Yokogawa YPC4000 Operating Manual

Users
Model YPC 4000 Series
Manual
Portable Modular Calibrator
YPC 4000 Calibrator
YPC 4010 Calibrator with HART
®
©Yokogawa Corporation of America 2 Dart Road, Newnan, GA 30265 770-254-0400
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Models
YPC 4000 Modular Calibrator
YPC 4010 Modular Calibrator / HART® Communicator
IMPORTANT NOTICE
ASSISTANCE
For customer assistance please contact the local Yokogawa Representative or Yokogawa Corporation of America directly. For a geographic listing of Representatives and their contact information, visit our web site at www.us.yokogawa.com/mi 254-0400 or by e-mail at info@us.yokogawa.com. Direct all assistance inquiries to the Meter & Instrument group.
®
HART
is a registered trademark of the HART Communication Foundation.
Important information on the product is contained in this manual.
Read this manual carefully and completely before operating the
product. For the safety of the operator and the system, a thorough
understanding of this manual is necessary before commissioning,
using or maintaining the product.
. Contact Yokogawa Corporation of America directly by phone at (770)
YOKOGAWA CORPORATION OF AMERICA
2 Dart Road
Newnan, GA 30265
TELEPHONE: (770) 254-0400 FAX: (770) 254-2088
E-mail: info@us.yokogawa.com
Web Site: www.us.yokogawa.com/mi
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TABLE OF CONTENTS
Subject Page
YPC 4000 Overview................................................................................................................................... 1
Keypad Overview ....................................................................................................................................... 1
Single Function Keys ............................................................................................................................ 1
Dual Function Keys ............................................................................................................................... 2
Soft Keys............................................................................................................................................... 3
Alphanumeric Data Entry ...................................................................................................................... 3
Measure Mode ........................................................................................................................................... 4
Header-line Symbols............................................................................................................................. 4
Display Screen ........................................................................................................................................... 5
Soft Key Options ........................................................................................................................................ 5
Zero....................................................................................................................................................... 5
Mn/Max.................................................................................................................................................. 5
Damp..................................................................................................................................................... 6
More ...................................................................................................................................................... 6
Hold....................................................................................................................................................... 6
Sensr..................................................................................................................................................... 6
Rcal ....................................................................................................................................................... 6
Pon ........................................................................................................................................................ 6
Poff ........................................................................................................................................................ 6
Vrng....................................................................................................................................................... 6
YPC Configuration Settings ....................................................................................................................... 7
Users .................................................................................................................................................. 7
Measurements ................................................................................................................................... 7
Damping ........................................................................................................................................ 7
Units .............................................................................................................................................. 7
Applications........................................................................................................................................ 7
EJA Accuracy Program ………………………………………………………………………………….7
Lockouts............................................................................................................................................. 9
Master Lockout.............................................................................................................................. 9
PV Prompt..................................................................................................................................... 9
Unlocking a YPC ........................................................................................................................... 9
Changing the Lockout Code........................................................................................................ 10
Clock/Timers .................................................................................................................................... 10
Others .............................................................................................................................................. 10
Model Info ................................................................................................................................... 10
Battery Type Select..................................................................................................................... 11
Enter PC Comm. mode ............................................................................................................... 11
General Operation.................................................................................................................................... 12
Sensor Installation/Removal ............................................................................................................ 12
Change Units / Removing & Restoring Sensors on Display ............................................................ 12
Sensor Module Engineering Units ................................................................................................... 13
Installation & Removal of Batteries – Standard YPCs ..................................................................... 13
Install & Remove Batteries – Intrinsically Safe YPCs ...................................................................... 13
Over pressurization – Pressure Modules......................................................................................... 14
Media compatibility – Pressure Modules ......................................................................................... 14
Applications.............................................................................................................................................. 14
Gauge Pressure Calibration................................................................................................................. 14
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Subject Page
Differential Pressure Calibration .............................................................................................................. 15
Additional DP Application Information...................................................................................................... 16
Vacuum and Absolute Pressure Calibration ............................................................................................ 16
Electrical Connections.............................................................................................................................. 17
Milliamp transmitters ............................................................................................................................ 17
Voltage transducers ............................................................................................................................. 17
Field Recalibration .................................................................................................................................. 18
DB-9 Connection Port .............................................................................................................................. 20
Hazardous Area Use (Intrinsically Safe Option) ...................................................................................... 21
YPC 4000 Series - Model Specific Features............................................................................................ 23
Calibrate Key – YPC 4000, YPC 4010......................................................................................................24
Output (Conventional / HART / Fieldbus transmitter, or Local Indicator)………………………… ........24
Procedure…………………………………………………………………… ................... ………………… 25
Cal type……………………………………………………………………… .................... …………………26
Loop…………………………………………………………………………..................... ………………… 27
Sensor…………………………………………………………………………….....................……………..27
Quick Cal..............................................................................................................................................27
Smart Trim ...........................................................................................................................................28
4 mA Analog Trim ...........................................................................................................................29
20 mA Analog Trim .........................................................................................................................29
Zero Trim ........................................................................................................................................30
Lower Sensor Trim .........................................................................................................................31
Upper Sensor Trim .........................................................................................................................31
View Results ........................................................................................................................................32
Clear Cal Memory ............................................................................................................................... 33
Documenting Calibration Results..............................................................................................................34
Entering Calibration Documentation Mode ...........................................................................................34
Manual Calibrations and Documentation ..............................................................................................36
Stored Procedure Calibrations and Documentation .............................................................................39
Loop Calibrations and Documentation – Manual..................................................................................42
Loop Calibrations and Documentation – Stored ...................................................................................45
Deleting Files and Clearing Calibration Memory ..................................................................................45
YPC 4010 with HART
®
Communications..................................................................................................47
HART Commands .................................................................................................................................47
HART Connections ...............................................................................................................................47
HART Communications.........................................................................................................................49
Communications Trouble Shooting.................................................................................................49
Multidrop Polling..............................................................................................................................49
Cloning HART devices ....................................................................................................................49
Saving Configurations for Multivariable HART devices (PV Prompt).............................................50
More Status Message.....................................................................................................................50
HART Offline Mode ...............................................................................................................................51
List/Show DOFs ..............................................................................................................................51
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List/Edit Configs ..............................................................................................................................51
Create Configs ................................................................................................................................52
Delete Configs / Clean Configuration Memory ...............................................................................52
HART Online Mode ...................................................................................................................................52
Device Configuration........................................................................................................................53
Pressure Trim...................................................................................................................................58
Analog Trim......................................................................................................................................60
Scaled D/A Trim ...............................................................................................................................61
Loop Test .........................................................................................................................................63
Basic Info .........................................................................................................................................64
HART Output....................................................................................................................................66
Diagnostics.......................................................................................................................................67
Review/Edit ......................................................................................................................................68
Quick Menu Key (HART support key).......................................................................................................69
YPC 4010 Device Specific & Generic HART Communications ................................................................70
Documenting HART Configurations..........................................................................................................71
Download Site Information – DOFs, Firmware, Utilities............................................................................71
Who has access....................................................................................................................................71
PC Requirements..................................................................................................................................71
Preparing the YPC for updating ............................................................................................................71
Preparing to Download..........................................................................................................................71
Using the Download Site.......................................................................................................................72
Subscriber Options................................................................................................................................72
Installer Utility (DPC Manager) .............................................................................................................72
Returning the YPC for Repairs..................................................................................................................73
APPENDIX
YPC Specifications ...............................................................................................................................74
YPC Models, Options, Ordering Information..................................................................................
. 75-76
Sensor Modules List..............................................................................................................................77
YPC Accessories List............................................................................................................................78
TIO0110 T/C Measurement Module Instruction....................................................................................79
VMA0055 Voltage and Current Module Instruction ..............................................................................84
RIO4000 RTD Measurement and Simulation Module Instruction.........................................................91
Intrinsic Safety Control Document ......................................................................................................105
HART Command Structure Menu Tree Examples.................................................................... 106 - 107
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YPC 4000 SERIES OVERVIEW

