Condec UPC5200 User manual

63259
UPC5200 & UPC5210
Portable & Rack-mountable Pneumatic
High Pressure Calibration Console
Operation and Maintenance Manual
CONDEC Sales Phone No. [phone]
CONDEC Web Site: www.4condec.com

Copyright © 2002 Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Specifications subject to change without notice.
February 2002
Contents
About This Manual................................................................................................................................... 1
1.0 Introduction.................................................................................................................................. 1
2.0 Operation...................................................................................................................................... 4
2.1 Pressure Cylinder (PN 59533) Filling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Initial Setup Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Pressure Measurement Sequence (Gage Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Pressure Measurement Sequence (Absolute Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.0 Calibration.................................................................................................................................... 9
3.1 Pneumatic Calibration Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Instrument Calibration Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Zero/Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Linearity and Hysteresis Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Shunt Resistor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Current Input Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7 Permanent Data Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.8 Normal Mode Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.9 Self-Check Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.0 Maintenance & Service............................................................................................................. 14
4.1 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Maintenance & Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 Panel/Chassis Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.2 Accumulator, Intensifier & ORION-3A (PN 55287) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.3 ORION-3A Manifold, Valve Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.4 ORION-3A Manifold, Vernier Control Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.5 ORION-3A Manifold, Vernier Control Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.6 ORION-3A Manifold, Valve Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.7 Accumulator, Intensifier and ORION-3A Manifold, Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.8 ORION-3A Manifold, Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.9 Accumulator Assembly, O-ring (PN 58051) Replacement, Filter (PN 56993) Cleaning. . . . . . . . . . . . . 21
4.2.10 Intensifier Assembly, O-rings/Seals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.11 Regulator (Standard Pneumatic) and Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.12 Regulator (Standard Pneumatic) and Solenoid Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.13 Regulator (Tescom) and Solenoid Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.14 Regulator (Tescom) and Solenoid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.15 Panel Gauge Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2.16 Test Port Quick-Connect Fitting (PN 59004) and Filter (PN 54188), Removal and Installation . . . . . . . 28
4.2.17 Test Port (output) Hose Quick-Connect Fitting and Filter (PN 56991), Removal and Installation. . . . . . 28
4.2.18 Input Port Filter (PN 54188), Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.19 Input Port Hose Quick-Disconnect Female Fitting, Removal and Installation . . . . . . . . . . . . . . . . . . . . 29
4.2.20 AC Fuse (PN 57472), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.21 Panel Mounted AC Power/EMI Line Filter (PN 58870), Removal and Installation . . . . . . . . . . . . . . . . . 30
4.2.22 Chassis Mounted EMI Line Filter (PN 59015), Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.23 Pump Control Switch (PN 60307), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.24 Power Switch (PN 58878), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.25 Range Select Switch (PN 55924) and Display Select Switch (PN 55933), Removal and Installation. . . 32
4.2.26 Zero Switch (PN 58886), Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2.27 CPU Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2.28 Pump Control Board Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3 ORION-3A Valve Assembly (55287) Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.4 Intensifier Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.0 Model Number System .............................................................................................................. 44
6.0 Ranges and Resolutions ............................................................................................................ 45
7.0 Options, Replacement Kits ........................................................................................................ 46
8.0 Specifications............................................................................................................................ 47
UPC5200/UPC5210 Warranty and Return Policy ................................................................................... 49
UPC5200/UPC5210 Return Material Authorization Form....................................................................... 50

Introduction 1
About This Manual
This manual is intended for use by service technicians
responsible for installing and servicing
UPC5200/UPC5210 pressure calibrators.
The UPC5200 portable pneumatic pressure calibrator
and the rack-mounted UPC5210 are rugged, compact
instruments manufactured by Condec. They are
designed to provide superior accuracy, range of
calibration and ease of operation when used for the
calibration of a wide variety of pressure sensing and
measuring devices.
This manual has been written to give the user a simple
and clear explanation of how to operate, calibrate and
maintain these instruments.
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
The UPC5200/UPC5210 pressure calibrators utilize an extremely repeatable sensor coupled to
microprocessor-based electronic circuitry and a selectable units display system. This provides easily readable
and accurate digital representation of the measured pressure. This all electro-mechanical device utilizes our
precision Orion-3A vernier, which has one test port. Front panel gages tell the operator accumulator pressure, as
well as regulated input pressure. The pressure regulator acts as a pressure limiter so that the operator can adjust
input system pressure to 1/10 of the target value. Fill and test hoses are supplied for the customer. Standard front
panel buttons and switches provide selection of the desired pressure range, push-button zeroing and the unique
internal self-check feature. For field use, the UPC5200 has a separate 83.3 cubic foot, 2,216 psi cylinder to
provide many hours of use.
Utilizing microprocessor technology, the UPC5200 and rack-mounted UPC5210 instruments 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 calibration models are available.
•Automatic self-check: Computer-controlled internal circuitry provides automatic maintenance of both zero
and span calibration data to insure long-term stability and accuracy.
•Digital Display: Eliminates parallax, interpolation and operator judgement errors. Large, bright, red LED.
digits provide excellent readability under all lighting conditions (also available with an LCD).
•Using a manually adjustable regulator, the maximum system input pressure is adjusted to any desired value
higher (typically 20 to 50%) than the full scale range of the device being tested. By virtue of this technique,
the unit under test is fully protected from being inadvertently over-pressurized.
•Portable: These compact, self-contained systems are easily carried and operated by only one person. Total
weight is approximately 50 lbs.
•System Calibration: The instruments may be completely calibrated without being removed from the
external case. A separate plug-in calibration console (PN 60109) provides access to the computer when
calibration is to be performed. No manual alignment or potentiometer adjustments are required.
Warning

