Condec UPC5110 User Manual

UPC5100/UPC5110

Portable & Rack-mountable Pneumatic

Pressure Calibration Console

Operation & Maintenance Manual

CONDEC Sales Phone No. [phone]

CONDEC Web Site: www.4condec.com

63257

Contents

About This Manual................................................................................................................................... 1

1.0 Introduction.................................................................................................................................. 1

2.0 Operation...................................................................................................................................... 4

2.1 Pressure Cylinder Filling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Shop Air Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Initial Setup Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Pressure Measurement Sequence (Gage Only Unit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.5 Vacuum Measurement Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.6 Battery Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.0 Calibration.................................................................................................................................... 9

3.1 Pneumatic Calibration Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 Instrument Calibration Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Zero/Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.4 Linearity and Hysteresis Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.5 Shunt Resistor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.6 Voltage/Current Input Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.7 Permanent Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.8 Normal Mode Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.0 Maintenance and Service.......................................................................................................... 14

4.1 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2 Maintenance and Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2.1 UPC5100/UPC5110 Panel/Chassis - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2.2 Nitrogen Cylinder Assembly (PN 59531) - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.2.3 ORION-2D Manifold Removal (PN 55286). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2.4 ORION-2D Manifold - Valve Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2.5 ORION-2D Manifold - Vernier Control Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2.6 ORION-2D Manifold - Vernier Control Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2.7 ORION-2C Manifold - Valve Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2.8 ORION-2D Manifold - Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2.9 ORION-2D Manifold - Valve Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2.10 Chassis Mounted Regulator (PN 55502) - Removal, Installation and Adjustment. . . . . . . . . . . . . . . . . 21

4.2.11 Pressure Limit Control (PN 58409) - Regulator Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . 22

4.2.12 Supply Pressure (PN 59730) and Pressure Limit Monitor (PN 59706) Gauges-Removal and Installation. . . . . . . . . 23

4.2.13 Test Port Quick-Connect Fitting (PN 59762) - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 23

4.2.14 Test Port Filter (PN 54188) - Removal, Cleaning and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.2.15 Vacuum Generator - Removal, Cleaning and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.2.16 Vacuum Control Regulater (PN 59765) - Removal, Installation and Adjustment. . . . . . . . . . . . . . . . . . 26

4.2.17 Inlet Check Valve, Nitrogen Fill Port (PN 60263) - Removal, Disassembly and Installation . . . . . . . . . . 27

4.2.18 AC Fuse (PN 58076) - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.2.19 AC Power/EMI Line Filter (PN 58870) - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.2.20 Power Switch (PN 55187) for Battery Units - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 28

4.2.21 Power Switch (PN 58878) for Non-Battery Units - Removal and Installation . . . . . . . . . . . . . . . . . . . . 29

4.2.22 Range Select (PN 54186) and Display Select Switches (PN 59429) - Removal and Installation . . . . . . 29

4.2.23 Zero Switch (PN 58886) - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.2.24 Power Supply Assembly (Battery Units Only) - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 31

4.2.25 BATTERY (Replacement Kit PN 55354) - Removal, Installation and Adjustments . . . . . . . . . . . . . . . . 31

4.3 Orion-2D Valve Assembly Component Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Copyright © 2002 Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.

Specifications subject to change without notice.

January 2002

5.0 Model Number System .............................................................................................................. 36

6.0 Available Ranges, Conversions and Resolutions...................................................................... 37

7.0 Options - Replacement Kits....................................................................................................... 38

8.0 Specifications............................................................................................................................ 39

UPC5100/UPC5110 Warranty and Return Policy................................................................................... 51

UPC5100/UPC5110 Return Material Authorization Form....................................................................... 52

About This Manual

This manual is intended for use by service technicians
responsible for installing and servicing the
UPC5100/UPC5110 pneumatic pressure console.

The UPC5100 portable pneumatic pressure calibrator
and the rack-mounted UPC5110 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. This provides an
easy-to-read and accurate digital representation of the
measured pressure. This all electro-mechanical device
combines a 7 cu. ft., 2216 PSI cylinder with our
precision ORION-2D vernier. The unit has one test
port and front panel gauges that indicate system
pressure and remaining pressure in the internal
cylinder . A pressure regulator acts as a pressure limiter
so that the operator can not over-pressurize a unit
under test. Fill and test hoses are supplied for the
customer. Standard front panel buttons and switches
provide selection of the desired mode, (pressure or
vacuum), pressure range, push-button zeroing and
internal self-check feature. This manual has been
written to give the user a simple and clear explanation
of how to operate, calibrate, and maintain these
instruments.

