K2SS lssue No.

1
Druck PV 411
Pneumatlc/Hydraullc Hand-pump
User Manual
Druck Llmlted 2000
This documenl is lhe properl, of Druck Limiled and ma, nol be copied or olherwise repro-
duced, communicaled in an, wa, lo lhird parlies, nor slored in an, Dala Processing S,slem
wilhoul lhe express wrillen aulhorisalion of Druck Limiled.
Druck PV 411 User Manual
Page l K2SS lssue No. 1
lntroductlon
This lechnica| manua| provides operaling inslruclions for lhe PV 4!!
Pneumalic/h,drau|ic hand-pump compalib|e wilh lhe requiremenls
of |ine operalion.
Safety
The manufaclurer has designed lhis equipmenl lo be safe when
operaled using lhe procedures delai|ed in lhis manua|. The user
musl nol use lhis equipmenl for an, olher purpose lhan lhal slaled.
On|, use h,drau|ic f|uids slaled in lhe specificalion.
This manua| conlains safel, and operaling inslruclions which musl
be fo||owed lo make sure of safe operalion and lo keep lhe
equipmenl in a safe condilion. The safel, inslruclions are eilher
warnings or caulions issued lo prolecl lhe user and lhe equipmenl
from injur, or damage. Use suilab|, qua|ified personne| and good
engineering praclice for a|| procedures in lhis manua|.
Pressure
Do nol app|, pressure grealer lhan lhe safe working pressure
slaled in lhe specificalion.
Technlcal advlce
For lechnica| advice conlacl lhe manufaclurer or subsidiar,.
+-
This producl meels lhe essenlia| requiremenls of lhe re|evanl
EEC direclives.
Druck PV 411 User Manual
K2SS lssue No. 1 Page ll
ABBREVlATlONS
The fo||owing abbrevialions are used in lhis pub|icalion.
Noze
Abbrevia:ions are :he sane in :he singu|ar and p|ura|.
C degrees Ce|sius
BSP Brilish slandard pipe lhread
cm cenlimelre
F degrees Fahrenheil
inHg inches of mercur,
|bs pounds
SO nlernaliona| Slandards Organisalion
kg ki|ogram
m melre
mbar mi||ibar
mm mi||imelre
mmH
2
O mi||imelres of waler
NPT Naliona| pipe lhread
PFV pressure re|ief va|ve
psi pounds per square inch
PTFE po|,lelraf|ouroelh,|ene
SAE Sociel, of Aulomolive Engineers
UUT Unil under lesl
Symbols
The fo||owing s,mbo|s mark lhis equipmenl:
Fead lhe manua| before use.
Fefer lo lhe manua|.
Druck PV 411 User Manual
Page lll K2SS lssue No. 1
CONTENTS
Til|e page
nlroduclion ............................................................................................... !
Pneumalic pump .................................................................................... !
H,drau|ic pump ...................................................................................... !
Specificalion ........................................................................................... 3
Operalion ............................................................................................... 4
Pressure/vacuum configuralion ............................................................. 4
Connecling lhe pump ....................................................................... 5
Se|eclor va|ve ................................................................................... 5
Scissor-aclion hand|es |imil adjusler ................................................ 6
Pneumalic Operalion ........................................................................................ 7
Vo|ume adjusler ................................................................................ 7
Ceneraling pneumalic pressure and vacuum................................... 3
Pressure ............................................................................................ 3
Vacuum ............................................................................................. 3
H,drau|ic Operalion ........................................................................................ !0
F|uid reservoir ....................................................................................... !0
Filling......................................................................................... !2
Fi||ing ......................................................................................... !2
Priming lhe s,slem .............................................................................. !3
Vacuum priming......................................................................... !3
Pre-fi||ing .................................................................................... !4
Selling pressure re|ief va|ve ................................................................ !4
Ceneraling h,drau|ic pressure ............................................................. !5
u|limedia ........................................................................................... !6
F|ushing ..................................................................................... !6
Fau|l finding.......................................................................................... !7
Approved service agenls ..................................................................... !3
Annex A
Felurned Coods Procedure ................................................................. !9
lLLUSTRATlONS
Figure lil|e page
! Cenera| view ............................................................................... 2
2 Filling lhe reservoir ................................................................... !!
Druck PV 411 User Manual
Page 1 K2SS lssue No. 1
lntroductlon
The PV 4!! hand-pump generales eilher pneumalic pressure and
vacuum or h,drau|ic pressure. The scissor-aclion hand|es provide
pneumalic pressure and vacuum generalion and, in lhe h,drau|ic
mode, provides h,drau|ic pressure generalion for s,slem priming.