2 UPC5200/UPC5210 Operation and Maintenance Manual
•Calibration Integrity: Tamper-proof design. Once calibrated, numerous safeguards guarantee the integrity
of pressure readings obtained. Display prompting provides the operator with functional status information
during both operation and calibration.
•Pressure Source (UPC5200 only): An external supply cylinder with a volume of 83.3 std. cu. ft. of N
2
provides up to 2,216 psig of pressure for calibration and test. This pressure source drives a pneumatically
operated 10 to 1 intensifier contained within the UPC5200. Therefore, a 1,000 PSI input is amplified to
10,000 PSI.
•Simple Operation: All controls, indicators and pressure ports are accessible from the front panel.
Accompanying operator's manual provides clear, concise instructions for system operation.
•Data Input Capability: A front panel-mounted connector and selector switch permit the 4-20 mA current
signal from the gauge-under-test or voltage to be displayed. Transducer excitation voltage of 28 VDC is
provided standard.
•Safe, Clean Operation: All pressure components are made of stainless steel and proof-tested to at least
150% of maximum operating pressure. In addition, the system contains a high-pressure burst disk to
protect both the operator and system components from harm in the event of inadvertent over-pressurization.
The heart of this calibration system is a highly stable and repeatable pressure transducer. These sensors produce
an electrical output signal which is linearly proportional to the applied pressure. By combining the sensors with
sophisticated microprocessor-based circuitry, an even higher degree of operational accuracy and precision has
been accomplished. For example, computer-generated correction curves for both the non-linearity and the
hysteresis of the sensors improve these characteristics by an order of magnitude or more. In addition, a self-check
feature ensures long-term accuracy by utilizing the computer to generate and control an internal shunt calibration
mode of operation. The indicators full-scale reading is compared against, and if necessary, corrected to the
digitally-stored value for full scale obtained at the time of initial pressure calibration.
In addition to the features, the UPC5200/UPC5210 pressure calibrator is easy to use. Two micro-metering valves
and vernier are provided to control the internally intensified nitrogen while the digital display indicates precisely
the magnitude of the applied test pressure. Also, a simple push-button switch provides zeroing of the pressure
display. The
Range
selection, as well as,
Pressure
and
Current
display selections are accomplished via a pair of
clearly marked rotary switches. Over-pressure protection is provided through a fully-adjustable pressure
regulator, which is manually set for each new device being tested.
With respect to calibration, the instruments have been designed and programmed to provide the operator with
various prompting symbols and legends during each phase of the calibration sequence. Also, to prevent
unauthorized tampering or calibrations, programming or calibration can only be achieved with the aid of a
separate, plug-in calibration console (PN 60109). Also, the electronic circuitry has been designed without any
potentiometers or adjustments, eliminating the possibility of unwanted changes. Finally, the computer has been
programmed with a series of internal self-diagnostic routines which continually monitor and check every bit of
data stored and processed by this system. The computer immediately notes or shuts down operation in the event
of an out-of-tolerance reading or any outright failures.

