Fluke PG7202 V2.03, PG7102 V2.03, PG7302 V2.03, PG7601 V2.03 Operation and Maintenance Manual

PG7000™ PISTON GAUGES

PG7102™, PG7202™,

PG7302™, PG7601™

(Ver. 2.03 and Higher)

Operation and Maintenance Manual

©1998-2002 DH Instruments, Inc.

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 - 2002 DH Instruments, Inc. 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, Inc. 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, Inc.

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: 5,142,483, 5,257,640, 5,331,838, 5,445,035. Other U.S. and international patents pending.

Document No. 550099k 020612

Printed in the USA

© 1998-2002 DH Instruments, Inc

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS ...............................................................				I
TABLES ..................................................................................				V
FIGURES ................................................................................				VI
ABOUT THIS MANUAL ............................................................				VII
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 ...............................................................................................................................................	14
		2.1.1.3	PISTON-CYLINDER MODULE(S)............................................................................................................	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 THE 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

Page I

© 1998-2002 DH Instruments, Inc.

PG7000™ OPERATION AND MAINTENANCE MANUAL
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 ...........................................................................................................................................	28
2.4.3	SET LOCAL GRAVITY VALUE ...................................................................................................................	29
2.4.4	SETUP PRESSURE EQUATION VARIABLE INPUT SOURCES .....................................................	29
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 ................................			51
	3.9.4	[MODE] ........................................................................................................................................................				52
	3.9.4.1		DIFFERENTIAL MEASUREMENT MODE (PG7601 ONLY) ........................................................			54
	3.9.4.2		HIGH LINE DIFFERENTIAL MEASUREMENT MODE (PG7102 AND PG7202 ONLY) ..........................			61
	3.9.5	[SYSTEM] ....................................................................................................................................................				73
	3.9.5.1		FIRST SYSTEM RUN SCREEN...............................................................................................................			74
	3.9.5.2		SECOND SYSTEM RUN SCREEN..........................................................................................................			75
	3.9.6	[AMBIENT]...................................................................................................................................................				76
	3.9.7	[HEAD] .........................................................................................................................................................				77
	3.9.8	[ROTATE] (OPTIONAL ON PG7102, PG7202 AND PG7302) ....................................................................				79
	3.9.9	[GEN] (OPTIONAL)......................................................................................................................................				80
	3.9.10	[RES]............................................................................................................................................................				81
	3.9.11	[ENTER] FROM RUN SCREEN...................................................................................................................				82
	3.9.11.1 [ENTER] IN PRESSURE TO MASS MODE.............................................................................................					83
	3.9.11.2 [ENT] IN MASS TO PRESSURE MODE..................................................................................................					85
	3.9.12	[P OR M] ......................................................................................................................................................				86
	3.9.13	[		]		86
3.10	[SETUP] MENU......................................................................................................................................					87
	3.10.1	<1SELECT> .................................................................................................................................................				89
	3.10.2	<2VIEW> ......................................................................................................................................................				89
	3.10.3	<3EDIT> .......................................................................................................................................................				90
3.11	[SPECIAL] MENU ..................................................................................................................................					92
	3.11.1	<1PC/MS>....................................................................................................................................................				93
	3.11.1.1		CREATE PISTON-CYLINDER MODULE.................................................................................................			94
	3.11.1.2 EDIT PISTON-CYLINDER MODULE INFORMATION .............................................................................					97
	3.11.1.3		VIEW PISTON-CYLINDER MODULE ......................................................................................................			97
	3.11.1.4		DELETE PISTON-CYLINDER MODULE .................................................................................................			98
	3.11.1.5 SELECT THE ACTIVE PISTON-CYLINDER MODULE ...........................................................................					98
	3.11.1.6		ADD MASS SET.......................................................................................................................................			98
	3.11.1.7		EDIT MASS SET ....................................................................................................................................			102
	3.11.1.8		VIEW MASS SET ...................................................................................................................................			103
© 1998-2002 DH Instruments, Inc.					Page II

