Condec UPC5110 User Manual

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Page 1

UPC5100/UPC5110

Portable & Rack-mountable Pneumatic

Pressure Calibration Console

Operation & Maintenance Manual

CONDEC Sales Phone No. (888) 295-8475

CONDEC Web Site: www.4condec.com

63257

Page 2

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

Speciﬁcations subject to change without notice.

January 2002

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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

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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

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

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• 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

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

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

Figure 1-1. UPC5100/UPC5110 Flow Diagram

Introduction

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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

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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

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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

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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

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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

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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

Page 13

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"

0.000 0.000 0.000 Note 1 below

100 PSI

+/-400"

2700" H

O — Remarks

+/-100

kPa

Remarks

below

Table 3-1. Zero and Span Calibration Sequence

10 UPC5100/UPC5110 Operation & Maintenance Manual

Page 14

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

Page 15

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

Page 16

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

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

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

Page 17

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

Page 18

UPC5100 Installation:

1. Lift the panel and chassis by ﬁrst grasping the ﬁll port ﬁtting 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.

UPC5110 Removal:

1. Verify that power toggle switch is in the OFF position. Loosen and remove the fourteen screws (PN

14862) from top, bottom, and sides that secure the panel assembly to the enclosure.

2. Lift the panel and chassis by grasping the handles located on the front of the rack mountable panel. 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.

UPC5110 Installation:

1. Lift the panel and chassis by grasping the handles located on the front of the rack-mountable panel.

2. Gently place panel/chassis assembly into enclosure. Ensure that the wire harnesses do not catch and snag.

3. Align mounting holes and install fourteen screws (PN 14862) from top, bottom, and sides that secure the panel/chassis assembly to the enclosure.

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

NOTE: Condec strongly recommends that the internal nitrogen supply cylinder be pressure-tested and re-certiﬁed

every ﬁve years from date cylinder was manufactured per U.S. DOT. 3AL Regulation, Title 49 CFR, parts 173 and 178.

Tools required: 7/16" open end wrench

Flat bladed 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)

Removal:

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 and carefully set on a bench top.

3. Using a 7/16" wrench, remove all tubing sections from the cylinder.

4. Loosen the two mounting clamps from around the cylinder.

5. Remove the cylinder assembly.

6. If installing a new cylinder, remove the ﬁtting/tee assembly and Teﬂon seal ring and inspect for any damage. If no damage is present these items may be used in the new cylinder.

Installation:

1. Install the Teﬂon ring seal (PN 59217), ﬁtting (PN 59287), and branch tee (PN 59750) on the new cylinder and tighten until snug. Prior to installation wrap two layers of Teﬂon tape on the pipe threads of branch tee ﬁtting. Also, place a small amount of Krytox grease on both sides of Teﬂon ring seal prior to installation.

2. Mount the cylinder in the chassis making sure that the tee ﬁtting is correctly oriented to accept tubing sections and cylinder nameplate is legible.

3. Tighten the two clamps (PN 55250).

4. Install the tubing sections, tightening all ﬁtting nuts 1/4 turn from ﬁnger-tight using a 7/16" wrench.

5. Fill the cylinder to approximately 1000 PSIG and check all ﬁttings for leaks. If there are no leaks ﬁll nitrogen supply cylinder to maximum pressure. See Section 2.1 on page 4 for cylinder reﬁlling procedure.

6. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

Maintenance and Service 15

Page 19

4.2.3 ORION-2D Manifold Removal (PN 55286)

Tools required: Phillips screwdriver

11/32" wrench or nutdriver .061" hex wrench adjusting screwdriver (small ﬂat blade) 11/32" open end wrench (thin) 7/16" open end wrench

NOTE: See Table 4-6 on page 33 and Figure 4-1 on page 34 for additional parts information.

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14, and place unit on a bench top.

3. Remove the tubing section from the

VENT outlet ﬁtting on the ORION-2D, using a 7/16" wrench

4. Remove the ﬂexible tubing going to the transducer port. Also the ﬂexible tubing coming from the vacuum generator, compressed air port, and the mode select assembly.

NOTE: Marking ﬂexible tubing ends may be helpful for reinstalling ORION-2D.

5. If the transducer is wired via a connector, remove the connector by turning counter-clockwise. If the transducer is hard-wired, loosen and remove the four transducer wires (red, white, green, black) from the terminal block, TB1, on the CPU board, using the small ﬂat-blade screwdriver.

6. Break the wire ties that hold the transducer wires so that the wires are free.

7. Using the 11/32" thin wrench, loosen and carefully remove the transducer from the ORION-2D manifold.

8. Remove the panel knobs from the

COARSE (pressure), VERNIER and VENT valves using the .061" hex

wrench.

NOTE: Earlier manufactured units may have the vacuum generator mounted to the ORION-2D manifold body. If so, remove the mufﬂer, coupling and long nipple assembly from the vacuum generator.

9. While holding ORION-2D, loosen and remove the two panel screws (PN 60837) from the panel front that secure the manifold to the panel. Remove the ORION-2D.

4.2.4 ORION-2D 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 4-6 on page 33 and Figure 4-1 on page 34 for additional parts information.

1. Use a bench vise to secure the manifold by its center portion, with the valve knobs pointing upward.

2. Using the .061" hex wrench, loosen and remove the knob inserts (4) from the pressure and vent valve stems.

3. Loosen the 3/4" locknuts (1) on the

COARSE (pressure) and VENT valve threaded needle housings (10).

4. Using the needle housing socket (65580) and socket wrench, loosen and remove the needle/housing assembly (10, 11).

5. To disassemble the isolation valves (inner valve), ﬁrst remove the valve needle (18) by turning the gear (6) clockwise.

6. Loosen and remove the valve housings (19) using the isolation valve housing removal socket (68509) and socket wrench.

16 UPC5100/UPC5110 Operation & Maintenance Manual

Page 20

7. Remove the valve stem seats (8) and valve needle seats (9) using the needle-nose pliers.

8. Remove the inner and outer O-rings (28, 27) and back-up rings (31, 30) from the valve stem seats and wash all parts in solvent (de-natured alcohol).

9. To remove valve seats (7) from either the

COARSE (pressure), VENT, or ISOLATION valves, try blowing

compressed air through the inlet and outlet ﬁttings. Otherwise, the center holes will have to be drilled and a tap used to extract the seat (Steps 10-13).

10. Using the electric hand drill with a No. 43 bit, carefully drill out the seat hole, ensuring that the drill does not touch the hole in the manifold housing directly beneath the seat.

11. Blow out any chips from the seat area using compressed air.

12. While holding the 4-40 tap steady and perpendicular to the seat, slowly turn until the tap starts to engage the seat.

13. When the tap has engaged into the seat, use a small hammer and gently knock upward against the tap handle to extract the seat.

14. After the seat has been removed, blow any remaining chips from the seat area.

4.2.5 ORION-2D Manifold - Vernier Control Disassembly

Tools required: A/R solvent (de-natured alcohol)

1-1/4" open end wrench screwdriver (ﬂat-blade) socket wrench isolation valve needle housing socket (PN 68509)

NOTE: See Table 4-6 on page 33 and Figure 4-1 on page 34 for additional parts information.

1. With the manifold housing mounted in a vise, turn the vernier shaft (14) clockwise until the piston is bottomed.

2. Loosen and remove the end cap (13) using a 1-1/4" wrench. At certain points during removal the end cap will appear to lock up. If this occurs, rotate the shaft (14) clockwise until the end cap is free to turn.

3. Remove the O-ring (29) from the end cap.

4. Remove the self-sealing screw (36) that acts as the piston key.

5. Extract the piston (15) by partially screwing in the threaded end of the shaft (14) and pulling.

6. Remove the O-ring (32) from the piston groove.

7. To disassemble the end cap/shaft assembly, mount the end cap (13) in the vise.

8. 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). Remove the mylar bearing washers (41 or 42) from both sides of the shaft ﬂange.

10. Use a small pick or screwdriver to remove the O-ring (27) from the inner groove of the end cap (13).

11. Wash all parts in solvent and blow dry with compressed air.

4.2.6 ORION-2D Manifold - Vernier Control Reassembly

Tools required: tube ﬂuorinated Krytox grease (PN 55593)

1-1/4" wrench screwdriver (ﬂat-blade) socket wrench isolation valve needle housing socket (PN 68509)

NOTE:

See Table 4-6 on page 33 and Figure 4-1 on page 34 for additional parts information.

1. Coat all new O-rings with ﬂuorinated Krytox grease before installing.

2. Install the small O-ring (27) into the end cap (13) inner groove.

3. Add mylar washers (41) or (42) to each side of shaft (14).

NOTE: Part number and quantity will var y. Washers are used to adjust vertical play in shaft (14). Try one item (41) on

each side to start.

Maintenance and Service 17

Page 21

4. Apply a small amount of ﬂuorinated Krytox grease to the shaft threads and install the shaft (14) into the end cap.

5. Install the end bushing (12) and tighten until snug using the isolation valve needle housing socket (PN

68509) and socket wrench.

6. Feel vertical motion of shaft (14). If motion exists, remove end bushing (12) and add a thicker washer at Step 3, otherwise continue to Step 7.

7. Install the locknut (20) and tighten until snug using the isolation valve needle housing socket (PN 68509) and socket wrench.

8. Install the O-ring (32) in the piston groove and install the piston (15) into the

VERNIER cavity. Ensure

that the piston keyway is facing the hole into which the self-sealing screw (36) is assembled.

9. Install the self-sealing screw (36) and tighten until snug.

10. Apply a thin coat of ﬂuorinated Krytox grease and install the O-ring (29) on the end cap/shaft assembly, install into manifold and tighten until snug.

4.2.7 ORION-2C Manifold - Valve Seat Installation

Tools required: needle-nose pliers

tube ﬂuorinated Krytox grease (PN 55593) No. 43 drill A/R solvent (de-natured alcohol) hex wrench (.061") torque wrench socket wrench 3/4" socket needle housing socket (PN 65580) isolation valve needle housing socket (PN 68509)

NOTE: See Table 4-6 on page 33 and Figure 4-1 on page 34 for additional parts information.

1. Install a new seat (7) by placing it into the seat well with the needle-nose pliers. Ensure that the seat is centered within the cavity and gently tap it with a blunt end of a drill bit to install.

2. Install the valve needle seat (9) with the smaller diameter end facing outward.

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. For

COARSE (pressure) and VENT valves (two outer valves), disassemble the valve needle (11) from its

housing (10) and check for any burrs or dirt on the threads which might interfere with smooth operation.

6. Clean both the needle (11) and housing (10) in solvent, dry the parts and apply a small amount of ﬂuorinated Krytox grease to the needle threads before reassembly.

7. Assemble the valve needle (11) into the valve needle housing (10) and turn it until it stops.

8. Reinstall the needle/housing assembly into the valve cavity until ﬁnger tight.

9. Mount the manifold body (16) in a vise. For the

COARSE (pressure) and VENT valves only, torque the

needle/housing assembly to 325 in-lb. using the needle housing socket (PN 65580).

10. Install the housing lock nuts (1) onto the housing (10) and tighten until snug with the 3/4" socket.

11. Install the knob insert (4) over the valve needle (11) shaft, align the set screws (23) with the indents and tighten with the .061" hex wrench.

12. For the

ISOLATION valve (inner valve), install the needle housing (19) and tighten until snug using the

isolation valve housing installation socket (PN 68509) and torque wrench.

NOTE: There is no speciﬁed torque, so use care when tightening so as not to break the socket nibs.

13. Install the gear (6) over the isolation valve needle (18) shaft, align the set screws (26) with the indents and tighten with the .061" hex wrench.

