DH Instruments OPG1-30000-AF Operation And Maintenance Manual Download Page 28

 

OPG1™ Operation and Maintenance Manual 

 

 

 

 

©2000 

DH Instruments, Inc

.

  

Page

 

22

 

 

With the 

INLET valve 

(5) closed, use the 

DRIVE SET regulator 

(4) and the 

PUMP DRIVE 

gauge 

(3) indication to set the desired maximum pump output pressure.  This is generally 

done at the beginning of a test or calibration based on the maximum pressure of 
the calibration.  It is good practice to set the pump output pressure below the maximum 
pressure desired to avoid accidental overpressure.  The PDVV can then be used for the final 
pressure adjustment at the maximum pressure (see Section 3.2.3).  

 

 The DRIVE SET regulator sets the oil pressure output of the hydropneumatic pump.  When the 

INLET valve is opened, this pressure can be generated very rapidly in the system connected 
to OPG1.  Use caution in setting the pump drive pressure and always check the setting and 
adjust if necessary before using the INLET valve (see Sections 2.4.2 and 3.2.1). 

3.2.2

 

ROUGH PRESSURE GENERATION/CONTROL, INLET AND OUTLET 

VALVE OPERATION 

Numerical references in this section refer to Section 3.2, Figure 6. 

The 

INLET valve 

(5) and 

OUTLET valve 

(8) are high pressure needle valves. 

 

Their operation is highly progressive over a half-turn with mechanical stops at each end so 
they cannot be overtightened.  The valve is turned CW to close and CCW to open.  A WHITE 
dot on the handle body indicates its current open/close position. 

The 

INLET valve 

(5) controls the flow of oil from the hydropneumatic pump into the 

test system.  When the 

INLET valve

 is closed, the pump is shut off from the test system and 

dead ended.  When the 

INLET valve 

is open, the pump output is connected to the test 

system and can fill and generate pressure into the system. 

The 

OUTLET valve 

(8) controls the flow of oil from the test system back to the tank.  When it 

is closed, the test system is shut off from the tank.  When the 

OUTLET valve 

is open, the 

system returns oil to the tank and is opened to atmospheric pressure. 

The 

INLET valve 

(5) and 

OUTLET valve 

(8) are used to execute large pressure changes in 

the test system and for rough pressure control.  The 

INLET valve

 is used to connect to the 

pump to purge and prime the test system at the beginning of a test or calibration.  
The 

OUTLET valve

, when fully opened, is the means of opening the test to atmosphere and 

setting zero

 pressure.  The 

INLET valve

 and 

OUTLET valve

 are not generally used for 

ON/OFF action but progressively to roughly set the desired pressure.  Exercise caution when 
operating the valves to not open them too quickly which may cause pressure in the system to 
change much more rapidly than desired.  

 

 

 The INLET valve connects the output of the hydropneumatic pump to the test system.  

When the INLET valve is opened, high pressure can be generated very rapidly in the system 
connected to OPG1.  Use caution in opening the INLET valve and always check the PUMP DRIVE 
gauge before doing so (see Sections 2.4.2 and 3.2.1). 

 

Summary of Contents for OPG1-30000-AF

Page 1: ...T O 33A6 4 30 1 1 August 2000 2000 DH Instruments Inc OPG1 30000 AF Oil Pressure Generator Controller Operation and Maintenance Manual NSN 6685 01 470 8667 1 of 2...

Page 2: ...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 t...

Page 3: ...TIC POWER DRIVE AIR 13 2 4 2 ADJUST HYDROPNEUMATIC PUMP DRIVE AIR PRESSURE 14 2 4 3 CHECK PROPER OPERATION OF HYDROPNEUMATIC PUMP AND LEAK CHECK 14 2 4 3 1 STEP ONE PURGING AIR FROM THE HYDRAULIC PUMP...

Page 4: ...OIL AND PURGING CONTAMINATED OIL 29 4 4 PRIMING THE HYDROPNEUMATIC PUMP 30 4 4 1 PRIMING THE HYDROPNEUMATIC PUMP BY SYRINGE INJECTION 30 4 4 2 INTERNAL PURGE OF HYDROPNEUMATIC PUMP 31 4 5 CLEANING REP...

