HPICAL Operation & Data Logging Procedures. Click spacebar to advance through slides 1
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1 HPICAL Operation & Data Logging Procedures Click spacebar to advance through slides 1
2 WARNING Always wear proper safety equipment when using high pressure equipment. Do not exceed 125 psi air pressure. Never exceed the maximum pressure rating of the gauge being tested. Be sure pressures on air and water systems are relieved before disconnecting any hoses or fittings. Pressurization of any materials is dangerous follow all OSHA procedures for stored energy and pressurization precautions pertaining to the fluids used. Read and understand all instructions before performing a test/calibration. 2
3 Control & Feature Overview Air Regulator System Pressure & Data Logging Gauge Auxiliary Test Port Pressure Adjust Valve Air On-Off Valve Bleed Valve Water On-Off Valve Main Test Port Air Pressure Gauge 3
4 Before introducing air or water to the system, turn air and water valves to OFF Rotate Air Regulator Knob Counter Clock-wise to Off = Open Position Turn Both Air and Water Valves Clock-wise to Off Position 4
5 Water, Air and Power Connections Connect Air Line Here (3/8 NPT)* 90 PSI Air Supply Required No lubrication is required, and should be avoided Plug gauge AC adapter into power strip Connect Water Line Here (1/2 NPT)* Clean water supply required at normal street pressure. NOTE: System contains a 40 micron in-line strainer (PC-1039), which can be replaced as necessary. Connect to a drain if desired, or use supplied drain bottle** *NPT fittings should be installed with Teflon (PTFE) tape. Use 1 ½ - 2 wraps of tape, then tighten 1 ½ - 3 turns past hand tight. **If using the supplied drain bottle, be sure to empty it periodically Plug AC cord into standard 120V outlet 5
6 Additel Digital Logger Gauge Overview PEAK Button POWER Button ZERO Button ANALOGUE DIAL Button UNITS Button BACKLIGHT Button 6
7 Setting Date and Time 1. Press Power button to turn on gauge. 2. Press and hold the PEAK button to enter main menu. 3. Press the ZERO button to enter Logging menu (Option 1). 4. Press the ZERO button again to enter date and time settings (option 1). 5. Press the ZERO button again to begin setting year. 6. Press the UNITS, PEAK and BACKLIGHT buttons to change the year, month, day and time. 7. When all are set correctly, press the ZERO button to accept the changes. 8. Press the POWER button to escape to the main screen. 9. NOTE: If the gauge loses power (unplugged from AC power), the date and time will reset to the factory set date and time, and must be re-set. 7
8 Connecting to Remote Device Using Main Test Port Remove Adapter Cap (PC-1032) from Main Test Port Adapter (PC-1029) and store safely. Attach green Test Hose (PC-1019) to Main Test Port Adapter (PC-1029) and tighten firmly. Test Hose (PC-1019) Main Test Port Adapter (PC-1029) Adapter Cap (PC-1032) Install Auxiliary Test Port Plug (PC-1031) and Gland Nut (PC ) into Auxiliary Test Port and tighten firmly. Gland Nut (PC ) Auxiliary Test Port Plug (PC-1031) 8
9 Connecting to Remote Device Using Main Test Port (Cont d) Be sure Isolation Valve (if present) is fully closed. Install appropriate adapter for Test Hose to remote device being tested and attach Test Hose (PC-1019).* (HPIC D unit shown being tested for reference.) *The Test Hose (PC-1019) has standard 9/16 -M hose fittings at each end. A ½ NPT male to 9/16 -M Adapter (PC-1030) is supplied. Other adapters are available upon request. NPT fittings should be installed with Teflon (PTFE) tape. Use 1 ½ - 2 wraps of tape, then tighten 1 ½ - 3 turns past hand tight. ½ NPT to 9/16-M Adapter (PC-1030) 9
10 Connecting to Gauge Using Auxiliary Test Port Remove Auxiliary Test Port Plug (PC-1031) and Gland Nut (PC ) from Auxiliary Test Port and store safely. Install appropriate adapter for the gauge being tested.* Main Test Port Adapter (PC-1029) NOTE: A ¼ NPT Female Adapter* (PC /4NPT) is supplied. Other adapters are available upon request. Remove Test Hose (PC-1019) from Main Test Port and store safely. Install Adapter Cap (PC-1032) onto Main Test Port Adapter (PC-1029) and tighten firmly. Install gauge to be tested. Adapter Cap (PC-1032) *NPT fittings should be installed with Teflon (PTFE) tape. Use 1 ½ - 2 wraps of tape, then tighten 1 ½ - 3 turns past hand tight. 10
