Fluke Calibration 4322-SYS-NAVAIR User manual

4322-SYS-NAVAIR
Automated
Pressure
Calibrator
Service Manual

Reproduction and Distribution Notice
In accordance Section 130 of title 10, United States Code, a DoD Distribution marking
system for technical data has been established by DoD Directive 5230.24. IAW this directive
and NAVAIR METCAL Policy, the below distribution statement needs to be added to the
covers of all Technical Manuals acquired by the NAVAIR METCAL Program:
DISTRIBUTION STATEMENT C. Distribution authorized to U.S. Government Agencies and their
contractors for official use or for administrative or operational purposes, determined on
(September 28, 2011). Other requests for this document shall be referred to NAVAIR
METCAL Program Office, Fleet Support Team Building 1403, 22113 Fortin Circle, Patuxent
River, MD 20670-1118
About the Product Manual Set
Product manual set consists of a Model Number 4322 Operators Manual and a Model
Number 4322 Service Manual available as Print On Demand documents hosted on the
Technical Manual Application System (TMAPS - NATEC’s Technical manual master database).
System Calibration
For Navy calibration actions calibrate IAW NA 17-35MTL-3.

PN 4133214
September 2013 Rev. 2, 2/15
© 2013-2014 Fluke Corporation. All rights reserved. Specifications are subject to change without notice.
All product names are trademarks of their respective companies.
4322
Automated Pressure Calibrator
Service Manual
Reproduction and distribution of this technical
manual is authorized for U.S. Government purposes.

LIMITED WARRANTY AND LIMITATION OF LIABILITY
Each Fluke product is warranted to be free from defects in material and workmanship under normal use and
service. The warranty period is one year and begins on the date of shipment. Parts, product repairs, and
services are warranted for 90 days. This warranty extends only to the original buyer or end-user customer of
a Fluke authorized reseller, and does not apply to fuses, disposable batteries, or to any product which, in
Fluke's opinion, has been misused, altered, neglected, contaminated, or damaged by accident or abnormal
conditions of operation or handling. Fluke warrants that software will operate substantially in accordance
with its functional specifications for 90 days and that it has been properly recorded on non-defective media.
Fluke does not warrant that software will be error free or operate without interruption.
Fluke authorized resellers shall extend this warranty on new and unused products to end-user customers
only but have no authority to extend a greater or different warranty on behalf of Fluke. Warranty support is
available only if product is purchased through a Fluke authorized sales outlet or Buyer has paid the
applicable international price. Fluke reserves the right to invoice Buyer for importation costs of
repair/replacement parts when product purchased in one country is submitted for repair in another country.
Fluke's warranty obligation is limited, at Fluke's option, to refund of the purchase price, free of charge repair,
or replacement of a defective product which is returned to a Fluke authorized service center within the
warranty period.
To obtain warranty service, contact your nearest Fluke authorized service center to obtain return
authorization information, then send the product to that service center, with a description of the difficulty,
postage and insurance prepaid (FOB Destination). Fluke assumes no risk for damage in transit. Following
warranty repair, the product will be returned to Buyer, transportation prepaid (FOB Destination). If Fluke
determines that failure was caused by neglect, misuse, contamination, alteration, accident, or abnormal
condition of operation or handling, including overvoltage failures caused by use outside the product’s
specified rating, or normal wear and tear of mechanical components, Fluke will provide an estimate of repair
costs and obtain authorization before commencing the work. Following repair, the product will be returned to
the Buyer transportation prepaid and the Buyer will be billed for the repair and return transportation charges
(FOB Shipping Point).
THIS WARRANTY IS BUYER'S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. FLUKE SHALL NOT BE LIABLE
FOR ANY SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OR LOSSES,
INCLUDING LOSS OF DATA, ARISING FROM ANY CAUSE OR THEORY.
Since some countries or states do not allow limitation of the term of an implied warranty, or exclusion or
limitation of incidental or consequential damages, the limitations and exclusions of this warranty may not
apply to every buyer. If any provision of this Warranty is held invalid or unenforceable by a court or other
decision-maker of competent jurisdiction, such holding will not affect the validity or enforceability of any other
provision.
Fluke Corporation
P.O. Box 9090
Everett, WA 98206-9090
U.S.A.
Fluke Europe B.V.
P.O. Box 1186
5602 BD Eindhoven
The Netherlands
11/99

