Atec Druck PV 411 User Manual

K258 Issue No. 1

Druck PV 411

Pneumatic/Hydraulic Hand-pump

User Manual

© Druck Limited 2000

This document is the property of Druck Limited and may not be copied or otherwise repro­duced, communicated in any way to third parties, nor stored in any Data Processing System
without the express written authorisation of Druck Limited.

Advanced Test Equipment Rentals

www.atecorp.com 800-404-ATEC (2832)

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Druck PV 411 User Manual

Page i K258 Issue No. 1

Introduction

This technical manual provides operating instructions for the PV 411
Pneumatic/hydraulic hand-pump compatible with the requirements
of line operation.

Safety

The manufacturer has designed this equipment to be safe when
operated using the procedures detailed in this manual. The user
must not use this equipment for any other purpose than that stated.
Only use hydraulic fluids stated in the specification.

This manual contains safety and operating instructions which must
be followed to make sure of safe operation and to keep the
equipment in a safe condition. The safety instructions are either
warnings or cautions issued to protect the user and the equipment
from injury or damage. Use suitably qualified personnel and good
engineering practice for all procedures in this manual.

Pressure

Do not apply pressure greater than the safe working pressure
stated in the specification.

Technical advice

For technical advice contact the manufacturer or subsidiary.

+-

This product meets the essential requirements of the relevant
EEC directives.

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K258 Issue No. 1 Page ii

ABBREVIATIONS

The following abbreviations are used in this publication.

Note

Abbreviations are the same in the singular and plural.

°C degrees Celsius
BSP British standard pipe thread
cm centimetre
°F degrees Fahrenheit
inHg inches of mercury
lbs pounds
ISO International Standards Organisation
kg kilogram
m metre
mbar millibar
mm millimetre
mmH

2

O millimetres of water
NPT National pipe thread
PRV pressure relief valve
psi pounds per square inch
PTFE polytetraflouroethylene
SAE Society of Automotive Engineers
UUT Unit under test

Symbols

The following symbols mark this equipment:

Read the manual before use.

Refer to the manual.

Druck PV 411 User Manual

Page iii K258 Issue No. 1

CONTENTS

Title page

Introduction ............................................................................................... 1

Pneumatic pump .................................................................................... 1

Hydraulic pump ...................................................................................... 1

Specification ........................................................................................... 3

Operation ............................................................................................... 4

Pressure/vacuum configuration ............................................................. 4

Connecting the pump ....................................................................... 5

Selector valve ................................................................................... 5

Scissor-action handles limit adjuster ................................................ 6

Pneumatic Operation ........................................................................................ 7

Volume adjuster ................................................................................ 7

Generating pneumatic pressure and vacuum ................................... 8

Pressure ............................................................................................ 8

Vacuum ............................................................................................. 8

Hydraulic Operation ........................................................................................ 10

Fluid reservoir ....................................................................................... 10

Fitting ......................................................................................... 12

Filling ......................................................................................... 12

Priming the system .............................................................................. 13

Vacuum priming ......................................................................... 13

Pre-filling .................................................................................... 14

Setting pressure relief valve ................................................................ 14

Generating hydraulic pressure ............................................................. 15

Multimedia ........................................................................................... 16

Flushing ..................................................................................... 16

Fault finding .......................................................................................... 17

Approved service agents ..................................................................... 18

Annex A

Returned Goods Procedure ................................................................. 19

ILLUSTRATIONS

Figure title page

1 General view ............................................................................... 2

2 Fitting the reservoir ................................................................... 11

Druck PV 411 User Manual

Page 1 K258 Issue No. 1

Introduction

The PV 411 hand-pump generates either pneumatic pressure and
vacuum or hydraulic pressure. The scissor-action handles provide
pneumatic pressure and vacuum generation and, in the hydraulic
mode, provides hydraulic pressure generation for system priming.

Pneumatic pump (Figure 1)

A selector valve vents the system, to atmosphere, between
selections of pressure and vacuum. Operating the scissor-action
handles provides the pumping stroke, for pressure generation.
A volume adjuster allows small adjustments of the system
pressure.

Hydraulic pump (Figure 1)

The selector valve vents the system, to the reservoir, between
selections of pressure and vacuum (used in the priming process).
The volume adjuster generates the required system pressure. A
fluid reservoir, screwed into the inlet port on the top of the hand­pump completes the hydraulic circuit. A pressure relief valve can
be set to limit maximum pressure between 30 to 700 bar.

