DH Instruments OPG1-30000-AF User manual

T.O. 33A6-4-30-1
1 August 2000
©2000 DH Instruments, Inc.
OPG1-30000-AF™
Oil Pressure Generator/Controller
Operation and Maintenance Manual
NSN 6685-01-470-8667
(1 of 2)

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc.
High pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases can
be released unexpectedly and with extreme force. High pressure systems should be assembled and
operated only by personnel who have been instructed in proper safety practices.
©2000 DH Instruments, Inc. All rights reserved.
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, Inc. 4765 East Beautiful Lane Phoenix AZ 85044-5318 USA.
DH Instruments makes sincere efforts to ensure accuracy and quality of its published materials; however, no
warranty, expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or
indirect damages resulting from the use of the information in this manual or products described in it. Mention of any
product or brand does not constitute an endorsement by DH Instruments of that product or brand. This manual was
originally composed in English and was subsequently translated into other languages. The fidelity of the translation
cannot be guaranteed. In case of conflict between the English version and other language versions, the English
version predominates.
DH Instruments, DH, DHI, OPG1, OPG1-30000-AF, RPM3, RPM3/HPMS, PG7000 and CalTool are trademarks,
registered and otherwise, of DH Instruments, Inc.
Swagelok is a registered trademark of the Swagelok Company.
Teflon is a registered trademark of the 3M Corporation.
Document No. 550114-01
20000120
Printed in the USA

OPG1™ Operation and Maintenance Manual
Page i©2000 DH Instruments, Inc.
T
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TABLE OF CONTENTS ............................................................................... i
TABLES................................................................................................... iii
FIGURES ................................................................................................. iii
ABOUT THIS MANUAL ............................................................................. iv
1. INTRODUCTION .................................................................................... 1
1 . 1 PRODUCT OVERVIEW .............................................................................................................................1
1 . 2 SPECIFICATIONS .....................................................................................................................................2
1 . 3 INSTRUMENT LAYOUT ............................................................................................................................3
1.3.1 FRONT PANEL ..................................................................................................................................................3
1.3.2 OVERALL DIMENSIONS...................................................................................................................................4
1.3.3 SYSTEM SCHEMATIC.......................................................................................................................................5
2. INSTALLATION..................................................................................... 7
2.1 UNPACKING AND INSPECTION ..............................................................................................................7
2.1.1 REMOVING FROM PACKAGING......................................................................................................................7
2.1.2 INSPECTING CONTENTS .................................................................................................................................7
2 . 2 SITE REQUIREMENTS..............................................................................................................................8
2 . 3 INITIAL SETUP..........................................................................................................................................9
2.3.1 PREPARING FOR OPERATION .......................................................................................................................9
2.3.1.1 SET UP THE OPG1-30000-AF ..........................................................................................................9
2.3.1.2 CONNECT PNEUMATIC POWER (DRIVE AIR) ...............................................................................9
2.3.1.3 MAKE HYDRAULIC PRESSURE INTERCONNECTIONS ..............................................................11
2.3.1.4 CONNECTING TO A DEVICE UNDER TEST .................................................................................12
2 . 4 POWER UP AND VERIFICATION...........................................................................................................13
2.4.1 APPLY PNEUMATIC POWER (DRIVE AIR) ...................................................................................................13
2.4.2 ADJUST HYDROPNEUMATIC PUMP DRIVE AIR PRESSURE.....................................................................14
2.4.3 CHECK PROPER OPERATION OF HYDROPNEUMATIC PUMP AND LEAK CHECK ................................14
2.4.3.1 STEP ONE: PURGING AIR FROM THE HYDRAULIC PUMP CIRCUIT........................................14
2.4.3.2 STEP TWO: GENERATING A PRESSURE ...................................................................................15
2.4.4 PRECAUTIONS TO TAKE BEFORE GENERATING PRESSURE/SAFETY CONSIDERATIONS ................16
2 . 5 SHORT TERM SHUT-DOWN ..................................................................................................................18
2 . 6 LONG TERM STORAGE AND SHIPPING ..............................................................................................18
3. GENERAL OPERATION ....................................................................... 19
3 . 1 OPERATING PRINCIPLE........................................................................................................................19
3 . 2 OPERATIONAL FUNCTIONS .................................................................................................................21
3.2.1 SETTING INLET PRESSURE, DRIVE SET REGULATOR ADJUSTMENT....................................................21
3.2.2 ROUGH PRESSURE GENERATION/CONTROL, INLET AND OUTLET VALVE OPERATION ....................22
3.2.3 FINE PRESSURE ADJUSTMENT, PDVV (+) AND (-) VALVE OPERATION .................................................23
3.2.4 CONNECTING A DEVICE UNDER TEST (DUT).............................................................................................24
3.2.5 PURGING AIR FROM THE DUT/SYSTEM UNDER TEST..............................................................................24
3.2.6 MEASUREMENT REFERENCE LEVEL WHEN VENTED ..............................................................................25
3 . 3 TYPICAL OPERATING SEQUENCE FOR A COMPLETE CALIBRATION OR TEST............................26
4. MAINTENANCE ADJUSTMENTS AND CALIBRATION ............................. 27
4 . 1 OVERVIEW ..............................................................................................................................................27

