Fluke Calibration 4322-SYS-NAVAIR Service Manual Download Page 3

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PN 4133214

September 2013 Rev. 2, 2/15

All product names are trademarks of their respective companies.

4322

Automated Pressure Calibrator

Service Manual

Reproduction and distribution of this technical
manual is authorized for U.S. Government purposes.

Summary of Contents for 4322-SYS-NAVAIR

Page 1: ...4322 SYS NAVAIR Automated Pressure Calibrator Service Manual...

Page 2: ...encies and their contractors for of cial use or for administrative or operational purposes determined on September 28 2011 Other requests for this document shall be referred to NAVAIR METCAL Program O...

Page 3: ...ts reserved Specifications are subject to change without notice All product names are trademarks of their respective companies 4322 Automated Pressure Calibrator Service Manual Reproduction and distri...

Page 4: ...nearest Fluke authorized service center to obtain return authorization information then send the product to that service center with a description of the difficulty postage and insurance prepaid FOB D...

Page 5: ...ations Handheld 1 9 2 Theory of Operation 2 1 Introduction 2 3 Controller 2 3 Pressure Control 2 4 External Supply Pressure Control 2 6 Internal Pump Pressure Generation and Control 2 7 Removable Comp...

Page 6: ...Panel Separation 4 10 Pump Bracket 4 15 Manifold 4 17 Display 4 20 Keypad Encoder or Encoder Wheel 4 21 Communications Box 4 22 Pressure Transducers and Barometer 4 24 Contamination Prevention System...

Page 7: ...Vent or Isolation Valve 5 28 Electronic Pressure Sensor 5 29 Overpressure Relief Valve 5 30 Power Entry Module 5 30 Power Supply PCA and Intensifier PCA 5 31 Quick Connect Fittings QC and Filter 5 32...

Page 8: ...ure Selection and LED Indications 8 7 Abnormal Noises 8 7 Pressure Generation and Indication Problems 8 8 Valves and Quick Connect Problems 8 8 9 Wiring Schematics 9 1 Introduction 9 3 Controller Wiri...

Page 9: ...Final Assembly 7 4 7 2 Accessory Kit Assembly 7 6 7 3 Adapter Kit Assembly 7 8 7 4 Spares Kit Assembly not shown 7 9 7 5 Controller Top Level Assembly 7 10 7 6 A1 Control Panel Assembly 7 12 7 7 A8 Sy...

Page 10: ...4322 Service Manual vi...

Page 11: ...8 4 3 Controller Case and Chassis 4 9 4 4 Control Panel Removal 4 12 4 5 Electronics Box Cables 4 13 4 6 Power Module and Tubeweld 4 14 4 7 Piston and Pump Head Assembly Removal 4 16 4 8 Pressure Lin...

Page 12: ...Adapter 6 6 7 1 Final Assembly 7 5 7 2 Accessory Kit Assembly 7 7 7 3 Adapters Kit Assembly 7 8 7 4 Controller Top Level Assembly 7 11 7 5 A1 Control Panel Assembly 7 14 7 6 System Manifold Assembly 7...

Page 13: ...e Introduction 1 3 Product Overview 1 3 Safety Information 1 4 The Product Manual Set 1 5 General Specifications 1 6 Pressure Limits 1 7 Measurement Specifications 1 8 Pressure Control Specifications...

Page 14: ...4322 Service Manual 1 2...

Page 15: ...ges digital gauges pressure transducers pressure switches and other pressure devices Pressure Controller the Controller Pressure Intensifier the Intensifier Nitrogen Cylinder Accessory Kit Handheld Co...

Page 16: ...hese liquids and gases can be released unexpectedly and with extreme force High pressure systems should be assembled and operated only by personnel who have been instructed in proper safety practices...

Page 17: ...ge between the terminals or between each terminal and earth ground Do not touch voltages 30 V ac rms 42 V ac peak or 60 V dc Do not use the Product around explosive gas The Product Manual Set The Cali...

Page 18: ...ng temperature range Safety IEC 61010 1 Overvoltage Category II Pollution Degree2 Electromagnetic Compatibility EMC International IEC 61326 1 Controlled Electromagnetic Environment CISPR 11 Group 1 Cl...

Page 19: ...der Assembly Cylinder Valve CGA580 female coupler 20 MPa 3 000 psi Regulator Inlet CGA580 nipple 20 MPa 3 000 psi Regulator Outlet Miniature QC female coupler 20 MPa 3 000 psi Note 1 IQC70 is a Fluke...

Page 20: ...in H2O at 20 C 28 kPa to 70 MPa 4 psi to 10 000 psi gauge 0 1 of reading Absolute 3 5 kPa to 130 kPa 0 5 psi to 19 psi absolute 25 Pa 0 0036 psi 0 1 in H2O at 20 C 130 kPa to 70 MPa 19 to 10 000 psi...

Page 21: ...s no greater than 70 kPa 10 psi using with external gas supply 3 Assumes 50 cc test volume and pressure steps no greater than 700 kPa 100 psi using with external gas supply 4 Assumes 25 cc test volume...

Page 22: ...4322 Service Manual 1 10...

Page 23: ...re Generation and Control 2 7 Removable Components 2 10 Pressure Transducer Modules 2 10 Barometer 2 11 Contamination Prevention System 2 12 CalCheck 2 15 AutoZero and BaroCheck 2 15 Emergency Pressur...

