pressure gauge

1. OPERATING
MANUAL
PG4 Series
PG4 Series
PG4 Series
PG4 Series
PG4 Series
M
M
M
M
Mec
ec
ec
ec
ech
h
h
h
hanic
anic
anic
anic
anical
al
al
al
al Pr
Pr
Pr
Pr
Pre
e
e
e
es
s
s
s
ss
s
s
s
sur
ur
ur
ur
ure G
e G
e G
e G
e Gaug
aug
aug
aug
auge
e
e
e
es
s
s
s
s
P/N 974081
05/05 Rev. D
ECO # 29918

2. OPERATING
MANUAL
T
T
T
T
TABLE
ABLE
ABLE
ABLE
ABLE OF
OF
OF
OF
OF C
C
C
C
CONTENTS
ONTENTS
ONTENTS
ONTENTS
ONTENTS
Content
Content
Content
Content
Content Page
Page
Page
Page
Page Icon
Icon
Icon
Icon
Icon
1. General 3
2. Notes on Safety 5
3. TechnicalData 6
4. Transport/Delivery 11
5. Installation 12
6. Commissioning 15
7. Maintenance 16
8. Accessories 19
9. Troubleshooting 20

3. 3
GENERAL
1.
1.
1.
1.
1. G
G
G
G
GENERAL
ENERAL
ENERAL
ENERAL
ENERAL
1.1 ImportantInformation............................................................................................................ 6
1.2 Copyright .............................................................................................................................. 6
1.3 Explanation of Icons .............................................................................................................. 6
1.4 Abbreviations.........................................................................................................................7
1.5 Principle of Operation.............................................................................................................7
1.1
1.1
1.1
1.1
1.1 I
I
I
I
IMPOR
MPOR
MPOR
MPOR
MPORT
T
T
T
TANT
ANT
ANT
ANT
ANT INFORMA
INFORMA
INFORMA
INFORMA
INFORMATION
TION
TION
TION
TION
This manual applies to the PG4 series only. It must be kept near the equipment in a readily and
immediately accessible location at all times. The content of this manual must be read, understood and
followed in its entirety. This applies in particular to the notes on safety. Following the safety
instructions will help to prevent accidents, defects and malfunctions.
Models covered by this manual include the PG441R, PG442R and TPG443R.
D
D
D
D
DYNISC
YNISC
YNISC
YNISC
YNISCO
O
O
O
O will not be held liable for any injury, loss or damage resulting from failure to follow the
instructions in this manual.
If the product malfunctions, in spite of having followed the operating instructions, please contact the
D
D
D
D
DYNISC
YNISC
YNISC
YNISC
YNISCO
O
O
O
O customer service department (See the back of the manual for contact information). This
applies in particular during the warranty period.
1.2
1.2
1.2
1.2
1.2 C
C
C
C
COPYRIGHT
OPYRIGHT
OPYRIGHT
OPYRIGHT
OPYRIGHT
Copyright law requires that this manual be used for intended purposes only.
It is strictly forbidden to allow reproduction of any kind “in whole or in part” to persons outside of
Dynisco, without approval from Dynisco.
1.
1.
1.
1.
1.3
3
3
3
3 E
E
E
E
EXPLANA
XPLANA
XPLANA
XPLANA
XPLANATION
TION
TION
TION
TION OF
OF
OF
OF
OF IC
IC
IC
IC
ICONS
ONS
ONS
ONS
ONS
The manual uses icons to indicate information pertaining to safety:
Risk of destruction or damage to equipment, machines or installations
General danger to life or limb
Specific danger to life or limb

4. 4
GENERAL
You MUST do this
The safety instructions are provided again in the individual chapters of the manual.
1.4
1.4
1.4
1.4
1.4 A
A
A
A
ABBREVIA
BBREVIA
BBREVIA
BBREVIA
BBREVIATIONS
TIONS
TIONS
TIONS
TIONS
The following abbreviations are used:
OM Operating Manual
PG Pressure Gauge
f.s. of full scale
BFSL Best Fit Straight Line
1.
1.
1.
1.
1.5
5
5
5
5 P
P
P
P
PRINCIPLE
RINCIPLE
RINCIPLE
RINCIPLE
RINCIPLE OF
OF
OF
OF
OF O
O
O
O
OPERA
PERA
PERA
PERA
PERATION
TION
TION
TION
TION
The mechanical system (a filled assembly) consists of a lower diaphragm, a filled capillary tube, and a
Bourdon tube. The filled assembly transmits pressure from the process to the Bourdon tube which then
rotates the needle on the face plate of the pressure gauge. The filled assembly isolates the electronics
from the high process temperatures.
The lower diaphragm is the surface in contact with the media being measured. This diaphragm can be
made from a choice of materials. The standard material is heat-treated 15-5 stainless steel with Titanium
Nitride coating. This has average corrosion and abrasion resistance and is similar to 17-4 stainless steel.
Behind the lower diaphragm is a capillary tube filled to the upper diaphragm. As the process pressure
deflects the lower diaphragm, the fill is displaced through the capillary tube and applies pressure to the
Bourdon tube.