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc.Page ii
4 . 2 FILLING THE TANK ................................................................................................................................28
4 . 3 REPLACING OIL AND PURGING CONTAMINATED OIL ......................................................................29
4 . 4 PRIMING THE HYDROPNEUMATIC PUMP ........................................................................................... 30
4.4.1 PRIMING THE HYDROPNEUMATIC PUMP BY SYRINGE INJECTION ........................................................30
4.4.2 INTERNAL PURGE OF HYDROPNEUMATIC PUMP .....................................................................................31
4 . 5 CLEANING/REPLACING DRIVE AIR FILTER ELEMENTS....................................................................32
5. TROUBLESHOOTING .......................................................................... 33
6. APPENDIX.......................................................................................... 35
6 . 1 WARRANTY STATEMENT......................................................................................................................35
GLOSSARY............................................................................................. 37

OPG1™ Operation and Maintenance Manual
Page iii ©2000 DH Instruments, Inc.
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Table 1. OPG1-30000-AF Parts List .......................................................................................................7
Table 2. Pneumatic Power (Drive Air) Requirements ........................................................................... 10
Table 3. OPG1 Troubleshooting Checklist ............................................................................................ 33
Table 4. DHI Authorized Service Providers........................................................................................... 36
F
FI
IG GU UR RE ES S
Figure 1. Front Panel ................................................................................................................................ 3
Figure 2. Front and Side Views with Dimensions..................................................................................... 4
Figure 3. System Schematic..................................................................................................................... 5
Figure 4. Connecting OPG1-30000-AF to an RPM3/HPMS................................................................... 11
Figure 5. System Schematic................................................................................................................... 20
Figure 6. Front Panel .............................................................................................................................. 21
Figure 7. PDDV Position Indicator .......................................................................................................... 23
Figure 8. Fluid Head Level When Vented, INLET Valve Open .............................................................. 25
Figure 9. Oil Tank ................................................................................................................................... 28
Figure 10. Hydropneumatic Pump............................................................................................................31
Figure 11. Drive Air Filters ........................................................................................................................ 32

