Condec UPC5200 Operating Manual

UPC5200 & UPC5210

Portable & Rack-mountable Pneumatic

High Pressure Calibration Console

Operation and Maintenance Manual

CONDEC Sales Phone No. [phone]

CONDEC Web Site: www.4condec.com

63259

Contents

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

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

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

2.1 Pressure Cylinder (PN 59533) Filling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Initial Setup Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3 Pressure Measurement Sequence (Gage Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Pressure Measurement Sequence (Absolute Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

3.6 Current Input Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.7 Permanent Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

3.9 Self-Check Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.0 Maintenance & Service............................................................................................................. 14

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

4.2 Maintenance & Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2.1 Panel/Chassis Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2.2 Accumulator, Intensifier & ORION-3A (PN 55287) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2.3 ORION-3A Manifold, Valve Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2.4 ORION-3A Manifold, Vernier Control Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2.5 ORION-3A Manifold, Vernier Control Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2.6 ORION-3A Manifold, Valve Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2.7 Accumulator, Intensifier and ORION-3A Manifold, Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2.8 ORION-3A Manifold, Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2.9 Accumulator Assembly, O-ring (PN 58051) Replacement, Filter (PN 56993) Cleaning. . . . . . . . . . . . . 21

4.2.10 Intensifier Assembly, O-rings/Seals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.2.11 Regulator (Standard Pneumatic) and Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2.12 Regulator (Standard Pneumatic) and Solenoid Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2.13 Regulator (Tescom) and Solenoid Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.2.14 Regulator (Tescom) and Solenoid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.2.15 Panel Gauge Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.2.16 Test Port Quick-Connect Fitting (PN 59004) and Filter (PN 54188), Removal and Installation . . . . . . . 28

4.2.17 Test Port (output) Hose Quick-Connect Fitting and Filter (PN 56991), Removal and Installation. . . . . . 28

4.2.18 Input Port Filter (PN 54188), Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.2.19 Input Port Hose Quick-Disconnect Female Fitting, Removal and Installation . . . . . . . . . . . . . . . . . . . . 29

4.2.20 AC Fuse (PN 57472), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.2.21 Panel Mounted AC Power/EMI Line Filter (PN 58870), Removal and Installation . . . . . . . . . . . . . . . . . 30

4.2.22 Chassis Mounted EMI Line Filter (PN 59015), Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 30

4.2.23 Pump Control Switch (PN 60307), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.2.24 Power Switch (PN 58878), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.2.25 Range Select Switch (PN 55924) and Display Select Switch (PN 55933), Removal and Installation. . . 32

4.2.26 Zero Switch (PN 58886), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.2.27 CPU Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.2.28 Pump Control Board Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.3 ORION-3A Valve Assembly (55287) Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.4 Intensifier Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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

Specifications subject to change without notice.

February 2002

5.0 Model Number System .............................................................................................................. 44

6.0 Ranges and Resolutions ............................................................................................................ 45

7.0 Options, Replacement Kits ........................................................................................................ 46

8.0 Specifications............................................................................................................................ 47

UPC5200/UPC5210 Warranty and Return Policy................................................................................... 49

UPC5200/UPC5210 Return Material Authorization Form....................................................................... 50

About This Manual

This manual is intended for use by service technicians
responsible for installing and servicing
UPC5200/UPC5210 pressure calibrators.

The UPC5200 portable pneumatic pressure calibrator
and the rack-mounted UPC5210 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.

This manual has been written to give the user a simple
and clear explanation of how to operate, calibrate and
maintain these instruments.

Warning

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.

Before attempting to use either style
pressure calibrator, the following
instructions must be carefully read
and understood by personnel using
the equipment. This is a high-pressure

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

www.4condec.com

.