5. 5
SAFETY
2.
2.
2.
2.
2. N
N
N
N
NOTES
OTES
OTES
OTES
OTES ON
ON
ON
ON
ON SAFETY
SAFETY
SAFETY
SAFETY
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.
D
D
D
D
DYNISC
YNISC
YNISC
YNISC
YNISCO
O
O
O
O will not be held liable for any injury, loss or damage resulting from failure to
follow the instructions in this manual.
T
T
T
T
To
o
o
o
ox
x
x
x
xic
ic
ic
ic
ic Haz
Haz
Haz
Haz
Hazar
ar
ar
ar
ard!
d!
d!
d!
d!
The PG contains a very small amount of mercury (Hg) 0.00322 in³ typically with a 6/18
configuration, as its transmission medium. If the diaphragm is damaged, mercury may
escape. Never transport or store the PG without the protective cap. Remove the cap
shortly before installation.
If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
Mercury is hazardous waste and must be disposed of in accordance with applicable laws.
D
D
D
D
DYNISC
YNISC
YNISC
YNISC
YNISCO
O
O
O
O will accept defective PG’s. If mercury escapes, use airtight packaging!
T
T
T
T
Temper
emper
emper
emper
emperat
at
at
at
atur
ur
ur
ur
ure
e
e
e
e
The PG4 series of pressure gauges can be used in media temperatures up to 400°C. If the pressure
gauge is used in other applications, the safety and accident prevention regulations specific to that
application must be followed. Ambient temperature for the case max. +135°C.
Higher temperature can result in damage and malfunction. Do not install the pressure gauge in places
where this temperature is exceeded.

6. 6
TECHNICAL
DATA
3.
3.
3.
3.
3. T
T
T
T
TE
E
E
E
ECHNICAL
CHNICAL
CHNICAL
CHNICAL
CHNICAL D
D
D
D
DA
A
A
A
AT
T
T
T
TA
A
A
A
A
3.1 Ordering Guide for PG4 Series................................................................................................ 6
3.2 Ordering Example ................................................................................................................. 6
3.3 OrderingInformation ..............................................................................................................7
3.3.1 Temperature Option ...............................................................................................................7
3.3.2 Configuration .........................................................................................................................7
3.3.3 Pressure Range......................................................................................................................7
3.3.4 Rigid Stem & Flexible Capillary ................................................................................................7
3.3.5 Mounting ...............................................................................................................................7
3.3.6 ThermocoupleType ............................................................................................................... 8
3.4 Performance Characteristics .................................................................................................. 8
3.4.1 CombinedError(Accuracy) ..................................................................................................... 8
3.4.2 ZeroAdjustability .................................................................................................................. 8
3.4.3 Max. Overload ...................................................................................................................... 8
3.4.4 Needle Sweep ...................................................................................................................... 8
3.4.5 ThermocoupleOption ............................................................................................................ 8
3.5 Materials .............................................................................................................................. 8
3.6 Torque .................................................................................................................................. 8
3.7 Weight ................................................................................................................................. 9
3.8 Dimensions........................................................................................................................... 9
3.1
3.1
3.1
3.1
3.1 O
O
O
O
ORDERING
RDERING
RDERING
RDERING
RDERING G
G
G
G
GUIDE
UIDE
UIDE
UIDE
UIDE FOR
FOR
FOR
FOR
FOR PG4 S
PG4 S
PG4 S
PG4 S
PG4 SERIES
ERIES
ERIES
ERIES
ERIES
The exact meanings of the letter/digit combinations are given in the corresponding sections of
Chapter 3.
T PG44 3R-5M-6/30-U
J-TypeThermocouple
Rigid Snout, Flexible Stem and Thermocouple
5,000psi
6” Snout Length
30” Flexible Capillary Length
Face Up Mounting
X PG44 XR-XX-X/XX-X-X
Temperature Option
Configuration
Pressure Range
Snout Length
Flexible Capillary Length
Mounting
ThermocoupleType
3.2
3.2
3.2
3.2
3.2 O
O
O
O
ORDERING
RDERING
RDERING
RDERING
RDERING E
E
E
E
EXAMPLE
XAMPLE
XAMPLE
XAMPLE
XAMPLE

