AMETEK GaugeCalHP Hydraulic Pressure Generator System Instruction Manual

AMETEK GaugeCalHP Hydraulic Pressure Generator System

Overview

INTRODUCTION

Thank you for purchasing a Gauge CalHP™ Pressure Comparator from Crystal Engineering. The Gauge CalHP is a self-contained, precision hydraulic pressure comparator intended for the calibration of pressure gauges rated up to 15 000 psi / 1000 bar / 100 MPa. You may fill the Gauge CalHP with your choice of water or oil.

Using this comparator for calibration is much faster than deadweight testers and most automated pressure controllers. The Gauge CalHP is so quick and easy to use, it is ideal for calibrating those low cost gauges that are often overlooked for ISO9000 compliance.

In fact, you can calibrate most gauges, transmitters, pressure safety valves, sensors, and switches in less than ten minutes (5 to 10 test points, increasing and decreasing pressure) using the methods described in this manual.

The Gauge CalHP hydraulic comparator may be ordered as part of a Pump System, complete with a Crystal Pressure Indicator. Gauge CalHP Pump Systems include the most commonly used pressure fittings, seals, etc. All packaged in a carrying case with custom insert.

Spend a few minutes to read this manual and learn how you can get the most benefit from your Gauge CalHP.

Note: We recommend using one of the following indicators with the Gauge CalHP

• **nVision Reference Recorder

**

• **30 Series Pressure Calibrator

**

• **XP2i Digital Pressure Gauge

**

FEATURES AND PARTS LISTS

Each comparator includes a fine adjust for precise pressure adjustments. The reference indicator threads directly to the CPF Male fitting.
The device under test connects to the supplied 1/4” Female NPT fitting. For more sizes see the Connection Diagram on page 13 and the CPF Datasheet.
U.S. Patent No. 8,794,677

Parts Included with the Gauge CalHP

Part Number

| Description
---|---
—|

CPF Male Fittings (2)—non-removable

MPF15K-1/4FPT

| 1/4″ Female NPT Fitting (1)
5102|

Fine Adjust (installed)

Parts Included with Pump Systems

Part Number

| Description|

System G GOX and GWX Part Number Description (GaugeCalHP)

---|---|---
MPF15K-1/4FPT| CPF Female to 1/4″ NPT Female Fitting|

■

MPF-1/4BSPF *| CPF Female to 1/4″ BSP Female Fitting|

■

MPF-1/8MPT *| 1/8” MPT Fitting (for 30 Series Calibrator) **|

■ (2)

MPF-CAP *| CPF Female Cap Fitting|

■ (2)

60R120| 1/4” Bonded Seals|

■

5102| Fine Adjust (installed)|

■

1351| Test Leads; Red & Black, including clips **|

■

5249| Protective Vinyl Cap|

■(4)

60I104| Pack Tape (1 roll)|

■

5101| Rolling Waterproof Carrying Case|

■

• These fittings are rated to 10 000 psi/100 bar.
  ** The MPF-1/8MPT fittings and 1351 Test Leads are included only with Pump Systems for the 30 Series Calibrator.

Hydraulic Fluid

Gauge CalHP comparators are only available delivered empty. You will still need to specify what fluid type you are going to use (for example; GOX for Oil or GWX for Water).

Ordering a Pump System

Any Gauge CalHP Pump System may be ordered with or without a reference indicator. The table below provides an explanation of the Pump System ordering scheme when ordering a system without an indicator. For details on ordering the Pump Systems with an indicator, see the indicator datasheet.

Reference Indicator

| Reference Indicator Included| Pump System|

Liquid

---|---|---|---

nVision. . . . NV

| No. . . . -NONE| System G (Gauge CalHP–oil). . . . . . -GOX|

Drained. . . -E

30 Series. . . IS30

|

System G (Gauge CalHP–water). . . -GWX

XP2i. . . . . . . XP2i

|

m1. . . . . . . . . M1

|

• X SAMPLE PART NUMBERS

NV-NONE-GOX-E . . . . . . System G pump system (for an nVision), drained of fluid, for use with oil.
IS30-NONE-GWX-E . . . System G pump system (for an nVision), drained of fluid, for use with water.
15KPSIXP2i-GWX-E . . System G pump system, drained, for use with water, with a 15 000 psi XP2i gauge included

Setup

ASSEMBLY

• Install the Handle Assembly

  • Install the handle assembly by tightening the captive screw using the included wrench.
    

