GE Sensing - Masterflex
Contents
1. i Weight Float Range FIGURE 4 1 FLOAT HEIGHT INDICATOR POST Note This is the PCU mid float position which is the point at which all internal corrections have been made with reference to the pressure datum at the top of the test port The recessed area is simply a guide for the operator to indicate the PCU travel limits 4 3 Gently rotate the weight stack clockwise such that it is turning between approximately 10 and 60 rpm Avoid side loads when turning the weights by placing the palms of the hands on either side and rolling the stack by pulling in opposite directions see Figure 4 2 DO NOT rotate weights when the piston is against the top or bottom limits of travel 4 1 OPERATION 4 4 FIGURE 4 2 WEIGHT ROTATION Allow a few moments for the system to stabilize before taking any readings especially after large changes in system pressure Note Large sudden changes in pressure will cause the system temperature to rise or fall 4 5 4 6 4 7 4 8 which can cause instrument readings to change as the fluid in the system expands or contracts thus increasing or decreasing the pressure For the next higher calibration point repeat from step 4 1 above To measure reducing pressures remove the necessary weights and turn the capstan out so that the weight stack floats at the correct height then rotate clockwise Depressurize the system by turning the capstan FULLY OUT Never release the system pres2. Item numbers 1 through 5 6 2 MAINTENANCE amp SERVICING ITEM DESCRIPTION PART ITEM DESCRIPTION PART 2 CYLINDER 5 6 JORING_________ P102803 4 SUPPORTRING 01820 8 SUMPRNG P109280 FIGURE 6 1 10mm PCU ASSEMBLY 6 3 MAINTENANCE SERVICING 6 2 PCU ASSEMBLY 2 amp 3 mm NOMINAL DIAMETERS Piston Disassembly 6 2 1 Lift off the weight carrier assembly 1 2 and unscrew the piston nut 5 Use the dowel hole if the nut is tight Remove the piston cylinder assembly 6 2 2 Loosen set screw 3 in piston cap 4 and gently pull the piston cap from the piston DO NOT PULL IN SUCH A WAY THAT THE PISTON CAN BEND The piston and cylinder assembly 6 7 amp 8 can now be removed from the piston nut 6 2 3 withdraw the piston 8 from the cylinder 6 Piston Cleaning 6 2 4 Use non fluffing non abrasive lint free tissue or absorbent cloth Hold the piston by the larger head end and rub the tissue back and forth along its length 6 2 5 To remove all traces of contamination especially important with Water Operated Testers the piston can be cleaned in a suitable solvent Note O ring seals where fitted are Nitrile rubber and should not be immersed in solvents as they will become damaged They should be wiped carefully with a new tissue 6 2 6 After removal from the solvent using a NEW tissue repeat the cleaning procedure in 6 2
3. 5 6 2 7 Place piston carefully a NEW tissue where it will not be damaged while the cylinder is cleaned IMPORTANT NEVER TOUCH THE WORKING SURFACE OF A CLEAN PISTON WITH BARE FINGERS THE NATURAL OIL IN VOUR SKIN CAN CAUSE THE PISTON AND CVLINDER TO STICK 6 2 8 Wipe excess fluid from the outside surfaces of the cylinder 6 6 29 Roll a NEW tissue into a tapered rod of appropriate size Force the tissue through the cvlinder bore whilst rotating Ensure that the tissue is a tight fit inside the bore so that dirt and contamination is removed 6 2 10 Repeat 6 2 9 using a NEW tissue but from the opposite end of the cvlinder 6 2 11 Immerse the cvlinder in a suitable clean solvent see note in 6 2 5 above 6 2 12 After removal from the solvent using a NEW tissue repeat the cleaning procedure in 6 2 9 amp 10 Piston Re assembly 6 2 13 Replace o ring 7 in the counter bore in the underside of the cvlinder F ensuring that it is located correctly and evenly 6 4 MAINTENANCE 8 SERVICING 6 2 14 6 2 15 6 2 16 6 2 17 6 2 18 6 2 19 6 2 20 Holding the piston by the larger head end dip the other end into a container of clean operating fluid and transfer to the bore in the underside of the cylinder Allow the fluid to run through the bore Repeat this 2 or 3 times to ensure a good film of clean operating fluid exists in the cylinder bore Carefully introduce the piston into the underside of the cylind
4. 71 247 BEARING RING P104163 PISTON NUT P104103 HP PCU BODY P109283 6 CYLINDER SPEC SUMP RING P109280 FIGURE 6 2 2 amp 3mm PCU ASSEMBLY 6 6 MAINTENANCE amp SERVICING 6 3 PCU ASSEMBLY 5 mm NOMINAL DIAMETER Piston Disassembly 6 3 1 Lift off the weight carrier assemblv 1 amp 2 and unscrew the piston nut 5 Use the hole if the nut is tight Remove the piston cylinder assembly 6 3 2 Loosen set screw 3 in piston cap 4 and gently pull the piston cap from the piston DO NOT PULL IN SUCH A WAY THAT THE PISTON CAN BEND The piston and cylinder assembly 7 can now removed from the piston nut 6 3 3 Gently withdraw the piston 6 from the cylinder 7 Piston Cleaning 6 3 4 Use non fluffing non abrasive lint free tissue or absorbent cloth Hold the piston by the larger head end and rub the tissue back and forth along its length 6 35 To remove all traces of contamination especially important with Water Operated Testers the piston can be cleaned in a suitable solvent Note O ring seals where fitted are Nitrile rubber and should not be immersed in solvents as they will become damaged They should be wiped carefully with a new tissue 6 3 6 After removal from the solvent using a NEW tissue repeat the cleaning procedure in 6 3 5 6 3 7 Place piston carefully on a NEW tissue where it will not be damaged while the cylinder is cleaned IMPORTANT NEVER TOUCH THE WO
5. reservoir valve one turn counter clockwise and turn capstan fully in 3 2 Pumpthe priming pump two times 3 3 Close valve and turn capstan fully out 3 4 Open valve and turn capstan fully in Note During this operation bubbles may appear in the reservoir as trapped air is expelled For large volumes repeat steps 3 3 amp 3 4 until no further bubbles appear 3 5 With valve open turn capstan fully out and close valve The tester is now ready for use WARNING Turning the capstan out with the reservoir valve closed will generate approximately 15 inHg 0 5 bar vacuum If the DUT is vacuum sensitive leave valve open during priming operation 3 1 PRIMING THIS PAGE INTENTIONALLY LEFT BLANK 3 2 PRIMING SECTION 4 0 OPERATION 4 1 Select the required weights and stack them on the appropriate piston assembly The pressure measured is the sum of the weights plus the piston weight carrier Dual PCU models The PCU s are matched in a ratio of effective areas 20 1 or 10 1 depending upon model and the weights will be marked accordingly with both high and low pressure values Note The priming pump is intended for system priming only and cannot be used to generate high pressures 4 2 Turn the capstan in clockwise to generate pressure When the piston rises ensure that the bottom face of the lowest weight is level with the groove midway in the recessed area on the indicator post Weight Low Pressure Low Pressure Float Range