Introduction 3
Figure 1-1 provides an overview of the UPC5200/UPC5210’s function.
Figure 1-1. UPC5200/UPC5210 Flow Diagram

4 UPC5200/UPC5210 Operation and Maintenance Manual
2.0 Operation
2.1 Pressure Cylinder (PN 59533) Filling Procedure
NOTE: Condec strongly recommends that the external nitrogen supply cylinder be pressure-tested and re-certified
every five years from date cylinder was manufactured per U.S. DOT. 3AL Regulation, Title 49 CFR, parts 173 and 178.
To initially fill or refill the external pressure cylinder (2,216 PSI max.), proceed as described below.
1. Close the CYLINDER valve by rotating clockwise until it stops.
2. Connect the customer supplied fill hose, to a clean regulated nitrogen source, with an output pressure
gauge and vent valve.
3. Connect the other end of the customer supplied fill hose to the female CGA-580 brass
CYLINDER
valve
fitting.
4. Open the
CYLINDER
valve by rotating counter-clockwise until it stops.
5. Slowly open the valve on the nitrogen source and allow the gas to flow into the pressure cylinder. The
customer supplied output pressure gauge indicates the amount of pressure within the internal cylinder.
NOTE: Cylinder is equipped with a rupture disk.
6. Use the following procedure to fill the cylinder:
a) Fill cylinder to 1,000 PSI at a rate of charge equal to a minimum of two minutes, then wait five
minutes for system to stabilize.
b) Fill cylinder from 1,000 PSI to 2,216 PSI at a rate of charge equal to a minimum of two minutes.
c) Wait five minutes for cylinder to stabilize before using.
7. Close the
CYLINDER
valve by rotating clockwise until it stops.Vent nitrogen source and remove fill hose.
2.2 Initial Setup Procedure
To prepare for actual calibration usage, see Figure 2-1 below and proceed as follows:
1. Check that the
COARSE ADJUSTMENT
valve (2) is closed (rotate clockwise until it stops) and that the
Vent valve (8) is open (two turns counter-clockwise from its stop). Verify that the REGULATOR (1) is
closed (rotate counter-clockwise until it stops).
2. Plug in the power cord (7) and energize the unit by depressing the
POWER
switch (18). The
UPC5200/UPC5210 performs an internal functional self-check.Allow at least 10 minutes warm-up time.
3. Select the desired full scale pressure range via the three-position rotary switch (19). For the best
accuracy, the selected range must be greater than, but close as possible to, the full scale range of the
device-under-test.
NOTE: Do not switch pressure ranges during a calibration cycle.
4. Set the
DISPLAY SELECT
switch (16) to the PRESSURE position.
5. Connect the male end of the test hose to the TEST PORT (17) fitting.
6. Connect the swivel fitting end (7/16-20) of the test (output) hose to the device-under-test using adapters
if required. Tighten all connections properly.
7. UPC5200: Connect the male end of the input hose (3) to the female CGA-580 brass
CYLINDER
(5) valve
fitting.
UPC5210: Connect the male end of the input hose (3) to the female CGA-580, customer supplied,
pressure source.
8. Connect the swivel fitting end (7/16-20) of the input hose (3) to the INPUT PORT (4) fitting. Tighten all
connections properly.