Page 24: ...4322 Service Manual 2 2...

Page 25: ...th as follows When the target pressure is 4 psig the Controller must use the internal pump See Internal Pressure Source Internal Pump on page 2 7 For target pressures between 4 psig and 305 psig the u...

Page 26: ...overpressure The limits are used when the target pressure is manually set from the Main menu If the target pressure entered is more than the upper limit or less than the lower limit the Controller wil...

Page 27: ...Theory of Operation Controller 2 2 5 View from Bottom PV1 V7 V6 V5 PV2 VH1 Pump Head Assembly C1 F1 CPS Dock Assembly VH3 CPS VH2 A1 hbx077 eps Figure 2 1 Location of the Pressure Valves...

Page 28: ...ressure transducer module has a specific range of pressure it measures and is isolated by control valves V5 V6 and VH1 to prevent overpressure damage 6 As pressure increases the microprocessor reads t...

Page 29: ...4 psig Between 4 psig and 300 psig either the pump or external supply can be selected When the internal pump is used the microprocessor closes PV1 and PV2 to isolate the external supply Note For best...

Page 30: ...4322 Service Manual 2 8 hbx064 eps Figure 2 2 Pressure Valve Schematic...

Page 31: ...External Source CTRL CTRL OPN CLSD CLSD 1 CLSD OPN OPN CLSD CLSD ATM OPN OPN CLSD Pressure between 1 650 psig to 10 000 psig External Source CTRL CTRL CLSD CLSD OPN 1 OPN OPN OPN CLSD CLSD ATM OPN OPN...

Page 32: ...t with a specific pressure range Caution To prevent damage to the pressure modules turn off power prior to removal and installation Each pressure module has three internal sensor elements that make th...

Page 33: ...urements The barometer gets an atmospheric pressure reading through the ATM port on the front panel on the Controller The barometer is a serviceable and replaceable module that must be regularly calib...

Page 34: ...ion Prevention System CPS During ascending pressure excursions the controller increases pressure to near the set point by introducing gas with the compressor internal supply or through PV1 fine contro...

Page 35: ...ich is inserted into the waste bottle when the CPS is mounted into the Controller The purpose of this filter is to prevent vaporized test medium being expelled from the Controller Caution To prevent d...

Page 36: ...ine Up Control Valve OPEN Waste Fine Coalescing Filter To UUT Coarse Coalescing Filter Fine Coalescing Filter Coarse Coalescing Filter Particles Fine Down Control Valve CLOSED Fine Down Control Valve...

Page 37: ...through the ATM port on the front panel of the Controller and is not exposed to the pressure excursions seen by the pressure modules This limited use and the intrinsic measurement characteristics of t...

Page 38: ...er is displaying the BaroCheck indication the operator will be prompted to first perform the BaroCheck routine If more than 35 days has passed since the last successful BaroCheck routine the Controlle...

Page 39: ...es Pressure generated by the boost pump is contained in a 15 cc internal accumulator and in the system pressure lines An electrical pressure sensor monitors and measures the pressure in the accumulato...

Page 40: ...t the boost pressure to the lowest available selection that is equal to or higher than the highest pressure necessary to complete the UUT calibrations For example if the highest pressure in the calibr...

Page 41: ...ls the internal motor The electronic pressure sensor must be field aligned if the pressure generation amount is off by more than 10 or if the Intensifier stabilizes at a pressure less than what the Co...

Page 42: ...4322 Service Manual 2 20...

Page 43: ...n and Alignment Title Page Introduction 3 3 Fundamentals 3 3 Required Equipment 3 4 Environmental Conditions 3 4 Equipment Setup 3 5 Preliminary Operations 3 5 Module Calibration Procedure 3 7 Module...

Page 44: ...4322 Service Manual 3 2...

Page 45: ...is not recommended the coefficients can be manually adjusted in View Edit Calibration menu Calibration is performed with the automated self calibration function that is a feature of the Controller Whe...

Page 46: ...ith Fluke 4322 Test hose 10 000 psi Fluke 4322 QC stem King Nutronics QC stem Supplied with Fluke 4322 Reference pressure standard Gauge pressure 0 to 4 psig 0 001 psi 4 to 10 000 psig 0 025 of readin...

Page 47: ...pment Setup Preliminary Operations Prepare for the calibration procedure as follows 1 Turn on the 4322 Pressure Controller the Controller and let it warm up for at least 1 hour 2 Turn on the reference...

Page 48: ...to the TEST port on the reference pressure standard Note For connection to the reference pressure standard the female QC adaptor must be removed from the test hose and an adaptor from the AN4 female h...

Page 49: ...2 Select 3 Select Calibration to edit the Calibration menu 4 Select Run Calibration 5 Select the desired module as shown in Figure 3 4 hbx067 jpg Figure 3 2 Module Selection 6 Fill in the Run Calibrat...

Page 50: ...own on the screen a new screen appears that shows the deviation calculations Module Alignment Procedure This procedure supplies instructions on how to perform the alignment procedure on the G70M G10M...

Page 51: ...ser entry c Use Tol Yes to use the Adjustment tol from the last step or No d Head Relative to 4322 0 if on the same surface If not measure the head height difference and enter it into the field Use a...

