Attachment A - Automated Pressure Calibration System 4322 to 4322AUP Upgrade Specifications.pdf

Attachment A

Automated Pressure Calibration System

4322 TO 4322AUP UPGRADE SPECIFICATIONS

1. Introduction

The intent of work outlined in this proposal is to upgrade 4322 automated pressure calibration systems to the current 4322AUP design. Equipment upgraded in this program will result in systems with configuration and performance consistent with the current 4322AUP revision. Each upgraded 4322AUP will be covered under manufacturer’s warranty for one-year.

2. Hardware Upgrade Outline

2.1 Systematic Improvements

2.1.1 BaroCheck

The BaroCheck feature is a regularly-performed automated taring feature to ensure the 4322 meets target measurement uncertainty requirements with a one-year calibration interval. The

BaroCheck routine is automatically performed by the 4322 pressure controller with no external reference or other hardware needed.

Removal of BaroCheck results in an adjustment of the specification on the A150K module from

±0.0036 to ±0.0054 psi. This assumes a one-year calibration interval. All other transducers continue with the same specification. There will be a modest increase in the overall time required to calibrate the 4322AUPcontroller due to new additional test points better covering the operating range of the A150K. Removal of BaroCheck will improve efficiency, eliminate downtime and extend the effective operational life of the system.

The overall measurement specifications for the 4322AUP are:

Absolute Mode

0.5 to 19 psi: ±0.0054 psi (±0.15 in H₂O)

>19 to 10,000 psi: ±0.1% of indicated value

Gauge Mode (includes sub-atmospheric gauge pressure, as in “Vacuum Mode” and “Compound

Gauge Mode”)

-14.2 to 5 psig: ±0.0054 psi (±0.15 in H₂O)

>5 to 10,000 psig: ±0.1% of reading

2.1.2 Calibration Procedure

The alignment procedure for the A150K pressure module is modified to accommodate removal of the BaroCheck routine and improve alignment. The updated alignment procedure includes additional test points for better alignment across its entire range of measurement.

2.1.3 Quick-Connect (QC) Couplings

Each 4322 system includes seven safety-interlock quick connect couplings: two on the intensifier, one on the controller, one on each of the two contamination-prevention system (CPS) modules and one on each of the two test hoses. Core components of the couplings will be upgraded.

QC couplings in the 4322AUP configuration are of an improved design for better tolerance against conditions that cause excessive friction. For manifold-mount QC couplings (all but the test hose couplings) a new base flange element is integrated for better alignment of seals during initial installation and after the unit has been fielded. All QC couplings include lower-durometer seals, improved finishing processes and tolerancing of components for reduced friction and better lock/unlock pressure consistency.

2.1.4 Item Serialization and Identification

The Model Number and serial number of each upgraded unit will be changed to communicate that the unit is a 4322AUP that was upgraded from a 4322.

2.2 Pressure Controller Component Upgrade

4322 firmware and hardware elements will be upgraded to bring the pressure controller component up to new 4322AUP configuration specifications.

2.2.1 Update Firmware

Firmware on the 4322 pressure controller will be updated to the latest 4322AUP firmware revision. In addition to removal of BaroCheck and changes in A150K alignment procedure, the

4322AUP revision includes a number of minor bug corrections and improved features from current 4322 firmware.

Issue Type Issue Key Summary

New Feature NAVNP-31 Need to detect if the THM door switch is unplugged or has faulty wiring

Bug NAVNP-42 The Cal Cert printed shows the temperature in °F even when the unit is set to°C.

Bug NAVNP-43 Changing the time format to 24hr reverts back to 12hr after a power cycle

Improvement NAVNP-38 A150K Exercise with pressure points to match the calibrated range.

Bug NAVNP-34 False fail indication for calibration results

Bug NAVNP-37 Cannot delete Test Sequence

Bug NAVNP-36 False indications of Outside of

Adjustment Tolerance

Bug NAVNP-33 140 psi pause during calibration exercise

New Feature NAVNP-1 Add "1-1/2-1%" and "2-1-2%" tolerance types

New Feature NAVNP-47 Remember previous user entry edits

New Feature NAVNP-41 Add ability to select a pressure value for the tolerance type.

Improvement NAVNP-35 Improved Switch Test sequencing

Bug NAVNP-29 Remote command ABORT causes an error

Bug NAVNP-30 PMAX error could occur when starting a compound test.

New Feature NAVNP-44 Remove BaroCheck

New Feature NAVNP-45 Modify A150K alignment points

New Feature NAVNP-33* Option for low speed pressure control at pressures below 150 psi (combined with item NAVNP-33)

2.2.2 Upgrade Pressure/Vacuum Pump Assembly

The pressure/vacuum pump assembly will be upgraded to 4322AUP configuration. This includes replacement of the solenoid valve components to a new design that is more resistant to corrosion.

