Fluke 6270A User manual

August 2016 Rev. 1, 6/17
© 2016-2017 Fluke Corporation. All rights reserved. Specifications are subject to change without notice.
All product names are trademarks of their respective companies.
6270A
Pressure Controller/Calibrator
Service Manual

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
Title Page
Introduction............................................................................................ 1
Contact Fluke Calibration...................................................................... 2
Safety Information ................................................................................. 2
Symbols................................................................................................. 3
The Product Manual Set........................................................................ 4
Specifications ........................................................................................ 4
Control Specifications............................................................................ 6
Pressure Measurement Specifications.............................................. 6
PM200 Modules................................................................................. 7
PM600 Modules................................................................................. 8
Theory of Operation .............................................................................. 9
Overview............................................................................................ 9
Accessories ....................................................................................... 9
Pneumatic and Electrical Configuration............................................. 9
Pneumatic Interfaces......................................................................... 11
Over Pressure Protection .................................................................. 11
Electrical............................................................................................ 13
Module Connector ............................................................................. 14
PCA Overview ................................................................................... 15
Communications / Firmware.............................................................. 16
System Boot ...................................................................................... 17
Software Upgrades................................................................................ 17
Maintenance.......................................................................................... 18
Access the Module Bay..................................................................... 18
PMM and PCM Removal................................................................... 19
Clean the Exterior.............................................................................. 21
Pressure Leakage Test (on-board diagnostics)................................. 21
Fuse Replacement ............................................................................ 22
Manifold Replacement....................................................................... 23
Repair and Replacement....................................................................... 25
Feet and Tilt Stands .......................................................................... 25
Remove and Replace Handles.......................................................... 27
Top Panel .......................................................................................... 29
Module Guide Rails............................................................................... 30
Communications Tray........................................................................ 32
The CPU............................................................................................ 33
PMM Dock Assembly ........................................................................ 35

6270A
Service Manual
ii
G- and B-Series Valves..................................................................... 39
Remove and Inspect the B-Series Valves..................................... 40
Install the B-Series Valves............................................................. 43
Remove and Inspect the G-Series Valves..................................... 44
Install the G-Series Valves ............................................................ 44
Power Supply and Fan.......................................................................... 45
Remove the Power Supply................................................................ 46
Remove the Fan................................................................................ 48
Remove the Power Entry Module...................................................... 49
Front Panel and Display Assembly ....................................................... 50
Remove Front-Panel Assembly......................................................... 50
Remove Keypad PCA and Knob from the Front-Panel Assembly..... 52
Remove Display Components from the Display Panel Shell............. 54
Remove the Module Bay Latch Assembly......................................... 57
PCM Assembly...................................................................................... 59
Replace the Control Valves............................................................... 62
Inspect the Control Valves................................................................. 64
PCM Supply, Test, Exhaust Sensor Alignment ................................. 66
Calibrate the Sensors........................................................................ 67
Supply Port (ATM and 3,000 psi) ...................................................... 68
Exhaust Port (Hard Vacuum then ATM)............................................ 70
Calibration Sled and PMM..................................................................... 70
PM200 and PM600 Modules................................................................. 72
PM600 Digital Barometer Optimization ................................................. 73
Setup ................................................................................................. 73
Return to Service – Safety Validation Recommendations..................... 75
Electrical............................................................................................ 75
Pressure ............................................................................................ 75
Calibration Adjustment .......................................................................... 76
PM200 ............................................................................................... 76
PM600 ............................................................................................... 77
Calibration and Adjustment Procedures................................................ 78
Required Equipment.......................................................................... 78
Preliminary Operations...................................................................... 80
Setup ................................................................................................. 81
Module Calibration ................................................................................ 84
Calibration of Modules in Chassis ..................................................... 84
Calibration of Modules in Calibration Sled......................................... 85
Calibration Tables ................................................................................. 88
PM200 Calibration Definition ............................................................. 88
PM600 Calibration Definition ............................................................. 89
PM200 Test Definition Matrices......................................................... 90
PM600 Test Definition Matrices......................................................... 102
Calibration with COMPASS for Pressure .......................................... 110
Troubleshooting..................................................................................... 111
Reset Controller Settings................................................................... 113
Diagnostics........................................................................................ 113
System............................................................................................... 114
Measure............................................................................................. 114
Control............................................................................................... 115
Leak Test........................................................................................... 115
Remote Interface............................................................................... 116
Contamination Prevention System (CPS) ............................................. 116
CPS Cleaning and Inspection............................................................ 116
Separate the Lower and Upper Housing ....................................... 120

