DH Instruments PG7601-SYS-AF User manual

© 2007 DH Instruments, a Fluke Company
PG7601-SYS-AF™
Gas Operated Piston Gauge
Pressure Calibration System
Operation and Maintenance Manual
NSN 6695-01-551-5125
Consists of Base System and Exchange Pack

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company
High-pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases
can be released unexpectedly and with extreme force. High-pressure systems should be assembled and
operated only by personnel who have been instructed in proper safety practices.
©2007 DH Instruments, a Fluke Company All rights reserved.
Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any
form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments, a
Fluke Company. 4765 East Beautiful Lane Phoenix Arizona 85044-5318 USA.
DH Instruments makes sincere efforts to ensure the accuracy and quality of its published materials; however, no warranty,
expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages
resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not
constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was
subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the
English version and other language versions, the English version predominates.
DH Instruments, DH, DHI, PG7601-AF, PG7601, PPPC3, CalTool and COMPASS are trademarks, registered and otherwise, of
DH Instruments, a Fluke Company.
Swagelok is a registered trademark of the Swagelok Company.
Krytox is a registered trademark of the Dupont de Nemours Company.
Products described in this manual are manufactured under international patents and one or more of the following U.S.
patents: 6,701,791, 5,142,483, 5,257,640, 5,331,838, 5,445,035. Other U.S. and international patents pending.
Document No. 550152a-01
071001
Printed in the USA

TABLE OF CONTENTS
Page I © 2007 DH Instruments, a Fluke Company
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TABLE OF CONTENTS...............................................................I
TABLES................................................................................VII
FIGURES................................................................................IX
ABOUT THIS MANUAL .............................................................XI
1. INTRODUCTION .................................................................1
1.1 SPECIFICATIONS....................................................................................................................................1
1.1.1 OVERALL SYSTEM SPECIFICATIONS........................................................................................................1
1.1.1.1 PRESSURE MEASUREMENTS................................................................................................................2
1.1.2 PISTON GAUGE PLATFORM (PG7601-AF).................................................................................................2
1.1.2.1 EMBEDDED FEATURES...........................................................................................................................3
1.1.2.2 MEASUREMENT OF AMBIENT AND INSTRUMENT CONDITIONS........................................................4
1.1.3 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, -50, -200)............................................................5
1.1.4 MASS SET (MS-7001-35-AF)........................................................................................................................6
1.1.5 PRESSURE CONTROLLER (PPC3-7M-AF).................................................................................................7
1.1.6 REFERENCE VACUUM PUMP (D16B).........................................................................................................7
2. SYSTEM AND COMPONENT OVERVIEW AND DESCRIPTION....9
2.1 SYSTEM OVERVIEW (PG7601-SYS-AF)................................................................................................9
2.2 PISTON GAUGE PLATFORM AND TERMINAL (PG7601-AF).............................................................12
2.2.1 PLATFORM..................................................................................................................................................13
2.2.2 PG TERMINAL.............................................................................................................................................14
2.3 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, -50, -200)...............................................15
2.4 MASS SET (MS-7001-35-AF).................................................................................................................16
2.5 PRESSURE CONTROLLER (PPC3-7M-AF) .........................................................................................16
2.6 REFERENCE VACUUM PUMP (D16B).................................................................................................18
3. INSTALLATION ................................................................ 19
3.1 UNPACKING AND INSPECTION...........................................................................................................19
3.1.1 UNPACKING AND INSPECTION OF PG7601-BAS-AF BASE SYSTEM...................................................19
3.1.1.1 PLATFORM, TERMINAL AND BELL JAR (PG7601-AF)........................................................19
3.1.1.2 PRESSURE CONTROLLER (PPC3-7M-AF)...........................................................................................20
3.1.1.3 REFERENCE VACUUM PUMP (D16B)...................................................................................................20
3.1.1.4 PRESSURE INTERCONNECTIONS KIT (PK-7601-P-AF) ......................................................20
3.1.1.5 VACUUM INTERCONNECTIONS KIT (PK-7601-V-AF)..........................................................................21
3.1.1.6 DOCUMENTATION AND ACCESSORIES..............................................................................................21
3.1.2 UNPACKING AND INSPECTION OF PG7601-EXC-AF EXCHANGE PACKAGE......................................21
3.1.2.1 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, PC-7100/7600-50, PC-7100/7600-200) AND
ACCESSORIES .......................................................................................................................................22
3.1.2.2 MASS SET (MS-7001-35-AF)..................................................................................................................22
3.1.2.3 DOCUMENTATION AND ACCESSORIES..............................................................................................23
3.2 SITE REQUIREMENTS..........................................................................................................................23
3.3 PHYSICAL SETUP.................................................................................................................................25
3.3.1 SETTING UP THE PLATFORM...................................................................................................................25
3.3.2 SETTING UP THE PRESSURE CONTROLLER.........................................................................................26
3.3.3 SYSTEM PRESSURE INTERCONNECTIONS............................................................................................26
3.3.4 SETTING UP THE MASS SET ....................................................................................................................27
3.3.5 INSTALLING A PISTON-CYLINDER MODULE INTO THE PLATFORM....................................................28

