Condec UPC5000 Manual

63256
UPC5000/UPC5010
Portable & Rack-mountable Pneumatic
Pressure Calibration Console
CONDEC Sales Phone No. [phone]
CONDEC Web Site: www.4condec.com
Operation & Maintenance Manual

Copyright © 2001 Condec. All rights reserved. Printed in the United States of America.
Specifications subject to change without notice.
December 2001
Contents
About This Manual................................................................................................................................... 1
1.0 Introduction.................................................................................................................................. 1
2.0 Operation...................................................................................................................................... 3
2.1 Pressure Cylinder Filling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Initial Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Pressure Measurement Sequence for Absolute/Gage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Pressure Measurement Sequence for Gage Only Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Pressure Measurement Sequence for Absolute Only Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Battery Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.0 Calibration.................................................................................................................................... 8
3.1 Pneumatic Calibration Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Instrument Calibration Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Zero/Span Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Linearity and Hysteresis Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Shunt Resistor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Voltage/Current Input Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Permanent Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.8 Required Barometric Offset for Absolute/Gage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.9 Normal Mode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.10 Self-Check Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.0 Maintenance and Service.......................................................................................................... 14
4.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Maintenance and Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 Panel/Chassis Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.2 Nitrogen Cylinder Assembly Removal (PN 59531). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.3 Installing New Nitrogen Cylinder Assembly (PN 59531). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.4 ORION-2C Manifold Removal (PN 55283). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.5 ORION-2C Manifold, Valve Seat Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.6 ORION-2C Manifold, Vernier Control Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.7 ORION-2C Manifold, Vernier Control Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.8 ORION-2C Manifold, Valve Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.9 ORION-2C Manifold, Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.10 ORION-2C Manifold, Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.11 Pressure Limit Control (Standard Pneumatic), Regulator Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.12 Pressure Limit Control (Standard Pneumatic), Regulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.13 Pressure Limit Control (Tescom), Regulator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.14 Pressure Limit Control (Tescom), Regulator Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.15 Panel Gauge Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.16 Panel Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.17 Test Port Quick-Connect Fitting (PN 55426), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.18 Test Port Filter (PN 54188), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.19 Inlet Check Valve - Nitrogen Fill Port (PN 60263). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.20 AC Fuse (PN 58076), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.21 AC Power/EMI Line Filter (PN 58870), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.22 Power Switch (PN 55187), Removal and Installation (Battery Units). . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.23 Power Switch (PN 58878), Removal and Installation (Non-Battery Units). . . . . . . . . . . . . . . . . . . . . . . 27
4.2.24 Range Select and Display Select Switches (PN 55924), Removal and Installation . . . . . . . . . . . . . . . 27
4.2.25 Absolute and Zero Switches (PN 58886), Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.26 Power Supply Assembly, Removal and Installation (Battery Units). . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.27 Battery (Replacement Kit PN 55354) Removal, Installation and Adjustments. . . . . . . . . . . . . . . . . . . . 29
4.3 Orion 2C Valve Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.0 Model Number System .............................................................................................................. 46
6.0 Available Ranges, Conversions and Resolutions...................................................................... 47
7.0 Options, Replacement Kits ........................................................................................................ 50
8.0 Specifications............................................................................................................................ 51
UPC5000/UPC5010 Warranty and Return Policy ................................................................................... 52
UPC5000/UPC5010 Return Material Authorization Form....................................................................... 53

Introduction 1
About This Manual
The UPC5000 portable pneumatic pressure calibrator
and the rack-mounted UPC5010 are rugged, compact
instruments manufactured by Condec. They are
designed to provide superior accuracy, range of
calibration and ease of operation when used for the
calibration of a wide variety of pressure sensing and
measuring devices.
These instruments utilize a repeatable sensor coupled
to microprocessor-based electronic circuitry and a
selectable unit display system. This provides an
easy-to-read and accurate digital representation of the
measured pressure. This all electro-mechanical device
combines a 7 cu. ft., 2216 PSI cylinder with our
precision ORION-2C vernier. The unit has one test
port and front panel gauges that indicate system
pressure and remaining pressure in the internal
cylinder.A pressure regulator acts as a pressure limiter
so that the operator can not over-pressurize a unit
under test. Fill and test hoses are supplied for the
customer. Standard front panel buttons and switches
provide selection of the desired pressure range,
push-button zeroing and internal self-check feature.
This manual has been written to give the user a simple
and clear explanation of how to operate, calibrate, and
maintain these instruments.
Before attempting to use either style
pressure calibrator, the following
instructions must be carefully read
and understood by personnel using
the equipment. This is a high-pressure system. It is
strongly recommended that only personnel formally
trained in the use of pneumatic pressure equipment be
permitted to operate it. Potentially dangerous conditions
can be produced through negligent handling or operation
of the console due to the high pressure cylinder
contained within the unit.
These units are strictly for use with pneumatic pressures.
Erroneous readings and potential damage can result from
the introduction of hydraulic fluids into the internal tubing
lines.
Authorized distributors and their
employees can view or download this
manual from the Condec distributor site
at
www.4condec.com
.
1.0 Introduction
Utilizing microprocessor technology, the UPC5000 and rack-mounted UPC5010 instruments offer 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 calibrations available via front panel switch selection.
•Automatic self-check: Computer-controlled internal circuitry provides automatic maintenance of both zero
and span calibration data to ensure long-term stability and accuracy.
•Digital Display: Large LED digits provide excellent readability under all lighting conditions (also available
with a Liquid Crystal Display).
•Using a manually adjustable regulator, the maximum system input pressure is adjusted to any value higher
(typically 20 to 50%) than the full scale range of the device being tested and, the unit under test is fully
protected from being inadvertently over-pressurized.
•Portable: These compact, self-contained systems are easily carried and operated by only one person. Total
weight is less than 40 pounds.
•System Calibration: The instruments can be completely calibrated without being removed from the external
case. A separate plug-in Condec Calibration Module (PN 60109) provides access to the computer when
calibration is performed. No manual alignment or potentiometer adjustments are required.
Warning