7. 7
TECHNICAL
DATA
3.
3.
3.
3.
3.3
3
3
3
3 O
O
O
O
ORDERING
RDERING
RDERING
RDERING
RDERING I
I
I
I
INFORMA
NFORMA
NFORMA
NFORMA
NFORMATION
TION
TION
TION
TION
XPG44XR-XX-X/XX-X-X
3.
3.
3.
3.
3.3.1
3.1
3.1
3.1
3.1 T
T
T
T
TEMPERA
EMPERA
EMPERA
EMPERA
EMPERATURE
TURE
TURE
TURE
TURE O
O
O
O
OP
P
P
P
PTION
TION
TION
TION
TION
X
X
X
X
XPG44XR-XX-X/XX-X-X
Blank = NoTemperatureSensor
T = J-TypeThermocouple
3.
3.
3.
3.
3.3.2
3.2
3.2
3.2
3.2 C
C
C
C
CONFIGURA
ONFIGURA
ONFIGURA
ONFIGURA
ONFIGURATION
TION
TION
TION
TION
XPG44X
X
X
X
XR-XX-X/XX-X-X
1 = Rigid Snout Only
2 = Rigid Snout with Flexible Stem
3 = RigidSnout with FlexibleStem and Temperature Option
3.
3.
3.
3.
3.3.
3.
3.
3.
3.3
3
3
3
3 P
P
P
P
PRESSURE
RESSURE
RESSURE
RESSURE
RESSURE R
R
R
R
RANGE
ANGE
ANGE
ANGE
ANGE
XPG44XR-XX
XX
XX
XX
XX-X/XX-X-X
5M = 5,000psi
10M= 10,000 psi
3.
3.
3.
3.
3.3.4
3.4
3.4
3.4
3.4 R
R
R
R
RIGID
IGID
IGID
IGID
IGID STEM
STEM
STEM
STEM
STEM & F
& F
& F
& F
& FLEXIBLE
LEXIBLE
LEXIBLE
LEXIBLE
LEXIBLE C
C
C
C
CAPILLARY
APILLARY
APILLARY
APILLARY
APILLARY
XPG44XR-XX-X/XX
X/XX
X/XX
X/XX
X/XX-X-X
6 = 6” Rigid Stem/0” Flexible Capillary
6/30 = 6” Rigid Stem/30” Flexible Capillary
12 = 12” Rigid Stem/0” Flexible Capillary
12/30 = 12” Rigid Stem/30” Flexible Capillary
3.
3.
3.
3.
3.3.
3.
3.
3.
3.5
5
5
5
5 M
M
M
M
MOUNTING
OUNTING
OUNTING
OUNTING
OUNTING
XPG44XR-XX-X/XX-X
X
X
X
X-X
Blank = Face Down
U = Face Up

8. 8
TECHNICAL
DATA
3.
3.
3.
3.
3.3.
3.
3.
3.
3.6
6
6
6
6 T
T
T
T
THERMOC
HERMOC
HERMOC
HERMOC
HERMOCOUPLE
OUPLE
OUPLE
OUPLE
OUPLE T
T
T
T
TYPE
YPE
YPE
YPE
YPE (PG44
(PG44
(PG44
(PG44
(PG443R O
3R O
3R O
3R O
3R ONL
NL
NL
NL
NLY
Y
Y
Y
Y)
)
)
)
)
XPG44XR-XX-X/XX-X-X
X
X
X
X
Blank = JTypeThermocouple
K = KTypeThermocouple
3.4
3.4
3.4
3.4
3.4 P
P
P
P
PERFORMANCE
ERFORMANCE
ERFORMANCE
ERFORMANCE
ERFORMANCE CHARACTERISTICS
CHARACTERISTICS
CHARACTERISTICS
CHARACTERISTICS
CHARACTERISTICS
3.4.1
3.4.1
3.4.1
3.4.1
3.4.1 C
C
C
C
COMBINED
OMBINED
OMBINED
OMBINED
OMBINED E
E
E
E
ERROR
RROR
RROR
RROR
RROR (A
(A
(A
(A
(AC
C
C
C
CC
C
C
C
CURA
URA
URA
URA
URACY
CY
CY
CY
CY)
)
)
)
)
Combined error is also known as accuracy which includes linearity, hysteresis and repeatability, and is
determined by BFSL (Best Fit Straight Line).
±2.0% of full scale
3.4.2
3.4.2
3.4.2
3.4.2
3.4.2 Z
Z
Z
Z
ZERO
ERO
ERO
ERO
ERO A
A
A
A
ADJUS
DJUS
DJUS
DJUS
DJUST
T
T
T
TABILIT
ABILIT
ABILIT
ABILIT
ABILITY
Y
Y
Y
Y
7.5% of full scale
3.4.
3.4.
3.4.
3.4.
3.4.3
3
3
3
3 M
M
M
M
MAX
AX
AX
AX
AX. O
. O
. O
. O
. OVERL
VERL
VERL
VERL
VERLO
O
O
O
OAD
AD
AD
AD
AD (
(
(
(
(WITHOUT
WITHOUT
WITHOUT
WITHOUT
WITHOUT INFL
INFL
INFL
INFL
INFLUENCING
UENCING
UENCING
UENCING
UENCING OPERA
OPERA
OPERA
OPERA
OPERATING
TING
TING
TING
TING D
D
D
D
DA
A
A
A
AT
T
T
T
TA
A
A
A
A)
)
)
)
)
1.5 x full scale pressure
3.4.4
3.4.4
3.4.4
3.4.4
3.4.4 N
N
N
N
NEEDLE
EEDLE
EEDLE
EEDLE
EEDLE S
S
S
S
SWEEP
WEEP
WEEP
WEEP
WEEP
270o
3.4.
3.4.
3.4.
3.4.
3.4.5
5
5
5
5 T
T
T
T
THERMOC
HERMOC
HERMOC
HERMOC
HERMOCOUPLE
OUPLE
OUPLE
OUPLE
OUPLE O
O
O
O
OP
P
P
P
PTION
TION
TION
TION
TION
J-TypeThermocouple for 6” snout (Dynisco P/N 901746)
J-TypeThermocouple for 12” snout (Dynisco P/N 901747)
K-TypeThermocouple for 6” snout(Dynisco P/N 901748)
3.
3.
3.
3.
3.5
5
5
5
5 M
M
M
M
MA
A
A
A
ATERIALS
TERIALS
TERIALS
TERIALS
TERIALS
Standard Diaphragm 15-5PH with Titanium Nitride Coating
StandardStem(Snout) 17-4PH
3.6
3.6
3.6
3.6
3.6 T
T
T
T
TORQUE
ORQUE
ORQUE
ORQUE
ORQUE
max.56.5Nm
(500inch-lbs.)
min. 11.3 Nm
(100inch-lbs.)

