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