DH Instruments PG7000 - V3.0 User manual

© 1998-2009 DH Instruments, a Fluke Company
PG7000™ PISTON GAUGES
PG7102™, PG7202™,
PG7302™, PG7601™
(Ver. 3.0 and Higher)
Operation and Maintenance Manual

PG7000™ OPERATION AND MAINTENANCE MANUAL
© 1998-2009 DH Instruments, a Fluke Company
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 - 2009 DH Instruments, a Fluke Company All rights reserved.
Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any
form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments 4765
East Beautiful Lane Phoenix Arizona 85044-5318 USA.
DH Instruments makes sincere efforts to ensure the accuracy and quality of its published materials; however, no warranty,
expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages
resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not
constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was
subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the
English version and other language versions, the English version predominates.
DH Instruments, DH, DHI, PG7000, PG7102, PG7202, PG7302, PG7601, CalTool and COMPASS are trademarks, registered and
otherwise, of DH Instruments, a Fluke Company.
Swagelok is a registered trademark of the Swagelok Company.
Krytox is a registered trademark of the Dupont de Nemours Company.
Products described in this manual are manufactured under international patents and one or more of the following U.S.
patents: 6,701,791, 5,142,483, 5,257,640, 5,331,838, 5,445,035. Other U.S. and international patents pending.
Document No. 3152117
090615
Printed in the USA

TABLE OF CONTENTS
Page I © 1998-2009 DH Instruments, a Fluke Company
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TABLE OF CONTENTS...............................................................I
TABLES..................................................................................V
FIGURES................................................................................VI
ABOUT THIS MANUAL ............................................................VII
1. INTRODUCTION .................................................................1
1.1 PRODUCT OVERVIEW............................................................................................................................1
1.2 SPECIFICATIONS....................................................................................................................................2
1.2.1 GENERAL SPECIFICATIONS.......................................................................................................................2
1.2.1.1 EMBEDDED FEATURES...........................................................................................................................3
1.2.1.2 AMBIENT AND INSTRUMENT CONDITION MEASUREMENTS..............................................................4
1.2.2 PISTON-CYLINDER MODULES....................................................................................................................5
1.2.2.1 PC-7100/7600............................................................................................................................................5
1.2.2.2 PC-7200.....................................................................................................................................................6
1.2.2.3 PC-7300.....................................................................................................................................................7
1.2.3 MASS SETS...................................................................................................................................................8
1.2.4 PRESSURE MEASUREMENTS ....................................................................................................................8
1.2.4.1 PC-7100/7600............................................................................................................................................8
1.2.4.2 PC-7200.....................................................................................................................................................9
1.2.4.3 PC-7300...................................................................................................................................................10
1.3 TERMINAL AND PLATFORM FRONT AND REAR PANELS ...............................................................11
1.3.1 TERMINAL FRONT AND REAR PANELS ..................................................................................................11
1.3.1.1 PG TERMINAL FRONT PANEL...............................................................................................................11
1.3.1.2 PG TERMINAL REAR PANEL.................................................................................................................12
1.3.2 PLATFORM REAR PANELS.......................................................................................................................12
2. INSTALLATION ................................................................ 13
2.1 UNPACKING AND INSPECTION...........................................................................................................13
2.1.1 REMOVING FROM PACKAGING................................................................................................................13
2.1.1.1 PLATFORM..............................................................................................................................................13
2.1.1.2 MASS SET...............................................................................................................................................13
2.1.1.3 PISTON-CYLINDER MODULE(S) ...........................................................................................................14
2.1.1.4 AUTOMATED MASS HANDLER .............................................................................................................14
2.1.2 INSPECTING CONTENTS...........................................................................................................................14
2.1.2.1 PLATFORM..............................................................................................................................................14
2.1.2.2 MASS SET...............................................................................................................................................19
2.1.2.3 PISTON-CYLINDER MODULE(S) ...........................................................................................................21
2.2 SITE REQUIREMENTS..........................................................................................................................22
2.3 SETUP....................................................................................................................................................23
2.3.1 PREPARING FOR OPERATION .................................................................................................................23
2.3.1.1 SETTING UP THE PLATFORM...............................................................................................................23
2.3.1.2 SYSTEM PRESSURE INTERCONNECTIONS .......................................................................................24
2.3.1.3 SETTING UP A MASS SET.....................................................................................................................24
2.3.2 INSTALLING A PISTON-CYLINDER MODULE INTO THE PLATFORM....................................................25
2.3.3 SWITCHING A PG7202 BETWEEN GAS OPERATION AND OIL OPERATION .......................................27
2.4 POWER UP AND VERIFICATION .........................................................................................................28
2.4.1 POWER UP..................................................................................................................................................28
2.4.2 CHECK THAT ON-BOARD PISTON-CYLINDER MODULE AND MASS SET INFORMATION ARE
CORRECT....................................................................................................................................................29
2.4.3 SET LOCAL GRAVITY VALUE ...................................................................................................................29
2.4.4 SETUP PRESSURE EQUATION VARIABLE INPUT SOURCES.....................................................29