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page II
3.3.6 SETTING UP THE REFERENCE VACUUM PUMP AND VACUUM INTERCONNECTIONS.....................29
3.3.7 CONNECTING TEST GAS SUPPLY...........................................................................................................29
3.3.8 CONNECTING CONTROL VACUUM SUPPLY...........................................................................................30
3.4 POWER UP AND VERIFICATION .........................................................................................................30
3.4.1 POWER UP PLATFORM AND PRESSURE CONTROLLER......................................................................30
3.4.2 CHECK THAT ON-BOARD PISTON-CYLINDER MODULE AND MASS SET DIGITAL IDS ARE
CORRECT....................................................................................................................................................31
3.4.3 SET LOCAL GRAVITY VALUE ...................................................................................................................31
3.4.4 CHECK/SET SECURITY LEVEL.................................................................................................................31
3.4.5 CHECK PROPER OPERATION OF AMBIENT CONDITION MEASUREMENTS ......................................31
3.4.6 TURN ON AUTOGEN AND AUTOROTATE................................................................................................32
3.4.7 APPLY SUPPLY PRESSURE .....................................................................................................................32
3.4.8 APPLY CONTROL VACUUM......................................................................................................................32
3.4.9 APPLY REFERENCE VACUUM..................................................................................................................32
3.4.10 SET A GAUGE MODE PRESSURE, CHECK AUTOGEN AND AUTOROTATE FUNCTIONS ..................32
3.4.11 CHECK PISTON BEHAVIOR MEASUREMENTS.......................................................................................34
3.4.12 CHECK REFERENCE VACUUM SYSTEM AND ABSOLUTE MODE OPERATION..................................34
3.5 ADDITIONAL PRECAUTIONS TO TAKE TO MAKE GOOD PRESSURE MEASUREMENTS.............36
4. GENERAL OPERATION ..................................................... 37
4.1 OPERATING PRINCIPLES....................................................................................................................37
4.1.1 FUNDAMENTAL OPERATING PRINCIPLE................................................................................................37
4.1.2 PRESSURE CONTROL, MANUAL AND AUTOMATED.............................................................................38
4.1.3 PRESSURE READY/NOT READY INDICATION........................................................................................39
4.1.3.1 PISTON POSITION READY/NOT READY ..............................................................................................39
4.1.3.2 PISTON ROTATION READY/NOT READY.............................................................................................40
4.1.3.3 VACUUM REFERENCE READY/NOT READY.......................................................................................40
4.1.4 PISTON POSITION......................................................................................................................................41
4.1.5 MASS LOADING PROTOCOL ....................................................................................................................42
4.2 USER INTERFACE ................................................................................................................................45
4.2.1 PISTON GAUGE (SYSTEM INTERFACE) ..................................................................................................45
4.2.1.1 KEYPAD LAYOUT AND PROTOCOL......................................................................................................45
4.2.1.2 MAIN RUN SCREEN................................................................................................................................46
4.2.1.3 GENERAL FUNCTION/MENU FLOW CHART........................................................................................48
4.2.1.4 SOUNDS..................................................................................................................................................48
4.2.2 PRESSURE CONTROLLER........................................................................................................................49
4.2.2.1 KEYPAD LAYOUT AND PROTOCOL......................................................................................................49
4.2.2.2 DIRECT PRESSURE CONTROL KEYS..................................................................................................50
4.2.2.3 MAIN RUN SCREEN................................................................................................................................51
4.2.2.4 SOUNDS..................................................................................................................................................52
4.3 DIRECT FUNCTION KEYS....................................................................................................................53
4.3.1 DIRECT FUNCTION KEYS SUMMARY......................................................................................................53
4.3.2 [P-C], VIEW AND SELECT PISTON-CYLINDER MODULES.....................................................................53
4.3.3 [UNIT], SELECT PRESSURE UNIT OF MEASURE....................................................................................55
4.3.4 [MODE], SELECT PRESSURE MEASUREMENT MODE...........................................................................56
4.3.5 [SYSTEM], VIEW SYSTEM CONDITIONS MEASUREMENT SCREENS..................................................57
4.3.5.1 FIRST SYSTEM RUN SCREEN ..............................................................................................................57
4.3.5.2 SECOND SYSTEM RUN SCREEN .........................................................................................................58
4.3.6 [AMBIENT], VIEW AMBIENT CONDITIONS MEASUREMENTS SCREEN ...............................................59
4.3.7 [HEAD], SET FLUID HEAD CORRECTION HEIGHT..................................................................................60
4.3.8 [ROTATE], MANAGE MOTORIZED PISTON ROTATION..........................................................................62
4.3.8.1 <2PRE-DECEL>.......................................................................................................................................64
4.3.9 [GEN], MANAGE AUTOMATED PRESSURE GENERATION....................................................................64
4.3.9.1 <2TARGET>.............................................................................................................................................66
4.3.9.2 <3RAISE> ................................................................................................................................................66
4.3.9.3 <4UL>.......................................................................................................................................................66
4.3.9.4 <5TOL>....................................................................................................................................................67
4.3.9.5 <6REFLOAT>...........................................................................................................................................67
4.3.9.6 VIEWING AND SETTING PPC3-7M-AF COM1 PORT SETTINGS.........................................................68
4.3.10 [RES], SET MASS LOADING RESOLUTION .............................................................................................68
4.3.11 [SET P], SET OR MEASURE A PRESSURE..............................................................................................69
4.3.11.1 [SET P] IN PRESSURE TO MASS MODE...............................................................................................71
4.3.11.2 [SET P] IN MASS TO PRESSURE MODE...............................................................................................72
4.3.11.3 COMMANDS FOR ZERO PRESSURE, ENDING A TEST......................................................................73
4.3.12 [P OR M], SET PRESSURE TO MASS OR MASS TO PRESSURE OPERATING MODE.........................73
4.3.13 [] AND [ ], [←], MANUAL CONTROL OF MOTORIZED ROTATION ...............................................74