1.0 Introduction

The UPC5200/UPC5210 pressure calibrators utilize an extremely repeatable sensor coupled to
microprocessor-based electronic circuitry and a selectable units display system. This provides easily readable
and accurate digital representation of the measured pressure. This all electro-mechanical device utilizes our
precision Orion-3A vernier, which has one test port. Front panel gages tell the operator accumulator pressure, as
well as regulated input pressure. The pressure regulator acts as a pressure limiter so that the operator can adjust
input system pressure to 1/10 of the target value. Fill and test hoses are supplied for the customer. Standard front
panel buttons and switches provide selection of the desired pressure range, push-button zeroing and the unique
internal self-check feature. For field use, the UPC5200 has a separate 83.3 cubic foot, 2,216 psi cylinder to
provide many hours of use.

Utilizing microprocessor technology , the UPC5200 and rack-mounted UPC5210 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:

• Three independent switch-selectable pressure ranges per instrument.

•Accuracy of each range equal to or better than ±0.05% Full Scale.

•Both gage and absolute pressure calibration models are available.

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

•Digital Display: Eliminates parallax, interpolation and operator judgement errors. Large, bright, red LED.
digits provide excellent readability under all lighting conditions (also available with an LCD).

•Using a manually adjustable regulator, the maximum system input pressure is adjusted to any desired value
higher (typically 20 to 50%) than the full scale range of the device being tested. By virtue of this technique,
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 approximately 50 lbs.

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

Introduction

1

2

•Calibration Integrity: Tamper-proof design. Once calibrated, numerous safeguards guarantee the integrity
of pressure readings obtained. Display prompting provides the operator with functional status information
during both operation and calibration.

• Pressure Source (UPC5200 only): An external supply cylinder with a volume of 83.3 std. cu. ft. of N
provides up to 2,216 psig of pressure for calibration and test. This pressure source drives a pneumatically

operated 10 to 1 intensifier contained within the UPC5200. Therefore, a 1,000 PSI input is amplified to
10,000 PSI.

• Simple Operation: All controls, indicators and pressure ports are accessible from the front panel.
Accompanying operator's manual 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 gauge-under-test or voltage to be displayed. Transducer excitation voltage of 28 VDC is
provided standard.

• Safe, Clean Operation: All pressure components are made of stainless steel and proof-tested to at least
150% of maximum operating pressure. In addition, the system contains a high-pressure burst disk to
protect both the operator and system components from harm in the event of inadvertent o v er -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 the sensors with
sophisticated 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.

2

In addition to the features, the UPC5200/UPC5210 pressure calibrator is easy to use. Two micro-metering valves
and vernier are provided to control the internally intensified nitrogen while the digital display indicates precisely
the magnitude of the applied test pressure. Also, a simple push-button switch provides zeroing of the pressure
display. The

selection, as well as,

Range

Pressure

and

Current

display selections are accomplished via a pair of
clearly marked rotary switches. Over-pressure protection is provided through a fully-adjustable pressure
regulator, which is manually set for each new device being tested.

With respect to calibration, the instruments have been designed and programmed to provide the operator with
various prompting symbols and legends during each phase of the calibration sequence. Also, to prevent
unauthorized tampering or calibrations, programming or calibration can only be achieved with the aid of a
separate, plug-in calibration console (PN 60109). Also, the electronic circuitry has been designed without any
potentiometers or adjustments, eliminating the possibility of unwanted changes. Finally, the computer has been
programmed with a series of internal self-diagnostic routines which continually monitor and check every bit of
data stored and processed by this system. The computer immediately notes or shuts down operation in the event
of an out-of-tolerance reading or any outright failures.

UPC5200/UPC5210 Operation and Maintenance Manual

Figure 1-1 provides an overview of the UPC5200/UPC5210’s function.

Figure 1-1. UPC5200/UPC5210 Flow Diagram

Introduction

3

4

2.0 Operation

2.1 Pressure Cylinder (PN 59533) Filling Procedure

NOTE: Condec strongly recommends that the external 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.

To initially fill or refill the external pressure cylinder (2,216 PSI max.), proceed as described below.

1. Close the

CYLINDER

valve by rotating clockwise until it stops.

2. Connect the customer supplied fill hose, to a clean regulated nitrogen source, with an output pressure
gauge and vent valve.

3. Connect the other end of the customer supplied fill hose to the female CGA-580 brass

CYLINDER

fitting.

