Source 3000 Operation and Maintenance Manual
Contents
1. NOS PN Description Quantity 1 57482 Nut Valve Needle Housing 9 16 18 Width Across Flats 75 Thickness 12 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 57906 Bushing End 1 13 59378 Cap End 1 14 59495 Shaft 1 15 59241 Piston 1 16 55714 Body Dual Valve 1 17 57580 Knob 1 18 55533 Valve Needle 2 19 55159 Housing Valve Needle 2 Table 3 2 Orion 2C Valve Assembly Parts List Maintenance 13 Ref Number PN Description Quantity 20 56784 Locknut 9 16 18UNF 3A SST 1 21 59845 Plug Expansion 1562 0000 0012 Hole Diameter 14 23 59383 Setscrew 6 32NCx1 8 SST 4 24 58342 Screw Cap Hex Socket Head 2 56UNC 3A Purchase per MIL Spec 16995 2 6 25 59322 Setscrew 6 32NCx1 4 SST 6 26 59326 Setscrew 2 56NCx1 8 alloy steel 4 27 55554 O ring AS568A Dash No 010 Buna N Nitrile 70 Durometer Color Black 5 28 55536 O ring AS568A Dash No 002 Buna N Nitrile 70 Durometer Color Black 4 29 55573 O ring AS568A Dash No 117 Buna N Nitrile 70 Durometer Color Black 1 30 60633 Retainer Packing Backup Single Turn Tetrafluoroethylene 4 31 55570 Washer Backing 04 Thick Tetrafluoroethylene Resin 4 32 55577 O ring AS568A Dash No 111 Buna N Nitrile 702. PRESSURE LIMIT CONTROL PRESSURE LIMIT MONITOR COARSE ADJ USTMENT VERNIER VENT 3 2 Source Figure 2 2 Initial Setup Procedure Pressure Measurement Sequence To apply pressure close the VENT valve 2 approximately two turns until it stops then open the COARSE ADJ USTMENT valve 1 approximately 1 2 turn counter clockwise until the display begins to move The pressure may change rapidly until reaching approximately 90 of the desired final value Use either the COARSE ADJ USTMENT or VENT valve to obtain a specific pressure reading Both provide precise control As the pressure approaches the desired value the valve being used for control should be rotated slowly clockwise to its closed position With a little experience pressure values very close to the desired final value may be quickly achieved To obtain exact pressure readings slowly rotate the VERNIER control 3 knob in the direction required clockwise to increase pressure as indicated by the electronic standard display Source 3000 Operation and Maintenance M anual 3 0 Maintenance 3 1 Troubleshooting Symptom Problem Remedy Customers electronic standard display Leak in system Check all compression and pipe fittings slowly decreases over time with soap solution Electronic standard display does not No Vernier control Readjust isolation valves on Orion respond when Vernier knob is turned replace O ring
3. Rating Type 3400 PSIG nominal Stainless steel outer case Pressure Media Filter Rating Type 20 microns nominal Field replaceable Orion 2C Control Valve Type Material Internal Piping Tubing Couplings Vent Port Style Pressure Rating Material Fill Port Style Pressure Rating Material Test Port Pressure Rating Material Micro metering with replaceable soft seat Aluminum body clear anodized Aluminum knobs black anodized All other parts 300 series stainless steel 1 8 in O D 0 028 in wall thickness seamless stainless steel 316 stainless steel Swagelok type 1 4 37 AN male 3400 PSIG 316 series stainless steel 1 4 37 AN flare male 3400 PSIG rated 3050 PSIG operating 316 series stainless steel 5000 PSIG rated 3000 PSIG operating 300 series stainless steel Pressure Hose Fittings Quantity Supplied Three one input two test port fittings Style Input fitting 1 4 37 female AN swivel one end 1 8 NPT male on the other Test port fittings Quick disconnect plug SS on one end 1 4 NPT female on the other Input and test port hoses are supplied by customer Pressure Limit Control Regulator Type Single stage self venting non bleed Pressure Rating 3000 PSIG max inlet Carrying Case Type Aluminum case with latched cover and handle Material thickness 0 090 in nominal Finish Enamel paint textured finish Color
4. Durometer Color Black 1 33 59245 Washer 8 Screw Size 187 ID x 440 OD x 040 Thick Nylon 2 34 60202 Setscrew hex 2 35 60837 Screw MACH Pan Head 10 32NFx1 2 Phillips Head 300 Series SST 2 36 58976 Screw Self Sealing 8 32 x 5 8 Modified to Print al 38 53308 Label Roll 1 25x1 25 Polytrans 3000 Void 3 Core 8 OD 1 41 59878 Spacer 005 thk Mylar 2 42 59880 Spacer 007 thk Mylar 2 Figure 3 1 Standard Pneumatic Regulator PN 65455 14 Table 3 2 Orion 2C Valve Assembly Parts List INSERT POPPET SPRING BODY Source 3000 Operation and Maintenance Manual GS Q3 O RING PN 66654 INSERT LOCK SCREW Figure 3 2 Nitrogen Inlet Check Valve Assembly PN 60263 22 lni 7 7 Gy Figure 3 3 Orion 2C Exploded View 4 0 Specifications Pressure Specifications Pressure range Based on vendor s electronics Available pressure calibrations Overall accuracy Gage only absolute only or gage and absolute Based on vendor s electronics Operating Temperature 40 to 110 F 4 4 to 443 3 C Storage Temperature 0 to 185 F 17 8 to 85 C Pressure Media Dry gaseous nitrogen standard Internal Pressure Cylinder Capacity Volume Rating Test Pressure Material Pressure Supply Gage Size Range Test Pressure 15 2 ft Ny 3000 PSIG 133 in 3000 PSIG 5000 PSIG 6061 Aluminum 2 in diameter 0 4000 PSIG 4000 PSIG Over pressure Rupture Disk
