Fluke PG7302 V2.07, PG7102 V2.07, PG7202 V2.07, PG7601 V2.07 Operation and Maintenance Manua

PG7000™ PISTON GAUGES

PG7102™, PG7202™,

PG7302™, PG7601™

(Ver. 2.07a through 2.07g) Operation and Maintenance Manual

© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

High-pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases can be released unexpectedly and with extreme force. High-pressure systems should be assembled and operated only by personnel who have been instructed in proper safety practices.

© 1998 - 2008 DH Instruments, a Fluke Company All rights reserved.

Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments 4765 East Beautiful Lane Phoenix Arizona 85044-5318 USA.

DH Instruments makes sincere efforts to ensure the accuracy and quality of its published materials; however, no warranty, expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the English version and other language versions, the English version predominates.

DH Instruments, DH, DHI, PG7000, PG7102, PG7202, PG7302, PG7601, CalTool and COMPASS are trademarks, registered and otherwise, of DH Instruments, a Fluke Company.

Swagelok is a registered trademark of the Swagelok Company.

Krytox is a registered trademark of the Dupont de Nemours Company.

Products described in this manual are manufactured under international patents and one or more of the following U.S. patents: 6,701,791, 5,142,483, 5,257,640, 5,331,838, 5,445,035. Other U.S. and international patents pending.

Document No. 550099p 080123

Printed in the USA

© 1998-2008 DH Instruments, a Fluke Company

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS ...............................................................				I
TABLES ..................................................................................				V
FIGURES ................................................................................				VI
ABOUT THIS MANUAL ............................................................				VII
1.	INTRODUCTION .................................................................			1
	1.1	PRODUCT OVERVIEW............................................................................................................................		1
	1.2	SPECIFICATIONS....................................................................................................................................		2
		1.2.1	GENERAL SPECIFICATIONS .......................................................................................................................	2
		1.2.1.1	EMBEDDED FEATURES...........................................................................................................................	3
		1.2.1.2	AMBIENT AND INSTRUMENT CONDITION MEASUREMENTS..............................................................	4
		1.2.2	PISTON-CYLINDER MODULES....................................................................................................................	5
		1.2.2.1	PC-7100/7600 ............................................................................................................................................	5
		1.2.2.2	PC-7200 .....................................................................................................................................................	6
		1.2.2.3	PC-7300 .....................................................................................................................................................	7
		1.2.3	MASS SETS...................................................................................................................................................	8
		1.2.4	PRESSURE MEASUREMENTS ....................................................................................................................	8
		1.2.4.1	PC-7100/7600 ............................................................................................................................................	8
		1.2.4.2	PC-7200 .....................................................................................................................................................	9
		1.2.4.3	PC-7300 ...................................................................................................................................................	10
	1.3 TERMINAL AND PLATFORM FRONT AND REAR PANELS ...............................................................			11
		1.3.1 TERMINAL FRONT AND REAR PANELS ..................................................................................................		11
		1.3.1.1	PG TERMINAL FRONT PANEL...............................................................................................................	11
		1.3.1.2	PG TERMINAL REAR PANEL .................................................................................................................	12
		1.3.2	PLATFORM REAR PANELS .......................................................................................................................	12
2.	INSTALLATION ................................................................			13
	2.1	UNPACKING AND INSPECTION...........................................................................................................		13
		2.1.1	REMOVING FROM PACKAGING................................................................................................................	13
		2.1.1.1	PLATFORM..............................................................................................................................................	13
		2.1.1.2	MASS SET ...............................................................................................................................................	13
		2.1.1.3	PISTON-CYLINDER MODULE(S) ...........................................................................................................	14
		2.1.1.4	AUTOMATED MASS HANDLER .............................................................................................................	14
		2.1.2	INSPECTING CONTENTS...........................................................................................................................	14
		2.1.2.1	PLATFORM..............................................................................................................................................	14
		2.1.2.2	MASS SET ...............................................................................................................................................	19
		2.1.2.3	PISTON-CYLINDER MODULE(S) ...........................................................................................................	21
	2.2	SITE REQUIREMENTS..........................................................................................................................		22
	2.3	SETUP....................................................................................................................................................		23
		2.3.1	PREPARING FOR OPERATION .................................................................................................................	23
		2.3.1.1	SETTING UP THE PLATFORM ...............................................................................................................	23
		2.3.1.2	SYSTEM PRESSURE INTERCONNECTIONS .......................................................................................	24
		2.3.1.3	SETTING UP A MASS SET .....................................................................................................................	24
		2.3.2 INSTALLING A PISTON-CYLINDER MODULE INTO THE PLATFORM....................................................		25
		2.3.3 SWITCHING A PG7202 BETWEEN GAS OPERATION AND OIL OPERATION .......................................		27
	2.4 POWER UP AND VERIFICATION .........................................................................................................			28
		2.4.1	POWER UP..................................................................................................................................................	28

2.4.2CHECK THAT ON-BOARD PISTON-CYLINDER MODULE AND MASS SET INFORMATION ARE

	CORRECT....................................................................................................................................................	29
2.4.3	SET LOCAL GRAVITY VALUE ...................................................................................................................	29
2.4.4	SETUP PRESSURE EQUATION VARIABLE INPUT SOURCES .....................................................	29

Page I

© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

2.4.5	CHECK PROPER OPERATION OF AMBIENT CONDITION MEASUREMENTS ......................................	29
2.4.6	APPLY PRESSURE TO THE PISTON-CYLINDER MODULE ....................................................................	30
2.4.7	CHECK PROPER BEHAVIOR OF MOTORIZED PISTON ROTATION (IF PRESENT)..............................	30
2.4.8	CHECK PROPER OPERATION OF PISTON BEHAVIOR MEASUREMENTS...........................................	31
2.4.8.1	VERIFY VACUUM REFERENCE (PG7601 ONLY) .................................................................................	31
2.4.9	CHECK AUTOMATED PRESSURE GENERATION (IF PRESENT) ....................................................	32
2.4.10	CHECK/SET SECURITY LEVEL.................................................................................................................	32
2.4.11	ADDITIONAL PRECAUTIONS TO TAKE BEFORE MAKING PRESSURE MEASUREMENTS ................	32
2.5 SHORT TERM STORAGE .....................................................................................................................		33

3. GENERAL OPERATION .....................................................	35
3.1 FUNDAMENTAL OPERATING PRINCIPLES........................................................................................	35