		TABLE OF CONTENTS
	3.11.1.9	DELETE MASS SET ..............................................................................................................................	103
	3.11.1.10	SELECT MASS SET ..............................................................................................................................	103
	3.11.1.11	ADD MASS LOADING BELL..................................................................................................................	103
	3.11.1.12	EDIT MASS LOADING BELL INFORMATION.......................................................................................	105
	3.11.1.13	VIEW MASS LOADING BELL ................................................................................................................	105
	3.11.1.14	DELETE MASS LOADING BELL ...........................................................................................................	105
	3.11.1.15	SELECT MASS LOADING BELL ...........................................................................................................	106
	3.11.2	<2PRESU>.................................................................................................................................................	106
	3.11.3	<3HEAD> ...................................................................................................................................................	106
	3.11.3.1	<3HEAD>, <1FLUID>.............................................................................................................................	107
	3.11.3.2	<3HEAD>, <2UNIT>...............................................................................................................................	107
	3.11.3.3	<3HEAD>, <3ATM> ...............................................................................................................................	108
	3.11.3.4	<3HEAD>, <4PISTON>..........................................................................................................................	108
	3.11.4	<4PREFS> .................................................................................................................................................	109
	3.11.4.1	<4PREFS>, <1SCRSVR> ......................................................................................................................	109
	3.11.4.2	<4PREFS>, <2SOUND> ........................................................................................................................	109
	3.11.4.3	<4PREFS>, <3TIME> ............................................................................................................................	110
	3.11.4.4	<4PREFS>, <4ID> .................................................................................................................................	110
	3.11.5	<5REMOTE>..............................................................................................................................................	111
	3.11.5.1	COM1, COM2 AND COM3 (RS232) ......................................................................................................	111
	3.11.5.2	IEEE-488 ................................................................................................................................................	112
	3.11.5.3	RS232 SELF TEST ................................................................................................................................	112
	3.11.5.4	EXTERNAL BAROMETER (RPM) COMMUNICATIONS (COM2).........................................................	113
	3.11.6	<6GL> ........................................................................................................................................................	115
	3.11.7	<7CAL> ......................................................................................................................................................	115
	3.11.8	<8LEVEL>..................................................................................................................................................	115
	3.11.8.1	SECURITY LEVELS...............................................................................................................................	116
	3.11.9	<9RESET> .................................................................................................................................................	119
	3.11.9.1	<9RESET>, <1SETS>............................................................................................................................	119
	3.11.9.2	<9RESET>, <2UNITS> ..........................................................................................................................	120
	3.11.9.3	<9RESET>, <3COM>.............................................................................................................................	120
	3.11.9.4	<9RESET>, <4CAL> ..............................................................................................................................	120
	3.11.9.5	<9RESET>, <5SETUPS>.......................................................................................................................	121
	3.11.9.6	<9RESET>, <6ALL>...............................................................................................................................	121
4. REMOTE OPERATION ......................................................			123
4.1	OVERVIEW..........................................................................................................................................		123
4.2	INTERFACING.....................................................................................................................................		123
	4.2.1	RS232 INTERFACE ...................................................................................................................................	123
	4.2.1.1	COM1 .....................................................................................................................................................	123
	4.2.1.2	COM2 AND COM3 .................................................................................................................................	124
	4.2.2	IEEE-488 (GPIB)........................................................................................................................................	124
4.3	COMMANDS........................................................................................................................................		125
	4.3.1	COMMAND SYNTAX .................................................................................................................................	125
	4.3.2	COMMAND SUMMARY .............................................................................................................................	126
	4.3.3	ERROR MESSAGES .................................................................................................................................	128
	4.3.4	COMMAND DESCRIPTIONS.....................................................................................................................	129
	4.3.4.1	IEEE STD. 488.2 COMMON AND STATUS COMMANDS .....................................................	129
	4.3.4.2	PG7000 COMMANDS............................................................................................................................	131
4.4	STATUS SYSTEM ...............................................................................................................................		152
	4.4.1	STATUS REPORTING SYSTEM ...............................................................................................................	152
	4.4.1.1	STATUS BYTE REGISTER....................................................................................................................	153
	4.4.1.2	STANDARD EVENT REGISTER ...........................................................................................................	154
4.5 HIGH LINE DIFFERENTIAL MODE PROGRAMMING EXAMPLES ...................................................			155
	4.5.1	RECOMMENDED SEQUENCE FOR A HOST PROGRAM TO REMOTELY SET A NEW
		HIGH LINE PRESSURE AND ENABLE HIGH LINE DIFFERENTIAL MODE ..........................................	155
	4.5.2	RECOMMENDED SEQUENCE FOR A HOST PROGRAM TO REMOTELY ENABLE
		HIGH LINE DIFFERENTIAL MODE USING THE LAST LINE PRESSURE SETTING .............................	157

Page III

© 1998-2002 DH Instruments, Inc.

