SERIES 8100 HAND-OPERATED PRESSURE CALIBRATION UNITS

Transcription

1 SERIES 8100 HAND-OPERATED PRESSURE CALIBRATION UNITS PORTABLE PRESSURE SOURCE USED WITH A PRESSURE GAUGE TO FIELD CALIBRATE A VARIETY OF PRESSURE DEVICES, i.e., PRESSURE SWITCHES, GAUGES, DIFFERENTIAL PRESSURE METERS, ETC * * Pneumatic Duplex * Hydraulic *DOES NOT INCLUDE GAUGE FEATURES Versatile - Self-contained pressure source for calibration of pressure gauges and switches Safe - No electrical power or high pressure bottles. Pressure tested to 2x rated pressure Accurate - 1/4% full scale with the 3D line of test gauges (optional) Adjustable - Precision vernier provides for a wide range of pressure adjustment User friendly - Compact size and light weight Easier to use - Low handle force at all pressures Rugged - ''Industrial strength'' construction Flexible - Compatible with most hand-held electronic calibrations such as the 3D Star Calibrator SPECIFICATIONS PRESSURE RANGE(S): PSIG PSIG/0-25" Hg Vac PSIG WEIGHT: 1.3 lbs. (0.6 kg) 1.4 lbs. (0.65 kg) 1.75 lbs. (0.79 kg) PHYSICAL DIMENSIONS: 9 L x 5 W x 3''D (HandPump only) 10 L x 5 W x 3 D (HandPump only) 11 L x 5 W x 3 D (HandPump only) TEST CONNECTIONS: 1/4'' NPT Female 1/4'' NPT Female 1/4'' NPT Female MATERIALS OF Machined aluminum body, stainless steel shaft and needle valve, ABS plastic handles, brass tee and connector CONSTRUCTION HOSE: Nylon Nylon Nylon with braided metal covering SEALS: Viton Viton Viton 3D The Direct Drive Difference

2 PRESSURE GAUGE (optional) 1/4'' N.P.T. GAUGE CONNECTION VERNIER ADJUSTMENT GAUGE CONNECTION CARRYING CASE (optional) QUIK CONNECT HOSE KIT (optional) HYDRAULIC PUMP 1/4 N.P.T. Gauge Connection DUPLEX PUMP DESIGN AND SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE. ORDERING INFORMATION PART NUMBER DESCRIPTION PUMPS Pneumatic Pump with Vernier, 0 to 300 psig Includes hose and fittings, without gauge. CARRYING CASE Duplex Pump with Vernier, 0 to 300 psig/25'' Hg to 0 vacuum Includes hose and fittings, without gauge Hydraulic Pump with Vernier, 0 to 3000 psig Includes hose and fittings, without gauge. (or) ABS Plastic Case with foam lining for pump and one 41/2'' gauge. Case accommodates , or Same as 0115 except hi-impact, waterproof, heavy duty cycolac. OPTIONS Consult factory for gauges and other hoses. Consult Handy Cal data sheet No. KT-018 for complete kit configurations. AN ISO 9000 REGISTERED COMPANY 3D Instruments, LLC Chemical Lane, Huntington Beach, CA 92649, USA - 714/ Fax 71 4/ Web site: info@3dinstruments.com D Instruments, LLC. Printed in U.S.A 3D Pressure Calibration Units No. KT-011 8/98

3 PNEUMATIC HANDPUMP With Vernier Fine Pressure Adjustment The 3D Hand-Operated Calibration Unit is a compact, lightweight and portable hand-operated pressure source. When a 3D pressure gauge or Star Digital Calibrator is added, the unit can be used to calibrate or check pressure measuring devices in the field. The calibration units are safe: no electrical power or high pressure bottles are required. The units are completely assembled and ready to connect to the pressure device to be calibrated. Calibration is quick and simple because the unit is taken to the pressure device rather than vice-versa. The units can be supplied with or without a 3D 1/4% accuracy gauge or Star Digital Calibrator (see order information for correct model number). The pneumatic model is used for pressures to 300 psig. Options available include carrying cases, special gauges and hoses with fittings. OPERATING INSTRUCTIONS The Pneumatic Calibration Unit provides a source of air pressure from 0 to 300 psig. 1. Isolate device to be calibrated. CAUTION: Avoid connecting to high pressure sources. These precautions and safe operating procedures must be observed to avoid damage to the unit or personal injury. Connect the 1/4 ' NPT (F) hose fitting to the pressure device to be calibrated. Make sure connection is pressure tight to prevent leakage. 