Contents (continued)
iii
Inspect and Replace the CPS valves ............................................ 122
Replacement Parts................................................................................ 124
Screw Torque........................................................................................ 136

6270A
Service Manual
iv

1
Introduction
The Fluke Calibration 6270A Pressure Controller/Calibrator (the Product)
precisely measures and controls pneumatic pressures up to 20 MPa (3000 psi).
Use the Product to calibrate, characterize, or test a wide variety of pressure
measurement devices that include transmitters, gauges, and switches.
The Product uses interchangeable Pressure Measurement Modules (PMMs) and
a Pressure Control Module (PCM) to regulate pressure output. The touchscreen
display features a multi-language user interface (UI). See Instrument Setup Menu
in the 6270A Operators Manual for more information.
This manual provides performance test, calibration adjustment, theory of
operation, troubleshooting, and repair procedures necessary to verify and
maintain Product performance.
The performance tests are based on the published 1-year specifications for the
Product. Fluke Calibration recommends the performance test as an acceptance
test when the Product is first received and later as a procedure to ensure that the
Product meets its published specifications. Fluke Calibration recommends a
1-year calibration cycle for the Product.
Use calibration adjustments to correct out-of-tolerance parameters so they meet
published specifications. If the Product fails the performance test, it is an
indication that the Product requires calibration adjustment and/or repair. While
calibration adjustment can be accomplished without removal of the covers, repair
requires access to the interior of the Product.
Environmental and warm up conditions required for the performance test and
calibration adjustments are stated at the beginning of each of the respective
sections.
Note
Repairs detailed in this manual are to the Modular-level only. Return
the Product to Fluke Calibration or take the Product to a local Fluke
Calibration Service Center for deeper-level repair.

6270A
Service Manual
2
Contact Fluke Calibration
To contact Fluke Calibration, call one of the following telephone numbers:
•Technical Support USA: 1-877-355-3225
•Calibration/Repair USA: 1-877-355-3225
•Canada: 1-800-36-FLUKE (1-800-363-5853)
•Europe: [phone]
•Japan: [phone]
•Singapore: [phone]
•China: [phone]
•Brazil: [phone]
•Anywhere in the world: [phone]
To see product information or download manuals and the latest manual
supplements, visit Fluke Calibration’s website at www.flukecal.com.
To register your product, visit http://flukecal.com/register-product.
Safety Information
A Warning identifies conditions 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.
Warnings
To prevent possible electrical shock, fire, or personal injury:
•Only assemble and operate high-pressure systems if you
know the correct safety procedures. High-pressure liquids
and gases are hazardous and the energy from them can be
released without warning.
•Read all safety information before you use the Product.
•Carefully read all instructions.
•Do not use the Product around explosive gas, vapor, or in
damp or wet environments.
•Do not operate the Product with covers removed or the case
open. Hazardous voltage exposure is possible. Pressure
modules may be exchanged through the front panel while
the Product is turned on.
•Use this Product indoors only.
•Do not put the Product where access to the mains power
cable is blocked.
•Use only the mains power cable and connector approved for
the voltage and plug configuration in your country and rated
for the Product.

Pressure Controller/Calibrator
Symbols
3
•Make sure the ground conductor in the mains power cable is
connected to a protective earth ground. Disruption of the
protective earth could put voltage on the chassis that could
cause death.
•Replace the mains power cable if the insulation is damaged
or if the insulation shows signs of wear.
•Use the Product only as specified, or the protection
supplied by the Product can be compromised.
•Before the Product is used to apply pressure, ensure the
integrity of all components to be pressurized and make sure
they are rated to adequate working pressure.
•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 if it operates incorrectly.
•Disable the Product if it is damaged.
•Use only specified replacement parts.
•Have an approved technician repair the Product.
•Do not disable safety interlocks or pressure-relief devices.
Symbols
The symbols shown in Table 1 are used in this manual or on the Product.
Note
The CE marking below does not apply to the 6270A-NPT-NA,
PM600-A10M-NA, or PM600-A14M-NA.
Table 1. Symbols
Symbol Description Symbol Description
WARNING. HAZARDOUS
VOLTAGE. Risk of electric shock. Certified by CSA Group to North American safety standards.
WARNING.RISK OF DANGER. Conforms to European Union directives.
Fuse Conforms to relevant Australian EMC standards.
Earth Conforms to relevant South Korean EMC
Standards.
 Consult user documentation. 
This product complies with the WEEE Directive
marking requirements. The affixed label indicates
that you must not discard this electrical/electronic
product in domestic household waste. Product
Category: With reference to the equipment types
in the WEEE Directive Annex I, this product is
classed as category 9 "Monitoring and Control
Instrumentation" product. Do not dispose of this
product as unsorted municipal waste.