2.2.3 CPS Circuit Upgrade

The CPS driver circuit and CPS valve can be damaged from excess current if the CPS valve driver contacts are shorted together, a condition most likely caused by excess liquid spill or buildup on the pressure controller CPS dock. The 4322AUP configuration includes a fuse in the circuit between the CPS contacts and the driver board to prevent damage in the event the CPS valve contacts are shorted.

To upgrade to 4322AUP, the bottom-right (looking downward from user’s point of view) corner of the 4322 pressure controller plastic deck will be mechanically modified with a hole. A user-facing, panel-mounted fuse holder will be installed to allow simple fuse replacement without removing the pressure controller from its enclosure.

In addition to the fuse, the CPS dock in the 4322AUP includes a physical barrier protection to reduce the potential of the driver contacts shorting due to liquid contamination on the dock.

2.2.4 CPS Filter Assembly Upgrade

In order to simplify the cleaning and replacement of filters, the CPS filter assembly in the

4322AUP has been modified such that no tools are required to remove or replace the filters.

2.2.5 Pressure Transducer Modules

All modules will be calibrated to the 4322AUP specifications.

2.2.6 Pressure Controller Quick-Connect (QC) Coupling

The supply pressure QC coupling will be replaced with a new-generation 4322AUP QC coupling.

2.2.7 Pressure Controller Lid Storage Area

To reduce the potential of damage to the controller display caused by improper storage of items in the controller lid, the lid storage area in the 4322AUP is replaced with a permanently attached foam insert and a label stating, “NO STORAGE IN THE LID.”

2.2.8 Pressure Controller Protection from Fluids

To protect the controller internals from oil or other liquids, a protective rubber barrier is installed around the CPS docking area on the top surface of the pressure controller. This barrier is designed to allow for easy clean up of spilled liquids or excess fluids.

2.2.9 Pressure Controller Identification Plate

The identification plate will be removed from the pressure controller enclosure and replaced with a new identification plate of equivalent design. The new identification plate will reflect new configuration designation, component and system serialization, 2-D bar coding and other information as specified by the end user.The product label above the display is also updated to show 4322AUP in place of 4322.

2.3 Pressure Intensifier Component

Hardware elements will be upgraded to bring the pressure intensifier component up to new

4322AUP configuration specifications. The Intensifier cam will be case-hardened to reduce wear and flaking. In addition, the motor encoder sensor will be isolated to eliminate malfunction due to particle contamination.

2.3.1 Intensifier Cam Components

The Intensifier cam will be case-hardened to reduce wear and flaking.

2.3.2 Intensifier Quick-Connect (QC) Couplings

Both the input (from N2 cylinder) and output (to pressure controller) pressure QC couplings will be upgraded to the new-generation 4322AUP QC couplings.

2.3.3 Intensifier Identification Plate

The identification plate will be removed from the intensifier enclosure and replaced with a new identification plate of equivalent design. The new identification plate will reflect new configuration designation, component and system serialization, 2-D bar coding and other information as specified by the end user.

The product label on the top panel of the Intensifier is also updated to show 4322AUP in place of

4322.

2.4 Accessory Kit Component

The accessory kit will be upgraded to 4322AUP configuration.

2.4.1 Contamination Prevention System (CPS) Modules

One each blue and orange CPS module is to be returned to Fluke with each system for upgrade.

2.4.1.1 Upgrade CPS Quick-Connect (QC) Coupling

Each CPS QC coupling will be replaced with a new-generation 4322AUP QC coupling.

2.4.1.2 Upgrade CPS Exhaust Components

Aluminum components in the CPS exhaust circuit have been reported to corrode when exposed to harsher use cases. To prevent premature corrosion, the purge manifold and filter retainer will be replaced with new stainless-steel versions of the components.

2.4.2 Test Hoses

One each blue and orange test hose is to be returned to Fluke with each system for upgrade. The QC couplings will be upgraded to the new 4322AUP-generation QC couplings.

2.4.3 Adaptor Kit

The 4322 adaptor kit, including its complete set of adaptors, is to be returned to Fluke with each system for upgrade to the 4322AUP Adaptor Set. These adaptors allow for the same connection types but are built to improved tolerances.

2.4.4 Spares Kit

The 4322 spares kit and all the unused spare parts (to the extent possible) are to be returned to Fluke with each system for upgrade. The spares kit will be replaced with the

4322AUP spares kit, which includes additional fuses and other items to support the upgraded components.