5. Gray Control Panel Material Aluminum 5052 H32 Thickness 0 090 in Finish Gray enamel paint with black silkscreen nomenclature Physical Specifications Weight 25 Ib Case Dimensions Height 11 59 294 4 mm Width 18 00 457 2 mm Depth 7 19 182 6 mm Options PN 67248 Test port output 5 long hose with quick disconnect male hose fitting PN 78939 Fill port input 5 long hose with CGA 580 Cylinder connection fitting and Cheat Seal Pad PN 58483 Pressure trap See literature sheet 58609 PN 79423 Hose bag will fit inside top cover qanm 18 00 7 19 _ F g 1 11 59 3 20 E 4 Fas 7 Specifications 16 Source 3000 Warranty and Return Policy 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 turn around times Warni Vent all pressure lines and the nitrogen cylinder to the atmosphere before shipping A arning When factory service is required send in only the unit for repair Retain fittings m
6. hex wrench 7 Remove the regulator by sliding out from the panel rear 8 Mount the regulator in a bench vise by the flats in the base 9 Note the orientation of the inlet and outlet fittings in the regulator Remove the fittings and any remnants of Teflon tape from the pipe threads 3 2 12 Pressure Limit Control PN 65455 Regulator Installation Tools required Phillips screwdriver 7 16 wrench 9 16 wrench A R Teflon tape PN s 60911 amp 60575 bottle liquid leak gas detector PN 64781 NOTE See Table 3 2 on page 13 and Figure 3 3 on page 15 for additional parts information 10 1 Wrap two layers of Teflon tape on the pipe threads of each fitting and install into the inlet and outlet of the regulator and ensure that each is oriented properly Use a bench vise when doing this Insert the new regulator into the panel through hole Pass the adjusting end through the mounting ring Do not tighten cap screw until adjusting knob is installed Install the tubing sections to the inlet and outlet fittings Install the adjusting knob on the threaded shaft by turning clockwise Turn adjusting knob on threaded shaft until bottomed and install locking nut and tighten Turn knob until it bottoms Position the regulator so that the bottom of the knob is 1 2 from the panel surface then tighten the cap screw on the mounting collar Fill the cylinder to approximately 1000 PSIG and check all fittings for leaks See Section 2 1 on page 3 for cyl
7. 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 just stops at the seat ORION 2C Manifold Panel Installation Tools required 7 16 wrench Phillips screwdriver hex wrench 061 With the panel facing down against the bench install the manifold with the Port 1 and Port 2 side facing the panel bottom Install the two mounting screws PN 60837 from the panel front and tighten until snug 2 If not already done remove the panel knobs from the PRESSURE VERNIER and VENT valves using the 061 hex wrench 3 Install the panel knob onto the vernier valve shaft Align the set screws with the indentations and tighten until snug using the 061 hex wrench 4 To install and adjust the PRESSURE and VENT valve knobs follow the procedure in Section 3 2 10 5 Install the tubing sections from Port 1 fitting PN 65485 and Port 2 fitting PN 59833 on the Orion 2C using a 7 16 wrench 6 Install the tubing sections from the vent and pressure inlet fittings PN 59833 on the Orion 2C using a 7 16 wrench 7 Install all tubing sections that attach to the manifold 3 2 10 ORION 2C Manifold Valve Adjustment Procedure Tools required customer supplied electronic calibrator hex wrench 050 hex wrench 061 bottle of leak gas detector PN 64781 1 Fill the cylinder to approximately 1000 PSIG and check all fi
8. Remove the knob Align the two set screws with the indentations on the knob insert Install the knob on the knob insert while engaging the knob gear with the isolation valve gear Tighten the two set screws with the 061 hex wrench The PRESSURE valve is now adjusted To adjust the VENT valve follow steps 3 and 4 Close the VENT valve knob insert clockwise until slightly snug With the supply pressure between 500 and 1000 PSIG open the pressure valve until the indicated pressure stabilizes and then close the PRESSURE valve Slowly turn the VENT valve counter clockwise until the displayed starts to decrease then turn the knob insert until the indicated stops decreasing Follow steps 10 through 15 The VENT valve is now adjusted Pressure Limit Control PN 65455 Regulator Removal 7 16 wrench 9 16 wrench A R Teflon tape PN s 60911 amp 60575 1 2 socket 1 4 hex wrench NOTE See Figure 3 3 on page 15 1 Vent any remaining gas from the nitrogen cylinder to atmosphere 2 Remove front panel from its enclosure as described in Section 3 2 1 on page 5 and carefully place on a bench top 3 Remove regulator knob cap Remove two screws that secure the round plate 4 Loosen and remove the locknut using a 1 2 socket while holding the knob Remove the knob by turning counter clockwise 5 Remove all tubing sections that connect to the regulator inlet and outlet fittings 6 Loosen the mounting collar in the panel rear using a 1 4