Before attempting to use either style

Caution

the equipment. This is a high-pressure system. It is
strongly recommended that only personnel formally
trained in the use of pneumatic pressure equipment be
permitted to operate it. Potentially dangerous conditions
can be produced through negligent handling or operation
of the console due to the high pressure cylinder
contained within the unit.

These units are strictly for use with pneumatic pressures.
Erroneous readings and potential damage can result from
the introduction of hydraulic fluids into the internal tubing
lines.

pressure calibrator, the following
instructions must be carefully read
and understood by personnel using

Authorized distributors and their
employees can view or download this
manual from the Condec distributor site

www.4condec.com

at

.

1.0 Introduction

Utilizing microprocessor technology , the UPC5100 and rack-mounted UPC5110 instruments of fer a combination
of features, performance, versatility, and reliability not previously available in a single, self-contained pressure
calibration instrument. Some of the features are listed below:

• Independent switch-selectable pressure ranges.

•Accuracy of each range equal to or better than ±0.05% full scale.

•Both pressure and vacuum calibrations available via front panel switch selection.

•Automatic self-check: Computer-controlled internal circuitry provides automatic maintenance of both zero
and span calibration data to ensure long-term stability and accuracy.

•Digital Display: Large LED digits provide excellent readability under all lighting conditions (also a vailable
with a Liquid Crystal Display).

•Using a manually adjustable regulator, the maximum system input pressure is adjusted to any value higher
(typically 20 to 50%) than the full scale range of the device being tested and, the unit under test is fully
protected from being inadvertently over-pressurized.

• Portable: These compact, self-contained systems are easily carried and operated by only one person. Total
weight is less than 40 pounds.

Introduction

1

2

• System Calibration: The instruments can be completely calibrated without being removed from the e xternal
case. A separate plug-in Condec Calibration Module (PN 60109) provides access to the computer when
calibration is performed. No manual alignment or potentiometer adjustments are required.

•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 N

provides up to 2015

2

PSIG of pressure for calibration and test. A quick-disconnect fitting with a check valve provides
re-charging capability.

• Simple Operation: All controls, indicators and pressure ports are accessible from the front panel. Section 2
provides clear, concise instructions for system operation.

•Data Input Capability: A front panel-mounted connector and selector switch permit the 4-20 mA current
signal from the gage-under-test or voltage to be displayed. Transducer excitation voltage of 18 VDC is
provided as a standard feature.

• Safe, Clean Operation: All pressure components are made of brass, copper, aluminum or stainless steel and
proof-tested to at least 150% of maximum operating pressure. In addition, the system contains a
high-pressure burst disk and relief valves to protect both the operator and system components from harm in
the event of over-pressurization.

The heart of this calibration system is a highly stable and repeatable pressure transducer. These sensors produce
an electrical output signal which is linearly proportional to the applied pressure.

By combining these sensors with microprocessor-based circuitry, an even higher degree of operational accuracy
and precision has been accomplished. For example, computer-generated correction curves for both the
non-linearity and the hysteresis of the sensors improve these characteristics by an order of magnitude or more. In
addition, a self-check feature ensures long-term accuracy by utilizing the computer to generate and control an
internal shunt calibration mode of operation. The indicators full-scale reading is compared against, and if
necessary, corrected to the digitally-stored value for full scale obtained at the time of initial pressure calibration.

The computer is programmed with a series of internal self-diagnostic routines that continually monitor and check
every bit of data stored and processed by this system. The system either notes or shuts down operation in the
event of an out-of-tolerance reading or outright failure.

The UPC5100 has an internal, rechargeable 12 volt lead acid battery, that provides a minimum of six hours of
complete portability when fully charged. An ON/OFF and battery test switch is provided to conserve energy
when the instrument is not in use and to provide the operator with battery voltage status during use. It also has a

LO BATT

indicator on display.