6. to the very close fit of these components the water film can break down very quickly after use due to evaporation surface tension and capillary action effects Before using the instrument after a period of inactivity Low Pressure Hold the weight carrier table and gently lift the piston assembly vertically slowlv turning to check for freedom of movement High Pressure Lift off the weight carrier tube assemblv Hold the piston cap and gentiv lift the piston assembly vertically slowly turning to check for freedom of movement Under no circumstances should excessive force be used on the piston assembiv as this may lead to permanent damage It should never be forced or pulled in such a way that a bending movement is applied to it To aid in piston lubrication and movement it is sometimes helpful to gently pressurize the system to a maximum of 15 psi 1 bar If any resistance or grittiness is felt the PCU has either dried out too much to use in its current condition or the svstem has been contaminated In either case the PCU must be removed and dismantled for cleaning see Section 6 If after cleaning the PCU s performance deteriorates quickly it confirms that the system is contaminated If this is the case the instrument must be completely dismantled and cleaned before further operation of the PCU assembiv 4 3 OPERATION THIS PAGE INTENTIONALLY LEFT BLANK 4 4 OPERATION SECTION 5 0 CALIBRATION IN DIFFERENT PRESSUR
7. E UNITS The deadweight tester can be used to calibrate in different pressure units in either of two methods 5 1 CONVERSION WEIGHTS 5 2 A set of Conversion Weights can be supplied marked the required pressure unit and adjusted the correct mass for use with the existing piston s The set includes where applicable a replacement low pressure weight carrier table and a replacement high pressure weight carrier ring These items are simplv exchanged for the original items when using the conversion weights Calibration is carried out as described above with logical pressure increments throughout the operating range avoiding the need to perform pressure unit conversion calculations SOFTWARE PressCal software is available for use with deadweight testers and will allow users to applv all necessarv corrections e g local gravitv temperature pressure head etc to enhance the pressure measurement accuracy of the instrument It will allow calibration in any of 12 different pressure units using the existing weight set 5 1 CALIBRATION IN DIFFERENT PRESSURE UNITS THIS PAGE INTENTIONALLY LEFT BLANK 5 2 CALIBRATION IN DIFFERENT PRESSURE UNITS SECTION 6 0 MAINTENANCE amp SERVICING IMPORTANT The piston cylinder assembly is the most critical and sensitive part of the deadweight tester To maintain accuracy the piston must always slide freely in the cylinder and the hydraulic fluid must remain clean The Figu
8. GE Sensing Houston Center User s Manual Printing amp Assembly Instructions PRINTING 1 FRONT amp BACK COVER PAGES Front and Back cover pages first and last pages will be printed in color single sided on 8 1 2 x 11 65 lbs white paper 2 INTRODUCTION PAGES Introduction section pages up to Section 1 0 will be printed in color single sided on 8 1 2 x 11 24 Ibs white paper 3 SECTION amp APPENDIX PAGES All Sections and Appendix pages will be printed in color double sided on 8 1 2 x 11 24 Ibs white paper ASSEMBLY User s Manual will be assembled with front and back 8 3 4 x 11 1 4 Clear View Plastic Covers bound with black spines of appropriate size PACKAGING The assembled User s Manual will be packed in a clear plastic bag or Saran wrapped The package is labeled with bar coded part number as per purchase order GE Sensing Models covered Pressurements Oil Operated Instruments P3111 P3112 P3113 P3114 P3115 P3116 P3125 P3124 P3125 Distilled Water Operated Instruments P3211 P3213 P3214 P3223 P3224 Hydraulic Deadweight Tester User s Manual imagination at work HYDRAULIC DEADWEIGHT TESTER PRESSUREMENTS MODELS P3100 amp P3200 SERIES USER S MANUAL GE SENSING 10311 WESTPARK DRIVE HOUSTON TEXAS 77042 713 975 0547 FAX 713 975 6338 Release 3100P 1D01 Revision B Date 09 27 06 WARRANTY GE Sensing warrants its products to co
9. RKING SURFACE OF A CLEAN PISTON WITH BARE FINGERS THE NATURAL OIL IN YOUR SKIN CAN CAUSE THE PISTON AND CYLINDER TO STICK 6 3 8 Wipe excess fluid from the outside surfaces of the cylinder 6 6 3 9 Roll a NEW tissue into a tapered rod of appropriate size Force the tissue through the cylinder bore whilst rotating Ensure that the tissue is a tight fit inside the bore so that dirt and contamination is removed 6 3 10 Repeat 6 3 9 using a NEW tissue but from the opposite end of the cylinder 6 3 11 Immerse the cylinder in a suitable clean solvent see note in 6 3 5 above 6 3 12 After removal from the solvent using a NEW tissue repeat the cleaning procedure in 6 3 9 amp 10 Piston Re assembly 6 3 13 Holding the piston by the larger head end dip the other end into a container of clean operating fluid and transfer to the bore in the underside of the cylinder Allow the fluid to run through the bore Repeat this 2 or 3 times to ensure a good film of clean operating fluid exists in the cylinder bore 6 7 MAINTENANCE 8 SERVICING 6 3 14 Carefully introduce the piston into the underside of the cylinder and push 6 3 15 6 3 16 6 3 17 6 3 18 6 3 19 gently through NEVER FORCE THE PISTON INTO ITS CVLINDER OR DAMAGE WILL RESULT If resistance is felt introduce more fluid If resistance continues re clean piston cvlinder or both 1f after repeated cleaning the piston still will not slide freelv within the cvli
10. T PUMP BLOCK P109295 6 PUMPCHECKFLANGE 109336 O RING 54 700 11 SCREW 70 165 2100 BULLET P104731 CHECK VALVE P109318 5 SPRING P104733 10 CONNECTOR 25 1086 FIGURE 6 7 CHECK VALVE ASSEMBLIES ITEM 3 ORNG 154 7008 8 ELBOW 25 148 91 LS 6 16 MAINTENANCE amp SERVICING 6 8 RESERVOIR ASSEMBLY 6 8 1 6 8 2 6 8 3 6 8 4 6 8 5 6 8 6 6 8 7 6 8 8 6 8 9 6 8 10 6 8 11 6 8 12 To drain the fluid from the reservoir first remove any weights and raise the instrument a few inches by placing suitably sized blocks under the feet Place a suitable catchment tray or bowl below the reservoir drain 13 Open the valve by turning valve stem 1 counter clockwise Remove gland nut and plug 13 amp 12 and allow the fluid to drop into the catchment tray To completely disassemble the reservoir the top plate must be removed from the instrument case Refer to Section 6 4 Disconnect the high pressure tubing by unscrewing the gland nuts fitted to the reservoir body 11 The low pressure feed to the priming pump is disconnected by pressing down on the black plastic ring at the top of the connector and gently pulling on the nylon tubing Remove valve stem completely by turning counter clockwise taking care not to lose the spring 2 and nylon washer 3 Lift off reservoir cover 4 Remove three screws from reservoir spacers that hold the assembly to the top plate Th
