Keller HTP1 User manual

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Hydraulic Hand Pump HTP1

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About this operating manual 23
1 Device description 24
1.1 Intended use 25
1.2 Exclusion of liability 25
2 Safety instructions 26
3 Construction and function 27
3.1 Importantnotesonpressureuctuations 28
4 Purging hydraulic lines 29
5 Handling 30
5.1 Generating pressure 31
5.2 Pressure measurements 33
5.3 Releasing pressure 34
6 Problems 35
7 Maintenance / cleaning, storage and transportation 36
8 Disposal 37
9 Technical data 38
Contents

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● Theoperatingmanualisaimedatspecialistsandsemi-skilledpersonnel.
● Beforeeachstep,readthroughtherelevantadvicecarefullyandkeeptothespe-
ciedorder.
● Thoroughlyreadandunderstandtheinformationinthesection“Safetyinstructions”.
If you have any problems or questions, please contact your supplier or contact us
directly at:
KELLER AG für Druckmesstechnik
St. Gallerstrasse 119
CH-8404 Winterthur
[phone]
[email protected]
www.keller-druck.com
About this operating manual

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The hand pump creates positive pressure
fortheinspection,adjustmentorcalibration
of all kinds of pressure-measuring devices.
The lightweight, compact design makes this
handpump ideal for on-site testing.
The hand pump and the pressure hose have
Minimess®connections. When the hand
pump is used, it needs to be connected to a
reference gauge and to the test item.
Scope of delivery
Check the delivered items:
âHand pump
âPressure hose
âOperation manual
âAccessories
Transportation cases, Minimess®-adapter,
adapter sets and seal sets are optional ac-
cessories.
● Transportationcase:
The transportation case provides optimal
protection for the hand pump and other
accessories with its tight-tting rigid
foam inlay. A document compartment is
located in the lid behind the burl foam
inlay.
● Minimess®Adapter
● Fillingbottle
● Adapterset:
The adapter set comprises 7 adapters for all common pressure connections with or
without pins.
● Sealset:ThesealsetcontainsatsealsmadeofplasticandO-ringsforallcommon
pressure connections.
Reference gauge
VariousreferencemodelsfromKELLER’sproductrangecanbeused.
1 Device description
Pressure hose
Hand pump
Reference Gauge
Hydraulische Handpumpe HTP1
Hydraulic Hand Pump HTP1 Page21
Pompe hydraulique manuelle HTP1 Page41
03/2017

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1.1 Intended use
The HTP1 hand pump can only be used for generating pressure in low-volume
measuring devices. The device is only designed for use with hydraulic oil or deminera-
lized water, other media will result in damage to the hand pump.
The hand pump may not be attached to external pressure sources.
WARNING! No safety component!
The hand pump of the series HTP1 is not safety component in accordance with Direc-
tive 2006-42-EC (Machine Directive).
âNever use the HTP1 as a safety component.
The operational safety of the device supplied is only guaranteed by intended use. Do
NOTexceedthespeciedlimits(➝paragraph9:“Technicaldata”).
CAUTION! Risk of injury or material damage!
By connecting the HTP1, the measuring device is hydraulically connected to the
handpump.Ifthepressurereliefvalveisopened,acompressedmediumcanow
throughthepressurehoseintothehandpump’sstoragecontainer.Atsufcientlylarge
volumes,thereservoirmayoverow.
âNever connect the HTP1 directly to the hydraulic system with large volumes
 (constructionmachines,etc.)oranaggressivemedium(suchasbrakeuid).
Before ordering and installation, check that the hand pump is suitable for your appli-
cations.
1.2 Exclusion of liability
We accept no liability for any damage or malfunctions resulting from incorrect in-
stallation, in-appropriate use of the device or failure to follow the instructions in this
operating manual.
1 Device description

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Before you install the HTP1, read through this operating manual carefully. If the
instructions contained within it are not followed, especially the safety guidelines, this
could result in danger for people, the environment, and the device and the system it
is connected to.
The HTP1 corresponds with state-of-the-art technology. This concerns the accuracy,
the operating mode and the safe operation of the device.
In order to guarantee that the device operates safely, the operator must act compe-
tently and be conscious of safety issues.
KELLER provides support for the use of its products either personally or via relevant
literature. The customer assumes responsibility for any testing to determine applica-
tion suitablility. KELLER is not reponsible for damages due to misuse or application
incompatability.
Qualied personnel
● ThepersonnelwhoarechargedfortheinstallationandoperationoftheHTP1must
holdarelevantqualication.Thiscanbebasedontrainingorrelevantexperience.
The personnel must be aware of this operating manual and have access to it at all
times.
General safety instructions
● In all work, the existing national regulations for accident prevention and safety in the
workplace must be complied with. Any internal regulations of the operator must also
be complied with, even if these are not mentioned in this manual.
● Neverusethehandpumptogetherwithanexternalpressuresource.Donotattach
an external pressure generator to the hand pump.
● Donotusebrakeuidorotheraggressivemedia.
● Do not remove any attached components (test item, pressure hose, reference gauge)
when the hand pump is under pressure:
– Open the pressure relief valve before removing any of the components.
 –DonotuseTeontapetosealthepressureconnections.SurplusTeontapecan
enter the hand pump and damage it.
– Only use adapters and seals that are available as accessories.
– Non-pressurised storage: Only store the hand pump with the pressure relief valve
open. This ensures that no pressure can be built up by unintentional pumping
movements.
– Avoid external force of all kinds towards the hand pump and its operating
elements.
– Do not use the hand pump if it is damaged or defective.
2 Safety instructions