Operation 5
Figure 2-1. Initial Setup Procedure
NOTE: UPC5200 shown, AC Input (7) and Input Port (4) are on back side of UPC5210 Rack Mountable Calibrator.
9. Optional - if the current (4.000 to 20.000 mA) measurement features are to be used, connect the
provided Transducer Test Cable (PN 55092) to the Transducer Test Jacks (14).
When connected, this cable provides +28VDC excitation. The internal impedance (load) is 10 ohms. The display
scaling for these current measurements are as follows:
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 2-1
on page 5 (14).
2.3 Pressure Measurement Sequence (Gage Only)
NOTE: See Figure 2-2 on page 6, when following these steps.
1. Note that the indicator on the right end of the display indicates GAGE mode (10).
2. Zero unit by depressing the
ZERO
switch (12) for less than five seconds. The instrument can be zeroed at
any time, as long as the VENT valve (8) is open, by depressing the
ZERO
switch (12).
NOTE: If ZERO switch is depressed longer than 5 seconds unit will perform an internal, functional self-check.
3. UPC5200: Open the cylinder valve (5) by rotating counter-clockwise slowly until it stops.
UPC5210: Open the, customer supplied, pressure source valve.
SWITCH POSITION DISPLAY READING
Current 0-20.000 mA by 0.005 mA
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 UPC5200/UPC5210 Operation and Maintenance Manual
4. Using the REGULATOR (1), adjust the maximum intensifier pump input pressure, as read by the
REGULATED PRESSURE gauge (6), to 1/10 of the full-scale range of the device-under-test. The unit
utilizes an internal intensifier with a 10:1 ratio. As an example, setting regulated pressure to 300 PSI
would generate an output pressure of 3,000 PSI. Using this technique, the device under test is fully
protected from being accidentally over-pressurized.
5. To generate pressure, enable the
PUMP CONTROL
switch (20) and monitor the pressure as it builds in
the ACCUMULATOR gauge (9). Turn the
PUMP CONTROL
switch (20) off when 10% more than the
target pressure has been achieved.
NOTE: The intensifier PUMP CONTROL switch (20) can be operated in two modes. The up position is
continuous and the down position is momentary/jog.
6. To apply pressure, the
VENT
valve (8) must remain closed. Open the
COARSE ADJUSTMENT
valve (2),
approximately 1/2 turn counter-clockwise, until the numerical display begins to move. In general, the
pressure may be changed rapidly until reaching approximately 90% of the desired final value.
7. Use either the
COARSE ADJUSTMENT
(2) or
VENT
valve (8) to obtain a specific pressure reading. Both
provide precise control. As the pressure approaches the desired value, the valve being used for control
should be rotated slowly clockwise to its closed position. With a little experience, pressure values very
close to the desired final value may be quickly achieved.
NOTE: Use the intensifier PUMP CONTROL switch if the ACCUMULATOR gauge (9) reading falls below
required target pressure value.
8. To obtain exact pressure readings, slowly rotate the VERNIER control (13) knob in the direction required
(clockwise to increase pressure) as indicated by the electronic numerical display.
9. Transducer Current Measurement - the current signal from the transducer may be displayed at any time
simply by placing the
DISPLAY SELECT
switch (16) to its CURRENT position.
Figure 2-2. Pressure Measurement Sequence (Gage Only)
NOTE: UPC5200 shown, AC Input (7) and Input Port (4) are on back side of UPC5210 Rack Mountable Calibrator.
2.4 Pressure Measurement Sequence (Absolute Only)
NOTE: See Figure 2-3 on page 8, when following these steps.
1. Note that the indicator on the right end of the display indicates ABSOLUTE mode (10).
2. If only pressure measurements greater than barometric are required, continue to step 2.1. If pressure
measurements below atmospheric pressure are required go to step 3.
2.1. UPC5200: Open the cylinder valve (5) by rotating counter-clockwise slowly until it stops.
UPC5210: Open the pressure source valve (customer supplied).

Operation 7
2.2. Using the REGULATOR (1), adjust the maximum intensifier pump input pressure, as read by the
REGULATED PRESSURE gauge (6), to 1/10 of the full-scale range of the device-under-test. The
unit utilizes an internal intensifier with a 10:1 ratio. As an example, setting regulated pressure to 300
PSI would generate an output pressure of 3,000 PSI. Using this technique, the device under test is
fully protected from being accidentally over-pressurized.
2.3. To generate pressure, enable the
PUMP CONTROL
switch (20) and monitor the pressure as it builds
in the ACCUMULATOR gauge (9). Turn the
PUMP CONTROL
switch (20) off when 10% more
than the target pressure has been achieved.
2.4. To apply pressure, close the VENT valve (8) approximately two turns to its stop and open the
COARSE ADJUSTMENT valve (2) approximately 1/2 turn counter-clockwise until the numerical
display begins to move. In general, the pressure may be changed rapidly until reaching
approximately 90% of it desired final value.
2.5. Use either the COARSE ADJUSTMENT (2) or VENT valve (8) to obtain a specific pressure
reading. Both provide precise control. As the pressure approaches the desired value, the valve being
used for control should be rotated slowly clockwise to its closed position. With a little experience,
pressure values very close to the desired final value may be quickly achieved.
NOTE: Use the intensifier PUMP CONTROL switch if the ACCUMULATOR gauge (9) reading falls below
required target pressure value.
2.6. To obtain exact pressure readings, slowly rotate the VERNIER control (13) knob in the direction
required (clockwise to increase pressure) as indicated by the electronic numerical display.
3. If pressure measurements below atmospheric pressure are required, connect a vacuum pump to the
VENT/VACUUM port (15) as shown in Figure 2-3 on page 8.
3.1. Open the VENT valve (8), but the COARSE ADJUSTMENT valve (2) must remain closed. Apply
power to the vacuum pump and allow it to evacuate the system for several minutes or until the
digital display reading reaches equilibrium near 0 PSIA. Press the
ZERO
button to establish a zero
reference on the display.
3.2. With the vacuum pump still running, close the VENT valve (8) and check for system leaks. If there
are none, continue to step 3.3.
3.3. Remove the vacuum pump.
3.4. To apply vacuum, COARSE ADJUSTMENT (2) valve must remain closed. Open the VENT valve
(8) counter-clockwise slowly until the numerical display begins to move.
3.5. As the pressure approaches the desired value, the VENT valve (8) should be rotated slowly
clockwise to its closed position. With a little experience, pressure values very close to the desired
final value may be quickly achieved.
3.6. To obtain exact PSIA readings, slowly rotate the VERNIER control (13) knob in the direction
required (clockwise to increase pressure) as indicated by the electronic numerical display.
4. Transducer Current Measurement - the current signal from the transducer may be displayed at any time
simply by placing the
DISPLAY SELECT
switch (16) to its CURRENT position.