11. URE PCU INSTRUMENT 1 5 INTRODUCTION THIS PAGE INTENTIONALLY LEFT BLANK 1 6 INTRODUCTION SECTION 2 0 PREPARATION The deadweight tester must be set up on a level stable workbench or similar surface Remove spokes from tool roll and fit to capstan hub Level the tester using the four adjustable feet to the bubble level attached to the top plate Rotate reservoir dust cover through turn and fill reservoir approximately full with the appropriate fluid Rotate dust cover back to cover hole 2 1 OPERATING FLUID 2 11 Oil The instrument is supplied with Shell Spindle Oil 22 our reference 55 655 2 1 2 Water Only Distilled or De ionized Water should be used in the instrument Great care must be taken when operating any deadweight tester that uses water as it s operating fluid as any contamination present within the system will result in degradation of performance and eventual irreparable damage to the PCU s The impurities found in ordinary water supplies are sufficient to affect the spin and sensitivity of the PCU assemblies and damage the PCU s WARNING The system is designed for use with the fluids described above only use of other fluids can effect the operation and performance of the instrument and CAN CAUSE PERMENANT DAMAGE To avoid damage to the instrument the operator should check the quality of the operating fluid during use If the fluid becomes discolored cloudy or particles appear the reservoir the syste
12. URE UNITS 5 1 SI CONVERSION WEISE SSR nr 5 1 Se as 5 1 6 0 MAINTENANCE amp SERVICING une 6 1 6 1 PCU ASSEMBLY 10 mm NOMINAL DIAMETERL ee ee 6 1 6 2 PCU ASSEMBLY 2 amp 3 mm NOMINAL DIAMETERS 6 4 6 3 PCU ASSEMBLY 5 mm NOMINAL DIAMETER seis ae 6 7 BA SOP PEATE REMOVAL TZ rS uu een Ruten 6 10 SEREWRUMPASSEME 6 11 6 6 PRIMING PUMP ASSEMBLY essen 6 13 SCHECK WALL B e Sense 6 15 6 8 RESERVOIR ASSEMBLY au 6 17 7 0 8 0 9 0 FAULT FINDING AAA AN 7 1 POOR PELSPIN SENSINIVITV au sn ln sinne 7 1 7 2 AIGH PCU FALE Sessel 7 2 7 3 SYSTEM WILE NOT PRIME oras 7 2 SYSTEM MILE NOTRE SS snn s 7 2 7 5 PRIMING PUMP MALF UNC ON san 7 3 7 6 CANNOT REACH MAXIMUM PRESSURE une 7 5 STORAGE TRANSPORTATION u a 8 1 8 1 ci 8 1 111 SAA 8 1 ANCILLARY EQUIPMENT uuu nee ee 9 1 9 1 LIQUID TO LIQUID SEPERATOR Model Laine 9 1 9 27 ANGLEADAPTER Mode Bgm 9 1 9 3 POINTER REMOVER PUNCH Model 5551 ak RAA 9 2 vi Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 2 2A Figure 2 2B Figure 2 2C Figure 4 1 Figure 4 2 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 LIST OF FIGURES Hydraulic CIRCUIESCREMOUC reset 1 2 DU GLP CUS EGU L late 1 4 Single High Pressure PCU Instru
13. UT P102420 O RING 54 700 111 6 PUMPSHAFT JP109291 13 ORING 54 70046 7 BAL JP101022 14 PUMPBLOCKASSEMBY FIGURE 6 6 PRIMING PUMP ASSEMBLY 6 14 MAINTENANCE amp SERVICING 6 7 CHECK VALVES Inlet Check Valve The inlet check valve is a bought in item and is not readily user serviceable To remove 6 7 1 Disconnect nylon tubing from connector 9 by pressing in the collar at the top of the connector and gently pulling on the tubing 6 7 2 Unscrew and remove connector 6 7 3 Remove check valve assembiv 8 6 7 4 When replacing the check valve assembly take care to remove all traces of PTFE or Teflon sealing tape on the mating threads of elbow 7 New tape or similar sealing method must be applied to ensure a pressure tight joint 6 7 5 Reassembly is the reverse of removal Outlet Check Valve 6 7 6 Remove screws 7 and pump check flange 6 taking care not to drop the check valve bullet 3 and spring 4 6 7 7 Inspect the parts for cleanliness and damage particularly the sealing surfaces 6 7 8 When removing O rings take care not to use any tool that may have a sharp 6 7 9 edge that will scratch the surfaces of the mating groove otherwise it may leak when reassembled Reassembly is the reverse of removal but care mast be taken to ensure that the spring and bullet are seated correctly 6 15 MAINTENANCE amp SERVICING ITEM DESCRIPTION PART ITEM DESCRIPTION PAR
14. al and can be removed by unwinding it from the rambler 6 5 4 When removing the rambler seal 5 take care not to use any tool that may have a sharp edge that will scratch the surfaces of the rambler otherwise it may leak when reassembled 6 5 5 replacement rambler seal can be eased over the front of the rambler and into the groove 6 5 6 Similarly the new anti extrusion ring can be wound into the groove in the rambler behind the rambler seal 6 5 7 If it is necessary to remove the barrel 6 the locknut 7 must be loosened approximately turn The barrel can then be unscrewed from the test station 9 Note It is often easier to remove the barrel support bracket 11 to allow greater movement remove the 2 screws 12 from the upper side of the top plate 6 5 8 Before re fitting the barrel ensure that the barrel seal 8 is correctly located in the counter bore in the front of the barrel Screw the barrel fully in to the test station and secure with the locknut 6 5 9 Re align the barrel support bracket if removed and secure through the top plate with the 2 screws 12 6 5 10 Ensure that the rambler assembly is correctly located on the end of the lead screw assembly Carefully introduce the rambler into the open end of the barrel making sure that it does not tilt when entering the barrel 6 5 11 Push the lead screw assembly fully in to the barrel ensuring that the key in the nut locates correctly in the s
