Fluke PG9000 Series User manual

© 2011 Fluke Calibration
PG9000™ Piston Gauges
PG9602™
Operation and Maintenance Manual
Via Acquanera, 29 22100 Como
tel. 031.526.566 (r.a.) fax 031.507.984
[e-mail] www.calpower.it

© 2011 Fluke Calibration Page ii
Warning
To prevent possible electrical shock, fire, or personal injury:
•Read all safety Information before you use the product.
•Use the product only as specified, or the protection supplied by the
product can be compromised.
•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.
•Use only the main power cord and connector approved for the voltage and
plug configuration in your country and rated for the product.
•Make sure the ground conductor in the main power cord is connected to a
protective earth ground. Disruption of the protective earth could put
voltage on the chassis that could cause death.
•Replace the main power cord if the insulation is damaged or if the
insulation shows signs of wear.
•Do not put the product where access to the main power cord is blocked.
•Do not use and disable the product if it is damaged.
•Use this product indoors only.
©1998 - 2011 Fluke Calibration 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 Fluke Calibration, 4765
East Beautiful Lane, Phoenix, Arizona 85044-5318 USA.
Fluke Calibration makes sincere efforts to ensure the accuracy and quality of its published materials; however, no warranty,
expressed or implied, is provided. Fluke Calibration 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 Fluke Calibration 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.
Fluke Calibration, DH, DHI, PG9000, PG9602, CalTool and COMPASS are trademarks, registered and otherwise, of Fluke
Corporation.
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. 3995967
110818
Printed in the USA

Page III © 2011 Fluke Calibration
Table of Contents
Table of Contents ................................................................. III
Tables ................................................................................ VII
Figures.............................................................................. VIII
About This Manual................................................................ IX
1. Introduction .....................................................................1
1.1 Product Overview...................................................................................................................................1
1.2 Specifications.........................................................................................................................................2
1.2.1 General Specifications............................................................................................................................. 2
1.2.1.1 AMH Automated Mass Handler (Optional).............................................................................................. 3
1.2.1.2Embedded Features............................................................................................................................... 3
1.2.1.3 Ambient and Instrument Condition Measurements ................................................................................. 4
1.2.2 Piston-Cylinder Modules ......................................................................................................................... 5
1.2.3 Mass Sets ................................................................................................................................................. 6
1.2.4 Pressure Measurements.......................................................................................................................... 6
1.3 Front and Rear Panels ...........................................................................................................................7
1.3.1 PG Terminal Front and Rear Panels........................................................................................................ 7
1.3.2 Remote Electronics Module (REM) Rear Panel...................................................................................... 8
1.3.3 Base Rear Panel....................................................................................................................................... 8
2. Installation.......................................................................9
2.1 Unpacking and Inspection.....................................................................................................................9
2.1.1 Removing From Packaging ..................................................................................................................... 9
2.1.1.1 Platform ................................................................................................................................................. 9
2.1.1.2 Piston-Cylinder Assemblies.................................................................................................................. 10
2.1.1.3 Vacuum Reference Hardware (optional)............................................................................................... 10
2.1.1.4 AMH-100, Automated Mass Handler (optional)..................................................................................... 10
2.1.1.5 AMH Mass Set (optional)...................................................................................................................... 10
2.1.1.6 Manual Mass Set ................................................................................................................................. 10
2.1.2 Inspecting Contents............................................................................................................................... 11
2.1.2.1 Platform ............................................................................................................................................... 11
2.1.2.2 Piston-cylinder Modules ....................................................................................................................... 12
2.1.2.3 Vacuum Reference Hardware (optional)............................................................................................... 13
2.1.2.4 AMH-100, Automated Mass Handler (optional)..................................................................................... 14
2.1.2.5 Mass Sets............................................................................................................................................ 14
2.2 Site Requirements................................................................................................................................15
2.3 Setup .....................................................................................................................................................17
2.3.1 Preparing for Operation......................................................................................................................... 17
2.3.1.1 Setting Up the Platform ........................................................................................................................ 18
2.3.1.2 System Pressure Interconnections....................................................................................................... 19
2.3.1.3 Setting up a Manual Mass Set.............................................................................................................. 19
2.3.1.4 Setting Up an AMH Mass Set............................................................................................................... 21
2.3.1.5 Setting Up An AMH Automated Mass Handler (optional)...................................................................... 22
2.3.1.6 Setting Up Vacuum Reference Hardware (optional) ............................................................................. 24
2.3.2 Installing a Piston-Cylinder module...................................................................................................... 25
2.4 Power Up And Verification ..................................................................................................................26
2.4.1 Power Up ................................................................................................................................................ 26
2.4.2 Verify correct Piston-Cylinder and Mass Set Information................................................................... 27
2.4.3 Set Local Gravity Value ......................................................................................................................... 27
2.4.3.1 Check/Set Security Level ..................................................................................................................... 27
2.4.4 Verify Input Sources .............................................................................................................................. 27
2.4.5 Verify Proper Operation of Ambient Conditions Measurements......................................................... 28
2.4.6 Apply Pressure To The Piston-Cylinder Module.................................................................................. 28
2.4.7 Check Proper Behavior Of Motorized Piston Rotation ........................................................................ 29
2.4.8 Verify Proper Operation Of Piston Behavior Measurements............................................................... 29
2.4.9 Verify Vacuum Reference...................................................................................................................... 29

