DH Instruments OPG1 User manual

OPG1™
Hydraulic Pressure Generator/Controller
Operation and Maintenance Manual
© 1998-2007 DH Instruments, a Fluke Company

OPG1™ OPERATION AND MAINTENANCE MANUAL
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.
©1999-2007 DH Instruments, a Fluke Company 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, a Fluke Company 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, RPM3, PG7000 and CalTool are trademarks, registered and otherwise, of DH
Instruments, a Fluke Company.
Swagelok is a registered trademark of the Swagelok Company.
Teflon is a registered trademark of the 3M Corporation.
Document No. 550108c
020930
Printed in the USA
© 1998-2007 DH Instruments, a Fluke Company

TABLE OF CONTENTS
T
TA
AB BL LE E
O
OF
F
C
CO
ON NT TE EN NT TS S
TABLE OF CONTENTS ...............................................................I
TABLES .................................................................................III
FIGURES................................................................................III
ABOUT THIS MANUAL .............................................................IV
1. INTRODUCTION ................................................................. 1
1.1 PRODUCT OVERVIEW ...........................................................................................................................1
1.2 SPECIFICATIONS ...................................................................................................................................1
1.3 INSTRUMENT LAYOUT ..........................................................................................................................2
1.3.1 FRONT PANEL ..............................................................................................................................................2
1.3.2 OVERALL DIMENSIONS...............................................................................................................................3
1.3.3 SYSTEM SCHEMATIC ..................................................................................................................................4
2. INSTALLATION .................................................................. 5
2.1 UNPACKING AND INSPECTION ............................................................................................................5
2.1.1 REMOVING FROM PACKAGING..................................................................................................................5
2.1.2 INSPECTING CONTENTS.............................................................................................................................5
2.2 SITE REQUIREMENTS............................................................................................................................6
2.3 INITIAL SETUP........................................................................................................................................7
2.3.1 PREPARING FOR OPERATION ...................................................................................................................7
2.3.1.1 SET UP THE OPG1 ...................................................................................................................................7
2.3.1.2 CONNECT PNEUMATIC POWER (DRIVE AIR)........................................................................................7
2.3.1.3 MAKE HYDRAULIC PRESSURE INTERCONNECTIONS ......................................................................11
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.................................................................13
2.4.3 CHECK PROPER OPERATION OF HYDROPNEUMATIC PUMP AND LEAK CHECK.............................13
2.4.3.1 STEP ONE: PURGING AIR FROM THE HYDRAULIC PUMP CIRCUIT ................................................13
2.4.3.2 STEP TWO: GENERATING A PRESSURE............................................................................................14
2.4.3.3 PRIMING THE HYDROPNEUMATIC PUMP BY SYRINGE INJECTION.................................................15
2.4.3.4 INTERNAL PURGE OF HYDROPNEUMATIC PUMP .............................................................................15
2.4.4 PRECAUTIONS TO TAKE BEFORE GENERATING PRESSURE/SAFETY
CONSIDE RATIONS.................................................................................................................................16
2.5 SHORT TERM SHUT-DOWN ................................................................................................................17
2.6 LONG TERM STORAGE AND SHIPPING.............................................................................................17
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 .................................................22
3.2.4 CONNECTING A DEVICE UNDER TEST (DUT).........................................................................................23
3.2.5 PURGING AIR FROM THE DUT/SYSTEM UNDER TEST..........................................................................24
3.2.6 MEASUREMENT REFERENCE LEVEL WHEN VENTED ..........................................................................24
3.3 TYPICAL OPERATING SEQUENCE FOR A COMPLETE CALIBRATION OR TEST ..........................25
Page I © 1998-2007 DH Instruments, a Fluke Company