4. Open the

CYLINDER

valve by rotating counter-clockwise until it stops.

5. Slowly open the valve on the nitrogen source and allow the gas to flow into the pressure cylinder. The
customer supplied output pressure gauge indicates the amount of pressure within the internal cylinder.

NOTE: Cylinder is equipped with a rupture disk.

6. Use the following procedure to fill the cylinder:

a) Fill cylinder to 1,000 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 1,000 PSI to 2,216 PSI at a rate of charge equal to a minimum of two minutes.
c) Wait five minutes for cylinder to stabilize before using.

7. Close the

CYLINDER

valve by rotating clockwise until it stops.Vent nitrogen source and remove fill hose.

2.2 Initial Setup Procedure

To prepare for actual calibration usage, see Figure 2-1 below and proceed as follows:

1. Check that the

COARSE ADJUSTMENT

Vent valve (8) is open (two turns counter-clockwise from its stop). Verify that the REGULATOR (1) is
closed (rotate counter-clockwise until it stops).

2. Plug in the power cord (7) and energize the unit by depressing the
UPC5200/UPC5210 performs an internal functional self-check. Allo w at least 10 minutes warm-up time.

3. Select the desired full scale pressure range via the three-position rotary switch (19). For the best
accuracy, the selected range must be greater than, but close as possible to, the full scale range of the
device-under-test.

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

4. Set the

DISPLAY SELECT

switch (16) to the PRESSURE position.

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

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

7. UPC5200: Connect the male end of the input hose (3) to the female CGA-580 brass
fitting.

valve (2) is closed (rotate clockwise until it stops) and that the

POWER

switch (18). The

CYLINDER

valve

(5) valve

UPC5210: Connect the male end of the input hose (3) to the female CGA-580, customer supplied,
pressure source.

8. Connect the swivel fitting end (7/16-20) of the input hose (3) to the INPUT PORT (4) fitting. Tighten all
connections properly.

UPC5200/UPC5210 Operation and Maintenance Manual

Figure 2-1. Initial Setup Procedure

NOTE: UPC5200 shown, AC Input (7) and Input Port (4) are on back side of UPC5210 Rack Mountable Calibrator.

9. Optional - if the current (4.000 to 20.000 mA) measurement features are to be used, connect the
provided Transducer Test Cable (PN 55092) to the Transducer Test Jacks (14).

When connected, this cable provides +28 VDC e xcitation. The internal impedance (load) is 10 ohms. The display
scaling for these current measurements are as follows:

SWITCH POSITION

Current 0-20.000 mA by 0.005 mA

Table 2-1. Display Select Switch (16)

DISPLAY READING

The test cable connector wiring is as follows:

CONNECTOR PIN DESIGNATION FUNCTION

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 2-1
on page 5 (14).

2.3 Pressure Measurement Sequence (Gage Only)

NOTE: See Figure 2-2 on page 6, when following these steps.

1. Note that the indicator on the right end of the display indicates GAGE mode (10).

2. Zero unit by depressing the
any time, as long as the VENT valve (8) is open, by depressing the

NOTE: If ZERO switch is depressed longer than 5 seconds unit will perform an internal, functional self-check.

3. UPC5200: Open the cylinder valve (5) by rotating counter-clockwise slowly until it stops.
UPC5210: Open the, customer supplied, pressure source valve.

switch (12) for less than five seconds. The instrument can be zeroed at

ZERO

switch (12).

ZERO

Operation

5

6

4. Using the REGULATOR (1), adjust the maximum intensifier pump input pressure, as read by the
REGULATED PRESSURE gauge (6), to 1/10 of the full-scale range of the device-under-test. The unit
utilizes an internal intensifier with a 10:1 ratio. As an example, setting regulated pressure to 300 PSI
would generate an output pressure of 3,000 PSI. Using this technique, the device under test is fully
protected from being accidentally over-pressurized.

