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Condec UPS3000 Installation, Operation & Maintenance Manual

Portable & rack-mountable pneumatic pressure standards
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UPS3000, UPS3110 &
UPS3210
Portable & Rack-mountable Pneumatic Pressure Standards
Operation & Maintenance
Manual
CONDEC Sales Phone No.: (888) 295-8475
CONDEC Web Site: WWW.4CONDEC.COM
63253

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  • Page 1 UPS3000, UPS3110 & UPS3210 Portable & Rack-mountable Pneumatic Pressure Standards Operation & Maintenance Manual CONDEC Sales Phone No.: (888) 295-8475 CONDEC Web Site: WWW.4CONDEC.COM 63253...
  • Page 2 UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...

  • Page 3: Table Of Contents

    2.7 UPS3000 or UPS3210 Initial Setup Sequence ......... 13 2.7.1 UPS3000 or UPS3210 Display of Pressure Sequence GAGE Mode ......13 2.7.2 UPS3000 or UPS3210 Display of Pressure Sequence Absolute (ABS) Mode.
  • Page 4 4.5 UPS3000 Assembly Drawings ........
  • Page 5 About This Manual The bench-top UPS3000 and the rack-mountable UPS3110 and UPS3210 pneumatic pressure standards are rugged, compact instruments manufactured by CONDEC. They are designed to provide superior accuracy, range of calibration and ease of operation when used to assist in the manufacture, test and/or calibration of a wide variety of pressure sensing and measuring devices.

  • Page 6: Introduction

    The heart of this indicator/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. This transduction technique has been employed by CONDEC for many years and has realized hundreds of thousands of hours of reliable operation.
  • Page 7 With all its sophistication however, a great deal of effort has been expended to make the instruments simple to operate and easy to calibrate. Two micro-metering valves and vernier are provided to control the UPS3110 pressure source while the digital display indicates precisely the magnitude of the applied test pressure.

  • Page 8: Operation

    Standard Display/Keyboard Front Panel Functions UPS3000 See Figure 2-1 on page 5, UPS3110 See Figure 2-2 on page 5, UPS3210 See Figure 2-3 on page 6. 1. Six Digit LED display of the measured pressure. This display also prompts if a problem occurred in performing an operation.
  • Page 9 Figure 2-1. UPS3000 Desktop/Panel-mountable Pressure Indicator Display/Keyboard Functions Figure 2-2. UPS3110 Rack-mountable Front Pressure Calibrator Panel Functions Operation...

  • Page 10: Rear Panel Configuration

    Figure 2-3. UPS3210 Rack-mountable Pressure Indicator Front Panel Functions Rear Panel Configuration UPS3000 Series, See Figure 2-4 below, contains the following: AC power cord, and input receptacle (17). port J1 (16), 7/16-20, 37 -4 AN male fitting. INPUT PRESSURE Application of pressures greater than 1.5 times the highest pressure range of the indicator may cause calibration errors or even permanent damage to the pressure transducer.
  • Page 11 UPS3110 Rack-mountable Series, See Figure 2-5 below, contains the following: 1. AC power cord, fuse holder and input receptacle (17). port (16), 7/16-20, 37 -4 AN male fitting. Location of port for AC only units. INPUT PRESSURE NOTE: The maximum input pressure, supplied by user, is noted below port. 3.

  • Page 12: Configuration Switch Settings

    Figure 2-6. UPS3210 Rack-mountable Pressure Indicator Rear View Configuration Switch Settings As normally supplied, the UPS3000, UPS3110 and UPS3210 will be fully calibrated and configured to the requirements specified by the customer purchase order. However, there are several functions or operational features that may be selected or altered by the operator during usage.

  • Page 13: Apc4000/Apc4001 Interface Option Enable

    The APC4000 interface enable is activated only for models that are purchased and used with the PCM1000-1 controller or part of an APC4001 controller system. When UPS3000 or UPS3210 is used in conjunction with a controller, Peak Hold, Freeze Mode or MIN/MAX Mode options are not available.

