Condec PIN8000 Operating Manual
PIN8000 & PIN8010
Portable & Rack-mountable Pneumatic
High Pressure Intensifier Console
Operation and Maintenance
Manual
CONDEC Sales Phone No.: (888) 295-8475
CONDEC Website: www.4CONDEC.com
132626
Contents
About This Manual ................................................................................................................................... 1
1.0 Safety ........................................................................................................................................... 1
1.1 Safety Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Safety.......................................................................................................................................... 2
2.0 Introduction.................................................................................................................................. 3
3.0 Operation...................................................................................................................................... 3
3.1 Optional External Pressure Cylinder (PN 59533) Filling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Initial Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.0 Maintenance & Service ............................................................................................................... 5
4.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Maintenance & Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2.1 Panel/Chassis Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.2 Accumulator, Intensifier & Orion 3A (PN 55287) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.3 Orion 3A Manifold, Valve Seat Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.4 Orion 3A Manifold, Vernier Control Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.5 Orion 3A Manifold, Vernier Control Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.6 Orion 3A Manifold, Valve Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2.7 Accumulator, Intensifier and Orion 3A Manifold, Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2.8 Orion 3A Manifold, Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2.9 Accumulator Assembly, O-ring (PN 58051) Replacement, Filter (PN 56993) Cleaning . . . . . . . . . . . . . 12
4.2.10 Intensifier Assembly, O-rings/Seals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.11 REG 1000 (Regulator) and Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.12 REG 1000 (Regulator) and Solenoid Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.13 Panel Gauge Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.14 Output (Test) Port Quick-Connect Fitting (PN 59004) and Filter (PN 54188), Removal and Installation . 17
4.2.15 Output (Test) Port Hose Quick-Connect Fitting and Filter (PN 56991), Removal and Installation . . . . . 18
4.2.16 Input Port Filter (PN 54188), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.17 Input Port Hose Quick-Disconnect Female Fitting, Removal and Installation . . . . . . . . . . . . . . . . . . . . 19
4.2.18 AC Fuse (PN 57472), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.19 Panel Mounted AC Power/EMI Line Filter (PN 58870), Removal and Installation . . . . . . . . . . . . . . . . . 20
4.2.20 Power Switch (PN 60307), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.21 Pump Control Board Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Orion 3A Valve Assembly (PN 55287) Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4 Intensifier Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.0 Model Number System .............................................................................................................. 29
6.0 Options and Replacement Kits .................................................................................................. 30
7.0 Specifications............................................................................................................................ 32
PIN8000/PIN8010 Warranty and Return Policy ..................................................................................... 33
PIN8000/PIN8010 Return Material Authorization Form ........................................................................ 34
© 2012 Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Specifications subject to change without notice.
Rice Lake Weighing Systems is an ISO 9001 registered company.
Version 1.0, October 2012
i
ii PIN8000/PIN8010 Operation and Maintenance Manual
About This Manual
WARNING
Important
CAUTION
WARNING
DANGER
This manual is intended for service technicians responsible for installing and servicing PIN8000/PIN8010
pressure intensifiers.
The PIN8000 portable pneumatic pressure intensifier an
d the rack-mounted PIN8010 are rugged, compact
instruments manufactured by Condec. They are designed for custom use and ease of operation.
This manual has been written to give the
user a simple and clear explanation of how to operate and maintain
these instruments.
Before attempting to use either style
pressure intensifier, the following
instructions
and understood. This is a
high-pressure system. It is strongly recommended that
only personnel trained in the use of pneumatic pressure
equipment be permitted to operate it. Potentially
dangerous conditions can be produced through negligent
handling or operation of the console due to the high
pressure output of the unit.
These units are strictly for use with pneumatic pressures.
Erroneous readings and po
the introduction of hydraulic fluids into internal tubing
lines.
must be carefully read
tential damage can result from
Authorized distributors and their
employees can view or download this
manu
al from the Condec distributor site at
www.4condec.com.
1.0 Safety
1.1 Safety Signals
Safety Symbol Definitions:
Indicates an imminently hazardous situation that, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation that, if not avoided, could result in death or
ser
ious injury, and includes hazards that are exposed with misuse of unit.