9. 9
TECHNICAL
DATA
3.
3.
3.
3.
3.7
7
7
7
7 W
W
W
W
WEIGHT
EIGHT
EIGHT
EIGHT
EIGHT
The weight varies depending on product configuration. Average weight range is 2 to 3 pounds.
3.8
3.8
3.8
3.8
3.8 D
D
D
D
DIMENSIONS
IMENSIONS
IMENSIONS
IMENSIONS
IMENSIONS
See Figure 3-1.

10. 10
TECHNICAL
DATA
Fig. 3-1
Fig. 3-1
Fig. 3-1
Fig. 3-1
Fig. 3-1 PG4 Series
PG4 Series
PG4 Series
PG4 Series
PG4 Series
2.38
60.3
1.57
39.9
1.00
25.4
1.05
26.6
10
20
25
5
0
0
0
40
00
3000
AR x 10
2000
100
0
p
s
i
15
35
5 30
SST CASE &
COVER
PROTECTIVE
SAFETY GLASS
4.35
110.6
NOMINAL
1.94
49.3
NOMINAL
EXTERNAL
ZERO ADJUST
O
E
Z
R
Dynisco
MODEL
SER.NO.
RANGE
FLEX ARMOR
.28 ( 7.1 ) OD
J
_
+
J
_
+
.42
10.7
O
.50
12.7
O
.440
11.18
.214
5.44
.414
.412
10.52
10.46
O
.307
.305
7.8
7.75
O
DIM "A"
1.06
26.9
1/2-20 UNF-2A
RIGID
STEM
LENGTH
RIGID
STEM
LENGTH
1/2-20 UNF-2A
1.06
26.9
DIM "A"
.307
.305
7.8
7.75
O
.414
.412
10.52
10.46
O
.214
5.44
.440
11.18
.50
12.7
O
.42
10.7
O
( 14.7 )
5/8 HEX
NO.4-40 SET SCREW
THERMOCOUPLE LOCK
1.25
31.8
O 1.41
35.8
.69
17.6
O
FLEX LENGTH
DIM 'B' u .12
FLEX ARMOR
.28 ( 7.1 ) OD
T/C CONNECTOR
TYPE J, MALE
T/C CONNECTOR
TYPE J, FEMALE
SUPPLIED WITH
MODELS
PG442R & TPG443R
CLAMP ASSY
P/N 200941
1.57
39.9
.42
10.7
O
.50
12.7
O
.440
11.18
.214
5.44
.307
.305
7.8
7.75
O
1.06
26.9
1/2-20 UNF-2A
( 14.7 )
5/8 HEX
FLEX LENGTH
DIM 'B' u .12
DIM "A"
RIGID
STEM
LENGTH
.98
24.8
.69
17.6
O
.414
.412
10.52
10.46
O