i
Table of Contents
Chapter Title Page
1 Introduction and Specifications......................................................... 1-1
Introduction........................................................................................................ 1-3
Product Overview .............................................................................................. 1-3
Safety Information ............................................................................................. 1-4
The Product Manual Set .................................................................................... 1-5
General Specifications ....................................................................................... 1-6
Pressure Limits .................................................................................................. 1-6
Measurement Specifications .............................................................................. 1-8
Pressure Control Specifications ......................................................................... 1-9
Pressure Switch Testing Specifications (Handheld) .......................................... 1-9
2 Theory of Operation ............................................................................ 2-1
Introduction........................................................................................................ 2-3
Controller........................................................................................................... 2-3
Pressure Control ............................................................................................ 2-4
External Supply Pressure Control ............................................................. 2-6
Internal Pump Pressure Generation and Control....................................... 2-7
Removable Components................................................................................ 2-10
Pressure Transducer Modules ................................................................... 2-10
Barometer.................................................................................................. 2-11
Contamination Prevention System............................................................ 2-12
CalCheck ....................................................................................................... 2-15
AutoZero and BaroCheck.............................................................................. 2-15
Emergency Pressure Relief............................................................................ 2-16
Intensifier ........................................................................................................... 2-17
Set Pressure and Generation .......................................................................... 2-17
Pressure On-Demand..................................................................................... 2-17
Overpressure Relief ....................................................................................... 2-19
Electronic Pressure Sensor and Gauge .......................................................... 2-19

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Service Manual
ii
3 Calibration and Alignment.................................................................. 3-1
Introduction........................................................................................................ 3-3
Fundamentals ..................................................................................................... 3-3
Required Equipment .......................................................................................... 3-4
Environmental Conditions ................................................................................. 3-4
Equipment Setup................................................................................................ 3-5
Preliminary Operations ...................................................................................... 3-5
Module Calibration Procedure........................................................................... 3-7
Module Alignment Procedure............................................................................ 3-8
4 Controller Maintenance....................................................................... 4-1
Introduction........................................................................................................ 4-3
Safety ................................................................................................................. 4-3
Standard Torque Look-Up Table....................................................................... 4-3
Maintenance Procedures .................................................................................... 4-4
Event Log ...................................................................................................... 4-4
Front-Panel and Case Cleaning ..................................................................... 4-4
Pressure Leakage Test ................................................................................... 4-5
Pressure Generation Test (On-Board Motor) ................................................ 4-6
Fuse Replacement.......................................................................................... 4-7
Controller Part Replacement.............................................................................. 4-9
Chassis........................................................................................................... 4-9
Control Panel Separation ............................................................................... 4-10
Pump Bracket ................................................................................................ 4-15
Manifold ........................................................................................................ 4-17
Display........................................................................................................... 4-20
Keypad, Encoder, or Encoder Wheel ............................................................ 4-21
Communications Box .................................................................................... 4-22
Pressure Transducers and Barometer ............................................................ 4-24
Contamination Prevention System (CPS)...................................................... 4-26
Fine and Coarse CPS Filters (Internal) ..................................................... 4-26
CPS Vent Filter (External) ........................................................................ 4-26
CPS Dock and NC Isolation Valve ........................................................... 4-27
Piston Pump Head Solenoid Assembly ......................................................... 4-29
Piston Pump Head Clippard Valves .............................................................. 4-29
Piston Seal ..................................................................................................... 4-31
Piston Pump Seal........................................................................................... 4-32
Precision, Isolation, and Control Valves and Backplane PCA...................... 4-33
Precision Control Valve ............................................................................ 4-33
Control Valves .......................................................................................... 4-33
Backplane PCA ......................................................................................... 4-33
NC Isolation Valve.................................................................................... 4-35
PCAs.............................................................................................................. 4-35
Access the Electronics Box....................................................................... 4-36
Power Supply PCA ................................................................................... 4-36
Processor PCA .......................................................................................... 4-36
Main PCA and P-VLV PCA ..................................................................... 4-37
Amplifier PCA .......................................................................................... 4-38
Quick Connect Fittings (QC) and Filter ........................................................ 4-40