15. amp Storage Specification DEVICE UNDER TEST Pra FIGURE 1 1 RESERVOIR PRIMING PUMP Temperature and relative humidity ranges for operation and storage of the deadweight tester Operation Storage Temperature 18 to 28 C 10 to 50 C 64 to 82 F 50 to 122 F Relative Humidity 20 to 75 0 to 90 Non Condensing 1 2 INTRODUCTION 1 2 ENVIRONMENTAL CORRECTIONS The deadweight tester has been calibrated to the Gravity Temperature and Air Density stated on the certificate Equations and factors are given on the certificate to adjust for any variations in these environmental conditions 121 GRAVITY 1 2 2 Gravity varies greatly with geographic location and so will the deadweight tester reading Due to the significant change in gravity throughout the world 0 5 ensure that the tester has either been manufactured to your local gravity or that you have applied the correction from the calibrated gravity Example Deadweight Tester calibrated gravity 980 665 cm s 980 665 cm s is the International Standard Gravity Gravity at site 981 235 cm s Indicated Pressure 250 psi TRUEPRESSURE 281332050 980 665 TRUE PRESSURE 250 1453psi The ability to determine the local gravity value will depend on the data available in the country that the instrument is to be used Some countries have geographic geological survey mapping organizations that have the data
16. any person of such revision TRADEMARK NOTICE is a registered trademark of General Electric Corporation Trademarks or trade names are subject to state and federal laws concerning their unauthorized use or other infringements The fact that the product marks or names in this manual do not bear a trademark symbol DOES NOT mean that the product name of mark is not registered as a trademark or trade name Any queries concerning the ownership or existence of any trademarks or trade names mentioned in this manual should be independently confirmed with the manufacturer or distributor of the product li REVISION NOTICE RELEASE DATE OF NUMBER REV RELEASE DESCRIPTION 3100P 1D01 A 05 31 06 Original release per DC RO 25047 3100P 1D01 B 09 27 06 Pump check valve changed Hi SAFETY SUMMARY The following are general safety precautions that are not related to any specific procedures and do not appear elsewhere in this publication These are recommended precautions that personnel must understand and apply during equipment operation and maintenance to ensure safety and health and protection of property COMPRESSED LIQUID Use of compressed liquids can create an environment of propelled foreign matter Pressure system safety precautions apply to all ranges of pressure Care must be taken during testing to ensure that all hydraulic connections are properly and tightly made prior to applying pressure Personne
17. arp edge that will scratch the surfaces of the groove in the rambler otherwise it may leak when reassembled The replacement rambler seal can be eased over the front of the rambler and into the groove Similarly the new anti extrusion ring can be wound into the groove in the rambler behind the rambler seal If it is necessary to remove the barrel 4 the locknut 2 must be loosened approximately Y turn The barrel can then be unscrewed from the pump block assembly 1 Reassembly 6 6 12 6 6 13 6 6 14 6 6 15 6 6 16 6 6 17 Before re fitting the barrel ensure that the O ring 3 is correctly located in the counter bore in the front of the barrel Screw the barrel fully in to the test station and secure with the locknut Ensure that the rambler assembly is correctly located on the end of the pump shaft Carefully introduce the rambler into the open end of the barrel making sure that it does not tilt when entering the barrel Slide the pump bearing 10 over the shaft and locate it inside the barrel Re introduce the pump assemblv from the underside of the top plate and secure with the union nut 11 Replace locknut 12 and clevis 13 reconnect pump arm assembly and secure with pin clip Reconnect hvdraulic tubing 6 13 MAINTENANCE amp SERVICING ITEM DESCRIPTION PART ITEM DESCRIPTION PART PIVOT CLIP P104213 8 RAMBLER 102838 CLEVIS P104214 9 BACK UP RING P104708 LOCKN
18. at the cleaning procedure in 6 1 5 6 1 8 Place piston carefully on a NEW tissue where it will not be damaged while the cylinder is cleaned IMPORTANT NEVER TOUCH THE WORKING SURFACE OF A CLEAN PISTON WITH BARE FINGERS THE NATURAL OIL IN YOUR SKIN CAN CAUSE THE PISTON AND CYLINDER TO STICK 6 1 9 Wipe excess fluid from the outside surfaces of the cylinder 2 6 1 MAINTENANCE amp SERVICING 6 1 10 6 1 11 6 1 12 6 1 13 Roll a NEW tissue into a tapered rod of appropriate size Force the tissue through the cylinder bore whilst rotating Ensure that the tissue is a tight fit inside the bore so that dirt and contamination is removed Repeat 6 1 10 using a NEW tissue but from the opposite end of the cylinder Immerse the cylinder in a suitable clean solvent see note in 6 1 6 above After removal from the solvent using a NEW tissue repeat the cleaning procedure in 6 1 10 8 11 Piston Re assembly 6 1 14 6 1 15 6 1 16 6 1 17 6 1 18 6 1 19 Replace the clean support ring 4 over the tapered end of the piston followed by the o ring 3 Slide the o ring to the bottom of the piston so that it holds the support ring in place Holding the piston by the larger head end dip the other end into a container of clean operating fluid and transfer to the bore in the underside threaded end of the cylinder Allow the fluid to run through the Repeat this 2 or 3 times to ensure a good film of clean ope
19. der to perform maintenance procedures on the hydraulic system the Top Plate Assembly must first be removed from the instrument case 641 Depressurize the system open the reservoir valve and turn the capstan fully in 6 4 2 Disconnect any DUT from the test station and remove the fluid from the reservoir 6 4 3 Remove the spokes from the capstan hub of the screw pump 6 4 4 Remove the 4 screws from the instrument top plate 1 at the mid point of each edge 6 4 5 Hold the top plate assembly by the test station and tilt the plate so that the rear edge is lifted but the front edge remains in contact with the instrument case 6 4 6 Slide the top plate towards the rear until the capstan hub of the screw pump is clear of the front lip of the instrument case 6 4 7 Liftoutthe top plate assembiv The reservoir is fitted with a drain plug which can be accessed from the underside of the instrument case Refer to section 6 8 IMPORTANT When handling the top plate assembly it is good practice to remove the piston assemblies to avoid accidental damage Note Replacement is simply the reverse of the above procedure 6 10 MAINTENANCE amp SERVICING 6 5 SCREW PUMP ASSEMBLY 6 5 1 Unscrew the large union nut just behind the inner hub of the screw press assembly 6 5 2 Withdraw the lead screw assembly from the barrel 6 taking care not to drop the rambler assembly 3 6 5 3 The white anti extrusion ring 4 is a PTFE spir