PG9602™ OPERATION AND MAINTENANCE MANUAL
© 2011 Fluke Calibration Page IV
2.4.10 AMH Initialization / Startup.................................................................................................................... 30
2.4.11 Check Automated Pressure Generation............................................................................................... 31
2.4.12 Setup Verification Step to Take Before Making Pressure Measurements.......................................... 32
2.5 Short Term Storage..............................................................................................................................32
3. General Operation...........................................................33
3.1 Fundamental Operating Principles.....................................................................................................33
3.2 Keypad Layout And Protocol..............................................................................................................34
3.3 Sounds..................................................................................................................................................35
3.4 Pressure Ready/Not Ready Indication................................................................................................35
3.4.1 Piston Position Ready/Not Ready......................................................................................................... 36
3.4.2 Piston Rotation Rate Ready/Not Ready ................................................................................................ 36
3.4.3 Vacuum Reference Ready/Not Ready................................................................................................... 37
3.5 Piston Position .....................................................................................................................................37
3.6 Manual Mass Loading Protocol...........................................................................................................38
3.7 AMH Mass Loading ..............................................................................................................................40
3.7.1 Operating Principals.............................................................................................................................. 40
3.7.2 AMH Operation....................................................................................................................................... 42
3.7.2.1 Installing an AMH on the PG9000 Platform .......................................................................................... 43
3.7.2.2 Removing a Mass Handler from the PG9000 Platform ......................................................................... 45
3.7.2.3 AMH Mass-to-pressure or Pressure-to-mass Operation............................................................................ 45
3.7.2.4 Direct Control of AMH Functions.......................................................................................................... 45
3.7.2.5 Making and Breaking Reference Vacuum with AMH............................................................................. 46
3.7.2.6 Accessing the Piston-Cylinder Module with AMH ................................................................................. 46
3.7.2.7 AMH Indicator LED .............................................................................................................................. 46
3.7.2.8 AMH Error Messages........................................................................................................................... 47
3.8 Main Run Screen..................................................................................................................................49
3.9 General Function/Menu Flow Chart....................................................................................................50
3.10 Direct Function Keys............................................................................................................................50
3.10.1 Direct Function Keys Summary ............................................................................................................ 50
3.10.2 [P-C]........................................................................................................................................................ 52
3.10.3 [UNIT]...................................................................................................................................................... 53
3.10.3.1 Customizing Pressure Units Available Under the UNIT Function.......................................................... 54
3.10.4 [MODE].................................................................................................................................................... 55
3.10.4.1 Differential Measurement Mode............................................................................................................ 56
3.10.5 [SYSTEM]................................................................................................................................................ 63
3.10.5.1 First System Run Screen...................................................................................................................... 64
3.10.5.2 Second System Run Screen ................................................................................................................ 64
3.10.5.3 Third System Run Screen .................................................................................................................... 65
3.10.6 [AMBIENT].............................................................................................................................................. 66
3.10.7 [HEAD] .................................................................................................................................................... 67
3.10.8 [ROTATE]................................................................................................................................................ 69
3.10.8.1 <2Pre-Decel>....................................................................................................................................... 70
3.10.9 [GEN]....................................................................................................................................................... 71
3.10.9.1 <2target>.............................................................................................................................................. 73
3.10.9.2 <3raise>............................................................................................................................................... 73
3.10.9.3 <4UL>.................................................................................................................................................. 73
3.10.9.4 <5tol>................................................................................................................................................... 73
3.10.9.5 <6refloat>............................................................................................................................................. 74
3.10.10 [RES]....................................................................................................................................................... 74
3.10.11 [ENT / SET P].......................................................................................................................................... 76
3.10.11.1 [ENT / SET P] In Pressure-to-Mass mode............................................................................................ 77
3.10.11.2 [ENT / SET P] In Mass-to-Pressure mode............................................................................................ 78
3.10.11.3 Commands for zero pressure, ending a test......................................................................................... 79
3.10.12 [P OR M]................................................................................................................................................... 79
3.10.13 [ ] and [ ] + [←]................................................................................................................................ 80
3.11 [SETUP] Menu.......................................................................................................................................81
3.11.1 <1select> ................................................................................................................................................ 82
3.11.2 <2view>................................................................................................................................................... 83
3.11.3 <3edit>.................................................................................................................................................... 84

