Druck PV 103R - GE Measurement & Control
Contents
1. Pump ON ch e K ele stees Pump fan CHECK uu aa meer BS 1 and 2 ETI check BS 3 and 4 ETI check Pressure bleed valve open check Pressure too low check Pressure too high check Water drain not Purging Power input check Pump not running Check sassa Pump speed check 5 3 Supplement tests Re BEE E eov m TesL4 c ILLUSTRATIONS figure title 5 1 PSU and Motor controller PCB connections 5 2 BS 1 Wiring diagram 5 38 BS2 Wiring diagram EE 5 4 BS 3 Wiring diagram 5 5 BS 4 Wiring diagram page 5 2 5 2 5 6 5 7 5 8 5 9 5 11 5 12 5 13 5 14 5 15 5 17 5 18 5 19 5 19 5 19 5 19 5 20 K232 Issue No 2 Page 5 1 Druck PV 103 R Service Manual 5 5 1 TESTING Standard Serviceability Test Test equipment description Pressure gauge to measure pump output pressure to 4 0 bar gauge vacuum to 20 mbar absolute 7 16 UNC 37 flare AN4 adaptor 9 16 UNC 37 flare AN6 adaptor 1 Apply power and check that t2. PV103 BS1 PV103 BS2 PV103 BS3 PV103 BS4 Para fig 6 2 6 3 K232 Issue No 2 Page 6 1 Druck PV 103 R Service Manual Illustrated Parts List 6 1 Introduction 1 The purpose of this list is to itemise the parts that comprise the unit It is intended for use in provisioning requisitioning and storing replacement parts 2 In general parts are listed in order of disassembly and are indented to show their relationship to the next higher assembly 3 Numerical indexes are provided to assist in locating part numbers in the Parts List 4 Items that are non procurable are indicated in the QTY column by the letters NP Items that are for reference are indicated by the letters ref Items that are not illustrated have a t symbol next the item ref number K232 Issue No 2 Page 6 2 Druck PV 103 R Service Manual intentionally left blank K232 Issue No 2 Page 6 3 Druck PV 103 R Service Manual SN J LZ a ye e i e ei Wi Figure 6 1 PV103 BS1 Page 6 4 K232 Issue No 2 Druck PV 103 R Service Manual 6 2 Parts Lists Build Standards 1 2 3 and 4 Ref Pump unit PV103 Build standard 1 IA2127 1 V0 OBSOLETE superseded by BS4 PSU Mod 00 superseded by item 2a ADTS405 1728 86 M0 PSU Mod 01 supersedes item 2 ADTS405 1728 73 M1 Controller motor speed superseded by item 3a ADTS405 1728 74 M0 Controller motor speed supersedes i
3. Pump ON check LOW OK HIGH Pressure too high Small airflow detected from water drain Water drain not purging Y Y Check vacuum at pump output Supplementary Test 4 Y OK Pump check completed UNIT SERVICEABLE N Y Visully inspect for leaks or damaged or kinked pipes in the pump unit CAUTION Do not use bubble solution on the vacuum system Continued on next page K232 Issue No 2 Page 5 5 Druck PV 103 R Service Manual MAIN SYSTEMS CHECK AND FAULT TREE Continued Carry out pump servicing 1000 hour filter change or 3000 hour piston seal change Replace pump and motor assembly Re test through main fault tree BS2 BS3 and BS4 PUMP ON CHECK Check pump on signal at motor controller PCB CON3 pin 3 is 5V 1V with respect to pin 2 OK Y Check pump on signal at expansion connector pin 13 is 5V 1V with respect to Replace motor pin 1 controller PCB N OK Check and repair control loom according to appropriate schematic circuit Y RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 6 Druck PV 103 R Service Manual PUMP FAN CHECK Is this a build standard 3 4 unit two fuses in the front panel Y Y Find out if fan is set for internal or external control Internal Fa
4. 4 15 Anti vibration mounting 4 16 Power supply filter connector 4 17 ASSEMBLING rich Seat eue tics rues 4 18 Power supply filter connector 4 19 Anti vibration mounting 4 20 Cylinder EE 4 21 Dump valve solenoid BS 3 4 22 K232 Issue No 2 Page 4 1 Druck PV 103 R Service Manual CONTENTS continued title para Water cooler trap assembly BS4 0001100 4 23 Water cooler trap assembly BS 2 and 3 4 24 Water drain filter BS T 4 25 Pressure release valve 4 26 LED assembly gege 4 27 SWITCH eebe 4 28 Elapsed time indicator 4 29 Fan assembly E 4 30 zig EUN 4 31 Pump and Motor assembly 4 32 Motor controller PCB 4 33 Power Supply Unit 4 34 Kaell aise DEN 4 35 ILLUSTRATIONS title fig Fan assembly BS 3 3 1 LED assembly e neda 3 2 Water drain filter BS1 3 3 Water cooler trap assembly BS2 and 3 3 4 Cooler water trap assembly BS4 3 5 K232 Issue No 2 Page 4 2 Druck PV 103 R Service Manual
5. OK N Y Y Check pump fan is running by checking for air flow from the Vent pressure and vacuum outputs on rear panel for 5 seconds and then close again rear finger guard N OK Pump now Check running pump H fan Y Is pump fitted with a 15 way D Power N expansion connector on indicator LED Check pump speed the rear of the chassis BS 2 3 and 4 Y Y Pump not Temporarily link pin 6 of the running Power input connector to the pump chassis Check that the motor slows to about half speed B ON checks Continued on next page K232 Issue No 2 Page 5 3 Druck PV 103 R Service Manual MAIN SYSTEMS CHECK AND FAULT TREE Continued Check pump on signal present at expansion connector 5V 1 V at pin 14 with respect to chassis OV Locked in pressure has prevented pump from starting Pump ON check Is this a BS 3 or 4 unit two fuses on front panel Is the ETI time e visible Y BS 3and4 Y ETI check Is the ETI incrementing BS 1 and 2 ETI check Continued on next page Pressure bleed valve open check K232 Issue No 2 Page 5 4 Druck PV 103 R Service Manual MAIN SYSTEMS CHECK AND FAULT TREE Continued Check pressure at pump output Supplementary Test 3
6. 4 REPLACING PARTS 4 1 DISMANTLING General 1 Disconnect the power supply from the pump unit before dismantling Unscrew and remove the screws securing the top panel to gain access to the components 2 Chapter 6 contains part numbers and details of all the replacement parts described in this chapter 4 22 Power Supply Unit 1 Release the pump motor assembly cable from the clamp on top of the PSU Disconnect the two connectors on top of the PSU Unscrew and remove the four screws securing the PSU to the rear panel Carefully remove the PSU from the pump rack and disconnect the cable connectors on the PSU 4 33 Motor Controller PCB BS1 1 Note the connections to the PCB and then disconnect the cables 2 Unscrew and remove the two screws securing the PCB bracket to the rear panel BS2 BS3 and 4 1 To access the PCB remove the PSU as detailed in paragraph 4 2 above 2 Unscrew and remove the screws securing the cover of the PSU and remove the PCB 4 4 Pump and Motor Assembly 1 Disconnect the two vacuum and one pressure output pipes with the swivel right angle fittings on the cylinder heads of the pump Note On earlier pump motor assemblies output pipes are pipe compressing nut unions 2 Release the cable loom from the cable clamp and disconnect the two electrical connectors from the PSU BS1 3 Unscrew the four nuts securing pump and motor assembly to the mounting pillars then remove the nuts and washers 4 Carefully remo
7. Jeuuo 1 jees pue g deo uojsid Bunsixe uee eq 2 Ie s Meu sseJduio25 L oDpo A q q es lt Page 3 5 K232 Issue No 2 Druck PV 103 R Service Manual 3 3 Build standard conversions This section provides instructions to convert the water drain trap assembly of old build standards to the water cooler assembly of the latest build standard BS 1 to BS 4 Fig 2 2 and 2 4 New component list Ref 3 10at Cooling assembly water trap post MOD 04 Body cooler AS405 17 1728M1 Valve pressure release AS405 18 1728M1 Screw M4x 30 Pipe assembly Cable looms assembly AS405 24 1728M1 set of 5 looms see fig 3 5 to manufacture cable Housing mist filter OBSOLETE pre MOD 04 Coil cooling OBSOLETE pre MOD 04 Pipe assembly OBSOLETE pre MOD 04 Procedure 1 Unscrew and disconnect the output union and the input union of the water drain trap 2 Cut the tyrap securing the water drain filter 3 Release the water drain trap from the spring clip remove the drain pipe from the clear nylon bowl Discard the water drain trap Unscrew and remove the two screws securing the spring clip discard the screws and spring clip Unscrew and remove the clips retaining the cooling coil Discard the cooling coil and clips Disconnect the pressure output pipe from the pump head Remove and discard the pipes and cooling coil 6 Front panel Note Take appropriate precautions to prevent swarf contaminat
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9. 9 securing the cylinder head 7 Collect a plain washer 8 from each hexagonal socket head bolt 9 Note Some cylinder heads may have one or more shims fitted these are matched items 4 Remove the cylinder head complete with valve plates 3 and 5 and spacer 4 Record the number and position of any shims for use in assembly 4 16 Anti vibration mounting 1 Remove pump motor assembly as detailed in paragraph 4 5 BS 1 2 Remove the two halves of the anti vibration mounting from the mounting flange of the pump motor assembly BS 2 3 and 4 3 Unscrew and remove four nuts bolts and washers securing the anti vibration mounting in the bracket 4 Repeat the procedure for all the anti vibration mountings 3 17 Power supply filter connector BS 1 and 2 1 Disconnect the output cables of the power supply filter connector at the fuse terminal block and earth ground connection 2 Unscrew and remove the four screws and washers securing the power supply filter connector from the rear panel BS 3 and 4 3 Disconnect the output cables of the power supply filter connector at the fuses and earth ground connection 4 Unscrew and remove the four screws and washers securing the power supply filter connector from the rear panel K232 Issue No 2 Page 4 9 Druck PV 103 R Service Manual 4 18 ASSEMBLING 4 19 Power supply filter connector BS1 and 2 1 Locate the power supply filter connector on the rear panel