PG7000™ OPERATION AND MAINTENANCE MANUAL
© 1998-2009 DH Instruments, a Fluke Company Page II
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......................................................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
3.1.1 GAS OPERATED, LIQUID LUBRICATED PISTON-CYLINDER OPERATING PRINCIPLE
(PG7202) ....................................................................................................................................................36
3.2 KEYPAD LAYOUT AND PROTOCOL ...................................................................................................37
3.3 SOUNDS ................................................................................................................................................38
3.4 PRESSURE READY/NOT READY INDICATION...................................................................................38
3.4.1 PISTON POSITION READY/NOT READY ..................................................................................................39
3.4.2 PISTON ROTATION READY/NOT READY.................................................................................................39
3.4.3 VACUUM REFERENCE READY/NOT READY (PG7601 ONLY) .....................................................40
3.5 PISTON POSITION................................................................................................................................41
3.6 MASS LOADING PROTOCOL...............................................................................................................42
3.7 MAIN RUN SCREEN..............................................................................................................................45
3.8 GENERAL FUNCTION/MENU FLOW CHART ......................................................................................46
3.9 DIRECT FUNCTION KEYS....................................................................................................................47
3.9.1 DIRECT FUNCTION KEYS SUMMARY......................................................................................................47
3.9.2 [P-C].............................................................................................................................................................48
3.9.3 [UNIT]...........................................................................................................................................................49
3.9.3.1 CUSTOMIZING PRESSURE UNITS AVAILABLE UNDER THE UNIT FUNCTION................................50
3.9.4 [MODE] ........................................................................................................................................................52
3.9.4.1 DIFFERENTIAL MEASUREMENT MODE (PG7601 ONLY)........................................................53
3.9.4.2 HIGH LINE DIFFERENTIAL MEASUREMENT MODE (PG7102, PG7302 AND PG7202 ONLY)...........60
3.9.5 [SYSTEM] ....................................................................................................................................................72
3.9.5.1 FIRST SYSTEM RUN SCREEN ..............................................................................................................73
3.9.5.2 SECOND SYSTEM RUN SCREEN .........................................................................................................73
3.9.6 [AMBIENT]...................................................................................................................................................74
3.9.7 [HEAD].........................................................................................................................................................75
3.9.8 [ROTATE].....................................................................................................................................................77
3.9.8.1 <2PRE-DECEL>.......................................................................................................................................79
3.9.9 [GEN] (OPTIONAL)......................................................................................................................................79
3.9.9.1 <2TARGET>.............................................................................................................................................81
3.9.9.2 <3RAISE> ................................................................................................................................................82
3.9.9.3 <4UL>.......................................................................................................................................................82
3.9.9.4 <5TOL>....................................................................................................................................................82
3.9.9.5 <6REFLOAT>...........................................................................................................................................83
3.9.9.6 <7VOL>....................................................................................................................................................83
3.9.10 [RES]............................................................................................................................................................84
3.9.11 [ENTER/SET P] FROM RUN SCREEN.......................................................................................................85
3.9.11.1 [ENTER/SET P] IN PRESSURE TO MASS MODE .................................................................................86
3.9.11.2 [ENTER/SET P] IN MASS TO PRESSURE MODE .................................................................................88
3.9.11.3 COMMANDS FOR ZERO PRESSURE, ENDING A TEST .....................................................89
3.9.12 [P OR M] ......................................................................................................................................................89
3.9.13 [] AND [ ], [←]....................................................................................................................................90
3.10 [SETUP] MENU......................................................................................................................................91
3.10.1 <1SELECT>.................................................................................................................................................93
3.10.2 <2VIEW>......................................................................................................................................................93
3.10.3 <3EDIT>.......................................................................................................................................................94
3.11 [SPECIAL] MENU ..................................................................................................................................96
3.11.1 <1PC/MS>....................................................................................................................................................97
3.11.1.1 CREATE PISTON-CYLINDER MODULE.................................................................................................99
3.11.1.2 EDIT PISTON-CYLINDER MODULE.....................................................................................................101
3.11.1.3 VIEW PISTON-CYLINDER MODULE....................................................................................................102
3.11.1.4 DELETE PISTON-CYLINDER MODULE...............................................................................................102
3.11.1.5 SELECT THE ACTIVE PISTON-CYLINDER MODULE.........................................................................102
3.11.1.6 ADD MASS SET.....................................................................................................................................103