2. Turn knurled knob on needle valve (item 7) clockwise to close. NOTE: Hand tighten only, to prevent damage to needle valve seat. 3. Squeeze the handles until desired pressure is obtained. More force is required as pressure increased. 4. Turn knurled vernier knob (item 8) clockwise to increase (counterclockwise to decrease) pressure. 5. Turn knurled knob on needle valve (item 7) counterclockwise to release pressure. 6. When calibration procedure is complete reduce pressure to zero before disconnecting unit to prevent personal injury. 7. Store unit in carrying case or safe location. TROUBLE SHOOTING 1. If the desired pressure can't be reached or maintained: a. Check to ensure the needle valve (item 7) is closed. b. Check all connections for leaks. 2. If the pressure fails to increase when the handles are squeezed and there are no leaks: a. Remove screws (item 25) and the pins (item 16) from the handle (item 12) where it attaches to the base (item 5). c. Remove screws (item 25) from the yoke (item 11). Compress the spring (item 10) and unscrew the yoke (item 11) and relieve the spring (item 10). d. Remove pin (item 27) and inspect the o-rings (items 20 & 21) for damage. Replace the o-rings if damaged and replace the pin (item 27) with a new pin. e. Check the operation of the piston (item 3) and the shaft (item 9). Pull the piston (item 3) and the shaft (item 9) in opposite directions and the pin (item 27) should contact the hole in the piston (item 3). Push the piston (item 3) and the shaft (item 9) together and the pin (item 27) should not contact the hole in the piston (item 3). Replace the piston (item 3) if the check is not met. f. Reassemble using the instructions found in the notes. 3. If the pressure rises when the handles are squeezed but decreases when the handles are released: a. Remove screws (item 25) and the pins (item 16) from the handle (item 12) where it attaches to the base (item 5). c. Remove the valve plug (item 28) and inspect the o-ring (item 19) and seal (item 22) for damage. Replace if damaged. d. Reassemble using the instructions found in the notes. 4. If the handles fail to open when relieved: a. Check all of the pins (items 14, 15 & 16) for free action. Adjust and relock the screws (item 25) per the notes. 5. If it is difficult to obtain a full stroke with the handles: a. Remove screws (item 25) and the pins (item 16) from the handle (item 12) where it attaches to the base (item 5). c. Inspect the piston (item 3), and body bore (item 1) and the shaft hole in the base (item 5) for excessive wear. Replace worn or damaged parts. d. Reassemble using the instructions found in the notes Chemical Lane, Huntington Beach, California USA Phone: (714) Fax. (714) Internet: info@3dinstruments.com KT-044 Pneumatic Handpump /98