Contents (continued)
iii
5 Intensifier Maintenance....................................................................... 5-1
Introduction........................................................................................................ 5-3
Safety ................................................................................................................. 5-3
Standard Torque Look-Up Table....................................................................... 5-4
Intensifier Hour Meter ....................................................................................... 5-5
Maintenance Procedures .................................................................................... 5-7
Front-Panel and Case Cleaning ..................................................................... 5-7
Pressure Generation and Leak Test ............................................................... 5-7
Electronic Pressure Sensor Alignment .......................................................... 5-8
Seal Replacements......................................................................................... 5-9
Fuse Replacement.......................................................................................... 5-9
Intensifier Part Replacement.............................................................................. 5-11
Chassis........................................................................................................... 5-11
Pump Cam ..................................................................................................... 5-14
Pump Cam Disassembly ........................................................................... 5-16
Pump Cam Reassembly............................................................................. 5-17
Motor Controller............................................................................................ 5-19
Planetary Gears and Gear Bearings ............................................................... 5-20
Pressure Port Shaft and Seals ........................................................................ 5-22
ICM ............................................................................................................... 5-23
Piston Clevis Bearing, Roller, and Piston Seals ............................................ 5-23
Pressure Gauge .............................................................................................. 5-27
Vent or Isolation Valve ................................................................................. 5-28
Electronic Pressure Sensor ............................................................................ 5-29
Overpressure Relief Valve............................................................................. 5-30
Power Entry Module...................................................................................... 5-30
Power Supply PCA and Intensifier PCA....................................................... 5-31
Quick Connect Fittings (QC) and Filter ........................................................ 5-32
6 Nitrogen Cylinder Maintenance.......................................................... 6-1
Introduction........................................................................................................ 6-3
Safety ................................................................................................................. 6-3
Visual Inspection ............................................................................................... 6-4
External Cylinder Cleaning Procedure .............................................................. 6-4
Internal Cylinder Cleaning Procedure ............................................................... 6-4
Nitrogen Recharge Procedure ............................................................................ 6-5
7 List of Replaceable Parts.................................................................... 7-1
Introduction........................................................................................................ 7-3
How to Order Replacement Parts ...................................................................... 7-3
Calibrator Final Assembly ................................................................................. 7-4
Controller Final Assembly................................................................................. 7-10
Intensifier Final Assembly................................................................................. 7-22
8 Troubleshooting .................................................................................. 8-1
Introduction........................................................................................................ 8-3
Controller Troubleshooting................................................................................ 8-3
Controller Fault Codes .................................................................................. 8-3
Electrical Problems........................................................................................ 8-5
Pressure Generation and Indication Problems............................................... 8-5
CPS and Quick-Connect Problems................................................................ 8-6
Intensifier Troubleshooting................................................................................ 8-6

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Service Manual
iv
Electrical Problems........................................................................................ 8-6
Pressure Selection and LED Indications ....................................................... 8-7
Abnormal Noises ........................................................................................... 8-7
Pressure Generation and Indication Problems............................................... 8-8
Valves and Quick-Connect Problems............................................................ 8-8
9 Wiring Schematics .............................................................................. 9-1
Introduction........................................................................................................ 9-3
Controller Wiring Schematics............................................................................ 9-3
Intensifier Wiring Schematics............................................................................ 9-6

