PDK PDPG-H Operation & User’s Manual

1 Introduction ......................................................................................................... 3 1.1 Product Overview ....................................................................................................... 3 1.2 Specifications ............................................................................................................ 3 1.3 Product Figures ........................................................................................................ 4 2 Installation & Operation ............................................................................ 6 2.1 Unpacking And Inspection .......................................................................................... 6 2.2 Product Requirement ................................................................................................ 7 2.3 Setup .......................................................................................................................... 8 2.4 General Operation ..................................................................................................... 9 2.5 Defined Pressure Calculations ................................................................................. 12 2.6 Storage ....................................................................................................................... 13 3 Troubleshooting ................................................................................................ 14 3.1 Overview .................................................................................................................... 14 3.2 PDPG Troubleshooting Checklist ............................................................................. 14

Measurement uncertainty 0.008 % of reading Piston cylinder material Tungsten carbide Mass material Stainless Steel Mass set Oil - 50 kg set / up to 100 kg available Test port Oil - 9/16" UNF Cone & Thread (AE F250C, HIP HF4) Weight 12 kg Power Requirements 220 VAC, 50/60 Hz Media Hydraulic - Oil (Sebacate Oil recommended) P/C and pressure range Mass Piston Piston 0.1 kg Piston+Bell 0.5 kg 50 kg 100 kg 0.2 MPa / kg 0.02 MPa 0.1 MPa 10 MPa 20 MPa 0.5 MPa / kg 0.05 MPa 0.25 MPa 25 MPa 50 MPa 1 MPa / kg 0.1 MPa 0.5 MPa 50 MPa 100 MPa 2 MPa / kg 0.2 MPa 1 MPa 100 MPa 200 MPa 1. Introduction 1.1 Product Overview Dead-Weight Tester is used as a generator of an accurately known pressure. It measures pressure as force per unit area. Therefore, Dead-Weight Tester is the most accurate pressure calibrator. M (Mass) x g (Acceleration Of Gravity) P (Pressure) = ------------------------------------------------------------- Ae (Effective Area) A typical PDPG Dead-Weight Tester system includes PDPG main platform body, Piston-Cylinder Module, Mass and Pressure Controller that user can be selected depending on user's system configuration. 1.2 Specifications

1.3.1 Front Panel Figure 1. Front Panel 1.3.2 Product Dimension Figure 1 Front And Side Appearance & Dimension [W:39 cm, D:30 cm , H:33 cm]

Figure 2. Appearance Of System No. Parts No. Parts ① Piston - Cylinder Module ⑥ Height Adjustment Knob ② Bell ⑦ Manual Piston Rotation button ③ Mass ⑧ Automatic Piston Rotation Button ④ Instrument Platform Handle ⑨ Piston Position Indicator ⑤ Platform Table 1. Description of [Figure 2. Appearance Of System]

2.1.1 Unpacking PDPG Dead-Weight Tester delivered via PDK or shipped and packed with wooden case that included basic accessories. 2.1.2 Inspection Checking all of the parts from PDPG system. Refer to Table2 when its unpacking. PARTS PART # PDPG-H System Included Accessaries: Pressure Controller ( OPS - J ) 1 Piston-Cylinder Module 1 Mass set 1 Mass Tray 1 Fitting and Adaptor Set 1 SUS Tube 1 Power Cable 1 Sebacate Oil ( 1 Liter ) 1 User Manual 1 KOLAS Certificated Calibration Report 1 ☞ Parts on above equipped directly to the product can be shipped. Table 2. PDPG Parts List

PDPG is composed of separate with pressure generator. To use the equipment, it required to install a pressure controller. Basically PDPG system includes pressure controller OPS-J. Before PDPG system installing, the following points should be noted. ▶ The stability of the table : PDPG weight is approximately 12 kg. 35 kg of Mass set can be raised. The table should selected with no change horizontally when mass set raised to the maximum weight. ▶ The location of the platform other than the equipment and components : It required sufficient space to install the Multi-test port, pressure controller and etc. External pressure connection tubing and fitting MUST use same as PDPG maximum pressure or more.

table. ▶ After placed PDPG system, using height adjustment knob and see the level for adjusting horizontal. ▶ User can choose the placement of the platform and pressure controller. but here is recommended placement is as follows. ex) From left side Mass Set → PDPG Platform → Pressure Controller → Multi-Test port 2.3.2 Pressure Tubing Connection General information for connection ▶ Connect the PDPG platform with pressure controller that using PDK supplied connection kit. ▶ Using tubing line(PDK Supplied) to connect rear test port of PDPG platform and side port of pressure controller.