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc. Page iv
A
AB
BO OU UT T T
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MA
AN NU UA AL L
This manual provides the user with the information necessary to operate an OPG1-30000-AF
Hydraulic Pressure Generator/Controller. It also includes a great deal of additional information
provided to help you optimize OPG1-30000-AF use and take full advantage of its many features
and functions.
FOR THOSE OF YOU WHO “DON’T READ MANUALS”, GO DIRECTLY TO SECTION 2.3 TO SET
UP YOUR OPG1-30000-AF. READ SECTION 2.4.4 AND GO TO SECTION 3.3. THIS WILL GET YOU UP
AND RUNNING QUICKLY WITH MINIMAL RISK OF CAUSING DAMAGE TO YOURSELF OR YOUR OPG1.
THEN… WHEN YOU HAVE QUESTIONS OR START TO WONDER ABOUT ALL THE GREAT FEATURES
YOU MIGHT BE MISSING, GET INTO THE MANUAL!
Manual Conventions
(CAUTION) is used throughout the manual to identify user warnings and cautions.
(NOTE) is used throughout the manual to identify operating and applications advice and
additional explanations.

OPG1™ Operation and Maintenance Manual
Page 1 ©2000 DH Instruments, Inc.
1. INTRODUCTION
1.1 PRODUCT OVERVIEW
The OPG1-30000-AF Hydraulic Pressure Generator/Controller is a stand alone, pressure generating
and controlling component intended to be used as the pressure source and means of pressure
adjustment in hydraulic calibration and test systems. It is capable of both generating and precisely
adjusting pressure from atmosphere to 200 MPa (30 000 psi).
OPG1-30000-AF combines the versatility, speed and reliability of direct operator control with the
convenience and effort-free operation of automation. It is the standard pressure generating and
control component in an HGC-30000-AF Hydraulic Gauge Calibration system as well as in a PG7302
piston gauge system.
OPG1-30000-AF includes an on-board hydropneumatic pump to fill the system under test and
generate pressures up to 200 MPa (30 000 psi). Two progressive needle valves control the inlet of
pressure from the pump to increase pressure and outlet back to the reservoir to decrease pressure.
Very fine pressure adjustment and generation of small pressure excursions is accomplished using a
Pneumatically Driven Variable Volume (PDVV) with push button control. Pneumatic power (drive air)
of up to 850 kPa (120 psi) is needed to drive the hydropneumatic pump and PDVV.

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc.Page 2
1.2 SPECIFICATIONS
Electrical Power Requirements None
Pneumatic Power Requirements Clean, dry, compressed air @ 50 slm (1.8 scfm) flow. Maximum
pressure needed depends on maximum oil pressure desired:
- 70 MPa (10 000 psi): 550 kPa (80 psi)
- 140 MPa (20 000 psi): 700 kPa (100 psi)
- 200 MPa (30 000 psi): 850 kPa (120 psi)
Operating Temperature Range 10 to 45 °C
Weight 27 kg (60 lb)
Dimensions 30 cm H x 30 cm W x 53.5 cm D (11.75 in. x 11.75 in. x 21.0 in.)
(Height: Top of tank which is 8.5 cm (3.3 in.) above the top
instrument surface)
Pressure Range 0 to 200 MPa (30 000 psi)
Maximum output pressure depends on pneumatic power supply
(see above)
Operating Medium Di-2-Ethyl Hexyl Sebacate (same as PG7302 piston gauge) and
other non-corrosive oils
Pneumatic Power Connection(s) 1/4 in. NPT F (can be configured into two independent
connections, one for pump drive and one for variable volume drive)
Hydraulic Test Connections (3) DH500 F test connections (one at back of either side and one
on top of reservoir)
NOTE: DH500 is a gland and collar type fitting for 1/4 in. (6.35
mm) coned and left hand threaded tube. DH500 is equivalent to
AE F250C, HIP HF4, etc.
Reservoir Capacity 200 cc (12 in3)
Pneumatically Actuated
Variable Volume (PDVV)
Displacement
1 cc (0.06 in3)
Typical Pressure Generation
Time (0 to 200 MPa/30 000 psi)
into air purged 50 cc volume
Less than 12 seconds