TABLE OF CONTENTS
Page V © 2011 Fluke Calibration
3.12 [SPECIAL] Menu...................................................................................................................................86
3.12.1 <1PC/MS> ............................................................................................................................................... 87
3.12.1.1 Create a Piston-Cylinder Module.......................................................................................................... 88
3.12.1.2 Edit a Piston-Cylinder Module .............................................................................................................. 90
3.12.1.3 View a Piston-Cylinder Module............................................................................................................. 90
3.12.1.4 Delete a Piston-Cylinder Module .......................................................................................................... 91
3.12.1.5 Select The Active Piston-Cylinder Module............................................................................................ 91
3.12.1.6 Add a Mass Set.................................................................................................................................... 91
3.12.1.7 Edit a Mass Set.................................................................................................................................... 96
3.12.1.8 View a Mass Set .................................................................................................................................. 96
3.12.1.9 Delete a Mass Set................................................................................................................................ 96
3.12.1.10 Select Mass Set................................................................................................................................... 96
3.12.1.11 Add a Mass Loading Bell...................................................................................................................... 97
3.12.1.12 Edit a Mass Loading Bell...................................................................................................................... 98
3.12.1.13 View a Mass Loading Bell .................................................................................................................... 98
3.12.1.14 Delete A Mass Loading Bell ................................................................................................................. 99
3.12.1.15 Select a Mass Loading Bell.................................................................................................................. 99
3.12.2 <2presU> ................................................................................................................................................ 99
3.12.3 <3head>.................................................................................................................................................. 99
3.12.3.1 <3head>, <1fluid>...............................................................................................................................100
3.12.3.2 <3head>, <2unit>................................................................................................................................101
3.12.3.3 <3head>, <3atm>................................................................................................................................101
3.12.3.4 <3head>, <4piston> ............................................................................................................................101
3.12.4 <4prefs>.................................................................................................................................................102
3.12.4.1 <4prefs>, <1ScrSvr>...........................................................................................................................102
3.12.4.2 <4prefs>, <2sound>............................................................................................................................102
3.12.4.3 <4prefs>, <3time>...............................................................................................................................103
3.12.4.4 <4prefs>, <4ID>..................................................................................................................................103
3.12.4.5 <4prefs>, <5level> ..............................................................................................................................104
3.12.5 <5remote>..............................................................................................................................................106
3.12.5.1 COM1, COM2, COM3 and COM4 (RS232).........................................................................................107
3.12.5.2 IEEE-488.............................................................................................................................................107
3.12.5.3 RS232 Self Test..................................................................................................................................107
3.12.5.4 External Barometer (RPM) Communications (COM2)..........................................................................108
3.12.5.5 External Vacuum Gauge Communications (COM2).............................................................................110
3.12.6 <6gl> ......................................................................................................................................................112
3.12.7 <7cal>.....................................................................................................................................................113
3.12.8 <8AMH> .................................................................................................................................................113
3.12.8.1 <2control>, <1up/down>......................................................................................................................114
3.12.8.2 <2control>, <2discreet>.......................................................................................................................114
3.12.8.3 <2control>, <3loadall>.........................................................................................................................114
3.12.8.4 <2control>, <4unloadall>.....................................................................................................................115
3.12.9 <9reset>.................................................................................................................................................115
3.12.9.1 <9reset>, <1sets> ...............................................................................................................................115
3.12.9.2 <9reset>, <2units>..............................................................................................................................116
3.12.9.3 <9reset>, <3com>...............................................................................................................................116
3.12.9.4 <9reset>, <4cal>.................................................................................................................................117
3.12.9.5 <9reset>, <5setups> ...........................................................................................................................117
3.12.9.6 <9reset>, <6all>..................................................................................................................................117
4. Remote Operation ......................................................... 119
4.1 Overview .............................................................................................................................................119
4.2 Interfacing...........................................................................................................................................119
4.2.1 RS232 interface.....................................................................................................................................119
4.2.1.1 COM1 .................................................................................................................................................119
4.2.1.2 COM2, COM3 and COM4 ...................................................................................................................120
4.2.2 IEEE-488 (GPIB).....................................................................................................................................120
4.3 Commands..........................................................................................................................................121
4.3.1 Command Syntax..................................................................................................................................121
4.3.2 Command Summary .............................................................................................................................121
4.3.3 Error Messages.....................................................................................................................................123
4.3.3.1 AMH Errors.........................................................................................................................................124
4.3.4 Command Descriptions........................................................................................................................124
4.3.4.1 IEEE Std. 488.2 Common And Status Commands..............................................................................124
4.3.4.2 PG9000 Commands............................................................................................................................126
4.4 Status System.....................................................................................................................................151
4.4.1 Status Reporting System......................................................................................................................151
4.4.1.1 Status Byte Register............................................................................................................................151
4.4.1.2 Standard Event Register.....................................................................................................................153