8 UPC5200/UPC5210 Operation and Maintenance Manual
Figure 2-3. Pressure Measurement Sequence (Absolute Only)
NOTE: UPC5200 shown, AC Input (7) and Input Port (4) are on back side of UPC5210 Rack Mountable Calibrator.

Calibration 9
3.0 Calibration
Follow the procedure on the following pages for calibrating the UPC5200/UPC5210.
NOTES:
• When calibrating, the computer within the UPC5000/UPC5010 is actually being re-programmed, therefore it is
important that the pressure standard being used is in satisfactory operating condition and that the technician
fully understands its operating characteristics and methods of usage. In addition, the UPC5000/UPC5010 itself
must be properly warmed up (approximately 10 minutes) and electrically stabilized prior to performing a
calibration cycle.
• The Condec Repair Lab is equipped to do calibrations on Condec calibrators and pressure standards.
Calibrations include a certification and are traceable to N.I.S.T (see “UPC5200/UPC5210 Return Material
Authorization Form” on page 50).
3.1 Pneumatic Calibration Set-Up
A typical GAGE calibration set-up using a floating piston type dead weight tester is shown in Figure 3-1. While
doing anABSOLUTE only unit calibration, a vacuum pump with a PSIA test standard is required where the dead
weight tester/pressure source is shown in Figure 3-1. This enables going below local barometric pressure.
NOTE: Any type of precision pressure or vacuum standard is acceptable as long as its basic accuracy is ±0.025% of
point or better.
To permit proper calibration, at least an ON/OFF and a VENT valve (connected as shown in Figure 3-1) must be
provided.
3.2 Instrument Calibration Set-Up
The UPC5200/UPC5210 is placed into its calibrate mode by connecting a Condec Calibration Module, PN
60109, via the multi-pin jack. The jack is located behind the small slide plate near the lower left corner of the
panel (see Figure 3-1).
The Condec Calibration Module, provides access to the calibrator's various program modes via a five-position
rotary switch. It also provides a means of entering and storing data via four other momentary action switches.
In the calibrate mode, the UPC5200/UPC5210's numerical display is used to provide operator prompting
symbols as well as displaying the various data formats employed. For example, in Figure 3-2, the data format
shown is obtained as soon as the ZERO/SPAN position of the rotary switch has been selected.
Figure 3-1. Instrument Calibration Set-Up
NOTE: UPC5200 shown, Power (AC Input) and Input Port are on back side of UPC5210 Rack Mountable Calibrator.

10 UPC5200/UPC5210 Operation and Maintenance Manual
3.3 Zero/Span Calibration
Selecting the ZERO/SPAN position on the Condec Calibration Module (PN 60109) places the instrument into its
ZERO/SPAN calibration mode. The display is shown in Figure 3-2.
NOTE: Absolute only unit requires vacuum pump with PSIA test standard to obtain readings below local barometric
pressure.
Figure 3-2. Zero/Span Calibration for Gage Only Units
Starting with the instrument's lowest pressure range, perform steps 1 and 2 shown in Table 3-1 for each pressure
range.
NOTE: Perform step 1 in all ranges prior to doing step 2.
Perform the following for each step:
1. Gage Only Units: Adjust input pressure to the appropriate (either 0 or 100%) value.
Absolute Only Units: Must use a vacuum pump with PSIA test standard, to reach as close to 0 PSIA as
possible (maximum .05 PSIA).
2. Perform the action indicated by Table 3-1 when pressure input readings are stable.
NOTES:
1. If readings are not stable or are not within ± 20% of zero, the zero correction cannot be entered.
2. If readings are not stable or are not within ± 5% of 100%, the span correction cannot be entered.
3. Absolute only unit: Maximum PSIA test standard display reading of 0.05 PSIA.
3.4 Linearity and Hysteresis Calibration
Install the Condec Calibration Module, (PN 60109), and select the LYN/HYS position of the rotary switch on the
module. This places the UPC5200/UPC5210 into its linearization/hysteresis calibration mode. The display is
shown in Figure 3-3 below.
NOTE: The Zero/Span Calibration needs to be performed prior to Linearity and Hysteresis Calibration . For Absolute only
unit, vacuum pump with PSIA test standard must be used to obtain readings below local barometric pressure.
STEP NO. PRESSURE
INPUT VALUE OPERATOR ACTION REQUIRED RESULTING DISPLAY INDICATION REMARKS
10%
(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

