Omega | PPP-700 | Owner Manual | Omega PPP-700 Owner Manual

Omega PPP-700 Owner Manual
User’s Guide
Shop online at
www.omega.com
e-mail: info@omega.com
PPP-700
Hydraulic Pressure Pump
OMEGAnet ® Online Service
www.omega.com
Internet e-mail
info@omega.com
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ISO 9001 Certified
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Tel: (203) 359-1660
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Tel: (514) 856-6928
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FAX: (514) 856-6886
For immediate technical or application assistance:
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Toll Free in France: 0800 466 342
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Servicing Europe:
Germany/Austria: Daimlerstrasse 26, D-75392 Deckenpfronn, Germany
Tel: +49 (0)7056 9398-0
Toll Free in Germany: 0800 639 7678
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FAX: +49 (0)7056 9398-29
United Kingdom: One Omega Drive, River Bend Technology Centre
ISO 9002 Certified
Northbank, Irlam, Manchester
M44 5BD United Kingdom
Tel: +44 (0)161 777 6611
FAX: +44 (0)161 777 6622
Toll Free in United Kingdom: 0800-488-488
e-mail: sales@omega.co.uk
It is the policy of OMEGA to comply with all worldwide safety and EMC/EMI regulations that
apply. OMEGA is constantly pursuing certification of its products to the European New Approach
Directives. OMEGA will add the CE mark to every appropriate device upon certification.
The information contained in this document is believed to be correct, but OMEGA Engineering, Inc. accepts
no liability for any errors it contains, and reserves the right to alter specifications without notice.
WARNING: These products are not designed for use in, and should not be used for, human applications.
CONTENTS
1 DESCRIPTION ................................................................................. 2
1.1 Standard Accessories ........................................................................... 2
1.2 Optional Accessories ........................................................................... 2
2 OPERATION .................................................................................... 3
2.1 Reservoir Fluid Level ........................................................................... 4
3 TROUBLESHOOTING/MAINTENANCE .......................................... 5
3.1 About Bonded Seals .............................................................................
3.2 Seal Replacement ................................................................................
3.2.1 Main Piston Seal .......................................................................
3.2.2 Fine Control Seal ......................................................................
3.2.3 PPP-700 Vent Valve Seal .........................................................
5
6
6
6
6
4 SPECIFICATIONS ............................................................................ 8
4.1 The Pump Unit ..................................................................................... 8
4.1 The Pressure Measurement Hose ....................................................... 8
5 NOTES. .......................................................................................... 10
6 WARNINGS .................................................................................... 11
(8801400) / UEPPP-700 / 010303
1
1 DESCRIPTION
The PPP-700 hydraulic pressure pump is designed to manually generate up to 700
bar (70 MPa, 10 000 psi) for quick and accurate calibration of pressure gauges,
transducers and other pressure measurement instruments.
Recommended test fluids to be used with the pump are: Low viscosity mineral
based hydraulic oils or distilled water. Do not use solvents or synthetic fluids that
will adversely affect the operation of the pump.
1.1 Standard Accessories
The standard accessories are as follows:
∗
∗
∗
∗
∗
∗
∗
Carrying case
G 3/8 (3/8" BSP) plug to blank off the connection for an optional pressure
gauge or module.
G 3/8 (3/8" BSP) to G 1/4 (1/4" BSP) adapter for connecting the optional
pressure gauge or module.
A Pressure Measurement Hose for PPP-700 with two 1215 Special female
connectors.
A G 1/4 (¼” BSP) male / 1215 Special male connector to connect the Pressure
Measurement Hose to the PPP-700.
A 1/4" NPT male / 1215 Special male connector to connect the Pressure
Measurement Hose to the instrument to be calibrated.
A filling bottle.
1.2 Optional Accessories
The optional accessories are as follows:
∗
∗
2
Service kit containing a set of seals, code 8003200
Relief valves for over-pressure protection
max. pressure
10 to
50 bar, code
max. pressure
50 to 200 bar, code
max. pressure 200 to 400 bar, code
max. pressure 300 to 700 bar, code
7230600
7231600
7232500
7236000
2 OPERATION
1.
