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Pr Pr
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Pr Pr
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PG4 SeriesPG4 Series
PG4 Series
PG4 SeriesPG4 Series
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OPERATING MANUAL
P/N 974081
05/05 Rev. D
ECO # 29918
TT
ABLEABLE
T
ABLE
ABLEABLE
TT
OFOF
OF
OFOF
C C
C
C C
ONTENTSONTENTS
ONTENTS
ONTENTSONTENTS
ContentContent
Content
ContentContent
1. General 3
OPERATING MANUAL
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
PagePage
Page
PagePage
IconIcon
Icon
IconIcon
9. Troubleshooting 20
1.1.
1.
1.1.
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
GG
ENERALENERAL
G
ENERAL
ENERALENERAL
GG
1.11.1
1.1
1.11.1
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
YNISCYNISC
D
YNISC
DD
YNISCYNISC
instructions in this manual.
If the product malfunctions, in spite of having followed the operating instructions, please contact the
DD
YNISCYNISC
D
YNISC
DD
YNISCYNISC
applies in particular during the warranty period.
1.21.2
1.2
1.21.2
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.
33
1.
3
1.1.
33
II
MPORMPOR
I
MPOR
MPORMPOR
II
OO
O will not be held liable for any injury, loss or damage resulting from failure to follow the
OO
OO
O customer service department (See the back of the manual for contact information). This
OO
CC
OPYRIGHTOPYRIGHT
C
OPYRIGHT
OPYRIGHTOPYRIGHT
CC
EE
XPLANAXPLANA
E
XPLANA
XPLANAXPLANA
EE
TT
ANTANT
T
ANT
TT
ANTANT
INFORMAINFORMA
INFORMA
INFORMAINFORMA
TIONTION
TION
TIONTION
OFOF
OF
OFOF
TIONTION
TION
TIONTION
ICIC
ONSONS
IC
ONS
ICIC
ONSONS
GENERAL
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
3
You MUST do this
The safety instructions are provided again in the individual chapters of the manual.
1.41.4
1.4
1.41.4
The following abbreviations are used:
GENERAL
1.1.
55
1.
5
1.1.
55
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.
AA
BBREVIABBREVIA
A
BBREVIA
BBREVIABBREVIA
AA
OM Operating Manual
PG Pressure Gauge
f.s. of full scale
BFSL Best Fit Straight Line
PP
RINCIPLERINCIPLE
P
RINCIPLE
RINCIPLERINCIPLE
PP
TIONSTIONS
TIONS
TIONSTIONS
O O
OFOF
OF
O
OFOF
O O
PERAPERA
PERA
PERAPERA
TIONTION
TION
TIONTION
4
2.2.
2.
2.2.
NN
N
NN
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.
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follow the instructions in this manual.
TT
oo
T
o
TT
oo
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!
OTESOTES
OTES
OTESOTES
xx
icic
Haz Haz
x
ic
Haz
xx
icic
Haz Haz
ONON
SAFETYSAFETY
ON
SAFETY
ONON
SAFETYSAFETY
OO
O will not be held liable for any injury, loss or damage resulting from failure to
OO
arar
d!d!
ar
d!
arar
d!d!
Mercury is hazardous waste and must be disposed of in accordance with applicable laws.
DD
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D
DD
TT
emperemper
atat
urur
T
emper
TT
emperemper
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.
at
atat
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OO
YNISC
O will accept defective PG’s. If mercury escapes, use airtight packaging!
YNISCYNISC
OO
SAFETY
5
3.3.
3.
3.3.
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
TT
EE
CHNICALCHNICAL
T
E
CHNICAL
EE
CHNICALCHNICAL
TT
D D
D
D D
AA
TT
AA
A
T
A
AA
TT
AA
3.13.1
3.1
3.13.1
The exact meanings of the letter/digit combinations are given in the corresponding sections of
Chapter 3.
OO
RDERINGRDERING
O
RDERING
RDERINGRDERING
OO
G G
G
G G
UIDEUIDE
UIDE
UIDEUIDE
FORFOR
FOR
FORFOR
PG4 S PG4 S
PG4 S
PG4 S PG4 S
ERIESERIES
ERIES
ERIESERIES
X PG44 XR-XX-X/XX-X-X
TECHNICAL DATA
3.23.2
3.2
3.23.2
OO
RDERINGRDERING
O
RDERING
RDERINGRDERING
OO
E E
XAMPLEXAMPLE
E
XAMPLE
XAMPLEXAMPLE
E E
Temperature Option
Configuration
Pressure Range
Snout Length
Flexible Capillary Length
Mounting
Thermocouple Type
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
6
3.3.