2 UPC5000/UPC5010 Operation & Maintenance Manual
•Calibration Integrity: Once calibrated, the tamper-proof design provides numerous safeguards that
guarantee the integrity of pressure readings obtained. The LED provides the operator with status
information during both operation and calibration.
•Pressure Source: An internal supply cylinder with a volume of 7.0 std. cu. ft. of N
2
provides up to 2216
PSIG of pressure for calibration and test. A check valve quick disconnect fitting provides re-charging
capability.
•Simple Operation: All controls, indicators and pressure ports are accessible from the front panel. Section 2
provides clear, concise instructions for system operation.
•Data Input Capability: A front panel-mounted connector and selector switch permit the 4-20 mA current
signal from the gage-under-test or voltage to be displayed. Transducer excitation voltage of 18 VDC can be
provided standard, or by special order 28 VDC.
•Safe, Clean Operation: All pressure components are made of brass, copper, aluminum or stainless steel and
proof-tested to at least 150% of maximum operating pressure. In addition, the system contains a
high-pressure burst disk and relief valves to protect both the operator and system components from harm in
the event of over-pressurization. An all stainless steel version is available by special order.
The heart of this calibration system is a highly stable and repeatable pressure transducer. These sensors produce
an electrical output signal which is linearly proportional to the applied pressure.
By combining these sensors with microprocessor-based circuitry, an even higher degree of operational accuracy
and precision has been accomplished. For example, computer-generated correction curves for both the
non-linearity and the hysteresis of the sensors improve these characteristics by an order of magnitude or more. In
addition, a self-check feature ensures long-term accuracy by utilizing the computer to generate and control an
internal shunt calibration mode of operation. The indicators full-scale reading is compared against, and if
necessary, corrected to the digitally-stored value for full scale obtained at the time of initial pressure calibration.
The computer is programmed with a series of internal self-diagnostic routines that continually monitor and check
every bit of data stored and processed by this system. The system either notes or shuts down operation in the
event of an out-of-tolerance reading or outright failure.
The UPC5000 has an internal, rechargeable 12 volt lead acid battery, that provides a minimum of six hours of
complete portability when fully charged. An ON/OFF and battery test switch is provided to conserve energy
when the instrument is not in use and to provide the operator with battery voltage status during use. It also has a
LO BATT
indicator on display.
The following schematic provides an overview of the UPC5000/UPC5010’s function.
Figure 1-1. UPC5000/UPC5010 Flow Diagram
VALVE
CHECK
MONITOR
PRESSURE LIMIT
RELIEF
VALVE
2216 PSI MAX.
N FILL PORT
2
+ or - 50 PSI
3000 PSI
BURST DISK 2216 PSI MAX.
N SUPPLY
INTERNAL
CONTROL
PRESSURE LIMIT
2
SUPPLY PRESSURE
FILTER
10u
0-3000 PSI
MICROPROCESSOR-BASED
DIGITAL INDICATOR
TRANSDUCER
VENT
VENT/VACUUM
PORT
(QUICK DISCONNECT)
PRESSURE
INCREASE
VERNIER
TEST PORT20u
FILTER
ADJUST

Operation 3
2.0 Operation
The following sections explains the various procedures for operating the UPC5000/UPC5010.
2.1 Pressure Cylinder Filling Procedure
To initially fill or refill the internal pressure cylinder (2216 PSI max) of the UPC5000/UPC5010, see Figure 2-1
and proceed by following these steps:
1. Rotate the
PRESSURE LIMIT CONTROL
(1) counter-clockwise until it stops. Close the
COARSE
ADJUSTMENT
valve (2) by rotating clockwise until it stops.
2. Connect the fill hose (3), to a clean regulated nitrogen source (5).
3. Connect the other end of the fill hose (3) to the male fill port fitting (4).
4. Slowly open the valve on the nitrogen source and allow the gas to flow into the pressure cylinder. The
SUPPLY PRESSURE
gauge (6) indicates the amount of pressure within the internal cylinder.
NOTE:
The Inlet Check Valve (PN 60263) and the Nitrogen Fill Port (Section 4.2.19 on page 25; Figure 4-3 on page 35)
can be damaged if pressure is released too fast.
5. Use the following procedure for filling 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 system to stabilize before using.
Figure 2-1. Pressure Cylinder Fill Procedure
NOTE:
UPC5000 shown, AC Input (7) and Fill Port (4) are on back of UPC5010 Rack Mountable Calibrator.