The YPC 4000 Multi-Function Tester (YPC) is a modular calibrator with three sensor bays accommodating up to three independent pressure, temperature or special function modules. The base YPC incorporates a voltage and current meter, several keys for user interface and will display up to four measurements simultaneously. The YPC 4010 adds HART communication capability to the same handheld base unit for greater flexibility and versatility in commissioning, reconfiguring, and maintaining HART field devices.
Note: For Intrinsically Safe YPC models, consult the Hazardous Area Use section of this manual for specific details on use of approved YPCs and applicable restrictions.

KEYPAD OVERVIEW

The following is an overview of the YPC 4000 series keypad operations. The YPC keypad has three basic key types (the functions of each are described below): Single function keys, dual­function keys, and soft keys. Single function keys control a dedicated YPC function. Dual-function keys, through the use of the Shift key, control two separate functions. Soft key functions change depending on the operating mode. Their definitions are displayed at the bottom of the LCD, just above each white soft key.

Single Function Keys

On/Off
Pressing the On/Off key powers up the YPC. As the unit powers up, it performs an internal diagnostic check of its systems. Any abnormalities are posted on the display. The unit will briefly display the YPC model number and the installed sensor module ranges and bay locations (S1, S2, or S3) before the unit enters the Measure Mode.
Measure Mode
Pressing the Measure Mode button will instantly return the unit to measure mode from any menu or sub-menu. Measure will appear on the upper left of the display.
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Display Contrast
This key allows the user to adjust the contrast of the LCD display for ambient conditions or user preferences. Pressing and holding this key will cycle through all available contrast settings. If the display is faded or blacked out, simply depress the key until the display returns to an acceptable level. After adjusting Contrast, wait at least five (5) seconds before turning unit off to insure storage of new contrast setting.
Shift
The Shift key is pressed to access the functions labeled in blue on the dual-function keys. Pressing the Shift key will allow the user to access and/or alter the corresponding properties. Shift remains on until it is depressed again. When the Shift key is active, an up arrow will appear at the top of the display left of the battery power or AC wall plug icon.

Dual Function Keys

Units Sensor1
The Units Sensor1 key changes the engineering units for the module in sensor bay 1. The Shift key must be active before the units can be changed.
HART (Active only with YPC 4010)
The HART key puts the YPC 4010 series calibrator into its HART Communications mode and initiates communications via the HART connections at the bottom of the YPC.
Units Sensor2
The Units Sensor2 key changes the engineering units for the module in sensor bay 2. The
Shift key must be active before the units can be changed.
Settings
Provides access to the settings menu. This menu shows the current unit settings and allows the user to customize YPC settings. See Settings section for more details.
Units Sensor3
The Units Sensor3 key changes the engineering units for the module in sensor bay 3. The
Shift key must be active before the units can be changed. Quick Menu (Active only with YPC 4010)
This key provides a list of frequently used HART configuration and maintenance function menus. User can quickly scroll to any desired menu.
Units mA / V
Toggles between voltage, current (mA), and off display for the integral voltage and current meter. This measurement is designated by “V/I” on the display.
Calibrate
This key enters the YPC into calibration mode for local indicators, conventional transmitters, HART transmitters, Fieldbus transmitters, and mA loop calibrations.
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Soft Keys

Soft Keys (unlabled)
The four white keys located below the display are the Soft Keys. The specific functions of these keys change depending on the operating mode of the YPC. Current defintions are displayed at the bottom of the LCD display.

Alphanumeric Data Entry

For YPC applications requiring alpha, numeric, and symbol entry (examples: tagging or messaging), the YPC uses three display grids, the SHIFT key to change from one grid to another, and four soft keys used for cursor movement and selection of characters and text. YPC and HART communication functions that require alpha and numeric entry automatically call up the appropriate grid and make the other grids accessible using the SHIFT key. Row and Column soft keys are used to move the flashing cursor through the displayed grid. The Select soft key enters the indicated character in the text line and the Done soft key accepts the displayed text line and returns the YPC to service.
Character grids are provided for numeric, alpha, and symbol characters to permit complete editing of text fields. Each grid includes back space (), forward space (), delete (del) and space (spc) operators to accommodate text editing needs.
User Interface
The displays shown below illustrate the alphanumeric entry grids and soft key functions. Pressing the YPC’s SHIFT key changes the display from one grid to another allowing text messages to be developed using all three grids when needed.
HART Tag No PT-3456
A B C D E F G H I J K L M N O P Q R S T U V W X Y Z  . > < del spc
PT_
Row Col Select Done
Alpha entry grid Numeric entry grid
When using any character grid, pressing Row or Col keys will move the flashing cursor one character across or down the gird. Pressing and holding the Row or Col key causes the cursor to advance down or across, respectively, at a regular rate. Releasing the key when the cursor is under the desired character stops the cursor movement and allows the selection of the character using the Select key. Press the Done soft key when the character string is completed to enter the string and continue YPC operations.
HART Tag No PT-3456
1 2 3 4 5 6 7 8 9
. 0 +  > < del spc
PT3456_
Row Col Select Done
HART Tag No PT-3456
@ [ \ ] ^ “ ” # $ % ( ) ’ & * + . / : ; < = > ? , ! > < del spc
PT3456 OUTPUT < 50% @_
Row Col Select Done
Symbol grid
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Numeric Entry: Many HART functions require only numeric entry. For these functions the YPC uses an Increment and Decrement scheme to change the input field one place at a time. Press the Inc / Dec soft keys to move through a scroll of -, . , 0, 1…9, and space until the desired value is displayed. Press the Next soft key to enter that value and advance to the next place in the input field. Repeat as necessary. Press the Done soft key to end the numeric entry session.
HART 3051: PT-3456 Output:
6.5_ mA
Inc Dec Next Done
Numeric Only Entry Screen