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Page III © 1998-2009 DH Instruments, a Fluke Company
3.11.1.7 EDIT MASS SET....................................................................................................................................107
3.11.1.8 VIEW MASS SET...................................................................................................................................107
3.11.1.9 DELETE MASS SET..............................................................................................................................108
3.11.1.10 SELECT MASS SET..............................................................................................................................108
3.11.1.11 ADD MASS LOADING BELL..................................................................................................................109
3.11.1.12 EDIT MASS LOADING BELL.................................................................................................................110
3.11.1.13 VIEW MASS LOADING BELL................................................................................................................110
3.11.1.14 DELETE MASS LOADING BELL...........................................................................................................110
3.11.1.15 SELECT MASS LOADING BELL...........................................................................................................111
3.11.2 <2PRESU>.................................................................................................................................................111
3.11.3 <3HEAD> ...................................................................................................................................................111
3.11.3.1 <3HEAD>, <1FLUID>.............................................................................................................................112
3.11.3.2 <3HEAD>, <2UNIT>...............................................................................................................................112
3.11.3.3 <3HEAD>, <3ATM> ...............................................................................................................................113
3.11.3.4 <3HEAD>, <4PISTON>..........................................................................................................................113
3.11.4 <4PREFS> .................................................................................................................................................114
3.11.4.1 <4PREFS>, <1SCRSVR>......................................................................................................................114
3.11.4.2 <4PREFS>, <2SOUND>........................................................................................................................114
3.11.4.3 <4PREFS>, <3TIME> ............................................................................................................................115
3.11.4.4 <4PREFS>, <4ID> .................................................................................................................................115
3.11.4.5 <4PREFS>, <5LEVEL>..........................................................................................................................116
3.11.5 <5REMOTE>..............................................................................................................................................118
3.11.5.1 COM1, COM2 AND COM3 (RS232)......................................................................................................119
3.11.5.2 IEEE-488................................................................................................................................................119
3.11.5.3 RS232 SELF TEST................................................................................................................................120
3.11.5.4 EXTERNAL BAROMETER (RPM) COMMUNICATIONS (COM2).........................................................120
3.11.5.5 EXTERNAL VACUUM GAUGE COMMUNICATIONS (COM2) (PG7601 ONLY)..................................122
3.11.6 <6GL> ........................................................................................................................................................124
3.11.7 <7CAL>......................................................................................................................................................125
3.11.8 <8AMH> .....................................................................................................................................................125
3.11.8.1 <2CONTROL>, <1UP/DOWN>..............................................................................................................126
3.11.8.2 <2CONTROL>, <2DISCREET>.............................................................................................................126
3.11.8.3 <2CONTROL>, <3LOADALL>...............................................................................................................127
3.11.8.4 <2CONTROL>, <4UNLOADALL>..........................................................................................................127
3.11.9 <9RESET> .................................................................................................................................................127
3.11.9.1 <9RESET>, <1SETS> ...........................................................................................................................128
3.11.9.2 <9RESET>, <2UNITS>..........................................................................................................................128
3.11.9.3 <9RESET>, <3COM>.............................................................................................................................129
3.11.9.4 <9RESET>, <4CAL>..............................................................................................................................129
3.11.9.5 <9RESET>, <5SETUPS> ......................................................................................................................130
3.11.9.6 <9RESET>, <6ALL> ..............................................................................................................................130
4. REMOTE OPERATION ......................................................131
4.1 OVERVIEW ..........................................................................................................................................131
4.2 INTERFACING .....................................................................................................................................131
4.2.1 RS232 INTERFACE...................................................................................................................................131
4.2.1.1 COM1.....................................................................................................................................................132
4.2.1.2 COM2 AND COM3.................................................................................................................................132
4.2.2 IEEE-488 (GPIB)........................................................................................................................................133
4.3 COMMANDS........................................................................................................................................133
4.3.1 COMMAND SYNTAX.................................................................................................................................133
4.3.2 COMMAND SUMMARY.............................................................................................................................134
4.3.3 ERROR MESSAGES .................................................................................................................................136
4.3.3.1 AMH ERRORS.......................................................................................................................................137
4.3.4 COMMAND DESCRIPTIONS.....................................................................................................................137
4.3.4.1 IEEE STD. 488.2 COMMON AND STATUS COMMANDS.....................................................137
4.3.4.2 PG7000 COMMANDS............................................................................................................................139
4.4 STATUS SYSTEM................................................................................................................................166
4.4.1 STATUS REPORTING SYSTEM...............................................................................................................166
4.4.1.1 STATUS BYTE REGISTER ...................................................................................................................166
4.4.1.2 STANDARD EVENT REGISTER...........................................................................................................167
4.5 HIGH LINE DIFFERENTIAL MODE PROGRAMMING EXAMPLES....................................................168
4.5.1 RECOMMENDED SEQUENCE FOR A HOST PROGRAM TO REMOTELY SET A NEW HIGH LINE
PRESSURE AND ENABLE HIGH LINE DIFFERENTIAL MODE..............................................................168
4.5.2 RECOMMENDED SEQUENCE FOR A HOST PROGRAM TO REMOTELY ENABLE HIGH LINE
DIFFERENTIAL MODE USING THE LAST LINE PRESSURE SETTING.................................................171

