Condec PIN8000 Operating Manual

PIN8000 & PIN8010

Portable & Rack-mountable Pneumatic

High Pressure Intensifier Console

Operation and Maintenance

Manual

CONDEC Sales Phone No.: [phone]
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

4.2.4 Orion 3A Manifold, Vernier Control Disassembly

Note

Note

Tools required:

• A/R solvent (de-natured alcohol)

• 1-1/4" open end wrench

• screwdriver (flat-blade)

•socket wrench



See Table 4-2 on page 22 and Figure 4.3 on page 22 for additional Orion 3A parts information.

• isolation valve needle housing socket 
(PN 68508)

• isolation valve needle housing socket 
(PN 68509)

1. With the manifold housing mounted in a vise, turn the vernier shaft (14) clockwise until the piston is
bottomed.

2. Loosen and remove the end cap (13) using a 1-1/4" wrench. At certain points during removal, the end
cap might appear to lock up. If

this occurs, rotate the shaft clockwise until the end cap is free to turn.

3. Remove the O-ring (29) from the end cap.

4. Remove the self-sealing

5. Extract the piston (15) by partially screwing in

screw (36) which acts as the piston key.

the threaded end of the shaft and pulling.

6. Remove the O-ring (32) from the piston groove.

7. To disassemble the end cap/shaft assembly

8. Loosen and remove the locknut (20) using the isolation valve needle housing socket (PN

, mount the end cap in the vise.

68509) and

socket wrench.

9. Loosen and remove the end bushing (12) using the isolation v alve housing so cket (PN 6 8508) and socket
wrench. Re

10. Use a small pick or screwdriver to remove the O-rin

move the shaft (14). Remove the ball bearings (41) from both sides of the shaft flange.

g (27) from the inner groove of the end cap (13).

Also, remove backup retainer (39) from inner groove of the end cap (13).

11. Wash all parts in solvent and blow dry with compress

ed air.

4.2.5 Orion 3A Manifold, Vernier Control Reassembly

Tools required:

• tube fluorinated Krytox grease (PN 55593)

• 1-1/4" wrench

• screwdriver (flat-blade)

•socket wrench

• isolation valve needle housing socket 
(PN 68508)

• isolation valve needle housing socket 
(PN 68509)

• torque wrench



See Table 4-2 on page 22 and Figure 4.3 on page 22 for additional Orion 3A parts information.

1. Coat all new O-rings with fluorinated Krytox grease before installing.

2. Install the small O-ring (27) into the end ca

p inner groove. Also, install the backup retainer (39) into the

inner groove of the end cap (13).

3. Hold the shaft (14) vertically with the end that goes t

hrough the end bushing (12) toward the ceiling.
Place a light coating of grease on the shaft’s threads. Place a thick coating of grease on top of the shaft
bearing surface.

4. Allowing grease to hold the ball bearin

gs in place, slide the end bushing (12) over the top of the shaft and

down to contact the top of the ball bearings.

5. Rotate the shaft assembly 180°, placing the e

nd bushing towards the floor. Be careful not to displace ball
bearings. Place a thick coating of grease on the shaft and bearing surface. Place 16 chrome ball bearings
(41) on the greased surface, allowing grease to hold them in place.

6. Install the shaft (14) with bearings (41) into t

he end cap. 

8 PIN8000/PIN8010 Operation and Maintenance Manual

7. Install the end bushing (12) and tighten until snug using the isolation valve needle housing socket (PN

Note

Important

68508) and socket wrench.

8. Tighten so the shaft rotates but is firm. Feel the vertical

motion of the shaft (14). If motion exists,

retighten the end bushing.

9. Install the locknut (20) into the end

cap (13) using the isolation valve needle housing socket (PN 68509)

and torque wrench. Torque to approximately 325 in/lbs.

10. Install the O-ring (32) in the piston groove and install

the piston (15) into the vernier cavity. Ensure that

the piston keyway is facing the hole into which the self-sealing screw (36) is assembled.

11. Install the self-sealing screw (36) and tighten until snug.

12. Apply a thin coat of fluorinated Krytox grease and install the O-ring (29) and backup washer (38) on the
end ca

p/shaft assembly. Install into the manifold and tighten until snug.

4.2.6 Orion 3A Manifold, Valve Seat Installation

Tools required:

• needle-nose pliers

• tube fluorinated Krytox grease (PN 55593)

• No. 43 drill

• A/R solvent (de-natured alcohol)

• hex wrench (.050")

• hex wrench (.061")

• torque wrench

• socket wrench

•3/4" socket

• n eedle housing socket (PN 65580)

• isolation valve needle housing socket 
(PN 68509)

• female socket (PN 65581)



See Table 4-2 on page 22 and Figure 4.3 on page 22 for additional Orion 3A parts information.

1. Install a new seat (7) by placing it into the seat well with the needle-nose pliers. Ensure that the seat is
centered within the cavity and gently tap it with the blunt end of a drill bit to install.

2. Install the valve needle seat (9) with the sma

3. Install new O-rings (28, 27) inside and outside of the

ller diameter end facing outward.

valve stem seat. Coat all O-rings and back-up rings
(30, 31) with fluorinated Krytox grease before installation. Make sure the rings are installed in the proper
order.

4. Install the valve stem seat (8) by grasping the small diameter

end with the needle-nose pliers and

positioning in the valve cavity, then gently pushing with the blunt end of a drill bit.

5. For pressure (coarse) and vent valves (two outer valves), dis

assemble the valve needle (11) from its

housing (10) and check for any burrs or dirt on the threads which might interfere with smooth operation.

6. Clean both the needle (11) and housing (10) in solvent, dry the parts and apply a small amount of
fluorina

7. Assemble the valve needle (11) i

8. Reinstall the needle/housing assembly into the

9. Mount the manifold body (16) in a
needle/housing assembly to 325 in-lb. using the needle housing socket (PN 65580) and

ted Krytox grease to the needle threads before reassembly.

nto the valve needle housing (10) and turn it until it stops.

valve cavity until it is finger tight.

vise. For the pressure (coarse) and vent valves only, torque the

torque wrench.

10. Install the housing lock nuts (1) onto the housing (10) and tighten with the 3/4" socket until snug.

11. Using the .050" hex wrench, install and tighten

12. Install the knob insert (4) over the

valve needle (11) shaft. Align the set screws (23) with the indents and

the lock nut (2) and set screw (34).

tighten with the .061" hex wrench.

13. For the isolation valves (two inner valves), install the needle

housing (19) and tighten until snug using

the isolation valve needle housing installation socket (PN 68509) and torque wrench.



There is no specified torque, so use care when tightening so as not to break the socket nibs.



Maintenance & Service 9

14. Install the gear (6) over the isolation valve needle (18) shaft. Align the set screws (26) with the indents

Note

Note

Note

DANGER

and tighten with the .061" hex wrench.

15. Apply a small amount of fluorinated Krytox grease to the threads of the isolation valve needles (18) and
install into the valve by turning counter-clockwise. Rotate the gear until the needle stops at the seat.

4.2.7 Accumulator, Intensifier and Orion 3A Manifold, Panel Installation

See Table 4-2 on page 22 and Figure 4.3 on page 22, for additional parts information.
(* denotes reference to Figure 2-1 on page 4.)

