UPC5000/UPC5010 Portable & Rack-mountable Pneumatic Pressure Calibration Console Operation & Maintenance Manual CONDEC Sales Phone No. (888) 295-8475 CONDEC Web Site: www.4condec.
Contents About This Manual ................................................................................................................................... 1 1.0 Introduction.................................................................................................................................. 1 2.0 Operation...................................................................................................................................... 3 2.1 2.2 2.3 2.4 2.5 2.6 3.
5.0 Model Number System .............................................................................................................. 46 6.0 Available Ranges, Conversions and Resolutions ...................................................................... 47 7.0 Options, Replacement Kits ........................................................................................................ 50 8.0 Specifications .............................................................................................
About This Manual The UPC5000 portable pneumatic pressure calibrator and the rack-mounted UPC5010 are rugged, compact instruments manufactured by Condec. They are designed to provide superior accuracy, range of calibration and ease of operation when used for the calibration of a wide variety of pressure sensing and measuring devices. These instruments utilize a repeatable sensor coupled to microprocessor-based electronic circuitry and a selectable unit display system.
• Calibration Integrity: Once calibrated, the tamper-proof design provides numerous safeguards that guarantee the integrity of pressure readings obtained. The LED provides the operator with status information during both operation and calibration. • Pressure Source: An internal supply cylinder with a volume of 7.0 std. cu. ft. of N2 provides up to 2216 PSIG of pressure for calibration and test. A check valve quick disconnect fitting provides re-charging capability.
2.0 Operation The following sections explains the various procedures for operating the UPC5000/UPC5010. 2.1 Pressure Cylinder Filling Procedure To initially fill or refill the internal pressure cylinder (2216 PSI max) of the UPC5000/UPC5010, see Figure 2-1 and proceed by following these steps: 1. Rotate the PRESSURE LIMIT CONTROL (1) counter-clockwise until it stops. Close the COARSE ADJUSTMENT valve (2) by rotating clockwise until it stops. 2.
2.2 Initial Setup Procedure To prepare for actual calibration usage, see Figure 2-2 below and proceed as follows: 1. Check that the COARSE ADJUSTMENT valve (2) is closed (rotate clockwise until it stops) and that the VENT valve (8) is open (two turns counter-clockwise from its stop). 2. Plug in the power cord (7) and energize the unit by flipping the power switch (18) to OPERATE. The UPC5000/UPC5010 will perform an internal functional self-check. If acceptable, a 100.
. Optional - if the current (4.000 to 20.000 mA) measurement features are used, connect the provided transducer test cable, (PN 55092), to the transducer test jacks (14). When connected, the transducer test cable provides +32 VDC excitation on non-battery units, or +18 VDC excitation on battery units. The internal impedance (load) is 10 ohms. NOTE: + EXCITATION VOLTAGE will only operate while units power cord is plugged into AC wall outlet. Battery units may be ordered special to obtain +28 VDC excitation.
Figure 2-3. Pressure Measurement Sequence (Gage Only) NOTE: UPC5000 shown, AC Input (7) and Fill Port (4) are on back side of UPC5010 Rack Mountable Calibrator. 2.5 Pressure Measurement Sequence for Absolute Only Unit 1. If only pressure measurements greater than barometric are required, continue to step 1.1. If pressure measurements above and below atmospheric pressure are required, go to Step 2. 1.1.
4.2. Use either the COARSE ADJUSTMENT (2) or VENT valve (8) to obtain a specific pressure reading. Both provide precise control. As the pressure approaches the desired value, the valve being used for control should be rotated slowly clockwise to its closed position. 4.3. To obtain exact pressure readings, slowly rotate the VERNIER control (13) knob in the direction required (clockwise to increase pressure) as indicated by the electronic numerical display. Figure 2-4.
3.0 Calibration Follow the procedure on the following pages for calibrating the UPC5000/UPC5010. NOTES: • • 3.1 When calibrating, the computer within the UPC5000/UPC5010 is actually being re-programmed, therefore it is important that the pressure standard being used is in satisfactory operating condition and that the technician fully understands its operating characteristics and methods of usage.
