P/N 974081
05/05 Rev. D
ECO # 29918

OPERATING MANUAL

PG4 Series
Mec
hanic
al Pr
essur
e G
aug
es
Pre
ure
Gaug
auge
ech
anicalOPERATING MANUALTABLE OF CONTENTS
Content

Page

1.

General32.

Notes on Safety

53.

Technical Data

6

4.

Transport/Delivery

115.

Installation

12

6.

Commissioning

15

7.

Maintenance16

8.

Accessories

19

9.

Troubleshooting

20

Icon

1.
1.1
1.2
1.3
1.4
1.5

1.1

G ENERAL
Important Information ............................................................................................................ 6
Copyright .............................................................................................................................. 6
Explanation of Icons .............................................................................................................. 6
Abbreviations ......................................................................................................................... 7
Principle of Operation ............................................................................................................. 7I MPORTION
MPORTTANT INFORMAINFORMATION

Models covered by this manual include the PG441R, PG442R and TPG443R.
DYNISCO will not be held liable for any injury, loss or damage resulting from failure to follow the
YNISCO
instructions in this manual.
If the product malfunctions, in spite of having followed the operating instructions, please contact theO customer service department (See the back of the manual for contact information). This
YNISCODYNISCapplies in particular during the warranty period.

1.2

C OPYRIGHT

Copyright law requires that this manual be used for intended purposes only.
It is strictly forbidden to allow reproduction of any kind “in whole or in part” to persons outside of
Dynisco, without approval from Dynisco.

1.
3
1.3

E XPLANATION OF ICONSXPLANATIONICONSThe manual uses icons to indicate information pertaining to safety:
Risk of destruction or damage to equipment, machines or installations
General danger to life or limb

Specific danger to life or limb

3

GENERAL

This manual applies to the PG4 series only. It must be kept near the equipment in a readily and
immediately accessible location at all times. The content of this manual must be read, understood andfollowed in its entirety. This applies in particular to the notes on safety. Following the safety
instructions will help to prevent accidents, defects and malfunctions.

You MUST do thisThe safety instructions are provided again in the individual chapters of the manual.

1.4

A BBREVIATIONSBBREVIATIONS

The following abbreviations are used:
GENERAL

OM
PG
f.s.
BFSL

1.
5
1.5

Operating Manual
Pressure Gaugeof full scale
Best Fit Straight LineP RINCIPLE OF OPERATIONPERATION

The mechanical system (a filled assembly) consists of a lower diaphragm, a filled capillary tube, and a
Bourdon tube. The filled assembly transmits pressure from the process to the Bourdon tube which thenrotates the needle on the face plate of the pressure gauge. The filled assembly isolates the electronics
from the high process temperatures.
The lower diaphragm is the surface in contact with the media being measured. This diaphragm can bemade from a choice of materials. The standard material is heat-treated 15-5 stainless steel with Titanium
Nitride coating. This has average corrosion and abrasion resistance and is similar to 17-4 stainless steel.
Behind the lower diaphragm is a capillary tube filled to the upper diaphragm. As the process pressure
deflects the lower diaphragm, the fill is displaced through the capillary tube and applies pressure to the
Bourdon tube.

4

2.

NOTES ON SAFETY
The operator or owner of the larger overall system is responsible for following the safety
and accident prevention regulations that apply to the specific application.
DYNISCO will not be held liable for any injury, loss or damage resulting from failure to
YNISCO
follow the instructions in this manual.
Toxic Haz
ar
d!
Hazar
ard!
The PG contains a very small amount of mercury (Hg) 0.00322 in³ typically with a 6/18
configuration, as its transmission medium. If the diaphragm is damaged, mercury may
escape. Never transport or store the PG without the protective cap. Remove the cap
shortly before installation.
If mercury is inhaled or swallowed, seek medical attention immediately!

Temperatureemperataturure
The PG4 series of pressure gauges can be used in media temperatures up to 400°C. If the pressuregauge is used in other applications, the safety and accident prevention regulations specific to thatapplication must be followed. Ambient temperature for the case max. +135°C.
Higher temperature can result in damage and malfunction. Do not install the pressure gauge in places
where this temperature is exceeded.

5

SAFETY

Mercury is hazardous waste and must be disposed of in accordance with applicable laws.
O will accept defective PG’s. If mercury escapes, use airtight packaging!
YNISCODYNISC3.