Page 52: ...measurements data from the KN 3689 over the GPIB connection The measurements are compared by the Controller When the Alignment procedure is complete a new screen will appear that shows the test resul...

Page 53: ...r Wheel 4 23 Communications Box 4 24 Pressure Transducers and Barometer 4 26 Contamination Prevention System CPS 4 28 Fine and Coarse CPS Filters Internal 4 28 CPS Vent Filter External 4 28 CPS Dock a...

Page 54: ...4322 Service Manual 4 2...

Page 55: ...page 4 33 Replace CPS fiber filter Annually or as required See page 4 28 Clean CPS metal filter Annually or as required See page 4 28 Safety To ensure safety read the warnings below prior to performin...

Page 56: ...libration Event Log The Event Log is an automated event recorder used by maintenance personnel to see if the Controller has experienced any failures overpressures or exceedences Each recorded event ha...

Page 57: ...Leak Test menu opens 4 Enter the leak test time in seconds into the Leak Time field Note The leak test menu contains an Average Rate dP pressure change and Time values These values are leak test resu...

Page 58: ...r 5 minutes 4 Push to stop pressure control then wait 30 seconds 5 Run the Leak Test tool or if remotely operated send the rate command See the 4322 Operators Manual for remote operation instructions...

Page 59: ...able 4 4 Warning To prevent possible electrical shock fire or personal injury use only specified replacement parts Table 4 4 Replacement Fuse Controller Fuse Fluke Part Number FUSE FUSE 5X20MM 1A 250V...

Page 60: ...4322 Service Manual 4 8 Intensifier Controller Fuse Holder 1 2 3 4 A B C gxj081 eps Figure 4 2 Controller Fuse Replacement...

Page 61: ...ss to the parts and subassemblies inside the case Use the following instructions and reference Figure 4 3 to remove chassis from the case Warning To prevent injury and electric shock disconnect the po...

Page 62: ...ers and barometer 2 Remove the two screws that secure the control panel to the chassis 3 Remove the four screws and washers that secure the handles to the control panel 4 Remove the six screws and was...

Page 63: ...he tubeweld to the manifold Note It is critical to have the fitting facing front panel display facing down on the work bench up when removed to ensure that the spring and ball are not lost The seat ch...

Page 64: ...ronics cover power supplies see Figure 4 5 11 Install the six screws and washers that secure the electronics cover power supplies 12 Install the four screws and washers that secure the handles to the...

Page 65: ...Controller Maintenance Controller Part Replacement 4 4 13 1 7 5 2 6 To CPS Dock To Keypad To Display To Display Backlight 8 9 3 4 CPS Dock 10 12 13 14 11 hbx068 eps Figure 4 4 Control Panel Removal...

Page 66: ...J13 Controller Main Harness J14 Keypad J16 Display Backlight J7 Display J9 V5 6 7 Clippard Valves J10 VH1 J4 VH2 J6 VH3 J8 Comm Box J11 Internal Motor J1 Fan Cable J3 View of the Electronics Box Wiri...

Page 67: ...Controller Maintenance Controller Part Replacement 4 4 15 Bottom View 1 2 4 5 6 7 8 9 10 3 hbx097 eps Figure 4 6 Power Module and Tubeweld...

Page 68: ...ews and and washers items and that secure the pump bracket assembly to the chassis The cross member bracket does not need to be removed from the chassis to remove the pump bracket assembly 4 Pull the...

Page 69: ...lacement 4 4 17 10 9 Red Brown Purple Green Grey White Black Blue White White To CPS Dock Wiring Harness Fan Wire Note Red dot on motor indicates positive terminal 1 3 4 6 7 5 8 2 11 hbx032 eps Figure...

Page 70: ...is one screw is button head to accommodate clearance for the communication box c Remove the four screws and washers and that secure the left side of the manifold to the chassis 4 Extract the manifold...

Page 71: ...tors which are not interchangeable This helps to ensure the correct connection e Connect the ribbon cable from the THM backplane PCA f Connect the N L and G wires to the power entry module Warning To...

Page 72: ...4322 Service Manual 4 20 Bottom View 15 2 1 3 4 5 7 8 11 12 13 14 9 10 16 hbx075 eps Figure 4 8 Pressure Line and Power Lines...

Page 73: ...Controller Maintenance Controller Part Replacement 4 4 21 View from the CPS side View from the CPS side 3 1 4 1 2 hbx076 eps Figure 4 9 Manifold Removal...

Page 74: ...ribbon cable J9 and the backlight power connector J7 shown in Figure 4 20 3 Remove the two screws that secure the display to the control panel 4 Tilt the display forward to gain access to the four hin...

Page 75: ...emove the nut and washer from the encoder using a nut driver 4 Remove the eight screws that secure the keypad to the control panel 5 Remove the keypad and put the new keypad in the control panel 6 Ins...

Page 76: ...following instructions and reference Figure 4 12 to replace the communications box 1 Use the instructions in Chassis and Control Panel on page 4 9 to remove the chassis Note The control panel does no...

Page 77: ...s box to the chassis To do this install the four screws and washers and on each flange 9 Use the instructions in Chassis and Control Panel on page 4 9 to install the control panel and put the chassis...

Page 78: ...ay forward to expose the transducer and barometer modules 3 Loosen the two knobs on the top of the pressure transducer module 4 Lift up to remove 5 To put the module into the slot align the pressure t...

