Condec UPC5200 Operating Manual

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UPC5200 & UPC5210

Portable & Rack-mountable Pneumatic

High Pressure Calibration Console

Operation and Maintenance Manual

CONDEC Sales Phone No. (888) 295-8475

CONDEC Web Site: www.4condec.com

63259

Page 2

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

Speciﬁcations subject to change without notice.

February 2002

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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

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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

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•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.

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

Page 6

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

Figure 1-1. UPC5200/UPC5210 Flow Diagram

Introduction

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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

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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

Page 9

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

Page 10

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

Page 11

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

Page 12

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

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.

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

ENTER

Table 3-1. Zero and Span Calibration Sequence

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

Page 14

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

. 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

Page 15

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

Page 16

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.

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

Page 17

4.0 Maintenance & Service

This section outlines the mechanical and basic electrical repair procedures for the UPC5200/UPC5210.

4.1 Troubleshooting

Use Table 4-1 below for information on troubleshooting the UPC5200/UPC5210.

Symptom Problem Remedy

Display does not light up. 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 does not stay in CAL, display shows "o", display reads a high value @ zero PSIG.

Display does not show zero. Display will not zero. Perform a ZERO/SPAN calibration. Display shifts, will not be steady. Transducer drifts or Possible over

Unit does not cycle when Pump Control switch is on.

Unit cycles, but does not pressurize. Debris in check valve seat in intensiﬁer,

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.

Replace transducer.

pressure. Fuse blown on Pump Control Board.

No power.

deformity in seat.

Replace fuse. Check that power is on.

Remove seats in intensiﬁer and clean and/or replace.

No supply pressure.

Check to see if there is sufﬁcient supply pressure.

Table 4-1. UPC5200/UPC5210 Troubleshooting

4.2 Maintenance & Service Procedures

The repair procedures cover the major components and sub-assemblies which are critical to the proper functioning of the calibrators and that 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

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 and high-pressure components. Unit must always be unplugged from power source.

14 UPC5200/UPC5210 Operation and Maintenance Manual

Page 18

Figure 4-1. UPC5200/UPC5210 Wiring Diagram

Maintenance & Service 15

Page 19

4.2.1 Panel/Chassis Removal and Installation

UPC5200 Removal

Tools required: Phillips screwdriver

1. Loosen and remove the 10 screws (PN 14862) that secure the panel assembly to the enclosure.

2. Lift the panel and chassis by ﬁrst grasping the regulator knob and test port and second, grasping under the panel edges. Tilt the panel at an angle by lifting the right side before the left side as you face the 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 with the accumulator supported by a screwdriver handle.

UPC5200 Installation

Tools required: Phillips screwdriver

1. Lift the panel and chassis by ﬁrst grasping the regulator knob and test port.

2. Gently place panel/chassis assembly into enclosure. Tilt the panel at an angle by lifting the right side before the left side as you face the panel. Ensure that the wire harnesses do not catch and snag.

3. Align mounting holes and install the 10 screws (PN 14862) that secure the panel assembly to the enclosure.

UPC5210 Remo

Tools required: Phillips screwdriver

val

1. Loosen and remove the 14 screws (PN 14861) from top, bottom, and sides that secure the panel assembly to the enclosure. Also, loosen and remove the three screws (P/N 14861) from the rear of unit that secure the enclosure to the AC INPUT/INPUT PORT panel.

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 with the accumulator supported by a screwdriver handle.

UPC5210 Installation

Tools required: Phillips screwdriver

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 14 screws (PN 14862) from top, bottom, and sides that secure the panel/chassis assembly to the enclosure. Also, align mounting holes and install the three screws (P/N

14862) from the rear of unit that will secure the enclosure to the AC INPUT/INPUT PORT panel.

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

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 4-2 on page 34 and Figure 4-2 on page 35 for additional ORION-3A parts information.

1. Vent the system to atmosphere before attempting to work on the unit. Disconnect the power cord from the 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 the following tubing sections:

•Accumulator to supply pressure gauge (1/8" dia.)

•Accumulator to pressure inlet on ORION-3A manifold (1/8" dia.)

•Accumulator to intensiﬁer outlet (1/4" dia.)

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Page 20

4. Loosen and remove the six screws that secure the two clamps that hold the intensiﬁer and accumulator.

5. Remove the accumulator by sliding out.

6. Loosen the ﬁtting nut at the intensiﬁer end of the long 1/4" diameter tubing section that connects the solenoid valve to the intensiﬁer. There is no need to remove the tubing.

7. Remove the two clamps and the intensiﬁer.

8. Using a 7/16" wrench, remove the following tubing sections:

• Vent port to ORION-3A manifold vent outlet (1/8" dia.)

9. 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.

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

11. Using the 11/32" thin wrench, loosen and carefully remove the transducer from the ORION-3A manifold.

12. Remove the panel knobs from the Coarse (pressure), Vernier and Vent valves using the .061" hex wrench.

13. Loosen and remove the two panel scre ws (PN 60837) from the panel front that secure the manifold to the panel.

14. Remove the ﬁve retaining nuts and lock washers that secure the chassis to the panel.

15. Lift the chassis enough to allow the ORION-3A manifold to clear and remove the manifold.

16. Reposition the chassis over the mounting studs and secure with at least two nuts.

4.2.3 ORION-3A Manifold, Valve Seat Removal

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

socket wrench 3/4" socket needle housing socket (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 4-2 on page 34 and Figure 4-2 on page 35 for additional parts information.

1. Secure the manifold by its center portion, in a bench vise, 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 pressure and vent valve threaded needle housings (10).

4. Using the needle housing socket (65580) and torque wrench, loosen and remove the needle/housing assembly (10, 1).

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

6. Loosen and remove the valve housings (19) using the isolation valve housing removal socket (59793) female socket (65581) and torque wrench.

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 have to be drilled and a tap used to extract the seat (Steps 10-13).

10. Using the electric hand drill with the 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.

Maintenance & Service 17

Page 21

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.

4.2.4 ORION-3A 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 68508) isolation valve needle housing socket (PN 68509)

NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 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 might appear to lock up. If this occurs, rotate the shaft 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 and pulling.

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

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

8. Loosen and remove the locknut (20) using the isolation valve needle housing socket (PN

68509), and

socket wrench.

9. Loosen and remove the end bushing (12) using the isolation valve housing socket (PN 68508) and socket wrench. Remove the shaft (14). Remove the ball bearings (41) 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). Also, remove backup retainer (39) from inner groove of the end cap (13).

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

4.2.5 ORION-3A 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 68508) isolation valve needle housing socket (PN 68509)

torque wrench

NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 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 inner groove. Also, install backup retainer (39) in inner groove of the end cap (13).

3. Hold shaft (14) vertically with end that goes through end bushing (12) tow ard ceiling. Place light coating of grease on threads of shaft. Place thick coating of grease on top of shaft bearing surface.

4. Allowing grease to hold ball bearings in place, slide end bushing (12) over top of shaft and down to contact top of ball bearings.