9. SIG and check all fittings for leaks See Section 2 1 on page 3 for cylinder refilling procedure Maintenance 11 3 2 16 Port 1 Port 2 and Fill Port Filter PN 54188 The port filter is a sintered element filter which is easily removed for inspection and cleaning Tools required Phillips screwdriver 7 16 wrench 9 16 wrench A R solvent de natured alcohol bottle of liquid leak gas detector PN 64781 Port 1 or Port 2 Filter Removal 1 2 3 4 5 Vent any remaining gas from the nitrogen cylinder to atmosphere Remove front panel from its enclosure as described in Section 3 2 1 on page 5 and carefully place on a bench top Loosen and remove the tubing end nut from the tube adapter reducer fitting PN 59830 NOTE Use PN 54047 for field replacement Loosen and remove the tube reducer and remove the filter Clean the filter PN 54188 in solvent de natured alcohol and blow dry with compressed air Port 1 or Port 2 Filter Installation 1 2 To reinstall reverse the order of steps 2 through 4 of the Fill Port Filter Removal procedure above Fill the cylinder to approximately 1000 PSIG and check all fittings for leaks See Section 2 1 on page 3 for cylinder refilling procedure Fill Port Filter Removal 1 2 3 5 6 Vent any remaining gas from the nitrogen cylinder to atmosphere Remove front panel from its enclosure as described in Section 3 2 1 on page 5 and carefully set on a be
10. Source 3000 Self Contained Pressure Source Console Operation and Maintenance Manual p CONDEC Genuine Quality Proven Performance Sa Source 3000 Operation and Maintenance Manual Contents About This Mahua sesenscesscocecesessawevasxcsucevcavnsasuedecassdesvasauaeuccasesoseavsenncecayestsmniesendenee dacasranececanateaenttnaanersinn 1 0 2 0 3 0 4 0 1 Lrnugere V ono a REP RR ND b l 3 ORG AT OM m I 2 1 Pressure Cylinder Filing erres criaria ta aA RIA I HH I n 3 2 2 Irittial Setups ete ER EET REGERE EAR RED e ERE A S er ERR 4 2 3 Pressure Measurement Sequence 1 0 06 cece 4 Maintenance LIELELE LEE L LLL iii 5 3 1 Troubleshooting xs RRRERERIRERR eee fleet epee Sig a lee Ree ee FS 5 3 2 Maintenance Procedures ssepe eel eo neds Oa Meda nee a eo 5 3 24 Front Panel Removal Ses nitis odi hike sed lb a eee ir oo RA ode ee Bete dong ed ob Gee ag dee pd 5 3 2 2 Nitrogen Cylinder Assembly Removal PN 65622 sssssssssee ee en 5 3 2 3 Installing New Nitrogen Cylinder Assembly PN 65622 00 cece tee 6 3 2 4 ORION 2C Manifold Removal PN 58822 0 ccc ccc cee e 6 3 2 5 ORION 2C Manifold Valve Seat Removal anuau aaua 6 3 2 6 ORION 2C Manifold Vernier Control Disassembly 0 00 tees 7 3 2 7 ORION 2C Manifold Vernier Control Reassembly 0 0 cc es 8 3 2 8 ORION 2C Manifold Valve Seat Installation 0 0 0 0 e
11. anel Accompanying operator s manual provides clear concise instructions for system operation Safe Clean Operation All pressure components are made of brass aluminum or stainless steel and 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 Introduction 1 The heart of the Source 3000 are the two micro metering valves and the vernier provided for control of the internal nitrogen source Overpressure protection is provided by a fully adjustable pressure regulator which is manually set for each new device being tested The Source 3000 is designed for compatibility with all major manufacturer s electronic calibration equipment The following schematic provides an overview of the Source 3000 s function VERNIER ADJUST SUPPLY PRESSURE PRESSURE LIMIT ACTUAL 0 3000 PSI MONITOR FILTER FITER CHECK 20u VALVE 20u PORT1 Q N2 FILL PORT 3000 PSI MAX PRESSURE PRESSURE LIMIT ARENSE CONTROL QUICK DISCONNECT FILTER 20u PORT2 INTERNAL N2 SUPPLY 3000 PSI MAX QUICK DISCONNECT BURST DISK 3200 PSI 100 PSI VENT PORT Figure 1 1 Source 3000 Flow Diagram 2 Source 3000 Operation and Maintenance Manual 2 0 2 1 Operation Pressure Cylinder Filling To initially fill or refill the int
12. anuals 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 at the following address CONDEC 3 SIMM LANE DOOR D UNIT 2A NEWTOWN CT 06470 ATTN PRESSURE PRODUCTS REPAIR LAB Each unit s I D plate is stamped with a date code week year prior to shipment Our warranty is twelve 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 charge of not less than fifty U S dollars 50 00 will be charged 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 contact name with fax and telephone numbers Contact numbers are necessary to provide a job estimate and in case further questions arise at the factory 17 Source 3000 Operation and Maintenance Manual Source 3000 Return Material Authorization Form The repair lab is also equipped to do calibrations on our calibrators and pressure standards Calibrations include a certific
