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Assembly Manual

P13631: Process Control Gravity Fed

2013-12-10

Table of Contents

Utility Cart Assembly...................................................................................................................................2

Top Shelf Frame...........................................................................................................................................5

Bottom Shelf Frame.....................................................................................................................................9

Cart + Table + Frame Assembly..................................................................................................................13

Top Control Valve Assembly......................................................................................................................18

Mass Flow Sensor Assembly......................................................................................................................21

Bottom Control Valve Assembly................................................................................................................25

Inlet Valve Assembly..................................................................................................................................27

Outlet Valve Assembly...............................................................................................................................29

Reservoir Assembly....................................................................................................................................32

Cart + Components Assembly....................................................................................................................36

Cart Apparatus...........................................................................................................................................43

Appendix....................................................................................................................................................52

1

1. Assembly of the Utility Cart

1.1 Components in this assembly

1. Top Shelf (1)2. Bottom Shelf (1)3. Leg 1 (2)4. Leg 2 (2)5. Fixed Wheel Assembly (2)6. Caster Wheel Assembly (1)7. Locking Caster Wheel Assembly (1)8. Top Shelf Screw (4)9. Wheel Bolt (16)10. Wheel Bolt Washer (28)11. Wheel Bolt Nut (16)

1.2 Assembly Procedure

Align each leg up with the recess in the bottom shelf, and fit each of the 16 wheel bolts through their respective holes.

2

Move the cart onto its side to attach the wheels. At this point the directionality of the cart it established. The fixed wheel assembly will be located at the front of the cart, and the caster wheels will be located at the rear. On one end of the car, slide the fixed wheel assemblies onto the wheel bolts. Follow with a wheel bolt washer and wheel bolt nut.

On the other side of the cart, pick which end for the locking caster wheel assembly to be attached. For this manual, the locking caster wheel assembly will be installed on the right side of the car. For this wheel specifically, stack four washers onto each wheel bolt before sliding the locking caster wheel assembly onto the bolts. This is to create the necessary stand off for all four wheels to be of equal height. For the other (non-locking) caster wheel assembly, simply install the wheel as was done for the

3

fixed wheels. Slide the caster wheel assembly onto the wheel bolts, and finish with a wheel bolt washer and a wheel bolt nut.

Next align the legs with the top shelf. Orient the top shelf so the handle is on the same side as the caster wheels. Secure the top shelf with a top shelf screw, one per leg.

4

2. Assembly of the Top Shelf Frame


1. 1.5" Aluminum Extrusion - 12" (3)2. 1.5" Aluminum Extrusion - 15" (2)3. 1.5" Aluminum Extrusion - 28.75" (1)4. 5 Hole Bracket (2)5. 4 Hole Bracket (2)6. 2 Hole Bracket (1)7. Aluminum Slot Fastener Assembly (20)


The two 15 inch long pieces of extrusion make up the base of the top frame. Two of the 12 inch long pieces are the vertical portion, and the 28.75 inch piece makes up the top horizontal portion. First take one 15 inch member and lay it on its side. Line up a 12 inch member as shown below with the 3 inch spacing.

5

Install three nuts into the base 15 inch member, and two in the vertical 12 inch member (refer to assembly procedure for aluminum slot fastener assembly if necessary). Attach the 5 hole bracket to the two members.

Repeat this two build the right side of the top shelf frame. Slide three nuts into the vertical 12 inch member on the outer most side (far left and far right of the top shelf frame). Attach the 4 hole bracket to both.

6

Slide an aluminum slot fastener nut into the slot of the face of the left side of the of the top shelf frame. Attach the 2 hole bracket.

Position the 28.75 inch member on top of the two vertical members. To secure this member, an aluminum slot fastener nut is not needed. Simple screw one of the screws into the exiting hole in the extrusion.

7

Attach the remaining 12 inch member to the 2 hole bracket. Position so that the distance from the top of the new 12 inch member to the bottom of the 28.75 inch member is 7 inches.

