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4.2 Bypass Valve Test
1.
Remove the pump assembly from the reservoir and
place it on a test bench, lying on its side so the bottom
of the pump can be easily observed.
2.
Measure the bypass cap height shown in Figure 4. This
dimension should closely match the value shown in the
Test Specification Table.
3.
Replace the pump assembly into a test bench sump or
the pump reservoir.
4.
Attach a V-152 relief valve to advance port of the valve
on the pump. Install a 0-15,000 psi pressure gauge
onto the extra V-152 port and a low restriction return
hose to the bottom (tank port) of the V-152. Route the
return hose back to the sump or reservoir.
5.
Plug pump into an electrical power supply.
6.
Place the pump valve in the advance position and
fully open the V-152 valve (turning its handle counter-
clockwise).
7.
Start the pump motor.
8.
Monitor the pump pressure and amperage while slowly
closing the V-152 valve by turning its handle clockwise.
The bypass valve should be set so that the maximum
current draw at bypass pressure is the same or slightly
below the current draw at the maximum rated pressure of
the pump.
9.
If an ammeter is not available, check the Test Specification
Table for the approximate pressure setting of the bypass
valve.
10. If the maximum current draw at bypass pressure exceeds
that of maximum pressure, or if the bypass pressure is more
than 200 psi off, adjust the bypass setting. Unplug the
pump from its power supply, lift the pump assembly from
the sump or reservoir and turn the bypass cap (Fig. 4, Item
12) (clockwise to increase the setpoint, counterclockwise
to decrease). Repeat steps 5 through 10 until the proper
bypass setting is reached.
11. Stop the pump motor and unplug the pump from its power
supply. Remove the V-152 valve and pressure gauge and
restore the pump to its original condition.
4.3 Safety Relief Valve Test
1.
Remove the existing valve from the pump and install a
VM-2 valve in its place (NOTE: this is required due to the
presence of an internal check valve in most other valve
models).
2.
Remove the pump assembly from the reservoir and place it
on a test bench, lying on its side so the bottom of the pump
can easily be observed.
3.
Connect a 0-10,000 psi hand pump with a 0-15,000 psi
pressure gauge to the VM-2 outlet. Fully close the VM-2
valve.
4.
Operate the hand pump and monitor the pressure gauge.
Note the pressure at which the pump safety valve begins to
relieve at.
5.
If this value is outside the limits listed for the appropriate
model in the Test Specification Table, adjust the setpoint by
inserting a 5mm Allen wrench into the end of the relief valve
and turning the adjustment screw (clockwise to increase
the setpoint, counterclockwise to decrease). Repeat steps
4 and 5 until the proper setting is reached.
6.
Release the system pressure and remove the hand pump
and pressure gauge.
Outlet
Internal Relief Valve
By-Pass
Valve
HP
7.
Replace the pump assembly into a test bench sump or the
pump reservoir.
8.
Attach a V-152 relief valve to advance port of the valve on
the pump. Install the pressure gauge onto the extra V-152
port and a low restriction return hose to the bottom (tank
port) of the V-152. Route the return hose back to the sump
or reservoir.
9.
Fully close the VM-2 valve and fully open the V-152 valve
(turning its handle counter-clockwise).
10. Plug pump into an electrical power supply.
11. Start the pump motor.
12. Verify the safety valve relief setting by slowly closing the
V-152 valve (turning its handle clockwise) and monitoring
the system pressure.
13. If this value is outside the limits listed for the appropriate
model in the Test Specification Table, repeat steps 2
through 12 until the proper setting is reached.
14. Stop the pump motor and unplug the pump from its power
supply.
Remove the V-152 valve, pressure gauge and
VM-2 valve and restore the pump to its original condition.
5.0 FLOW TEST PROCEDURE
FLOW METER METHOD (requires test bench)
5.1 Low Pressure Flow Measurement
1.
Connect an unrestricted hose from the advance port of the
pump valve to the test bench flow meter supply. Route the
flow meter return hose back to the return port of the pump
valve (for 4 way valves) or the reservoir (for 3 way valves).
2.
Plug the pump into an electrical power supply.
3.
Start the motor and operate the pump in the advance mode
for 30 seconds.
4.
Check Test Specification Table. If pump does not meet 1st
stage flow rating see Section 1.0 Troubleshooting.
5.
Stop the pump motor and unplug the pump from its
electrical power supply.
6.
Disconnect the flow meter hoses from the pump and return
the pump to its original condition.
14
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