Page 5: ...orized Service Providers 36 F FI IG GU UR RE ES S Figure 1 Front Panel 3 Figure 2 Front and Side Views with Dimensions 4 Figure 3 System Schematic 5 Figure 4 Connecting OPG1 30000 AF to an RPM3 HPMS 1...

Page 6: ...features and functions FOR THOSE OF YOU WHO DON T READ MANUALS GO DIRECTLY TO SECTION 2 3 TO SET UP YOUR OPG1 30000 AF READ SECTION 2 4 4 AND GO TO SECTION 3 3 THIS WILL GET YOU UP AND RUNNING QUICKL...

Page 7: ...ence and effort free operation of automation It is the standard pressure generating and control component in an HGC 30000 AF Hydraulic Gauge Calibration system as well as in a PG7302 piston gauge syst...

Page 8: ...MPa 30 000 psi Maximum output pressure depends on pneumatic power supply see above Operating Medium Di 2 Ethyl Hexyl Sebacate same as PG7302 piston gauge and other non corrosive oils Pneumatic Power...

Page 9: ...d indications needed to set and adjust pressure 1 PDVV Drive Air Test Oil Pressure Gauge 2 PDVV Piston Position Indicator 3 Pump Drive Air Inlet Oil Pressure Gauge 4 Pump Drive Air Set Regulator 5 Tes...

Page 10: ...OPG1 Operation and Maintenance Manual 2000 DH Instruments Inc Page 4 1 3 2 OVERALL DIMENSIONS Figure 2 Front and Side Views with Dimensions...

Page 11: ...3 PDVV DRIVE Air Connection 4 Top TEST Connection 14 Common DRIVE Air Connection 5 Oil Return Overflow Tube 15 DRIVE Air Filters 6 Right Side TEST Connection 16 PUMP DRIVE Pressure Gauge 7 Left Side T...

Page 12: ...OPG1 Operation and Maintenance Manual 2000 DH Instruments Inc Page 6 N NO OT TE ES S...

Page 13: ...l items are present and have NO visible damage Verify the items received against the parts list in Table 1 Table 1 OPG1 30000 AF Parts List DESCRIPTION PART NO OPG1 30000 AF Instrument 401602 Operatio...

Page 14: ...tubing and fittings provided with the OPG1 accessories can also be used to connect to other systems If interconnections other than the OPG1 accessories are used select tubing and fittings rated to han...

Page 15: ...sible Fill tank with oil if necessary Back off the tank cover until a gap for oil passage can be seen between the DUT connection shaft and the cover Pour in oil to just under the overflow tube see Sec...

Page 16: ...ally supplied from an N2 or Air K bottle The OPG1 PDVV DRIVE connection must be supplied with NON LUBRICATED drive air The internal components are permanently lubricated The oil in lubricated air can...

Page 17: ...ut and to identify the parts used from the interconnection kit Figure 4 shows the RPM3 HPMS installed to the right of the OPG1 It may be installed on either side using either one of OPG1 s rear side t...

Page 18: ...nk s oil return overflow tube see Section 3 2 6 2 3 1 4 CONNECTING TO A DEVICE UNDER TEST In an HGC 30000 AF system the device under test DUT is intended to be connected on the top of the OPG1 at the...

Page 19: ...o assure that fittings and devices connected to OPG1 are rated for the pressures at which they will be used If the DUT connection is lower than the OPG1 oil tank when the OUTLET valve is open and the...

Page 20: ...and observe the PUMP DRIVE Gauge to set the drive air pressure to the desired level the BLUE indication on outside of gauge gives the approximate maximum oil pressure that will be generated 2 4 3 CHE...

Page 21: ...e to the OPG1 and or the system connected to it be sure that all pressure vessels and connections are rated for the pressure levels that will be applied and that all connections have been properly tig...

Page 22: ...1 is connected or in OPG1 itself The time required for pressure to stabilize after the pressure has been changed is directly proportional to the volume connected to OPG1 and the mechanical stability o...

Page 23: ...lve to prime only only until pressure starts rising then use PDVV for all pressure control The and push button valves can increase pressure very quickly Observe pressure evolution carefully when opera...

Page 24: ...disconnect the DRIVE and PDVV DRIVE pressure connection s Cap both ports with plastic caps if available Close the OUTLET valve and INLET valve Disconnect all hydraulic pressure connections and plug th...

