Fluke GB-152-AF User Manual

GB-152-AF™

Gas Booster With Control Kit

Operation and Maintenance Manual

NSN 6685-01-529-6990 RN (3 of 3)

GB-152-AF™ OPERATION AND MAINTENANCE MANUAL

This equipment described in this manual is designed and manufactured for the intended purpose of generating high pressure gas. Certain precautions need to be followed during installation and operation of this device. Reading and understanding this material is essential to the safe and correct operation of the unit.

Pressurized equipment is potentially dangerous. The equipment described in this manual generates and controls very high gas pressures. It should not be operated by anyone who has not become thoroughly familiar with this manual. Additional training in general and pressure specific safety procedures will help assure protection from harm or damage to personnel or property. Responsibility for the proper and safe operation of this instrument rests with the user.

High pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases can be released unexpectedly and with extreme force. High pressure systems should be assembled and operated only by personnel who have been instructed in proper safety practices.

This instrument is not to be operated in any other manner than that specified by the manufacturer.

Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments 4765 East Beautiful Lane Phoenix AZ 85044-5318 USA.

DH Instruments makes every effort to ensure the accuracy and quality of its published materials; however, no warranty, expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was subsequently translated into other languages. The fidelity of subsequent translations cannot be guaranteed. In case of conflict between the English version and another language version, the English version takes precedence.

Products described in this manual are manufactured under international patents and one or more of the following U.S. patents: 5,142,483; 5,257,640; 5,331,838; 5,445,035. Other U.S. and international patents pending.

DH Instruments, DH, DHI, PGC, PPC, PPC3, RPM4, GPC1 and CalTool are trademarks, registered and otherwise.

Swagelok is a registered trademark of the Swagelok Company.

Teflon is a registered trademark of the 3M Corporation.

Document No. 550137b-01 070628

Printed in the USA

TABLE OF CONTENTS

TABLE OF CONTENTS ...............................................................				I
TABLES .................................................................................				III
FIGURES ................................................................................				III
ABOUT THIS MANUAL ..............................................................				V
1.	INTRODUCTION .................................................................			1
	1.1	PRODUCT OVERVIEW ...........................................................................................................................		1
	1.2	LOCATION AND DESCRIPTION OF THE COMPONENTS....................................................................		2
		1.2.1	GAS BOOSTER .............................................................................................................................................	2
		1.2.2 DRIVE AIR CONTROL KIT............................................................................................................................		3
	1.3	SPECIFICATIONS ...................................................................................................................................		4
2.	INSTALLATION ..................................................................			5
	2.1	UNPACKING AND INSPECTION ............................................................................................................		5
	2.2	PGC-10000-AF SYSTEM.........................................................................................................................		6
	2.3	SITE REQUIREMENTS............................................................................................................................		7
		2.3.1	SITE................................................................................................................................................................	7
		2.3.2	GAS SUPPLIES .............................................................................................................................................	7
		2.3.2.1	DRIVE AIR SUPPLY ..................................................................................................................................	7
		2.3.2.2 HIGH PRESSURE INSTRUMENT GAS.....................................................................................................		7
	2.4	INSTALLATION AND INITIAL SETUP ....................................................................................................		8
		2.4.1	GENERAL CONSIDERATIONS.....................................................................................................................	8
		2.4.2	INSTALLATION .............................................................................................................................................	8
		2.4.2.1	BOOSTER INSTALLATION .......................................................................................................................	9
		2.4.2.2 DRIVE AIR CONTROL KIT INSTALLATION..............................................................................................		9
		2.4.2.3 BOOSTER HIGH PRESSURE INSTRUMENT GAS SUPPLY CONNECTION........................................		10
		2.4.2.4 BOOSTER HIGH PRESSURE OUTPUT CONNECTION ........................................................................		10
	2.5	INITIAL START UP ................................................................................................................................		12
3.	OPERATION .....................................................................			13
	3.1	GENERAL OPERATING PRINCIPLE AND INFORMATION.................................................................		13
	3.2	OPERATION ..........................................................................................................................................		14
		3.2.1 SETTING THE BOOSTER OUTPUT PRESSURE ......................................................................................		14
		3.2.2 TURNING THE BOOSTER ON AND OFF ...................................................................................................		15
4.	MAINTENANCE AND ADJUSTMENTS ..................................			17
	4.1	MAINTENANCE .....................................................................................................................................		17
	4.2	ILLUSTRATED PARTS BREAKDOWN.................................................................................................		17