14. Apply a small amount of Krytox grease to the threads of the

ISOLATION valve needles (18) and install

into the valve by turning counter-clockwise. Rotate the gear until the needle just stops at the seat.

18 UPC5100/UPC5110 Operation & Maintenance Manual

Page 22

4.2.8 ORION-2D Manifold - Panel Installation

Tools required: 7/16" open end wrench

Phillips screwdriver hex wrench (.061") snoop, liquid leak gas detector (PN 64781)

11/32" open end wrench (thin)

1. If not already done, remove the panel knobs from the COARSE (pressure), VERNIER, and VENT valves using the .061" hex wrench.

2. Install the manifold with the transducer port side facing the panel bottom. Install the two mounting screws (PN 60837) from the panel front and tighten until snug.

NOTE: Some manufactured units may have the vacuum generator mounted to the ORION-2D manifold body . If so, install the mufﬂer, coupling and long nipple assembly into the vacuum generator.

3. Install the VERNIER knob (17) onto the VERNIER valve shaft (14). Align the set screws (25) with the indentations on the vernier valve shaft and tighten until snug using the .061" hex wrench.

4. To install and adjust the

COARSE (pressure) and VENT valve knobs, follow the procedure in

Section 4.2.9.

5. Install the transducer into the manifold port, tighten with the 11/32" thin wrench and reconnect its wire connector.

NOTE: If transducer is hard-wired, connect the four wires to the terminal block TB1 on the CPU board per Table 4-2.

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

6. Install the ﬂexible tubing going to the transducer port. Also the ﬂexible tubing coming from the vacuum generator, compressed air port, and the mode select assembly.

7. Install the tubing section from the

VENT outlet ﬁtting on the ORION-2D, using a 7/16" wrench.

8. Fill the cylinder to approximately 1000 PSIG and check all ﬁttings for leaks. If there are no leaks, ﬁll nitrogen supply cylinder to maximum pressure. See Section 2.1 on page 4 for cylinder reﬁlling procedure.

9. Install panel/chassis assembly in its enclosure as described in Table 4.2.1 on page 14.

4.2.9 ORION-2D Manifold - Valve Adjustment Procedure

Tools required: hex wrench (.050")

hex wrench (.061") snoop, leak gas detector (PN 64781)

NOTE: See Table 4-6 on page 33 and Figure 4-1 on page 34 for parts information. * denotes reference to Figure 2-2 on

page 5.

1. Energize the unit and let it warm up, 10 to 15 minutes minimum. Rotate the SUPPLY SELECT valve to the N2 position, the RANGE SELECT switch to the 100 PSI range, DISPLAY SELECT switch and the

MODE SELECT valve to pressure position.

2. To adjust the

3. If not already done, remove the ORION-2D

COARSE valve, go to next step. To adjust the VENT valve, go to step 18.

COARSE valve knob (3) using the .061" hex wrench

4. Using a .050" hex wrench, loosen the set screw (34) on the locknut (2) and turn the locknut clockwise to its stop.

5. Check to see that the knob insert (4) is securely fastened to the valve shaft (11). If it is loose, tighten the

Maintenance and Service 19

Page 23

set screws (23) with the .061" hex wrench.

6. Close the

COARSE valve by turning the knob insert (4) clockwise until you feel the valve needle seat on

the O-ring (valve is now in the closed position).

7. Rotate gear (6) on the

ISOLATION valve (inner valve), counter-clockwise until stopped, then rotate

clockwise 1/2 turn (opening isolation valves).

8. Use the

PRESSURE LIMIT CONTROL (*1), to increase the supply pressure to between 80% and 100% of

full scale.

9. Open the

VENT valve (*8) to atmosphere, zero the indicator (press ZERO switch [*12] less than 5

seconds), then close the VENT valve (*8).

10. Slowly open the

COARSE valve by turning the knob insert (4) counter-clockwise until you notice the

displayed pressure increase. Then turn the knob insert slightly clockwise until the pressure stops rising.

11. Mark a radial line at the 12 o'clock position on the knob insert.

12. Turn the knob insert (4) clockwise to move the mark to the 6 o'clock position.

13. Turn the locknut (2) counter-clockwise until it contacts the bottom of the stop washer. Tighten the set screw (34) on the locknut with the .050" hex wrench.

14. Re-check the unit to see if displayed pressure stops when the radial line is at the 12 o'clock position.

15. Install the

COARSE valve knob (3) on the knob insert (4) and engage its gear (5) with the smaller

isolation valve gear (6). Turn the knob clockwise until the isolation valve is slightly snug.

Caution

Do not use excessive torque when adjusting valve. The seat can be damaged.

16. Remove the COARSE valve knob. Align the set screws (25) with the indentations on the knob insert Install the knob on the insert while engaging the knob gear (5) with the isolation valve gear (6).

17. Tighten the set screws (25) with the .061" hex wrench. The

18. To adjust the

VENT valve, remove the ORION-2D VENT valve knob (3) using the .061" hex wrench

COARSE valve is now adjusted.

19. use a .050" hex wrench, to loosen the set screw (34) on the locknut (2) and turn the locknut clockwise to its stop.

20. Check to see that the knob insert (4) is securely fastened to the valve shaft (11). If it is loose, tighten the set screws (23) with the .061" hex wrench.

21. Close the

22. Open the

COARSE valve by turning the COARSE knob (*2) clockwise.

VENT valve (*8) to atmosphere, zero the indicator (press ZERO switch [*12] less than 5

seconds), then close the VENT valve knob insert (4) clockwise until slightly snug.

23. Use the

PRESSURE LIMIT CONTROL (*1), to increase the supply pressure to between 80% and 100% of

full scale.

24. Open the

25. Slowly turn the

COARSE valve until the indicated pressure stabilizes and then close the COARSE valve.

VENT valve knob insert (4) counter-clockwise until the display starts to decrease, then

turn the knob insert (4) slightly until the indicated pressure stops decreasing.

26. Mark a radial line at the 12 o'clock position on the knob insert.

27. Turn the knob insert (4) clockwise to move the mark to the 6 o'clock position.

28. Turn the locknut (2) counter-clockwise until it contacts the bottom of the stop washer. Tighten the set screw (34) on the locknut with the .050" hex wrench.

29. Re-check the unit to see if displayed pressure stops when the radial line is at the 12 o'clock position.

30. Align the set screws (25) with the indentations on the knob insert Install the

VENT valve knob (3) on the

knob insert (4).

Caution

Do not use excessive torque when adjusting valve. The seat can be damaged.

31. Tighten the set screws (25) with the .061" hex wrench. The VENT valve is now adjusted.

20 UPC5100/UPC5110 Operation & Maintenance Manual

Page 24

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

Tools required: channel locks

adjustable wrench ﬂat blade screwdriver (small) 7/16" open end wrench 9/16 " open end wrench hex wrench (1/4") A/R 1/4" wide Teﬂon tape, (PN 60575)

A/R 1/2" wide Teﬂon tape, (PN 60911)

snoop, liquid leak gas detector (PN 64781) 1/2" socket socket wrench plug ﬁtting (PN 69199)

Removal:

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14, and carefully place on a bench top.

3. Note the orientation and remove the tubing sections that connect to the regulator inlet and outlet ﬁttings.

4. Loosen and remove the locknut using channel locks while holding the assembly from bottom of chassis.

5. Remove the regulator by sliding out from the panel rear.

6. Remove rupture disk identiﬁcation label and mount the regulator in a bench vise by the ﬂats in the base.

7. Note the orientation of the inlet and outlet ﬁttings in the regulator. Remove the ﬁttings and any remnants of Teﬂon tape from the pipe threads.

Installation:

NOTE: After installation regulator must be adjusted for an output pressure of 150-155 PSI.

1. If applicable, remove top cap, loosen locknut on shaft with 1/2" socket. Remove shaft locknut, and knob. Discard top cap and knob. Replace shaft locknut ﬁnger tight.

2. Wrap two layers of Teﬂon tape on the pipe threads of each ﬁtting and install into the inlet and outlet of the regulator and ensure that each is oriented properly (same as old regulator assembly). Use a bench vise when doing this.

3. Replace rupture disk identiﬁcation label on bottom of regulator and use wire to hold in place.

4. Remove large locknut from body and insert the new regulator into the chassis through bottom of mounting hole.

5. Orient assembly such that Burst Disk is perpendicular to ﬁll port side of panel. Verify MODE SELECT assembly does not interfere.

6. Tighten the locknut using channel locks while holding the assembly from bottom of chassis.

7. Install the tubing sections to the inlet and outlet ﬁttings.

8. Fill the cylinder to approximately 1000 PSIG and check all ﬁttings for leaks. If there are no leaks, vent unit and continue to adjustment procedure.

Adjustment:

NOTE: Customer must supply: Standard which has, test port and display capable of reading the test port pressure. A

regulated N working pressure of 275 PSI. Fittings to go from the nylon tubing to the test port on the customer’s standard.

pressure source of 250 PSI with an on-off valve. 5/32" O.D. Nylon tube with a .025 wall rated at a minimum

1. Verify COARSE valve and PRESSURE LIMIT MONITOR are closed. To close PRESSURE LIMIT MONITOR pull regulator knob outward and turn counter-clockwise. When closed, push knob inward. VENT valve should be left open.

2. Rotate SUPPLY SELECT to N

position.

3. Turn customer supplied N2 source valve to the off position, vent pressure line, then install line to ﬁll port of UPC5100/UPC5110.

Maintenance and Service 21

Page 25

4. Remove end of nylon tubing that goes to the SUPPLY SELECT assembly, other end stays connected to vacuum control assembly. Install customer supplied nylon tube, with ﬁtting on other end, into SUPPLY SELECT assembly. Install ﬁtting end into test port of customer supplied Standard

5. Remove section of copper tubing that goes from

Chassis Mounted Regulator to cylinder tee ﬁtting. Tighten

plug ﬁtting (PN 69199) where copper tubing section was on regulator.

6. Input customer supplied N

source to regulated pressure of 250 PSI.

7. Turn Chassis Mounted Regulator shaft locknut counter-clockwise, to approximately 1/4" from top of shaft.

8. Use ﬂat head screwdriv er to rotate shaft, clockwise to increase, until Standard display reads 150-155 PSI.

9. Tighten shaft locknut, while holding screwdriver in position.

10. Shut off customer supplied N

source, and vent Standard.

11. Remove customer supplied nylon tube, with ﬁtting on other end, from SUPPLY SELECT assembly and test port of customer supplied Standard.

12. Replace end of nylon tubing that goes to the SUPPLY SELECT assembly, other end is connected to vacuum control assembly

13. Remove plug ﬁtting on regulator. Install section of copper tubing that goes from regulator assembly to cylinder tee ﬁtting.

14. Fill the cylinder to approximately 1000 PSIG and check all ﬁttings for leaks. If there are no leaks, ﬁll nitrogen supply cylinder to maximum pressure. See Section 2.1 on page 4 for cylinder reﬁlling procedure.

15. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

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

Tools required: 7/16" open end wrench

hex wrench (.186") channel locks A/R 1/4" wide Teﬂon tape, (PN's 60575)

snoop, liquid leak gas detector (PN 64781)

Removal:

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14, and carefully place on a bench top.

3. Note the orientation and remove the tubing sections that connect to the regulator inlet and outlet ﬁttings.

4. Loosen and remove regulator mounting nut from the front of panel, by using channel locks.

5. Note the orientation, then remove the regulator by sliding out from the panel rear.

6. Note the orientation of the inlet and outlet ﬁttings in the regulator. Remove the ﬁttings and any remnants of Teﬂon tape from the pipe threads.

Installation:

1. Wrap two layers of Teﬂon tape on the pipe threads of each ﬁtting and install into the inlet and outlet of the regulator and ensure that each is oriented properly.