PG7000™ OPERATION AND MAINTENANCE MANUAL

5 . MAINTENANCE, ADJUSTMENTS AND CALIBRATION ...........			159
5.1	INTRODUCTION..................................................................................................................................		159
5.2	PLATFORM .........................................................................................................................................		160
	5.2.1	CALIBRATION/ADJUSTMENT OF ON-BOARD MEASUREMENT FUNCTIONS....................................	160
	5.2.1.1	PRINCIPLES ..........................................................................................................................................	160
	5.2.1.2	BAROMETRIC PRESSURE SENSOR...................................................................................................	161
	5.2.1.3	AMBIENT TEMPERATURE SENSOR ...................................................................................................	161
	5.2.1.4	RELATIVE HUMIDITY SENSOR............................................................................................................	162
	5.2.1.5 PISTON-CYLINDER MODULE TEMPERATURE SENSOR .....................................................		162
	5.2.1.6	REFERENCE VACUUM GAUGE (PG7601 ONLY) ...............................................................................	164
	5.2.2	PISTON POSITION DETECTION ADJUSTMENT.....................................................................................	165
	5.2.3	EMPTYING OIL RUN-OFF TRAY (PG7202 AND PG7302 ONLY).................................................	165
	5.2.4	PURGE MOUNTING POST LIQUID RUN OFF (PG7202 ONLY) ..............................................	166
	5.2.5	DRIVE BELT REPLACEMENT..................................................................................................................	166
5.3	PISTON-CYLINDER MODULES..........................................................................................................		167
	5.3.1	DISASSEMBLY, CLEANING AND MAINTENANCE .................................................................................	167
	5.3.2	DISASSEMBLY AND REASSEMBLY .......................................................................................................	168
	5.3.2.1	DISASSEMBLY AND REASSEMBLY OF GAS OPERATED, GAS LUBRICATED
		PISTON-CYLINDER MODULES (PC-7100/7600) .......................................................................	168

5.3.2.2DISASSEMBLY AND REASSEMBLY OF GAS OPERATED, LIQUID LUBRICATED PISTON-CYLINDER

MODULES (PC-7200) ............................................................................................................................

172

5.3.2.3DISASSEMBLY AND REASSEMBLY OF OIL OPERATED, OIL LUBRICATED

PISTON-CYLINDER MODULES (PC-7300) ..........................................................................................

174

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

			MODULE RESERVOIR WITH LIQUID ......................................................................................................	176
		5.3.4	CLEANING PISTON-CYLINDERS.............................................................................................................	177
		5.3.5	RECALIBRATION ......................................................................................................................................	179
		5.3.5.1	UPDATING PISTON-CYLINDER MODULE FILES................................................................................	179
	5.4	MASS SETS.........................................................................................................................................		179
		5.4.1	CLEANING.................................................................................................................................................	179
		5.4.2	RECALIBRATION ......................................................................................................................................	179
		5.4.2.1	UPDATING ON-BOARD MASS SET FILES ..........................................................................................	179
	5.5	RELOADING EMBEDDED SOFTWARE INTO PG7000 FLASH MEMORY........................................		180
	5.6	DISASSEMBLY AND REASSEMBLY OF PG7000 .............................................................................		180
		5.6.1	PLATFORM................................................................................................................................................	180
		5.6.2	TERMINAL .................................................................................................................................................	180
6.	TROUBLESHOOTING .......................................................			181
	6.1	OVERVIEW..........................................................................................................................................		181
7.	APPENDIX ......................................................................			183
	7.1	CONVERSION OF NUMERICAL VALUES..........................................................................................		183
		7.1.1	PRESSURE................................................................................................................................................	183
	7.2	DEFINED PRESSURE CALCULATIONS............................................................................................		183
		7.2.1 PG7102, PG7202 AND PG7302 ................................................................................................................		185
		7.2.2	PG7601 ......................................................................................................................................................	186
		7.2.3	FLUID HEADS ...........................................................................................................................................	187
		7.2.3.1	FLUID HEAD COMPONENTS ...............................................................................................................	187
		7.2.3.2	OVERALL FLUID HEAD CORRECTION ...............................................................................................	188
	7.3	GLOSSARY .........................................................................................................................................		189
	7.4	WARRANTY STATEMENT..................................................................................................................		191

© 1998-2002 DH Instruments, Inc.