TECHNICAL DATA

3.1
3.2
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.5
3.6
3.7
3.8

3.1

TECHNICAL DATA
Ordering Guide for PG4 Series ................................................................................................ 6
Ordering Example ................................................................................................................. 6
Ordering Information .............................................................................................................. 7
Temperature Option ............................................................................................................... 7
Configuration ......................................................................................................................... 7
Pressure Range ...................................................................................................................... 7
Rigid Stem & Flexible Capillary ................................................................................................ 7
Mounting ............................................................................................................................... 7
Thermocouple Type ............................................................................................................... 8
Performance Characteristics .................................................................................................. 8
Combined Error (Accuracy) ..................................................................................................... 8
Zero Adjustability .................................................................................................................. 8
Max. Overload ...................................................................................................................... 8
Needle Sweep ...................................................................................................................... 8
Thermocouple Option ............................................................................................................ 8
Materials .............................................................................................................................. 8
Torque .................................................................................................................................. 8
Weight ................................................................................................................................. 9
Dimensions ........................................................................................................................... 9O RDERING GUIDE FOR PG4 SERIESThe exact meanings of the letter/digit combinations are given in the corresponding sections of
Chapter 3.

X PG44 XR-XX-X/XX-X-X
Temperature Option
Configuration
Pressure Range
Snout Length
Flexible Capillary Length
Mounting
Thermocouple Type

3.2

O RDERING EXAMPLE
T PG44 3R-5M-6/30-U
J-Type Thermocouple
Rigid Snout, Flexible Stem and Thermocouple
5,000 psi6” Snout Length30” Flexible Capillary Length
Face Up Mounting
6

3.
3
3.3

O RDERING INFORMATION
NFORMATION

XPG44XR-XX-X/XX-X-X

3.
3.1
3.3.1

T EMPERATURE OPTIONEMPERATURE

X PG44XR-XX-X/XX-X-X
Blank
T

3.
3.2
3.3.2

=
=

No Temperature Sensor
J-Type Thermocouple

CONFIGURATION
ONFIGURATION

XPG44X
X R-XX-X/XX-X-X
1
2
3

3.
3.
3
3.3.
3.3

=
=
=

Rigid Snout Only
Rigid Snout with Flexible Stem
Rigid Snout with Flexible Stem and Temperature Option

PRESSURE RANGE

XPG44XR-XX
XX-X/XX-X-X
XX

3.
3.4
3.3.4

5,000 psi
10,000 psi

RIGID STEM & FLEXIBLE CAPILLARY

XPG44XR-XX-X/XX
X/XX-X-X
X/XX
6
6/30
12
12/30

3.
3.
5
3.3.
3.5

=
=
=
=

6” Rigid Stem/0” Flexible Capillary
6” Rigid Stem/30” Flexible Capillary
12” Rigid Stem/0” Flexible Capillary
12” Rigid Stem/30” Flexible Capillary

M OUNTING

XPG44XR-XX-X/XX-X
X -X
Blank
U

=
=

Face Down
Face Up

7

TECHNICAL DATA

5M =
10M=

3.
3.
6
3.3.
3.6

THERMOC
3R ONLOUPLE T YPE (PG44Y)
HERMOCOUPLE
NLY(PG443R

XPG44XR-XX-X/XX-X-X
X
Blank
K

=
=

J Type Thermocouple
K Type Thermocouple

3.4

P ERFORMANCE CHARACTERISTICS

3.4.1

COMBINED ERROR (ACCURA
CY)
URACY

Combined error is also known as accuracy which includes linearity, hysteresis and repeatability, and isdetermined by BFSL (Best Fit Straight Line).
±2.0% of full scale

3.4.2

Z ERO ADJUS
Y
DJUSTTABILITABILITY

7.5% of full scale

3.4.
3
3.4.3

MAX. OVERLOAD (WITHOUT INFL
UENCING OPERA
TING DATA)VERLOINFLUENCINGOPERATINGTECHNICAL DATA

1.5 x full scale pressure

3.4.4

N EEDLE SWEEP

270o

3.4.
5
3.4.5

T HERMOCOUPLE OPTIONHERMOCOUPLE

J-Type Thermocouple for 6” snout (Dynisco P/N 901746)
J-Type Thermocouple for 12” snout (Dynisco P/N 901747)
K-Type Thermocouple for 6” snout (Dynisco P/N 901748)

3.
5
3.5

M ATERIALSStandard DiaphragmStandard Stem(Snout)

3.6

15-5PH with Titanium Nitride Coating
17-4PHT ORQUE

max. 56.5 Nm(500 inch-lbs.)
min. 11.3 Nm(100 inch-lbs.)
8

3.
7
3.7

W EIGHTThe weight varies depending on product configuration. Average weight range is 2 to 3 pounds.

3.8

DIMENSIONS

See Figure 3-1.