Page 79: ...oller Maintenance Controller Part Replacement 4 4 27 1 3 4 2 Pressure Transducer Modules Pressure Modules Barometer Module Turn off power W gxj079 eps Figure 4 13 Pressure Transducer and Barometer Rem...

Page 80: ...in access to the fine filter 7 Remove the fine filter Filter installation 1 Install the fine filter 2 Carefully align the upper filter retainer and on the pressure port and push it into place The scre...

Page 81: ...anel does not need to be removed for this procedure 2 Remove the pump bracket assembly from the chassis See Pump Bracket on page 4 14 3 Remove the NC isolation valve as follows see Figure 4 16 a Remov...

Page 82: ...he bottom of the CPS dock Note The o ring and anti extrusion ring should remain in CPS dock Items and should stay on the tubeweld HM2 fitting g Install the four screws that secure the CPS dock to the...

Page 83: ...Controller Maintenance Controller Part Replacement 4 4 31 4 2 1 5 3 6 hbx069 eps Figure 4 15 CPS Dock Replacement...

Page 84: ...o loosen counterclockwise the knurled retaining ring Once loose turn it by hand to back it off from the threads Remove the solenoid body from the pump head Note Since the solenoid is upright when the...

Page 85: ...ecting rod with an orientation marking Make sure this mark is showing when reinstalled 6 Remove the crank screw Use a pair of rubber gripped pliers to hold the piston crank in place while turning the...

Page 86: ...ons and reference Figure 4 18 to replace a control valve items or 1 To replace a control valve items or insert a small pointed screwdriver into the side of the valve Pry counterclockwise to remove the...

Page 87: ...Maintenance Controller Part Replacement 4 4 35 1 3 7 8 9 10 11 12 4 2 Manifold shown fully assembled View of valves installed on the manifold 9 12 11 10 5 6 hbx035 eps Figure 4 18 System Manifold Exp...

Page 88: ...ase of the NC isolation valve to the manifold assembly 6 With a soft grip pair of channel locks turn the NC isolation valve clockwise to install 2 1 3 4 Isolation Valve Shown Fully Assembled hbx037 ep...

Page 89: ...ng instructions and reference Figure 4 20 to replace the power supply pca items and 1 Use the instructions in Access the Electronics Box to open the electronics box 2 After the cover is removed with t...

Page 90: ...he electronics box 6 Lift the p vlv pca out of the electronics box The amplifier pca assemblies will stay in the electronics box 7 Carefully align the new p vlv pca on top of the amplifier pca assembl...

Page 91: ...and Control Panel on page 4 9 to remove the chassis and take off the control panel Remove all the screws and washers that secure the electronics box to the chassis Rotate the electronics box 45 degre...

Page 92: ...er J12 Hinge Switch J5 Backplane PCA J13 Controller Main Harness J14 Keypad J16 Display Backlight J7 Display J9 V5 6 7 Clippard Valves J10 VH1 J4 VH2 J6 VH3 J8 Comm Box J11 Internal Motor J1 Fan Cable...

Page 93: ...lter and o ring in the new quick connect 8 Position the quick connect fitting on the control panel and install the o ring 9 Position the QC adapter in the control panel and secure it to the quick conn...

Page 94: ...4322 Service Manual 4 42...

Page 95: ...Replacement 5 9 Intensifier Part Replacement 5 11 Chassis 5 11 Pump Cam 5 14 Pump Cam Disassembly 5 17 Pump Cam Reassembly 5 18 Motor Controller 5 20 Planetary Gears and Gear Bearings 5 22 Pressure P...

Page 96: ......

Page 97: ...Item Time Interval Instructions Pressure Generation and Leak Test 1 year or 750 hours whichever occurs first Complete after maintenance is performed on the Intensifier See page 5 7 Electronic Pressur...

Page 98: ...ue value is listed in the procedure next to the hardware For example Install the low profile screw that secures the planet gear to the lower cam mount plate Torque to 7 8 Nm 69 0 in lb Table 5 2 Stand...

Page 99: ...eter is the total amount of hours the Intensifier has been used since it was manufactured The total hour meter starts at the factory and cannot be reset How to read the maintenance and total hour mete...

Page 100: ...9 7 000 7 999 x 800 899 8 000 8 999 x 900 999 9 000 9 999 x 1 000 1 099 10 000 10 999 x and x 1 100 1 199 11 000 11 999 x and x 1 200 1 299 12 000 12 999 x and x 1 300 1 399 13 000 13 999 x and x 1 40...

Page 101: ...the key illuminates and stays illuminated until is pushed 5 Watch the pressure gauge and keep track of how long it takes for the pressure gauge to reach 10 000 psi The pressure should generate to more...

Page 102: ...o the next step 7 Close the VENT valve on the Intensifier 8 On the Controller set a target pressure of 1 000 psi After 1 000 psi is set wait for Controller ready signal green light 9 On the Intensifie...

Page 103: ...24 and the piston seals portion of the procedure in Clevis Bearing Roller and Piston Seals Replacement on page 5 25 These seals come in kits that are orderable and defined in Chapter 7 in Rebuild Kit...

Page 104: ...4322 Service Manual 5 10 Intensifier Controller Fuse Holder 1 2 3 4 A B C gxj081 eps Figure 5 1 Fuse Replacement...