TABLE OF CONTENTS
Page III © 2007 DH Instruments, a Fluke Company
4.4 [SETUP] MENU, MANAGE PRESSURE EQUATION VARIABLE SOURCES......................................75
4.4.1 <1SELECT>.................................................................................................................................................77
4.4.2 <2VIEW>......................................................................................................................................................77
4.4.3 <3EDIT>.......................................................................................................................................................78
4.5 [SPECIAL] MENU ..................................................................................................................................81
4.5.1 <1PC/MS>, MANAGE METROLOGICAL ELEMENT DIGITAL IDS............................................................82
4.5.1.1 CREATE PISTON-CYLINDER MODULE.................................................................................................83
4.5.1.2 EDIT PISTON-CYLINDER MODULE.......................................................................................................86
4.5.1.3 VIEW PISTON-CYLINDER MODULE......................................................................................................86
4.5.1.4 DELETE PISTON-CYLINDER MODULE.................................................................................................87
4.5.1.5 SELECT THE ACTIVE PISTON-CYLINDER MODULE...........................................................................87
4.5.1.6 ADD MASS SET.......................................................................................................................................87
4.5.1.7 EDIT MASS SET......................................................................................................................................91
4.5.1.8 VIEW MASS SET.....................................................................................................................................91
4.5.1.9 DELETE MASS SET................................................................................................................................91
4.5.1.10 SELECT MASS SET................................................................................................................................92
4.5.1.11 ADD MASS LOADING BELL....................................................................................................................92
4.5.1.12 EDIT MASS LOADING BELL...................................................................................................................93
4.5.1.13 VIEW MASS LOADING BELL..................................................................................................................94
4.5.1.14 DELETE MASS LOADING BELL.............................................................................................................94
4.5.1.15 SELECT MASS LOADING BELL.............................................................................................................94
4.5.2 <2PRESU>, CUSTOMIZE UNIT FUNCTION SELECTIONS.......................................................................94
4.5.3 <3HEAD>, CUSTOMIZE FLUID HEAD FUNCTIONS .................................................................................96
4.5.3.1 <3HEAD>, <1FLUID>...............................................................................................................................97
4.5.3.2 <3HEAD>, <2UNIT>.................................................................................................................................97
4.5.3.3 <3HEAD>, <3ATM> .................................................................................................................................97
4.5.3.4 <3HEAD>, <4PISTON>............................................................................................................................98
4.5.4 <4PREFS>, SET USER PREFERENCES ...................................................................................................98
4.5.4.1 <4PREFS>, <1SCRSVR>........................................................................................................................98
4.5.4.2 <4PREFS>, <2SOUND>..........................................................................................................................99
4.5.4.3 <4PREFS>, <3TIME> ..............................................................................................................................99
4.5.4.4 <4PREFS>, <4ID> ...................................................................................................................................99
4.5.4.5 <4PREFS>, <5LEVEL>..........................................................................................................................100
4.5.5 <5REMOTE>, MANAGE REMOTE COMMUNICATION INTERFACES....................................................103
4.5.5.1 COM1, COM2 AND COM3 (RS232)......................................................................................................104
4.5.5.2 IEEE-488................................................................................................................................................104
4.5.5.3 RS232 SELF TEST................................................................................................................................105
4.5.5.4 EXTERNAL BAROMETER (RPM) COMMUNICATIONS (COM2).........................................................105
4.5.5.5 EXTERNAL VACUUM GAUGE COMMUNICATIONS (COM2) .............................................................107
4.5.6 <6GL>, SET VALUE OF LOCAL GRAVITY..............................................................................................110
4.5.7 <7CAL>, MANAGE INTERNAL MEASUREMENT SENSOR CALIBRATIONS........................................110
4.5.8 <8AMH>, OPERATE AUTOMATED MASS HANDLER (NOT INCLUDED)..............................................110
4.5.9 <9RESET>, USE SYSTEM RESETS.........................................................................................................111
4.5.9.1 <9RESET>, <1SETS> ...........................................................................................................................111
4.5.9.2 <9RESET>, <2UNITS>..........................................................................................................................112
4.5.9.3 <9RESET>, <3COM>.............................................................................................................................112
4.5.9.4 <9RESET>, <4CAL>..............................................................................................................................112
4.5.9.5 <9RESET>, <5SETUPS> ......................................................................................................................113
4.5.9.6 <9RESET>, <6ALL> ..............................................................................................................................113
5. REMOTE OPERATION ......................................................115
5.1 OVERVIEW ..........................................................................................................................................115
5.2 INTERFACING.....................................................................................................................................115
5.2.1 RS232 INTERFACE...................................................................................................................................115
5.2.1.1 COM1.....................................................................................................................................................116
5.2.1.2 COM2 AND COM3.................................................................................................................................116
5.2.2 IEEE-488 (GPIB)........................................................................................................................................117
5.3 COMMANDS........................................................................................................................................117
5.3.1 COMMAND SYNTAX.................................................................................................................................117
5.3.2 COMMAND SUMMARY.............................................................................................................................117
5.3.3 ERROR MESSAGES .................................................................................................................................120
5.3.4 COMMAND DESCRIPTIONS.....................................................................................................................121
5.3.4.1 IEEE STD. 488.2 COMMON AND STATUS COMMANDS.....................................................121
5.3.4.2 PG7601-AF COMMANDS......................................................................................................................123
5.4 STATUS SYSTEM................................................................................................................................148
5.4.1 STATUS REPORTING SYSTEM...............................................................................................................149
5.4.1.1 STATUS BYTE REGISTER ...................................................................................................................149
5.4.1.2 STANDARD EVENT REGISTER...........................................................................................................150