  • Page 14: Conversion Enable

    “shunt calibration mode” of operation wherein the indicator reading obtained is compared against, and if necessary, corrected to the digitally-stored value for the same shunt calibration reading obtained at the time of initial pressure calibration. UPS3000/UPS3110/UPS3210 Operation & Maintenance Manual...

  • Page 15: Freeze Mode Option Wiring

    Freeze Mode Option Wiring See Figure 2-7 on page 8 for TB location on CPU. Connections may be made using the Freeze Mode Kit, see “Freeze Mode Option - PN 57778” on page 54. The small five pin connector (pins A & B) which, in turn, are connected to the main CPU board via terminal block TB2-7 (+) (Pin A) and TB2-8 (Gnd Ret) (Pin B).

  • Page 16: Engineering Conversion With Peak Hold Or Max/Min Option

    7. Open the following rocker switches S1 position 3 and S3 positions 1 and 3. NOTE: Verify rocker switches S1 and S3 conform to original settings which had been recorded earlier. 8. To verify proper conversion is active remove and restore power to the UPS3000/UPS3110/UPS3210. UPS3000/UPS3110/UPS3210 Operation & Maintenance Manual...

  • Page 17: Ups3000 Or Ups3210 Initial Setup Sequence

    UPS3000 or UPS3210 Initial Setup Sequence For UPS3000, refer to Figure 2-1 on page 5 and Figure 2-4 on page 6. For UPS3210, refer to Figure 2-3 on page 6 and Figure 2-6 on page 8. 1. Connect the pressure source to the instrument via the...

  • Page 18: Ups3110 Initial Setup Sequence

    (clockwise to increase pressure) as indicated by the electronic numerical display. Application of pressures greater than 1.5 times the highest pressure range of the indicator may cause calibration errors or even permanent damage to the pressure transducer. UPS3000/UPS3110/UPS3210 Operation & Maintenance Manual...

  • Page 19: Ups3110 Pressure Measurement Sequence Absolute (Abs) Mode

    (clockwise to increase pressure) as indicated by the electronic numerical display. GAGE Mode Self-Check For UPS3000, refer to Figure 2-1 on page 5 and Figure 2-4 on page 6. For UPS3110, refer to Figure 2-2 on page 5 and Figure 2-5 on page 7.

  • Page 20: 2.10 Battery Operation

    2.11.1 Hardware Configuration NOTE: See “Case Removal and Installation” on page 28. UPS3000 Required Parts: PN 60607 Quantity 1, PN 58707 Quantity 1, PN 14839 Quantity 2, PN 58302, Quantity 1. UPS3110 and UPS3210 Required Parts: Contact factory for requirements.

  • Page 21: Data Format Table

    5. At this time, record the settings of switch S1. These settings must be changed in order to program the serial output configuration. 6. After the data format and baud rate have been selected, refer to the “SERIAL OUTPUT CONFIGURATION TABLE” in this section for the appropriate values for the M.S.D. “M” and the L.S.D.

  • Page 22: Serial Output Configuration Table

    MSD = MOST SIGNIFICANT DIGIT, LSD = LEAST SIGNIFICANT DIGIT All serial characters are ASCII and consist of the following: 1 Start Bit 7 Data Bits Odd Parity 2 Stop Bits Table 2-10. Serial Character Settings UPS3000/UPS3110/UPS3210 Operation & Maintenance Manual...

  • Page 23: Calibration And Adjustment Procedure

    The simple step-by-step calibration sequence provided on the following pages will permit a qualified technician to calibrate an entire UPS3000, UPS3110 or UPS3210 instrument in a matter of 45 minutes. However, it must be strongly emphasized that when performing these tests, the computer within the instrument is...

  • Page 24: Instrument Calibration Set-Up

    NOTE: See“Case Removal and Installation” on page 28 and Figure 2-7 on page 8 to locate DIP switch S3 on CPU board. UPS3000 is placed into its calibrate mode by momentarily opening instrument drawer and setting the DIP switch, S3 in accordance with Table 3-1. Connect Test Standard to UPS3000 Input Port.