2.4.1. The selection of Piston-Cylinder module and Mass combination PDPG be able to use many different ranges by replacing each range of Piston Cylinder module. ▶ Piston Cylinder Module : 1 MPa/kg ▶ Composition Of Mass 1) Piston Cylinder : 1 bar 2) Bell : 4 bar 3) 1 bar 4) 2 bar - 1 5) 2 bar - 2 6) 5 bar 7) 10 bar 8) 20 bar - 1 9) 20 bar - 2 10) Make-Up 45 bar 11) 50 bar - 1 12) 50 bar - 2 13) 50 bar - 3 14) 50 bar - 4 15) 50 bar - 5 16) 50 bar - 6 17) 50 bar - 7 18) 50 bar - 8 19) 50 bar - 9 20) 50 bar - 10 21) 50 bar - 11 22) 50 bar - 12

▶ Purging Air on Pressure Generator/Controller before connect PDPG base. ① Open the Vent Valve then operate lever type hand pump for 4 - 5 times. ② It can see the Air bubble on left hole in oil reserver during step ①. ③ After finished step ②, turn Volume Controller to end of CW direction then operate lever type hand pump for 4 - 5 times to see bubble coming out. ④ If there is no bubble, turn back to CCW direction, do step ① again. 2.4.3 Calibration/Adjustment Verified that the default setting of the PDPG system has been complete before started. ▶ Connect UUT(Unit Under Test) to Pressure generator or test port. ▶ Loading mass on mass loading bell as much as user wants to measure the pressure. ① Close Vent Valve then using lever type hand pump to generate initial pressure generating. ② After initial pressure generated using Volume Adjust to increasing the pressure slowly. (Volume Adjust : CW - Pressurize, CCW - Reduce Pressure) ③ Pressurize with checking the Piston location during Step ②. measure when LED indicates "Green color". ④ 9 of LED indicator located on front panel for measuring piston position. Approximately 1 mm height difference on each LED.

○ Yellow : Instability area (Piston is a little float or down) ○ Green : Measurable area ⑤ In order to reduce the friction of the piston and the cylinder, rotate the piston. 1) Red Button Only : When this button is pressed, motor works then piston rotates always. If piston is fully float or in the bottom, piston does not rotate and motor rotates only. Even piston is in out of measuring area, motor always works therefore we recommend between measurable area. 2) Red+Green Button : When these buttons are pressed, motor works and piston rotates when piston is in measurable area. Automatically stop the piston and motor rotation when piston is in out of measuring area.

- At this point reference pressure means pressure value that total mass loaded. - After finished measuring, if next measuring point is UP(pressurized), make a piston position a bit lower then stop the piston rotates, repeat step ②. - If pressure is Down point, make a piston a bit higher then stop the piston rotates, repeat step ②. 2.5. Reference Pressure Calculation ▶ Basic Calculation : Add Bell+Piston Cylinder's pressure value with loaded masses that pressure value marked on masses. Ex) Basically Bell + Piston : 5 bar If masses are as following, 45 bar 1ea, 50 bar 3 ea Total pressure value is 5+45+50+50+50 = 200 bar ▶ Precision Reference Pressure Calculation m = Total masses loaded on piston g = Local gravity ρa = Air density ρm = Mass density γ = Surface tension coefficient of Oil (Does not applied pneumatic) C = Circumference of piston (Does not applied pneumatic) Ao = Piston effective area at standard temperature λ = Piston-Cylinder pressure coefficient Pn = Nominal pressure αp = Piston linear thermal expansion coefficient αc = Cylinder linear thermal expansion coefficient T = Piston-Cylinder tem perature Tr = Reference pressure (ρf-ρa)gh = Head correction

When the equipment is not use for a short term ▶ Unload all of masses. ▶ Vent Open Vent valve to vent the pressure. ▶ Close the Inlet valve. 2.6.2. Long Term Storage And Moving When the equipment is not use for a long term or moving PDPG system for calibration ▶ Turn Piston-Cylinder module CCW to remove from PDPG platform then store in Piston-Cylinder module case. ▶ Store all of masses in mass set case. ▶ Remove the tubing from test port on rear PDPG platform then plugged. ▶ Packing well the PDPG platform in carrying case to prevent shaken. When it need to move, do not shake or turn the PDPG platform carrying case.

descend. Piston and Cylinder contaminated. Disassemble P/C module to cleaning. Piston does not rotate. 1. Piston position is fully floating or in the bottom. 2. Motor trouble or disconnected belt. 1. Pressurized or reduce pressure to make correct piston position. 2. Replace motor or belt. Piston dropped very quickly. Internal or external leaks. Find the leaks point then tighten or change the fitting to remove the leaks. Piston does not float. Damaged Pressure generator/controller O-ring. Replace Pressure generator/controller O-ring. 3. Trouble Shooting 3.1. Overview PDPG has precision machining technology and high electronic engineering technology therefore, it need to handle carefully. Parts of the defect and the damage can lead to unexpected and dangerous results. User needs to get training from who is well-acquainted with operation of PDPG system. 3.2. Troubleshooting Checklist

COMPANY ADDRESS TEL. FAX. e-mail PDK Co., Ltd. 10-6, EXPO-RO 339 BEON-GIL, YUSEONG-GU, DAEJEON, KOREA ZIP 34122 042-862-6880 042-862-6881 [email protected] Solution for Pressure Measurement & Calibration