OPG1™ Operation and Maintenance Manual
Page 3 ©2000 DH Instruments, Inc.
1.3 INSTRUMENT LAYOUT
1.3.1 FRONT PANEL
The front panel provides all of the controls and indications needed to set and adjust pressure.
1. PDVV Drive Air/Test Oil Pressure Gauge
2. PDVV Piston Position Indicator
3. Pump Drive Air/Inlet Oil Pressure Gauge
4. Pump Drive Air Set Regulator
5. Test Inlet Valve Knob
6. PDVV Increase Fast and Slow Buttons
7. PDVV Decrease Fast and Slow Buttons
8. Test Outlet Valve Knob
Figure 1. Front Panel
65
4
3
2
1
87

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc.Page 4
1.3.2 OVERALL DIMENSIONS
Figure 2. Front and Side Views with Dimensions

OPG1™ Operation and Maintenance Manual
Page 5 ©2000 DH Instruments, Inc.
1.3.3 SYSTEM SCHEMATIC
20
21
1. Pump Drive Air Set Regulator 11. Fast and Slow PDVV Decrease Valves
2. Hydropneumatic Pump 12. Fast and Slow PDVV Increase Valves
3. Tank 13. PDVV DRIVE Air Connection
4. Top TEST Connection 14. Common DRIVE Air Connection
5. Oil Return Overflow Tube 15. DRIVE Air Filters
6. Right Side TEST Connection 16. PUMP DRIVE Pressure Gauge
7. Left Side TEST Connection 17. PDVV Plunger Position Indicator
8. Test Outlet Valve 18. PDVV DRIVE Pressure Gauge
9. Test Inlet Valve 19. PDVV DRIVE to PDVV Connection
10. Pneumatically Drive Variable Volume
(PDVV)
20. Oil Filter
Figure 3. System Schematic

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc.Page 6
N
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OT TE ES S

OPG1™ Operation and Maintenance Manual
Page 7 ©2000 DH Instruments, Inc.
2. INSTALLATION
2.1 UNPACKING AND INSPECTION
2.1.1 REMOVING FROM PACKAGING
OPG1-30000-AF is delivered, along with its standard accessories in a corrugated container
with corrugated and polyurethane inserts to hold it in place.
Remove the OPG1 and its accessories from the shipping container and remove each
element from its protective plastic bag.
Retain the packaging in case of future OPG1 shipments.
2.1.2 INSPECTING CONTENTS
Check that all items are present and have NO visible damage. Verify the items received
against the parts list in Table 1.
Table 1. OPG1-30000-AF Parts List
DESCRIPTION PART NO.
OPG1-30000-AF Instrument 401602
Operation and Maintenance Manual 550114
Accessories: 401580
Mat, Top Surface Protection 122998
Sebacate (synthetic oil), 1 qt. 400503
Syringe, 10 cc 102817
O-ring, Brown Viton, 2-104 102758
Interconnections Kit: 401603
1 ea. Nipple, 2.75 in., DH500 100207
1 ea. Nipple, 6 in., DH500 100208
1 ea. Nipple, 24 in., DH500 100270
1 ea. Elbow, 24 in., DH500 123136
1 ea. Adaptor, DH500 F x 1/4 in. NPT M 102889
1 ea. Adaptor, DH500 F x 1/4 in. NPT F 102820
1 ea. Adaptor, DH500 F x 37 degree (AN4) Mi 102888
2 ea. Gland, DH500 100271
5 ea. Collar, DH500 100201