11 Bleeding the System When Testing a Gauge directly Using the Auxiliary Test Port Be sure the Pressure Adjust Valve is backed all the way off (counter clockwise) 1. Open the Bleed Valve (only 1/4-1/2 of a turn is necessary) 2. Zero the Calibration Station gauge (Press and hold ZERO for 3 seconds) 3. Zero the gauge being tested (if applicable) 4. DATA LOGGING should be started now (see page 14) 5. Turn the Water Valve to the ON position 6. Let the water run through the system for about 5-10 seconds, until full. 7. Close the Bleed Valve firmly 8. Open the Bleed valve again and repeat steps 6 &7 to ensure all air is removed from the system 11
12 Bleeding the System When Testing a Remote Device Using the Main Test Port Be sure the Pressure Adjust Valve is backed all the way off (counter clockwise) 1. Open the Bleed Valve (1/4-1/2 turn) on the Calibration Station 2. Open the Bleed Valve on the device being tested 3. Zero the Calibration Station gauge (Press and hold ZERO for 3 seconds) 4. Zero the gauge being tested (if applicable) 5. DATA LOGGING can also be started now (see page 14) 6. Turn the Water Valve to the ON position 7. Let the water run through the system for 5-10 seconds, until full 8. Close the Bleed Valve firmly on the device being tested 9. Close the Bleed Valve firmly on the Calibration Station 10. Open both Bleed Valves again and repeat steps 7,8 & 9 to ensure all air is removed from the system (HPIC-1000-D unit shown for reference) 12
13 Building Pressure 1. Follow all previous instructions on connecting air and water inputs, connecting a gauge directly or a remote device and bleeding the system. 2. Be sure the regulator is backed all the way off (counter clockwise) 3. Turn the Air Valve to the ON position 4. SLOWLY turn the air regulator clockwise to increase the system pressure 5. Increase the pressure slowly until it reaches PSI BELOW the desired test pressure 6. Back the regulator off COMPLETELY (counter clockwise) NOTE: this will cause the system pressure to drop slightly due to the check valves seating 7. Turn the Pressure Adjust Valve clockwise to raise the pressure to the exact desired test pressure 8. Turn the Pressure Adjust Valve counter clockwise to reduce pressure 9. To relieve system pressure: Back the Pressure Adjust Valve all the way out (counterclockwise), then open Bleed Valve slightly to relieve pressure. Close Bleed Valve firmly and repeat steps 4 8 to build pressure to next desired test pressure. 10. When testing is complete, back Pressure Adjust Valve all the way out (counter clockwise) Turn air and water valves to the OFF position and open bleed valve(s) to relieve system pressure 13
14 General Data Logging Instructions 1. Press and hold the PEAK button to reach the main menu. 2. Press the ZERO button to enter Logging menu (Option 1). 3. Press the BACKLIGHT button to scroll down to the GAP setting (Option 5). The GAP is the time interval between readings recorded by the gauge. The default GAP is 1 second. If a different GAP is desired, it must be set every time a new session is started by following steps Press the UNITS button to move over until the correct digit is flashing. 5. Press the PEAK and BACKLIGHT buttons to move the interval up or down. 6. Press the ZERO button to accept your set interval. 7. Press the BACKLIGHT button to scroll down to the OFF setting (Option 6). If LOGGING is active, this option will read ON 8. Press the ZERO button to turn on Logging. (At this point the % should be flashing to indicate Logging is active) 9. Press the POWER button twice to escape to the main screen. 10. To turn off Logging, repeat steps 1,2,7 and 8. 14
15 Inspection vs. Calibration Inspection is performed to verify that the gauge is working properly and is within the accuracy percentage range. In the case of the Ashcroft gauge in the HPIC D, the accuracy is ±0.25% of full scale, or ±25 PSI. Calibration is performed if the tested gauge is outside of its specified range (verified by the Calibration Station). 15
16 General Gauge Inspection Procedure Follow instructions for attaching a device or gauge to the Calibration Station (see pages 8-10). Follow instructions for bleeding the system (see pages 11 & 12). Build the system pressure to half of the full range of the gauge (5000 PSI for a PSI gauge) following the Building Pressure instructions (see page 13). Compare the pressure on device or gauge being tested to the gauge on the Calibration station. If it is within the manufacturer s intended accuracy percentage range, it does not need to be calibrated. If the gauge is not within range, it will need to be calibrated according to the manufacturer s instructions. 16