13. ation and are traceable to N I S T COMPANY NAME STREET CITY STATE ZIP TELEPHONE FAX CONTACT PERSON MODEL NUMBER SERIAL NUMBER PROBLEM WITH UNIT PLEASE BE SPECIFIC IS THIS A WARRANTY REPAIR YES NO SHIP TO Address COMPANY NAME STREET CITY STATE ZIP ATTN CONDEC 3 SIMM LANE DOOR D UNIT 2A NEWTOWN CT 06470 ATTN PRESSURE PRODUCTS REPAIR LAB TEL 888 295 8475 FAX 203 364 1556 or 715 234 6967 WEB SITE www 4condec com Specifications 18
14. dd thicker washer at step 3 otherwise continue to step 7 7 Install the locknut 20 and tighten until snug using the isolation valve socket female socket and wrench 8 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 is assembled 9 Install the self sealing screw 36 and tighten until snug 10 Apply a thin coat of grease and install the O ring 29 on the end cap shaft assembly install into manifold and tighten until snug 3 2 8 ORION 2C 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 061 torque wrench socket wrench 3 4 socket needle housing socket PN 65580 isolation valve socket PN 59793 female socket PN 65581 NOTE See Table 3 2 on page 13 and Figure 3 3 on page 15 for additional 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 a blunt end of a drill bit to install Install the valve needle seat 9 with the smaller diameter end facing outward 3 Install new O rings 28 27 inside and outside of the valve stem seat Coat all O rings and back up rings 30 31 with fluorinated Krytox grease before installation Make sure that the r
15. e M anual 4 Remove the male reducing adapter run tee assembly from the check valve 5 Remove the check valve from the female elbow fitting Remove any remnants of Teflon tape from the pipe threads Note direction of flow arrow Check Valve Disassembly 1 Remove lock screw from the inlet end tail of flow arrow using a 5 32 hex wrench 2 Force insert out by pushing against poppet with a blunt pin inserted into outlet Remove poppet and spring and clean in solvent If any damage to O ring is noticed replace check valve PN 66654 Blow dry parts before reassembly NOTE Apply a small amount of fluorinated Krytox grease on both sides of O ring PN 66654 3 Reassemble the check valve per as shown in Figure 3 2 on page 14 4 Torque insert lock screw to 85 inchpounds Check Valve Installation 1 Wrap two turns of Teflon tape on the check valve threads 2 Install the inlet end end opposite direction flow arrow is pointing of check valve into the female elbow fitting and tighten until snug 3 Install the other end of the check valve into the male reducing adapter run tee assembly 4 Install and tighten the tubing end nuts from the tee fitting PN 65386 5 Fill the cylinder to approximately 1000 PSIG and check all fittings for leaks See Section 2 1 on page 3 for cylinder refilling procedure 3 3 Orion 2C Valve Assembly Parts List The following table lists the component parts of the Orion 2C
16. ecommends that the internal nitrogen supply cylinder be pressure tested and re certified every five years from date cylinder was manufactured per U S DOT 3AL Regulation Title 49 CFR parts 173 and 178 Tools required 7 16 wrench Phillips screwdriver 1 1 8 wrench 3 8 wrench Procedure 1 Vent any remaining gas from the cylinder to atmosphere Remove front panel from its enclosure as described in Section 3 2 1 and carefully set on a bench top Using a 7 16 wrench remove flexible tubing PN 65384 from the cylinder elbow Remove the 4 mounting nuts and 2 clamps for the cylinder Remove the cylinder assembly Nu pwd If installing a new cylinder remove the fitting elbow assembly and Teflon seal and inspect for any damage If there is no damage reuse these items on the new cylinder Maintenance 5 3 2 3 Installing New Nitrogen Cylinder Assembly PN 65622 Tools required 7 16 wrench Phillips screwdriver 1 1 8 wrench 3 8 wrench 4 of 1 4 wide Teflon tape PN 60575 4 of 1 2 wide Teflon tape PN 60911 tube of fluorinated Krytox grease PN 55593 bottle of liquid leak gas detector PN 64781 1 Install the Teflon O ring PN 59217 fitting PN 59287 and elbow PN 59874 on the new cylinder PN 65458 and tighten until snug Place a small amount of Krytox grease on both sides of Teflon O ring prior to installation If installing new parts Teflon tape is required 2 Mount the cylinder in the enclosure making