  • Page 25: Zero/Span Calibration

    Zero/Span Calibration Pressing the push-button switch once places the instrument into its calibration mode. The STEPPER ZERO/SPAN display will be shown in Figure 3-3. Figure 3-3. Zero/Span Calibration for Gage Only Units (Each Range) Starting with the instrument’s lowest pressure range, sequentially perform steps 1 and 2 shown in Table 3-2 for each pressure range.
  • Page 26 2. If entry is valid, the display will momentarily indicate 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. UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...

  • Page 27: Shunt Resistor Calibration

    With the UPS3000/UPS3110/UPS3210’s highest pressure range selected, perform the four step sequence described below: 1. Be sure the input pressure to the UPS3000/UPS3110/UPS3210 is at zero psig. NOTE: For Absolute Only Unit, vacuum pump with PSIA indicator must be used to obtain zero reading.

  • Page 28: For Ups3000/Ups3210 Absolute/Gage Switch Selectable Units Only

    0.15 PSI: Positive Delta Offset Complete the following steps NOTE: UPS3000 refer to Figure 2-1 on page 5 and Figure 2-4 on page 6. UPS3210 refer to Figure 2-3 on page 6 and Figure 2-6 on page 8. 1. Connect Test Standard to UPS3000/UPS3210 Input Port similar to Figure 3-1 on page 19.
  • Page 29 Figure 3-6. Vacuum Pump Setup Complete the following steps: NOTE: UPS3000 refer to Figure 2-1 on page 5 and Figure 2-4 on page 6. UPS3210 refer to Figure 2-3 on page 6 and Figure 2-6 on page 8. 1. Connect Vacuum Test Standard to UPS3000/UPS3210 Input Port similar to Figure 3-6. A vacuum pump...

  • Page 30: For Ups3110 Absolute/Gage Switch Selectable Units Only

    Repeat this step for the middle and high ranges. 4. Close the valve (12). Select the lowest pressure range of the UPS3110. VENT 5. Turn the (11) of the UPS3110 counter-clockwise, creating a vacuum until the display reads the VERNIER UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...
  • Page 31 value of the Negative Delta Pressure, -0.05 PSI as in this example. 6. Depress the push-button on the UPS3110. The display reads zero. Without touching the ENTER VERNIER (11) knob repeat this step for the middle and high ranges. 7. Using the push-button, as shown in Figure 3-2 on page 20, place the unit into STEPPER SHUNT RESISTOR...

  • Page 32: Maintenance & Service

    This section outlines the mechanical and BASIC electrical repair procedures for the portable pneumatic pressure calibrator, model UPS3000/UPS3110/UPS3210. The repair procedures cover the major components and sub-assemblies which are critical to the proper functioning of the calibrators and that will likely need periodic maintenance over the life of the unit.

  • Page 33: Orion-2C (Pn 55283) Or Orion-3A (Pn 55287) Manifold Removal

    UPS3110/UPS3210 Removal/Installation Removal Tools required: Phillips screwdriver 1. Vent system and remove input pressure source. Disconnect power cord, hoses, connectors, etc. from rear of UPS3110/UPS3210. Remove from rack, if applicable, by grasping the handles located on the front of the unit and gently set the rack-mount assembly on a bench top. It can be rested on the panel bottom and chassis edge.

  • Page 34: Orion Manifold - Valve Seat Removal

    14. When the tap has engaged into the seat, use a small hammer and gently knock upward against the tap handle to extract the seat. 15. After the seat has been removed, blow any remaining chips from the seat area. UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...

  • Page 35: Orion Manifold - Vernier Control Disassembly

    4.2.4 ORION Manifold - Vernier Control Disassembly ORION 2C: Refer to “ORION 2C Valve Assembly Parts List” on page 45 and Figure 4-1 on the following foldout 11 x 17 sheet. ORION 3A: Refer to “ORION 3A Valve Assembly Parts List” on page 47 and Figure 4-2 on the second foldout 11 x 17 sheet.