2. Insert the new regulator into the panel through rear of panel and rotate to proper position. Thread and tighten the mounting nut onto the regulator body from the panel front.

3. Install the tubing sections to the inlet and outlet ﬁttings.

4. Close PRESSURE LIMIT MONITOR by pulling regulator knob outward and turning counter -clockwise. When closed, push knob inward.

5. Fill the cylinder to approximately 1000 PSIG and check all ﬁttings for leaks. If there are no leaks, ﬁll nitrogen supply cylinder to maximum pressure. See Section 2.1 on page 4 for cylinder reﬁlling procedure.

6. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

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

Tools required: 7/16" wrench

9/16 " wrench A/R 1/4" wide Teﬂon tape (PN 60575) snoop, liquid leak gas detector (PN 64781)

Removal:

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14, and carefully place on a bench top.

3. Disconnect the tubing section that connects to the gauge ﬁtting.

4. Loosen the two thumb-nuts that hold the gauge mounting U-clamp.

5. While gripping the square portion of the gauge port with the 9/16" wrench, remove the female tube connector from the gauge, PN 59721, for Supply Pressure or PN 57684 for Pressure Limit Monitor.

6. Remove the two thumb-nuts, the mounting U-clamp, and the gauge.

Installation:

1. Before installing a new gauge, wrap two layers of new Teﬂon tape on the port.

2. Install gauge into panel, secure with U-clamp and tighten the two thumb screws.

3. While gripping the square portion of the gauge port with the 9/16" wrench, tighten the female tube connector on to the gauge.

4. Attach the tubing section that connects to the gauge ﬁtting.

6. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

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

If there is leakage out of the port, replace the test port quick-connect ﬁtting.

Tools required: 5/8" two open end wrenches

7/16" open end wrench A/R 1/4" wide Teﬂon tape (PN 60575) A/R 1/2" wide Teﬂon tape (PN 60911) snoop, liquid leak gas detector (PN 64781)

Removal:

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14, and carefully set on a bench top.

3. From rear of panel, remove the quick-connect tubing end nut and ferrules (note orientation) from test port quick-connect ﬁttng. Remove ﬁlter and place aside.

NOTE: Do not remove ﬁttings attached to tubing.

4. Grasp the hex nut at the panel face with a 5/8" wrench and using a second wrench on the lock nut on rear side of panel, turn the lock nut counter-clockwise. Slide quick-connect ﬁtting out of panel from front.

Installation:

1. Remove the tubing end nut and ferrules (note orientation) from test port quick-connect ﬁtting. Install the quick-connect ﬁtting thru front of panel. Thread and tighten lock nut, from rear of panel, on quick-connect ﬁttng.

2. Slide ﬁlter into fractional tube adapter ﬁtting (PN 56223), attached to nylon tubing. Slide tubing end nut and ferrules, in proper order, over fractional tube adapter ﬁtting.

3. Slide fractional tube adapter ﬁtting into quick-connect ﬁtting from rear of panel. Thread and tighten tubing end nut, on quick-connect ﬁttng.

Maintenance and Service 23

Page 27

4. Fill the cylinder to approximately 1000 PSIG and check all ﬁttings for leaks. If there are no leaks ﬁll nitrogen supply cylinder to maximum pressure. See Section 2.1 on page 4 for cylinder reﬁlling procedure.

5. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

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

The port ﬁlter is a sintered element ﬁlter that can be easily removed for inspection and cleaning.

Tools required: Phillips screwdriver

7/16" open end wrench 9/16" open end wrench A/R solvent (de-natured alcohol) snoop, of liquid leak gas detector (PN 64781)

Removal and Cleaning:

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14, and carefully place on a bench top.

3. From rear of panel, remove the quick-connect tubing end nut and ferrules (note orientation) from test port quick-connect ﬁttng. Remove ﬁlter.

NOTE: Do not remove ﬁttings attached to tubing.

4. Clean the ﬁlter (PN 54188) in solvent (de-natured alcohol) and blow-dry with compressed air.

Installation:

1. Slide ﬁlter into fractional tube adapter ﬁtting (PN 56223), attached to nylon tubing. Slide tubing end nut and ferrules in proper order over fractional tube adapter ﬁtting.

2. Slide fractional tube adapter ﬁtting into test port quick-connect ﬁtting

(PN 59762), from rear of panel.

thread and tighten tubing end nut, on quick-connect ﬁttng.

3. Fill the cylinder to approximately 1000 PSIG and check all ﬁttings for leaks. If there are no leaks ﬁll nitrogen supply cylinder to maximum pressure. See Section 2.1 on page 4 for cylinder reﬁlling procedure.

4. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

4.2.15 Vacuum Generator - Removal, Cleaning and Installation

The vacuum generator is a Venturi device which creates a vacuum ﬂow by use of a regulated air ﬂow. The generator can be removed for cleaning should any contamination be found. There are two styles that may be used, one of which has a plastic body and is mounted to the panel and connected by nylon tubing to the ORION-2D manifold. The other has an aluminum body and comprises an assembly including a mufﬂer and a long nipple that is mounted directly to the ORION-2D manifold.

Tools required: 3/16" nutdriver

Phillips screwdriver 7/16" open end wrench 9/16" open end wrench A/R 1/4" wide Teﬂon tape (PN 60575) A/R 1/2" wide Teﬂon tape (PN 60911) A/R solvent (de-natured alcohol) snoop, liquid leak gas detector (PN 64781)

Removal and Cleaning - Plastic Body (PN 57026)

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14, and carefully place on a bench top.

3. Remove nylon tubing from the compressed air port (top/input) and the vacuum port (front/output) of the vacuum generator.

4. Using nutdriver remove nylon spacers, (PN 60472), and remove vacuum generator.

24 UPC5100/UPC5110 Operation & Maintenance Manual

Page 28

NOTE: Some vacuum generators are mounted with screws and nuts or adhesive.

5. Clean the vacuum generator by using compressed air.

Warning

Removal and Cleaning - Aluminum Body (PN 54965)

Do not use solvent for cleaning.

1. Remove ORION-2D manifold from front panel as described in Section 4.2.3 on page 16, and carefully place on a bench top.

NOTE: Remove the mufﬂer and long nipple from the vacuum generator’s exhaust port prior to removing the two manifold mounting screws.

2. Mount the ORION-2D manifold in a vise. Rotate the vacuum generator counter-clockwise 900 on the elbow ﬁtting that connects it to the ORION-2D manifold body

3. Unscrew the generator from the 90

elbow ﬁtting using 7/16" wrench. Remove any remnants of Teﬂon

tape from the threads.

4. Clean vacuum generator in solvent. Blow dry all passages with compressed air.

Installation - Plastic Body (PN 57026)

There are numerous ﬁttings that come with unit. For this application install the following per manufacturer’s data sheet and discard the rest. Using the 9/16" wrench install the compressed air port (top/input), male 5/32" tube adapter ﬁtting, and the vacuum port (front/output), 5/32" tube female ﬁtting.

1. Install vacuum generator on the two studs with the compressed air port (top/input) pointing upward. Using nutdriver, install and tighten nylon spacers (PN 60472).

NOTE: Some vacuum generators are mounted with screws and nuts or adhesive tape.

2. Replace nylon tubing in the compressed air port (top/input) and the vacuum port (front/output) of vacuum generator.

4. Install panel/chassis assembly in its enclosure as described in Table 4.2.1 on page 14.

Installation - Aluminum Body (PN 54965)

1. Wrap two layers of Teﬂon tape on vacuum generators inlet ﬁtting threads and install into the 900 elbow located in the ORION-2D manifold body. Turn until the inlet ﬁtting is snug and the vacuum generators largest side is parrallel to the manifold’s side.

2. Turn the 90

elbow ﬁtting 1/4 turn clockwise so that the vacuum generator’s exhaust port points to the

VENT valve.

3. Install the ORION-2D manifold onto front panel as described in Section 4.2.8 on page 19.

NOTE: Install the mufﬂer and long nipple into the vacuum generator’s exhaust port prior to installing the two manifold mounting screws.

4. Fill the cylinder to approximately 1000 PSIG and check all ﬁttings for leaks. If there are no leaks, ﬁll nitrogen supply cylinder to maximum pressure. See Section 2.1 on page 4 for cylinder reﬁlling procedure.

5. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14

Maintenance and Service 25

Page 29

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

The vacuum control regulator is located furthest from front panel on the chassis. Some v acuum control regulators have a locking screw in place of pulling knob outward.

Tools required: 7/16" open end wrench

hex wrench (.186") adjustable wrench

channel locks

Phillips screwdriver

snoop, liquid leak gas detector (PN 64781) Removal:

A/R 1/4" wide Teﬂon tape, (PN's 60575)

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14 and place on a bench top.

3. Note the orientation and remove the tubing sections that connect to the regulator inlet and outlet ﬁttings.

4. Loosen and remove regulator mounting nut from the top of chassis, by using channel locks.

5. Note the orientation, then remove the regulator by sliding out from the bottom of chassis.

6. Note the orientation of the inlet and outlet ﬁttings in the regulator. Remove the ﬁttings and any remnants of Teﬂon tape from the pipe threads.

Installation:

1. Wrap two layers of Teﬂon tape on the pipe threads of each ﬁtting and install into the inlet and outlet of the regulator and ensure that each is oriented properly.

2. Insert the new regulator into the chassis from bottom and rotate to proper position. Thread and tighten the mounting nut onto the regulator body from the panel front.

3. Install the tubing sections to the inlet and outlet ﬁttings.

5. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14

Vacuum Level Adjustment:

Field adjustment may be required at times if there is a large difference in barometric pressure at site.

1. Verify cylinder is ﬁlled to a minimum of 500 PSIG. See Section 2.1 on page 4 for cylinder reﬁlling procedure.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14, and carefully place on a bench top.

3. Verify COARSE valve and PRESSURE LIMIT MONITOR are closed. To close PRESSURE LIMIT MONITOR pull regulator knob outward and turn counter-clockwise. When closed, push knob inward. VENT valve should be left open.

4. Turn the MODE SELECT knob on the front panel to VACUUM position.

5. Turn RANGE SELECT switch to +/- 28 in. Hg.

6. Energize UPC5100/UPC5110 and allow warmup time.

7. Push the ZERO button (less than 5 seconds), then close the VENT valve.

8. Open the COARSE valve completely.

9. Pull VACUUM CONTROL regulator knob outward and turn clockwise to increase vacuum to a minimum display reading of 27.5. Display will be unstable and a popping sound may be heard. turn knob approximately 1/4 turn further clockwise to stabilize reading. When completed push knob inward to lock.

10. Fill the cylinder to approximately 1000 PSIG and check all ﬁttings for leaks. If there are no leaks, ﬁll nitrogen supply cylinder to maximum pressure. See Section 2.1 on page 4 for cylinder reﬁlling procedure.

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Page 30

11. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14

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

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 hex wrench (5/32") tube ﬂuorinated Krytox grease (PN 55593) A/R solvent (de-natured alcohol) snoop, liquid leak gas detector (PN 64781) torque wrench

NOTE: See Figure 4-4 on page 35.

Removal:

1. Vent any remaining nitrogen from cylinder to atmosphere. Disconnect power cord from power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 14 and place on a bench top.

3. Loosen and remove the tubing end nuts from the ﬁll port tube connector ﬁtting (PN 59760) and chassis mounted regulator tee ﬁtting (PN 59727).

4. Remove the ﬁll port tube connector ﬁtting (PN 59760) from the check valve.

5. Remove the check valve from the ﬁll port ﬁtting. Remove any remnants of Teﬂon tape from the pipe threads. Note direction of ﬂow arrow.