PG7000™ OPERATION AND MAINTENANCE MANUAL
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5. MAINTENANCE, ADJUSTMENTS AND CALIBRATION...........173
5.1 INTRODUCTION..................................................................................................................................173
5.2 PLATFORM..........................................................................................................................................174
5.2.1 CALIBRATION/ADJUSTMENT OF ON-BOARD MEASUREMENT FUNCTIONS....................................174
5.2.1.1 PRINCIPLES..........................................................................................................................................174
5.2.1.2 BAROMETRIC PRESSURE SENSOR ..................................................................................................174
5.2.1.3 AMBIENT TEMPERATURE SENSOR...................................................................................................175
5.2.1.4 RELATIVE HUMIDITY SENSOR ...........................................................................................................176
5.2.1.5 PISTON-CYLINDER MODULE TEMPERATURE SENSOR.....................................................176
5.2.1.6 REFERENCE VACUUM GAUGE (PG7601 ONLY)...............................................................................178
5.2.2 PISTON POSITION DETECTION ADJUSTMENT.....................................................................................179
5.2.3 EMPTYING OIL RUN-OFF TRAY (PG7202 AND PG7302 ONLY).................................................180
5.2.4 PURGE MOUNTING POST LIQUID RUN OFF (PG7202 ONLY)..............................................180
5.2.5 DRIVE BELT REPLACEMENT..................................................................................................................181
5.3 PISTON-CYLINDER MODULES..........................................................................................................182
5.3.1 DISASSEMBLY, CLEANING AND MAINTENANCE.................................................................................182
5.3.2 DISASSEMBLY AND REASSEMBLY.......................................................................................................183
5.3.2.1 DISASSEMBLY AND REASSEMBLY OF GAS OPERATED, GAS LUBRICATED
PISTON-CYLINDER MODULES (PC-7100/7600).......................................................................183
5.3.2.2 DISASSEMBLY AND REASSEMBLY OF GAS OPERATED, LIQUID LUBRICATED
PISTON-CYLINDER MODULES (PC-7200)..........................................................................................187
5.3.2.3 DISASSEMBLY AND REASSEMBLY OF OIL OPERATED, OIL LUBRICATED
PISTON-CYLINDER MODULES (PC-7300)..........................................................................................189
5.3.3 FILLING OR EMPTYING GAS OPERATED, LIQUID LUBRICATED PISTON-CYLINDER MODULE
RESERVOIR WITH LIQUID.......................................................................................................................191
5.3.4 CLEANING PISTON-CYLINDERS.............................................................................................................192
5.3.5 LUBRICATING PISTON-CYLINDER MODULES......................................................................................194
5.3.6 RECALIBRATION......................................................................................................................................198
5.3.6.1 UPDATING PISTON-CYLINDER MODULE FILES................................................................................198
5.4 MASS SETS.........................................................................................................................................198
5.4.1 CLEANING.................................................................................................................................................198
5.4.2 RECALIBRATION......................................................................................................................................198
5.4.2.1 UPDATING MASS SET FILES...............................................................................................................198
5.5 RELOADING EMBEDDED SOFTWARE INTO PG7000 FLASH MEMORY........................................199
5.6 DISASSEMBLY AND REASSEMBLY OF PG7000 .............................................................................199
5.6.1 PLATFORM................................................................................................................................................199
5.6.2 TERMINAL.................................................................................................................................................199
5.6.3 AMH AUTOMATED MASS HANDLER REMOVAL...................................................................................199
6. TROUBLESHOOTING .......................................................201
6.1 OVERVIEW ..........................................................................................................................................201
7. APPENDIX ......................................................................205
7.1 CONVERSION OF NUMERICAL VALUES..........................................................................................205
7.1.1 PRESSURE................................................................................................................................................205
7.2 DEFINED PRESSURE CALCULATIONS ............................................................................................205
7.2.1 PG7102, PG7202 AND PG7302................................................................................................................207
7.2.2 PG7601 ......................................................................................................................................................208
7.2.3 FLUID HEADS ...........................................................................................................................................209
7.2.3.1 FLUID HEAD COMPONENTS...............................................................................................................209
7.2.3.2 OVERALL FLUID HEAD CORRECTION...............................................................................................210
7.3 GLOSSARY..........................................................................................................................................211
7.4 WARRANTY STATEMENT ..................................................................................................................213