4 UPC5000/UPC5010 Operation & Maintenance Manual
2.2 Initial Setup Procedure
To prepare for actual calibration usage, see Figure 2-2 below and proceed as follows:
1. Check that the
COARSE ADJUSTMENT
valve (2) is closed (rotate clockwise until it stops) and that the
VENT
valve (8) is open (two turns counter-clockwise from its stop).
2. Plug in the power cord (7) and energize the unit by flipping the power switch (18) to
OPERATE
. The
UPC5000/UPC5010 will perform an internal functional self-check. If acceptable, a 100.00 flashes briefly
and the display returns to a normal reading. Allow at least ten minutes warm-up time, then zero unit by
momentarily depressing the ZERO switch (12) for less than five seconds. The instrument can be zeroed
at any time, as long as theVENT valve (8) is open, by momentarily depressing the ZERO switch (12) for
less than five seconds.
NOTE:
If ZERO switch is depressed longer than 5 seconds unit will perform an internal functional self-check.
3. Select the desired full scale pressure range via the three-position
RANGE SELECT
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. Using the
PRESSURE LIMIT CONTROL
regulator (1), adjust the maximum system input pressure (as read
by the
PRESSURE LIMIT MONITOR
[9]), to any desired value higher (typically 20–50% higher) than the
full-scale range of the device under test. Using this technique, the device under test is fully protected
from being accidentally over-pressurized.
5. Set the DISPLAY SELECT switch (16) to the PRESSURE position.
6. Connect the male end of the test hose to the
TEST PORT
(17) fitting.
7. Connect the swivel fitting end (7/16-20) of the test (output) hose to the device-under-test (use adapters if
required). Tighten all connections properly.
Figure 2-2. Initial Setup Procedure
NOTE : UPC5000 shown, AC Input (7) and Fill Port (4) are on back side of UPC5010 Rack Mountable Calibrator.

Operation 5
8. Optional - if the current (4.000 to 20.000 mA) measurement features are used, connect the provided
transducer test cable, (PN 55092), to the transducer test jacks (14).
When connected, the transducer test cable provides +32 VDC excitation on non-battery units, or +18 VDC
excitation on battery units. The internal impedance (load) is 10 ohms.
NOTE: + EXCITATION VOLTAGE will only operate while units power cord is plugged into AC wall outlet. Battery units
may be ordered special to obtain +28 VDC excitation.
The display scaling for these current measurements are as follows:
NOTE:
UPC5000/UPC5010 reads a 4-20 mA signal only, but will display as either 4-20 mA or 20-100 mV.
The test cable connector wiring is as follows:
NOTE:
Connector pin designations are for reference only, and are no longer a connector on newer units. See Figure 2-2
on page 4 (14).
2.3 Pressure Measurement Sequence for Absolute/Gage Unit
1. Check that the indicator on the right end of the display indicates desired mode (10). If not, momentarily
depress the ABS/GAGE switch (11) to obtain mode.
2. If operating unit in GAGE mode go to Section 2.4. If operating unit in ABSOLUTE mode go to Section
2.5.
2.4 Pressure Measurement Sequence for Gage Only Unit
NOTE:
See Figure 2-3 on page 6 when following these steps.
1. To apply pressure, close the
VENT
valve (8), approximately two turns, until it stops, then open the
COARSE ADJUSTMENT
valve (2) approximately 1/2 turn counter-clockwise until the numerical display
begins to move. The pressure may change rapidly until reaching approximately 90% of the desired final
value.
2. Use either the
COARSE ADJUSTMENT
(2) or
VENT
valve (8) to obtain a specific pressure reading. Both
provide precise control. As the pressure approaches the desired value, the valve being used for control
should be rotated slowly clockwise to its closed position.
3. To obtain exact pressure readings, slowly rotate the
VERNIER
control (13) knob in the direction required
(clockwise to increase pressure) as indicated by the electronic numerical display.
4. The transducer current measurement can be displayed at any time by placing the
DISPLAY SELECT
switch (16) to its
CURRENT
position.
SWITCH POSITION DISPLAY READING
Current 0-20.000 mA by 0.005 mA
* Voltage 0-100.00 mV by 0.02 mV
Table 2-1. Display Select Switch (16)
CONNECTOR PIN DESIGNATION FUNCTION
A+VDC
B+SIGNAL
C NOT USED
D VOLTAGE & SIGNAL COMMON
Table 2-2. Transducer Test Cable (PN 55092)