UPC5100/UPC5110 Operation & Maintenance Manual

The following schematic provides an overview of the UPC5100/UPC5110’s function.

Figure 1-1. UPC5100/UPC5110 Flow Diagram

Introduction

3

4

2.0 Operation

The following sections explain the various procedures for operating the UPC5100/UPC5110.

2.1 Pressure Cylinder Filling Procedure

To initially fill or refill the internal pressure cylinder (2015 PSI max) of the UPC5100/UPC5110, see Figure 2-1
and proceed by following these steps:

NOTE: Check the Nitrogen Fill Port markings on Pressure Console, some units may be 2216 PSI max.

1. Close PRESSURE LIMIT CONTROL (1) by pulling regulator knob outward and turning
counter-clockwise. When closed, push knob inward. Close the COARSE ADJUSTMENT valve (2) by
rotating clockwise until it stops.

2. Connect the fill hose (3), to a clean regulated nitrogen source (5).

3. Connect the other end of the fill hose (3) to the male fill port fitting (4).

4. Slowly open the valve on the nitrogen source and allow the gas to flow into the pressure cylinder. The
SUPPLY PRESSURE gauge (6) indicates the amount of pressure within the internal cylinder.

NOTE: The Inlet Check Valve (PN 60263) and the Nitrogen Fill Port (Section 4.2.17 on page 32; Figure 4-4 on page 41)
can be damaged if pressure is released too fast.

5. Use the following procedure for filling the cylinder:

a) Fill cylinder to 1000 PSI at a rate of charge equal to a minimum of two minutes, then wait five
minutes for system to stabilize.

b) Fill cylinder from 1000 PSI to maximum pressure at a rate of charge equal to a minimum of two
minutes.

c) Wait five minutes for system to stabilize before using.

NOTE:

Figure 2-1. Pressure Cylinder Fill Procedure

UPC5100 shown, AC Input (7) and Fill Port (4) are on back of UPC5110 Rack Mountable Calibrator.

UPC5100/UPC5110 Operation & Maintenance Manual

2.2 Shop Air Operation

1. Turn the SUPPLY SELECT valve (7) to the SHOP AIR position and connect a shop air hose to the male
fill port (4). Maximum input pressure is 150 PSI.

2.3 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
UPC5100/UPC5110 will perform an internal functional self-check. If acceptable, a 100.00 flashes briefly
and the display returns to a normal reading. Allow at least ten minutes warm-up time. Select the desired
full scale pressure range via the five-position RANGE SELECT rotary switch (19). For the best accuracy,
the selected range must be greater, but close as possible to, the full scale range of the device under test.

NOTE: Do not switch pressure ranges during a calibration cycle.

3. Set the DISPLAY SELECT switch (16) to the PRESSURE position.

4. Connect the male end of the test hose to the TEST PORT (17) fitting.

5. Connect the swivel fitting end (7/16-20) of the test (output) hose to the device-under-test (use adapters if
required). Tighten all connections properly.

Figure 2-2. Initial Setup Procedure

NOTE: UPC5100 shown, AC input (7) and fill port (4) are on back side of UPC5110 Rack Mountable Calibrator.

6. Optional - if the current (4.0000 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: The +excitation voltage is only available 110-120 VAC operation.

Operation

5

6

The display scaling for these current measurements are as follows:

SWITCH POSITION

Current 0-20.000 mA by 0.005 mA

*Voltage 0-100.00 mV by 0.02 mV

Table 2-1. Display Select Switch (16)

NOTE: UPC5100/UPC5110 reads a 4-20 mA signal only, but will display as either 4-20 mA or 20-100 mV.

DISPLAY READING

The test cable connector wiring is as follows:

CONNECTOR PIN DESIGNATION

A+ VDC
B+ SIGNAL
C NOT USED
D VOLTAGE & SIGNAL COMMON

Table 2-2. Transducer Test Cable (PN 55092)

NOTE: Connector pin designations are for reference only, and are no longer a connector on newer units. See Figure 2-2
on page 5 (14).

