Related Manuals for DH Instruments GB-K-152
Summary of Contents for DH Instruments GB-K-152
- Page 1 GB-K-75 and GB-K-152 Gas Booster Packages For PPCK+ Pressure Controller/Calibrator Operation and Maintenance Manual © 1998 - 2000 DH Instruments, Inc.
- Page 2 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.
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Page 3: Table Of Contents
GB-K Gas Booster Package Operation and Maintenance Manual TABLE OF CONTENTS ................i TABLES ....................iii FIGURES ....................iii ABOUT THIS MANUAL ................iv 1. INTRODUCTION ..................1 PRODUCT OVERVIEW ..........................1 LOCATION AND DESCRIPTION OF THE COMPONENTS..............1 SYSTEM SCHEMATIC ..........................4 SPECIFICATIONS .............................5 2. - Page 4 GB-K Gas Booster Package Operation and Maintenance Manual 5. TROUBLESHOOTING ................23 GENERAL INFORMATION........................23 BOOSTER WILL NOT RUN........................23 BOOSTER RUNS TOO SLOWLY ......................24 PRESSURE GENERATES TOO SLOWLY OR NOT AT ALL..............24 BOOSTER CONTINUOUSLY RUNS .......................25 CANNOT ACHIEVE PRESSURE (LP & HP) ................... 25 5.6.1 LOW PRESSURE.............................25 5.6.2...
- Page 5 GB-K Gas Booster Package Operation and Maintenance Manual 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 Page iii ©...
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Page 6: About This Manual
GB-K Gas Booster Package Operation and Maintenance Manual 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. Page iv ©... -
Page 7: Introduction
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. -
Page 8: Figure 2. Control Panel
GB-K Gas Booster Package Operation and Maintenance Manual 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. - Page 9 GB-K Gas Booster Package Operation and Maintenance Manual CONTROL PANEL: 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).
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Page 10: System Schematic
GB-K Gas Booster Package Operation and Maintenance Manual SYSTEM SCHEMATIC Drive Air Gauge Low Pressure Outlet Gauge SHOP DRIVE AIR INLET Port HIGH PRESSURE OUTLET Port Drive Air Regulator 10. High Pressure Outlet Gauge Drive Air Shut-Off Valve 11. HIGH PRESSURE ADJUST Regulator SUPPLY INLET Port 12. -
Page 11: Specifications
Low Pressure Regulator: 0.14 to 1.2 MPa (20 to 180 psi) Ranges: 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) Booster Piston Ration: 75:1 for GB-K-75 152:1 for GB-K-152 Due to a policy of continual product improvement, all specifications are subject to change without notice. - Page 12 GB-K Gas Booster Package Operation and Maintenance Manual Page 6 © 1998 - 2000 DH Instruments, Inc.
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Page 13: Installation
If damage is noted, report it to your Receiving Department for appropriate action. Inspect for any missing components or accessories using Table 1. Should any items be missing, contact DHI or you local supplier. Table 1. GB-K-75 or GB-K-152 Parts List DESCRIPTION PART # GB-K-75 Instrument or... -
Page 14: Site Requirements
- For operation up to 50 MPa (7 500 psi) with GB-K-75: 0.7 MPa (100 psi) minimum - For operation up to 50 MPa (7 500 psi) with GB-K-152: 0.4 MPa (60 psi) minimum - For operation up to 76 MPa (11 000 psi) with GB-K-152: 0.5 MPa (75 psi) minimum... -
Page 15: Installation And Setup
GB-K Gas Booster Package Operation and Maintenance Manual INSTALLATION AND SETUP Installation of the GB-K depends on the specific application. For a detailed description of the theory of operation see Section 3.1. Refer to Section 2.2 before attempting installation. The orientation of the instrument is of no consequence to its operation. It may be installed vertically, horizontally or any combination of the two with no effect on performance or maintenance. - Page 16 If the Low Pressure Outlet is not being used, plug the fitting using a 1/8 in. NPTM plug. Connect the DH 200F High Pressure Outlet Fitting (1) to the point of use with the tubing rated for at least 50 MPa (7 500) psig with GB-K-75 or 76 MPa (11 000 psig) with GB-K-152 working pressure.
- Page 17 GB-K Gas Booster Package Operation and Maintenance Manual Using connecting tubing with a working pressure below the maximum rated output pressure may result in a failure in the tubing that could cause damage to the instrument and/or cause personal injury. If the High Pressure Outlet is not being used, plug the fitting.
- Page 18 GB-K Gas Booster Package Operation and Maintenance Manual Page 12 © 1998 - 2000 DH Instruments, Inc.