5. Rotate shaft assembly 180˚, placing end bushing towards the ﬂoor. Be careful not to displace ball bearings. Place thick coating of grease on shaft and bearing surface. Place sixteen chrome ball bearings (41) on greased surface, allowing grease to hold them in place.

6. Install shaft (14) with bearings (41) into end cap.

18 UPC5200/UPC5210 Operation and Maintenance Manual

Page 22

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

68508) and socket wrench.

8. Tighten so that shaft rotates, but should be ﬁrm. Feel vertical motion of shaft (14). If motion exists, retighten end bushing.

9. Install the locknut (20) into end cap (13) and using the isolation valve needle housing socket (PN 68509) and torque wrench. Torque to approximately 325 in/lbs. (may not get to torque on all sub-assemblies).

10. 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.

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

12. Apply a thin coat of ﬂuorinated Krytox grease and install the O-ring (29) and backup washer (38) on the end cap/shaft assembly, install into manifold and tighten until snug.

4.2.6 ORION-3A 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 (.050") hex wrench (.061") torque wrench socket wrench 3/4" socket needle housing socket (PN 65580) isolation valve needle housing socket (PN 68509) female socket (PN 65581)

NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 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 valv e 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) and

torque wrench.

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

11. Using the .050" hex wrench, install and tighten the lock nut (2) and set screw (34).

12. 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.

13. For the isolation valves (two inner valves), install the needle housing (19) and tighten until snug using the isolation valve needle 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.

14. 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.

15. Apply a small amount of ﬂuorinated 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.

Maintenance & Service 19

Page 23

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

NOTE: See Figure 2-1 on page 5, for the items listed in parenthesis.

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. With the panel facing down against the bench, if not already done, remove the ﬁve retaining nuts and lock washers that secure the chassis to the panel. Lift up the chassis enough so that the ORION-3A manifold is able to clear.

3. 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.

4. Secure the chassis to the panel with the ﬁve nuts and lock washers (tighten until snug).

5. 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.

NOTE: To install the COARSE (pressure) and VENT Valve Knobs, and perform a valve adjustment, follow the procedure in Section 4.2.8 after completing the following steps.

6. 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 the following:

(+ Excitation) TB1-4 Green wire (- Signal) TB1-6 Red wire (+ Signal) TB1-5 White wire (- Excitation) TB1-7 Black wire

7. Using a 7/16" wrench, install the following tubing section that goes from vent port to ORION-3A manifold vent outlet (1/8" dia.)

8. Replace the intensiﬁer and the two clamps.

9. Realign and tighten the ﬁtting nut at the intensiﬁer end of the long 1/4" diameter tubing section that connects the solenoid valve to the intensiﬁer.

10. Replace the accumulator by sliding in thru the clamps.

11. Thread and tighten the six screws that secure the two clamps that hold the intensiﬁer and accumulator.

12. Using a 7/16" wrench, realign and tighten the following tubing sections:

• accumulator to intensiﬁer outlet (1/4" dia.)

• accumulator to pressure inlet on ORION-3A manifold (1/8" dia.)

• accumulator to supply pressure gauge (1/8" dia.)

13. Using a pressure source connected to the input port (4) set input pressure to 100 PSI. Enable the

CONTROL switch (20) and monitor the pressure as it builds in the ACCUMULATOR gauge (9). Turn the PUMP CONTROL switch (20) off when 1,000 PSI has been achie v ed. Check all ﬁttings for leaks. If there

PUMP

are no leaks vent system and remove pressure source.

NOTE: See Section 2.2 on page 4 for pressure source connection procedure.

14. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

4.2.8 ORION-3A Manifold, Valve Adjustment Procedure

Tools required: hex wrench (.050")

hex wrench (.061")

NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 for additional parts information (* denotes reference to Figure 2-1 on page 5).

1. If not already done, remove the ORION-3A COARSE and VENT valve knobs (3) using the .061" hex wrench.

20 UPC5200/UPC5210 Operation and Maintenance Manual

Page 24

2. Energize the unit and let warm up. Turn RANGE SELECT switch to highest range. To adjust the COARSE valve, go to step 3.

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

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

5. 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 closed position).

6. Rotate gears on both ISOLATION valves (two inner valves), counter-clockwise until they stop, then rotate clockwise 1/2 turn (opening isolation valves).

7. With a pressure source connected to the INPUT PORT (*4). Use the REGULATOR (*1), to increase the regulated pressure (monitor REGULATED PRESSURE gauge) to 1/10 of Full Scale. Enable the

CONTROL switch (20) and monitor the pressure as it builds in the ACCUMULATOR gauge (*9). Turn

PUMP

the PUMP CONTROL switch (20) off when 80% to 100% of Full Scale has been achieved.

8. Open the VENT valve (*8) to atmosphere, then close the VENT valve (*8).

9. 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.

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

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

12. 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.

13. 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 tightening coarse valve knob. Doing so may damage seat.

14. Remove the COARSE valve knob. Align the set screws (25) with the indentations on the knob insert . Install the knob on the knob insert while engaging the knob gear (5) with the ISOLATION valv e gear (6).

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

16. To adjust the VENT valve, follow steps 3 and 4.

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

18. Close the VENT valve knob insert (4) clockwise until slightly snug.

19. With a pressure source connected to the INPUT PORT (*4). Use the REGULATOR (*1), to increase the regulated pressure to 1/10 of full scale. Enable the

PUMP CONTROL switch (20) and monitor the

pressure as it builds in the ACCUMULATOR gauge (*9). Turn the PUMP CONTROL switch (20) off when 80% to 100% of Full Scale has been achieved. Open the COARSE valve until the indicated pressure stabilizes and then close the COARSE valve.

20. Slowly turn the 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.

21. Follow steps 10 through 15 replacing the term "COARSE valve" with "VENT valve". The VENT valve is now adjusted.

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

Tools required: Phillips screwdriver

5/8" open end wrench adjustable wrench A/R 1/4" wide teﬂon tape, (PN's 60575) tube ﬂuorinated Krytox grease (PN 55593)

A/R solvent (de-natured alcohol)

Disassembly:

1. Remove accumulator assembly from UPC5200/UPC5210 per Section 4.2.2 on page 16.

2. Place accumulator body in vise, using ﬂats.

3. Remove plug adapter ﬁtting (PN 57134) using adjustable wrench.

Maintenance & Service 21

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4. Remove O-ring (PN 58051) and back-up ring (PN 59735).

5. Remove accumulator body from vise and place adapter ﬁtting in vise, using ﬂats, threads facing upwards.

6. Remove ﬁlter retainer ﬁtting (PN 57811) using wrench.

7. Remove plug adapter ﬁtting from vise, turn up side down, and remove ﬁlter.

8. Clean the ﬁlter (PN 56993) in solvent (de-natured alcohol) and blow-dry with compressed air.

Assembly:

1. Place ﬁlter (PN 56993) into ﬁlter retainer ﬁtting (PN 57811).

2. Finger tighten ﬁlter retainer ﬁtting into plug adapter ﬁtting (PN 57134).

3. Place plug adapter ﬁtting (PN 57134) in a vise and tighten ﬁlter retainer ﬁtting.

4. Grease O-ring/back-up ring groove on plug adapter ﬁtting.

5. Grease both sides of O-ring (PN 58051) and back-up ring (PN 59735). Then install backup ring onto plug adapter ﬁtting, followed by O-ring.

