HYDRAULIC CALIBRATION PUMP
MODEL PGHH
operating instructions
version 1.0a
Table of contents
General information 3
Typographic conventions 3
1 Introduction 4
1.1 Description 4
1.2 Standard delivery 5
1.3 Optional accessories 5
2 Operation 6
2.1 Operating instructions 6
2.2 Reservoir (fluid level) 11
3 Maintenance and troubleshooting 12
3.1 Periodic maintenance 12
3.2 Troubleshooting 14
3.3 Available spare parts 14
3.4 Disposal 14
4 Specifications 15
4.1 The Pump Unit 15
4.2 The Pressure Measurement Hose 15
4.3 Storage 16
2
General information
Dear user,
We have made every effort to ensure the accuracy of the contents of this manual.
Should any errors be detected, we would greatly appreciate to receive suggestions to
improve the quality of the contents of this manual.
The above notwithstanding, we can assume no responsibility for any errors in this manual
or their eventual consequences.
We reserve rights to make modifications to this manual without any further notice.
For more detailed technical data about the Instruction manual for PGHH Hydraulic
Pressure Pump, please contact the manufacturer.
Typographic conventions
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Indicates a hazardous situation, which if not avoided, could result in minor or
moderate injury.
Points out tips and recommendations for efficient and trouble-free operation.
Indicates a non-immediate or potential hazardous situation, which if not
avoided, could result in damage of property and equipment.
3
1 Introduction
1.1 Description
The PGHH hydraulic calibration 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.
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 pump. Incorrect use may result in damage to the pump,
the instrument connected to the pump and/or personal injury.
Recommended test fluids to be used with the pump are: mineral based hydraulic oils or distilled water.
Do not use solvents or synthetic fluids that will adversely affect the operation of the pump.
If used with distilled water:
• After each usage, the instrument has to be emptied and let dry out (drain screw at the bottom
of the reservoir);
• As soon as first cloudiness, particles or dirt become visible: change the fluid.
4
1.2 Standard delivery
The standard delivery includes:
• Carrying case;
• G 1/4 (1/4’’ BSP) plug to blank off the connection for an optional Beamex EXT
External Pressure Measurement module;
• G 1/4 (1/4” BSP) adapter (on the top) for connecting the optional Beamex EXT
External Pressure Measurement module;
• A Pressure Measurement Hose for PGHH 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 PGHH;
• A 1/4” NPT male / 1215 special male connector to connect the Pressure
Measurement Hose to the instrument to be calibrated;
• A filling bottle;
• User manual;
• Copper seals;
• 1 x bonded seal under the plug.
1.3 Optional accessories
The optional accessories include:
• Maintenance kit 8003190
• Copper seal kit for EXT modules, code 8072700
• EXT bonded seal kit, code 8003545
• Mineral oil (Aral Vitam DE22), for more information ask Beamex
5
2 Operation
Wear protective glasses.
Do not use PGHH in any other way than as described in this manual.
Use only the connectors provided with the pump. Impurities from wrong materials may plug the pump.
Do not exceed the maximum operating pressure of the pump and the hose. Also observe the pressure
limit set by environmental conditions and the used pressure medium.
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.
If you use water as the pressure medium, make sure that you store PGHH in temperatures above the
freezing point.
2.1 Operating instructions
1. Connect the optional external pressure module (EXT) to the pump (see 3 in figure 1)
using the appropriate seals (it is strongly recommended that the bonded seal
under the plug is used under 600 bar and copper seal above 600 bars).
Ensure that the measurement range of the connected module is appropriate.
2. Remove filling plug and fill reservoir (for 2/3 to max. 3/4) with the appropriate fluid
(don’t exceed the maximum level) and replace plug.
6
1 2
3 4
5
6
1. Fine control
7
8
2. Connector for Pressure
Measurement hose
3. Connector for optional Beamex
External Pressure module
4. Vent valve
5. Reservoir filling plug
6. 200 cc’s Reservoir
7. Stroke selector Prime / High
8. Pump handles
Figure 1. Detailed picture of PGHH Hydraulic Pressure Pump (For connectors see figure 4).
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 200 cc (12.2 cubic inches).
The volume inside PGHH 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.
7
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 (see figure 2).
Do not connect the pump to the external pressure source.
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 Beamex. Observe the effect of the operational conditions to
the maximum pressure allowed in the hose. The specifications can be found in chapter 4.
The pump is made out of anodized aluminium - avoid too much strength while tightening the connectors.
The maximum torque is 15 Nm.
1
4
2
1. EXT Module
2. PGHH pump
3. Pressure transmitter
4. Calibrator
3
Figure 2. An example of the connections.
8
switching
knob
(selector)
Priming pressure
Figure 3. Selecting prime versus high pressure mode with switching knob.
High pressure
4. Adjust the fine control (1 in figure 1) to “the middle”. Make sure the stroke
selector /switching knob (7 in figure 1) is set to prime fully out. If not, squeeze
handles fully in and press the selector (see figure 3).
To expel the air from the pump:
close the vent valve, increase the pressure (for example up to 50 bar) and after
that, open the vent valve.
or optionally
connect the hose to PGHH but not the instrument to be calibrated. Pump until
drops of water/oil come out of the end of the hose. Then connect the instrument
and raise pressure as described in the previous paragraph.
5. 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.
Vent external systems before connecting to the pump.