PG9602™ OPERATION AND MAINTENANCE MANUAL
© 2011 Fluke Calibration Page VI
5. Maintenance, Adjustments And Calibration ..................... 155
5.1 Introduction ........................................................................................................................................155
5.2 Platform...............................................................................................................................................156
5.2.1 Calibration / Adjustment Of On-board Measurement Functions........................................................156
5.2.1.1 Principles ............................................................................................................................................156
5.2.1.2 Barometric Pressure Sensor ...............................................................................................................156
5.2.1.3 Ambient Temperature sensor..............................................................................................................157
5.2.1.4 Relative Humidity Sensor....................................................................................................................158
5.2.1.5 Piston-Cylinder Module Temperature Sensors ....................................................................................158
5.2.1.6 Reference Vacuum Sensor (optional)..................................................................................................160
5.2.2 Piston Position Detection Adjustment.................................................................................................161
5.2.3 Drive Belt Replacement ........................................................................................................................162
5.3 Piston-Cylinder Modules: Disassembly, Cleaning, and Maintenance ...........................................162
5.3.1 Disassembly and Reassembly: 10 and 20 kPa/kg...............................................................................163
5.3.1.1 Piston Insertion Tool (10 kPa/kg only).................................................................................................168
5.3.2 Disassembly and Reassembly: 50, 100 and 200 kPa/kg..........................................................................169
5.3.3 Cleaning Piston-Cylinders....................................................................................................................172
5.3.3.1 Water / Detergent Cleaning method: ...................................................................................................173
5.3.3.2 Quick Method:.....................................................................................................................................173
5.3.4 Lubricating Piston-Cylinder Modules..................................................................................................174
5.3.5 Recalibration .........................................................................................................................................175
5.3.5.1 Updating Piston-Cylinder Module Files................................................................................................175
5.3.5.2 Updating Mass Set Files .....................................................................................................................175
5.4 Mass Sets............................................................................................................................................176
5.4.1 Cleaning.................................................................................................................................................176
5.4.2 Recalibration .........................................................................................................................................176
5.5 Updating Embedded Software for PG9000.......................................................................................176
5.6 Disassembly and Reassembly of PG9000........................................................................................176
5.6.1 Platform .................................................................................................................................................176
5.6.2 Terminal.................................................................................................................................................177
5.6.3 AMH Removal........................................................................................................................................177
6. Troubleshooting............................................................ 179
6.1 Overview .............................................................................................................................................179
7. Appendix...................................................................... 183
7.1 Conversion Of Numerical Values......................................................................................................183
7.1.1 Pressure ................................................................................................................................................183
7.2 Defined Pressure Calculations..........................................................................................................184
7.2.1 Calculations...........................................................................................................................................185
7.2.2 Fluid Heads............................................................................................................................................186
7.2.2.1 Fluid Head Components......................................................................................................................186
7.2.2.2 Overall Fluid Head Correction .............................................................................................................187
7.3 Glossary..............................................................................................................................................188
7.4 Limited Warranty and Limitation of Liability....................................................................................190

Page VII © 2011 Fluke Calibration
Tables
Table 1. PG9602 Parts List........................................................................................................................11
Table 2. Piston-Cylinder Modules Parts List..............................................................................................12
Table 3. PG9000 Vacuum Reference Hardware .......................................................................................13
Table 4. AHM-100-VAC Parts List .............................................................................................................14
Table 5. Manual Mass Set Parts List (excluding 80 and 100 kg)...............................................................14
Table 6. Manual Mass Set Parts List (80 and 100 kg)...............................................................................14
Table 7. AMH-100 Mass Set Parts List......................................................................................................15
Table 8. Mass Set Compositions ...............................................................................................................15
Table 9. Drive Air Pressure Requirement by Mass Set .............................................................................16
Table 10. AMH Errors ................................................................................................................................47
Table 11. Summary of PG9000 Direct Function Key Operations..............................................................51
Table 12. Pressure Units of Measure Available.........................................................................................54
Table 13. Valve Settings for Setting Differential Mode Static Pressure.....................................................59
Table 14. Valve Settings to Apply PG9000 Pressure to the RPM for Differential Mode Offsetting...........60
Table 15. Valve Settings for Operating in Differential Mode......................................................................62
Table 16. SETUP File Choices, Factory Preferred Choice and Normal Value..........................................82
Table 17. Security Levels - Functions NOT Executed Per Function/Level..............................................105
Table 18. COM1, COM2, COM3 and COM4 Available Settings..............................................................107
Table 19. COM1 DB-9F Pin Designation.................................................................................................120
Table 20. COM2, COM3 and COM4 DB-9M Pin Designation.................................................................120
Table 21. Command Summary................................................................................................................121
Table 22. Error Messages........................................................................................................................123
Table 23. Status Byte Register................................................................................................................151
Table 24. Standard Event Register..........................................................................................................153
Table 25. PG9000 Troubleshooting Checklist .........................................................................................179
Table 26. Pressure Unit of Measure Conversions...................................................................................183
Table 27. PG9000 Defined Pressure Calculation Variables....................................................................184
Table 28. Fluke Calibration Authorized Service Providers ......................................................................191

