Fluke GB-K-152, GB-K-75 User Manual

GB-K-75 and GB-K-152

Gas Booster Packages

For PPCK+ Pressure Controller/Calibrator

Operation and Maintenance Manual

GB-K Gas Booster Package Operation and Maintenance Manual

This equipment described in this manual is designed and manufactured for the intended purpose of

generating high pressure gas and regulating two independent gas output pressures. Certain precautions need to be followed during installation and operation of this device. Reading and understanding the 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 thoroughly familiarized themselves 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.

Do not use oxygen. This instrument is not compatible with the use of oxygen. Hydrocarbon elastomers

and lubricants are present.

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.

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, Inc. 4765 East Beautiful Lane Phoenix AZ 85044-5318 USA.

DH Instruments makes every effort to ensure the accuracy and quality of it’s 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 predominates.

DH Instruments, DH , DHI, PPC, PPCK+, PPC2+, RPM3 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. 550082a 000822 Printed in the USA.

GB-K Gas Booster Package Operation and Maintenance Manual

AABBLLEE

TABLE OF CONTENTS................................................................................ i

TABLES................................................................................................... iii

FIGURES ................................................................................................. iii

ABOUT THIS MANUAL.............................................................................. iv

1. INTRODUCTION.................................................................................... 1

1.1 PRODUCT OVERVIEW .............................................................................................................................1

1.2 LOCATION AND DESCRIPTION OF THE COMPONENTS...................................................................... 1

1.3 SYSTEM SCHEMATIC ..............................................................................................................................4

1.4 SPECIFICATIONS ..................................................................................................................................... 5

2. INSTALLATION..................................................................................... 7

2.1 UNPACKING AND INSPECTION .............................................................................................................. 7

2.2 SITE REQUIREMENTS..............................................................................................................................8

2.3 INSTALLATION AND SETUP ...................................................................................................................9

3. OPERATION ....................................................................................... 13

3.1 GENERAL OPERATING PRINCIPLE AND INFORMATION...................................................................13

3.1.1 PNEUMATICALLY OPERATED GAS BOOSTER PUMP (6).......................................................................... 13

3.1.2 VALVE.............................................................................................................................................................. 14

3.1.3 VOLUME CYLINDER (ACCUMULATOR) .......................................................................................................14

3.1.4 REGULATORS.................................................................................................................................................14

3.1.5 GAUGES .......................................................................................................................................................... 15

3.2 SETTING LOW PRESSURE OUTPUT .................................................................................................... 15

3.2.1 INCREASING PRESSURE ..............................................................................................................................15

3.2.2 DECREASING PRESSURE .............................................................................................................................16

3.3 SETTING HIGH PRESSURE OUTPUT UP TO SUPPLY PRESSURE....................................................16

3.3.1 INCREASING PRESSURE ..............................................................................................................................16

3.3.2 DECREASING PRESSURE .............................................................................................................................17

3.4 SETTING HIGH PRESSURE OUTPUT ABOVE SUPPLY PRESSURE..................................................17

3.4.1 SETTING BOOSTER DRIVE PRESSURE.......................................................................................................17

3.4.2 INCREASING PRESSURE ..............................................................................................................................18

3.4.3 DECREASING PRESSURE .............................................................................................................................19

NTTEE

NTTSS

4. MAINTENANCE AND ADJUSTMENTS ................................................... 21

4.1 MAINTENANCE.......................................................................................................................................21

GB-K Gas Booster Package Operation and Maintenance Manual

5. TROUBLESHOOTING .......................................................................... 23

5.1 GENERAL INFORMATION......................................................................................................................23

5.2 BOOSTER WILL NOT RUN.....................................................................................................................23

5.3 BOOSTER RUNS TOO SLOWLY ...........................................................................................................24

5.4 PRESSURE GENERATES TOO SLOWLY OR NOT AT ALL................................................................. 24

5.5 BOOSTER CONTINUOUSLY RUNS.......................................................................................................25

5.6 CANNOT ACHIEVE PRESSURE (LP & HP) ........................................................................................... 25

5.6.1 LOW PRESSURE.............................................................................................................................................25

5.6.2 HIGH PRESSURE ............................................................................................................................................26