Disassembly:

1. Remove lock screw from the inlet end (tail of ﬂow arrow) using a 5/32" hex wrench.

2. Remove the insert, O-ring, poppet, and spring and clean in solvent. If any damage to O-ring is noticed, replace O-ring (PN 66654). Blow-dry parts before reassembly.

3. Apply a small amount of ﬂuorinated Krytox grease on both sides of O-ring (PN 66654)

4. Reassemble the check valve per as shown in Figure 4-4 on page 35.

5. Torque insert lock screw to 85 in. lbs.

Installation:

1. Wrap two turns of Teﬂon tape on the check valve threads.

2. Install the inlet end (end opposite direction ﬂow arrow is pointing) of check valve into the ﬁll port ﬁtting and tighten until snug.

3. Install the other end of the check valve into the ﬁll port tube connector ﬁtting.

4. Install and tighten the tubing end nuts to the ﬁll port tube connector ﬁtting (PN 59760) and chassis mounted regulator tee ﬁtting (PN 59727).

6. Install panel/chassis assembly in its enclosure as described in Table 4.2.1 on page 14.

4.2.18 AC Fuse (PN 58076) - Removal and Installation

1. Disconnect the power cord from the power source and line ﬁlter. Remove the fuse holder at AC INPUT.

2. Inspect fuse. If blown, replace with 1/4 Amp 250 Volt, 20mm x 5mm diameter (PN 58076).

3. Replace the fuse holder at

AC INPUT.

Maintenance and Service 27

Page 31

4.2.19 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.

NOTE: Some units may not have connectors and will have to have wire leads unsoldered.

3. Loosen and remove the line ﬁlter retaining nuts on the rear of panel.

NOTE: Some units may have screws on the front panel.

4. Remove the AC line ﬁlter through the panel front.

5. To install a new line ﬁlter, reverse the order of steps 1 through 4. Connect (or solder) wires to the new line ﬁlter as follows:

•Green wire to terminal (E) Ground

•White wire to terminal (N) Neutral

•Black wire to terminal (P) Line

4.2.20 Power Switch (PN 55187) for Battery Units - 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

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 and remove the nut on the panel front and remove the switch from the panel rear.

3. Remove cable clamp and unplug the switch wire harness connector from location J7 on the CPU board.

4. Unsolder and remove the nine wires from the switch terminals.

Installation:

1. Use shrink sleeving over wires/terminals for protection. Connect and solder the harness wires to the new switch terminals per the following:

Rear of Switch: 1 4 7 BATTERY TEST (Momentary)

2 5 8 OFF 3 6 9 OPERATE Green/white wire to switch terminal 1 Blue/White wire to switch terminal 2 Orange wire to switch terminal 3 Yellow wire to switch terminal 4 Yellow jumper wire between switch terminals 4 & 6 Brown wire to switch terminal 5 Violet wire to switch terminal 8 Black wire to switch terminal 9

2. Install the new switch through the rear of panel. Rotate switch so that the momentary position is toward

BA TTERY TEST and secure it from the front of panel with the mounting nut (discard orientation washer).

3. Plug in the harness connector to its receptacle J7 on the CPU board and install cable clamp.

4. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

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

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 Section 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. Loosen and remove the trim ring from the panel front.

4. Remove switch, lock washer and nut from rear of panel as one item.

5. Unsolder and remove the wires from the switch terminals.

Installation:

1. Slide shrink sleeving over wires, connect and solder the wires onto their respective switch terminals.

Color Terminal Black Normally open

Black (C) common

Table 4-3. Power Wire Colors/Switch Terminals

2. Pull shrink sleeving over switch and connections. Apply heat. Install the new switch, lock washer and nut through the panel rear as one item. Hand tighten the trim ring from front of panel.

3. Tighten the switch mounting nut and lock washer from the rear of panel.

Caution

If wrench is used, do not over-tighten or damage may occur to switch.

4. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

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

Tools required: Phillips screwdriver

9/16" open end wrench or nutdriver A/R soldering iron hex wrench (.061")

NOTE: See Figure 4-2 on page 35 and Figure 4-3 on page 35.

Removal:

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. Remove the switch knob using a .061" hex wrench.

3. Loosen and remove the mounting nut from the panel front.

4. Unsolder and remove the wires from the switch terminals.

Maintenance and Service 29

Page 33

Installation:

1. Connect and solder the wires onto their respective switch terminals (Table 4-4).

Range Select: Display Select:

Pole - T erminal Color Pole - Terminal Color

1 - 3 Yellow 2 - 2 Red

1 - 6 (common) Red 2 - 3 Blue

2 - 3 Orange 2 - 6 (common) Green 3 - 4 Brown

Table 4-4. Range Select and Display Select Wire Colors/Switch Terminals

2. Install the switch through the panel rear, align with front panel markings, and secure with mounting nut.

3. Install the switch knob using a .061" hex wrench.

4. Replace CPU if necessary.

5. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

4.2.23 Zero Switch (PN 58886) - Removal and Installation

Tools required: Phillips screwdriver

11/16" open end wrench A/R soldering iron

Removal:

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. Loosen the switch mounting nut and lock washer from the rear of panel.

3. Loosen and remove the trim ring from the panel front.

4. Remove switch, lock washer and nut from rear of panel.

5. Unsolder and remove the wires from the switch terminals.

Installation:

1. Connect and solder the wires onto their respecti ve switch terminals per T able 4-5 below:

Color Terminal

Yellow Normally open

Green (C) common

Table 4-5. 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.

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.

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

120 VAC input (PN 58727); 220 VAC input (PN 58733).

Tools required: Phillips screwdriver

Flat blade screwdriver (small) 11/32" open end wrench or nutdriver

Removal:

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. Disconnect the three wire connectors (black, white, green) that are between the AC ﬁlter cable (PN

55540) and the cable attached to the power supply board assembly.

3. Unplug the multi-pin connector of the CPU (J6) to power supply (J1) cable (PN 55023) from the power supply board.

4. Remove the two battery cable wires (PN 56367) from the terminal block (TB1) on the power supply board.

5. Loosen and remove the four nuts that hold the power supply board and remove the board.

Installation:

1. Position the new board over the four standoffs and install four nuts. Tighten the nuts until snug.

2. Install the two battery cable wire ends into the terminal block (TB1) on the power supply board, red wire (+) to TB1-3 and black wire (-) to TB1-1.

3. Plug the CPU (J6) to power supply cable (PN 55023) connector into the power supply board (J1).

4. Connect the three connectors (black, white, green) of the AC ﬁlter cable (PN 55540) and the cable from power supply board assembly. Connect like wire colors together.

5. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

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

Tools required: Phillips screwdriver

Flat blade screwdriver (small) 11/32" open end wrench or nutdriver DC voltmeter

11.5 VDC Power Source

Removal:

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. Disconnect the two battery cable wires (PN 56367) from the battery terminals, red wire from (+) and black wire from (-).

3. Remove the two nuts and two screws that secure the battery bracket (PN 58386).

4. Remove the bracket and battery.

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 - Charging Circuit:

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. Disconnect the two battery cable wires (PN 56367) from the battery terminals, red wire from (+) and black wire from (-).

3. Connect the leads of a DC voltmeter to the battery wires.

4. With the unit's power cord connected to a power source, but the power switch on the front panel adjust the potentiometer R3 on the power supply board until the voltmeter reads 14.0 volts.

OFF,

Maintenance and Service 31

Page 35

5. Unplug the power cord from the power source.

6. Disconnect the voltmeter and reconnect the battery leads to the battery terminals; red wire to (+) and black wire to (-).

7. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

Adjustment - Battery Voltage Display Reading

NOTE: The BATTERY TEST should only be performed with the UPC5100/UPC5110 operating at Zero pressure (VENT

valve open) and at the conclusion of the test, the unit's ZERO button will have to be re-pushed to re-zero the instrument.

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. Disconnect the two battery cable wires (PN 56367) from the battery terminals, red wire from (+) and black wire from (-).

3. Connect the leads of a DC voltmeter to the battery wires.

4. Take a reading from the voltmeter.

5. Reconnect the two battery cable wires (PN 56367) to the battery terminals; red wire to (+) and black wire to (-).

6. Push the

BATTERY TEST switch on the front panel. If the reading is the same as the voltmeter, go to step

8. If the reading is different, go to next step.

7. While holding toggle switch in the BATTERY TEST mode, adjust potentiometer R12 located on power supply board to be the same as previous voltmeter reading.

8. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.

Adjustment - Low Battery Display Annunciation

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. Disconnect the two battery cable wires (PN 56367) from the battery terminals; red wire from (+) and black wire from (-).

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.

32 UPC5100/UPC5110 Operation & Maintenance Manual

Page 36

4.3 Orion-2D Valve Assembly Component Parts List

Ref #r PN Description Quantity

1 57482 Nut, Valve Needle Housing 9/16-18 2 2 54401 Locknut 2 3 58079 Knob 2 4 57889 Knob, Insert 2 5 57256 Gear, Spur 40 Teeth 2 6 59233 Gear, Spur 18-tooth 2 7 55896 Valve Seat 4 8 59387 Valve Seat, Stem 4

9 59045 Valve, Needle Seat 4 10 54540 Housing, Valve Needle 2 11 59551 Valve Needle 2 12 57906 Bushing, End 1 13 59378 Cap, End 1 14 59495 Shaft 1 15 59241 Piston 1 16 56874 Body, Dual Valve 1 17 57580 Knob 1 18 55533 Valve Needle 2 19 55159 Housing, Valve Needle 2 20 56784 Locknut, 9/16-18UNF-3A, SST 1 21 59845 Plug, Expansion 14 23 59383 Setscrew, 6-32NCx1/8 SST 4 24 58342 Screw,Cap Hex Socket Head, #2-56UNC-3A 6 25 59322 Setscrew, 6-32NCx1/4 SST 6 26 59326 Setscrew, 2-56NC x 1/8, alloy steel 4 27 55554 O-ring, Buna N (Nitrile) 70 Durometer Color Black 5 28 55536 O-ring, Buna N (Nitrile) 70 Durometer Color Black 4 29 55573 O-ring, Buna N (Nitrile) 70 Durometer Color Black 1 30 60633 Retainer, Packing Backup 4 31 55570 Washer, Backing 4 32 55577 O-ring, Buna N (Nitrile) 70 Durometer Color Black 1 33 59245 Washer, #8 Screw Size 2 34 60202 Setscrew, hex 2 35 60837 Screw, MACH Pan Head #10- 32NFx1/2 Phillips Head 300 Series SST 2 36 58976 Screw, Self Sealing 1 38 53308 Label 1 39 59738 Fitting, Male Connector 1/8 tube x 1/8 NPT brass 1 40 41944 Connector, Male Swivel Elbow 1/8 NPT x 5/32 tube O.D. 2 41 59878 Spacer .005 thk 2 42 59880 Spacer .007 thk 2 43 57699 Fitting, Tube Male Connector 5/32 tube O.D. x 1/8 NPT 2

Table 4-6. Orion 2D Valve Assembly Parts List

Maintenance and Service 33

Page 37

21/6X

NOTES:

LIGHTLY COAT THE FOLLOWING WITH LUBRICANT (PN 55593):

O-RINGS, ITEMS 27, 28, 29 & 32. THREADS ON VALVE NEEDLES, ITEMS 11 & 18.

43/2X40/2X

35/2X

26/2X

23/2X

THESE COMPONENTS TO BE INSTALLED AT LOCATIONS A & C

25/2X

24/3X

25/2X

ITEMS 41 & 42 QUANTITY AND USAGE TO BE SELECTED

DEPENDENT ON FIT, SEE VERNIER CONTROL REASSEMBLY IN MANUAL.

FOR REFERENCE ONLY:

THESE COMPONENTS TO BE INSTALLED AT LOCATION

“C” ONLY.