Connect the optional external pressure module or gauge to the pump (refer to the
picture on page 1) using the appropriate seals. Ensure the measurement range
of the connected module is appropriate.
2.
Remove filling plug and fill reservoir with the appropriate fluid (don’t exceed the
maximum level) and replace plug.
3.
Connect the instrument to be tested to the Pressure Measurement Hose and
attach it to the pump. Be sure that all the output connectors are properly plugged
or connected to an instrument to avoid leakage.
4.
Adjust the fine control to “fully-out”. Make sure the stroke selector is set to prime.
If not, squeeze handles fully in and turn the selector counterclockwise.
5.
Ensure that PPP-700’s vent valve is open (turn fully clockwise then one turn
counterclockwise).
6.
Operate handles several times to expel air from the pump (ensure that the liquid
inlet tube remains immersed in fluid at all times).
7.
Make sure no gas is left in the measurement system during the calibration procedure. Keep for example a valve connected to the measurement system open
while priming the system until all gas is removed or temporarily connect a vacuum
pump to remove gas from the measurement system. Remember to remove the
vacuum pump from the system before increasing the pressure.
8.
Close PPP-700’s vent valve fully clockwise.
9.
Prime the system by squeezing handles together and then releasing, allowing
the fluid to enter the pump cylinder. Repeat as necessary until system is fully
primed and low pressure is indicated on either a calibrator or the test instrument.
10. Test how much pressure increase can be done using the fine control. If it is enough,
continue to step 12.
11. With handles fully squeezed in, select the high pressure position on the stroke
selector and operate handles to generate approximate pressure. The rate of the
pressure increase depends on the volume of the measurement system. Carefully
follow the reading of the pressure indicator in order to avoid exceeding the maximum pressure of the measurement system. NOTE: Smaller handle strokes enable easier pressure generation at high pressures.
12. Adjust pressure to required value using the fine control. Immediately after pressure generation, the pressure may fall slightly due to the stretching of the pressure measurement hose. Thermodynamic effects may also cause pressure variation. In that case, adjust the pressure back to required value using the fine control.
13. The principal tool for releasing pressure from the measurement system is
3
PPP-700’s fine control. Use of PPP-700’s vent valve is also possible, but requires caution in order to avoid pressure shocks to the measurement system.
14. To totally release pressure from the system, turn PPP-700’s vent valve one turn
counterclockwise. Return the stroke selector to prime position after first squeezing handles fully in.
WARNINGS!
Do not exceed the max. operating pressure of the pump and the hose. Also
observe the pressure limit set by environmental conditions and the used pressure medium.
If there is a strong counterforce while operating the handles, but no pressure
increase is indicated, stop pumping and locate the fault. Always keep a reliable
indicator connected to the measurement system.
The glass reservoir does not withstand high pressure but it is not pressurized
when PPP-700 is used correctly. Do not add fluid to the glass reservoir when
increasing pressure. The reservoir may overflow and explode when the pressure is released and all the excess fluid returns from system to the reservoir.
A full list of warnings is on page 11.
2.1 Reservoir Fluid Level
If the fluid level in the reservoir falls considerably during use, a partial vacuum can
be created in the reservoir which may affect the pump performance. To avoid this,
simply allow air to enter reservoir by partly unscrewing the filling plug.
4
3 TROUBLESHOOTING/MAINTENANCE
If the pump assembly fails to indicate a pressure increase after considerable pumping action of the handle, the following items should be examined:
•
The pump unit may have been mistakenly opened by rotating the handles counterclockwise. Correction: Squeeze the handles fully in and rotate clockwise to
retighten the pump unit.
•
Check to assure that the connections between the pump, the hose end and the
attached instrument(s) are tight and repeat operating instructions items 6 and 7.
Check to assure that all the unused output connectors are properly plugged.
If a pressure increase still cannot be obtained, it’s possible that one or more of the
seals in the Pressure Pump is leaking and needs to be replaced.
Do not continue pumping if the functionality of the pump is not normal.
Locate the fault before you continue using the pump.
3.1 About Bonded Seals
Bonded seals are metallic rings with an elastic material attached to the inner side of
the ring. They are used in several places in PPP-700. When tightening a connection sealed with a bonded seal, keep in mind that firm
hand tightening is recommended. Other tightening methods may
result in leakage, and possibly broken seals or threads.
