OPERATING MANUAL
PG4 SeriesPG4 Series
PG4 SeriesPG4 Series
PG4 Series
MM
MM
Mecec
ecec
echh
hh
hanicanic
anicanic
anicalal
alal
al Pr Pr
Pr Pr
Pree
ee
ess
ss
sss
ss
surur
urur
ure Ge G
e Ge G
e Gaugaug
augaug
augee
ee
ess
ss
s
P/N 974081
05/05 Rev. D
ECO # 29918
OPERATING MANUAL
TT
TT
TABLEABLE
ABLEABLE
ABLE
OFOF
OFOF
OF C C
C C
C
ONTENTSONTENTS
ONTENTSONTENTS
ONTENTS
ContentContent
ContentContent
Content PagePage
PagePage
Page IconIcon
IconIcon
Icon
1. General 3
2. Notes on Safety 5
3. Technical Data 6
4. Transport/Delivery 11
5. Installation 12
6. Commissioning 15
7. Maintenance 16
8. Accessories 19
9. Troubleshooting 20
3
GENERAL
1.1.
1.1.
1. GG
GG
GENERALENERAL
ENERALENERAL
ENERAL
1.1 Important Information ............................................................................................................ 6
1.2 Copyright .............................................................................................................................. 6
1.3 Explanation of Icons .............................................................................................................. 6
1.4 Abbreviations .........................................................................................................................7
1.5 Principle of Operation............................................................................................................. 7
1.11.1
1.11.1
1.1 II
II
IMPORMPOR
MPORMPOR
MPORTT
TT
TANTANT
ANTANT
ANT
INFORMAINFORMA
INFORMAINFORMA
INFORMATIONTION
TIONTION
TION
This manual applies to the PG4 series only. It must be kept near the equipment in a readily and
immediately accessible location at all times. The content of this manual must be read, understood and
followed in its entirety. This applies in particular to the notes on safety. Following the safety
instructions will help to prevent accidents, defects and malfunctions.
Models covered by this manual include the PG441R, PG442R and TPG443R.
DD
DD
DYNISCYNISC
YNISCYNISC
YNISCOO
OO
O will not be held liable for any injury, loss or damage resulting from failure to follow the
instructions in this manual.
If the product malfunctions, in spite of having followed the operating instructions, please contact the
DD
DD
DYNISCYNISC
YNISCYNISC
YNISCOO
OO
O customer service department (See the back of the manual for contact information). This
applies in particular during the warranty period.
1.21.2
1.21.2
1.2 CC
CC
COPYRIGHTOPYRIGHT
OPYRIGHTOPYRIGHT
OPYRIGHT
Copyright law requires that this manual be used for intended purposes only.
It is strictly forbidden to allow reproduction of any kind “in whole or in part” to persons outside of
Dynisco, without approval from Dynisco.
1.1.
1.1.
1.33
33
3EE
EE
EXPLANAXPLANA
XPLANAXPLANA
XPLANATIONTION
TIONTION
TION
OFOF
OFOF
OF
ICIC
ICIC
ICONSONS
ONSONS
ONS
The manual uses icons to indicate information pertaining to safety:
Risk of destruction or damage to equipment, machines or installations
General danger to life or limb
Specific danger to life or limb
4
GENERAL
You MUST do this
The safety instructions are provided again in the individual chapters of the manual.
1.41.4
1.41.4
1.4 AA
AA
ABBREVIABBREVIA
BBREVIABBREVIA
BBREVIATIONSTIONS
TIONSTIONS
TIONS
The following abbreviations are used:
OM Operating Manual
PG Pressure Gauge
f.s. of full scale
BFSL Best Fit Straight Line
1.1.
1.1.
1.55
55
5PP
PP
PRINCIPLERINCIPLE
RINCIPLERINCIPLE
RINCIPLE
OFOF
OFOF
OF O O
O O
O
PERAPERA
PERAPERA
PERATIONTION
TIONTION
TION
The mechanical system (a filled assembly) consists of a lower diaphragm, a filled capillary tube, and a
Bourdon tube. The filled assembly transmits pressure from the process to the Bourdon tube which then
rotates the needle on the face plate of the pressure gauge. The filled assembly isolates the electronics
from the high process temperatures.
The lower diaphragm is the surface in contact with the media being measured. This diaphragm can be
made from a choice of materials. The standard material is heat-treated 15-5 stainless steel with Titanium
Nitride coating. This has average corrosion and abrasion resistance and is similar to 17-4 stainless steel.