17. ect e 8 3 2 9 ORION 2C Manifold Panel Installation 00 isses eh 9 3 2 10 ORION 2C Manifold Valve Adjustment Procedure 0 0 0 cece tees 9 3 2 11 Pressure Limit Control PN 65455 Regulator Removal 0 0 00 000 cece eee 10 3 2 12 Pressure Limit Control PN 65455 Regulator Installation liie essen 10 3 2 13 Panel Gage Removal sr R RDER Wie OIX REX EQ EEXEx E A adde E Meis 11 3 2 14 Panel Gage Installation is sirrinin na eem hr 11 3 2 15 Port1 amp Port 2 Quick Connect Fitting PN 55426 Removal and Installation 11 3 2 16 Port 1 Port 2 and Fill Port Filter PN 54188 0 0 ccc eee eens 12 3 2 17 Inlet Check Valve PN 60263 Nitrogen Fill Port 0 ec ccc eee fmm 12 3 3 Orion 2C Valve Assembly Parts List 0 eects 13 Specific aBOns iiscinicu mgr a EC TU FORM UCIEQ EU EUM AUS DEVIS CREER E C MARE ER RARE a a LO Source 3000 Warranty and Return Policy eene LD Source 3000 Return Material Authorization Form mms LO Copyright 2003 Rice Lake Weighing Systems All rights reserved Printed in the United States of America Specifications subject to change without notice August 2003 Source 3000 Operation and Maintenance Manual About This Manual The Source 3000 is a portable self contained pneumatic pressure console with precision vernier A rugged compact instrument manufactured by Condec designed to provide ease of operation when used in conju
18. ernal pressure cylinder 3000 PSI max of the Source 3000 see Figure 2 1 below and proceed as described below NOTE The pressure cylinder used as the filling source must be regulated to provide a maximum output of 3049 PSIG 1 2 3 Rotate the PRESSURE LIMIT CONTROL 1 counter clockwise until it stops Close the COARSE ADJ USTMENT valve 2 by rotating clockwise until it stops Connect the fill hose 3 supplied by customer to a clean regulated nitrogen source 5 Connect the other end of the fill hose 3 supplied by customer to the male fill port fitting 4 Use supplied AN to 1 8 male NPT adapter fitting PNs 59839 and 59708 and cheat seal pad PN 54854 between fill hose amp fill port Slowly open the valve on the nitrogen source and allow the gas to flow into the pressure cylinder NOTE Inlet check valve could be damaged if pressure is released too fast The SUPPLY PRESSURE gage 6 indicates the amount of pressure within the internal cylinder Use the following procedure for filling the cylinder a Fill cylinder to 1000 PSI at a rate of charge equal to a minimum of two minutes then wait five minutes for system to stabilize b Fill cylinder from 1000 PSI to 2000 PSI at a rate of charge equal to a minimum of two minutes then wait five minutes for system to stabilize c Fill cylinder from 2000 PSI to 3000 PSI at a rate of charge equal to a minimum of two minutes Wait five minutes for system to stabilize bef
19. g 32 from the piston groove To disassemble the end cap shaft assembly mount the end cap in the vise 9o SL ON M Loosen and remove the locknut 20 using the isolation valve housing socket PN 59793 female socket 65581 and socket wrench 9 Loosen and remove the end bushing 12 using the same socket Remove the shaft 14 Remove the mylar bearing washers 41 or 42 from both sides of the shaft flange 10 Use a small pick or screwdriver to remove the O ring 27 from the inner groove of the end cap 13 11 Wash all parts in solvent and blow dry with compressed air Maintenance 7 3 2 7 ORION 2C Manifold Vernier Control Reassembly Tools required tube fluorinated Krytox grease PN 55593 1 1 4 wrench screwdriver flat blade socket wrench isolation valve socket PN 59793 female socket PN 65581 1 Coat all new O rings with fluorinated Krytox grease before installing 2 Install the small O ring 27 into the end cap inner groove 3 Add mylar washers 41 or 42 to each side of shaft 14 NOTE Part number and quantity will vary Washers are used to adjust vertical play in shaft 14 Try one item 41 on each side to start 4 Apply a small amount of fluorinated Krytox grease to the shaft threads and install the shaft 14 into the end cap 5 Install the end bushing 12 and tighten until snug using the isolation valve socket female socket and wrench 6 Feel vertical motion of shaft 14 If motion exists a
20. inder refilling procedure Source 3000 Operation and Maintenance Manual 3 2 13 Panel Gage Removal Tools required Phillips screwdriver 7 16 wrench 9 16 wrench 1 Vent any remaining gas from the nitrogen cylinder to atmosphere 2 Remove front panel from its enclosure as described in Section 3 2 1 on page 5 and carefully place on a bench top 3 Disconnect the tubing section that connects to the gage fitting 4 Loosen the two thumb nuts that hold the gage mounting U clamp 5 While gripping the square portion of the gage port with the 9 16 wrench remove the fitting from the gage 6 Remove the two thumb nuts the mounting U clamp and the gage 3 2 14 Panel Gage Installation Tools required Phillips screwdriver 7 16 wrench 9 16 wrench A R 1 4 wide Teflon tape PN 60575 bottle liquid leak gas detector PN 64781 1 Before installing a new gage wrap two layers of new Teflon tape on the port 2 To install the gage reverse the order of steps 2 through 6 of the Panel Gage Removal procedure above 3 Fill the cylinder to approximately 1000 PSIG and check all fittings for leaks See Section 2 1 on page 3 for cylinder refilling procedure 3 2 05 Port 1 amp Port 2 Quick Connect Fitting PN 55426 Removal and Installation There is relatively little maintenance that has to be done to the port fitting Every 2 months a little coating of Silicone grease should be applied to the inner seal The pressure cap PN 55434 should be p