33
3.
3
3.3.
33
XPG44XR-XX-X/XX-X-X
3.3.
3.13.1
3.
3.1
3.3.
3.13.1
XX
XPG44XR-XX-X/XX-X-X
XX
3.3.
3.23.2
3.
3.2
3.3.
3.23.2
XPG44
3.3.
3.3.
33
3.
3.
3
3.3.
3.3.
33
OO
RDERINGRDERING
RDERING
O
RDERINGRDERING
OO
TT
EMPERAEMPERA
T
EMPERA
EMPERAEMPERA
TT
Blank = No Temperature Sensor
T = J-Type Thermocouple
CC
ONFIGURAONFIGURA
C
ONFIGURA
ONFIGURAONFIGURA
CC
XX
XR-XX-X/XX-X-X
XX
1 = Rigid Snout Only
2 = Rigid Snout with Flexible Stem
3 = Rigid Snout with Flexible Stem and Temperature Option
PP
RESSURERESSURE
P
RESSURE
RESSURERESSURE
PP
I I
NFORMANFORMA
NFORMA
I
NFORMANFORMA
I I
TURETURE
TURE
TURETURE
TIONTION
TION
TIONTION
R R
ANGEANGE
R
ANGE
ANGEANGE
R R
O O
O
O O
PP
TIONTION
P
TION
PP
TIONTION
TIONTION
TION
TIONTION
XPG44XR-
3.3.
3.43.4
3.
3.4
3.3.
3.43.4
XPG44XR-XX-
3.3.
3.3.
3.
3.
3.3.
3.3.
XPG44XR-XX-X/XX-
XXXX
XX-X/XX-X-X
XXXX
55
5
55
5M = 5,000 psi
10M= 10,000 psi
RR
IGIDIGID
R
IGID
IGIDIGID
RR
X/XXX/XX
X/XX-X-X
X/XXX/XX
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
MM
OUNTINGOUNTING
M
OUNTING
OUNTINGOUNTING
MM
Blank = Face Down
U = Face Up
STEMSTEM
STEM
STEMSTEM
XX
X-X
XX
& F & F
& F
& F & F
LEXIBLELEXIBLE
LEXIBLE
LEXIBLELEXIBLE
C C
APILLARYAPILLARY
C
APILLARY
APILLARYAPILLARY
C C
TECHNICAL DATA
7
3.3.
3.
3.3.
3.3.
3.
3.3.
66
6
66
TT
HERMOCHERMOC
HERMOC
T
HERMOCHERMOC
TT
OUPLEOUPLE
OUPLE
OUPLEOUPLE
TT
T
TT
YPEYPE
YPE
YPEYPE
(PG44 (PG44
(PG44
(PG44 (PG44
3R O3R O
3R O
3R O3R O
NLNL
NL
NLNL
))
YY
Y
)
YY
))
XPG44XR-XX-X/XX-X-
Blank = J Type Thermocouple
K = K Type Thermocouple
3.43.4
3.4
3.43.4
3.4.13.4.1
3.4.1
3.4.13.4.1
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
3.4.2
3.4.23.4.2
7.5% of full scale
3.4.3.4.
33
3.4.
3
3.4.3.4.
33
1.5 x full scale pressure
3.4.43.4.4
3.4.4
3.4.43.4.4
o
270
PP
P
PP
CC
C
CC
ZZ
Z
ZZ
MM
M
MM
NN
N
NN
XX
X
XX
ERFORMANCEERFORMANCE
ERFORMANCE
ERFORMANCEERFORMANCE
A A
A
A A
. O. O
. O
. O. O
E E
E
E E
DJUSDJUS
DJUS
DJUSDJUS
VERLVERL
VERL
VERLVERL
S S
WEEPWEEP
S
WEEP
WEEPWEEP
S S
OMBINEDOMBINED
OMBINED
OMBINEDOMBINED
EROERO
ERO
EROERO
AXAX
AX
AXAX
EEDLEEEDLE
EEDLE
EEDLEEEDLE
CHARACTERISTICSCHARACTERISTICS
CHARACTERISTICS
CHARACTERISTICSCHARACTERISTICS
(A (A
RRORRROR
RROR
RRORRROR
TT
ABILITABILIT
T
ABILIT
TT
ABILITABILIT
OO
ADAD
O
AD
OO
ADAD
CC
(A
C
CC
(A (A
YY
Y
YY
( (
WITHOUTWITHOUT
(
WITHOUT
WITHOUTWITHOUT
( (
CC
C
CC
URAURA
URA
URAURA
CYCY
CY
CYCY
INFLINFL
INFL
INFLINFL
))
)
))
UENCINGUENCING
UENCING
UENCINGUENCING
OPERAOPERA
OPERA
OPERAOPERA
TINGTING
TING
TINGTING
))
DD
AA
TT
AA
D
A
T
A
)
DD
AA
TT
AA
))
TECHNICAL DATA
3.4.3.4.
