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Pilot Valve Tester Operating Manual

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Summary of Contents for 21001119

Page 1: ...P N 96654 September 2021 Revision 0 PILOT VALVE TESTER 6KSI GAS AND WATER OPERATING MANUAL MACHINE SERIAL NUMBER 21001119 AND HIGHER ORIGINAL INSTRUCTIONS ...

Page 2: ......

Page 3: ...ut CLIMAX products or services please call CLIMAX or e mail info cpmt com For quick and accurate service please provide your representative with the following Your name Shipping address Telephone number Machine model Serial number if applicable Date of purchase CLIMAX World Headquarters 2712 East 2nd Street Newberg Oregon 97132 USA Telephone worldwide 1 503 538 2815 Toll free North America 1 800 3...

Page 4: ...Page B Pilot Valve Tester Operating Manual CLIMAX GLOBAL LOCATIONS ...

Page 5: ...P N 96654 Rev 0 Page C CE DOCUMENTATION ...

Page 6: ...Page D Pilot Valve Tester Operating Manual ...

Page 7: ...factory representative and return the part or repaired machine shipping pre paid to the factory CLIMAX will at its option either repair or replace the defective part and or correct any defect in the labor performed both at no charge and return the part or repaired machine shipping prepaid These warranties do not apply to the following Damage after the date of shipment not caused by defects in mate...

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Page 9: ... 3 2 LIFTING AND RIGGING 15 3 3 SECURING THE TEST STAND 15 3 3 1 Cement in place option 1 recommended 16 3 3 2 Drill and anchor option 2 16 3 4 INSTALLING UTILITIES 17 3 4 1 Connecting water from the source 17 3 4 2 High pressure sources for testing 17 3 4 3 Connecting to pilot valves 17 3 4 4 Connecting to drain port 18 4 OPERATION 19 4 1 PRE OPERATION CHECKS 19 4 2 CONDUCTING AN AIR TEST 20 4 2 ...

Page 10: ...rating Manual TABLE OF CONTENTS CONTINUED CHAPTER SECTION PAGE 6 1 1 Short term storage 25 6 1 2 Long term storage 25 6 2 SHIPPING 25 6 3 DECOMMISSIONING 25 APPENDIX A ASSEMBLY DRAWINGS 27 APPENDIX B SCHEMATICS 39 APPENDIX C SDS 47 ...

Page 11: ...embly 30 A 4 Pilot Valve Tester flexible hose assembly 31 A 5 Pilot Valve Tester assembly parts list 1 32 A 6 Pilot Valve Tester assembly parts list 2 33 A 7 Pilot Valve Tester assembly parts list 3 34 A 8 Digital leakage measurement sensor assembly P N 98873 35 A 9 Digital leakage measurement sensor assembly P N 98873 36 A 10 Digital leakage measurement sensor assembly P N 98873 37 B 1 DAAS assem...

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Page 13: ...t checklist after set up 5 1 3 Labels 6 2 1 Console controls identification 10 2 2 Right side controls identification 11 2 3 Specifications 13 3 1 Components to secure the test stand 16 5 1 Maintenance intervals and tasks 23 A 1 Collar locations for P N 98873 36 A 2 Digital leakage configuration identification 37 ...

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Page 15: ... to aid in setup operation and maintenance tasks Read this entire manual to familiarize yourself with the Pilot Valve Tester before attempting to set it up or operate it 1 2 SAFETY ALERTS Pay careful attention to the safety alerts printed throughout this manual Safety alerts will call your attention to specific hazardous situations that may be encoun tered when operating this machine Examples of s...

Page 16: ...ou the end user are responsible for conducting a risk assess ment of each job site before setting up and operating this machine Intended use Use this machine in accordance with the instructions and precautions in this manual Do not use this machine for any purpose other than its intended use as described in this manual Personal protective equipment Always wear appropriate personal pro tective gear...

Page 17: ...hine or working around it Hazardous environments Do not operate the machine in environments where potentially explosive materials toxic chemicals or radiation may be present Pressurization Do not over pressurize the valve test system beyond the limits described in this manual and on machine labels Do not pressurize the system while the side panels are removed from the test console Test gauges Do n...

Page 18: ...re of high pressure valve testing iden tifying one or more hazards that must be addressed is typical When performing the on site risk assessment it is important to consider the valve tester and the workpiece as a whole WARNING High pressure valve testing may result in the sudden unexpected release of stored energy with the potential to cause property damage or personnel injury Potential hazards ma...