6270A
Service Manual
4
The Product Manual Set
The Product manuals include:
•6270A Safety Information (ships with the Product)
•6270A Operators Manual (available on the Fluke Calibration)
•6270A Remote Programmers Guide (available on the Fluke Calibration
website)
•6270A Service Manual (available on the Fluke Calibration website)
To order, contact a Fluke Calibration sales representative. See Contact Fluke
Calibration.
Specifications
General Specifications
Power Requirements ..........................100 V ac to 240 V ac, 47 Hz to 63 Hz
Fuse....................................................T2A 250 V ac
Max Power Consumption....................100 W
Operating Ambient
Temperature Range............................15 °C to 35 °C
Storage Temperature..........................-20 °C to 70 °C
Relative Humidity
Operating......................................<80 % to 30 °C, <70 % to 40 °C
Storage .........................................<95 %, non-condensing. A power stabilization period of four days may
be required after extended storage at high temperature and humidity.
Vibration..............................................MIL-T-28800E
Altitude (Operation).............................<2000 m
Ingress Protection...............................IEC 60529: IP20
Safety..................................................IEC 61010-1, Installation Category II, Pollution degree 2
Warmup Time .....................................15 minutes after power up or module installation, when items previously stored
within Operating Ambient Temperature Range.

Pressure Controller/Calibrator
Specifications
5
Electromagnetic Compatibility (EMC)
IEC 61326-1
(Controlled EM environment)..............IEC 61326-2-1; CISPR 11: Group 1, Class A
Group 1 equipment has intentionally generated and/or use conductively coupled
radio-frequency energy which is necessary for the internal functioning of the
equipment itself.
Class A equipment is equipment suitable for use in all establishments other than
domestic and those directly connected to a low voltage power supply network
which supplies buildings used for domestic purposes.
Emissions which exceed the levels required by CISPR 11 can occur when the
equipment is connected to a test object. The equipment may not meet the
immunity requirements of 61326-1 when test leads and/or test probes are
connected.
USA (FCC)..........................................47 CFR 15 subpart B, this product is considered an exempt device per clause
15.103
Korea (KCC) .......................................Class A Equipment (Industrial Broadcasting & Communication Equipment)
This product meets requirements for industrial (Class A) 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.
Weight
Chassis only .......................................13 kg (28.5 lbs)
Dimensions
Height..................................................147 mm (5.78 in)
Width...................................................452 mm (17.79 in)
Depth ..................................................488 mm (19.2 in)
Rack Mount Dimensions.....................3U-19-inch rack
Chassis Pressure Limits
Supply Port ........................................23 MPa (3300 psi) gauge
Test Port ............................................20 MPa (3000 psi) gauge
Reference Port ...................................150 kPa (22 psi) absolute
Vent Port ............................................150 kPa (22 psi) absolute
Relief Valves
Chassis Supply port relief valve is set to 24.1 MPa (-0/+700 kPa), 3500 psi (-0/+100 psi)
Exhaust port relief valve is set to ~700 kPa (100 psi).
Each PMM includes a module-specific pressure protection device.
Supply Gas Type
Clean Dry N2or Air – Industrial Grade Nitrogen, 99.5 %+
Particulate Contamination...................≤1.25 micrometer (50 microinches)
Maximum Moisture Content................-50 °C dew point
Maximum Hydrocarbon Content .........30 ppm
Vacuum Supply
>50 liters per minute capacity with Auto Vent feature
Appropriate protections for High Pressure Gauge work system exhaust gas will pass through the Vacuum supply
system.