3.1.1GAS OPERATED, LIQUID LUBRICATED PISTON-CYLINDER OPERATING PRINCIPLE

		(PG7202) ....................................................................................................................................................					36
3.2	KEYPAD LAYOUT AND PROTOCOL ...................................................................................................						37
3.3	SOUNDS ................................................................................................................................................						38
3.4	PRESSURE READY/NOT READY INDICATION...................................................................................						38
	3.4.1	PISTON POSITION READY/NOT READY ..................................................................................................					39
	3.4.2	PISTON ROTATION READY/NOT READY.................................................................................................					39
	3.4.3	VACUUM REFERENCE READY/NOT READY (PG7601 ONLY) .....................................................					40
3.5	PISTON POSITION ................................................................................................................................						41
3.6	MASS LOADING PROTOCOL...............................................................................................................						42
3.7	MAIN RUN SCREEN..............................................................................................................................						45
3.8	GENERAL FUNCTION/MENU FLOW CHART ......................................................................................						46
3.9	DIRECT FUNCTION KEYS ....................................................................................................................						47
	3.9.1	DIRECT FUNCTION KEYS SUMMARY ......................................................................................................					47
	3.9.2	[P-C].............................................................................................................................................................					48
	3.9.3	[UNIT]...........................................................................................................................................................					49
	3.9.3.1		CUSTOMIZING PRESSURE UNITS AVAILABLE UNDER THE UNIT FUNCTION ................................				50
	3.9.4	[MODE] ........................................................................................................................................................					52
	3.9.4.1		DIFFERENTIAL MEASUREMENT MODE (PG7601 ONLY) ........................................................				53
	3.9.4.2		HIGH LINE DIFFERENTIAL MEASUREMENT MODE (PG7102, PG7302 AND PG7202 ONLY)...........				60
	3.9.5	[SYSTEM] ....................................................................................................................................................					72
	3.9.5.1		FIRST SYSTEM RUN SCREEN ..............................................................................................................				73
	3.9.5.2		SECOND SYSTEM RUN SCREEN .........................................................................................................				73
	3.9.6	[AMBIENT]...................................................................................................................................................					74
	3.9.7	[HEAD] .........................................................................................................................................................					75
	3.9.8	[ROTATE].....................................................................................................................................................					77
	3.9.8.1		<2PRE-DECEL>.......................................................................................................................................				79
	3.9.9	[GEN] (OPTIONAL)......................................................................................................................................					79
	3.9.9.1		<2TARGET>.............................................................................................................................................				81
	3.9.9.2		<3RAISE> ................................................................................................................................................				82
	3.9.9.3		<4UL>.......................................................................................................................................................				82
	3.9.9.4		<5TOL> ....................................................................................................................................................				82
	3.9.9.5		<6REFLOAT>...........................................................................................................................................				83
	3.9.9.6		<7VOL>....................................................................................................................................................				83
	3.9.10	[RES]............................................................................................................................................................					84
	3.9.11	[ENTER/SET P] FROM RUN SCREEN .......................................................................................................					85
	3.9.11.1		[ENTER/SET P] IN PRESSURE TO MASS MODE .................................................................................				86
	3.9.11.2		[ENTER/SET P] IN MASS TO PRESSURE MODE .................................................................................				88
	3.9.11.3 COMMANDS FOR ZERO PRESSURE, ENDING A TEST .....................................................						89
	3.9.12	[P OR M] ......................................................................................................................................................					89
	3.9.13	[		] AND [		], [←]	90
3.10	[SETUP] MENU......................................................................................................................................						91
	3.10.1	<1SELECT> .................................................................................................................................................					93
	3.10.2	<2VIEW> ......................................................................................................................................................					93
	3.10.3	<3EDIT> .......................................................................................................................................................					94
3.11	[SPECIAL] MENU ..................................................................................................................................						96
	3.11.1	<1PC/MS>....................................................................................................................................................					97
	3.11.1.1		CREATE PISTON-CYLINDER MODULE.................................................................................................				98
	3.11.1.2		EDIT PISTON-CYLINDER MODULE .....................................................................................................				101
	3.11.1.3		VIEW PISTON-CYLINDER MODULE ....................................................................................................				101
	3.11.1.4		DELETE PISTON-CYLINDER MODULE ...............................................................................................				102
	3.11.1.5 SELECT THE ACTIVE PISTON-CYLINDER MODULE .........................................................................						102
	3.11.1.6		ADD MASS SET.....................................................................................................................................				102

© 1998-2008 DH Instruments, a Fluke Company

Page II

		TABLE OF CONTENTS
	3.11.1.7	EDIT MASS SET....................................................................................................................................	107
	3.11.1.8	VIEW MASS SET...................................................................................................................................	107
	3.11.1.9	DELETE MASS SET ..............................................................................................................................	107
	3.11.1.10	SELECT MASS SET ..............................................................................................................................	108
	3.11.1.11	ADD MASS LOADING BELL..................................................................................................................	108
	3.11.1.12	EDIT MASS LOADING BELL .................................................................................................................	110
	3.11.1.13	VIEW MASS LOADING BELL................................................................................................................	110
	3.11.1.14	DELETE MASS LOADING BELL ...........................................................................................................	110
	3.11.1.15	SELECT MASS LOADING BELL ...........................................................................................................	111
	3.11.2	<2PRESU>.................................................................................................................................................	111
	3.11.3	<3HEAD> ...................................................................................................................................................	111
	3.11.3.1	<3HEAD>, <1FLUID>.............................................................................................................................	112
	3.11.3.2	<3HEAD>, <2UNIT>...............................................................................................................................	112
	3.11.3.3	<3HEAD>, <3ATM> ...............................................................................................................................	113
	3.11.3.4	<3HEAD>, <4PISTON>..........................................................................................................................	113
	3.11.4	<4PREFS> .................................................................................................................................................	114
	3.11.4.1	<4PREFS>, <1SCRSVR>......................................................................................................................	114
	3.11.4.2	<4PREFS>, <2SOUND>........................................................................................................................	114
	3.11.4.3	<4PREFS>, <3TIME> ............................................................................................................................	115
	3.11.4.4	<4PREFS>, <4ID> .................................................................................................................................	115
	3.11.4.5	<4PREFS>, <5LEVEL>..........................................................................................................................	116
	3.11.5	<5REMOTE>..............................................................................................................................................	118
	3.11.5.1	COM1, COM2 AND COM3 (RS232) ......................................................................................................	119
	3.11.5.2	IEEE-488................................................................................................................................................	119
	3.11.5.3	RS232 SELF TEST ................................................................................................................................	120
	3.11.5.4	EXTERNAL BAROMETER (RPM) COMMUNICATIONS (COM2).........................................................	120
	3.11.5.5	EXTERNAL VACUUM GAUGE COMMUNICATIONS (COM2) (PG7601 ONLY) ..................................	122
	3.11.6	<6GL> ........................................................................................................................................................	124
	3.11.7	<7CAL> ......................................................................................................................................................	125
	3.11.8	<8AMH> .....................................................................................................................................................	125
	3.11.8.1	<2CONTROL>, <1UP/DOWN> ..............................................................................................................	126
	3.11.8.2	<2CONTROL>, <2DISCREET> .............................................................................................................	126
	3.11.8.3	<2CONTROL>, <3LOADALL> ...............................................................................................................	127
	3.11.8.4	<2CONTROL>, <4UNLOADALL> ..........................................................................................................	127
	3.11.9	<9RESET> .................................................................................................................................................	127
	3.11.9.1	<9RESET>, <1SETS> ...........................................................................................................................	128
	3.11.9.2	<9RESET>, <2UNITS> ..........................................................................................................................	128
	3.11.9.3	<9RESET>, <3COM>.............................................................................................................................	129
	3.11.9.4	<9RESET>, <4CAL>..............................................................................................................................	129
	3.11.9.5	<9RESET>, <5SETUPS> ......................................................................................................................	130
	3.11.9.6	<9RESET>, <6ALL> ..............................................................................................................................	130
4. REMOTE OPERATION ......................................................			131
4.1	OVERVIEW ..........................................................................................................................................		131
4.2	INTERFACING .....................................................................................................................................		131
	4.2.1	RS232 INTERFACE ...................................................................................................................................	131
	4.2.1.1	COM1 .....................................................................................................................................................	132
	4.2.1.2	COM2 AND COM3 .................................................................................................................................	132
	4.2.2	IEEE-488 (GPIB)........................................................................................................................................	133
4.3	COMMANDS ........................................................................................................................................		133
	4.3.1	COMMAND SYNTAX .................................................................................................................................	133
	4.3.2	COMMAND SUMMARY .............................................................................................................................	134
	4.3.3	ERROR MESSAGES .................................................................................................................................	136
	4.3.3.1	AMH ERRORS .......................................................................................................................................	137
	4.3.4	COMMAND DESCRIPTIONS.....................................................................................................................	137
	4.3.4.1	IEEE STD. 488.2 COMMON AND STATUS COMMANDS .....................................................	137
	4.3.4.2	PG7000 COMMANDS............................................................................................................................	139
4.4	STATUS SYSTEM................................................................................................................................		166
	4.4.1	STATUS REPORTING SYSTEM ...............................................................................................................	166
	4.4.1.1	STATUS BYTE REGISTER ...................................................................................................................	166
	4.4.1.2	STANDARD EVENT REGISTER ...........................................................................................................	167
4.5 HIGH LINE DIFFERENTIAL MODE PROGRAMMING EXAMPLES....................................................			168

4.5.1RECOMMENDED SEQUENCE FOR A HOST PROGRAM TO REMOTELY SET A NEW HIGH LINE

PRESSURE AND ENABLE HIGH LINE DIFFERENTIAL MODE..............................................................