Indicates a potentially hazardous
moderate injury.
Indicates information about procedures that, if not observed, could result in damage to
e
quipment or corruption to and loss of data.
1.2 Safety Precautions
Do not operate or work on this equipment unless you have read and understand the
instructions and warnings in the manual. Failure to follow the instructions or heed the
warnings could
for replacement manuals. Proper care is your responsibility.
situation that, if not avoided, may result in minor or
result in injury or death. Contact any Rice Lake Weighing Systems dealer
Safety 1
General Safety
WARNING
Before attempting to operate this unit, make sure every individual who operates or works with this unit has
read and understands the following safety information. Failure to heed may result in serious injury or death.
DO NOT allow minors (children) or inexperienced persons to operate this unit.
DO NOT operate without fully reading and
DO NOT step on the unit.
DO NOT jump up and down on the unit.
DO NOT use for purposes other than its intended use.
DO NOT place fingers into possible pinch points.
DO NOT drop or throw unit.
DO NOT use this product if any of the components are cracked or leaking.
DO NOT exceed the rated pressure limit of the unit.
DO NOT make alterations or
DO NOT remove or obscure warning labels.
DO NOT use near water.
Before opening the unit, ensure the power cord is disconnected from the outlet.
Keep hands, feet, and loose clothing away from moving parts.
modifications to the unit.
understanding operating instructions.
2 PIN8000/PIN8010 Operation and Maintenance Manual
2.0 Introduction
Note
The PIN8000/PIN8010 pressure intensifier is an electro-mechanical device that can be used in conjunction with
a NIST traceable calibration standard to allow calibrations up to 10,000 PSIG. Each PIN8000/PIN8010 utilizes
Condec’s patented ORION 3A type micro-metering valves and vernier for pressure adjustment and venting. The
unit has two output (test) ports, one input port and three front panel gauges. This allows the operator to monitor
accumulator pressure, regulated input pressure, and intensified output pressure. Two output (test) ports allow one
to be connected to a NIST traceable calibration standard and the other to the device under test (DUT).
The Condec REG 1000 pressure regulator acts as a pressure limiter so that
pressure to 1/10 of the target value. A fill hose, output hose, and output fitting (located within the top cover) are
supplied. A front panel switch provides selection of the desired pump control mode, momentary (jog) or
continuous. For field use, the PIN8000 has an optional 83.3 cubic foot, 2,216 PSI cylinder is available to provide
many hours of use.
The PIN8000 and 19-inch rack-mount version PIN8010
performance, versatility and reliability not previously available in a pressure intensified instrument. Features
include:
• Two output (test) ports for DUT and NIST
rd
standa
• Switch-selectable pressure pump control
mo
de, momentary (jog) and continuous.
• Pressure monitoring: Three front panel
mounted gauges
• Using the Condec REG 1000 pressure
regulator
is adjusted to slightly above 1/10 desired
value of the full scale range of the device
being tested. By using this technique, the
device that is to be pressurized is fully
protected from being inadvertently
over-pressurized.
• Compact and self-contained, easily carried
8 lb.) and operated by only one person.
(3
• Pressure source: nitrogen or clean dry air is
supplied by the customer
instrument, the pressure source drives a
In addition to the features listed above, the PIN8000/PIN8010
micro-metering valves and vernier are provided to control the internally intensified nitrogen, while the output
pressure gauge and customer-supplied calibration standard (connected to one of the output ports) indicates the
magnitude of the applied test pressure. Over-pressure protection is provided through a fully-adjustable Condec
REG 1000 pressure regulator, which is manually set for each new device being tested.
, the maximum system input pressure
Actual output pressure is controlled through the vernier and micro-metering valves.
provide excellent readability .
. In either
instruments offer a combination of features,
pneumatically operated 10 to 1 intensifier
contained within the PIN8000/PIN8010.
Therefore, a 1,000 PSI input is amplified to
10,000 PSI. An optional external supply
cylinder may be purchased that will contain a
volume of 83.3 standard cubic feet of nitrogen
and provide up to 2,216 PSIG of pressure for
calibration and test.
• Simple operation: all controls, indicators and
pressure ports (PIN8000 only) are acces
from the front panel.