11. 11
TRANSPORT
4.
4.
4.
4.
4. T
T
T
T
TRANSPORT
RANSPORT
RANSPORT
RANSPORT
RANSPORT/D
/D
/D
/D
/DELIVERY
ELIVERY
ELIVERY
ELIVERY
ELIVERY
4.1 Transport/Packing/Transport Damage................................................................................... 11
4.2 Storage ............................................................................................................................... 11
4.3 Scope of Delivery ................................................................................................................. 11
T
T
T
T
To
o
o
o
ox
x
x
x
xic
ic
ic
ic
ic h
h
h
h
haz
az
az
az
azar
ar
ar
ar
ard!
d!
d!
d!
d!
The PG contains a small amount of mercury (Hg) as its transmission medium. If the
diaphragm is damaged, mercury may escape.
Never transport or store the PG without the protective shell bolted in place. Remove the
shell shortly before installation.
If mercury is inhaled or swallowed, seek medical attention immediately.
If mercury is inhaled or swallowed, seek medical attention immediately.
If mercury is inhaled or swallowed, seek medical attention immediately.
If mercury is inhaled or swallowed, seek medical attention immediately.
If mercury is inhaled or swallowed, seek medical attention immediately.
Mercury is hazardous waste and must be disposed of in accordance with applicable laws.
D
D
D
D
DYNISC
YNISC
YNISC
YNISC
YNISCO
O
O
O
O will accept defective PGs.
If mercury escapes, use airtight packaging!
4.1
4.1
4.1
4.1
4.1 T
T
T
T
TRANS
RANS
RANS
RANS
RANSPOR
POR
POR
POR
PORT
T
T
T
T/
/
/
/
/P
P
P
P
PA
A
A
A
ACKING
CKING
CKING
CKING
CKING/
/
/
/
/TRANS
TRANS
TRANS
TRANS
TRANSPOR
POR
POR
POR
PORT
T
T
T
T D
D
D
D
DAMAGE
AMAGE
AMAGE
AMAGE
AMAGE
• Do not let the PG be damaged by other items during transit.
• Use only the original packaging.
• Reporttransportdamage to D
D
D
D
DYNISC
YNISC
YNISC
YNISC
YNISCO
O
O
O
O immediately in writing.
4.2
4.2
4.2
4.2
4.2 S
S
S
S
STORAGE
TORAGE
TORAGE
TORAGE
TORAGE
• Store the PG in original packaging only.
• Protect against dust and moisture.
4.
4.
4.
4.
4.3
3
3
3
3 S
S
S
S
SC
C
C
C
COPE
OPE
OPE
OPE
OPE OF
OF
OF
OF
OF D
D
D
D
DELIVERY
ELIVERY
ELIVERY
ELIVERY
ELIVERY
• PG with diaphragm protection cap
• Fastening clip (transmitter with flexible stem only)
• Calibrationsheet
• Operating manual

12. 12
I
NSTALLATION
5.
5.
5.
5.
5. I
I
I
I
INS
NS
NS
NS
NST
T
T
T
TALLA
ALLA
ALLA
ALLA
ALLATION
TION
TION
TION
TION
5.1 GeneralMountingInformation .............................................................................................. 12
5.2 Mounting HoleTorque .......................................................................................................... 13
5.3 MountingHoleDimensions ...................................................................................................14
5.4 Mounting the Pressure Gauge............................................................................................... 14
5.5 Thermocouple or RTD Assembly, Removal and Installation ...................................................... 14
5.1
5.1
5.1
5.1
5.1 G
G
G
G
GENERAL
ENERAL
ENERAL
ENERAL
ENERAL M
M
M
M
MOUNTING
OUNTING
OUNTING
OUNTING
OUNTING I
I
I
I
INFORMA
NFORMA
NFORMA
NFORMA
NFORMATION
TION
TION
TION
TION
Do not remove the protective cap on the PG until ready to install.
Before mounting the PG, check mounting hole carefully. The PG must only be mounted in holes that
satisfy the requirements below. A hole that does not satisfy these requirements can damage the
pressure gauge.
Insure the mounting hole is clear of any frozen polymer or debris and is machined to the proper
dimensions.
Coat the threads with a high temperature anti-seize grease or a suitable parting agent, this will help
prevent the PG snout from sticking permanently in the mounting hole.
Install unit into the process connection. (Do NOT torque transmitter into the hole at this time!) Allow time
for the pressure gauge snout temperature to equalize to the process temperature. This will help
eliminate thread galling and ease removal later. There should be NO pressure applied at this time.
Always use a torque wrench applied to the designated hexagon collar bolts while screwing the pressure
gauge in and out. Do not apply the tool to the housing or housing/sensor connection.
After temperatures have equalized, apply proper torque as described in Section 3.6 or 5.2 of the Manual
and tighten the sensor into mounting hole.
After the correct torque has been applied units with flexible capillary require the electronics to be
mounted away from the process heat using mounting hardware, P/N 200941.
Make sure that the medium is in molten condition during sensor removal. Removing the sensor while
the medium is in solidified condition can damage the sensor diaphragm.
When removing the PG, carefully clean the diaphragm of the transmitter with a soft cloth while the
medium is still malleable.
Always remove the pressure gauge prior to cleaning the machine with abrasives or steel wire brushes.