168

4.5.2RECOMMENDED SEQUENCE FOR A HOST PROGRAM TO REMOTELY ENABLE HIGH LINE

DIFFERENTIAL MODE USING THE LAST LINE PRESSURE SETTING.................................................

171

Page III

© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION ...........			173
5.1	INTRODUCTION ..................................................................................................................................		173
5.2	PLATFORM..........................................................................................................................................		174
	5.2.1 CALIBRATION/ADJUSTMENT OF ON-BOARD MEASUREMENT FUNCTIONS....................................		174
	5.2.1.1	PRINCIPLES..........................................................................................................................................	174
	5.2.1.2	BAROMETRIC PRESSURE SENSOR ..................................................................................................	175
	5.2.1.3	AMBIENT TEMPERATURE SENSOR ...................................................................................................	175
	5.2.1.4	RELATIVE HUMIDITY SENSOR ...........................................................................................................	176
	5.2.1.5	PISTON-CYLINDER MODULE TEMPERATURE SENSOR.....................................................	176
	5.2.1.6	REFERENCE VACUUM GAUGE (PG7601 ONLY) ...............................................................................	178
	5.2.2	PISTON POSITION DETECTION ADJUSTMENT.....................................................................................	179
	5.2.3	EMPTYING OIL RUN-OFF TRAY (PG7202 AND PG7302 ONLY).................................................	180
	5.2.4	PURGE MOUNTING POST LIQUID RUN OFF (PG7202 ONLY) ..............................................	180
	5.2.5	DRIVE BELT REPLACEMENT..................................................................................................................	181
5.3	PISTON-CYLINDER MODULES..........................................................................................................		182
	5.3.1 DISASSEMBLY, CLEANING AND MAINTENANCE .................................................................................		182
	5.3.2	DISASSEMBLY AND REASSEMBLY .......................................................................................................	183
	5.3.2.1	DISASSEMBLY AND REASSEMBLY OF GAS OPERATED, GAS LUBRICATED
		PISTON-CYLINDER MODULES (PC-7100/7600) .......................................................................	183
	5.3.2.2	DISASSEMBLY AND REASSEMBLY OF GAS OPERATED, LIQUID LUBRICATED
		PISTON-CYLINDER MODULES (PC-7200) ..........................................................................................	187
	5.3.2.3	DISASSEMBLY AND REASSEMBLY OF OIL OPERATED, OIL LUBRICATED
		PISTON-CYLINDER MODULES (PC-7300) ..........................................................................................	189

5.3.3FILLING OR EMPTYING GAS OPERATED, LIQUID LUBRICATED PISTON-CYLINDER MODULE

			RESERVOIR WITH LIQUID .......................................................................................................................	191
		5.3.4	CLEANING PISTON-CYLINDERS.............................................................................................................	192
		5.3.5	LUBRICATING PISTON-CYLINDER MODULES ......................................................................................	194
		5.3.6	RECALIBRATION ......................................................................................................................................	198
		5.3.6.1	UPDATING PISTON-CYLINDER MODULE FILES................................................................................	198
	5.4	MASS SETS.........................................................................................................................................		198
		5.4.1	CLEANING.................................................................................................................................................	198
		5.4.2	RECALIBRATION ......................................................................................................................................	198
		5.4.2.1	UPDATING MASS SET FILES...............................................................................................................	198
	5.5	RELOADING EMBEDDED SOFTWARE INTO PG7000 FLASH MEMORY........................................		199
	5.6	DISASSEMBLY AND REASSEMBLY OF PG7000 .............................................................................		199
		5.6.1	PLATFORM................................................................................................................................................	199
		5.6.2	TERMINAL .................................................................................................................................................	199
		5.6.3 AMH AUTOMATED MASS HANDLER REMOVAL ...................................................................................		199
6.	TROUBLESHOOTING .......................................................			201
	6.1	OVERVIEW ..........................................................................................................................................		201
7.	APPENDIX ......................................................................			205
	7.1	CONVERSION OF NUMERICAL VALUES..........................................................................................		205
		7.1.1	PRESSURE................................................................................................................................................	205
	7.2	DEFINED PRESSURE CALCULATIONS ............................................................................................		205
		7.2.1 PG7102, PG7202 AND PG7302 ................................................................................................................		207
		7.2.2	PG7601 ......................................................................................................................................................	208
		7.2.3	FLUID HEADS ...........................................................................................................................................	209
		7.2.3.1	FLUID HEAD COMPONENTS ...............................................................................................................	209
		7.2.3.2	OVERALL FLUID HEAD CORRECTION ...............................................................................................	210
	7.3	GLOSSARY..........................................................................................................................................		211
	7.4	WARRANTY STATEMENT ..................................................................................................................		213

© 1998-2008 DH Instruments, a Fluke Company

Page IV

TABLES AND FIGURES

TABLES
Table 1.	PG7102 Parts List........................................................................................................................	15
Table 2.	PG7202 Parts List........................................................................................................................	16
Table 3.	PG7302 Parts List........................................................................................................................	17
Table 4.	PG7601 Parts List........................................................................................................................	18
Table 5.	Manual Mass Set Parts List (excluding 80 and 100 kg) ..............................................................	19
Table 6. Manual Mass Set Parts List (80 and 100 kg)...............................................................................		19
Table 7. AMH-38 Mass Set Parts List........................................................................................................		19
Table 8. AMH-100 Mass Set Parts List......................................................................................................		19
Table 9. Mass Set Compositions ...............................................................................................................		20
Table 10.	Mass Set Compatibility ..............................................................................................................	20
Table 11.	PC-7100/7600 Piston-Cylinder Modules Parts List ...................................................................	21
Table 12.	PC-7200 Piston-Cylinder Modules Parts List ............................................................................	21
Table 13. PC-7300 Piston-Cylinder Modules Parts List ...........................................................................		22
Table 14. Summary of PG7000 Direct Function Key Operations ..............................................................		47
Table 15.	Pressure Units of Measure Available.........................................................................................	51
Table 16.	Valve Settings for Setting Differential Mode Static Pressure.....................................................	56
Table 17.	Valve Settings to Apply PG7000 Pressure to the RPM for Differential Mode Offsetting...........	57
Table 18.	Valve Settings for Operating in Differential Mode......................................................................	59
Table 19. SETUP File Choices, Factory Preferred Choice and Normal Value..........................................		92
Table 20.	Security Levels - Functions NOT Executed Per Function/Level..............................................	117
Table 21. COM1, COM2 and COM3 Available Settings..........................................................................		119
Table 22. COM1 DB-9F Pin Designation.................................................................................................		132
Table 23. COM2 and COM3 DB-9M Pin Designation .............................................................................		132
Table 24. Command Summary ................................................................................................................		134
Table 25. Error Messages........................................................................................................................		136
Table 26.	Status Byte Register ................................................................................................................	166
Table 27.	Standard Event Register..........................................................................................................	167
Table 28.	Mounting Post Wire Colors, Description and Location ............................................................	178
Table 29.	PG7000 Troubleshooting Checklist .........................................................................................	201
Table 30. Pressure Unit of Measure Conversions...................................................................................		205
Table 31.	PG7000 Defined Pressure Calculation Variables....................................................................	206
Table 32.	DHI Authorized Service Providers ...........................................................................................	213