TECHNICAL DATA

9

Fig. 3-1 PG4 Series

25
4000

1000

10
5

4.35
110.6
NOMINAL

30

RANGE

20

SER.NO.

15

Dynisco

30
00

00

MODEL

20

PROTECTIVE
SAFETY GLASSAR x 10
RO

35
00

ZE

50

i
ps

2.38
60.3

SST CASE &
COVER

EXTERNAL
ZERO ADJUST

1.00
25.4

5/8 HEX( 14.7 )

1.05
26.6

1.94
49.3
NOMINAL

1.57
39.9

FLEX ARMOR.28 ( 7.1 ) OD

+ +

O

.42
10.7

_ J

.50
12.7
FLEX LENGTH
DIM 'B' u .12

T/C CONNECTOR
TYPE J, MALE

FLEX LENGTH
DIM 'B' u .12

1/2-20 UNF-2A

NO.4-40 SET SCREWTHERMOCOUPLE LOCKFLEX ARMOR.28 ( 7.1 ) OD

.440
11.18

5/8 HEX( 14.7 )

.98
24.8

O

1.25
31.8

1.41
35.8

.214
5.44

O

.414
.412
10.52
10.46

O

.307
.305
7.8
7.75

_

O

1.06
26.9

T/C CONNECTOR
TYPE J, FEMALEJTECHNICAL DATA

.69
17.6

.69
17.6

O

DIM "A"RIGID
STEM
LENGTH

O

1.57
39.9

O

.50
12.7

O

.42
10.7

DIM "A"RIGID
STEM
LENGTH

CLAMP ASSY
P/N 200941

1/2-20 UNF-2A

O

.50
12.7

O

.42
10.7

DIM "A"RIGID
STEM
LENGTH

1/2-20 UNF-2A
.214
5.44

1.06
26.9

SUPPLIED WITH
MODELS
PG442R & TPG443R

.214
5.44

O

.307
.305
7.8
7.75

1.06
26.9

.440
11.18

O

10

.414
.412
10.52
10.46

O

.414
.412
10.52
10.46

.440
11.18

O

.307
.305
7.8
7.75

4.
4.1
4.2
4.3

T RANSPORT/DELIVERYTransport/Packing/Transport Damage ................................................................................... 11
Storage ............................................................................................................................... 11
Scope of Delivery ................................................................................................................. 11
ar
d!
az
haz
azar
ard!
Toxic hThe PG contains a small amount of mercury (Hg) as its transmission medium. If thediaphragm is damaged, mercury may escape.
Never transport or store the PG without the protective shell bolted in place. Remove theshell shortly before installation.
If mercury is inhaled or swallowed, seek medical attention immediately.
Mercury is hazardous waste and must be disposed of in accordance with applicable laws.
O will accept defective PGs.
YNISCODYNISCIf mercury escapes, use airtight packaging!

4.1
•
•
•

4.2

T RANSPOR
PORRANSPORPORTT / PACKING/ TRANS
TRANSPOR
PORTT D AMAGE
Do not let the PG be damaged by other items during transit.
Use only the original packaging.
O immediately in writing.
Report transport damage to DYNISC
YNISCOS TORAGE••

Store the PG in original packaging only.
Protect against dust and moisture.

4.
3
4.3

S COPE OF DELIVERY
PG with diaphragm protection cap
Fastening clip (transmitter with flexible stem only)
Calibration sheet
Operating manual

11

TRANSPORT••••

INSTALLATION

5.
5.1
5.2
5.3
5.4
5.5

5.1

I NS
TION
NSTTALLA
ALLATION
General Mounting Information .............................................................................................. 12
Mounting Hole Torque .......................................................................................................... 13
Mounting Hole Dimensions ................................................................................................... 14
Mounting the Pressure Gauge ............................................................................................... 14
Thermocouple or RTD Assembly, Removal and Installation ...................................................... 14

GENERAL MOUNTING INFORMATION
NFORMATION

Do not remove the protective cap on the PG until ready to install.
Before mounting the PG, check mounting hole carefully. The PG must only be mounted in holes thatsatisfy the requirements below. A hole that does not satisfy these requirements can damage thepressure gauge.
Insure the mounting hole is clear of any frozen polymer or debris and is machined to the proper
dimensions.
Coat the threads with a high temperature anti-seize grease or a suitable parting agent, this will help
prevent the PG snout from sticking permanently in the mounting hole.
Install unit into the process connection. (Do NOT torque transmitter into the hole at this time!) Allow time
for the pressure gauge snout temperature to equalize to the process temperature. This will help
eliminate thread galling and ease removal later. There should be NO pressure applied at this time.
Always use a torque wrench applied to the designated hexagon collar bolts while screwing the pressuregauge in and out. Do not apply the tool to the housing or housing/sensor connection.
After temperatures have equalized, apply proper torque as described in Section 3.6 or 5.2 of the Manualand tighten the sensor into mounting hole.
After the correct torque has been applied units with flexible capillary require the electronics to be
mounted away from the process heat using mounting hardware, P/N 200941.
Make sure that the medium is in molten condition during sensor removal. Removing the sensor while
the medium is in solidified condition can damage the sensor diaphragm.
When removing the PG, carefully clean the diaphragm of the transmitter with a soft cloth while themedium is still malleable.
Always remove the pressure gauge prior to cleaning the machine with abrasives or steel wire brushes.
12