• Safe and clean operation: all pressure
com
proof-tested to at least 150% of maximum
operating pressure. In addition, the system
contains a high-pressure burst disk to protect
both the operator and system components
from harm in the event of inadvertent
over-pressurization.
the operator can adjust input system
sible
ponents are made of stainless steel and
pressure intensifier is easy to use. Two
Introduction 3
Figure 2-1 provides an overview of the PIN8000/PIN8010’s functions.
RELEIF PORT
RUPTURE DISK
±100 PSI
3000 PSI
MUFFLER
1/4 AMP
250 V
POWER
VERNIER
VENT
VALVE
PRESSURE
PORT
VENT
MAX. PRESSURE OF
10,000 PSI
COARSE
ADJUSTMENT
INLET PORT
2,000 PSIG
MAX.
7 MICRON
FILTER
REGULATOR
0-1000 PSIG
OUTPUT
POWER INPUT
PIN8000A[]
120 VAC
PIN8000B[]
220 VAC
REGULATED
PRESSURE
GAUGE
3-WAY
SOLENOID VALVE
BOOSTER PUMP
10:1 RATIO
ACCUMULATOR
2.5 CU IN.
ACCUMULATOR
PRESSURE
GAUGE
OUTPUT
PRESSURE
GAUGE
OUTPUT (TEST) PORT
(QUICK DISCONNECT)
20 MICRON
FILTER
OUTPUT (TEST) PORT
(QUICK DISCONNECT)
20 MICRON
FILTER
Figure 2-1. PIN8000/PIN8010 Flow Diagram
4 PIN8000/PIN8010 Operation and Maintenance Manual
3.0 Operation
WARNING
Note
0
NIUTP
MAX
200
PORT
MIMU
SPI
PNIACREUT
SDAUG LET RPES ERU
SRPSEEUR
VNTE
TEVN TROP
5
3
4
1
6
2
11
12
13
8
9
7
10
WOPER
CCAALUUM POTR USSRE RE
T
OUT RUPPTSESURE
OPUUT
OUPTUTORPT2
TROP1
TERLUGAOR
INCREASE
DECREASE
RVE RENI
14
PIN8000
3.1 Optional External Pressure Cylinder (PN 59533) Filling Procedure
Condec strongly recommends that the external nitrogen supply cylinder be pressure-tested and
re-certified every five years from the date the cylinder was manufactured per U.S. DOT. 3AL
gulation, Title 49 CFR, parts 173 and 178.
Re
To initially fill or refill the external pressure cylinder (2,216 PSI max.),
1. Close the cylinder
2. Connect the customer-supplied fill hose or optional Condec P
hose to a clean regulated nitrogen source, with an output pressure gauge and vent valve.
3. Connect the other end of the customer-supplied fill
female CGA-580 brass cylinder valve fitting.
4. Open the cylinder valve by rotati
5. Slowly open the valve on the nitrogen source and allow
customer-supplied output pressure gauge indicates the amount of pressure within the internal cylinder.
The cylinder is equipped with a rupture disk.
6. Fill the cylinder to 1,000 PSI at a rate of charge equal to a minimum of two minutes, then wait five
minutes for the system to stabilize.
7. Fill the cylinder from 1,000 PSI to 2,216 PSI at a rate of charge equal to a minimum of two minutes. W ait
five
minutes for the cylinder to stabilize before using.
8. Close the cylinder valve by rotating clockwise until
9. Vent the nitrogen source and remove the fill hose.
valve by rotating clockwise until it stops.
N 150613 (male CGA-580 both ends) fill
hose or optional Condec PN 150613 fill hose to the
ng counter-clockwise until it stops.
the gas to flow into the pressure cylinder. The
it stops.
3.2 Initial Setup Procedure
To prepare for actual intensifier usage, see Figure 3-1 and proceed as follows:
Figure 3-1. PIN8000 Components
Operation 3
1. Check that the pressure valve (11) is closed (rotate clockwise until it stops) and that the vent valve (12) is
Note
Note
DANGER
Note
open (two turns counter-clockwise from its stop). Verify that the Condec REG 1000 (10) is closed by
rotating counter-clockwise until it stops.