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page IV
6. GENERAL MAINTENANCE AND ADJUSTMENTS ..................153
6.1 OVERVIEW ..........................................................................................................................................153
6.2 ILLUSTRATED PARTS BREAKDOWN...............................................................................................154
6.3 PISTON-CYLINDER MODULES..........................................................................................................173
6.3.1 DISASSEMBLY AND REASSEMBLY.......................................................................................................173
6.3.1.1 PC-7100/7600-10-L (10 KPA/KG) DISASSEMBLY AND REASSEMBLY..............................................174
6.3.1.2 PC-7100/7600-10-L (10 KPA/KG) PISTON INSERTION TOOL............................................................178
6.3.1.3 PC-7100/7600-50 AND -200 (50 AND 200 KPA/KG) DISASSEMBLY AND REASSEMBLY ................180
6.3.2 CLEANING PISTON-CYLINDERS.............................................................................................................182
6.3.2.1 OVERVIEW............................................................................................................................................182
6.3.2.2 WATER/DETERGENT METHOD...........................................................................................................183
6.3.2.3 QUICK METHOD ...................................................................................................................................184
6.3.3 LUBRICATING PISTON-CYLINDER MODULES......................................................................................185
6.4 PLATFORM..........................................................................................................................................186
6.4.1 PISTON POSITION DETECTION ADJUSTMENT.....................................................................................186
6.4.2 DRIVE BELT REPLACEMENT..................................................................................................................187
6.4.3 DISASSEMBLY AND REASSEMBLY OF PG7601-AF.............................................................................187
6.4.3.1 PLATFORM............................................................................................................................................187
6.4.3.2 TERMINAL.............................................................................................................................................188
6.5 ADJUSTING PRESSURE CONTROLLER INTERNAL PRESSURE SENSOR...................................189
6.6 REFERENCE VACUUM PUMP............................................................................................................191
6.6.1 CHECK/TOP OFF OIL LEVEL...................................................................................................................191
6.6.2 DRAIN AND REFILL OIL...........................................................................................................................191
6.7 RELOADING EMBEDDED SOFTWARE INTO PLATFORM OR PRESSURE CONTROLLER FLASH
MEMORY.............................................................................................................................................192
6.8 STORAGE AND SHIPPING .................................................................................................................192
6.8.1 SHORT AND LONG TERM STORAGE.....................................................................................................192
6.8.2 PREPARATION FOR SHIPPING...............................................................................................................193
6.8.2.1 PISTON-CYLINDER MODULES............................................................................................................193
6.8.2.2 MASS SET.............................................................................................................................................193
6.8.2.3 PLATFORM............................................................................................................................................193
6.8.2.4 PRESSURE CONTROLLER..................................................................................................................194
6.8.2.5 VACUUM PUMP ....................................................................................................................................194
7. MAINTENANCE OF TRACEABILITY AND RECALIBRATION...195
7.1 PRINCIPLES OF SYSTEM TRACEABILITY MAINTENANCE ............................................................195
7.2 LOCAL METROLOGICAL MAINTENANCE BETWEEN RECALIBRATIONS.....................................195
7.2.1 OVERVIEW................................................................................................................................................195
7.2.2 PLATFORM, ADJUST ON-BOARD P, T, H SENSORS............................................................................195
7.2.2.1 BAROMETRIC PRESSURE SENSOR ..................................................................................................196
7.2.2.2 AMBIENT TEMPERATURE SENSOR...................................................................................................197
7.2.2.3 RELATIVE HUMIDITY SENSOR ...........................................................................................................198
7.3 RECALIBRATION................................................................................................................................198
7.3.1 OVERVIEW................................................................................................................................................198
7.3.2 CALIBRATION OF PISTON-CYLINDER MODULES................................................................................199
7.3.2.1 PREPARING FOR CALIBRATION.........................................................................................................199
7.3.2.2 UPDATING PISTON-CYLINDER MODULE DIGITAL IDS......................................................199
7.3.3 CALIBRATION OF MASS SET..................................................................................................................200
7.3.3.1 PREPARING FOR CALIBRATION.........................................................................................................200
7.3.3.2 UPDATING MASS SET DIGITAL ID......................................................................................................200
7.3.4 CALIBRATION OF PISTON-CYLINDER MODULE TEMPERATURE SENSOR......................................200
7.3.4.1 OVERVIEW............................................................................................................................................200
7.3.4.2 PROCEDURE ........................................................................................................................................201
7.3.4.3 CALCULATING AND UPDATING PISTON-CYLINDER TEMPERATURE SENSOR INFORMATION..201
7.3.5 CALIBRATION OF RESIDUAL VACUUM GAUGE...................................................................................202
7.3.5.1 OVERVIEW............................................................................................................................................202
7.3.5.2 PROCEDURE ........................................................................................................................................203
7.3.5.3 CALCULATING AND UPDATING VACUUM GAUGE CALIBRATION INFORMATION ........................204