Tools required:

• 7/16" open end wrench

• Phillips screwdriver

• Snoop®, liquid leak gas detector (PN 64781)

• 11/32" open end wrench (thin)



• Hex wrench (.061")

1. If not already done, remove the panel knobs from the press

ure (coarse), vernier and vent valves using the

.061" hex wrench.

2. With the panel facing down against the bench, if no

t already done, remove the five retaining nuts and
lock washers which secure the chassis to the panel. Lift up the chassis enough so that the Orion 3A
manifold is able to clear.

3. Install the manifold with the outp

ut port connections side facing the panel bottom. Install the two

mounting screws (PN 60837) from the panel front and tighten until snug.

4. Secure the chassis to the panel with

5. Install the vernier knob (17) onto the vernier valve shaft

the five nuts and lock washers. Tighten until snug.

(14). Align the set screws (25) with the

indentations on the vernier valve shaft and tighten until snug using the .061" hex wrench.

To install the pressure (coarse) and vent valve knobs, and perform a valve adjustment, follow the procedure in
Section 4.2.8 after completing the following steps.

6. Install and tighten tubing connections located near the bottom of the Orion 3A manifold that are
connected to panel output ports.

7. Using a 7/16" wrench, i

nstall the following tubing section that goes from the vent port to the Orion 3A

manifold vent outlet (1/8" dia.)

8. Replace the intensifier and the two clamps.

9. Realign and tighten the fitting nut at the intensifier end of the long 1/

4" diameter tubing section which

connects the solenoid valve to the intensifier.

10. Replace the accumulator by sliding in

11. Thread and tighten the six screws that secure the two clamps

12. Using a 7/16" wrench, realign and tighten t

thru the clamps.

that hold the intensifier and accumulator.

he following tubing sections:

• accumulator to intensifier outlet (1/4" dia.)

• accumulator to pressure inlet on Orion 3A manifold (1/8" dia.)

• accumulator to supply pressure gauge (1/8" dia.)

13. With a pressure source connected to the input port

(*4), use the Condec REG 1000 (*10) set the input
pressure to 100 PSI. Enable the power switch (*2) and monitor the pressure as it builds in the
accumulator gauge (*7). Turn the power switch (*2) off when 1,000 PSI has been achieved. Check all
fittings for leaks. If there are no leaks, vent the system and remove the pressure source.



See Section 3.2 on page 3 for pressure source connection procedure.



Do not operate the unit in continuous mode without an operator being present.



14. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 6.

10 PIN8000/PIN8010 Operation and Maintenance Manual

4.2.8 Orion 3A Manifold, Valve Adjustment Procedure

Note

DANGER

Important

Tools required: hex wrench (.050")

hex wrench (.061")

See Table 4-2 on page 22 and Figure 4.3 on page 22 for additional parts information.
(* denotes reference to Figure 2-1 on page 5.)



1. Locate the male end of the supplied output port fitting (PN 55542) found within the top cover. Connect
with the output port (*9).

2. 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.

3. 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 male end of the input hose (*3) to the female

CGA-580, customer-supplied, regulated pressure source.

4. 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.

5. If not already done, remove the Orion 3A pressure and vent valve knobs (3) usin g the .061" hex wrench.

6. Energize the electronic calibration standard attached to one of the output ports (9) and let it warm up.

7. To adjust the pressure (coarse) valve, use a .050" hex

wrench to loosen the set screw (34) on the locknut

(2) and turn the locknut clockwise to its stop.

8. Check to see that the knob insert (4) is securely fastened

to the valve shaft (11). If it is loose, re-tighten

the set screws (23) with the .061" hex wrench.

9. Close the pressure (coarse) valve by turning

the knob insert (4) clockwise until you feel the valve needle

seat on the O-ring (valve is now in closed position).

10. Rotate gears on both isolation valves (t

wo inner valves), counter-clockwise until they stop, then rotate

clockwise 1/2 turn (opening isolation valves).

11. With a pressure source connected to the input port (*

4). Use the Condec REG 1000 (*10), to increase the
regulated pressure (monitor the regulated pressure gauge [*7]) to 1,000 PSIG. Enable the power switch
(*2) and monitor the pressure as it builds in the accumulator gauge (*7). Turn the power switch (*2) off
when 8,000-10,000 PSIG has been achieved.



Do not operate the unit in continuous mode without an operator being present.



12. Open the vent valve (*12) to atmosphere, then close the ven t valve (*12).

13. Slowly open the pressure (coarse) valve by turning the knob insert (4) counter

-clockwise until the

displayed pressure increases. Then turn the knob insert slightly clockwise until the pressure stops rising.

14. Mark a radial line at the 12 o'clock position on the knob insert.

15. Turn the knob insert (4) clockwise to move t

16. Turn the locknut (2) counter-clockwise until it contacts the

he mark to the 6 o'clock position.

bottom of the stop washer. Tighten the set

screw (34) on the locknut with the .050" hex wrench.

17. Install the pressure (coarse) valve knob (3) on the knob

insert (4) and engage its gear (5) with the smaller

isolation valve gear (6). Turn the knob clockwise until the isolation valve is slightly snug.



Do not use excessive torque when tightening pressure (coarse) valve knob. Doing so may damage the seat.

18. Remove the pressure (coarse) valve knob. Align the set screws (25) with indentations on the knob insert
(4). Install the knob on the knob insert while engaging the knob gear (5) with the isolation valve gear (6).

19. Tighten the set screws (25) with the

20. To adjust the vent valve, follow steps 7-8 replacing the term pr

.061" hex wrench. The pressure (coarse) valve is now adjusted.

essure (coarse) valve with vent valve.

Maintenance & Service 11

21. Close the pressure (coarse) valve by turning the pressure (coarse) knob (*11) clockwise.

DANGER

Note

Note

22. Close the vent valve knob insert (4) clockwise until slightly snug.

23. With a pressure source connected to the input port

(*4). Use the Condec REG 1000 (*10), to increase the
regulated pressure to 1,000 PSIG. Enable the power switch (*2) and monitor the pressure as it builds in
the accumulator gauge (*7). Turn the power switch (*2) off when 8,000-10,000 PSIG has been achieved.
Open the pressure (coarse) valve until the indicated pressure viewed on the electronic calibration
standard, attached to one of the output ports (*9), stabilizes and then close the pressure (coarse) valve.



Do not operate the unit in continuous mode without an operator being present.

24. Slowly turn the vent valve knob insert (4) counter-clockwise until the electronic calibration standard
display, attached to one of the output ports (*9) starts to decrease, then turn the knob insert (4) slightly
until the indicated pressure stops decreasing.

25. Follow steps 13 through 19 replacing the term pr

essure (coarse) valve with vent valve. The vent valve is

now adjusted.

4.2.9 Accumulator Assembly, O-ring (PN 58051) Replacement, Filter (PN 56993) Cleaning

Tools required:

• Phillips screwdriver

• 5/8" Open end wrench

• Adjustable wrench

Disassembly:

• A/R 1/4" wide teflon tape, (PN 60575)

• Tube fluorinated Krytox grease (PN 55593)

• A/R solvent (de-natured alcohol)

1. Remove the accumulator assembly from PIN8000/PIN8010 per Section 4.2.2 on page 6.

2. Place the accumulator body in vis

3. Remove the plug adapter fitting (PN 57134) using

e, using flats.

an adjustable wrench.