v
List of Tables
Table Title Page
1-1. Symbols.................................................................................................................. 1-4
2-1. Valve and Solenoid Positions................................................................................. 2-9
3-1. Calibration Equipment ........................................................................................... 3-4
4-1. Controller Maintenance Time Schedule................................................................. 4-3
4-2. Standard Hardware Torque Values ........................................................................ 4-3
4-3. Leak Test Parameters ............................................................................................. 4-5
4-4. Replacement Fuse (Controller) .............................................................................. 4-7
5-1. Intensifier Maintenance Time Schedule................................................................. 5-3
5-2. Standard Hardware Torque Values ........................................................................ 5-4
5-3. Hour Meter Conversion Table................................................................................ 5-6
5-4. Replacement Fuse (Intensifier) .............................................................................. 5-9
7-1. Calibrator Final Assembly ..................................................................................... 7-4
7-2. Accessory Kit Assembly ........................................................................................ 7-6
7-3. Adapter Kit Assembly............................................................................................ 7-8
7-4. Spares Kit Assembly (not shown) ......................................................................... 7-9
7-5. Controller Top-Level Assembly............................................................................. 7-10
7-6. A1 Control Panel Assembly................................................................................... 7-12
7-7. A8 System Manifold Assembly ............................................................................. 7-14
7-8. A9 Pump Bracket Assembly .................................................................................. 7-16
7-9. A10 Electronics Box Assembly ............................................................................. 7-18
7-10. A15 CPS Assembly................................................................................................ 7-20
7-11. A1 Intensifier Assembly......................................................................................... 7-22
7-12. A1 Control Panel Assembly (Page 1) .................................................................... 7-24
7-13. A1 Control Panel Assembly (Page 2) .................................................................... 7-26
7-14. A2 Booster Pump Assembly .................................................................................. 7-28
7-15. A2/A2 Pump Cam Assembly ................................................................................. 7-30
7-16. A2/A3 Cam Plate and Planetary Gears Assembly ................................................. 7-32
7-17. ICM and Shaft Assembly ....................................................................................... 7-33
7-18. Piston and Clevis Assembly................................................................................... 7-34

4322
Service Manual
vi

vii
List of Figures
Figure Title Page
1-1. The 4322 Automated Pressure Calibrator .............................................................. 1-3
2-1. Location of the Pressure Valves............................................................................. 2-5
2-2. Pressure Valve Schematic ...................................................................................... 2-8
2-4. Contamination Prevention System (CPS) .............................................................. 2-12
2-5. CPS Pressure Routing (Cross-Section View)......................................................... 2-14
2-6. CalCheck Indicator................................................................................................. 2-15
2-7. Intensifier Schematic (Shown on Front Panel)....................................................... 2-18
3-1. Equipment Setup .................................................................................................... 3-5
3-2. Module Selection ................................................................................................... 3-7
3-3. Calibration Menu Configuration ............................................................................ 3-8
3-4. Module Selection ................................................................................................... 3-9
3-5. Alignment Menu Configuration ............................................................................. 3-9
4-1. Spray Test............................................................................................................... 4-6
4-2. Controller Fuse Replacement ................................................................................. 4-8
4-3. Controller Case and Chassis................................................................................... 4-9
4-4. Control Panel Removal .......................................................................................... 4-12
4-5. Electronics Box Cables .......................................................................................... 4-13
4-6. Power Module and Tubeweld ................................................................................ 4-14
4-7. Piston and Pump Head Assembly Removal ........................................................... 4-16
4-8. Pressure Line and Power Lines .............................................................................. 4-18
4-9. Manifold Removal ................................................................................................. 4-19
4-10. Display Assembly .................................................................................................. 4-21
4-11. Keypad Replacement ............................................................................................. 4-22
4-12. Communications Box Replacement ....................................................................... 4-23
4-13. Pressure Transducer and Barometer Removal ....................................................... 4-25
4-14. Coarse and Fine Filters........................................................................................... 4-27
4-15. CPS Dock Replacement ......................................................................................... 4-28
4-16. Pump Head and Piston Removal............................................................................ 4-30
4-17. Piston Seal Installation........................................................................................... 4-31
4-17. NC Isolation Valve................................................................................................. 4-34
4-18. System Manifold Exploded View .......................................................................... 4-34
4-19. NC Isolation Valve Removal ................................................................................. 4-35
4-21. Quick-Connect Fitting............................................................................................ 4-40
5-1. Fuse Replacement .................................................................................................. 5-10
5-2. Intensifier Case Removal ....................................................................................... 5-12

