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.