4. Remove the O-ring (PN 58051) and back-up ring (PN 59735).

5. Remove the accumulator body from the

vise and place the adapter fitting in the vise, using flats with

threads facing upwards.

6. Remove the filter retainer fitting (P

7. Remove the plug adapter fitting from the vise, turn upside

8. Clean the filter (PN 56993) in solvent (de-natured alcohol) and blow-dry with compr

N 57811) using a wrench.

down, and remove the filter.

essed air.

Assembly:

1. Place the filter (PN 56993) into the filter retainer fitting (PN 57811).

2. Finger-tighten the filter retainer fitting into the plug adapter fitt

3. Place the plug adapter fitting (PN 57134) in a vise and tighten

ing (PN 57134).

the filter retainer fitting.

4. Grease the O-ring/back-up ring groove on the plug adapter fitting.

5. Grease both sides of the O-ring (PN 58051) and back-up ring (PN 59735). Install the back-up ring
the plug adapter fitting, followed by the O-ring.

Use a pointed bent pick when installing the O-ring to prevent damage. Verify the backup ring split is properly aligned.

6. Place the accumulator body in a vise using flats. Grease the accumulator body in the O-ring seat area,
then slowly thread the plug adapter fitting using an adjustable wrench into the accumulator body.

To help seat the back-up ring, hand-tighten the plug adapter fitting close to bottoming, then wrap an 8" piece of 22
AWG, solid buss wire around the
adapter fitting. Pull the buss wire ends to squeeze the back-up ring into the proper position within the accumulator
body. Verify the back-up ring split is properly aligned and overlapping properly.

edge of the back-up ring with a gap between the accumulator body and plug

7. Tighten the plug adapter fitting.

8. Install the accumulator assembly

12 PIN8000/PIN8010 Operation and Maintenance Manual

into PIN8000/PIN8010 per Section 4.2.7 on page 10.

onto

4.2.10 Intensifier Assembly, O-rings/Seals Replacement

Note

Note

Note

Important

Tools required:

• Phillips screwdriver

• 5/8" Open end wrench

•1/4” Hex key

• 3/16” Hex key

•3/8” Hex key

• Adjustable wrench

• Check valve seat tool (PN 70711)



See Table 4-3 on page 24 and Figure 4-3 on page 25 for additional parts information.

Disassembly Rings and Seals:

• Fitting holder tool (PN 70710)

• Tapered packing retainer tool (PN 70712)

• Check valve fitting tool (PN 70709)

• A/R 1/4" wide teflon tape, (PN 60575)

• Tube fluorinated Krytox grease (PN 55593)

• Oil lubricant, (PN 60944)

• A/R solvent (de-natured alcohol)

1. Remove the intensifier assembly from PIN8000/PIN8010 per Section 4.2.2 on page 6.

2. Remove the 10 cap screws

(1) and washers (2) from the end cap which has the single elbow fitting (23).

3. Remove the end cap (3) and O-ring (4).

4. Remove the piston (18).

5. Remove the small piston retainer (24)

and three piston rings (22).

6. Remove the large piston O-ring (21) and two packing retainers (20).

Disassembly of Check Valves:

1. Remove the inlet check valve fitting (12) and outlet (16) port.

2. For the outlet valve, remove, in order, the spring housing (8), spring (9), poppet (10) and sea

3. For the inlet valve remove, in order, th

e seat (15), poppet (10) and spring (9).

Reassembly of Check Valves:

t (11).

Clean all parts with solvent and use an air hose to remove any dust particles from all mechanical parts, except
screws and washers. Replace all damaged parts with new ones.

For ease of assembly and to prevent damage to

• check valve seat tool (PN 70711)

• fitting holder tool (PN 70710)

For the outlet valve:

parts, it is recommended to use the following tools during assembly:

• tapered packing retainer tool (PN 70712),

• check valve fitting tool (PN 70709)

1. Assemble the spring (9) and check valve (10) into the spring housing (8).

2. Press the check valve seat (11) into the spring housing (8) using the la

rge diameter end of the check valve
seat tool (PN 70711). Be sure the check valve seat (11) is seated. Coat grease in the bottom groove marks
and in the hole of the end cap (19) where fitting item 16 goes.

The larger of the two seats belongs to the outlet check valve. It is very important not to get grease in the
counter-sunk hole located at th

e center of groove marks.

3. Place grease on the bottom of items (11/8) sub-assembly.



Take care to not get grease on item 10.

4. Slide the (11/8) sub-assembly into the end cap (19) until it is properly seated on the bottom. Thread the
high pressure tube fitting (16) into the end cap (19) and tighten using a 5/8” wrench.

5. For the inlet valve, perform the following steps:

6. Thread the “AN” side of the inlet check valve fit

7. Place a small amount of grease (PN 55593) on the inlet c

ting (12) into the fitting holder tool (PN 70710).

heck valve fitting (12) between the groove area

Maintenance & Service 13

and the top of the fitting to enable ease of installation of the packing retainer (13).

Note

Important

8. Place the tapered packing retainer tool (PN 70712), stepped part, into the hole in the packing retainer
(13). Place grease on sides of the tool.

9. Slide the packing retainer (13) onto the p

acking retainer tool (PN 70712) and down into the groove of the

inlet check valve fitting (12).

10. Remove the packing retainer tool (PN

11. Grease both sides of the O-ring (14) and install into

12. Use the stepped part of the packing retainer tool (PN 70

70712) and wipe grease from the tool.
the groove on the inlet check valve fitting (12).

712) on the check valve seat (15) to install into
the recessed end of the inlet check valve fitting (12). The check valve seat (15) must seat flat. If needed,
tap the tool very lightly to seat, but make sure no damage occurs to the inlet check valve fitting (12).

13. If required, tap the round dowel (25) into the hole on the

threaded shaft of the piston ring retainer (24).
Leave extra material protruding from both sides of the shaft. Trim the round dowel (25), using cutters, to
the top of threads on both sides. Thread the piston ring retainer (24) into the piston (18), two or three
turns, to form threads on the round dowel (25). Remove the piston ring retainer (24) from the piston (18).

14. Grease the inside wall of the end cap (19) where the inlet check valve fitti

ng (12), sub-assembly, O-ring,

and back-up ring will touch.

15. Place the spring (9) and check valve (10) into the end c

16. Thread the “AN” side of the inlet

check valve fitting (12), sub-assembly into the fitting holder tool (PN

ap (19).

70710). Now place the sub-assembly into the check valve fitting tool (PN 70709) so the flat side of item
15 goes through the beveled side of the tool.

17. Slide item 12 back and forth in the tool a few times to

align the O-ring and backup ring. Remove the

sub-assembly from the check valve fitting tool (PN 70709) and unthread from the fitting holder tool (PN

70710). Thread item 12 sub-assembly into the e nd cap (19), where the spring (9) and check valve (10)
were previously installed. Tighten using a 5/8” wrench.

Reassembly of Rings and Seals:

Clean all parts with solvent and use an air hose to remove any dust particles from all mechanical parts, except
screws and washers. Wipe the bores of the in
all damaged parts with new ones.

tensifier housing with a clean cloth before installing the piston. Replace

1. Smear a medium amount of grease in the O-ring cavity on piston (18). Grease both sides of the two
back-up rings (20) and the O-ring (21). Install into the groove on piston (18).