Page V

© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

FIGURES
Figure 1.	PG Terminal Front Panel ............................................................................................................	11
Figure 2. PG Terminal Rear Panel.............................................................................................................		12
Figure 3. PG Platform Rear Panel .............................................................................................................		12
Figure 4.	Piston-Cylinder Module Installation ............................................................................................	26
Figure 5.	Piston Gauge Operating Principle ..............................................................................................	35
Figure 6.	Gas Operated, Liquid Lubricated Piston-Cylinder (PC-7200) Operating Principle ...................	37
Figure 7. PG7000 Keypad Layout..............................................................................................................		37
Figure 8.	Piston Stroke and Zones ............................................................................................................	41
Figure 9. Run Screen Flow Chart ..............................................................................................................		46
Figure 10.	Differential Mode Controller Schematic....................................................................................	55
Figure 11.	High Line Differential Mode Schematic ....................................................................................	63
Figure 12.	Status Byte Register ...............................................................................................................	166
Figure 13. PG7202 Mounting Post Drain.................................................................................................		181
Figure 14. 10 and 20 kPa/kg Gas Piston-Cylinder Module (Expanded View) .........................................		184
Figure 15.	10 kPa/kg Piston Insertion Tool..............................................................................................	185
Figure 16.	Gas Piston-Cylinder Module Sleeve Nut Tool ........................................................................	185
Figure 17. 50, 100 and 200 kPa/kg Gas Piston-Cylinder Modules (Expanded View) .............................		186
Figure 18.	Gas Operated, Liquid Lubricated Piston-Cylinder Module (Expanded View) .......................	188
Figure 19.	Oil Piston-Cylinder Module (Expanded View) ........................................................................	190
Figure 20.	Filling Gas Operated, Liquid Lubricated Piston-Cylinder Module Reservoir (PC-7200) .......	192
Figure 21. Gas Operated, Gas Lubricated Piston-Cylinder Module Lubrication Chart ............................		195
Figure 22.	Gas Operated, Liquid Lubricated Piston-Cylinder Module Lubrication Chart ........................	196
Figure 23.	Oil Operated Piston-Cylinder Module Lubrication Chart ........................................................	197

© 1998-2008 DH Instruments, a Fluke Company

Page VI

ABOUT THIS MANUAL

ABOUT THIS MANUAL

This manual provides the user with the information necessary to operate various PG7000 Piston Gauges. It also includes a great deal of additional information provided to help you optimize PG7000 use and take full advantage of its many features and functions.

This manual covers four PG7000 models: PG7102, PG7202, PG7302 and PG7601. The four models have many features and characteristics in common as well as individual differences. When discussing features that are common to all four models, they are referred to collectively as PG7000. When providing information pertaining to a specific model, that model is referred to by its specific model number.

Before using the manual, take a moment to familiarize yourself with the Table of Contents structure. All first time PG7000 users should read Sections 1 and 2. Section 3 provides a comprehensive description of general PG7000 operating principles. Section 4 covers remote communication with an external computer. Section 5 provides maintenance and calibration information. Section 6 is a quick troubleshooting guide. Use the information in Section 6 to troubleshoot unexpected PG7000 behavior based on the symptoms of that behavior.

Certain words and expressions have specific meaning as they pertain to PG7000s. The Glossary (see Section 7) is useful as a quick reference for the definition of specific words and expressions as they are used in this manual.

FOR THOSE OF YOU WHO “DON’T READ MANUALS”, GO DIRECTLY TO SECTION 2.3 TO SET UP YOUR PG7000. THEN GO TO SECTION 2.4. THIS WILL GET YOU RUNNING QUICKLY WITH MINIMAL RISK OF CAUSING DAMAGE TO YOURSELF OR YOUR PG7000. THEN… WHEN YOU HAVE QUESTIONS OR START TO WONDER ABOUT ALL THE GREAT FEATURES YOU MIGHT BE MISSING, GET INTO THE MANUAL!

Manual Conventions

(CAUTION) is used throughout the manual to identify user warnings and cautions.

(NOTE) is used throughout the manual to identify operating and applications advice and additional explanations.

[ ] indicates direct function keys (e.g., [RANGE]).

< > indicates PG7000 screen displays (e.g., <1yes>)

Page VII

© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

NOTES

© 1998-2008 DH Instruments, a Fluke Company

Page VIII

1. INTRODUCTION

1.INTRODUCTION

1.1PRODUCT OVERVIEW

PG7000 Piston Gauges are reference level pressure standards that operate on the piston gauge principle. Pressure is defined by balancing it against the force exerted by a known mass accelerated by gravity on the effective area of a piston-cylinder.

A PG7000 piston gauge consists of the PG7000 Platform, one or several piston-cylinder modules, a mass set. An automated mass handling system is available. A PG7000 system normally also includes the means to generate and adjust pressures and to interconnect the system components and a device being calibrated or tested. The pressure generation component can be manual or automated. COMPASS® for Pressure software may also be included to assist in executing test sequences, acquiring test data and producing test reports.

There are four PG7000 Platforms: PG7102, PG7202, PG7302 and PG7601. These have a common PG7000 presentation and features. They are distinguished by their normal operating medium (oil and/or gas) and the capability to define pressures relative to a vacuum reference.

•PG7102 - Gas operated with gas lubricated piston-cylinder modules (PC-7100/7600 modules)

-Maximum pressure is 11 MPa (1 600 psi)

-Does not support definition of pressure against a vacuum reference

•PG7202 - Gas operated, liquid lubricated piston-cylinder modules (PC-7200 modules)

-Oil operated piston-cylinder modules (PC-7300 modules)

-Maximum pressure is 110 MPa (16 000 psi) when operated with a PC-7200 module

-Maximum pressure is 200 MPa (30 000 psi) when operated with a PC-7300 module

-Does not support definition of pressure against a vacuum reference

•PG7302 - Oil operated (PC-7300 modules)

-Maximum pressure is 500 MPa (72 500 psi)

•PG7601 - Gas operated, gas lubricated piston-cylinder modules (PC-7100/7600 modules)

-Maximum pressure is 7 MPa (1 000 psi)

-Supports definition of pressure against a vacuum reference

PG7000 platforms, piston-cylinder modules, mass sets and mass handling systems are designed to maximize metrological performance and ease of operation. They include many features that enhance the fundamental precision and stability of pressure measurements as well as simplifying use and reducing operator influence on the measurements. Extensive monitoring and controlling capability and advanced local and remote user interfaces are integrated into PG7000 Platforms.

Operator interaction with PG7000 and its extensive capabilities and peripherals is accomplished through a single display and keypad on the PG Terminal or from a computer via a single standard RS232 or IEEE-488 interface.