3.3 Zero/Span Calibration Selecting the ZERO/SPAN position on the Condec Calibration Module (PN 60109) places the instrument into its ZERO/SPAN calibration mode. The display is shown in Figure 3-2. NOTE: Absolute Only Unit requires vacuum pump with PSIA indicator to obtain readings below local barometric pressure. Figure 3-2. Zero/Span calibration for Absolute/GageUnit Starting with the instrument’s lowest pressure range, perform Steps 1 and 2 shown in Table 3-1 for each pressure range.
Figure 3-3. Linearity and Hysteresis Calibration Starting with the instrument’s lowest pressure range, sequentially perform the thirteen steps described in Table 3-2, for each pressure range being calibrated. Perform the following for each step: 1. Adjust input pressure to the appropriate value without overshooting the setting. If value is overshot, vent unit and repeat steps. 2. Perform the action as indicated when the readings are stable.
NOTES: 1. 2. 3. 4. 3.5 If reading is in motion or correction required is not within ±0.8% of full-scale, no entry is made. If entry is valid, the display momentarily indicates the correction value (in percent) and the memory location at which it is stored. If 100% ±0.05% is not obtained, repeat the zero/span calibration sequence. Absolute only unit: Maximum vacuum standard display reading of 0.04 PSIA.
3.7 Permanent Data Storage After completing the above calibration procedures, the new data that has been entered into the computer must be permanently stored. The sequence to do this is as follows: 1. Select the DATA RECALL position of the rotary switch on the Condec Calibration Module (PN 60109). 2. Press the STORE button on the module. 3. When the data is accepted, the four-digit number on the display indicates 1 020 for as long as the STORE button is pressed. 3.
Complete the following steps (refer to Figure 2-2 on page 4 and Figure 3-1 on page 8): 1. Open the VENT valve (8) and close the COARSE ADJUSTMENT valve (2). 2. Using the RANGE SELECT switch (19), select the lowest pressure range on the UPC5000/UPC5010. 3. Select the ZERO/SPAN position on the Condec Calibration Module (PN 60109). The UPC5000/UPC5010 displays three dashes on the left side of the display to indicate this mode. 4. Depress the ENTER button on the module. The UPC5000/UPC5010 display reads zero.
4.0 Maintenance and Service This section outlines the mechanical and basic electrical repair procedures for the UPC5000/UPC5010. 4.1 Troubleshooting Use Table 4-1 below for information on troubleshooting the UPC5000/UPC5010.
UPC5000 Installation Tools required: Phillips screwdriver 1. Lift the panel and chassis by first grasping the regulator knob and test port. 2. Gently place panel/chassis assembly into enclosure. Ensure that the wire harnesses do not catch and snag. 3. Align mounting holes and install the eight screws (PN 14862) that secure the panel assembly to the enclosure. UPC5010 Removal Tools required: Phillips screwdriver 1.
4.2.3 Installing New Nitrogen Cylinder Assembly (PN 59531) Tools required: 7/16" open end wrench Phillips screwdriver 1-1/8" open end wrench 3/8" open end wrench A/R 1/4"-wide Teflon tape (PN 60575) A/R 1/2"-wide Teflon tape (PN 60911) tube of fluorinated grease (PN 55593) snoop, bottle of liquid gas leak detector (PN 64781) 1. Install the Teflon O-ring (PN 59217), fitting (PN 59287), and branch tee (PN 59750) on the new cylinder and tighten until snug.
4.2.5 ORION-2C Manifold, Valve Seat Removal Tools required: A/R solvent (de-natured alcohol) socket wrench 3/4" socket needle housing socket (PN 65580) isolation valve needle housing socket (PN 68509) hex wrench (.050") hex wrench (.061") needle-nose pliers tube fluorinated Krytox grease (PN 55593) electric hand drill No. 43 drill bit No. 4-40 tap tap handle small hammer NOTE: See Table 4-7 on page 32 and Figure 4-1 on page 33 for additional parts information. 1.
4. 5. 6. 7. 8. Remove the self-sealing screw (36) that acts as the piston key. Extract the piston (15) by partially screwing in the threaded end of the shaft (14) and pulling. Remove the O-ring (32) from the piston groove. To disassemble the end cap/shaft assembly, mount the end cap (13) in the vise. Loosen and remove the locknut (20) using the isolation valve housing socket (PN 68509) and socket wrench. 9. Loosen and remove the end bushing (12) using the same socket. Remove the shaft (14).