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Page V © 2007 DH Instruments, a Fluke Company
7.4 MANAGING METROLOGICAL ELEMENT DIGITAL IDS WITH CALTOOL™ FOR PG7000
SOFTWARE.........................................................................................................................................205
7.4.1 OVERVIEW................................................................................................................................................205
7.4.2 OPERATION ..............................................................................................................................................205
7.4.2.1 GETTING STARTED..............................................................................................................................206
7.4.2.2 PROCESSING A NEW DIGITAL ID FILE (AFTER RECALIBRATION)...................................207
7.4.2.3 STORING DIGITAL IDS FROM THE PG7601-AF IN THE CALTOOL DATABASE OR TO *.DID FILE207
7.4.2.4 ARCHIVING DIGITAL IDS .....................................................................................................................208
8. TROUBLESHOOTING .......................................................209
8.1 OVERVIEW ..........................................................................................................................................209
9. APPENDIX ......................................................................213
9.1 CONVERSION OF NUMERICAL VALUES..........................................................................................213
9.1.1 PRESSURE................................................................................................................................................213
9.2 DEFINED PRESSURE CALCULATIONS ............................................................................................213
9.2.1 PG7601-AF ................................................................................................................................................215
9.2.2 FLUID HEADS ...........................................................................................................................................215
9.2.2.1 FLUID HEAD COMPONENTS...............................................................................................................215
9.2.2.2 OVERALL FLUID HEAD CORRECTION...............................................................................................217
9.3 GLOSSARY..........................................................................................................................................217
9.4 WARRANTY STATEMENT..................................................................................................................219

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TABLES & FIGURES
Page VII © 2007 DH Instruments, a Fluke Company
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Table 1. Base system, PG7601-BAS-AF, packing guide ..........................................................................19
Table 2. Platform, PG7601-AF, packing list...............................................................................................20
Table 3. Pressure interconnections kit, PK-7601-P-AF, packing list.........................................................20
Table 4. Vacuum interconnections kit, PK-7601-V-AF, packing list ..........................................................21
Table 5. Base system accessories kit packing list.....................................................................................21
Table 6. Exchange pack, PG7601-EXC-AF, packing guide ......................................................................22
Table 7. Piston-cylinder modules, PC-7100/7600-10-L, PC-7100/7600-50,
PC-7100/7600-200, packing list..............................................................................................22
Table 8. Mass set, MS-7001-35-AF, packing list.......................................................................................23
Table 9. Exchange pack accessories packing list.....................................................................................23
Table 10. Summary of PG7601-AF PG Terminal direct function key operations......................................53
Table 11. SETUP file choices, factory preferred choice and normal value...............................................76
Table 12. Piston-cylinder module digital ID fields......................................................................................84
Table 13. Mass set digital ID fields............................................................................................................88
Table 14. Mass loading bell digital ID fields...............................................................................................92
Table 15. Pressure units of measure available..........................................................................................95
Table 16. Security levels - functions NOT executed per function/level ...................................................102
Table 17. COM1, COM2 and COM3 available settings...........................................................................104
Table 18. COM1 DB-9F pin designation..................................................................................................116
Table 19. COM2 and COM3 DB-9M pin designation ..............................................................................116
Table 20. Command summary.................................................................................................................118
Table 21. Error messages........................................................................................................................120
Table 22. Status byte register..................................................................................................................149
Table 23. Standard event register............................................................................................................150
Table 24. Mechanical maintenance procedures......................................................................................153
Table 25. Top Level Illustrated Parts Breakdown (see Figure 23) .........................................................154
Table 26. PG7601 Illustrated Parts Breakdown for Mass Set, Cases, and Covers (see Figure 24)......156
Table 27. PG7601 Illustrated Parts Breakdown for Piston Cylinders (see Figure 25) ...........................157
Table 28. PG7601 Illustrated Parts Breakdown for Piston Cylinder Cases (see Figure 26)..................157
Table 29. PG7601 Illustrated Parts Breakdown for PG Main Board (see Figure 27).............................159
Table 30. PG7601 Illustrated Parts Breakdown for PG Base Underside (see Figure 28)......................160
Table 31. PG7601 Illustrated Parts Breakdown for PG Base Outside (see Figure 29)..........................162
Table 32. PG7601 Illustrated Parts Breakdown for PG Terminal Outside (see Figure 30)....................163
Table 33. PG7601 Illustrated Parts Breakdown for PG Terminal Inside (see Figure 31).......................164
Table 34. PG7601 Illustrated Parts Breakdown for PPC3 Outside (see Figure 32)...............................165
Table 35. PG7601 Illustrated Parts Breakdown for PPC3 Pneumatic Module (see Figure 33).............167
Table 36. PG7601 Illustrated Parts Breakdown for PPC3 Inside (see Figure 34) .................................169
Table 37. PG7601 Illustrated Parts Breakdown for PPC3 Manifold detail (see Figure 35)....................170
Table 38. PG7601 Illustrated Parts Breakdown for PK-7601-P-AF (see Figure 36)..............................171
Table 39. PG7601 Illustrated Parts Breakdown for Accessories Kit (see Figure 37).............................172

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page VIII
Table 40. PG7601-AF mounting post wire colors, description and location............................................188
Table 41. Metrological maintenance procedures.....................................................................................195
Table 42. Recalibration requirements......................................................................................................199
Table 43. Troubleshooting checklist........................................................................................................209
Table 44. Pressure unit of measure conversions ....................................................................................213
Table 45. Defined pressure calculation variables....................................................................................214
Table 46. DHI Authorized Service Providers...........................................................................................219