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.	Mass Parts List (excluding 80 and 100 kg)..................................................................................	19
Table 6.	Mass Parts List (80 and 100 kg) ..................................................................................................	19
Table 7.	Mass Set Definitions ....................................................................................................................	20
Table 8.	Mass Set Compatibility ................................................................................................................	20
Table 9.	PC-7100/7600 Piston-Cylinder Modules Parts List .....................................................................	21
Table 10.	PC-7200 Piston-Cylinder Modules Parts List ............................................................................	21
Table 11. PC-7300 Piston-Cylinder Modules Parts List ...........................................................................		21
Table 12. Summary of PG7000 Direct Function Key Operations..............................................................		47
Table 13.	Pressure Units of Measure Available.........................................................................................	51
Table 14.	Valve Settings for Setting Differential Mode Static Pressure.....................................................	57
Table 15.	Valve Settings to Apply PG7000 Pressure to the RPM for Differential Mode Offsetting...........	57
Table 16.	Valve Settings for Operating in Differential Mode......................................................................	59
Table 17. SETUP File Choices, Factory Preferred Choice and Normal Value..........................................		88
Table 18. COM1, COM2 and COM3 Available Settings..........................................................................		111
Table 19.	Security Levels - Functions NOT Executed Per Function/Level..............................................	117
Table 20. COM1 DB-9F Pin Designation.................................................................................................		124
Table 21. COM2 and COM3 DB-9M Pin Designation .............................................................................		124
Table 22. Command Summary................................................................................................................		126
Table 23. Error Messages........................................................................................................................		128
Table 24.	Status Byte Register ................................................................................................................	153
Table 25.	Standard Event Register..........................................................................................................	154
Table 26.	Mounting Post Wire Colors, Description and Location ............................................................	164
Table 27.	PG7000 Troubleshooting Checklist .........................................................................................	181
Table 28. Pressure Unit of Measure Conversions...................................................................................		183
Table 29.	PG7000 Defined Pressure Calculation Variables....................................................................	184
Table 30.	DHI Authorized Service Providers ...........................................................................................	191

Page V

© 1998-2002 DH Instruments, Inc.

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 ....................................................................................	64
Figure 12.	Status Byte Register...............................................................................................................	153
Figure 13. PG7202 Mounting Post Drain.................................................................................................		166
Figure 14. 10 kPa/kg Gas Piston-Cylinder Module (Expanded View) .....................................................		169
Figure 15.	10 kPa/kg Piston Insertion Tool..............................................................................................	170
Figure 16.	Gas Piston-Cylinder Module Sleeve Nut Tool ........................................................................	170
Figure 17. 50 and 200 kPa/kg Gas Piston-Cylinder Modules (Expanded View) .....................................		171
Figure 18.	Gas Operated, Liquid Lubricated Piston-Cylinder Module (Expanded View) .......................	173
Figure 19.	Oil Piston-Cylinder Module (Expanded View) ........................................................................	175
Figure 20.	Filling Gas Operated, Liquid Lubricated Piston-Cylinder Module Reservoir (PC-7200) .......	177

© 1998-2002 DH Instruments, Inc.

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

© 1998-2002 DH Instruments, Inc.

PG7000™ OPERATION AND MAINTENANCE MANUAL

NOTES

© 1998-2002 DH Instruments, Inc.

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 and a mass set. A PG7000 system also includes the means to generate and adjust pressures and to interconnect the system components and a device being calibrated or tested. The system may also include COMPASS® software to assist in executing test sequences, acquiring test data and producing test reports.

There are four PG7000 Platforms: Model PG7102, PG7202, PG7302 and PG7601. These have common PG7000 presentation and features. They are distinguished by their normal operating medium (oil 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)

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

-Its 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 11 MPa (1 600 psi)

-Supports definition of pressure against a vacuum reference

PG7000 platforms, piston-cylinder modules and mass sets 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 the 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 is accomplished through the display and keypad of the PG Terminal or from a computer via a standard RS232 or IEEE-488 interface.