3. Install new O-rings (28, 27) inside and outside of the valve stem seat. Coat all O-rings and back-up rings (30, 31) with fluorinated Krytox grease before installation. Make sure that the rings are installed in the proper order. 4. Install the valve stem seat (8) by grasping the small diameter end with the needle-nose pliers and positioning in the valve cavity, then gently pushing with the blunt end of a drill bit. 5.
Transducer Wires Terminal Block Wires + Excitation TB1-4 (Green wire) - Signal TB1-6 (Red wire) + Signal TB1-5 (White wire) - Excitation TB1-7 (Black wire) Table 4-2. Transducer Wire to Terminal Block Wire Connections 7. Install all tubing sections that attach to the ORION-2C manifold. 8. Install the nitrogen cylinder and its associated tubing. 9. Fill the cylinder to approximately 1000 PSIG and check all fittings for leaks. If there are no leaks, fill nitrogen supply cylinder to 2200 PSIG.
16. 17. 18. 19. To adjust the VENT valve, follow Steps 3 and 4 above. Close the COARSE valve by turning the COARSE knob (*2) clockwise. Close the VENT valve knob insert (4) clockwise until slightly snug. With the supply pressure at 100% of full scale, open the COARSE valve until the indicated pressure stabilizes and then close the COARSE valve. 20.
3. Install the adjusting knob on the threaded shaft by turning clockwise. Turn adjusting knob on threaded shaft until bottomed and install locking nut and tighten. Turn knob until it bottoms. Position the regulator so that the bottom of the knob is 1/2" from the panel surface, then tighten the cap screw on the mounting collar. 4. Fill the cylinder to approximately 1000 PSIG and check all fittings for leaks. If there are no leaks fill nitrogen supply cylinder to 2200 PSIG. See Section 2.
7. 8. 9. 10. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14. Energize the unit and let warm up. Turn RANGE SELECT switch to highest range. Close the COARSE valve by turning the COARSE knob clockwise. Turn the regulator knob clockwise until reaching between 5-10% of full scale, but not enough to disturb pressure relief valve. NOTE: If pressure can not be attained loosen locknut on shaft, rotate knob a few turns counter-clockwise, re-tighten locknut.
If there is leakage out of the port when the pressure cap is in place, replace the port fitting. Tools required: Phillips screwdriver 3/4" two open end wrenches 9/16" open end wrench A/R 1/4" wide Teflon tape (PN 60575) A/R 1/2" wide Teflon tape (PN 60911) tube fluorinated Krytox grease (PN 55593) snoop, liquid leak gas detector (PN 64781) 1. Vent any remaining gas from the nitrogen cylinder to atmosphere. Disconnect the power cord from the power source. 2.
4.2.19 Inlet Check Valve - Nitrogen Fill Port (PN 60263) Remove the check valve if it does not hold the pressure of the N2 cylinder. The check valve can be disassembled for cleaning should any debris foul the seat area. Tools required: Phillips screwdriver 7/16" open end wrench 9/16" open end wrench A/R 1/2" Teflon tape, PN 60911 5/32" hex wrench tube fluorinated Krytox grease (PN 55593) snoop, liquid leak gas detector (PN 64781) torque wrench NOTE: See Figure 4-3 on page 35. Check Valve Removal 1.
4.2.21 AC Power/EMI Line Filter (PN 58870), Removal and Installation Tools required: Phillips screwdriver 1/4" open end wrench or nutdriver A/R soldering iron A/R shrink sleeving (PN 60735) A/R heat gun 1. Disconnect the power cord from the power source and line filter. Remove front panel from its enclosure as described in Table 4.2.1 on page 14, and carefully set on a bench top. 2. Remove the three cable connectors from the line filter terminals.
4.2.23 Power Switch (PN 58878), Removal and Installation (Non-Battery Units) Tools required: Phillips screwdriver 11/16" open end wrench A/R soldering iron A/R shrink sleeving (PN 64567) A/R heat gun Removal: 1. Disconnect the power cord from the power source and line filter. Remove front panel from its enclosure as described in Table 4.2.1 on page 14, and carefully set on a bench top. 2. Loosen the switch mounting nut and lock washer from the rear of panel. 3.