O-RING, ITEM 27, .239 ID O-RING, ITEM 28, .042 ID O-RING, ITEM 29, .799 ID O-RING, ITEM 32, .424 ID

UPC5100/UPC5110 Operation & Maintenance Manual

THESE COMPONENTS TO BE INSTALLED AT LOCATION B

Figure 4-1. ORION-2D, Exploded View

Page 38

Figure 4-2. Range Select Switch Wiring

Figure 4-3. Display Select Switch Wiring

Figure 4-4. N2 Inlet Check Valve Assembly (PN 60263)

Page 39

5.0 Model Number System

UPC 5100 - ____ ____ UPC 5110 - ____ ____ ≠ ≠

+------------------------------------- + ≠ ≠ POWER REQUIREMENTS ≠ ≠

A - AC Only (120 VAC)*** ≠ B - Battery Operation & 120 VAC ≠ C - AC Only (220 VAC)*** ≠ D - Battery Operation & 220 VAC ≠ ≠ +-------------------------------------------- --+

≠ DISPLAY

≠

A – Light Emitting Diode (LED) B – liquid Crystal (LCD)

≠

*** UPC5100, Available as a Special

36 UPC5100/UPC5110 Operation & Maintenance Manual

Page 40

6.0 Available Ranges, Conversions and Resolutions

NOTE: Non-standard ranges are available by special order.

Calibrator Conversion Factors:

• kPa = PSI x 6.89476

•Bar = PSI x 0.0689476

• mBar = PSI x 68.9476

•Torr = PSI x 51.7149

• mm Hg = PSI x 51.7149

NOTE: Display resolution 0.02% of selected range, unless it is not devisable by 1, 2, or 5.

RANGES RESOLUTION

• in Hg (0˚F) = PSI x 2.036

•Kg/cm

• in H

•cm H

= PSI x 0.070308

O (60˚F) = PSI x 27.71

O = PSI x 70.308

+-28.000 in Hg / +-387.00 in H

+-760.0 Torr / +-1.0000 Bar / 7.0000 Bar / +-96.00 kPa / 100.00 PSI 0.1 / 0.0002 / 0.001 / 0.02 / 0.02

+-28.000 in Hg / +-387.00 in H

+-724.0 mm Hg / +-960.0 cm H

+-28.000 in Hg / +-387.00 in H

O / 2771.0 in H2O / +-96.00 kPa / 100.00 PSI

(Standard)

O / 2771.0 in H2O / +-724.0 mm Hg / 100.00 PSI 0.005 / 0.05 / 0.5 / 0.1 / 0.02

O / 1034.0 mBar / +-100.00 in H2O / 15.000 PSI 0.005 / 0.05 / 0.2 / 0.05 / 0.002

O / 7031 cm H2O / +-96.00 kPa / 689.0 kPa 0.1 / 0.2 / 1 / 0.02 / 0.1

O / 775.0 mm Hg / +-96.00 kPa / 15.000 PSI 0.005 / 0.05 / 0.1 / 0.02 / 0.002

O / 5542 in H2O / +-724.0 mm Hg / 200.00 PSI 0.005 / 0.05 / 1 / 0.1 / 0.02

O / 2771.0 in H2O / +-14.000 PSI / 100.00 PSI 0.005 / 0.05 / 0.5 / 0.002 / 0.02

O / 5542 in H2O / +-14.000 PSI / 200.00 PSI 0.005 / 0.05 / 1 / 0.002 / 0.02

0.005 / 0.05 / 0.5 / 0.02 / 0.02

Table 6-1. Display Resolutions

Available Ranges, Conversions and Resolutions 37

Page 41

7.0 Options - Replacement Kits

There are numerous replacement PN’s mentioned through out manual that can be ordered.

ORION-2D O-Ring Replacement Kit (Data Sheet # 65308):

• Nitrile Buna-N (standard) - PN 58499

• Ethylene-Propylene - PN 58506

• Silicone - PN 58509

Note: A small coating of Fluorinated Krytox grease, (PN 55593), should be applied to both sides of O-ring prior to installation.

Pressure Trap (Data Sheet # 58621) - PN 58487

Note: For UPC5100/UPC5110 model’s prior to serial number A1300, approximate date prior to 7-9-1990 use Pressure Trap, PN 58492, Data Sheet # 58627.

Battery Replacement Kit - PN 55354

Test Port (output) Attachment Swivel Fitting - PN 55291

Test Port (output) Quick-Disconnect Male Hose ﬁtting - PN 60195 Fill Port (input) Quick-Disconnect Female Hose ﬁtting - PN 57716 Test Port (output) Hose, with Quick-Disconnect Male ﬁtting:

• 5' Long - PN 55281

• 10' Long - PN 55328

Fill Port (intput) Hose, with Quick-Disconnect Female ﬁtting:

• 5' Long - PN 55282

• 10' Long - PN 55313

• Neoprene - PN 58515

• Fluorocarbon “Viton” - PN 55277

• 15' Long - PN 55336

• 20' Long - PN 55341

• 15' Long - PN 55319

• 20' Long - PN 55322

38 UPC5100/UPC5110 Operation & Maintenance Manual

Page 42

8.0 Speciﬁcations

Pressure Speciﬁcations:

Pressure ranges: +- 0-28 in Hg

+- 0-387.00 in H2O

+ 0-

Available Pressure Calibrations: Gage and Vacuum

Overall Accuracy: < ±0.05% Full Scale Max. Accuracy

Operating Temperature: +40° to +122°F (+4.4° to +50.0° C) Storage Temperature: 0° to +185° F (–17.8° to +85°C) Pressure Media: Dry gaseous nitrogen, or 150 PSI Max.

2771.0 in H2O

+- 0-96.00 kPa + 0-

100.00 PSI

gage and absolute statement includes all effects of linearity,

hysteresis, repeatability and ambient temperature

shop air

Internal Pressure Cylinder:

Capacity: 7.0 ft3 N2 @ 2216 PSIG Volume: 80 in

Rating: 2216 PSIG Test Pressure: 3360 PSIG Material: 6061 Aluminum

Note: Some pressure cylinders may only be rated for a working pressure of 2015 PSIG. See information located on panel below ﬁll port.

Pressure Supply Gage:

Size: 2-in. diameter Range: 0–3000 PSIG Test Pressure: 4500 PSIG

Over-pressure Rupture Disk:

Rating: 3000 PSIG, nominal Type: Stainless steel outer case

Pressure Media Filter:

Rating: 20 microns, Test Port Type: Field replaceable

Orion-2D Control Valve:

Type: Micro-metering with replaceable soft seat Material: Aluminum body, clear anodized aluminum

Relief Valve Type: Adjustable, atmospheric bleed Relief Valve Setting: Adjustable to 10% above highest

Relief Valve Material: 300 series stainless steel

knobs, black anodized All other parts 300 series stainless steel

calibrated pressure

Internal Piping:

Tubing: 1/8" O.D., 0.030" wall thickness seamless

Couplings: Brass, Swagelok and Legris type

Cu 5/32" O.D., 0.025" wall thickness Nylon

Fill Port:

Style: Quick-disconnect. Pressure Rating: 3000 PSIG connected, 2000 PSIG

Material: 300 series stainless steel

disconnected

Test Port:

Pressure Rating: 2000 PSIG

Material:Brass Vent Port:

Style: 1/4" 37° AN male Pressure Rating: 2500 PSIG Material: Brass

Pressure Hoses:

Quantity Supplied: Two; one input, one output Length: 5 ft. nominal, each hose Style: Fill (input) hose

synthetic braid, polyurethane cover. Fitted with quick-disconnect (Brass) socket on one end and 1/4" 37˚ female AN swivel pressure ﬁtting on opposite end

est Port (output) hose - Nylon-lined core tube with synthetic braid, polyurethane cover. Fitted with quick-disconnect plug (Brass) on one end and 1/4" 37˚ female AN swivel tube coupling on the other

- Nylon-lined cor e tube with

Pressure Limit Control Regulator (Panel Mounted):

Type: Single stage, self-venting, bleed Pressure Rating: 300 PSIG max. inlet

Pressure Limit Control Regulator (Chassis Mounted):

Type: Single stage, captured vent, non-bleed Pressure Rating: 3500 PSIG max. inlet

Vacuum Control Regulator (Chassis Mounted):

Type: Single stage, self-venting, non-bleed Pressure Rating: 300 PSI max. inlet

Internal Pressure Sensor:

Type: Bonded, metal foil strain gage, sputtered Sensitivity: 3 mV/V nominal

Construction: Completely weld-sealed stainless steel

thin-ﬁlm or equivalent

outer body and pressure cavity

Battery:

Type: Rechargeable, lead-acid gel Nominal Voltage: 12V Approx. Weight: 2.86 lbs Case: Polystyrene/H.I. ABS

Specifications 39

Page 43

Carrying Case UPC5100 only:

Type: Aluminum case with latched cover and

handle Material Thickness: 0.090 in., nominal Finish: Enamel paint, textured ﬁnish Color: Gray

Control Panel:

Material: Aluminum (5052-H32) Thickness: 0.125 in Finish: Gray enamel paint with black silkscreen

nomenclature

Physical Speciﬁcations:

UPC5100 Weight: 34 lbs. including all hoses and cables UPC5110 Weight: 36 lbs. UPC5100 Case Dim’s: 10" wide x 16" long x 11.5" high UPC5110 Case Dim’s: 19" wide x 8.1" deep x 10.5" high (Case dimensions excluding front handles)

40 UPC5100/UPC5110 Operation & Maintenance Manual

Page 44

NOTES: 1- FOR SCHEMATIC SEE DWG. (D)KHP7316.

OBSERVE POLARITY OF ICs, CAPACITORS, DIODES, AND TRANSISTORS.

3- TEST PROCEDURE: (A)KUA7317 4- MARK APPLICABLE DASH NUMBER, REVISION LEVEL, AND

DATE IN 1/8 INCH HIGH CHARACTERS. USE BLACK EPOXY INK.

5- ITEM 30 REFERENCE DESIGNATIONS: R16, R26, R41, R42,

R44, R46, R47, R54, WITH R28 IN KEU8924-1 & KEU8924-3 ONLY.

6- TRANSFORMER SHIELD TO BE INSTALLED AFTER TEST.

(REFERENCE PART NUMBER MB80-1)

7- ITEM 3 REFERENCE DESIGNATIONS: U1, U2, U3, U26, WITH

U23 IN KEU8924-1 & KEU8924-3 ONLY

8- ITEM 56 REFERENCE DESIGNATIONS: C8, C10-C20, WITH

C28 IN KEU8924-1 & KEU8924-3 ONLY

9- ITEM 65 REFERENCE DESIGNATIONS: CR4, CR5, CR7-CR9,

AND CR12, WITH CR10 IN KEU8924-1 & KEU8924-3 ONLY

10- TB1 IS MADE UP OF ONE (1) ITEM 82 AND ONE (1) ITEM 91,

TB2 IS MADE UP OF ONE (1) ITEM 82.

11- FOR 220VAC: REMOVE JUMPERS ON TRANSFORMER, ITEM 69,

12- REFERENCE:

BETWEEN PINS 1 & 3 AND 2 & 4.

ADD JUMPER BETWEEN PINS 2 & 3.

RE-MARK PART NUMBER AS APPLICABLE.

120VAC KEU8924-1 KEU8924-2 KEU8924-3

220VAC KEU8924-4 KEU8924-5 KEU8924-6

USED IN UPC5000, UPC5200 UPS3000 UPC5100

13- ON KEU8924-2, ADD JUMPER TO E11 AND E12.

14- ON KEU8924-1 & -3:

15- ON KEU8924-3 ONLY, ADD JUMPER BETWEEN E3 AND TP7.

