPTs in a PPCH system....................................................................36
Table 7. Settings and to what they are specific (range, measurement mode, Q-RPT, system) ...............37
Table 8. Summary of PPCH function key operation..................................................................................38
Table 9. Settings made by AutoRange......................................................................................................43
Table 10. Default pressure control parameters .........................................................................................70
Table 11. AutoZ ON and OFF....................................................................................................................76
Table 12. Reset – Sets...............................................................................................................................83
Table 13. Reset – Cal ................................................................................................................................84
Table 14. Reset – All..................................................................................................................................84
Table 15. Security levels............................................................................................................................88
Table 16. UNIT function - available units of measure................................................................................90
Table 17. COM1 pin designations and connections..................................................................................97
Table 18. COM2 DB-9F pin designations..................................................................................................98
Table 19. Program message list..............................................................................................................101
Table 20. Error numbers (#) and descriptions.........................................................................................102
Table 21. 8 Bit status byte register ..........................................................................................................128
Table 22. 8 bit standard event register ....................................................................................................130
Table 23. 8 bit ready status register.........................................................................................................130
Table 24. Program message list..............................................................................................................131
Table 25. PPCH maintenance parts ........................................................................................................136
Table 26. Calibration point sequence, standard class, Q-RPTs..............................................................140
Table 27. Troubleshooting guide .............................................................................................................173
Table 28. External drivers current output.................................................................................................177
Table 29. External drivers pin outs ..........................................................................................................177
Table 30. Pressure unit of measure conversion coefficients...................................................................178
Table 31. DHI Authorized Service Providers...........................................................................................179

PPCH™ OPERATION AND MAINTENANCE MANUAL
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Figure 1. Front panel....................................................................................................................................7
Figure 2. Rear panel ....................................................................................................................................8
Figure 3. Internal reservoir setup...............................................................................................................11
Figure 4. External reservoir setup..............................................................................................................12
Figure 5. Installing the exhaust filter/muffler..............................................................................................13
Figure 6. Connecting PPCH to an RPM4 or PG7302 using the standard
PPCH interconnection accessories.........................................................................................16
Figure 7. Keypad layout.............................................................................................................................23
Figure 8. Direct pressure control keys.......................................................................................................24
Figure 9. Pressure control system schematic............................................................................................27
Figure 10. Dynamic pressure control operation.........................................................................................29
Figure 11. Ready/Not Ready in dynamic pressure control mode..............................................................30
Figure 12. Static pressure control operation..............................................................................................30
Figure 13. Ready/Not Ready in static control mode..................................................................................31
Figure 14. Monotonic pressure control operation......................................................................................32
Figure 15. Ready/Not Ready in monotonic pressure control mode...........................................................32
Figure 16. Ramp pressure control operation.............................................................................................33
Figure 17. Ready/Not Ready in ramp pressure control mode...................................................................33
Figure 18. Status register schematic .......................................................................................................129
Figure 19. Internal reservoir schematic ...................................................................................................146
Figure 20. External reservoir schematic ..................................................................................................147
Figure 21. Electronic module, internal view.............................................................................................167
Figure 22. Mechanical module, internal view...........................................................................................169
Figure 23. Drivers connector schematic..................................................................................................177
Figure 24. Remote [ENT/SET P] connector schematic ...........................................................................178

ABOUT THIS MANUAL
Page VII © 2009 DH Instruments, a Fluke Company
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This manual is intended to provide the user with the basic information necessary to operate a PPCH
pressure controller/calibrator. It also includes a great deal of additional information provided to allow you
to optimize PPCH 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 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 operating principles. Section 4 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 behavior based on the symptom of that behavior. Certain words and
expressions have specific meaning as they pertain to PPCH. 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 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. 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 screen displays (e.g., <1yes>).

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1. INTRODUCTION
Page 1 © 2009 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 is a stand-alone, pressure controller intended to precisely generate, adjust and control hydraulic
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.
PPCH 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 four external Q-RPTs in one or two external Reference
Pressure Monitors (RPM4s), can also be integrated into a PPCH system. A barometer is also included
for atmospheric pressure compensation of gauge mode measurements and as a reference for AutoZero
in absolute measurement mode.
PPCH generates high liquid pressure internally using a hydropneumatic pump driven by a drive air supply.
Pressure control is achieved by servo-motor controlled, high pressure needle valves and a thermal
pressure control system.
PPCH 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 models are available to measure and control pressure in ranges from as low as 20 MPa (3 000 psi)
to 200 MPa (30 000 psi) in absolute and gauge measurement modes.