6 UPC5000/UPC5010 Operation & Maintenance Manual
Figure 2-3. Pressure Measurement Sequence (Gage Only)
NOTE :
UPC5000 shown, AC Input (7) and Fill Port (4) are on back side of UPC5010 Rack Mountable Calibrator.
2.5 Pressure Measurement Sequence for Absolute Only Unit
1. If only pressure measurements greater than barometric are required, continue to step 1.1. If pressure
measurements above and below atmospheric pressure are required, go to Step 2.
1.1. To apply pressure, close the
VENT
valve (8) (approximately two turns to its stop) and open the
COARSE ADJUSTMENT
valve (2) approximately 1/2 turn counter-clockwise until the numerical
display begins to move. In general, the pressure may be changed rapidly until reaching
approximately 90% of its desired final value.
1.2. Use either the
COARSE ADJUSTMENT
(2) or
VENT
valve (8) to obtain a specific pressure reading.
Both provide precise control. As the pressure approaches the desired value, the valve being used for
control should be rotated slowly clockwise to its closed position.
1.3. To obtain exact pressure readings, slowly rotate the
VERNIER
control (13) knob in the direction
required (clockwise to increase pressure) as indicated by the electronic numerical display.
2. If pressure measurements above and below atmospheric pressure are required, connect a vacuum pump
to the VACUUM/VENT port (15) as shown in Figure 2-4 on page 7.
3. Open the
VENT
valve (8), close the
COARSE ADJUSTMENT
valve (2) and apply power to the vacuum
pump and allow it to evacuate the system for several minutes or until the digital display reading reaches
equilibrium near zero PSIA. Press the
ZERO
button to establish a zero reference on the display.
4. With the vacuum pump still running, close the
VENT
valve (8) and check for system leaks. If there are
none, continue to step 4.1.
4.1. To apply pressure, close the
VENT
valve (8) (approximately two turns to its stop) and open the
COARSE ADJUSTMENT
valve (2) (approximately 1/2 turn counter-clockwise until the numerical
display begins to move). In general, the pressure may be changed rapidly until reaching
approximately 90% of its desired final value.

Operation 7
4.2. Use either the
COARSE ADJUSTMENT
(2) or
VENT
valve (8) to obtain a specific pressure reading.
Both provide precise control. As the pressure approaches the desired value, the valve being used for
control should be rotated slowly clockwise to its closed position.
4.3. To obtain exact pressure readings, slowly rotate the
VERNIER
control (13) knob in the direction
required (clockwise to increase pressure) as indicated by the electronic numerical display.
Figure 2-4. Pressure Measurement Sequence (Absolute Only)
2.6 Battery Operation
When supplied with the battery, the UPC5000/UPC5010 has an internal, rechargeable 12 volt, lead acid battery
which provides a minimum of six hours of completely portable usage before having to be recharged.
An
ON/OFF
/
BATTERY TEST
switch (18) is provided to conserve energy when the instrument is not in use, and to
provide the operator with information as to the status of the battery voltage during use.
The UPC5000/UPC5010 can be operated and recharged by connecting to a standard AC outlet via the line cord
(supplied). The battery re-charge cycle time is approximately 16 to 20 hours with the ON/OFF switch in the OFF
position. The charging circuit is designed to be left on indefinitely without adversely affecting battery life.
When selected, the momentary action
BATTERY TEST
switch (18) (Figure 2-4 on page 7) is used to read the
actual battery voltage. The battery voltage reading typically is between 11.5 and 13.0 volts. When the battery
voltage reads 11.5 volts, there are approximately one to two hours of useful operation left and a
low battery
indicator is illuminated. For LED display units, a red LED in the left center of the display turns on. For LCD
display units, five LED segments in the left of the display window illuminate in a "U" shape. The instrument
ceases to function when the battery voltage is 11.0 volts or less.
NOTE: The battery test should only be performed with the UPC5000/UPC5010 operating at zero PSIG (VENT valve
open) and at the conclusion of the test, the unit's ZERO button will have to be pushed again to re-zero the instrument.

8 UPC5000/UPC5010 Operation & Maintenance Manual
3.0 Calibration
Follow the procedure on the following pages for calibrating the UPC5000/UPC5010.
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 ten 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 “UPC5000/UPC5010 Return Material
Authorization Form” on page 53).
3.1 Pneumatic Calibration Set-up
Figure 3-1 defines a typical gage or absolute/gage calibration set-up using a floating piston-type, dead weight
tester. While doing an ABSOLUTE Only Unit calibration, a vacuum pump with an indicator capable of reading
PSIA will be 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 UPC5000/UPC5010 is placed into its calibrate mode by connecting a Condec Calibration Module (PN
60109) via the multi-pin jack. The jack is located behind the small slide plate near the fill port (see Figure 3-1).
The Condec Calibration Module provides access to the calibrator’s various program modes via a five-position
rotary switch. It also provides a means of entering and storing data via four other momentary action switches.
In the calibrate mode, the UPC5000/UPC5010’s numerical display is used to provide operator prompting
symbols as well as displaying the various data formats. For example, in Figure 3-2, the data format shown is that
obtained as soon as the ZERO/SPAN position of the rotary switch is selected.
Figure 3-1. Gage Only Unit or Absolute/Gage Unit nstrument Calibration Set-up
NOTE: UPC5000 shown, AC input and Fill Port are on backside of UPC5010 Rack Mountable Calibrator.