Page 105: ...oster pump assembly After the chassis is removed the booster pump assembly must be separated to gain access to the internal components Use the following instructions and Figure 5 2 to remove chassis f...

Page 106: ...4322 Service Manual 5 12 1 2 3 hbx008 eps Figure 5 2 Intensifier Case Removal...

Page 107: ...ly from the control panel assembly 3 Remove the eight hex nuts items and and lock washers items and secures the booster pump assembly to the control panel assembly 4 Separate the control panel assembl...

Page 108: ...embly screws Pump Cam Separating the cam assembly from the pump rotor housing is a critical process Familiarize yourself with the following steps before beginning the disassembly This process will req...

Page 109: ...3 Slowly lower the booster pump assembly onto the pump cam assembly Align the planetary gears with the sun gear and the outer gear ring Note To align the gears rotate the gears with a rubber tipped pr...

Page 110: ...e top and install the eight outer screws and lock washers securing both the sheet metal cover and the upper shaft mount plate to the pump assembly housing Add Loctite to Hardware when Tightened LT LT...

Page 111: ...the upper cam mount plate to the lower cam mount plate 5 Remove the four screws that secures the upper shaft bearing hub to the upper piston guide plate 6 Carefully lift the and remove the upper cam...

Page 112: ...f the cam mounting plate 6 Place the cam on top of the lower cam mount plate while positioning each piston so they fit inside the cam The top side of the cam is identified with a small milled oval slo...

Page 113: ...placement 5 5 19 Add Loctite to Hardware when Tightened LT Add Teflon Grease when Installed TG LT LT LT LT LT LT LT LT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27 TG hbx...

Page 114: ...t bracket to the control panel assembly and handles and remove the grommets from between the panel and the handles 4 Remove the support bracket begin by partially lifting and sliding the bracket to cl...

Page 115: ...Intensifier Maintenance Intensifier Part Replacement 5 5 21 1 2 3 4 5 6 8 7 hbx016 eps Figure 5 7 Motor Controller Replacement...

Page 116: ...next step 6 Remove the internal retaining rings and from the planet gear 7 Install the internal retaining rings and in the new planet gear 8 Install the bearings and into the planet gear Use a bench t...

Page 117: ...ntensifier Part Replacement 5 5 23 0 70 mm 1 70 mm Bearing Installation Depth in Planet Gears Bearing Pin Bearings Planet Gear 3 4 5 6 7 8 9 10 Larger Chamfer on Clip Side 1 2 hbx020 eps Figure 5 8 Pl...

Page 118: ...ed from the pump cam assembly remove the pressure port shaft from the cylinder housing by pushing it out 5 Remove the two o rings and and replace with new o rings Caution To prevent damage to the o ri...

Page 119: ...n position 9 Remove the ICM assembly from the cylinder housing Note The ICM assembly is held together with small pins Handle the ICM very carefully 10 Slide the new ICM assembly into the cylinder hous...

Page 120: ...e they are not used again e Place the new o ring seal and centering ring on the piston as shown in Figure 5 10 Add a small amount of Loctite 222 to the threads of the seal retainer Fully tighten the s...

Page 121: ...is not at the tip of the piston seals Do not let Krytox work its way to the ICM inlet valve c Carefully and slowly insert piston seal into insertion tool and then into ICM cylinder as shown in step 2...

Page 122: ...Piston Insertion 6 To replace the roller refer to Figure 5 12 a Remove the c clip that retains the bearing b Push the roller shaft through the roller block Use of a bench top press is recommended c Re...

Page 123: ...page 5 18 7 To replace the piston clevis bearings and a Remove the c clips and that retains the bearings and b Replace the bearings then install the c clips and that retains the bearings and c Remove...

Page 124: ...5 7 remove the four screws that secures the support bracket to the control panel assembly and handles 4 As shown in Figure 5 7 remove the support bracket 5 Disconnect the pressure supply connection t...

Page 125: ...ace upside down using support blocks to keep it raised above the surface 3 Disconnect the HF 2 gland to the valve or 4 Remove the two hex nuts that secures the valve bracket to the control panel 5 Rem...

Page 126: ...e pressure sensor wire ribbon connecter from the pca 4 Remove the pressure sensor from the manifold 5 Install the new pressure sensor in the manifold wrapping the NPT threads with PTFE tape 6 Connect...

Page 127: ...nd put into the case See Chassis on page 5 11 Power Entry Module Use the following instructions and Figure 5 16 to replace the power entry module 1 Remove the chassis and separate the chassis See Chas...

Page 128: ...he pca The ribbon cable connector releases by lifting up on the left and right side edges 4 Remove the four screws that secures the intensifier pca to the standoffs 5 For power supply pca replacement...

Page 129: ...reful not to lose the small filter element from the underside of the QC adaptor as it is free to fall out when the adaptor is removed from the quick connect body 5 Remove the quick connect from the co...

Page 130: ...4322 Service Manual 5 36 2 3 4 5 6 7 8 9 10 11 12 1 Intensifier front panel shown Procedure the same for the Controller hbx030 eps Figure 5 17 Quick Connect Fitting Removal...

Page 131: ...er 6 Nitrogen Cylinder Maintenance Title Page Introduction 6 3 Safety 6 3 Visual Inspection 6 4 External Cylinder Cleaning Procedure 6 4 Internal Cylinder Cleaning Procedure 6 4 Nitrogen Recharge Proc...