  • Page 36: Orion Manifold - Valve Seat Installation

    INPUT VENT needle/housing assembly to 325 in-lb. using the needle housing socket (PN 65580). 10. Install the housing lock nuts (1) onto the housing (10) and tighten until snug with the 3/4" socket. UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...

  • Page 37: Orion - Manifold, Panel Installation

    11. Using the .050" hex wrench, install and tighten the lock nut (2) and set screw (34). 12. Install the Knob Insert (4) over the Valve Needle (11) shaft, align the Set Screws (23) with the indents and tighten with the .061" hex wrench. 13.

  • Page 38: Orion 2C Manifold - Valve Adjustment Procedure

    Valve Knob Insert (4) counter-clockwise until the display starts to decrease, then VENT turn the Knob Insert (4) slightly clockwise until the indicated pressure stops decreasing. 21. Follow steps 10 through 15 replacing the term Valve with Valve. The Valve is now INPUT VENT VENT adjusted. UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...

  • Page 39: Orion 3A Manifold - Valve Adjustment Procedure

    4.2.9 ORION 3A Manifold - Valve Adjustment Procedure For UPS3110 5000 PSI and above Models. ORION 3A: Refer to “ORION 3A Valve Assembly Parts List” on page 47 and Figure 4-2 on the second foldout 11 x 17 sheet. Tools required: Hex wrench (.050") Hex wrench (.061") Snoop, leak gas detector (PN 64781)

  • Page 40: Pressure Limit Control (Standard Pneumatic), Regulator Removal

    1/2" Socket Socket wrench NOTE: See Figure 4-1 on page 49. Call CONDEC for replacement Part No.’s. 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. Use a bench vise when doing this.

  • Page 41: Pressure Limit Control (Tescom), Regulator Removal

    Snoop, liquid leak gas detector (PN 64781) NOTE: See Figure 4-1 on page 49. Call CONDEC for replacement Part No.’s. 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 42: Panel Gauge Removal

    Phillips screwdriver 7/16" Wrench 9/16 " Wrench NOTE: Call CONDEC for replacement Part No.’s. 1. Remove cover from its enclosure as described in Section 4.2.1 on page 28, and carefully place on a bench top. 2. Disconnect the tubing section that connects to the gauge fitting.

  • Page 43: Test Port Quick-Connect Fitting (Pn 59762) Removal And Installation - 15, 50 And 100 Full Scale Psi

    4.2.16 Test Port Quick-Connect Fitting (PN 59762) Removal and Installation - 15, 50 and 100 Full Scale PSI Models UPS3110[]DA, UPS3110[]DB, UPS3110[]EA, UPS3110[]EB and UPS3110[]JA only. If there is leakage out of the port, replace the test port fitting. Tools required: Phillips screwdriver 5/8"...

  • Page 44: Test Port Filter (Pn 54188), Removal And Installation - 500, 1000 And 2000 Full Scale Psi

    2. Using a pressure source set input pressure to approximately 100% of full scale rating of UPS3110 and check all fittings for leaks. 3. Install cover on its enclosure as described in Section 4.2.1 on page 28. UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...

  • Page 45: Test Port Quick-Connect Fitting (Pn 59004) And Filter (Pn 54188) Removal And Installation - 5000 And 10000 Full Scale Psi

    4.2.20 Test Port Quick-Connect Fitting (PN 59004) and Filter (PN 54188) Removal and Installation - 5000 and 10000 Full Scale PSI Models UPS3110[]A[], and UPS3110[]GA only. Every two months, a coating of fluorinated Krytox grease should be applied to the inner seal of the test port fitting.

  • Page 46: Ac Power/Emi Line Filter (Pn 58870), Removal And Installation

    3. Loosen and remove the trim ring from the panel front. 4. Remove switch, lock washer and nut from rear of panel as one item. 5. Unsolder and remove the wires from the switch terminals. UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...