55
3.4.
5
3.4.3.4.
55
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.
55
3.
5
3.3.
55
Standard Diaphragm 15-5PH with Titanium Nitride Coating
Standard Stem(Snout) 17-4PH
3.63.6
3.6
3.63.6
max. 56.5 Nm
(500 inch-lbs.)
min. 11.3 Nm
(100 inch-lbs.)
TT
HERMOCHERMOC
T
HERMOC
HERMOCHERMOC
TT
MM
AA
TERIALSTERIALS
M
A
TERIALS
AA
TERIALSTERIALS
MM
TT
ORQUEORQUE
T
ORQUE
ORQUEORQUE
TT
OUPLEOUPLE
OUPLE
OUPLEOUPLE
O O
O
O O
PP
TIONTION
P
TION
PP
TIONTION
8
3.3.
77
3.
7
3.3.
77
The weight varies depending on product configuration. Average weight range is 2 to 3 pounds.
WW
EIGHTEIGHT
W
EIGHT
EIGHTEIGHT
WW
3.83.8
3.8
3.83.8
See Figure 3-1.
DD
IMENSIONSIMENSIONS
D
IMENSIONS
IMENSIONSIMENSIONS
DD
TECHNICAL DATA
9
Fig. 3-1Fig. 3-1
Fig. 3-1
Fig. 3-1Fig. 3-1
PROTECTIVE
SAFETY GLASS
SST CASE &
COVER
PG4 SeriesPG4 Series
PG4 Series
PG4 SeriesPG4 Series
3
0
0
0
2
15
10
0
0
0
1
0
0
0
20
25
530
AR x 1 0
35
p
s
i
5
0
0
0
o
c
s
i
n
y
D
4
0
0
0
4.35
110.6
NOMINAL
L
E
D
O
M
SER.NO.
RANGE
O
R
E
Z
2.38
60.3
1.00
25.4
5/8 HEX
( 14.7 )
.50
O
12.7
DIM "A"
.42
RIGID
O
10.7
STEM
LENGTH
1/2-20 UNF-2A
1.06
26.9
TECHNICAL DATA
.214
5.44
.414
.412
O
10.52
10.46
.307
.305
O
7.8
7.75
CLAMP ASSY
P/N 200941
SUPPLIED WITH
MODELS
PG442R & TPG443R
.440
11.18
1.05
26.6
DIM "A"
RIGID
STEM
LENGTH
FLEX LENGTH
DIM 'B'
5/8 HEX
( 14.7 )
1/2-20 UNF-2A
1.06
26.9
.214
5.44
O
EXTERNAL
ZERO ADJUST
1.57
39.9
u
.12
.50
O
12.7
.42
O
10.7
.307
.305
7.8
7.75
.69
O
17.6
FLEX ARMOR
.28 ( 7.1 ) OD
.98
24.8
.440
11.18
.414
.412
O
10.52
10.46
FLEX LENGTH
DIM 'B'
1.57
39.9
u
.12
1.25
O
31.8
O
O
1/2-20 UNF-2A
O
1.94
49.3
NOMINAL
.50
12.7
.42
10.7
1.06
26.9
.414
.412
10.52
10.46
O
.69
17.6
.440
11.18
O
FLEX ARMOR
.28 ( 7.1 ) OD
1.41
35.8
DIM "A"
RIGID
STEM
LENGTH
.214
5.44
.307
.305
7.8
7.75
T/C CONNECTOR
TYPE J, FEMALE
+
J
J
_
_
T/C CONNECTOR
TYPE J, MALE
NO.4-40 SET SCREW
THERMOCOUPLE LOCK
+
10
4.4.
4.
4.4.
4.1 Transport/Packing/Transport Damage................................................................................... 11
4.2 Storage ............................................................................................................................... 11
4.3 Scope of Delivery ................................................................................................................. 11
TT
RANSPORTRANSPORT
T
RANSPORT
RANSPORTRANSPORT
TT
TT
oo
xx
icic
h h
azaz
T
o
x
ic
h
az
TT
oo
xx
icic
h h
azaz
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
YNISCYNISC
D
DD
If mercury escapes, use airtight packaging!
OO
YNISC
O will accept defective PGs.
YNISCYNISC
OO
arar
ar
arar
d!d!
d!
d!d!