MEASURE MODE

After the YPC performs its power up diagnostics and displays the model number and sensor data,
it defaults to the Measure Mode. The word Measure appears on the upper left of the display, confirming this mode is active. The soft key definitions in this mode are directed toward
measurement and information functions.
Section 1.01 Header-line Symbol Key (see location at right)
heart symbol indicates active HART communication
u up arrow indicates SHIFT key is activated
D “D” indicates Damp (exponential) function is activated
~ “~” indicates all damping is off
H “H” indicates Hold (display freeze) function is activated
battery symbol indicates YPC under battery power;
filled portion indicates remaining battery life
electrical plug symbol indicates the AC adapter (P/N A36742) is connected and powering the YPC
BUSY text box replaces either power symbol when
BUS
the microprocessor is busy executing requested tasks
NOTE: Power icons may temporarily disappear during certain HART Communication operations
©Yokogawa Corporation of America 2 Dart Road, Newnan, GA 30265 770-254-0400
Hart u
3051: PT-19C
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DISPLAY SCREEN

The display screen displays measurements from the modules installed in sensor bays S1, S2, and S3 plus the voltage or current measured by the YPC base unit. Measurements are identified on the display by lines with “S1”, “S2”, and “S3” designators for sensor module bay locations and by “V/I” for voltage or current measurements. The measured values are shown with the corresponding unit of measure.
Measure Mode Main Screen
Measured values displayed here are subject to the YPC’s Smart Damp system unless otherwise changed using the Damp Soft Key (see details in the section below). Smart Damp eliminates electronic circuit noise but does not slow the display of changes in measured signal. The result is a very stable but responsive digital display of measured values.
SOFT KEY MENU OPTIONS
On the bottom of the main menu screen in Measure Mode the following definitions are displayed just above the white soft keys. These definitions indicate the function of each soft key.
Zero Mn/Max Damp More

Zero

Zeros the installed sensor modules and integral mA/Volts meter. The LCD will display “Zero in Progress” as this function is carried out. Sensors should be zeroed prior to making measurements to provide an accurate zero reference. Make sure that no physical signal is applied to the YPC when performing this function. To prevent unintentional zero offset, a Zero command will be aborted if more than ±5% of full scale signal is being measured by any YPC sensor. Absolute pressure modules cannot be zeroed until the applied pressure is less than 5% of full scale. This prevents the accidental corruption of the absolute zero reference essential to absolute pressure module performance.

Mn/Max

The Mn/Max key allows the user to display the minimum and maximum measured value each sensor has measured since this function was activated. The min/max values are displayed below the normal pressure or V/mA reading. To reset the Mn/Max function, toggle the Mn/Max key once for off and again to restart.
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Damp

The YPCs default Measure Mode includes Smart Damp for the most stable yet responsive display of measured values. This can be changed to exponential Damp or completely removed using the Damp Soft Key.
Pressing the Damp soft key once from normal mode initiates an exponential averaging function over a user selectable time constant. This function smoothes the peaks and valleys of pulsating measurements for a more stable display. A “D” symbol appears in the top line of the LCD display when this feature is activated. To change the time setting for Damp refer to the YPC
Configuration Settings section of this manual.
Pressing the Damp soft key again will remove all forms of damping. This mode is indicated at the
top of the LCD display by a “~” symbol.

More

This option takes the user to more soft key menu options. After pressing More from the menu options above, the following soft key options are made available:
Hold Sensr Rcal More

Hold

Pressing the Hold button freezes the measurements on the display to allow convenient reading or transcription of data. An “H” symbol appears on the top of the LCD display when this feature is active. Pressing Hold again returns the YPC to normal Measure Mode.

Sensr

Pressing the Sensr key provides detailed information about the installed modules. The first screen provides information pertaining to the sensor in module bay 1, including the sensor model, serial number, and the date the unit was last calibrated. Pressing Next consecutively scrolls through the remaining installed sensors, then the electrical inputs, and finally the YPC itself.
The YPC information provides the model number of the unit, the serial number, firmware revision, and the date the firmware was installed.
Pressing Next after scrolling through all available information returns the user to the Measure
Mode screen.

Rcal

Pressing the Rcal key enters the YPC into the Field Recalibration mode. This allows the unit’s sensors and modules to be recalibrated in the field to maintain optimal accuracy. See section on Field Recalibration for details.
Pon Poff Vrng More
Pon Used to turn on the 24V dc supply feature of the VMA0055 module. See the VMA0055 manual in
the Appendix for more information.

Poff Used to turn off the 24V dc supply feature of the VMA0055 module.

Vrng Used to select the V dc measurement range best suited to the application. See the VMA0055

manual in the Appendix for more information.
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YPC CONFIGURATION SETTINGS

Press the Settings key to review the preferences on the YPC for Users, Measurements, Applications, Lockouts, Clock/Timers and Other options. This will display the Settings menu. Note: Not all options will be active on all YPC models.
The Settings menu shows the current settings for the YPC and allows the user to make adjustments through the use of the soft keys:

Users (active only on 21CFR Part 11 capable YPCs)

Displays the approved Users for Configuration changes and Calibrations – See the YPC 21CFR Part 11 User’s Manual for more information.

Measurements Allows user to set exponential Damp rate, display units for Sensor Bays 1, 2, and 3, plus the integral volts / current display.