2.4.5 Accessory Kit Identification Plate

The identification plate will be removed from the accessory kit enclosure and replaced with a new identification plate of equivalent design. The new identification plate will reflect new configuration designation, component and system serialization, 2-D bar coding and other information as specified by the end user.

2.5 N2 Cylinder Component

The N2 cylinders will not be modified with the upgrade. The bottle(s) should not be sent to

Fluke. A new identification label will be created and shipped with the upgraded system to reflect new configuration designation, component and system serialization, 2-D bar coding and other information as specified by the end user. The label is adhesive and will be applied to the N2 bottle by the end user.

3. Packaging and Shipping

The end user is responsible for the costs and logistics to appropriately package and ship legacy

4322 equipment to Fluke for upgrade. Packaging and return shipment of upgraded systems to the end user in USA locations is included in the scope of this proposal. International shipments may incur additional charges.

4. Upgrade Process

Return Material Authorization (RMA) notices will be issued for legacy 4322 system(s) to be upgraded. An RMA will be issued during the course of the proposed contract for each system or group of systems which is sent to Fluke. The corresponding RMA number is to be referenced with the shipment. Quantity, frequency and scheduling of RMA notices will be as agreed upon by the end user and Fluke.

5. System Management and Labeling

Legacy 4322 components sent to Fluke for upgrade are to be sent in sets, complete with the hardware as agreed upon by the end user and Fluke. Upgraded 4322AUP system(s) will be labeled and returned in complete set(s).

6. Unit Completeness

Each unit will be inspected upon receipt to identify missing items. Appendix B provides a list of component kits that can be ordered as line items. Each kit comes with factory installation on a model 4322 system being upgraded. Units needing major component replacement or repair outside of the work detailed here will be returned to the end user for a separate repair contract.

7. Aesthetics

Cosmetic flaws are likely to be common with the fielded test equipment. This proposal is not intended to cover scratches, chips, dents, wear, discoloration or any other cosmetic defects for components returned for upgrade.

8. Procedure and Documentation Updates

Recommended preventative maintenance procedures and timing will be updated to reflect changes from legacy 4322 design to the new 4322AUP configuration, including the changes outlined in this proposal. 4322 Operation and Service manuals will be updated to reflect the firmware, maintenance, calibration and other changes. Hardcopies of the updated 4322AUP manuals will be sent with each upgraded system.

9. Warranty

Systems upgraded from legacy 4322 configuration to 4322AUP configuration as described in this proposal will be covered for a period of one year from return of the upgraded components to the end user. Labels will be applied to the instruments to reflect the new warranty period.

Appendix A: Summary of Key Maintenance Items

Procedure Level 4322 Configuration

Schedule

4322AUP Configuration

Schedule

Replace seal, and lubricate pump

Depot Lesser of 2 years, 1,000 hours or as required

Lesser of 2 years, 1,000 hours or as required (same)

Replace pump low-pressure valves

Depot N/A Lesser of 2 years, 1,000 hours or as required (new)

Replace CPS fine

(fiber) filter

User 1 year or as required 1 year or as required (same)

Replace CPS course (metal) filter

User 1 year or as required 1 year or as required (same)

Flush CPS User N/A As required

Pressure controller fuse replacement

User As required As required (same)

CPS circuit fuse replacement

User N/A As required (new)

BaroCheck User 30 days N/A (eliminated)

Calibration User All ranges 1 year All ranges 1 year

System leak check User As required As required (same)

Intensifier fuse replacement

User As required As required (same)

Intensifier pressure generate/leak test

User Lesser of 1 year, 750 hours or as required

Lesser of 1 year, 750 hours or as required (same)

Intensifier pressure sensor alignment

Depot Lesser of 2 years, 1,500 hours or as required

Lesser of 2 years, 1,500 hours or as required (same)

Intensifier seals replacement

Depot Lesser of 2 years, 1,000 hours or as required

Lesser of 2 years, 1,000 hours or as required (same)

Appendix B: Available Component Kits

Kit Name Description Required for Upgrade

CPS-4322-BLUE Contamination Prevention System Module for 4322, Blue

Yes

CPS-4322-ORANGE Contamination Prevention System Module for 4322, Blue

Yes

HOSE-4322-BLUE High-Pressure Test Hose, 10 ft, blue Yes

HOSE-4322-ORANGE High-Pressure Test Hose, 10 ft, orange Yes

KIT-4322-REM Remote Pendant No 4322-5937 Pressure Regulator Assembly No

WRENCH 10 in Adjustable Wrench No

8-636 GPIB Cable No

HOSE, INTERCONNECT Interconnect Hose, 6 Ft No

4322AUP CPS SPARES Extra filters and seals kit for CPS No