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Condec UPC5200 Operation And Maintenance Manual

Portable & rack-mountable pneumatic high pressure calibration console
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UPC5200 & UPC5210
Portable & Rack-mountable Pneumatic
High Pressure Calibration Console
Operation and Maintenance Manual
CONDEC Sales Phone No. (888) 295-8475
CONDEC Web Site: www.4condec.com
63259

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Summary of Contents for Condec UPC5200

  • Page 1 UPC5200 & UPC5210 Portable & Rack-mountable Pneumatic High Pressure Calibration Console Operation and Maintenance Manual CONDEC Sales Phone No. (888) 295-8475 CONDEC Web Site: www.4condec.com 63259...

  • Page 2: Table Of Contents

    Contents About This Manual ........................... 1 Introduction..........................1 Operation............................4 2.1 Pressure Cylinder (PN 59533) Filling Procedure ......... 4 2.2 Initial Setup Procedure.
  • Page 3 Model Number System ......................44 Ranges and Resolutions ......................45 Options, Replacement Kits ......................46 Specifications ..........................47 UPC5200/UPC5210 Warranty and Return Policy ................... 49 UPC5200/UPC5210 Return Material Authorization Form............... 50...

  • Page 4: About This Manual

    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.
  • Page 5 • Pressure Source (UPC5200 only): An external supply cylinder with a volume of 83.3 std. cu. ft. of N provides up to 2,216 psig of pressure for calibration and test. This pressure source drives a pneumatically operated 10 to 1 intensifier contained within the UPC5200.
  • Page 6 Figure 1-1 provides an overview of the UPC5200/UPC5210’s function. Figure 1-1. UPC5200/UPC5210 Flow Diagram Introduction...

  • Page 7: Operation

    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 (5) valve CYLINDER fitting.

  • Page 8: Pressure Measurement Sequence (Gage Only)

    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).

  • Page 9: Pressure Measurement Sequence (Absolute Only)

    DISPLAY SELECT 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. Pressure Measurement Sequence (Absolute Only) NOTE: See Figure 2-3 on page 8, when following these steps.
  • Page 10 2.2. Using the REGULATOR (1), adjust the maximum intensifier pump input pressure, as read by the REGULATED PRESSURE gauge (6), to 1/10 of the full-scale range of the device-under-test. The unit utilizes an internal intensifier with a 10:1 ratio. As an example, setting regulated pressure to 300 PSI would generate an output pressure of 3,000 PSI.
  • Page 11 Figure 2-3. Pressure Measurement Sequence (Absolute Only) NOTE: UPC5200 shown, AC Input (7) and Input Port (4) are on back side of UPC5210 Rack Mountable Calibrator. UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 12: Calibration

    ZERO/SPAN position of the rotary switch has been selected. Figure 3-1. Instrument Calibration Set-Up NOTE: UPC5200 shown, Power (AC Input) and Input Port are on back side of UPC5210 Rack Mountable Calibrator. Calibration...

  • Page 13: Zero/Span Calibration

    3. Absolute only unit: Maximum PSIA test standard display reading of 0.05 PSIA. 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.
  • Page 14 Figure 3-3. Linearity and Hysteresis Calibration Starting with the instrument's lowest pressure range, sequentially perform the thirteen steps described in Table 3-2, for each pressure range being calibrated. Perform the following for each step: 1. Adjust input pressure to the appropriate value without overshooting the setting. If value is overshot by more than 1%, vent unit and repeat steps.

  • Page 15: Shunt Resistor Calibration

    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...

  • Page 16: Normal Mode Test

    . The display shows ZERO 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. Calibration...

  • Page 17: Maintenance & Service

    Maintenance & Service This section outlines the mechanical and basic electrical repair procedures for the UPC5200/UPC5210. Troubleshooting Use Table 4-1 below for information on troubleshooting the UPC5200/UPC5210. Symptom Problem Remedy Display does not light up. Unit will not energize. Check fuse, check power source, check power switch.
  • Page 18 Figure 4-1. UPC5200/UPC5210 Wiring Diagram Maintenance & Service...

  • Page 19: Panel/Chassis Removal And Installation

    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.) UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 20: Orion-3A Manifold, Valve Seat Removal

    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.

  • Page 21: Orion-3A Manifold, Vernier Control Disassembly

    Place thick coating of grease on shaft and bearing surface. Place sixteen chrome ball bearings (41) on greased surface, allowing grease to hold them in place. 6. Install shaft (14) with bearings (41) into end cap. UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 22: Orion-3A Manifold, Valve Seat Installation

    7. Install the end bushing (12) and tighten until snug using the isolation valve housing socket (PN needle 68508) and socket wrench. 8. Tighten so that shaft rotates, but should be firm. Feel vertical motion of shaft (14). If motion exists, retighten end bushing.