PG9602™ OPERATION AND MAINTENANCE MANUAL
© 2011 Fluke Calibration Page VIII
Figures
Figure 1. PG Terminal Front Panel..............................................................................................................7
Figure 2. PG Terminal Rear Panel............................................................................................................... 7
Figure 3. PG9000 Remote Electronics Module Rear Panel ........................................................................8
Figure 4. PG9602 Base Rear Panel ............................................................................................................8
Figure 5. Setting up the PG9602 electrical connections............................................................................18
Figure 6. PG9602 Interconnections ...........................................................................................................19
Figure 7. Mass sizes ..................................................................................................................................20
Figure 8. Fractional masses.......................................................................................................................21
Figure 9. AMH Mass Set............................................................................................................................21
Figure 10. Vacuum vent kit assembly........................................................................................................25
Figure 11. Piston-Cylinder Module Installation ..........................................................................................26
Figure 12. Piston Gauge Operating Principle ............................................................................................33
Figure 13. PG9000 Keypad Layout............................................................................................................34
Figure 14. Piston Stroke and Zones ..........................................................................................................38
Figure 15. AMH cut away view ..................................................................................................................42
Figure 16. AMH Installation on PG9000 Platform......................................................................................43
Figure 17. AMH Indicator location..............................................................................................................47
Figure 18. Run Screen Flow Chart ............................................................................................................50
Figure 19. Differential Mode Controller Schematic....................................................................................58
Figure 20. PG9000 Platform Reference Level Location ............................................................................68
Figure 21. Status Byte Register...............................................................................................................151
Figure 22. PG9602 bottom panel detail. ..................................................................................................159
Figure 23. 10 kPa/kg piston-cylinder module (expanded view) ...............................................................167
Figure 24. Gas piston-cylinder module sleeve nut tool............................................................................167
Figure 25. 10 kPa/kg piston insertion tool................................................................................................168
Figure 26. 50, 100 and 200 kPa/kg gas piston-cylinder modules (exploded view) .................................172
Figure 27. Gas Operated, Gas Lubricated Piston-Cylinder Module Lubrication Chart............................175

Page IX © 2011 Fluke Calibration
About This Manual
This manual provides the user with the information necessary to operate the PG9602 Piston Gauge. It
also includes a great deal of additional information provided to help optimize PG9602 use and take full
advantage of its many features and functions.
Before using the manual, take a moment to become familiar with the Table of Contents structure. All first
time PG9000 users should read Sections 1 and 2. Section 3 provides a comprehensive description of
general PG9000 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 PG9000 behavior
based on the symptoms of that behavior.
Certain words and expressions have specific meaning as they pertain to PG9000s. 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.
Note
For those who “don’t read manuals”, go directly to section 2.3 to set up
the PG9602. Then go to section 2.4. This will get you running quickly with minimal
risk of causing damage to yourself or your PG9602. 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
“Caution” is used in throughout the manual to identify conditions or actions that could
cause harm to the PG9602 or to the devices that are connected to the PG9602.
Warning
“Warning” is used in throughout the manual to identify actions that could pose a
hazard to the user of the PG9602.
Note
“Note” is used throughout the manual to identify operating and applications advice
and additional explanations.
[ ] indicates direct function keys (e.g., [RANGE]).
< > indicates PG9602 screen displays (e.g., <1yes>)

PG9602™ OPERATION AND MAINTENANCE MANUAL
© 2011 Fluke Calibration Page X
Notes

Page 1 © 2011 Fluke Calibration
1. Introduction
1.1 Product Overview
PG9000 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 PG9000 piston gauge consists of the PG9000 Platform, a piston-cylinder module and a mass set.
Optional hardware for vacuum reference operation is available. An optional automated mass handling
system is available. A PG9000 system typically includes the means to generate and adjust pressure and
the interconnection hardware to connect the system components and a device under test (“DUT”). The
pressure generation component can be manual or automated. COMPASS®for Pressure software may
also be included to assist in automating the tasks of executing test sequences, acquiring test data and
producing test reports.
The PG9000 Platform consists of the PG9000 Base, PG Terminal and Remote Electronics Module. Local
user interface is through the keypad and display on the PG Terminal. Remote communications and all on
board (built in) sensors are located inside or are connected to the Remote Electronics Module.
PG9000 is a family of piston gauges with common presentation and features designed to operate with a
mass set up to 100 kg. There are two PG9000 platforms – PG9602 and PG9607. They are both
designed for laboratories to realize and dissembinate fundamental pressure measurements.
The PG9602 uses type 7100/7600 gas operated gas lubricated piston cylinders to define
measurements in the range of 12 to 1 100 kPa.A 100 kg mass set allows for more overlap between
piston-cylinders across the working range.
The PG9607 uses a 50 mm piston-cylinder with controlled clearance capability to obtain dimensionally
traceable measurements in the range of 11 to 500 kPa. It is available on a limited basis and,
generally, is only offered for use in national measurement institutes or other laboratories performing
fundamental research in pressure metrology.
PG9000 platform, piston-cylinder module, mass set and optional automated mass handling system 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. The automated mass handler sits under the vacuum
bell jar thus allowing sustained low vacuum pull down without the need to break vacuum to effect a mass
load change. Extensive monitoring and controlling capability and advanced local and remote user
interfaces are integrated into the PG9000 Platform.
Operator interaction with PG9000 and its extensive capabilities and peripherals is accomplished through
a single display and keypad on the PG Terminal or from a computer via a RS232 or IEEE-488 interface.