Page 19: ...y fluid escape or workpiece fragmentation and have installed appropriate protective barriers I read the machine assembly instructions Section 3 and took inventory of all the items required but not supplied Section 2 3 I considered how this machine operates and identified the best placement for the controls cabling and the operator I evaluated and mitigated any other potential risks specific to my ...

Page 20: ... or missing contact CLIMAX immediately for replacements TABLE 1 3 LABELS P N 29154 ID plate P N 79328 Label read the operating manual P N 81008 Warning label wear ear and eye protection P N 82144 Warning label P N 87258 Calder label P N 87593 Warning label read the operating man ual P N 89229 Calder label P N 89548 Warning label do not block port ...

Page 21: ...ploded views in Appendix A P N 90160 Warning label water release hazard P N 91683 Label pressure specifications P N 98052 Label air inlet 6 000 psi 413 bar maximum P N 98121 Label water supply 70 psi 5 bar maxi mum P N 98842 CE label water filter P N 98843 CE label drain TABLE 1 3 LABELS ...

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Page 23: ...lve Tester is a system designed to test and set pilot valves using water or air WARNING This machine is for testing safety relief valves only Using the machine to test other valves control valves gate valves etc could cause severe damage to the machine and injure personnel Principal components of the Pilot Valve Tester include a test console that has a maximum pressure rating of 6 000 psi 414 bar ...

Page 24: ...L GAUGE DOME VESSEL PRESSURE GAUGE BLOCK VALVE DRAIN VALVE TEST PRESSURE CONTROL 2 3 4 5 7 8 9 10 6 1 11 TABLE 2 1 CONSOLE CONTROLS IDENTIFICATION Number Component ID Component 1 G 04 Test pressure digital gauge 2 G 03 Test pressure gauge 3 G 02 Dome vessel pressure gauge 4 V 01 Vessel selection valve 5 V 02 Vessel outgas valve 6 V 05 Drain valve 7 V 06 Block valve 8 PCV 01 Test pressure control 9...

Page 25: ... AIR INLET 6000 PSI 413 BAR MAXIMUM DRAIN WATER INLET 70 PSI 5 BAR MAXIMUM WATER INLET FILTER 2 3 4 1 TABLE 2 2 RIGHT SIDE CONTROLS IDENTIFICATION Number Component ID Component 1 High pressure air inlet 6000 psi 413 bar maximum 2 Drain 3 F 01 Water inlet filter 4 Walter inlet 70 psi 5 bar maximum MOUNTING RAIL WITH 6 mm T SLOT NUTS AND 6 mm x 16 mm BOLTS ...

Page 26: ...Page 12 Pilot Valve Tester Operating Manual 2 3 DIMENSIONS Figure 2 4 shows the machine dimensions FIGURE 2 4 DIMENSIONS 36 30 51 67 63 95 ...

Page 27: ...rranty 2 5 ITEMS REQUIRED BUT NOT SUPPLIED High pressure air with a maximum of 6 000 psi 413 bar is required but not sup plied by CLIMAX TABLE 2 3 SPECIFICATIONS Test media Water air Maximum water test pressure 6 000 psi 414 bar Maximum air test pressure 6 000 psi 414 bar Types of valves that can be tested Pilot valves Water quick fill 3 gpm 11 4 l min minimum Approximate machine weight 400 lbs 18...

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Page 29: ...r to shipment and packaged for normal shipment conditions CLIMAX does not guarantee the condition of your machine upon delivery When you receive your CLIMAX product perform the following receipt checks 1 Inspect the shipping containers for damage 2 Check the contents of the shipping containers against the included invoice to make sure that all components have been shipped 3 Inspect all components ...

Page 30: ...e or personnel severe injury or death 3 3 1 Cement in place option 1 recommended Cement the anchor bolts into the floor The exposed threads of the anchor must protrude a minimum of two threads past the nut and washer See Figure 3 1 3 3 2 Drill and anchor option 2 Drill holes into the floor for an expanding type anchor sleeve A 0 5 12 7 mm lag bolt will require a minimum of 1 5 38 1 mm thread engag...

Page 31: ...or gas at this location WARNING Exceeding the rated pressure for the inlet could result in machine damage or personnel injury 3 4 3 Connecting to pilot valves When connecting to the Dome Port only use fittings and components rated to or above 6 000 psi 413 bar When connecting to the Pilot Port only use fittings and components rated to or above 6 000 psi 414 bar WARNING Failure to utilize fittings ...