8

3. Assembly of the Bottom Shelf Frame


1. 1.5" Aluminum Extrusion - 12" (2)2. 1.5" Aluminum Extrusion - 13.6" (2)3. 1.5" Aluminum Extrusion - 24.4" (1)4. 1.5" Aluminum Extrusion - 27.4" (1)5. 5 Hole Bracket (2)6. 4 Hole Bracket (2)7. 2 Hole Bracket (2)8. 1.5" Aluminum Slot Fastener Assembly (22)


In this assembly, the 13.6 inch members make up the base, and the 12 inch members make up the vertical portions. Lay a 13.6 inch member down and position a 12 inch member as shown below with a 3 inch spacing.

9

Install three nuts into the base 13.6 inch member, and two in the vertical 12 inch member (refer to assembly procedure for aluminum slot fastener assembly if necessary). Attach the 5 hole bracket to the two members.

Repeat this two build the right side of the bottom shelf frame. Slide three nuts into the vertical 12 inch member on the outer most side (far left and far right of the top shelf frame). Attach the 4 hole bracket to both.

10

Slide an aluminum slot fastener nut into the slot of the inner face of the left and right sides of the bottom shelf frame. Attach the 2 hole bracket.

Position the 27.4 inch member on top of the two vertical members. To secure this member, an aluminum slot fastener nut is not needed. Simple screw one of the screws into the exiting hole in the extrusion. Attach the 24.4 to the bottom of the two 2 hole brackets via fastener assemblies.

11

4. Assembly of the Cart + Table + Frame Assembly


1. Cart, Modified (1)2. Top Shelf Frame (1)3. Bottom Shelf Frame (1)4. Piano Hinge (1)5. Leaf Table (1)6. Leaf Table Brace (2)7. Leaf Table Brace Screw (8)8. #10-24 x 1 Flat Head Machine Screw (12)9. #10 Flat Washer (18)10. #10-24 Hex Nut (6)11. #10 Lock Washer (6)12. #10-24 Acorn Nut (6)13. Aluminum Slot Fastener Assembly (8)


Attach the piano hinge to the modified cart by lining up the existing holes on right side of the cart with the hinge, and fastening via one #10-24 machine screw, one #10 flat washer, and one #10-24 hex nut per hole.

13

Attach the leaf table to the piano hinge via one #10-24 machine screw, two #10 flat washers, one #10 lock washer, and one #10-24 acorn nut per hole.

14

For each side of the leaf table attach the leaf table brace. The longer arm of the brace should be attached to the cart, and the shorter arm of the brace should be attached to the table. Secure each of the four holes per brace via the leaf table brace screw, using the shorter screws in the table.

15

To attach the bottom shelf frame, slide two aluminum slot fastener nuts into bottom slots of each of the bottom frame members. Line up these nuts with the existing holes on the bottom shelf, and center the frame. From the bottom of the cart, fasten the bottom shelf frame to the cart via aluminum slot fastener screws.

16

Repeat the previous steps similarly to fix the top shelf frame to the top shelf of the cart assembly.

17

5. Assembly of the Top Control Valve Assembly


1. Research Control Valve (1)2. Top Control Valve Bracket (1)3. 1/4"-20 x 1.5" Socket Head Cap Screw (2)4. 1/4" Clipped Flat Washer (4)5. 1/4" Flat Washer (2)6. 1/4"-20 Hex Nut (2)7. 1/4" NPT - 1/4" Tube Push-To-Connect Fitting (2)8. 1/2" NPT - 3/8" Tube Fitting (2)


Cover threads of all the Push-To-Connect fittings and the 1/2" NPT fittings in Teflon tape. Tightly screw the Push-To-Connect fittings and the 1/2" NPT fittings into the control valve as shown below.

18

Attach the bracket to the control valve oriented as such in the image below. Secure with the two socket head cap screws. Place two of the clipped washers at the top of each screw. Secure at the bottom of the screw with one washer and nut per screw.