4322
Service Manual
viii
5-3. Housing Assembly Removal.................................................................................. 5-13
5-4. Pump Cam Assembly Removal.............................................................................. 5-15
5-5. Cam Assembly Replacement ................................................................................. 5-18
5-6. Motor Controller Replacement............................................................................... 5-19
5-7. Planetary Gear Replacement .................................................................................. 5-21
5-8. ICM Shaft Assembly.............................................................................................. 5-22
5-9. Seal Installation Tool ............................................................................................. 5-24
5-10. Piston Insertion....................................................................................................... 5-25
5-11. Piston Clevis Assembly Replacement.................................................................... 5-26
5-12. Pressure Gauge Replacement ................................................................................. 5-27
5-13. Isolation and Vent Valve Replacement.................................................................. 5-28
5-14. Pressure Transducer Replacement ......................................................................... 5-29
5-15. Power Entry Module and Power Supply PCA Replacement ................................. 5-31
5-16. Quick Connect Fitting Removal............................................................................. 5-34
6-1. Nitrogen Fill Adapter ............................................................................................. 6-6
7-1. Final Assembly....................................................................................................... 7-5
7-2. Accessory Kit Assembly ........................................................................................ 7-7
7-3. Adapters Kit Assembly .......................................................................................... 7-8
7-4. Controller Top-Level Assembly............................................................................. 7-11
7-5. A1 Control Panel Assembly................................................................................... 7-14
7-6. System Manifold Assembly ................................................................................... 7-15
7-7. A9 Pump Bracket Assembly .................................................................................. 7-17
7-8. A10 Electronics Box Assembly ............................................................................. 7-19
7-9. A15 CPS Assembly................................................................................................ 7-21
7-10. Intensifier Final Assembly ..................................................................................... 7-23
7-11. Control Panel Assembly (Page 1) .......................................................................... 7-25
7-12. Control Panel Assembly (Page 2) .......................................................................... 7-27
7-13. A2 Booster Pump Assembly .................................................................................. 7-29
7-14. A2 Pump Cam Assembly ....................................................................................... 7-31
7-15. A2 Cam Plate and Planetary Gears Assembly ....................................................... 7-32
7-16. ICM and Shaft Assembly ....................................................................................... 7-33
7-17. Piston and Clevis Assembly................................................................................... 7-34
9-1. Controller Wiring Harness Part Numbers .............................................................. 9-3
9-2. Wiring Harness Schematics (Sheet 1).................................................................... 9-4
9-3. Wiring Harness Schematics (Sheet 2).................................................................... 9-5
9-4. Wiring Harness Schematics (Sheet 3).................................................................... 9-6

1-1
Chapter 1
Introduction and Specifications
Title Page
Introduction........................................................................................................1-3
Product Overview ..............................................................................................1-3
Safety Information .............................................................................................1-4
The Product Manual Set ....................................................................................1-5
General Specifications .......................................................................................1-6
Pressure Limits ..................................................................................................1-7
Measurement Specifications ..............................................................................1-8
Pressure Control Specifications .........................................................................1-8
Pressure Switch Testing Specifications (Handheld) ..........................................1-9

4322
Service Manual
1-2

Introduction and Specifications
Introduction 1
1-3
Introduction
This chapter supplies information about the Product, the manual set, safety information,
contact information, and specifications.
Product Overview
The Fluke 4322 Automated Pressure Calibrator (the Product or Calibrator) is a
transportable system including an automated controller for calibration and testing of
pressure measurement instruments (see Figure 1-1). The Calibrator can calibrate and test
analog gauges, digital gauges, pressure transducers, pressure switches, and other pressure
devices.
Pressure Controller
“the Controller”
Pressure Intensifier
“the Intensifier”
Nitrogen
Cylinder Accessory
Kit
Handheld
Control
gxj039.eps
Figure 1-1. Main Components of 4322-SYS-NAVAIR Configuration of 4322 Automated Pressure
Calibrator
For maximum versatility and portability, the Calibrator consists of a Pressure Controller
(the Controller), a Pressure Intensifier (the Intensifier), a Nitrogen Cylinder, and an
Accessory Kit that can be used in three different configurations. Determination of which
configuration to use depends on how much pressure is necessary to complete the
calibration.