Page 25: ...e oil pressure reaches 200 MPa 30 000 psi The pump draws oil from the oil tank on top of OPG1 The DRIVE SET regulator 1 is used to set the pneumatic drive pressure to the pump and thus the oil output...

Page 26: ...E Air Connection 4 Top TEST Connection 14 Common DRIVE Air Connection 5 Oil Return Overflow Tube 15 DRIVE Air Filters 6 Right Side TEST Connection 16 PUMP DRIVE Pressure Gauge 7 Left Side TEST Connect...

Page 27: ...s determines the oil pressure that the pump will generate before stalling and that is available on demand when the INLET valve 5 is opened The PUMP DRIVE gauge 3 indicates the pump drive pressure on i...

Page 28: ...open close position The INLET valve 5 controls the flow of oil from the hydropneumatic pump into the test system When the INLET valve is closed the pump is shut off from the test system and dead ende...

Page 29: ...d a pressure point The actual rate of pressure change caused by the PDVV valves and PDVV valves is dependent on the test volume that is connected to OPG1 Increasing the test volume lowers the rates an...

Page 30: ...to 200 MPa 30 000 psi It is the user s responsibility to assure that fittings and devices connected to OPG1 are rated for the pressures at which they will be used If the DUT connection is lower than...

Page 31: ...wo conditions or incorrect fluid head corrections will be applied and the zero point will be inconsistent with other measurements See the RPM3 HPMS A30000 A6000 AF Operation and Maintenance Manual for...

Page 32: ...no back pressure is applied to the DUT when checking the DUT zero point Initialize the test on the RPM3 HPMS A30000 A6000 AF see the RPM3 HPMS Operation and Maintenance Manual Press ENTER on the keyp...

Page 33: ...ause the oil to become contaminated It should then be replaced and the OPG1 hydraulic system purged see Section 4 3 Prime hydropneumatic pump if it becomes cavitated If the hydropneumatic pump is run...

Page 34: ...at is NOT covered under the product warranty and or may void the product warranty 4 2 FILLING THE TANK The oil level in the OPG1 tank should be maintained at all times Opening the INLET valve and oper...

Page 35: ...or similar device Clean out the tank with paper towels or rags Remove all particulates that may be present Refill the tank with fresh oil to just under the overflow tube To purge OPG1 of dirty oil pro...

Page 36: ...only required if the regular purge procedure fails see Section 2 4 3 1 Numerical references in this section refer to Section 4 2 Figure 9 To prime the pump with the syringe proceed as follows Back off...

Page 37: ...ile keeping the OPG1 in its normal horizontal operating position This is accomplished by placing either end on separate tables and accessing the pump from beneath OPG1 or by slightly lifting the front...

Page 38: ...for the PDVV DRIVE filter 3 and 8 10 for DRIVE filter 9 Remove the filter 3 and or 9 To reinstall the filter make the filter connections 2 and 4 or 8 and 10 Take care to insure that the filter is orie...

Page 39: ...losed Leak in INLET valve or leak in PDVV valve s Isolate leak to INLET valve or PDVV valve s by checking whether pressure continues to increase when PDVV valves are opened or PDVV is at end of stoke...

Page 40: ...ank empty Purge and prime pump 4 4 Pump cycles continuously without generating pressure OUTLET valve is open Close OUTLET valve 3 2 2 Pump cycles continuously without generating pressure There is a la...

Page 41: ...es all liability vis vis third parties in respect of its acts or omissions involving use of the products In NO event shall DH Instruments be liable to purchaser for any unforeseeable or indirect damag...

Page 42: ...nstruments Inc 4765 East Beautiful Lane Phoenix AZ 85044 5318 USA Tel 602 431 9100 Fax 602 431 9559 jbaines dhinstruments com Worldwide Minerva I P M B V Handelsweg 13 Postbus 76 1270 AB Huizen NETHER...

Page 43: ...ic pump Sets maximum inlet pressure DUT Device or System Under Test The device that is connected to OPG1 to be tested or calibrated Gland The jam nut in a DH500 fitting that pushes the collar on the t...

Page 44: ...that release air drive pressure from the PDVV actuator causing the PDVV plunger to move back decompressing oil and decreasing the test pressure Used to decrease pressure and for fine pressure adjustme...

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