Fluke GB-152-AF, Operation And Maintenance Manual

Page 1: ... 2007 DH Instruments a Fluke Company GB 152 AF Gas Booster With Control Kit Operation and Maintenance Manual NSN 6685 01 529 6990 RN 3 of 3 ...

Page 2: ...d 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 ho...

Page 3: ... 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 OPERAT...

Page 4: ... 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 5: ...bly Illustrated Parts Breakdown 17 Table 3 DHI Authorized Service Providers 23 F FI IG GU UR RE ES S 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 ...

Page 6: ...GB 152 AF OPERATION AND MAINTENANCE MANUAL 2007 DH Instruments a Fluke Company Page IV N NO OT TE ES S ...

Page 7: ... 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 ...

Page 8: ...GB 152 AF OPERATION AND MAINTENANCE MANUAL 2007 DH Instruments a Fluke Company Page VI N NO OT TE ES S ...

Page 9: ...as 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 ...

Page 10: ...TION OF THE COMPONENTS 1 2 1 GAS BOOSTER Figure 1 GB 152 AF 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 ...

Page 11: ...ve air shutoff valve 4 High pressure instrument gas supply port 5 High pressure outlet port to GPC1 10000 AF SUPPLY port 6 Booster pump 7 1 4 in PFA tubing 8 Drive air inlet port Figure 3 System schematic 1 Drive air supply connection not visible 2 Drive pressure adjust regulator 3 Drive pressure indication gauge 4 Drive air shut off valve 5 Drive air out connection to booster not visible ...

Page 12: ...ssure output is high pressure supply times 25 Supply Flow Rates Shop Drive Air High Pressure Supply Gas 15 to 75 scfm 425 to 2 125 slm 5 to 20 scfm 140 to 560 slm Pressure Connections Drive Air Supply Inlet High Pressure Gas Supply Inlet High Pressure Outlet 1 4 in NPT female 1 4 in NPT female DH 500 female DH500 F is a gland and collar type fitting for coned and left hand threaded 1 4 in 6 mm OD ...

Page 13: ...ceiving Department for appropriate action A new GB 152 AF includes all items listed in Table 1 Table 1 GB 152 AF Parts List DESCRIPTION PART NO GB 152 AF Gas Booster 402163 ACCESSORIES 1 ea PGC 10000 AF Documentation Disk including RPM4 HPMS A70M A20M AF Operation and Maintenance Manual p n 550136 GPC1 10000 AF Operation and Maintenance Manual p n 550135 GB 152 AF Operation and Maintenance Manual ...

Page 14: ...00 psi 70 MPa to the GPC1 10000 AF pressure controller Each of the three components of the PGC 10000 AF system has its own Operation and Maintenance Manual and individual setup and start up instructions Figure 4 shows the typical setup configuration of the complete PGC 10000 AF system Figure 4 Typical PGC 10000 AF installation layout CAUTION GPC1 10000 AF Gas Pressure Controller RPM4 HPMS A70M A20...

Page 15: ... 3 2 2 2 3 2 1 DRIVE AIR SUPPLY The drive air supply provides power to operate the booster The booster s very high pressure output is approximately the drive air pressure multiplied by 152 This supply is usually shop or factory air Drive air requirements are Flow rate 15 scfm 425 slm minimum Cleanliness Not critical use 60 micron filter Humidity 20 to 50 RH Do not use dry gas Pressure 75 psi 500 k...

Page 16: ...ntrol Kit high pressure instrument gas to the booster very high pressure gas output from the booster to the GPC1 10000 AF Gas Pressure Controller Figure 4 presents a typical layout of a complete PGC 10000 AF system including the GB 152 AF gas booster system The orientation of the booster is of no consequence to its operation It may be installed vertically horizontally or any combination of the two...

Page 17: ...ve air supply and from the Control Kit bracket to the booster when selecting a location The kit bracket is often mounted on the front bottom surface of a work bench Figure 4 shows a typical installation configuration for a complete PGC 10000 AF system Mount the Drive Air Control Kit bracket onto the desired location using the bracket mounting holes provided Back off rotate counterclockwise the DRI...

Page 18: ...0000 AF Operation and Maintenance Manual The GB 152 AF includes an interconnection kit with fittings necessary to connect the high pressure OUT port to a GPC1 To connect the GB 152 AF high pressure OUT port to the GCP1 SUPPLY port proceed as follows n Remove the orange plastic dummy plug from the DH500 fitting in the GB 152 OUT port Retain the collar that is on the plug Remove the orange plastic d...

