MPG1 - Pressure Calibration
Contents
1. MANUAL L5 SYSTEM SCHEMATIC 1 1 RESERVOIR ISOLATION valve 4 TEST1 connection 2 Reservoir 5 TEST ISOLATION valve 3 TEST2 connection 6 Variable volume Figure 5 System Schematic 2004 2007 DH Instruments a Fluke Company Page 4 2 INSTALLATION DH DH Instruments A Fluke Company 2 INSTALLATION 2 1 UNPACKING AND INSPECTION MPG1 is delivered along with its standard accessories in a corrugated container held in place by expandable foam The MPG1 is delivered with its valves closed and the variable volume VV fully screwed in The reservoir and the MPG1 plumbing are free of fluid Remove MPG1 and its accessories from the shipping container and remove each item from its protective bag Check that all items are present and have no visible signs of damage Table 1 MPG1 Parts List DESCRIPTION PART 4 MPG1 200M instrument 402122 Accessories including 1 ea Plug DH500 100285 1 Operation and Maintenance Manual 550134 2 2 SITE REOUIREMENTS There are two main site requirements for installing the MPG1 e 1 should be installed on a stable surface to which the MPG1 housing be anchored using the mounting holes in the bottom of the housing This is to hold the MPG1 firmly in place when turning the variable volume particularly at high pressures and to avoid applying the torgue from variable volume rotation to the tubing and fittings which may be connected to the MPGI e As the variabl2. of conflict between the English version and other language versions the English version predominates DH Instruments DH DHI MPG1 OPG1 GPC1 PG7000 RPM4 are trademarks registered and otherwise of DH Instrumenis a Fluke Company Document No 550134a 070405 Printed in the USA 2004 2007 DH Instruments a Fluke Company TABLE OF CONTENTS DHI DH Instruments TABLE OF CONTENTS ven TABLE OF CONTENTS ana TABLES Kau o n E NA eaten Il FIGURES MAN ENSE M eee Il ABOUT THIS MANUAL na a Peer du esee ie leto eae ideae betae T INTRODUCTION ses ala dokon Ni Eau o E ORA a 1 11 PRODUCT OVERVIEW un due o 1 12 SPEGIFIGATIONSs LE ob db o TR So o o ony 1 1 3 LOCATION OF THE 8 2 1 4 DIMENSIONAL SCHEMATICS dites aan o 3 1 5 SYSTEM SCHEMATIC en eie on 4 2 ona oak cost nes aa teintes 5 2 1 UNPACKING AND INSPECTION nn 5 22 SITE REQUIREMENTS eiiieaen duet 5 232 INITIAL SETUP 2 4 ne ne Edu 6 OPERATION a scree nese kates 7 3 1 GENERAL OPERATING PRINCIPLES AND INFORMATION 7 3 1 1 OVERVIEW
3. orange plastic dummy plugs installed These are NOT intended to hold high pressure They should be removed and replaced with appropriate fittings or stainless steel plugs before high pressure operation Each dummy plug carries a DH500 collar Remove and retain the collar for use in connecting to the mating tube e Fill the fluid reservoir Close the RESERVOIR ISOLATION valve Remove the reservoir cover by lifting it off gently Pour the desired fluid into the reservoir Do not overfill MPG1 is tested with a low viscosity fluorinated liquid and should be free of significant fluid residue as delivered O Prime and leak check pressurized system see Section 3 2 2004 2007 DH Instruments a Fluke Company Page 6 3 1 3 OPERATION DH DH Instruments A Fluke Company OPERATION GENERAL OPERATING PRINCIPLES AND INFORMATION 311 OVERVIEW See Section 1 5 Figure 5 MPG1 is used to manually generate and adjust liquid pressure from atmosphere to 100 MPa 15 000 psi or 200 MPa 30 000 psi using two valves and a variable volume Fittings for connecting to a device or system under test are located on the top and rear left side of the instrument housing A reservoir holds a supply of fluid 3 L2 VALVES The RESERVOIR ISOLATION and TEST ISOLATION valves are manually operated needle valves The RESERVOIR ISOLATION valve isolates the reservoir from the pressurized circuit It is opened to fill the variable volume with fluid and to open the