The split of each backup ring (20), must be 180o from each other with the ends properly overlapping.

2. Lightly coat the edges of backup rings (20) and the O-ring (21) with oil lubricant (PN 60944).

3. Lightly coat both inside diameters of

4. Place grease on the piston ring retainer (24)

the housing (17) with oil lubricant.

where the piston rings (22) seat.

5. Place grease on both sides of the three piston rings (22) and install the three piston rings (beveled sides
aligned) onto the piston ring retainer (24).

6. Slide the piston (18) into the housing (17), being careful

not to damage wall areas. Slide until the smaller

diameter of the piston (18) is exposed from the side of housin g (17).

7. Thread item 24 with the three piston rings (22)

into the piston (18) approximately four turns.

8. Stand housing 17 on end, with the piston ring retainer (24) facing upward. Push the piston ring retainer to
verify it

will fully go into the housing. The top of the piston ring retainer (24) must be slightly below the

surface of housing (17).

9. Place the housing (17) on its side. Place a 3/16" hex key

in the piston ring retainer (24) and a 1/4" hex

key in the piston (18). Rotate the 1/4" hex key to tighten.

10. Remove the 3/16" hex key and verify the piston (18) will rotate. If

the piston rotates, remove the 1/4" hex

key. If it does not rotate, loosen the piston slightly.

11. Grease both sides of the O-ring (4) and end cap (3) O-ring groove. Install the O-ring (4) into the groove
of the end cap (3).

14 PIN8000/PIN8010 Operation and Maintenance Manual

12. Place the housing (17) sub-assembly with large I.D. upward and install the end cap (3) into the housing

Note

Note

WARNING

(17).

13. Place the cap screw (1) through the washer (2) and thread finger-tight into the end cap (3). Repeat for the
other nine cap screws.

14. Use a torque wrench and 1/4" hex key socket to torque each bolt to 325 in/lbs.

Torque cap screws in a side-to-side pattern (do not use a circular pattern) and in small increments to ensure the end
cap (item 3) is seated flat to the housing surface.

15. If previously removed, place the 1/4" tape, two turns, on the 90o NPT elbow (23). Thread and tighten the

o

NPT elbow (23) into the end cap (3). Align so the 90o NPT elbow (23) is parallel with the small hole

90
located on the side of housing (17).

16. Grease both sides of the O-ring (7) and O-ring seat area

on the end cap (19). Install the O-ring (7) onto
the end cap (19) and place onto the housing (17). Orient such that the small hole located on the housing
side is on your left at the "9 o’clock" position. The inlet check valve fitting (12) placement hole located
on the end cap (19) must be at the 6 o’clock position.

17. Place the cap screw (5) through the was

her (6) and end cap (19) and thread finger-tight into the housing
(17). Repeat for the other nine cap screws. Use a torque wrench and 3/8” hex key socket to torque each
bolt to 325 in/lbs.

Torque cap screws in a side-to-side pattern (do not use a circular pattern) and in small increments to ensure end cap
(item 19) is seated flat to the housing surface.



18. Install the intensifier assembly into PIN8000/PIN8010 per Section 4.2.7 on page 10.

4.2.11 REG 1000 (Regulator) and Solenoid Removal

Solenoid 120 VAC input - PN 56851, Solenoid 220 VAC input - PN 54366
Tools required:

• Phillips screwdriver

• 7/16" Open end wrench

• 9/16" Open end wrench

• A/R 1/4" wide teflon tape, (PN 60575)

Vent any remaining gas from the system to the atmosphere. Disconnect the power cord from the power
source.

• A/R 1/2" wide teflon tape, (PN 60911)

• 1/2" Socket

• Socket wrench

• 1/4" Hex wrench

1. Remove the front panel from its enclosure as described in Section 4.2.1 on page 6 and carefully place on
a bench top.

2. Remove the regulator knob cap and two scre

3. Loosen and remove the locknut using a 1/2" socket

ws which secure the round plate.

while holding the knob.

4. (PIN8010 Only) Loosen tube nuts on the input port and output (test) port fittings. Remove
screws and AC input/input port/output (test) port panel.

5. Remove all tubing sections that connect to

6. Loosen the mounting collar in the panel rear

7. Remove the regulator/solenoid assembly

8. Mount the regulator in a bench vise

by the flats in the base.

9. Note the orientation of the solenoids, as well as the inlet and

the regulator/solenoid assembly.

using a 1/4" hex wrench.

by sliding out from the panel rear.

outlet fittings in the regulator. Remove the

fittings and any remnants of teflon tape from the pipe threads.

the two

Maintenance & Service 15

4.2.12 REG 1000 (Regulator) and Solenoid Installation

Important

Note

DANGER

WARNING

Solenoid 120 VAC input - PN 56851, Solenoid 220 VAC input - PN 54366
Tools required:

• Phillips screwdriver

• 7/16" Open end wrench

• 9/16" Open end wrench

• A/R 1/4" wide teflon tape, (PN 60575)

• A/R 1/2" wide teflon tape, (PN 60911)

• Snoop, liquid leak gas detector (PN 64781)

• 1/2" Socket

• Socket wrench

1. Wrap two layers of teflon tape on the pipe threads of each fitting, and using
install into the inlet and outlet of the regulator. Ensure that each, as well as, solenoids are oriented
properly. Use a bench vise when doing this.

2. Insert the new regulator/solenoid assembly into the panel through
the mounting ring.



Do not tighten cap screw until adjusting knob is installed.

3. Install the tubing sections to the inlet and outlet fittings.
PIN8010 only: Replace the AC input/input

port/output (test) port panel and two mounting screws.

Thread and tighten tube nuts on the input port and output (test) port fittings.

4. Install the adjusting knob on the threaded shaft by

turning clockwise. Turn the adjusting knob on the
threaded shaft until it is bottomed, then install the locking nut and tighten. Turn the knob until it bottoms.
Position the regulator so the bottom of the knob is 1/2" from the panel surface, then tighten the cap screw
on the mounting collar.

5. Using a pressure source connected to

the input port (4), set the regulator (10) pressure to 100 PSI. Enable
the power switch (2) and monitor the pressure as it builds in the accumulator pressure gauge (7). Turn the
power switch (2) off when 1,000 PSI has been achieved. Check all fittings for leaks. If there are no leak s,
vent the system and remove the pressure source.



Do not operate the unit in continuous mode without an operator being present.

previously noted orientation,

hole. Pass the adjusting end through

See Figure 3-1 on page 3 for items in parenthesis.



6. Install the panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 6.

4.2.13 Panel Gauge Removal and Installation

• Regulated pressure gauge (PN 59751), 0–1,500 PSIG

• Accumulator or Output pressure gauge (PN 59696), 0–15,000 PSIG

Tools required:

• Phillips screwdriver

• 7/16" Wrench

• A/R 1/4" wide teflon tape (PN 60575)

• Snoop, liquid leak gas detector (PN 64781)

• 9/16" Wrench

Panel Gauge Removal

Vent any remaining gas from the system to the atmosphere. Disconnect the power cord from the power



source.

1. Remove the front panel from its enclosure as described in Section 4.2.1 on page 6 and carefully place on
a bench top.

2. Disconnect the tubing section which connects to

3. Loosen the two thumb-nuts that ho

ld the gauge mounting U-clamp.

