Airdive manufactures non-water jacket test panels which comply to Australian Standards in a number of configurations the most popular of which is the Hydro 8000 Hydrostatic Test Panel. The unit comes complete with a master test gauge and four cylinder test adaptors for connecting the unit to various cylinder neck threads for testing purposes.

Airdive has supplied major companies Australia wide for nearly 20 years and can supply spare parts and advice to repair units if required.

Easily fitted into standard work shop areas the test panel utilises a Haskel or Kempe Fluid Air air driven pump to attain test pressures up to 8000 PSI. The unit is constructed of powder coated galvanised steel for the case and is fitted with gauges made to AS 1349 with stainless steel Bourdon movement for long life. Internal construction comprises Airdive EHP panel valves, and all pressure piping is stainless steel.

Airdive can supply up to 15 different test adaptors for a wide range of cylinder neck threads as well as various testing equipment accessories. Scales, inspection mirrors, cylinder rumblers and fibre optic lights are just some of the items available. We can also supply Haskel® MS series pumps and spare parts as well as service these pumps.

These test units are ideally suited to testing scuba cylinders and breathing apparatus cylinders but can be utilised for testing larger bank cylinders up to 95 litres water capacity if required.

SPECIFICATIONS

Dimensions: 600 MM Wide X 900 MM High X 200 MM Deep

Maximum Test Pressure: 8000 PSI

Pump Drive: 700 kPa of compressed air

Maximum Cylinder Size 95 litre water content to 8000 PSI test pressure.

SUPPLIED COMPLETE WITH MASTER TEST GAUGE AND 4 TEST ADAPTORS (CUSTOMER TO SPECIFY)

Note! This unit is designed primarily for testing portable breathing apparatus, SCUBA of Co2 cylinders. The system can test 50 litre and above storage cylinders if required on an occasional basis, but is not recommended for this size cylinder in general operation as the pump stoke volume would make testing time consuming.

Haskel® is a registered trade name of Haskel Inc. Burbank, C.A. USA

SERVICE NOTES

GENERAL

For current owners, the most likely wear parts of the hydrostatic test unit are the pump hydraulic seals and the hydrostatic return valve, panel valve number 6 on the units. Service kits are available for the panel valves (part number 20157099k) as well as the Haskel® MS series pumps. Airdive strongly recommends that customers only use genuine Haskel® parts in pump repairs as non-genuine parts generally fail within weeks. Airdive can service the MS series range of pumps if required. The same applies for Kempe Fluid Air pumps. Genuine Fluid Hydraulics parts should be used if a Fluid Hydraulics (Kempe) has been fitted to the test unit.

IMPORTANT -If working on piping or valves of unit make sure all pressure is relieved from unit, both hydrostatic and air pressure or injury could result. Check the gauge pressure of all gauges which should be reading zero pressure and open all high pressure section gauges. Open pump drive vent valve to vent residual air in hydrostatic pump. Remember SAFETY FIRST!

ALWAYS WEAR EYE PROTECTION WHEN OPERATING UNIT IN CASE OF AIR OR HYDRAULIC PIPE OR FLEXIBLE LINE FAILURE DURING OPERATION

Airdive strongly suggests the unit be mounted in such a way that the back of the unit is easily accessible for service and inspection such as on a solid frame.


If working on piping, always use two spanners so that fittings are not damaged. Do not over-tighten olive fittings or they will need to be replaced including the pipe section if damaged. All piping used in test units is 1/4' (6.35) diameter of 3/8' diameter. Do not mix metric piping and imperial ferrule sets.

All units a checked in factory before shipment. If alteration to the drain pipe (pipes) from sight glass tube(s) supplied with the unit is required, contact Airdive for details first as incorrect drain pipe alteration will cause incorrect readings to result. All drain pipes must be free flowing and open into larger bores or airlocks will result.

PANEL VALVES

If fitting a replacement panel valve take note of the inlet / outlet ports before disassembly so that valves are placed in the correct orientation (direction). On valve 6 of the unit, the inlet side must be toward the high pressure section of the test unit (inlet port faces towards centre of unit) with cross pipe assembly up to gauges) and the outlet port faces towards outside of case with return pipe to bottom of pump inlet. If this is not done then difficult operation of the valve will occur and possible gauge damage through rapid depressurisation could result.

Panel valve 6 will wear out over time. Seat pitting through fine particles of rust from cylinders or from the water supply itself do find their way into the water. Water filters prior to the inlet to the unit can prolong seat and pump seal life in areas with high mineral content water supplies such as Western Australia. Check seat condition before installing a new service kit. A torch will assist this inspection greatly.

NOTE! If the hydrostatic return valve (number 6) leaks, the test unit will not hold pressure as water will leak back to the low pressure side.and back into the reservoir tank. If the test unit will not hold pressure but shows no water loss, then a leaking hydrostatic return valve is the most likely problem. Alternatively there could be a dual inlet/outlet check valve failure in the hydrostatic pump but this would be very unusual.

If there is water loss from the system then there is a system pipe leak or a faulty hydraulic seal in the hydrostatic pump.

HYDROSTATIC PUMPS

If the exhaust section (muffler) shows misting of water during operation and there is difficulty in maintaining pressure or the unit seems to be loosing water then the likely explanation is worn hydraulic seal in the hydraulic seal section of the pump. The pump must be removed and the hydraulic seals replaced. If it is suspected that there is a hydraulic lead fix the pump as soon as possible as this will prevent corrosion of the internal return spring and damage to the air drive barrel through corrosion. Further, if the pump is leaking then the unit cannot comply with the relevant testing standards until the unit is repaired as inaccurate test results will occur. Note! wetness on the muffler is normal in clod weather as the cold air being exhausted from the pump condensed moisture in the air on cold days. If in doubt put the blank plug in the test hose and pressurise the unit to 40 MPA up to 10 times. Don't add water. The water level should be a the same level set at the beginning of the process. If there is progressive water loss each pressurisation, there is a water leak.

AIR REMOVAL FROM SYSTEM -GENERAL GUIDELINES

For proper operation all air must be removed from the system. This is most successfully carried out using the blanking plug fitted to the outlet hose assembly. Air should be forced to the top or the unit using the water supply. Keep valve 2 closed during this operation so that water does not preferentially fill the reservoir tank at the side of the unit. Open valve 8 at the top of the test unit and allow the water to drain from the top of the unit outlet by opening the water fill valve (valve number 1). When no more air can bee seen in the outlet water the valve is closed off and the reservoir tank is then filled as per tank top up. Valve 6 should be alternatively opened and closed during this operation. The air drive valve (number 3) can be opened to run the pump to force water and trapped air from the top of the unit as well, butvalve 6 must be open or pressure will build up in the high pressure side of the unit when you do this. When complete return all valve settings to normal operating settings and remove the blank plug. The unit is now ready to continue hydrostatic testing.

AIRDIVE HYDRO 8000 TEST PANEL

airdive

HYDROSTATIC TEST PANELS