OPG1™ OPERATION AND MAINTENANCE MANUAL
4. MAINTENANCE ADJUSTMENTS AND CALIBRATION ............. 27
4.1 PRODUCT OVERVIEW .........................................................................................................................27
4.2 FILLING THE TANK ..............................................................................................................................27
4.3 REPLACING OIL AND PURGING CONTAMINATED OIL .................................................................... 28
4.4 CLEANING/REPLACING DRIVE AIR FILTER ELEMENTS..................................................................28
5. TROUBLESHOOTING ........................................................ 31
5.1 OVERVIEW ............................................................................................................................................31
6. APPENDIX ....................................................................... 33
6.1 OPG1 TERMS, LABELS, AND SYMBOLS (GLOSSARY) ....................................................................33
6.2 WARRANTY STATEMENT....................................................................................................................34
© 1998-2007 DH Instruments, a Fluke Company Page II

TABLES & FIGURES
T
TA
AB BL LE ES S
Table 1. OPG1 Parts List............................................................................................................................. 5
Table 2. Pneumatic Power (Drive Air) Requirements ................................................................................. 8
Table 3. OPG1 Troubleshooting Checklist ................................................................................................31
Table 4. DHI Authorized Service Providers............................................................................................... 34
F
FI
IG GU UR RE ES S
Figure 1. Front Panel................................................................................................................................... 2
Figure 2. Front and Side Views with Dimensions ....................................................................................... 3
Figure 3. System Schematic ....................................................................................................................... 4
Figure 4. Configuring Pneumatic Power Connections .............................................................................. 11
Figure 5. Connecting OPG1 to PG7302 or RPM3 .................................................................................... 12
Figure 6. Hydropneumatic Pump .............................................................................................................. 16
Figure 7. System Schematic ..................................................................................................................... 20
Figure 8. Front Panel................................................................................................................................. 21
Figure 9. PDVV Position Indicator............................................................................................................. 23
Figure 10. Fluid Head Level When Vented, INLET Valve Open .............................................................. 24
Figure 11. Oil Tank.................................................................................................................................... 28
Figure 12. Drive Air Filters ........................................................................................................................ 29
Page III © 1998-2007 DH Instruments, a Fluke Company

OPG1™ OPERATION AND MAINTENANCE MANUAL
A
AB
BO OU UT T
T
TH
HI IS S
M
MA
AN NU UA AL L
This manual provides the user with the information necessary to operate an OPG1 Hydraulic Pressure
Generator/Controller. It also includes a great deal of additional information provided to help you optimize
OPG1 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. THEN GO TO SECTION 4.3. THIS WILL GET YOU 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.
© 1998-2007 DH Instruments, a Fluke Company Page IV

1. INTRODUCTION
1. INTRODUCTION
1.1 PRODUCT OVERVIEW
The OPG1 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 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 a
DHI PG7302 piston gauge system or combined with an RPM3 digital pressure monitor to configure a
transfer standard based calibration system.
OPG1 includes an on-board hydropneumatic pump to fill the system under test and generate pressures
up to 200 MPa (30 000 psi). Two highly progressive, half-turn 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.
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 Connections 1/4 in. NPT F (can be configured into one common connection, for
both pump drive and variable volume drive)
Hydraulic Test Connections (3) DH500 F test connections (one at back of either side and one on
top of reservoir)
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
Page 1 © 1998-2007 DH Instruments, a Fluke Company

OPG1™ OPERATION AND MAINTENANCE MANUAL
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
© 1998-2007 DH Instruments, a Fluke Company Page 2

1. INTRODUCTION
1.3.2 OVERALL DIMENSIONS
Figure 2. Front and Side Views with Dimensions
Page 3 © 1998-2007 DH Instruments, a Fluke Company