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K258 Issue No. 1 Page 2

Figure 1, General view

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Page 3 K258 Issue No. 1

Specification

Pressure range

Pneumatic .........................................................................0 to 60 bar

Vacuum .................................................................. 0 to -0.95 bar *

Hydraulic ....................................................................... 0 to 700 bar

Maximum safe working pressure ........................................... 700 bar

Hydraulic fluid .................................................. Demineralised water

or mineral-based oils

Hydraulic fluids must be compatible with:

Stainless steel, anodised aluminium, nitrile rubber,

PTFE, polypropylene, delrin, acrylic and nylon.

Pressure connections: .................................1/4 BSP parallel female

Weight (approximate): .............................................................. 1.1 kg

Dimensions

Length ............................................................................ 260 mm

Width ............................................................................ 135 mm

Depth .............................................................................. 95 mm

* This value assumes atmospheric pressure at 1 bar and will vary
depending on atmospheric pressure.

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K258 Issue No. 1 Page 4

Operation

WARNINGS

1BEFORE APPLYING PRESSURE, MAKE SURE ALL CONNECTIONS

ARE

CORRECT AND EQUIPMENT IS INTERNALLY CLEAN AND

FREE

FROM DAMAGE.

2M

AKE SURE THAT ALL EQUIPMENT IS TO THE CORRECT

PRESSURE

RATING.

3D

O NOT EXCEED THE MAXIMUM OPERATING PRESSURE

STATED

IN THE SPECIFICATION.

4O

BSERVE THE RELEVANT HEALTH AND SAFETY PRECAUTIONS.

Note

Wherever possible, use o-ring seals in the connection ports
this is the recommended method of sealing.

Pressure/vacuum Configuration (Figure 1)

In pressure mode, air/fluid is drawn in through the inlet port on the
top of the pump and forced out through the two outlet ports.

In vacuum mode, the air/fluid flow is reversed as air/fluid is drawn
in through the top and rear outlet ports and expelled through the
inlet port.

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Page 5 K258 Issue No. 1

Connecting the Pump

Connections can be made to the pump either directly or using the
range of adaptors supplied in the optional test kit.

Direct

The ports can be fitted with any suitable length 1/4 BSP male
connector, sealing either with an o-ring at the bottom of the port or
a bonded seal at the top. Fit a suitable blanking plug to an unused
port.

Swivel Adaptors

The single, 1/4 BSP, swivel adaptor connects with a range of fixed
adaptors. Using the knurled grip-feature, hand-tighten (clockwise)
the swivel adaptor, until it is fully inserted.

Swivel pump head

The pump head swivels through 140° providing optimum viewing
angle and bench-top operation. Placing the pump on the bench
allows greater force to be applied to the scissor-action handles.
Internal stops prevent further rotation of the pump head.

Note

Do not use excessive force when rotating the pump head.

Selector Valve

Pressure

Turn the selector valve fully clockwise (in) position.

Vacuum

Turn the selector valve fully anti-clockwise (out) position.

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K258 Issue No. 1 Page 6

Vent

Slowly turn the selector valve to the centre position.

CAUTION:

AVOID DAMAGING THE INSTRUMENT UNDER TEST BY USING THE

VOLUME

ADJUSTER TO RELEASE HYDRAULIC PRESSURE.

Scissor-action Handles Limit Adjuster

Turning the adjuster anti-clockwise reduces the stroke, turning the
limit adjuster clockwise increases the stroke.
For maximum pneumatic pressure generation, turn the limit
adjuster fully clockwise.

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Page 7 K258 Issue No. 1

Pneumatic Operation

Volume Adjuster

The volume adjuster can be used in different modes:

Low pressure

With the selector valve set to vent (open), turn the volume adjuster
fully anti-clockwise (out).

Turn the selector valve to the fully clockwise (in) position to select
pressure.

Turn the volume adjuster clockwise to generate pressure.

High pressure

Turn the volume adjuster to the mid-position. In this position fine
adjustments of the generated pressure can be made. Using the
scissor-action handles, generate the approximate pressure; then
turn the volume adjuster clockwise (in) to increase the pressure or
turn the volume adjuster anti-clockwise (out) to decrease the
pressure.

Vacuum

Turn the selector valve fully anti-clockwise (out) position.

Turn the volume adjuster to the mid-position. In this position fine
adjustments of the generated vacuum can be made.

Using the scissor-action handles, generate the approximate
vacuum; then turn the volume adjuster clockwise (in) to decrease
the vacuum or turn the volume adjuster anti-clockwise (out) to
increase the vacuum.

For low vacuum use the volume adjuster only.

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K258 Issue No. 1 Page 8

Generating pneumatic pressure and vacuum

Connect the pump as detailed on page 5.

Notes

Compressing a gas generates heat. Gas heated or cooled in
an enclosed volume causes a pressure change. It is
important to allow enough time for the heated gas to cool and
the pressure to stabilize.