• Install the No Mess Drip Tray

• • Press the no mess drip tray onto the pivot manifold
    

MOUNTING

The Gauge CalHP includes rubber feet that stabilize the unit up to 5000 psi. At pressures above 5000 psi, the force required to rotate the handle may cause the base of the comparator to lift. One of two methods may be used to mount the Gauge CalHP to a bench or table.

Using the Mounting Brackets

1. Loosen the mounting bracket screws.
2. Rotate the brackets, then slide them over the front of your table (max thickness of 1.75”).
3. Tighten the mounting bracket screws
   Rotate the mounting brackets
   
   then slide them over the front of your table.
   

Note: To ensure the comparator is mounted securely, grip and compress the brackets to the underside of the table while tightening the mounting screws.

• Install Onto a Tabl
  • Order the optional Table Mount Kit (P/N 5191) to bolt to a table

Safety Instructions

Follow these instructions for safe and reliable operation of your GaugeCalHP Pressure Comparator.

GENERAL CAUTIONS

• Avoid knocking, bumping or dropping the pressure system. This can cause permanent damage to the system and loss of accuracy.

• The pressure system must not be used for any purposes other than those described in this manual and for any application other than precision pressure calibration jobs.

• The pressure system should only be used by TRAINED PERSONNEL.

• None of our calibration systems are cleaned or prepared for OXYGEN SERVICE. DO NOT USE our systems for this purpose.

• Do not disconnect any parts from the system when pressurized.

• Do not connect any external pressure source to this system. This system is designed to test pressure measuring devices connected to the manifold only.
  Pressure from an external source can result in explosion of the fluid reservoir and possible personal injuries.

• The pressure inside the pump can be extremely high. Ensure that all pressure connections have been established correctly

Operating Instructions

GENERATING PRESSURE

• Prepare the Fine Adjust

  • Turn the fine adjust counter-clockwise about 10 rotations to provide room to increase or decrease pressure as needed.
    

• Fill the Reservoir
  The test fluid can be either water or lightweight oil.

Note: If using oil, we recommend AMETEK MGAAA oil.

1. Turn the handle fully counter-clockwise until it stops.

2. Turn the reservoir knob fully counter-clockwise and remove it from the reservoir.
   

3. Fill the reservoir to the fill line.
   

• Bleed Air from the System
  • Tighten the reservoir knob clockwise until fluid comes out of the fittings. The drip tray will collect the spilled fluid.
• Install the Device Under Test
  Your Gauge CalHP comes with two CPF male fittings (non-removable) and an adapter to 1/4″ Female NPT that is rated to 15000 psi (P/N MPF15K 1/4FPT).

1. Connect the adapter to your device under test.
   You will need to use thread tape or sealant to create a leak free seal.

2. Loosely tighten (3 turns only) the other end of the adapter to the connection manifold.

Note: For additional sizes and pressure ratings, see the Connection Diagram on page 13.
For applications up to 10000 psi, create finger-tight, leak-free seals by using CPF fittings. Visit the website for more information on CPF

Note: If you are using CPF quick test fittings, do not use thread tape.

! CAUTION: Never use a wrench to tighten quick test fittings.

Install the Reference Indicator

1. Loosely tighten (3 turns only) the reference to the connection manifold.
   Note: If the reference will not fit because you have a large device under test, turn the pivoting manifold to create extra space.
   Shown with a Quick Test Fitting (not included).

2. Bleed the system of remaining air by turning the reservoir knob clockwise until fluid drips out of the CPF weep hole on the base of the reference and on the connection fitting.
   Turn the reservoir knob…
   
   until fluid drips from the CPF weep hole.
   

3. Tighten the reference and the device under test. The connection only needs to be finger tight for a seal to 15 000 psi.

4. If necessary, continue to turn the devices clockwise until they are in the desired position.
   

OPERATION

Perform a Calibration

1. Vent the system by turning the reservoir knob counter-clockwise until a gap is visible between the reservoir knob and the lid.
   

2. Turn on the reference indicator, and then select the pressure units required for the gauge to be tested.
   For detailed operating instructions, refer to the documentation you received with your reference.

3. Press the (zero) button on your reference.
   We recommend that you exercise the device under test by applying the full scale pressure one or more times.

4. To apply pressure… Turn the handle in a clockwise direction.

5. To decrease pressure… Turn the handle in a counter-clockwise direction.
   After decreasing the pressure to zero, recheck the fluid level in the reservoir and rezero the reference, if necessary. You will notice that the application of pressure is non-linear, therefore pressure increases at a more rapid rate at higher pressures.