20. e assembly can now be withdrawn from the underside of the top plate The reservoir body 11 and reservoir cap 5 are a close fit to the reservoir tube 7 and both rely on the O ring seal 6 to hold them in place These parts can be separated by gentiv pulling them apart The valve vent 9 is disassembled from the reservoir body by removing the three screws 8 Reassembly is the reverse of the above procedure 6 17 MAINTENANCE amp SERVICING ITEM DESCRIPTION PART ITEM DESCRIPTION PART VALVE STEM PPA9218 9 WASHER 91 200 6 JORING 54 700 145 14 ELBOW 25401 8 SCREW 70 167 2101 GLAND NUT 24 937 FIGURE 6 8 RESERVOIR ASSEMBLY 6 18 MAINTENANCE amp SERVICING SECTION 7 0 FAULT FINDING 7 1 PCU SPIN SENSITIVITY General The weights floating on a clean PCU assembly will rotate freely slowing down gradually to a complete stop If the rotation stops quickly then the PCU may be dirty and require cleaning DO NOT ROTATE THE PISTON IF IT IS DIRTY AS PERMENANT DAMAGE CAN OCCUR If the spin sensitivity of a recently cleaned PCU deteriorates quickly then it is likely that the hydraulic system has become contaminated During the normal operation of a deadweight tester the working fluid flows slowly through the tiny gap between the piston and its cylinder If the hydraulic system has become contaminated any particles will tend to move towards the PCU s and thus aff
21. ect their performance and possibly damage them If this is the case the system must be completely dismantled thoroughly cleaned and rebuilt before further calibration is carried out 7 11 10 mm PCU Assembly Plug the test station to prevent leakage and open the reservoir valve Hold the weight carrier 1 and lift gently up and down the piston should slide freely within its cylinder If any resistance greater than fluid drag or a gritty sensation is detected then the PCU must be removed and cleaned Refer to Section 6 1 712 2 amp 3 mm PCU Assembly Pressurize the system with 1 large weight so that the piston is rotating and floating correctly Gentiv push down on the rotating weight carrier 2 and release This should result in a smooth bouncing oscillation If the piston does not rotate or bounce freely it must be removed and cleaned Refer to section 6 2 713 5 mm PCU Assembly Plug the test station to prevent leakage and open the reservoir valve Remove the weight carrier assembly 1 amp 2 Hold the piston cap 4 and lift gently up and down the piston should slide freely within its cylinder If any resistance greater than fluid drag or a gritty sensation is detected then the PCU must be removed and cleaned see section 6 3 Pressurize the system with 1 large weight so that the piston is rotating and floating correctly If the piston does not rotate freely it must be removed and cleaned R
22. efer to Section 6 3 7 1 FAULT FINDING 7 2 HIGH PCU FALL RATE General The piston will always fall slowly due to a small leak between the piston and cylinder This fall rate will never be so fast that a stable reading cannot be made 7 2 1 7 2 2 LES 7 2 4 7 3 7 4 If the system has been pressurized quickly then sufficient time must be allowed for the instrument to thermally stabilize Continue re floating the piston until the fall rate stabilizes this should take no longer than one minute If PCU has just been re fitted after cleaning Air pockets can be introduced when re fitting a PCU This will cause the piston to fall faster while the air bleeds between the piston and cylinder Continue to re float the piston until the fall rate slows down If the piston continues to fall quickly then check for fluid leakage around the base of the PCU assembly Check for loose damaged dirty seal under the PCU tighten clean or replace as necessary Refer to sections 6 1 6 2 6 3 Reservoir valve may be leaking Observe fluid level it will rise slowly if the valve is leaking This indicates that the valve seat may be damaged or dirty or the o ring below the valve vent may be damaged It should be disassembled cleaned and inspected then retested or replaced as necessary Refer to section 6 8 Rambler seal may be leaking Check lead screw in screw pump for wetness when extended the screw thread should be greased not r
23. er and push gentiv through NEVER FORCE THE PISTON INTO ITS CVLINDER OR DAMAGE WILL RESULT If resistance is felt introduce more fluid If resistance continues re clean piston cvlinder or both 1f after repeated cleaning the piston still will not slide freelv within the cvlinder then permanent damage mav have occurred In which case the parts should be returned to the factorv for evaluation or replacement Insert piston cylinder assembly into piston nut 5 through the threaded end such that the shoulder on the cvlinder is located within the central bore of the nut Replace piston cap 4 and secure with set screw 3 DO NOT OVERTIGHTEN Carefully screw the assembly into the instrument ensuring that the o ring 10 is clean and undamaged and correctly fitted to the piston post 11 Replace weight carrier assemblv 1 amp 2 ensuring that it locates correctly on the piston cap Replacement PCU Assembly Note The piston and cylinder are a matched pair which is calibrated and adjusted to a calculated mass figure If for any reason the piston or cylinder becomes damaged then the entire assembly must be replaced The replacement assembly consists of the following components Item numbers 1 through 8 6 5 MAINTENANCE amp SERVICING ITEM DESCRIPTION PART ITEM DESCRIPTION PART CARRIER RING SPEC O RING P101801 CARRIER TUBE SPEC 8 PISTON SPEC PISTON CAP SPEC 9 JORING 54 700 111 SET SCREW
24. ew Pump As liquids are considered incompressible the displaced liquid causes the pistons to rise within their cylinders to balance the downward force of the weights Fluids at the same height in a system are at the same pressure so when the system is in equilibrium i e the piston and weights are floating freely rotating and falling at it s natural sink rate the pressure generated by the combined mass of the piston and weights equals the pressure within the device under test The design of a Piston Cylinder Unit PCU fitted to a deadweight tester allows for a very small clearance gap between the piston and cylinder This is required to allow the working fluid to pass between the components providing a lubricating film and preventing metal to metal contact Therefore during the normal operation of a deadweight tester the working fluid in the system will slowly pass through this clearance gap This is perfectly normal and there are Sump Rings around the piston bodies to collect the excess fluid Although calibration is carried out using one PCU at a time there is a point during normal operation of a dual PCU instrument where both PCU s will rise This is due to the overlap in pressure range of the two PCU s The PCU that is not in use will seal in the fully extended position to avoid additional fluid loss 1 1 INTRODUCTION HIGH LOW PRESSURE PRESSURE PCU PCU SCREW PUMP HYDRAULIC CIRCUIT SCHEMATIC Operating