10. Absolute Alternating current Altitude Calibrated airspeed Direct current For example End of conversion Engine pressure ratio Electrically programmable read only memory And so on Figure Foot Gauge Mercury Hertz Indicated airspeed That is Institute of Electrical and Electronic Engineers standard 488 data Inch Kilogram Light emitting diode Magnesium alloy Metre Milliampere Maximum Millibar Minute or minimum Millimetre Millivolts Number Newton metre Paragraph Static pressure Pounds per square inch Total pressure Differential pressure Ps Pt Local atmospheric pressure Barometric pressure at sea level Rate of climb Standard commands for programmable instruments True airspeed Test equipment Volts Calibrated velocity True velocity Positive Negative Degrees Celsius K232 Issue No 2 Page v Druck PV 103R Service Manual K232 Issue No 2 Page vi Druck PV 103R Service Manual Chapter 1 Description CONTENTS INtFOGUCTION EE Build standard 1 Brief Description Mn Specification Build standard 1 Build standard 2 2u xu uu uuu S sss Specification Build standard 2 Build standard 3 Specification Build standard 3 Build standard A Specification Build standard 4 Illustrations Build standard 1 General view Build standard 1 Schemat
11. Druck PV 103 R Service Manual Water cooler trap assembly Fig 2 4 BS 3 Procedure Unscrew and remove the two screws and washers securing the bracket to the cooler block Disconnect the drain pipe from the clear nylon bowl unscrew and remove the clear nylon bowl and collect the filter Fit a new filter screw the clear nylon bowl into the filter body Connect the drain pipe to the clear nylon bowl Secure the bracket with the two screws and washers Carry out a standard serviceability test detailed in Chapter 5 hexagonal socket Spring head screw washer assembled pressure regulator and water drain body filter element cooler body Fig 2 4 Water cooler trap assembly build standard 4 Water cooler trap assembly BS 4 1 2 Unscrew and remove the four hexagonal socket head screws and four spring washers Carefully separate the assembled pressure regulator and water drain body from the cooler body attached to the front panel Replace the filter element make sure the o ring fits correctly and refit the assembled pressure regulator and water drain body to the cooler body Secure the assembled water drain with the four hexagonal socket head screws and four spring washers K232 Issue No 2 Page 2 5 Druck PV 103 R Service Manual Pneumatic Filters BS1 1 Two of the four pump heads are filtered by high density polythene porous plastic muffler silencers mufflers The pressure pump h
12. a more satisfactory state to manipulate controls levers linkages etc to return equipment from an out of tolerance condition to an in tolerance condition Align To bring into line to line up to bring into precise adjustment correct relative position or coincidence Assemble To fit and secure together the several parts of to make or form by combining parts Calibrate To determine accuracy deviation or variation by special measurement or by comparison with a standard Check Make a comparison of a measure of time pressure temperature resistance dimension or other quality with a known figure for that measurement Disconnect To detach the connection between to separate keyed or matched equipment parts Dismantle To take apart to the level of the next smaller unit or down to all removable parts Ensure To confirm that a proper condition exists to find out with certainty Examine To perform a critical visual observation or check for specific conditions to test the condition of Fit Correctly attach one item to another Inspect Review the work carried out by Specialists to ensure it has been performed satisfactorily Install To perform operations necessary to properly fit an equipment unit into the next larger assembly or system Maintain To hold or keep in any particular state or condition especially in a state of efficiency or validity Operate Ensure that an item or system functions correctly
13. build standard 3 1 Unscrew and remove the four screws 10 and washers 9 securing the assembly to the front panel Disconnect the output union 3 input union 8 and drain pipe 4 3 Remove the assembly from unit K232 Issue No 2 Page 4 7 Druck PV 103 R Service Manual 4 13 Cooler water trap assembly Figure 4 5 BS 4 1 Unscrew and disconnect the right angled input pipe 4 and collect the bonded seal 2 Unscrew and remove the four screws and washers 5 securing the assembly to the front panel of the unit Disconnect the release valve connections 3 Disconnect the water drain and the output pipe 7 Remove the assembly from the unit 1 Pressure regulator 2 Pressure release valve 3 Release valve connections 4 Input pipe 5 Screw 6 Washer T Output pipe 8 Cooler block Figure 4 5 Water cooler trap assembly K232 Issue No 2 Page 4 8 Druck PV 103 R Service Manual 4 14 Dump valve solenoid BS3 1 Disconnect the two cables to the dump valve Unscrew and remove the two screws and washers securing the valve to the chassis of the pump unit 2 Unscrew and disconnect the unions of the input and output pipes 4 15 Cylinder block JP Remove the pump motor assembly as described in para 4 4 2 Dismantle the pump motor assembly as described in Chapter 2 para 2 2 Note The procedure is the same for each of the four pump cylinder heads 3 Unscrew and remove the four hexagonal socket head bolts
14. component list on page 3 6 and to figure 3 1 to produce a new cable loom Connect the new cable loom to the Molex socket on the PSU Connect the 1 4 Faston red wire connector to the 24 V on the motor controller PCB Connect the 1 4 Faston black wire connector to the O V on the motor controller PCB Connect the two push on terminals to the 2 way terminal block observe the colour coding 6 Carry out a standard serviceability test detailed in Chapter 5 Power supply unit To replace the original type with the upgraded PSU proceed as follows 1 Disconnect the 5 way and 8 way connectors from the pump motor assembly 2 Disconnect the 3 way and 7 way Molex power supply sockets from the PSU 3 Remove and discard the PSU 4 Using a new 4 way Molex connector Fig 3 2 remove the red wire terminal 3 from the 7 way connector and insert it into terminal 3 Repeat this procedure for the black wire terminal 4 inserting it into terminal 4 of the new 4 way Molex connector 5 Connect the two red wires from the 7 way connector terminals 1 and 2 to the red flying cable from the new PSU Connect the three black wires from the 7 way connector terminals 5 6 and 7 to the black flying cable from the new PSU 6 Temporarily position the new PSU in the pump unit case Connect the 5 way connector to CON1 and the 4 way connector to CON 2 on the new PSU CAUTION The M3 screws securing the PSU must not be longer than 6 mm Longer screws damage the int
15. of the pressure air intake air is drawn from inside the crankcase through an end mounted porous plate A robust three axis anti vibration mounting reduces the effects of external vibration Originally designed and developed for the ADTS 405F this mounting fits into a surface mounting adaptor cradle K232 Issue No 2 Page 1 6 Druck PV 103R Service Manual J PRESSURE VACUUM 1 WARNING CONSULT HANDBOOK BEFORE OPERATION SUPPLY INLET VOLTAGE 90 260VAC FREQUENCY 47 440 Hz e MAXIMUM VA 300W Q OUTLE WATER DR power connector cooling output IEC type grill pneumatic output connectors expansion connector Figure 1 4 Build standard 2 Rear Panel Power supply Controller circuit Expansion connector Power and elapsed time indicator Vacuum output Vacuum output water drain filter Pressure output filter DN 8M constant bleed drain Pressure output Water vent Figure 1 5 Build standard 2 Schematic Diagram K232 Issue No 2 Page 1 7 Druck PV 103R Service Manual Specification Build standard 2 13 Input Power supply ee 90 230 Vac 50 60 Hz nominal 110 Vac 400 Hz nominal uiui D MU EL continuous rating 300 VA Output Pressure NOEL TTE I ee ee 3 5 bar abs 100 inHg abs Airspeed Ne 1 Mach min
16. of the water drain trap and the output connection of the rear panel Connect the water drain pipe make sure the other end locates in the grommet for correct venting of the water cooler assembly 11 Carry out an inspection of the unit look for loose connections and or disturbance of the internal components 12 Carry out a Standard Serviceability Test detailed in Chapter 5 K232 Issue No 2 Page 3 7 Druck PV 103 R Service Manual BS 2 to BS 4 Fig 2 2 and 2 4 New component list Ref 3 10at Cooling assembly water trap post MOD 04 Body cooler AS405 17 1728M1 Valve pressure release AS405 18 1728M1 Screw M4x 30 Pipe assembly Cable looms assembly AS405 24 1728M1 set of 5 looms see fig 3 5 to manufacture cable Redundant component list Ref Filter water drain ADTS405 1728 17 M0 OBSOLETE pre MOD 04 Pipe assembly OBSOLETE pre MOD 04 Procedure 1 Unscrew and disconnect the right angled output union from the pressure output of the pump motor assembly and collect the bonded seal Cut the tyrap securing the water drain filter Release the water drain trap from the spring clip remove the drain pipe from the clear nylon bowl Discard the water drain trap Unscrew and remove the two screws securing the spring clip discard the screws and spring clip Unscrew and remove the clips retaining the cooling coil Discard the cooling coil and clips Front panel Note Take appropria
17. remove the piston seal Fig 2 7 item 3 and retainer Fig 2 7 item 4 Note Piston seals must be preformed in accordance with instructions in the seal kit see Fig 2 10 4 Replace the preformed piston seal Fig 2 7 item 3 on the retainer Note The piston seal faces outwards on the pressure piston head and inwards on the vacuum piston heads On earlier units with cylinders of the style shown in Fig 2 6 item 1a all seals point outwards see Fig 2 7 a K232 Issue No 2 Page 2 7 Druck PV 103 R Service Manual 1 Cylinder 2 O ring seal 1a Cylinder earlier pumps 3 Valve plate 4 Spacer 5 Valve plate 6 O ring seal 7 Cylinder head 8 Plain washer 9 Hexagonal socket head bolt 10 O ring seal Fig 2 6 Cylinder head 5 Apply Loctite grade 222 to the threads of the central countersunk screw Fig 2 5 Item 5 Locate the assembled piston seal Fig 2 7 Item 3 and retainer Fig 2 7 Item 4 on the connecting rod Fig 2 7 Item 1 and secure with the central countersunk screw Fig 2 7 Item 5 Note The head of the central countersunk screw must not protrude above the rim of the retainer 6 Fit a new o ring seal 2 to the inner bore of the cylinder 1 The next step is to fit the cylinder over the piston head the piston seal can be damaged if the fitting is not carried out with great care The recommended method is as follows i Move the piston head to top dead centre and then to one side position t