Damping

Allows users to select between Smart Damp, exponential Damp or no damping at all. Smart Damp if the factory default mode and provides the most stable yet responsive display of measured values. This can be changed to exponential Damp to provide the user with control the averaging time constant or damping can be completely removed. Move the cursor to the Damping menu line of the Measurements Menu Screen and press the Chng Soft key scroll through the available options and select the desired damping.

Units

The Units menu line of the Measurements Menu Screen allows the user to scroll through and select the available units of any of the three Sx sensor module bays and the integral YPC volts/current meter. Move the cursor to the desired line and press the Chng Soft key to scroll through the available options.

Applications Allows user to select special applications available on the YPC. Follow the on-screen prompts and directions to utilize these Applications.

EJA Accuracy

This program is designed to aid in the calibration of the Yokogawa EJA / EJX Pressure Transmitter series. The program will calculate the maximum error based on design accuracy of the EJA / EJX and the pressure module used when performing a calibration with the YPC.
Configuration # Current Settings Users Measurements Applications Lockouts Clock/Timers Other
Up Down Chng Back
Settings Main Menu Screen
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Configuration Current Settings: Damping: Smart S1 Units: inW20C S2 Units: PSI S3 Units: deg F S1 Units: inW20C IV Units: mA
Up Down Chng Back
Measurements Menu Screen
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Get HART Data
If the EJA / EJX has HART Communications, the program will automatically read all necessary information needed to perform the calculations. If the EJA / EJX does not have HART Communications an “EJA not found” error will be displayed. Data can be input manually into the program for non-HART units.
EJA Model:
This data can be obtained automatically by selecting “Get HART Data” or manually input by selecting the Chng soft key.
Pres Unit:
The pressure units can be obtained automatically by selecting “Get HART Data” or manually input by selecting the Chng soft key.
Zero (LRV):
The Low Range Value can be obtained automatically by selecting “Get HART Data” or manually input by selecting the Chng soft key.
Span (HRV):
The High Range Value can be obtained automatically by selecting “Get HART Data” or manually input by selecting the Chng soft key.
Module:
Select the position of the pressure module (S1, S2, S3, or None) used for the calibration. If a module is selected then the accuracy of the pressure module is used to determine overall error. If “None” is selected then the design accuracy of the EJA / EJX is calculated. If no pressure module is installed, “n/a” is displayed and the design accuracy of the EJA / EJX is calculated.
Calculate
Calculates data and goes to the results screen. If a pressure module was selected, the message “Accuracy is dependent on the span of the pressure module used” is displayed for 3 seconds.
Accuracy %
This is the maximum error of the calibration of the EJA / EJX in % of span. If a pressure module was selected, then the accuracy of the pressure module is included in the calculation to determine overall error. If “None” is selected then the design accuracy of the EJA / EJX is used to calculate the overall error.
Accuracy mA
This is the maximum error of the calibration of the unit in mA. If a pressure module was selected then the accuracy of the pressure module is included in the calculation to determine overall error. If “None” is selected then the design accuracy of the EJA / EJX is used to calculate the overall error.
Min Span
Displays the minimum span of the EJA / EJX unit.
Max Span
Displays the maximum span of the EJA / EJX unit.
LRL
Displays the lower Range Limit of the EJA / EJX unit.
URL
Displays the upper Range Limit of the EJA / EJX unit.
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Lockouts

The YPC HART Communicator can be programmed to lock out all adjustable functions or only certain functions that a supervisor may wish to control. These are Enabled or Disabled individually on the Lockout Details screen shown at right. To access, select the Cfg soft key from the Configuration Main Screen, then the Lockouts option, and finally the View Details option. “Disable” on this screen means the particular menu function will not be locked out and “Enabled” means the particular menu function will be locked out once the Master Lockout is Enabled. Move the cursor to the desired line and use the Chng soft key to change the status of each line.
All - all YPC functions listed on Lockout Details screen Zero - zeroing of installed sensor modules and integral volts / current (see the “Zero” section of this manual for details) Recal - Rcal feature of YPC (see the “Rcal” section of this
manual for details)
Settings - clock, timers, battery type, PC comm mode Units - changing units of measure for sensor modules and integral volts /
current meter
DOFs - the ability to install new DOFs (YPC 4010 only) Configs - the ability to edit saved configurations in Offline mode (YPC 4010 only) Firmware - the ability to install new firmware PV Prompt - the ability to lock out the PV Prompt (see the “Saving Configurations for Multivariable HART Devices PV Prompt” section of this manual for more
details) (YPC 4010 only)

Master Lockout

Once the Lockout Detail status (Disable or Enabled) is correct, select the Back soft key to arrive at the Current Settings screen shown at right. To activate the lockout features previously selected on the Lockout Details screen, move the cursor to the Lockout option line and press the Chng soft key. If there is an active Lockout code, then the display will prompt the user to enter the code. Use the Inc, Dec, Next, and Store soft keys to enter and store a 3-digit code. If no Lockout code is active, then using the Chng soft key to change the status to Enable will cause the unit to request a 3-digit lockout code of the user’s choosing. Once the code is stored and power is cycled, all Lockout Details selected are locked out from use.

PV Prompt

PV Prompt option on this display allows the user to “Disable” the PV Prompt question for multivariable HART devices or to “Enable” the display of this question and its capabilities. The question reads:
“Multivariable device, allow PV changes? Yes / No”
See the “Saving Configurations for Multivariable HART Devices” section of this manual for more details.

Unlocking a YPC

To perform any changes to the YPC’s settings when lockout is engaged the user will be prompted to input the lockout code prior to allowing any changes. Use the Increment, Decrement and Next Soft Keys to input a lockout code value. When you are satisfied with the lockout code value, press Store to unlock the YPC.
Configuration
Lockout Details All : Disabled Zero : Disabled Recal : Disabled Setting : Disabled Units : Disabled DOFs : Disabled Configs : Disabled Firmware : Disabled PV Prompt : Enabled
Up Down Chng Back
Lockout Details Screen
Configuration # Current Settings: Lockout: Disable PV Prompt: Disable View Details
Up Down Chng Back
Master Lockout Enable / Disable
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Changing the Lockout Code

To change the lockout code, disable the Master Lockout option on the Current Settings screen. You will be prompted for the old code before any change is made. Press the Chng soft key until Enable is displayed again and then press the Chng one more time. The unit will prompt for entry of a new 3­digit code. Press Store soft key and cycle power to complete.
Important note
: All YPC units are shipped with the PV Prompt locked out with a lockout code of 3-2-1. See the “Saving Configurations for Multivariable HART Devices” section of this manual for more information on PV Prompt.
Important note
: After the lockout code is entered, the user must cycle the power to activate the lockout mechanism! BE SURE TO SAVE THIS CODE IN A SAFE PLACE IN THE EVENT YOU FORGET THE NUMBER. ACCESS TO LOCKED-OUT FEATURES WILL BE DENIED WITHOUT THE PROPER CODE.
Important note
: Check Lockout status after each YPC firmware update install session to ensure desired status has been maintained.