The number of pumps required to generate a pressure
depends on the volume of the system. Therefore, keep the
system volume to a minimum.

Pressure

1 Turn the selector valve fully clockwise (in) position.

2 Operate the scissor-action handles to generate the
approximate pressure, allow time for thermal stabilization.

3 If necessary, use the volume adjuster to adjust the required
pressure.

4 After attaining the required pressure operate the scissor­action handles to generate a higher pressure. Alternatively, vent
the pressure to atmosphere by slowly turning (anti-clockwise) the
selector valve to the centre position.

Vacuum

1 Turn the selector valve fully anti-clockwise (out) position.

2 Operate the scissor-action handles to generate the
approximate vacuum, allow time for thermal stabilization.

3 If necessary, use the volume adjuster to adjust the required
vacuum.

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Page 9 K258 Issue No. 1

4 After attaining the required vacuum operate the scissor-action
handles to generate a higher vacuum. Alternatively, vent
atmosphere into the vacuum by slowly turning (anti-clockwise) the
selector valve to the centre position.

After completion, depressurize the pump and disconnect from the
pipes and equipment.

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K258 Issue No. 1 Page 10

Hydraulic Operation

CAUTIONS

/ DO NOT MIX HYDRAULIC FLUIDS.

/ ONLY USE COMPATIBLE FLUIDS, REFER TO THE SPECIFICATION.

/ ONLY FIT APPROPRIATE SEALS ON CONNECTIONS.

/ OBSERVE ABSOLUTE CLEANLINESS WHEN USING THIS PUMP. DAMAGE

CAN

BE CAUSED IF EQUIPMENT CONNECTED TO THIS PUMP IS

CONTAMINATED

. AVOID PARTICULATE CONTAMINATION.

Note

Wherever possible, use o-ring seals in the connection ports,
this is the recommended method of sealing.

Fluid Reservoir (Figure 2)

The main body of the reservoir is transparent acrylic providing a
clear view of the contents.

The reservoir can be removed from the pump without the need to
empty the fluid, a self-sealing connection prevents leakage. The
spring-loaded top cover seals under atmospheric pressure
conditions, but vents excess internal pressure harmlessly in the
event of inadvertent pressurization.

The reservoir, connects to the inlet port on the top of the pump and
supplies fluid to the pump system for pressure generation.

In vacuum mode, used in priming, the fluid flow is reversed, fluid is
drawn from the two outlet ports and through to the inlet port and
the reservoir.

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Page 11 K258 Issue No. 1

Figure 2, Fitting the Reservoir

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Fitting

Make sure that the correct o-ring seal is fitted to the inlet port to
prevent leakage. Screw the reservoir (clockwise) into the inlet port.

Note:

Demineralised water is used to test the pump at
manufacture. On shipment, there will be traces of
demineralised water in the system.

Filling

Unscrew the reservoir cover lock nut and remove the reservoir
cover.

Using clean, recommended fluid fill the reservoir to approximately
2/3 full.

Refit the reservoir cover and re-tighten the reservoir cover lock nut.

Connect the required pipes and equipment to the outlet ports.

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Page 13 K258 Issue No. 1

Priming the system

There are two methods: vacuum priming to extract the air or pre­filling the system.

Notes:

1 If air remains in the system, full pressure cannot be
achieved as the air in the fluid compresses. Air must be
removed from the system fluid.

2 Both priming methods require the pump to be held in
the vertical position to keep the reservoir bleed hole in fluid.
Do not allow air to enter the system through this bleed hole.

Vacuum priming (Figure 2)

Connect the equipment as detailed on page 5.

Air can be removed using the vacuum facility on the pump.

Note:

This method should not be used with vacuum-sensitive
equipment.

Turn selector valve fully out, anti-clockwise (vacuum position).

Pump until bubbles stop appearing in the reservoir, (this generates
a vacuum in the system).

Turn the selector valve fully in, (this action releases the vacuum and
rapidly fills the system with fluid from the reservoir).

The pump and connected system is ready for use.

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K258 Issue No. 1 Page 14

Pre-filling

Connect the equipment as detailed on page 5.

Turn the selector valve fully clockwise (in) position.

Loosen the reservoir cover lock nut to open the reservoir cover and
let atmospheric pressure into the top of the reservoir.

Open the bleed valve on the UUT.

Carefully operate the scissor-action handles to fill the system. Stop
pumping when fluid comes out of the bleed valve.

Close the bleed valve on the UUT.

If necessary, top-up the reservoir to the 2/3 level with clean fluid.

Secure the reservoir cover by tightening the reservoir cover lock nut.

The pump and connected system is ready for use.