18. to 550 knots Seege into a volume of 10 litres 600 cu mi ESTERE 900 knots min up to 850 knots ort into a volume of 2 litres 120 cu mi Vacuum MaK secacoGouteedihlmo ta ae enda ados 20 mbar abs 0 49 inHg abs 85 000 ft Altitude rate 6 000 ft min rate of climb to 55 000 ft EE into a volume of 17 litres 1000 cu in T 15 000 ft min rate of climb to 85 000 ft M into a volume of 4 litres 240 cu mi Note The vacuum performance is the combined output of Vacuum 1 and Vacuum 2 these are internally linked Dimensions Meu 483 mm 19 in uie E 178 mm 7 in GE DUN acer 266 mm 10 5 in e E 9 5kg 21 Ibs Environment Temperature 10 C to 50 C 14 F to 122 F continuous operation Position of the unit The unit must only be operated with the front panel in the vertical position Note The unit must not be operated in any other position because an internal water drain will be inverted Calibration and adjustments not required K232 Issue No 2 Page 1 10 Druck PV 103R Service Manual Build Standard 4 16 This build standard replaces obsolete parts and improves on the revised chassis design new cooler and water drain assembly and a water release valve of build standard 3 In this standard improvements were made that increased efficiency e The main improvement co
19. up to 550 knots SE Ee into a volume of 10 litres 600 cu mi PH 900 knots min up to 850 knots dated ete into a volume of 2 litres 120 cu in Vacuum MaX E 20 mbar abs 0 49 inHg abs 85 000 ft Altitude rate 6 000 ft min rate of climb to 55 000 ft EE into a volume of 17 litres 1000 cu in mm 15 000 ft min rate of climb to 85 000 ft into a volume of 4 litres 240 cu mi Note The vacuum performance is the combined output of Vacuum 1 and Vacuum 2 these are internally linked Dimensions Width ME 483 mm 19 in ET le EE 178 mm 7 in GO DUN ME 266 mm 10 5 in IETS See ee nee ere emer arene ee ee en yaaa amalaya B Ree ae 9 5kg 21 Ibs Environment Ee e 10 C to 50 C 14 F to 122 F continuous operation Position of the unit The unit must only be operated with the front panel in the vertical position Note The unit must not be operated in any other position because an internal water drain will be inverted Calibration and adjustments not required K232 Issue No 2 Page 1 8 Druck PV 103R Service Manual Build Standard 3 14 This standard includes a completely revised chassis design new cooler and water drain assembly and a water release valve In this standard two improvements were made that increased efficiency e The replacement of the copper co
20. 3 20 4 26 PV103R 4 1 ADTS405 1728 32 MO 5 3 ADTSA05F 1728 36 MO 1 16 2 14 3 15 4 14 ADTS405F 1728 39 MO 5 1 ADTS405F 1728 49 MO 5 2 ADTS405 1728 62 M1 3 1 ADTS405 1728 63 MO 1 18 2 16 3 17 4 16 ADTS405 1728 64 MO 2 18 K232 Issue No 2 Page 6 13 Druck PV 103 R Service Manual K232 Issue No 2 Page 6 14
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22. E TOO LOW Is this a build standard 3 4 unit Two fuses in the front panel i l If possible adjust the release valve to release at the correct pressure detailed in Supplementary Test 3 Y Return to main test sequence Carry out 1000 hour Has the filter set been replaced in the last 1000 hours filter service Check water bowl and cooling coil or blocked hoses back to the pump head for leaks m Carry out the 3000 hour pump head service Repair hose joints or replace leaking components RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 11 Druck PV 103 R Service Manual PRESSURE TOO HIGH Is this a build standard 3 4 unit Two fuses in N the front panel Y Y Y Check the water separator Check the drain hose path back bowl bleed needle valve through the release valve to the and drain connection hose water separator bowl for for blockages blockage or sticking valve s lt L gt Y I Replace pressure Adjust pressure Check measuring release valve or release valve to gauges used are clear blockages as give correct reading correctly and appropriate pressures detailed verify that all hoses are in Supplementary correctly routed test 4 detailed in the internal pneumatic circuit Y Replace the bleed needle assembly part of filter
23. GE Infrastructure Sensing Druck PV 103R Pump unit Service manual K232 LAPSE m q Ka is o D E FORET Har w b L Eu um Zu ing die Druck PV 103R Service Manual INTRODUCTION Purpose This technical manual provides servicing instructions and a parts list to an intermediate level of maintenance for the Druck PV 103 pump units Scope This technical manual contains a constructional description a functional description explaining the theory of operation servicing replacing parts and testing procedures An illustration parts list details the parts that can be replaced The test equipment and special tools required for the recommended maintenance level are listed A supplementary servicing chapter describes procedures to update older units to the latest build standard Associated Druck Documents K141 PV 103R User Manual K232 Issue No 2 Page i Druck PV 103R Service Manual TABLE OF CONTENTS Preliminary pages Table of contents this table Introduction Purpose Scope Glossary Abbreviations Chapter 1 DESCRIPTION 2 SCHEDULED SERVICING 3 SUPPLEMENTARY SERVICING 4 REPLACING PARTS 5 TESTING 6 ILLUSTRATED PARTS LIST K232 Issue No 2 Page ii Druck PV 103R Service Manual GLOSSARY Terminology The terminology used in this manual is specific and individual interpretation must not be introduced The terms are defined as follows Adjust To bring to
24. Page 1 13 Druck PV 103R Service Manual Specification Build standard 4 17 Input Power supply Eege 88 260 Vac 47 440 Hz nominal EET Ene continuous rating 300 VA Output Pressure MAX E 3 5 bar gauge 100 inHg gauge Airspeed RN 1 Mach min up to 550 knots into a volume of 10 litres 600 cu mi EET TIENE 900 knots min up to 850 knots into a volume of 2 litres 120 cu mi Vacuum JEE e ei coe die te ete tdt 20 mbar abs 0 49 inHg abs 85 000 ft Altitude rate 6 000 ft min rate of climb to 55 000 ft Mr into a volume of 17 litres 1000 cu in 15 000 ft min rate of climb to 85 000 ft EE into a volume of 4 litres 240 cu mi Note The vacuum performance is the combined output of Vacuum 1 and Vacuum 2 Dimensions Toi ER 483 mm 19 in WEIT le em EET 178 mm 7 in qepi u ss 266 mm 10 5 in EE 9 5kg 21 Ibs Environment Temperature eee en erent ee ee vane emer 10 C to 50 C 14 F to 122 F continuous operation Position of the unit The unit must only be operated with the front panel in the vertical position Note The unit must not be operated in any other position because an internal water drain will be inverted Calibration and adjustments not required K232 Issue No 2 Page 1 14 Druck PV 103 R Service Manual Ch
25. and secure with the four screws and washers 2 Connect the output cables of the power supply filter connector to the fuse terminal blaock and earth ground connection BS 3 and 4 3 Locate the power supply filter connector on the rear panel and secure with the four screws and washers 4 Connect the output cables of the power supply filter connector to the two fuses live and neutral and earth ground connection 4 20 Anti vibration mounting BS 1 1 Fitthe two halves of the anti vibration mounting in the pump motor flange mounting Repeat the procedure for all the anti vibration mountings BS 2 3 and 4 2 Fitthe new anti vibration mounting in the bracket and secure with four nuts bolts and washers Tighten to the correct dimension 3 Repeat the procedure for all the anti vibration mountings D 4 Refit the pump motor assembly as detailed in paragraph 4 13 4 21 Cylinder block 1 Carry out the procedures detailed in Chapter 2 3000 hour servicing fitting new cylinder block and replacing the piston seals 4 22 Dump valve solenoid BS 3 1 Connect the input and output pipes to the valve and tighten the unions Locate the valve on the pump unit chassis and secure with the two screws and washers 14 5 mm 2 Connect the two cables to the dump valve 4 23 Water cooler trap assembly BS4 Fig 4 5 1 Reconnect the water drain and output pipe 7 Reconnect the release valve connections 3 2 Refit th
26. apter 2 Scheduled Servicing CONTENTS title para SOPVIGIINU egene ee 1 Maintenance uuu u xu a Es 2 Scheduled Procedures 2 1 1000 elei 2 2 Saile IL 2 3 ILLUSTRATIONS title fig Bulkhead fittings uu uu pe aussi sawa asas qasawssssaqasa 2 1 Water drain filter build standard 1 and 2 2 2 Water cooler trap assembly build standard 3 2 3 Water cooler trap assembly build standard 4 2 4 Cylinder head AEN 2 5 Piston head vevatvenstaaesteeaeveanenss 2 6 K232 Issue No 2 Page 2 1 Druck PV 103 R Service Manual 1 SERVICING WARNING VOLTAGES IN EXCESS OF 30 VOLTS RMS AC OR 50 VOLTS DC IN CERTAIN CIRCUMSTANCES CAN BE LETHAL CARE MUST BE TAKEN WHEN WORKING ON LIVE EXPOSED CONDUCTORS General 1 Absolute cleanliness of the work area tools and equipment must be observed Expendable items must be discarded 2 Disconnect and remove all the electrical and pneumatic connections Cover 3 Unscrew and remove the ten screws and shakeproof washers securing the cover to the chassis Slide cover off to the rear 2 MAINTENANCE General 1 To maintain the unit in a safe and serviceable condition carry out the following scheduled maintenance procedures 2 1 SCHEDULED PROCEDURES The scheduled maintenance procedures are carried out at 1000 and 3000 hours recorded on the elapsed time indicator on the front panel of the unit The recommended period of servicin