4. While gripping the square portion of the gauge port

the gauge fitting.

with the 9/16" wrench, remove the tube connector

fitting from the gauge.

5. Remove the two thumb-nuts, the mo

unting U-clamp, and the gauge.

16 PIN8000/PIN8010 Operation and Maintenance Manual

Panel Gauge Installation

Note

DANGER

Important

Note

WARNING

Note

1. Before installing a new gauge, wrap two layers of new Teflon tape on the port.

2. Install the gauge into the panel,

3. While gripping the square portion of the gauge port

secure with a U-clamp, and tighten the two thumb-screws.

with the 9/16" wrench, tighten the female tube

connector onto the gauge.

4. Attach the tubing section which connect

5. Using a pressure source connected to the

s to the gauge fitting.

input port (4), set the Condec REG 1000 (10) pressure to 100
PSI. Enable the power switch (2) and monitor the pressure as it builds in the accumulator pressure gauge
(7). Turn the power

switch (2) off when 1,000 PSI has been achieved. Check all fittings for leaks. If there

are no leaks, vent the system and remove the pressure source.



Do not operate the unit in continuous mode without an operator being present.



See Figure 3-1 on page 3 for items in parenthesis.

6. Install the panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 6.

4.2.14 Output (Test) Port Quick-Connect Fitting (PN 59004) and Filter (PN 54188), Removal and Installation

Every two months, a coating of fluorinated Krytox grease should be applied to the inner seal of the output (test)
port fitting. The pressure cap (PN 58216) should be plugged in whenever the unit is not in use.

Apply fluorinated Krytox grease to the outside surface between the sealing lip and the end of mating pressure cap.
Do not put grease on the flat end of the tip, as this may al
to the atmosphere. Plug the pressure cap into the output (test) port. Rotate the pressure cap clockwise and
counter-clockwise to transfer fluorinated Krytox grease to the O-ring seal.

low grease to enter the system. Vent the unit line pressure



If there is leakage out of the port when the pressure cap is in place, replace the port fitting.

Tools required:

• Phillips screwdriver

• 11/16" open-end wrench

• adjustable wrench

• 9/1 6" open-end wrench

• A/R 1/4" wide Teflon tape (PN 60575)

• A/R 1/2" wide Teflon tape (PN 60911)

• Tube fluorinated grease (PN 55593)

• Snoop, liquid leak gas detector (PN 64781)

• A/R solvent (de-natured alcohol)

Vent any remaining gas from the system to the atmosphere. Disconnect the power cord from the power
source.

1. Remove the front panel from its enclosure as described in Section 4.2.1 on page 6 and carefully set on a
bench top.

2. Loosen and remove the tubing end



Use PN 54047 for reducing tube fitting field replacement.

nut from the reducing tube fitting (PN 59830).

3. Loosen and remove the reducing tube fitting and filter (PN 54188) from the output (test) port
quick-connect fitting.

4. Clean the filter (PN 54188) in solvent (de-natured alcohol) and blow-dry

5. Grasp the output (test) port quick-connect fitting on the flats from the rear of panel with a

with compressed air.

11/16" wrench

and using an adjustable wrench, turn the locknut counter-clockwise to remove the locknut.

6. Remove the old output (test) port quick-connect fitting and install

a new output (test) port quick-connect

fitting (PN 59004) through the panel’s front.

7. Thread and tighten the locknut by grasping the output (test) port quick-connect fitti

ng on the flats from

the rear of the panel with a 11/16" wrench and using an adjustable wrench, turn the locknut clockwise.

Maintenance & Service 17

8. Slide the filter (PN 59764) into the reducing tube fitting and install it into the output (test) port

Note

DANGER

quick-connect fitting.

9. Replace and tighten the tubing end nut on the reducing tube fitting.

10. Using a pressure source connected to the

input port (4), set the Condec REG 1000 (10) pressure to 100
PSI. Enable the power switch (2) and monitor the pressure as it builds in the accumulator pressure gauge
(7). Turn the power switch (2) off when 1,000 PSI has been achieved. Check all fittings for leaks. If there
are no leaks, vent the system and remove the pressure source.



Do not operate the unit in continuous mode without an operator being present.



See Figure 3-1 on page 3 for items in parenthesis.

11. Install the panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 6.

4.2.15 Output (Test) Port Hose Quick-Connect Fitting and Filter (PN 56991), Removal and Installation

Tools required:

• 5/8" Open end wrench

• 3/4" Open end wrench

• A/R solvent (de-natured alcohol)

• Tube fluorinated grease (PN 55593)

• 13/16" Open end wrench

Removal:

1. Loosen and unthread the quick-connect fitting assembly from output (test) port hose using 3/4" and 5/8"
wrenches.

2. Remove the cheat seal pad (PN 54854) from

3. Place the quick-connect fitting assembly in a vise using

4. Loosen and unthread

5. Remove the filter fitting (P

the quick-connect fitting (PN 59034) using a 13/16" wrench.

N 59588) from the vise.

6. While holding the filter fitting (PN 59588) vertically, remove the filter

the “AN” thread side of the adapter fitting (PN 60803)

the filter fitting (PN 59588) as a clamping area.

(PN 56991) and then O-ring (PN

55608) from the filter fitting.

7. Inspect and clean parts in solvent (de-natured alcohol)

and blow-dry with compressed air. Replace worn

or damaged parts with new ones.

Installation:

1. Grease the inside cavity on the bottom flat (none allowed in hole) of the quick-connect fitting (PN

59034).

2. Grease the O-ring seat groove area in the fil

3. Grease both sides of the O-ring (PN 55608). While holding the

ter fitting (PN 59588).

filter fitting (PN 59588) vertically, place

the O-ring (PN 55608) and then filter (PN 56991) into the filter fitting (PN 59588).

4. Thread the quick-connect fitting (PN 59034) onto the f

5. Place the filter fitting (PN 59588) in a vise and tighten the quick-connect fitting (PN

ilter fitting (PN 59588).

59034) using a

13/16" wrench.

6. Remove from the vise.

7. Place a cheat seal pad, (PN 54854) on the “AN” part of

the assembly and thread into the output (test) port

hose. Tighten the assembly using 5/8" and 3/4" wrenches.

18 PIN8000/PIN8010 Operation and Maintenance Manual

4.2.16 Input Port Filter (PN 54188), Removal and Installation

WARNING

Note

Note

DANGER

The port filter is a sintered element filter, which is easily removed for inspection and cleaning.
Tools required:

• Phillips screwdriver

• 7/1 6" open-end wrench

• A/R solvent (de-natured alcohol)

• Snoop, of liquid leak gas detector (PN 64781)

• 9/1 6" open-end wrench

Input Port Filter Removal

Vent any remaining gas from the system to the atmosphere. Disconnect the power cord from the power
source.

1. Remove the front panel from its enclosure as described in Section 4.2.1 on page 6 and carefully place on
a bench top.

2. Loosen and remove the tubing end nut from the tube union (PN 59886).

3. Loosen and remove the tubing end

nut from the input port bulkhead “AN” fitting (PN 59707).

4. Remove the tube union (PN 59886), port connector (PN 59746) and filter from the bulkhead “AN”

ng (PN 59707).

fitti



Use PN 55705 for port connector field replacement.