Pneumatlc pump (Flgure 1)
A se|eclor va|ve venls lhe s,slem, lo almosphere, belween
se|eclions of pressure and vacuum. Operaling lhe scissor-aclion
hand|es provides lhe pumping slroke, for pressure generalion.
A vo|ume adjusler a||ows sma|| adjuslmenls of lhe s,slem
pressure.
Hydraullc pump (Flgure 1)
The se|eclor va|ve venls lhe s,slem, lo lhe reservoir, belween
se|eclions of pressure and vacuum (used in lhe priming process.
The vo|ume adjusler generales lhe required s,slem pressure. A
f|uid reservoir, screwed inlo lhe in|el porl on lhe lop of lhe hand-
pump comp|eles lhe h,drau|ic circuil. A pressure re|ief va|ve can
be sel lo |imil maximum pressure belween 30 lo 700 bar.
Druck PV 411 User Manual
K2SS lssue No. 1 Page 2
Flgure 1, General vlew
Druck PV 411 User Manual
Page 3 K2SS lssue No. 1
Speclflcatlon
Pressure range
Pneumalic ......................................................................... 0 lo 60 bar
Vacuum .................................................................. 0 lo -0.95 bar
H,drau|ic ....................................................................... 0 lo 700 bar
aximum safe working pressure ........................................... 700 bar
H,drau|ic f|uid .................................................. Deminera|ised waler
or minera|-based oi|s
H,drau|ic f|uids musl be compalib|e wilh:
Slain|ess slee|, anodised a|uminium, nilri|e rubber,
PTFE, po|,prop,|ene, de|rin, acr,|ic and n,|on.
Pressure conneclions: ................................. !/4" BSP para||e| fema|e
veighl (approximale: .............................................................. !.! kg
Dimensions
Lenglh ............................................................................ 260 mm
vidlh ............................................................................ !35 mm
Deplh .............................................................................. 95 mm
This va|ue assumes almospheric pressure al ! bar and wi|| var,
depending on almospheric pressure.
Druck PV 411 User Manual
K2SS lssue No. 1 Page 4
Operatlon
WARNlNGS
1 BEFORE APPLYlNG PRESSURE, MAKE SURE ALL CONNECTlONS
ARE CORRECT AND EOUlPMENT lS lNTERNALLY CLEAN AND
FREE FROM DAMAGE.
2 MAKE SURE THAT ALL EOUlPMENT lS TO THE CORRECT
PRESSURE RATlNG.
3 DO NOT EXCEED THE MAXlMUM OPERATlNG PRESSURE
STATED lN THE SPEClFlCATlON.
4 OBSERVE THE RELEVANT HEALTH AND SAFETY PRECAUTlONS.
Noze
vherever possib|e, use o-ring sea|s in :he connec:ion por:s
:his is :he reconnended ne:hod o! sea|ing.
Pressure/vacuum Conflguratlon (Flgure 1)
n pressure mode, air/f|uid is drawn in lhrough lhe in|el porl on lhe
lop of lhe pump and forced oul lhrough lhe lwo oul|el porls.
n vacuum mode, lhe air/f|uid f|ow is reversed as air/f|uid is drawn
in lhrough lhe lop and rear oul|el porls and expe||ed lhrough lhe
in|el porl.
Druck PV 411 User Manual
Page S K2SS lssue No. 1
Connectlng the Pump
Conneclions can be made lo lhe pump eilher direcl|, or using lhe
range of adaplors supp|ied in lhe opliona| lesl kil.
Drecz
The porls can be filled wilh an, suilab|e |englh !/4 BSP ma|e
conneclor, sea|ing eilher wilh an o-ring al lhe bollom of lhe porl or
a bonded sea| al lhe lop. Fil a suilab|e b|anking p|ug lo an unused
porl.