27. as far as possible without the use of test equipment or reference to measurement Readjust To adjust again to move back to a specified condition to bring back to an in tolerance condition Reconnect To rejoin or refasten that which has been separated Refit Fit an item which has previously been removed K232 Issue No 2 Page ili Druck PV 103R Service Manual Terminology continued Remove To perform operations necessary to take an equipment unit out of the next larger assembly or system To take off or eliminate To take or move away Repair To restore damaged worn out or malfunctioning equipment to a serviceable usable or operable condition Replace Remove an item and fit a new or a serviced item Reset To put back into a desired position adjustment or condition Service To perform such operations as cleaning lubricating and replenishing to prepare for use Test Ascertain by using the appropriate test equipment that a component or system functions correctly K232 Issue No 2 Page iv Druck PV 103R Service Manual Abbreviations The following abbreviations are used in this manual the abbreviations are the same in the singular and plural A abs a c ALT CAS d c e g EOC EPR EPROM etc Fig ft g Hg Hz IAS i e IEEE 488 in kg LED M m mA max mbar min mm mV No N m Para Ps psi Pt Qc QFE QNH ROC SCPI TAS Vc Vt ve ve Ampere
28. assembly as detailed in Figure 3 6 Connect the new pressure output pipe to the output port of the pump head Connect the other end to the input connection of the water cooler assembly Connect the new pipe to the output union of the water drain trap and the output connection of the rear panel Connect the water drain pipe make sure the other end locates in the grommet for correct venting of the water cooler assembly Carry out an inspection of the unit look for loose connections and or disturbance of the internal components Carry out a Standard Serviceability Test detailed in Chapter 5 K232 Issue No 2 Page 3 10 Druck PV 103 R Service Manual title Chapter 4 Replacing Parts CONTENTS para REPLACING PARTS DISMANTLING vrisnin ennen 4 1 Power Supply Unit 4 2 Motor controller PCB 4 3 Pump and Motor assembly 4 4 e Ir ennen 4 5 Fan assembly toe tecla npo leta 4 6 Elapsed time indicator 4 7 cM 4 8 LED assembly eec pM 4 9 Pressure release valve 4 10 Water drain filter BS 1 and 2 4 11 Water cooler trap assembly BS 3 4 12 Water cooler trap assembly BS4 4 13 Dump valve solenoid BS 3 4 14 Cylinder block
29. ation and adjustments not required K232 Issue No 2 Page 1 5 Druck PV 103R Service Manual Build Standard 2 10 The second standard included improvements in materials and assembly methods that had been well proven during design development of the military versions A improved power supply included an upgraded motor control PCB When this unit is used with an ADTS 405 the speed of the motor is controlled by the mode selection of the ADTS 405 During measurement mode the motor speed slows to reduce noise output and wear An additional 15 way D type connector was fitted to the rear panel to connect to the ADTS 405 mode selection 11 Build standard 2 introduced a profiled spacer on the piston crown enabling the piston seals to be reversed for more effective vacuum generation A new style of cylinder with hard anodising and high polish improved seal wear and reduced leakage To keep stroke lengths correct a similar profile spacer is used on the pressure piston Improvements to piston alignment with the piston seal changes has increased the servicing interval to 3000 hours The output pressures can be sustained at 3 5 bar and 20 mbar absolute O AS ur 1 a b c Piston head for pumps Piston head for pumps of build standard 2 of build standard 1 1 Connecting rod 4 Retainer 2 Spacer 5 Central countersunk screw 3 Piston seal 12 Noise reduction has been achieved by increasing the filter area
30. copper cooling coil located behind the front panel air intake grill Any moisture in the cooled air condenses a coalescing filter bowl traps the condensed moisture A constant air bleed forces the discharge of condensed moisture water through a needle restrictor to the water drain pipe K232 Issue No 2 Page 1 2 Druck PV 103R Service Manual po a y e W le D e H m py 103 PUMP UNIT oem amp c2 POWER a CONSULT MANDERA A BEFORE OPERATING O 1 ITA is us FE QA HBC Figure 1 1 Build standard 1 General view fuse Power G Motor supply a PSU m Controller supply PCB switch DC brushless motor Power and elapsed time indicator Auxiliary vacuum pump assembly e four head pump system Vacuum output cooling coil Pressure filter output water filter ecco constant fan bleed Water drain vent Figure 1 2 Build standard 1 Schematic Diagram K232 Issue No 2 Page 1 3 Druck PV 103R Service Manual POWER ON ANDBOOK SULT HE RATING cU A FENDRE o C N o FUB TA HEC POWER SURELY vonage D K Frequenev 47 MO Manum 300 1 Water drain filter 7 Power supply unit 2 Pneumatic output connections 8 Elapsed time indicator 3 Pump and Motor assembly 9 Fuse holder 4 Fan assembly 10 Switch 5 Moto
31. e ADTS405 1728 82 MO Switch ADTS405 1729 92 MO LED and clip ADTS405 1729 91 MO Filter water drain ADTS405 1728 17 MO OBSOLETE pre MOD 04 superseded by item 4 10 Block cylinder set of 4 ADTS405 1728 14 MO Mounting antivibration set of 3 ADTS405 1728 15 MO Connector filter power supply ADTS405 1728 07 MO Servicing kits and ancilliary equipment Kit fuse o ring ADTS405F 1728 36 M0O Fuse T5 0A 250V HBC 20 mm Kit pump seals ADTS405 1728 63 MO Kit hose OBSOLETE see items 5 2 and 5 3 in list of accessories Kit bulkhead fitting ADTS405 1728 64 MO OBSOLETE superseded by item 4 18 Kit filter ADTS405 1728 09 MO see item 4 18 for details Kit pneumatic ADTS405 1728 21 MO K232 Issue No 2 Page 6 7 Druck PV 103 R Service Manual Figure 6 3PV103 BS3 Page 6 8 K232 Issue No 2 Druck PV 103 R Service Manual Ref Pump unit PV103 Build standard 3 ADTS405 1728 62 M1 OBSOLETE pre MOD 04 PSU and controller Pump Universal AC ADTS405 1728 86 M0 Pump and Motor Assembly ADTS405 1728 85 M1 Filter fan part of item 19 Fan assembly ADTS405 1728 79 M0 Elapsed time indicator ADTS405 1728 81 M0 Switch ADTS405 1728 92 MO LED and clip ADTS405 1728 91 MO Valve pressure relief ADTS405 1728 18 MO OBSOLETE pre MOD 04 Cooling assembly water trap ADTS405 1728 18 M1 post MOD 04 Filter water drain ADTS405 1728 17 MO OBSOLETE pre MOD 04 Filter wat
32. e assembly and secure with the four screws 5 and washers 6 Fit a new bonded seal and reconnect the right angled input pipe 4 4 24 Water cooler trap assembly BS 3 Fig 4 4 1 Reconnect the drain pipe 4 output union 3 and input union 8 2 Refit the assembly and secure with the four screws 10 and washers 9 4 25 Water drain filter BS1 and 2 Fig 4 3 ale Locate the water drain filter in the spring clip and secure with the tyrap 5 Connect the input and output unions 6 and 7 to the water drain filter 2 Connect the drain pipe 4 to the clear nylon bowl 2 Note On build standard 1 and 2 a constant flow of air comes from the water drain pipe this requires checking after assembly K232 Issue No 2 Page 4 10 Druck PV 103 R Service Manual 4 26 Pressure relief valve BS3 Fig 4 4 1 Locate the pressure relief valve in the bracket and secure with the retaining nut and washer Connect the two pipes to the pressure relief valve 4 27 LED assembly 1 Locate the LED 1 in the front panel Locate the insulating sleeve 3 over each wire 2 Using the colour code recorded on removal solder the two wires 3 to the positive and negative connection wires of the LED assembly Note The long wire of the LED assembly connects to the positive supply 3 Push the insulating sleeve 3 over the solder connections 4 28 Switch 1 Locate the switch in the front panel and secure with the washer and retianing nut C
33. ead has two intake mufflers used as filters and the initial vacuum head has one discharge muffler used as a silencer 2 Unscrew the existing mufflers and screw the new mufflers hand tight Note Over tightening could damage the muffler threads muffler BS2 BS3 and BS4 1 An end mounted porous plate fitted to the crankcase provides the pressure air intake filter the pressure pump draws air from inside the crankcase The initial vacuum head has one discharge muffler used as a silencer 2 Unscrew the existing muffler and screw the new muffler hand tight Note Over tightening could porous plate damage the muffler threads 3 Unscrew the four screws and washers securing the porous plate to the crankcase Fit a new porous plate and secure with the four screws and washers BS3 and BS4 1 Two in line filters connect in the vacuum output pipes muffler 2 Disconnect the pipe from each end of the in line filter by releasing the clip Connect a new filter and secure with the clips for each filter Completion 1 Refit the cover and reconnect the external pipes and connectors K232 Issue No 2 Page 2 6 Druck PV 103 R Service Manual 2 2 3000 Hours WARNING DISCONNECT THE POWER SUPPLY BEFORE PROCEEDING WITH MAINTENANCE Every 3000 hours replace the following components Piston seals 0 Cylinder head o ring seals Preparation 1 Absolute cleanliness of the work area tools and equipment m