5. Clean the filter (PN 54188) in solvent (de-natured alcohol) and blow-dry with compressed air.

Input Port Filter Installation

1. To reinstall, reverse the order of steps 3, 4 and 5 of the "Input Port Filter Removal" procedure above.

2. Using a pressure source connected to the

input port (4), set the REG 1000 (10) pressure to 100 PSI.
Enable the power switch (2) and monitor the pressure as it builds in the accumulator pressure gauge (7).
Turn the power switch (2) off when 1,000 PSI has been achieved. Check all fittings for leaks. If there are
no leaks, vent the system and remove the pressure source.



Do not operate the unit in continuous mode without an operator being present.



See Figure 3-1 on page 3 for items in parenthesis.

3. Install the panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 6.

4.2.17 Input Port Hose Quick-Disconnect Female Fitting, Removal and Installation

Tools required:

• 3/4" Open end wrench

• 9/16" Open end wrench

Removal:

• A/R solvent (de-natured alcohol)

• A/R 1/2" wide Teflon tape (PN 60911)

1. Loosen and unthread the quick-disconnect fitting from the inp ut hose using 3/4" and 9/16” wrenches.

2. Remove the cheat seal pad (PN 54854) from the “AN” thread side of the adapter fitti

ng (PN 60803) and

place the CGA-580 nipple (PN 57150) pressure fitting in a vise, holding by flats located on the nipple.

3. Loosen and unthread the adapter fitting (PN 60803) from the CGA-580 nipple pressure fitting using a
3/4

" wrench.

4. Remove the CGA-580 nut (PN 57154) by

5. Remove remnants of tape from the

fittings.

6. Inspect and clean parts in solvent (de-natured alcohol)

sliding over threads of the CGA-580 nipple pressure fitting.

and blow-dry with compressed air. Replace worn

or damaged parts with new ones.



Maintenance & Service 19

Installation:

Note

WARNING

Note

Note

Note

1. Wrap two turns of 1/2" Teflon tape around threads of the CGA-580 nipple (PN 57150) pressure fitting.

2. Hold the CGA-580 nipple pressure fitting in a vise

by flats located on the nipple.

3. Slide the CGA-580 nut (PN 57154) over threads of the CGA-580 nipple pressure fitting.

4. Thread and tighten the adapter fitting (PN 60803) onto the

CGA-580 nipple pressure fitting using a 3/4"

wrench.

5. Remove the assembly from the vise and install a cheat

seal pad (PN 54854) on the “AN” thread side of

the adapter fitting (PN 60803).

6. Thread into the input hose and tighten using 3/4" and 9/16" wrenches.

4.2.18 AC Fuse (PN 57472), Removal and Installation

1. Disconnect the power cord and line filter. Remove the fuse holder at the AC input.

2. Inspect the fuse. If blown, replace with a 1/2 amp 250 volt, 20mm x 5mm diameter fuse (PN 57472).

3. Replace the fuse holder at

4.2.19 Panel Mounted AC Power/EMI Line Filter (PN 58870), Removal and Installation



See Figure 4-1 on page 5 for wiring diagram.

the AC input location.

Tools required:

• Phillips screwdriver

• 1/4" open-end wrench or nutdriver

• A/R shrink sleeving (PN 60735)

• A/R heat gun

• A/R soldering iron



Disconnect the power cord from the power source and line filter.

1. Remove the front panel from its enclosure as described in Section 4.2.1 on page 6 and carefully set on a
bench top.

2. Remove the three cable



Some units may not have connectors and will require wire leads to be unsoldered.

connectors from the line filter terminals.

3. Loosen and remove the line filter retaining nuts on the rear of panel.



Some units may have screws on the front panel.

4. Remove the AC line filter.

5. To install a new line filter, reverse the order of steps 1 through 4. Connect (or solder) wires to the new
line filter as

Green wire to terminal (E) Ground
White wire to terminal (N) Neutral
Black wire to terminal (P) Line

4.2.20 Power Switch (PN 60307), Removal and Installation



See Figure 4-1 on page 5 for wiring diagram.

follows:

Tools required:

• Phillips screwdriver

• Flat screwdriver

• 1/4" open-end wrench or nutdriver

• A/R soldering iron

• A/R shrink sleeving (PN 60735)

• A/R heat gun

20 PIN8000/PIN8010 Operation and Maintenance Manual

Removal:

WARNING

Note

WARNING

Note



Disconnect the power cord from the power source and line filter.

1. Remove the front panel from its enclosure as described in Section 4.2.1 on page 6 and carefully set on a
bench top.

2. Remove the two black wires from the pump control board TB2 terminals 1 and 2.

3. Loosen and remove the nut on the panel front and remove the

4. Unsolder and remove the three w

Installation:

ires from the switch terminals.

switch from the panel rear.

1. Use shrink sleeving over wires/terminals for protection. Connect and solder the harness wires to the new
switch terminals per the following:

Terminal Function

Rear of Switch 1 On
2 Off
3 Momentary

Black wire to switch terminal 1
Black wire to switch terminal 2
Black jumper wire between switch terminals 1 & 3

2. Install the new switch through the panel’s rear. Rotate the switch so the momentary position is toward the

bottom of the panel and secure it from the panel’s front with the mounting nut.

3. Replace the two black wires to the pump control board TB2.

Connect terminal 1 of the switch to terminal

1 of TB2, and terminal 2 of the switch to terminal 2 of TB2.

4. Install the panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 6.

4.2.21 Pump Control Board Assembly, Removal and Installation



See Figure 4-1 on page 5 for wiring diagram.

120 VAC input - PN 56679, 220 VAC input - PN 56682
Tools required:

• Phillips screwdriver

• 11/32" open-end wrench or nutdriver

• flat blade screwdriver (small)

Removal of Pump Control Board:



Disconnect the power cord from the power source and line filter.

1. Remove the front panel from its enclosure as described in Section 4.2.1 on page 6 and carefully set on a

bench top.

2. Disconnect the wires from the terminal blocks locate

d on the pump control board assembly. Make note

of the wire locations for future re-connection.

3. Loosen and remove the four nuts which hold th

Installation of Pump Control Board:

e pump control board and remove the board.

1. Position the new board over the four standoffs and install four nuts. Tighten the nuts until they are snug.

2. Connect the wires to the terminal blocks loca



Refer to the wiring diagram Figure 4-1 on page 5.

ted on the pump control board assembly.

3. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 6.

Maintenance & Service 21

4.3 Orion 3A Valve Assembly (PN 55287) Parts List

The following table lists the component parts of the Orion 3A.