6270A
Service Manual
6
Interface / Communications
Primary remote Interfaces ..................IEEE, Ethernet, RS232, USB
System Connection.............................Supports interconnection of 2 or 3 systems
Switch Test Connection......................Standard 4 mm Jack:
Nominal 24 V dc isolated drive
Maximum 30 V dc w.r.t. chassis ground
Aux Drivers .........................................4 external Solenoid Drivers
24 V dc Drive (Maximum drive 6 W continuous per channel)
Control Specifications
Control Precision (Dynamic Mode)
PM200-BG2.5K...................................0.005 % Range Span
All other Ranges .................................0.001 % Range Span
Control Turndown ...............................10:1 (Typical)
Control turndown is defined as the relationship between the provided supply pressure and the appropriate supply
pressure for the range. For example, a unit with a 7 MPa (1000 psi) and 700 kPa range (100 psi) with a supply pressure
of 7.7 MPa (1100 psi) will provide control precision of 0.001 % range because 7 MPa is 10 times greater than 700 kPa. A
system with ranges of 20 MPa (3000 psi) and 700 kPa (100 psi) with supply pressure of 22 MPa (3300 psi) will have
0.001 % range control precision on the 20 MPa range but only 0.003 % control precision on the 700 kPa range. Control
precision of 0.001 % on the low range can be achieved by reducing the supply pressure.
Low Control Point ...............................1 kPa (0.15 psi) absolute
Time to Setpoint (Typical)
PM200-BG2.5K...................................40 seconds
PM200, all other ranges .....................20 seconds
PM600 ................................................35-55 seconds
Typical set time is the time required to be within 0.005 % of setpoint for 10 % steps into volumes of 0 to 50 cm3and
pressures above 50 kPa (7.25 psi) absolute. Lower absolute pressures will require longer set times depending upon
quality of the vacuum pump, diameter and material of tubing used, and test volume.
Maximum Overshoot...........................0.01 % Range Span
Pressure Measurement Specifications
The product specifications describe the Absolute Instrumental Uncertainty of the Product. The product specifications
include linearity, hysteresis, repeatability, resolution, reference standard measurement uncertainty, 1 year stability, and
temperature effects from 18 to 28 °C. The product specifications are provided at a 95 %, k=2, normally distributed, level of
confidence.

Pressure Controller/Calibrator
Control Specifications
7
PM200 Modules
Model Range (SI Units) Range (Imperial Units) Measurement Mode 1-Year
Specification
(%FS)
PM200-BG2.5K -2.5 kPa to 2.5 kPa -10 inH₂0 to 10 inH₂0 gauge 0.20 %
PM200-BG35K -35 kPa to 35 kPa -5 psi to 5 psi gauge 0.05 %
PM200-BG40K -40 kPa to 40 kPa -6 psi to 6 psi gauge 0.05 %
PM200-A100K 2 kPa to 100 kPa 0.3 psi to 15 psi absolute 0.10 %
PM200-BG100K -100 kPa to 100 kPa -15 psi to 15 psi gauge 0.02 %
PM200-A200K 2 kPa to 200 kPa 0.3 psi to 30 psi absolute 0.10 %
PM200-BG200K -100 kPa to 200 kPa -15 psi to 30 psi gauge 0.02 %
PM200-BG250K -100 kPa to 250 kPa -15 psi to 36 psi gauge 0.02 %
PM200-G400K 0 kPa to 400 kPa 0 psi to 60 psi gauge 0.02 %
PM200-G700K 0 kPa to 700 kPa 0 psi to 100 psi gauge 0.02 %
PM200-G1M 0 MPa to 1 MPa 0 psi to 150 psi gauge 0.02 %
PM200-G1.4M 0 MPa to 1.4 MPa 0 psi to 200 psi gauge 0.02 %
PM200-G2M 0 MPa to 2 MPa 0 psi to 300 psi gauge 0.02 %
PM200-G2.5M 0 MPa to 2.5 MPa 0 psi to 360 psi gauge 0.02 %
PM200-G3.5M 0 MPa to 3.5 MPa 0 psi to 500 psi gauge 0.02 %
PM200-G4M 0 MPa to 4 MPa 0 psi to 580 psi gauge 0.02 %
PM200-G7M 0 MPa to 7 MPa 0 psi to 1000 psi gauge 0.02 %
PM200-G10M 0 MPa to 10 MPa 0 psi to 1500 psi gauge 0.02 %
PM200-G14M 0 MPa to 14 MPa 0 psi to 2000 psi gauge 0.02 %
PM200-G20M 0 MPa to 20 MPa Psi 0 to 3000 psi gauge 0.02 %
Notes
•Gauge mode modules (PM200-GXXX or PM200-BGXXX) with ranges of 100 kPa (15 psi) or greater will support absolute mode
measurement when used with a Barometric Reference Module.
•For temperatures from 15 °C to 18 °C and 28 °C to 35 °C, add 0.003 % FS/°C. Uncertainty for gauge mode modules assumes
routine zeroing. Uncertainty for absolute mode modules includes 1-year zero stability. This specification can be reduced to
0.05 % FS if the PM200 module is zeroed on a continuing basis to remove the 1-year zero stability component. Instrumental
Measurement Uncertainty for gauge mode modules used in absolute mode by addition of a barometric reference module is
calculated as the uncertainty of the gauge mode module plus the uncertainty of the barometric reference module.
•Instrumental Measurement Uncertainty for gauge mode modules used in absolute mode by addition of a barometric reference
module is calculated as the uncertainty of the gauge mode module plus the uncertainty of the barometric reference module.
•For temperatures from 15 to 18 C and 28 to 35 C, add 0.003 % FS/C.