21. ings 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 Forthe two outer valves disassemble 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 fluorinated Krytox grease to the needle threads before reassembly Assemble the needle into the valve housing and turn it until it stops 8 Reinstall the needle housing assembly into the valve cavity until finger tight 8 Source 3000 Operation and Maintenance Manual 9 10 11 12 13 32 9 Mount the manifold body 16 in a vise For the pressure and vent valves only torque the needle housing assembly to 325 in lb using the needle housing socket PN 65580 Install the housing lock nuts 1 onto the housing 10 and tighten until snug with the 3 4 socket Install the knob insert 4 over the needle shaft align the set screws with the indents and tighten with the 061 hex wrench Install the needle housing 19 and tighten until snug using the housing installation socket PN 59793 female socket PN 65581 and torque wrench There is no specified torque so use care when tightening so as not to break the socket nibs
22. lugged in whenever the unit is not in use Note For simplest method apply fluorinated Krytox grease to the outside surface between sealing lip and end of mating quick disconnect fitting Vent unit line pressure to atmosphere Plug quick connect fitting into applicable testport Rotate fitting clockwise and counter clockwise to transfer fluorinated Krytox grease to O ring seal If there is leakage out of the port when the pressure cap is in place replace the port fitting Tools required Phillips screwdriver 2 3 4 wrenches 9 16 wrench A R Teflon tape PNs 60911 amp 60575 tube fluorinated grease PN 55593 bottle liquid leak gas detector PN 64781 Vent any remaining gas from the nitrogen cylinder to atmosphere Remove front panel from its enclosure as described in Section 3 2 1 on page 5 and carefully set on a bench top Grasp the hex at the panel face with a 3 4 wrench and using a second wrench turn the port fitting counter clockwise The short nipple PN 59112 may or may not be removed at the same time If the short nipple remains in the panel fitting a new port can be installed on it Remove any remnants of sealing tape and wrap two turns of Teflon tape to the threads Install the new quick connect fitting PN 55426 by turning clockwise If the nipple PN 59112 is removed along with the old fitting the nipple cannot be reused Install a new nipple along with the new port Fill the cylinder to approximately 1000 P
23. natured alcohol socket wrench 3 4 socket female socket 65581 needle housing socket 65580 isolation valve needle housing socket PN 59793 hex wrench 061 torque wrench needle nose pliers electric hand drill No 43 drill bit No 4 40 tap tap handle small hammer NOTE See Table 3 2 on page 13 and Figure 3 3 on page 15 for additional parts information Source 3000 Operation and Maintenance M anual 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 and vent valve threaded needle housings 10 4 Using the needle housing socket 65580 and torque wrench loosen and remove the needle housing assembly 10 1 5 To disassemble the isolation valve 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 59793 female socket 65581 and torque wrench Remove the valve stem seats 8 and valve needle seats 9 using the needle nose pliers 8 Remove the inner and outer O rings 28 27 and back up rings 31 30 from the valve stem seats and wash all parts in solvent de natured alcohol 9 To remove valve seats 7 from either the pressure vent or isolation valves try blowing compressed air through the i
24. nch top Loosen and remove the tubing end nuts from the tee fitting PN 65386 Loosen and remove the input port fitting nut located closest to the port connector fitting PN 59746 Loosen and remove the port connector fitting PN 59746 and the filter NOTE Use PN 55705 for field replacement of port connector fitting Clean the filter PN 54188 in solvent de natured alcohol and blow dry with compressed air Fill Port Filter Installation 1 2 3 2 17 To reinstall reverse the order of steps 2 through 4 of the Fill Port Filter Removal procedure above Fill the cylinder to approximately 1000 PSIG and check all fittings for leaks See Section 2 1 on page 3 for cylinder refilling procedure Inlet Check Valve PN 60263 Nitrogen Fill Port Remove the check valve if it does not hold the pressure of the N cylinder The check valve can be disassembled for cleaning should any debris foul the seat area Tools required Phillips screwdriver 7 16 wrench 9 16 wrench A R 1 2 Teflon tape PN 60911 5 32 hex wrench tube fluorinated grease PN 55593 bottle liquid leak gas detector PN 64781 torque wrench Check Valve Removal l 2 3 12 Vent any remaining gas from the nitrogen cylinder to atmosphere Remove front panel from its enclosure as described in Section 3 2 1 on page 5 and place on a bench top Loosen and remove the tubing end nuts from the tee fitting PN 65386 Source 3000 Operation and Maintenanc