Behind the lower diaphragm is a capillary tube filled to the upper diaphragm. As the process pressure
deflects the lower diaphragm, the fill is displaced through the capillary tube and applies pressure to the
Bourdon tube.
5
SAFETY
2.2.
2.2.
2. NN
NN
NOTESOTES
OTESOTES
OTES
ONON
ONON
ON
SAFETYSAFETY
SAFETYSAFETY
SAFETY
The operator or owner of the larger overall system is responsible for following the safety
and accident prevention regulations that apply to the specific application.
DD
DD
DYNISCYNISC
YNISCYNISC
YNISCOO
OO
O will not be held liable for any injury, loss or damage resulting from failure to
follow the instructions in this manual.
TT
TT
Too
oo
oxx
xx
xicic
icic
ic Haz Haz
Haz Haz
Hazarar
arar
ard!d!
d!d!
d!
The PG contains a very small amount of mercury (Hg) 0.00322 in³ typically with a 6/18
configuration, as its transmission medium. If the diaphragm is damaged, mercury may
escape. Never transport or store the PG without the protective cap. Remove the cap
shortly before installation.
If mercury is inhaled or swallowed, seek medical attention immediately!If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
Mercury is hazardous waste and must be disposed of in accordance with applicable laws.
DD
DD
DYNISCYNISC
YNISCYNISC
YNISCOO
OO
O will accept defective PG’s. If mercury escapes, use airtight packaging!
TT
TT
Temperemper
emperemper
emperatat
atat
aturur
urur
uree
ee
e
The PG4 series of pressure gauges can be used in media temperatures up to 400°C. If the pressure
gauge is used in other applications, the safety and accident prevention regulations specific to that
application must be followed. Ambient temperature for the case max. +135°C.
Higher temperature can result in damage and malfunction. Do not install the pressure gauge in places
where this temperature is exceeded.
6
TECHNICAL DATA
3.3.
3.3.
3. TT
TT
TEE
EE
ECHNICALCHNICAL
CHNICALCHNICAL
CHNICAL D D
D D
D
AA
AA
ATT
TT
TAA
AA
A
3.1 Ordering Guide for PG4 Series................................................................................................6
3.2 Ordering Example ................................................................................................................. 6
3.3 Ordering Information .............................................................................................................. 7
3.3.1 Temperature Option ............................................................................................................... 7
3.3.2 Configuration ......................................................................................................................... 7
3.3.3 Pressure Range ...................................................................................................................... 7
3.3.4 Rigid Stem & Flexible Capillary ................................................................................................ 7
3.3.5 Mounting ............................................................................................................................... 7
3.3.6 Thermocouple Type ............................................................................................................... 8
3.4 Performance Characteristics .................................................................................................. 8
3.4.1 Combined Error (Accuracy) ..................................................................................................... 8
3.4.2 Zero Adjustability .................................................................................................................. 8
3.4.3 Max. Overload ...................................................................................................................... 8
3.4.4 Needle Sweep ...................................................................................................................... 8
3.4.5 Thermocouple Option ............................................................................................................ 8
3.5 Materials .............................................................................................................................. 8
3.6 Torque .................................................................................................................................. 8
3.7 Weight ................................................................................................................................. 9
3.8 Dimensions ........................................................................................................................... 9
3.13.1
3.13.1
3.1 OO
OO
ORDERINGRDERING
RDERINGRDERING
RDERING G G
G G
GUIDEUIDE
UIDEUIDE
UIDE
FORFOR
FORFOR
FOR PG4 S PG4 S
PG4 S PG4 S
PG4 SERIESERIES
ERIESERIES
ERIES
The exact meanings of the letter/digit combinations are given in the corresponding sections of
Chapter 3.
T PG44 3R-5M-6/30-U
J-Type Thermocouple
Rigid Snout, Flexible Stem and Thermocouple
5,000 psi
6” Snout Length
30” Flexible Capillary Length
Face Up Mounting
X PG44 XR-XX-X/XX-X-X
Temperature Option
Configuration
Pressure Range
Snout Length
Flexible Capillary Length
Mounting
Thermocouple Type
3.23.2
3.23.2
3.2 OO
OO
ORDERINGRDERING
RDERINGRDERING
RDERING E E
E E
E
XAMPLEXAMPLE
XAMPLEXAMPLE
XAMPLE
7
TECHNICAL DATA
3.3.