TABLES AND FIGURES
Page V © 1998-2009 DH Instruments, a Fluke Company
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Table 1. PG7102 Parts List........................................................................................................................15
Table 2. PG7202 Parts List........................................................................................................................16
Table 3. PG7302 Parts List........................................................................................................................17
Table 4. PG7601 Parts List........................................................................................................................18
Table 5. Manual Mass Set Parts List (excluding 80 and 100 kg) ..............................................................19
Table 6. Manual Mass Set Parts List (80 and 100 kg)...............................................................................19
Table 7. AMH-38 Mass Set Parts List........................................................................................................19
Table 8. AMH-100 Mass Set Parts List......................................................................................................19
Table 9. Mass Set Compositions...............................................................................................................20
Table 10. Mass Set Compatibility ..............................................................................................................20
Table 11. PC-7100/7600 Piston-Cylinder Modules Parts List ...................................................................21
Table 12. PC-7200 Piston-Cylinder Modules Parts List ............................................................................21
Table 13. PC-7300 Piston-Cylinder Modules Parts List ...........................................................................22
Table 14. Summary of PG7000 Direct Function Key Operations..............................................................47
Table 15. Pressure Units of Measure Available.........................................................................................51
Table 16. Valve Settings for Setting Differential Mode Static Pressure.....................................................56
Table 17. Valve Settings to Apply PG7000 Pressure to the RPM for Differential Mode Offsetting...........57
Table 18. Valve Settings for Operating in Differential Mode......................................................................59
Table 19. SETUP File Choices, Factory Preferred Choice and Normal Value..........................................92
Table 20. Security Levels - Functions NOT Executed Per Function/Level..............................................117
Table 21. COM1, COM2 and COM3 Available Settings..........................................................................119
Table 22. COM1 DB-9F Pin Designation.................................................................................................132
Table 23. COM2 and COM3 DB-9M Pin Designation .............................................................................132
Table 24. Command Summary................................................................................................................134
Table 25. Error Messages........................................................................................................................136
Table 26. Status Byte Register ................................................................................................................166
Table 27. Standard Event Register..........................................................................................................167
Table 28. Mounting Post Wire Colors, Description and Location............................................................178
Table 29. PG7000 Troubleshooting Checklist.........................................................................................201
Table 30. Pressure Unit of Measure Conversions...................................................................................205
Table 31. PG7000 Defined Pressure Calculation Variables....................................................................206
Table 32. DHI Authorized Service Providers ...........................................................................................213

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

ABOUT THIS MANUAL
Page VII © 1998-2009 DH Instruments, a Fluke Company
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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>)

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1. INTRODUCTION
Page 1 © 1998-2009 DH Instruments, a Fluke Company
1
1. . I IN
NT TR RO OD DU UC CT TI IO ON N
1.1 PRODUCT OVERVIEW
PG7000 Piston Gauges are reference level pressure standards that operate on the piston
gauge principle. Pressure is defined by balancing it against the force exerted by a known mass
accelerated by gravity on the effective area of a piston-cylinder.
A PG7000 piston gauge consists of the PG7000 Platform, one or several piston-cylinder modules, a mass
set. An automated mass handling system is available. A PG7000 system normally also includes the
means to generate and adjust pressures and to interconnect the system components and a device being
calibrated or tested. The pressure generation component can be manual or automated. COMPASS®for
Pressure software may also be included to assist in executing test sequences, acquiring test data and
producing test reports.
There are four PG7000 Platforms: PG7102, PG7202, PG7302 and PG7601. These have a common
PG7000 presentation and features. They are distinguished by their normal operating medium (oil and/or
gas) and the capability to define pressures relative to a vacuum reference.
•PG7102 - Gas operated with gas lubricated piston-cylinder modules (PC-7100/7600 modules)
- Maximum pressure is 11 MPa (1 600 psi)
- Does not support definition of pressure against a vacuum reference
•PG7202 - Gas operated, liquid lubricated piston-cylinder modules (PC-7200 modules)
- Oil operated piston-cylinder modules (PC-7300 modules)
-Maximum pressure is 110 MPa (16 000 psi) when operated with a PC-7200 module
-Maximum pressure is 200 MPa (30 000 psi) when operated with a PC-7300 module
- Does not support definition of pressure against a vacuum reference
•PG7302 - Oil operated (PC-7300 modules)
- Maximum pressure is 500 MPa (72 500 psi)
•PG7601 - Gas operated, gas lubricated piston-cylinder modules (PC-7100/7600 modules)
- Maximum pressure is 7 MPa (1 000 psi)
- Supports definition of pressure against a vacuum reference
PG7000 platforms, piston-cylinder modules, mass sets and mass handling systems are designed to
maximize metrological performance and ease of operation. They include many features that enhance the
fundamental precision and stability of pressure measurements as well as simplifying use and reducing
operator influence on the measurements. Extensive monitoring and controlling capability and advanced
local and remote user interfaces are integrated into PG7000 Platforms.
Operator interaction with PG7000 and its extensive capabilities and peripherals is accomplished through
a single display and keypad on the PG Terminal or from a computer via a single standard RS232 or
IEEE-488 interface.