Setting Pressure Relief Valve (Figure 1)

The pressure relief valve (PRV) can be set at pressures from 30 to
700 bar.

If the system pressure exceeds the set pressure, the PRV opens
and vents fluid through the inlet port to the reservoir. When the
pressure decreases, the PRV closes.

To set the PRV, loosen the PRV locking screw
and turn the PRV to release at the required
pressure.

Hold the PRV and turn the collar fully
anti-clockwise.

Tighten the PRV locking screw.

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Page 15 K258 Issue No. 1

Generating Hydraulic Pressure

Note

Pressurizing a fluid generates heat. A fluid heated or cooled
in an enclosed volume causes a pressure change. Allow
enough time thermally stabilize.

Open the selector valve anti-clockwise 1 turn.

Screw the volume adjuster fully out (anti-clockwise).

Close the selector valve.

Use the scissor-action handles to generate the initial pressure.

Then turn the volume adjuster clockwise to generate the required
pressure, allow time for thermal stabilization.

To reduce the pressure, turn the volume adjuster out (anti­clockwise) to the required pressure.

After completion, turn the volume adjuster fully out (anti-clockwise)
and turn the selector valve to depressurize the pump. Disconnect
from the pipes and equipment.

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K258 Issue No. 1 Page 16

Multimedia

Changing from fluid to gas:

Turn the volume adjuster fully clockwise (in).

Use the vacuum selection, operate the scissor-action handles to
draw fluid into the reservoir.

Depressurize the pump.

Unscrew and remove the reservoir.

Invert the pump and, using the vacuum selection, operate the
scissor-action handles to draw residual fluid out through the inlet
port.

WARNING:

WHEN OUTLET PORTS ARE OPEN AND WITH THE SELECTOR

VALVE

SET TO PRESSURE, OPERATING THE SCISSOR-ACTION

HANDLES

RAPIDLY EXPELS FLUID.

Pneumatic venting, after fluid use, can generate a fluid mist spray
out of the inlet port.

Flushing

If necessary, use soapy water to remove any oil residue.

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Page 17 K258 Issue No. 1

Fault Finding

If system pressure reduces, check the following:

1. Check the selector valve is in the correct position and properly
tightened.

2. Allow sufficient time after pressure generation for the
temperature to stabilize.

3. Check the adaptors, flexible pipe and connections between
the pump and equipment under test for leaks. Tighten any loose
joints and replace any seals that are worn or damaged.

4. In hydraulic mode, if the volume adjuster can be wound fully
in, but maximum pressure cannot be achieved, there is probably air
trapped in the system. Re-prime, and repeat.

If, for any reason, a fault occurs within the pump, it is
recommended that the equipment be returned to an appointed
agent.

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K258 Issue No. 1 Page 18

Approved Service Agents

The following are approved agents for the servicing of Druck
products.

Japan

Druck Japan KK,
Medie Corp Building 8,
2-4-14 Kichijyoji-Honcho,
Musashino,
Tokyo 180,
Japan.
Tel: [phone]
Fax: [phone]

UK

Druck Limited,
Fir tree Lane
Groby,
Leicester LE6 0FH
England.
Tel: [phone]
Fax: [phone]

USA

Druck Incorporated,
4 Dunham Drive,
New Fairfield,
Connecticut 06812,
U.S.A.
Tel: [phone]
Fax: [phone]

France

Druck SA.,
19 Rue Maurice Pellerin,
92600 Asnières,
France.
Tel: [phone]
Fax: [phone]

Germany

Druck Messtechnik GmbH,
Auf dem Hohenstein 7,
61231 Bad Nauheim,
Germany.
Tel: [phone]
Fax: [phone]

Holland

Druck Nederland b.v.,
Postbus 232,
Zuideinde 37,
2991 Lj Barendrecht,
The Nederlands.
Tel: [phone]
Fax: [phone]

Italy

Druck Italia Srl.,
Via Capecelatro 11,
20148 Milano,
Italy.
Tel: [phone]
Fax: [phone]

Druck PV 411 User Manual

Page 19 K258 Issue No. 1

Annex A

Returned goods procedure

Should the unit become unserviceable and require repair it can be
returned to the Druck Service Department.

Please contact our Service Department, either by 'phone or fax, to
obtain a Returned Goods Authorization (RGA) number, providing the
following information:

Product (i.e. PV 411)
Pressure medium (i.e. pneumatic, hydraulic )
Serial number
Details of defect/work to be undertaken
Operating conditions

Safety Precautions

You must also tell us if the product has been in contact with
anything hazardous or toxic and the relevant COSH references and
precautions to be taken when handling.

Important notice

Service by unauthorized sources will affect the warranty and may
not guarantee further performance.