Calibration 9
3.3 Zero/Span Calibration
Selecting the ZERO/SPAN position on the Condec Calibration Module (PN 60109) places the instrument into its
ZERO/SPAN calibration mode. The display is shown in Figure 3-2.
NOTE: Absolute Only Unit requires vacuum pump with PSIA indicator to obtain readings below local barometric
pressure.
Figure 3-2. Zero/Span calibration for Absolute/GageUnit
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 or Absolute/Gage Unit: Adjust input pressure to the appropriate (either 0 or 100%) value.
Absolute Only Units: Must use a vacuum pump with PSIA display, to reach as close to 0 PSIA as
possible.
2. Perform the action indicated in Table 3-1 when pressure input readings are stable.
NOTES:
1. If readings are not stable or are not within ±20% of zero, the zero correction can’t be entered.
2. If readings are not stable or are not within ±5% of 100%, the span correction cannot be entered.
3. Absolute only unit: Maximum vacuum standard display reading of 0.04 PSIA.
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 UPC5000/UPC5010 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 indicator must be used to obtain readings below local barometric pressure.
Step No. Pressure Input Value Operator Action Required Resulting Display Indication Remarks
1 0% (see Note 3
below) Press ENTER button 0% Note 1 below
2 100% Press ENTER button 100% Note 2 below
Table 3-1. Zero and Span Calibration Sequence

10 UPC5000/UPC5010 Operation & Maintenance Manual
Figure 3-3. Linearity and Hysteresis Calibration
Starting with the instrument’s lowest pressure range, sequentially perform the thirteen steps described in
Table 3-2, for each pressure range being calibrated. Perform the following for each step:
1. Adjust input pressure to the appropriate value without overshooting the setting. If value is overshot, vent
unit and repeat steps.
2. Perform the action as indicated when the readings are stable. On units below 2000 PSI it should not take
longer than five minutes. Units above 2000 PSI and all absolute only units should take no longer than
fifteen minutes. If it is taking longer, check system for leaks. If no leaks are found, the CPU or transducer
may be defective.
When Step 11 is reached, the display changes so that the left most status symbol is H. This remains for Step 12
and down to approximately 0.00 PSI.
Step Input Pressure % of Range Operator Action Required Status Symbol in
Left-most Digit Remarks
10(see note 4 below) Press ZERO switch L Zero on display
210Press ENTER button L Notes 1 & 2 below
320Press ENTER button L Notes 1 & 2 below
430Press ENTER button L Notes 1 & 2 below
540Press ENTER button L Notes 1 & 2 below
650Press ENTER button L Notes 1 & 2 below
760Press ENTER button L Notes 1 & 2 below
870Press ENTER button L Notes 1 & 2 below
980Press ENTER button L Notes 1 & 2 below
10 90 Press ENTER button L Notes 1 & 2 below
11 100 No Action Required H Note 3 below
12 50 Press ENTER button H Notes 1 & 2 below
13 0 (see note 4 below) No Action Required L
Table 3-2. Linearization and Hysteresis Calibration Sequence

Calibration 11
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 vacuum standard display reading of 0.04 PSIA.
3.5 Shunt Resistor Calibration
To place the UPC5000/5010 into shunt calibration mode, install the Condec Calibration Module (PN 60109) and
select the SHUNT MODE position of the rotary switch. The display is shown in Figure 3-4.
Figure 3-4. Display in Shunt Resistor Calibration Mode.
With the UPC5000/UPC5010’s highest pressure range selected, perform the four step sequence described below.
1. Gage Only and Absolute/Gage Units: be sure the input pressure is set at 0 PSIG.
NOTE: Absolute Only Units: Must use a vacuum pump with PSIA display, to reach as close to 0 PSIA as possible
(maximum vacuum standard display reading of 0.04 PSIA).
2. Press and hold the ZERO button on the module until a stable zero indication is obtained.
3. Release the ZERO button and allow the display to stabilize at its shunt resistor calibration number (100 ±
5.00%).
4. Press the ENTER button on the module. When accepted, the bottom half of all display digits
momentarily illuminate.
3.6 Voltage/Current Input Calibration
To calibrate a current generator capable of generating 20 mA, it should be connected to the COMMON and
CURRENT INPUT jacks (Figure 2-2 on page 4 [14]). The DISPLAY SELECT switch (16) should be in the
VOLTAGE position.
1. Set the Condec Calibration Module (PN 60109) to the ZERO/SPAN position (see Figure 3-2 on page 9 for
display reading).
2. Press the ENTER button on the module. The display reads 0.00.
3. Set the current generator for 20 mA output. Press the ENTER button on the module. The display should
read 100.000.
4. Turn the DISPLAY SELECT switch (16) to the CURRENT position. Display will read 20.000.
5. Disconnect the current generator.
NOTE: If the display reading is off, set the Current Generator to 0, and press the ENTER button on the Condec
Calibration Module. Set the Current Generator for 20 mA output. The display will read 20.000. If the display reading is
off, press the ENTER button on the module. If the display reading is not 20.000, CPU is faulty and requires servicing.