Page 1

© 1998-2002 DH Instruments, Inc.

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
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 and pass through communications
	IEEE-488	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:		100 kPa to 110 MPa (15 to 16 000 psi)
		Absolute:		200 kPa to 110 MPa (30 to 16 000 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:		5 kPa to 7 MPa (0.7 to 1 000 psi)
		Absolute:		5 kPa to 7 MPa (0.7 to 1 000 psi)
		Differential:		90 to 350 kPa (-12 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
Maximum Mass Load
	PG7102	100 kg, while not exceeding 11 MPa (1 600 psi)
	PG7102	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	35 kg

© 1998-2002 DH Instruments, Inc.

Page 2

1. INTRODUCTION

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
	DH200	and	DH500 are gland and collar type fittings for
	1/4 in.	(6	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.

•Interfacing and automatic exploitation of any external barometer (RS232).

•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.

•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).

•Built-in drivers for automated pressure control components and piston floating with override capability.

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

Page 3

© 1998-2002 DH Instruments, Inc.

PG7000™ OPERATION AND MAINTENANCE MANUAL

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

© 1998-2002 DH Instruments, Inc.

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.

PC-7100/7600-10
Operation	Gas operated, gas lubricated
Piston Material	Ceramic (tungsten carbide available, higher mass)
Cylinder Material	Tungsten carbide
Nominal Diameter	35 mm
Nominal Area	1 000 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-7100/7600-200
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

Page 5

© 1998-2002 DH Instruments, Inc.

PG7000™ OPERATION AND MAINTENANCE MANUAL

1.2.2.2 PC-7200

Gas operated, liquid lubricated piston-cylinder module characteristics.

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 Material	Tungsten carbide
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 Material	Tungsten carbide
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 Material	Tungsten carbide
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 Material	Tungsten carbide
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 Material	Tungsten carbide
Cylinder Material	Tungsten carbide
Nominal Diameter	2.5 mm
Nominal Area	4.9 mm2
Mounting System	Negative free deformation

© 1998-2002 DH Instruments, Inc.

Page 6

1. INTRODUCTION

1.2.2.3 PC-7300

Oil operated, oil lubricated piston-cylinder module characteristics.

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 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 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 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 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 Material	Tungsten carbide
Nominal Diameter	2.0 mm
Nominal Area	2.0 mm2
Mounting System	Simple free deformation

Page 7

© 1998-2002 DH Instruments, Inc.

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
Uncertainty of Measured Values	± 5 ppm or 1 mg, whichever is greater
Masses < 50g	Conform to NIST S1

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 DHI Technical Note 7920TN01.

PC-7100/7600-10
Sensitivity1	0.02 Pa + 0.5 ppm
Reproducibility2	± 2 ppm
Typical Drop Rate (35 kg)	0.2 mm/min
PC-7100/7600-50
Sensitivity1	0.1 Pa + 0.5 ppm
Reproducibility2	± 3 ppm
Typical Drop Rate (35 kg)	0.5 mm/min
PC-7100/7600-200
Sensitivity1	0.4 Pa + 0.5 ppm
Reproducibility2	± 5 ppm
Typical Drop Rate (35 kg)	1.0 mm/min

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.

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

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

© 1998-2002 DH Instruments, Inc.

Page 8

1. INTRODUCTION

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 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.

Page 9

© 1998-2002 DH Instruments, Inc.

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 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.

© 1998-2002 DH Instruments, Inc.

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 (i.e., PG7102, PG7202, PG7302, PG7601).

1. Fluorescent display

2. Keypad

Figure 1. PG Terminal Front Panel

Page 11

© 1998-2002 DH Instruments, Inc.

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

2. Fuse (25-pin)

3. Power Receptacle

4. Connector for Cable to PG7000

5. Cooling Fan

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, # 6).

1. COM2 (RS232) - External Barometer and

Pass Through Communications

2. COM3 (RS232) - Automated Pressure

Generation/Control Component

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

© 1998-2002 DH Instruments, Inc.

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 (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.

Page 13

©1998-2002 DH Instruments, Inc.

PG7000™ OPERATION AND MAINTENANCE MANUAL

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.

2.1.1.3 PISTON-CYLINDER MODULE(S)

The piston-cylinder modules are shipped in PVC 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.

2.1.2 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.