ABOUT THIS MANUAL
Page IX © 2007 DH Instruments, a Fluke Company
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Figure 1. System, PG7601-SYS-AF, standard installation........................................................................10
Figure 2. System, PG7601-SYS-AF, pneumatic schematic ......................................................................11
Figure 3. System, PG7601-SYS-AF, communications schematic.............................................................11
Figure 4. Piston gauge operating principle ................................................................................................12
Figure 5. Platform, PG7601-AF, rear view.................................................................................................13
Figure 6. PG Terminal front panel..............................................................................................................14
Figure 7. PG Terminal rear panel ..............................................................................................................14
Figure 8. Piston-cylinder modules, PC-7100/7600-10-L, -50, -200...........................................................15
Figure 9. Mass set, MS-7100-35-AF..........................................................................................................16
Figure 10. Pressure controller, PPC3-7M-AF, front panel.........................................................................17
Figure 11. Pressure controller, PPC3-7M-AF, rear panel..........................................................................17
Figure 12. Reference vacuum pump, D16B, front and side views ............................................................18
Figure 13. Piston-cylinder module installation...........................................................................................28
Figure 14. Piston gauge operating principle ..............................................................................................37
Figure 15. Piston stroke and zones ...........................................................................................................42
Figure 16. PG Terminal keypad layout ......................................................................................................45
Figure 17. Platform MAIN run screen display fields...................................................................................47
Figure 18. RUN screen flow chart..............................................................................................................48
Figure 19. Pressure controller keypad layout............................................................................................49
Figure 20. Pressure controller direct pressure control keys......................................................................50
Figure 21. Pressure controller MAIN run screen display fields..................................................................52
Figure 22. Status byte register.................................................................................................................149
Figure 23. Top Level Illustrated Parts Breakdown for PG7601-SYS-AF..................................................155
Figure 24. PG7601 Illustrated Parts Breakdown for Mass Sets, Cases, and Covers..............................156
Figure 25. PG7601 Illustrated Parts Breakdown for Piston Cylinders......................................................158
Figure 26. PG7601 Illustrated Parts Breakdown for Piston Cylinder Cases ............................................158
Figure 27. PG7601 Illustrated Parts Breakdown for PG Main Board .......................................................159
Figure 28. PG7601 Illustrated Parts Breakdown for PG Base Underside................................................161
Figure 29. PG7601 Illustrated Parts Breakdown for PG Base Outside....................................................162
Figure 30. PG7601 Illustrated Parts Breakdown for PG Terminal Outside..............................................163
Figure 31. PG7601 Illustrated Parts Breakdown for PG Terminal Inside.................................................164
Figure 32. PG7601 Illustrated Parts Breakdown for PPC3 Outside.........................................................166
Figure 33. PG7601 Illustrated Parts Breakdown for PPC3 Pneumatic Module........................................168
Figure 34. PG7601 Illustrated Parts Breakdown for PPC3 Inside............................................................169
Figure 35. PG7601 Illustrated Parts Breakdown for PPC3 Manifold detail..............................................170
Figure 36. PG7601 Illustrated Parts Breakdown for PK-7601-P-AF ........................................................171
Figure 37. PG7601 Illustrated Parts Breakdown for Accessories Kit.......................................................172
Figure 38. 10 kPa/kg piston-cylinder module (expanded view)...............................................................177
Figure 39. Gas piston-cylinder module sleeve nut tool............................................................................177
Figure 40. 10 kPa/kg piston insertion tool................................................................................................178
Figure 41. 50, 200 kPa/kg gas piston-cylinder modules (expanded view)..............................................182
Figure 42. Piston-cylinder module lubrication chart..................................................................................186
Figure 43. Vacuum gauge calibration setup.............................................................................................204

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page X
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ABOUT THIS MANUAL
Page XI © 2007 DH Instruments, a Fluke Company
A
AB
BO OU UT T T
TH
HI IS S M
MA
AN NU UA AL L
This manual provides the user with the information necessary to operate and maintain a PG7601-SYS-AF
gas operated piston gauge system.
Before using the manual, take a moment to familiarize yourself with the Table of Contents structure.
All first time PG7601-AF users should read Section 2 and 4. Section 5 covers remote communication
with an external computer. Sections 6 and 7 provide maintenance and calibration information. Section 1
is a quick troubleshooting guide. Use the information in Section 1 to troubleshoot unexpected PG7601-
AF behavior based on the symptoms of that behavior.
Certain words and expressions have specific meaning as they pertain to PG7601-AFs. The Glossary
(see Section 9.3) is useful as a quick reference for the definition of specific words and expressions as
they are used in this manual.
The PG7601-SYS-AF system includes a PPC3-7M-AF pressure controller. This manual covers the
pressure controller to the extent necessary for normal operation of the PG7601-AF system. The PPC3-7M-AF
has a complete, independent manual that is included on the PG7601-SYS-AF Support Disc.
FOR THOSE OF YOU WHO “DON’T READ MANUALS”, GO DIRECTLY TO SECTION 3.3 TO SET UP
YOUR PG7601-AF. THEN GO TO SECTION 3.5. THIS WILL GET YOU RUNNING QUICKLY WITH MINIMAL RISK OF
CAUSING DAMAGE TO YOURSELF OR YOUR PG7601-AF. THEN… WHEN YOU HAVE QUESTIONS OR START TO
WONDER ABOUT ALL THE GREAT FEATURES YOU MIGHT BE MISSING, GET INTO THE MANUAL!
Manual Conventions
(CAUTION) is used 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., [UNIT]).
< > indicates PG7601-AF screen displays (e.g., <1yes>)