17 General Gauge Calibration Procedure Follow instructions for attaching a device or gauge to the Calibration Station (see pages 8-10). Follows instructions for bleeding the system (see pages 11 & 12). Be sure DATA LOGGING is active (flashing % on Additel gauge; see page 14). Follow the manufacturer s instructions for calibration of the gauge. See the following slides for instructions on calibrating the Ashcroft gauge standard in the HPIC D. After calibration is complete the DATA LOGGING can be turned off (see page 14). Turn Air and Water valves to the OFF positions. Be sure regulator is backed all the way off (counterclockwise). Open the Bleed Valve and relieve the system of all pressure At this point the data obtained can be uploaded to the laptop supplied using the Additel/Land software and used to create a calibration report (see pages 24-28). 17
18 Ashcroft Gauge Calibration ON/OFF ZERO/CLEAR MENU ENTER ARROW DOWN ARROW UP 18
19 HPIC D Unit/Ashcroft Gauge Calibration- Step 1 1. Press the MENU button 2. Press the (up arrow key) or (down arrow key) on the keypad until the word CONFIG appears. 3. Press ENTER 19
20 Ashcroft Gage Calibration- Step 2 4. Enter user password if it has been programmed. 5. Press (up arrow key) or (down arrow key) until the word RECAL appears. 6. Press ENTER. 7. The gauge will show 0 on the top line and flash between INPUT and unit of measure on the lower line. Apply zero pressure to the gauge. 8. Press ENTER. Zero pressure is now set. 20
21 Ashcroft Gage Calibration- Step 3 9. The gauge will display full-scale pressure (10000 PSI). Apply full-scale pressure to the gauge. (see page 13) 10. Press ENTER. Full-scale pressure is now set. 11. The gauge will now display mid-scale pressure (5000 PSI). Apply mid-scale pressure to the gauge. (see page 13) 12. Press ENTER. Mid-scale pressure is now set. 21
22 Ashcroft Gage Calibration - Finish After zero, full-scale and mid-scale calibration have been set, the word SAVE appears on the gauge display. Press ENTER to finalize calibration. 22
23 General System Shutdown Procedure After all desired tests have been performed: Be sure Data Logging is turned off. (no flashing %) Turn Air and Water valves OFF. Be sure regulator is backed all the way off (counter clockwise). Open the Bleed Valve to relieve the system of all pressure. 23
24 Uploading Data to Laptop 1. Connect the gauge to the USB port using the included adapter cable. 2. Open the Additel/Land software on the laptop. 3. Click the scan button to search for the gauge. 4. Click on the gauge when it appears. 5. Click the DATA LOGGING button to access the data 6. Select desired units for pressure and temperature. 7. Click UPLOAD. 24
25 Exporting Data The data that has been uploaded can now be viewed in a graph in the Additel/Land software or exported to an Excel Spreadsheet. The only way to save the data is to export it to Excel. To do this, simply click the export button. You will be prompted to save the file. After saving, the file will automatically open in Excel. Do not close the Additel/Land window. 25
26 Creating a Certificate of Calibration Open the Certificate of Calibration Template. Only certain fields in this file can be edited. Input the Additel gauge serial number, your name, and the model and serial number of the gauge/device being tested. 26
27 Certificate Continued Go back to the exported Excel sheet and copy the points at 0 PSI, PSI and 5000 PSI as shown. Go back to the Certificate and click on the first cell under Results. Paste the values using Cntrl+C. The graph will automatically update to the values pasted. You can now print and SAVE AS. 27
28 Deleting Data on Gauge After all data is exported AND SAVED, the data can now be deleted from the gauge. Go back to the Additel/Land window. Click the Delete button. Input the password (211) for the Additel gauge and select OK. You can now start another logging session. 28
29 If there are any questions, concerns or comments do not hesitate to contact: HPI Manufacturing, Inc. (203)
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