Condec UVC1000 User manual

UVC1000/UVC1010

Table Top & Rack-mountable Pneumatic

Vacuum Generator/Pressure Controller

Operation and Maintenance

Manual

Condec Web Site: www.4condec.com

Condec Sales Phone Number: (888) 295-8475 69481

Speciﬁcations subject to change without notice.

September 2001

Contents

About This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.0 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Input Air Pressure Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Pressure Measurement Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2 Test and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2.1 Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2.2 UVC1000/UVC1010 Cover - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2.3 Pressure Limit Control (PN 58409) - Regulator Removal and Installation. . . . . . . . . . . . . . . . 5

3.2.4 Vacuum Monitor (PN 59230) and Pressure Limit Monitor (PN 59706) Gauges -

Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2.5 Pressure and Vacuum Port Quick-Connect Fitting (PN 59997) -

Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2.6 Input Port (PN 59761) - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2.7 Input Port Filter (PN 54188) - Removal, Cleaning and Installation . . . . . . . . . . . . . . . . . . . . . 7

3.2.8 Vacuum Generator (PN 57960) - Removal, Cleaning and Installation . . . . . . . . . . . . . . . . . . 8

4.0 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

UVC1000/UVC1010 Warranty and Return Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

UVC1000/UVC1010 Return Material Authorization Form. . . . . . . . . . . . . . . . . . . . . . . . 11

Introduction

About This Manual

The UVC1000/UVC1010 is a rugged, compact

instrument manufactured by Condec, designed to

provide ease of operation, 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

provides up to 29 inches Hg vacuum in areas that are

off limits to vacuum pumps.The operator uses existing

shop air lines working with a built in vacuum

converter inside the unit. The unit has multiple ports,

including one for low pressure and one for vacuum.

Front panel gages tell the operator system pressure. 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.

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

negligent handling or operation of the

UVC1000/UVC1010.

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 UVC1000/UVC1010 offers a combination of features, performance, versatility and reliability. Some of the

more outstanding features are listed below:

• Two models available: table top and 19" rackmount.

• Portable: These compact, self-contained systems are easily carried and operated by only one person. Total

weight is approximately 7 pounds.

• An internal input ﬁlter: Easily removed for inspection and cleaning.

• Simple Operation: All control regulator, gages, vacuum port and pressure port are accessible from the front

panel. The input port is located on the rear of unit.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.

Overpressure protection and clean line pressure must be provided by the customer. By virtue of this technique,

the UVC1000/UVC1010 and unit under test is fully protected from being inadvertently overpressurized.

Warning

UVC1000/UVC1010 Operation and Maintenance Manual

The following schematic provides an overview of the UVC1000/UVC1010’s function.

Figure 1-1. UVC1000/UVC1010 Flow Diagram

Operation

2.0 Operation

2.1 Input Air Pressure Supply

See Figure 2-1 below and proceed as described below.

NOTE:

The air pressure source used must have a vent valve and be regulated to provide a maximum output of 160

PSIG.

1. Pull

PRESSURE LIMIT CONTROL

(1) knob outward and rotate counter-clockwise until it stops.

2. Connect the input hose, supplied by customer, to a clean regulated shop air source.

3. Connect the other end of the input hose, supplied by customer, to the male input port ﬁtting located on

rear of unit. Use a customer supplied AN-4 37° adapter ﬁtting, and cheat seal pad (recommended)

between input hose & input port.

Figure 2-1. Input Operation Procedure

NOTE:

UVC1000 shown, UVC1010 Rack Mount unit also has an input port on back of unit.

2.2 Pressure Measurement Sequence

To prepare for actual calibration usage, see Figure 2-1 above and proceed as follows:

1. Check that the

PRESSURE LIMIT CONTROL

valve (1) is closed (pull knob outward and rotate clockwise

until it stops). Turn MODE SELECT knob to the required mode of operation.

2. Connect the male quick disconnect end of the port hose, supplied by customer, to one of the ports,

Pressure Port (5) or Vacuum Port (6). Use supplied 1/4 female NPT quick disconnect ﬁtting, (PN 60195)

between port hose and Pressure Port or Vacuum Port.

3. Connect the other end of the port hose, supplied by customer, to the unit under test, using adapters if

required. Tighten all connections properly.

4. Set the customer regulated input pressure to a maximum of 160 PSI.

5. Pressure Mode: Using the

PRESSURE LIMIT CONTROL

regulator (1), adjust the maximum system input

pressure, as read by the PRESSURE LIMIT MONITOR (3), to any desired value (100 PSI max.) within

scale range of the device under test. Using this technique, the device under test is fully protected from

being accidentally over-pressurized.