6. Turn the handle clockwise until the approximate pressure is obtained.

7. Allow time for the adiabatic effect to stabilize.

8. Use the fine adjust knob to obtain the exact pressure.

9. Compare the pressure on the device under test to the pressure displayed on the reference, and record the reading.
   Checking the accuracy of an analog pressure gauge against the display of the reference.
   

Perform a Quick Test Calibration

An alternative method eliminates the time required to wait for thermal pressure stability. This method works with the Crystal XP2i and nVision, but not with the 30 Series

1. Set the reference to detect peaks and clear any stored peak value.

2. Slowly increase pressure to the first major graduation on the device under test (or to the first calibration point).
   Increase pressure slowly, so that you don’t overshoot the mark (or point).
   The maximum pressure displayed on the reference will be the pressure that was applied—even if actual pressure drops again immediately.

3. Record the peak reading and continue to the next test point or mark.
   If you are also checking the gauge for hysteresis, the procedure is the same, except that you start at full scale and set the reference for the peak low. Eliminating the time required to wait for thermal equilibrium, significantly shortens the amount of time it takes to calibrate a gauge.
   Note: To automatically collect the readings directly from the reference, use Fast CalXP calibration software.

• To vent the system
  • Turn the handle counter-clockwise until it stops.

Vacuum Use

To Generate Vacuum

1. Loosen the reference indicator about 3 turns counter-clockwise.
2. Turn the handle clockwise and verify that fluid is dripping out of the CPF weep hole into the drip tray. Continue to turn the handle until it stops.
3. Tighten the reference.
4. Rotate the handle counter-clockwise to generate a vacuum.
   You can generate up to -12.5 psi.
   Note: Be aware that the system will vent during the last inch of travel

Connection Diagram

GAUGECALHP TO CRYSTAL REFERENCE INDICATOR

• These parts are included with the pump. All other parts are supplied as part of a pump system, or may be ordered separately. All BSP connections require bonded seals.

Specifications

PERFORMANCE

Hydraulic Pressure

Maximum . . . . . . . . . . . . . . . . . . . . . . . 15000 psi/ 1000 bar
Vacuum . . . . . . . . . . . . . . . . . . . . . . . . .-12.5 psi/-0.86 bar/-86.2 kPa

Pneumatic Pressure

Maximum . . . . . . . . . . . . . . . . . . . . . . .400 inH2O/ 995 mbar
Sensitivity (fine adjust) . . . . . . . . . . . 0.01 inH2O/ 0.025 mbar

Burst Pressure

Pressure . . . . . . . . . . . . . . . . . . . . . . . . .>25000 psi/ 1700 bar

MATERIALS

Wetted Materials. . . . . . . . . . . . . . . . . Stainless Steel plus Seals and Acrylic Reservoir
Enclosure . . . . . . . . . . . . . . . . . . . . . . . .Anodized Aluminum
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . .Buna N (Nitrile), Viton, and Urethane
Test Media . . . . . . . . . . . . . . . . . . . . . . .Water, Oil, or Air

DIMENSIONS

Width . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3 in / 210 mm
Length . . . . . . . . . . . . . . . . . . . . . . . . . .20.50 in / 520 mm
Height (base) . . . . . . . . . . . . . . . . . . . .5.5 in / 140 mm
Height (with handles) . . . . . . . . . . . . 11 in / 280 mm
Weight . . . . . . . . . . . . . . . . . . . . . . . . . .20 lbs/ 9 kg
Piston Stroke Volume . . . . . . . . . . . . 0.8 in3 / 13.1 cm3
Reservoir Volume . . . . . . . . . . . . . . . .10.8 in3 / 176.9 cm3

ACCESSORIES

Included
Adapter . . . . . . . . . . . . . . . . . . . . . . . . .1/4” Female NPT (P/N MPF15K-1/4FPT)

 SHIPPING INFORMATION

Shipping Weight . . . . . . . . . . . . . . . . . 22 lbs/ 9.9 kg
Dimensions . . . . . . . . . . . . . . . . . . . . . . 24 in x 12 in x 12 in / 610 mm x 305 mm x 305 mm

Support

TROUBLESHOOTING

Unstable Pressure

• Problem: Pressure cannot be generated correctly, or set pressure does not remain stable.
  