13. 13
I
NSTALLATION
Also, do not clean the PG with hard objects, such as a screwdriver, a wire brush, etc. this will possibly
damage the transmitter.
Before reinstalling the PG, ensure that the mounting hole is free from hardened plastic. A mounting
hole cleaning tool kit is available to aid in removing of the material. (Dynisco Part Number 200100.) A
gauge plug to check the hole is included in this kit.
The most common causes of sensor damage are: installation in improperly
machined or plugged mounting holes and cold starts. The tip of the PG consists of a
stainless steel diaphragm that must be protected from severe abrasives, dents and
scores.
Burn Hazard!
Burn Hazard!
Burn Hazard!
Burn Hazard!
Burn Hazard! The PG must be removed with the melt in the molten condition. The
PG can be very hot when removed. WEAR PROTECTIVE GLOVES!
Careful attention should be paid to correctly machine the mounting port. Failure to use the
recommended mounting port may result in erroneous pressure measurement, difficult sensor removal,
premature sensor failure, process fluid leaks, and personnel injury. In applications involving high
temperature operation and/or repeated thermal cycling a good high quality anti-seize compound should
be applied to the threaded surfaces.
5.2
5.2
5.2
5.2
5.2 M
M
M
M
MOUNTING
OUNTING
OUNTING
OUNTING
OUNTING H
H
H
H
HOLE
OLE
OLE
OLE
OLE T
T
T
T
TORQUE
ORQUE
ORQUE
ORQUE
ORQUE
max.56.5Nm
(500inch-lbs.)
min. 11.3 Nm
(100inch-lbs.)
5.
5.
5.
5.
5.3
3
3
3
3 M
M
M
M
MOUNTING
OUNTING
OUNTING
OUNTING
OUNTING H
H
H
H
HOLE
OLE
OLE
OLE
OLE D
D
D
D
DIMENSIONS
IMENSIONS
IMENSIONS
IMENSIONS
IMENSIONS
See Figure 5-1.

14. 14
I
NSTALLATION
Fig. 5-1
Fig. 5-1
Fig. 5-1
Fig. 5-1
Fig. 5-1 1/2-20 UNF Mounting Hole
1/2-20 UNF Mounting Hole
1/2-20 UNF Mounting Hole
1/2-20 UNF Mounting Hole
1/2-20 UNF Mounting Hole
5.4
5.4
5.4
5.4
5.4 M
M
M
M
MOUNTING
OUNTING
OUNTING
OUNTING
OUNTING THE
THE
THE
THE
THE P
P
P
P
PRESSURE
RESSURE
RESSURE
RESSURE
RESSURE G
G
G
G
GAUGE
AUGE
AUGE
AUGE
AUGE
Dynisco offers a set of mounting hole-machining tools with all the necessary drills, taps, and reamers
for the Dynisco standard ½-20UNF-2A mounting holes used in high temperature and plastics processing
applications (Dynisco Part Number 200925). Detailed instructions are sent with the machining kits.
Copies of the instructions are available from Dynisco upon request.
When machining the hole pay careful attention to the concentricity between the threads and the 0.312/
0.314 diameter. Since the pressure seal is on the 45° seating surface, this surface should be examined
for good finish, free from burrs, etc.
It is general good practice to check the mounting hole before installing the PG. One procedure is to coat
a gauge plug (Dynisco Part Number 200908 for the 1/2 –20 standard port), with Dykem blue on surfaces
below the thread. Insert the gauge plug into the mounting hole and rotate until surface binding is
encountered. Remove and inspect. Bluing should only be scraped off of the 45° sealing chamfer. If
bluing has been removed from other surfaces, the mounting hole has not been machined properly.
5.
5.
5.
5.
5.5
5
5
5
5 T
T
T
T
THERMOC
HERMOC
HERMOC
HERMOC
HERMOCOUPLE
OUPLE
OUPLE
OUPLE
OUPLE R
R
R
R
REMO
EMO
EMO
EMO
EMOV
V
V
V
VAL
AL
AL
AL
AL AND
AND
AND
AND
AND I
I
I
I
INS
NS
NS
NS
NST
T
T
T
TALLA
ALLA
ALLA
ALLA
ALLATION
TION
TION
TION
TION
1. To remove, loosen setscrew on side of snout.
2. Without twisting, pull the thermocouple probe carefully out of snout.
3. To install, slide the new thermocouple into snout
4. Lock in place with setscrew.

15. 15
COMMISSIONING
6.
6.
6.
6.
6. C
C
C
C
COMMISSIONING
OMMISSIONING
OMMISSIONING
OMMISSIONING
OMMISSIONING
6.1 Gauge Enclosure Rotation .................................................................................................... 15
6.2 ZeroAdjustment .................................................................................................................. 15
6.1
6.1
6.1
6.1
6.1 G
G
G
G
GA
A
A
A
AUGE
UGE
UGE
UGE
UGE E
E
E
E
ENCL
NCL
NCL
NCL
NCLO
O
O
O
OSURE
SURE
SURE
SURE
SURE R
R
R
R
RO
O
O
O
OT
T
T
T
TA
A
A
A
ATION
TION
TION
TION
TION (PG44
(PG44
(PG44
(PG44
(PG441R O
1R O
1R O
1R O
1R ONL
NL
NL
NL
NLY
Y
Y
Y
Y)
)
)
)
)
Once installation has been completed, the PG enclosure can be swiveled 300o
to provide optimum
visibility.
To rotate the enclosure to the desired location, first back out the set screw at the base of the enclosure.
Once the set screw is loose, the enclosure can be rotated to the desired position. Do not attempt to
force the enclosure beyond the built in mechanical stops. Once the enclosure is at the desired location,
tighten the set screw. See Figure 6-1.
6.2
6.2
6.2
6.2
6.2 Z
Z
Z
Z
ZERO
ERO
ERO
ERO
ERO A
A
A
A
ADJUSTMENT
DJUSTMENT
DJUSTMENT
DJUSTMENT
DJUSTMENT
To adjust the zero setting of the gauge, it is important that no pressure be applied to the diaphragm. In
addition, the gauge must be secured by the mounting bracket (except for rigid configurations). Using a
slotted screw driver, adjust the zero screw on the gauge case until the dial pointer is centered in the
zero box on the gauge scale. See Figure 6-1.
Fig. 6-1
Fig. 6-1
Fig. 6-1
Fig. 6-1
Fig. 6-1 Rotation Set Screw and Zero Adjustment
Rotation Set Screw and Zero Adjustment
Rotation Set Screw and Zero Adjustment
Rotation Set Screw and Zero Adjustment
Rotation Set Screw and Zero Adjustment
ZeroAdjustment
Screw
Enclosure
Rotation Set
Screw