25. l must wear eye protection to prevent injury HEAVY WEIGHTS Lifting and movement of heavy weights can create an environment of strain and impact hazards Care must be taken during testing to ensure that weight masses are lifted in a manner that avoids over reaching or twisting and that the masses are not dropped Personnel must wear reinforced safety shoes to prevent injury PERSONAL PROTECTIVE EQUIPMENT Wear eye protection and reinforced safety shoes approved for the materials and tools being used TABLE OF CONTENTS COPYRIGHT NOTICE DISCLAIMER a eurer TRADEMARK NOTICE A a a li REVISION NOTICE u u u e e SRA ill SAFELY SUMMARY nn ae iv COMPRESSED LIQUIDO nn a FR ain RENNEN iv HEAVY WEIGHTS O Le N SS IV PERSONAL PROTECTIVE EQUIPMENT zu IV TABLE OR CONTENTS V LIST OP FIGURES Eye 10 GENERALUINFORMATION aiii A 1 1 II gt OPERANNGPRINEIREE sera 1 1 1 2 ENVIRONMENTAL CORRES TON Sarai 1 3 OO a ku 1 3 1 2 27 TEMPERATURE ga np nama nanan Een 1 3 1 23 FEUD AAA AAA 1 4 1 3 MODELVARIA HONS ker l 4 20 PREPARATION uuu O 2 1 2d sa u 2 1 22 CONNECTION S O Be GOA 2 1 3 0 uu 3 1 4 0 OPERATION ass 4 1 5 0 CALIBRATION IN DIFFERENT PRESS
26. lot in the barrel 6 5 12 Re tighten the barrel union nut Note If the lead screw assembly shows signs of excessive wear then it is very likely that the associated components have worn also therefore the screw press assembly is available as a spare part see diagrams for part numbers 6 11 MAINTENANCE 8 SERVICING PART DESCRIPTION 1 1 109282 6 JORING 4 102809 54 700 15 BACK UP RING 3 BARRELLOCKNUT 2109284 8 102811 4 BARREL 109286 9 BALL 0102 FIGURE 6 5 SCREW PUMP ASSEMBLY 6 12 MAINTENANCE amp SERVICING 6 6 PRIMING PUMP ASSEMBLY Disassembiv 6 6 1 6 6 2 6 6 3 6 6 4 6 6 5 6 6 6 6 6 7 6 6 8 6 6 9 6 6 10 6 6 11 On the underside of the top plate disconnect the hvdraulic tubing from the pump block assembly 1 On the upper side of the top plate unscrew locknut 12 turn and remove clip pin from clevis 13 The pump arm assemblv can be swung out of the wav Remove locknut 12 and clevis 13 Unscrew union nut 11 and withdraw pump assembly from below the top plate Withdraw pump shaft 9 taking care not to drop shaft bearing 10 or rambler assembly 7 The white anti extrusion ring 6 a PTFE spiral and can be removed by unwinding it from the rambler When removing the rambler seal 5 take care not to use any tool that may have a sh
27. m should be drained and flushed with clean fluid If the device under test DUT is from a system operating on different fluid from that of the deadweight tester the Liquid Separator Model 5521 can be mounted to the test port of the deadweight tester This will allow the calibration of the DUT in its normal operating fluid and prevent cross contamination of the system See Section 9 1 2 1 PREPARATION 2 2 CONNECTIONS Fit the device under test DUT to the test port using the method described below IMPORTANT Ensure that all devices are internally clean and free from contamination before connecting to the tester Particle contamination can damage the sensitive piston assemblies valve seats and screw pump To avoid cross contamination from other fluids and protect the system from particulates we recommend the use of a Liquid to Liquid Separator Refer to section 9 0 Ancillary Equipment WARNING DO NOT use Teflon PTFE tape on these connections as this will prevent correct sealing The Gauge Adapter sealing system is designed for hand tight sealing up to 20 000 psi 1 400 bar wrenches or similar tools are not required over tightening can cause damage to threads or sealing faces Before connection ensure that there is an O ring fitted to the test port Check that the sealing face of the device to be fitted is clean and undamaged as scratches or dents can form leak paths 2 2 PREPARATION NOTE The thread on the te
28. mage the inlet check valve 7 6 CANNOT REACH MAXIMUM PRESSURE If maximum pressure cannot be reached even after the screw press has been turned fully in and the checks above have been made 7 6 1 7 6 2 Ensure that the screw press is FULLV OUT and the priming pump is used for initial pressurization If the DUT has a large internal volume or there is air in the svstem then re prime Refer to section 3 increasing the initial pressurization with the priming pump from 100 psi 7 bar to at least 200 psi 14 bar 7 3 FAULT FINDING THIS PAGE INTENTIONALLY LEFT BLANK 7 4 FAULT FINDING 8 1 8 2 SECTION 8 0 STORAGE amp TRANSPORTATION INSTRUMENT 8 1 1 8 1 2 8 1 3 8 1 4 With the test station plugged open the reservoir valve and turn capstan fullv in close reservoir valve Remove spokes from capstan hub and store in tool roll Remove screw in handle from pump arm and store in tool roll If fluid is to remain in the reservoir ensure that the tester is kept level at all times to avoid spills If not drain the reservoir as described in Section 6 8 8 1 5 Refit instrument lid ensuring that the hinges are correctly engaged and secure with toggle clips at the sides WEIGHTS 8 2 1 Starting with the largest increments first stack all appropriate weights in the 8 2 2 8 2 3 8 2 4 wooden weight case Pass the threaded rod of the weight clamp assembly down through the center of the weight stack and l
29. ment 1 5 Single Low Pressure PCU Instrument een 1 5 Making pressure aaa ania a 2 2 Making Pressure COn os 2 3 A nn 2 4 Float Height Indicator AS 4 1 Weignt Rotat 4 2 A ee eo 6 3 2 amp 3 Mm PCU ASS SIO Vs 6 6 SIE Vasen 6 9 Screw Pump Assembly ii 6 12 Priming POM SACO ana ee ner 6 14 Check Valve Assemblies see a AAS 6 16 Reservoir Assembly ee en 6 18 SECTION 1 0 GENERAL INFORMATION 1 1 OPERATING PRINCIPLE Deadweight Testers are the primarv standard for pressure measurement Utilizing the well proven Piston Gauge system consisting of a vertically mounted precision lapped Piston and Cylinder assemblv accurately calibrated weight masses Force are loaded on the piston Area which rises freelv within its cvlinder These weights balance the upward force created bv the pressure within the svstem PRESSURE PORO AREA Each weight is marked with the tester serial number and the pressure measured when placed on a correctly spinning and floating piston The total pressure measured is the summation of the weights plus the piston weight carrier assembly The schematic diagram below shows the basic hydraulic circuit for a dual PCU Piston Cylinder Unit instrument The system is primed with liquid from the Reservoir and the system pressure is increased by means of the Scr