PPCH™ OPERATION AND MAINTENANCE MANUAL
© 2009 DH Instruments, a Fluke Company Page 2
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 50 kg (110 lb) approx
Dimensions Without optional enclosure: 26 cm H x 44 cm W x 55.5 cm D (10.2 in. x 17.3
in. x 21.9 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 55.5 cm D
(11.8 in. x 20.5 in. x 21.9 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
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)
Pressure Ranges Four controller models from 70 MPa (10 000 psi max to 200 MPa (30 000 psi)
max.
Low uncertainty measurement provided by selection of Quartz Reference
Pressure transducer(s) (Q-RPTs)
Operating Medium
Internal Reservoir Capacity
Di-2-Ethyl Hexyl Sebacate (other fluids optional)
300 cc
Pressure Connections DRIVE: 1/8 in. NPT F
TEST: DH500 F
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.
EXTERNAL: 1/8 in. NPT F
OVERFLOW: 1/8 in. NPT F
FILL/DRAIN: 1/4 in. swage M
ATM: 10-32 UNF
Pressure Limits Maximum Working:
Test Pressure: Controller or Hi Q-RPT maximum
Maximum Test Pressure:
without Damage: 115 % controller or Hi Q-RPT maximum
Required Drive Air Pressure:
Supply: H-70M: 500 kPa (75 psi) min, 850 kPa (120 psi)
max; 330 l/m (10 cfm)
H-100M: 700 kPa (100 psi) min, 850 kPa (120 psi)
max; 330 l/m (10 cfm)
H-140M: 500 kPa (75 psi) min, 850 kPa (120 psi)
max; 450 l/m (15 cfm)
H-200M: 700 kPa (100 psi) min, 850 kPa (120 psi)
max; 450 l/m (15 cfm)

1. INTRODUCTION
Page 3 © 2009 DH Instruments, a Fluke Company
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 to obtain
high precision and low uncertainty pressure measurement. One or two Q-RPTs can
be included in the PPCH and/or additional Q-RPTs can be used externally mounted
in DHI RPM4 Reference Pressure Monitors (see Section 3.2.5).
All PPCH Q-RPTs are of the absolute pressure type (Axxx) using an evacuated,
permanently sealed reference. Axxx Q-RPTs used in PPCH can measure
absolute and gauge pressure. Gauge pressure with an Axxx (absolute) Q-RPT 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.
PPCHs configured with two Q-RPT modules have only one TEST port. PPCH internal
valves and logic handle switching between the two Q-RPTs as needed.
Table 1. Reference pressure transducer (Q-RPT) designations and ranges
SI VERSION US VERSION
RPT
DESIGNATION MAXIMUM PRESSURE
Absolute and Gauge [MPa]
MAXIMUM PRESSURE
Absolute and Gauge [psi]
A200M 200 30 000
A140M 140 20 000
A100M 100 15 000
A70M 70 10 000
A40M 40 6 000
A20M 20 3 000
Warm Up Time 30 minute temperature stabilization recommended for
best performance from cold power up.
Resolution To 1 ppm, user adjustable
Compensated Temperature Range 5 to 35 °C
Acceleration Affect ± 0.008 % /g maximum, worst axis
Allows operation at ± 20° from reference plane without
significant effect
<A200M A200M
Precision1± 0.012 % of reading5± 0.015 % of reading5
Predicted Stability2± 0.005 % of reading5± 0.005 % of reading5
Measurement Uncertainty3± 0.013 % of reading5± 0.018 % of reading5
Delivered Pressure Uncertainty4± 0.015 % of reading5± 0.020 % of reading5
1. Combined linearity, hysteresis, repeatability.
2. 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).
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 controlled pressure from the true value including measurement uncertainty and dynamic
control hold limit.
5. % of reading applies to 30 to 100 % of Q-RPT span. Under 30 % of Q-RPT span, the value is a constant which is the % of
reading value times 30 %.

PPCH™ OPERATION AND MAINTENANCE MANUAL
© 2009 DH Instruments, a Fluke Company Page 4
1.2.2.2 UTILITY SENSOR
Base PPCH 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-70M: 70 MPa (10 000 psi) absolute and gauge
PPCH-100M: 100 MPa (15 000 psi) absolute and gauge
PPCH-140M: 140 MPa (15 000 psi) absolute and gauge
PPCH-200M: 200 MPa (30 000 psi) absolute and gauge
Resolution
Precision
0.001 % of span
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
Predicted Stability
0.1 % of span
0.05 kPa/yr (0.008 psi/yr)
1.2.3 PRESSURE CONTROL SPECIFICATIONS
ALL MODELS
Control Precision (Standard Dynamic Mode) to ± 0.003 % of Q-RPT span
Default Dynamic Control Hold Limit ± 0.01 % of AutoRanged range
Lowest Controllable Pressure (absolute,
gauge modes) 1 MPa (150 psi)
Typical Control Ready Time (Dynamic Mode) 60 to 120 seconds.
Slew Rate (0 to FS) 60 seconds
TEST Volume 0 to 100 cc, 50 cc optimum (operates in larger
volumes but pressure stabilizing time increases)