2. Plug in the power cord (1).
3. Connect the male end of the test (output) hose to output port 1 or port 2 (9).
4. Connect the swivel fitting end (7/16-20) of the test
(output) hose to the input of the device to be
pressurized using adapters if required. Properly tighten all connections.
5. Locate the male end of the supplied output port fitting P
N 55542 found within the top cover. Connect
with the output port (9).
6. Connect the other end of the output port fitting, male 7/16-20 37 degree (AN-4) JIC thread, to Condec
3030, Conde
c DPDG, or the customer-supplied pressure electronic calibration standard. If necessary, use
adapters or a hose. Use a cheat seal pad PN 54854 between the output port fitting (PN 55542) and the
hose/adapter. Properly tighten all connections.
7. If using the
optional external cylinder PN 59533, connect the male end of the input hose (3) to the
female CGA-580 brass cylinder (5) valve fitting.
If not using the optional external cylinder, connect the ma
le end of the input hose (3) to the female
CGA-580, customer-supplied, regulated pressure source.
8. Connect the swivel fitting end (7/16-20) of the input hose (3)
to the input port (4) fitting using a cheat
seal pad PN 54854 between the mating surfaces. Properly tighten all connections.
PIN8000 shown, AC Input (1), one of the output (test) ports (9) and input port (4) are on back side of the
PIN8010 rack-mountable intensifier.
3.3 Operating Instructions
See Figure 3-1 when following these steps.
1. If using the optional exte
counter-clockwise until it stops.
If not using the optional external cylinder,
max. input pressure source valve.
2. Using the Condec REG 1000 (10), adjust the maximum intensifier
regulated pressure gauge (6), to 1/10 of the target value. The unit utilizes an internal intensifier with a
10:1 ratio. For example, setting regulated pressure to 300 PSI would generate an output pressure of 3,000
PSI. This protects the device from being accidentally over-pressurized.
3. To generate pressure, enable the power switch (2)
accumulator pressure gauge (7). Turn the power switch (2) off when 10% more than the target pressure
has been achieved.
The intensifier power switch (2) can be operated in two modes. The “up” position is continuous and the
“down” position is momentary/jog.
rnal cylinder PN 59533, open the cylinder valve (5) by slowly rotating
slowly open the customer-supplied regulated, 2000 PSIG
pump input pressure, as read by the
and monitor the pressure as it builds in the
Do not operate the unit in continuous mode without an operator being present.
4. To apply pressure, the vent valve (12) must be closed by rotating the knob clockwise. Slowly open the
pressure valve (11) counter-clockwise, while monitoring the electronic calibration standard display
previously attached to one of the output ports (9), until reaching near the target value. The analog output
pressure gauge (8) will also give a reading; however, it will be less accurate.
5. Use either the pressure (11) or vent valve (8) to obtain a pres
sure reading near the target value. Both
provide precise control. As the pressure approaches the desired valu e, the valve being used for control
should be slowly rotated clockwise to its closed position.
6. To obtain exact pressure readings, slowly rotate the verni
er control (14) knob in the required direction
(clockwise to increase pressure) as indicated by the electronic calibration standard display.
Use the intensifier power switch (2) if the accumulator pressure gauge (7) reading falls below the required
target pressure value.
4 PIN8000/PIN8010 Operation and Maintenance Manual
4.0 Maintenance & Service
POWER
AC INPUT
LINE (P)
KBK8924-1, (56679)
BLACK
PUMP CONTROL BOARD ASSEMBLY
NOTE: MARKINGS SHOWN WITHIN " " ARE ACTUAL
PART NO.
SOLENOID
RED
56851
VALV E
YEL
GRN/
RED
MARKINGS ON UNIT.
SOLENOID
VALV E
PART NO.
56851
YEL
GRN/
RED RED
BLACK
BLACK
1 2 3
TB1
GREEN
WHITE
BLACK
4 1 32 GNDLOHI
NEUTRAL
GROUND
TB2 TB3
LINE FILTER
(N)
(E)
(1)
(2)
(3)
(ON)
(OFF)
(MOM)
CAUTION
This section outlines the mechanical and basic electrical repair procedures for the PIN8000/PIN8010.