5.7 LEAKS ..................................................................................................................................................... 26

5.8 GAS CONTINUOUSLY VENTS THROUGH EXHAUST MUFFLER........................................................27

6. WARRANTY STATEMENT .................................................................... 29

6.1 WARRANTY STATEMENT......................................................................................................................29

GB-K Gas Booster Package Operation and Maintenance Manual

AABBLLEES

Table 1. GB-K-75 or GB-K-152 Parts List ............................................................................................... 7

Table 2. DHI Authorized Service Providers........................................................................................... 30

Figure 1. Pneumatic Connection Panel .................................................................................................... 1

Figure 2. Control Panel............................................................................................................................. 2

Figure 3. System Schematic..................................................................................................................... 4

IIG

URREESS

GB-K Gas Booster Package Operation and Maintenance Manual

(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.

BBO

UTT

HIISS

Manual Conventions

AAN

UAALL

GB-K Gas Booster Package Operation and Maintenance Manual

1..

1.1 PRODUCT OVERVIEW

GB-K-75 and GB-K-152 are gas booster packages intended to be used to provide the gas pressure supplies required by DHI PPCK+ controller/calibrators for high pressure gas.

Both models include a pneumatically driven, piston type, self-cycling gas booster with regulated output to provide the PPCK+ high pressure supply. The gas booster boosts a lower pressure (3.5 MPa minimum), generally supplied from a bottle to higher pressure. The high pressure gas is stored in an accumulator volume to assure stable supply to the PPCK+. GB-K-75 has a maximum output pressure of 50 MPa (7 500 psi) and is used with PPCK+ A3000 and A6000. GB-K-152 has a maximum output of 76 MPa (11 000 psi) and is used with PPCK+ A10000.

Both models also include an independent low pressure regulator and gauge to supply the PPCK+ drive air requirement.

With a GB-K gas booster, all of the PPCK+ pressure supply requirements are taken care of in one simple package requiring on the connection of a clean gas source of 2 MPa (300 psi) or higher clean compressed gas source and a shop air supply to power the booster.

NTTRR

UCCTTII

1.2 LOCATION AND DESCRIPTION OF THE COMPONENTS

Figure 1. Pneumatic Connection Panel

GB-K Gas Booster Package Operation and Maintenance Manual

791

PNEUMATIC CONNECTION PANEL:

1. High Pressure Outlet Fitting: a stainless steel DH 200 female coned end fitting used to

connect the high pressure output to a point-of-use (usually the PPCK+ SUPPLY port).

DH200 F is a gland and collar type fitting for coned and left hand threaded 1/4 in. (6.35 mm) OD

tube, equivalent to AE SF250C, HIP LF4, etc. DO NOT USE INCORRECT FITTINGS; DAMAGE TO THE FITTING AND DANGER TO THE OPERATOR COULD RESULT.

2. Low Pressure Outlet Fitting: a stainless steel 1/8 in. NPT female fitting used to connect the low

pressure output to a point-of-use (usually the PPCK+ DRIVE IN port).

3. Supply Inlet Fitting: a stainless steel 1/8 in. NPT female fitting used to connect an external

source of high pressure gas. This is the gas pressure that will be boosted to obtain very high pressure at the High Pressure Outlet and regulated to provide low pressure at the Low Pressure Outlet.

Figure 2. Control Panel

GB-K Gas Booster Package Operation and Maintenance Manual

CONTROL PANEL:

4. High Pressure Outlet Gauge: a 4 in. (102 mm) diameter dial gauge constructed of stainless

steel with a range of zero to 70 MPa (10 000 psig) or zero to 103 MPa (15 000 psig). It is used to indicate the output of the High Pressure Outlet Regulator (7).

5. Low Pressure Outlet Gauge: a 2 in. (51 mm) diameter dial gauge constructed of stainless steel

with a range of zero to 300 psig (2 MPa). It is used to indicate the output of the Low Pressure Outlet Regulator (12).

6. Pneumatically Operated Gas Booster Pump: a Pascal press utilizing two pistons connected

together on the same axis having a nominal area ratio of either 75:1 or 152:1. The booster is a two-stroke, single stage reciprocating pump.