Clock/Timers The Clock Edit option allows the user to correct the date and time of the YPC’s internal clock. To select the Clock Edit feature, select the Clock Edit option and press Chng. Choose a clock or date option to adjust by selecting the desired menu line. Press Chng to choose that option. Enter the correct value using the numeric keypad and text edit key if needed. When complete, press Done. You will be asked if you wish to save the new data. Press Yes to accept the new value. Pressing No will take you back to the Clock Edit without making any changes to the YPC clock.

Configuration # Current Settings: Clock Edit Backlight: 1 min Off Timer: 1 min
Up Down Chng Back
The Backlight Timer – not yet available
Lockout Enable / Disable
The Off Timer can be used to conserve battery life by setting the timer to shut off after a period of keypad inactivity. To change the Off Timer on the unit, select the Off Timer option and press Chng until the desired time period is displayed. The Off Timer can be disabled or set to shut off after time periods from 1 minute up to 2 hours.
NOTE: The Off Timer is disabled when the optional AC Adapter (P/N A36742) is powering the YPC.
NOTE: When replacing the batteries, the date and time will remain active. Date & time information is continuously powered by an internal, 10-year life back-up battery. This battery is not serviceable by the user.

Other This menu option provides access to Model Information, Battery type setup and PC Comm Mode setup

The “Model Info” menu option gives all the information about the model. It shows the model name, serial number, firmware version, and date of last firmware update. It also displays information about number of DOFs installed, number of configuration stored, and percentage of free memory for each.
Configuration # Current Settings: Model Info Battery: Alkaline Off Timer: 1 min
Up Down Chng Back
Lockout Enable / Disable
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The “Battery” menu option allows the user to set the battery type being used. Alkaline, NiMH and Lithium batteries all have different discharge curves. Selecting the correct battery type provides the most accurate battery gauge icon performance. To change the battery type, select the menu option line until the correct type is shown.
The “Enter PC Comm Mode”menu option could be needed for communication with a PC. When the YPC is connected to a PC for updates via MFx Installer (see MFx Installer section in this manual), a DB-9 serial cable is used. Occasionally a DB-9 Serial cable is encountered that does not have a DTR line. The DTR line is important to the update process because it is used to initiate and confirm communication between the two machines. If a DB-9 cable without a DTR line is used, the YPC must be manually placed in the Enter PC Comm. Mode. Go to the YPC Main display and select YPC. Scroll down to the Enter PC Comm. Mode menu option and press Select. Proceed with update and cycle YPC power when the update is complete. It is recommended to use fresh batteries or an AC adaptor during update procedures. This mode will automatically time-out after approx. 2 minutes of inactivity and return to the main display. Pressing the Back soft key at this point will return to the previous screen. Pressing the Back soft key
when in any of the Settings sub-menus will return to the previous screen without
changes.
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GENERAL OPERATION

Sensor Installation/Removal

To install a new sensor module into a sensor bay, make sure the spring-loaded sensor lock is
facing toward the rear of the YPC. Depress the sensor lock until the base of the sensor module passes into the sensor bay. Push module into bay until it locks into place.
Once installed, the YPC will immediately read the data from the sensor and load it into the system. The display will briefly show what sensor has been installed. The engineering units that were previously assigned to that sensor module will automatically be displayed. Sensor modules may
be installed in any sensor bay.
To remove a sensor module from a sensor bay, depress the spring-loaded sensor lock corresponding to the module you wish to remove. The sensor lock needs to be depressed so that it clears the YPC housing. While pressing down on the sensor lock, simultaneously pull upward on the module. A pen or small screwdriver may be used to depress the sensor lock far enough to clear the housing.
Once a sensor module is removed from a bay, the display will clear that sensor’s information from the display screen.
Note: Modules may be “hot swapped” or changed while the YPC is on or off. For intrinsically safe versions, however, installation, removal or hot swapping must be done in a non-hazardous environment only. See Hazardous Area Use section for more details.
Sensor Module Locations
S1: Sensor Bay 1 (Left) S2: Sensor Bay 2 (Center) S3: Sensor Bay 3 (Right)

Changing Units / Removing & Restoring Sensors on Display

Specific sensors can be turned on and off individually if they are not required. To turn off a specific sensor, press the Shift key and select the corresponding Units Sensor key for the sensor you wish to remove from the display. Repeatedly pressing the Units Sensor key will cycle through the available engineering units. Before the unit cycle repeats, the sensor display will go blank. The sensor is now off. Press the Shift key again to return to normal operation.
To reactivate a sensor that has been removed from the display, press the Shift key then press the corresponding Units Sensor key. Continue to cycle through the engineering units by pressing the Units Sensor key until the desired unit appears on the display. Press the Shift key to accept the engineering unit and return to normal Measure Mode.
Note: Open sensor bays on the YPC should be filled with dummy modules (P/N A36741) to protect the electrical connector and avoid contamination of or damage to the sensor bays. Dummy modules are shipped as needed to fill YPC bays.
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Sensor Module Engineering Units

Pressure Temperature
PSI º Fahrenheit Inches of Water @ 20° Celsius Inches of Water @ 60º Fahrenheit º Rankin Inches of Water @ 4º Celsius º Kelvin Kilograms/cm
2
Ohms Kilopascals milli-Volts MilliBars Bars Centimeters of Water @ 20º Celsius Inches of Mercury (Referenced @ 0º C) Millimeters of Mercury (Referenced @ 0º C)
2
oz/in

Installation & Removal of Batteries – standard YPCs

To install or remove the batteries, turn the YPC face down and pull down on the loose end of the Velcro strap to separate it from the opposite side, then pull the strap through the lower metal strap guide. Use a finger to push down and pull back on the battery cover latch to remove the cover. Be sure to follow the polarity diagram shown on the bottom of the battery holders when installing the batteries. Make sure all batteries are firmly secured. Replace cover, reinsert strap through metal strap guide, and re-secure the Velcro.
Note: Replace all six (6) AA batteries at once with alkaline or NiMH cells. Do not mix alkaline or NiMH batteries with each other or with other battery types. Batteries replacement is recommended when battery icon shows one segment; however, the YPC will function briefly after the battery icon is empty.
Note: When replacing the batteries, the date and time will remain active. Date & time information is continuously powered by an internal, 10-year life back-up battery. This battery is not serviceable by the user.