4 NOTES: UNLESS OTHERWISE SPECIFIED 1 LUBRICATE O-RING WITH PARKER SUPER-O-LUB OR EQUIV. 2 INSTALL SCEW WITH PERMALOC GRADE LM113 OR EQUIV. 3 INSTALL SCEW WITH PERMALOC GRADE LM113 OR EQUIV. AND TORQUE 13 TO 15 IN-LBS. 4 LUBRICATE BORE WITH A LIGHT COAT OF PARKER SUPER-O-LUBE OR EQUIV. 5. APPROXIMATE WEIGHT 1.3 LBS. 6. APPROXIMATE LENGTH 9 INCHES. 7 ITEM 30 CONSISTS OF ITEMS AND 27 8 SECURE ITEM 31 (HOSE ASSEMBLY) TO NPT THREADS OF ITEM 1 (BODY). ITEM PART NO. QT DESCRIPTION BODY, MACHINED PNEUMATIC HAND PUMP PISTON, VERNIER PNEUMATIC HAND PUMP PISTON, BODY PNEUMATIC HAND PUMP BASE, VERNIER PNEUMATIC HAND PUMP BASE, BODY PNEUMATIC HAND PUMP VALVE, NEEDLE KNOB, NEEDLE RELIEF VALVE PNEUMATIC HAND KNOB, VERNIER PNEUMATIC HAND PUMP SHAFT, PNEUMATIC HAND PUMP SPRING, RETURN YOKE, MACHINED PNEUMATIC HAND PUMP HANDLE, UNIVERSAL, HAND PUMP LINK, PNEUMATIC HAND PUMP PIN, PIVOT PIN, PIVOT PARTS LIST FOR PNEUMATIC HAND PUMP WITH VERNIER FINE PRESSURE ADJUSTMENT ITE PART NO. Q DESCRIPTION PIN, PIVOT O-RING, SIZE O-RING, SIZE O-RING, SIZE O-RING, SIZE O-RING, SIZE SEAL, VALVE IDENTIFICATION LABEL SCREW, SET 6-32 X.50 LG SCREW, BUTTON HID 6-32 X 1/4 LG SCREW, PAN HO 6-32 X.38 LG PIN, SPRING 3/32 X 3/ VALVE PLUG PNEUMATIC HAND PUMP SCREW, 100' CSK HO 6-32 X.38 LG SPARE PARTS KIT HOSE ASSEMBLY

5 DUPLEX HANDPUMP With Vernier Fine Pressure Adjustment The 3D Hand-Operated Calibration Unit is a compact, lightweight and portable hand-operated pressure and vacuum source. When a 3D pressure gauge or Star Digital Calibrator is added the unit can be used to calibrate or check pressure measuring devices in the field. The Calibration units are safe; no external power or high pressure bottles are required. The units are completely assembled and ready to connect to the pressure device to be calibrated. Calibration is quick and simple because the HandPump is taken to the pressure device rather than vice versa. The units can be supplied with or without a 3D 1/4% accuracy gauge or Star Digital Calibrator. Refer to gauge ordering information. OPERATING INSTRUCTIONS The Duplex Handpump provides a source of air pressure: psig or vacuum: 0-25 In. Hg. 1. Isolate the device to be calibrated. CAUTION: avoid connecting to highpressure sources. These precautions and safe operating procedures must be observed to avoid damage to the unit or personal injury. Connect the 1/4NPTF adapter and hose to the pressure device to be calibrated. Make sure the connection is pressure-tight to prevent leakage. 2. Turn the knurled knob on the needle valve (item 7) clockwise to close. NOTE: HAND TIGHTEN ONLY to prevent damage to the valve seat. 3. Set the shuttle valve (item 30) to ''pressure or volume'' 4. Squeeze the handles (item 12) until the desired, or close to the desired pressure is obtained. Additional force is required as the pressure is increased. 5. The pressure can be decreased with the needle valve (item 7). 6. The pressure can be ''fine tuned'' with the vernier knob (item 8). To increase pressure, turn the vernier knob clockwise and counterclockwise to decrease pressure. Note: the vacuum reading increases when the vernier knob is turned counterclockwise. 7. When the calibration procedure is completed, bleed the pressure before disconnecting the unit to prevent personal injury. 8. Store the unit in a Handy-Cal or Star-Cal carrying case or other safe location. TROUBLE SHOOTING 1. If the desired pressure can't be reached or maintained. a. Check to ensure the needle valve (item 7) is closed. b. Check all connections for leaks. 