Page 32: ...cting to the drain use 1 2 13 mm hose minimum or 3 4 20 mm recommended Route the hose and tube away from areas that could pinch the hose which would obstruct the flow WARNING Failure to keep the drain hose or tube clear of obstructions could result in machine damage or personnel injury ...

Page 33: ...k that all valves including the Block Valve Drain Valve Select Valve Water Fill Valve Vessel Outgas Valve and Vessel Select Valve are in the closed position and that the Test Pressure Control is turned counter clockwise until it stops 5 Check that the test piece is securely mounted to the test rail see Figure 2 3 on page 11 NOTICE Follow any pressure ratings indicated on the hose assemblies Exceed...

Page 34: ... leakage testing See Section 4 4 for details Do the following for an air test 1 Open the Inlet Outlet Valve for the supply hose at the pressure source 2 Open the Block Valve The Test Pressure Gauges should show 0 psi bar 3 Check that the Drain Valve and Vessel Outgas Valve are closed at the con trol panel 4 Set the Select Valve to Pilot 5 Set the Vessel Select Valve to Pilot Vessel 6 Turn the Test...

Page 35: ...ing the hoses under pressure may result in the sudden unexpected release of stored energy with the potential to cause property damage or personal injury The operator must ensure that the pressure indicator light is not illuminated and the test pressure gauges show 0 psi When no more adjustments are necessary do the following to remove the test piece 1 Rotate the Test Pressure Control counter clock...

Page 36: ...losed 8 Set the Vessel Selection Valve to Dome Vessel 9 Open the Drain Valve Water will begin draining from the Drain Port If water is not draining increase the pressure at the Test Pressure Control 10 When only air is emitted from the Drain Port close the Drain Valve 11 If Port D is not connected to anything do the following a Open the Block Valve to Port P to purge water from it b When only air ...

Page 37: ...ated tasks TABLE 5 1 MAINTENANCE INTERVALS AND TASKS Interval Task Before each use Inspect the testing unit including all hose connections inlet supply lines and outlet lines After each use Wipe the component parts clean and dry to prevent corrosion Once a month Check the water filter P N 92305 and replace as necessary ...

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Page 39: ...emove the workpiece from the machine 5 Spray all unpainted surfaces with LPS 2 to prevent corrosion 6 Store the Pilot ValveTester in its original shipping box 6 1 2 Long term storage Do the following for long term storage longer than three months 1 Follow the short term storage instructions but use LPS 3 instead of LPS 2 2 Add a desiccant pouch to the shipping container Replace according to manufa...

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Page 41: ...Y 31 FIGURE A 5 PILOT VALVE TESTER ASSEMBLY PARTS LIST 1 32 FIGURE A 6 PILOT VALVE TESTER ASSEMBLY PARTS LIST 2 33 FIGURE A 7 PILOT VALVE TESTER ASSEMBLY PARTS LIST 3 34 FIGURE A 8 DIGITAL LEAKAGE MEASUREMENT SENSOR ASSEMBLY P N 98873 35 FIGURE A 9 DIGITAL LEAKAGE MEASUREMENT SENSOR ASSEMBLY P N 98873 36 TABLE A 1 COLLAR LOCATIONS FOR P N 98873 36 FIGURE A 10 DIGITAL LEAKAGE MEASUREMENT SENSOR ASS...

Page 42: ...T INSTALLATION SCALE 1 10 VIEW T T SCALE 1 8 DETAIL V SCALE 1 4 T T V 55 49 19 20 64 50 96 41 79 61 11 127 83 87 14 7 127 47 38 112 42 25 36 95 15 91 32 71 92 15 110 55 32 35 35 26 4 80 11 80 37 90 16 41 30 114 112 24 79 121 86 84 94 96 96 86 94 34 50 121 25 15 93 34 91 89 79 16 34 90 89 30 24 16 79 114 16 24 30 ...

Page 43: ... A 2 PILOT VALVE TESTER SIDE PANEL ASSEMBLY SIDE PANEL EQUIPMENT INSTALLATION SCALE 1 10 VIEW J J SCALE 1 10 J J 56 54 67 66 56 54 67 3 12 82 123 123 18 61 76 22 76 62 123 51 30 62 123 51 30 82 6 12 122 80 80 67 81 80 53 56 56 53 61 ...