34. ead fitting remove the bulkhead fitting Inspect and clean the bulkhead fitting wire knitmesh filter and if necessary replace the bulkhead fitting Refit the bulkhead fitting and secure with the two screws Fit a new bonded seal and refit the union to the bulkhead fitting Locate the pneumatic output pipe on the union and secure with the union nut Water Drain Filter Fig 2 2 Build standard 1 and 2 This unit contains a constant bleed water drain producing a small flow of exhaust air The exhaust air must be checked when the pumps are running Replace the water drain filter as follows 1 2 Disconnect the drain pipe to the water drain filter Cut the tyrap securing the water drain filter Unscrew the clear nylon bowl from the water drain filter body Remove the clear plastic drain pipe from the clear nylon bowl and replace the drain inserted in the bowl Refit the clear plastic drain pipe to the nylon bowl Replace the filter element and refit the clear nylon bowl to the water drain filter body Secure the assembled water drain filter with a tyrap Carry out a standard serviceability test detailed in Chapter 5 K232 Issue No 2 Page 2 3 Druck PV 103 R Service Manual filter element water ejector tyrap cooler block filter element clear nylon bowl output screw Fig 2 3 Water cooler trap assembly build standard 3 K232 Issue No 2 Page 2 4
35. er drain ADTS405 1728 17 M1 post MOD 04 Solenoid dump valve ADTS405 1728 05 MO OBSOLETE pre MOD 04 Block cylinder set of 4 ADTS405 1728 14 MO Mounting antivibration set of 3 ADTS405 1728 15 MO Connector filter power supply ADTS405 1728 07 MO Servicing kits and ancilliary equipment Kit fuse o ring ADTS405 1728 36 MO Fuse T5 0A 250V HBC 20 mm Kit pump seals ADTS405 1728 63 MO Kit hose OBSOLETE see item 5 2 in list of accessories Kit filter ADTS405 1728 09 MO see item 4 18 for details Kit pneumatic ADTS405 1728 21 MO K232 Issue No 2 Page 6 9 Druck PV 103 R Service Manual LS Figure 6 4 PV103 BS4 Page 6 10 N K232 Issue Druck PV 103 R Service Manual Description Manufacturer s Part Number Pump unit PV103 Build standard 4 PV103R PSU and controller ADTS405 1728 86 M0 Pump assembly Pressure vacuum ADTS405 1728 85 M1 Fan assembly ADTS405 1728 79 M0 Filter vent part of item 18 Indicator elapsed time ADTS405 1728 81 M0 Switch ON OFF ADTS405 1728 92 M0 LED and clip ADTS405 1728 91 M0 Valve pressure release ADTS405 1728 18 M1 Water trap ADTS405 1728 17 M1 Block cylinder set of 4 ADTS405 1728 14 M0 Mounting antivibration set of 3 ADTS405 1728 15 M0 Connector filter power supply ADTS405 1728 07 M0 Servicing kits and ancilliary equipment Kit fuse o ring ADTS405 1728 36 M0 Fuse T5 0A 250V HBC 20 mm Kit pump
36. ernal PCB and components 7 Locate and secure the new PSU to the pump unit case with the correct screws and washers 8 Connect the 8 way connector and the 3 way connector on the new PSU K232 Issue No 2 Page 3 3 Druck PV 103 R Service Manual Fitting the new type PSU and motor controller PCB continued 9 Carry out a standard serviceability test detailed in Chapter 5 Druck part no 159 022 Nr i 1 4 Faston blue A Druck part no 300 mm Dee 16 0 20 black cable terminals 5 6 amp 7 Druck part no TX 59 022 1 4 Faston blue 300 mm 6 0 20 red cable terminals 1 2 amp 3 Druck part no 165 036 7 way 0 156 amp 6 x crimps part no 146 005 iC v Oo O4Lt Fig 3 1 Motor controller cable loom black black from new PSU red new 4 way terminal block e gt Dart no 165 003 connects to CON 2 red 3 ofthe new PSU ei red er SEE red kaz red from new PSU Fig 3 2 New PSU and motor controller cable loom K232 Issue No 2 Page 3 4 Druck PV 103 R Service Manual s nbiuu2 Jjuawuooejda eos uolsid g Du Ajquiesse ysisse o poljdde aq Aew e y epnuoec dwnd o Ajquiasse euuou 8J0Jeq SOINUIW 0 Z JO 91897 eoeyins zej 1suieDe 9JOq Jepui Ao olu UMOP SS ld 3 yoolgq 1epuiAo Bunsixe 01 Aua pe gAeq y 140 SAG615 lquu sse e s uonisoq Bull o 1 pui o v weJos Buisn q
37. from the power supply switch at the rear of the front panel Replace power supply switch Continued on next page K232 Issue No 2 Page 5 14 Druck PV 103 R Service Manual POWER INPUT CHECKS continued Check for correct power supply output of 24 V DC 3V at the front panel terminal block TB2 next to the LED assembly OK Y Y Replace LED assembly Check for correct power supply output of 24 V DC 3V at the rear chassis terminal block TB1 BS1 amp 2 TB3 BS3 amp 4 above the power supply filter OK N Y Replace power cable and retest Y Y Disconnect the motor Controller PCB 24V supply from inside the PSU and check the output voltage at TB1 BS1 amp 2 TB3 BS3 amp 4 WARNING EXPOSED LIVE TERMINALS OK N Y Replace pump power supply Y Disconnect motor from PL1 and PL2 on pump power supply reconnect motor controller PCB red and black cables to the power supply and recheck output voltage at TB2 BS1 TB1 BS2 TB3 BS3 amp 4 e Replace motor Replace pump controller PCB motor assembly C RE RUN MAIN SYSTEMS CHECK TREE E K232 Issue No 2 Page 5 15 Druck PV 103 R Service Manual PUMP NOT RUNNING Check blue body of motor can be rotated by hand N OK Y Replace Check for motor drive pulses and hall pump motor effect
38. g is based on a temperate environment If the unit is used in an environment with higher humidity or higher levels of dust the periodicity must be increased accordingly Consult DRUCK if there is any doubt 2 2 1000 Hours WARNING DISCONNECT THE POWER SUPPLY BEFORE PROCEEDING WITH MAINTENANCE Every 1000 hours replace the following components o Bulkhead fittings Water drain filter internal o Pneumatic filters mufflers internal Bulkhead Fittings BS1 BS2 and BS3 Fig 2 1 The pneumatic output connectors consist of bulkhead fitting with an integral wire knitmesh filter and located in a small groove an o ring seal The bulkhead fittings are secured by two screws to the front or rear panels The pneumatic output pipe connects to the bulkhead fitting by a union nut and a union screwed into the bore of the bulkhead fitting The small o ring located in the groove of each bulkhead fitting requires regular inspection for damage and if necessary replacement Note BS4 bulkhead fittings have an integral o ring seal should this become damaged the bulkhead fitting must be replaced K232 Issue No 2 Page 2 2 Druck PV 103 R Service Manual Procedure o ring seal _ 0 cng bulkhead fitting Fig 2 1 Bulkhead fitting Build standard 1 2 and3 1 2 3 4 5 Unscrew the union nut disconnect the pneumatic output pipe and collect the bonded seal Unscrew the two screws securing the bulkh
39. he cylinder 1 at an angle to the piston head K232 Issue No 2 Page 2 8 Druck PV 103 R Service Manual edge of cylinder S can damage zd piston seal pump body ii Carefully move the cylinder over the piston head making sure the piston seal is not distorted Carefully push the cylinder over the piston head until it is fully inserted making sure the piston seal is not distorted and is formed in the correct way see above iii Align the holes of the cylinder with the threaded holes of the pump body NETS a b c Piston head for earlier pumps Piston head for later pumps Connecting rod 4 Retainer Spacer 5 Central countersunk screw Piston seal Fig 2 7 Piston head Before assembly check the valve plates 3 and 5 and spacer 4 remove any dirt by polishing Assemble a valve plate 3 and 5 on each side of the spacer 4 locating each plate on the keys on the spacer Refit any shims in the recorded position Fit a new o ring seal 6 to the mating face of the cylinder head 7 Fit a new small o ring seal 10 to the recess of the cylinder head 7 Locate the cylinder head 7 complete with valve plates and spacer over the cylinder 1 and loosely retain with the four hexagonal socket head bolts 9 and washers 8 Carefully rotate by hand the pump and if necessary reposition the assembled cylinder head for the smoothest rotation Tighten the four hexagonal
40. he motor can be heard Check that the cooling fans operate Note On BS 3 and 4 units a default setting can be made so that the cooling fans operate on connection of the power supply When using the 15 way expansion port connector applying 24 V to pin 8 ve and pin 15 ve also causes the cooling fans to operate 2 Check that there is no excessive or abnormal mechanical noise 3 Switch off and connect a pressure gauge and if necessary an adaptor to the pressure or vacuum outlet 4 Switch on and measure the pressure and vacuum outlet BS1 and 2 Pressure outlet between 2 5 and 2 9 bar gauge 36 3 to 42 psi gauge BS3 and 4 Pressure outlet between 3 4 and 3 8 bar gauge 49 3 to 55 1 psi gauge Vacuum outlet pressure less than 20 mbar abs Note When new piston seals have been fitted the pump may have to run for a few hours before achieving this performance 5 Switch off and disconnect the pressure gauge and the adaptor 5 2 Fault Finding Limited fault finding and rectification can be carried out in the following procedures WARNING DISCONNECT THE POWER SUPPLY BEFORE PROCEEDING WITH MAINTENANCE Procedure These procedures must be used in conjunction with the instructions and procedures in this chapter K232 Issue No 2 Page 5 2 Druck PV 103 R Service Manual MAIN SYSTEMS CHECK AND FAULT TREE Blank off pump outputs and switch pump on Check that pump can be heard operating
41. he wires and terminations connected to the switch Disconnect the wires to the switch Unscrew and remove the retaining nut securing the switch to the front panel remove the switch and collect the washer 1 LED 2 Locking collar 3 Insulating sleeve 4 Cables Figure 4 2 LED assembly 4 9 LED assembly 1 Remove the insulating sleeve 3 from the rear of the assembly 1 2 Note and record the colours of the cable to the positive and negative cables 4 of the LED assembly Unsolder the two cables 4 3 Push out the locking collar 2 and then the push the LED assembly out of the front panel K232 Issue No 2 Page 4 5 Druck PV 103 R Service Manual 4 10 Pressure relief valve BS 3 1 Disconnect the two pipes to the pressure relief valve Unscrew the retaining nut and washer and remove the pressure relief valve 4 14 Water drain filter Figure 4 3 BS 1 and 2 5 j Filter element 2 Clear nylon bowl 3 Water ejector 4 Drain pipe 5 Tyrap 6 Input union 7 Output union Figure 4 3 Water drain filter 1 Unscrew and disconnect the output union 7 and the input union 6 Cut the tyrap 5 securing the water drain filter Remove the unit from the spring clip K232 Issue No 2 Page 4 6 Druck PV 103 R Service Manual 4 15 Water cooler trap assembly 1 Cooler block 2 Water trap 3 Output union 4 Drain pipe 5 Pressure relief valve 6 Bracket 7 Screw 8 Input union 9 Washer 10 Screw Figure 4 4 Water cooler trap assembly