Vacuum Mode: Using the

PRESSURE LIMIT CONTROL

regulator (1), adjust the maximum system input

pressure, as read by the VACUUM MONITOR (4), to any desired value within scale range of the device

under test (-29 in Hg max).

UVC1000/UVC1010 Operation and Maintenance Manual

3.0 Maintenance

3.1 Troubleshooting

3.2 Test and Maintenance Procedures

This section outlines the test and mechanical repair procedures for the UVC1000/UVC1010 Vacuum

Generator/Pressure Controller. The repair procedures cover the major components and subassemblies which are

critical to the proper functioning of the UVC1000/UVC1010 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. Although some mechanical sub-assemblies could be replaced without venting line pressure, it

is not recommended. All safety precautions should be observed.

3.2.1 Test Procedure

Tools required: Snoop

, liquid leak gas detector (PN 64781)

1. Remove cover from its enclosure as described in Section 3.2.2, and place on a bench top.

NOTE:

Do not remove Input hose.

2. Verify MODE SELECT is on PRESSURE, turn knob to the left.

3. Connect shop air to the unit, at the INPUT, on the rear of the unit.

NOTE:

The air pressure source used must have a vent valve and be regulated to provide a maximum output of 160

PSIG.

4. Pull out the PRESSURE LIMIT CONTROL, until you hear a click. Turn the knob clockwise until you

get a reading of 100 PSI. Push knob inward.

5. Check all pipe connections for leaks by using Snoop

6. Turn the MODE SELECT to VACUUM mode slowly.

7. Verify the vacuum gage is reading -28.5 to 29 psi.

NOTE:

The air pressure source and PRESSURE LIMIT CONTROL may have to be increased to obtain reading

(maximum 160 PSIG).

8. Install cover on its enclosure as described in Section 3.2.2.

3.2.2 UVC1000/UVC1010 Cover - Removal and Installation

Tools required: Phillips screwdriver

UVC1000 Cover Removal:

1. Vent input line pressure and remove input and port hoses.

2. Pull out the PRESSURE LIMIT CONTROL knob, until you hear a click. To close regulator, rotate knob

counter-clockwise, until it stops. Push knob inward.

3. Loosen and remove the six screws (PN 14839) that secure the cover to the enclosure.

4. Lift and remove the cover.

Symptom Problem Remedy

Pressure Limit Monitor gauge or Vacuum

Monitor gauge slowly decreases over

time

Leak in system Check all compression and pipe ﬁttings

with soap solution or Snoop

(PN

64781)

Applicable gauge does not respond

when Pressure Limit Control knob is

turned

No regulator control Try other mode of operation. If o.k,

replace gauge, otherwise replace

Pressure Limit Control regulator

Table 3-1. UVC1000/UVC1010 Troubleshooting

!Caution

Maintenance

UVC1000 Cover Installation:

1. Vent input line pressure.

2. Pull out the PRESSURE LIMIT CONTROL knob, until you hear a click. Close regulator, rotate knob

counter-clockwise, until it stops. Push knob inward.

3. Replace and align cover.

4. Install and tighten the six screws (PN 14839) that secure the cover to the enclosure.

5. Replace input hose, if not previously attached.

UVC1010 Cover Removal:

1. Vent input line pressure and remove input and port hoses.

2. Pull out the PRESSURE LIMIT CONTROL knob, until you hear a click. To close regulator, rotate knob

counter-clockwise, until it stops. Push knob inward.

3. Loosen and remove the two screws (PN 14839) on front of panel (1) and on rear of unit (1). These secure

the cover to the enclosure.

4. Lift and remove the cover.

UVC1010 Cover Installation:

1. Vent input line pressure.

2. Pull out the PRESSURE LIMIT CONTROL knob, until you hear a click. Close regulator, rotate knob

counter-clockwise, until it stops. Push knob inward.

3. Replace and align cover.

4. Install and tighten the two screws (PN 14839) that secure the cover to the enclosure.

5. Replace input hose, if not previously attached.

3.2.3 Pressure Limit Control (PN 58409) - Regulator Removal and Installation

Tools required: 7/16” open end wrench

hex wrench (.186")

channel locks

A/R 1/4" wide Teﬂon tape, (PN 60575)

Removal:

1. Remove cover from its enclosure as described in Section 3.2.2 on page 4, and place on a bench top.

2. Note the orientation and remove the tubing sections that connect to the regulator inlet and outlet ﬁttings.

3. Loosen and remove regulator mounting nut from the front of panel, by using channel locks.

NOTE:

Be careful not to scratch front of panel.