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page XII
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1. INTRODUCTION
Page 1 © 2008 DH Instruments, a Fluke Company
1
1. . I IN
NT TR RO OD DU UC CT TI IO ON N
PG7601-SYS-AF is a very high performance pressure calibration system for the validation and calibration
of pressure measuring devices using gas as the pressurized medium. It operates on the piston gauge
principle. Pressure is defined by balancing it against the force exerted by a known mass accelerated by
gravity on the effective area of a piston-cylinder.
PG7601-SYS-AF covers the pressure range of 7 to 7000 kPa (1 to 1 000 psi) in absolute and gauge
modes with semi-automated operation and state of the art measurement uncertainty.
A PG7601-SYS-AF is made up of:
PG7601-BAS-AF, p/n 402351, the “base” system, including the piston gauge platform, pressure
controller, vacuum pump and interconnecting hardware (everything except the piston-cylinder modules
and masses).
PG7601-EXC-AF, p/n 402350, the “exchange package”, including the piston gauge’s three different size
piston-cylinder modules and the mass set.
1.1 SPECIFICATIONS
1.1.1 OVERALL SYSTEM SPECIFICATIONS
Power requirements
Instruments
Reference vacuum pump (D16B)
85 to 264 VAC, 50/60 Hz, 52 VA max. consumption
100 to 120 VAC, 50/60 Hz, 1430 VA max. consumption, full load 9.4
to 13 A
Operating temperature range 15 to 35 °C
Storage temperature range 5 to 90 °C (vacuum pump), -40 to 100 °C (other components)
Operating humidity range 5 to 95% R.H., non-condensing
Storage humidity range 5 to 95% R.H., non-condensing
Dimensions
Bench space needed for installation
65 cm x 56 cm (65 in. x 22 in.)
Weight (shipping)
PG7601-AF platform in case
PG7601-AF vacuum bell jar
PPC3-7M-AF pressure controller
D16B vacuum pump
Base system accessories
35 kg mass set, main masses case
35 kg mass set, fractional masses case
(3) piston-cylinder modules in case
Exchange pack accessories
36 kg (79 lb)
5 kg (11 lb)
18 kg (40 lb)
40 kg (88 lb)
12 kg (26 lb)
35 kg (77 lb)
20 kg (44 lb)
10 kg (22 lb)
6 kg (13 lb)
System external communication ports RS 232 (COM1), IEEE-488
Overall pressure ranges
Actual range depends on piston-cylinder
installed
7 kPa to 7 MPa (1 to 1000 psi), gauge and absolute
Operating media air, helium, nitrogen

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 2
Pressure connections
Device under test (DUT)
Test pressure supply (PPC3)
Control vacuum supply
Swagelok®SS-QC4-B1-400 quick connector with quick connector
stems of 1/4 in. NPT F, 1/8 in. NPT F, AN4 M, 1/4 in. Swage
1/8 in. NPT F
1/8 in. NPT F
1.1.1.1 PRESSURE MEASUREMENTS
The pressure measurement specifications of the PG7601-AF depend upon the
piston-cylinder module used.
PC-7100/7600-10-L (10 kPa/kg)
Sensitivity1
Reproducibility2
Measurement uncertainty3
0.02 Pa + 0.5 ppm
±4 ppm
± (0.2 Pa + 15 ppm)
PC-7100/7600-50 (50 kPa/kg)
Sensitivity1
Reproducibility2
Measurement uncertainty3
0.1 Pa + 0.5 ppm
±4 ppm
± (0.5 Pa + 20 ppm)
PC-7100/7600-200 (200 kPa/kg)
Sensitivity1
Reproducibility2
Measurement uncertainty3
0.4 Pa + 0.5 ppm
±6 ppm
± (2 Pa + 25 ppm)
1. Sensitivity: The smallest variation in input detectable in output.
2. Reproducibility: Combined long term stability of piston-cylinder effective area and masses predicted for 30
months.
3.Measurement uncertainty: Maximum deviation of the PG7601-AF indicatied pressure from the true value of pressure, in
gauge and absolute measurement modes, at the PG7601-AF reference level including precision, predicted 30 month stability,
temperature effect and calibration uncertainty, combined and expanded (k=2) following the ISO “Guide to the Expression of
Uncertainty in Measurement. Assumes the PG7601-AF platform sensors are properly adjusted, use of MS-7001-35-AF mass
set with measurement uncertainty of ± 5 ppm, uncertainty of not more than ± 2 ppm in the value of local acceleration due to
gravity entered into the PG7601-AF Terminal.
1.1.2 PISTON GAUGE PLATFORM (PG7601-AF)
Power requirements 85 to 264 VAC, 50/60 Hz, 22 VA max. consumption.
Operating temperature range 15 to 25 °C
Weight Instrument platform
PG Terminal
17 kg (37 lb)
1.4 kg (3 lb)
Dimensions Instrument platform
PG Terminal
36 cm H (top of bell jar) x 40 cm W x 35 cm D (14.5 in. x 15.8 in. x
13.8 in.)
12 cm H x 15 cm W x 20 cm D (4.7 in. H x 5.9 in. W x 7.9 in. D)
Microprocessors
Instrument platform
PG Terminal
Motorola 68302
Hitachi 64180
Communication ports RS232
IEEE-488
COM1: Host computer communications
COM2: Not used (may be used for optional external barometer or
vacuum gauge)
COM3: PPC3 pressure controller communications
Host comptuer