NOTE: Use pointed bent pick when installing O-ring to Prevent damage. Verify Backup ring split is properly aligned.

6. Place accumulator body in vise using ﬂats. Grease accumulator body in O-ring seat area, then slowly thread plug adapter ﬁtting using an adjustable wrench into accumulator body.

NOTE: To help seat back-up ring hand tighten plug adapter ﬁtting close to bottoming, then wrap an 8" piece of 22 AWG, solid buss wire around the edge of back-up ring within gap between accumulator body and plug adapter ﬁtting. Pull buss wire ends to squeeze back-up ring into proper position within accumulator body. Verify backup ring split is properly aligned.

7. Tighten plug adapter ﬁtting.

8. Install accumulator assembly into UPC5200/UPC5210 per Section 4.2.7 on page 20.

4.2.10 Intensiﬁer Assembly, O-rings/Seals Replacement

NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 for additional parts information.

Tools required: Phillips screwdriver

5/8" open end wrench 1/4” hex key 3/16” hex key 3/8” hex key adjustable wrench check valve seat tool (PN 70711) ﬁtting holder tool (PN 70710) tapered packing retainer tool (PN 70712) check valve ﬁtting tool (PN 70709) A/R 1/4" wide teﬂon tape, (PN's 60575) tube ﬂuorinated Krytox grease (PN 55593)

Oil lubricant, (PN 60944) A/R solvent (de-natured alcohol)

Disassembly Rings and Seals:

1. Remove intensiﬁer assembly from UPC5200/UPC5210 per Section 4.2.2 on page 16.

2. Remove the 10 cap screws (1) and washers (2) from the end cap which has the single elbow ﬁtting (23).

3. Remove the end cap (3) and O-ring (4).

4. Remove the piston (18).

5. Remove the small piston retainer (24) and 3 piston rings (22).

6. Remove the large piston O-ring (21) and 2 packings (20).

Disassembly of Check Valves:

1. Remove inlet check valve ﬁtting (12) and outlet (16) ports.

2. For the outlet valve, remove, in order, the spring housing (8), spring (9), poppet (10) and seat (11).

3. For the inlet valve remove, in order, the seat (15), poppet (10) and spring (9).

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Reassembly of Check Valves:

NOTES:

• Clean all parts with solvent and use shop air hose to remove any dust particles from all mechanical parts, except screws and washers. Wipe the bores of the intensiﬁer housing with a clean cloth before installing the piston. Replace all damaged parts with new ones.

• For ease of assembly and to prevent damage to parts it is recommended to use the following tools during assembly:

• check valve seat tool (PN 70711)

• ﬁtting holder tool (PN 70710)

• tapered packing retainer tool (PN 70712),

• check valve ﬁtting tool (PN 70709)

For the outlet valve:

1. Assemble spring (9) and check valve (10) into spring housing (8).

1.1. Press check valve seat (11) into spring housing (8), using large diameter end of check valve seat tool (PN 70711). Be sure check valve seat (11) is seated. Coat grease in bottom groove marks, in hole of end cap (19) where fitting item (16) goes.

NOTE: The larger of the 2 seats belongs to the outlet check valve. Very important not to get grease in counter-sunk hole located at center of groove marks.

1.2. Place grease on bottom of items (11/8) sub-assembly.

NOTE: Very important not to get grease on item 10.

1.3. Slide (11/8) sub-assembly into end cap (19), until properly seated on bottom. Thread high pressure tube ﬁtting (16) into end cap (19) and tighten using a 5/8” wrench.

2. For the inlet valve, perform the following steps:

2.1. Thread AN side of inlet check valve fitting (12) into fitting holder tool (PN 70710).

2.2. Place a small amount of grease (PN 55593) on inlet check valve fitting (12) between groove area and top of fitting to enable ease of installation of packing retainer (13).

2.3. Place tapered Packing Retainer Tool (PN 70712), stepped part, into hole in packing retainer (13). Place Grease on sides of tool.

2.4. Slide packing retainer (13) onto packing retainer tool (PN 70712) and down into groove of inlet check valve fitting (12).

2.5. Remove packing retainer tool (PN 70712) and wipe the grease from tool.

2.6. Grease both sides of O-ring (14) and install into groove on inlet check valve fitting (12).

2.7. Use stepped part of packing retainer tool (PN 70712) on check valve seat (15) to install into recessed end of inlet check valve fitting (12). Check valve seat (15) must seat flat. If needed, tap tool very lightly to seat, but make sure no damage occurs to inlet check valve fitting (12).

2.8. Tap round dowel (25) into hole on threaded shaft of piston ring retainer (24). Leave extra material protruding from both sides of shaft. Trim round dowel (25), using cutters, to top of threads on both sides. Thread piston ring retainer (24) into piston (18), two or three turns, to form threads on round dowel (25). Remove piston ring retainer (24) from piston (18).

2.9. Grease inside wall of end cap (19) where inlet check valve fitting (12), sub-assembly, O-ring & backup ring will touch.

2.10. Place spring (9) and check valve (10) into end cap (19).

2.11. Thread “AN” side of inlet check valve fitting (12), sub-assembly into Fitting Holder Tool (PN

70710). Now place sub-assembly into Check Valve Fitting Tool (PN 70709), such that, flat side of item (15) goes through beveled side of tool.

2.12. Slide item (12) back and forth in tool a few time to align O-ring and backup ring. Remove sub-assembly from check valve fitting tool (PN 70709) and unthread from fitting holder tool (PN

70710). Thread item (12) sub-assembly into end cap (19), where spring (9) and check valve (10) were previously installed. Tighten using a 5/8” wrench.

Maintenance & Service 23

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Reassembly of Rings and Seals:

NOTE: Clean all parts with solvent and use shop air hose to remove any dust particles from all mechanical parts, except screws and washers. Wipe the bores of the intensiﬁer housing with a clean cloth before installing the piston. Replace all damaged parts with new ones.

1. Smear a medium amount of grease in O-ring cavity on piston (18). Grease both sides of the two backup rings (20) and O-ring (21). Install into groove on piston (18).

NOTE: Split of each backup ring, item 84, must be 180o from each other and ends overlapping properly.

2. Lightly coat edges of backup rings (20) and O-ring (21) with oil lubricant (PN 60944).

3. Lightly coat both inside diameters of housing (17).

4. Place grease on piston ring retainer (24) where piston rings (22) seat.

5. Place grease on both sides of the three piston rings (22) and install the three piston rings (beveled sides aligned) onto piston ring retainer (24).

6. Slide piston (18) into housing (17), being careful not to damage wall areas. Slide until smaller diameter of piston (18) is exposed from side of housing (17).

7. Thread item (24), with the three piston rings (22) into piston (18) approximately four turns.

8. Stand housing (17) on end, with piston ring retainer (24) facing upward. Push piston ring retainer (24) to verify it will go into housing (17) fully. Top of piston ring retainer (24) must be slightly below surface of housing (17).