5
3.2 Seal Replacement
Depending on the frequency of use, the Main Piston Seal (and others) will eventually need replacing. Although the replacement seals are an optional accessory, the
same instructions for fitting the seals are included in this manual as in the replacement package.
3.2.1 Main Piston Seal
Withdraw handle/piston assembly from cylinder by removing the two M5 socket
head screws shown in the picture.
Clean the piston and the cylinder and remove the old piston seal and the backup
ring.
Fit the new piston seal (o-ring) and the backup ring. Lightly grease piston seal and
the piston using silicone grease. Reassemble.
3.2.2 Fine Control Seal
Place a 19 mm A/F spanner on the flats (see the picture on the adjacent page) and
a 27 mm A/F spanner on the large nut and unscrew the piston assembly.
Clean the piston and the cylinder and remove the old piston seal and backup ring.
Fit the new piston seal (o-ring) and the backup ring. Lightly grease the piston seal
and backup ring using silicone grease. Reassemble.
3.2.3 PPP-700 Vent Valve Seal
Turn vent valve knob fully counterclockwise and pull out the valve screw from its
body. Take care not to loose the steel ball that lies beneath the screw.
Remove the old seal from its groove in the valve screw and replace with a new one.
Lightly grease the seal with silicone grease and reassemble ensuring the steel ball
is correctly in place.
6
S te e l b a ll
O - r in g
P T F E B a c k u p R in g
O - r in g
F la ts
O - r in g
P T F E B a c k u p R in g
M 5 s o c k e t h e a d s c re w s
7
4 SPECIFICATIONS
4.1 The Pump Unit
Weight
Dimensions
Height
Width
Depth
Pressure range*
1.6 kg
3.53 lb
236 mm
159 mm
70 mm
approx. 9.3"
approx. 6.3"
approx. 2.8"
0 to 700 bar /
Pressure media
0 to 70 MPa /
0 to 10 000 psi
Low viscosity Mineral based Hydraulic Oil
or Distilled water
Glass reservoir for pressure media
100 cc, not to be pressurized
Output connectors
·
·
·
G 1/4 (1/4" BSP) female connector for Pressure Measurement Hose
G 3/8 (3/8" BSP) female (for External Pressure Measurement Module, or
gauge)
G 1/4 (1/4" BSP) female for overpressure pretection valve use only.
Blanked off unless the optional relief valve is installed.
4.1 The Pressure Measurement Hose
Length
1m
Connectors (both ends)
Internal diameter
2 mm
0.08"
External diameter
5 mm
0.2"
Operating pressure
*
• 0°C (+32°F)
• 30°C (+86°F)
• 50°C (+122°F)
• 80°C (+176°F)
• 100°C (+212°F)
• 120°C (+248°F)
Bursting pressure in
20°C (68°F)
Operable temperature range
768 bar
693 bar
630 bar
535 bar
485 bar
428 bar
76.8 MPa
69.3 MPa
63 MPa
53.5 MPa
48.5 MPa
42.8 MPa
11148
10051
9137
7767
7036
6213
1950 bar
195 MPa
28200 psi
-20°C to +100°C
Smallest bending radius
• below -20°C (-4°F)
8
3 ft 3.3”
1215 Special, female
20 mm
30 mm
psi
psi
psi
psi
psi
psi
-4°F to +212°F
0.78"
1.18"
* The environmental conditions and the used pressure medium may restrict the allowable
maximum pressure to a lower level than the pump and the hose enables. In that case
please consider using a relief valve.
3 /8 " p lu g ...
o r w h e n a p p lic a b le ,
th e X P M /E X T a d a p te r
G
to
c o
c o
M
1 /4 (1 /4 " B S P )
1 2 1 5 S p e c ia l
n n e c to r to
n n e c t th e P re s s u re
e a s u re m e n t H o s e
1 2 1 5 S p e c ia l
1 /4 "
3 /8 "
3 /8 "
1 /4 "
1 /4 "
1 /4 " p
o r w h
a p p lic
th e re
v a lv e
p ic tu r
b e lo w
lu g ...
e n
a b le ,
lie f
(s e e
e
)
PPP-700’s output connectors viewed from the Fine Control side.