30. nder then permanent damage mav have occurred In which case the parts should be returned to the factorv for evaluation or replacement Insert piston cylinder assembly into piston nut 5 through the threaded end such that the shoulder on the cvlinder is located within the central bore of the nut Replace piston cap 4 and secure with set screw 3 DO NOT OVERTIGHTEN Carefully screw the assembly into the instrument ensuring that the o ring 9 is clean and undamaged and correctiv fitted to the piston post 10 Replace weight carrier assemblv 1 amp 2 ensuring that it locates correctly on the piston cap Replacement PCU Assemblv Note The piston and cylinder assembly is a matched pair which is calibrated and adjusted to a calculated mass figure If for any reason the piston or cvlinder becomes damaged then the entire assemblv must be replaced The replacement assembly consists of the following components Item numbers 1 through 7 6 8 MAINTENANCE amp SERVICING ITEM DESCRIPTION PART ITEM DESCRIPTION PART CARRIER RING SPEC PISTON SPEC CARRIER TUBE SPEC O RING 54 700 111 ma 8 3 PISTONCAP 5 9 BEARINGRING 04163 10 11 6 7 SET SCREW 71 247 10 HP PCU BODY P109283 PISTON NUT P104103 11 SUMP RING P109280 CYLINDER SPEC EA FIGURE 6 3 5mm PCU ASSEMBLY 6 9 MAINTENANCE amp SERVICING 6 4 TOP PLATE REMOVAL Note In or
31. nform to or exceed the specifications as set forth in its catalogs in use at the time of sale and reserves the right at its own discretion without notice and without making similar changes in articles previously manufactured to make changes in materials designs finish or specifications GE Sensing warrants products of its own factory against defects of material or workmanship for a period of one year from date of shipment Liability of GE Sensing under this warranty shall be limited to replacing free of charge FOB Houston Texas any such parts proving defective within the period of this warranty but will not be responsible for transportation charges or consequential damages The warranty is not made for products manufactured by others which are illustrated and described in GE Sensing catalogs or incorporated in GE Sensing products in essentially the same form as supplied by the original manufacturer However GE Sensing agrees to use its best efforts to have original suppliers make good their warranties COPYRIGHT NOTICE Copyright 2006 by GE Sensing All rights reserved This document may not be reproduced in part or in whole without the express written consent of GE Sensing DISCLAIMER No representations or warranties are made with respect to the contents of this user s manual Further GE Sensing reserves the right to revise this manual and to make changes from time to time in the content hereof without obligation to notify
32. ocate in the base of the weight box Secure the weights by screwing the clamp assembly in clockwise ensuring that the stepped rim of the clamping disc locates correctly in the center of the weight stack Close lid and secure with catches at front WARNING The weight set is HEAVY can be up to 80 Ibs 36 kg per individual box so care must be taken when moving it Both handles must be used when lifting the set for stability and we recommend that it be carried between two people 8 1 STORAGE amp TRANSPORTATION THIS PAGE INTENTIONALLY LEFT BLANK 8 2 STORAGE amp TRANSPORTATION SECTION 9 0 ANCILLARY EQUIPMENT 9 1 SEPERATOR Model 5521 or 5522 If there is any doubt that the instrument to be tested is not internally clean then the addition of the 5521 Liquid Separator will protect the deadweight tester from contamination and possible damage The 5521 is also particularly useful in applications where the instruments under test are used on systems that must not be contaminated by the operating fluid from the deadweight tester The unit contains a flexible diaphragm that separates the two working fluids preventing transfer either way Model 5521 has a Viton diaphragm and seals and a maximum working pressure range of 10 000 psi 700 bar Model 5522 has a PTFE diaphragm and EPDM seals and a maximum working pressure range of 7 000 psi 500 bar This unit is specificallv designed for use with brake fluids Skyd
33. rating fluid exists in the cylinder bore Carefully introduce the piston into the underside of the cylinder and push gently through the piston will normally slide freely through due to its own weight NEVER FORCE THE PISTON INTO ITS CYLINDER OR DAMAGE WILL RESULT If resistance is felt introduce more fluid If resistance continues re clean piston cylinder or both If after repeated cleaning the piston still will not slide freely within the cylinder then permanent damage may have occurred In which case the parts should be returned to the factory for evaluation or replacement Stand assembly upright on a clean hard stable surface Ensure that the o ring 3 and support ring 4 are both located centrally around the piston Push the cylinder down so that the o ring is forced evenly inside the support ring Ensure that the weight carrier 1 is clean especially the central mounting hole and place on the tapered end of the piston Tap lightly using the palm of the hand to locate on the taper Carefully screw the assembly into the instrument ensuring that the seal 6 is clean and undamaged and correctly re fitted Replacement PCU Assembly Note The piston and cylinder assembly is a matched pair which is calibrated and adjusted to a calculated mass figure If for any reason the piston or cylinder becomes damaged then the entire assembly must be replaced The replacement assembly consists of the following components
34. readily available If not the countries National Standards Laboratory may be able to recommend a source of suitable information TEMPERATURE Temperature and Air Density variations are less significant than gravity Variations should be corrected for when maximum accuracy is required Temperature variation example Deadweight Tester calibrated temperature 20 C Operating temperature 24 Percentage change per C 0 002 Indicated Pressure 250 psi 0 002 TRUE PRESSURE 250 20 24 x 250 TRUE PRESSURE 249 98 psi 1 3 INTRODUCTION 1 2 3 HEAD OF FLUID The pressure measured is at the top of the test port seal Vertical height difference between this datum point and the connection to the instrument under test should be corrected for To correct for vertical heights above and below the datum line either subtract or add respectively the amount stated on the certificate To ensure accuracy is maintained the piston and weights must be kept clean and undamaged The tester is accurate when the piston and weights are floating and rotating freely 1 3 MODEL VARIATIONS This manual covers many pressure ranges and models within the 3100 and 3200 series of instruments The following illustrations detail the physical appearance of the three basic models Models 3123 3223 3124 3224 FIGURE 1 2 DUAL PCU INSTRUMENT 1 4 INTRODUCTION FIGURE 1 3 SINGLE HIGH PRESSURE PCU INSTRUMENT FIGURE 1 4 SINGLE LOW PRESS