PG7000™ OPERATION AND MAINTENANCE MANUAL
© 1998-2009 DH Instruments, a Fluke Company Page 2
1.2 SPECIFICATIONS
1.2.1 GENERAL SPECIFICATIONS
Power Requirements 85 to 264 VAC, 50/60 Hz, 22 VA max. consumption.
Operating Temperature Range 15 to 35 °C
Operating Humidity Range 5 to 95% R.H., non-condensing
Weight
Instrument platform with no mass loaded.
PG7102
PG7202
PG7302
PG7601
PG Terminal
13 kg (29 lb)
13 kg (29 lb)
13 kg (29 lb)
17 kg (37 lb)
1.4 kg (3 lb)
Dimensions Instrument Platform
PG Terminal
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.)
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
PG Terminal
Motorola 68302
Hitachi 64180
Communication Ports
RS232
IEEE-488
COM1: Host computer
COM2: External barometer or vacuum gauge (PG7601) and pass
through communications
COM3: Automated pressure generator/controller
Host computer
Overall Pressure Ranges
Actual range depends on piston-cylinder
and mass set selection
PG7102 Gauge: 5 kPa to 11 MPa (0.7 to 1 600 psi)
Absolute: 105 kPa to 11 MPa (15 to 1 600 psi)
Differential: DP + static pressure < 11 MPa (1 600 psi)
PG7202 Gauge (gas): 100 kPa to 110 MPa (15 to 16 000 psi)
Absolute (gas):200 kPa to 110 MPa (30 to 16 000 psi)
Gauge (oil): (PG7302 module): 1 to 200 MPa (150 to 30 000 psi)
Absolute (oil): (PG7302 module) 1.1 to 200 MPa (165 to 30 000 psi)
Differential: DP + static pressure < 110 MPa (16 000 psi)
PC-7200 can be operated in oil up to 200 MPa (30 000 psi)
when used with PC-7300 oil operated piston-cylinders.
PG7302 Gauge: 20 kPa to 500 MPa (3 to 75 000 psi)
Absolute: 120 kPa to 500 MPa (20 to 75 000 psi)
PG7601 Gauge: 4 kPa to 7 MPa (0.6 to 1 000 psi)
Absolute: 7 kPa to 7 MPa (0.7 to 1 000 psi)
Differential: - 90 to 350 kPa (-13 to 50 psi) at
15 to 200 kPaa (2 to 30 psia) static pressure
Operating Media PG7102
PG7202
PG7302
PG7601
Gas: air, helium, nitrogen
Gas: any non-corrosive
Oil: Di2-EthylHexyl Sebacate (synthetic oil)
Oil: Di2-EthylHexyl Sebacate (synthetic oil)
Gas: air, helium, nitrogen

1. INTRODUCTION
Page 3 © 1998-2009 DH Instruments, a Fluke Company
Maximum Mass Load PG7102
PG7202
PG7302
PG7601
100 kg, while not exceeding 11 MPa (1 600 psi)
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
100 kg
38 kg
Pressure Connections PG7102
PG7202
PG7302
PG7601
Test port: DH200
Test port: DH500
Drain port: DH500
Test port: DH500
Test port: DH200
Bell Jar Vent Port: DH200
Vacuum Reference
Pump Down Port: KF25 (KF40 available on optional AMH
automated mass handler)
External Vacuum Port: Optional KF25 on bell jar (KF40 available
on optional AMH automated mass handler)
DH200 and DH500 are gland and collar type fittings for
1/4 in. (6.35 mm) coned and left hand threaded tubes.
DH200 is equivalent to AE SF250C, HIP LF4, etc.
DH500 is equivalent to AE F250C, HIP HF4, etc.
CE Conformance Available, must be specified.
1.2.1.1 EMBEDDED FEATURES
•Local control with 2 x 20 vacuum fluorescent display and 4 x 4 function
driven keypad.
•Real time (1 second update rate) display and measurement of ambient
(pressure, temperature, humidity) and instrument (piston-cylinder
temperature, piston position, piston drop rate, piston rotation rate, piston
rotation decay rate, reference vacuum) conditions.
•Real time (1 second update rate) mass-to-pressure and pressure-to-mass
calculations taking into consideration all environmental and operational
variables.
•Full gas and liquid fluid head corrections including DUT head correction and
piston position head correction.
•Adjustable mass loading resolution (0.01 g to 0.1 kg).
•Audible prompts of instrument status (piston movement, Ready/Not Ready indication)
with override capability.
•Integrated automated mass handling option (AMH-38 or AMH-100).
•Interfacing and automatic exploitation of external barometer via RS232.
•Interfacing and automatic exploitation of any external vacuum gauge via
RS232 (PG7601 only).
•Automated differential mode to define low differential pressures at various
static pressures between vacuum and two atmospheres.
•Automated high line differential mode to define differential pressure at high
line pressure.