SwveI Adapzors
The sing|e, !/4 BSP, swive| adaplor connecls wilh a range of fixed
adaplors. Using lhe knur|ed grip-fealure, hand-lighlen (c|ockwise
lhe swive| adaplor, unli| il is fu||, inserled.
SwveI pump head
The pump head swive|s lhrough !40 providing oplimum viewing
ang|e and bench-lop operalion. P|acing lhe pump on lhe bench
a||ows grealer force lo be app|ied lo lhe scissor-aclion hand|es.
nlerna| slops prevenl furlher rolalion of lhe pump head.
Noze
Do no: use excessive !orce vhen ro:a:ing :he punp head.
Selector Valve
Pressure
Turn lhe se|eclor va|ve fu||, c|ockwise (in posilion.
Vacuum
Turn lhe se|eclor va|ve fu||, anli-c|ockwise (oul posilion.
Druck PV 411 User Manual
K2SS lssue No. 1 Page S
Venz
S|ow|, lurn lhe se|eclor va|ve lo lhe cenlre posilion.
CAUTlON:
AVOlD DAMAGlNG THE lNSTRUMENT UNDER TEST BY USlNG THE
VOLUME ADJUSTER TO RELEASE HYDRAULlC PRESSURE.
Sclssor-actlon Handles Llmlt Adjuster
Turning lhe adjusler anli-c|ockwise reduces lhe slroke, lurning lhe
|imil adjusler c|ockwise increases lhe slroke.
For maximum pneumalic pressure generalion, lurn lhe |imil
adjusler fu||, c|ockwise.
Druck PV 411 User Manual
Page 7 K2SS lssue No. 1
Pneumatlc Operatlon
Volume Adjuster
The vo|ume adjusler can be used in differenl modes:
Low pressure
vilh lhe se|eclor va|ve sel lo venl (open, lurn lhe vo|ume adjusler
fu||, anli-c|ockwise (oul.
Turn lhe se|eclor va|ve lo lhe fu||, c|ockwise (in posilion lo se|ecl
pressure.
Turn lhe vo|ume adjusler c|ockwise lo generale pressure.
Hgh pressure
Turn lhe vo|ume adjusler lo lhe mid-posilion. n lhis posilion fine
adjuslmenls of lhe generaled pressure can be made. Using lhe
scissor-aclion hand|es, generale lhe approximale pressure, lhen
lurn lhe vo|ume adjusler c|ockwise (in lo increase lhe pressure or
lurn lhe vo|ume adjusler anli-c|ockwise (oul lo decrease lhe
pressure.
Vacuum
Turn lhe se|eclor va|ve fu||, anli-c|ockwise (oul posilion.
Turn lhe vo|ume adjusler lo lhe mid-posilion. n lhis posilion fine
adjuslmenls of lhe generaled vacuum can be made.
Using lhe scissor-aclion hand|es, generale lhe approximale
vacuum, lhen lurn lhe vo|ume adjusler c|ockwise (in lo decrease
lhe vacuum or lurn lhe vo|ume adjusler anli-c|ockwise (oul lo
increase lhe vacuum.
For |ow vacuum use lhe vo|ume adjusler on|,.
Druck PV 411 User Manual
K2SS lssue No. 1 Page S
Generatlng pneumatlc pressure and vacuum
Connecl lhe pump as delai|ed on page 5.
Nozes
Conpressing a gas genera:es hea:. Gas hea:ed or coo|ed in
an enc|osed vo|une causes a pressure change. : is
inpor:an: :o a||ov enough :ine !or :he hea:ed gas :o coo| and
:he pressure :o s:abi|ize.
The nunber o! punps required :o genera:e a pressure
depends on :he vo|une o! :he s,s:en. There!ore, keep :he
s,s:en vo|une :o a nininun.
Pressure
! Turn lhe se|eclor va|ve fu||, c|ockwise (in posilion.
2 Operale lhe scissor-aclion hand|es lo generale lhe
approximale pressure, a||ow lime for lherma| slabi|izalion.