1. INTRODUCTION
Page 3 © 2007 DH Instruments, a Fluke Company
Overall pressure range 7 kPa to 7 MPa (1 to 1000 psi), gauge and absolute (actual range
depends on piston-cylinder selected)
Operating media air, helium, nitrogen
Mass load range 0.7 to 36.2 kg
Pressure connections
TEST port
Bell jar vent (VACUUM) port
Referencevacuum pump down port
DH200 (for 1/4 in. OD tube, equivalent to AE SF250C, HIP LF4)
DH200
KF25
CE Conformance Available, must be specified.
1.1.2.1 EMBEDDED FEATURES
•Local control with 2 x 20 vacuum fluorescent display and 4 x 4 function
driven keypad.
•Real time (1 second update rate) display and measurement of ambient
(pressure, temperature, humidity) and instrument (piston-cylinder
temperature, piston position, piston drop rate, piston rotation rate, piston
rotation decay rate, reference vacuum) conditions.
•Real time (1 second update rate) mass-to-pressure and pressure-to-mass
calculations taking into consideration all environmental and operational
variables.
•Full gas and liquid fluid head corrections including DUT head correction and
piston position head correction.
•Adjustable mass loading resolution (0.01 g to 0.1 kg).
•Audible prompts of instrument status (piston movement, Ready/Not Ready indication)
with override capability.
•Integrated automated mass handling (optional).
•Interfacing and automatic exploitation of optional external barometer via
RS232 (optional).
•Interfacing and automatic exploitation of external vacuum gauge via RS232
(optional).
•Storage and one step activation of metrological data digital IDs on up to 18 piston-
cylinder modules, (3) mass sets and (3) mass loading bells.
•Continuous pressure Ready/Not Ready indication based on measured
conditions.
•Motorized, intelligent piston drive system based measured rotation rate with
operator alert and manual override.
•Integrated automated pressure control with PPC3-7M-AF pressure controller.
•Full RS232 and IEEE-488 communications with multi-level commands to set
and read all instrument functions.

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 4
1.1.2.2 MEASUREMENT OF AMBIENT AND INSTRUMENT
CONDITIONS
Temperature Range
Resolution
Measurement uncertainty
Ambient Piston Cylinder Module
15 to 25o C 15 to 25 oC
0.1 0.01
±1 ±0.1
Barometric Pressure
with Internal Sensor
Range
Resolution
Measurement uncertainty
70 to 110 kPa
10 Pa
±140 Pa
Barometric pressure can also be read automatically with any
RS232 device such as a DHI RPM (not included in
PG7601-SYS-AF).
Relative Humidity Range
Resolution
Measurement uncertainty
5 to 95 % RH
1 % RH
±10 % RH
Piston Position Range
Resolution
Measurement uncertainty
±4.5 mm
0.1 mm
±0.2 mm
Piston Rotation
(Rate and deceleration)
Range
Resolution
2 to 99 rpm
1 rpm
Vacuum Range
Resolution
Measurement uncertainty
0 to 20 Pa
0.1 Pa
±0.1 Pa or 10 % of reading, whichever is greater

1. INTRODUCTION
Page 5 © 2007 DH Instruments, a Fluke Company
1.1.3 PISTON-CYLINDER MODULES (PC-7100/7600-10-L, -50, -200)
The PG7601-SYS-AF piston-cylinders are integrated modules including mounting hardware
delivered in individual shipping and storage bullet cases.
PC-7100/7600-10-L Range
Operation
Piston material
Nominal mass of piston assembly
Cylinder material
Nominal diameter
Nominal area
Mounting system
Typical drop rate (35 kg load)
Nominal mass to pressure 10 kPa/kg (1.5 psi/kg)
7 to 350 kPa (1 to 50 psi)
Gas operated, gas lubricated
Tungsten carbide
0.4 kg
Tungsten carbide
35 mm
1 000 mm2
Simple free deformation
0.1 mm/min
PC-7100/7600-50 Range
Operation
Piston Material
Nominal mass of piston assembly
Cylinder Material
Nominal Diameter
Nominal Area
Mounting system
Typical drop rate (35 kg load)
Nominal mass to pressure 50 kPa/kg (7.5 psi/kg)
25 to 1750 kPa (3.6 to 254 psi)
Gas operated, gas lubricated
Tungsten carbide
0.2 kg
Tungsten carbide
16 mm
200 mm2
Negative free deformation
0.5 mm/min
PC-7100/7600-200 Range
Operation
Piston Material
Nominal mass of piston assembly
Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Typical drop rate (35 kg load)
Nominal mass to pressure 200 kPa/kg (14.5 psi/kg)
100 to 7000 kPa (14.5 to 1015 psi)
Gas operated, gas lubricated
Tungsten carbide
0.2 kg
Tungsten carbide
8 mm
50 mm2
Negative free deformation
1.0 mm/min

PG7601-SYS-AF™ OPERATION AND MAINTENANCE MANUAL
© 2007 DH Instruments, a Fluke Company Page 6
1.1.4 MASS SET (MS-7001-35-AF)
Set composition 1 x 4.5 kg disc(makeup mass)
5 x 5 kg disc
2 x 2 kg disc
1 x 1 kg disc
1 x 0.5 kg puck
2 x 0.2 kg puck
1 x 0.1 kg puck
1 x 0.3 kg mass loading bell
Trim mass set of 50 g to 0.01 g (total 100 g)
Mass discs and pucks
Material
Finish
Adjustment tolerance
Uncertainty in measured values
304L non-magnetic stainless steel
Electropolished
±20 ppm of nominal value
±5 ppm
Mass loading bell
Material
Finish
Adjustment tolerance
Uncertainty in measured value
6AL-4V titanium (bell and hanger), 304L stainless steel
(adjustment ring), nickel plated 1018 steel (speed ring)
Mechanically polished
±20 ppm of nominal value
±8 mg
Trim masses < 50g
Adjustment tolerance
Uncertainty in measured value
Adjusted to nominal value
±1 mg