5. To generate pressure, enable the

PUMP CONTROL

the ACCUMULATOR gauge (9). Turn the

PUMP CONTROL

switch (20) and monitor the pressure as it builds in

switch (20) off when 10% more than the

target pressure has been achieved.

NOTE: The intensifier PUMP CONTROL switch (20) can be operated in two modes. The up position is
continuous and the down position is momentary/jog.

6. To apply pressure, the

VENT

valve (8) must remain closed. 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 the desired final value.

7. Use either the

COARSE ADJUSTMENT

(2) or

valve (8) to obtain a specific pressure reading. Both

VENT

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. With a little experience, pressure values very
close to the desired final value may be quickly achieved.

NOTE: Use the intensifier PUMP CONTROL switch if the ACCUMULATOR gauge (9) reading falls below
required target pressure value.

8. 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.

9. Transducer Current Measurement - the current signal from the transducer may be displayed at any time
simply by placing the

DISPLAY SELECT

switch (16) to its CURRENT position.

Figure 2-2. Pressure Measurement Sequence (Gage Only)

NOTE: UPC5200 shown, AC Input (7) and Input Port (4) are on back side of UPC5210 Rack Mountable Calibrator.

2.4 Pressure Measurement Sequence (Absolute Only)

NOTE: See Figure 2-3 on page 8, when following these steps.

1. Note that the indicator on the right end of the display indicates ABSOLUTE mode (10).

2. If only pressure measurements greater than barometric are required, continue to step 2.1. If pressure
measurements below atmospheric pressure are required go to step 3.

2.1. UPC5200: Open the cylinder valve (5) by rotating counter-clockwise slowly until it stops.
UPC5210: Open the pressure source valve (customer supplied).

UPC5200/UPC5210 Operation and Maintenance Manual

2.2. Using the REGULATOR (1), adjust the maximum intensifier pump input pressure, as read by the
REGULATED PRESSURE gauge (6), to 1/10 of the full-scale range of the device-under-test. The
unit utilizes an internal intensifier with a 10:1 ratio. As an example, setting regulated pressure to 300
PSI would generate an output pressure of 3,000 PSI. Using this technique, the device under test is
fully protected from being accidentally over-pressurized.

2.3. To generate pressure, enable the

PUMP CONTROL

in the ACCUMULATOR gauge (9). Turn the

switch (20) and monitor the pressure as it builds

PUMP CONTROL

switch (20) off when 10% more

than the target pressure has been achieved.

2.4. 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 it desired final value.

2.5. 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. With a little experience,
pressure values very close to the desired final value may be quickly achieved.

NOTE: Use the intensifier PUMP CONTROL switch if the ACCUMULATOR gauge (9) reading falls below
required target pressure value.

2.6. 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.

3. If pressure measurements below atmospheric pressure are required, connect a vacuum pump to the
VENT/VACUUM port (15) as shown in Figure 2-3 on page 8.

3.1. Open the VENT valve (8), but the COARSE ADJUSTMENT valve (2) must remain closed. 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 0 PSIA. Press the

button to establish a zero

ZERO

reference on the display.

3.2. With the vacuum pump still running, close the VENT valve (8) and check for system leaks. If there
are none, continue to step 3.3.

3.3. Remove the vacuum pump.

3.4. To apply vacuum, COARSE ADJUSTMENT (2) valve must remain closed. Open the VENT valve
(8) counter-clockwise slowly until the numerical display begins to move.

3.5. As the pressure approaches the desired value, the VENT valve (8) should be rotated slowly
clockwise to its closed position. With a little experience, pressure values very close to the desired
final value may be quickly achieved.

3.6. To obtain exact PSIA readings, slowly rotate the VERNIER control (13) knob in the direction
required (clockwise to increase pressure) as indicated by the electronic numerical display.

4. Transducer Current Measurement - the current signal from the transducer may be displayed at any time
simply by placing the

DISPLAY SELECT

switch (16) to its CURRENT position.

Operation

7

8

Figure 2-3. Pressure Measurement Sequence (Absolute Only)

NOTE: UPC5200 shown, AC Input (7) and Input Port (4) are on back side of UPC5210 Rack Mountable Calibrator.