2. INSTALLATION
Page 5 © 2009 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 is delivered in a wooden crate with high density polyethylene inserts to hold it in place.
Remove the PPCH and its accessories from the shipping container and remove each
element from its protective plastic bag.
PPCH 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 includes all
items indicated in Table 2.
Table 2. PPCH packing list
DESCRIPTION PART #
1 ea. PPCH Pressure Controller/Calibrator FAM0010
1 ea. PPCH Enclosure (optional) 06-01
ACCESSORIES: 402038 (402038-CE)
1 ea. Operation and Maintenance Manual 550132
1 ea. Calibration Report 550100
1 ea. Test Report 550200
1 ea. Power Cord (7.5 ft.) 100770 (100770-CE)
1 ea. Reservoir fill tube assembly 402039
1 ea. Reservoir fill tube bracket 123832
2 ea. Bolts, SHC, M3 x 8 101010-Z
1 ea. Funnel 123959
1 ea. Filter/muffler, pump drive exhaust, 1/4. in. NPT M 103897
1 ea. Gland, DH200 100272
1 ea. Plug, DH200 100279
1 qt. Sebacate (synthetic oil). If PPCH is delivered filled with a fluid other than
Sebacate, this item is not included. 400503 or none
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™ OPERATION AND MAINTENANCE MANUAL
© 2009 DH Instruments, a Fluke Company Page 6
2.2 SITE REQUIREMENTS
PPCH weighs more than 50 kg (110 lb). Be sure that the location in which it’s installed is adequate to
support the load.
The PPCH can be installed on any flat, stable surface at a convenient height. The PPCH can also be
mounted in a standard 19 in. rack (see Section 2.2.1).
Minimizing the distance between the PPCH and the device or system under test will enhance control
performance and reduce pressure setting times.
Ready access to the PPCH rear panel should be considered to facilitate making and breaking
pressure connections.
Also consider:
•Access to the internal reservoir FILL/DRAIN port if an external reservoir is not being used (see
Section 2.3.6).
•Location and connections to an external reservoir, if used (see Section 2.3.6.2).
•Hydraulic 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 2.3.9.1).
•Location and connections to the device or system into which pressure is to be controlled (see
Section 2.3.9.4).
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 DRIVE port. Required
pressure varies with PPCH model (see Section 2.4.2).
ALWAYS use external tubing and fittings rated for pressures equal to or greater than the maximum
pressure PPCH will generate.
2.2.1 INSTALLATION IN A 19 IN. RACK MOUNT
PPCH is dimensioned to be ready for direct mounting in a standard 19 in. rack mount system.
If PPCH 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 into the rack mount system using heavy duty front panel bolts provided by the rack
vendor. Due to PPCH’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 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 adequately on the sides and/or rear when installing it in
a rack mount system.