OPG1™ OPERATION AND MAINTENANCE MANUAL
1.3.3 SYSTEM SCHEMATIC
21
21
1. Pump Drive Air Set Regulator 12. Fast and Slow PDVV Increase Valves
2. Hydropneumatic Pump 13. PDVV DRIVE Air Connection (use optional)
3. Tank 14. Common DRIVE Air Connection
4. Top TEST Connection 15. DRIVE Air Filters
5. Oil Return Overflow Tube 16. PUMP DRIVE Pressure Gauge
6. Right Side TEST Connection 17. PDVV Plunger Position Indicator
7. Left Side TEST Connection 18. PDVV DRIVE Pressure Gauge
8. Test Outlet Valve 19. DRIVE to PDVV Common Connection (optional -
9. Test Inlet Valve replace PDVV DRIVE to PDVV Independent Connection)
10. Pneumatically Drive Variable Volume 20. PDVV DRIVE to PDVV Independent Connection
(PDVV) (as delivered)
11. Fast and Slow PDVV Decrease Valves 21. Oil Filters
Figure 3. System Schematic
© 1998-2007 DH Instruments, a Fluke Company Page 4

2. INSTALLATION
2. INSTALLATION
2.1 UNPACKING AND INSPECTION
2.1.1 REMOVING FROM PACKAGING
OPG1 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.
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 Parts List
DESCRIPTION PART #
OPG1 Instrument 401497
ACCESSORIES INCLUDING:
1 Mat, Top Surface Protection 122998
1 qt. Sebacate (synthetic oil) 400503
1 Syringe, 10 cc 102817
1 O-ring, Brown Viton, 2-104 102758
1 Operation and Maintenance Manual 550108
1 General Accessories Disk (white CD) 102987
INTERCONNECTIONS KIT: 401536
2 ea. Nipple, 2.75 in. (70 mm), DH500 100207
1 ea. Nipple, 6 in. (152 mm), DH500 100208
2 ea. Nipple, 12 in. (305 mm), DH500 100209
1 ea. Union, DH500 100295
1 ea. Elbow, DH500 100168
1 ea. Tee, DH500 100291
2 ea. Gland, DH500 100271
3 ea. Plug, DH500 100285
5 ea. Collar, DH500 101201
1 ea. Nipple, 5 in. x 1/8 in. (127 mm x 3 mm), DH500 tips 123019
2 ea. Adaptor, DH500 F x 1/8 in. NPT M 102819
1 ea. Adaptor, DH500 F x 1/4 in. NPT F 102820
Page 5 © 1998-2007 DH Instruments, a Fluke Company

OPG1™ OPERATION AND MAINTENANCE MANUAL
2.2 SITE REQUIREMENTS
The exact OPG1 system installation is affected by the components other than the OPG1 that make up the
system. This generally includes a pressure measuring reference such as a transfer standard or piston
gauge.
When selecting and preparing a site to set up the OPG1 system, the following should be considered:
•Bench Stability: The OPG1 weighs about 27 kg (60 lb). Consider its weight and that of other
components, including possible items to be tested, when selecting a bench.
•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. OPG1 has TEST ports on both
its right and left rear sides to allow it to be placed to the right or left in the setup. Select
interconnecting 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 glands, 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.
If the OPG1 is to be used with a DHI RPM3 or PG7302 reference device, OPG1 accessories include
the hardware necessary for setting up in a standard configuration (see Sections 2.1.2 and 2.3.1.3,
Connecting to a DHI RPM3 or PG7302 Using Standard OPG1 Interconnection Accessories).
•Pressure Supply: Plan the pneumatic power to OPG1. This requires an air or nitrogen source: See
Section 2.3.1.2. for detailed requirements. 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 (see Section 2.3.1.3).
ALWAYS use external tubing and fittings rated for pressures equal to or greater than the
maximum pressure that OPG1 will be used to generate.
© 1998-2007 DH Instruments, a Fluke Company Page 6

2. INSTALLATION
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
To set up the OPG1 proceed as follows:
nPlace the OPG1 platform on the site table in the proper orientation with the
front panel controls conveniently accessible.
oFill 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).
pLeave tank cover open to allow oil to drain from the DUT connection and air
to escape when venting oil back to tank.
qInstall 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 7).
The drive air supply to these two components may be common on one
connection for both components or two independent connections may be
required depending on the maximum oil pressure to be generated and drive air
pressure supply available (see Section 3.1, Figure 7). The requirements for the
two different components are summarized in Table 2. To determine whether
your application and resources allow a single connection or require two
independent connections, see Table 2 to characterize your application and then
follow the recommendations in Section 2.3.1.2, One or Two Pneumatic Power
Connections?. Finally, follow the instructions in Section 2.3.1.2, Making Two
Independent Pneumatic Power Connections for two independent drive
air connections and Making a Single Pneumatic Power Connection for a single,
common drive air connection.
OPG1 is delivered configured for two independent drive air connections as
described in Section 2.3.1.2, Making Two Independent Pneumatic Power
Connections. This is the recommended configuration.
Page 7 © 1998-2007 DH Instruments, a Fluke Company