Page 19: ... port 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 Be sure to connect the booster high pressure output using fittings and tubing rated for the maximum expected pre...

Page 20: ...d damage the instrument and or cause personal injury Adjust the DRIVE ADJUST regulator Rotate the DRIVE ADJUST regulator knob clockwise while observing the set pressure on the DRIVE gauge Set the drive pressure to the maximum desired high pressure output divided by the booster ratio 152 for GB 152 AF Do not set the regulator to more than 65 psi 450 kPa Remember that when the SHUTOFF valve is in th...

Page 21: ...oximately 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 This section provides the reciprocating action and compression force needed to operate the booster and generate the high pressure gas Drive air is channeled to the appropriate side of the piston compression or suction stroke by the air cycling v...

Page 22: ...to decrease pressure to a value lower than the desired set pressure This is necessary because the regulator is not self venting Put the SHUTOFF valve in the OFF position Rotate the DRIVE ADJUST regulator knob clockwise while observing the set pressure on the DRIVE gauge Set the drive pressure to the maximum desired high pressure output divided by the booster ratio 152 1 For example if the desired ...

Page 23: ...SHUTOFF valve to the OFF position to interrupt drive pressure to the booster and stop its operation When the booster is OFF the high pressure supply is still present at the high pressure gas OUT port This feature makes it easy to operate using the high pressure supply only when the booster is not needed Emergency shut down of the gas booster pump can be performed at any time by closing the Drive A...

Page 24: ...GB 152 AF OPERATION AND MAINTENANCE MANUAL 2007 DH Instruments a Fluke Company Page 16 N NO OT TE E ...

Page 25: ...T NO 1 Gas Booster AG152 1 High pressure gas filter 4205T 2PP 1 Nipple 1 4 inch 4NP 316 1 Reducer 28 223 1 Adaptor 4CF4 1 Boss 6 1 4F50G 1 DH500 bulkhead 123812 01 3 DH500 gland 60 2HM4 316 3 DH500 collar 60 2H4 316 1 Tube SS 20 9M4 316 1 Mounting plate 123492 1 Drive air control panel 123571 1 Regulator 44 2213 242 009 1 Pressure gauge 25 120 300PSI 1 Shutoff valve B 42S4 1 Adaptor straight 10147...

Page 26: ...GB 152 AF OPERATION AND MAINTENANCE MANUAL 2007 DH Instruments a Fluke Company Page 18 ...

Page 27: ...lve is in the ON position If not set the valve fully to the ON position Check that drive air pressure supply is actually present at the DRIVE ADJUST regulator inlet connection If not ensure drive air is supplied at the proper pressure and flow value see Section 2 3 2 1 Check that the DRIVE ADJUST regulator is set to a pressure of 20 psig 150 kPa or higher and that minimum flow requirements are met...

Page 28: ...si 2 MPa If the supply is too low increase supply pressure Speed of booster pressure generation is directly related to the pressure of the high pressure instrument gas supply For example pressure will be generated twice as fast with instrument gas supply of 2 000 psi 14 MPa than with 1 000 psi 7 MPa Check that there are no restrictions in the high pressure gas supply line to the booster If a restr...

Page 29: ...s see Section 2 3 2 2 Check that the high pressure circuit connected to the booster OUT port is not open to atmosphere or doesn t have a severe leak If the shop drive air supply pressure is above 40 psig 250 kPa adjust to below this limit If the booster stops running increase high pressure supply to IN port instrument gas supply and try again 5 6 CANNOT ACHIEVE DESIRED PRESSURE Check that the high...

Page 30: ...r replacement 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 These leaks are very difficult to isolate and detect If no leaks can be found following the above procedures it is likely the problem is within the booster Contact a DHI Authorized Service Provider for assistance Section 6 Table 2 5 8 GAS CONTINUOUSLY...

Page 31: ...t for the purpose of this warranty such indirect damage includes but is not limited to loss of production profits revenue or goodwill even if DHI has been advised of the possibility thereof and regardless of whether such products are used individually or as components in other products Items returned to DHI under warranty claim but determined to not have a defect covered under warranty or to not h...

Page 32: ...GB 152 AF OPERATION AND MAINTENANCE MANUAL 2007 DH Instruments a Fluke Company Page 24 N NO OT TE ES S ...