FUNCTION

2.4 Pressure Measurement Sequence (Gage Only Unit)

NOTE: See Figure 2-3 on page 5 when following these steps:

1. Turn the MODE SELECT valve (10) to the PRESSURE position.

2. Close the COARSE ADJUSTMENT valve (2), clockwise, and open the VENT valve (8),
counter-clockwise.

3. Using the PRESSURE LIMIT CONTROL regulator (1), (pull knob outward while adjusting) adjust the
maximum system input pressure (as read by the PRESSURE LIMIT MONITOR [9]), to any desired value
higher (typically 20-50% higher) than the full-scale range of the device under test. Using this technique,
the device under test is fully protected from being accidentally over-pressurized.

4. Zero unit by momentarily depressing the ZERO switch (12) for less than five seconds.

NOTE: The instrument can be zeroed at any time, as long as the VENT valve (8) is open, by momentarily depressing the
ZERO switch (12) for less than five seconds.

5. To apply pressure, close the VENT valve (8), approximately tw o turns clockwise, until it stops, then open
the COARSE ADJUSTMENT valve (2) approximately 1/2 turn counter-clockwise until the numerical
display begins to move. The operator may change the pressure rapidly until reaching approximately 90%
of the desired final value.

6. 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.

7. 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.

8. The transducer current measurement can be displayed at any time by placing the DISPLAY SELECT
switch (16) in its CURRENT position.

UPC5100/UPC5110 Operation & Maintenance Manual

Figure 2-3. Pressure or Vacuum Measurement Sequence

NOTE: UPC5100 shown, AC Input (7) and Fill Port (4) are on back side of UPC5110 Rack Mountable Calibrator.

2.5 Vacuum Measurement Sequence

See Figure 2-3 above and proceed as follows:

1. Turn the MODE SELECT valve (10) to the VACUUM position.

2. Close the COARSE ADJUSTMENT valv e (2) clockwise and open the VENT valv e (8), counter-clockwise.

3. Zero the unit by pressing the ZERO button (12).

4. If only pressure measurements greater than atmospheric pressure are required continue to step 4.1. If
simultaneous pressure measurements above and below atmospheric pressure, or if a vacuum level higher
than 27” Hg are required, go to step 5.

4.1 Close the VENT valve (8) (approximately two turns to its stop) and open the COARSE

ADJUSTMENT valve (2) slowly by rotating knob counter-clockwise until the numerical display

begins to move. It will immediately acti vate the vacuum conv erter. A v acuum as lo w as 27” Hg can
be maintained in the system without the use of an external vacuum pump. In general, the pressure
may be changed rapidly until reaching approximately 90% of its desired final value. Closing the

COARSE ADJUSTMENT valve (2), clockwise will deactivate the vacuum converter and trap the

vacuum in the system.

NOTE: The vacuum may be vented by opening VENT valve counter-clockwise or switching the MODE SELECT to the
PRESSURE position and opening the COARSE ADJUSTMENT valve counter-clockwise.

4.2 Use the COARSE ADJUSTMENT (2) and 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 (counter-clockwise to increase vacuum) as indicated by the electronic numerical display.

5. If simultaneous pressure measurements above and below atmospheric pressure are required, or if a
vacuum lev el higher than 27” Hg are required, connect a vacuum pump to the VACUUM/VENT port (15)
as shown in Figure 2-3 on page 7.

6. Open the VENT valve (8). Close the COARSE ADJUSTMENT valve (2) and apply power to the vacuum
pump and allow it to evacuate the system for several minutes or until the digital display reading reaches
equilibrium near zero PSIA. Press the ZERO button to establish a zero reference on the display.

Operation

7

8

7. With the vacuum pump still running, close the VENT valve (8) and check for system leaks. If there are
none, continue to step 7.1

7.1 To apply pressure, close the VENT valve (8) (approximately two turns to its stop) and open the

COARSE ADJUSTMENT valve (2) (approximately 1/2 turn counter-clockwise until the numerical

display begins to move). In general, the pressure may be changed rapidly until reaching
approximately 90% of its desired final value.

7.2 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.

7.3 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.

2.6 Battery Operation

When supplied with the battery, the UPC5100/UPC5110 has an internal, rechargeable 12 volt, lead acid battery
which provides a minimum of six hours of completely portable usage before having to be recharged.