3.3.
3.33
33
3OO
OO
ORDERINGRDERING
RDERINGRDERING
RDERING I I
I I
I
NFORMANFORMA
NFORMANFORMA
NFORMATIONTION
TIONTION
TION
XPG44XR-XX-X/XX-X-X
3.3.
3.3.
3.3.13.1
3.13.1
3.1 TT
TT
TEMPERAEMPERA
EMPERAEMPERA
EMPERATURETURE
TURETURE
TURE O O
O O
O
PP
PP
PTIONTION
TIONTION
TION
XX
XX
XPG44XR-XX-X/XX-X-X
Blank = No Temperature Sensor
T = J-Type Thermocouple
3.3.
3.3.
3.3.23.2
3.23.2
3.2 CC
CC
CONFIGURAONFIGURA
ONFIGURAONFIGURA
ONFIGURATIONTION
TIONTION
TION
XPG44XX
XX
XR-XX-X/XX-X-X
1 = Rigid Snout Only
2 = Rigid Snout with Flexible Stem
3 = Rigid Snout with Flexible Stem and Temperature Option
3.3.
3.3.
3.3.3.
3.3.
3.33
33
3PP
PP
PRESSURERESSURE
RESSURERESSURE
RESSURE R R
R R
R
ANGEANGE
ANGEANGE
ANGE
XPG44XR-XXXX
XXXX
XX-X/XX-X-X
5M = 5,000 psi
10M= 10,000 psi
3.3.
3.3.
3.3.43.4
3.43.4
3.4 RR
RR
RIGIDIGID
IGIDIGID
IGID
STEMSTEM
STEMSTEM
STEM & F & F
& F & F
& FLEXIBLELEXIBLE
LEXIBLELEXIBLE
LEXIBLE C C
C C
C
APILLARYAPILLARY
APILLARYAPILLARY
APILLARY
XPG44XR-XX-X/XXX/XX
X/XXX/XX
X/XX-X-X
6 = 6” Rigid Stem/0” Flexible Capillary
6/30 = 6” Rigid Stem/30” Flexible Capillary
12 = 12” Rigid Stem/0” Flexible Capillary
12/30 = 12” Rigid Stem/30” Flexible Capillary
3.3.
3.3.
3.3.3.
3.3.
3.55
55
5MM
MM
MOUNTINGOUNTING
OUNTINGOUNTING
OUNTING
XPG44XR-XX-X/XX-XX
XX
X-X
Blank = Face Down
U = Face Up
8
TECHNICAL DATA
3.3.
3.3.
3.3.3.
3.3.
3.66
66
6TT
TT
THERMOCHERMOC
HERMOCHERMOC
HERMOCOUPLEOUPLE
OUPLEOUPLE
OUPLE
TT
TT
TYPEYPE
YPEYPE
YPE (PG44 (PG44
(PG44 (PG44
(PG443R O3R O
3R O3R O
3R ONLNL
NLNL
NLYY
YY
Y))
))
)
XPG44XR-XX-X/XX-X-XX
XX
X
Blank = J Type Thermocouple
K = K Type Thermocouple
3.43.4
3.43.4
3.4 PP
PP
PERFORMANCEERFORMANCE
ERFORMANCEERFORMANCE
ERFORMANCE
CHARACTERISTICSCHARACTERISTICS
CHARACTERISTICSCHARACTERISTICS
CHARACTERISTICS
3.4.13.4.1
3.4.13.4.1
3.4.1 CC
CC
COMBINEDOMBINED
OMBINEDOMBINED
OMBINED E E
E E
E
RRORRROR
RRORRROR
RROR (A (A
(A (A
(ACC
CC
CCC
CC
CURAURA
URAURA
URACYCY
CYCY
CY))
))
)
Combined error is also known as accuracy which includes linearity, hysteresis and repeatability, and is
determined by BFSL (Best Fit Straight Line).
±2.0% of full scale
3.4.23.4.2
3.4.23.4.2
3.4.2 ZZ
ZZ
ZEROERO
EROERO
ERO A A
A A
A
DJUSDJUS
DJUSDJUS
DJUSTT
TT
TABILITABILIT
ABILITABILIT
ABILITYY
YY
Y
7.5% of full scale
3.4.3.4.
3.4.3.4.