42. ic diagram Build standard 1 Internal view Build standard 2 Rear panel Build standard 2 Schematic diagram Build standard 3 Schematic diagram Build standard 4 Schematic diagram K232 Issue No 2 Page 1 1 Druck PV 103R Service Manual INTRODUCTION 1 Since the introduction of the PV 103 in March 1994 there have been four build standards With all four build standards there are two variants the rack and flightline Each standard has improved either the performance and reliability or extended the servicing period 2 The PV 103R rack mounted variant provides pressure and vacuum supplies for use with other rack mounted equipment such as the ADTS 405 as part of an instrument and air data component servicing and testing facility Alternatively the unit can be fitted in a trolley as part of a mobile air data test system Note The suffix R was added in 1998 to show the difference between the two variants 3 The PV 103 flightline variant is part of the ADTS 405F air data test system providing complete pressure and vacuum measuring and control for on aircraft sense and leak testing and functional tests of air data instruments components and systems The ADTS 405F comprises an electronics rack ADTS 405 and pump rack PV 103 enclosed in a high density polyethylene case The opera
43. ion of the unit from the following procedure Service tip turn unit upside down when arilling Mark out the front panel using the dimensions detailed in figure 3 4 Drill four M3 holes in the front panel 7 Locate the new water cooler assembly and secure to the front panel with the four screws and washers 8 Connect the wires for the pressure bleed valve solenoid on the water cooler assembly as detailed in Figure 3 5 9 Connect the new pressure output pipe to the output port of the pump head Connect the other end to the input connection of the water cooler assembly K232 Issue No 2 Page 3 6 Druck PV 103 R Service Manual 483 96 12 375 177 Figure 3 4 Front panel drilling dimensions Pressure bleed TEM valve solenoid k Water drain S RD 4 RD 4 gt BK 5 BK 5 circuit identification numbers change with build standard t ag 4 X x X X X X x Xx x x x x x x x X X X X X X X X X X X X X Item Description part no qty Item Description part no qty Housing Molex 165 019 1 Sleeve 208 167 1 Crimp 164 004 4 Braid 208 339 a r Cable black 192 073 a r Cable red 192 078 a r Item Manufacturer part no Item Manufacturer part no 22 01 2025 Raychem CGAT 6 2 1 2m 08 55 0111 Hellerman Helagain 3 mm grey 08 56 0115 Druck 192 078 192 073 Figure 3 5 Water cooler assembly new wires 10 Connect the new pipe to the output union
44. kit or clear other blockages as appropriate RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 12 Druck PV 103 R Service Manual WATER DRAIN NOT PURGING Is this a BS3 Y or BS4 unit de Check the drain hose path back through the release valve to the water separator bowl for leaks particularly the high pressure bowl to release valve section Check drain hose back to the water separator bowl connection for leaks or blow off N OK Check water bowl and cooling coil or block hoses back to the pump head for leaks Repair or remake hose Note Bubble solution may be used in checking for pressure leaks E GE Service pump assembly to 1000 hour filter and 3000 hour seals procedures to restore efficiency Repair hose joints or replace leaking components path RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 13 Druck PV 103 R Service Manual POWER INPUT CHECKS Continuity check front panel fuses OK N Y Y Does power cable pass continuity and short check Replace fuses and retest Check for correct power supply voltage to the power supply switch at the rear of the front panel Replace power cable and retest Replace AC filter bulkhead power connector Check for correct power supply voltage
45. mbines the cooler and water drain into one assembly with a compact cooler block Heat is dissipated through the block and then to the chassis A reduced number of pipe interconnections reduces the potential leak paths Both changes improve pumping efficiency c A pressure release valve in the regulator only purges the water drain filter when the pump s back pressure rises to 3 5 bar gauge At power down an energised closed solenoid valve opens discharging air from the pressure head Nie SS Pri F 3 Ster D n Da VOER sy Fus ed Se Boo PLY E Du Be RE Vane Figure 1 7 Build standard 4 General view K232 Issue No 2 Page 1 11 Druck PV 103R Service Manual Power PSU Motor supply i Controller circuit Expansion connector Power and elapsed time indicator Vacuum output Filter Vacuum output gt silencer Filter Pressure i output pressure fan release Bed Water drain filter and cooler assembly Figure 1 8 Build standard 4 Schematic Diagram K232 Issue No 2 Page 1 12 Druck PV 103R Service Manual 1 Water trap cooler assembly 6 Power supply unit 2 Pneumatic output connections 7 Switch 3 Pump and Motor assembly 8 Fuse holder 4 Fan assembly 9 Elapsed time indicator 5 Power supply filter connector 10 Filter Figure 1 9 Build standard 4 Internal view K232 Issue No 2
46. ms see fig 3 5 to manufacture cable Redundant component list Item Description Manufacturer s Part Number QTY Ref 3 10 NP Valve pressure relief ADTS405 1728 18 MO OBSOLETE pre MOD 04 Filter water drain ADTS405 1728 17 MO NP OBSOLETE pre MOD 04 Solenoid pressure bleed valve 401 207 NP OBSOLETE pre MOD 04 K232 Issue No 2 Page 3 9 Druck PV 103 R Service Manual BS 3 to BS 4 Fig 3 5 continued Procedure he 10 11 12 19 14 Unscrew and disconnect the right angled output union from the pressure output of the pump motor assembly and collect the bonded seal Unscrew and disconnect the right angled input union from the bottom of the water cooler block and collect the bonded seal Unscrew and disconnect the right angled output union and collect the bonded seal Withdraw the drain pipe from the rear panel grommet Unscrew and remove the four screws and washers securing the assembly to the chassis of the unit Remove the assembly and discard Disconnect the two cables to the pressure bleed valve Unscrew and remove the two screws and washers securing the dump valve to the chassis of the pump unit Remove and discard the dump valve Disconnect remove and discard the existing pressure bleed valve cable loom Locate the new water cooler assembly and secure to the front panel with the four screws and washers Connect the wires for the pressure bleed valve solenoid on the water cooler
47. n the Y LCD Check for 5V DC 1V across the input pins 1 Check LCD for correct display and 2 of the ETI module showing numeric data with the hour glass symbol flashing at approximate rate of 5 seconds on and 1 second off Y N Y N Check for 5V DC 1V Replace ETI across the input pins 2 and 3 of CON 3 on the Replace ETI motor controller PCB Y OK N Check and repair wiring from the motor controller PCB CON 3 pins 2 and 3 according to schematic Replace motor No Fault circuit controller PCB Found RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 9 Druck PV 103 R Service Manual PRESSURE BLEED VALVE OPEN CHECK Check for 24V DC 3V across the input terminals to the pressure bleed valve solenoid coil N OK Temporarily disconnect one of the 24 V DC supply cables to the terminals of the pressure bleed valve solenoid coil v Check and repair wiring back to power supply unit according to schematic circuit Did the valve click as it changed state Was air heard purging from the system as the valve de energised v Check and repair any Replace blocked pneumatic feed or discharge pipe pressure bleed No fault found valve assembly RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 10 Druck PV 103 R Service Manual PRESSUR
48. n wired to black red pair 24V loom from PSU default recommended External Fan wired to orange white pair from expansion port Is fan set to internal or external operation Check for 24V DC 3V at the fan terminal block BS 1 EXTERNAL TB2 BS2 TB1 Y Check for wiring continuity from expansion connector to fan terminal block Confirm fan is functioning by temporarily Y transferring of wiring to unused connectors on the internal control 24V terminals N o Y No fault found Return wiring to external control only if the fan is to be used with external thermostatic power feed Check and repair wiring to power switch supply unit according to schematic circuit Replace fan assembly RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 7 Druck PV 103 R Service Manual BS1 and BS2 ETI CHECK with the least significant digit Check for correct hours update rate incrementing approximately every 36 seconds N OK Y Check for 24V DC 3V across the input pins of the ETI module Y OK N Check and repair wiring back to power supply unit according Heplace ET to schematic circuit No Fault Found RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 8 Druck PV 103 R Service Manual BS3 and BS4 ETI CHECK Is anything N visible o
49. neering practice for all the procedures Absolute cleanliness must be maintained in the work area K232 Issue No 2 Page 3 2 Druck PV 103 R Service Manual 3 2 Servicing supplement The following is additional information that is intended to assist in the servicing procedures Build standard 1 Power supply unit and motor controller PCB These two components were upgraded and the originals are now obsolete It is possible to use an original PSU with an upgraded motor controller PCB and vice versa it requires a change of the electrical loom to achieve this type of replacement The following instructions detail the necessary replacement procedures Motor controller PCB To replace the original type with the upgraded PCB proceed as follows 1 Disconnect the 8 way and 3 way connectors from the pump motor assembly 2 Disconnect and discard the cable loom with the 7 way Molex socket at one end PSU and to the 2 way terminal block and the terminal block at the top of the motor controller PCB at the other 3 Remove and discard the motor controller PCB Fitting the new motor controller PCB 1 If necessary from the top fixing hole for the old motor controller PCB measure 60 mm vertically down the rear panel and mark for drilling Using a 3 5 mm drill bit drill a hole in the marked position 2 Fit the new motor controller PCB and secure using the two M3 x 6 mm pozidrive panhead screws and shakeproof washers Refer to the new