7. High Pressure Outlet Regulator: a self-venting type regulator constructed of 303 stainless

steel, Kel-F, Buna-N, and Teflon wetted materials with an outlet pressure control range of 1.5 MPa (200 psi) to 50 MPa (7 500 psig) or 76 MPa (11 000 psig).

8. Shop Drive Air Inlet Fitting: a brass fitting with a 1/4 in. NPT female connection.

9. Shop Drive Air Pressure Gauge: a 1.5 in. (38 mm) diameter dial gauge constructed of brass

with a range of zero to 1.4 MPa (200 psig). It is used to indicate the output pressure of the Shop Drive Air Regulator (10).

10. Shop Drive Air Regulator: a self-venting type regulator constructed of 316 stainless steel and

nylon wetted components with an outlet pressure control range of 0.9 MPa (125 psig). Maximum supply pressure is 1 MPa (150 psig). The control knob is pulled out to make adjustments; pushed in to lock into position. To prevent accidental pressure changes the knob can easily be removed (pulled off).

11. Shop Drive Air Shut-off Valve: a brass ball-type, shut-off valve with a 90° full turn operation.

It is used to prevent flow of shop drive air to the booster. This valves turns the booster on and off.

12. Low Pressure Outlet Regulator: a non-venting regulator constructed of aluminum, Viton,

stainless steel and Nylatron wetted materials with an outlet pressure control range of 0.15 to

1.25 MPa (20 to 180 psig). Maximum pressure supply is 20 MPa (3 000 psig).

13. Drive Air Exhaust Muffler: a painted aluminum tube with vent slits, 1/2 in. NPT female

connection fittings and noise reduction material inside. Used to muffle the noise of the booster drive air exhaust.

GB-K Gas Booster Package Operation and Maintenance Manual

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1.3 SYSTEM SCHEMATIC

1. Drive Air Gauge 8. Low Pressure Outlet Gauge

2. SHOP DRIVE AIR INLET Port 9. HIGH PRESSURE OUTLET Port

3. Drive Air Regulator 10. High Pressure Outlet Gauge

4. Drive Air Shut-Off Valve 11. HIGH PRESSURE ADJUST Regulator

5. SUPPLY INLET Port 12. Volume Cylinder (Accumulator)

6. LOW PRESSURE ADJUST Regulator 13. Booster Pump

7. LOW PRESSURE OUTLET Port

Figure 3. System Schematic

GB-K Gas Booster Package Operation and Maintenance Manual

1.4 SPECIFICATIONS

Dimensions: 430 mm (17 in.) H x 355 mm (14 in.) W x 290 mm (11.5 in.) D

Weight: 18.6 kg (41 lbs)

Pressure Supply

Pressure Range:

Supply Flow Rates:

Cleanliness:

Pressure Connections: Shop Drive Air Supply Inlet: 1/4 in. NPT female

Output Pressure

Ranges:

Booster Piston Ration: 75:1 for GB-K-75

Due to a policy of continual product improvement, all specifications are subject to change without notice.

Shop Drive Air: 0.15 to 1 MPa (20 to 150 psi)

High Pressure Supply Gas: 2 to 20 MPa (300 to 3 000 psi)

Shop Drive Air: 425 to 2 125 slm (15 to 75 scfm)

High Pressure Supply Gas: 140 to 560 slm (5 to 20 scfm)

Shop Drive Air: 60 micron filtration @ 20 to 50 % relative humidity

High Pressure Supply Gas: 10 micron filtration with dew point of –20 °C

High Pressure Gas Supply Inlet: 1/8 in. NPT female

Low Pressure Outlet: 1/8 in. NPT female

High Pressure Outlet: DH 200 female (DH200 F is a gland and collar type fitting for coned and left hand threaded 1/4 in. (6.35 mm) OD tube, equivalent to AE SF250C, HIP LF4, etc.)

Low Pressure Regulator: 0.14 to 1.2 MPa (20 to 180 psi)

High Pressure Regulator (GB-K-75): 0.35 to 50 MPa (200 to 7 500 psi)

High Pressure Regulator (GB-K-152): 0.35 to 86 MPa (200 to 11 000 psi)

152:1 for GB-K-152

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