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© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.2SPECIFICATIONS

1.2.1	GENERAL SPECIFICATIONS
Power Requirements		85 to 264 VAC, 50/60 Hz, 22 VA max. consumption.
Operating Temperature Range		15 to 35 °C
Operating Humidity Range		5 to 95% R.H., non-condensing
Weight
Instrument platform with no mass loaded.
	PG7102	13 kg (29 lb)
	PG7202	13 kg (29 lb)
	PG7302	13 kg (29 lb)
	PG7601	17 kg (37 lb)
	PG Terminal	1.4 kg (3 lb)
Dimensions
	Instrument Platform	36 cm H x 40 cm W x 35 cm D (14.5 in. x 15.8 in. x 13.8 in.)
		(Height: Top of mounting post with piston-cylinder module installed
		for PG7102/PG7202/PG7302; top of bell jar for PG7601.)
	PG Terminal	12 cm H x 15 cm W x 20 cm D (4.7 in. H x 5.9 in. W x 7.9 in. D)
Microprocessors
	Instrument Platform	Motorola 68302
	PG Terminal	Hitachi 64180
Communication Ports
	RS232	COM1: Host computer
		COM2: External barometer or vacuum gauge (PG7601) and pass
	IEEE-488	through communications
		COM3: Automated pressure generator/controller Host computer
Overall Pressure Ranges
Actual range depends on piston-cylinder
and mass set selection
	PG7102	Gauge:		5 kPa to 11 MPa (0.7 to 1 600 psi)
		Absolute:		105 kPa to 11 MPa (15 to 1 600 psi)
		Differential:		DP + static pressure < 11 MPa (1 600 psi)
	PG7202	Gauge (gas):		100 kPa to 110 MPa (15 to 16 000 psi)
		Absolute (gas):200 kPa to 110 MPa (30 to 16 000 psi)
		Gauge (oil): (PG7302 module): 1 to 200 MPa (150 to 30 000 psi)
		Absolute (oil): (PG7302 module) 1.1 to 200 MPa (165 to 30 000 psi)
		Differential:		DP + static pressure < 110 MPa (16 000 psi)
		PC-7200 can be operated in oil up to 200 MPa (30 000 psi)
		when used with PC-7300 oil operated piston-cylinders.
	PG7302	Gauge:		20 kPa to 500 MPa (3 to 75 000 psi)
		Absolute:		120 kPa to 500 MPa (20 to 75 000 psi)
	PG7601	Gauge:		4 kPa to 7 MPa (0.6 to 1 000 psi)
		Absolute:		7 kPa to 7 MPa (0.7 to 1 000 psi)
		Differential:		- 90 to 350 kPa (-13 to 50 psi) at
				15 to 200 kPaa (2 to 30 psia) static pressure
Operating Media
	PG7102	Gas:	air, helium, nitrogen
	PG7202	Gas:	any non-corrosive
		Oil:	Di2-EthylHexyl Sebacate (synthetic oil)
	PG7302	Oil:	Di2-EthylHexyl Sebacate (synthetic oil)
	PG7601	Gas:	air, helium, nitrogen

© 1998-2008 DH Instruments, a Fluke Company

Page 2

1. INTRODUCTION

Maximum Mass Load

PG7102 100 kg, while not exceeding 11 MPa (1 600 psi)

PG7202 100 kg, while not exceeding 110 MPa (16 000 psi) when operated with PC-7200 piston-cylinder modules or 200 MPa (30 000 psi) when operated with PC-7300 piston-cylinder modules

PG7302	100 kg
PG7601	38 kg
Pressure Connections
PG7102	Test port:		DH200
PG7202	Test port:		DH500
	Drain port:		DH500
PG7302	Test port:		DH500
PG7601	Test port:		DH200
	Bell Jar Vent Port:		DH200
	Vacuum Reference
	Pump Down Port:		KF25 (KF40 available on optional AMH
			automated mass handler)
	External Vacuum Port: Optional KF25 on bell jar (KF40 available
			on optional AMH automated mass handler)
	DH200	and	DH500 are gland and collar		type	fittings	for
	1/4 in. (6.35 mm) coned and			left hand	threaded tubes.
	DH200 is	equivalent to AE		SF250C,	HIP	LF4,	etc.

DH500 is equivalent to AE F250C, HIP HF4, etc.

CE Conformance

Available, must be specified.

1.2.1.1 EMBEDDED FEATURES

•Local control with 2 x 20 vacuum fluorescent display and 4 x 4 function driven keypad.

•Real time (1 second update rate) display and measurement of ambient (pressure, temperature, humidity) and instrument (piston-cylinder temperature, piston position, piston drop rate, piston rotation rate, piston rotation decay rate, reference vacuum) conditions.

•Real time (1 second update rate) mass-to-pressure and pressure-to-mass calculations taking into consideration all environmental and operational variables.

•Full gas and liquid fluid head corrections including DUT head correction and piston position head correction.

•Adjustable mass loading resolution (0.01 g to 0.1 kg).

•Audible prompts of instrument status (piston movement, Ready/Not Ready indication) with override capability.

•Integrated automated mass handling option (AMH-38 or AMH-100).

•Interfacing and automatic exploitation of external barometer via RS232.

•Interfacing and automatic exploitation of any external vacuum gauge via RS232 (PG7601 only).

•Automated differential mode to define low differential pressures at various static pressures between vacuum and two atmospheres.

•Automated high line differential mode to define differential pressure at high line pressure.

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© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

•Storage and one step activation of metrological data on up to 18 piston-cylinder modules, (3) mass sets and (3) mass loading bells.

•Continuous pressure Ready/Not Ready indication based on measured conditions.

•Motorized, intelligent piston drive system based measured rotation rate with operator alert and manual override (motorization optional on PG7102 and PG7302).

•Integrated automated pressure control with standard DHI pressure controllers.

•Full RS232 and IEEE-488 communications with multi-level commands to set and read all instrument functions.

1.2.1.2 AMBIENT AND INSTRUMENT CONDITION MEASUREMENTS

Temperature	Ambient	Piston Cylinder Module
Range	0 to 40 o C	0 to 40 oC
Resolution	0.1	0.01
Measurement Uncertainty	± 1	± 0.1
Barometric Pressure
with Internal Sensor
Range	70 to 110 kPa
Resolution	10 Pa
Measurement Uncertainty	± 140 Pa
	Barometric pressure can also be read automatically with any
	RS232 device such as a DHI RPM.
Relative Humidity
Range	5 to 95 % RH
Resolution	1 % RH
Measurement Uncertainty	± 10 % RH
Piston Position
Range	± 4.5 mm
Resolution	0.1 mm
Measurement Uncertainty	± 0.2 mm
Piston Rotation
(Rate and deceleration)
Range	2 to 99 rpm
Resolution	1 rpm
Vacuum
(PG7601 only)
Range	0 to 20 Pa
Resolution	0.01 Pa
Measurement Uncertainty	± 0.1 Pa or 10 % of reading, whichever is greater

© 1998-2008 DH Instruments, a Fluke Company

Page 4

1. INTRODUCTION

1.2.2 PISTON-CYLINDER MODULES

All piston-cylinders are integrated modules including mounting hardware delivered in individual shipping and storage bullet cases.

1.2.2.1 PC-7100/7600

Gas operated, gas lubricated piston-cylinder characteristics. Used in PG7102 and PG7601 platforms.

PC-7100/7600-10, TC

PC-7100/7600-10-L

Operation	Gas operated, gas lubricated
Piston Material	Tungsten carbide
Cylinder Material	Tungsten carbide
Nominal Diameter	35 mm
Nominal Area	1 000 mm2
Mounting System	Simple free deformation
PC-7100/7600-20
Operation	Gas operated, gas lubricated
Piston Material	Tungsten carbide
Cylinder Material	Tungsten carbide
Nominal Diameter	25 mm
Nominal Area	500 mm2
Mounting System	Simple free deformation
PC-7100/7600-50
Operation	Gas operated, gas lubricated
Piston Material	Tungsten carbide
Cylinder Material	Tungsten carbide
Nominal Diameter	16 mm
Nominal Area	200 mm2
Mounting system	Negative free deformation
PC-7100/7600-100
Operation	Gas operated, gas lubricated
Piston Material	Tungsten carbide
Cylinder Material	Tungsten carbide
Nominal Diameter	11 mm
Nominal Area	98 mm2
Mounting System	Negative free deformation
PC-7100/7600-200
Operation	Gas operated, gas lubricated
Piston Material	Tungsten carbide
Cylinder Material	Tungsten carbide
Nominal Diameter	8 mm
Nominal Area	50 mm2
Mounting System	Negative free deformation

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© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.2.2.2 PC-7200

Gas operated, liquid lubricated piston-cylinder module characteristics. Used in PG7202 platform.

