Phone: +1 (763) 682-6096
Fax: +1 (763) 682-6197
303 12th Avenue South
Buffalo, MN 55313
Phone: +1 (763) 682-6096 · Fax: +1 (763) 682-6197 · 3303 12th Avenue South · Buffalo, MN 55313



Which machines can have the Push Button Amplifier Boards installed?

Any existing RSG Gas Filling Machine with a thermal conductivity sensor set up for argon gas can have the Push Button Amplifier Boards installed (which means all FDR machines except the old DCL machines - if you're unsure then please ask).  If the gas sensor does not have orange leads then the gas sensor must be upgraded at no charge.


What should I purchase if I only want to upgrade 1 line on a multi line machine?

1 - Push Button Calibration Board

1 - Temp Sensor

1 - 7 Segment Display (choose the correct color) optional


What should I purchase if I want to upgrade all of the lines on my machine?

4 - Push Button Calibration Board

1 - Temp Sensor

1 - 7 Segment Display (Red) optional

1 - 7 Segment Display (Blue) optional

1 - 7 Segment Display (Green) optional

1 - 7 Segment Display (Yellow) optional




Installing the Push Button Amplifier Boards is an EASY process.


Installation Steps:

1. Install the Temp Sensor in the open end of the heated aluminum block which holds the Orange Lead gas sensors.  Only one Temp Sensor is required for the entire machine.  Thermal conductive paste is included and should be used liberally on the outside of the metal end of the sensor before inserting in the aluminum block.

2. If replacing all the amplifier boards in the machine, turn the OMRON Temperature Controller all the way down (counterclockwise) to 0°F.  If some of the amplifier boards will be the old style with potentiometers then the OMRON Temperature Controller should be left at 130°F.  It is recommended to upgrade all of the amplifier boards to the Push Button style, but not required.

3. Remove the old amplifier boards.

4. Wire the new Push Button amplifier boards using the detachable terminal posts.  Use the diagram on the side of the board for reference.  Make sure to daisy chain terminals 5 and 6 (Black and Red) to each of the Push Button amplifier boards (black and red wires will be included upon request).  

5. Connect the optional 7 Segment Display to the connector labeled "Display A" on the Push Button Amplifier Board.  Adhesive-backed Velcro is included with the displays to secure them to the aluminum enclosure above the amplifier boards.





Calibration Steps:

1. Sensor O-ride up.

2. Station running w/lance(s) sucking air.

3. Press Zero button until flashing green light.

4. Station running with lance(s) in test jug with 1/2" positive pressure.

5. Press Span button until flashing green light.

6. Sensor O-ride down.

7. Repeat for each station.


Setting The Shutoff Point:

On the front of the push button amplifier board there is a series of DIP switches labeled "GAS LEVEL ADJUST".  From the bottom up, they have the values 1, 2, 4, and 8.  When the DIPS are positioned to the right they are in the "on" state and their corresponding number should be added to 90.  For example, if 1 (bottom DIP) and 4 (third from the bottom DIP) are positioned to the right the anticipated argon shutoff level would be (90 + 1 + 4) = 95 % argon.  Since there are many variables this is an anticipated rate and cannot be guaranteed.   


Indicator Lights on the the push button amplifier boards

During Calibration:

        Red Flashing = Reading not stable, try again.

        Red 10 Seconds = Check for leaks and start calibration over.

        Green Flashing = Calibration successful

Not During Calibration:

        Red Flashing = Check temp sensor.

        Green Flashing = Check thermal conductivity sensor.





7 Segment Displays

There are 3 buttons on the display board. When no button is pressed the display is showing the gas percentage (1-100).


TEMP °F - Indicates the temperature of the Temp Sensor which should be inside the aluminum block surrounded with thermal conductive paste.

SENSOR RESISTANCE AT 72° - When this button is pressed there will be 4 digits that appear (for example 7069).  The first 2 digits (70) are the calculated orange lead sensor resistance for the air setting.  The last 2 digits (69) are the calculated orange lead sensor resistance for the argon setting. If there is too big a difference between these two numbers that would indicate a vacuum or argon leak.

RAW SENSOR BITS - Displays the actual raw orange lead sensor bits.  Useful for advanced troubleshooting.  


To increase the brightness, hold the "TEMP °F" and "SENSOR RESISTANCE AT 72°" buttons at the same time.  

To decrease the brightness, hold the "SENSOR RESISTANCE AT 72°" and "RAW SENSOR BITS" buttons at the same time.  

While adjusting the brightness, a number from 1 to 9 will indicate the brightness level.