4322
Service Manual
1-4
Safety Information
A Warning identifies condition and procedures that are dangerous to the user. A
Caution identifies conditions and procedures that can cause damage to the Product or the
equipment under test.
See Table 1-1 for a list of symbols used in this manual and on the Calibrator.
Table 1-1. Symbols
Symbol Description Symbol Description
Risk of Danger. Important
information. See manual. Conforms to relevant North American Safety Standards.
Conforms to European Union
directives 
Do not dispose of this product as
unsorted municipal waste. Go to
Fluke’s website for recycling
information.
Earth ground Hazardous voltage
Conforms to relevant Australian EMC requirements
 Warning
To prevent possible electrical shock, fire, or personal injury:
•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.
•Read all safety Information before you use the Product.
•Carefully read all instructions.
•Use the Product only as specified, or the protection
supplied by the Product can be compromised.
•Examine the case before you use the Product. Look for
cracks or missing plastic. Carefully look at the insulation
around the terminals.
•Do not use the Product if it operates incorrectly.
•Do not use and disable the Product if it is damaged.
•Use only the mains power cord and connector approved for
the voltage and plug configuration in your country and rated
for the Product.
•Replace the mains power cord if the insulation is damaged
or if the insulation shows signs of wear.
•Make sure the ground conductor in the mains power cord is
connected to a protective earth ground. Disruption of the
protective earth could put voltage on the chassis that could
cause death.

Introduction and Specifications
The Product Manual Set 1
1-5
•Before using this equipment to generate or apply pressure,
ensure integrity of all components to be pressurized and
that they are rated to adequate working pressure.
•Do not put the Product where access to the mains power
cord is blocked.
•Do not use test leads if they are damaged. Examine the test
leads for damaged insulation and measure a known voltage.
•Do not exceed the Measurement Category (CAT) rating of
the lowest rated individual component of a Product, probe,
or accessory.
•Keep fingers behind the finger guards on the probes.
•Do not apply more than the rated voltage, between the
terminals or between each terminal and earth ground.
•Do not touch voltages > 30 V ac rms, 42 V ac peak, or
60 V dc.
•Do not use the Product around explosive gas.
The Product Manual Set
The Calibrator includes an Operators Manual and a Service Manual. Both manuals are
online at www.flukecal.com and on a CD in the Accessory Kit.
Note
Not all available components are included in every configuration of a 4322
system. Both manuals assume model 4322-SYS-NAVAIR, which includes all
major components available, except for the 4322-REM Handheld Control,
which is ordered separately.
•The 4322 Operators Manual contains basic system and feature information,
operation instructions, and basic user maintenance and troubleshooting information.
•This 4322 Service Manual contains service, calibration, and repair information and
instructions.