• Solutions:

  • Check that all adapters and pressure fittings have been tightened sufficiently to eliminate leaks.
  • Confirm test fluid does not contain air (air in the fluid can increase adiabatic effects). You may have to adjust the pressure a few times before the pressure is stable enough for calibration. Replace test fluid if necessary
  • Adiabatic and thermodynamic effects may be affecting the pressure reading. High pressure hydraulic systems are sensitive to temperature and movements. This effect will disappear after a period of time.

If the pressure is still not stabilizing, the system may be in need of service. Please contact your local distributor for advice.
Note: Always readjust the pressure after 5 to 10 minutes to allow time for settling of above effects.

Users should/must carry out the following cleaning procedures when required:

Standard exterior cleaning . . . . . . .Clean using a soft, damp cloth.
Heavily soiled cleaning . . . . . . . . . . . The instrument may also be cleaned using isopropyl alcohol when heavily soiled.
Reservoir . . . . . . . . . . . . . . . . . . . . . . . .Can be removed for easy cleaning. Turn the GaugeCalHP onto its side and loosen the two screws holding the reservoir in place. Slide the screws through the hole and quickly remove the reservoir as fluid may leak out of the bottom.
To clean the clear acrylic reservoir tube use a soft cloth or soap and water only. Never use chemical cleaners.

ORDERING INFORMATION, SPARE PARTS, AND FITTING KITS

Ordering Information

P/N GAUGECALHP GaugeCalHP Pressure Comparator
Pressure Comparator, two CPF male fittings (installed), and one 1/4″ FNPT adapter (P/N MPF15K-1/4FPT).

Spare Parts
P/N 5102 Fine Adjust (included)
P/N 5101 Rolling Case
Two MPF-CAP fittings to prevent leaks while in transit, two hold-down straps, and fluid bottle.
P/N FASTCALXP Gauge and Transmitter Calibration Software
FastCalXP software, USB Security Key, CD, and USB-RS232 adapter.
P/N 3327 USB Footswitch for FastCalXP
P/N 5191 Mounting Kit
P/N 5103 Rebuild Kit

Fitting Kits

P/N 4013 Quick Test NPT Kit—A set of CPF conversion fittings for connecting to 1/8″, 1/4″, and 1/2″ male NPT; without tools or thread tape.
Finger-tight to working pressure up to 10000 psi/700 bar.
Includes (1) MPF-1/8QTF, (1) MPF-1/4QTF, and (1) MPF-1/2QTF CPF fitting.
P/N 4015 BSP Test Kit—CPF conversion fittings to connect to male BSP: G 1/8, G 1/4, G 3/8, and G 1/2. Working pressure up to 10000 psi/700 bar. Includes (1) MPF-1/8BSPF, (1) MPF-1/4BSPF, (1) MPF-3/8BSPF, and (1) MPF 1/2BSPF CPF fitting

Test Fluid

Recommended Oil
P/N: MGAAA/QT. . . Hydraulic Oil. Quart.
P/N: MGAAA/GL. . . Hydraulic Oil. Gallon.

FACTORY SERVICE

Please complete the Return Material Authorization (RMA) form to generate an authorization number and provide return instructions.

WARRANTY

Crystal Engineering Corporation warrants the Gauge CalHP Comparator to be free from defects in material and workmanship under normal use and service for one (1) year from date of purchase to the original purchaser. It does not apply to batteries or when the product has been misused, altered or damaged by accident or abnormal conditions of operation.
Crystal Engineering will, at our option, repair or replace the defective device free of charge and the device will be returned, transportation prepaid. However, if we determine the failure was caused by misuse, alteration, accident or abnormal condition of operation, you will be billed for the repair.
CRYSTAL ENGINEERING CORPORATION MAKES NO WARRANTY OTHER THAN THE LIMITED WARRANTY STATED ABOVE. ALL WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE, ARE LIMITED TO A PERIOD OF ONE (1) YEAR FROM THE DATE OF PURCHASE.
CRYSTAL ENGINEERING SHALL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER IN CONTRACT, TORT OR OTHERWISE.
Note: (USA only) Some states do not allow limitations of implied warranties or the exclusion of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may have other rights which vary from state to state.

Customer Support

1.888.610.7664
www.calcert.com
sales@calcert.com

Documents / Resources

| AMETEK GaugeCalHP Hydraulic Pressure Generator System [pdf] Instruction Manual
GaugeCalHP Hydraulic Pressure Generator System, GaugeCalHP, Hydraulic Pressure Generator System, Pressure Generator System, Generator System
---|---

References

• Calcert

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