PG9602™ OPERATION AND MAINTENANCE MANUAL
Page 2 © 2011 Fluke Calibration
1.2 Specifications
1.2.1 General Specifications
Power Requirements 50/60 Hz, 60 VA max. consumption.
100 to 240 VAC, operating altitude: <2000m
100 to 150 VAC, operating altitude: <5000m
Operating Temperature Range 15 to 35 °C
Operating Humidity Range 5 to 95% R.H., non-condensing
Weight
Instrument platform with no mass or
piston-cylinder loaded.
PG9602 (without vacuum hardware)
Remote Electronics Module
PG Terminal
Optional Vacuum Reference Hardware
34 kg (74 lb)
1.9 kg (4 lb)
1.4 kg (3 lb)
16 kg (36 lb)
Dimensions
PG9602 Base (without vacuum hardware)
PG9602 Base (with optional vacuum bell
jar and vacuum gauge connected)
Remote Electronics Module
PG Terminal
34.1 cm H x 54.3 cm W x 52.3 cm D (13.4 in x 21.4 in x 20.6 in)
(Height: top of piston-cylinder assembly)
56 cm H x 54.3 cm W x 52.3 cm D (22 in x 21.4 in x 20.6 in)
(Height: Top of bell jar)
10.2 cm H x 35.1 cm W x 19.6 cm D (4 in. 13.8 in. x 7.7 in.)
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: Residual vacuum sensor (external)
COM3: Automated pressure generator/controller
COM4: Unused/spare or pass through
Host computer
Fuses PEM Fuse: 1A, 250V, 5x20mm, Slow blow
Internal power supply Fuse: 3.15A, 250V
Overall Pressure Range Gauge: 12 kPa to 11 000 kPa (1.7 to 1 600 psi)
Absolute: 12 kPa to 11 000 kPa (1.7 to 1 600 psi)
Differential: - 95 to 985 kPa (-13.7 to 143 psi) at
15 to 110 kPaa (2.2 to 16 psia) static pressure
Operating Media Gas: nitrogen, helium, dry air (dew point ≤-40 °C)
Maximum Mass Load 100 kg1, while not exceeding 11 MPa (1 600 psi)2
1MS-AMH-100 mass set contains approximately 104.4 kg of mass.
Choice of piston-cylinder will add 0.2 to 0.5 kg of mass.
2The PC-7100/7600-200 piston-cylinder is limited to use of 55 kg.
Pressure Connections PG 9602 Base
AMH Drive
AMH Vent
Remote Electronics Module
Vacuum Connections (Bell Jar)
Test port: DH200
Quick connector equivalent to Swagelok QM Series (QM2-B-200),
Use with DESO (double end shut off) type stem
Quick connector equivalent to Swagelok QM Series (QM2-B-200),
Use with SESO (single end shut off) type stem only.
Note
DH200 is a gland and collar type fitting for 1/4 in. (6.35
mm) coned and left hand threaded tubes.
DH200 is equivalent to AE SF250C, HIP LF4, etc.
ATM port: 10-32 UNF
3 each KF40, 1 each KF50 (top)
CE Conformance All PG9000 models conform to CE requirements and are CE
marked.

1. INTRODUCTION
Page 3 © 2011 Fluke Calibration
1.2.1.1 AMH Automated Mass Handler (Optional)
Power Requirements:
Operating Temperature:
Dimensions:
15 VDC @ 2 A, 30 W max. consumption 15 to 35 ºC
41 cm H x 41 cm W x 36 cm D (16.3 in. x 16.1 in. x 14.1 in.)
Weight:
Power/Communications: 12 kg (25 lbs)
Custom 8 pin connector
AMH Drive Air Supply: 550 kPa (80 psi), ± 10%, minimal flow
AMH Vacuum Supply: At least 50 kPa (7.5 pi) under atmosphere, minimal flow
Pressure Connections: Pressure:
Vacuum: Quick connector DESO (double end shut off) type stem Quick connector SESO (single end shut off) type stem
CE conformance: Available, must be specified
1.2.1.2 Embedded Features
•Local control with 2 x 20 vacuum fluorescent display and 4 x 4 function
driven keypad.
•Real time 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 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. Barometer head correction included for
atmosphere reference operation (gauge mode).
•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-100-VAC).
•Interfacing and automatic exploitation of external barometer via RS232.
•Interfacing and automatic exploitation of any external vacuum gauge via
RS232.
•Semi-automated differential mode to define low differential pressures at
various static pressures between vacuum and two atmospheres.
•Storage and one step activation of metrological data on up to 17 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 Fluke Calibration
pressure controllers.
•Full RS232 and IEEE-488 communications with multi-level commands to set
and read all instrument functions.