An ON/OFF/BATTERY TEST switch (18) (Figure 2-3 on page 7) is provided to conserve energy when the
instrument is not in use, and to provide the operator with information as to the status of the battery voltage during
use.

The UPC5100/UPC5110 can be operated and recharged by connecting to a standard AC outlet via the line cord
(supplied). The battery re-charge cycle time is approximately 16 to 20 hours with the ON/OFF switch in the OFF
position. The charging circuit is designed to be left on indefinitely without adversely affecting battery life.

When selected, the momentary action BATTERY TEST switch (18) is used to read the actual battery voltage. The
battery voltage reading typically is between 11.5 and 13.0 volts. When the battery voltage reads 11.5 volts, there
are approximately one to two hours of useful operation left and a low battery indicator is illuminated. For LED
display units, a LED in the left center of the display turns on. For LCD display units, five LED segments in the
left of the display window illuminate in a “U” shape. The instrument ceases to function when the battery voltage
is 11.0 volts or less.

NOTE: The battery test should only be performed with the UPC5100/UPC5110 operating at zero PSIG (VENT valve open)
and at the conclusion of the test, the unit’s ZERO button will have to be pushed again to re-zero the instrument.

UPC5100/UPC5110 Operation & Maintenance Manual

3.0 Calibration

Follow the procedure on the following pages for calibrating the UPC5100/UPC5110.

NOTES:

• When calibrating, the computer within the UPC5100/UPC5110 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. In addition, the UPC5100/UPC5110 itself must be properly warmed up (approximately
thirty minutes) and electrically stabilized prior to performing a calibration cycle.

• The CONDEC Repair Lab is equipped to do calibrations on CONDEC calibrators and pressure standards. Calibrations include a
certification and are traceable to N.I.S.T (see “UPC5100/UPC5110 Return Material Authorization Form” on page 52).

3.1 Pneumatic Calibration Set-up

Figure 3-1 defines a typical calibration set-up using a floating piston-type, air dead weight tester and a vacuum
dead weight tester. A vacuum pump will be required to enable calibrating the -14 PSIG of the Bi-directional
ranges.

Any type of precision standard is acceptable as long as its basic accuracy is ±0.025% of point or better.

NOTE:

To permit proper calibration, at least an

ON/OFF

and a

VENT valve (connected as shown in Figure 3-1) must be

provided.

3.2 Instrument Calibration Set-up

The UPC5100/UPC5110 is placed into its calibrate mode by connecting a Condec Calibration Module (PN

60109) via the multi-pin jack. The jack is located behind the small slide plate near the fill port (see Figure 3-1).
The Condec Calibration Module provides access to the calibrator’s various program modes via a five-position

rotary switch. It also provides a means of entering and storing data via four other momentary action switches.
In the calibrate mode, the UPC5100/UPC1010’s numerical display is used to provide operator prompting

symbols as well as displaying the various data formats. For example, in Figure 3-2, the data format shown is that
obtained as soon as the

ZERO/SPAN position of the rotary switch is selected.

Figure 3-1. Instrument Calibration Set-up

NOTE: UPC5100 shown, AC input and Fill Port are on backside of UPC5110 Rack Mountable Calibrator.

Calibration

9

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.

Figure 3-2. Zero/Span calibration for Gage-Only Units

The unit needs to be calibrated to only one positive and one bi-directional range. All bi-directional ranges are
calibrated over 0 to +14 PSI and 0 to -14 PSI. All the positive ranges from 0 to 100 PSI. Starting with one of the
instrument’s ranges, perform the steps shown in Table 3-1. Perform the following for each step:

1. Adjust input pressure to the appropriate (either 0 or full-scale) value.

2. Perform the action indicated in Table 3-1 when pressure input readings are stable.

NOTE: A vacuum pump will be required to enable calibrating the -14 PSI of the bi-directional ranges.

Resulting Calibration Standard

Pressure Input Value

(For Bi-directional

Step No.

10 PSI
2 +14 PSI Press ENTER button 28.505 387.95 96.52 Notes 2 & 3

30 PSI Press ENTER button 0.000 0.000 0.000 Note 1 below
4 -14 PSI Press ENTER button -28.505-387.95-96.52 Notes 2 & 3

Step No.

