User manual FLUKE GB-152-AF

[. . . ] Operation and Maintenance Manual NSN 6685-01-529-6990 RN (3 of 3) GB-152-AFTM Gas Booster With Control Kit © 2007 DH Instruments, a Fluke Company GB-152-AFTM 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. [. . . ] Depending on the drive pressure set by the DRIVE ADJUST regulator, GB-152-AF may generate pressure over 70 MPa (10 000 psi). To limit the maximum pressure that can be generated by the booster, limit the drive air supply to the Drive Air Control Kit to 75 psi (500 kPa) (see Section 2. 3. 2. 1). Supply high pressure instrument gas: Check that all connections to the high pressure IN and OUT ports are secure. Apply high pressure gas to the high pressure IN port (see Section 2. 3. 2. 2 for information on high pressure instrument gas). Pressure above this may result in a failure that could damage the instrument and/or cause personal injury. Adjust the DRIVE ADJUST regulator: while observing the set pressure on the desired high pressure output divided by regulator to more than 65 psi (450 kPa). position, the booster will operate until the the booster ratio. Rotate the DRIVE ADJUST regulator knob (clockwise) DRIVE gauge. Set the drive pressure to the maximum the booster ratio (152 for GB-152-AF). Do not set the Remember that when the SHUTOFF valve is in the ON high pressure output is equal to the drive air setting times The DRIVE ADJUST regulator is NOT self venting so it cannot be used to set pressure lower than the current pressure when the SHUTOFF valve is OFF. If you overshoot the desired set point, set the SHUTOFF valve to ON until the DRIVE pressure is lower than your desired setting. Then set the SHUTOFF valve to OFF and use the regulator to adjust the pressure in the ascending direction. Generate high pressure: Check that the booster high pressure output is properly connected. If it is connected to a GPC1-10000-AF, be sure the GPC1's INLET valve is closed. The booster will begin to cycle and will continue to cycle until it stalls. When it stalls, the high pressure output is roughly equal to the drive pressure setting times the booster's ratio (152:1). © 2007 DH Instruments, a Fluke Company Page 12 3. OPERATION 3. 3. 1 OPERATION GENERAL OPERATING PRINCIPLE AND INFORMATION The purpose of the GB-152-AF booster is to automatically boost gas pressure to very high pressure. The value of very high pressure that is generated depends on the drive air pressure setting. The unit generates high pressure using a Pneumatically Operated Gas Booster Pump and a Drive Air Control Kit. GAS BOOSTER PUMP The booster pump is a Pascal press utilizing two pistons connected together on the same axis having a normal area ratio of 152:1. The booster is a two-stroke, single stage reciprocating pump that generates gas pressure 152 times greater than the shop drive air applied to the pump. The pump operates automatically, provided drive air is supplied to the DRIVE ADJUST regulator and the regulator is set to at least 140 kPa (20 psig). Operation is continuous until the outlet pressure is 152 times the shop drive air pressure. Then, the opposing forces within the pump are in equilibrium and the pump stalls. For example, using a GB-152-AF with the drive air pressure set to 45 psi (300 kPa), the pump will run until the high pressure output reaches approximately 152 x 45 = 6840 psi. The drive air (low pressure) section of the booster consists of a piston, cylinder, air cycling valve, pilot valve and vent section. [. . . ] Since it is impractical to produce a troubleshooting guide that will cover every conceivable leak, the source of your leak may not be covered in this guide. Repair or replace leaking regulators. · · Never tighten a fitting while it is under pressure. If pressure is in the system and the fitting should fail while being tightened, you or those around you may be injured. Do not over-torque the DH500 fittings that are inside the booster. Recommended torque on a DH500 fitting gland is 15 Nm. It is possible that a leak exists in the high pressure section of the gas booster. [. . . ]