19

6. Assembly of the Mass Flow Sensor Assembly


1. Mass Flow Transmitter (1)2. Blue Swagelok Clamp Assembly (2)3. Mass Flow Transmitter T Bracket (2)4. Tri-Clamps (4)5. Tri-Clamp Gasket (4)6. 3/8" Tube 90 deg Bend (2)7. 3/8" Tube - Tri-Clamp Fitting (2)8. 1/4"-20 x 2 Socket Head Cap Screw (4)9. 1/4" Flat Washer (8)10. 1/4"-20 Hex Nut (4)11. Level Mount (2)12. 5/16"-18 Coupling Nut (2)13. 5/16"-18 x 3 Hex Head Cap Screw (2)14. 5/16"-20 Hex Nut (4)


Attach the blue swagelok clamps and T brackets simultaneously by fixing them to the existing inlet and outlet tubes of the mass flow sensor. Secure them via the 1/4" socket head cap screws, two flat washers per screw, and a 1/4" hex nut.

21

Assemble the legs for the mass flow sensor. Thread a 5/16"-18 hex nut onto a 5/16"18 x 3 screw to the head. Slide the screw through one of the through holes in the mass flow sensor. Thread another 5/16"-18 hex nut onto the screw. Cap the end of the screw with a coupling nut. Connect the other end of the coupling nut to a level mount. Use the two hex nuts to adjust the height of the leg. Repeat for the other leg.

To the downstream side of the mass flow sensor, attach the 3/8" Tube - tri-clamp fitting with a tri-clamp gasket in between. Secure the two ends with a tri-clamp.

22

On the upstream side, connect the bent tubing and 3/8" tube - tri-clamp fitting via the tri-clamps shown below making sure to install gaskets wherever a tri-clamp is used.

Have the tubes angled at approximately 45 degrees to the horizontal. This is to move around the 5 hole bracket of the top shelf frame.

23

7. Assembly of the Bottom Control Valve Assembly


1. Research Control Valve (1)2. Bottom Control Valve Bracket (1)3. 1/4" NPT - 1/4" Tube Push-To-Connect Fitting (2)4. 1/2" NPT - 3/8" Tube Fitting (2)


Connect the bottom control valve bracket to the top of the control valve's flange on the side of the protrusion, using the existing control valves screws as shown.

25

Cover threads of all the Push-To-Connect fittings and the 1/2" NPT fittings in Teflon tape. Tightly screw the Push-To-Connect fittings and the 1/2" NPT fittings into the control valve as shown below.

26

8. Assembly of the Inlet Valve Assembly


1. Small Swagelok Ball Valve (1)2. 3/8" x 1" Tubing (1)3. 3/8"-1/2" Reducer (1)


Insert the 3/8" tubing to either end of the ball valve. Tighten fastener down until the tubing does not move.

27

Secure the 3/8" end of the reducer to the protruding end of the 3/8" tubing. Tighten until the assembly does not move.

28

9. Assembly of the Outlet Valve Assembly:

9.1 Components in this assembly:

1. Small Ball Valve (1)2. 3/8" x 1" Tubing (1)3. 3/8"-1/2" Reducer (1)4. 1/2" Bent Tubing (1)5. 1/2" T Fitting (1)


Insert the 3/8" tubing into either end of the ball valve. Tighten the fastener until the tubing cannot move.

29

Secure the 3/8" end of the reducer to the protruding end of the 3/8" tubing. Tighten until the assembly does not move.

Attached one end of the 1/2" tubing to the 1/2" end of the reducer. Tighten the fastener until the tubing cannot move.

30

Attached the T fitting to the free end of the 1/2" tubing as shown. One free end of the T fitting should point down, and the other should point away.