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Special safety instructions
Warningsthatarespecicallyrelevanttoindividualoperatingproceduresoractivities
can be found at the beginning of the relevant sections of this operating manual.
Connections
➀Minimess® connection
pressure hose
➁Connector reference gauge
Operating elements
➂Fineadjustmentvalve(handwheel)
➃Pressure relief valve (rotary knob)
➄Seal reservoir with safety valve
➅Hand grips
Main components
➆Upperandlowerpumpbody
➇Reservoir with suction and
relief outlets
➈Piston rod with
internal spring
➉Pressure hose with
Minimess®connection
Function
Thereferenceandthetestsampleorthepressuredevicetobetested(hereafter“test
sample”)areconnectedtothehandpump.
Pumping is carried out by repeatedly pushing the hand grips together. An internal
spring returns the hand grips to their start position.
The pumping movements are transferred to the pistons in the pump body via the push
rods. The hydraulic liquid is then suctioned from the storage container and pressed
through valves to the test item.
2 Safety instructions
3 Construction and function
➀➁➂
➃
➄
➅
➆
➇
➈
➉
➆
➀➀

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When properly purged, the hand pump will generate positive pressure quickly. The
construction of the hand pump means that the same pressure is generated for the test
item as for the reference test gauge.
Thepressureissettothenecessaryvalueusingtheneadjustmentvalve.Withthe
pressure relief valve, the pressure can be relieved into the reservoir.
For the assessment of the test sample, the pressure displayed on the reference
manometer is compared with the measurement value.
3.1Importantnotesonpressureuctuations
It is completely normal that the pressure is not constant from the start. In the event
of changes to the pressure in the measurement device, it always lasts a few minutes
until the pressure stabilises.
Thisisinuencedbyavarietyoffactors.Themostimportantinuencefactorsare:
● Improperpurging:
If there is still air in the measurement device, the pressure build-up lasts signi-
cantlylonger.Moreover,thereisafall-offinpressureoveralimitedperioddueto
diffusion processes.
● Mechanicalcharacteristicsofthepressurehose:
Bending or rolling up the pressure hose causes a reduction in the volume and thus
leads to an increase in pressure.
At high pressure, the pressure hose extends. Furthermore, enclosed air can be
diffused through the pressure hose. In both cases, a drop in pressure results.
● Temperatureinuence:
Temperature changes lead to a change in volume in the measurement device and
therefore to changes in pressure. The smaller the volume is, the greater the change
in pressure.
● Settlingtimesofreferenceandtestsample:
Observe the required waiting times after the reference and test sample have been
switched on. More information on this can be found in the corresponding operating
manual.
3 Construction and function

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In order for the hand pump to be operated, it is vital that its connections with the refe-
rence gauge and the test item are pressure-resistant.
Furthermore, for the best measurement procedure possible, sufcient and correct
purging of the measurement device is required. Only then can you reduce the pres-
sureuctuation(➝paragraph 3.1) to a minimum.
CAUTION! Material damage!
The test sample, the adapter and the seal must be free from impurities to prevent
damage to the hand pump or hydraulic lines.
Maximum torque of the pressure connections:
Reference: 15 Nm
Test item: 15 Nm
Carry out the following steps* for the purging air from the hydraulic lines of the hand
pump.Forthis,notealsothewarningsinsectionparagraph5.1“Generatingpressure”.
â Fill the storage container to approximately two-thirds capacity with the required
 hydraulicuid.
âOpen the pressure relief valve by turning counter clockwise.
âTurnthereferencemanometerwithmatchingsealinthehandpump’sconnection
(G1/4).
IMPORTANT! Do not tighten the reference yet!
âCarefully pump until the hydraulic liquid escapes at the connection and the piston
system has been ventilated.
âOnly then should you tighten the reference.
âPump 5…10 times to prime the hydraulic lines.
âTurnthepressurereliefvalvecounterclockwiseuntilitisrmlyclosedt.
âConnect the pressure hose to the hand pump’s Minimess®connection, and
tighten the connection.
âTightly screw the Minimess®adapter on the pressure hose.
âSelectthesuitableadaptersandsealsforthetestitem’sconnection.
âScrew the adapter for the test sample onto the Minimess®adapter.
âTurn the test sample with seal in the adapter.
IMPORTANT! Do not yet tighten the test item!
âNowpumpuntilthehydraulicliquidescapesatthetestsample’sconnection.The
pressure hose and the test sample connection are now ventilated.
4 Purging hydraulic lines

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CAUTION! Demineralized water!
During the quality inspection of the HTP1, a functional test is carried out with demine-
ralised water. The reservoir may therefore contain residues of this liquid.
âCheck the compatibility with your application and remove the residue using appro-
priate measures (e.g. rinsing out with the hydraulic liquid).
* Therststepsupto“Tighteningofthereference”areonlyrequiredfortherstcommissioningorduringremovalofthe
reference.
4 Purging hydraulic lines
Adhere to the following safety instructions when operating the hand pump:
CAUTION! Crushing hazard!
Duringthepumpingprocedureensurethatngersorotherbodypartsarekeptaway
from the area between the hand grips and the piston rod.
CAUTION! Material damage to valve stop!
If put under too much strain the stop and the hand pump will be damaged.
âOnlycontinuetotightenthevalves(theneadjustmentandpressurereliefvalves)
by hand, once the stop has been reached.
Before creating pressure consider
Before you create pressure with the hand pump you should check for the following
requirements:
– The reference gauge is connected to the hand pump.
–Thetestitemisjoinedtothepressurehosewiththecorrectadaptersandseals.
– All pressure connections are correctly in place, so that they resist pressure.
– The hand pump, the pressure hose and the test sample have been properly venti-
lated (➝paragraph 4) .
5 Handling