CUT CLAD AT CUT MARKS "G" & "E" AND BETWEEN R23A

MOUNTING HOLES.

USE TWO 8" LENGTHS OF ITEM 109, #22AWG BLK.INS.WIRE,

16-

TO CONNECT COMMON CLAD AS SHOWN IN HIDDEN LINES, COMPONENT SIDE VIEW, SHEET 2.

17- ITEM 22 REFERENCE DESIGNATIONS: K5, WITH K4 USED IN

KEU8924-1 AND KEU8924-3 ONLY.

18- ITEM 32 REFERENCE DESIGNATIONS:

AND KEU8924-3, WITH R23, R23B USED IN KEU8924-3 ONLY.

19- ITEM 33 REFERENCE DESIGNATIONS: R55, WITH R11 IN

KEU8924-1 & KEU8924-2 ONLY

20- ITEM 35 REFERENCE DESIGNATIONS: R15, WITH R3 & R4

IN KEU8924-1 & KEU8924-2 ONLY

21- ITEM 37 REFERENCE DESIGNATIONS: R8, R9, R10, R18,

WITH R32 IN KEU8924-3 ONLY

22- ITEM 39 REFERENCE DESIGNATIONS: R59, WITH R58 USED

IN KEU8924-1 ONLY.

23- ITEM 53 REFERENCE DESIGNATIONS: C3, C29, WITH C9

KEU8924-1 AND KEU8924-3 ONLY.

24- ITEM 64 REFERENCE DESIGNATIONS: CR2, WITH CR1 USED

IN KEU8924-1 & KEU8924-2 ONLY

25- ITEM 66 REFERENCE DESIGNATIONS: CR6, WITH CR11 USED

IN KEU8924-1 & KEU8924-3 ONLY. EATON P/N KGF327A MAY BE USED AS A SUBSTITUTE.

26- ITEM 83 REFERENCE DESIGNATIONS:

ITEM 84 REFERENCE DESIGNATIONS:

27 CUT ITEM 101 TO REQUIRED LENGTHS. ON CIRCUIT SIDE OF

BOARD ASSEMBLY JUMPER U8 PINS 9 AND 10 TO U8-7(GND).

DELETE J2 PINS 6 THRU 10, DELETE J2 PINS 16 THRU 20, & CUT CLAD GOING TO PINS 1 & 14 JUMPER PINS J2-1 & J2-2

R30 USED IN KEU8924-1

XU4, XU6, XU7, XU8, XU13. XS1, XU5, XU14, XU15.

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. SEE PICTORIAL.

29- KEU8924-1 ONLY: INSTALL ITEM 11 AND ITEM 31 IN SERIES AT

R33 LOCATION. TWIST, DO NOT SOLDER, LEADS TOGETHER. LEAVE APPROXIMATELY 1/4" LEAD LENGTH ON EACH RESISTER. NOTE TO CONDEC MANUFACTURING: ITEMS 11 & 31 REQUIRED FOR UPC5200 &UPC5210 UNITS. REMOVE ITEM 11 AND SOLDER ITEM 31 ONLY PRIOR TO INSTALLING INTO UPC5000 OR UPC5010.

CPU ASSEMBLY

-1----

---111

---A/R A/R A/R

---333

---1--

---1" 60628

---222

---333

---111

---222

---444

---555

---222

---3-3

---111

222---

CPU ASSEMBLY

113

---1--

CPU ASSEMBLY

112

111 WIRE, 22AWG, WHITE---6"6"6"

4 1/2"4 1/2"

101

30 AWG WIRE-WRAP

LOCK WASHER, INTERNAL TOOTH

TEST POINT KFU307A

SOCKET, IC SOCKET, IC SOCKET, IC SOCKET, IC SOCKET, IC SOCKET, IC SOCKET, IC

CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR

---111

---212

---767

---122

---1--

---2--

---1- 1

---222

---333

-6 -5 -4 -3 -2

QTY REQD FOR DASH NO.

111---

131213---

222--- C6,C7CM05ED200J03CAPACITOR, MICA55

-1

CAPACITOR, ELECTROLYTIC CAPACITOR, ELECTROLYTIC CAPACITOR, ELECTROLYTIC

CAPACITOR, CERAMIC

ITEM

NOMENCLATURE OR

NO.

DESCRIPTION

LIST OF MATERIALS (CONTINUED)

-115 KEU8924-31- - - - -

--KEU8924-2 KEU8924-1

- M22759/11-22-9

-110 WIRE, 22AWG, GREEN M22759/11-22-5---6"6"6"

-109 WIRE, 22AWG, BLACK M22759/11-22-0---27" 27" 27"

-108 WIRE, BUS QQW343H22SIT NOTE 11, 13, 141" 1" 1" 2" 3" 2"

-107 STRAP, TIE-DOWN MS3367-4-9---111

B106 NAMEPLATE, INFORMATION KBY7236

-105 SHRINK TUBING

M23053/2-209-0

B104 INSULATOR KYV297M

-103 TAPE, ADHESIVE F1011---A/R A/R A/R

C102 RESISTOR, METAL FILM KPW310H R11

-100 COMPOUND, THERMO S1069---A/R A/R A/R

B99 SCREW, SEMS KKP83B

-98 SCREW, NYLON, PAN HD. MS18212-13

A97 TERMINAL LUG KEG307C---111 A96 FUSE HOLDER KLL252 XF1---111 A95 FUSE, SLOW-BLOW KJ350C F1

-94 MS35333-113

C93 BRACKET, POWER SUPPLY KBE7287--- 111 A92 B91 TERMINAL BLOCK KUH3300C TB1 B90 SOCKET, IC KD251B XU11 B89 KD251C XU9 B88 KD251A XU10

KE251E

B87 XU12

KE251D

B86 XU22

KE251C

B85 XS3, XU20 B84

KE251B

B83

KE251A

B82 TERMINAL BLOCK KUH3300A TB1 & TB2 B81 CONNECTOR, CONTACT KRM354A B80 KRH354A C79 KPC354C J1 C78 KBN7354B B77 KNM354D J2 NOTE 14 20 PIN---111 B76 KNM354B B75 KNM354C J5 B74 CONNECTOR KNM354A J6 B73 SWITCH, 4 POSITION DIP KTF182G S3 B72 SWITCH, MOMENTARY KAH7182A S2 B71 SWITCH, 8 POSITION DIP KTF182F S1

-70 BARRIER, DIELECTRIC MB80-1 NOTE 6---A/R A/R A/R

C69 TRANSFORMER KR7301A T1---111 A68 CRYSTAL KF357A Y1 B67 FEMALE DISCONNECT KAF7307A----3B66 FULL WAVE BRIDGE KGF327B A65 DIODE, SILICONE KBV327A NOTE 9 A64 DIODE KFL327B

-62 RESISTOR, METAL FILM RN55C2491F R33

-61 RESISTOR, METAL FILM RN55C1502F R3,R4

B60 KAU7311B C27 B59 KAU7311J C23,C24 B58 KAU7311F C22,C25,C26

KAU7311KCAPACITOR, ELECTROLYTIC57 B

DWG SIZE

IDENTIFYING NO.

PART OR

NOTE 11

POLARIZED 6.8uF 20% 35V

C4, C5KGE311QCAPACITOR, ELECTROLYTIC114 B NOTE 11 NOTE 11

NOTE 16

"1/4 AMP 250V"

3/4" DIA.

TO-220

1.75K 1% 1/8W

NOTES 27 & 28

#6-32 X 1/4 LG #4-40 X 1/4 LG

1/4 AMP 250V 1/2" I.D.

TP1-TP15---151515

4 POS, NOTE 10 28 PIN DIP 40 PIN DIP 24 PIN DIP 20 PIN DIP

18 PIN DIP

NOTE 26 NOTE 26

8 PIN DIP 16 PIN DIP 14 PIN DIP 3 POS, NOTE 10 MATE-N-LOCK MATE-N-LOCK 4 PIN 8 PIN

14 PIN 16 PIN 10 PIN 4 SPST PUSH BUTTON 8 SPST

3 IN. X 2 3/8 IN.

4.9152 MHZ

NOTE

3N249/KB04 1N4002 FDH300

2.49K 1% 0.1W 15K 1% 0.1W

470uF 20% 50V

1000uF 20% 35V

100uF 20% 16VPOLARIZED

+80

.01uF % 100V

-20

20pF 5% 500V

REMARKS

NOTE 25

NOTE 24

POLARIZED

POLARIZED 4700uF20% 16V

SPECIFICATION

C21 NOTE 8KHV311A56

MATERIAL OR

-1/2" 116 -1/2"1/2"1/2"1/2"1/2" WIRE, BUS QQW343H18SIT

-----1

---111

QTY REQD FOR DASH NO.

--1-323---

111--11----

--1--- R21RN55C2000FRESISTOR, METAL FILM50 11---- R32KPW310ZRESISTOR, METAL FILM49 C 111--- R34KBY338FPOTENTIOMETER48 C

--1--- R23CKPW310MRESISTOR, METAL FILM47 C 1-1--- R20RESISTOR, COMPOSITION46 -

--1--- R12KPW310DRESISTOR, METAL FILM45 C 1-1--- R7RN55C6041FRESISTOR, METAL FILM44 333--111--222--111--211--222--- R56,R57RESISTOR, METAL FILM38 C 445--- RESISTOR, METAL FILM37 C 222--331--- RESISTOR, METAL FILM35 C 11---- R13RESISTOR, METAL FILM34 C 221--- RESISTOR, METAL FILM33 C 1-3--- KPW310ERESISTOR, METAL FILM32 C 1----- NOTE 29RN55C1402FRESISTOR, METAL FILM31 989--- SEE NOTE 5RN55C1001FRESISTOR, METAL FILM30 555--- R35-R39RN55C8062FRESISTOR, METAL FILM29 11---- R21RN55C4321FRESISTOR, METAL FILM28 333--111--222--1-1--333--- K1,K2,K3KJU431BRELAY23 C 212--- KJU431ARELAY22 C 111--1-1--1-1--111--- U1918 C 111--- U18KHY1918B17 C 111--- U17KHY1918C16 C 111--- U16 111--- U15IC, 4 BIT BINARY COUNTER14 C 111--- U14KBE8918BD13 C 111--- U12KBE8918BL12 C

111--333--111--111--111--111--545---

-1-2-3-4-5-6

CAPACITOR, POLYCARBONATE CAPACITOR, METAL POLY

RESISTOR, COMPOSITION RESISTOR, COMPOSITION

IC, VOLTAGE REGULATOR IC, VOLTAGE REGULATOR IC, VOLTAGE REGULATOR IC, VOLTAGE REGULATOR IC, VOLTAGE REGULATOR15 B

IC, NONINVERTED 3 STATE OUT. IC, OCTAL D TYPE FLIP-FLOP RESISTER, METAL FILM

NOMENCLATURE OR

ITEM

NO.

DESCRIPTION

C B

KDE7311B53 A C

RCR07G241JS

RCR07G103JS

KBY338BPOTENTIOMETER39 B

KPW310G

KPW310N

KPW310

KPW310W

KPW310AY

KPW310R

KHY1918F

KBH1918D

KBE8918AG

RN55C50001F

D1 PRINTED CIRCUIT BOARD KKY7361

DWG

IDENTIFYING NO.

SIZE

LIST OF MATERIALS

MATERIAL

SEE BILL

OF MATERIAL

TREATMENT

NONE

THIRD ANGLE PROJECTION

PART OR

MFG.ENG. APPROVED

DES.ENG. APPROVED

SPECIFICATION

UNLESS OTHERWISE SPECIFIED

UNITS TO BE INCHES

ALL THREADS TO BE CLASS 2

ALL DIMENSIONS APPLICABLE AFTER TREATMENT

DRAWING TOLERANCES

DO NOT SCALE

UNLESS OTHERWISE SPECIFIED

DRAWING

FOR RLWS USE ONLY

TOL. DECIMAL

SURFACE

FINISH

2 PLC 3 PLC

---

ANGLE

JEW 5/7/87

S.V. 5/11/87 DJS 6/15/00

CKD.