Ref Number PN Description Quantity

1 57482 Nut, valve needle housing 2

2 54401 Locknut 2

3 58079 Knob 2

4 57889 Knob, insert 2

5 57256 Gear, spur 40 teeth 2

6 59233 Gear, spur 18-tooth 2

7 55896 Valve Seat 4

8 59387 Valve Seat, stem 4

9 59045 Valve, needle seat 4

10 54540 Housing, valve needle 2

11 59551 Valve Needle 2

12 57600 Bushing, end 1

13 58554 Cap, end 1

14 58699 Shaft 1

15 58597 Piston 1

16 59309 Body, dual valve 1

17 57580 Knob 1

18 55533 Valve Needle 2

19 55159 Housing, valve needle 2

20 56784 Locknut,9/16-18UNF-3A, SST 1

21 58464 Setscrew,12-24NCx1/4 SST 14

22 58308 Ball, Tungsten Carbide 14

23 59383 Setscrew, 6-32NCx1/8 SST 4

24 58342 Screw, cap hex socket head, #2-56UNC-3A 6

25 59322 Setscrew, 6-32NCx1/4 SST 6

26 59326 Setscrew, 2-56NCx1/8, alloy steel 4

27 55569 O-ring, Fluorocarbon (Viton)

28 55552 O-ring, Fluorocarbon (Viton) color black w/white dot 4

29 58090 O-ring, Fluorocarbon (Viton) color black w/white dot 1

30 60633 Retainer, Packing Backup 4

31 55570 Washer, backing 4

32 58045 O-ring, Fluorocarbon (Viton)

33 59245 Washer, nylon 2

34

35 60837 Screw, MACH #10- 32NF SST 2

36 54905 Screw, self sealing 1

38 57027 Washer, backup 1

39 54448 Retainer, packing backup 1

40 55615 O-ring, Fluorocarbon (Viton)

41 58314 Ball, chrome, steel 32

42 59731 Male connector, 1/8 tube x 1/8 NP

60202 Setscrew, hex 2

color black w/white dot 5

color black w/white dot 1

color black w/white dot 1

T, stainless steel 3

Table 4-2. Orion 3A Valve Assembly Parts List

22 PIN8000/PIN8010 Operation and Maintenance Manual

15

32

20

12

41/16X

14

41/16X

29

13

27

17

25/2X

25/2X

23/2X

3

4

5

24/3X

33

34

2

1

10

11

8

30

27

31

31

28

9

7

8

30

27

19

6

18

26/2X

43

21/14X

16

36

35/2X

B

A

C

D

1

1

1

1

2

1

1

1

1

2

2

2

1

2

2

2

42/3X

7

9

28

38

39

40

22/14X

1

2

NOTES:

LIGHTLY COAT THE FOLLOWING WITH LUBRICANT, PN 55593

O-RINGS, ITEMS 27, 28, 29, 32 & 40.

THREADS ON VALVE NEEDLES, ITEMS 11 & 18.

1

2

FOR REFERENCE ONLY:

O-RING, ITEM 27, .239 ID

O-RING, ITEM 28, .042 ID

O-RING, ITEM 29, .799 ID

O-RING, ITEM 32, .424 ID

O-RING, ITEM 40, .145 ID

THESE COMPONENTS TO BE INSTALLED

AT LOCATIONS B & C

THESE COMPONENTS TO BE INSTALLED

AT LOCATIONS A & D

Figure 4-2. Orion 3A Valve Assembly Exploded View

Maintenance & Service 23

4.4

Intensifier Assembly Parts List

Ref

Number

1 59328

2 60704

3 59548

4 55589

5 59333

6 59508

7 55579

8 60133

9 60343

10 57410

11 56714

12 57236

13 54456

14 55596

15 57114

16 59785

17 60333

18 59070

19 58786

20 60579

21 55600

22 54614

23 59794

24 58752

25 69435

PN Description Quantity

Screw, cap, socket

Washer, flat

Cap, end

O-ring, Buna-N (Nitrile) 70 Durometer color black

Screw, cap, socket head

Washer, flat

O-ring, Flourocarbon (Viton) 90 Durometer color black w/white dot

Housing, spring

Spring

Check valve

Seat, check valve

Fitting, check valve inlet

Retainer, packing backup

O-ring, Flourocarbon (Viton) 90 Durometer color black w/white dot

Seat, check valve

Adapter, High Pressure 1/4 NPT Male to Swagelok

Housing, piston

Piston

Cap, end

Retainer, packing

O-ring, Buna-N (Nitrile) 70 Durometer color black

Ring, piston

Elbow, 90 Tube to Male NPT

Retainer, piston ring

Dowel, round

10

10

1

1

10

10

1

1

2

2

1

1

1

1

1

1

1

1

1

2

1

3

1

1

1

Table 4-3. Intensifier Parts List

24 PIN8000/PIN8010 Operation and Maintenance Manual

6

5

10

9

11

9

10

12

14

15

13

16

8

3

22

18

24

23

2

1

4

20

21

17

19

7

25

20

Figure 4-3. Intensifier Exploded View

Figure 4-4. Condec REG1000 Regulator Mounting

Maintenance & Service 25

5.0 Model Number System

PIN8000 ____ ____
PIN8010 ____ ____
¦ ¦

+-------------------------------------+ ¦
¦ POWER REQUIREMENTS ¦
¦ ¦

A - 120 VAC 50/60 Hz ¦
B - 220 VAC 50/60 Hz ¦
¦
+----------------------------------------------+
A - Standard
(Only applicable letter)

Model Number System 29

6.0 Options and Replacement Kits

Note

Note

Orion 3A O-Ring Replacement Kit (Data Sheet # 65308):

• Fluorocarbon “Viton” (standard)...........

• Nitrile Buna-N.......................................................................................PN 58499

• Ethylene-Propylene...............................................................................PN 58506

• Silicone..................................................................................................PN 58509

• Neoprene ...............................................................................................PN 58515

A small coating of fluorinated Krytox grease, (PN 55593), should be applied to both sides of the O-ring prior to
installation.

• Pressure Trap (Data Sheet # 58596)......................................................PN 58478

• Output (Test) Port Quick-Disconnect Hose Fitting Male Coupling 
Body, other end 7/16-20 Male, with
(standard, requires Cheat Seal PN 54854)

• Output (Test) Port Quick-Disconnect Fitting Male Coupling Body, 
other end 1/4-18 NPT Female, with Internal 40 Mi
be used to connect DPDG Gauge

see Figure 6-4 on page 31. ....................................................................PN 151017

• Output (Test) Port Quick-Disconnect Fitting Male Coupling Body, 
other end 1/4-18 NPT Female, no Filter (may be

DPDG Gauge to Output Port). See Figure 6-5 on page 31...................PN 151019

• Five-Foot Hose with CGA-580 Male
filling optional External Pressure Cylinder

• Input Port Hose Nitrogen Bottle

Mating fitting (for connecting 

External Pressure Cylinder PN 59533 to Internal Port,

Cheat Seal Pad...................................PN 54854

Hose Adapter fitting..........................PN 60803

CGA-580 Nipple...............................PN 57150

CGA-580 Nut....................................PN 57154



For Input Port Quick-Disconnect Female Hose fitting assembly instructions see Section 4.2.17 on page 19.