Also, do not clean the PG with hard objects, such as a screwdriver, a wire brush, etc. this will possibly
damage the transmitter.

The most common causes of sensor damage are: installation in improperly
machined or plugged mounting holes and cold starts. The tip of the PG consists of astainless steel diaphragm that must be protected from severe abrasives, dents andscores.
Burn Hazard! The PG must be removed with the melt in the molten condition. The
PG can be very hot when removed. WEAR PROTECTIVE GLOVES!
Careful attention should be paid to correctly machine the mounting port. Failure to use therecommended mounting port may result in erroneous pressure measurement, difficult sensor removal,premature sensor failure, process fluid leaks, and personnel injury. In applications involving hightemperature operation and/or repeated thermal cycling a good high quality anti-seize compound should
be applied to the threaded surfaces.

5.2

M OUNTING HOLE TORQUE

max. 56.5 Nm(500 inch-lbs.)
min. 11.3 Nm(100 inch-lbs.)

5.
3
5.3

M OUNTING HOLE DIMENSIONS

See Figure 5-1.

13

INSTALLATION

Before reinstalling the PG, ensure that the mounting hole is free from hardened plastic. A mounting
hole cleaning tool kit is available to aid in removing of the material. (Dynisco Part Number 200100.) A
gauge plug to check the hole is included in this kit.

INSTALLATION

Fig. 5-1 1/2-20 UNF Mounting Hole
5.4
M OUNTING THE PRESSURE GAUGE
Dynisco offers a set of mounting hole-machining tools with all the necessary drills, taps, and reamers
for the Dynisco standard ½-20UNF-2A mounting holes used in high temperature and plastics processing
applications (Dynisco Part Number 200925). Detailed instructions are sent with the machining kits.
Copies of the instructions are available from Dynisco upon request.
When machining the hole pay careful attention to the concentricity between the threads and the 0.312/
0.314 diameter. Since the pressure seal is on the 45° seating surface, this surface should be examinedfor good finish, free from burrs, etc.
It is general good practice to check the mounting hole before installing the PG. One procedure is to coata gauge plug (Dynisco Part Number 200908 for the 1/2 –20 standard port), with Dykem blue on surfaces
below the thread. Insert the gauge plug into the mounting hole and rotate until surface binding is
encountered. Remove and inspect. Bluing should only be scraped off of the 45° sealing chamfer. If
bluing has been removed from other surfaces, the mounting hole has not been machined properly.

5.
5
5.5

THERMOCOUPLE REMO
VAL AND INS
TION
HERMOCOUPLEEMOVNSTTALLA
ALLATION
1.
2.
3.
4.

To remove, loosen setscrew on side of snout.
Without twisting, pull the thermocouple probe carefully out of snout.
To install, slide the new thermocouple into snout
Lock in place with setscrew.
14

6.
6.1
6.2

6.1

C OMMISSIONING
Gauge Enclosure Rotation .................................................................................................... 15
Zero Adjustment .................................................................................................................. 15

GAUGE ENCL
1R ONLOSURE ROTATION (PG44
Y)
NCLO
NLY
(PG441R

To rotate the enclosure to the desired location, first back out the set screw at the base of the enclosure.
Once the set screw is loose, the enclosure can be rotated to the desired position. Do not attempt toforce the enclosure beyond the built in mechanical stops. Once the enclosure is at the desired location,tighten the set screw. See Figure 6-1.

6.2

Z ERO ADJUSTMENT

To adjust the zero setting of the gauge, it is important that no pressure be applied to the diaphragm. In
addition, the gauge must be secured by the mounting bracket (except for rigid configurations). Using aslotted screw driver, adjust the zero screw on the gauge case until the dial pointer is centered in thezero box on the gauge scale. See Figure 6-1.

Fig. 6-1 Rotation Set Screw and Zero Adjustment

Zero Adjustment
Screw
Enclosure
Rotation Set
Screw

15

COMMISSIONING

Once installation has been completed, the PG enclosure can be swiveled 300o to provide optimum
visibility.