2. If the pressure fails to increase when the handles (item 12) are squeezed and there are no leaks: a. Remove screws (item 25) and pins (item 16) from the handle (item 12) where it attaches to the base (item 5). c. Remove screws (item 25) from the yoke (item 11). Compress the spring (item 10) and unscrew the yoke (item 11) and relieve the spring. d. Remove pin (item 27) and inspect the o-rings (items 20, 21, & 34) for damage. Replace the o-rings if damaged and replace the pin (item 27) with a new pin. e. Check the operation of the piston (item 3) and the shaft (item 9). Pull the piston and shaft (item 9) in opposite directions f and the pin (item 27) should contact the hole in the piston (item 3). Push the piston (item 3) and the shaft (item 9) together and the pin (item 27) should not contact the hole in the piston (item 3). Replace the piston (item 3) if the check is not met. Remove knob (item 31), note screw thread, and remove the spool (item 30). Inspect the o-rings (item 32) for damage. Replace the o-rings if damaged. g. Reassemble using instructions found in the notes. 3. If the pressure rises when the handles (item 12) are squeezed but decreases when they are released: a. Remove screws (item 25) and pins (item 16) from the handle (item 12) where it attaches to the base (item 5). c. Remove the valve plug (item 28) and inspect the o-ring (item 19) and the sea] (item 22) for damage. Replace if damaged. d. Reassemble using instructions found in the notes. 4. If the handles (item 2) fail to open when relieved: a. Check all the pins (items 14, 15 & 16) for free action. Adjust and re-lock the screws (item 25) per the notes. 5. If it is difficult to obtain a full stroke with the handles (item 12): a. Remove screws (item 25) and pins (item 16) from the handle (item 12) where it attaches to the base (item 5). c. Inspect the piston (item 3), the body bore (item 1) and the shaft hole m the base (item 5). Replace worn or damaged parts. d. Reassemble using the instructions found m the notes Chemical Lane, Huntington Beach, California USA Phone: (714) Fax. (714) Internet: . Info@3dinstruments.com KT-048 Duplex Handpump 8/98

6 NOTES: UNLESS OTHERWISE SPECIFIED 1 LUBRICATE O-RING WITH PARKER SUPER-O-LUB OR EQUIV. 2 INSTALL SCEW WITH LOCTITE #425 OR EQUIV. 3 INSTALL SCEW WITH PERMALOC GRADE LM113 OR EQUIV. AND TORQUE 13 TO 15 IN-LBS. 4 LUBRICATE BORE WITH A LIGHT COAT OF PARKER SUPER-O-LUBE OR EQUIV. 5 APPROXIMATE WEIGHT 1.4 LBS. 6 APPROXIMATE LENGTH 10 INCHES. 7 ITEM 37 CONSISTS OF ITEMS 17 22, 27, 32 AND PRIOR TO SECURING ITEM 38 (HOSE ASSEMBLY) TO ITEM 1 (BODY) APPLY TEFLON TAPE TO NPT THREADS. 9 LIGHTLY LUBRICATE THREADS WITH KRYTOX GPL-200 GREASE OR EQUIV. PARTS LIST FOR DUPLEX HAND PUMP WITH VERNIER FINE PRESSURE ADJUSTMENT ITEM PART NO. OTY. DESCRIPTION BODY, MACHINED PNEUMATIC HAND PUMP PISTON, VERNIER PNEUMATIC HAND PUMP PISTON, BODY PNEUMATIC HAND PUMP BASE, VERNIER PNEUMATIC HAND PUMP BASE, BODY PNEUMATIC HAND PUMP VALVE, NEEDLE KNOB, NEEDLE RELIEF VALVE PNEUMATIC HAND KNOB, VERNIER PNEUMATIC HAND PUMP SHAFT, PNEUMATIC HAND PUMP SPRING, RETURN YOKE, MACHINED PNEUMATIC HAND PUMP HANDLE, UNIVERSAL, HAND PUMP LINK, PNEUMATIC HAND PUMP PIN, PIVOT PIN, PIVOT PIN, PIVOT O-RING, SIZE O-RING, SIZE O-RING, SIZE ITEM PART NO. QTY. DESCRIPTION O-RING, SIZE O-RING, SIZE SEAL, VALVE SCREW, SET 4-40 X.38 LG SCREW, SET 6-32 X.50 LG SCREW, BUTTON HD 6-32 X 1/4 LG SCREW, PAN HID 6-32 X.38 LG PIN, SPRING 3/32 X 3/ VALVE PLUG PNEUMATIC HAND PUMP SCREW, 100' CSK HD 6-32 X.38 LG SPOOL, DUPLEX HAND PUMP KNOB, SHUTTLE DUPLEX HAND PUMP O-RING, SIZE IDENTIFICATION LABEL O-RING, SIZE CASKET, BASE DUPLEX HAND PUMP SPARE PARTS KIT HOSE ASSEMBLY