10 PSI Press ENTER button 0.00 0.00 Note 1 below
2 100 PSI Press ENTER button 100.00 2771.0 Notes 2 & 3

range)

(For positive direction

range)

Operator Action Required

Press ENTER

Operator Action Required

button

Display Indication

+/-30"

Hg

0.000 0.000 0.000 Note 1 below

100
PSI

+/-400"

H

2

2700"
H

O — Remarks

2

+/-100

0

kPa

Remarks

below

below

below

Table 3-1. Zero and Span Calibration Sequence

10 UPC5100/UPC5110 Operation & Maintenance Manual

NOTES:

1. If readings are not stable or are not within ±20% of zero, the zero correction can’t be entered.

2. If readings are not stable or are not within ±5% of 100%, the span correction cannot be entered.

3. For ease of calibration, do the Linearity/Hysteresis calibration , prior to doing ZERO/SPAN of next range.

3.4 Linearity and Hysteresis Calibration

Install the Condec Calibration Module (PN 60109) and select the LYN/HYS position of the rotary switch on the
module. This places the UPC5100/UPC5110 into its linearization/hysteresis calibration mode. The display is
shown in Figure 3-3 below.

NOTE: The zero/span calibration needs to be performed prior to linearity and hysteresis calibration.

Figure 3-3. Linearity and Hysteresis Calibration

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, 1 to 2 minutes. If it is taking longer, check
system for leaks. If no leaks are found, the CPU or transducer may be defective.

UPC5100/UPC5110

CONDEC Calibration Module

Step Input Pressure % of Range

10 Press ZERO switch Upper Circle Zero on display
210Press ENTER button Upper Circle Notes 1 & 2 below
320Press ENTER button Upper Circle Notes 1 & 2 below
430Press ENTER button Upper Circle Notes 1 & 2 below
540Press ENTER button Upper Circle Notes 1 & 2 below
650Press ENTER button Upper Circle Notes 1 & 2 below
760Press ENTER button Upper Circle Notes 1 & 2 below
870Press ENTER button Upper Circle Notes 1 & 2 below

Operator Action Required

Display Status Symbol in

Left-most Digit

Remarks

980Press ENTER button Upper Circle Notes 1 & 2 below

10 90 Press ENTER button Upper Circle Notes 1 & 2 below

Table 3-2. Linearization and Hysteresis Calibration Sequence

Calibration 11

UPC5100/UPC5110

CONDEC Calibration Module

Step Input Pressure % of Range

11 100 No Action Required Lower Circle Note 3 below
12 50 Press ENTER button Lower Circle Notes 1 & 2 below
13 0 No Action Required Upper Circle

Table 3-2. Linearization and Hysteresis Calibration Sequence (Continued)

Operator Action Required

Display Status Symbol in

Left-most Digit

Remarks

When Step 11 is reached, the display changes so that the left most status symbol is a lower circle. This remains
for Step 12 and down to approximately 0.00 PSI.

NOTES:

1. If reading is in motion or correction required is not within ±0.8% of full-scale, no entry is made.

2. If entry is valid, the display momentarily indicates the correction value (in percent) and the memory location at which it is
stored.

3. If 100% (±0.05%) is not obtained, repeat the zero/span calibration sequence.

3.5 Shunt Resistor Calibration

To place the UPC5100/UPC5110 into shunt calibration mode, install the Condec Calibration Module (PN 60109)
and select the SHUNT MODE position of the rotary switch. The display is shown in Figure 3-4.

Figure 3-4. Display in Shunt Resistor Calibration Mode.

Perform the four step sequence on the UPC5100/UPC5110 as described below.

1. Be sure the input pressure is set at 0 PSIG.

2. Press and hold the

3. Release the

ZERO button and allow the display to stabilize at its shunt resistor calibration number (100 ±

ZERO button on the module until a stable zero indication is obtained.

5.00%).

4. Press the

ENTER button on the module. When accepted, the bottom half of all display digits

momentarily illuminate.

3.6 Voltage/Current Input Calibration

To calibrate unit, a current generator capable of generating 20 mA, must be connected to the COMMON and

CURRENT INPUT jacks (Figure 2-3 on page 7 [14]). The DISPLAY SELECT switch (16) should be in the
VOLTAGE position.