  • Page 47: Range Select Switch Cable (Pn 56014), Removal And Installation

    Installation: 1. Slide shrink sleeving over wires, connect and solder the wires onto their respective switch terminals: Terminal Color Normally open Black (C) common Black 2. Pull shrink sleeving over switch and connections. Apply heat. Install the new switch, lock washer and nut.

  • Page 48: Battery (55851), Removal, Installation And Adjustments

    3. Connect the leads of a 11.5 VDC power source to the battery cable wires that are connected to TB1 on the Power Supply Board. Adjust potentiometer R9 located on power supply board to illuminate low battery indicator. 4. Install panel/chassis assembly in its enclosure as described in Section 4.2.1 on page 28. UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...

  • Page 49: Orion 2C Valve Assembly Parts List

    ORION 2C Valve Assembly Parts List The following table lists the component parts of the Orion 2C and the pullout 11x17 drawing on the next page illustrates the Orion 2C exploded view of those parts. Number Description Quantity 57482 Valve Needle Housing Nut 54401 Locknut 58079...
  • Page 50 UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...
  • Page 51 THESE COMPONENTS TO BE THESE COMPONENTS TO BE THESE COMPONENTS TO BE INST ALLED AT LOCA TIONS A & D INST ALLED AT LOCA TIONS A & D INSTALLED AT LOCATIONS A & D 25/2X 23/2X 24/3X 35/2X 21/14 25/2X 26/2X THESE COMPONENTS TO BE THESE COMPONENTS TO BE...

  • Page 52: Orion 3A Valve Assembly Parts List

    ORION 3A Valve Assembly Parts List The following table lists the component parts of the Orion 3A and the pullout 11x17 drawing on the next page illustrates the Orion 3A exploded view of those parts Number Description Quantity 57482 Valve Needle Housing Nut 54401 Locknut 58079...
  • Page 53 UPS3000/UPS3110/UPS3210 Operation and Maintenance Manual...
  • Page 54 THESE COMPONENTS TO BE INSTALLED AT LOCATIONS A & D 25/2X 23/2X 24/3X 35/2X 41/16X 22/14X 21/14X 25/2X 26/2X 41/16X 42/3X NOTES: LIGHTLY COAT THE FOLLOWING WITH LUBRICANT, PN 55593 O-RINGS, ITEMS 27, 28, 29, 32 & 40. THREADS ON VALVE NEEDLES, ITEMS 11 & 18. FOR REFERENCE ONLY: O-RING, ITEM 27, .239 ID O-RING, ITEM 28, .042 ID...

  • Page 55: Ups3000 Assembly Drawings

    67655 CPU, Battery Power Pressure Indicator Schematic 58723 Power Supply Assembly 67654 Power Supply Schematic 55952 Display Board Assembly KBT7316 Pressure Indicator Display Board 57999 Expander Board Assembly KWH7316 Expander Board Assembly Table 4-3. UPS3000 Assembly Drawings Maintenance & Service...

  • Page 56: Model Number System

    Model Number System UPS3000/UPS3110/UPS3210 Operation & Maintenance Manual...