3 f necessar,, use lhe vo|ume adjusler lo adjusl lhe required
pressure.
4 Afler allaining lhe required pressure operale lhe scissor-
aclion hand|es lo generale a higher pressure. A|lernalive|,, venl
lhe pressure lo almosphere b, s|ow|, lurning (anli-c|ockwise lhe
se|eclor va|ve lo lhe cenlre posilion.
Vacuum
! Turn lhe se|eclor va|ve fu||, anli-c|ockwise (oul posilion.
2 Operale lhe scissor-aclion hand|es lo generale lhe
approximale vacuum, a||ow lime for lherma| slabi|izalion.
3 f necessar,, use lhe vo|ume adjusler lo adjusl lhe required
vacuum.
Druck PV 411 User Manual
Page 9 K2SS lssue No. 1
4 Afler allaining lhe required vacuum operale lhe scissor-aclion
hand|es lo generale a higher vacuum. A|lernalive|,, venl
almosphere inlo lhe vacuum b, s|ow|, lurning (anli-c|ockwise lhe
se|eclor va|ve lo lhe cenlre posilion.
Afler comp|elion, depressurize lhe pump and disconnecl from lhe
pipes and equipmenl.
Druck PV 411 User Manual
K2SS lssue No. 1 Page 10
Hydraullc Operatlon
CAUTlONS
DO NOT MlX HYDRAULlC FLUlDS.
ONLY USE COMPATlBLE FLUlDS, REFER TO THE SPEClFlCATlON.
ONLY FlT APPROPRlATE SEALS ON CONNECTlONS.
OBSERVE ABSOLUTE CLEANLlNESS WHEN USlNG THlS PUMP. DAMAGE
CAN BE CAUSED lF EOUlPMENT CONNECTED TO THlS PUMP lS
CONTAMlNATED. AVOlD PARTlCULATE CONTAMlNATlON.
Noze
vherever possib|e, use o-ring sea|s in :he connec:ion por:s,
:his is :he reconnended ne:hod o! sea|ing.
Fluld Reservolr (Flgure 2)
The main bod, of lhe reservoir is lransparenl acr,|ic providing a
c|ear view of lhe conlenls.
The reservoir can be removed from lhe pump wilhoul lhe need lo
empl, lhe f|uid, a se|f-sea|ing conneclion prevenls |eakage. The
spring-|oaded lop cover sea|s under almospheric pressure
condilions, bul venls excess inlerna| pressure harm|ess|, in lhe
evenl of inadverlenl pressurizalion.
The reservoir, connecls lo lhe in|el porl on lhe lop of lhe pump and
supp|ies f|uid lo lhe pump s,slem for pressure generalion.
n vacuum mode, used in priming, lhe f|uid f|ow is reversed, f|uid is
drawn from lhe lwo oul|el porls and lhrough lo lhe in|el porl and
lhe reservoir.
Druck PV 411 User Manual
Page 11 K2SS lssue No. 1
Flgure 2, Flttlng the Reservolr
Druck PV 411 User Manual
K2SS lssue No. 1 Page 12
Fzzng
ake sure lhal lhe correcl o-ring sea| is filled lo lhe in|el porl lo
prevenl |eakage. Screw lhe reservoir (c|ockwise inlo lhe in|el porl.
Noze:
Deninera|ised va:er is used :o :es: :he punp a:
nanu!ac:ure. Cn shipnen:, :here vi|| be :races o!
deninera|ised va:er in :he s,s:en.
FIIng
Unscrew lhe reservoir cover |ock nul and remove lhe reservoir
cover.
Using c|ean, recommended f|uid fi|| lhe reservoir lo approximale|,
2/3 fu||.
Fefil lhe reservoir cover and re-lighlen lhe reservoir cover |ock nul.
Connecl lhe required pipes and equipmenl lo lhe oul|el porls.
Druck PV 411 User Manual
Page 13 K2SS lssue No. 1
Prlmlng the system
There are lwo melhods: vacuum priming lo exlracl lhe air or pre-
fi||ing lhe s,slem.