UPC5200/UPC5210 Operation and Maintenance Manual

3.0 Calibration

Follow the procedure on the following pages for calibrating the UPC5200/UPC5210.

NOTES:

• When calibrating, the computer within the UPC5000/UPC5010 is actually being re-programmed, therefore it is
important that the pressure standard being used is in satisfactory operating condition and that the technician
fully understands its operating characteristics and methods of usage. In addition, the UPC5000/UPC5010 itself
must be properly warmed up (approximately 10 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 “UPC5200/UPC5210 Return Material
Authorization Form” on page 50).

3.1 Pneumatic Calibration Set-Up

A typical GAGE calibration set-up using a floating piston type dead weight tester is shown in Figure 3-1. While
doing an ABSOLUTE only unit calibration, a vacuum pump with a PSIA test standard is required where the dead
weight tester/pressure source is shown in Figure 3-1. This enables going below local barometric pressure.

NOTE: Any type of precision pressure or vacuum standard is acceptable as long as its basic accuracy is ±0.025% of

point or better.

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 UPC5200/UPC5210 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 lower left corner of the
panel (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 UPC5200/UPC5210's numerical display is used to provide operator prompting
symbols as well as displaying the various data formats employed. For example, in Figure 3-2, the data format
shown is obtained as soon as the ZERO/SPAN position of the rotary switch has been selected.

Figure 3-1. Instrument Calibration Set-Up

NOTE: UPC5200 shown, Power (AC Input) and Input Port are on back side of UPC5210 Rack Mountable Calibrator.

Calibration

9

10

3.3 Zero/Span Calibration

Selecting the ZERO/SPAN position on the Condec Calibration Module (PN 60109) places the instrument into its
ZERO/SPAN calibration mode. The display is shown in Figure 3-2.

NOTE: Absolute only unit requires vacuum pump with PSIA test standard to obtain readings below local barometric
pressure.

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

Starting with the instrument's lowest pressure range, perform steps 1 and 2 shown in Table 3-1 for each pressure
range.

NOTE: Perform step 1 in all ranges prior to doing step 2.

Perform the following for each step:

1. Gage Only Units
Absolute Only Units:

: Adjust input pressure to the appropriate (either 0 or 100%) value.

Must use a vacuum pump with PSIA test standard, to reach as close to 0 PSIA as

possible (maximum .05 PSIA).

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

STEP NO. PRESSURE

INPUT VALUE

10%

(Note 3 below)

2 100%

NOTES:

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

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

3. Absolute only unit: Maximum PSIA test standard display reading of 0.05 PSIA.

OPERATOR ACTION

REQUIRED

ENTER

Press

Press

ENTER

Table 3-1. Zero and Span Calibration Sequence

button

button

RESULTING DISPLAY

INDICATION

0% Note 1 below

100% Note 2 below

REMARKS

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 UPC5200/UPC5210 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 . For Absolute only
unit, vacuum pump with PSIA test standard must be used to obtain readings below local barometric pressure.

UPC5200/UPC5210 Operation and Maintenance Manual

Figure 3-3. Linearity and Hysteresis Calibration

Starting with the instrument's lowest pressure range, sequentially perform the thirteen steps described in
Table 3-2, for each pressure range being calibrated. Perform the following for each step:

1. Adjust input pressure to the appropriate value without overshooting the setting. If value is overshot by
more than 1%, vent unit and repeat steps.

2. Perform the action as indicated when the readings are stable. Should not take longer than 15 minutes. If
it takes longer, check system for leaks. If no leaks are found, the CPU or transducer may be defective.

STEP

NO.