  • Page 23: Accumulator, Intensifier And Orion-3A Manifold, Panel Installation

    NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 for additional parts information (* denotes reference to Figure 2-1 on page 5). 1. If not already done, remove the ORION-3A COARSE and VENT valve knobs (3) using the .061" hex wrench. UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 24: Accumulator Assembly, O-Ring (Pn 58051) Replacement, Filter (Pn 56993) Cleaning

    fluorinated Krytox grease (PN 55593) A/R solvent (de-natured alcohol) Disassembly: 1. Remove accumulator assembly from UPC5200/UPC5210 per Section 4.2.2 on page 16. 2. Place accumulator body in vise, using flats. 3. Remove plug adapter fitting (PN 57134) using adjustable wrench.

  • Page 25: Intensifier Assembly, O-Rings/Seals Replacement

    fitting. Pull buss wire ends to squeeze back-up ring into proper position within accumulator body. Verify backup ring split is properly aligned. 7. Tighten plug adapter fitting. 8. Install accumulator assembly into UPC5200/UPC5210 per Section 4.2.7 on page 20. 4.2.10 Intensifier Assembly, O-rings/Seals Replacement NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 for additional parts information.
  • Page 26 Reassembly of Check Valves: NOTES: • Clean all parts with solvent and use shop air hose to remove any dust particles from all mechanical parts, except screws and washers. Wipe the bores of the intensifier housing with a clean cloth before installing the piston. Replace all damaged parts with new ones.
  • Page 27 NOTE: Torque cap screws in a side to side pattern (do not use a circular pattern) and in small increments to ensure end cap (item 83) is seated flat to housing surface. 18. Install intensifier assembly into UPC5200/UPC5210 per Section 4.2.7 on page 20. UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 28: Regulator (Standard Pneumatic) And Solenoid Removal

    4.2.11 Regulator (Standard Pneumatic) and Solenoid Removal Solenoid 120 VAC input - PN 56851, Solenoid 220 VAC input - PN 54366 Tools required: Phillips screwdriver 7/16" open end wrench 9/16" open end wrench A/R 1/4" wide teflon tape, (PN's 60575) A/R 1/2"...

  • Page 29: Regulator (Tescom) And Solenoid Removal

    (PN 64781) NOTE: See Table 4-4 on page 37. Call Condec for replacement part numbers. 1. Wrap two layers of teflon tape on the pipe threads of each fitting and install into the inlet and outlet of the regulator and ensure that each is oriented properly.

  • Page 30: Panel Gauge Removal And Installation

    Turn the switch (20) off when 1,000 PSI has been achieved. Check all fittings for PUMP CONTROL leaks. If there are no leaks vent system and remove pressure source. 7. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 16. 8.

  • Page 31: Test Port Quick-Connect Fitting (Pn 59004) And Filter (Pn 54188), Removal And Installation

    6. While holding filter fitting (PN 59588) vertically, remove filter (PN 56991) and then O-ring (PN 55608) from filter fitting. 7. Inspect and clean parts in solvent (de-natured alcohol) and blow-dry with compressed air. Replace worn or damaged parts with new ones. UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 32: Input Port Filter (Pn 54188), Removal And Installation

    Installation: 1. Grease inside cavity on bottom flat (none allowed in hole) of quick-connect fitting (PN 59034). 2. Grease O-ring seat groove area in filter fitting (PN 59588). 3. Grease both sides of O-ring (PN 55608). While holding filter fitting (PN 59588) vertically, place O-ring (PN 55608) and then filter (PN 56991) into filter fitting (PN 59588).

  • Page 33: Ac Fuse (Pn 57472), Removal And Installation

    5. To install a new line filter, reverse the order of steps 1 through 4. Connect wires to the two wire side of new line filter as follows: Blue wire to CPU White wire Brown wire to CPU Black wire UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 34: Pump Control Switch (Pn 60307), Removal And Installation

    Connect wires to the three wire side of new line filter as follows: Green/Yellow wire to AC INPUT Green wire from terminal (E) Ground Blue wire to AC INPUT White wire from terminal (N) Neutral Brown wire to pump control board, black wire from TB3 terminal HI NOTE: Some units may have POWER marking in place of AC INPUT on panel.

  • Page 35: Range Select Switch (Pn 55924) And Display Select Switch (Pn 55933), Removal And Installation

    2. Loosen the switch mounting nut and lock washer from the rear of panel. 3. Loosen and remove the trim ring from the panel front. 4. Remove switch, lock washer and nut from rear of panel. 5. Unsolder and remove the wires from the switch terminals. UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 36: Cpu Assembly, Removal And Installation

    Installation: 1. Connect and solder the wires onto their respective switch terminals: Zero: Terminal Color Normally open Yellow (C) common Green 2. Install the new switch, lock washer and nut through the panel rear. Hand tighten the trim ring from front of panel.