© 1998-2002 DH Instruments, Inc.

Page 14

2. INSTALLATION

Table 1. PG7102 Parts List

PG7102

PG7102

PG7102

PG7102

DESCRIPTION

P/N 401141

P/N 401141-CE

P/N 401140

P/N 401140-CE

MOTORIZED

MOTORIZED

NON-MOTORIZED

NON-MOTORIZED

ROTATION

ROTATION

ROTATION

ROTATION

NON-CE

CE

NON-CE

CE

Platform

401294

401294-CE

401293

401293-CE

Mass Bell

401132

Bell Jar and Seal

Terminal

401284

PG Terminal to Platform Cable

Non-CE (DB25M -DB25F,

102227

102227

≈ 1.8 meters)

CE (DB25M - DB25F,

102227-CE

102227-CE

≈ 1.5 meters)

Power Cable

100770 (Black)

100770-CE (Gray)

100770 (Black)

100770-CE (Gray)

Accessory Kit

401560

NIP, SS, DH200, 2.75 in.

100204

ADPT, SS, DH200 F x 2 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

Wrench, 5/8 in.

Collar, SS, DH500

Krytox GPL205/6 0.5 oz.

102496

Gift Kit with Gloves

400511

Valve, Vacuum Relief

Union, SS, 2P

Valve, Toggle 2T,OGS2

Instruction Sheet,

PG7600 Vac Relief

ADPT, DH200 M x 2T

ADPT, SS, DH200M x 2T

Frl, SS, Front, Gyr 2T

Frl, SS, Rear, Gyr, 2T

Nut, SS, Gyr, 2T

Documentation

Calibration Report (PG Platform)

550100

Calibration Report (Mass Bell)

550100

Technical Data

550101

PG7000 Operation &

Maintenance Manual

550099

Documentation CD

102987

Page 15

© 1998-2002 DH Instruments, Inc.

PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 2. PG7202 Parts List

PG7202

PG7202

PG7202

PG7202

DESCRIPTION

#401722

#401722-CE

#401721

#401721-CE

MOTORIZED

MOTORIZED

NON-MOTORIZED

NON-MOTORIZED

ROTATION

ROTATION

ROTATION

ROTATION

NON-CE

CE

NON-CE

CE

Platform

401725

401725-CE

401724

401724-CE

Mass Bell

401132

Bell Jar and Seal

Terminal

401284

PG Terminal to Platform Cable

Non-CE (DB25M -DB25F,

102227

102227

≈ 1.8 meters)

CE (DB25M - DB25F,

102227-CE

102227-CE

≈ 1.5 meters)

Power Cable

100770 (Black)

100770-CE (Gray)

100770 (Black)

100770-CE (Gray)

Accessory Kit

401134

NIP, SS, DH200, 2.75 in.

100204

ADPT, SS, DH200 F x 2 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

Wrench, 5/8 in.

103044

Collar, SS, DH500

101201

Krytox GPL205/6 0.5 oz.

102496

Gift Kit with Gloves

400511

Valve, Vacuum Relief

Union, SS, 2P

Valve, Toggle 2T,OGS2

Instruction Sheet, PG7600

Vac Relief

ADPT, DH200 M x 2T

ADPT, SS, DH200M x 2T

Frl, SS, Front, Gyr 2T

Frl, SS, Rear, Gyr, 2T

Nut, SS, Gyr, 2T

Documentation

Calibration Report (PG)

550100

Calibration Report (Mass Bell)

550100

Technical Data

550101

PG7000 Operation &

550099

Maintenance Manual

Documentation CD

102987

© 1998-2002 DH Instruments, Inc.

Page 16

2. INSTALLATION

Table 3. PG7302 Parts List

PG7302

PG7302

PG7302

PG7302

DESCRIPTION

P/N 401298

P/N 401298-CE

P/N 401297

P/N 401297-CE

MOTORIZED

MOTORIZED

NON-MOTORIZED

NON-MOTORIZED

ROTATION

ROTATION

ROTATION

ROTATION

NON-CE

CE

NON-CE

CE

Platform

401292

401292-CE

401291

401291-CE

Mass Bell

401132

Bell Jar and Seal

Terminal

401284

PG Terminal to Platform Cable

Non-CE (DB25M -DB25F,

102227

102227

≈ 1.8 meters)

CE (DB25M - DB25F,

102227-CE

102227-CE

≈ 1.5 meters)

Power Cable

100770 (Black)

100770-CE (Gray)

100770 (Black)

100770-CE (Gray)

Accessory Kit

401134

NIP, SS, DH200, 2.75 in.