4. Note the orientation, then remove the regulator by sliding out from the panel rear.

5. 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.

Installation:

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.

2. Insert the new regulator into the panel through rear of panel and rotate to proper position. Thread and

tighten the mounting nut onto the regulator body from the panel front.

3. Attach the tubing sections to the inlet and outlet ﬁttings.

4. Test UVC1000/UVC1010 as described in Section 3.2.1 on page 4.

UVC1000/UVC1010 Operation and Maintenance Manual

3.2.4 Vacuum Monitor (PN 59230) and Pressure Limit Monitor (PN 59706) Gauges - Removal and Installation

Tools required: 7/16" wrench

9/16" wrench

A/R 1/4" wide Teﬂon tape (PN 60575)

Removal:

1. Remove cover from its enclosure as described in Section 3.2.2 on page 4, and place on a bench top.

2. Disconnect the tubing section that connects to the gauge ﬁtting.

3. Loosen the two thumb-nuts that hold the gauge mounting U-clamp.

4. While gripping the square portion of the gauge port with the 9/16" wrench, remove the female tube

connector (PN 57695) from the gauge.

5. Remove the two thumb-nuts, the mounting U-clamp, and the gauge.

Installation:

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

2. Install gauge into panel, secure with U-clamp and tighten the two thumb screws.

3. While gripping the square portion of the gauge port with the 9/16" wrench, tighten the female tube

connector onto the gauge.

4. Attach the tubing section that connects to the gauge ﬁtting.

5. Test UVC1000/UVC1010 as described in Section 3.2.1 on page 4.

3.2.5 Pressure and Vacuum Port Quick-Connect Fitting (PN 59997) - Removal and Installation

NOTE: If there is leakage out of the port, replace the test port quick-connect

ﬁtting.

Tools required: 1/2" open end wrench

5/8" open end wrench

11/16" open end wrench

A/R 1/4" wide Teﬂon tape (PN 60575)

A/R 1/2" wide Teﬂon tape (PN 60911)

Removal:

1. Remove cover from its enclosure as described in Section 3.2.2 on page 4, and place on a bench top.

2. From inside of front panel, disconnect the tubing section that connects to the female tube connector (PN

57695) ﬁtting.

3. Grasp the hex nut at the panel face with a 5/8" wrench and using a 1/2" wrench on the female tube

connector ﬁtting on inside of front panel, turn the female tube connector ﬁtting counter-clockwise and

remove.

4. Grasp the hex nut at the panel face with a 5/8" wrench and using a 11/16" open end wrench on the lock

nut on rear side of panel, turn the lock nut counter-clockwise. Slide quick-connect ﬁtting out of panel

from front.

Installation:

1. Before installing a new Quick-Connect Fitting, wrap two layers of new Teﬂon tape on the port.

2. Install the quick-connect ﬁtting through front of panel. Thread and tighten lock nut on quick-connect

ﬁtting, from inside of front panel.

3. Thread and tighten female tube connector (PN 57695) ﬁtting into port.

4. Attach the tubing section that connects to the female tube connector ﬁtting.

5. Test UVC1000/UVC1010 as described in Section 3.2.1 on page 4.

Maintenance

3.2.6 Input Port (PN 59761) - Removal and Installation

Tools required: Phillips screwdriver

7/16" open end wrench

9/16" open end wrench

5/8" open end wrench

Removal:

1. Remove cover from its enclosure as described in Section 3.2.2 on page 4, and place on a bench top.

2. From inside of back panel, disconnect the tubing section that connects to the male tube connector (PN

57705) ﬁtting.

3. Remove the AN bulkhead end nut and ferrules, note orientation, from AN bulkhead ﬁtting.

4. Remove from bulkhead, but leave assembled, tube adapter (PN 56223) and male tube connector (PN

57705) ﬁttings. Remove ﬁlter (PN 54188) from inside tube adapter ﬁtting.

5. Using a wrench on the AN bulkhead lock nut from inside of back panel, turn the lock nut

counter-clockwise. Slide input portAN bulkhead ﬁtting out from outside of back panel.

Installation:

1. Before installing a new input portAN bulkhead ﬁtting, remove the end nut and ferrules (note orientation)

from AN bulkhead ﬁtting.

2. Slide input port AN bulkhead ﬁtting in from outside of back panel. Adjust the AN bulkhead ﬁtting to

line-up with the fastener.