35. res on the following pages detail the components of each assembiv together with the relevant part numbers Where SPEC appears as part number this indicates that this particular component varies with the specification of the deadweight tester and is usually associated with other components in an assembly for replacement purposes 6 1 PCU ASSEMBLY 10 mm NOMINAL DIAMETER Piston Disassembiv 6 1 1 Hold the weight carrier 1 and lift the piston to its full extent Tap the carrier sharply down onto the cylinder 2 to release the tapered fit between the piston and carrier Remove the weight carrier 6 1 2 Unscrew the PCU assembly from the instrument use the dowel hole if the cylinder is tight 6 1 3 Carefully withdraw the piston from the cylinder 6 1 4 If required lift support ring 4 from around o ring 3 the o ring can now be withdrawn from the piston Piston Cleaning 6 1 5 Use non fluffing non abrasive lint free tissue or absorbent cloth Hold the piston by the larger head end and rub the tissue back and forth along its length 6 1 6 To remove all traces of contamination especially important with Water Operated Testers the piston can be cleaned in a suitable solvent Note O ring seals where fitted are Nitrile rubber and should not be immersed in solvents as they will become damaged They should be wiped carefully with a new tissue 6 1 7 After removal from the solvent using a NEW tissue repe
36. rol and similar liquids 9 1 ANCILLARY EQUIPMENT 9 2 ANGLE ADAPTER Model 5543 To calibrate gauges with the pressure connection on the rear e g panel mount gauges in their correct position an angle adapter should be used The angle adapter fits directly onto the test station converting it through 90 degrees allowing the standard adapters to be used er 9 3 POINTER REMOVER PUNCH Model 5551 To remove and refit the pointer of a pressure gauge This tool has a spring loaded plunger to quickly and consistently refit the pointer 9 2 ANCILLARY EQUIPMENT U S A 10311 Westpark Drive Houston TX 77042 T 713 975 0547 F 713 975 6338 imagination at work 3100P 1D01 Revision September 27 2006
37. st port and the lower part of the gauge adapters is LEFT HANDED The following procedure details the correct method for mounting devices using these adapters 1 Screw the appropriate gauge adapter fully on to the instrument to be tested 2 Screw assembly down COUNTER CLOCKWISE on to test port Note Hand tight is sufficient ensure that the bottom face contacts the O ring on the test port FIGURE 2 2A MAKING PRESSURE CONNECTIONS 2 3 PREPARATION 3 To adjust the position to face forward hold the gauge adapter and turn the instrument COUNTER CLOCKWISE so that it faces forward 4 Hold the instrument steady whilst turning the gauge adapter COUNTER CLOCKWISE until it pulls down onto the O ring FIGURE 2 2B MAKING PRESSURE CONNECTIONS 2 4 PREPARATION TEST PORT INSERT For devices with 1 8 BSP or NPT mounting threads the diameter of the thread is very close to the effective sealing diameter of the O ring fitted to the test This can make it difficult to achieve a good seal When mounting these devices use the test port insert stored in the spare seals container as shown in Figure 2 2C PART FIGURE 2 2C TEST PORT INSERT To calibrate panel mounted gauges with pressure connections in the rear use an Angle Adapter Refer to section 9 0 Ancillarv Equipment 2 5 THIS PAGE INTENTIONALLY LEFT BLANK 2 6 PREPARATION SECTION 3 0 PRIMING 3 1 Open
38. sure without turning the capstan fully out as sudden depressurization will cause the weight stack to fall quickly which may damage the piston assembly Remove weight stack Note The design of a Piston Cylinder Unit PCU fitted to a deadweight tester allows for a very small clearance gap between the piston and cylinder This is required to allow the working fluid to pass between the components providing a lubricating film and preventing metal to metal contact Therefore during the normal operation of a deadweight tester the working fluid in the system will be slowlv pass through this clearance gap This is perfectly normal and does not mean that the system is leaking However over time it will collect and run down the side of the PCU mounting bodies The design of this instrument includes Sump Rings around the base of the PCU mounting bodies to collect the excess fluid these should be wiped clean periodically to avoid overflowing on to the instrument top plate The sump ring is also fitted at the base of the test station as it is common for fluid to fall from the DUT when it is disconnected from the instrument after calibration This should also be kept clean to prevent spills on the top plate 4 2 OPERATION IMPORTANT NOTES FOR CORRECT OPERATION OF WATER OPERATED INSTRUMENTS 3200 Series To avoid damage to the sensitive PCU s it is vital to ensure that there is a continuous film of water between piston and cylinder Due
39. unning with operating fluid If lead screw is wet then replace rambler seal and anti extrusion ring Refer to Section 6 5 SYSTEM WILL NOT PRIME 7 3 1 Check reservoir valve is closed 7 3 2 Check for sufficient fluid in reservoir 7 3 3 Check for damaged missing dirty O ring on test station 7 3 4 Check that the face of the DUT is contacting the O ring and that the surface is not scored or dented SYSTEM WILL NOT PRESSURIZE 7 4 1 Ensure correct valve operation during priming process 7 4 2 Check DUT is not leaking 7 4 3 Clean system externally check for fluid leak by continually trying to pressurize Wherever fluid appears replace the seal check sealing faces are clean and undamaged before re assembiv 7 2 FAULT FINDING 7 5 PRIMING PUMP MALFUNCTION 7 5 1 7 5 2 7 5 3 Note pumping does not generate pressure then the inlet check valve has probably failed and requires replacement If the system pressurizes and depressurizes in conjunction with the downward and upward strokes of the pump then the outlet check valve has failed completely This should be disassembled and inspected for dirt or damage to valve seat and seal After inspection clean all parts carefully replace as required and re assemble correctly If the pump handle rises during normal system pressurization then the outlet check valve is leaking Inspect as above Do not continue to pressurize if pump handle rises as this can da
Download Pdf Manuals
Related Search