31

10. Assembly of the Reservoir Assembly


1. Reservoir Assembly SF (1)2. 3/8" Tube Elbow Fitting (2)3. 3/8" Tube Fitting (2)4. 1/2" Tube Fitting (2)5. 1/2" Bent Tube (1)6. 3/8" Clear Tubing (1)


Attach the two 3/8" tube elbow fittings to the two tubes protruding outward on the front of the semi-finished reservoir assembly. Tighten so that they do not move, and orient so that they point towards each other.

32

Insert the 3/8" clear tubing into both ends of the just installed fittings. Tighten so that the tube does not move.

On the left side of the semi-finished reservoir assembly, attach the straight 3/8" tube fitting to the protruding 3/8" tube.

33

On the bottom of the semi-finished reservoir assembly, attach the other straight 3/8" tube fitting to the protruding 3/8" tube.

On the rear of the semi-finished reservoir assembly, attach a 1/2" tube fitting to the protruding 1/2" tube. Attach the bent 1/2" tube to that fitting so that it is oriented downward. On the free end of the 1/2" tube, attach the second 1/2" tube fitting. Tighten all fittings so that no components are able to move.

34

11. Assembly of the Cart + Components Assembly


1. Cart + Table + Frame Assembly (1)2. Top Control Valve (1)3. Bottom Control Valve4. I/P (2)5. Mass Flow Transmitter Assembly (1)6. Mass Flow Sensor (1)7. Regulator Assembly (1)8. Manifold Assembly (1)9. Electrical Box Assembly (1)10. Reservoir Assembly (1)11. Level Transmitter (1)12. Level Transmitter Cover (1)13. Aluminum Slot Fasteners (22)


Fix the top control valve assembly to the front of the top bar of the top frame assembly as shown. Secure fasteners with the valve bracket approximately 4 inches from the left edge of the frame assembly.

36

Fix one of the I/Ps to the front of the top bar of the top frame assembly. Orient so the push-top-connect fittings are towards the bottom. Secure with aluminum slot fasteners with the left side of the I/P approximately 12 inches from the left edge of the frame assembly.

Place the reservoir assembly on the top shelf of the cart. Insert the bottom tube and fitting on the reservoir assembly into the large hole on the shelf. Orient so that the visual level gauge is facing toward the operator.

37

Place the manifold assembly on the back face of the top bar in the top shelf frame assembly. Position it to be approximately 13 inches from the left side of the top shelf frame assembly. Orient so the outlets point down. Secure by zip-tying to the frame.

Attach the mass flow sensor assembly to the lower hanging bar of the top shelf frame assembly via aluminum slot fasteners. Adjust the level mounts of the mass flow sensor assembly so that it is level. Align the sensor so that it is close to being centered underneath the top control valve.

38

Attached the regulator assembly to the top of the top bar on the top shelf frame via aluminum slot fasteners. The gauge should face the operator. It may be necessary to remove the regulator bracket from the regulator and first attach it to the frame then reattach the regulator.

Attach the bottom control valve to the front of the top bar on the bottom shelf frame via aluminum slot fasteners as shown below. Position the assembly so that the bracket is approximately 3 inches from the left side of the frame.

39

Attach the mass flow transmitter to the front faces of the top and bottom horizontal bars of the bottom shelf frame using two aluminum slot fasteners for the top and two for the bottom. Position the transmitter approximately at the midpoint.

Attach the I/P for the second control loop on the front face of the top bar of the bottom shelf assembly in the same manner used for the I/P in the first control loop. Position the I/P so that it is approximately 4 inches from the right side of the bottom shelf frame assembly. Orient the I/P so that the push-to-connect fittings are towards the bottom.

40

Connect the wiring from the mass flow sensor to the mass flow transmitter, running the wire in front of the cart.

Connect the electrical box to the rear of the bottom shelf frame using four aluminum slot fasteners as shown. Position the box to be approximately 3.5 inches from the left side of the cart.

41

Slide the level transmitter into the 1 inch acrylic tube. Slide that assembly into the reservoir assembly. Attached the level transmitter to the front face of the top bar of the top shelf frame assembly via double sided tape. Attach the acrylic tube to the inner diameter of the reservoir.