Page 132: ...4322 Service Manual 6 2...

Page 133: ...ce of the product and to prevent injury Do not ship the Cylinder while pressurized or with the regulator assembly attached Do not alter or obscure the Cylinder markings Do not allow your Cylinder to r...

Page 134: ...aluminum Internal Cylinder Cleaning Procedure Clean the inside of the Nitrogen Cylinder as follows Warning To prevent personal injury keep the threads and inside of the cylinder dry and free from oil...

Page 135: ...render the cylinder dangerous Before the Cylinder is recharged visually inspect the Cylinder as instructed in Visual Inspection section Verify that the Cylinder has a working pressure PW stamped on th...

Page 136: ...ect the filling regulator and the fill adapter 9 Reconnect the Nitrogen Cylinder Regulator Nitrogen Cylinder Fill Adapter supplied Example Fill Regulator not supplied Nitrogen Cylinder Regulator suppl...

Page 137: ...7 1 Chapter 7 List of Replaceable Parts Title Page Introduction 7 3 How to Order Replacement Parts 7 3 Calibrator Final Assembly 7 4 Controller Final Assembly 7 9 Intensifier Final Assembly 7 21...

Page 138: ...4322 Service Manual 7 2...

Page 139: ...r Parts price information is available from the Fluke Corporation or its representatives To contact Fluke Calibration call one of the following telephone numbers Technical Support USA 1 877 355 3225 C...

Page 140: ...2 4322 INTENSIFIER 4237653 A3 4322 NITROGEN CYLINDER 4221336 A4 HANDHELD CONTROL 4113229 A5 4322 ACCESSORY KIT 4208134 Not Shown 4322 ACCESSORY DOCUMENATION KIT 4362344 Pressure Controller the Control...

Page 141: ...351 1 A14 WASTE BOTTLES 3139463 4 A15 CPS ASSEMBLY BLUE 4591465 1 A16 CPS ASSEMBLY ORANGE 4591476 1 A17 HOSE BUCKET 4221918 1 GPIB CABLE 3866449 1 PORTABLE SUPPLY HOSE 4218163 1 HOSE INTERCONNECT 4218...

Page 142: ...4322 Service Manual 7 6 A5 A10 A16 A15 A13 A14 A17 A11 Top Case Bottom Case A10 A9 A11 A8 A7 A5 A2 A1 hbx060 eps Figure 7 2 Accessory Kit Assembly...

Page 143: ...846 1 H5 FITTING 1 2 MALE PIPE THREAD NPT 4150854 1 H6 FITTING 1 8 FEMALE PIPE THREAD NPT 4150868 1 H7 FITTING 1 4 FEMALE PIPE THREAD NPT 4150879 1 H8 FITTING 1 2 FEMALE PIPE THREAD NPT 4150887 1 H9 F...

Page 144: ...ING CAST URETHANE 90 DURO 003 0 060 W X 0 056 ID 4261927 9 SEAL ASSEMBLY HIGH PRESSURE T61 SEAL P02 BACKUP RING FKM O RING 4338494 4 O RING URETHANE 3 5 MM ID X 1 MM C S PU90 DURO YELLOW COMPOUND U900...

Page 145: ...rt Number Notes A1 CONTROL PANEL ASSEMBLY A2 PRESSURE TRANSDUCER MODULE 150 KPA ABS 21 5 PSIA TESTED 4237225 A3 PRESSURE TRANSDUCER MODULE 700 KPA 100 PSIG TESTED 4237233 A4 PRESSURE TRANSDUCER MODULE...

Page 146: ...Service Manual 7 10 A8 A9 A10 PCAs electronics box and chassis walls A11 A2 A3 A4 A5 A1 Removable Modules A6 A7 Pressure Transducers Barometer CPS A12 hbx090 eps Figure 7 4 Controller Top Level Assem...

Page 147: ...9 4 H14 DIE CUT FOAM TAPE 4357511 1 H15 O RING 4318510 1 H16 8 MM ANTI EXTRUSION RING 4155801 1 H17 QC SLEEVE ACTUATOR 4155593 1 H18 WAVE SPRING 4234535 1 H19 TUBEWELD ASSEMBLY 4213731 1 H20 FITTING C...

Page 148: ...A3 H1 H8 H2 H3 H4 H7 H9 H8 H10 H11 H12 A5 H13 A8 H30 H31 H29 H28 H27 CPS Dock H5 H6 H16 H15 H17 H18 H19 H14 H20 H2 CPS DOCK O RING NOT SHOWN H23 H24 H25 H26 H22 H23 H32 H8 H37 H33 H35 H36 H34 hbx091 e...

Page 149: ...0 32X 2T ELBOW 3141147 2 H7 PLUG 1 16 IN ANPT 5 32 IN HOLLOW HEX SS 3000 PSI 4408221 1 H8 10 32 OSEAL PLUG 3136178 1 H9 O RING 1 MM W X 2 MM ID 90 DURO 4326327 4 H10 SHCS M4 X 30 4235051 4 H11 FILTER...

Page 150: ...nual 7 14 A2 A4 A2 A1 A6 H1 A7 A5 A2 A2 A4 A1 H2 H4 H3 H5 H6 H12 H6 H26 H25 H7 H10 H8 H9 H11 Lower Port H3 H13 H14 H15 H16 H17 H23 H3 H18 H12 H3 H12 H3 H20 H21 H19 H22 hbx092 eps Figure 7 6 System Man...