Page 44: ... TESTER REAR PANEL ASSEMBLY REAR PANEL EQUIPMENT INSTALLATION SCALE 1 16 VIEW Y Y SCALE 1 16 DETAIL K SCALE 1 8 Y Y K 27 1 120 78 30 119 108 108 104 104 118 119 30 118 119 30 23 22 73 73 21 65 46 128 73 18 65 18 126 106 106 106 106 107 106 105 106 106 106 106 106 105 ...

Page 45: ...GURE A 4 PILOT VALVE TESTER FLEXIBLE HOSE ASSEMBLY FLEXIBLE HOSE INSTALLATION SCALE 1 16 SECTION P P SCALE 1 16 SOME ITEMS OMITTED FOR CLARITY P P 101 103 98 5 37 100 37 37 80 98 30 29 80 80 6 30 114 121 30 120 98 98 101 98 103 ...

Page 46: ... TEE 1 4 NPTF X 1 4 NPTM X 1 4 NPTF RUN TEE SS 25 2 83133 FTG STRAIGHT 1 4 MNPT X 1 4 TUBE PRESTOLOK 26 1 83135 FTG BUSHING 1 2 NPTM x 1 4 NPTF BRASS 27 8 83557 NUT 3 8 16 HEX NYLOCK ZINC 28 1 83714 FTG HEX NIPPLE 1 4 NPTM 29 1 83981 FTG CROSS 1 2 FNPT BRASS 30 7 84367 FTG ADAPTER 4 JICM X 1 4 NPTM SS 31 1 84517 GAUGE DIGITAL PRESSURE PEEK HOLD 1 4 NPTM 10KSI 32 2 84571 FTG TEE 1 4 NPT STREET BRAS...

Page 47: ...AWAY 24 X 24 X 100 CAPACITY 77 1 91683 LABEL CE TESTING REQUIREMENTS QUICKSET SRV 78 1 91977 FTG ADAPTER PIPE 1 NPTM X 1 2 NPTF 79 3 92935 VALVE BALL 3 WAY 1 4 NPTF 6 KSI SS 80 5 93011 FTG ADAPTER 1 2 NPTM X 3 8 TUBE F PRESTOLOCK 81 1 94749 FTG POLY REDUCER BUSHING 3 4 NPTM X 1 2 NPTF 82 1 94751 FTG ADAPTER 1 4 NPTF X JIC 4M STEEL WITH NUT 83 1 96603 LABEL INSTRUMENT PANEL FRONT PILOT VALVE 84 1 9...

Page 48: ...BHSCS SS 114 2 97528 FTG ADAPTER 1 4 NPTM X 3 8 TUBE F PRESTOLOK 115 1 98052 LABEL AIR INLET 6000 PSI 413 BAR MAX 116 1 98121 LABEL WATER SUPPLY 117 3 98280 NOT SHOWN CORDSET EXTENSION M12 EUROFAST OR MICRO LINK 4 CONDUCTOR PVC JACKET 2M LONG 118 2 98516 VESSEL 6 KSI 1 GAL 119 3 98560 FTG BUSHING 1 NPTM X 1 4 NPTF SS 120 1 98574 FTG ADAPTER 6 JICM X 1 2 NPTM SS 121 2 98604 FTG ELBOW 90 DEG PRESTOL...

Page 49: ...NG 90036 1 5 GRADUATED CYLINDER 100 ML POLYPROPYLENE SQUAT FORM 1 5 INCH OD 90038 1 6 COLLAR SHAFT 8MM ID SET SCREW 304 STAINLESS 90198 2 7 SCREW 1 4 14 X 3 4 SELF DRILLING FLAT HEAD 410 STAINLESS 90199 1 8 SENSOR 50MM FORK INFRARED NPN OUTPUT 24VDC M8 X 1 CONNECTOR 90200 1 9 TUBING POLYURETHANE VERY FLEXIBLE 1 4 ID X 3 8 OD 40F 180F 30 PSI 90201 96 10 NOT SHOWN SYRINGE 60 ML CLEAR POLYPROPYLENE 9...

Page 50: ...ROOVE SHOULD BE LOCATED FLUSH TO TOP OF HOUSING INSTALL BOTTOM COLLAR AGAINST BOTTOM OF HOUSING GROOVE LOCATIONS 1 2 3 4 TABLE A 1 COLLAR LOCATIONS FOR P N 98873 Number Text 1 Groove locations 2 Groove should be located flush to the top of the housing 3 Install the bottom collar against the bottom of the housing 4 Collar locations ...