1. Set the Condec Calibration Module (PN 60109) to the
for display reading).

12 UPC5100/UPC5110 Operation & Maintenance Manual

ZERO/SPAN position (see Figure 3-2 on page 10

2. Press the ENTER button on the module. The display reads 0.00.

3. Set the current generator for 20 mA output. Press the

ENTER button on the module. The display should

read 100.000.

4. Turn the

DISPLAY SELECT switch (16) to the CURRENT position. Display will read 20.000.

5. Disconnect the current generator.

NOTE: If the display reading is off, set the Current Generator to 0, and press the ENTER button on the Condec

Calibration Module. Set the Current Generator for 20 mA output. The display will read 20.000. If the display reading is
off, press the ENTER button on the module. If the display reading is not 20.000, CPU is faulty and requires servicing.

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

2. Press the

3. When the data is accepted, the four-digit number on the display indicates

DA TA RECALL position of the rotary switch on the Condec Calibration Module (PN 60109).

STORE button on the module.

1 020 for as long as the STORE

button is pressed.

3.8 Normal Mode Test

After completing the above calibration procedures, you must perform a normal mode test.

1. Set the Condec Calibration Module to the

2.

DISPLAY SELECT switch should still be in the CURRENT position. Display will read 20.000.

3. Turn the

DISPLAY SELECT switch to the VOLT AGE position. Display will read 100.00.

4. The pneumatic portion of the calibration is now complete and the pressure standard and the module can
now be disconnected.

NORMAL MODE position.

Calibration 13

4.0 Maintenance and Service

This section outlines the mechanical and basic electrical repair procedures for the UPC5100/UPC5110.

4.1 Troubleshooting

Use Table 4-1 below for information on troubleshooting the UPC5100/UPC5110.

Symptom Problem Remedy

No lit display Unit will not energize Check fuse, check power source, check

power switch

Display slowly decreases over time Leak in system Check all compression and pipe fittings

with snoop, bottle of liquid leak gas
detector (PN 64781)

Display does not respond when Vernier
knob is turned

Display increases or decreases when
COARSE (Pressure) or VENT valves are
closed

Unit will not stay in CAL; display shows
"o" and reads a high value at zero PSIG.

Low battery indicator on display
illuminates when unit is powered

No display when in battery mode after
charging

Display will not zero Display will not zero Perform a ZERO/SPAN calibration
Display shifts Transducer drifts or possible over

Gas escapes when external supply
pressure is bled

No Vernier control Readjust isolation valves on Orion;

replace O-ring on Vernier piston

No Pressure or Vent control Replace valve seats or O-rings in valves;

check valve needles

Transducer over-pressurized Replace transducer

Low or no battery power Re-charge battery, check power supply

charging voltage

Battery will not hold charge Replace battery

Replace transducer

pressure
Nitrogen cylinder will not remain charged Remove inlet check valve; clean or

replace

Table 4-1. UPC5100/UPC5110 Troubleshooting

4.2 Maintenance and Service Procedures

The repair procedures cover the major components and sub-assemblies which are critical to the proper
functioning of the calibrators and may need periodic maintenance over the life of the unit.

Only those persons who are formally trained as skilled technicians should attempt to repair these units.

Caution

4.2.1 UPC5100/UPC5110 Panel/Chassis - Removal and Installation

Tools required: Phillips screwdriver

UPC5100 Removal:

1. Verify that power toggle switch is in the OFF position. Loosen and remove the eight screws (PN 14862)
that secure the panel assembly to the enclosure.

2. Lift the panel and chassis by grasping the fill port fitting and vent/vacuum port. Then grasp under the
panel edges. Ensure that the wire harnesses do not catch and snag.

3. Gently set the panel/chassis assembly on a bench top. It can be rested on the panel bottom and pressure
cylinder, with the panel tilted at an angle from its vertical.

Although some mechanical sub-assemblies could be replaced without venting cylinder it is not
recommended. All safety precautions should be observed due to the presence of electrical
components and high-pressure cylinders. Unit must always be unplugged from power source.

14 UPC5100/UPC5110 Operation & Maintenance Manual