Page 151: ...00 MICRONS CLIPPARD 4399544 2 H3 FINE SEAT 4241933 1 H4 FILTER 4375674 1 H5 O RING 1 MM X 2 MM ID 4326327 2 H6 TUBE FITTING 4420504 1 H7 PUMP HEAD 4148743 1 H8 COARSE SEAT 4241925 1 H9 M2 FLAT WASHER...

Page 152: ...4322 Service Manual 7 16 A4 A5 H5 A3 A2 H1 H7 H17 H12 Complete Assembly A1 H2 H8 H4 H5 H6 H2 H8 H13 H11 H10 H9 H14 H15 H16 H13 H18 H20 H19 H12 H13 hbx093 eps Figure 7 7 A9 Pump Bracket Assembly...

Page 153: ...92 1 H15 PIN ALIGN THM 4219249 2 H16 BARO MANIFOLD 4143111 1 H17 ELBOW 3141147 1 H18 LEFT CHASSIS WALL 4154791 1 H19 RIBBON RETAINER 4228632 3 H20 PLATE 4293932 1 H21 FOAM 50 MM 4330126 2 H22 M3 X 10...

Page 154: ...H7 H12 H11 H7 H15 H14 H13 H16 H17 H18 H1 H3 H1 H3 H19 H11 H7 H20 H21 H22 H11 H7 H23 H24 H11 H25 H26 H27 H7 H30 H28 H29 H11 H7 H11 H7 H11 H7 H11 H7 H31 H33 H1 H3 H39 H38 H26 H34 H22 H35 H36 H37 H11 H7...

Page 155: ...6 X 5 SHCS 4219120 3 H7 UPPER FILTER DISK 4155755 1 H8 FILTER DISK GASKET 4155770 1 H9 LOWER FILTER DISK 4155762 1 H10 PURGE TUBE 4155820 1 H11 COARSE FILTER METAL FILTER 4155812 1 H12 LOWER FILTER RE...

Page 156: ...4322 Service Manual 7 20 H1 H2 H3 H4 30 mm H5 H6 H7 H8 H9 H10 H11 H12 H13 H14 H18 H17 H4 20 mm H16 H15 H19 H20 H21 H22 H23 hbx101 eps Figure 7 9 A15 CPS Assembly...

Page 157: ...H3 BOOSTER SUPPLY TUBE 4243427 1 H4 M6 HEX NUT 2536890 8 H5 M6 LOCK WASHER 3153533 4 H6 1 4 FLAT WASHER 4424884 4 H7 GROMMET 2213849 8 H8 C CLIP 3330240 4 H9 CORNER GUSSET 4139472 4 H10 SPACER 416067...

Page 158: ...4322 Service Manual 7 22 H3 A1 H9 4X H11 H10 H8 H7 H6 H4 H5 H4 H2 H12 H13 A3 H14 H1 A2 H15 H17 H16 hbx042 eps Figure 7 10 Intensifier Final Assembly...

Page 159: ...1 4NPT HEX PLUG SS 4 HP 4212390 1 H5 M3 HEX NUT 2678004 11 H6 M3 LOCK WASHER 3153752 20 H7 GAUGE COWL 4139460 1 H8 30 21 HF2 NFB HF2 1 4 NPT ADAPTER 4212352 1 H9 SUPPLY TUBE CONTROL PANEL 4322 5802 42...

Page 160: ...322 Service Manual 7 24 H1 H2 A1 H3 H4 H5 A2 H6 A3 H7 H8 A6 A7 H9 A4 A5 H10 H11 H12 H13 H14 H15 H16 H17 H5 H6 H18 H19 H20 H21 H6 H22 A8 H23 H24 H25 hbx049 eps Figure 7 11 Control Panel Assembly Page 1...

Page 161: ...8 H3 M3 X 30 STANDOFF 3140491 4 H4 KNOB 3337089 2 H5 HANDLE 4340703 2 H6 WASHERS 4334721 4 H7 M4 X 10 SHCS 3153272 2 H8 M4 LWASH 3153914 2 H9 BRACKET 4139451 1 H10 M5 LWASH 3154144 4 H11 M5 X 12 SHCS...

Page 162: ...4322 Service Manual 7 26 H5 A1 A2 A4 H9 A3 H4 H7 H8 H10 H11 H14 H13 H12 H17 H18 H19 H15 H16 H17 H18 H20 H1 H2 H1 H2 H3 H6 hbx100 eps Figure 7 12 Control Panel Assembly Page 2...

Page 163: ...2 H1 M4 X 12 SHCS 3153285 4 H2 M4 LOCK WASHER 3153914 4 H3 UPPER SHAFT MOUNT PLATE 4139956 1 H4 C CLIP 4218936 1 H5 M3 X 8 SHCS 3153249 2 H6 M3 LOCK WASHER 3153752 12 H7 ENCODER MOUNT PLATE 4140079 1...

Page 164: ...4322 Service Manual 7 28 H1 H2 H10 H3 H6 H9 H4 H8 H6 A1 H7 H6 H5 A2 A3 hbx043 eps Figure 7 13 A2 Booster Pump Assembly...