Installation: 1. Connect and solder the wires onto their respective switch terminals (Table 4-4). Range Select: Display Select: Terminal Color Terminal Color 1 Grey 3 Blue 2 Violet 2 Red (C) common Brown (C) common Green (C) common Green Table 4-4. Range Select and Display Select Wire Colors/Switch Terminals 2. 3. 4. 5. Install the switch through the panel rear, align with front panel markings, and secure with mounting nut. Install the switch knob using a .061" hex wrench.
Color Terminal Yellow Normally open Green (C) common Table 4-6. Wire to switch terminal connections: Zero 2. Install the new switch, lock washer and nut through the panel rear. Hand tighten the trim ring from front of panel. 3. Tighten the switch mounting nut and lock washer from the rear of panel. Replace CPU if necessary. ! Caution If wrench is used, do not over tighten, damage may occur to switch. 4. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14. 4.2.
Installation 1. To install a new battery, reverse steps 2 through 4 of above. 2. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14. Adjustment of Charging Circuit Tools required: Phillips screwdriver Flat blade screwdriver (small) 11/32" open end wrench or nutdriver DC voltmeter 1. Disconnect the power cord from the power source and line filter. Remove front panel from its enclosure as described in Section 4.2.1 on page 14, and carefully set on a bench top. 2.
3. Connect the leads of a 11.5 VDC power source to the battery cable wires that are connected to TB1 on the power supply board. Adjust potentiometer R9 located on power supply board to illuminate low battery indicator. For LED display type units a red LED in the left center of the display will turn on. For LCD display type units, 5 LED segments in the left of display window will illuminate in the shape of a "U." 4. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.
4.3 Orion 2C Valve Assembly Parts List The following table lists the component parts of the ORION-2C.
THESE COMPONENTS TO BE INSTALLED AT LOCATIONS A & D D 38 16 10 1 2 33 25/2X 34 23/2X 4 D C 7 32 24/3X 9 3 28 31 15 27 35/2X 20 30 8 12 41 OR B 5 42 17 7 21/14 X 11 14 A 27 9 25/2X 28 41 26/2X 31 OR 36 42 27 29 30 8 13 19 18 6 THESE BE THESE COMPONENTS TO BE INSTALLED LOCATIONS B B && D C INSTALLED AT LOCATIONS A C Figure 4-1.
Figure 4-2. Tescom and Standard Pneumatic Regulator Mounting Body Spring O-ring P/N 66654 Poppet Insert Lock Screw Insert Figure 4-3.
REVISIONS REV REFERENCE AF ECO10483: DELETED ITEMS 10 & 11; REDRAWN ON RLW FORMAT AG DELETED ITEM NUMBER 2 . ECO11898: ADDED NOTE 27, ADDED INFO TO ITEM NO. 101 ON AH LIST OF MAT'L, ADDED INFO TO ITEM 31, ADDED NOTE 28 AND 29, REMOVED SPEC. FROM ITEM 61, 62, 65 AND 1 THRU 54 28- KEU8924-1 (54254) & KEU8924-3 (54263) ONLY: ON CIRCUIT SIDE OF BOARD, CUT CLAD BETWEEN CR12 ANODE AND VIA UNDER U10. CUT CLAD BETWEEN CR10 ANODE AND U6-4. ADD 3 1/2" 30 AWG WIRE, ITEM 101, BETWEEN CR10 ANODE AND VIA UNDER U10.
Figure 4-5.
Figure 4-6.
REVISIONS REFERENCE REV W THRU AB INIT SEE C/N'S FOR CHG. DESCRIPTIONS W-C/N D2858, Y-C/N D2900, AA-C/N D2948, AB-C/N D2968. AC AD AE AF AG AH AJ C/N D3121; IT. 95 QTY WAS 11 1/2 IN. C/N D3710, ITEM 10 WAS KBF8918B; IT. 24 WAS RN55010ROF; IT. 57 WAS KLY3118; IT. 95 WAS M16878/4BGBO. C/N D4003 L/M: ITEM 53 PART# WAS: KJE3118; DESC. WAS CAPACITOR, MYLAR. QTY OF ITEM 96 WAS: -1=0; -2=1 1/2"; -3=0; -4=1 1/2" ; ADD'D NOTE 27; UPDT'D SHT. 2. DELETED ITEMS 2, 10, AND 11.