4.1 Troubleshooting
Symptom Problem Remedy
The customer’s electronic standard
display or th
e output pressure gauge
slowly decreases over time.
The electronic standard display or output
essure gauge fluctuates when the
pr
output pressure or vent valves are
closed.
The electronic standard display or output
pr
essure gauge does not respond when
the vernier knob is turned.
The unit does not cycle when the pump
ntrol switch is on.
co
The unit cycles, but does not pressurize. Debris in check-valve seat in intensifier,
Leak in the system. Check all compression and pipe fittings
with Snoop®, bottle of liquid leak gas
detector (PN 64781).
No pressure or vent control. Replace the valve seats or O-rings in
valves; check valve needles.
No vernier control. Re-adjust the isolation valves on the
Orion 3A; replace the vernier piston’s
O-ring.
Fuse blown on the pump control board.
No power.
Replace the fuse.
Check that the power is on.
Remove seats in the intensifier and clean
deformity in seat.
No supply pressure.
and/or replace.
Check to see if there is sufficient supply
essure.
pr
4.2 Maintenance & Service Procedures
The repair procedures cover the major components and sub-assemblies which are critical to the proper
functioning of the calibrators and that need periodic maintenance over the life of the unit.
Only those persons who are formally trained as skilled technicians should attempt to repair these
units. All safety precautions should be observed due to
components. The unit must always be unplugged from the power source and properly vented.
Table 4-1. PIN8000/PIN8010 Troubleshooting
the presence of electrical and high-pressure
Figure 4-1. PIN8000/PIN8010 Wiring Diagram
Maintenance & Service 5
4.2.1 Panel/Chassis Removal and Installation
Note
PIN8000 Removal
Tools required: Phillips screwdriver
1. Loosen and remove the 10 screws (PN 14862) whic
2. Lift the panel and chassis by first grasping the regulator
h secure the panel assembly to the enclosure.
knob and output (test) port; and second, grasping
under the panel edges. Tilt the panel at an angle by lifting the right side before the left side as you face
the panel. Ensure that the wire harnesses do not catch and snag.
3. Gently set the panel/chassis assembly on
a bench top. It can be rested on the panel bottom with the
accumulator supported by a screwdriver handle.
PIN8000 Installation
Tools required: Phillips screwdriver
1. Lift the panel and chassis by first grasping the regulator knob and outpu t (test) po r t.
2. Gently place the panel/chassis assembly
into the enclosure. Tilt the panel at an angle by lifting the right
side before the left side as you face the panel. Ensure that the wire harnesses do not catch and snag.
3. Align the mounting holes and install the 10 screws (PN 14862)
which secure the panel assembly to the
enclosure.
PIN8010 Removal
Tools required: Phillips screwdriver
1. Loosen and remove the 14 screws (PN 14861) from the top, bottom, and sides which secure the panel
assembly to the enclosure. Loosen and remove the three screws (P/N 14861) from the re ar of unit whic h
secure the enclosure to the output (test) port/AC input/input port panel.
2. Lift the panel and chassis by grasping the handles locat
ed on the front of the rack-mountable panel.
Ensure that the wire harnesses do not catch and snag.
3. Gently set the panel/chassis assembly on
a bench top. It can be rested on the panel bottom with the
accumulator supported by a screwdriver handle.
PIN8010 Installation
Tools required: Phillips screwdriver
1. Lift the panel and chassis by grasping the handles located on the fro nt of the rack-mountable panel.
2. Gently place the panel/chassis assembly into the e
nclosure. Ensure that the wire harnesses do not catch
and snag.
3. Align the mounting holes a
nd install 14 screws (PN 14862) from the top, bottom, and sides which secure
the panel/chassis assembly to the enclosure. Also, align the mounting holes and install the three screws
(PN 14862) from the rear of unit which will secure the enclosure to the output (test) port/AC input/input
port panel.
4.2.2 Accumulator, Intensifier & Orion 3A (PN 55287) Removal
Tools required:
• Phillips screwdriver
• 11/32" wrench or nutdriver
• .061" hex wrench
See Table 4-2 on page 22 and Figure 4.3 on page 22 for additional Orion 3A parts information.
