Calder 21001119 User manual

P/N 96654

September 2021

Revision 0

PILOT VALVE

TESTER

6KSI GAS AND WATER

OPERATING MANUAL

MACHINE SERIAL NUMBER: 21001119 AND HIGHER

ORIGINAL INSTRUCTIONS

P/N 96654, Rev. 0 Page A

Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem-

inated, downloaded, or stored in any storage medium, without the express prior written consent of CLIMAX.

CLIMAX hereby grants permission to download a single copy of this manual and of any revision hereto onto

an electronic storage medium to be viewed and to print one copy of this manual or any revision hereto, pro-

vided that such electronic or printed copy of this manual or revision must contain the complete text of this

revision hereto is prohibited.

At CLIMAX, we value your opinion.

For comments or questions about this manual or other CLIMAX documentation, please e-mail

documentation@cpmt.com.

For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail

[email protected]. For quick and accurate service, please provide your representative with the following:

• Your name

• Shipping address

• Telephone number

• Machine model

• Serial number (if applicable)

• Date of purchase

CLIMAX World Headquarters

2712 East 2nd Street

Newberg, Oregon 97132 USA

Telephone (worldwide): +1-503-538-2815

Toll-free (North America): 1-800-333-8311

Fax: 503-538-7600

H&S Tool World Headquarters

715 Weber Dr.

Wadsworth, OH 44281 USA

Telephone: +1-330-336-4550

Fax: 1-330-336-9159

hstool.com

CLIMAX | H&S Tool (UK Headquarters)

Unit 7 Castlehill Industrial Estate

Bredbury Industrial Park

Horsfield Way

Stockport SK6 2SU, UK

Telephone: +44 (0) 161-406-1720

CLIMAX | H&S Tool (European Headquarters)

CLIMAX GmbH

Am Langen Graben 8

52353 Düren, Germany

Telephone: +49 (0) 2421 9177 0

E-mail: [email protected]

CLIMAX | H&S Tool (Asia Pacific Head-

quarters)

316 Tanglin Road #02-01

Singapore 247978

Telephone: +65-9647-2289

Fax: +65-6801-0699

CLIMAX | H&S Tool (Middle East Headquarters)

Warehouse #5, Plot: 369 272

Um Sequim Road

Al Quoz 4

PO Box 414 084

Dubai, UAE

Telephone: +971-04-321-0328

Page B Pilot Valve Tester Operating Manual

CLIMAX GLOBAL LOCATIONS

P/N 96654, Rev. 0 Page C

CE DOCUMENTATION

Page D Pilot Valve Tester Operating Manual

P/N 96654, Rev. 0 Page E

LIMITED WARRANTY

CLIMAX Portable Machine Tools, Inc. (hereafter referred to as “CLIMAX”) warrants that all new

machines are free from defects in materials and workmanship. This warranty is available to the original pur-

chaser for a period of two years after delivery. If the original purchaser finds any defect in materials or work-

manship within the warranty period, the original purchaser should contact its factory representative and

return the entire machine, shipping prepaid, to the factory. CLIMAX will, at its option, either repair or

replace the defective machine at no charge and will return the machine with shipping prepaid.

CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all labor has

been performed properly. This warranty is available to the customer purchasing parts or labor for a period of

90 days after delivery of the part or repaired machine or 180 days on used machines and components. If the

customer purchasing parts or labor finds any defect in materials or workmanship within the warranty period,

the purchaser should contact its factory representative and return the part or repaired machine, shipping pre-

paid, to the factory. CLIMAX will, at its option, either repair or replace the defective part and/ or correct any

defect in the labor performed, both at no charge, and return the part or repaired machine shipping prepaid.

These warranties do not apply to the following:

• Damage after the date of shipment not caused by defects in materials or workmanship

• Damage caused by improper or inadequate machine maintenance

• Damage caused by unauthorized machine modification or repair

• Damage caused by machine abuse

• Damage caused by using the machine beyond its rated capacity

All other warranties, express or implied, including without limitation the warranties of merchantability and

fitness for a particular purpose are disclaimed and excluded.

Terms of sale

Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms control and

limit your rights with respect to the goods purchased from CLIMAX.

About this manual

CLIMAX provides the contents of this manual in good faith as a guideline to the operator. CLIMAX cannot

guarantee that the information contained in this manual is correct for applications other than the application

described in this manual. Product specifications are subject to change without notice.

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P/N 96654, Rev. 0 Page i

TABLE OF CONTENTS

CHAPTER/SECTION PAGE

1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1

1.1 HOW TO USE THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 SAFETY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 GENERAL SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.5 RISK ASSESSMENT AND HAZARD MITIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.6 RISK ASSESSMENT CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.7 LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -9

2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.5 ITEMS REQUIRED BUT NOT SUPPLIED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 SETUP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15

3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 LIFTING AND RIGGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3 SECURING THE TEST STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3.1 Cement in place (option 1 – recommended). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3.2 Drill and anchor (option 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4 INSTALLING UTILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.1 Connecting water from the source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.2 High-pressure sources for testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.3 Connecting to pilot valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.4 Connecting to drain port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -19

4.1 PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2 CONDUCTING AN AIR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2.1 Test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.3 CONDUCTING HYDROSTATIC OR WATER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.3.1 Test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.4 PREPARING FOR THE TEST PIECE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.5 PURGING WATER FROM THE VESSELS AND TEST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5 MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23

5.1 MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6 STORAGE AND SHIPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -25

6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION PAGE

6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.2 SHIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25