25. nction with multiple manufacturers electronic calibrators for the calibration of a wide variety of pressure sensing and measuring devices Equipped to perform rapid on site calibrations these instruments have proven to substantially reduce the cost system down time and man hours of labor normally associated with these routine service functions This instrument is an all mechanical device that combines a 15 cubic foot 3000 PSI cylinder with our precision Orion 2C vernier The unit has multiple ports Front panel gages tell the operator system pressure as well as remaining pressure in the internal cylinder A pressure regulator will act as a pressure limiter so that the operator can not over pressure a unit under test Adapter fittings are supplied for the customer to put on their fill hose and test hose This manual has been written to give the user a simple and clear explanation of how to operate and troubleshoot these instruments Before attempting to use the Source 3000 Self Contained Pressure Source the following A Warning instructions must be carefully read and understood by personnel utilizing the equipment This is a high pressure system While a substantial effort has been expended to make this equipment safe simple and fool proof to operate it is strongly recommended that only personnel formally trained in the use of pneumatic pressure equipment be permitted to Operate it Potentially dangerous conditions could be produced through
26. negligent handling or operation of the console due to the high pressure cylinder contained within the unit These units are strictly for use with pneumatic pressures Erroneous readings and potential damage could result from the introduction of hydraulic fluids into the internal tubing lines Authorized distributors and their employees can view or download this manual from the Condec distributor site at www 4condec com 1 0 Introduction The Source 3000 represents the latest in technology offering a combination of features performance versatility and reliability not previously available in a single self contained pressure source instrument Some of the more outstanding features are listed below Using a manually adjustable regulator the maximum system input pressure is adjusted to any desired value higher typically 20 to 5096 than the full scale range of the device being tested By virtue of this technique the unit under test is fully protected from being inadvertently over pressurized e Portable These compact self contained systems are easily carried and operated by only one person Total weight is approximately 25 pounds e Pressure Source An internal supply cylinder with a volume of 15 0 std cu ft of N provides up to 3000 PSIG of pressure for calibration and test A check valve quick disconnect fitting provides re charging capability Simple Operation All controls gages and pressure ports are accessible from the front p
27. nlet and outlet fittings Otherwise the center holes will have to be drilled and a tap used to extract the seat 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 the 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 3 2 6 ORION 2C Manifold Vernier Control Disassembly Tools required A R solvent de natured alcohol 1 1 4 wrench screwdriver flat blade socket wrench isolation valve socket PN 59793 female socket PN 65581 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 will appear to lock up If this occurs rotate the shaft clockwise until the end cap is free to turn Remove the O ring 29 from the end cap Remove the self sealing screw 36 that acts as the piston key Extract the piston 15 by partially screwing in the threaded end of the shaft and pulling Remove the O rin
28. on Vernier piston Electronic standard display increases or No Pressure or Vent control Replace valve seats or O rings in valves decreases when PRESSURE or VENT check valve needles valves are closed Gas escapes when external supply N cylinder will not remain charged Remove inlet check valve clean or pressure is bled replace Table 3 1 Source 3000 Troubleshooting 3 2 Maintenance Procedures This section outlines the mechanical repair procedures for the Source 3000 pressure source The repair procedures cover the major components and subassemblies which are critical to the proper functioning of the calibrators and that will likely 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 relevant safety precautions should be observed due to the presence of high pressure cylinders 3 2 1 Front Panel Removal Tools required Phillips screwdriver 1 Loosen and remove the ten screws PN 60837 that secure the panel assembly to the enclosure 2 Lift the panel by first grasping the regulator knob and Port 1 then grasping under the panel edges Ensure that the flexible pressure cable does not catch or snag 3 Gently set the panel assembly on a bench top It can be rested on the panel bottom and regulator edge with the panel tilted at an angle from its vertical 3 2 2 Nitrogen Cylinder Assembly Removal PN 65622 Condec strongly r