3. Thread AN bulkhead lock nut and turn clockwise ﬁnger tight.

4. If required, install hex plate fastener (PN 59712) over AN bulkhead input port ﬁtting and onto rear panel,

with screw (PN 14845). Adjust the AN bulkhead ﬁtting to line-up the screw hole with the fastener.

5. Using a 5/8" wrench on the AN bulkhead lock nut from inside of back panel, turn the lock nut clockwise

to tighten.

6. Install ﬁlter (PN 54188) inside tube adapter ﬁtting (PN 56223).

7. From inside of back panel, install the AN bulkhead end nut and ferrules (in proper orientation) on AN

bulkhead ﬁtting. Thread end nut loosely.

8. Slide assembled, tube adapter (PN 56223) and male tube connector (PN 57705) ﬁttings (with ﬁlter) into

AN bulkhead ﬁtting.

9. Tighten the AN bulkhead end nut approximately 1-1 /4 turns beyond ﬁnger tight, using 9/16" wrench.

10. Attach the tubing section that connects to the male tube connector (PN 57705) ﬁtting.

11. Test UVC1000/UVC1010 as described in Section 3.2.1 on page 4.

3.2.7 Input Port Filter (PN 54188) - Removal, Cleaning and Installation

The port ﬁlter is a sintered element ﬁlter that can be easily removed for inspection and cleaning.

Tools required: 7/16" open end wrench

9/16" open end wrench

A/R solvent (de-natured alcohol)

Removal and Cleaning:

1. Remove cover from its enclosure as described in Section 3.2.2 on page 4, and place on a bench top.

2. From inside of rear panel, remove the AN bulkhead tubing end nut and ferrules (note orientation) from

input port AN bulkhead ﬁtting. Remove ﬁlter (PN 54188) from inside tube adapter ﬁtting (PN 56223).

NOTE:

Leave ﬁttings attached to tubing.

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

Installation:

1. Slide ﬁlter into fractional tube adapter ﬁtting (PN 56223), attached to nylon tubing.

2. Slide tubing end nut and ferrules in proper order over AN bulkhead ﬁtting. Thread end nut loosely.

UVC1000/UVC1010 Operation and Maintenance Manual

3. Slide fractional tube adapter ﬁtting into input port AN bulkhead ﬁtting

(PN 59761),

from inside of rear

panel.

4. Tighten the AN bulkhead end nut approximately 1-1 /4 turns beyond ﬁnger tight, using 9/16" wrench.

5. Test UVC1000/UVC1010 as described in Section 3.2.1 on page 4.

3.2.8 Vacuum Generator (PN 57960) - Removal, Cleaning and Installation

The vacuum generator is a Venturi device which creates a vacuum ﬂow by use of a regulated air ﬂow. The

generator can be removed for cleaning should any contamination be found.

Tools required: Phillips screwdriver

7/16" open end wrench

A/R 1/4" wide Teﬂon tape (PN 60575)

A/R 1/2" wide Teﬂon tape (PN 60911)

Removal and Cleaning:

1. Remove cover from its enclosure as described in Section 3.2.2 on page 4, and place on a bench top.

2. Note the orientation and remove the tubing sections that connect to the vacuum generators inlet and

outlet port ﬁttings.

3. Remove and set aside the two mounting screws (PN 60811) that hold the vacuum generator to the rear

panel.

4. Unscrew the air inlet port elbow (PN 57708) and vacuum outlet port tee ﬁtting (PN 57701). Remove any

remnants of Teﬂon tape from the pipe threads.

5. Using a wrench, unthread and remove the mufﬂer (PN 56056) from the vacuum generator exhaust port.

Remove any remnants of Teﬂon tape from the pipe threads.

6. Blow clean dry compressed air through all passages to remove contamination.

Installation:

1. Wrap two layers of Teﬂon tape on vacuum generators air inlet port elbow and vacuum outlet port tee

ﬁttings.

2. Install and tighten the ﬁttings into the vacuum generator inlet and outlet ports.

3. Wrap two layers of Teﬂon tape on the mufﬂer port. Using a wrench thread and tighten mufﬂer into the

vacuum generator exhaust port.

4. Mount vacuum generator to inside of rear panel, using two screws (PN 60811). Mufﬂer to be positioned

toward bottom of chassis and parallel with front panel VACUUM PORT marking.

5. Install the tubing sections that connect to the vacuum generator inlet port and outlet port ﬁttings.

6. Test UVC1000/UVC1010 as described in Section 3.2.1 on page 4.

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