/D/D
ELIVERYELIVERY
/D
ELIVERY
ELIVERYELIVERY
/D/D
4.14.1
4.1
4.14.1
• Do not let the PG be damaged by other items during transit.
• Use only the original packaging.
• Report transport damage to
4.24.2
4.2
4.24.2
• Store the PG in original packaging only.
• Protect against dust and moisture.
4.4.
33
4.
3
4.4.
33
• PG with diaphragm protection cap
• Fastening clip (transmitter with flexible stem only)
• Calibration sheet
• Operating manual
TT
RANSRANS
T
RANS
RANSRANS
TT
SS
TORAGETORAGE
S
TORAGE
TORAGETORAGE
SS
SS
CC
OPEOPE
S
C
OPE
CC
OPEOPE
SS
PORPOR
POR
PORPOR
OFOF
OF
OFOF
//
TT
PP
T
/
P
TT
PP
//
D D
ELIVERYELIVERY
D
ELIVERY
ELIVERYELIVERY
D D
AA
CKINGCKING
A
CKING
AA
CKINGCKING
DD
D
DD
//
/
//
YNISCYNISC
YNISC
YNISCYNISC
TRANSTRANS
TRANS
TRANSTRANS
PORPOR
POR
PORPOR
OO
O immediately in writing.
OO
TT
T
TT
DD
AMAGEAMAGE
D
AMAGE
DD
AMAGEAMAGE
TRANSPORT
11
5.5.
5.
5.5.
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
INSTALLATION
5.5 Thermocouple or RTD Assembly, Removal and Installation ...................................................... 14
II
NSNS
I
NS
NSNS
II
TT
ALLAALLA
T
ALLA
TT
ALLAALLA
TIONTION
TION
TIONTION
5.15.1
5.1
5.15.1
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.
GG
ENERALENERAL
G
ENERAL
ENERALENERAL
GG
M M
OUNTINGOUNTING
M
OUNTING
OUNTINGOUNTING
M M
I I
NFORMANFORMA
I
NFORMA
NFORMANFORMA
I I
TIONTION
TION
TIONTION
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.
12
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!
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
5.2
5.25.2
max. 56.5 Nm
(500 inch-lbs.)
min. 11.3 Nm
(100 inch-lbs.)
MM
OUNTINGOUNTING
M
OUNTING
OUNTINGOUNTING
MM
The PG must be removed with the melt in the molten condition. The
H H
H
H H
OLEOLE
OLE
OLEOLE
T T
ORQUEORQUE
T
ORQUE
ORQUEORQUE
T T
I
NSTALLATION
5.5.
33
5.
3
5.5.
33
See Figure 5-1.
MM
OUNTINGOUNTING
M
OUNTING
OUNTINGOUNTING
MM
H H
H
H H
OLEOLE
OLE
OLEOLE
D D
IMENSIONSIMENSIONS
D
IMENSIONS
IMENSIONSIMENSIONS
D D
13
INSTALLATION
Fig. 5-1Fig. 5-1
Fig. 5-1
Fig. 5-1Fig. 5-1
5.45.4
5.4
5.45.4
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.
55
5.
5
5.5.
55
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.
1/2-20 UNF Mounting Hole1/2-20 UNF Mounting Hole
1/2-20 UNF Mounting Hole
1/2-20 UNF Mounting Hole1/2-20 UNF Mounting Hole
MM
OUNTINGOUNTING
M
OUNTING
OUNTINGOUNTING
MM
TT
HERMOCHERMOC
T
HERMOC
HERMOCHERMOC
TT
THETHE
THE
THETHE
OUPLEOUPLE
OUPLE
OUPLEOUPLE
P P
RESSURERESSURE
P
RESSURE
RESSURERESSURE
P P
R R
EMOEMO
R
EMO
EMOEMO
R R
G G
G
G G
VV
ALAL
ANDAND
V
AL
AND
VV
ALAL
ANDAND
AUGEAUGE
AUGE
AUGEAUGE
I I
I
I I
NSNS
NS
NSNS
14
TT
ALLAALLA
T
ALLA
TT
ALLAALLA
TIONTION
TION
TIONTION
6.6.
6.
6.6.