4. out of the TEST1 port Refill the reservoir with fresh liquid Pressurize MPG1 by plugging the TEST1 and TEST2 ports closing the RESERVOIR ISOLATION valve opening the TEST ISOLATION valve and using the variable volume to generate pressure Then crack the TESTI fitting to let fluid out Screw the variable volume all the way in to empty the variable volume out of the TEST1 port Repeat until the liquid coming out of the TEST1 port is clean Page 11 2004 2007 DH Instruments a Fluke Company MPG1 USER S MANUAL NOTES 2004 2007 DH Instruments a Fluke Company Page 12 5 WARRANTY STATEMENT DH DH Instruments A Fluke Company 5 WARRANTY STATEMENT Except to the extent limited or otherwise provided herein DH Instruments a Fluke Company DHI warrants for one year from purchase each new product sold by it or one of its authorized distributors only against defects in workmanship and or materials under normal service and use Products which have been changed or altered in any manner from their original design or which are improperly or defectively installed serviced or used are not covered by this warranty DHI and any of its Authorized Service Providers obligations with respect to this warranty are limited to the repair or replacement of defective products after their inspection and verification of such defects All products to be considered for repair or replacement are to be returned to DHI or its Authorized Service Provide
5. pressurized circuit to atmosphere vent The TEST ISOLATION valve isolates the TEST1 and TEST2 ports from the rest of the MPG1 circuit It can be used to isolate the variable volume and reservoir from the pressurized test system for example if it becomes necessary to refill the variable volume with fluid when it reaches end of stroke As the valve needle displaces fluid when it is operated it can also be used as a very fine variable volume for very fine pressure adjustment 3 L3 VARIABLE VOLUME VV The variable volume VV is a piston cylinder type screw press Rotating the variable volume handle moves the piston in or out decreasing or increasing the volume and therefore increasing or decreasing pressure The VV is used to generate and adjust pressure in the system to which MPG1 is connected when the TEST ISOLATION valve is open The torque necessary to rotate the VV handle is proportional to the pressure in the variable volume Generally the starting position of the VV when beginning to generate pressure from atmosphere is with the piston fully retracted handles rotated maximum CCW so that the full stroke of the VV is available to fill the test system and generate pressure During operation if the VV runs out of stroke the TEST ISOLATION and RESERVOIR ISOLATION valves can be used in sequence to allow the variable volume to be refilled without releasing the pressure on the TEST1 and TEST2 port see Section 3 2 3 The maximum
6. 02 431 9100 cal repair dhinstruments com Company Phoenix AZ 85044 5318 Fax 602 431 9559 USA Ohte Giken Inc Technology Center Tel 0298 55 8778 tohte ohtegiken co jp 258 1 Nakadai Nihari Gun Fax 0298 55 8700 Ibaraki 300 0133 JAPAN DHI Products Technical National Institute of Metrology Tel 010 64291994 ext5 cxcen mx cei go cn Service Division Heat Division Tel 010 64218637 ext 5 Pressure amp Vacuum Lab Fax 010 64218703 NO 18 Bei San Huan Donglu Beijing 100013 PR China Minerva Meettechniek B V Chrysantstraat 1 Tel 31 33 46 22 000 info minervaipm com 3812 WX Amersfoort Fax 31 33 46 22 218 the NETHERLANDS 2004 2007 DH Instruments a Fluke Company Page 14
7. 3 REFILLING OR EMPTYING THE VARIABLE VOLUME WITHOUT RELEASING TEST PRESSURE When working high pressure ranges with large test volumes or test volumes that are not fully purged of air the volume displaced by a single stroke of the variable volume may not be sufficient to generate the maximum pressure desired Conversely when lowering pressure the variable volume may run out of stroke before it is desirable to use the RESERVOIR ISOLATION valve to release pressure rapidly In these cases the variable volume can be backed off and refilled without releasing the pressure in the test system To refill or empty the variable volume without releasing test pressure proceed as follows Close the TEST ISOLATION valve This isolates the test system connected to the TEST ports from the variable volume and the RESERVOIR ISOLATION valve Note that after refilling the variable volume the TEST ISOLATION valve will be opened again At that time the pressure on both sides of the valve will not be perfectly equal so the pressure in the system connected to the TEST port s will change Consider this possibility before closing the TEST ISOLATION valve For example if using a piston gauge put the piston gauge piston at its bottom stop before closing the TEST ISOLATION valve Open the RESERVOIR ISOLATION valve This vents the pressure in the variable volume and connects it to the reservoir Back out the variable volume CCW to fill it or screw it in CW t