  • Page 57: Available Ranges, Multi-Conversions And Resolutions

    Available Ranges, Multi-Conversions and Resolutions Approximately 1994 multi-conversion software was added to UPS3000 models, therefore UPS3000 and PCM1000 units made prior to this will not work with the ones manufactured after that date. Consult factory for information on upgrading units manufactured prior to 1994.
  • Page 58 55420/27710/11084 10/5/2 Conversion Ranges, HI/MED/LO Resolution HI/MED/LO 1000.0/500.0/200.0 0.2/0.1/0.05 6895/3447.5/1379.0 1/0.5/0.2 mm Hg 51710/25855/10342 10/5/2 68.95/34.475/13.790 0.01/0.005/0.002 in Hg 2036.0/1018.0/407.2 0.5/0.2/0.1 mBar 68950/34475/13790 10/5/2 cm H 70310/35.155/14.062 0.01/0.005/0.002 70.31/35.155/14.062 0.01/0.005/0.002 Kg/cm in H 27710/13856/5542 5/2/1 UPS3000/UPS3110/UPS3210 Operation & Maintenance Manual...
  • Page 59 Conversion Ranges, HI/MED/LO Resolution HI/MED/LO 500.0/250.00/100.00 0.1/0.05/0.02 3447.5/1723.6/689.5 0.5/0.2/0.1 mm Hg 25855/12928/5171 5/2/1 34.475/17.236/6.895 0.005/0.002/0.001 in Hg 1018.0/509.0/203.6 0.2/0.1/0.05 mBar 34475/17236/6895 5/2/1 cm H 35155/17576/7031 5/2/1 35.155/17.576/7.031 0.005/0.002/0.001 Kg/cm in H 13856/6928/2771.0 2/1/0.5 Conversion Ranges, HI/MED/LO Resolution HI/MED/LO 100.00/50.00/20.000 0.02/0.01/0.005 689.5/344.75/137.90 0.1/0.05/0.02 mm Hg...

  • Page 60: Options, Replacement Kits

    • Inputs are a +5 VDC logic level. Sinking current approximately 0.5 mA. Peak Hold Option UPS3000[][]A, UPS3000[][]B, UPS3210[][]A, UPS3110[][]A, UPS3110[][]B, UPS3210[][]B use PN 57775 UPS3000[][]C, UPS3210[][]C, UPS3210[][]C use PN 57798 NOTES: Recommended factory installed option requires software configuration. This option may not be used with APC 4000 or APC4001 interface option or MIN/MAX Option.

  • Page 61: Min And Max Mode Option

    NOTE: For configuration setup See “Peak Hold or MAX/MIN Option Enable” on page 9. Min and Max Mode Option UPS3000[][]A, UPS3000[][]B, UPS3210[][]A, UPS3110[][]A, UPS3110[][]B, UPS3210[][]B use PN 57790 UPS3000[][]C, UPS3210[][]C, UPS3210[][]C use PN 57796 NOTES: Recommended factory installed option requires software configuration.

  • Page 62: Analog Output Option (0 Vdc To +10 Vdc)

    While the indicator is at 0 psi, adjust R1 until the output current is +4 ma DC. Now apply full scale pressure for that range and adjust R2 until the output current is + 20mADC. UPS3000/UPS3110/UPS3210 Operation & Maintenance Manual...

  • Page 63: Rs232 Simplex Output Option Mode

    Continuous Mode: Model is continuously sending data. Demand Mode: Must be done from the front panel of the UPS3000 using a button. The button is the hidden one between the CONV and CAL button’s This is not a two-way mode and cannot be done externally by PC.
  • Page 64 • APC4001 Interface Cable Kit................PN 55590 NOTE: Used with model’s APC4001 & UPS3110 only. The kit is a replacement cable available for UPS3110 units that were purchased in conjunction with CONDEC APC4001 pressure controllers. • Battery Replacement Kit..................PN 55844 When fully charged, the 12-volt rechargeable battery will provide up to six hours of portable operation.

  • Page 65: Specifications

    Specifications Pressure Specifications: UPS3110 Internal Piping: Pressure range: Three independent pressure ranges Tubing: Based on Model, per instrument. See “Model Number seamless Cu. or St Stl. System” on page 50 for available UPS3110 Couplings: Based on Model, Brass or Stainless ranges.
  • Page 66 UPS 3210: Approx. 11 lbs. UPS 3000 Case Dim’s: 10.75" wide x 8.9" deep x 4.9" high UPS 3110 & UPS 3210 Case Dim’s: 19" wide x 8.1" deep x 6.9" high (Case Dimensions excluding front handles). UPS3000/UPS3110/UPS3210 Operation & Maintenance Manual...
  • Page 67 UPS3000/UPS3110/UPS3210 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 68 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 UPS3000, UPS3110 and UPS3210 Operation & Maintenance Manual...

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