3.4.33
33
3MM
MM
MAXAX
AXAX
AX. O. O
. O. O
. OVERLVERL
VERLVERL
VERLOO
OO
OADAD
ADAD
AD ( (
( (
(WITHOUTWITHOUT
WITHOUTWITHOUT
WITHOUT
INFLINFL
INFLINFL
INFLUENCINGUENCING
UENCINGUENCING
UENCING
OPERAOPERA
OPERAOPERA
OPERATINGTING
TINGTING
TING
DD
DD
DAA
AA
ATT
TT
TAA
AA
A))
))
)
1.5 x full scale pressure
3.4.43.4.4
3.4.43.4.4
3.4.4 NN
NN
NEEDLEEEDLE
EEDLEEEDLE
EEDLE S S
S S
S
WEEPWEEP
WEEPWEEP
WEEP
270o
3.4.3.4.
3.4.3.4.
3.4.55
55
5TT
TT
THERMOCHERMOC
HERMOCHERMOC
HERMOCOUPLEOUPLE
OUPLEOUPLE
OUPLE O O
O O
O
PP
PP
PTIONTION
TIONTION
TION
J-Type Thermocouple for 6” snout (Dynisco P/N 901746)
J-Type Thermocouple for 12” snout (Dynisco P/N 901747)
K-Type Thermocouple for 6” snout (Dynisco P/N 901748)
3.3.
3.3.
3.55
55
5MM
MM
MAA
AA
ATERIALSTERIALS
TERIALSTERIALS
TERIALS
Standard Diaphragm 15-5PH with Titanium Nitride Coating
Standard Stem(Snout) 17-4PH
3.63.6
3.63.6
3.6 TT
TT
TORQUEORQUE
ORQUEORQUE
ORQUE
max. 56.5 Nm
(500 inch-lbs.)
min. 11.3 Nm
(100 inch-lbs.)
9
TECHNICAL DATA
3.3.
3.3.
3.77
77
7WW
WW
WEIGHTEIGHT
EIGHTEIGHT
EIGHT
The weight varies depending on product configuration. Average weight range is 2 to 3 pounds.
3.83.8
3.83.8
3.8 DD
DD
DIMENSIONSIMENSIONS
IMENSIONSIMENSIONS
IMENSIONS
See Figure 3-1.
10
TECHNICAL DATA
Fig. 3-1Fig. 3-1
Fig. 3-1Fig. 3-1
Fig. 3-1 PG4 SeriesPG4 Series
PG4 SeriesPG4 Series
PG4 Series
2.38
60.3
1.57
39.9
1.00
25.4
1.05
26.6
10
20
25
5000
4000
3000
AR x 10
2000
1000
psi
15
35
530
SST CASE &
COVER
PROTECTIVE
SAFETY GLASS
4.35
110.6
NOMINAL
1.94
49.3
NOMINAL
EXTERNAL
ZERO ADJUST
O
E
Z
R
Dynisco
MODEL
SER.NO.
RANGE
FLEX ARMOR
.28 ( 7.1 ) OD
J
_
+
J
_
+
.42
10.7
O
.50
12.7
O
.440
11.18
.214
5.44
.414
.412
10.52
10.46
O
.307
.305
7.8
7.75
O
DIM "A"
1.06
26.9
1/2-20 UNF-2A
RIGID
STEM
LENGTH
RIGID
STEM
LENGTH
1/2-20 UNF-2A
1.06
26.9
DIM "A"
.307
.305
7.8
7.75
O
.414
.412
10.52
10.46
O
.214
5.44
.440
11.18
.50
12.7
O
.42
10.7
O
( 14.7 )
5/8 HEX
NO.4-40 SET SCREW
THERMOCOUPLE LOCK
1.25
31.8
O
1.41
35.8
.69
17.6
O
FLEX LENGTH
DIM 'B'
u
.12
FLEX ARMOR
.28 ( 7.1 ) OD
T/C CONNECTOR
TYPE J, MALE
T/C CONNECTOR
TYPE J, FEMALE
SUPPLIED WITH
MODELS
PG442R & TPG443R
CLAMP ASSY
P/N 200941
1.57
39.9
.42
10.7
O
.50
12.7
O
.440
11.18
.214
5.44
.307
.305
7.8
7.75
O
1.06
26.9
1/2-20 UNF-2A
( 14.7 )
5/8 HEX
FLEX LENGTH
DIM 'B'
u
.12
DIM "A"
RIGID
STEM
LENGTH
.98
24.8
.69
17.6
O
.414
.412
10.52
10.46
O
11
TRANSPORT
4.4.