12 UPC5000/UPC5010 Operation & Maintenance Manual
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 Calibration Module (PN 60109).
2. Press the STORE button on the module.
3. When the data is accepted, the four-digit number on the display indicates 1020 for as long as the STORE
button is pressed.
3.8 Required Barometric Offset for Absolute/Gage Unit
Note: This section can only be completed after Sections 3.3 through 3.7 have been done.
Obtain the current barometric pressure from a pressure standard with an accuracy of .025% or better, to calibrate
the absolute zero at the current barometric pressure.
If the current barometric pressure is below 14.7 PSIA, the offset is positive, see Example 1. If the current
barometric pressure is above 14.7 PSIA, the offset is negative, see Example 2. If the current barometric pressure
is 14.7 PSIA, then no offset is needed.
Example 1:
If the current barometric pressure is lower than 14.70 PSIA, subtract the current barometric pressure from 14.70.
14.70 PSI: UPC5000/UPC5010 reference point
-14.55 PSI: Current barometric pressure
0.15 PSI: Positive Delta Offset
Complete the following steps (refer to Figure 2-2 on page 4 and Figure 3-1 on page 8):
1. Open the VENT valve (8) and close the COARSE ADJUSTMENT (2) valve.
2. Using the RANGE SELECT switch (19), select the lowest pressure range on the UPC5000/UPC5010.
3. Select the ZERO/SPAN position on the Condec Calibration Module (PN 60109). The
UPC5000/UPC5010 displays three dashes on the left side of the display to indicate this mode.
4. Press the ENTER button on the Condec Calibration Module. The UPC5000/UPC5010 display reads zero.
Repeat this step for the mid and high ranges.
5. Close the VENT valve (8). Select the lowest pressure range of the UPC5000/UPC5010.
6. Turn the VERNIER (13) of the UPC5000/UPC5010 clockwise, creating a pressure until the display reads
0.15 PSI.
7. Depress the ENTER button on the Condec Calibration Module. The UPC5000/UPC5010 display reads
zero. Repeat this step for the mid and high ranges.
8. Select DATA RECALL on the Condec Calibration Module. The display shows 1XXX (three digits).
9. Press the STORE button on the Condec Calibration Module. The display reads 1 020 or 1 377 when the
button is pressed.
Example 2:
If the current barometric pressure is above 14.70 PSIA, subtract the current barometric pressure from 14.70.
14.70 PSI: UPC5000/UPC5010 reference point
-14.75 PSI: Current barometric pressure
-.05 PSI: Negative Delta Offset
NOTE: Normally the negative offset is small enough to prevent the need of a vacuum pump.

Calibration 13
Complete the following steps (refer to Figure 2-2 on page 4 and Figure 3-1 on page 8):
1. Open the VENT valve (8) and close the COARSE ADJUSTMENT valve (2).
2. Using the RANGE SELECT switch (19), select the lowest pressure range on the UPC5000/UPC5010.
3. Select the ZERO/SPAN position on the Condec Calibration Module (PN 60109). The
UPC5000/UPC5010 displays three dashes on the left side of the display to indicate this mode.
4. Depress the ENTER button on the module. The UPC5000/UPC5010 display reads zero. Repeat this step
for the mid and high ranges.
5. Close the VENT valve (8). Select the lowest pressure range of the UPC5000/UPC5010.
6. Turn the VERNIER (13) of the UPC5000/UPC5010 counter-clockwise to create a vacuum until the
display reads -0.05 negative offset.
7. Depress the ENTER button on the module. The UPC5000/UPC5010 display reads zero. Repeat this step
for the mid and high ranges.
8. Select DATA RECALL on the module. The display reads 1XXX (three digits).
9. Press the STORE button on the module. The display reads 1 020 or 1 377 when the button is pressed.
3.9 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
(14). The DISPLAY SELECT switch (16) should be on the CURRENT position.
1. Set the Condec Calibration Module to the NORMAL MODE position.
2. DISPLAY SELECT switch should still be in the CURRENT position. Display will read 20.000.
3. Turn the DISPLAY SELECT switch to the VOLTAGE position. Display will read 100.00.
4. The pneumatic portion of the calibration is now complete and the pressure standard and the module can
now be disconnected.
3.10 Self-Check Test
Complete the following steps (see Figure 2-2).
1. Remove the CONDEC Calibration Module.
2. Depress the ZERO push-button (12) on the UPC5200/UPC5210 until the unit shows "CAL". The display
will show "100" to verify the unit's accuracy, then it will return to the normal mode automatically.
3. The pneumatic portion of the calibration is now complete and the pressure standard and the CONDEC
Calibration Module can now be disconnected.