S e a l
P P P -7 0 0
T h e r e lie f
v a lv e
P re s s u re
R e s e r v o ir
PPP-700 with the optional relief valve for over-pressure protection installed
9
5 NOTES.
The pump is tested using water. Small amounts of water may still be inside the
pump when you receive it. Flush the pump with the pressure media to be used
before connecting any instruments to it.
Ensure that the process media is compatible with the pressure media used in
the pump. Make sure that impurities are removed from the measurement system. From time to time the pressure media used in the pump should be renewed.
The maximum total volume of the measurement system may not exceed 100 ml
(6.1 cubic inches). The volume inside PPP-700 is less than 1 ml (on the pressurized side, not the reservoir, with maximum volume in the fine control). The volume of the unpressurized Pressure Measurement Hose is 3.5 ml per meter.
Ensure that there always is a reliable pressure indicator connected to the pump
when the pump is used.
If the pump is accidentally dropped, it may be damaged. Do not use the pump
before it is inspected at Omega’s service.
Please include information on used pressure media when sending the pump
for service.
10
6 WARNINGS
Read the instruction manual carefully prior to setting up and using the pressure
pump. The pressure built up internally during use can be extremely high.
Only personnel with good experience and knowledge of high pressure media,
high pressure instruments and connections are allowed to work with the pressure pump. Incorrect use may result in damage to the pump, the instrument
connected to the pump and/or personal injury.
Use protective goggles. The use of a relief valve for over-pressure protection is
recommended. If a relief valve is used, remember to occasionally check its functionality.
Do not connect the pump to an external pressure source.
The glass reservoir does not withstand high pressure, but it is not pressurized when PPP-700 is used correctly.
Do not overfill the glass reservoir. Also: do not refill it while increasing pressure. The reservoir may overflow and explode when the pressure is released
and all the excess fluid returns from system to the reservoir.
The measurement system must only contain the measurement fluid and no gas.
See chapter 2 OPERATION for guidance on how to remove the gas from the
measurement system.
Vent external systems before connecting to the pump. Do not use pump if the
reservoir is damaged.
Ensure that all connections are made correctly and that the hose and the connectors are undamaged. Do not use faulty hoses or connectors.
Use only the measuring hose provided by Omega. Observe the effect of the
operational conditions to the maximum pressure allowed in the hose. The specifications can be found on page 8 in the manual.
The environmental conditions and the used pressure medium may restrict the
allowable maximum pressure to a lower level than the pump and the hose enable. In that case please consider using a relief valve.
Always depressurize PPP-700 when it is left on its own.
If you use water as the pressure medium, make sure that the you store PPP-700
in temperatures above the freezing point.
Use only the connectors provided with the pump. Impurities from wrong materials may plug the pump.
Do not use PPP-700 in any other way than as described in this manual.
11
O u tp u t c o n n e c to rs
C o n n e c to r fo r P re s s u re
M e a s u re m e n t h o s e
O n th e o p p o s ite s id e :
A c o n n e c to r fo r th e o p tio n a l
o v e r p r e s s u r e p r o te c tio n v a lv e .
C o n n e c to r fo r o p tio n a l
E x te rn a l P re s s u re
M o d u le o r g a u g e
F in e c o n tr o l
V e n t v a lv e
R e s e r v o ir fillin g p lu g
T h e p lu g is e q u ip p e d w ith a
r e lie f v a lv e fo r p r o te c tin g
th e r e s e r v o ir .
1 0 0 c c 's r e s e r v o ir
6 m m
H Y D R A U L IC C A L IB R A T IO N P U M P
0 to 7 0 0 b a r / 7 0 M P a / 1 0 0 0 0 p s i
M A X IM U M O U T P U T P R E S S U R E 7 0 0 b a r
D o n o t p r e s s u r iz e g la s s r e s e r v o ir
F lu id le v e l
m a x im u m
L iq u id in le t tu b e
G H
H I
IM E
P R
S tr o k e s e le c to r
P r im e / H ig h
A more detailed picture of PPP-700’s
output connectors is on page 9.