9. Place housing (17) on its side. Place 3/16" hex key in item (24) and 1/4" hex key in piston (18). Rotate 1/4" hex key to tighten.

10. Remove the 3/16" hex key and verify piston (18) will rotate. If piston rotates remove 1/4" hex key. If it doesn’t rotate, loosen piston slightly.

11. Grease both sides of O-ring (4), and end cap (3) O-ring groove. Then install O-ring (4) into groove of end cap (3).

12. Place housing (17) sub-assembly with large I.D. upward and install end cap (3) into housing (17).

13. Place cap screw (1) through washer (2) and thread ﬁnger tight into end cap (3). Repeat for the other nine cap screws.

14. Use torque wrench and 1/4" hex key socket to torque each bolt to 325 in/lbs.

NOTE: Torque cap screws in a side to side pattern, (do not use a circular pattern), and in small increments to insure end cap, item 67 is seated ﬂat to Housing surface.

15. If previously removed, place 1/4" Teﬂon tape, two turns, on 90o NPT elbow (23). Thread and tighten 90 NPT elbow (23) into end cap (3). Align so that 90o NPT elbow (23) is parallel with the small hole located

on the side of housing (17).

16. Grease both sides of O-ring (7) and O-ring seat area on end cap (19). Install O-ring (7) onto end cap (19) and in turn place onto housing (17). Orient such that the small hole located on housing side is on your left at the "9 o’clock" position. The inlet check valve ﬁtting (12) placement hole located on end cap (19) must be at the 6 o’clock position.

17. Place Cap Screw (5), thru Washer (6), end cap (19) and thread ﬁnger tight into housing (17). Repeat for the other nine cap screws. Use torque wrench and 3/8” hex key socket to torque each bolt to 325 in/lbs.

NOTE: Torque cap screws in a side to side pattern (do not use a circular pattern) and in small increments to ensure end cap (item 83) is seated ﬂat to housing surface.

18. Install intensiﬁer assembly into UPC5200/UPC5210 per Section 4.2.7 on page 20.

24 UPC5200/UPC5210 Operation and Maintenance Manual

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4.2.11 Regulator (Standard Pneumatic) and Solenoid Removal

Solenoid 120 VAC input - PN 56851, Solenoid 220 VAC input - PN 54366

Tools required: Phillips screwdriver

7/16" open end wrench 9/16" open end wrench A/R 1/4" wide teﬂon tape, (PN's 60575) A/R 1/2" wide teﬂon tape, (PN's 60911) 1/2" socket socket wrench 1/4" hex wrench

NOTE: See Figure 4-4 on page 37.

1. Vent any remaining gas from the system to atmosphere. Disconnect the power cord from the power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 16, and carefully place on a bench top.

3. Remove regulator knob cap and two screws that secure the round plate.

4. Loosen and remove the locknut using a 1/2" socket while holding the knob. Remove the knob by turning counter-clockwise.

5. (UPC5210 Only) Loosen tube nut on INPUT PORT ﬁtting. Remove the two screws and POWER/INPUT PORT panel.

6. Remove all tubing sections that connect to the regulator/solenoid assembly.

7. Loosen the mounting collar in the panel rear using a 1/4" hex wrench.

8. Remove the regulator/solenoid assembly by sliding out from the panel rear.

9. Mount the regulator in a bench vise by the ﬂats in the base.

10. Note the orientation of the solenoids, as well as the inlet and outlet ﬁttings in the regulator. Remove the ﬁttings and any remnants of teﬂon tape from the pipe threads.

4.2.12 Regulator (Standard Pneumatic) and Solenoid Installation

Solenoid 120 VAC input - PN 56851, Solenoid 220 VAC input - PN 54366

Tools required: Phillips screwdriver

7/16" open end wrench 9/16 " open end wrench A/R 1/4" wide teﬂon tape, (PN's 60575) A/R 1/2" wide teﬂon tape, (PN's 60911) snoop, liquid leak gas detector (PN 64781) 1/2" socket socket wrench

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, as well as, solenoids are oriented properly. Use a bench vise when doing this.

2. Insert the new regulator/solenoid assembly into the panel through hole. Pass the adjusting end through the mounting ring. Do not tighten cap screw until adjusting knob is installed.

3. Install the tubing sections to the inlet and outlet ﬁttings. (UPC5210 only) Replace the POWER/INPUT PORT panel and 2 mounting screws. Thread and tighten

tube nut on INPUT PORT ﬁtting.

4. Install the adjusting knob on the threaded shaft by turning clockwise. Turn adjusting knob on threaded shaft until bottomed and install locking nut and tighten. T urn knob until it bottoms. Position the regulator so that the bottom of the knob is 1/2" from the panel surface, then tighten the cap screw on the mounting collar.

5. Using a pressure source connected to the input port (4) set regulated pressure to 100 PSI. Enable the

PUMP CONTROL switch (20) and monitor the pressure as it builds in the ACCUMULATOR gauge (9).

Turn the

PUMP CONTROL switch (20) off when 1,000 PSI has been achieved. Check all ﬁttings for

leaks. If there are no leaks vent system and remove pressure source.

6. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

Maintenance & Service 25

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4.2.13 Regulator (Tescom) and Solenoid Removal

Solenoid 120 VAC input - PN 56851, Solenoid 220 VAC input - PN 54366

Tools required: Phillips screwdriver

7/16" open end wrench 9/16" open end wrench A/R 1/4" wide teﬂon tape, (PN's 60575) A/R 1/2" wide teﬂon tape, (PN's 60911) 1/2" socket socket wrench 1/4" hex wrench ﬂat blade screwdriver (small) channel locks

NOTE: See Figure 4-4 on page 37.

1. Vent any remaining gas from the system to atmosphere. Disconnect the power cord from the power source. .

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 16, and carefully place on a bench top.

3. Remove regulator knob cap by prying off with small screwdriver.

4. Loosen and remove the locknut using a 1/2" socket while holding the knob. Remove the knob by turning counter-clockwise.

(UPC5210 only) Loosen tube nut on INPUT PORT ﬁtting. Remove the 2 screws and POWER/INPUT PORT panel.

5. Remove all tubing sections that connect to the regulator inlet and outlet ﬁttings.

6. Loosen and remove the panel mounting nut using channel locks.

7. Remove the regulator/solenoid assembly by sliding out from the panel rear.

8. Mount the regulator in a bench vise by the ﬂats in the base.

9. Note the orientation of the solenoids, as well as the inlet and outlet ﬁttings in the regulator. Remove the ﬁttings and any remnants of teﬂon tape from the pipe threads.

4.2.14 Regulator (Tescom) and Solenoid Installation

Solenoid 120 VAC input - PN 56851, Solenoid 220 VAC input - PN 54366

Tools required: Phillips screwdriver

7/16" open end wrench 9/16" open end wrench 1/2" socket socket wrench torque wrench A/R 1/4" wide teﬂon tape, (PN's 60575) A/R 1/2" wide teﬂon tape, (PN's 60911) snoop, liquid leak gas detector (PN 64781)

NOTE: See Table 4-4 on page 37. Call Condec for replacement part numbers.