14 UPC5000/UPC5010 Operation & Maintenance Manual
4.0 Maintenance and Service
This section outlines the mechanical and basic electrical repair procedures for the UPC5000/UPC5010.
4.1 Troubleshooting
Use Table 4-1 below for information on troubleshooting the UPC5000/UPC5010.
4.2 Maintenance and Service Procedures
The repair procedures cover the major components and sub-assemblies which are critical to the proper
functioning of the calibrators and that need periodic maintenance over the life of the unit. Although some
mechanical sub-assemblies could be replaced without venting cylinder it is not recommended.
Only those persons who are formally trained as skilled technicians should attempt to repair these units.
All safety precautions should be observed due to the presence of electrical components and
high-pressure cylinders. Unit must always be unplugged from power source.
4.2.1 Panel/Chassis Removal and Installation
UPC5000 Removal
Tools required: Phillips screwdriver
1. Loosen and remove the eight screws (PN 14862) that secure the panel assembly to the enclosure.
2. Lift the panel and chassis by grasping the regulator knob and test port and grasping under the panel
edges. Ensure that the wire harnesses do not catch and snag.
3. Gently set the panel/chassis assembly on a bench top. It can be rested on the panel bottom and chassis
edge with the panel tilted at an angle from its vertical.
Symptom Problem Remedy
No lit display Unit will not energize Check fuse, check power source, check
power switch
Display slowly decreases over time Leak in system Check all compression and pipe fittings
with snoop, bottle of liquid leak gas
detector (PN 64781)
Display does not respond when Vernier
knob is turned No Vernier control Readjust isolation valves on Orion; replace O-ring on Vernier piston
Display increases or decreases when
COARSE (Pressure) or VENT valves are
closed
No Pressure or Vent control Replace valve seats or O-rings in valves;
check valve needles
Unit will not stay in CAL; display shows
"o" and reads a high value at zero PSIG. Transducer over-pressurized Replace transducer
Low battery indicator on display
illuminates when unit is powered Low or no battery power Re-charge battery, check power supply charging voltage
No display when in battery mode after
charging Battery will not hold charge Replace battery
Display will not zero Display will not zero Perform a ZERO/SPAN calibration
Display shifts Transducer drifts or possible over
pressure Replace transducer
Gas escapes when external supply
pressure is bled Nitrogen cylinder will not remain charged Remove inlet check valve; clean or replace
Table 4-1. UPC5000/UPC5010 Troubleshooting
!
Caution

Maintenance and Service 15
UPC5000 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. Ensure that the wire harnesses do not catch and
snag.
3. Align mounting holes and install the eight screws (PN 14862) that secure the panel assembly to the
enclosure.
UPC5010 Removal
Tools required: Phillips screwdriver
1. Loosen and remove the fourteen screws (PN 14862) from top, bottom, and sides that secure the panel
assembly to the enclosure. Also, loosen and remove the three screws (PN 56444) from the rear of unit
that secure the enclosure to the AC INPUT/FIILL 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 and chassis
edge with the panel tilted at an angle from its vertical.
UPC5010 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 fourteen 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 (PN
56444) from the rear of unit that secure the enclosure to the AC INPUT/FIILL PORT panel.
4.2.2 Nitrogen Cylinder Assembly Removal (PN 59531)
NOTE: Condec strongly recommends that the internal nitrogen supply cylinder be pressure-tested and re-certified
every five years from date cylinder was manufactured per U.S. DOT. 3AL Regulation, Title 49 CFR, parts 173 and 178.
Tools required: 7/16" open end wrench
Phillips screwdriver
1-1/8" open end wrench
3/8" open end wrench
Procedure:
1. Vent any remaining gas from the cylinder to atmosphere. 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 all tubing sections from the cylinder.
4. Remove the four mounting nuts and two clamps from the cylinder.
5. Remove the cylinder assembly.
6. If installing a new cylinder, remove the fitting/tee assembly and Teflon seal and inspect for any damage.
If there is no damage, reuse these items on the new cylinder.