4322
Service Manual
1-6
General Specifications
Power Requirements ............................................ 100 V ac to 240 V ac (-15 %, +10 %), 50 Hz to 60 Hz
Maximum Power Consumption
Controller ............................................................ 110 VA
Intensifier ............................................................ 250 VA
Operating Temperature Range ............................ 0 °C to 50 °C
Storage Temperature Range................................ -30 °C to 71 °C
Humidity................................................................. 5 % to 95 %
Vibration ................................................................ Meets MIL-T-28800D
Altitude (operation)............................................... 2,000 m
Weight
Controller ............................................................ ~12 kg (27 lb)
Intensifier ............................................................ ~14 kg (31 lb)
Accessory Kit with Handheld Control.................. ~12 kg (27 lb)
Nitrogen Cylinder ................................................ ~12 kg (26 lb)
Dimensions
Controller, Intensifier, and Accessory Kit............ 33 cm Height x 31 cm Width x 31 cm Depth
(13 in Height x 12 in Width x 12 in Depth)
Nitrogen Cylinder ................................................ 69 cm Height x 18 cm Diameter (27 in Height x 7 in Diameter)
Remote Communication Interfaces..................... RS-232, USB type B, IEEE-488.2, USB type A (PRINTER port only)
Pressure Range..................................................... 3.5 kPa (0.5 psi) absolute to 70 MPa (10,000 psi)
Operating Medium ................................................ Dry nitrogen supply, or ambient air compressed by on-board pump.
Warm-up Time ....................................................... 15 minutes from power on, after at least 60 minutes ambient
temperature acclimation time within the working temperature range.
Safety ..................................................................... IEC 61010-1: Overvoltage Category II, Pollution Degree2,
Electromagnetic Compatibility (EMC)
International ...................................................... IEC 61326-1: Controlled Electromagnetic Environment
CISPR 11: Group 1, Class A
Group 1: Equipment has intentionally generated and/or uses
conductively-coupled radio frequency energy that is necessary for
the internal function of the equipment itself.
Class A: Equipment is suitable for use in all establishments other
than domestic and those directly connected to a low-voltage power
supply network that supplies buildings used for domestic purposes.
There may be potential difficulties in ensuring electromagnetic
compatibility in other environments due to conducted and radiated
disturbances.
Emissions that exceed the levels required by CISPR 11 can occur
when the equipment is connected to a test object.
Korea (KCC) ...................................................... Class A Equipment (Industrial Broadcasting & Communication Equipment)
Class A: Equipment meets requirements for industrial
electromagnetic wave equipment and the seller or user should take
notice of it. This equipment is intended for use in business
environments and not to be used in homes.
USA (FCC).......................................................... 47 CFR 15 subpart B. This product is considered an exempt device per clause
15.103.

Introduction and Specifications
Pressure Limits 1
1-7
Pressure Limits
Recommended Supply Pressure
Controller ............................................................ Greater of 700 kPa (100 psi) or 10 % above max target pressure, not
to exceed 73 MPa (10,500 psi).
Intensifier ............................................................ 3.5 MPa to 14 MPa (500 psi to 2,000 psi)
Max System Working Pressure ........................... 70 MPa (10,000 psi)
Max Supply Pressure
Controller ............................................................ 73 MPa (10,500 psi)
Intensifier ............................................................ 20 MPa (3,000 psi)
Max Nitrogen Cylinder Pressure ......................... 14 MPa (2,000 psi)
Max Regulator Pressure
Inlet ..................................................................... 28 MPa (4,000 psi)
Outlet .................................................................. 17 MPa (2,500 psi)
Connections, Accessories, and Adapters.......... Refer to the subsequent tables.
Controller, Intensifier, and Nitrogen Cylinder Connections
Unit Name Type of Fittings [1] Maximum Working Pressure Limit
Controller
TEST Port IQC70 female, coupler located on CPS
70 MPa (10,000 psi)SUPPLY Port IQC70 female coupler
Hose Purge IQC70 male stem, located on CPS
Intensifier SUPPLY Port IQC70 female coupler 70 MPa (10,000 psi)
OUTLET Port IQC70 female coupler
N2 Cylinder
Assembly
Cylinder Valve CGA580 female coupler 20 MPa (3,000 psi)
Regulator Inlet CGA580 nipple 20 MPa (3,000 psi)
Regulator Outlet Miniature QC female coupler 20 MPa (3,000 psi)
Note:
1. IQC70 is a Fluke Calibration interlocking quick connection nominally rated to 70 MPa (10,000 psi).
Adaptor Kit Fittings
Name Type of Fittings [1]
Maximum Working
Pressure Limit [2]
Fitting, 1/2 Male Pipe Thread (NPT)
IQC70 male stem 70 MPa (10,000 psi)
Fitting, 1/4 Male Pipe Thread (NPT)
Fitting, 1/8 Male Pipe Thread (NPT)
Fitting, 1/2 Female Pipe Thread (NPT)
Fitting, 1/4 Female Pipe Thread (NPT)
Fitting, 1/8 Female Pipe Thread (NPT)
Fitting, DH200 female (HF4 Equivalent)
Fitting, AN6 Female
Fitting, AN4 Female
Fitting, HM4 Equivalent
Fitting, AN6 Male
Fitting, AN4 Male
Fitting, 1/4 ID Hose Barb IQC70 male stem 700 kPa (100 psi)
Fitting, 1/8 ID Hose Barb IQC70 male stem 700 kPa (100 psi)
Notes:
1. IQC70 is a Fluke Calibration interlocking quick connection nominally rated to 70 MPa (10,000 psi).
2. Working pressures indicated are for adaptors only. Actual pressure capability may be limited by the integrity or maximum
working pressure of the fitting to which the adaptor is connected.