DR.BY

REV

ECO10483: DELETED ITEMS 10 & 11; REDRAWN ON RLW FORMAT

DELETED ITEM NUMBER 2 . ECO11898: ADDED NOTE 27, ADDED INFO TO ITEM NO. 101 ON

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

C1KMV311P54 SEE NOTE 23 C2KKF311BCAPACITOR, CERAMIC52 C1KMV311TCAPACITOR, MYLAR51

REVISIONS

REFERENCE

.1uF 10% 100V .5uF 10% 100V

1uF 20% 50V

.22uF 5% 100V

200 1% 0.1W

50K 0.1% 0.1W 500 10% 1/2W 200 0.1% 0.1W

240 5% 1/4W

1.5K 0.1% 0.1W

R40,R48,R49KMA310URESISTOR, SIP43 C R50KGE310AU42 C R51,R5241 R43RCR07G245JSRESISTOR, COMPOSITION40 SEE NOTE 22

6.04K 1% 0.1W

10K 2% .3W

430 5% 1/2W

10K 5% 1/4W

2.4M 5% 1/4W

20K 10% 1/2W

80K 0.1% 0.1W

SEE NOTE 21 R19,R22RESISTOR, METAL FILM36 C SEE NOTE 20

SEE NOTE 19 SEE NOTE 18

R5,R6,R45RN55C1002FRESISTOR, METAL FILM27 R25RN55C3011FRESISTOR, METAL FILM26 R1,R2KPW310BRESISTOR, METAL FILM25 C R29RN55C10R0FRESISTOR, METAL FILM24 -

NOTE 17 R17RN55C1741FRESISTOR, METAL FILM21 R24KBW338EPOTENTIOMETER20 C U25KGB1918C19 C

10K 0.1% 0.1W

SELECT

20K 0.1% 0.1W

13.3K 0.1% 0.1W

5K 0.1% 0.1W

1.0K 0.1% 0.1W

14K 1% 0.1W

1.0K 1% 0.1W

80.6K 1% 0.1W

4.32K 1% 0.1W 10K 1% 0.1W

3.01K 1% 0.1W 100K .1% 0.1W 10 1% 0.1W

1.74K 1% 0.1W

2K 10% 1/2W

LM317T 3 PIN 79M12 3 PIN 78M12 3 PIN 78M15 3 PIN 7805 3 PIN 74HCT161 16 PIN 74HCT257 16 PIN

R33 NOTE 29

U9KBF8918AIC, 8 BIT MICROCOMPUTER9C U8,U13,U7KBE8918AIC, 2 INPUT NAND8C U20KDH8918AIC, OPERATIONAL AMPLIFIER7B U6KAG1918AEIC, HEX BUFFER/DRIVER6C U5KEV1918DIC, QUAD SWITCH5A U4KER1918AIC, QUAD AMPLIFIER4A NOTE 7KBY1918UIC, OPERATIONAL AMPLIFIER3C

MATERIAL OR

THIS DRAWING AND ALL INFORMATION CONTAINED HEREIN IS AND REMAINS

THE PROPERTY OF RICE LAKE WEIGHING SYSTEMS INC. AND IS CONFIDENTIAL. IT IS SUBMITTED AND MAY BE USED ONLY IN CONNECTION WITH RICE LAKE WEIGHING SYSTEMS' PROPOSAL AND/OR ITS CUSTOMERS' ORDERS. IT SHALL NOT BE DISCLOSED TO OTHERS OR COPIED WITHOUT RICE LAKE WEIGHING SYSTEMS' SPECIFIC

WRITTEN CONSENT AND SHALL BE IMMEDIATELY RETURNED UPON REQUEST.

TITLE

---

74HCT374 20 PIN

5K 1% 0.1W

80C39 40 PIN 74HCT00 14 PIN AD708NJX 8 PIN

7417 14 PIN LF13333N 16 PIN HA4741 14 PIN

OP-07CJ 8 PIN

NOTE

REMARKS

ASSEMBLY,

CPU AND POWER SUPPLY

RICE LAKE WEIGHING SYSTEMS

SCALE

N/A

SHEET OF

DWG NO

REVISION

INIT

DJS KLL DJS KLL

KAL JEW

54254

DATE 6/15/00 10/4/00

12/12/01

Figure 8-1. CPU & POWER SUPPLY ASSEMBLY, Sheet 1(For Non-Battery Units Only)

Maintenance

Page 45

UPC5100/UPC5110 Operation & Maintenance Manual

Figure 8-2. CPU & POWER SUPPLY ASSEMBLY, Sheet 2 (For Non-Battery Units Only)

Page 46

Figure 8-3. POWER SUPPLY ASSEMBLY (For Battery Units Only)

Maintenance

Page 47

NOTES: 1- FOR SCHEMATIC SEE DWG. (D)KHN7316.

OBSERVE POLARITY OF ICs, CAPACITORS, DIODES, AND TRANSISTORS. 3- TEST PROCEDURE: (A)KUA7317 4- MARK APPLICABLE DASH NUMBER, REVISION LEVEL, AND

DATE IN 1/8 INCH HIGH CHARACTERS. USE BLACK EPOXY INK. 5- ITEM 30 REFERENCE DESIGNATIONS: R16, R26, R41, R42,

R44, R46, R47, R54, WITH R28 IN KET8924-1 & KET8924-3

7- ITEM 3 REFERENCE DESIGNATIONS: U1, U2, U3, U26, WITH

U23 IN KET8924-1 & KET8924-3 8- ITEM 56 REFERENCE DESIGNATIONS: C8 AND C10-C26,

WITH C28 IN KET8924-1 & KET8924-3

9- ITEM 65 REFERENCE DESIGNATIONS:

WITH CR10 IN KET8924-1 & KET8924-3

10- TB1 IS MADE UP OF ONE (1) ITEM 82 AND ONE (1) ITEM 91.

TB2 IS MADE UP OF ONE (1) ITEM 82.

USE TWO 8" LENGTHS OF ITEM 95, #20AWG BLK.INS.WIRE,

11-

TO CONNECT COMMON CLAD, AS SHOWN IN HIDDEN LINES,

COMPONENT SIDE VIEW, SHEET 2.

12- REFERENCE:

13- REFERENCE:

ASSEMBLY # KET8924-1

KET8924-3 KET8924-4

ASSEMBLY # QTY

KET8924-1 KET8924-2 KET8924-3

KET8924-4

14- ON KET8924-1 & KET8924-3:

ON KET8924-2:

15- ON KET8924-3 ONLY:

16- ITEM 22 REFERENCE DESIGNATIONS: K5, WITH K4 USED IN

KET8924-1 & KET8924-3 ONLY

17- ITEM 32 REFERENCE DESIGNATIONS: R30 USED IN KET8924-1

AND KET8924-3, R23 & R23B USED IN KET8924-3 ONLY.

18- ITEM 33 REFERENCE DESIGNATIONS: R55, WITH R11 USED IN

KET8924-1, KET8924-2, & KET8924-4.

19- ITEM 35 REFERENCE DESIGNATIONS: R15, WITH R3 & R4 USED IN

KET8924-1, KET8924-2, & KET8924-4.

20- ITEM 37 REFERENCE DESIGNATIONS: R8, R9, R10, & R18 WITH

R32 IN KET8924-3 ONLY.

21- ITEM 39 REFERENCE DESIGNATIONS: R59, WITH R58 USED IN

KET8924-1 & KET8924-3 ONLY.

22- ITEM 53 REFERENCE DESIGNATIONS: C3, C29, WITH C9 USED IN

KET8924-1 & KET8924-3 ONLY.

23- ITEM 64 REFERENCE DESIGNATIONS: CR2, WITH CR1 USED IN

KET8924-1, KET8924-2, & KET8924-4.

24- ITEM 75 REFERENCE DESIGNATIONS: J5, WITH J2 USED IN

KET8924-2 ONLY.

25- ITEM 83 REFERENCE DESIGNATIONS: XU4, XU6, XU7, XU8, XU13.

ITEM 84 REFERENCE DESIGNATIONS: XS1, XU5, XU14, XU15.

26- ITEM 92 REFERENCE DESIGNATIONS (28 PLACES): TP1-TP6,

TP8-TP12, TP14, TP15, E1-E5, E7-E16.

DELETE J2 PINS 6 THRU 10, AND 16 THRU 20. DELETE J2 PINS 9,10, & 19,20

CUT CLAD AT CUT MARKS "G" & "E"

AND BETWEEN R23A MOUNTING HOLES.

CR7, CR8, CR9, AND CR12,

USED IN

UPC5000 UPC5100

UPS3000

ITEM # ADD BETWEEN 66

66 66

E9 & E10, E12 & E13

E9 & E11, E12 & E15 E3 & E16, E9 & E10, E12 & E13 E9 & E11, E12 & E15

2 2 3

27- KET8924-1 AND KET8924-3:

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" 30AWG WIRE, ITEM 96, BETWEEN CR10 ANODE AND VIA UNDER UI0, SEE PICTORIAL.

28 - CAPACITOR LEADS TO BE WRAPPED WITH NONCONDUCTIVE TUBE TO PREVENT

ELECTRICAL ARCING.

29 - CAPACITOR TO BE LAID DOWN FLAT AGAINST BOARD, AND WRAPPED WITH

NONCONDUCTIVE SHRINK TUBE TO PREVENT ELECTRICAL ARCING.

30 - CUT ITEM 96 TO REQUIRED LENGTHS. ON CIRCUIT SIDE OF BOARD

ASSEMBLY JUMPER U8 PINS 9 AND 10 TO U8-7(GND).

-1 = 59037

-2 = 59040

-3 = 59048

-4 = 59052

19 19 19

A/R A/R A/R

A/R

28 28 28 28

1 111 1 111 1 111 1 111 1 111

1 111 2 222 4 444 5 555 2 222

1 111

1 ---

1 111

1121

1 111

4545 2122

2 222

-4 -3 -2

QTY REQD FOR DASH NO.

1-1-

-1

CONNECTOR PIN KEK7354A

SOCKET, IC SOCKET, IC SOCKET, IC SOCKET, IC SOCKET, IC SOCKET, IC SOCKET, IC

CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR

63 62 61 60 59

CAPACITOR, ELECTROLYTIC

ITEM

NOMENCLATURE OR

NO.

DESCRIPTION

LIST OF MATERIALS (CONTINUED)

-97 WIRE, BUS, 18 AWG QQW343H18SIT

-96 WIRE, WIRE WRAP, 30 AWG F985

-95 WIRE, BLACK, 20 AWG M22759/11-20-0

-93 SEALANT SA13-193 B92 B91 TERMINAL BLOCK KUH3300C TB1 B90 SOCKET, IC KD251B XU11 B89 KD251C XU9 B88 KD251A XU10

KE251E

B87 XU12

KE251D

B86 XU22

KE251C

B85 XS3,XU20 B84

KE251B

B83

KE251A B82 TERMINAL BLOCK KUH3300A TB1 & TB2 B81 CONNECTOR, CONTACT KMB354C1 111 B80 KMB354A C79 KPC354C J1 C78 KBN7354B J3 B77 KNM354D J2 B76 KNM354B J4 B75 KNM354C B74 CONNECTOR KPC354E J8 B73 SWITCH, 4 POSITION DIP KTF182G S3 B72 SWITCH, MOMENTARY KAH7182A S2 B71 SWITCH, 8 POSITION DIP KTF182F S1 B70 CONNECTOR KNM354A J2 C69 TRANSISTOR

KEA165A

A68 CRYSTAL

KF357A

B66 RECEPTACLE, SHORTING KEF7354A2 322

A65 DIODE, SILICONE KBV327A NOTE 9 A64 DIODE KFL327B

B58 KGE311Q C4,C5

KAU7311JCAPACITOR, ELECTROLYTIC57 B

DWG

PART OR

SIZE

IDENTIFYING NO.