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. Use a bench vise when doing this.

2. Insert the new regulator/solenoid assembly into the panel through hole. Thread the large mounting nut onto the body from the panel front.

3. Install the tubing sections to the inlet and outlet ﬁttings. (UPC5210 only) Replace the POWER/INPUT PORT panel and two mounting screws. Thread and

tighten tube nut on INPUT PORT ﬁtting.

4. Install the REGULATOR knob on the threaded shaft by turning clockwise, until it sits just low enough to allow locknut to be placed on threaded shaft. Hold knob in position and install the locknut.

5. Close REGULATOR, by turning regulator knob counter-clockwise.

6. Using a pressure source connected to the INPUT PORT (4) set regulated pressure to 100 PSI. Enable the

PUMP CONTROL switch (20) and monitor the pressure as it builds in the ACCUMULATOR gauge (9).

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Turn the PUMP CONTROL switch (20) off when 1,000 PSI has been achieved. Check all ﬁttings for leaks. If there are no leaks vent system and remove pressure source.

7. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

8. Energize the unit and let warm up. Turn range select switch to highest range.

9. Close the COARSE valve by turning the COARSE knob clockwise.

10. Using a pressure source connected to the INPUT PORT (4), turn the REGULATOR knob clockwise until reaching between .5% to 1% of full scale, but not enough to disturb pressure relief valve.

NOTE: If pressure cannot be attained loosen locknut on shaft, rotate knob a few turns counter-clockwise, and retighten locknut. If you hear the pressure relief valve open, rotate regulator knob counter-clockwise until relief valve shuts off.

11. Remove locknut from threaded shaft, and rotate knob counter-clockwise until bottoming out on large locknut. After touching large locknut rotate knob clockwise 1/8 turn. Hold knob in position, install and tighten the locknut with 40 - 50 in-lbs. of torque using a 1/2" socket.

12. Open REGULATOR completely, by turning REGULATOR knob clockwise. If you reach between 10-11% of full scale and pressure relief valve was not disturbed regulator has been adjusted properly.

13. Replace regulator knob cap.

4.2.15 Panel Gauge Removal and Installation

•Regulated pressure gauge (PN 59745), 0–600 PSIG

•Regulated pressure gauge (PN 59751), 0–1,500 PSIG

•Accumulator gauge (PN 59749), 0–6,000 PSIG

•Accumulator gauge (PN 59696), 0–15,000 PSIG

Tools required: Phillips screwdriver

7/16" wrench 9/16 " wrench A/R 1/4" wide teﬂon tape (PN 60575) snoop, liquid leak gas detector (PN 64781)

Panel Gauge Removal

1. Vent any remaining gas from the system to atmosphere. Disconnect the power cord from the power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 16, 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 tube connector ﬁtting from the gauge.

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

Panel Gauge Installation

Tools required: Phillips screwdriver

7/16" wrench 9/16" wrench A/R 1/4" wide teﬂon tape (PN 60575) snoop, liquid leak gas detector (PN 64781)

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 onto the gauge.

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

5. Using a pressure source connected to the INPUT PORT (4) set regulated pressure to 100 PSI. Enable the

PUMP CONTROL switch (20) and monitor the pressure as it builds in the ACCUMULATOR gauge (9).

Turn the

PUMP CONTROL switch (20) off when 1,000 PSI has been achieved. Check all ﬁttings for

leaks. If there are no leaks vent system and remove pressure source.

6. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

Maintenance & Service 27

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

Every two months, a coating of ﬂourinated Krytox grease should be applied to the inner seal of the test port ﬁtting. The pressure cap (PN 58216) should be plugged in whenever the unit is not in use.

NOTE: For simplest method, apply ﬂuorinated krytox grease to the outside surface between sealing lip and end of mating pressure cap. Do not put grease on ﬂat end of tip, as this may allow grease to enter system. Vent unit line pressure to atmosphere. Plug pressure cap into test port. Rotate pressure cap clockwise and counter-clockwise to transfer ﬂuorinated krytox grease to O-ring seal.

If there is leakage out of the port when the pressure cap is in place, replace the port ﬁtting.

Tools required: Phillips screwdriver

11/16" open end wrench adjustable wrench 9/16" open end wrench A/R solvent (de-natured alcohol) A/R 1/4" wide Teﬂon tape (PN 60575) A/R 1/2" wide Teﬂon tape (PN 60911) tube ﬂuorinated grease (PN 55593) snoop, liquid leak gas detector (PN 64781)

1. Vent any remaining gas from the system to atmosphere. Disconnect the power cord from the power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 16, and carefully set on a bench top.

3. Loosen and remove the tubing end nut from the reducing tube ﬁtting (PN 59830).

NOTE: Use PN 54047 for reducing tube ﬁtting ﬁeld replacement.

4. Loosen and remove the reducing tube ﬁtting and ﬁlter (PN 54188) from the test port quick-connect ﬁtting.

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

6. Grasp the test port quick-connect ﬁtting on the ﬂats from the rear of panel with a 11/16" wrench and using an adjustable wrench, turn the locknut counter-clockwise. Remove locknut.

7. Remove old and install new test port quick-connect ﬁtting (PN 59004) through front of panel.

8. Thread and tighten locknut by grasping the test port quick-connect ﬁtting on the ﬂats from the rear of panel with a 11/16" wrench and using an adjustable wrench, turn the locknut clockwise.

9. Slide ﬁlter (PN 59764) into reducing tube ﬁtting and install into the test port quick-connect ﬁtting.

10. Replace and tighten the tubing end nut on the reducing tube ﬁtting.

11. Using a pressure source connected to the INPUT PORT (4) set regulated pressure to 100 PSI. Enable the

PUMP CONTROL switch (20) and monitor the pressure as it builds in the ACCUMULATOR gauge (9).

Turn the

PUMP CONTROL switch (20) off when 1000 PSI has been achieved. Check all ﬁttings for

leaks. If there are no leaks vent system and remove pressure source.

12. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

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

Tools required: 5/8" open end wrench

3/4" open end wrench 13/16" open end wrench A/R solvent (de-natured alcohol) tube ﬂuorinated grease (PN 55593)

Removal:

1. Loosen and unthread quick-connect ﬁtting assembly from test port hose using 3/4" and 5/8" wrenches.

2. Remove cheat seal pad (PN 54854) from AN thread side of adapter ﬁtting (PN 60803)

3. Place quick-connect ﬁtting assembly in a vise using ﬁlter ﬁtting (PN 59588) as clamping area.

4. Loosen and unthread quick-connect ﬁtting (PN 59034) using 13/16" wrench.

5. Remove ﬁlter ﬁtting (PN 59588) from vise.

6. While holding ﬁlter ﬁtting (PN 59588) vertically, remove ﬁlter (PN 56991) and then O-ring (PN 55608) from ﬁlter ﬁtting.

7. Inspect and clean parts in solvent (de-natured alcohol) and blow-dry with compressed air. Replace worn or damaged parts with new ones.