................................................PN 55277

Internal 40 Micron Filter 

............................................PN 55542

cron Filter (may 

to Output Port). 

used to connect 

fitting, both ends, for use when

PN 59533..........................PN 150613

(one each of the following)

Output (Test) Port Hose, with Quick-Disconnect Male fitting:

• 5' Long...................................................................................................PN 55280

Input Port Hose, with Nitrogen Bottle Mati

ng fitting:

• 4' Long...................................................................................................PN 55360

• 10' Long.................................................................................................PN 55366

• 15' Long.................................................................................................PN 55369

• 20' Long.................................................................................................PN 55375

External Pressure Aluminum Cylinder with Shut-of
Carrying Handle, 83.3 cu ft. 3694 Test Pre

30 PIN8000/PIN8010 Operation and Maintenance Manual

ssure, 2216 PSI Service Pressure....PN 59533

f Valve, Rupture Disk and 

Figure 6-1. Pressure Trap (PN 58478)

Figure 6-3. Output (Test) Ports Quick-Disconnect Male

Hose Fitting (PN 55542)

Figure 6-4. Output (Test) Ports Quick-Disconnect Fitting

(PN 151017)

Figure 6-5. Output (Test) Port (output) Quick-Disconnect

Fitting (PN 151019)

Figure 6-2. External Pressur e Cylinder with Shut-off Valve

(PN 59533)

Options and Replacement Kits 31

7.0 Specifications

Temperature Range:

Operating Temp: +40° to +122°F (+4.4° to +50.0° C)
Storage Temperature: 0° to +185° F (–17.8° to +85°C)
Pressure Media: Dry gaseous nitrogen, standard

Optional External Pressure Cylinder:

Capacity: 83.3 ft3 N2 @ 2,216 PSIG

Volume: 960 in
Rating: 2,216 psig
Test Pressure: 3,694 psig
Material: Aluminum

Regulated Pressure Gauge:

Size: 2-1/2 in. diameter
Range: 0–3,000 PSIG
Test Pressure: 4,500 PSIG

Accumulator and Output Pressure Gauges:

Size: 2-1/2 in. diameter
Range: 0–15,000 PSIG
Test Pressure: 22,500 PSIG

Over-pressure Rupture Disk:

Rating: 3,000 PSIG, nominal
Type: Stainless steel outer case

Pressure Media Filter:

Rating: 20 microns, Output (Test) Ports and

Type: Field replaceable

Orion 3A Control Valves:

Type: Micro-metering with positive shut off,

Vernier Mechanical 
Rotation: 16 turns, nominal

Adjustable Sensitivity: 0.0005 PSI, minimum
Vernier Torque: Finger-tip adjust to 10,000 PSI
Material: Aluminum knobs, black anodized

Internal Piping:

Tubing: 1/8 in. O.D., 0.035 in. wall thickness,

Couplings: Stainless Steel, Swagelok type

Input Port:

Style: 1/4" 37° AN flare male
Pressure Rating: 2216 PSIG connected
Material: 300 series Stainless Steel

3

Input Port
40 microns, Output (Test) Port Hose

adjustable stop and replaceable seat,
non-destructible

All other parts 300 series stainless
steel

seamless Cu.
1/4 in. O.D., 0.035 and 0.065 in. wall

thickness, seamless 304 Stainless
Steel

Output (Test) Ports:

Style: Quick-disconnect type
Pressure rating: 10000 PSIG minimum, connected or

disconnected

Quantity supplied: Two Output Quick-disconnects 

(one, p/o output pressure hose)

Vent Port:

Style: 1/4" 37° AN male
Pressure Rating: 10,000 PSIG
Material: 300 series Stainless Steel

Pressure Hoses:

Quantity Supplied: Two; one input, one output
Length: 4 ft. nominal, input hose

5 ft. nominal, output hose

Style: Input hose - Nylon-lined core tube with

synthetic fiber braid and polyester
cover. Fitted with CGA-580 (Brass)
nipple fitting on one end and 1/4" 37°
female AN swivel pressure fitting on
opposite end.

Output hose - Nylon-lined core tube
with synthetic fiber braid and
polyurethane cover. Fitted with
quick-disconnect plug (St Stl) on one
end and 1/4" 37° female AN swivel
tube coupling on the other.

Condec REG1000 Regulator:

Type: Single stage, self-venting, non-bleed
Pressure Rating: 3,000 PSIG max. inlet

Carrying Case PIN8000 only:

Type: Aluminum case with latched cover and

handle
Material thickness: 0.090 in., nominal
Finish: Enamel paint, textured finish
Color: Gray

Control Panel:

Material: Aluminum (5052-H32)
Thickness: 0.125 in
PIN8000 Finish: Gray enamel paint with black

silkscreen nomeclature
PIN8010 Finish: Dark Tan enamel paint with black

silkscreen nomenclature

Physical Specifications:

Weight: 46 lbs including all hoses and cables
PIN8000 Case Dim’s: 11" wide x 18" long x 11.5" high
PIN8010 Case Dim’s: 19" wide x 8.1" deep x 10.5" high
(Case Dimensions excluding front handles).

32 PIN8000/PIN8010 Operation and Maintenance Manual

PIN8000/PIN8010 Warranty and Return Policy

CAUTION

If possible, please save original packing material which is specifically designed for the unit. Should it be
necessary to ship the unit back to the factory, a suitable shipping container must be used along with sufficient
packing material. Do not put a shipping label on the unit as a "suitable shipping container." Some units have been
severely damaged this way. This is a delicate, precision instrument. Any damage incurred because of poor
packaging procedures will ultimately result in added service charges and longer turnaround times.

Vent all pressure lines and the nitrogen cylinder, if applicable, to the atmosphere before
shipping.

When factory service is required, send in only the unit for repair. Retain fittings, nitrogen cylinder, manuals, etc. at
your facility. However, if there is a problem with a particular part, send in that part with the unit.

If a unit is found to be defective, it may be returned to our repair facility

CONDEC
3 SIMM LANE
DOOR D, UNIT 2A
NEWTOWN, CT 06470

ATTN: PRESSURE PRODUCTS/REPAIR LAB

at the following address:

Each unit's I.D. plate is stamped with a date code (week/year) prior to shipment. Our warranty is 12 months from
that date code and includes repair and/or replacement of the unit at our, Newtown facilities at no charge. Units
subjected to abuse or damaged by external influences, are not covered under warranty.

If the unit is found to be out of warranty, an evaluation fee

of not less than $150 (U.S. dollars) will be charged.
Our evaluation fee will be placed toward the unit’s repair cost unless the customer does not want the repair
completed. Please note on any attached paperwork if a repair estimate is required or if there are any other specific
instructions.

Please be explicit as to the nature of

the problem and/or its symptoms. Your documentation will save needless
time and expense. Also, please include a return shipping address (with a street address ) and a contac t name with
email, and fax and telephone numbers. Contact numbers are necessary to provide a job estimate and in case
further questions arise at the factory.



Specifications 33

PIN8000/PIN8010 Return Material Authorization Form

The repair lab is also equipped to do calibrations on our calibrators and pressure standards. Calibrations include a
certification and are traceable to N.I.S.T.

COMPANY NAME:

STREET:

CITY, STATE, ZIP:

TE LE P HO NE :

FAX:

CONTACT PERSON:

MODEL NUMBER:________________ SER

IAL NUMBER: _______________________________

PROBLEM WITH UNIT (PLEASE BE SPECIFIC):

IS THIS A WARRANTY REPAIR? ( ) YES

SHIP TO Address:

COMPANY NAME:

( ) NO

STREET:

CITY, STATE, ZIP:

ATTN:

CONDEC • 3 SIMM LANE • DOOR D, UNIT 2A • NEWTOWN, CT 06470

ATTN: PRESSURE PRODUCTS/REPAIR LAB

TEL: [phone] • FAX: [phone] or 715-234-6967

WEB SITE: www.4condec.com

34 PIN8000/PIN8010 Operation and Maintenance Manual

PN 132626 03/2012

Door D, Unit 2A ∙ 3 Simm Lane ∙ Newtown, CT 06470 ∙ USA

888-295-8475

www.4condec.com

©2012 Rice Lake Weighing Systems