4322
Service Manual
1-8
High-Pressure Hoses
Name Type of Fittings [1] Maximum Working Pressure Limit
Test hoses, 3 m (10 ft) IQC70 male stem at one end, and
IQC070 female coupling at the other. 70 MPa (10,000 psi)
Interconnect hose, 1.8 m (6 ft) IQC70 male stem at both ends. 70 MPa (10,000 psi)
Supply hose, 1.8 m (6 ft) IQC70 male stem at one end, and
miniature QC male stem at the other. 20 MPa (3,000 psi) [2]
Notes:
1. IQC70 is a Fluke Calibration interlocking quick connection nominally rated to 70 MPa (10,000 psi).
2. Hose limited to 3,000 psi due to miniature QC used to connect to the fitting on the regulator.
Measurement Specifications
Barometer Module Range .................................... 70 kPa to 110 kPa absolute (10 psi to 16 psi) absolute
Pressure Transducer Module Ranges
Note: Pressure modules are switched automatically and transparently to the operator.
A150k.................................................................. 3.5 kPa to 150 kPa absolute (0.5 psi to 22 psi)
G700k ................................................................. 50 kPa to 700 kPa gauge (7 psi to 100 psi)
G10M .................................................................. 700 kPa to 10 MPa gauge (100 psi to 1,500 psi)
G70M .................................................................. 10 MPa to 70 MPa gauge (1,500 psi to 10,000 psi)
Resolution ............................................................. Greater of 0.001% of reading or 0.00004 psi (0.28 Pa)
Measurement Uncertainty
Measurement
Mode Range Uncertainty [1]
Gauge [2] -98 kPa to +28 kPa (-14.2 psi to +4 psi) gauge ±25 Pa (0.0036 psi, 0.1 in H2O at 20 °C)
28 kPa to 70 MPa (4 psi to 10,000 psi) gauge ±0.1 % of reading
Absolute 3.5 kPa to 130 kPa (0.5 psi to 19 psi) absolute ±25 Pa (0.0036 psi, 0.1 in H2O at 20 °C)
130 kPa to 70 MPa (19 to 10,000 psi) absolute ±0.1 % of reading
Vacuum [2] 0 kPa to 98 kPa (0 to 14.2 psi, 0 to 29 inHg) ±25 Pa (0.0074 inHg)
Notes:
1. Measurement uncertainty is defined as the maximum deviation from the indicated value of measured pressure for 1 year
after alignment including hysteresis, linearity, repeatability, stability, temperature, humidity effects, and calibration reference
standard measurement uncertainty. Expression of uncertainty uses a coverage factor of 2 and conforms with the
recommendations of the ISO Guide to the Expression of Uncertainty in Measurement.
2. Negative gauge and vacuum pressure values assume the ambient atmospheric pressure is approximately 101 kPa
(14.7 psi) absolute.
Pressure Control Specifications
Control Precision .................................................. Greater of ± 0.025 % of reading or ± 25 Pa (0.0036 psi).
Control Ranges
Pressure Source Measure Mode Range
On-board Pump
Gauge [1] -98 kPa to 2 MPa (-14.2 to 300 psi)
Absolute 3.5 kPa to 2 MPa (0.5 to 300 psi)
Vacuum (negative gauge) [1] 0 to 98 kPa (0 to 14.2 psi, 0 to 29 inHg)
External Gas
Supply
Gauge 28 kPa to 70 MPa (4 to 10,000 psi)
Absolute 130 kPa to 70 MPa (19 to 10,000 psi)
Note:
1. Negative gauge and vacuum pressure values assume the ambient atmospheric pressure is approximately 101 kPa
(14.7 psi) absolute.