Page 51: ...MBLY P N 98873 CONFIGURED FOR DRIP DETECTION CONFIGURED FOR BUBBLE DETECTION WATER LEVEL EVEN WITH GROOVES 1 2 3 TABLE A 2 DIGITAL LEAKAGE CONFIGURATION IDENTIFICATION Number Text 1 Configured for drip detection 2 Water level even with grooves 3 Configured for bubble detection ...

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Page 53: ...CS Schematics list FIGURE B 1 DAAS ASSEMBLY P N 98880 41 FIGURE B 2 DAAS SCHEMATIC 1 P N 98933 1 42 FIGURE B 3 DAAS ASSEMBLY P N 98933 1 43 FIGURE B 4 CONTROL ENCLOSURE ASSEMBLY P N B00441 44 FIGURE B 5 CONTROL ENCLOSURE SCHEMATIC P N C00623 45 ...

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Page 55: ... 15509 SCALE D SIZE CAGE CODE DWG NO SHEET OF REVISION 98880 B 1 1 DMB 4 2 2021 NONE RJJ 4 2 2021 DMB 4 2 2021 4 A THESE PARTS ARE FOR REFERENCE ONLY THE PRESSURE SENSORS INDICATOR LIGHT PRESSURE SWITCH AND CORDSETS ARE NOT PART OF THE CONTROLLER ASSY POWER CORD AND LAPTOP COMES WITH CONTROL PANEL CONTROL PANEL COMES WIRED FOR OMEGA TRANSDUCERS MATCH WIRING OF THE CONTROL PANEL TO THE TRANDUCERS I...

Page 56: ...Page 42 Pilot Valve Tester Operating Manual FIGURE B 2 DAAS SCHEMATIC 1 P N 98933 1 ...

Page 57: ...PLATE SERIAL YEAR MODEL ELECTRICAL PANELS CE PER PRINT CH 2 CH 0 CH 1 PEC 1 TOP PLATE REAR VIEW NANUK CASE WITH TOP PLATE TOP VIEW 18 66 14 68 7 05 TOP PLATE 99 00036 3 55 1 29 Ø 61 1 3 4 5 6 7 5 1 98926 LABEL PS1 LAPTOP DAAS CONTROL PANEL 1 PULL LAPTOP COMPUTER 90148 AND SHIP TO AUTOMATION SOLUTIONS TO HAVE THEM INTEGRATE IT INTO THE CONTROL PANEL 97100 2 STAMP NAME PLATE 47981 AS SHOWN AND ATTAC...

Page 58: ...7 1 MULTIFUNCTION IO AND DAQMX MODULE NATIONAL INSTRUMENTS USB 6001 8 1 DIN RAIL 11 LENGTH MUL 9 1 TOP PLATE AUTOMATION SOLUTIONS 99 00036 10 1 POLYURETHANE STRIP W ADHESIVE 3 8 WIDTH 1 16 THICK MCMASTER CARR 93275K112 11 1 LEGEND PLATE AUTOMATION SOLUTIONS G00335 12 5 M12 RECEPTACLE FEMALE FEMALE THREADS TURCK FK 4 4 1 13 1 POWER ENTRY MODULE 10A 250VAC FUSED TE CONNECTIVITY PE0SXDHX0 14 1 PORTAB...

Page 59: ...8 107 TB 1 06 106 TB 1 04 105 TB 1 02 L1 N L2 GND 16AWG BK 16AWG WH L1B N L2B 18AWG BU 18AWG WH BU 202 100 200 201 200 BK BN WH BN WH BN WH BN WH BN BU 100 100 100 100 100 COM COM COM COM COM COM BU 202 POWER SUPPLY PULS ML60 241 IN 120VAC 0 5A OUT 24VDC 2 5A PRESSURE TRANSDUCER 24VDC 0 1A 0 10VDC SIGNAL PRESSURE TRANSDUCER 24VDC 0 1A 0 10VDC SIGNAL PRESSURE TRANSDUCER 24VDC 0 1A 0 10VDC SIGNAL PR...

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Page 61: ...P N 96654 Rev 0 Page 47 APPENDIX C SDS Contact CLIMAX for the latest Safety Data Sheets ...

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