28 UPC5200/UPC5210 Operation and Maintenance Manual

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Installation:

1. Grease inside cavity on bottom ﬂat (none allowed in hole) of quick-connect ﬁtting (PN 59034).

2. Grease O-ring seat groove area in ﬁlter ﬁtting (PN 59588).

3. Grease both sides of O-ring (PN 55608). While holding ﬁlter ﬁtting (PN 59588) vertically, place O-ring (PN 55608) and then ﬁlter (PN 56991) into ﬁlter ﬁtting (PN 59588).

4. Thread quick-connect ﬁtting (PN 59034) onto ﬁlter ﬁtting (PN 59588).

5. Place ﬁlter ﬁtting (PN 59588) in a vise and tighten quick-connect ﬁtting (PN 59034) using 13/16" wrench.

6. Remove from vise.

7. Place a cheat seal pad, cheat seal pad (PN 54854) on AN part of assembly and thread into test port (output) hose. Tighten assembly using 5/8" and 3/4" wrenches.

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

The port ﬁlter is a sintered element ﬁlter, which is 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)

Input Port Filter Removal

1. Vent any remaining gas from the system to atmosphere. Disconnect the power cord from the power source.

2. Remove front panel from its enclosure as described in Section 4.2.1 on page 16, and carefully place on a bench top.

3. Loosen and remove the tubing end nut from the tube union (PN 59886).

4. Loosen and remove the tubing end nut from the input port bulkhead AN ﬁtting (PN 59707).

5. Remove the the tube union (PN 59886), port connector (PN 59746) and ﬁlter from the bulkhead AN ﬁtting (PN 59707).

NOTE: Use PN 55705 for port connector ﬁeld replacement.

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

Input Port Filter Installation

1. To reinstall, reverse the order of steps 3, 4 and 5 of the "Input Port Filter Removal" procedure above.

2. Using a pressure source connected to the INPUT PORT (4) set regulated pressure to 100 PSI. Enable the

PUMP CONTROL switch (20) and monitor the pressure as it builds in the ACCUMULATOR gauge (9).

Turn the

PUMP CONTROL switch (20) off when 1,000 PSI has been achieved. Check all ﬁttings for

leaks. If there are no leaks vent system and remove pressure source.

3. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

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

Tools required: 3/4" open end wrench

9/16" open end wrench A/R solvent (de-natured alcohol) A/R 1/2" wide Teﬂon tape (PN 60911)

Removal:

1. Loosen and unthread

quick-disconnect ﬁtting from input hose using 3/4" and 9/16” wrenches.

2. Remove cheat seal pad (PN 54854) from “AN” thread side of adapter ﬁtting (PN 60803) and place CGA-580 nipple (PN 57150) pressure ﬁtting in vise, holding by ﬂats located on nipple.

3. Loosen and unthread adapter ﬁtting (PN 60803) from CGA-580 nipple (PN 57150) pressure ﬁtting using a 3/4" wrench.

4. Remove CGA-580 nut (PN 57154) by sliding over threads of CGA-580 nipple (PN 57150) pressure ﬁtting.

5. Remove remnants of teﬂon tape from ﬁttings.

Maintenance & Service 29

Page 33

6. Inspect and clean parts in solvent (de-natured alcohol) and blow-dry with compressed air. Replace worn or damaged parts with new ones.

Installation:

1. Wrap two turns of 1/2" Teﬂon Tape around threads of CGA-580 Nipple (PN 57150) pressure ﬁtting.

2. Hold CGA-580 nipple (PN 57150) pressure ﬁtting in vise by ﬂats located on nipple.

3. Slide CGA-580 nut (PN 57154) over threads of CGA-580 nipple (PN 57150) pressure ﬁtting.

4. Thread and tighten adapter ﬁtting (PN 60803) onto CGA-580 nipple (PN 57150) pressure ﬁtting using a 3/4" wrench.

5. Remove assembly from vise and install a cheat seal pad (PN 54854) on AN thread side of adapter ﬁtting (PN 60803).

6. Thread into input hose and tighten using 3/4" and 9/16" wrenches.

4.2.20 AC Fuse (PN 57472), Removal and Installation

1. Disconnect the power cord from the power source and line ﬁlter. Remove the Fuse holder at POWER.

2. Inspect fuse, if blown replace with 1/2 Amp 250 Volt, 20mm x 5mm diameter ( PN 57472).

3. Replace the Fuse holder at POWER location.

4.2.21 Panel Mounted 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 Section 4.2.1 on page 16, and carefully set on a bench top.

2. Remove the 3 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.

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

4.2.22 Chassis Mounted EMI Line Filter (PN 59015), 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 Section 4.2.1 on page 16, and carefully set on a bench top.

2. Remove the ﬁve cable connectors from the line ﬁlter terminals.

3. Loosen and remove the line ﬁlter retaining nuts on the side of chassis.

4. Remove the line ﬁlter.

5. To install a new line ﬁlter, reverse the order of steps 1 through 4.

Connect wires to the two wire side of new line ﬁlter as follows:

Blue wire to CPU White wire Brown wire to CPU Black wire

30 UPC5200/UPC5210 Operation and Maintenance Manual

Page 34

Connect wires to the three wire side of new line ﬁlter as follows:

Green/Yellow wire to AC INPUT Green wire from terminal (E) Ground Blue wire to AC INPUT White wire from terminal (N) Neutral Brown wire to pump control board, black wire from TB3 terminal HI

NOTE: Some units may have POWER marking in place of AC INPUT on panel.

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

Tools required: Phillips screwdriver

Flat 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 Section 4.2.1 on page 16, and carefully set on a bench top.

2. Remove the two black wires from pump control board TB2 terminals 1 and 2.

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

4. Unsolder and remove the three 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:

erminal Function

Rear of Switch 1 On 2 Off 3 Momentary

Black wire to switch terminal 1 Black wire to switch terminal 2 Black jumper wire between switch terminals 1 & 3

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

bottom of panel and secure it from the front of panel with the mounting nut.

3. Replace the two black wires to the pump control board TB2. Connect terminal 1 of switch to terminal 1

of TB2, and terminal 2 of switch to terminal 2 of TB2.

4. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

4.2.24 Power Switch (PN 58878), 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 16, 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:

Maintenance & Service 31

Page 35

Terminal Color

Normally open Black

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, damage may occur to switch.

4. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

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

Tools required: Phillips screwdriver

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

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 16, 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.

NOTE: Intensiﬁer and Accumulator will need to be removed prior to switch removal.

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

Installation:

1. Connect and solder the wires onto their respective switch terminals:

Range Select: T

1 Grey

erminal Color

2 Violet

Display Select: Terminal Color

2 Blue (C) common Green (C) common Green

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

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

4. Replace tubing and components as necessary.

5. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

4.2.26 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 16, 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.

32 UPC5200/UPC5210 Operation and Maintenance Manual

Page 36

Installation:

1. Connect and solder the wires onto their respective switch terminals:

Zero: T

Normally open Yellow (C) common Green

erminal Color

2. Install the new switch, lock washer and nut through the panel rear. Hand tighten the trim ring from front of panel.

3. Tighten the switch mounting nut and lock washer from the rear of panel. Replace CPU if necessary.

CAUTION: If wrench is used, do not over tighten, damage may occur to switch.

4. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

4.2.27 CPU Assembly, Removal and Installation

120 VAC input - PN 54254, 220 VAC input - PN 54268

Tools required: Phillips screwdriver

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

Removal of CPU Board:

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 16, and carefully set on a bench top.

2. Disconnect and/or unsolder the wire connections attached to the CPU board assembly.

NOTE: It may be helpful to mark ends of wire with location. Also refer to the wiring diagram Figure 4-1 on page 15.

3. Loosen and remove the ﬁve screws and two cable clamps (PN 59480) that hold the CPU board assembly and remove the board.

Installation of Power Supply Board:

1. Position the new board over the ﬁve standoffs and install ﬁve screws and two cable clamps. Tighten the screws until snug.

2. Connect and/or solder the wire connections attached to the CPU board assembly.

NOTE: Refer to the wiring diagram Figure 4-1 on page 15.

3. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

4.2.28 Pump Control Board Assembly, Removal and Installation

120 VAC input - PN 56679, 220 VAC input - PN 56682

Tools required: Phillips screwdriver

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

Removal of Pump Control Board:

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 16, and carefully set on a bench top.

2. Disconnect the wires from the terminal blocks located on the pump control board assembly.

NOTE: It may be helpful to mark ends of wire with location. Also refer to the wiring diagram Figure 4-1 on page 15.

3. Loosen and remove the four nuts that hold the pump control board and remove the board.

Installation of Power Supply Board:

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

2. Connect the wires to the terminal blocks located on the pump control board assembly (see Figure 4-1 on page 15.

3. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16.

Maintenance & Service 33

Page 37

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

The following table lists the component parts of the ORION-3A.

Ref Number PN Description Quantity

1 57482 Nut, valve needle housing 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 57600 Bushing, end 1 13 58554 Cap, end 1 14 58699 Shaft 1 15 58597 Piston 1 16 59309 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 58464 Setscrew,12-24NCx1/4 SST 14 22 58308 Ball, Tungsten Carbide 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, 2-56NCx1/8, alloy steel 4 27 55569 O-ring, Fluorocarbon (Viton) color black w/white dot 5 28 55552 O-ring, Fluorocarbon (Viton) color black w/white dot 4 29 58090 O-ring, Fluorocarbon (Viton) color black w/white dot 1 30 60633 Retainer, Packing Backup 4 31 55570 Washer, backing 4 32 58045 O-ring, Fluorocarbon (Viton) color black w/white dot 1 33 59245 Washer, nylon 2 34 60202 Setscrew, hex 2 35 60837 Screw, MACH #10- 32NF SST 2 36 54905 Screw, self sealing 1 38 57027 Washer, backup 1 39 54448 Retainer, packing backup 1 40 55615 O-ring, Fluorocarbon (Viton) color black w/white dot 1 41 58314 Ball, chrome, steel 32 42 59731 Male connector, 1/8 tube x 1/8 NPT, stainless steel 3

Table 4-2. ORION-3A Valve Assembly Parts List

34 UPC5200/UPC5210 Operation and Maintenance Manual

Page 38

Figure 4-2. ORION-3A Part No. 55287 Exploded View

Maintenance & Service 35

Page 39

4.4 Intensiﬁer Assembly Parts List

Ref

Number

1 59328 Screw, cap, socket 10 2 60704 Washer, ﬂat 10 3 59548 Cap, end 1 4 55589 O-ring, Buna-N (Nitrile) 70 Durometer color black 1 5 59333 Screw, cap, socket head 10 6 59508 Washer, ﬂat 10 7 55579 O-ring, Flourocarbon (Viton) 90 Durometer color black w/white dot 1 8 60133 Housing, spring 1

9 60343 Spring 2 10 57410 Check valve 2 11 56714 Seat, check valve 1 12 57236 Fitting, check valve inlet 1 13 54456 Retainer, packing backup 1 14 55596 O-ring, Flourocarbon (Viton) 90 Durometer color black w/white dot 1 15 57114 Seat, check valve 1 16 59785 Adapter, High Pressure 1/4 NPT Male to Swagelok 1 17 60333 Housing, piston 1 18 59070 Piston 1 19 58786 Cap, end 1 20 60579 Retainer, packing 2 21 55600 O-ring, Buna-N (Nitrile) 70 Durometer color black 1 22 54614 Ring, piston 3 23 59794 Elbow, 90 Tube to Male NPT 1 24 58752 Retainer, piston ring 1 25 69435 Dowel, round 1

PN Description Quantity

Table 4-3. Intensiﬁer Parts List

36 UPC5200/UPC5210 Operation and Maintenance Manual

Page 40

Figure 4-3. Intensiﬁer Exploded View

Figure 4-4. Tescom and Standard Pneumatic Regulator Mounting

Maintenance & Service 37

Page 41

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 25

NOTE 24

POLARIZED

POLARIZED 4700uF20% 16V

SPECIFICATION

C21 NOTE 8KHV311A56

MATERIAL OR

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

-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

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

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

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

R33 NOTE 29

U9KBF8918AIC, 8 BIT MICROCOMPUTER9C U8,U13,U7KBE8918AIC, 2 INPUT NAND8C U20KDH8918AIC, OPERATIONAL AMPLIFIER7B U6KAG1918AEIC, HEX BUFFER/DRIVER6C

CKD.

DR.BY

U5KEV1918DIC, QUAD SWITCH5A U4KER1918AIC, QUAD AMPLIFIER4A NOTE 7KBY1918UIC, OPERATIONAL AMPLIFIER3C

MATERIAL OR

---

LF13333N 16 PIN HA4741 14 PIN

NOTE

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

RICE LAKE WEIGHING SYSTEMS

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

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

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

74HCT374 20 PIN

5K 1% 0.1W

80C39 40 PIN 74HCT00 14 PIN AD708NJX 8 PIN

7417 14 PIN

OP-07CJ 8 PIN

REMARKS

ASSEMBLY,

CPU AND POWER SUPPLY

SHEET OF

SCALE

N/A

DWG NO

REVISION

INIT

DJS KLL DJS KLL

KAL JEW

54254

DATE 6/15/00 10/4/00

12/12/01

UPC5200/UPC5210 Operation and Maintenance Manual

Figure 4-5. CPU and Power Supply Assembly, Sheet 1(For Non-Battery Units Only)

Page 42

Figure 4-6. CPU and Power Supply Assembly, Sheet 1 (For Non-Battery Units Only)

Maintenance and Service

Page 43

UPC5200/UPC5210 Operation and Maintenance Manual

Figure 4-7. Power Supply Assembly (For Battery Units Only)

Page 44

Figure 4-8. CPU Schematic, Sheet 2 (For Battery Units Only)