Calibration 11
Figure 3-3. Linearity and Hysteresis Calibration
Starting with the instrument's lowest pressure range, sequentially perform the thirteen steps described in
Table 3-2, for each pressure range being calibrated. Perform the following for each step:
1. Adjust input pressure to the appropriate value without overshooting the setting. If value is overshot by
more than 1%, vent unit and repeat steps.
2. Perform the action as indicated when the readings are stable. Should not take longer than 15 minutes. If
it takes longer, check system for leaks. If no leaks are found, the CPU or transducer may be defective.
When step no. 11 is reached, the display changes so that the left most status symbol is
H
. This remains for step 12
and down to approximately 0.00 PSI.
NOTES:
1. If reading is in motion or correction required is not within ±0.8% of Full-Scale, no entry is made.
2. If entry is valid, the display momentarily indicates the correction value (in percent) and the memory location
at which it is stored.
3. If 100% ±0.05% is not obtained, repeat the Zero/Span calibration sequence.
4. Absolute only unit: Maximum PSIA test standard display reading of 0.05 PSIA.
STEP
NO. INPUT PRESSURE %
OF RANGE OPERATOR ACTION REQUIRED STATUS SYMBOL IN LEFT MOST DIGIT REMARKS
10(Note 4 below) Press
ZERO
Switch L Zero on Display
210 Press
ENTER
button L Notes 1 & 2 below
320 Press
ENTER
button L Notes 1 & 2 below
430 Press
ENTER
button L Notes 1 & 2 below
540 Press
ENTER
button L Notes 1 & 2 below
650 Press
ENTER
button L Notes 1 & 2 below
760 Press
ENTER
button L Notes 1 & 2 below
870 Press
ENTER button L Notes 1 & 2 below
980 Press 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 (Note 4 below) No Action Required L
Table 3-2. Linearization and Hysteresis Calibration Sequence

12 UPC5200/UPC5210 Operation and Maintenance Manual
3.5 Shunt Resistor Calibration
Install the Condec Calibration Module (PN 60109) and select the SHUNT position of the rotary switch on the
module. This places the UPC5200/UPC5210 into its SHUNT RESISTOR calibration mode. The display is
shown in Figure 3-4.
Figure 3-4. Shunt Resistor Calibration
With the UPC5200/UPC5210's highest pressure range selected, perform the four step sequence described below:
1. Gage Only Units: Be sure the input pressure to the UPC5200/UPC5210 is at 0 PSIG.
NOTE: Absolute Only Units: Must use a vacuum pump with PSIA test standard, to reach as close to 0 PSIA as
possible (maximum PSIA test standard display reading of 0.05 PSIA).
2. Press and hold the ZERO button on the Condec Calibration Module until a stable zero indication is
obtained.
3. Release the ZERO button and allow the display to stabilize at its shunt resistor calibration number.
(100 ± 5.00%)
4. Press the ENTER button on the Condec Calibration Module. When accepted, the bottom half of all
display digits are momentarily illuminated.
3.6 Current Input Calibration
To calibrate the current input, a current generator capable of generating 20 mA must be connected to the
COMMON and CURRENT INPUT jacks, see Figure 2.2 on page 4 (14). The DISPLAY SELECT switch (16)
should be on the CURRENT position.
1. Set the Condec Calibration Module (PN 60109) to the ZERO/SPAN position. The display is similar to
Figure 3-2 on page 10.
2. Press the ZERO 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 20.00.
NOTE: If the display reading is off, set the Current Generator to 0, and press the ENTER button on the Condec
Calibration Module. Set the Current Generator for 20 mA output. The display reads 20.000. If the display
reading is off, press the ENTER button on the module. If the display reading is not 20.000, CPU is faulty and
requires servicing.
4. Disconnect the current generator.
3.7 Permanent Data Storage
After completing the above calibration procedures, the new data that has been entered into the computer must be
permanently stored. The sequence to do this is as follows:
1. Select the DATA RECALL position of the rotary switch on the Condec Calibration Module, (PN 60109).
2. Press the STORE pushbutton on the module.
3. If the data is accepted, the four-digit number on the right side of the display indicates 1 020 for as long as
the STORE button is pressed.