7 HYDRAULIC HANDIPUMP With Vernier Fine Pressure Adjustment The 3D Hand-Operated Calibration Unit is a compact, lightweight and portable pressure source. When a 3D pressure gauge or Star Digital Calibrator is added, the unit can be used to calibrate or check pressure measuring devices in the field. The hydraulic HandPump is utilized for high pressure applications up to 3000 psig. The HandPump is safe because no electrical power or high pressure bottles are required. The unit is completely assembled and ready to be used in the field. Calibration is quick and simple because the pressure source is always ready to go to the calibration site. The HandPump can be supplied with a 3D %% accuracy test gauge or Star Digital Calibrator (see order information for correct model number). A carrying case, special gauges, and quick disconnect fittings are optional. OPERATING INSTRUCTIONS The Hydraulic HandPump provides a hydraulic pressure source from 1 to 3000 psig. A wide variety of pressure media may be utilized but distilled water is the preferred fluid. The seals are Fluorocarbon and the only other non-metallic materials are plastic. Viscous oils should not be utilized. CAUTION: Hydrocarbon fluids should never be used in oxygen service applications. 1. Isolate the device to be calibrated. CAUTION: Do not connect to high pressure sources. Safe operating procedures must be exercised to avoid personal injury and damage to the calibration system. 2. Remove the fill plug (item 17) and fill the reservoir (item 23) approximately 1/2full. Select a fluid compatible with the system and the HandPump. Don't allow the fluid level to drop below the reservoir. 3. Care should be exercised to minimize the total system volume. 3D pressure gauges may be filled with fluid by removing the filter, filling the fitting and replacing the filter. Connect the master gauge to the top of the street tee and the hose, connected to the system to be calibrated, to the other port. 4. NOTE: Air in the system should be minimized because it can effect calibration and high pressure gases can be dangerous. Adjust the vernier control (item 13) to the mid position and close the needle valve (item 12). Exercise the handles until a moderate pressure appears on the master gauge and open the needle valve. Repeat until bubbles are not seen in the reservoir. 5. Close the needle valve and squeeze the handles until the approximate desired pressure is reached. The volume control can be used to ''fine tune" the pressure. Systems with large volume may require additional bleeding. Continue until all pressure points are calibrated. At high pressures, the handle force can be reduced if the handles are not allowed to open completely when squeezing. 6. Manipulation of the needle valve, vernier control and the handles can produce any pressure desired within the HandPump operating range (O to 3000 psi). 