16. 16
COMMISSIONING
7
7
7
7
7.
.
.
.
. M
M
M
M
MAINTENANCE
AINTENANCE
AINTENANCE
AINTENANCE
AINTENANCE
7.1 Maintenance ....................................................................................................................... 16
7.2 Thermocouple/RTD Replacement .......................................................................................... 16
7.3 Repair/Disposal ................................................................................................................... 17
7.4 Warranty .............................................................................................................................18
7
7
7
7
7.1
.1
.1
.1
.1 M
M
M
M
MAINTENANCE
AINTENANCE
AINTENANCE
AINTENANCE
AINTENANCE
Burn hazard!
Burn hazard!
Burn hazard!
Burn hazard!
Burn hazard!
The PG must be removed with the melt in molten condition. The PG can be very hot when
removed.
Wear protective gloves!
Wear protective gloves!
Wear protective gloves!
Wear protective gloves!
Wear protective gloves!
Installation and Removal Instructions
• DO NOT REMOVE PROTECTIVE CAP UNTIL READY TO INSTALL.
• PRIORTO INITIAL INSTALLATION,VERIFY CORRECT MACHINING OF MOUNTING HOLE.
• WHEN REINSTALLING, MAKESURE MOUNTING HOLE ISCLEAR OF DEBRISOR HARDENED
PLASTIC.
• THEMEDIUM MUST BE IN MOLTEN CONDITION DURINGTRANSDUCER REMOVAL.
(Removing the transducer with the medium in a solidified condition can damage the
sensor diaphragm.)
• ALWAYS REMOVETHE PG BEFORE CLEANING THE MACHINE WITH ABRASIVES OR STEEL
WIRE BRUSHES, ETC.
• DO NOT CLEAN THE “SCREWED-IN” SECTION OF THE PG WITH HARD OBJECTS – THIS
WILL DAMAGE THE PG.
• ALWAYS USE ATORQUE WRENCH APPLIED TOTHE DESIGNATED HEXAGONALCOLLAR
WHEN SCREWING THE PG IN AND OUT. DO NOT APPLY THE TOOL TO THE HOUSING OR
HOUSING/SENSOR CONNECTION.
7
7
7
7
7.2
.2
.2
.2
.2 T
T
T
T
THERMOC
HERMOC
HERMOC
HERMOC
HERMOCOUPLE
OUPLE
OUPLE
OUPLE
OUPLE/R
/R
/R
/R
/RT
T
T
T
TD R
D R
D R
D R
D REPLA
EPLA
EPLA
EPLA
EPLAC
C
C
C
CEMENT
EMENT
EMENT
EMENT
EMENT
1. Replace J Type Thermocouples [Dynisco P/N 901746 (6”) or 901747 (12”)] and KType
Thermocouples [Dynisco P/N 901748 (6”)] are available for replacement.
2. To remove, loosen setscrew on side of snout.
3. Without twisting, pull the thermocouple probe or RTD stem carefully out of snout.
4. To install press thermocouple into snout carefully until top of probe shoulders against snout.
5. Lock in place with setscrew.

17. 17
MAINTENANCE
Fig. 7-1
Fig. 7-1
Fig. 7-1
Fig. 7-1
Fig. 7-1 Thermocouple
Thermocouple
Thermocouple
Thermocouple
Thermocouple
7
7
7
7
7.
.
.
.
.3
3
3
3
3 R
R
R
R
REP
EP
EP
EP
EPAIR
AIR
AIR
AIR
AIR/
/
/
/
/DIS
DIS
DIS
DIS
DISPO
PO
PO
PO
POS
S
S
S
SAL
AL
AL
AL
AL
T
T
T
T
To
o
o
o
ox
x
x
x
xic
ic
ic
ic
ic h
h
h
h
haz
az
az
az
azar
ar
ar
ar
ard!
d!
d!
d!
d!
The PG contains a small amount of mercury (Hg) as its transmission medium. If the
diaphragm is damaged, mercury may escape.
Never transport or store the PG without the protective cap bolted in place. Remove the cap
shortly before installation.
If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
If mercury is inhaled or swallowed, seek medical attention immediately!
Mercury is hazardous waste and must be disposed of in accordance with applicable
laws. D
D
D
D
DYNISC
YNISC
YNISC
YNISC
YNISCO
O
O
O
O will accept defective PGs.
If mercury escapes, use airtight packaging!
Please send defective pressure gauges back to your D
D
D
D
DYNISC
YNISC
YNISC
YNISC
YNISCO
O
O
O
O representative. For D
D
D
D
DYNISC
YNISC
YNISC
YNISC
YNISCO
O
O
O
O
addresses, see the back cover of the operating manual.