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Page 19: Operation
Regulator (10) and the regulator is set to at least 140 kPa (20 psig). Operation is continuous until the outlet pressure is 75 (GB-K-75) or 152 (GB-K-152) times the shop drive air pressure. At this point, the opposing forces within the pump reach equilibrium and the pump stalls. -
Page 20: Valve
GB-K Gas Booster Package Operation and Maintenance Manual 2. The instrument gas section (high pressure) consists of a small piston and an inlet/outlet check valve assembly. The small piston moves forward and backward with the air drive piston. During the suction stroke (backward movement), the outlet check valve closes and the inlet check valve opens letting instrument gas enter the compression chamber. -
Page 21: Gauges
GB-K Gas Booster Package Operation and Maintenance Manual 3.1.5 GAUGES There are three gauges in the unit used to indicate the Shop Drive Air Pressure, Low Pressure Outlet and High Pressure Outlet settings. 1. The Shop Drive Air Pressure Gauge (9) is constructed of brass and is 1.5 in. (38 mm) in diameter with a range of 0 to 1.38 MPa (200 psig). -
Page 22: Decreasing Pressure
GB-K Gas Booster Package Operation and Maintenance Manual Adjust the Low Pressure Outlet Regulator (12) by rotating the knob clockwise until the desired pressure is indicated on the Low Pressure Outlet Gauge (5). To correctly set the pressure, gas flow must not occur. If flow is present in the circuit when the regulator is adjusted, the pressure will increase when flow is reduced. -
Page 23: Decreasing Pressure
GB-K Gas Booster Package Operation and Maintenance Manual Plug the high pressure outlet circuit to prevent gas flow (circuit is dead ended). Adjust the High Pressure Outlet Regulator (7) by rotating the knob clockwise until the desired pressure is indicated on the High Pressure Outlet Gauge (4). To correctly set the pressure, gas flow must not occur. -
Page 24: Increasing Pressure
(80 psig) which is the pressure setting that should be made to the Shop Drive Regulator (10). For Model GB-K-152, perform the calculation substituting 152 for 75. It is often desirable to have a pressure setting to the inlet of the High Pressure Outlet Regulator (7) that is in excess of that required. -
Page 25: Decreasing Pressure
GB-K Gas Booster Package Operation and Maintenance Manual 3.4.3 DECREASING PRESSURE The High Pressure Outlet Regulator (7) is a venting type. Therefore, it is possible to regulate pressure down without gas flow through the regulator. Adjust the pressure down using the High Pressure Outlet Regulator (7) by rotating the knob counter-clockwise until a pressure below the setpoint is achieved as indicated on the High Pressure Outlet Gauge (4). - Page 26 GB-K Gas Booster Package Operation and Maintenance Manual Page 20 © 1998 - 2000 DH Instruments, Inc.
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Page 27: Maintenance And Adjustments
GB-K Gas Booster Package Operation and Maintenance Manual MAINTENANCE GB-K gas booster packages require no standard maintenance or adjustments. Page 21 © 1998 - 2000 DH Instruments, Inc. - Page 28 GB-K Gas Booster Package Operation and Maintenance Manual Page 22 © 1998 - 2000 DH Instruments, Inc.
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Page 29: Troubleshooting
GB-K Gas Booster Package Operation and Maintenance Manual GENERAL INFORMATION Numerical references in this section refer to Figure 2. The GB-K consists of a Pneumatically Operated Gas Booster Pump (6), a valve, a volume cylinder, three regulators, three pressure gauges and various tubing and fittings. Several predictable problems can arise and are addressed in this section. -
Page 30: Booster Runs Too Slowly
GB-K Gas Booster Package Operation and Maintenance Manual • Check that gas is not continuously venting from the exhaust muffler. If gas is venting through the muffler, see Section 5.8. • Check that the booster is not in a stall state. If booster is stalled, determine reason and remedy. A stall state will occur when the pressure in the high pressure section of the booster is equal to the pressure in the low pressure section times the ratio (75:1 or 152:1). -
Page 31: Booster Continuously Runs
If the booster does not stall when the instrument gas supply pressure is above 2 MPa (300 psi) and the shop drive air pressure is below 0.5 MPa (75 psig) for GB-K-152 or 0.25 MPa (40 psig) for GB-K-152, the check valves are the most likely cause. If the booster does not stall, contact a DHI Authorized Service Provider. -
Page 32: High Pressure
GB-K Gas Booster Package Operation and Maintenance Manual • Check that no leaks exist in the pressure circuit from the instrument gas supply to the point-of-use. Repair any leaks. 5.6.2 HIGH PRESSURE • Check that the instrument gas supply is set above 2 MPa (300 psi) (the minimum value). In some cases, the minimum pressure supply is 4 MPa (600 psi). -
Page 33: Gas Continuously Vents Through Exhaust Muffler
GB-K Gas Booster Package Operation and Maintenance Manual GAS CONTINUOUSLY VENTS THROUGH EXHAUST MUFFLER When the booster does not run and gas is venting through the muffler, the air cycling valve (spool valve) is stuck between its toggle points. This is normally caused by a low gas flow rate. There are two methods for restoring proper operation. - Page 34 GB-K Gas Booster Package Operation and Maintenance Manual Page 28 © 1998 - 2000 DH Instruments, Inc.
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Page 35: Warranty Statement
GB-K Gas Booster Package Operation and Maintenance Manual WARRANTY STATEMENT Except to the extent limited or otherwise provided herein, DH Instruments, Inc. (DHI) warrants for one year from purchase, each new product sold by it or one of its authorized distributors, only against defects in workmanship and/or materials under normal service and use. -
Page 36: Table 2. Dhi Authorized Service Providers
GB-K Gas Booster Package Operation and Maintenance Manual Table 2. DHI Authorized Service Providers DH INSTRUMENTS, INC. www.dhinstruments.com AUTHORIZED SERVICE PROVIDERS 2000 JULY NORMAL TELEPHONE, FAX SUPPORT COMPANY ADDRESS EMAIL REGION DH Instruments, Inc. 4765 East Beautiful Lane Tel 602.431.9100 Worldwide Phoenix AZ 85044-5318 Fax 602.431.9559...
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