INPUT PRESSURE %

OF RANGE

10 (Note 4 below)
210
320
430
540
650
760
870

980
10 90
11 100 No Action Required H Note 3 below

12 50
13 0 (Note 4 below) No Action Required L

OPERATOR ACTION REQUIRED

Press

ZERO

Switch

ENTER

Press

ENTER

Press

ENTER

Press

ENTER

Press

ENTER

Press

ENTER

Press

ENTER button

Press
Press ENTER button
Press ENTER button

ENTER button

Press

button
button
button
button
button
button

STATUS SYMBOL IN

LEFT MOST DIGIT

L Zero on Display
L Notes 1 & 2 below
L Notes 1 & 2 below
L Notes 1 & 2 below
L Notes 1 & 2 below
L Notes 1 & 2 below
L Notes 1 & 2 below
L Notes 1 & 2 below
L Notes 1 & 2 below
L Notes 1 & 2 below

H Notes 1 & 2 below

REMARKS

Table 3-2. Linearization and Hysteresis Calibration Sequence

When step no. 11 is reached, the display changes so that the left most status symbol is

H

. 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.

4. Absolute only unit: Maximum PSIA test standard display reading of 0.05 PSIA.

Calibration

11

3.5 Shunt Resistor Calibration

Install the Condec Calibration Module (PN 60109) and select the SHUNT position of the rotary switch on the
module. This places the UPC5200/UPC5210 into its SHUNT RESISTOR calibration mode. The display is
shown in Figure 3-4.

Figure 3-4. Shunt Resistor Calibration

With the UPC5200/UPC5210's highest pressure range selected, perform the four step sequence described below:

1. Gage Only Units: Be sure the input pressure to the UPC5200/UPC5210 is at 0 PSIG.

NOTE: Absolute Only Units: Must use a vacuum pump with PSIA test standard, to reach as close to 0 PSIA as
possible (maximum PSIA test standard display reading of 0.05 PSIA).

2. Press and hold the ZERO button on the Condec Calibration Module until a stable zero indication is
obtained.

3. Release the
(100 ± 5.00%)

4. Press the
display digits are momentarily illuminated.

ZERO button and allow the display to stabilize at its shunt resistor calibration number.

ENTER button on the Condec Calibration Module. When accepted, the bottom half of all

3.6 Current Input Calibration

To calibrate the current input, a current generator capable of generating 20 mA must be connected to the
COMMON and CURRENT INPUT jacks, see Figure 2.2 on page 4 (14). The DISPLAY SELECT switch (16)
should be on the CURRENT position.

1. Set the Condec Calibration Module (PN 60109) to the ZERO/SPAN position. The display is similar to
Figure 3-2 on page 10.

2. Press the

3. Set the Current Generator for 20 mA output. Press the
read

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 reads 20.000. If the display

reading is off, press the

requires servicing.

ZERO button on the module. The display reads 0.00.

ENTER button on the module. The display should

20.00.

ENTER button on the module. If the display reading is not 20.000, CPU is faulty and

4. Disconnect the current generator.

3.7 Permanent Data Storage

After completing the above calibration procedures, the new data that has been entered into the computer must be
permanently stored. The sequence to do this is as follows:

1. Select the DATA RECALL position of the rotary switch on the Condec

2. Press the

STORE pushbutton on the module.

3. If the data is accepted, the four-digit number on the right side of the display indicates

STORE button is pressed.

the

Calibration Module, (PN 60109).

1 020 for as long as

12 UPC5200/UPC5210 Operation and Maintenance Manual

3.8 Normal Mode Test

After completing the above calibration procedures, you must perform a normal mode test. A current generator
capable of generating 20 mA must be connected to the COMMON and CURRENT INPUT jacks, see Figure 2.2
on page 4 (14). The DISPLAY SELECT switch (16) should be on the CURRENT position.

1. Set the Condec Calibration Module to the NORMAL MODE position.

DISPLAY SELECT switch should be in the CURRENT position. The display reads 20.000.

2.

3.9 Self-Check Test

1. Remove the Condec Calibration Module.

2. Press the

100 to verify the unit's accuracy, then it returns to the normal mode automatically.

3. The pneumatic portion of the calibration is now complete. The pressure standard and the Condec
Calibration Module can now be disconnected.

ZERO pushbutton (12) on the UPC5200/UPC5210 until the unit sho ws CAL. The display sho ws

Calibration 13