18. 18
MAINTENANCE
7
7
7
7
7.4
.4
.4
.4
.4 W
W
W
W
WARRANTY
ARRANTY
ARRANTY
ARRANTY
ARRANTY
The PG4 Series of Dynisco Pressure gauges will provide excellent service and superior performance if
proper care is taken during handling, installation, and use. This DYNISCO product is warranted under
terms and conditions set forth in the DYNISCO web pages. Go to www.dynisco.com and click“warranty”
at the bottom of any page for complete details.

19. 19
ACCESSORIES
8.
8.
8.
8.
8. A
A
A
A
AC
C
C
C
CC
C
C
C
CE
E
E
E
ES
S
S
S
SSORIE
SORIE
SORIE
SORIE
SORIES
S
S
S
S
• Machining tool kit 1/2”-20UNF-2A P/N 200295
• Cleaning tool kit 1/2”-20UNF-2A P/N 200100
• Mounting Bracket P/N 200941
• Spare 6” J-TypeThemocouple P/N 901746
• Spare 12” J-TypeThemocouple P/N 901747
• Spare 6” K-TypeThemocouple P/N 901748

20. 20
TROUBLESHOOTING
9.
9.
9.
9.
9. T
T
T
T
TROUBLESHOOTING
ROUBLESHOOTING
ROUBLESHOOTING
ROUBLESHOOTING
ROUBLESHOOTING
Symptom
Symptom
Symptom
Symptom
Symptom Corrective Actions
Corrective Actions
Corrective Actions
Corrective Actions
Corrective Actions
Large Zero Shift when Screwing In 1) Check Hole with Gage Plug and Rework Hole as Required
2) CheckMounting Torque
No Response to Changes in 1) Confirm that needle is not against mechanical stop.
Applied Pressure 2) Check Port/Pipe for Blockage or Solidified Plastic
Pressure Variable Reading is Low or High 1) Check zero with no pressure applied.
2) Check Port/Pipe for Blockage or Solidified Plastic
PressureVariable Reading is Erratic 1) Check Port/Pipe for Blockage or Solidified Plastic

22. Visit us on the world wide web:
Visit us on the world wide web:
Visit us on the world wide web:
Visit us on the world wide web:
Visit us on the world wide web:
w
w
w
w
w
w
w
w
w
w
w
w
w
w
w.
.
.
.
.
d
y
d
y
d
y
d
y
d
yn
i
n
i
n
i
n
i
n
is
s
s
s
s
c
c
c
c
c
o
o
o
o
o
.
.
.
.
.
c
c
c
c
c
o
m
o
m
o
m
o
m
o
m
DyniscoLLC
38 Forge Parkway
Franklin, MA 02038
USA
Tel: +1 508 541 9400
Fax: +1 508 541 9436
Email: InfoInst@dynisco.com
Dynisco Extrusion
1291 19th St Ln NW
Hickory, NC 28601
Tel: 828-326-9888
Fax: 828-326-8882
Email: InfoExtr@dynisco.com
Dynisco Europe GmbH
Wannenäckerstraße 24
74078 Heilbronn
Deutschland
Tel: +49 7131 2970
Fax:+49 7131 23260
Email: DyniscoEurope@dynisco.com
Dynisco Instruments S.a.r.l.
466, rue du Marché Rollay
94500 Champigny sur Marne
France
Tel: +33 1 4881 8459
Fax: +33 1 4881 8334
Email: DyniscoFrance@dynisco.com
Dynisco.s.r.l.
Via Adriatico, 2/2
20162 Milano
Italia
Tel: +39 02 661 01733
Fax: +39 02 661 02908
Email: DyniscoItaly@dynisco.com
Dynisco UK Ltd.
Silver Birches Business Park
Aston Road, Bromsgrove
Worcestershire B60 3EU
Great Britain
Tel: +44 1527 577077
Fax: +44 1527 577070
Email: DyniscoUK@dynisco.com
Dynisco SPOL, S.R.O.
cp. 579
756 55 Dolni Becva
Czech Republic
Tel: +42 0571 647228
Fax: +42 0571 647224
Email: Dynisco_cz@ova.pvtnet.cz
Dynisco B.V.
Weidehek 53A
4824 At Breda
The Netherlands
Tel: +31 (0) 76 549 0530
Fax: +31 (0) 76 549 0540
Email: Dynisco-BV@dynisco.com