8. DH DH Instruments A Fluke Company MPG1 Manual Pressure Generator Controller for Hydraulic Pressure Operation and Maintenance Manual 2004 2007 DH Instruments a Fluke Company A 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 2004 2007 DH Instruments a Fluke Company All rights reserved Information in this document is subject to change without notice No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of DH Instruments a Fluke Company 4765 East Beautiful Lane Phoenix AZ 85044 5318 USA DH Instruments makes sincere efforts to ensure the accuracy and quality of its published materials however no warranty expressed or implied is provided DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described in it Mention of any product or brand does not constitute an endorsement by DH Instruments of that product or brand This manual was originally composed in English and was subsequently translated into other languages The fidelity of the translation cannot be guaranteed In case
9. G1 Manual Pressure Generator Controller It also includes additional information provided to help you optimize MPG1 use and take full advantage of its many features and functions s For those of you who don t read manuals go directly to section 2 5 to set up your MPG1 Then go to section 5 2 This will get you running guickly with minimal risk of causing damage to yourself or your MPG1 Then when you have guestions or start to wonder about all the great features you might be missing get into the manual Manual Conventions CAUTION is used throughout the manual to identify user warnings and cautions s NOTE is used throughout the manual to identify operating and applications advice and additional explanations Page III 2004 2007 DH Instruments a Fluke Company MPG1 USER S MANUAL NOTES 2004 2007 DH Instruments a Fluke Company Page IV 1 INTRODUCTION DH DH Instruments A Fluke Company 1 INTRODUCTION 11 PRODUCT OVERVIEW The DHI Manual Pressure Generator Controller for hydraulic pressure MPG1 provides a compact and easy to use system for manually generating setting and finely adjusting pressures between atmosphere and 200 MPa 30 000 psi in closed volumes MPG1 is a standard pressure generation and control component for working with DHI PG7302 piston gauges or liguid operated RPM4 reference pressure monitors 12 SPECIFICATIONS Pressure Range MPG1 200M Atmosphere to 200 MPa 30 000 psi V
10. ariable Volume Displacement MPG1 200M 11 cc 0 7 in Variable Volume Stroke 15 2 cm 6 in Reservoir Capacity 362 cc 22 1 in Pressure Connections 500 DH500 is gland and collar type fitting for 4 6 mm coned and left hand threaded tube DH500 is equivalent to AE F250C HIP HF4 etc Operating fluid Any non corrosive oil water water alcohol Inquire about other fluids Dimensions 260 mm x 144 mm x 410 mm WxHxD 10 2 in x 5 7 in x 16 1 in see Section 1 4 Variable volume handle span 457 mm 18 in Weight 20 kg 44 Ibs s Due to a policy of continual product improvement all specifications are subject to change without notice Page 1 2004 2007 DH Instruments a Fluke Company MPG1 USER S MANUAL 13 LOCATION OF THE COMPONENTS 1 TEST2 Connection DH500 4 Reservoir Cover 2 Reservoir isolation valve 5 Test isolation valve 3 TEST Connection DH500 6 Variable volume Figure 1 Front View 1 Reservoir 4 Reservoir isolation valve 2 Test isolation valve 5 TEST2 Connection DH500 3 TEST Connection DH500 6 Variable volume Figure 2 Rear View 2004 2007 DH Instruments a Fluke Company Page 2 1 INTRODUCTION L4 DIMENSIONAL SCHEMATICS All dimensions are in millimeter mm Figure 3 Front View with Dimensions 586 05 TO 738 45 Figure 4 Bottom and Side Views with Dimensions Page 3 2004 2007 DH Instruments a Fluke Company MPG1 USER S
11. be as free of air as possible See Section 3 2 1 to fill and prime the test system Once the system to which MPG1 is connected filled and primed to generate and adjust pressure proceed as follows 2004 2007 DH Instruments a Fluke Company Page 8 3 OPERATION Open the RESERVOIR ISOLATION valve close the TEST ISOLATION valve and back the variable volume all the way out CCW This fills the variable volume with fluid and makes the full stroke available to generate pressure Close the RESERVOIR ISOLATION valve open the TEST ISOLATION valve Use the variable volume to increase decrease and adjust pressure as desired Note that the TEST ISOLATION needle valve can be used as a mini variable volume for micro pressure adjustment if desired However closing the TEST ISOLATION valve complete isolates the test circuit from the main variable volume and the RESERVOIR ISOLATION valve Ifthe variable volume runs out of stroke when increasing or decreasing pressure it can be refilled without releasing pressure from the test system See Section 3 2 3 for instructions To release pressure from the test system and return pressure to atmosphere use the variable volume to reduce pressure as desired For a rapid release to atmosphere and full vent open the RESERVOIR ISOLATION VALVE Note that pressure will drop very quickly when the RESERVOIR ISOLATION valve is opened For a gentle pressure decrease always use the variable volume 3 2