OPG1™ OPERATION AND MAINTENANCE MANUAL
Table 2. Pneumatic Power (Drive Air) Requirements
INTERNAL
COMPONENT
DRIVE AIR
PRESSURE NEEDED
MINIMUM
FLOW
LUBRICATION
REQUIRED
CLEANLINESS
CRITICAL
Hydropneumatic
Pump
(Hydraulic output
pressure/400)
+ 100 kPa (15 psi)
50 slm
(1.8 scfm)
*This is fairly
high flow.
No No
PDVV 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)
200 sccm
(< 0.01 scfm)
*This is very
low flow.
No Yes
One or Two Pneumatic Power Connections?
Two pneumatic power connections are needed if:
•The high flow supply available for the hydropneumatic pump is not high enough
in pressure to drive the PDVV for the maximum oil pressure range needed.
•The high flow supply available for the hydropneumatic pump is low quality
shop or factory air that cannot be cleaned well enough to be used to supply
the PDVV and associated control valves.
•The drive air pressure needed for the PDVV, if accidentally supplied to the
hydropneumatic pump, could accidentally cause an overpressure situation
that would be hazardous to the system connected to the OPG1.
OPG1 is delivered set up for two independent pneumatic power connections.
This is the recommended configuration
Generally, when one drive air supply is used, it is “shop” or “plant” air with
relatively high volume flow that is adequate to supply both the
hydropneumatic pump and the PDVV.
When two supplies are used, non-lubricated “shop” or “plant” air with
relatively high volume flow supplies the hydropneumatic pump and a separate
supply of regulated, clean, dry compressed air or nitrogen from a bottle
supplies the PDVV.
Making Two Independent Pneumatic Power Connections
The OPG1, as delivered, is configured for two independent pneumatic
power connections. Make the connections following PDVV DRIVE Pneumatic
Power Connection (Left Side) Requirements and DRIVE Pneumatic Power
Connection (Right Side) Requirements below. Both connections are
1/4 in. NPTF. Use Teflon™tape or an other thread sealant to minimize leakage.
© 1998-2007 DH Instruments, a Fluke Company Page 8

2. INSTALLATION
PDVV DRIVE Pneumatic Power Connection (Left Side) Requirements
When the PDVV DRIVE port is used to provide an independent pressure supply
to the PDVV, since the flow requirements are very low, the supply is usually
regulated Nitrogen or instrument grade air from a compressed air bottle.
•Pressure: 550 to 900 kPa (80 to 130 psi), regulated ±20 kPa (3 psi)
•Must be regulated
•Flow: 200 sccm (< 0.01 scfm)
•NOT lubricated
•Instrument grade N2or air or high quality shop air with filter/dryer installed
upstream (0 °C dew point, 10 micron filter)
OPG1 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.
DRIVE Pneumatic Power Connection (Right Side) Requirements
•Pressure: 550 to 830 kPa (80 to 120 psi), regulated ±30 kPa (5 psi)
•Flow: 50 slm (1.8 scfm) minimum
•NOT lubricated
•Shop air with filter/dryer installed upstream (0 °C dew point, 10 micron filter)
The maximum output pressure of the hydropneumatic pump is the drive air
pressure x 400.
Making a Single Pneumatic Power Connection
This configuration is optional and requires reconfiguring the OPG1 internal
pneumatic connections (see Reconfiguring OPG1 for a Single Pneumatic Power
Connection). OPG1 is delivered set up for two independent pneumatic power
connections as described in Section 2.3.1.2, Making Two Independent
Pneumatic Power Connections.
Once the OPG1 is properly configured for a single pneumatic power connection,
connect the pneumatic pressure source to the 1/4 in. NPT F connection labeled
DRIVE on the right side of the OPG1 housing. Use Teflon™tape or another
thread sealant to minimize leakage.
When using the single DRIVE port to supply drive air to both the
hydropneumatic pump and the PDVV, there is no regulator for the PDVV drive
pressure in the OPG1. Therefore, the source connected to the DRIVE port
must be regulated appropriately to supply the PDVV (see Table 2).
Page 9 © 1998-2007 DH Instruments, a Fluke Company