Installation & Removal of Batteries – Intrinsically Safe YPCs

Intrinsically Safe rated YPCs have a battery compartment door fitted with two captive thumbscrews and a metallic bracket to mechanically secure the door to the YPC case. To install or remove batteries, follow the above instruction and unscrew the two thumbscrews to remove door. After battery maintenance is complete, replace door and tighten thumbscrews to re-secure.
º Celsius
Rear of Intrinsically Safe YPC shown
Thumbscrews / bracket
Battery door
Note: For Intrinsically Safe YPC models, replace batteries only with approved types. See the YPC Intrinsic Safety Control Document in the Appendix for approved battery details.
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Over Pressurization - Pressure Modules

If an YPC pressure sensor is over pressurized above its full scale pressure range, an “Overrange” warning appears on the LCD above the engineering units of the affected sensor. If the applied pressure exceeds 20% of the sensor’s full scale range, the affected pressure measurement is replaced by an “Overrange” warning. If this occurs, immediately release the pressure until the YPC displays a normal reading. Although pressures are displayed up to 20% over full scale range, specified accuracy is guaranteed for full scale range only.
x
GI (Gauge Isolated) and xAI (Absolute Isolated) Modules are capable of withstanding up to 2x the
sensor range without sustaining damage.
x
DN (Differential Non-Isolated) Modules are capable of withstanding up to 2x the sensor range
when pressurized on the high side only. When pressure is applied to both the high and low side simultaneously, all x
x
is a place holder for the sensor module accuracy designator. See information in the Appendix for
additional sensor module information.
Note: Subjecting pressure sensor modules to pressure limits beyond those listed above may damage the sensors and void the warranty.
DN sensors have a 150 PSI pressure limit.

Media Compatibility - Pressure Sensors

Gauge (x
GI) and Absolute (xAI) pressure sensor modules are compatible with fluid and gas
medias that are compatible with 316 stainless steel.
Differential (x
DN) pressure sensors are for use with clean, dry, non-corrosive gases only.

APPLICATIONS

Gauge Pressure Calibration

The diagram below shows two typical set-ups for calibrating a gauge pressure unit under test. If the process is a liquid, it is vital that the gauge under test be isolated and drained. If liquid enters a x
DN module, damage to the sensor can occur. To use a xDN sensor, connect the pressure source
to the high pressure port of the xDN sensor. Vent the low pressure port to atmosphere.
When calibrating a gauge pressure unit using a x exception that the x
GI sensor does not have an external vent to atmosphere.
GI sensor, the connection is the same with the
In some cases the actual process may be used as the pressure source for calibration. If you choose to use the process to perform the calibration, make sure the process is compatible with the sensor used, and that it provides a stable pressure. If your process has a fluctuating or pulsating pressure, use of an external pressure source is recommended to ensure the accuracy of your measurements and calibration.
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Differential Pressure Calibration

Differential pressure gauges and transmitters can be calibrated using x
DN or xGI sensor modules. The following drawing depicts a typical calibration set-up. The units under test should be isolated from the process and drained of liquids if necessary. The low pressure port of the DP unit under test is vented to atmosphere. Do not connect the low pressure port of a x
DN sensor to the low pressure port of the DP unit under test. Such a dead end connection can cause errors due to the expansion or contraction of trapped gas as a function of temperature change.
Yokogawa does not recommend using process pressure as the pressure source for DP pressure device calibration. Errors in measurement and calibration can easily creep in if the pressure source is unstable. In addition, x
DN sensors have a maximum overpressure limit of 150 PSI when a three valve equalizing manifold is used properly. Sensor damage can occur if more than 15 PSI is applied to the high or low side of a x
DN0020 or xDN0200 sensor through improper use of the
equalizing manifold.
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Additional DP Application Information

In addition to reading gauge pressures, the YPC can also be used to measure the pressure drop across a device in a pressurized pipe. Examples include measuring the differential pressure across positive displacement meters, filters, orifice plates or valves. Process compatibility and pressure ranges of the sensor modules need to be considered for each application.
A three valve equalizing manifold or push-to-read equalizing valve should be used to avoid damaging x
3-Valve Manifold: Make sure all shut-off valves are closed. Connect to the process. Slowly open the equalizing valve. Slowly open the high pressure valve and then the low pressure valve. Close the equalizing valve and take the measurement. Reverse the process to disconnect.
Push-to-read valve: Connect to the process. Open shut off valves. Push the push-to-read plunger to take the reading.
DN sensors. Follow the specific operating procedure for each type of valve manifold.

Vacuum and Absolute Pressure Calibration

Vacuum calibrations can be performed with a x
DN sensor module by venting the high pressure connection to atmosphere and applying the vacuum to the low pressure connection. Atmospheric pressure is the reference pressure for all vacuum measurements.
Absolute pressure calibrations use a x
AI sensor module. These sensor modules have an internal absolute zero reference. Simply connect the pressure (or vacuum) source to the single port on the module.
The following diagram shows the connection for both a vacuum and an absolute pressure measurement. If the process maintains a stable pressure, it can be used as the pressure source in some calibrations. Process compatibility and pressure ranges of the sensor modules need to be considered for each application.
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ELECTRICAL CONNECTIONS

See Hazardous Area Use Section of this manual for Intrinsically Safe guidelines / restrictions.

Milliamp Transmitter

The diagram below depicts the proper connection for measuring the current output from a transmitter. The YPC is connected in series with the loop using standard banana jacks.
Important: Use the transmitter’s working terminals to measure mA, not
the TEST terminals found on some transmitters. Do not use digital communication terminals found on smart transmitters. These terminals will give incorrect current reading.