2. INSTALLATION
Page 7 © 2009 DH Instruments, a Fluke Company
2.3 INITIAL SETUP
2.3.1 PREPARING FOR OPERATION
To prepare PPCH for check out and operation:
Remove the plastic caps from the PPCH 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 2.3.11.
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™ OPERATION AND MAINTENANCE MANUAL
© 2009 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. Internal reservoir fill funnel
11. Internal reservoir level sight tube
12. Reservoir FILL/DRAIN port
13. PUMP DRIVE OUT gas exhaust port
14. Reservoir FILL/DRAIN valve
15. EXTERNAL reservoir return port
16. Reservoir OVERFLOW port
17. RESERVOIR RETURN valve
18. DRIVE IN air supply port
19. Mechanical module pull out handles
20. TEST port
Figure 2. Rear panel
2.3.3 POWER CONNECTION
Check that the PPCH 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 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 © 2009 DH Instruments, a Fluke Company
2.3.5 CONNECTING PNEUMATIC POWER (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. It is important to proper PPCH pressure control
that the supply connection not excessively restrict flow. The tube should have an ID of at least 3
mm (1/8 in.) and not be more than 2 m (6 ft) long. Generally, a 3 mm ID tube has OD of at least
6.35 mm (1/4 in.). The DRIVE port connection is 1/8 in. NPT female.
The drive air supply is regulated internally by PPCH. Drive air requirements for the different
PPCH models are listed in Table 3.
Table 3. Drive air requirements
MODEL
MINIMUM DRIVE AIR
PRESSURE
MAXIMUM DRIVE AIR
PRESSURE
MINIMUM
UNINTERRUPTED
FLOW
PPCH-70M 500 kPa (75 psi)
PPCH-100M 700 kPa (100 psi) 330 l/m (10 cfm)
PPCH-140M 500 kPa (75 psi)
PPCH-200M 700 kPa (100 psi)
850 kPa (120 psi)
450 l/m (15 cfm)
2.3.6 SETTING UP AND FILLING THE FLUID RESERVOIR
The PPCH fluid reservoir holds the fluid that supplies PPCH’s hydropneumatic pump and
returns from its exhaust valve.
PPCH has an internal reservoir with a capacity of 300 cc that is filled from and whose level can
be viewed on the rear panel of the instrument. If greater capacity and/or remote reservoir filling
and level viewing are needed, external reservoir (part number 402102) may be installed.
See Section 2.3.6.1 to set up and fill the internal reservoir.
See Section 2.3.6.2 to set up and fill an external reservoir.
Take care not to let the PPCH reservoir become empty. Operating PPCH with an empty
reservoir will cause the hydropneumatic pump to draw air and lose its prime. A pump that has
lost its prime must be reprimed using a special procedure (see Section 5.10.1). PPCH has a low
fluid level warning displayed on the front panel that can be also checked by remote command (see
Section 3.5.7.3).
The system connected to the TEST port is connected to the reservoir when the PPCH is
vented ([VENT] LED ON). If there is an open point in the system below the fluid level in the
reservoir, liquid will run from the reservoir and out of the open point.
2.3.6.1 INTERNAL RESERVOIR
The PPCH is shipped with its internal reservoir filled with PPCH’s working fluid.
To operate without an external reservoir, the internal reservoir attachments must
be installed on the PPCH rear panel. These are included with the PPCH
accessories (see Table 2).

PPCH™ OPERATION AND MAINTENANCE MANUAL
© 2009 DH Instruments, a Fluke Company Page 10
The internal reservoir attachments include:
-Reservoir fill tube bracket, p/n 123832 (grey painted bracket)
-(2) M3 x 8 bolts, p/n 101010-Z
-Reservoir fill tube assembly, p/n 402039 (1/2 in. PFA tube with fittings
attached)
-Funnel p/n 123959
To prevent draining the reservoir accidentally, leave the RESERVOIR FILL/DRAIN
valve in the CLOSED position whenever the internal reservoir or external reservoir
attachments are not installed. Opening the FILL/DRAIN valve opens the FILL/DRAIN
port to the reservoir.
To set up to use the internal reservoir without an external reservoir, proceed as
follows (numeric references refer to Figure 3):
Install the reservoir fill tube bracket(1) to the PPCH rear panel using 2 ea. M3
x 8 bolts(3).
Install the reservoir fill tube assembly(4) by connecting the 1/4 in. swage
female on the assembly to the 1/4 in. swage male FILL/DRAIN connection.
Remove and retain the stainless steel cap that is installed on the connection
as delivered. Orient the PFA tube vertically. Bend the tube slightly to extend
through the reservoir fill bracket.
There is a red plug with a center pull tab in the end of the PFA tube. This
should be left in place when the funnel is not being used to prevent
contamination and/or evaporation of the fluid. The funnel(2) can be stored in
the holder just behind the tube.
Open the FILL/DRAIN valve(5). Fluid may enter the fill drain tube(4).
Check that the EXTERNAL port(6) is plugged. It is plugged when delivered.
If it is not, use a 1/8 in. NPT M plug with Teflon® tape on the threads to plug
it. Not plugging the EXTERNAL port when using the internal reservoir only
will cause the fluid exhausted from the PPCH to leak out rather than
returning to the reservoir.
Check that the OVERFLOW port(7) is open to atmosphere and
unobstructed. This assures the reservoir is open to atmosphere so proper
system venting and zeroing can occur.
Be sure the RESERVOIR RETURN valve(8) is on the INTERNAL position.
Check the level of the fluid in the fill/drain tube. If the level is below the MAX
FILL position, top off the tank. See Section 5.6.1 for information on filling
and draining the PPCH internal reservoir.
The PFA reservoir fill tube is delivered with a red plug with a center pull tab
installed. This plug can be used after the tube is installed to cover the opening
and reduce evaporation of the fluid. The plug is vented.