6. Close PGHH’s vent valve fully clockwise.
7. 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.
9
The measurement system must only contain the measurement liquid and no gas.
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.
8. Test how much pressure increase can be done using the fine control. If it is enough,
continue to step 10.
9. With handles fully squeezed in, select the high pressure position on the stroke
selector and operate handles to generate approximate pressure. Smaller handle
strokes enable easier pressure generation at high pressures. 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.
Ensure that there is always a reliable pressure indicator connected to the pump when the pump is
used.
10. 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.
11. The principal tool for releasing pressure from the measurement system is PGHH’s fine
control. Use of PGHH’s vent valve is also possible, but requires caution in order to
avoid pressure shocks to the measurement system.
12. To totally release pressure from the system, turn PGHH’s vent valve
counterclockwise. Return the stroke selector knob to prime position after first
squeezing handles fully in.
Never fully screw out the ent valve. The sealling ball, placed inside the pump, may wear off.
10
13. If operated with distilled water, the reservoir must be emptied after each use by
removing the drain screw from the bottom of the reservoir (see figure 5).
2.2 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 (5 in figure 1).
Do not overfill the glass reservoir. The glass reservoir does not withstand high pressure but it is not
pressurized when PGHH 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.
Do not use the pump if the reservoir is damaged.
11
3 Maintenance and troubleshooting
3.1 Periodic maintenance
Repairs must only be carried out by the manufacturer.
Cleaning the units and checking the liquid levels and quality is the only periodic
maintenance required. With normal use, no further maintenance should be necessary. If
required, the system can be returned to the manufacturer for reconditioning.
If used with distilled water, after each work the pump including reservoir must be emptied
and made dry.
Working with the maintenance kit is only allowed for skilled personnel (maintenance kit
order code 8003545).
Never use chemicals for cleaning the reservoir, just a wet and free of lint cloth.
1. Copper seal (8072700)
2. EXT bonded seal (8003545)
3. *Pressure compensation
screw and PVC gasket
4. *Bonded seal (Usit) for
1
2
3
9
8
7
volume
5. G 1/4 male / 1215 Special
male connector
6. *O-ring 8 x 2
7. *O-ring 3.17 x 1.78
8. G 3/8’’ male - G 1/4’’ female
adapter
9. O-ring
* included in Maintenance kit
6
4
5
Figure 4. PGHH Maintenance kit seals and connectors.
12
1. *Drain screw DIN 912, M5 x 6
1
2. *O-Ring 4 x 2
2
Figure 5. PGHH bottom view - reservoir drain screw.
• The O-rings must be coated with a very little bit of silicone oil;
• Screwed connections must be fixed with a torque of 25 Nm (Drain screw max. 15 Nm,
check correct placement of the o-ring 4 x 2 (2 in figure 5).
If the pump is accidentally dropped, it may be damaged. Do not use the pump before it is inspected
at Beamex’s service.
* included in Maintenance kit
Please include information on used pressure media when sending the pump for service.
Always depressurize PGHH when it is left on its own.
13
3.2 Troubleshooting
If the pump assembly fails to indicate a pressure increase after considerable pumping
action of the handle, the following should be examined:
• 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 is 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.
3.3 Available spare parts
The available spare parts include:
• Fine adjustment valve, complete set, code 8003186
• Pressure vent valve, complete set including the vent valve steel ball, code 8003187
• Vent valve steel ball, code 0500383
• 1/4” BSP female / 3/8” male adapter, code 8003189
• Plug 1/4” BSP male, code 7150120
3.4 Disposal
Incorrect disposal can put the environment at risk. Dispose of instrument components
and packaging materials in an environmentally compatible way and in accordance with
the country-specific waste disposal regulations.
14
4 Specifications
4.1 The Pump Unit
Weight 1.3 kg 2.87 lb
Height 265 mm approx. 10.4”
Dimensions
Pressure range 0 to 700 bar / 0 to 70 MPa / 0 to 10 000 psi
Pressure media Low viscosity Mineral based Hydraulic Oil or Distilled water
Glass reservoir for pressure
media
Output connectors
Width 160 mm approx. 6.3”
Depth 120 mm approx. 4.7”
200 cc, not to be pressurized
• G ¼’’ male / 1215 Special male connector
(for Pressure Measurement Hose)
• G ¼” female connector (for Beamex External Pressure
Measurement Module, XPM or EXT)
4.2 The Pressure Measurement Hose
Length 1 m 3 ft 3.3”
Connectors (both ends) 1215 Special, female
Internal diameter 2 mm 0.08”
External diameter 5 mm 0.2”
Max. working pressure 630 bar 63 MPa 9137 psi
Min. bursting pressure 2000 bar 200 MPa 29000 psi
Operable temperature range -35°C to 100°C -31°F to 212°F
Smallest bending radius 20 mm 0.78”
15
4.3 Storage
Permissible conditions at the place of storage
Storage temperature -10...50°C
Humidity 35...85% relative humidity
After each usage, the instrument has to be emptied and let dry out (drain screw at the
bottom of the reservoir).
Store the hydraulic calibration pump in its original packaging in a location that fulfills
conditions listed below.
Avoid exposure to following factors:
• Direct sunlight or proximity to hot objects
• Mechanical vibration, mechanical shock (putting it down hard)
• Soot, vapour, dust and corrosive gases
• Potentially explosive environments, flammable atmospheres
• Corrosive liquids
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.
16
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