16 UPC5000/UPC5010 Operation & Maintenance Manual
4.2.3 Installing New Nitrogen Cylinder Assembly (PN 59531)
Tools required: 7/16" open end wrench
Phillips screwdriver
1-1/8" open end wrench
3/8" open end wrench
A/R 1/4"-wide Teflon tape (PN 60575)
A/R 1/2"-wide Teflon tape (PN 60911)
tube of fluorinated grease (PN 55593)
snoop, bottle of liquid gas leak detector (PN 64781)
1. Install the Teflon O-ring (PN 59217), fitting (PN 59287), and branch tee (PN 59750) on the new cylinder
and tighten until snug. Place a small amount of Krytox grease on both sides of Teflon O-ring prior to
installation. If installing new parts, Teflon tape is required.
2. If required, wrap two bands of 1" wide rubber friction tape (PN 58838) completely around the perimeter
of the cylinder; one at the cylinder bottom and the second at approximately 5.3" from the cylinder
bottom.
NOTE: Prior to wrapping tape, verify and mark on cylinder, center placement of tape, while holding cylinder in mounted
position on chassis.
3. Mount the cylinder in the chassis making sure that the tee fitting is correctly oriented to accept tubing
sections.
4. Install the two clamps (PN 58871) and four mounting screws (PN 14862).
5. Install the tubing sections, tightening all fitting nuts 1/4 turn from finger-tight using a 7/16" wrench.
6. Fill the cylinder to approximately 1000 PSIG and check all fittings for leaks. If there are no leaks fill
nitrogen supply cylinder to 2200 PSIG. See See Section 2.1 on page 3 for cylinder refilling procedure.
7. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 14.
4.2.4 ORION-2C Manifold Removal (PN 55283)
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 4-7 on page 32 and Figure 4-1 on page 33 for additional parts information.
1. Vent any remaining gas from the nitrogen cylinder 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 14, and place unit on a
bench top.
3. Remove the nitrogen cylinder and its associated tubing as outlined in Section 4.2.2 on page 15.
4. Remove the test port to ORION-2C tubing section using a 7/16" wrench.
5. If the transducer is wired via a connector, remove the connector by turning counter-clockwise. If the
transducer is hard-wired, loosen and remove the four transducer wires (red, white, green, black) from the
terminal block, TB1, on the CPU board, using the small flat-blade screwdriver.
6. Break the wire ties that hold the transducer wires so that the wires are free.
7. Using the 11/32" thin wrench, loosen and carefully remove the transducer from the ORION-2C
manifold.
8. Remove the tubing sections from the VENT and COARSE (pressure) inlet fittings on the ORION-2C,
using a 7/16" wrench
9. Remove the panel knobs from the COARSE (pressure), VERNIER and VENT valves using the .061" hex
wrench.
10. Loosen and remove the two panel screws (PN 60837) from the panel front that secure the manifold to the
panel.
11. Remove the four retaining nuts that secure the chassis to the panel.
12. Lift the chassis enough to allow the ORION-2C manifold to clear and remove the manifold.

Maintenance and Service 17
4.2.5 ORION-2C Manifold, Valve Seat Removal
Tools required: A/R solvent (de-natured alcohol)
socket wrench
3/4" socket
needle housing socket (PN 65580)
isolation valve needle housing socket (PN 68509)
hex wrench (.050")
hex wrench (.061")
needle-nose pliers
tube fluorinated Krytox grease (PN 55593)
electric hand drill
No. 43 drill bit
No. 4-40 tap
tap handle
small hammer
NOTE: See Table 4-7 on page 32 and Figure 4-1 on page 33 for additional parts information.
1. Use a bench vise to secure the manifold by its center portion, with the valve knobs pointing upward.
2. Using the .061" hex wrench, loosen and remove the knob inserts (4) from the pressure and vent valve
stems.
3. Loosen the 3/4" locknuts (1) on the COARSE (pressure) and VENT valve threaded needle housings (10).
4. Using the needle housing socket (65580) and socket wrench, loosen and remove the needle/housing
assembly (10, 11).
5. To disassemble the isolation valves (two inner valves), first remove the valve needle (18) by turning the
gear (6) clockwise.
6. Loosen and remove the valve housings (19) using the isolation valve housing removal socket (68509)
and socket wrench.
7. Remove the valve stem seats (8) and valve needle seats (9) using the needle-nose pliers.
8. Remove the inner and outer O-rings (28, 27) and back-up rings (31, 30) from the valve stem seats and
wash all parts in solvent (de-natured alcohol).
9. To remove valve seats (7) from either the COARSE (pressure), VENT, or ISOLATION valves, try blowing
compressed air through the inlet and outlet fittings. Otherwise, the center holes will have to be drilled
and a tap used to extract the seat (Steps 10-13).
10. Using the electric hand drill with a No. 43 bit, carefully drill out the seat hole, ensuring that the drill does
not touch the hole in the manifold housing directly beneath the seat.
11. Blow out any chips from the seat area using compressed air.
12. While holding the 4-40 tap steady and perpendicular to the seat, slowly turn until the tap starts to engage
the seat.
13. When the tap has engaged into the seat, use a small hammer and gently knock upward against the tap
handle to extract the seat.
14. After the seat has been removed, blow any remaining chips from the seat area.
4.2.6 ORION-2C Manifold, Vernier Control Disassembly
Tools required: A/R solvent (de-natured alcohol)
1-1/4" open end wrench
screwdriver (flat-blade)
socket wrench
isolation valve needle housing socket (PN 68509)
NOTE: See Table 4-7 on page 32 and Figure 4-1 on page 33 for additional parts information.
1. With the manifold housing mounted in a vise, turn the vernier shaft (14) clockwise until the piston is
bottomed.
2. Loosen and remove the end cap (13) using a 1-1/4" wrench. At certain points during removal the end cap
will appear to lock up. If this occurs, rotate the shaft (14) clockwise until the end cap is free to turn.
3. Remove the O-ring (29) from the end cap.