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc.Page 8
2.2 SITE REQUIREMENTS
The OPG1-30000-AF is typically delivered as part of an HGC-30000-AF hydraulic gauge calibrator
that includes an RPM3/HPMS-A30000/A6000-AF that has its own Operation and
Maintenance Manual.
When selecting and preparing a site to set up the OPG1-30000-AF and HGC-30000-AF system, the
following should be considered:
•Bench Stability: The OPG1 weighs about 27 kg (60 lb). The RPM3/HPMS-A30000/A6000-AF
weighs about 10 kg (22 lbs). Consider the combined weight and that of other components,
including possible items to be tested, when selecting a bench.
•Footprint: The HGC-30000-AF system requires a minimum bench space approximately 84 cm
(33 in.) wide and 60 cm (24 in.) deep.
•Location of Other Components: Plan the space required and a convenient layout for the
complete system in which OPG1 is the pressure generation/control component.
If the OPG1 is to be used with an RPM3/HPMS, the OPG1 accessories include the hardware
necessary for setting up in a standard configuration (see Sections 2.1.2, 2.3.1.3). These allow
the RPM3/HPMS to be placed to the right or the left of the OPG1, as desired.
The interconnecting tubing and fittings provided with the OPG1 accessories can also be used to
connect to other systems. If interconnections other than the OPG1 accessories are used, select
tubing and fittings rated to handle the maximum pressures that will be generated. OPG1
hydraulic fittings are all DH500 (equivalent to AE F250C, HIP HF4, etc.). The female DH500
fittings are delivered with gland nuts and plugs installed. Collars are included in the accessory
kit.
If you do not plan to use OPG1’s top TEST port, consider where a device or system under test
(DUT) will be connected.
•Pressure Supply: Plan the pneumatic power to OPG1. This requires two separate sources:
a) 850 kPa (120 psi) from an N2 or Air bottle connected to the rear left of the OPG1; b) 620 kPa
(90 psi) non-lubricated compressed air connected to the rear right of the OPG1 (see
Section 2.3.1.2). The connections are 1/4 in. NPT female.
•System Interconnections: Plan the interconnections between OPG1 and other components in
the system. Minimizing the volume and maximizing the mass of all interconnecting elements will
reduce pressure generation and stabilization time. An extra nipple is provided in the OPG1
interconnection accessories for possible connection to an existing oil/air separator (see
Section 2.3.1.3).
ALWAYS use external tubing and fittings rated for pressures equal to or greater than the
maximum pressure OPG1 will be used to generate.

OPG1™ Operation and Maintenance Manual
Page 9 ©2000 DH Instruments, Inc.
2.3 INITIAL SETUP
2.3.1 PREPARING FOR OPERATION
Before setting up the OPG1, see Section 2.2 for general information on site requirements.
To prepare an OPG1 for check out and operation:
Set up the OPG1 (see Section 2.3.1.1).
Connect pneumatic power (see Section 2.3.1.2).
Make the system hydraulic pressure interconnections (see Section 2.3.1.3).
2.3.1.1 SET UP THE OPG1-30000-AF
To set up the OPG1, proceed as follows:
Place the OPG1 platform on the site table in the proper orientation with the front
panel controls conveniently accessible.
Fill tank with oil if necessary. Back off the tank cover until a gap for oil passage
can be seen between the DUT connection shaft and the cover. Pour in oil to just
under the overflow tube (see Section 4.2).
Leave tank cover open to allow oil to drain from the DUT connection and air to
escape when venting oil back to tank.
Install the mat delivered with accessories on top front of OPG1 around oil tank.
2.3.1.2 CONNECT PNEUMATIC POWER (DRIVE AIR)
OPG1 requires pneumatic power to drive two different components:
the hydropneumatic pump and the pneumatically driven variable volume (PDVV)
(see Section 3.1, Figure 6).
The drive air supply to the two components requires two independent connections
(see Section 3.1, Figure 6). The requirements for the two different components are
summarized in Table 2.