100204

ADPT, SS, DH200 F x 2 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

Wrench, 5/8 in.

103044

Collar, SS, DH500

101201

Krytox GPL205/6 0.5 oz.

102496

Gift Kit with Gloves

400511

Valve, Vacuum Relief

Union, SS, 2P

Valve, Toggle 2T,OGS2

Instruction Sheet, PG7600

Vac Relief

ADPT, DH200 M x 2T

ADPT, SS, DH200M x 2T

Frl, SS, Front, Gyr 2T

Frl, SS, Rear, Gyr, 2T

Nut, SS, Gyr, 2T

Documentation

Calibration Report (PG)

550100

Calibration Report (Mass Bell)

550100

Technical Data

550101

PG7000 Operation &

550099

Maintenance Manual

Documentation CD

102987

Page 17

© 1998-2002 DH Instruments, Inc.

PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 4. PG7601 Parts List

			PG7601				PG7601
	DESCRIPTION		P/N 400480				P/N 400480-CE
			MOTORIZED				MOTORIZED
			ROTATION				ROTATION
			NON-CE				CE
	Platform		401290				401290-CE
	Mass Bell			400578
	Bell Jar and Seal		122106 and 101546
	Terminal			401284
	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 2 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
	Wrench, 5/8”
	Collar, SS, DH500
	Krytox GPL205/6 .5 oz.			102496
	Gift Kit with Gloves			400511
	Valve, Vacuum Relief			401050
	Union, SS, 2P			101980
	Valve, Toggle 2T,OGS2			102119
	Instruction Sheet, PG7600			560002
	Vac Relief
	ADPT, DH200 M x 2T			400518
	ADPT, SS, DH200M x 2T			121692
	Frl, SS, Front, Gyr 2T			100179
	Frl, SS, Rear, Gyr, 2T			100181
	Nut, SS, Gyr, 2T			100183
	Documentation
	Calibration Report (PG)			550100
	Calibration Report (Mass Bell)			550100
	Technical Data			550101
	PG7000 Operation &			550099
	Maintenance Manual
	Documentation CD			102987

© 1998-2002 DH Instruments, Inc.

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, 6, 7).

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

DESCRIPTION	PART NO.
Mass Set	Refer to Table 7
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	123050 and 123051
Dust Covers	102814 and 102847
Calibration Report		550100

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

DESCRIPTION	PART NO.
Mass Set	Refer to Table 7
Reusable Molded Transit Case with Foam Inserts	122577		123035
80 kg set	1 ea.		2 ea.
100 kg set	1 ea.		3 ea.
Dust Covers	102846 and 102847
Calibration Report		550100

Page 19

© 1998-2002 DH Instruments, Inc.

PG7000™ OPERATION AND MAINTENANCE MANUAL

Table 7. Mass Set Definitions

	DESIGNATION			PART #			NOMINAL												MASS SET COMPOSITION
							TOTAL			10			5			2			1			0.5			0.2			0.1			TRIM SET			MAKE-UP
							MASS (KG)
										KG			KG			KG			KG			KG			KG			KG			50 TO 0.1 G			MASS (KG)
	MS-7001-35		401425			35				-		5			2			1			1			2			1			1			1 (4.5)
	MS-7002-35		401426			35				-		5			2			1			1			2			1			1			1 (4)
	MS-7002-40		401522			40				-		6			2			1			1			2			1			1			1 (4)
	MS-7002-45		401496			45				-		7			2			1			1			2			1			1			1 (4)
	MS-7002-55		401427			55				-		9			2			1			1			2			1			1			1 (4)
	MS-7002-80		401518			80				6		1			2			1			1			2			1			1			1 (9)
	MS-7002-100		401519			100				8		1			2			1			1			2			1			1			1 (9)

Table 8. 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

•

1: These 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)

The mass loading bell and piston make up part of the total mass load but are not included with the mass set. Piston-cylinder modules are purchased and delivered separately. The mass loading bell is delivered with the PG7000 Platform.

© 1998-2002 DH Instruments, Inc.

Page 20