7.

M AINTENANCE

7.1
7.2
7.3
7.4

Maintenance ....................................................................................................................... 16
Thermocouple/RTD Replacement .......................................................................................... 16
Repair/Disposal ................................................................................................................... 17
Warranty ............................................................................................................................. 18

M AINTENANCE

COMMISSIONING

7.1

Burn hazard!
The PG must be removed with the melt in molten condition. The PG can be very hot whenremoved.
Wear protective gloves!
Installation and Removal Instructions• DO NOT REMOVE PROTECTIVE CAP UNTIL READY TO INSTALL.
• PRIOR TO INITIAL INSTALLATION, VERIFY CORRECT MACHINING OF MOUNTING HOLE.
• WHEN REINSTALLING, MAKE SURE MOUNTING HOLE IS CLEAR OF DEBRIS OR HARDENED
PLASTIC.
• THE MEDIUM MUST BE IN MOLTEN CONDITION DURING TRANSDUCER REMOVAL.
(Removing the transducer with the medium in a solidified condition can damage thesensor diaphragm.)• ALWAYS REMOVE THE PG BEFORE CLEANING THE MACHINE WITH ABRASIVES OR STEELWIRE BRUSHES, ETC.
• DO NOT CLEAN THE “SCREWED-IN” SECTION OF THE PG WITH HARD OBJECTS – THISWILL DAMAGE THE PG.
• ALWAYS USE A TORQUE WRENCH APPLIED TO THE DESIGNATED HEXAGONAL COLLAR
WHEN SCREWING THE PG IN AND OUT. DO NOT APPLY THE TOOL TO THE HOUSING OR
HOUSING/ SENSOR CONNECTION.

7.2

T HERMOCOUPLE/RC EMENT/RTT D REPLAHERMOCOUPLE
EPLAC
1.

Replace J Type Thermocouples [Dynisco P/N 901746 (6”) or 901747 (12”)] and K Type
Thermocouples [Dynisco P/N 901748 (6”)] are available for replacement.
2. To remove, loosen setscrew on side of snout.
3. Without twisting, pull the thermocouple probe or RTD stem carefully out of snout.
4. To install press thermocouple into snout carefully until top of probe shoulders against snout.
5. Lock in place with setscrew.

16

Fig. 7-1 Thermocouple

MAINTENANCE

7.3

R EP
AIR/ DIS
PO
SAL
EPAIR
DISPO
POS
Toxic h
az
ar
d!
haz
azar
ard!
The PG contains a small amount of mercury (Hg) as its transmission medium. If thediaphragm is damaged, mercury may escape.
Never transport or store the PG without the protective cap bolted in place. Remove the cap
shortly before installation.
If mercury is inhaled or swallowed, seek medical attention immediately!
Mercury is hazardous waste and must be disposed of in accordance with applicableO will accept defective PGs.
laws. DYNISC
YNISCO
If mercury escapes, use airtight packaging!

O representative. For DYNISC
O
Please send defective pressure gauges back to your DYNISC
YNISCOYNISCO
addresses, see the back cover of the operating manual.

17

7.4

W ARRANTY

MAINTENANCE

The PG4 Series of Dynisco Pressure gauges will provide excellent service and superior performance if
proper care is taken during handling, installation, and use. This DYNISCO product is warranted underterms and conditions set forth in the DYNISCO web pages. Go to www.dynisco.com and click “warranty”
at the bottom of any page for complete details.

18

8.

A CCESSORIE
S
SORIES•

Machining tool kit 1/2”-20UNF-2A P/N 200295•

Cleaning tool kit 1/2”-20UNF-2A P/N 200100•

Mounting Bracket P/N 200941•

Spare 6” J-Type Themocouple P/N 901746•

Spare 12” J-Type Themocouple P/N 901747•

Spare 6” K-Type Themocouple P/N 901748

ACCESSORIES

19

9.

T ROUBLESHOOTINGCorrective Actions

Large Zero Shift when Screwing In

1) Check Hole with Gage Plug and Rework Hole as Required
2) Check Mounting Torque

No Response to Changes inApplied Pressure1) Confirm that needle is not against mechanical stop.
2) Check Port/Pipe for Blockage or Solidified Plastic

Pressure Variable Reading is Low or High

1) Check zero with no pressure applied.
2) Check Port/Pipe for Blockage or Solidified Plastic

Pressure Variable Reading is Erratic

1) Check Port/Pipe for Blockage or Solidified Plastic

TROUBLESHOOTING

Symptom

20DyniscoLLC
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