7. When the calibration is completed, open the needle valve to release the pressure. CAUTION: To prevent personal injury, the pressure must be reduced to zero before disconnecting any element of the system. Store the unit it a carrying case or another safe location. The HandPump may be stored with the operating fluid in the reservoir. It is recommended that the fluid being utilized be identified so that another potential operator of the HandPump will be so advised. TROUBLE SHOOTING If the pressure fails to increase: a. Insure the needle valve is tightly closed. b. Make sure there are no leaks in the system. Note that very small leaks can prevent pressurization. c. Make sure the fluid level has not dropped below the manifold level. d. Remove the master gauge and see if fluid rises in the street tee when the handles are exercised. If not, proceed to step e. e. Remove the reservoir and the manifold (item 2). Remove the valve plug (item 16) and inspect the check valve and check valve spring for damage. Make sure the pressure port is not plugged. Reassemble and repeat step d. If not, proceed to step f. f. Remove the street tee and remove the Nylon set screw (item 31). Remove and inspect the check valve spring. d Reassemble and repeat step d. If not, proceed to step g. g. Remove the top two handle pivots (item 26) and the four screws (item 32) in the base (item 4). Remove the entire assembly and inspect the o-ring. Reassemble and repeat step d. If desired pressure can't be maintained: a. Insure the needle valve is tightly closed. b. Make sure there are no leaks in the system. c. Air may be trapped in the system and can be removed by following OPERATING INSTRUCTION number Chemical Lane, Huntington Beach, California USA Phone: (714) Fax: (714) Internet: info@3dinstruments.com KT-060 Hydraulic Handpump 8/98

8 NOTES: UNLESS OTHERWISE SPECIFIED 1 LUBRICATE O-RING WITH PARKER SUPER-O-LUB OR EQUIV. 2 LUBRICATE BORE WITH A LIGHT COAT OF PARKER SUPER-O-LUB OR EQUIV. 3 INSTALL SCREW WITH LOCTITE # 425 OR EQUIV. 4 PURCHASE ITEM 41 (FILTER) AND ITEM 17 (PLUG) AS A SET. 5 ITEM 47 (HOSE ASSEMBLY) NOT SHOWN. ATTACHES TO 1/4-18 NPT PORT. ALSO OPTIONAL MICROBORE HOSE ASSEMBLY AVAILABLE. 6 INSTALL SCREW WITH PERMA-LOK LM113 OR EQUIV. 7 INSTALL SCREW WITH PERMA-LOK LM113 OR EQUIV AND TORQUE 13 TO 15 LBS. 8 INSTALL SET SCREW WITH PERMA-LOK LM113 OR EQUIV AND TORQUE 16 TO 20 LBS. 9 LIGHTLY LUBRICATE THE THREADS WITH KRYTOX GPL-200 GREASE OR EQUIV. PARTS LIST FOR HYDRAULIC HAND PUMP WITH VERNIER FINE PRESSURE ADJUSTMENT QTY. ITEM PART NO. DESCRIPTION BODY, HYDRAULIC HAND PUMP LINK, PNEUMATIC HAND PUMP HANDLE, UNIVERSAL, HAND PUMP (MACHINED) BASE, BODY PNEUMATIC HAND PUMP (MACHINED) SPRING, RETURN SPRING - CHECK VALVE HYDRAULIC PUMP SHAFT, HYDRAULIC HAND PUMP RESERVOIR ROD YOKE, HYDRAULIC HAND PUMP PISTON, VERNIER HYDRAULIC HAND PUMP KNOB, RELIEF VALVE PNEUMATIC HAND PUMP KNOB, VERNIER HYDRAULIC HAND PUMP CHECK VALVE VALVE. NEEDLE HYDRAULIC HAND PUMP VALVE PLUG HYDRAULIC HAND PUMP RESERVOIR PLUG HYDRAULIC HAND PUMP B38 ORING, BACKUP (FOR 2-005) PLATE, VERNIER HYDRAULIC HAND PUMP RESERVOIR END PLATE MANIFOLD, RESERVOIR HYDRAULIC HAND PUMP BUSHING, HYDRAULIC HAND PUMP RESERVOIR CYLINDER PIN, PIVOT QTY. ITEM PART NO. DESCRIPTION PIN, PIVOT PIN, PIVOT SCREW, PAN HD 6-32 X.38 LG SCREW, BUTTON HD 6-32 X 1/4 LG SCREW, SET 8-32 X.38 LG SCREW, 100 CSK HD 6-32 X.38 LG SCREW, SET, 3/8-24 X.312 I.G. MODIFIED SCREW, 100 CSK HD 6-32 X.50 LG CAP NUT, BRASS NUT, NYLON, BLACK O-RING, SIZE I-37 O-RING, SIZE O-RING, SIZE O-RING, SIZE I-39 O-RING, SIZE I-1 FILTER SLUG STANDARD FITTINGS B37 ORING, BACKUP (FOR 2-007) GASKET, MANIFOLD HYDRAULIC HAND PUMP GASKET, RESERVOIR IDENTIFICATION LABEL WASHER, FIBER HYDRAULIC HOSE ASSEMBLY LABEL, HYDRAULIC HAND PUMP