6270A
Service Manual
8
PM600 Modules
The product specifications describe the Absolute Instrumental Uncertainty of the Product. The product specifications
include linearity, hysteresis, repeatability, resolution, reference standard measurement uncertainty, 1 year stability, and
temperature effects from 15 to 35 °C. The product specifications are provided at a 95 %, k=2, normally distributed, level of
confidence.
Model Gauge Mode
Range
(SI Units)
Absolute Mode
Range
(SI Units)
Gauge Mode
Range
(Imperial Units)
Absolute Mode
Range
(Imperial Units)
1-Year Specification
Relative
Specification
(% Reading)
Threshold
Specification
(% Span)
Absolute Mode
Adder
(% Full Scale)
PM600-
BG15K -15 kPa to 15 kPa - -60 inH₂0 to
60 inH₂0 - 0.01 % 0.003 % -
PM600-
G100K 0 kPa to 100 kPa - 0 psi to 15 psi - 0.01 % 0.003 % -
PM600-
G200K 0 kPa to 200 kPa - 0 psi to 30 psi - 0.01 % 0.003 % -
PM600-
A100K -100 kPa to 0 kPa 6 kPa to 100 kPa -13.8 psi to 0 psi 0.9 psi to 15 psi 0.01 % 0.003 % 0.007 %
PM600-
A200K -90 kPa to 100 kPa 10 kPa to 200 kPa -13.2 psi to 15 psi 1.5 psi to 30 psi 0.01 % 0.003 % 0.007 %
PM600-
A350K -90 kPa to 250 kPa 10 kPa to 350 kPa -13.2 psi to 35 psi 1.5 psi to 50 psi 0.01 % 0.003 % 0.007 %
PM600-
A700K -82 kPa to 700 kPa 18 kPa to 700 kPa -12.1 psi to
100 psi 2.6 psi to 100 psi 0.01 % 0.003 % 0.007 %
PM600-
A1.4M -0.065 MPa to 1.4 MPa 0.035 MPa to 1.4 MPa -10 psi to 200 psi 5 psi to 200 psi 0.01 % 0.003 % 0.007 %
PM600-
A2M -0.03 MPa to 2 MPa 0.07 MPa to 2 MPa -5 psi to 300 psi 10 psi to 300 psi 0.01 % 0.003 % 0.007 %
PM600-
A3.5M -0.03 MPa to 3.5 MPa 0.07 MPa to 3.5 MPa -5 psi to 500 psi 10 psi to 500 psi 0.01 % 0.003 % 0.007 %
PM600-
A7M 0 MPa to 7 MPa atmosphere to
7 MPa 0 psi to 1000 psi atmosphere to 1000 psi 0.01 % 0.003 % 0.007 %
PM600-
A10M 0 MPa to 10 MPa atmosphere to 10 MPa 0 psi to 1500 psi atmosphere to 1500 psi 0.01 % 0.003 % 0.007 %
PM600-
A14M 0 MPa to 14 MPa atmosphere to 14 MPa 0 psi to 2000 psi atmosphere to 2000 psi 0.01 % 0.003 % 0.007 %
PM600-
A20M 0 MPa to 20 MPa atmosphere to 20 MPa 0 psi to 3000 psi atmosphere to 3000 psi 0.01 % 0.003 % 0.007 %
Notes
•Gauge mode uncertainty is the greater of the relative uncertainty and the threshold uncertainty. For absolute ranges used in gauge
mode there is an additional uncertainty of ±7 Pa for dynamic barometric compensation. When combined with other uncertainties this
changes the threshold uncertainty for the PM600-A100K to 0.008 % Span and for the PM600-A200K to 0.004 % Span.
•For absolute mode the % span for Threshold Uncertainty the span is calculated from zero to the full scale of that range.