4.4.
4. TT
TT
TRANSPORTRANSPORT
RANSPORTRANSPORT
RANSPORT/D/D
/D/D
/DELIVERYELIVERY
ELIVERYELIVERY
ELIVERY
4.1 Transport/Packing/Transport Damage................................................................................... 11
4.2 Storage ............................................................................................................................... 11
4.3 Scope of Delivery ................................................................................................................. 11
TT
TT
Too
oo
oxx
xx
xicic
icic
ic h h
h h
hazaz
azaz
azarar
arar
ard!d!
d!d!
d!
The PG contains a small amount of mercury (Hg) as its transmission medium. If the
diaphragm is damaged, mercury may escape.
Never transport or store the PG without the protective shell bolted in place. Remove the
shell shortly before installation.
If mercury is inhaled or swallowed, seek medical attention immediately.If mercury is inhaled or swallowed, seek medical attention immediately.
If mercury is inhaled or swallowed, seek medical attention immediately.If mercury is inhaled or swallowed, seek medical attention immediately.
If mercury is inhaled or swallowed, seek medical attention immediately.
Mercury is hazardous waste and must be disposed of in accordance with applicable laws.
DD
DD
DYNISCYNISC
YNISCYNISC
YNISCOO
OO
O will accept defective PGs.
If mercury escapes, use airtight packaging!
4.14.1
4.14.1
4.1 TT
TT
TRANSRANS
RANSRANS
RANSPORPOR
PORPOR
PORTT
TT
T//
//
/PP
PP
PAA
AA
ACKINGCKING
CKINGCKING
CKING//
//
/TRANSTRANS
TRANSTRANS
TRANSPORPOR
PORPOR
PORTT
TT
T
DD
DD
DAMAGEAMAGE
AMAGEAMAGE
AMAGE
• Do not let the PG be damaged by other items during transit.
• Use only the original packaging.
• Report transport damage to DD
DD
DYNISCYNISC
YNISCYNISC
YNISCOO
OO
O immediately in writing.
4.24.2
4.24.2
4.2 SS
SS
STORAGETORAGE
TORAGETORAGE
TORAGE
• Store the PG in original packaging only.
• Protect against dust and moisture.
4.4.
4.4.
4.33
33
3SS
SS
SCC
CC
COPEOPE
OPEOPE
OPE
OFOF
OFOF
OF D D
D D
D
ELIVERYELIVERY
ELIVERYELIVERY
ELIVERY
• PG with diaphragm protection cap
• Fastening clip (transmitter with flexible stem only)
• Calibration sheet
• Operating manual
12
INSTALLATION
5.5.
5.5.
5. II
II
INSNS
NSNS
NSTT
TT
TALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
5.1 General Mounting Information .............................................................................................. 12
5.2 Mounting Hole Torque .......................................................................................................... 13
5.3 Mounting Hole Dimensions ................................................................................................... 14
5.4 Mounting the Pressure Gauge............................................................................................... 14
5.5 Thermocouple or RTD Assembly, Removal and Installation ...................................................... 14
5.15.1
5.15.1
5.1 GG
GG
GENERALENERAL
ENERALENERAL
ENERAL M M
M M
M
OUNTINGOUNTING
OUNTINGOUNTING
OUNTING I I
I I
I
NFORMANFORMA
NFORMANFORMA
NFORMATIONTION
TIONTION
TION
Do not remove the protective cap on the PG until ready to install.
Before mounting the PG, check mounting hole carefully. The PG must only be mounted in holes that
satisfy the requirements below. A hole that does not satisfy these requirements can damage the
pressure gauge.
Insure the mounting hole is clear of any frozen polymer or debris and is machined to the proper
dimensions.
Coat the threads with a high temperature anti-seize grease or a suitable parting agent, this will help
prevent the PG snout from sticking permanently in the mounting hole.
Install unit into the process connection. (Do NOT torque transmitter into the hole at this time!) Allow time
for the pressure gauge snout temperature to equalize to the process temperature. This will help
eliminate thread galling and ease removal later. There should be NO pressure applied at this time.
Always use a torque wrench applied to the designated hexagon collar bolts while screwing the pressure
gauge in and out. Do not apply the tool to the housing or housing/sensor connection.