Page 165: ...3153224 56 H2 M3 LOCK WASHER 3153752 56 H3 M4 X 12 SHCS 3153285 8 H4 M3 X 8 FLAT HEAD 4212956 32 H5 CAM MOUNT PLATE 4136182 1 H6 SHAFT BEARING HUB 4136271 2 H7 BEARING 4212638 2 H8 WAVE SPRING 4212645...

Page 166: ...4322 Service Manual 7 30 H1 H2 H5 H3 H13 H6 H7 H8 H1 H2 H4 H9 H10 H11 A1 H12 H10 H9 H2 H1 H4 H8 H7 H6 H3 H2 H1 H13 hbx045 eps Figure 7 14 A2 A2 Pump Cam Assembly...

Page 167: ...rt Number Quantity Notes H1 LOW PROFILE SCREW 4212460 3 H2 BEARING PIN 4140031 3 H3 WAVE SPRING 4212650 3 H4 BEARING 4212505 6 H5 INTERNAL RETAINING RING 4216922 6 H6 C CLIP 4219005 3 H7 CAM MOUNT PLA...

Page 168: ...4 4 H1 O RING 2527053 2 H2 PRESSURE PORT SHAFT 4136175 1 H3 CYLINDER RETAINING NUT 4181212 4 H4 CYLINDER HOUSING 4136244 1 H5 O RING URETHANE 3 5 MM ID X 1 MM C S PU90 DURO YELLOW COMPOUND U9001Y 4398...

Page 169: ...3 SHIM 4140101 4 H4 PIN 4139995 1 H5 CAM FOLLOWER 4342531 1 H6 PISTON 4328000 1 H7 SEAL ASSEMBLY HIGH PRESSURE 4338494 1 H8 SEAL RETAINER 4139988 1 H9 SCREW SHOULDER EXTRA LOW HEAD M4 X 5 MM L 4 MM F...

Page 170: ...4322 Service Manual 7 34...

Page 171: ...3 Electrical Problems 8 5 Pressure Generation and Indication Problems 8 5 CPS and Quick Connect Problems 8 6 Intensifier Troubleshooting 8 6 Electrical Problems 8 6 Pressure Selection and LED Indicati...

Page 172: ...4322 Service Manual 8 2...

Page 173: ...the comm pca to the main pca 5 Replace comm pca See Chapter 4 for Controller part replacement procedures 02 Printer interface failure 21 Pressure transducer interface failure Fault codes 21 through 2...

Page 174: ...ted pca See Chapter 4 for Controller part replacement procedures 42 pressure transducer communication error 43 pressure transducer module calibration data corrupted 44 pressure transducer module commu...

Page 175: ...backlight cable failure LCD display flat cable failure LCD module failure Reseat LCD backlight cable Replace LCD backlight cable Reseat LCD flat cable Replace LCD flat cable Replace LCD module Pressur...

Page 176: ...sections to troubleshoot the Intensifier Warning Finger Amputation Hazard To prevent personal injury do not connect power or operate the Intensifier while servicing Intensifier outside its case The ro...

Page 177: ...her selections If other selection works single key is bad Replace the keypad See Chapter 5 for Intensifier part replacement procedures Abnormal Noises Problem Probable Cause Action Grinding sound when...

Page 178: ...5 to 8 above set pressure If this amount is more than 10 off or if generated pressure is below set pressure realign the pressure sensor Valves and Quick Connect Problems Problem Probable Cause Action...

Page 179: ...9 1 Chapter 9 Wiring Schematics Title Page Introduction 9 3 Controller Wiring Schematics 9 3 Intensifier Wiring Schematics 9 6...

Page 180: ...4322 Service Manual 9 2...

Page 181: ...L VLV PV2 TESTED PRECISION CONTROL VLV PV1 TESTED SAFETY SWITCH KEYPAD KNOB ENCODER LCD BACKLIGHT MANIFOLD VALVES V5 V6 V7 VH1 VH3 COMMUNICATIONS PCA 4213975 IEEE 488 CONNECTOR PUMP ASSEMBLY MAIN PCA...

Page 182: ...11 12 13 14 15 16 17 18 19 20 J1 J13 4319911 VAISALA BAROMETER 4219224 1 2 3 4 PINK GRAY GREEN BLUE P1 2 3 4 RED GREEN WHITE BLACK J1 PWR RX TX GND PWR RX TX GND J2 PWR RX TX GND PWR RX TX GND 1 2 3 4...

Page 183: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 4251018 21 22 23 24 25 26 27 28 29 30 31 32 33 20 21 22 23 24 25 26 27 28 29 30 31 32 33 20 V5 V5 V6 42...

Page 184: ...23 24 20 21 22 23 24 20 33 33 COMM PCA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 8 2 9 3 10 4 11 5 12 6 13 7 14 4244770 1 8 2 9 3 10 4 11 5 12 6 13 7 14 P1 J2 P2 BROWN RED ORANGE YELLOW GRAY VIOLET WHITE BLA...

Page 185: ...17 25 2 11 30 1 2 5 6 7 J2 4 3 2 1 3 10 1 2 3 4 5 6 7 1 3 2 Brown Violet Blue Frame GND Green Yellow Orange Black Blue Black Red 208925 Brown Encoder 4213347 4232506 4232506 White Blue Shield Black Re...

Page 186: ...4322 Service Manual 9 8...

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