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc.Page 10
Make the two drive air connections as follows (but do not supply the air before
reading Section 2.4.3.2):
“DRIVE” connection (right side, rear): Connect a regulated air supply meeting
the requirements of Table 2 to the 1/4 in. NPT F “DRIVE” connection. This is
usually a shop air supply.
The maximum output pressure of the hydropneumatic pump is the drive air
pressure x 400. To avoid accidentally generating greater pressure than desired,
do not supply more pressure than necessary to the “DRIVE” connection.
“PDVV DRIVE” connection (left side, read): Connect a regulated air supply
meeting the requirements of Table 2 to the 1/4 in. NPT F “PDVV
DRIVE” connection. This is usually supplied from an N2 or Air “K” bottle.
The OPG1 “PDVV DRIVE” connection must be supplied with NON-LUBRICATED
drive air. The internal components are permanently lubricated. The oil in
lubricated air can contaminate the small diameter tubing inside OPG1 and lead
to erratic behavior requiring difficult and costly cleaning. Install a filter/dryer on
the drive air line if necessary.
Table 2. Pneumatic Power (Drive Air) Requirements
CONNECTION FITTING
INTERNAL
COMPONENT
SUPPLIED
DRIVE AIR PRESSURE
NEEDED
MINIMUM
FLOW LUBRICATED
CLEANLINESS
CRITICAL
DRIVE
(right side,
rear)
1/4 in.
NPT F
Hydropneumatic
Pump
620 kPa (90 psig) 50 slm
(1.8 scfm)
*This is fairly
high flow.
No No
PDVV DRIVE
(left side, rear)
1/4 in.
NPT F
PDVV For 70 MPa (10 000 psi)
oil pressure:
550 kPa (80 psi)
For 140 Mpa (20 000 psi)
oil pressure:
700 kPa (100 psi)
For 200 Mpa (30 000 psi)
oil pressure:
850 kPa (120 psi)
200 sccm
(< 0.01 scfm)
*This is very low
flow.
No
(must be dry)
Yes

OPG1™ Operation and Maintenance Manual
Page 11 ©2000 DH Instruments, Inc.
2.3.1.3 MAKE HYDRAULIC PRESSURE INTERCONNECTIONS
CONNECTING TO THE RPM3/HPMS-A30000/A6000-AF
OPG1-30000-AF is delivered with a fittings accessory kit (see Section 2.1.2, Table 1).
This kit includes the high pressure hardware necessary to connect OPG1-30000-AF
to the RPM3/HPMS-A30000/A6000-AF. See Figure 4 for the recommended layout
and to identify the parts used from the interconnection kit. Figure 4 shows the
RPM3/HPMS installed to the right of the OPG1. It may be installed on either side
using either one of OPG1’s rear side test connections.
1. Optional connection to an existing oil/air interface or other device
(use 24 in. DH500 nipple P/N 100270)
2. OPG1-30000-AF
3. OPG1 TEST connection (DH500)
4. OPG1 to RPM3/HPMS connection (use 24 in. DH500 elbow P/N 123136)
5. RPM3/HPMS TEST connection (DH500)
6. RPM3/HPMS-A30000/A6000-AF
7. OPG1 connection for device under test
Figure 4. Connecting OPG1-30000-AF to an RPM3/HPMS
7
6
5
4
3
2
1

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc.Page 12
Always use external tubings and fittings rated for pressure equal to or greater than
the maximum pressure the OPG1 will be used to generate.
When planning system interconnections, consider that the time required to generate
and stabilize a pressure is a direct function of the test volume and the mechanical
stability of the test tubing and vessels. Always minimize volume to the extent
possible and use thick walled, high pressure tubing and vessels.
When planning a DUT or other fitting make and break point external to OPG1, consider
that if the point is lower than the OPG1 oil tank, oil will run out of the tank through
the open point when OPG1’s OUTLET valve is open.
The fluid head reference level of OPG1 when vented (OUTLET valve open), is the top of
the tank’s oil return overflow tube (see Section 3.2.6).
2.3.1.4 CONNECTING TO A DEVICE UNDER TEST
In an HGC-30000-AF system, the device under test (DUT) is intended to be
connected on the top of the OPG1 at the center of the oil tank (see Figures 6
and 10).
The top TEST connection is a DH500 F (DH500 is a gland and collar type fitting for
1/4 in. (6.35 mm) coned and left hand threaded tube. DH500 is equivalent to
AE F250C, HIP HF4, etc.
The OPG1-30000-AF fittings accessory kit includes adaptors to convert the DH500 F
TEST connection to other commonly used fittings. The adaptors are made by
combining a DH500 F adaptor with a 2.75 in. or 6 in. DH500 nipple. The nipple/adaptor
assembly is then installed on the DUT. Finally, the nipple/adaptor/DUT assembly is
installed on the OPG1’s DH500 F test connection. Note that the gland nut on the
adaptor/nipple assembly can be tightened into the DH500 F connection without rotating
the nipple or DUT. Adaptors available are:
•1/4 in. NPT F
•1/4 in. NPT M
•37 degree flare M (AN4 M)
The test connection is a DH500.