Voltage Transducer

The following diagram depicts the correct set-up for transducer calibrations.
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FIELD RECALIBRATION

The sensor modules and mA/V meter can be recalibrated in the field for zero, span, and linearity. The proper primary standards must be available prior to calibrating the YPC or modules. These standards should meet the accuracy requirements for your company or industry. Yokogawa Corporation of America follows the guidelines established by ANSI / NCSL Z540-1-1994 which requires that the primary standard be 4 times more accurate than the unit under test.
For sensors up to 200 PSI, Yokogawa recommends a ±0.0015% of reading deadweight tester for optimal accuracy. For sensors 200 PSI and above, a ±0.0030% of reading deadweight tester is recommended. If calibrating using inches of water units, be sure to match the reference temperature of water in both devices.
To enter Field Recalibration mode from the Measure Mode display, press the More soft key, then press the Rcal soft key. This will access the Field Recal Setup screen.
Field Recal Field Recal Setup: Start Module: 1 Units: inW20C Points: 3 Restore Defaults
Up Down Select Back
Field Recalibration Setup Screen
Module: Select to choose which sensor module (S1
, S2, S3) or mA/V (I or V) meter to calibrate.
Units: Allows the user to choose the engineering units to calibrate in. Yokogawa recommends the calibration be performed in the default units of the subject sensor. For example: a x
DN0200 sensor with a range of 0-200” of water referenced to 20º Celsius should be calibrated using a deadweight tester with the same units and temperature reference. Other engineering units or reference temperatures may be used but great care in units and temperature reference conversion must be used to achieve accurate calibration results.
Points: This option allows the user to select the number of calibration points desired. The example above would use 3 calibration points; 0%, 50%, and 100% of the full range of the sensor. The user may select 3, 5, or 9 point calibrations.
Start: Begins the recalibration process.
Restore Defaults: Restores factory calibraton coefficients for use
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e
Recalibration Set-Up Menu
Select the parameters desired and the sensor module to be calibrated using the options provided. Press the Up or Down soft keys to scroll to the desired parameter. Press the Select soft key to choose that parameter. A sub-menu opens showing the options for the selected parameter. Use the Up or Down soft keys to scroll to the desired option. Use the Save soft key to choose that option. The display will then return to the main recalibration set-up menu. If you choose not to make any changes to a selected parameter, the Back soft key returns the display to the main recalibration set-up menu without making any changes.
Repeat this procedure for each parameter that needs to be changed.
Procedure - Field Recalibration
Once all of the desired parameters and options have been set, scroll Down to Start on the main recalibration menu and press the Select soft key. This takes you into the recalibration display.
Field Recal Cal Point: 0% Apply: 0.00
S1: 0.00 inW20C Error: 0.000 % Adj Abort Next Back
Sample Field Recalibration Screen (xDN Pressure Modul
The recalibration screen shown above provides the following information:
Cal Point: This is the target calibration point expressed as a percentage of the sensor module full
scale pressure.
The next line shows the sensor bay location or analog sensor being calibrated (S1, S2, S3, V, or
mA). The pressure applied by the user is also shown in the engineering units previously selected.
Error: Is the percentage error between the applied calibration pressure and the recalibration target
pressure for the recalibration point (Apply value). + and – indicates whether the error is above or below the recalibration target pressure (Apply value).
Apply: This is the recalibration target pressure the YPC assigns based on the number of
calibration points set in the recalibration set-up menu.
Make sure your pressure source and calibration standard are properly connected to the sensor module under test. Connections must be leak free. The first recalibration target pressure is normally zero, so the first point should have all zeros. (As shown in example above—See section Adj for other options). Adjust the pressure source until the pressure you are applying matches the Apply pressure & the Error percentage goes to zero.
If the error percentage is not zero, attempt to adjust the applied pressure until the unit reads zero.
If zero error can’t be achieved, a small error percentage within the accuracy of the unit under test or error within company accuracy guidelines may be acceptable.
When the error % is within acceptable limits, press the Next soft key. This moves the unit to the
next calibration point. Repeat the procedure outlined above. When the final recalibration point is set, press Next to store the data.
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After completion of the calibration process for 3, 5, or 9 points, the YPC will inquire if the cal data
should be saved. Select Yes to accept the recalibration data or No for other options.
If Yes was selected, the screen will verify the new calibration by displaying the date and module
position number. Press the OK soft key. The YPC then returns to the Measure Mode.
Choosing No opens the Cal Not Saved screen with options:
Exit Cal: Does not save any new calibration data and returns the user to the Measure Mode.
Restart Cal: Takes the user back to the Recalibration set up screen to begin a new recalibration
procedure.
Save Cal: Gives the user a second opportunity to accept the recalibration data.
The user can verify sensor module or mA/V calibration status by pressing the Sensr soft key from
the Measure Mode display. The calibration data will show the sensor ID information and the most recent calibration date.
Other Recalibration Keys and Functions
Adj: Used at the start of the recalibration cycle, this option allows the user to redefine the
recalibration target points. For example: if the first calibration point is a value other than zero, press Adj and enter the desired target pressure using the Numeric Grid and soft keys. Press Select to go to the next digit. Once you are satisfied with the new target pressure press Done. The YPC will prompt the user to save this value. Pressing Yes will change the calibration pressure value for that point. Begin recalibration with the new point designated on the Apply line. Perform this adjustment on any calibration point you wish to customize.
Abort: Pressing the Abort key will immediately cancel all calibration value changes made to that
point, retain the previous calibration, and return to the Measure Mode.
Next: Takes the user to the next calibration point.
Back: In this mode, Back aborts the calibration procedure and returns the user to the
recalibration set-up screen. The previous calibration data is retained. It does not return the
user to the previous screen in the calibration procedure.
Exit Cal Restart Cal Save Cal

DB-9 CONNECTION PORT

All YPC models are equipped with a standard DB-9 connection for RS-232C communications. The DB-9 provides the hardware interface to facilitate download / upload operations from a host PC. This connection port facilitates download of YPC firmware improvements, HART
®
Device Object Files (DOFs) and documenting operations. All YPC upgrades are available via the Yokogawa Corporation of America Download Site accessible from www.us.yokogawa.com/mi/ypcyhc.com. The YPC does not need to be returned to Yokogawa or for firmware updates for additional DOF loading.
Note: Do not use the DB-9 connection port in Hazardous Areas. Use in non-hazardous areas only. See Intrinsic Safety Control Document in the Appendix for more details on I. S. YPC units.
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HAZARDOUS AREA USE