PG9602™ OPERATION AND MAINTENANCE MANUAL
© 2011 Fluke Calibration Page 4
1.2.1.3 Ambient and Instrument Condition Measurements
Temperature Range
Resolution
Measurement Uncertainty
Ambient1
0 to 40o C 0 to 40 oC
Piston Cylinder Module
0.1 o C 0.01 o C
±1 o C ±0.1 o C
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 Fluke Calibration RPM4.
Relative Humidity1
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 (Optional)Range
Resolution
Measurement Uncertainty
0 to 13 Pa
0.01 Pa
±0.05 Pa + 0.5 % of reading
1PG9000 uses a Fluke Hart Scientific 2626-S temperature and humidity probe specified and factory
calibrated to deliver ±0.25 ˚C uncertainty on temperature and ±3% on relative humidity. PG9000
performance requirements and factory calibration services require only the specifications listed above
to meet stated product uncertainties.

1. INTRODUCTION
Page 5 © 2011 Fluke Calibration
1.2.2 Piston-Cylinder Modules
All piston-cylinders are complete integrated metrological assemblies that include mounting
hardware, upper and lower travel stops, spring preloading system, and are delivered in
individual shipping and storage “bullet” cases.
Gas operated, gas lubricated piston-cylinders (PC-7100/7600) used with PG7000 are
compatible with PG9602.
Note
A piston-cylinder delivered with a PG7102 or PG7601 is compatible with
PG9602; however its metrological properties must be recertified for
operation to determine uncertainty at higher mass loads. Existing
PC-7100/7600-200 (200 kPa/kg) piston-cylinders are supported only up to
the mass set for which they were originally certified (35 kg or 55 kg if it
was delivered with a PG7102).
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

PG9602™ OPERATION AND MAINTENANCE MANUAL
© 2011 Fluke Calibration Page 6
1.2.3 Mass Sets
Note
A mass set delivered with a PG7000 is compatible with PG9602, however be
sure to be aware of potential differences between the nominal makeup mass
value and the nominal Piston mass + Mass Bell mass (i.e. using a 4.5 kg MKUP
mass with a 1 kg piston+bell).
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
Electro polished
±20 ppm of nominal value (manual AND AMH mass sets do
not have fixed adjustment tolerances)
±5 ppm or 1 mg, whichever is greater
Masses < 50g ±1 mg
1.2.4 Pressure Measurements
Note
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 Fluke Calibration
Technical Note 0180TN12, “Typical Pressure Measurement Uncertainty for
a PG9607 and PG9602 Piston Gauge”.
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
1Sensitivity: The smallest variation in input detectable in output.
2Reproducibility: The root sum square of the stability of effective area and stability of the
AMH-100 mass set for 1 year. Refer to Fluke Calibration Technical Note 0180TN12.

1. INTRODUCTION
Page 7 © 2011 Fluke Calibration
1.3 Front and Rear Panels
1.3.1 PG Terminal Front and Rear Panels
The front panel assembly provides a 2 x 20 vacuum fluorescent display and a
4 x 4 membrane keypad for local user interface. The terminal front panel assembly is the same
for all PG9000 models.
Display
Keypad
Figure 1. PG Terminal Front Panel
The rear panel assembly provides the communications connection to the PG9000 Remote
Electronics Module. The terminal rear panel assembly is the same for all PG9000 models.

Power switch
 Fuse

Power receptacle

Connector for 25 pin cable to PG
Remote Electronics Module
 Cooling fan
Figure 2. PG Terminal Rear Panel

PG9602™ OPERATION AND MAINTENANCE MANUAL
© 2011 Fluke Calibration Page 8
1.3.2 Remote Electronics Module (REM) Rear Panel
The PG9000 Remote Electronics Module houses all working electronics (processor, sensor
and communications) for the PG9000 in addition to sensors for ambient conditions
(temperature, pressure and humidity).