Pressure Controller/Calibrator
Theory of Operation
9
Theory of Operation
This section provides a block diagram discussion of the Product pneumatic,
mechanical, electrical, and communication design.
Note
In many of the procedures in this manual, the Product is referred to
as the Unit Under Test (UUT).
Overview
Main Chassis - includes the main processor with chassis interface, front-panel
processor, GUI interface, module interfaces, solenoid drivers, and distribution of
power, communications, and pneumatic pressure.
PMM - are available in multiple pressure ranges and performance ratings. All
PMMs use the same pneumatic and electrical connections. Each module carries
and applies full characterization and calibration data to the communicated output
pressure. The test port is protected by a relief valve. The power supply is fully or
partially isolated as required for the sensor type.
PCM - uses a different mechanical footprint from the PMMs and an identical
electrical connector. PCMs accept pressure supply from the main chassis up to
3300 psi, exhaust pressure to an exhaust port, and regulate pressure on the test
port. The PCM monitors and controls each port for safe operation. The primary
sensor controls feedback to the system-selected PMM.
Accessories
Isolation Valve - The isolation valve connects pneumatically to the UUT test
port. When activated in the main firmware, the isolation valve treats the UUT as a
module and protects the device during venting and pressure supply release. The
valve allows for internal-only leak testing.
CPS - Two-stage filter with exhaust and purge valves that capture contamination
from the UUT. Solenoids are driven from the UUT rear-panel solenoid driver
connector when activated in the main firmware.
Test Stand - Supports extension of the main chassis test port to a convenient
test connection.
Pneumatic and Electrical Configuration
This section provides a discussion of the pneumatic and electrical configuration.
Pneumatics - The main chassis accepts a maximum of five PMMs with full-scale
up to 20 MPa (3000 psi) and one PCM. The main chassis has independent
pneumatic isolation of both test and reference ports for each of the PMM slots.
For basic operation, a PCM and at least one PMM must be installed. System
configurations depend on the type of PMM modules installed. PMMs vary by
pressure range, absolute or gauge native mode, and if the PMM can be used as
a barometric sensor. Each PMM slot in the main chassis and the test port
handles the full range of available modules (0 psi - 3000 psi). See Figure 1.

6270A
Service Manual
10
20 MPa
(3000 psi)
2.5 kPa
(10inH )
2O
Pressure sensor – various ranges
Solenoid valve – 3000 psi
Solenoid valve – 200 psi
Pressure relief valve
6270A CONTROLLER – Pneumatic Diagram
SLOT 5
SLOT 4
SLOT 3SLOT 2SLOT 1SLOT PCM
CS
CE
S
E+
-
Std V
Solenoid Valve naming:
nT Slot n Test
nR Slot n Reference
CS Control Supply
CE Control Exhaust
CF Control Fine Supply
IT Isolation Test
IR Isolation Reference
IS Isolation Supply
IE Isolation Exhaust
VT Vent Test
VR Vent Reference BACK of 6270A
B1-1T B2-2T
G1-1R
B3-3T B1-4T B2-5T
G2-2R G3 - 3R G1- 4R
G2-5R
G3 -VR
B3 -VT
B4-IS
PCM Dock
PMM Dock
PCM
10 MPa
(1500 psi)
Barometer
700 kPa
(100 psi)
hxn306.eps
Figure 1. PCM Block Diagram

Pressure Controller/Calibrator
Theory of Operation
11
Pneumatic Interfaces
All PMMs use the same pneumatic interface. See Figure 2.
1
3
2
4
6
7 5
PMM Pneumatic Interface PCM Pneumatic Interface
hxn028.e
p
s
Reference port Supply port
Test port Guide bushing, threaded rods
Alignment bushing Test port
Reference port
Figure 2. Pneumatic Interface
Over Pressure Protection
Relief Valves - The main chassis contains two relief valves:
•A 3500 psi relief valve that protects the pressure supply input.
•A 120 psi relief valve on the exhaust port that limits exhaust port blockage.
Each PMM contains an overpressure protection device (resettable pressure
release valve). These valves are set to protect the module’s internal sensor. For
PM600, the relief valves are typically set to 10 % to 15 % over the module FS.
The PM200 are set higher based on how the sensors are scaled.
The chassis design prevents hazardous conditions that result from improper
connection of supply and accidental pressure over-range.
The main firmware has a user-settable autovent function to vent the system if
pressure is greater than autovent level.
All solenoids in the chassis are normally closed. In a power-off condition, all
pressure is trapped in the system to avoid rapid pressure changes. Remove the
pressure supply to reduce pressure in the entire system. The pressure in the
system is reduced to approximately 150 psi as pressure decreases through the
reversed-biased solenoids.