OPG1™ OPERATION AND MAINTENANCE MANUAL
Single pneumatic power connection air requirements (see Table 2):
•Pressure: 550 to 900 kPa (80 to 130 psi) regulated ± 20 kPa (3 psi)
•Flow: 50 slm (1.8 scfm) minimum
•NOT lubricated
•Filter/dryer installed upstream
OPG1 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.
Reconfiguring OPG1 for a Single Pneumatic Power Connection
Reconfigure OPG1 pneumatic connections using the following procedure:
Close the OPG1 tank cover fully and plug all hydraulic TEST ports.
Place the OPG1 back down on the bench, so that the front panel is straight
up and the open bottom is towards you. Make sure that there is enough oil
in the tank so that the pump draw port remains covered. Fill to just under oil
return tube (see Section 4.2).
Remove cap (5) from DRIVE port tee (7) and set aside.
Disconnect PFA PDVV supply tube (6) from the PDVV DRIVE port filter
connection (4) and reconnect it to the DRIVE port tee (7).
Install cap (5) onto the PDVV Drive port filter connection (4).
Connect recommended pressure to DRIVE port (11) (see Section 2.3.1.2,
Making Single Pneumatic Power Connection). Check all new connections
for leaks using a liquid leak detector. Correct leaks if present.
© 1998-2007 DH Instruments, a Fluke Company Page 10

2. INSTALLATION
SINGLE PNEUMATIC POWER CONNECTION
(OPTIONAL CONFIGURATION)
TWO INDEPENDENT PNEUMATIC POWER CONNECTIONS
(AS DELIVERED)
1. PDVV DRIVE Port (use optional) 5. Cap 9. DRIVE Filter
2. PDVV DRIVE Filter Upstream 6. PFA PDVV Supply Tube 10. DRIVE Filter Upstream
Connection 7. DRIVE Tee PDVV Connection
3. PDVV DRIVE Filter Connection 11. DRIVE Port
4. PDVV DRIVE Filter Downstream 8. DRIVE Filter Downstream
Connection Connection
Figure 4. Configuring Pneumatic Power Connections
2.3.1.3 MAKE HYDRAULIC PRESSURE INTERCONNECTIONS
Connecting to a DHI RPM3 or PG7302 Using Standard OPG1
Interconnection Accessories
OPG1 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 to a DHI RPM3
or PG7302 and operate at pressure up to 200 MPa (30 000 psi). See Figure 5
for the recommended layout and to identify the parts used from the
interconnection kit. These setups assume that the TEST port at the top of the
OPG1 oil tank or an open leg of the tee will be used to connect the DUT. To adapt
to the top test port connection, install one of the DH500 F x 1/8 in. NPT M or
DH500 F x 1/4 in. NPT F adaptors onto one of the 2.75 in. DH500 nipples and
install the nipple into the DH500 F of the top test port.
Page 11 © 1998-2007 DH Instruments, a Fluke Company