  • Page 37: Orion-3A Valve Assembly (55287) Parts List

    Washer, backup 54448 Retainer, packing backup 55615 O-ring, Fluorocarbon (Viton) color black w/white dot 58314 Ball, chrome, steel 59731 Male connector, 1/8 tube x 1/8 NPT, stainless steel Table 4-2. ORION-3A Valve Assembly Parts List UPC5200/UPC5210 Operation and Maintenance Manual...
  • Page 38 Figure 4-2. ORION-3A Part No. 55287 Exploded View Maintenance & Service...

  • Page 39: Intensifier Assembly Parts List

    Cap, end 60579 Retainer, packing 55600 O-ring, Buna-N (Nitrile) 70 Durometer color black 54614 Ring, piston 59794 Elbow, 90 Tube to Male NPT 58752 Retainer, piston ring 69435 Dowel, round Table 4-3. Intensifier Parts List UPC5200/UPC5210 Operation and Maintenance Manual...
  • Page 40 Figure 4-3. Intensifier Exploded View Figure 4-4. Tescom and Standard Pneumatic Regulator Mounting Maintenance & Service...
  • Page 41 LEAVE APPROXIMATELY 1/4" LEAD LENGTH ON EACH RESISTER. OBSERVE POLARITY OF ICs, CAPACITORS, DIODES, AND TRANSISTORS. NOTE TO CONDEC MANUFACTURING: ITEMS 11 & 31 REQUIRED FOR UPC5200 &UPC5210 UNITS. REMOVE 3- TEST PROCEDURE: (A)KUA7317 ITEM 11 AND SOLDER ITEM 31 ONLY PRIOR TO INSTALLING INTO UPC5000 OR UPC5010.
  • Page 42 Figure 4-6. CPU and Power Supply Assembly, Sheet 1 (For Non-Battery Units Only) Maintenance and Service...
  • Page 43 Figure 4-7. Power Supply Assembly (For Battery Units Only) UPC5200/UPC5210 Operation and Maintenance Manual...
  • Page 44 Figure 4-8. CPU Schematic, Sheet 2 (For Battery Units Only) Maintenance and Service...
  • Page 45 Figure 4-9. Pump Control Board Assembly UPC5200/UPC5210 Operation and Maintenance Manual...
  • Page 46 Figure 4-10. Pump Control Board Schematic Maintenance and Service...

  • Page 47: Model Number System

    ≠ ≠ MODE ≠ ≠ ≠ A - Gage Only ≠ B - Absolute Only ≠ +------------------------------------------------------+ ≠ DISPLAY ≠ A - Light Emitting Diode (LED) B - liquid Crystal (LCD) Available in Gage Only UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 48: Ranges And Resolutions

    Ranges and Resolutions NOTE: Display resolution, 0.02% of selected range, unless it is not devisable by 1, 2, or 5. RANGE (PSI) RESOLUTION HI/MED/LO Calibrator Mode HI/MED/LO 10000/5000.0/2000.0 Gage Only 2/1/0.5 5000.0/2500.0/1000.0 Gage Only or 1/0.5/0.2 Absolute Only Table 6-1. Ranges and Resolutions Ranges and Resolutions...

  • Page 49: Options, Replacement Kits

    Test Port (output) Hose, with Quick-Disconnect Male fitting: • 5' Long....................PN 55280 Input Port Hose, with Nitrogen Bottle Mating fitting: • 4' Long....................PN 55360 • 10' Long....................PN 55366 • 15' Long....................PN 55369 • 20' Long....................PN 55375 UPC5200/UPC5210 Operation and Maintenance Manual...

  • Page 50: Specifications

    2216 PSIG connected Storage Temperature: 0° to +185° F (–17.8° to +85°C) Material: 300 series Stainless Steel Pressure Media: Dry gaseous nitrogen, standard Test Port: External Pressure Cylinder, UPC5200 only: Pressure Rating: 10,000 PSIG. Material: 300 series Stainless Steel Capacity: 83.3 ft...
  • Page 51 Weight: 52 lbs. including all hoses and cables. Thickness: 0.125 in. UPC5200 Case Dim’s: 11" wide x 18" long x 11.5" high UPC5200 Finish: Gray enamel paint with black UPC5210 Case Dim’s: 19" wide x 8.1" deep x 10.5" high silkscreen nomeclature (Case Dimensions excluding front handles).

  • Page 52: Upc5200/Upc5210 Warranty And Return Policy

    UPC5200/UPC5210 Warranty and Return Policy If possible, please save original packing material which is specifically designed for the unit. Should it be necessary to ship the unit back to the factory, a suitable shipping container must be used along with sufficient packing material.

  • Page 53: Upc5200/Upc5210 Return Material Authorization Form

    COMPANY NAME: STREET: CITY, STATE, ZIP: ATTN: CONDEC • 3 SIMM LANE • DOOR D, UNIT 2A • NEWTOWN, CT 06470 ATTN: PRESSURE PRODUCTS/REPAIR LAB TEL: 888-295-8475 • FAX: 203-364-1556 or 715-234-6967 WEB SITE: www.4condec.com UPC5200/UPC5210 Operation and Maintenance Manual...

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