Though not recommended for day-to-day operation, PC-7200 modules can also be filled completely with oil and operated with oil as the test medium (see Section 2.3.3).

PC-7200-100
Operation	Gas operated, liquid lubricated
Lubricating Liquid	Synturion 6 (Krytox® optional)
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	11.2 mm
Nominal Area	98.1 mm2
Mounting System	Negative free deformation
PC-7200-200
Operation	Gas operated, liquid lubricated
Lubricating Liquid	Synturion 6 (Krytox® optional)
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	7.9 mm
Nominal Area	49.0 mm2
Mounting System	Negative free deformation
PC-7200-500
Operation	Gas operated, liquid lubricated
Lubricating Liquid	Di-2-ethylhexyl Sebacate (Krytox® optional)
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	5.0 mm
Nominal Area	19.6 mm2
Mounting System	Negative free deformation
PC-7200-1
Operation	Gas operated, liquid lubricated
Lubricating Liquid	Di-2-ethylhexyl Sebacate (Krytox® optional)
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	3.5 mm
Nominal Area	9.8 mm2
Mounting System	Negative free deformation
PC-7200-2
Operation	Gas operated, liquid lubricated
Lubricating Liquid	Di-2-ethylhexyl Sebacate (Krytox® optional)
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	2.5 mm
Nominal Area	4.9 mm2
Mounting System	Negative free deformation

© 1998-2008 DH Instruments, a Fluke Company

Page 6

1. INTRODUCTION

1.2.2.3 PC-7300

Oil operated, oil lubricated piston-cylinder module characteristics. Used in PG7302 and PG7202 platforms (1 MPa/kg and higher only in PG7202).

PC-7300 modules PC-7300-1, -2 and -5 may also be used in a PG7202 platform.

PC-7300-100
Operation	Oil operated, oil lubricated
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	11.2 mm
Nominal Area	98.1 mm2
Mounting System	Simple free deformation
PC-7300-200
Operation	Oil operated, oil lubricated
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	7.9 mm
Nominal Area	49.0 mm2
Mounting System	Simple free deformation
PC-7300-500
Operation	Oil operated, oil lubricated
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	5.0 mm
Nominal Area	19.6 mm2
Mounting System	Simple free deformation
PC-7300-1
Operation	Oil operated, oil lubricated
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	3.5 mm
Nominal Area	9.8 mm2
Mounting System	Simple free deformation
PC-7300-2
Operation	Oil operated, oil lubricated
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	2.5 mm
Nominal Area	4.9 mm2
Mounting System	Simple free deformation
PC-7300-5
Operation	Oil operated, oil lubricated
Piston and Cylinder Material	Tungsten carbide
Nominal Diameter	1.6 mm
Nominal Area	2.0 mm2
Mounting System	Simple free deformation

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© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.2.3 MASS SETS

All masses are delivered in molded, reusable, transit cases with custom inserts.

Masses > 50g
Material	304L non-magnetic stainless steel
Finish	Electropolished
Adjustment Tolerance	± 20 ppm of nominal value (manual mass sets, AMH
	automated mass handler mass sets do not have fixed
	adjustment tolerances)
Uncertainty of Measured Values	± 5 ppm or 1 mg, whichever is greater
Masses < 50g	± 1 mg

Masses designated “tare” are delivered without reported measured values and are intended only for use on the “tare” PG7000 in high line differential pressure measurement mode.

1.2.4 PRESSURE MEASUREMENTS

1.2.4.1 PC-7100/7600

For uncertainty in piston-cylinder effective area and typical measurement uncertainty in pressure defined by the piston gauge, see the piston-cylinder calibration report and current revision of DHI Technical Note 7920TN01.

PC-7100/7600-10

PC-7100/7600-10-L

Sensitivity1	0.02 Pa + 0.5 ppm
Reproducibility2	± 2 ppm
Typical Drop Rate (35 kg)	0.2 mm/min
PC-7100/7600-20
Sensitivity1	0.04 Pa + 0.5 ppm
Reproducibility2	± 2 ppm
Typical Drop Rate (35 kg)	0.3 mm/min
PC-7100/7600-50
Sensitivity1	0.1 Pa + 0.5 ppm
Reproducibility2	± 2 ppm
Typical Drop Rate (35 kg)	0.5 mm/min
PC-7100/7600-100
Sensitivity1	0.2 Pa + 0.5 ppm
Reproducibility2	± 3 ppm
Typical Drop Rate (35 kg)	0.7 mm/min
PC-7100/7600-200
Sensitivity1	0.4 Pa + 0.5 ppm
Reproducibility2	± 3 ppm
Typical Drop Rate (35 kg)	1.0 mm/min

1Sensitivity: The smallest variation in input detectable in output.

2Reproducibility: Combined long term stability of piston-cylinder effective area and masses.

© 1998-2008 DH Instruments, a Fluke Company

Page 8

1. INTRODUCTION

Piston-cylinder modules designated “tare” are delivered without reported values and are intended only for use on the “tare” PG7000 in high line differential pressure measurement mode.

1.2.4.2 PC-7200

For uncertainty in piston-cylinder effective area and typical measurement uncertainty in pressure defined by the piston gauge, see the piston-cylinder calibration report and current revision of DHI Technical Note 7920TN01.

PC-7200-100
Sensitivity1	2 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.10 mm/min
PC-7200-200
Sensitivity1	4 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.15 mm/min
PC-7200-500
Sensitivity1	10 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.20 mm/min
PC-7200-1
Sensitivity1	20 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.25 mm/min
PC-7200-2
Sensitivity1	40 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.50 mm/min

1Sensitivity: The smallest variation in input detectable in output.

2Reproducibility: Combined long term stability of piston-cylinder effective area and masses.

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© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.2.4.3 PC-7300

For uncertainty in piston-cylinder effective area and typical measurement uncertainty in pressure defined by the piston gauge, see the piston-cylinder calibration report and current revision of DHI Technical Note 7920TN01.

PC-7300-100
Sensitivity1	2 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.02 mm/min
PC-7300-200
Sensitivity1	4 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.04 mm/min
PC-7300-500
Sensitivity1	10 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.10 mm/min
PC-7300-1
Sensitivity1	20 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.20 mm/min
PC-7300-2
Sensitivity1	40 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	0.40 mm/min
PC-7300-5
Sensitivity1	100 Pa + 1 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (50 kg)	1.00 mm/min

1Sensitivity: The smallest variation in input detectable in output.

2Reproducibility: Combined long term stability of piston-cylinder effective area and masses.

© 1998-2008 DH Instruments, a Fluke Company

Page 10

1. INTRODUCTION

1.3TERMINAL AND PLATFORM FRONT AND REAR PANELS

1.3.1 TERMINAL FRONT AND REAR PANELS

1.3.1.1 PG TERMINAL FRONT PANEL

The front panel assembly provides a 2 x 20 vacuum fluorescent display and a 4 x 4 membrane keypad for local user interface. The terminal front panel assembly is the same for all PG7000 models.

1. Fluorescent display

2. Keypad

Figure 1. PG Terminal Front Panel

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PG7000™ OPERATION AND MAINTENANCE MANUAL

1.3.1.2 PG TERMINAL REAR PANEL

The rear panel assembly provides the communications connection to the PG7000 Platform and the power connection module. The terminal rear panel assembly is the same for all PG7000 models.

1.	Power switch	4.	Connector for cable to PG7000 (25-pin)
2.	Fuse	5.	Cooling fan
3.	Power receptacle

Figure 2. PG Terminal Rear Panel

1.3.2 PLATFORM REAR PANELS

The PG7000 Platform rear panels provide the connection to the PG Terminal, remote communication connections and pressure connection ports. The rear panels of all PG7000 models are identical except for the pressure connections (see Figure 3, # 7).

