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Pressure Systems, Inc. 98RK-1 & 9816 User’s Manual©
Page 127 www.PressureSystems.com
5.1.6.4 Calibration Manifold Piston O-Ring Replacement
Following is a step-by-step procedure to replace calibration manifold piston O-rings in a Model
9816 Intelligent Pressure Scanner. There are eight (8) pistons, each with an O-ring, inside the
calibration valve housing; one (1) on each end of the housing and three (3) on each side of the
calibration valve itself.
(1) Disassemble the module as described in Section 5.1.2.
(2) To minimize the possibility of damage, remove the PC-206 Amplifier/Multiplexer board as
described in Section 5.1.3.1. Lay the circuit board aside on an anti-static surface.
(3) Remove the tubing plate as described in Section 5.1.6.2.
(4) Using your index finger, shift the calibration manifold back and forth several times to
loosen its connection with the adapter plate O-rings. Carefully lift the calibration valve
housing with one hand and turn it over, allowing the calibration manifold fall into the free
hand. It is imperative that the calibration manifold does not fall on a hard surface since
scratches on the manifold could result in pneumatic leaks.
(5) To remove the six (6) pistons from their slots on the manifold valve, hold the valve in one
hand, and apply air pressure of approximately 30 psi (200 kPa) to the C3/C4 input
passages on the valve. The passages (0.043" diameter holes) are located on the side of
the valve next to the tubing plate, one hole on each side of the valve. Pressure on one
side will release three (3) pistons, and pressure on the other side will release the other
three (3). Thoroughly clean the pistons with a fast evaporating cleaning fluid that leaves
little or no residue (e.g., acetone, alcohol, Freon, etc.) and dry with supply air. Replace
the piston O-rings (PSI part number 61-03-58610) after lightly lubricating the rings with
Krytox
®
fluorinated grease. Replace the pistons in their cavity by placing the O-ring side
of the piston in first and then pressing the piston completely into its cavity with one finger.
(6) To remove the two (2) C1/C2 pistons from their slots on either end of the manifold valve
housing, hold the manifold valve housing in one hand, and apply approximately 30 psi
(200 kPa) to the two bulge tubes, one on either end of the housing end-plate. This will
result in the pistons being forced out of their cavity. If the pistons stick, apply a higher
pressure. Place your free hand over the calibration valve housing to prevent the pistons
from coming out of the housing. Clean the pistons, lubricate and replace the O-rings (PSI
part number 61-12-2023), and replace the pistons into their cavities as described in (5)
above.
(7) Thoroughly clean the calibration manifold with a fast evaporating cleaning fluid that
leaves little or no residue (e.g., acetone, alcohol, or Freon). Replace the calibration
manifold into the housing, making sure that the guiding pin fits into the slot of the
manifold housing.
(8) Replace the tubing plate as described in Section 5.1.6.2.
(9) Replace the PC-206 board as described in Section 5.1.3.1 and reassemble the module.
(10) Test your scanner to ensure proper operation.