OPG1™ OPERATION AND MAINTENANCE MANUAL
6a
6b
88
12a 3
7
1
2b 3
4
5b
4
5a
1. OPG1 5b. 5 in. (127 mm) DH500 1/8 in.
2a. 12 in. (305 mm) DH500 Nipple Tube Weld Nipple (slightly flexible)
2b. 6 in. (152 mm) DH500 Nipple 6a. PG7302
3. DH500 Tee 6b. RPM3
4. DH500 Plug 7. PG Terminal
5a. 2.75 in. (70 mm) DH 500 Nipple 8. TEST Port
Figure 5. Connecting OPG1 to PG7302 or RPM3
Other Hydraulic Pressure Interconnections
OPG1 is delivered with a fittings accessory kit (see Section 2.1.2, Table 1). This kit
is designed to provide a standard connection to a DHI OPG1 or PG7302. It is
configured of standard DH500 fittings and tubing and can be adapted for a
variety of connections to operate up to 200 MPa (30 000 psi).
The welded 1/8 in. tube can be very useful when a small amount of flexibility is
needed to make a connection. Take care not to kink the tube.
The DH500 x 1/4 in. NPT F and DH500 x 1/8 in. NPT M can be used to convert a
DH500 tube to standard NPT connections.
Always use external tubing 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).
© 1998-2007 DH Instruments, a Fluke Company Page 12

2. INSTALLATION
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 8):
nFully back off the DRIVE SET regulator (4).
oClose the TEST INLET valve (5).
pOpen the TEST OUTLET valve (8).
qConnect the drive air pressure to the DRIVE Port (and PDVV DRIVE Port, if used)
(see Section 2.3.1.2). The connections are 1/4 in. NPT F.
rAdjust the external drive air regulator(s) to apply the appropriate level of pressure to the
DRIVE Port (and PDVV DRIVE Port, if used) (see Section 2.3.1.2, Table 2).
2.4.2 ADJUST HYDROPNEUMATIC PUMP DRIVE AIR
PRESSURE
This section assumes that the OPG1 system has already been set up, including pressure
interconnection (see Section 2.3).
OPG1 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 approximate
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 7):
nVerify that there is oil in the tank and verify that all test connections are
plugged or dead ended.
oOpen the OUTLET valve (8) fully.
pOpen the INLET valve (9) fully.
qIf drive pressure has been properly connected and set, pump should begin cycling.
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OPG1™ OPERATION AND MAINTENANCE MANUAL
rObserve tank oil return overflow tube (5). Continue allowing pump to cycle
until bubble free oil flows regularly from the tube. If no oil appears, or
bubbles continue to appear, the internal purging procedure must be used
(see Section 2.4.3.3).
If hydropneumatic pump is filled with air (cavitated), closing inlet valve
will not stop pump from operating. To stop pump, turn AIR DRIVE
regulator (1) fully CCW to stop air flow.
sAfter a successful purge, close the INLET valve (8), then the OUTLET valve
(9) and proceed to STEP TWO (see Section 2.4.3.2) of hydropneumatic
pump operation checkout.
2.4.3.2 STEP TWO: GENERATING A PRESSURE
Before applying pressure to the OPG1 and/or the system connected to it, be
sure that all pressure vessels and connections are rated for the pressure
levels that will be applied and that all connections have been properly
tightened (see Section 2.4.4).
OPG1 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 pump drive air
pressure low enough so that the maximum pump output does not exceed the
maximum pressure rating of the devices to which OPG1 is connected (see
Sections 2.4.2 and 3.2.1).
Proceed as follows (numerical references refer to Section 3.1, Figure 7):
nVerify that there is oil in the tank.
oConnect a high pressure indicating device to one of the OPG1 TEST ports (4, 6,
7). Plug all other TEST ports (4, 6, 7).
There are three TEST ports: One on each lower, rear side and one on the
top in the middle of the tank.
pFully close the OUTLET valve (8).
qSlowly open INLET valve (9).
rThe pump should begin to cycle and the pressure indicated on the high
pressure device should increase. If the pump does not cycle, the drive
pressure is set too low or the pump is not operating correctly. If the
pump cycles but the pressure does not increase:
•the pump is not properly primed (see Section 2.4.3.1);
•there is a leak in the system to which OPG1 is connected or in the
OPG1 itself;
© 1998-2007 DH Instruments, a Fluke Company Page 14