NOTE 11

RTV162 NOTE 26

4 POS, NOTE 10

28 PIN DIP 40 PIN DIP 24 PIN DIP 20 PIN DIP 18 PIN DIP

NOTE 25 NOTE 25

J6 J7

NOTE 24

Q11- 1Y1

8 PIN DIP 16 PIN DIP 14 PIN DIP

3 POS, NOTE 10

12 PIN 9 PIN

4 PIN

8 PIN 20 PIN 14 PIN 16 PIN

3 PIN

4 SPST

PUSH BUTTON 8 SPST

10 PIN NOTE 14

2N4401

4.9152 MHZ

NOTE 13

NOTE 23

POLARIZED POLARIZED 1000uF20% 35V

SPECIFICATION

C27

MATERIAL OR

NOTE

1N4002 FDH300

6.8uF 20% 35V

REMARKS

19181918

2222 C6,C7CM05ED200J03CAPACITOR, MICA55 -

--13232 1111 11-1

-1-1 R31RESISTOR, COMPOSITION50 11-1 R32KPW310ZRESISTOR, METAL FILM49 C 1111 R34KBY338FPOTENTIOMETER48 C

--1- R21RN55C2000FRESISTOR, METAL FILM47 1-1- R20RESISTOR, COMPOSITION46 -

--1- R12KPW310DRESISTOR, METAL FILM45 C 1-1- R7RN55C3321FRESISTOR, METAL FILM44 3333

-1-1 2222 1111 2121 2222 R56,R57RESISTOR, METAL FILM38 C 4454 RESISTOR, METAL FILM37 C 2222 3313 RESISTOR, METAL FILM35 C 11-1 R13RESISTOR, METAL FILM34 C 2212 RESISTOR, METAL FILM33 C 1-3- KPW310ERESISTOR, METAL FILM32 C 1111 R17RN55C6981FRESISTOR, METAL FILM31 9898 SEE NOTE 5RN55C1001FRESISTOR, METAL FILM30 5555 R35-R39RN55C8062FRESISTOR, METAL FILM29 11-1 R21RN55C4321FRESISTOR, METAL FILM28 3333 1111 2222 1-13333 K1,K2,K3KJU431BRELAY23 C 2121 KJU431ARELAY22 C 1---

-1--

1 111

QTY REQD FOR DASH NO.

1-1-

1-1- IC, VOLTAGE REGULATOR15 1111 U15IC, 4 BIT BINARY COUNTER14 C 1111 U14KBE8918BD13 C 1111 U12KBE8918BL12 C

1111 3333 1111 1111 1111 1111 5454

-1

-2-3-4

CAPACITOR, CERAMIC

CAPACITOR, POLYCARBONATE CAPACITOR, METAL POLY

RESISTOR, COMPOSITION RESISTOR, COMPOSITION

RESISTOR, METAL FILM

RESISTOR, METAL FILM--1-

IC, NONINVERTED 3 STATE OUT. IC, OCTAL D TYPE FLIP-FLOP

KDE7311B53 B

RCR07G471J3

RCR07G241J3

RCR07G102J3 RCR07G103J3

KBY338BPOTENTIOMETER39 B KPW310G KPW310N

KPW310 KPW310W KPW310AY KPW310R

C C

KPW310M KPW310BACRESISTOR, METAL FILM--2- R3,R4 RN55C2491F- R33

KBE8918AG

D1 PRINTED CIRCUIT BOARD KKW7361

LIST OF MATERIALS

MATERIAL

TREATMENT

IDENTIFYING NO.SIZEDESCRIPTIONNO.

SEE BILL

OF MATERIAL

NONE

THIRD ANGLE PROJECTION

NOTE 8KHV311A56 A

C1KMV311P54 C NOTE 22 C2KKF311BCAPACITOR, CERAMIC52 A C1KMV311TCAPACITOR, MYLAR51 C

R40,R48,R49KMA310URESISTOR, SIP43 C R2742 R51,R5241 R43RCR07G245J3RESISTOR, COMPOSITION40 NOTE 21

NOTE 20 R19,R22RESISTOR, METAL FILM36 C

NOTE 19

NOTE 18 NOTE 17

R5,R6,R45RN55C1002FRESISTOR, METAL FILM27 R25RN55C1182FRESISTOR, METAL FILM26 R1,R2KPW310BRESISTOR, METAL FILM25 C R29RN55C10R0FRESISTOR, METAL FILM24 -

NOTE 16 R33RN55C1402FRESISTOR, METAL FILM21 R24KBW338EPOTENTIOMETER20 C

R11KPW310H

R23C

U25KGB1918C

TOL. DECIMAL

2 PLC

---

3 PLC

---

ANGLE

---

CKD.

DR.BY

MATERIAL ORPART ORDWGNOMENCLATURE ORITEM

SPECIFICATION

UNLESS OTHERWISE SPECIFIED

UNITS TO BE INCHES

ALL THREADS TO BE CLASS 2

ALL DIMENSIONS APPLICABLE AFTER TREATMENT

DRAWING TOLERANCES

DO NOT SCALE

UNLESS OTHERWISE SPECIFIED

DRAWING

FOR RLWS

SURFACE

USE ONLY

FINISH

---

MFG.ENG.

SV 8/25/87

APPROVED DES.ENG.

JEW 8/25/87 DJS 11/27/00

APPROVED

REV

SEE C/N'S FOR CHG. DESCRIPTIONS

THRU

W-C/N D2858, Y-C/N D2900, AA-C/N D2948, AB-C/N D2968.

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.

MODIFIED NOTE 27, "CATHODE" REPLACED WITH "ANODE"; REDRAWN ON RLWS FORMAT.

ADDED NOTES 28 AND 29.

ECO11898: ADDED NOTE 30, MODIFIED INFO IN ITEM NO. 96 ON LIST OF

MAT'L. REMOVED SPEC. FROM ITEM 65 AND 1 THRU 57.

LF13333N 16 PIN HA4741 14 PIN

NOTE

THIS DRAWING AND ALL INFORMATION CONTAINED HEREIN IS AND REMAINS

WRITTEN CONSENT AND SHALL BE IMMEDIATELY RETURNED UPON REQUEST.

TITLE

RICE LAKE WEIGHING SYSTEMS

REVISIONS

REFERENCE

+80

.01uF % 100V

-20

20pF 5% 500V .1uF 10% 100V .5uF 10% 100V

1uF 20% 50V .22uF 5% 100V 470 5% 1/4W 50K 0.1% 0.1W

500 10% 1/2W

200 1% 0.1W

240 5% 1/4W

1.5K 0.1% 0.1W

3.32K 1% 0.1W

10K 2% .3W

1K 5% 1/4W

10K 5% 1/4W

2.4M 5% 1/4W 20K 10% 1/2W 80K 0.1% 0.1W

10K 0.1% 0.1W

SELECT

20K 0.1% 0.1W

13.3K 0.1% 0.1W 5K 0.1% 0.1W

1.0K 0.1% 0.1W

6.98K 1% 0.1W

1.0K 1% 0.1W

80.6K 1% 0.1W

4.32K 1% 0.1W 10K 1% 0.1W

11.8K 1% 0.1W 100K 0.1% 0.1W 10 1% 0.1W

14K 1% 0.1W 2K 10% 1/2W

1.75K 0.1% 0.1W

200 0.1% 0.1W

15K 0.1% 0.1W

2.49K 1% 0.1W

LM317T 3 PIN

74HCT161 16 PIN 74HCT257 16 PIN

74HCT374 20 PIN

80C39 40 PIN 74HCT00 14 PIN

AD708NJX 8 PIN

7417 14 PIN

OP-07CJ 8 PIN

REMARKS

ASSEMBLY,

CPU AND BATTERY POWER

SHEET OF

SCALE

N/A

DWG NO

REVISION

INIT

JEW

JSL

DJS KLL DJS KLL DJS KLL DFH KLL

KAL JEW

59037

DATE SEE CHG #'S 7/7/94 3/17/98 11/8/99 8/4/00 10/5/00 11/27/00 12/28/00

12/12/01

UPC5100/UPC5110 Operation & Maintenance Manual

Figure 8-4. CPU ASSEMBLY, Sheet 1 (For Battery Units Only)

Page 48

Figure 8-5. CPU Assembly, sheet 2 (For Battery Units Only)

Maintenance

Page 49

UPC5100/UPC5110 Operation & Maintenance Manual

Figure 8-6. CPU & POWER SUPPLY SCHEMATIC, Sheet 1 (For Non-Battery Units Only)

Page 50

Figure 8-7. CPU & POWER SUPPLY SCHEMATIC, Sheet 2 (For Non-Battery Units Only)

Maintenance

Page 51

UPC5100/UPC5110 Operation & Maintenance Manual

Figure 8-8. POWER SUPPLY SCHEMATIC, (For Battery Units Only)

Page 52

Figure 8-9. CPU SCHEMATIC, Sheet 1 (For Battery Units Only)

Maintenance

Page 53

UPC5100/UPC5110 Operation & Maintenance Manual

Figure 8-10. CPU SCHEMATIC, Sheet 2 (For Battery Units Only)

Page 54

UPC5100/UPC5110 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. Any damage incurred because of poor packaging procedures will ultimately result in added service charges and longer turn-around times.

Vent all pressure lines and the nitrogen cylinder to the atmosphere before shipping.

Warning

When factory service is required, send in only the unit for repair. Retain ﬁttings, manuals, etc. at your facility. However, if there is a problem with a particular part, send in that part with the unit.

If a unit is found to be defective, it may be returned to our repair facility at the following address:

CONDEC 3 SIMM LANE DOOR D, UNIT 2A NEWTOWN, CT 06470 ATTN: PRESSURE PRODUCTS/REPAIR LAB

Each unit's I.D. plate is stamped with a date code (week/year) prior to shipment. Our warranty is twelve (12) months from that date code and includes repair and/or replacement of the unit at our Newtown facilities at no charge. Units subjected to abuse or damaged by external inﬂuences, are not covered under warranty.

If the unit is found to be out of warranty, an evaluation charge of not less than ﬁfty (U.S.) dollars ($50.00) will be charged. Please note on any attached paperwork if a repair estimate is required or if there are any other speciﬁc instructions.

Please be explicit as to the nature of the problem and/or its symptoms. Your documentation will save needless time and expense. Also, please include a return shipping address (with a street address) and a contact name with fax and telephone numbers. Contact numbers are necessary to provide a job estimate and in case further questions arise at the factory.

UPC5100/UPC5110 Warranty and Return Policy 51

Page 55

UPC5100/UPC5110 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.

Company Name:

Street:

City, State, ZIP: Telephone:

Fax: Contact Person:

MODEL NUMBER: SERIAL NUMBER: Problem with Unit (Please Be Speciﬁc):

IS THIS A WARRANTY REPAIR?( ) YES( ) NO SHIP TO Address:

Company Name: Street:

City, State, ZIP: ATTN:

CONDEC • 3 SIMM LANE • DOOR D, UNIT 2A • NEWTOWN, CT 06470

ATTN: PRESSURE PRODUCTS/REPAIR LAB

TEL: 888-295-8475 • FAX: 203-364-1556 or 715-234-6967

WEB SITE: www.4condec.com

52 UPC5100/5110 Operation & Maintenance Manual