OPG1™ Operation and Maintenance Manual
Page 13 ©2000 DH Instruments, Inc.
The DH500 test connection can be converted to 1/8 in. NPT M or 1/4 in. NPT M
using the 2.75 in. (7 mm) tube and DH500 F x 1/8 in. NPT M or DH500 F x 1/4 in.
NPT M adaptor supplied in the OPG1 accessories. Install the tube into the adaptor.
Any device connected to the OPG1 and/or HGC-30000-AF system should be purged
of air to the extent possible prior to being connected to the system (see
Section 3.2.5).
OPG1 covers a very wide range of pressures all the way up to 200 MPa (30 000 psi).
It is the user’s responsibility to assure that fittings and devices connected to OPG1
are rated for the pressures at which they will be used.
If the DUT connection is lower than the OPG1 oil tank, when the OUTLET valve is open
and the DUT connection is open, oil will run out of the tank through the
DUT connection.
2.4 POWER UP AND VERIFICATION
2.4.1 APPLY PNEUMATIC POWER (DRIVE AIR)
Proceed as follows (numerical references refer to Section 3.2, Figure 7):
Fully back off the DRIVE SET regulator (4).
Close the TEST INLET valve (5).
Open the TEST OUTLET valve (8).
Connect the drive air supplies to the DRIVE and PDVV DRIVE ports, if you haven’t
already done so (see Section 2.3.1.2).
Adjust the external drive air regulator(s) to apply the appropriate level of pressure to the
DRIVE and PDVV DRIVE ports (see Section 2.3.1.2, Table 2).

OPG1™ Operation and Maintenance Manual
©2000 DH Instruments, Inc.Page 14
2.4.2 ADJUST HYDROPNEUMATIC PUMP DRIVE AIR PRESSURE
This section assumes that the OPG1-30000-AF system has already been set up, including
pressure interconnection (see Section 2.3).
OGP1 hydraulic output pressure is directly proportional to pump DRIVE pressure. When the
OPG1 INLET valve is opened, the full pump pressure may be applied to the test system
very rapidly. ALWAYS adjust the pump pneumatic drive pressure low enough so that the
maximum pump output does not exceed the maximum pressure rating of the devices to which
OPG1 is connected.
Turn the DRIVE SET Regulator CW and observe the PUMP DRIVE Gauge to set the drive
air pressure to the desired level (the BLUE indication on outside of gauge gives the
approximate maximum oil pressure that will be generated).
2.4.3 CHECK PROPER OPERATION OF HYDROPNEUMATIC PUMP AND
LEAK CHECK
Checking the proper operation of the hydropneumatic pump and leak checking has two
steps. The first step is purging air from the pump hydraulic circuit. The second step is
generating high pressures.
2.4.3.1 STEP ONE: PURGING AIR FROM THE HYDRAULIC PUMP CIRCUIT
Proceed as follows (numerical references refer to Section 3.1, Figure 6):
Verify that there is oil in the tank and verify that all test connections are plugged
or dead ended.
Open the OUTLET valve (8) fully.
Open the INLET valve (9) fully.
If drive pressure has been properly connected and set (see Section 2.4.2), pump
should begin cycling.