After temperatures have equalized, apply proper torque as described in Section 3.6 or 5.2 of the Manual
and tighten the sensor into mounting hole.
After the correct torque has been applied units with flexible capillary require the electronics to be
mounted away from the process heat using mounting hardware, P/N 200941.
Make sure that the medium is in molten condition during sensor removal. Removing the sensor while
the medium is in solidified condition can damage the sensor diaphragm.
When removing the PG, carefully clean the diaphragm of the transmitter with a soft cloth while the
medium is still malleable.
Always remove the pressure gauge prior to cleaning the machine with abrasives or steel wire brushes.
13
INSTALLATION
Also, do not clean the PG with hard objects, such as a screwdriver, a wire brush, etc. this will possibly
damage the transmitter.
Before reinstalling the PG, ensure that the mounting hole is free from hardened plastic. A mounting
hole cleaning tool kit is available to aid in removing of the material. (Dynisco Part Number 200100.) A
gauge plug to check the hole is included in this kit.
The most common causes of sensor damage are: installation in improperly
machined or plugged mounting holes and cold starts. The tip of the PG consists of a
stainless steel diaphragm that must be protected from severe abrasives, dents and
scores.
Burn Hazard!Burn Hazard!
Burn Hazard!Burn Hazard!
Burn Hazard!
The PG must be removed with the melt in the molten condition. The
PG can be very hot when removed. WEAR PROTECTIVE GLOVES!
Careful attention should be paid to correctly machine the mounting port. Failure to use the
recommended mounting port may result in erroneous pressure measurement, difficult sensor removal,
premature sensor failure, process fluid leaks, and personnel injury. In applications involving high
temperature operation and/or repeated thermal cycling a good high quality anti-seize compound should
be applied to the threaded surfaces.
5.25.2
5.25.2
5.2 MM
MM
MOUNTINGOUNTING
OUNTINGOUNTING
OUNTING H H
H H
H
OLEOLE
OLEOLE
OLE T T
T T
T
ORQUEORQUE
ORQUEORQUE
ORQUE
max. 56.5 Nm
(500 inch-lbs.)
min. 11.3 Nm
(100 inch-lbs.)
5.5.
5.5.
5.33
33
3MM
MM
MOUNTINGOUNTING
OUNTINGOUNTING
OUNTING H H
H H
H
OLEOLE
OLEOLE
OLE D D
D D
D
IMENSIONSIMENSIONS
IMENSIONSIMENSIONS
IMENSIONS
See Figure 5-1.
14
INSTALLATION
Fig. 5-1Fig. 5-1
Fig. 5-1Fig. 5-1
Fig. 5-1 1/2-20 UNF Mounting Hole1/2-20 UNF Mounting Hole
1/2-20 UNF Mounting Hole1/2-20 UNF Mounting Hole
1/2-20 UNF Mounting Hole
5.45.4
5.45.4
5.4 MM
MM
MOUNTINGOUNTING
OUNTINGOUNTING
OUNTING
THETHE
THETHE
THE P P
P P
PRESSURERESSURE
RESSURERESSURE
RESSURE G G
G G
GAUGEAUGE
AUGEAUGE
AUGE
Dynisco offers a set of mounting hole-machining tools with all the necessary drills, taps, and reamers
for the Dynisco standard ½-20UNF-2A mounting holes used in high temperature and plastics processing
applications (Dynisco Part Number 200925). Detailed instructions are sent with the machining kits.
Copies of the instructions are available from Dynisco upon request.
When machining the hole pay careful attention to the concentricity between the threads and the 0.312/
0.314 diameter. Since the pressure seal is on the 45° seating surface, this surface should be examined
for good finish, free from burrs, etc.
It is general good practice to check the mounting hole before installing the PG. One procedure is to coat
a gauge plug (Dynisco Part Number 200908 for the 1/2 –20 standard port), with Dykem blue on surfaces
below the thread. Insert the gauge plug into the mounting hole and rotate until surface binding is
encountered. Remove and inspect. Bluing should only be scraped off of the 45° sealing chamfer. If
bluing has been removed from other surfaces, the mounting hole has not been machined properly.
5.5.
5.5.