50. oling coil with a compact cooler block Heat is dissipated through the block and then to the chassis The block contains a stainless steel knitmesh proving a large cooling area for the flow of air The existing water trap discharge system required a constant bleed of air this affected the efficiency of the pump To improve pumping efficiency a release valve style regulator only purges the water drain filter when the pump back pressure rises to 3 5 bar gauge At power down an energised closed solenoid valve opens discharging air from the pressure head This also prevents pump stall on restart with too much back pressure fuse Power supply PSU Motor i Controller power i circuit supply H switch Expansion connector Power and elapsed time indicator Vacuum output Vacuum output Pressure eegen output water drain filter and cooler assembly w s cow sees w pressure fan bleed Water vent Pressure release valve Figure 1 6 Build standard 3 Schematic Diagram K232 Issue No 2 Page 1 9 Druck PV 103R Service Manual Specification Build standard 3 15 Input Power supply E sa eee S E 90 230 Vac 50 60 Hz nominal 110 Vac 400 Hz nominal udi D RM RUM continuous rating 300 VA Output Pressure MIM E 3 5 bar abs 100 inHg abs Airspeed RE 1 Mach min up
51. onnect the the two wires to the correct previously noted terminals 4 29 Elapsed time indicator BS 3 and 4 1 Fit the elapsed time indicator in the front panel and secure with the two screws 2 Connect the plug to the elapsed time indicator BS 1 and 2 3 Push the elapsed time indicator firmly into the front panel and connect the two wires 4 30 Fan assembly Fig 4 1 1 Locate the fan assembly in the rear panel and secure with the four screws and spring washers Connect the two power supply cables to the terminal block 4 31 Fan filter Fig 4 1 1 Locate a new filter in the frame Place the assembled fan filter on the front panel and press firmly to secure 4 32 Pump and Motor Assembly BS1 1 Make sure that the anti vibration mountings are correctly fitted Locate the pump motor assembly on the four pillars and secure with the four nuts bolts and washers 2 Connect the output pressure pipe and the two vacuum output pipes to the corresponding cylinder heads 3 Connect the two electrical connectors to the PSU and secure the cable with the cable clamp BS 2 3 and 4 4 Locate the pump motor assembly in the bracket and secure with the three nuts bolts and washers 5 Fit the assembled bracket and pump motor assembly in the chassis and align the holes with the mounting pillar Secure with the four nuts bolts and washers BS 1 2 3 and 4 6 Connect the earth cable using the nut bolt and washer 7 Connect the t
52. p Duuu reg S S anbi4 JOyO UUOD prys 031 d em punoi6 uue3 jddns Jamod onen eseojai einsselg jquiesse q31 uresp Jojem Gp quiesse uey lAjquiesse den deser tunes Woo12v 49je 19 00 2 a uoniso lIonuos lonuoo WOOTIV 3 ue p I Es Ajquiasse 19j o1ju02 Jojoeuuoo AOJOW NSd ra d q uid L uonisod lonuoo 193130 NO dWAd eui x3 e o T FNO nano Ars el dod Ajquassy J llon uoS 10 0 pue duind JO OW yun Ajddns Jomod a33dS dWnd S JIA pal 81014 egd1o Sen EIA 1g NOO Iv eu 69 u ofr co o 40 09UU09 uoisuedx3 Z LNO WnnovA L LNO WnnovA Woo1 5a WOO11O31NO2 z wunnen 1 unnoen eunssaJgd piousjos aAje p lq ainsselq r pJepuejs ping jquiessy yun dung 01 Ad ureJp ew Page 5 23 K232 Issue No 2 Druck PV 103 R Service Manual K232 Issue No 2 Page 5 24 Druck PV 103 R Service Manual Introduction Parts List Chapter 6 Illustrated Parts List CONTENTS Index of Part Numbers
53. r controller PCB 11 Filter 6 Power supply filter connector Figure 1 3 Build standard 1 Internal view K232 Issue No 2 Page 1 4 Druck PV 103R Service Manual Specification Build standard 1 9 Input Power supply EE 90 230 Vac 50 60 Hz nominal Een 110 Vac 400 Hz nominal ee EE ass continuous rating 300 VA Output Pressure MIN u ou uy E 3 5 bar abs 100 inHg abs Airspeed rate c 1 Mach min up to 550 knots E into a volume of 10 litres 600 cu in ee ee 900 knots min up to 850 knots AO into a volume of 2 litres 120 cu in Mai Cibi MAX EE 20 mbar abs 0 49 inHg abs 85 000 ft Altitude ate eot x Eve 6 000 ft min rate of climb to 55 000 ft into a volume of 17 litres 1000 cu inj EET 15 000 ft min rate of climb to 85 000 ft e into a volume of 4 litres 240 cu in Note The vacuum performance is the combined output of Vacuum 1 and Vacuum 2 On later build standards Vacuum 1 and Vacuum 2 are internally linked Dimensions VI Le Lu E 483 mm 19 in WE IR 178 mm 7 in CE DUN WEE 266 mm 10 5 in e LE 9 5kg 21 Ibs Environment Temperature uuu E 10 C to 50 C 14 F to 122 F continuous operation Position of the unit The unit must only be operated with the front panel in the vertical position Note The unit must not be operated in any other position because an internal water drain will be inverted Calibr
54. seals ADTS405 1728 63 M0 Kit hose OBSOLETE see items 5 2 and 5 3 in list of accessories Kit filter ADTS405 1728 09 M0 Muffler Adaptor Plate cover Fitting bulkhead ANG Fitting bulkhead AN4 Filter in line Element water mist Kit pneumatic ADTS405 1728 21 MO K232 Issue No 2 Page 6 11 Druck PV 103 R Service Manual List of Accessories Ref 5 1 T Accessory Bag ADTS405F 1728 39 M0 2 T Kit Hose ADTS405F 1728 49 M0 3 T Cable Assembly Expansion port 2M ADTS405F 1728 32 M0 ck ok k zk K232 Issue No 2 Page 6 12 Index of Part Numbers Druck PV 103 R Service Manual Part Number Figure and item Part Number Figure and item number number IA2127 1 V0 1 1 ADTS405 1728 73 M1 1 2a IA2127 1 V1 2 1 ADTS405 1728 74 MO 1 3 ADTS405 1728 05 MO 3 11 ADTS405 1728 74 M1 1 3a 2 3 3 2 ADTS405 1728 07 MO 1 15 2 13 3 14 4 13 ADTS405 1728 77 MO 1 6 2 6 ADTS405 1728 09 MO 2 19 3 19 4 18 ADTS405 1728 79 MO 3 5 4 4 ADTS405F 1728 14 MO 1 11 2 11 ADTS405 1728 81 MO 3 6 4 6 3 12 4 11 ADTS405 1728 82 MO 1 7 2 7 ADTS405 1728 15 MO 2 12 3 13 4 12 ADTSA05F 1728 85 MO 2 4 ADTS405 1728 16 MO 1 14 ADTS405 1728 85 M1 3 3 4 3 ADTS405 1728 17 MO 2 10 3 10 ADTSA405 1728 86 MO 1 2 2 2 3 2 4 2 ADTS405 1728 17 M1 3 10a 4 10 ADTS405 1728 91 MO 1 9 2 9 ADTS405 1728 18 MO 3 9 3 8 4 8 ADTS405 1728 18 M1 3 9a 4 9 ADTSA405 1728 92 MO 1 8 2 8 3 7 4 7 ADTSA05F 1728 21 MO 1 20 2 20
55. sensor supply on motor controller assembly board connectors supplementary Test 1 Y OK N Replace Y pump motor assembly Check for position sense pulses from motor when rotating motor by hand Supplementary Test 2 Y OK N Replace motor Y controller PCB Replace pum uan assembly RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 16 Druck PV 103 R Service Manual CHECK PUMP SPEED Gain access to the rear panel end of the power supply unit and disconnect con3 from the motor controller Temporarily link pins 1 and 2 of the card connector and check that the motor speed slows to approximately half speed Check and repair wiring from E Y expansion connector to motor controller PCB controller connector CON 3 according to schematic eirouit RE RUN MAIN SYSTEMS CHECK TREE K232 Issue No 2 Page 5 17 Druck PV 103 R Service Manual 5 3 Supplementary Tests TEST 1 Check for motor drive pulses and Hall sensor supply from controller board connectors Remove power Disconnect PL1 motor drive loom from pump power supply Figure 5 1 c Apply power Using the DVM check on pump power supply Figure 5 1 for 5V DC 0 5 V between PL2 pin 2 red and pin 7 black PL2 is the 8 pin connector clipped into the side of the PSU d With PL1 still disconnected check using DVM on PL1 power supply side between pins 1 2 and 3 in t
56. socket head bolts 9 in turn and diagonally Repeat the procedure steps 1 to 9 for all four cylinder heads Slowly rotate the pump by hand to make sure the pump rotates smoothly If necessary readjust a cylinder head to produce a smooth rotation or reduce the noise as detailed in step 9 Completion 6 1 2 Refit the cover and reconnect the external pipes and connectors Test the pump as detailed the Standard Serviceability Test in Chapter 5 K232 Issue No 2 Page 2 9 Druck PV 103 R Service Manual K232 Issue No 2 Page 2 10 Druck PV 103 R Service Manual Chapter 3 Supplementary Servicing CONTENTS title para ET EE 3 1 Servicing Supplement 3 2 Build Standard Conversions 3 3 ILLUSTRATIONS title fig Motor controller cable loom 3 1 PSU and motor controller cable loom 3 2 Piston seal replacement techniques 3 3 Front panel drilling dimensions 3 4 Water cooler trap assembly new wires 3 5 BS3 Water cooler trap assembly 3 6 K232 Issue No 2 Page 3 1 Druck PV 103 R Service Manual 3 4 General This section contains procedures to replace an obsolete component or to upgrade the unit to a higher build standard Use suitably qualified personnel and good engi
57. tary Tests continued TEST 4 Check pump output vacuum a Remove power Connect a gauge 1000 mbar absolute to one of the vacuum output ports at the rear of the pump c Connect power switch the pump on and check for a pressure less than 41 mbar absolute 0 6 psi absolute d Remove power and disconnect the gauge and fit a blanking cap to the output port Connect power and return to the MAIN SYSTEMS CHECK flow chart PSU Motor Controller assembly CON2 ge o E ES CON3 6 RED BLK D CABLE CONNECTORS P 24V oV fa Motor Controller PCB CON1 Figure 5 1 PSU and Motor controller PCB connections K232 Issue No 2 Page 5 19 weibeip BuuM Leg Z S e1nBi4 931 1012euuo2 Jeyy A ddns somod pnis punoJB u4e3 LH FANS uos Ajquiasse uey uep J jem 143 Iqui sse q31 BuisnoH Je ISIN v D m 2 BE 8 Ajquiasse 19 o uoo i o n 2 AOJOW NSd ra 5 TR za RRS A6 LNOD RSS m add