PG7000™ OPERATION AND MAINTENANCE MANUAL
© 1998-2009 DH Instruments, a Fluke Company Page 4
•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.
•Integrated automated pressure control with standard DHI pressure
controllers.
•Full RS232 and IEEE-488 communications with multi-level commands to set
and read all instrument functions.
1.2.1.2 AMBIENT AND INSTRUMENT CONDITION
MEASUREMENTS
Temperature Range
Resolution
Measurement Uncertainty
Ambient Piston Cylinder Module
0 to 40o C 0 to 40 oC
0.1 0.01
±1 ±0.1
Barometric Pressure
with Internal Sensor
Range
Resolution
Measurement Uncertainty
70 to 110 kPa
10 Pa
±140 Pa
Barometric pressure can also be read automatically with any
RS232 device such as a DHI RPM.
Relative Humidity Range
Resolution
Measurement Uncertainty
5 to 95 % RH
1 % RH
±10 % RH
Piston Position Range
Resolution
Measurement Uncertainty
±4.5 mm
0.1 mm
±0.2 mm
Piston Rotation
(Rate and deceleration)
Range
Resolution
2 to 99 rpm
1 rpm
Vacuum
(PG7601 only) Range
Resolution
Measurement Uncertainty
0 to 20 Pa
0.01 Pa
±0.1 Pa or 10 % of reading, whichever is greater

1. INTRODUCTION
Page 5 © 1998-2009 DH Instruments, a Fluke Company
1.2.2 PISTON-CYLINDER MODULES
All piston-cylinders are integrated modules including mounting hardware delivered in individual
shipping and storage bullet cases.
1.2.2.1 PC-7100/7600
Gas operated, gas lubricated piston-cylinder characteristics. Used in PG7102
and PG7601 platforms.
PC-7100/7600-10, TC
PC-7100/7600-10-L Operation
Piston Material
Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Gas operated, gas lubricated
Tungsten carbide
Tungsten carbide
35 mm
1 000 mm2
Simple free deformation
PC-7100/7600-20 Operation
Piston Material
Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Gas operated, gas lubricated
Tungsten carbide
Tungsten carbide
25 mm
500 mm2
Simple free deformation
PC-7100/7600-50 Operation
Piston Material
Cylinder Material
Nominal Diameter
Nominal Area
Mounting system
Gas operated, gas lubricated
Tungsten carbide
Tungsten carbide
16 mm
200 mm2
Negative free deformation
PC-7100/7600-100 Operation
Piston Material
Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Gas operated, gas lubricated
Tungsten carbide
Tungsten carbide
11 mm
98 mm2
Negative free deformation
PC-7100/7600-200 Operation
Piston Material
Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Gas operated, gas lubricated
Tungsten carbide
Tungsten carbide
8 mm
50 mm2
Negative free deformation

PG7000™ OPERATION AND MAINTENANCE MANUAL
© 1998-2009 DH Instruments, a Fluke Company Page 6
1.2.2.2 PC-7200
Gas operated, liquid lubricated piston-cylinder module characteristics. Used in
PG7202 platform.
Though not recommended for day-to-day operation, PC-7200 modules can
also be filled completely with oil and operated with oil as the test medium
(see Section 2.3.3).
PC-7200-100 Operation
Lubricating Liquid
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Gas operated, liquid lubricated
Synturion 6 (Krytox®optional)
Tungsten carbide
11.2 mm
98.1 mm2
Negative free deformation
PC-7200-200 Operation
Lubricating Liquid
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Gas operated, liquid lubricated
Synturion 6 (Krytox®optional)
Tungsten carbide
7.9 mm
49.0 mm2
Negative free deformation
PC-7200-500 Operation
Lubricating Liquid
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Gas operated, liquid lubricated
Di-2-ethylhexyl Sebacate (Krytox®optional)
Tungsten carbide
5.0 mm
19.6 mm2
Negative free deformation
PC-7200-1 Operation
Lubricating Liquid
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Gas operated, liquid lubricated
Di-2-ethylhexyl Sebacate (Krytox®optional)
Tungsten carbide
3.5 mm
9.8 mm2
Negative free deformation
PC-7200-2 Operation
Lubricating Liquid
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Gas operated, liquid lubricated
Di-2-ethylhexyl Sebacate (Krytox®optional)
Tungsten carbide
2.5 mm
4.9 mm2
Negative free deformation

1. INTRODUCTION
Page 7 © 1998-2009 DH Instruments, a Fluke Company
1.2.2.3 PC-7300
Oil operated, oil lubricated piston-cylinder module characteristics. Used in
PG7302 and PG7202 platforms (1 MPa/kg and higher only in PG7202).
PC-7300 modules PC-7300-1, -2 and -5 may also be used in a PG7202
platform.
PC-7300-100 Operation
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Oil operated, oil lubricated
Tungsten carbide
11.2 mm
98.1 mm2
Simple free deformation
PC-7300-200 Operation
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Oil operated, oil lubricated
Tungsten carbide
7.9 mm
49.0 mm2
Simple free deformation
PC-7300-500 Operation
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Oil operated, oil lubricated
Tungsten carbide
5.0 mm
19.6 mm2
Simple free deformation
PC-7300-1 Operation
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Oil operated, oil lubricated
Tungsten carbide
3.5 mm
9.8 mm2
Simple free deformation
PC-7300-2 Operation
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Oil operated, oil lubricated
Tungsten carbide
2.5 mm
4.9 mm2
Simple free deformation
PC-7300-5 Operation
Piston and Cylinder Material
Nominal Diameter
Nominal Area
Mounting System
Oil operated, oil lubricated
Tungsten carbide
1.6 mm
2.0 mm2
Simple free deformation