5.55
55
5TT
TT
THERMOCHERMOC
HERMOCHERMOC
HERMOCOUPLEOUPLE
OUPLEOUPLE
OUPLE R R
R R
R
EMOEMO
EMOEMO
EMOVV
VV
VALAL
ALAL
AL
ANDAND
ANDAND
AND I I
I I
I
NSNS
NSNS
NSTT
TT
TALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
1. To remove, loosen setscrew on side of snout.
2. Without twisting, pull the thermocouple probe carefully out of snout.
3. To install, slide the new thermocouple into snout
4. Lock in place with setscrew.
15
COMMISSIONING
6.6.
6.6.
6. CC
CC
COMMISSIONINGOMMISSIONING
OMMISSIONINGOMMISSIONING
OMMISSIONING
6.1 Gauge Enclosure Rotation .................................................................................................... 15
6.2 Zero Adjustment .................................................................................................................. 15
6.16.1
6.16.1
6.1 GG
GG
GAA
AA
AUGEUGE
UGEUGE
UGE E E
E E
ENCLNCL
NCLNCL
NCLOO
OO
OSURESURE
SURESURE
SURE R R
R R
ROO
OO
OTT
TT
TAA
AA
ATIONTION
TIONTION
TION (PG44 (PG44
(PG44 (PG44
(PG441R O1R O
1R O1R O
1R ONLNL
NLNL
NLYY
YY
Y))
))
)
Once installation has been completed, the PG enclosure can be swiveled 300o to provide optimum
visibility.
To rotate the enclosure to the desired location, first back out the set screw at the base of the enclosure.
Once the set screw is loose, the enclosure can be rotated to the desired position. Do not attempt to
force the enclosure beyond the built in mechanical stops. Once the enclosure is at the desired location,
tighten the set screw. See Figure 6-1.
6.26.2
6.26.2
6.2 ZZ
ZZ
ZEROERO
EROERO
ERO A A
A A
A
DJUSTMENTDJUSTMENT
DJUSTMENTDJUSTMENT
DJUSTMENT
To adjust the zero setting of the gauge, it is important that no pressure be applied to the diaphragm. In
addition, the gauge must be secured by the mounting bracket (except for rigid configurations). Using a
slotted screw driver, adjust the zero screw on the gauge case until the dial pointer is centered in the
zero box on the gauge scale. See Figure 6-1.
Fig. 6-1Fig. 6-1
Fig. 6-1Fig. 6-1
Fig. 6-1 Rotation Set Screw and Zero AdjustmentRotation Set Screw and Zero Adjustment
Rotation Set Screw and Zero AdjustmentRotation Set Screw and Zero Adjustment
Rotation Set Screw and Zero Adjustment
Zero Adjustment
Screw
Enclosure
Rotation Set
Screw
16
COMMISSIONING
77
77
7..
..
.MM
MM
MAINTENANCEAINTENANCE
AINTENANCEAINTENANCE
AINTENANCE
7.1 Maintenance ....................................................................................................................... 16
7.2 Thermocouple/RTD Replacement .......................................................................................... 16
7.3 Repair/Disposal ................................................................................................................... 17
7.4 Warranty ............................................................................................................................. 18
77
77
7.1.1
.1.1
.1 MM
MM
MAINTENANCEAINTENANCE
AINTENANCEAINTENANCE
AINTENANCE
Burn hazard!Burn hazard!
Burn hazard!Burn hazard!
Burn hazard!
The PG must be removed with the melt in molten condition. The PG can be very hot when
removed.
Wear protective gloves!Wear protective gloves!
Wear protective gloves!Wear protective gloves!
Wear protective gloves!
Installation and Removal Instructions
•DO NOT REMOVE PROTECTIVE CAP UNTIL READY TO INSTALL.
•PRIOR TO INITIAL INSTALLATION, VERIFY CORRECT MACHINING OF MOUNTING HOLE.
•WHEN REINSTALLING, MAKE SURE MOUNTING HOLE IS CLEAR OF DEBRIS OR HARDENED
PLASTIC.
•THE MEDIUM MUST BE IN MOLTEN CONDITION DURING TRANSDUCER REMOVAL.
(Removing the transducer with the medium in a solidified condition can damage the
sensor diaphragm.)
•ALWAYS REMOVE THE PG BEFORE CLEANING THE MACHINE WITH ABRASIVES OR STEEL
WIRE BRUSHES, ETC.
•DO NOT CLEAN THE “SCREWED-IN” SECTION OF THE PG WITH HARD OBJECTS – THIS
WILL DAMAGE THE PG.