42

12. Assembly of the Cart Apparatus


1. Cart + Components Assembly (1)2. Fluid Tubing 1 (1)3. Fluid Tubing 2 (1)4. Fluid Tubing 3 (1)5. Fluid Tubing 4 (1)6. 3/8" x 1" Tubing (2)7. Control Valve Tubing (2)8. 3/8" Tube Fitting (2)9. Inlet Valve Assembly (1)10. Outlet Valve Assembly (1)11. Control Valve Tubing (2)12. Pneumatic Tubing 1 (1)13. Pneumatic Tubing 2 (1)14. Pneumatic Tubing 3 (1)15. Pneumatic Tubing 4 (1)16. Pneumatic Tubing 5 (1)17. Pneumatic Tubing 6 (1)18. Pneumatic Tubing 7 (1)

43


Attach a 3/8" x 1" Tube to the inlet side of the mass flow sensor assembly. Tighten so that the tube cannot move. To the free end of the tube, attach the inlet valve assembly. Orient so that the valve lever is on the top. Tighten so that the inlet valve assembly cannot move.

At the outlet end of the mass flow sensor assembly, attach one of the control valve tubes. The short end should into the mass flow sensor. Orient so that the tube bends upward. At this point tighten so that the tube is snug but can move.

44

To the free end of the tube, attach a 3/8" tube fitting and fluid tubing 1, a short 3/8" plastic tube only a few inches long. On the free end of that tube, attach another 3/8" tube fitting. Tighten only until snug.

Now simultaneously attach the free end of the 3/8" tube fitting which was just installed to the inlet end of the top control valve assembly. Orient all these fittings and tubes just installed and tighten so they cannot move.

45

Attach fluid tubing 2, a 3/8" plastic tube approximately 12 inches in length, to the outlet of the top control valve and the inlet of the reservoir assembly. Tighten fittings so that the tube cannot move.

Attach fluid tubing 3, a 3/8" plastic tube a few feet in length, to the outlet of the reservoir assembly, located at the bottom of the assembly to the inlet of the bottom control valve.

46

To the outlet of the bottom control valve, attach a 3/8" x 1" tube, then the inlet to the outlet valve assembly. Tighten fittings so no components can move.

Now attach fluid tubing 4, a 1/2" plastic tubing a few feet in length, to the rear outlet of the reservoir assembly and the rear facing end of the T fitting on the outlet valve assembly. Route around the electrical box. Tighten all fittings.

47

Now begin attaching the pneumatic tubing. Start with pneumatic tubing 1. Push connect one end into the outlet of the regulator, and push connect the other into the inlet of the manifold.

Push connect pneumatic tubing 2 into the first outlet of the manifold and into the inlet of first control loop's I/P.

48

Push connect pneumatic tubing 3 into the outlet of the first control loop's I/P and into the regulated inlet of the top control valve.

Push connect pneumatic tubing 4 into the non-regulated inlet of the top control valve and into the second outlet of the manifold.

49

Push connect pneumatic tubing 5 into the third outlet of the manifold and into the inlet of the second control loop's I/P, routing the tubing behind the cart.

50

Push connect pneumatic tubing 6 into the outlet of the second control loop's I/P and the regulated inlet of the bottom control valve.

Push connect pneumatic tubing 7 into the non-regulated inlet of the bottom control valve and into the fourth outlet of the manifold, routing the tubing behind the car.

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A. Appendix

A.1 Assembly procedure for aluminum slot fastener assembly

The aluminum slot fastener assembly is comprised of two components: a screw and a nut. The nut is what makes this fastener assembly work specifically for the 1.5" aluminum extrusion used in this apparatus. To assemble, first slide the nut into the channel of the extrusion via an open end and position it roughly where it should be. Make sure that the circular protrusion on the nut faces away from the extrusion. This will help to keep the nut properly oriented.

Line up the components being fastened to the extrusion and connect the screw to the nut normally.

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