PG7000™ OPERATION AND MAINTENANCE MANUAL
© 1998-2009 DH Instruments, a Fluke Company Page 8
1.2.3 MASS SETS
All masses are delivered in molded, reusable, transit cases with custom inserts.
Masses > 50g Material
Finish
Adjustment Tolerance
Uncertainty of Measured Values
304L non-magnetic stainless steel
Electropolished
±20 ppm of nominal value (manual mass sets, AMH
automated mass handler mass sets do not have fixed
adjustment tolerances)
±5 ppm or 1 mg, whichever is greater
Masses < 50g ±1 mg
Masses designated “tare” are delivered without reported measured values and are intended
only for use on the “tare” PG7000 in high line differential pressure measurement mode.
1.2.4 PRESSURE MEASUREMENTS
1.2.4.1 PC-7100/7600
For uncertainty in piston-cylinder effective area and typical measurement
uncertainty in pressure defined by the piston gauge, see the piston-cylinder
calibration report and current revision of DHI Technical Note 7920TN01.
PC-7100/7600-10
PC-7100/7600-10-L Sensitivity1
Reproducibility2
Typical Drop Rate (35 kg)
0.02 Pa + 0.5 ppm
±2 ppm
0.2 mm/min
PC-7100/7600-20 Sensitivity1
Reproducibility2
Typical Drop Rate (35 kg)
0.04 Pa + 0.5 ppm
±2 ppm
0.3 mm/min
PC-7100/7600-50 Sensitivity1
Reproducibility2
Typical Drop Rate (35 kg)
0.1 Pa + 0.5 ppm
±2 ppm
0.5 mm/min
PC-7100/7600-100 Sensitivity1
Reproducibility2
Typical Drop Rate (35 kg)
0.2 Pa + 0.5 ppm
±3 ppm
0.7 mm/min
PC-7100/7600-200 Sensitivity1
Reproducibility2
Typical Drop Rate (35 kg)
0.4 Pa + 0.5 ppm
±3 ppm
1.0 mm/min
1 Sensitivity: The smallest variation in input detectable in output.
2 Reproducibility: Combined long term stability of piston-cylinder effective area and masses.

1. INTRODUCTION
Page 9 © 1998-2009 DH Instruments, a Fluke Company
Piston-cylinder modules designated “tare” are delivered without reported
values and are intended only for use on the “tare” PG7000 in high line differential
pressure measurement mode.
1.2.4.2 PC-7200
For uncertainty in piston-cylinder effective area and typical measurement
uncertainty in pressure defined by the piston gauge, see the piston-cylinder
calibration report and current revision of DHI Technical Note 7920TN01.
PC-7200-100 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
2 Pa + 1 ppm
±5 ppm
0.10 mm/min
PC-7200-200 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
4 Pa + 1 ppm
±5 ppm
0.15 mm/min
PC-7200-500 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
10 Pa + 1 ppm
±5 ppm
0.20 mm/min
PC-7200-1 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
20 Pa + 1 ppm
±5 ppm
0.25 mm/min
PC-7200-2 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
40 Pa + 1 ppm
±5 ppm
0.50 mm/min
1 Sensitivity: The smallest variation in input detectable in output.
2 Reproducibility: Combined long term stability of piston-cylinder effective area and masses.

PG7000™ OPERATION AND MAINTENANCE MANUAL
© 1998-2009 DH Instruments, a Fluke Company Page 10
1.2.4.3 PC-7300
For uncertainty in piston-cylinder effective area and typical measurement
uncertainty in pressure defined by the piston gauge, see the piston-cylinder
calibration report and current revision of DHI Technical Note 7920TN01.
PC-7300-100 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
2 Pa + 1 ppm
±5 ppm
0.02 mm/min
PC-7300-200 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
4 Pa + 1 ppm
±5 ppm
0.04 mm/min
PC-7300-500 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
10 Pa + 1 ppm
±5 ppm
0.10 mm/min
PC-7300-1 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
20 Pa + 1 ppm
±5 ppm
0.20 mm/min
PC-7300-2 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
40 Pa + 1 ppm
±5 ppm
0.40 mm/min
PC-7300-5 Sensitivity1
Reproducibility2
Typical Drop Rate (50 kg)
100 Pa + 1 ppm
±5 ppm
1.00 mm/min
1 Sensitivity: The smallest variation in input detectable in output.
2 Reproducibility: Combined long term stability of piston-cylinder effective area and masses.