The YPC 40X0 Series Calibrator / Communicator is available with Intrinsically Safe Certification from MET Laboratories. MET Laboratories is a Nationally Recognized Test Lab (NRTL). The Communicator is certified by MET Laboratories to comply with standards CSA C22.2 No.1010.1, CSA C22.2 No. 157-92, and UL913 Fifth Edition Rev 2/21/97 for Class I, Division I, Groups A, B, C, and D, T5 hazardous areas. Refer to the Intrinsically Safe Control Document shipped with each unit for more information. An uncontrolled copy of the I.S. Control Document is included in the Appendix of this User’s Manual for reference only.
The following table identifies YPC model numbers and areas of acceptable use.
Model Number Non-hazardous
Area
YPC 4000-01-X-00-X-XX NO YPC 4000-01-X-01-X-XX
YPC 4010-01-X-00-X-XX NO
YPC 4010-01-X-01-X-XX
Intrinsically Safe YPCs can be identified by model number (see table above or Appendix), by special Intrinsically Safe Certification label and by WARNING label affixed to the YPC case. See the label samples below.
WARNING label for Intrinsically Safe YPC Units
Hazardous Area
C
MET
R
Intrinsically Safe Certification Label
Intrinsically Safe YPCs have special battery door hardware to prevent the accidental ejection of batteries. This hardware consists of threaded inserts in the YPC case plus a bracket and captive thumbscrews on the battery door. See the Installation and Removal of Batteries section of this manual for more details.
WARNING: Serious injury or death may result from explosions. Do not make connection to the DB – 9 connection port or to the AC adapter jack in a hazardous area
WARNING: Serious injury or death may result from explosions. Before making electrical connections to an Intrinsically Safe YPC at the V/Com/mA jacks or at the HART jacks, verify the instruments in the loop are installed in accordance with intrinsically safe field wiring practices.
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Note: Restrictions apply to the use of Intrinsically Safe YPC units in hazardous areas. Refer to the Intrinsically Safe Control Document in the Appendix for exact details. The manufacturer reserves the right to revise the Control Document without notice. Contact Yokogawa Corporation of America for the current Intrinsically Safe Control Document.
Note: Intrinsically Safe modules RTD1000, RIO4000, TIO0110 and VMA0055 require the use of electrical connections and leads. Any electrical connections made to Intrinsically Safe modules installed in an Intrinsically Safe YPC base unit must be made in non-hazardous areas only. Refer to the Intrinsically Safe Control Document in the Appendix for details.
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YPC 4000 SERIES
MODEL SPECIFIC FEATURES:
YPC 4000, YPC 4010
Previous sections of this manual have covered specifications and instructions that are common to all models of the YPC. The following sections address model specific instructions.
ELECTRICAL CONNECTIONS by YPC Model
YPC 4000 Calibrator
Electrical connections are shrouded standard banana jacks (3/4” center) for ±50 mA/volts measurements.
YPC 4010 Calibrator with HART®
Electrical connections are shrouded standard banana jacks (3/4” center) for ±50 mA/volts measurements. HART are also standard banana jacks.
For Intrinsically Safe YPC models, consult the Hazardous Area Use section of this manual for restrictions and special instructions for use and electrical connections.
®
loop connections
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CALIBRATE KEY – YPC 4000, 4010
Pressing the Calibrate key allows the user to set up the YPC to calibrate HART or non-HART devices. In YPCs that do not have the HART or Documentation options this key has no value. However, for YPCs with HART and / or Documentation the Calibrate key provides access to powerful calibration tools.
After pressing the Calibrate key the following screen will appear:
Begin Calibration: Select to perform a calibration. (see Documenting Calibration Results for more information)
Output (Conventional / HART / Fieldbus transmitters or Local Indicator): user to select between the calibration of a HART device, non-HART, or a Fieldbus (local indicator, Foundation Fieldbus, or Profibus) device. To select, make sure the selection arrow points to Output and press Select.
Conv (mA): This option is used for a non-HART transmitter device. The output selected is 4 –
20mA for calibration
Conv (V): This option is used for a non-HART transducer device. The output selected is 1 –
5V for calibration..
HART (mA): This option is used for a HART transmitter device. The output selected is 4 – 20 mA
from the HART transmitter for calibration.
HART (PV): This option is used for a HART transmitter used in multi-drop or burst mode. The
output selected is the HART PV signal for calibration.
Fieldbus: This option is used for local indicators or Fieldbus devices. Selecting Fieldbus
makes keyed input available for entering the indicator reading or reading relayed from the control room into the YPC.
Cal Cal: Pump 8
Begin Calibration
Output: HART (mA) Procedure: Manual Sensor : S1 Quick Cal Smart Trim View Results Clear Cal Memory
Up Down Select Back
Calibrate Key Main Menu Screen
Cal
Output : HART (mA) Conv (mA) Conv (V) HART (mA) HART (PV) Fieldbus
Up Down Save Back
This option allows the
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Press the Back soft key if you choose not to make any changes. The YPC will then return to the Calibrate key main menu screen.
To calibrate a Fieldbus device (local indicator or Fieldbus device), set Output to Fieldbus and select Begin Calibration. The following screen will appear.
Cal Manual Calibration
S1 : 0.004 inW20C FB: 0.000 inW20C
0 Points Saved
Save Entry Done
where,
S1 (sensor module bay 1): shows the input value applied to the device as measured by sensor S1. FB (Fieldbus): shows output value from the device under test that was keyed in by the user. This value is read from a local indicator or an external meter or relayed from the control room.
To enter a value in the FB line, press the Entry Soft key to activate the keyed entry system.
Use the Inc and Dec Soft keys to enter the first number of the value being input. Press the Next Soft key to move to the next place on the entry screen. Repeat until complete value is entered and press the Done Soft key. The user will be prompted, “Save New Data? Yes No”. Select Yes if correct. When satisfied with the value, press the Save key to save this calibration point and proceed to the next point. Continue until the calibration procedure is complete Press the Done key to complete the “As found” portion of the calibration.
Procedure: This option allows the user to select a Manual calibration (the user defines the procedure as he calibrates the device under test) or Stored calibration procedure (the procedure has previously been stored in the YPC memory for later use in the field). The Stored calibration option requires the YPC Documentation option and Device Management System from Yokogawa.

To select a calibration type, make sure the selection arrow points to Procedure and press Select. The following screen will appear:

Cal
Enter Xmitter Value
15_.000
Inc Dec Next Done
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