12
WARRANTY/DISCLAIMER
OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and
workmanship for a period of 13 months from date of purchase. OMEGA’s Warranty adds an
additional one (1) month grace period to the normal one (1) year product warranty to cover
handling and shipping time. This ensures that OMEGA’s customers receive maximum
coverage on each product.
If the unit malfunctions, it must be returned to the factory for evaluation. OMEGA’s Customer
Service Department will issue an Authorized Return (AR) number immediately upon phone or
written request. Upon examination by OMEGA, if the unit is found to be defective, it will be
repaired or replaced at no charge. OMEGA’s WARRANTY does not apply to defects resulting
from any action of the purchaser, including but not limited to mishandling, improper interfacing,
operation outside of design limits, improper repair, or unauthorized modification. This
WARRANTY is VOID if the unit shows evidence of having been tampered with or shows evidence
of having been damaged as a result of excessive corrosion; or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operating conditions outside of
OMEGA’s control. Components which wear are not warranted, including but not limited to
contact points, fuses, and triacs.
OMEGA is pleased to offer suggestions on the use of its various products. However,
OMEGA neither assumes responsibility for any omissions or errors nor assumes liability
for any damages that result from the use of its products in accordance with information
provided by OMEGA, either verbal or written. OMEGA warrants only that the parts
manufactured by it will be as specified and free of defects. OMEGA MAKES NO OTHER
WARRANTIES OR REPRESENTATIONS OF ANY KIND WHATSOEVER, EXPRESS OR
IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES INCLUDING ANY
WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE
HEREBY DISCLAIMED. LIMITATION OF LIABILITY: The remedies of purchaser set forth
herein are exclusive, and the total liability of OMEGA with respect to this order, whether
based on contract, warranty, negligence, indemnification, strict liability or otherwise, shall
not exceed the purchase price of the component upon which liability is based. In no event
shall OMEGA be liable for consequential, incidental or special damages.
CONDITIONS: Equipment sold by OMEGA is not intended to be used, nor shall it be used: (1) as
a “Basic Component” under 10 CFR 21 (NRC), used in or with any nuclear installation or activity;
or (2) in medical applications or used on humans. Should any Product(s) be used in or with any
nuclear installation or activity, medical application, used on humans, or misused in any way,
OMEGA assumes no responsibility as set forth in our basic WARRANTY/DISCLAIMER language,
and, additionally, purchaser will indemnify OMEGA and hold OMEGA harmless from any liability
or damage whatsoever arising out of the use of the Product(s) in such a manner.
RETURN REQUESTS/INQUIRIES
Direct all warranty and repair requests/inquiries to the OMEGA Customer Service Department.
BEFORE RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN
AUTHORIZED RETURN (AR) NUMBER FROM OMEGA’S CUSTOMER SERVICE DEPARTMENT
(IN ORDER TO AVOID PROCESSING DELAYS). The assigned AR number should then be
marked on the outside of the return package and on any correspondence.
The purchaser is responsible for shipping charges, freight, insurance and proper packaging to
prevent breakage in transit.
FOR WARRANTY RETURNS, please have
the following information available BEFORE
contacting OMEGA:
1. Purchase Order number under which
the product was PURCHASED,
2. Model and serial number of the product
under warranty, and
3. Repair instructions and/or specific
problems relative to the product.
FOR NON-WARRANTY REPAIRS, consult
OMEGA for current repair charges. Have the
following information available BEFORE
contacting OMEGA:
1. Purchase Order number to cover the COST
of the repair,
2. Model and serial number of the product, and
3. Repair instructions and/or specific problems
relative to the product.
OMEGA’s policy is to make running changes, not model changes, whenever an improvement is possible.
This affords our customers the latest in technology and engineering.
OMEGA is a registered trademark of OMEGA ENGINEERING, INC.
© Copyright 2003 OMEGA ENGINEERING, INC. All rights reserved. This document may not be copied, photocopied,
reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without
the prior written consent of OMEGA ENGINEERING, INC.
Where Do I Find Everything I Need for
Process Measurement and Control?
OMEGA…Of Course!
Shop online at www.omega.com
TEMPERATURE
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Wire: Thermocouple, RTD & Thermistor
Calibrators & Ice Point References
Recorders, Controllers & Process Monitors
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M3938/0303
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