Nozes:
1 ! air renains in :he s,s:en, !u|| pressure canno: be
achieved as :he air in :he !|uid conpresses. Air nus: be
renoved !ron :he s,s:en !|uid.
2 Bo:h prining ne:hods require :he punp :o be he|d in
:he ver:ica| posi:ion :o keep :he reservoir b|eed ho|e in !|uid.
Do no: a||ov air :o en:er :he s,s:en :hrough :his b|eed ho|e.
Vacuum prmng (Fgure 2)
Connecl lhe equipmenl as delai|ed on page 5.
Air can be removed using lhe vacuum faci|il, on lhe pump.
Noze:
This ne:hod shou|d no: be used vi:h vacuun-sensi:ive
equipnen:.
Turn se|eclor va|ve fu||, oul, anli-c|ockwise (vacuum posilion.
Pump unli| bubb|es slop appearing in lhe reservoir, (lhis generales
a vacuum in lhe s,slem.
Turn lhe se|eclor va|ve fu||, in, (lhis aclion re|eases lhe vacuum and
rapid|, fi||s lhe s,slem wilh f|uid from lhe reservoir.
The pump and connecled s,slem is read, for use.
Druck PV 411 User Manual
K2SS lssue No. 1 Page 14
Pre-IIIng
Connecl lhe equipmenl as delai|ed on page 5.
Turn lhe se|eclor va|ve fu||, c|ockwise (in posilion.
Loosen lhe reservoir cover |ock nul lo open lhe reservoir cover and
|el almospheric pressure inlo lhe lop of lhe reservoir.
Open lhe b|eed va|ve on lhe UUT.
Carefu||, operale lhe scissor-aclion hand|es lo fi|| lhe s,slem. Slop
pumping when f|uid comes oul of lhe b|eed va|ve.
C|ose lhe b|eed va|ve on lhe UUT.
f necessar,, lop-up lhe reservoir lo lhe 2/3 |eve| wilh c|ean f|uid.
Secure lhe reservoir cover b, lighlening lhe reservoir cover |ock nul.
The pump and connecled s,slem is read, for use.
Settlng Pressure Rellef Valve (Flgure 1)
The pressure re|ief va|ve (PFV can be sel al pressures from 30 lo
700 bar.
f lhe s,slem pressure exceeds lhe sel pressure, lhe PFV opens
and venls f|uid lhrough lhe in|el porl lo lhe reservoir. vhen lhe
pressure decreases, lhe PFV c|oses.
To sel lhe PFV, |oosen lhe PFV |ocking screw
and lurn lhe PFV lo re|ease al lhe required
pressure.
Ho|d lhe PFV and lurn lhe co||ar fu||,
anli-c|ockwise.
Tighlen lhe PFV |ocking screw.
Druck PV 411 User Manual
Page 1S K2SS lssue No. 1
Generatlng Hydraullc Pressure
Noze
Pressurizing a !|uid genera:es hea:. A !|uid hea:ed or coo|ed
in an enc|osed vo|une causes a pressure change. A||ov
enough :ine :herna||, s:abi|ize.
Open lhe se|eclor va|ve anli-c|ockwise ! lurn.
Screw lhe vo|ume adjusler fu||, oul (anli-c|ockwise.
C|ose lhe se|eclor va|ve.
Use lhe scissor-aclion hand|es lo generale lhe inilia| pressure.
Then lurn lhe vo|ume adjusler c|ockwise lo generale lhe required
pressure, a||ow lime for lherma| slabi|izalion.
To reduce lhe pressure, lurn lhe vo|ume adjusler oul (anli-
c|ockwise lo lhe required pressure.
Afler comp|elion, lurn lhe vo|ume adjusler fu||, oul (anli-c|ockwise
and lurn lhe se|eclor va|ve lo depressurize lhe pump. Disconnecl
from lhe pipes and equipmenl.
Druck PV 411 User Manual
K2SS lssue No. 1 Page 1S
Multlmedla
Changing from f|uid lo gas:
Turn lhe vo|ume adjusler fu||, c|ockwise (in.
Use lhe vacuum se|eclion, operale lhe scissor-aclion hand|es lo
draw f|uid inlo lhe reservoir.
Depressurize lhe pump.