Calibration 13
3.8 Normal Mode Test
After completing the above calibration procedures, you must perform a normal mode test. A current generator
capable of generating 20 mA must be connected to the COMMON and CURRENT INPUT jacks, see Figure 2.2
on page 4 (14). The DISPLAY SELECT switch (16) should be on the CURRENT position.
1. Set the Condec Calibration Module to the NORMAL MODE position.
2. DISPLAY SELECT switch should be in the CURRENT position. The display reads 20.000.
3.9 Self-Check Test
1. Remove the Condec Calibration Module.
2. Press the ZERO pushbutton (12) on the UPC5200/UPC5210 until the unit shows CAL. The display shows
100 to verify the unit's accuracy, then it returns to the normal mode automatically.
3. The pneumatic portion of the calibration is now complete. The pressure standard and the Condec
Calibration Module can now be disconnected.

14 UPC5200/UPC5210 Operation and Maintenance Manual
4.0 Maintenance & Service
This section outlines the mechanical and basic electrical repair procedures for the UPC5200/UPC5210.
4.1 Troubleshooting
Use Table 4-1 below for information on troubleshooting the UPC5200/UPC5210.
4.2 Maintenance & Service Procedures
The repair procedures cover the major components and sub-assemblies which are critical to the proper
functioning of the calibrators and that need periodic maintenance over the life of the unit.
Only those persons who are formally trained as skilled technicians should attempt to repair these units.
Although some mechanical sub-assemblies could be replaced without venting cylinder it is not
recommended. All safety precautions should be observed due to the presence of electrical and
high-pressure components. Unit must always be unplugged from power source.
Symptom Problem Remedy
Display does not light up. Unit will not energize. Check fuse, check power source, check
power switch.
Display slowly decreases over time. Leak in system. Check all compression and pipe fittings
with Snoop®, bottle of liquid leak gas
detector (PN 64781).
Display does not respond when Vernier
knob is turned. 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 does not stay in CAL, display shows
"o", display reads a high value @ zero
PSIG.
Transducer over-pressurized. Replace transducer.
Display does not show zero. Display will not zero. Perform a ZERO/SPAN calibration.
Display shifts, will not be steady. Transducer drifts or Possible over
pressure. Replace transducer.
Unit does not cycle when Pump Control
switch is on. Fuse blown on Pump Control Board.
No power.
Replace fuse.
Check that power is on.
Unit cycles, but does not pressurize. Debris in check valve seat in intensifier,
deformity in seat.
No supply pressure.
Remove seats in intensifier and clean
and/or replace.
Check to see if there is sufficient supply
pressure.
Table 4-1. UPC5200/UPC5210 Troubleshooting
!
Caution

Maintenance & Service 15
Figure 4-1. UPC5200/UPC5210 Wiring Diagram

16 UPC5200/UPC5210 Operation and Maintenance Manual
4.2.1 Panel/Chassis Removal and Installation
UPC5200 Removal
Tools required: Phillips screwdriver
1. Loosen and remove the 10 screws (PN 14862) that secure the panel assembly to the enclosure.
2. Lift the panel and chassis by first grasping the regulator knob and test port and second, grasping under
the panel edges. Tilt the panel at an angle by lifting the right side before the left side as you face the
panel. Ensure that the wire harnesses do not catch and snag.
3. Gently set the panel/chassis assembly on a bench top. It can be rested on the panel bottom with the
accumulator supported by a screwdriver handle.
UPC5200 Installation
Tools required: Phillips screwdriver
1. Lift the panel and chassis by first grasping the regulator knob and test port.
2. Gently place panel/chassis assembly into enclosure. Tilt the panel at an angle by lifting the right side
before the left side as you face the panel. Ensure that the wire harnesses do not catch and snag.
3. Align mounting holes and install the 10 screws (PN 14862) that secure the panel assembly to the
enclosure.
UPC5210 Removal
Tools required: Phillips screwdriver
1. Loosen and remove the 14 screws (PN 14861) from top, bottom, and sides that secure the panel assembly
to the enclosure. Also, loosen and remove the three screws (P/N 14861) from the rear of unit that secure
the enclosure to the AC INPUT/INPUT PORT panel.
2. Lift the panel and chassis by grasping the handles located on the front of the rack mountable panel.
Ensure that the wire harnesses do not catch and snag.
3. Gently set the panel/chassis assembly on a bench top. It can be rested on the panel bottom with the
accumulator supported by a screwdriver handle.
UPC5210 Installation
Tools required: Phillips screwdriver
1. Lift the panel and chassis by grasping the handles located on the front of the rack mountable panel..
2. Gently place panel/chassis assembly into enclosure. Ensure that the wire harnesses do not catch and
snag.
3. Align mounting holes and install 14 screws (PN 14862) from top, bottom, and sides that secure the
panel/chassis assembly to the enclosure. Also, align mounting holes and install the three screws (P/N
14862) from the rear of unit that will secure the enclosure to the AC INPUT/INPUT PORT panel.
4.2.2 Accumulator, Intensifier & ORION-3A (PN 55287) Removal
Tools required: Phillips screwdriver
11/32" wrench or nutdriver
.061" hex wrench
adjusting screwdriver (small flat blade)
11/32" open end wrench (thin)
7/16" open end wrench
NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 for additional ORION-3A parts information.
1. Vent the system to atmosphere before attempting to work on the unit. Disconnect the power cord from
the power source.
2. Remove front panel from its enclosure as described in Section 4.2.1 and carefully set on a bench top.
3. Using a 7/16" wrench, remove the following tubing sections:
•Accumulator to supply pressure gauge (1/8" dia.)
•Accumulator to pressure inlet on ORION-3A manifold (1/8" dia.)
•Accumulator to intensifier outlet (1/4" dia.)