•ALWAYS USE A TORQUE WRENCH APPLIED TO THE DESIGNATED HEXAGONAL COLLAR
WHEN SCREWING THE PG IN AND OUT. DO NOT APPLY THE TOOL TO THE HOUSING OR
HOUSING/ SENSOR CONNECTION.
77
77
7.2.2
.2.2
.2 TT
TT
THERMOCHERMOC
HERMOCHERMOC
HERMOCOUPLEOUPLE
OUPLEOUPLE
OUPLE/R/R
/R/R
/RTT
TT
TD RD R
D RD R
D REPLAEPLA
EPLAEPLA
EPLACC
CC
CEMENTEMENT
EMENTEMENT
EMENT
1. Replace J Type Thermocouples [Dynisco P/N 901746 (6”) or 901747 (12”)] and K Type
Thermocouples [Dynisco P/N 901748 (6”)] are available for replacement.
2. To remove, loosen setscrew on side of snout.
3. Without twisting, pull the thermocouple probe or RTD stem carefully out of snout.
4. To install press thermocouple into snout carefully until top of probe shoulders against snout.
5. Lock in place with setscrew.
17
MAINTENANCE
Fig. 7-1Fig. 7-1
Fig. 7-1Fig. 7-1
Fig. 7-1 ThermocoupleThermocouple
ThermocoupleThermocouple
Thermocouple
77
77
7..
..
.33
33
3RR
RR
REPEP
EPEP
EPAIRAIR
AIRAIR
AIR//
//
/DISDIS
DISDIS
DISPOPO
POPO
POSS
SS
SALAL
ALAL
AL
TT
TT
Too
oo
oxx
xx
xicic
icic
ic h h
h h
hazaz
azaz
azarar
arar
ard!d!
d!d!
d!
The PG contains a small amount of mercury (Hg) as its transmission medium. If the
diaphragm is damaged, mercury may escape.
Never transport or store the PG without the protective cap bolted in place. Remove the cap
shortly before installation.
If mercury is inhaled or swallowed, seek medical attention immediately!If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
Mercury is hazardous waste and must be disposed of in accordance with applicable
laws. DD
DD
DYNISCYNISC
YNISCYNISC
YNISCOO
OO
O will accept defective PGs.
If mercury escapes, use airtight packaging!
Please send defective pressure gauges back to your DD
DD
DYNISCYNISC
YNISCYNISC
YNISCO O
O O
O representative. For DD
DD
DYNISCYNISC
YNISCYNISC
YNISCOO
OO
O
addresses, see the back cover of the operating manual.
18
MAINTENANCE
77
77
7.4.4
.4.4
.4 WW
WW
WARRANTYARRANTY
ARRANTYARRANTY
ARRANTY
The PG4 Series of Dynisco Pressure gauges will provide excellent service and superior performance if
proper care is taken during handling, installation, and use. This DYNISCO product is warranted under
terms and conditions set forth in the DYNISCO web pages. Go to www.dynisco.com and click “warranty”
at the bottom of any page for complete details.
19
ACCESSORIES
8.8.
8.8.
8. AA
AA
ACC
CC
CCC
CC
CEE
EE
ESS
SS
SSORIESORIE
SORIESORIE
SORIESS
SS
S
• Machining tool kit 1/2”-20UNF-2A P/N 200295
• Cleaning tool kit 1/2”-20UNF-2A P/N 200100
• Mounting Bracket P/N 200941
• Spare 6” J-Type Themocouple P/N 901746
• Spare 12” J-Type Themocouple P/N 901747
• Spare 6” K-Type Themocouple P/N 901748
20
TROUBLESHOOTING
9.9.
9.9.
9. TT
TT
TROUBLESHOOTINGROUBLESHOOTING
ROUBLESHOOTINGROUBLESHOOTING
ROUBLESHOOTING
SymptomSymptom
SymptomSymptom
Symptom Corrective ActionsCorrective Actions
Corrective ActionsCorrective Actions
Corrective Actions
Large Zero Shift when Screwing In 1) Check Hole with Gage Plug and Rework Hole as Required
2) Check Mounting Torque
No Response to Changes in 1) Confirm that needle is not against mechanical stop.
Applied Pressure 2) Check Port/Pipe for Blockage or Solidified Plastic
Pressure Variable Reading is Low or High 1) Check zero with no pressure applied.
2) Check Port/Pipe for Blockage or Solidified Plastic
Pressure Variable Reading is Erratic 1) Check Port/Pipe for Blockage or Solidified Plastic
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