• adjusting screwdriver (small flat blade)
• 11/32" open end wrench (thin)
• 7/16" open end wrench
1. Vent the system to its atmosphere before attempting to work on the unit. Disconnect the power cord from
the power source.
2. Remove the front panel from its enclosure as described in Section 4.2.1 and carefully set on a bench top.
3. Using a 7/16" wrench, remove the following tubing sections:
• Accumulator to supply pressure ga
• Accumulator to pressure inlet on Orion 3A manifold (1/8" di
uge (1/8" dia.)
a.)
• Accumulator to intensifier outlet (1/4" dia.)
4. Loosen and remove the six screws securing the two clamps t
hat hold the intensifier and accumulator.
6 PIN8000/PIN8010 Operation and Maintenance Manual
5. Remove the accumulator by sliding out.
Note
6. Loosen the fitting nut at the intensifier end of the long 1/4" diameter tubing section which connects the
solenoid valve to the intensifier. There is no need to remove the tubing.
7. Remove the two clamps and the intensifier.
8. Using a 7/16" wrench, remove the vent port to
9. Loosen and remove the tubing connections located near
the Orion 3A manifold vent outlet (1/8" dia.).
the bottom of the Orion 3A manifold that go to
both panel output ports.
10. Remove the panel knobs from the pressure (coarse), vernier and vent valves using the .061" hex wrench.
11. Loosen and remove the two panel screws (PN 60837) from
the panel front which secures the manifold to
the panel.
12. Remove the five retaining nuts and lock wa
13. Lift the chassis enough to allow the Orion 3A manifold to
14. Reposition the chassis over the mounting studs and
4.2.3 Orion 3A Manifold, Valve Seat Removal
Tools required:
• A/R solvent (de-natured alcohol)
•socket wrench
• 3/4" socket
• needle housing socket (PN 65580)
• isolation valve needle
housing socket
(PN 68509)
• hex wrench (.050")
shers which secure the chassis to the panel.
clear. Then, remove the manifold.
secure with at least two nuts.
• needle-nose pliers
• tube fluorinated krytox grease (PN 55593)
• electric hand drill
• No. 43 drill bit
• No. 4-40 tap
• tap handle
• small hammer
• hex wrench (.061")
See Table 4-2 on page 22 and Figure 4.3 on page 22 for additional Orion 3A parts information.
1. Secure the manifold by its center portion, in a bench vise, with the valve knobs pointing upward.
2. Using the .061" hex wrench, loosen and remove the knob inserts (4) from the pressure and vent valve
stems.
3. Loosen the 3/4" locknuts (1) on the pressure an
4. Using the needle housing socket (PN 65580) and torqu
d vent valve threaded needle housings (10).
e wrench, loosen and remove the needle/housing
assembly (10, 1).
5. To disassemble the isolation valves (two inner valves), first
remove the valve needle (18) by turning the
gear clockwise.
6. Loosen and remove the valve housings (19) using the isolation valve housing removal socket
(PN 59793) female socket (PN 65581) and torque wrench.
7. Remove the valve stem seats (8) and valve needle sea
8. Remove the inner and outer O-rings (28, 27) and back-up rings (31, 30) from
ts (9) using the needle-nose pliers.
the valve stem seats. Wash
all parts in solvent (de-natured alcohol).
9. To remove valve seats (7) from either the pressure (co
arse), vent or isolation valves, try blowing
compressed air through the inlet and outlet fittings. If unsuccessful, continue with the following steps.
10. Using the electric hand drill with the No. 43
bit, carefully drill out the seat hole, ensuring that the drill
does not touch the hole in the manifold housing directly beneath the seat.
11. Blow out any chips from the seat area using compressed air.
12. While holding the 4-40 tap steady and perpendicular to t
he seat, slowly turn until the tap starts to engage
the seat.
13. When the tap has engaged into the
seat, use a small hammer and gently knock upward against the tap
handle to extract the seat.
14. After the seat has been removed, blow any remaining chips
from the seat area.
Maintenance & Service 7
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