Figure 4-8.
Figure 4-9.
Figure 4-10.
Figure 4-11.
Figure 4-12.
Figure 4-13.
5.0 Model Number System UPC 5000 - ____ ____ ____ ____ UPC 5010 - ____ ____ ____ ____ ≠ ≠ ≠ ≠ +-------------------------------------+ ≠ ≠ ≠ ≠ ≠ ≠ ≠ A - AC Only (120 VAC)*** ≠ ≠ ≠ B - Battery Operation & 120 VAC ≠ ≠ ≠ C - AC Only (220 VAC)*** ≠ ≠ ≠ D - Battery Operation & 220 VAC ≠ ≠ ≠ ≠ ≠ ≠ ≠ A - 2000/1000/400 ≠ ≠ B - 1000/500/200 ≠ ≠ C - 500/250/100 ≠ ≠ D - 100/50/20 * ≠ ≠ E - 50/25/10 * ≠ ≠ F - 15/7.
6.0 Available Ranges, Conversions and Resolutions NOTE: All ranges are available in bars only. Calibrator Mode: @ = Gage Only # = Absolute Only $ = Gage or Absolute NOTE: Calibrators have PSI and one conversion as shown in table. RANGE (PSI) A 2000/1000/400 @,$ 1000/500/200 @,$ 500/250/100 $ B $ C @ D E F @,$ @,$ $ @ $ @,$ @ 100/50/25 @ 50/25/10 @ 15/7.5/3 @ Table 6-1. PSI Conversion A: kPa = PSI x 6.89476 B: mm Hg = PSI x 51.7149 C: Bar = PSI x 0.
CONVERSION RANGES HI/MED/LO RESOLUTION HI/MED/LO PSI 1000.0/500.0/200.00 0.2/0.1/0.05 kPa 6895/3447.5/1379.0 1/0.5/0.2 mm Hg 51710/25855/10342 10/5/2 Bar 68.95/34.475/13.790 0.01/0.005/0.002 in Hg 2036.0/1018.0/407.2 0.5/0.2/0.1 in H2O 27710/13856/5542 5/2/1 Table 6-3. Resolutions (1000/500/200 PSI ranges) CONVERSION RANGES HI/MED/LO RESOLUTION HI/MED/LO PSI 500.0/250.00/100.00 0.1/0.05/0.02 kPa 3447.5/1723.6/689.5 0.5/0.2/0.1 mm Hg 25855/12928/5171 5/2/1 in Hg 1018.0/509.
CONVERSION RANGES HI/MED/LO RESOLUTION HI/MED/LO PSI 15.000/7.500/3.0000 0.002/0.001/0.0005 in H2O 415.65/207.80/83.13 0.05/0.05/0.01 Table 6-7. Resolutions (15/7.
7.0 Options, Replacement Kits There are numerous replacement part numbers mentioned throughout manual that can be ordered. ORION-2C O-Ring Replacement Kit (Data Sheet # 65308): • • • • • Nitrile Buna-N (standard) ....................................................PN 58499 Ethylene-Propylene .............................................................PN 58506 Silicone .................................................................................PN 58509 Neoprene .....................................
8.0 Specifications Pressure Specifications: Test Port: Pressure range: Pressure Rating: Material: Three independent pressure ranges per instrument. See “Part Number System” on page 36 for available ranges Available Pressure Calibrations: Gage only, absolute only, or gage and absolute Overall Accuracy: < ±0.05% Full Scale Max. Accuracy statement includes all effects of linearity, hysteresis, repeatability and ambient temperature Operating Temperature: +40° to +122°F (+4.4° to +50.
UPC5000/UPC5010 Warranty and Return Policy If possible, please save original packing material which is specifically designed for the unit. Should it be necessary to ship the unit back to the factory, a suitable shipping container must be used along with sufficient packing material. Do not put a shipping label on the unit as a shipping container. Some units have been severely damaged this way. This is a delicate, precision instrument.
UPC5000/UPC5010 Return Material Authorization Form The repair lab is also equipped to do calibrations on our calibrators and pressure standards. Calibrations include a certification and are traceable to N.I.S.T.