29. ore using Figure 2 1 Pressure Cylinder Fill Procedure Operation 3 2 2 Initial Setup To prepare for actual calibration usage see Figure 2 2 below and proceed as follows 1 2 2 3 1 2 3 4 ui Check that the COARSE ADJ USTMENT valve 1 is closed rotate clockwise until it stops and that the vent valve 2 is open two turns counter clockwise from its stop Using the PRESSURE LIMIT CONTROL regulator 5 adjust the maximum system input pressure as read by the pressure limit monitor 4 to any desired value higher typically 20 50 higher than the full scale range of the device under test Using this technique the device under test is fully protected from being accidentally over pressurized Connect the male quick disconnect end of the port hose supplied by customer to one of the port 6 fittings Use supplied 1 4 female NPT quick disconnect fitting PN 55394 between port hose and Port 1 or Port 2 Connect the other end of the port hose to the input port of the electronic standard using adapters if required Tighten all connections Connect the end of the test hose supplied by customer to the electronic standard output port and the other end to the unit under test Tighten all connections properly NOTE If using a tee type port test hose connection the electronic standard is connected between the port and unit under test
30. sure that the elbow fitting tube hole is correctly oriented toward the top of case 3 Install the two clamps PN 65385 and 4 mounting nuts PN 61439 4 Install the flexible tubing section PN 65384 tightening fitting nut 1 4 turn from finger tight using a 7 16 wrench 5 Fill the cylinder to approximately 1000 PSIG and check all fittings for leaks See Section 2 1 on page 3 for cylinder refilling procedure 3 2 4 ORION 2C Manifold Removal PN 58822 Tools required Phillips screwdriver 11 32 wrench or nutdriver 061 hex wrench adjusting screwdriver small flat blade 11 32 wrench thin 7 16 wrench NOTE See Table 3 2 on page 13 and Figure 3 3 on page 15 for additional parts information 1 Vent any remaining gas from the nitrogen cylinder to atmosphere 2 Remove front panel from its enclosure as described in Section 3 2 1 on page 5 and place unit on a bench top 3 Remove the tubing sections from Port 1 fitting PN 65485 and Port 2 fitting PN 59833 on the Orion 2C using a 7 16 wrench 4 Remove the tubing sections from the VENT and FILL PORT inlet fittings PN 59833 on the Orion 2C using a 7 16 wrench 5 Remove the panel knobs from the PRESSURE VERNIER and VENT valves using the 061 hex wrench 6 Loosen and remove the 2 panel screws PN 60837 from the panel front that secure the manifold to the panel 7 Remove the Orion 2C manifold 3 2 5 ORION 2C Manifold Valve Seat Removal Tools required A R solvent de
31. ttings for leaks See Section 2 1 on page 3 for cylinder filling procedure 2 Using a 050 hex wrench loosen the set screw on the lock nut and turn the lock nut clockwise to its stop 3 Check to see that the knob insert is securely fastened to the valve shaft If it is loose re tighten the set screws with the 061 hex wrench 4 Close the PRESSURE valve by turning the knob insert clockwise until the valve is slightly snug 5 Connect customer supplied electronic calibrator 6 Increase the supply pressure to between 500 and 1000 PSIG 7 Open the VENT valve to atmosphere zero the customer supplied electronic calibrator then close the VENT valve 8 Slowly open the PRESSURE valve by turning counter clockwise until you notice the displayed pressure increase Then turn the valve shaft clockwise until the pressure stops rising 9 Mark a radial line at the 12 o clock position on the knob insert 10 Turn the knob insert clockwise to move the mark to the 6 o clock position 11 Turn the locknut counter clockwise until it contacts the bottom of the stop washer Tighten the set screw on the lock nut with the 050 hex wrench 12 Install the knob on the knob insert and engage its gear with the smaller isolation valve gear Turn the Maintenance 9 13 14 15 16 17 18 19 3 2 11 Tools required Phillips screwdriver knob clockwise until the isolation valve is slightly snug To avoid damage to the seat do not use excessive torque
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