COM 2 (RS232) – External
Barometer, External Vacuum
Gauge and Pass through
Communication
 COM 3 (RS232) – Automated
Pressure Generation/Control
Component

PG DRIVER – 15 pin Cable to
PG Base
 ATM Connection (Barometer)
 Mounting Post PRT Connector to
PG Remote Electronics Module
 TH Probe Connector

COM 4 (RS232) – Pass Through

COM 1 (RS232) – Remote Host
Communications
 IEEE-488 – Remote Host
Communications
 AMH Connection
 Connector for 25 pin Cable to PG
TERMINAL
Figure 3. PG9000 Remote Electronics Module Rear Panel
1.3.3 Base Rear Panel
The PG9000 Platform rear panel provides the communications connection to the PG Remote
Electronics Module, Test port connection, a vacuum vent port connection, and connections for
the option Automated Mass Handler.
 PG Driver – to PG Remote
Electronics Module
 AMH Connection
 AMH Vent Port
 TEST Pressure Port
 AMH Drive Pressure Port
 PRT Connector – to Remote
Electronics Module
Figure 4. PG9602 Base Rear Panel

Page 9 © 2011 Fluke Calibration
2. Installation
2.1 Unpacking and Inspection
2.1.1 Removing From Packaging
A typical PG9000 system includes the PG9000 Platform (see Section 2.1.1.1), a mass set (see
Section 2.1.1.6), at least one piston-cylinder assembly (see Section 2.1.1.2) and other
accessories such as vacuum reference hardware (see Section 2.1.1.3), an automated mass
handler (see Section 2.1.1.4) and/or pressure generation and control components (see the
accessory Operation and Maintenance Manual or instruction sheet).
2.1.1.1 Platform
The PG9000 Platform consists of the PG9000 Base, Remote Electronics Module,
Terminal and interconnect accessories. The Base is shipped in a custom wooden
crate. The Platform components are shipped in a reusable, molded shipping and
storage case. The cables and accessories are shipped in a corrugated container
with other PG9000 accessories including operating instructions and calibration
reports.
 Open the PG9000 Base shipping crate (71 cm x 71 cm x 56 cm).
 Carefully lift the PG9000 Base from its position in the lower packing insert.
Note the orientation so that the same orientation will be used when PG9000
is repacked.
Warning
The PG9000 Base has a mass of 34 kg (74 lb). It is
recommended to remove it from the packaging with two people
on opposite sides of the shipping container. Removing or
lifting with only one person may lead to injury.
 Open the PG9000 components molded, reusable recalibration transit case
and the accessories corrugated shipping container.
 Remove the PG Terminal, Remote Electronics Module and Temperature-
Humidity Probe from the recalibration transit case and the Platform
accessories from the shipping container. Inspect and inventory the
accessories (see Section 2.1.2.1).
Reinstall the packing inserts into the shipping and storage cases and store in
a safe place.

PG9602™ OPERATION AND MAINTENANCE MANUAL
© 2011 Fluke Calibration Page 10
2.1.1.2 Piston-Cylinder Assemblies
The piston-cylinder modules are shipped in Acetal bullet cases that are packed in
corrugated containers with custom foam inserts.
Open the corrugated containers and remove the piston-cylinder modules
and accessories.
The bullet cases screw open by turning the lid counterclockwise.
2.1.1.3 Vacuum Reference Hardware (optional)
The optional PG9000 Vacuum Reference Hardware includes the vacuum Bell
Jar, reference vacuum sensor with power supply and interconnect cables and
fittings necessary for vacuum operation.
The PG9000 Bell Jar is packed in a large wooden crate (66 cm x 66cm x 71 cm).
The vacuum reference sensor, power supply and associated fittings and cables
are packed in a reusable molded Vacuum Measurement Kit transit case.
Remaining fittings and adaptors are shipped in the PG9000 accessories
corrugated container (see Section 2.1.2.3).
2.1.1.4 AMH-100, Automated Mass Handler (optional)
AMH-100-VAC is delivered in a corrugated container with foam cut outs to hold
the AMH in place. Accessories are bagged together and packaged in a separate
corrugated container with other PG9000 system accessories.
Remove all parts from the shipping boxes. See Section 2.1.2.4 for more detail.
2.1.1.5 AMH Mass Set (optional)
PG9000 AMH masses are shipped in reusable, molded shipping and storage
cases. One of the cases contains the binary masses, binary mass carrier, mass
bell and lifting shaft/trim mass tray. The other cases contain the main masses of
10 kg (see Section 2.1.2.2 for mass set content detail). Each mass is packed in a
plastic bag and then placed in a protective shipping insert. The PG9000 AMH
masses should be removed from their shipping cases and inventoried when
setting up the PG9000 system (see Section 2.1.1.6 for mass set content detail).
Caution
The stability over time of PG9000 pressure measurements is a
function of the stability of the masses loaded on the cylinder.
Precautions should be taken in handling the masses to minimize
influences that may change their mass. This includes always
wearing protective gloves when handling the masses to avoid
contaminating them with body oils and perspiration. Protective
gloves are provided in the accessory kits of PG9000 Platforms.
2.1.1.6 Manual Mass Set
The PG9000 manual masses are shipped in reusable, molded shipping and
storage cases. The PG9000 masses should be removed from their shipping
cases and inventoried when setting up the PG9000 system (see Section 2.1.2.2
for mass set content detail). The default manual mass set is the type MS-7002
which has a 4 kg makeup mass.