1. COM2 (RS232) - External Barometer, External Vacuum Gauge (PG7601 only) and Pass Through Communications

2. COM3 (RS232) - Automated Pressure Generation/Control Component, AMH Automated Mass Handler

3. COM1 (RS232) - Remote

Host Communications

4. Ambient Temperature Sensor

5. IEEE-488 - Remote Host Communications

6. Ambient Relative Humidity Sensor

7. Pressure Ports:

PG7102 - TEST port: DH200 PG7202 - TEST and DRAIN ports: DH500

PG7302 - TEST port: DH500 PG7601 - TEST and VACUUM vent ports: DH200

Vacuum pull down port on front left side: KF25

8. PG7000 Terminal Port

Figure 3. PG Platform Rear Panel

© 1998-2008 DH Instruments, a Fluke Company

Page 12

2. INSTALLATION

2.INSTALLATION

2.1UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

A typical PG7000 system includes the PG7000 Platform (see Section 2.1.1.1), a mass set, (see Section 2.1.1.2), one or more piston-cylinder modules (see Section 2.1.1.3) and other accessories such as an AMH automated mass handler and/or pressure generation and control components (see the accessory Operation and Maintenance Manual or Instruction Sheet).

2.1.1.1 PLATFORM

The mass loading bell is a metrological element that is part of the mass set. Like all of the masses, it is preferable not to handle it with bare hands. Protective gloves are provided in the accessory kit of each PG7000 Platform.

The PG7000 Platform is shipped in a reusable, molded shipping and storage case.

Open the PG7000 shipping and storage case (it is the large, 66 cm x 53 cm x 47 cm case).

Remove the PG Terminal and accessories from upper packing insert. Inspect and inventory the accessories (see Section 2.1.2).

Remove the upper packing insert.

Carefully lift the PG7000 Platform from its position in the lower packing insert. Note the orientation so that the same orientation will be used when PG7000 is repacked.

Reinstall the upper packing insert into the shipping and storage case and store in a safe place.

2.1.1.2 MASS SET

The stability over time of PG7000 pressure measurements is a function of the stability of the masses loaded on the piston. Precautions should be taken in handling the masses to minimize influences that may change their mass. This includes always wearing protective gloves when handling the masses to avoid contaminating them with body oils and perspiration. Protective gloves are provided in the accessory kits of PG7000 Platforms.

The mass set accessories are shipped in a separate corrugated container. Open the corrugated container and inspect and inventory the accessories.

The PG7000 masses are shipped in reusable, molded shipping and storage cases. The PG7000 masses should be removed from their shipping cases and inventoried when actually setting up the PG7000 system.

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PG7000™ OPERATION AND MAINTENANCE MANUAL

2.1.1.3 PISTON-CYLINDER MODULE(S)

The piston-cylinder modules are shipped in Acetal bullet cases that are packed in corrugated containers with custom foam inserts.

Open the corrugated containers and remove the piston-cylinder modules and accessories.

The bullet cases screw open by turning the lid counterclockwise.

When reinstalling an oil (PC-7300) or liquid lubricated (PC-7200) piston-cylinder module in its bullet case, be sure to empty out any liquid that may have collected in the hole in the bottom of the case. Excess liquid will not compress, making it difficult to fully close the case and could result in damaging it.

2.1.1.4 AUTOMATED MASS HANDLER

See the AMH-38/AMH-100 Operation and Maintenance Manual.

2.1.2 INSPECTING CONTENTS

Check that all items are present and have NO visible signs of damage. supplied is provided in Section 2.1.2.1 for PG7000, Section 2.1.2.2 Section 2.1.2.3 for piston-cylinder modules.

A parts list of items for mass sets, and

2.1.2.1 PLATFORM

Each PG7000 Platform is delivered complete with accessories as listed by part number in Tables 1 through 4.

© 1998-2008 DH Instruments, a Fluke Company

Page 14

2. INSTALLATION

Table 1. PG7102 Parts List

		PG7102				PG7102
		P/N 401141				P/N 401141-CE
	DESCRIPTION	MOTORIZED				MOTORIZED
		ROTATION				ROTATION
		NON-CE				CE
	Platform	402252				402252-CE
	Manual Mass Bell		401132
	Terminal		401284
	Cable, Null Modem		402114
	PG Terminal to Platform Cable
	Non-CE (DB25M -DB25F,	102227
	≈ 1.8 meters)
	CE (DB25M - DB25F,					102227-CE
	≈ 1.5 meters)
	Power Cable	100770 (Black)				100770-CE (Gray)
	Accessory Kit		401560
	NIP, SS, DH200, 2.75 in.		100204
	ADPT, SS, DH200 F x 1/8 in. NPT F		100299
	O-ring, Buna 2-242 (2 ea.)		101976
	Storage Cover, 7600 Type		102132
	Allen Wrench, 2.5 mm		102257
	Allen Wrench, 3 mm		102168
	Allen Wrench, 5 mm		102262
	Spanner Wrench (Metrological)		122568
	Krytox® GPL205/6 0.5 oz.		102496
	Gift Kit with Gloves		400511
	ADPT, DH200 M x 1/8 in. swage		400518
	Documentation
	Calibration Report (PG Platform)		550100
	Calibration Report (Mass Bell)		550100
	Technical Data		550101
	PG7000 Operation &
	Maintenance Manual		550099
	Documentation CD		102987

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PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 2. PG7202 Parts List

		PG7202				PG7202
		#401722				#401722-CE
	DESCRIPTION	MOTORIZED				MOTORIZED
		ROTATION				ROTATION
		NON-CE				CE
	Platform	402251				402251-CE
	Manual Mass Bell		401132
	Terminal		401284
	Cable, Null Modem		402114
	PG Terminal to Platform Cable
	Non-CE (DB25M -DB25F,	102227
	≈ 1.8 meters)
	CE (DB25M - DB25F,					102227-CE
	≈ 1.5 meters)
	Power Cable	100770 (Black)				100770-CE (Gray)
	Accessory Kit		401134
	DH500 M x 1/8 in. NPT F		103610
	O-ring, Buna 2-242 (2 ea.)		101976
	Storage Cover, 7600 Type		102132
	Allen Wrench, 2.5 mm		102257
	Allen Wrench, 3 mm		102168
	Allen Wrench, 5 mm		102262
	Wrench, 5/8 in.		103044
	Collar, SS, DH500		101201
	Krytox® GPL205/6 0.5 oz.		102496
	Gift Kit with Gloves		400511
	Documentation
	Calibration Report (PG)		550100
	Calibration Report (Mass Bell)		550100
	Technical Data		550101
	PG7000 Operation &
	Maintenance Manual		550099
	Documentation CD		102987

© 1998-2008 DH Instruments, a Fluke Company

Page 16

2. INSTALLATION

Table 3. PG7302 Parts List

		PG7302				PG7302
		P/N 401298				P/N 401298-CE
	DESCRIPTION	MOTORIZED				MOTORIZED
		ROTATION				ROTATION
		NON-CE				CE
	Platform	402241				402241-CE
	Manual Mass Bell		401132
	Terminal		401284
	Cable, Null Modem		402114
	PG Terminal to Platform Cable
	Non-CE (DB25M -DB25F,	102227
	≈ 1.8 meters)
	CE (DB25M - DB25F,					102227-CE
	≈ 1.5 meters)
	Power Cable	100770 (Black)				100770-CE (Gray)
	Accessory Kit		401134
	DH500 M x 1/8 in. NPT F		103610
	O-ring, Buna 2-242 (2 ea.)		101976
	Storage Cover, 7600 Type		102132
	Allen Wrench, 2.5 mm		102257
	Allen Wrench, 3 mm		102168
	Allen Wrench, 5 mm		102262
	Wrench, 5/8 in.		103044
	Collar, SS, DH500		101201
	Krytox® GPL205/6 0.5 oz.		102496
	Gift Kit with Gloves		400511
	Documentation
	Calibration Report (PG)		550100
	Calibration Report (Mass Bell)		550100
	Technical Data		550101
	PG7000 Operation &
	Maintenance Manual		550099
	Documentation CD		102987