12. e volume handles are wider than the MPG1 housing the MPG1 needs to be mounted so that the handles hang over the edge of the mounting surface for example over the front of a work bench Page 5 2004 2007 DH Instruments a Fluke Company MPG1 USER S MANUAL 2 3 INTIAL SETUP High pressure fluids are potentially hazardous Energy stored in pressurized fluids 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 To set up the MPG1 for operation proceed as follows Anchor the MPG1 to a stable working surface using the mounting holes on the bottom of the MPG1 platform The mounting hole diameter is 6 6 mm 0 26 in suitable for M6 or 1 4 in screws If mounting to a wood bench top use of threaded inserts and machine screws is recommended Connect the TEST1 and or TEST2 port to the system into which pressure is to be generated and controlled All MPG1 pressure connections are DH500 female DH500 is a gland and collar type fitting for 1 4 in 6 mm coned and left hand threaded tube DH500 is equivalent to AE F250C HIP HF4 etc If a TEST port is not being used plug it using a DH500 plug supplied in the MPG1 accessories ALWAYS use external tubing and fittings rated for pressures equal to or greater than the maximum pressure which MPG1 will be used to generate DH5OO F fittings are delivered with disposable
13. ew device to the system If possible leave an open connection or cracked fitting at a high point in the system to be pressurized Open the RESERVOIR ISOLATION valve and close the TEST ISOLATION valve e Fill the variable volume with fluid from the reservoir by screwing it all the way out CCW to its end of stroke O Close the RESERVOIR ISOLATION VALVE and open the TEST ISOLATION valve Screw in the variable volume CW while observing the open point in the test system When air free liquid comes out of the open point close the open point If the variable volume is screwed all the way in before the system is filled repeat steps 8 through as many times as necessary s The displacement of the variable volume of the MPG1 200M is 11 cc 0 7 in Proceed to generate and adjust pressure as desired see Section 3 2 1 The reservoir cover may be used to rapidly displace a large volume of fluid from the reservoir into the test system connected to the TEST ports s With the RESERVOIR ISOLATION valve closed remove the reservoir cover Open RESERVOIR ISOLATION and TEST ISOLATION valves Then while holding a finger over the vent hole in the cover slowly push the cover into position on the reservoir The cover acts as a piston pushing fluid out of the reservoir into the system 3 2 2 GENERATING AND ADJ USTING PRESSURE Before attempting to use the MGP1 to generate high pressure the system to which it is connected should
14. o empty it as desired Close the RESERVOIR ISOLATION VALVE DO NOT OPEN THE TEST ISOLATION VALVE YET Operate the variable volume as needed to generate a pressure equal to the pressure in the system connected to the TEST port s This is the pressure that was present on the variable volume before the TEST ISOLATION VALVE was closed in The pressure may be reasonably approximated by the feel torque on the variable volume Slowly open the TEST ISOLATION valve to equalize the pressure Proceed to generate and adjust pressure as desired see Section 3 2 2 Page 9 2004 2007 DH Instruments a Fluke Company MPG1 USER S MANUAL NOTES 2004 2007 DH Instruments a Fluke Company Page 10 4 MAINTENANCE AND ADJUSTMENTS DH DH Instruments A Fluke Company 4 MAINTENANCE AND ADJUSTMENTS MPG1 was designed for maintenance free operation The only recommended regular maintenance is to flush the hydraulic system and replace the operating liquid 4 1 REPLACING LIQUID AND FLUSHING HYDRAULIC SYSTEM Regular replacement of MPG1 s operating liquid and flushing of the hydraulic system is recommended To empty the reservoir remove the reservoir cover and siphon the bulk of liquid out of the reservoir Remove the balance of liquid from the system by cycling the variable volume with the TEST1 port plugged and TEST2 port open following the filling and priming procedure described in Section 3 2 1 Collect the used liquid as it comes