Maintenance and Service

Page 45

UPC5200/UPC5210 Operation and Maintenance Manual

Figure 4-9. Pump Control Board Assembly

Page 46

Figure 4-10. Pump Control Board Schematic

Maintenance and Service

Page 47

5.0 Model Number System

U P C 5 2 0 0 - ____ ____ ____ U P C 5 2 1 0 - ____ ____ ____ ≠ ≠ ≠

+-------------------------------------+ ≠ ≠ ≠ ≠ ≠ ≠ POWER and RANGE REQUIREMENTS ≠ ≠ ≠

A - 10000/5000/2000 120 VAC * ≠ ≠ B - 5000/2500/1000 120 VAC ≠ ≠ C - 10000/5000/2000 220 VAC * ≠ ≠ D - 5000/2500/1000 220 VAC ≠ ≠ ≠ ≠

+----------------------------------------------+ ≠ ≠ MODE ≠ ≠

A - Gage Only ≠ B - Absolute Only ≠

≠

+------------------------------------------------------+

≠

≠ ≠

≠ DISPLAY

≠

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

* Available in Gage Only

44 UPC5200/UPC5210 Operation and Maintenance Manual

Page 48

6.0 Ranges and Resolutions

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

RANGE (PSI)

HI/MED/LO

10000/5000.0/2000.0

5000.0/2500.0/1000.0

Calibrator Mode

Gage Only

Gage Only or

Absolute Only

Table 6-1. Ranges and Resolutions

RESOLUTION

HI/MED/LO

2/1/0.5

1/0.5/0.2

Ranges and Resolutions 45

Page 49

7.0 Options, Replacement Kits

There are numerous replacement part numbers mentioned throughout manual that can be ordered. ORION-3A O-Ring Replacement Kit (Data Sheet # 65370):

• Fluorocarbon “Viton” (standard)...........................................................PN 55277

•Nitrile Buna-N.......................................................................................PN 58499

• Ethylene-Propylene ...............................................................................PN 58506

• Silicone..................................................................................................PN 58509

•Neoprene...............................................................................................PN 58515

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 # 58596)......................................................PN 58478

•Test Port (output) Quick-Disconnect Male Hose ﬁtting........................PN 55542

• Input Port Hose Nitrogen Bottle Mating ﬁtting (one each of the following)

Cheat Seal Pad...................................PN 54854

Hose Adapter ﬁtting..........................PN 60803

CGA-580 Nipple...............................PN 57150

CGA-580 Nut....................................PN 57154

Note: For Input Port Quick-Disconnect Female Hose ﬁtting assembly instructions see Section 4.2.19 on page 29.

Test Port (output) Hose, with Quick-Disconnect Male ﬁtting:

• 5' Long...................................................................................................PN 55280

Input Port Hose, with Nitrogen Bottle Mating ﬁtting:

• 4' Long...................................................................................................PN 55360

• 10' Long.................................................................................................PN 55366

• 15' Long.................................................................................................PN 55369

• 20' Long.................................................................................................PN 55375

46 UPC5200/UPC5210 Operation and Maintenance Manual

Page 50

8.0 Speciﬁcations

Pressure Speciﬁcations:

Pressure range: Three independent pressure ranges

Available pressure calibrations: Gage only or absolute only, Overall accuracy: < ±0.05% Full Scale Max. Accuracy

Operating Temp: +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, standard

External Pressure Cylinder, UPC5200 only:

Capacity: 83.3 ft Volume: 960 in

Rating: 2,216 psig Test Pressure: 3,694 psig Material: Aluminum

Regulated Pressure Gage:

Size: 2-1/2 in. diameter Range: 5K model 0–600 PSIG,

Test Pressure: 5K model 900 PSIG,

Accumulator Gage:

Size: 2-1/2 in. diameter Range: 5K model 0–6,000 PSIG,

Test Pressure: 5K model 9,000 PSIG,

Over-pressure Rupture Disk:

Rating: 3,000 PSIG, nominal Type: Stainless steel outer case

Pressure Media Filter:

Rating: 20 microns, Test Port and Input Port

Type: Field replaceable

ORION-3A Control Valve:

Type: Micro-metering with replaceable soft Material: Aluminum knobs, black anodized

Relief Valve: Type: Adjustable, atmospheric bleed Setting: Adjustable, set between 525-550

Material: 300 series Stainless Steel.

per instrument. See Section 5.0 on page 44 for available ranges.

statement includes all effects of linearity, hysteresis, repeatability and ambient temperature

N2 @ 2,216 PSIG

10K model 0–3,000 PSIG

10K model 4,500 PSIG

10K model 0–15,000 PSIG

10K model 22,500 PSIG

40 microns, Test Port Hose

seat

All other parts 300 series stainless steel

PSIG

Internal Piping:

Tubing: 1/8 in. O.D., 0.035 in. wall thickness,

Couplings: Stainless Steel, Swagelok type Input Port:

Style: 1/4" 37° AN ﬂare male Pressure Rating: 2216 PSIG connected Material: 300 series Stainless Steel

Test Port:

Pressure Rating: 10,000 PSIG. Material: 300 series Stainless Steel

Vent Port:

Style: 1/4" 37° AN male Pressure Rating: 10,000 PSIG Material: 300 series Stainless Steel

Pressure Hoses:

Quantity Supplied: Two; one input, one output Length: 4 ft. nominal, input hose

Style: Input hose

Regulator:

Type: Single stage, self-venting, non-bleed Pressure Rating: 3,000 PSIG max. inlet

Internal Pressure Sensor:

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

Construction: Completely weld-sealed Stainless

Carrying Case UPC5200 only:

Type: Aluminum case with latched cover and Material thickness: 0.090 in., nominal

Finish: Enamel paint, textured ﬁnish Color: Gray

seamless Cu. 1/4 in. O.D., 0.035 and 0.065 in. wall

thickness, seamless 304 Stainless Steel

5 ft. nominal, output hose with synthetic ﬁber braid and polyester

cover. Fitted with CGA-580 (Brass) nipple ﬁtting on one end and 1/4" 37˚ female AN swivel pressure ﬁtting on opposite end.

Output hose with synthetic ﬁber braid and polyurethane cover. Fitted with quick-disconnect plug (St Stl) on one end and 1/4" 37˚ female AN swivel tube coupling on the other.

sputtered thin-ﬁlm or equivalent.

Steel outer body and pressure cavity.

handle

- Nylon-lined core tube

Specifications 47

Page 51

Control Panel:

Material: Aluminum (5052-H32) Thickness: 0.125 in. UPC5200 Finish: Gray enamel paint with black

silkscreen nomeclature

UPC5210 Finish: Dark Tan enamel paint with black

silkscreen nomenclature

Physical Speciﬁcations:

Weight: 52 lbs. including all hoses and cables. UPC5200 Case Dim’s: 11" wide x 18" long x 11.5" high UPC5210 Case Dim’s: 19" wide x 8.1" deep x 10.5" high (Case Dimensions excluding front handles).

48 UPC5200/UPC5210 Operation and Maintenance Manual

Page 52

UPC5200/UPC5210 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 "suitable shipping container." Some units ha v e 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.

Caution

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.

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

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.

UPC5200/UPC5210 Warranty and Return Policy 49

Page 53

UPC5200/UPC5210 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

50 UPC5200/UPC5210 Operation and Maintenance Manual