6.1 Gauge Enclosure Rotation .................................................................................................... 15
6.2 Zero Adjustment .................................................................................................................. 15
CC
OMMISSIONINGOMMISSIONING
C
OMMISSIONING
OMMISSIONINGOMMISSIONING
CC
6.16.1
6.1
6.16.1
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
6.2
6.26.2
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. 6-1
Fig. 6-1Fig. 6-1
GG
G
GG
ZZ
Z
ZZ
Rotation Set Screw and Zero AdjustmentRotation Set Screw and Zero Adjustment
Rotation Set Screw and Zero Adjustment
Rotation Set Screw and Zero AdjustmentRotation Set Screw and Zero Adjustment
AA
UGEUGE
A
UGE
AA
UGEUGE
EROERO
ERO
EROERO
E E
NCLNCL
OO
E
NCL
O
NCLNCL
OO
E E
A A
DJUSTMENTDJUSTMENT
A
DJUSTMENT
DJUSTMENTDJUSTMENT
A A
SURESURE
SURE
SURESURE
R R
R
R R
AA
TIONTION
A
TION
AA
TIONTION
(PG44 (PG44
(PG44
(PG44 (PG44
OO
TT
O
T
OO
TT
1R O1R O
1R O
1R O1R O
NLNL
NL
NLNL
))
YY
Y
)
YY
))
COMMISSIONING
Enclosure
Rotation Set
Screw
Zero Adjustment
Screw
15
77
..
7
.
77
..
7.1 Maintenance ....................................................................................................................... 16
7.2 Thermocouple/RTD Replacement .......................................................................................... 16
7.3 Repair/Disposal ................................................................................................................... 17
7.4 Warranty ............................................................................................................................. 18
77
.1.1
7
.1
77
.1.1
COMMISSIONING
Installation and Removal Instructions
MM
AINTENANCEAINTENANCE
M
AINTENANCE
AINTENANCEAINTENANCE
MM
MM
AINTENANCEAINTENANCE
M
AINTENANCE
AINTENANCEAINTENANCE
MM
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!
• 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
.2.2
7
.2
77
.2.2
1. Replace J Type Thermocouples [Dynisco P/N 901746 (6”) or 901747 (12”)] and K Type
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.
TT
HERMOCHERMOC
T
HERMOC
HERMOCHERMOC
TT
Thermocouples [Dynisco P/N 901748 (6”)] are available for replacement.
OUPLEOUPLE
OUPLE
OUPLEOUPLE
/R/R
/R
/R/R
TT
D RD R
T
D R
TT
D RD R
EPLAEPLA
EPLA
EPLAEPLA
CC
EMENTEMENT
C
EMENT
CC
EMENTEMENT
16
Fig. 7-1Fig. 7-1
Fig. 7-1
Fig. 7-1Fig. 7-1
77
..
33
7
.
3
77
..
33
ThermocoupleThermocouple
Thermocouple
ThermocoupleThermocouple
RR
R
RR
EPEP
EP
EPEP
AIRAIR
AIR
AIRAIR
//
/
//
DISDIS
DIS
DISDIS
POPO
PO
POPO
MAINTENANCE
SS
ALAL
S
AL
SS
ALAL
TT
oo
xx
icic
h h
azaz
arar
h
az
h h
azaz
DD
YNISCYNISC
D
YNISC
DD
YNISCYNISC
d!d!
ar
d!
arar
d!d!
OO
O will accept defective PGs.
OO
17
DD
D
DD
T
o
x
ic
TT
oo
xx
icic
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.
If mercury escapes, use airtight packaging!
Please send defective pressure gauges back to your
addresses, see the back cover of the operating manual.
YNISCYNISC
O O
YNISC
O representative. For
YNISCYNISC
O O
DD
YNISCYNISC
D
YNISC
DD
YNISCYNISC
OO
O
OO
77
.4.4
7
.4
77
.4.4
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
at the bottom of any page for complete details.
MAINTENANCE
WW
ARRANTYARRANTY
W
ARRANTY
ARRANTYARRANTY
WW
18
8.8.
8.
8.8.
• 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
AA
A
AA
CC
CC
EE
SS
SORIESORIE
C
C
E
S
SORIE
CC
CC
EE
SS
SORIESORIE
SS
S
SS
ACCESSORIES
19
9.9.
9.
9.9.
TT
ROUBLESHOOTINGROUBLESHOOTING
T
ROUBLESHOOTING
ROUBLESHOOTINGROUBLESHOOTING
TT
SymptomSymptom
Symptom
SymptomSymptom
Large Zero Shift when Screwing In 1) Check Hole with Gage Plug and Rework Hole as Required
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.
Pressure Variable Reading is Erratic 1) Check Port/Pipe for Blockage or Solidified Plastic
Corrective ActionsCorrective Actions
Corrective Actions
Corrective ActionsCorrective Actions
2) Check Mounting Torque
2) Check Port/Pipe for Blockage or Solidified Plastic
TROUBLESHOOTING
20
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