Maintenance & Service 17
4. Loosen and remove the six screws that secure the two clamps that hold the intensifier and accumulator.
5. Remove the accumulator by sliding out.
6. Loosen the fitting nut at the intensifier end of the long 1/4" diameter tubing section that connects the
solenoid valve to the intensifier. There is no need to remove the tubing.
7. Remove the two clamps and the intensifier.
8. Using a 7/16" wrench, remove the following tubing sections:
• Vent port to ORION-3A manifold vent outlet (1/8" dia.)
9. If the transducer is wired via a connector, remove the connector by turning counter-clockwise. If the
transducer is hard-wired, loosen and remove the four transducer wires (red, white, green, black) from the
terminal block, TB1, on the CPU board, using the small flat-blade screwdriver.
10. Break the wire ties that hold the transducer wires so that the wires are free.
11. Using the 11/32" thin wrench, loosen and carefully remove the transducer from the ORION-3A
manifold.
12. Remove the panel knobs from the Coarse (pressure),Vernier andVent valves using the .061" hex wrench.
13. Loosen and remove the two panel screws (PN 60837) from the panel front that secure the manifold to the
panel.
14. Remove the five retaining nuts and lock washers that secure the chassis to the panel.
15. Lift the chassis enough to allow the ORION-3A manifold to clear and remove the manifold.
16. Reposition the chassis over the mounting studs and secure with at least two nuts.
4.2.3 ORION-3A Manifold, Valve Seat Removal
Tools required: A/R solvent (de-natured alcohol)
socket wrench
3/4" socket
needle housing socket (65580)
isolation valve needle housing socket (PN 68509)
hex wrench (.050")
hex wrench (.061")
needle-nose pliers
tube fluorinated krytox grease (PN 55593)
electric hand drill
No. 43 drill bit
No. 4-40 tap
tap handle
small hammer
NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 for additional parts information.
1. Secure the manifold by its center portion, in a bench vise, with the valve knobs pointing upward.
2. Using the .061" hex wrench, loosen and remove the knob inserts (4) from the pressure and vent valve
stems.
3. Loosen the 3/4" locknuts (1) on the pressure and vent valve threaded needle housings (10).
4. Using the needle housing socket (65580) and torque wrench, loosen and remove the needle/housing
assembly (10, 1).
5. To disassemble the isolation valves (two inner valves), first remove the valve needle (18) by turning the
gear clockwise.
6. Loosen and remove the valve housings (19) using the isolation valve housing removal socket (59793)
female socket (65581) and torque wrench.
7. Remove the valve stem seats (8) and valve needle seats (9) using the needle-nose pliers.
8. Remove the inner and outer O-rings (28, 27) and back-up rings (31, 30) from the valve stem seats and
wash all parts in solvent (de-natured alcohol).
9. To remove valve seats (7) from either the COARSE (pressure), VENT or isolation valves, try blowing
compressed air through the inlet and outlet fittings. Otherwise, the center holes have to be drilled and a
tap used to extract the seat (Steps 10-13).
10. Using the electric hand drill with the No. 43 bit, carefully drill out the seat hole, ensuring that the drill
does not touch the hole in the manifold housing directly beneath the seat.