58. te precautions to prevent swarf contamination of the unit from the following procedure Service tip turn unit upside down when drilling Mark out the front panel using the dimensions detailed in figure 3 4 Drill four M3 holes in the front panel 6 Locate the new water cooler assembly and secure to the front panel with the four screws and washers 7 Connect the wires for the pressure bleed valve solenoid on the water cooler assembly as detailed in Figure 3 5 8 Connect the new pressure output pipe to the output port of the pump head Connect the other end to the input connection of the water cooler assembly 9 Connect the new pipe to the output union of the water drain trap and the output connection of the rear panel Connect the water drain pipe make sure the other end locates in the grommet for correct venting of the water cooler assembly 10 Carry out an inspection of the unit look for loose connections and or disturbance of the internal components 11 Carry out a Standard Serviceability Test detailed in Chapter 5 K232 Issue No 2 Page 3 8 Druck PV 103 R Service Manual Output union Drain pipe Water trap Pressure Ta relief Cooler valve block Bracket Screw Input union Washer Screw Figure 3 6 BS 3 Water cooler trap assembly BS 3 to BS 4 Fig 3 5 New component list Cooling assembly water trap AS405 17 1728M1 post MOD 04 Cable looms assembly AS405 24 1728M1 set of 5 loo
59. tem 3 ADTS405 1728 74 M1 matched with item 2a Pump and Motor Assembly OBSOLETE superseded by item 4 3 Filter fan OBSOLETE superseded by item 4 8 Fan assembly ADTS405 1728 77 M0 Indicator elapsed time ADTS405 1728 82 MO Switch ADTSA405 1729 92 MO LED and Clip ADTS405 1729 91 MO Housing mist filter OBSOLETE pre mod 04 superseded by item 4 10 Block cylinder set of 4 OBSOLETE Fitting bulkhead AN6 OBSOLETE see fig 2 item 19 Fitting bulkhead ANA OBSOLETE see fig 2 item 20 Mounting antivibration ADTS405 1728 16 MO Item deleted Connector filter power supply ADTS405 1728 07 MO Servicing kits and ancilliary equipment Kit fuse o ring ADTS405 1728 36 MO Fuse T5 0A 250V HBC 20 mm Kit pump seals ADTS405 1728 63 MO Kit hose OBSOLETE see item 5 2 in list of accessories Kit pneumatic ADTS405 1728 21 MO K232 Issue No 2 Page 6 5 Druck PV 103 R Service Manual O TIT A TITLES Figure 6 2 PV103 BS2 Page 6 6 N K232 Issue Druck PV 103 R Service Manual Description Manufacturer s Part Number Pump unit PV103 Build standard 2 IA2127 1 V1 OBSOLETE superseded by BS4 PSU Pump Universal AC ADTS405 1728 86 M0 Controller Motor PCB ADTS405 1728 74 M1 Pump and Motor Assembly ADTS405 1728 85 M0 OBSOLETE superseded by item 4 3 matched with item 4 10 Filter fan part of item 19 Fan assembly ADTS405 1728 77 M0 Indicator elapsed tim
60. ting details and service information for these flightline units are contained on Druck publications K114 ADTS 405 User Manual and K228 ADTS 405 Service Manual Build Standard 1 4 The first standard uses a compact custom pump assembly based on a brushless d c motor custom crankcase and eccentric driving four rocking PTFE sealed piston cylinder and flap valve assemblies The pressure vacuum output connect to Vacuum 1 and Vacuum 2 and to Pressure all located on the rear panel Brief Description 5 The pump consists of an electric motor driving a pump and controlled by a controller PCB The rack is cooled by an electric fan A power supply unit produces electrical power for the motor circuit fan and circuits to the electronics rack The power supply switch elapsed time indicator and fuses are located on the front panel of the rack 6 The pump is driven by a brushless DC motor Hall effect sensors provide feedback to the motor drive circuits The power supply unit receives power through a switch and fuse to produce 24 V DC for the motor drive circuits and the power indicator 7 The pump consists of four reciprocating pistons on a central eccentric One piston head is configured for pressure and the other three for vacuum Reed valves in the piston heads control the direction of air flow One of the vacuum heads provides an initial rough vacuum that in turn feeds the other two vacuum heads 8 Air from the pressure head passes through a
61. urn and chassis OV while slowly rotating the motor by hand Check that the voltage on each pin cycles between OV and 24 V 21V to 27V with 2 cycles per revolution of the motor e Remove power The unit must pass both tests c and d above f Return to the PUMP NOT RUNNING flow chart TEST 2 Check for position sense pulses from the motor when rotating by hand Remove power Disconnect PL1 motor drive from pump power supply Figure 5 1 c Apply power and using the DVM check for pulses on PL2 between pins 3 white 4 green and 8 grey and chassis OV while slowly rotating the motor by hand Each of the pin voltages should cycle between OV and 5 V 1V twice for each complete revolution of the motor d Remove power e Return to the PUMP NOT RUNNING flow chart TEST 3 Check pump output pressure Remove power Connect a gauge 0 to 4 bar gauge range to the pressure output port at the rear of the pump C Switch the pump on and check for the following pressure Build standard 1 and 2 to 2 5 to 2 9 bar gauge 36 3 to 42 psi gauge fitted with the bleed needle type water drain Build standard 3 and 4 to 3 4 to 3 8 bar gauge 49 3 to 55 1 psi gauge fitted with the release valve type water drain d Remove power and disconnect the gauge and fit a blanking cap to the output port Return to the MAIN SYSTEMS CHECK flow chart K232 Issue No 2 Page 5 18 Druck PV 103 R Service Manual 5 3 Supplemen
62. ust be observed Expendable items must be discarded 2 Disconnect and remove all the electrical and pneumatic connections Cover 3 Unscrew and remove the ten screws and shakeproof washers securing the cover to the chassis Slide cover off to the rear Cylinder head Fig 2 6 4 The four pump piston heads are identical in construction but with the pressure piston seal facing outwards The o ring seal locate in grooves in the cylinder head hexagonal socket head bolts secure the cylinder head to the pump body Interposed between the cylinder head and pump body are valve plates and a spacer Grooves in the plates locate on the spacer allowing the correct air flow Procedure Fig 2 6 5 Note The procedure is the same for each of the four pump cylinder heads 1 Unscrew and remove the four hexagonal socket head bolts 9 securing the cylinder head 7 Collect a plain washer 8 from each hexagonal socket head bolt 9 Note Some cylinder heads may have one or more shims fitted these are matched items 2 Remove the cylinder head complete with valve plates 3 and 5 and spacer 4 Record the number and position of any shims for use in assembly Note Inspect the cylinder block for distortion and cracks Inspect the bore of the cylinder block scoring or damage Replace any cylinder that fails inspection 3 Rotate by hand the pump to access the piston head Unscrew and remove the central countersunk screw Fig 2 7 item 5
63. ve the pump and motor assembly from the chassis BS2 BS3 and 4 5 Unscrew the four nuts bolts and washers securing the pump and motor assembly and bracket to the chassis 6 Carefully remove the pump and motor assembly from the bracket 7 Unscrew the three nuts bolts and washers securing the pump and motor assembly in the bracket and separate the pump and motor assembly and bracket K232 Issue No 2 Page 4 3 Druck PV 103 R Service Manual 1 Grill 5 Power supply cable connector 2 Screw 6 Screw 3 Spring washer 7 Spring washer 4 Fan 8 EMC grill BS 1 only Figure 4 1 Fan assembly BS1 BS2 BS3 and 4 K232 Issue No 2 Page 4 4 Druck PV 103 R Service Manual 4 5 Fan filter a Using a screwdriver carefully lever frame of the filter and remove the frame and filter from the front panel 4 6 Fan assembly 1 Remove the fan filter from the front panel of the unit as detailed in paragraph 4 5 above Disconnect the two power supply cable connectors 5 from the terminal block Unscrew and remove the four screws and washers securing the fan to the rear panel Unscrew and remove the four screws and washers securing the fan grill to the inner flange of the fan 4 7 Elapsed time indicator BS1 and 2 Je Disconnect the two wires push out the ETI BS3 and 4 2 Disconnect the two connections at the rear of the ETI Unscrew the two securing screws nuts and four washers and remove the ETI 4 8 Switch 1 Take note of t
64. wo plugs from the power supply and controller unit and secure the cable in the cable clamp K232 Issue No 2 Page 4 11 Druck PV 103 R Service Manual 8 Connect the vacuum pipe to the vacuum output connector 9 Connect the vacuum pipe at the top of the pump to the other vacuum output connector 10 Fita new bonded seal to the pressure output pipe and connect to the water drain filter 4 15 Motor Controller PCB BS 2 3 and 4 T Locate the PCB in the PSU and secure the cover of the PSU with screws and washers 2 Assemble the PSU as detailed in paragraph 4 16 below BS 1 3 Carry out the procedure detailed in the servicing supplement in Chapter 2 to fit a replacement motor controller PCB 4 16 Power Supply Unit BS 1 1 Carry out the procedure detailed in the servicing supplement in Chapter 2 to fit a replacement PSU BS 2 3 and 4 2 Connect the cable to the PSU and align the fixing holes of the PSU with the corresponding holes in the rear panel 3 Secure the PSU with the four screws and washers 4 Connect the two electrical connectors to the PSU and secure the cable with the cable clamp 4 17 Completion 1 After completion carry out a standard serviceability test detailed Chapter 5 K232 Issue No 2 Page 4 12 Druck PV 103 R Service Manual Chapter 5 Testing CONTENTS title 5 TESTING E 5 1 Standard Serviceability Test SNAM os i ge e e mr y E Mains systems check
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