Page 17

© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 4. PG7601 Parts List

		PG7601			PG7601
		P/N 400480			P/N 400480-CE
	DESCRIPTION	MOTORIZED			MOTORIZED
		ROTATION			ROTATION
		NON-CE			CE
	Platform	402359			402359-CE
	Manual Mass Bell		402135
	Bell Jar and Seal	122106 and 101546
	Terminal		401284
	Cable, Null Modem		402114
	PG Terminal to Platform Cable
	Non-CE (DB25M -DB25F,	102227
	≈ 1.8 meters)
	CE (DB25M - DB25F,				102227-CE
	≈ 1.5 meters)
	Power Cable	100770 (Black)			100770-CE (Gray)
	Accessory Kit		400987
	NIP, SS, DH200, 2.75 in.		100204
	ADPT, SS, DH200 F x 1/8 in. NPT F		100299
	O-ring, Buna 2-242 (2 ea.)		101976
	Storage Cover, 7600 Type		102132
	Allen Wrench, 2.5 mm		102257
	Allen Wrench, 3 mm		102168
	Allen Wrench, 5 mm		102262
	Spanner Wrench (Metrological)		122568
	Krytox® GPL205/6 .5 oz.		102496
	Gift Kit with Gloves		400511
	ADPT, DH200 M x 1/8 in. swage		400518
	Valve, Vacuum Relief		401050
	Union, SS, 4P		101984
	Valve, Toggle 4T,OGS2		103733
	ADPT, SS, 4P x 1/8 in. NPT F		103734
	Screen, Vent, SS, 1/8 in. NPT M		103735
	Instruction Sheet, PG7600		560002
	Vac Relief
	ADPT, DH200 M x 1/4 in. swage		400528
	ADPT, SS, DH200M x 1/4 in. swage		121782
	Frl, SS, Front, SWG, 1/4 in. swage		100248
	Frl, SS, Rear, SWG, 1/4 in. swage		100249
	Nut, SS, SWG, 1/4 in. swage		100247
	Documentation
	Calibration Report (PG)		550100
	Calibration Report (Mass Bell)		550100
	Technical Data		550101
	PG7000 Operation &
	Maintenance Manual		550099
	Documentation CD		102987

© 1998-2008 DH Instruments, a Fluke Company

Page 18

2. INSTALLATION

2.1.2.2

MASS SET

PG7000 mass sets are composed of different combinations of individual masses and accessories depending on the specific mass set ordered (see Tables 5 - 9).

Table 5. Manual Mass Set Parts List (excluding 80 and 100 kg)

DESCRIPTION	PART NO.
Mass Set	Refer to Table 9
Reusable Molded Transit Case with Foam Inserts	122577		123057
35 kg set	1 ea.		1 ea.
40 kg set	1 ea.		1 ea.
45 kg set	1 ea.		1 ea.
55 kg set	1 ea.		2 ea.
Mass Set Tray and Spindle	123051 and 123536
Dust Covers	102814 and 102847
Calibration Report		550100

Table 6. Manual Mass Set Parts List (80 and 100 kg)

DESCRIPTION	PART NO.
Mass Set	Refer to Table 9
Reusable Molded Transit Case with Foam Inserts	122577		123035
80 kg set	1 ea.		2 ea.
100 kg set	1 ea.		3 ea.
Mass Set Tray and Spindle	123051 and 123536
Dust Covers	102814 and 102846
Calibration Report		550100

Table 7. AMH-38 Mass Set Parts List

DESCRIPTION	PART NO.
Mass Set	Refer to Table 9
Reusable Molded Transit Case with Foam Inserts	402096		123949
13 kg set (MS-AMH-13)	1 ea.		1 ea.
25 kg set (MS-AMH-25)	1 ea.		1 ea.
39 kg set (MS-AMH-38)	1 ea.		1 ea.
Calibration Report		550100

Table 8. AMH-100 Mass Set Parts List

DESCRIPTION	PART NO.
Mass Set	Refer to Table 9
Reusable Molded Transit Case with Foam Inserts	402096		123035
40 kg set (MS-AMH-40)	1 ea.		1 ea.
60 kg set (MS-AMH-60)	1 ea.		2 ea.
80 kg set (MS-AMH-80)	1 ea.		2 ea.
100 kg set (MS-AMH-100)	1 ea.		3 ea.
Calibration Report		550100

Page 19

© 1998-2008 DH Instruments, a Fluke Company

PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 9. Mass Set Compositions

			NOMINAL												MASS SET COMPOSITION
DESIGNATION	PART #		TOTAL			10			5			2			1			0.5			0.2			0.1			MAKE-UP
			MASS (kg)																								MASS
						kg			kg			kg			kg			kg			kg			kg
																											(kg)
MS-7001-35	401425	35			-			5			2			1			1			2			1			1 (4.5)						-
MS-7002-35	401426	35			-			5			2			1			1			2			1			1 (4)						-
MS-7002-40	401522	40			-			6			2			1			1			2			1			1 (4)						-
MS-7002-45	401496	45			-			7			2			1			1			2			1			1 (4)						-
MS-7002-55	401427	55			-			9			2			1			1			2			1			1 (4)						-
MS-7002-80	401518	80			6			1			2			1			1			2			1			1 (9)						-
MS-7002-100	401519	100			8			1			2			1			1			2			1			1 (9)						-
DESIGNATION	PART #		NOMINAL												MASS SET COMPOSITION
			TOTAL			10			6.4			6.2			3.2			1.6			0.8			0.4			0.2			0.1		BELL, SHAFT,
			MASS (kg)																													BINARY MASS
						kg			kg			kg			kg			kg			kg			kg			kg			kg		CARRIER
																																(3 PARTS)
MS-AMH-13	402086	13			-			-			1			1			1			1			1			1				1		1
MS-AMH-25	402085	25			-			-			3			1			1			1			1			1				1		1
MS-AMH-38	402063	38			-			-			5			1			1			1			1			1				1		1
MS-AMH-40	402089	40			3			1			-			1			1			1			1			1				1		1
MS-AMH-60	402088	60			5			1			-			1			1			1			1			1				1		1
MS-AMH-80	402087	80			7			1			-			1			1			1			1			1				1		1
MS-AMH-100	402064	100			9			1			-			1			1			1			1			1				1		1

All mass sets also include a trim mass set of 50 g to 0.01 g (total 100 g)

Table 10. Mass Set Compatibility

DESIGNATOR

NOMINAL

PG7102

PG7202

PG7302

PG7601

TOTAL MASS (kg)

MS-7001-35

35

•

MS-7002-35

35

•

•

•

MS-7002-40

40

•

•

•

MS-7002-45

45

•

•

•

MS-7002-55

55

•

•

•

MS-7002-80

80

•1

•1

•

MS-7002-100

100

•1

•1

•

MS-AMH-13

13

•

MS-AMH-25

25

•

MS-AMH-38

38

•

MS-AMH-40

40

•

•

•

MS-AMH-60

60

•1

•1

•

MS-AMH-80

80

•1

•1

•

MS-AMH-100

100

•1

•1

•

1These mass sets, on certain piston-cylinder sizes, can cause the maximum working pressure of the PG Platform to be exceeded. Do not exceed the following maximum working pressures:

PG7201: 11 MPa (1 600 psi)

PG7202: When using PC-7200 piston-cylinder modules: 110 MPa (16 000 psi)

When using PC-7300 piston-cylinder modules: 200 MPa (30 000 psi)

PG7302:500 MPa (72 500 psi)

© 1998-2008 DH Instruments, a Fluke Company

Page 20