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GB-152-AF™ OPERATION AND MAINTENANCE MANUAL

5. TROUBLESHOOTING ........................................................		19
5.1	GENERAL INFORMATION....................................................................................................................	19
5.2	BOOSTER WILL NOT RUN...................................................................................................................	19
5.3	BOOSTER RUNS TOO SLOWLY .........................................................................................................	20
5.4	PRESSURE GENERATES TOO SLOWLY OR NOT AT ALL ...............................................................	20
5.5	BOOSTER RUNS (CYCLES) CONTINUOUSLY ...................................................................................	21
5.6	CANNOT ACHIEVE DESIRED PRESSURE..........................................................................................	21
5.7	LEAKS ...................................................................................................................................................	22
5.8	GAS CONTINUOUSLY VENTS THROUGH EXHAUST MUFFLER ......................................................	22
6. WARRANTY STATEMENT ..................................................		23
6.1	WARRANTY STATEMENT....................................................................................................................	23

Page II

TABLES & FIGURES

TABLES
Table 1.	GB-152-AF Parts List.....................................................................................................................	5
Table 2.	GB-152-AF Assembly Illustrated Parts Breakdown.....................................................................	17
Table 3.	DHI Authorized Service Providers ...............................................................................................	23
FIGURES
Figure 1. GB-152-AF Gas Booster...............................................................................................................		2
Figure 2.	Drive air control kit ........................................................................................................................	3
Figure 3. System schematic.........................................................................................................................		3
Figure 4.	Typical PGC-10000-AF installation layout....................................................................................	6
Figure 5. Connection of GB-152-AF high pressure OUT port to GPC1-10000-AF SUPPLY port ..................		11

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GB-152-AF™ OPERATION AND MAINTENANCE MANUAL

NOTES

Page IV

ABOUT THIS MANUAL

GB-152-AF is usually delivered as part of an PGC-10000-AF system which also includes an RPM4 A70M/A20M-AF reference pressure monitor and a GPC1-1000-AF pressure controller. The RPM4/HPMS and GPC1 have their own Operation and Maintenance Manuals.

Manual Conventions

(CAUTION) is used in throughout the manual to identify user warnings and cautions.

(NOTE) is used throughout the manual to identify operating and applications advice and additional explanations.

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GB-152-AF™ OPERATION AND MAINTENANCE MANUAL

NOTES

Page VI

1. INTRODUCTION

1.INTRODUCTION

1.1PRODUCT OVERVIEW

The GB-152-AF gas booster with control kit is intended to provide very high pressure gas supply in a PGC-10000-AF Pneumatic Gauge Calibration System.

The GB-152-AF includes a pneumatically driven, piston type, self-cycling gas booster. The gas booster boosts a lower pressure, generally supplied from a bottle (300 psi (20 MPa) minimum), to higher pressure. The booster is powered by drive air. The high pressure output is approximately equal to the drive air input times the nominal boosting ratio of 152. In the PGC-10000-AF system, the high pressure output is connected to the SUPPLY port of a GPC1-10000-AF Gas Pressure Controller.

The GB-152 also includes a drive air control kit and interconnecting tubing. The kit is on a bracket that can be mounted at a convenient location remote from the booster itself.

Page 1

GB-152-AF™ OPERATION AND MAINTENANCE MANUAL

1.2LOCATION AND DESCRIPTION OF THE COMPONENTS

1.2.1 GAS BOOSTER

1. High pressure instrument gas filter

2. High pressure instrument gas supply port

3. Drive air supply port (from Drive Air Control Kit) 4. Breather port

5. Low pressure piston body

6. Muffler

7. High pressure piston body

8. High pressure output port

Figure 1. GB-152-AF Gas Booster

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