6270A
Service Manual
12
When the module bay door is opened, the system vents and releases the supply
pressure. There may be a small residual pressure retained between solenoids IS
and CS, see Figure 1. This pressure could be up to150 psi after the supply is
removed. Loosen the PCM screws to safely release this pressure.
Table 2 shows the typical state of solenoids in Figure 1 during different operating
conditions. There are additional states as the system transitions between various
operational modes.
Note
The status of the measure slot solenoids is dependent on the type of
module. For example, if the PMM is an absolute model then the test
port solenoids (nT) opens and the reference port solenoid (nR)
closes since inside the module there is no connection to the
reference port.
Table 2. Solenoid States
6270A Main Manifold Control Module
Isolation
Manifold-
External
Option
Phase B1-
1T G1- 1R B2- 2T G2- 2R B3- 3T G3- 3R B1- 4T G1- 4R B2- 5T G2- 5R B3- VT G3- VR B4- IS CS CE IT
Power Off C C C C C C C C C C C C C C C C
Power On C C C C C C C C C C C C C C C O
Measure Slot 1* O O C C C C C C C C C C C C C O
Measure Slot 2* C C O O C C C C C C C C C C C O
Measure Slot 3* C C C C O O C C C C C C C C C O
Measure Slot 4* C C C C C C O O C C C C C C C O
Measure Slot 5* C C C C C C C C O O C C C C C O
Control Apply pd pd pd pd pd pd pd pd pd pd C C O modulate C O
Control Exhaust pd pd pd pd pd pd pd pd pd pd C C O C modulate O
Zero O O O O O O O O O O O O C C C C
Vent - final state O O O O O O O O O O O O C C C O
Door open final
state O O O O O O O O O O O O C C C C
Slot PCM - Empty C C C C C C C C C C C C C n/a n/a C
*O = OPEN, C = CLOSED, pd = product configuration dependent

Pressure Controller/Calibrator
Theory of Operation
13
Electrical
Figure 3 shows the electrical power distribution inside the Product chassis.
24 V dc power is the primary power distributed inside the chassis. Each module
uses the 24 V dc power to create the specific voltage supplies required. Each
module is isolated or filtered to provide appropriate power for the module
requirements.
RS-232 / GPIB/
USB Device / Ethernet CANbus
Main Processor
Back Panel
Manifold PCAs
Drivers:
4 External
Drivers:
14 External
Switch In /
Ext.Drivers
AC Power
Entry Module
Fused
MOV
ac / 24 Vdc
110 Watts
24 Vdc
24 V / 5 V /
3.3 V
Iso 24 V / 12 V
LCD / Touch / Keypad
Chassis Power
PMM PCM... x5
μP
Front Panel Process
CANbus /
ID pin
iso
PCA
1/2 W sol.
Driver
A/D
Filtered
24 Vdc
Valves
P
Sensor
P
CANbus / ID Pin iso
24 Vdc to 5/12/-12 Vdc
Switch
P
P
hxn308.eps
Figure 3. Electrical Block Diagram

6270A
Service Manual
14
Module Connector
All modules have the same electrical connector and pinout. The location of the
connector and the module mechanical shape are the same for all PMMs. The
PCM has unique physical dimensions. See Figure 4.
14
25
36
hxn030.eps
Pin
Number Function Pin
Number Function
1 V+ (24 V dc inside chassis) 4 Canbus_L
2 Ground - Power 5 RS232 Transmit
3 Canbus_H 6 RS232 Rcv / ID pin
Figure 4. Module Electrical Connector
•Canbus_H and Canbus_L is the communication used inside the Product
chassis.
•The RS232 interface is used in the PMM Calibration kit.
•In-chassis operation, Pin 6 - ID, is a digital I/O line that identifies which
chassis slot a module is located.