15. operating pressure of the variable volume is 200 MPa 30 OOO psi in MPG1 200M Do not generate pressure greater than the maximum operating pressure Page 7 2004 2007 DH Instruments a Fluke Company MPG1 USER S MANUAL 3 2 3 L4 RESERVOIR The reservoir is a 362 cc 22 1 in acrylic vessel mounted inside the MPG1 housing It is accessed for filling or cleaning by a friction fit lid through the top of the housing The reservoir is connected to the RESERVOIR ISOLATION valve by flexible tubing The reservoir lid can used to force fluid out of the reservoir into the system connected to the OPG1 OPERATION Operation of the MPG1 can be divided into three common tasks filling and priming the system under test See Section 3 2 1 generating and adjusting pressure see Section 3 2 2 filling or emptying the variable volume while maintaining test system pressure see Section 3 2 3 3 2 1 FILLING AND PRIMING THE SYSTEM UNDER TEST Before attempting to use the MGP1 to generate high pressure the system to which it is connected should be as free of air as possible Minimizing the air in the pressurized system increases the effectiveness of the variable volume in generating pressure When the MPG1 is first connected to a system to be pressurized or if a new device is connected to the system proceed as follows to fill and prime the system before attempting to generate high pressure Connect the MPG1 to the system under test or connect a n
16. r freight prepaid after receiving authorization from DHI or its Authorized Service Provider The buyer assumes all liability vis a vis third parties in respect of its acts or omissions involving use of the products In no event shall DHI be liable to purchaser for any unforeseeable or indirect damage it being expressly stated that for the purpose of this warranty such indirect damage includes but is not limited to loss of production profits revenue or goodwill even if DHI has been advised of the possibility thereof and regardless of whether such products are used individually or as components in other products Items returned to DHI under warranty claim but determined to not have a defect covered under warranty or to not have a defect at all are subject to an evaluation and shipping charge as well as applicable repair and or calibration costs The provisions of this warranty and limitation may not be modified in any respect except in writing signed by a duly authorized officer of DHI The above warranty and the obligations and liability of DHI and its authorized service providers exclude any other warranties or liabilities of any kind Page 13 2004 2007 DH Instruments a Fluke Company MPG1 USER S MANUAL Table 2 DHI Authorized Service Providers DH INSTRUMENTS A FLUKE COMPANY WWW DHINSTRUMENTS COM AUTHORIZED SERVICE PROVIDERS TELEPHONE COMPANY ADDRESS amp FAX EMAIL DH Instruments a Fluke 4765 East Beautiful Lane Tel 6
17. riad RV A 7 3 1 2 MORIA 7 3 1 3 MLNIDVIBZSORUIZQAA 7 3 1 4 RESERVOIR ee EA 8 8 25 OPERATION io NS E 8 3 2 1 FILLING AND PRIMING THE SYSTEM UNDER 5 2 0 22 0 0401 41 0 11 11 8 3 2 2 GENERATING AND ADJUSTING 55 00 2 2442421 111 nana na anana nana nanang aran anana na nana nenee 8 3 2 3 REFILLING OR EMPTYING THE VARIABLE VOLUME WITHOUT RELEASING TEST PRESSURE 9 4 MAINTENANCE AND ADJUSTMENTS 11 4 1 REPLACING LIQUID AND FLUSHING HYDRAULIC SYSTEM 11 5 WARRANTY STATEMENT n 13 Page 2004 2007 DH Instruments a Fluke Company MPG1 USER S MANUAL DH DH Instruments A Fluke Company TABLES Table MRG1 Parts List sag nasa Wd cde e La cte de dta et ed e do dte A dette at t 5 Table 2 DHI Authorized Service Providers iii nee 14 FIGURES Figure 15 Front ATEA AEE bee tl 2 Figure 2 Rear View i es ec Lage esp aie a iy an a e in ei 2 Figure 3 Front View with Dimensions sis 3 Figure 4 Bottom and Side Views with Dimensions 3 Flg re o System Schetmatie ua niente i net e En ha ede Fai ia oae pedes lana 4 2004 2007 DH Instruments a Fluke Company Page II ABOUT THIS MANUAL ABOUT THIS MANUAL DH Instruments A Fluke Company This manual provides the user with the information necessary to operate an MP
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