Unscrew and remove lhe reservoir.
nverl lhe pump and, using lhe vacuum se|eclion, operale lhe
scissor-aclion hand|es lo draw residua| f|uid oul lhrough lhe in|el
porl.
WARNlNG:
WHEN OUTLET PORTS ARE OPEN AND WlTH THE SELECTOR
VALVE SET TO PRESSURE, OPERATlNG THE SClSSOR-ACTlON
HANDLES RAPlDLY EXPELS FLUlD.
Pneumalic venling, afler f|uid use, can generale a f|uid misl spra,
oul of lhe in|el porl.
FIushng
f necessar,, use soap, waler lo remove an, oi| residue.
Druck PV 411 User Manual
Page 17 K2SS lssue No. 1
Fault Flndlng
f s,slem pressure reduces, check lhe fo||owing:
!. Check lhe se|eclor va|ve is in lhe correcl posilion and proper|,
lighlened.
2. A||ow sufficienl lime afler pressure generalion for lhe
lemperalure lo slabi|ize.
3. Check lhe adaplors, f|exib|e pipe and conneclions belween
lhe pump and equipmenl under lesl for |eaks. Tighlen an, |oose
joinls and rep|ace an, sea|s lhal are worn or damaged.
4. n h,drau|ic mode, if lhe vo|ume adjusler can be wound fu||,
in, bul maximum pressure cannol be achieved, lhere is probab|, air
lrapped in lhe s,slem. Fe-prime, and repeal.
f, for an, reason, a fau|l occurs wilhin lhe pump, il is
recommended lhal lhe equipmenl be relurned lo an appoinled
agenl.
Druck PV 411 User Manual
K2SS lssue No. 1 Page 1S
Approved Servlce Agents
The fo||owing are approved agenls for lhe servicing of Druck
producls.
Japan
Druck Japan KK,
edie Corp Bui|ding 3,
2-4-!4 Kichij,oji-Honcho,
usashino,
Tok,o !30,
Japan.
Te|: (3! 422 20 7!23
Fax: (3! 422 20 7!55
UK
Druck Limiled,
Fir lree Lane
Crob,,
Leicesler LE6 0FH
Eng|and.
Te|: (0!!6 23! 7!00
Fax: (0!!6 23! 7!03
USA
Druck ncorporaled,
4 Dunham Drive,
New Fairfie|d,
Conneclicul 063!2,
U.S.A.
Te|: (203 746 0400
Fax: (203 746 2494
France
Druck SA.,
!9 Fue aurice Pe||erin,
92600 Asnires,
France.
Te|: (! 43 34 24 75
Fax: (! 43 34 36 03
Germany
Druck esslechnik CmbH,
Auf dem Hohenslein 7,
6!23! Bad Nauheim,
Cerman,.
Te|: (6032 93300
Fax: (6032 933030
Holland
Druck Neder|and b.v.,
Poslbus 232,
Zuideinde 37,
299! Lj Barendrechl,
The Neder|ands.
Te|: (0!306 !!555
Fax: (0!306 !3!3!
ltaly
Druck la|ia Sr|.,
Via Capece|alro !!,
20!43 i|ano,
la|,.
Te|: (02 43707!66
Fax: (02 43705563
Druck PV 411 User Manual
Page 19 K2SS lssue No. 1
Anne A
Returned goods procedure
Shou|d lhe unil become unserviceab|e and require repair il can be
relurned lo lhe Druck Service Deparlmenl.
P|ease conlacl our Service Deparlmenl, eilher b, phone or fax, lo
oblain a Felurned Coods Aulhorizalion (FCA number, providing lhe
fo||owing informalion:
Producl (i.e. PV 4!!
Pressure medium (i.e. pneumalic, h,drau|ic
Seria| number
Delai|s of defecl/work lo be underlaken
Operaling condilions
Safety Precautlons
You musl a|so le|| us if lhe producl has been in conlacl wilh
an,lhing hazardous or loxic and lhe re|evanl COSH references and
precaulions lo be laken when hand|ing.
lmportant notlce
Service b, unaulhorized sources wi|| affecl lhe warranl, and ma,
nol guaranlee furlher performance.