User Manual

D34-595 v8.0 www.cincinnati-test.com

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IMPORTANT INFORMATION
Information in this document is subject to change without notice and does not represent a
commitment on the part of Cincinnati Test Systems, Inc. No part of the manual and/or
software may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording, or information storage and retrieval
systems, for any purpose, other than the purchaser’s personal use, without the express
permission of Cincinnati Test Systems, Inc.

No patent liability is assumed with respect to the use of the information contained herein.
While every precaution has been taken in the preparation of this book, Cincinnati Test
Systems, Inc. assumes no responsibility for errors or omissions.

Because of the variety of uses for this equipment and because of the differences between
this solid-state equipment and electromechanical equipment, the user of and those
responsible for applying this equipment must satisfy themselves as to the acceptability of
each application and use of the equipment. In no event will Cincinnati Test Systems be
responsible or liable for indirect or consequential damages resulting from the use or
application of this equipment.

The illustrations, charts, and layout examples shown in this manual are intended solely to
illustrate the text of this manual. Because of the many parameters and requirements
associated with any particular installation, Cincinnati Test Systems cannot assume
responsibility or liability for actual use based on the illustrative uses and applications.

CAUTION – When you see this warning symbol on the product, refer to the instruction
manual for information before proceeding.

CAUTION – To avoid personal injury due to electric shock, disconnect all power services
before servicing.

If this instrument is not used according to the instructions of this manual, the protection
provided by this equipment design may be compromised.

© 2022 Cincinnati Test Systems

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S E N T I N E L I 2 8 I N D E X

Table of Contents
Chapter 1 – Introduction ............................................................................. 1
Unpacking ....................................................................................... 1
Instrument Attachment & Clearance ................................................ 1
Installation ....................................................................................... 1
DC Power Connection ..................................................................... 2
User Interface Navigation ................................................................ 3
Menu Structure ................................................................................ 5
Chapter 2 – Setup....................................................................................... 7
Program Linking & Sequencing ....................................................... 8
Selection of Test Types ................................................................... 9
Test Type Table ...................................................................................... 10
Tooling Control .............................................................................. 12
Programming the Inputs and Outputs ............................................ 12
Channel Configuration ................................................................... 12
Setting the Units of Measure ................................................................... 12
Setting the Leak Standard Values .......................................................... 14
Program Configuration .................................................................. 15
Pressure Select ....................................................................................... 15
Selecting the Test Port ............................................................................ 15
Setting the Pneumatic Regulator ............................................................ 15
Setting the Test Parameters .......................................................... 16
Verifying Setup .............................................................................. 16
Security ......................................................................................... 16
Backup the Instrument Settings ..................................................... 16
Chapter 3 – Pressure Decay-∆P ............................................................... 17
Timer Parameters .......................................................................... 18
Pressure Parameters..................................................................... 19
Test Parameters ............................................................................ 20
Chapter 4 – Pressure Decay-∆P/∆T .......................................................... 21
Timer Parameters .......................................................................... 22
Pressure Parameters..................................................................... 23
Test Parameters ............................................................................ 25
Chapter 5 – Pressure Decay-Leak Std...................................................... 27
Auto Setup Sequence .................................................................... 28
Timer Parameters .......................................................................... 30
Pressure Parameters..................................................................... 31
Test Parameters ............................................................................ 32
Program Calibration ....................................................................... 34

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Initiating the Program Cal Sequence ...................................................... 35

Performance Factor ................................................................................ 35
Conditions for a Successful Calibration .................................................. 35
Calibration Parameters .................................................................. 37
Chapter 6 – Occlusion .............................................................................. 39
Timer Parameters .......................................................................... 40
Pressure Parameters..................................................................... 40
Test Parameters ............................................................................ 41
Chapter 7 – Pressure Verify ...................................................................... 43
Timer Parameters .......................................................................... 44
Pressure Parameters..................................................................... 44
Test Parameters ............................................................................ 45
Chapter 8 – Mass Flow ............................................................................. 47
Timer Parameters .......................................................................... 47
Pressure Parameters..................................................................... 49
Test Parameters ............................................................................ 50
Program Calibration....................................................................... 51
Initiating the Program Cal Sequence ...................................................... 51
Calibration Parameters .................................................................. 51
Direct Flow Parameter ................................................................... 52
Chapter 9 – Mass Flow-Leak Std .............................................................. 53
Timer Parameters .......................................................................... 54
Pressure Parameters..................................................................... 55
Test Parameters ............................................................................ 56
Program Calibration ....................................................................... 57
Initiating the Program Cal Sequence ...................................................... 57
Conditions for a Successful Calibration .................................................. 58
Calibration Parameters .................................................................. 59
Direct Flow Parameter ................................................................... 59
Chapter 10 – Ramp to ΔP Event ............................................................... 61
Timer Parameters .......................................................................... 62
Pressure Parameters..................................................................... 62
Test Parameters ............................................................................ 63
Chapter 11 – Ramp to Input Event ............................................................ 65
Timer Parameters .......................................................................... 66
Pressure Parameters..................................................................... 66
Test Parameters ............................................................................ 67
Chapter 12 – Ramp to Flow Event ............................................................ 69
Timer Parameters .......................................................................... 70
Pressure Parameters..................................................................... 70
Test Parameters ............................................................................ 71
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Chapter 13 – Ramp to Proof ..................................................................... 73

Timer Parameters .......................................................................... 74
Pressure Parameters..................................................................... 75
Test Parameters ............................................................................ 75
Chapter 14 – Program Linking .................................................................. 77
Parent Program Linking ................................................................. 77
Rules for Parent Program Linking ........................................................... 78
Example of Parent Program Linking ....................................................... 78
Link Execution Pause.............................................................................. 80
Timer Parameters .......................................................................... 81
Sequential Linking ......................................................................... 81
Chapter 15 – Percent Volume ................................................................... 83
Timer Parameters .......................................................................... 84
Pressure Parameters..................................................................... 85
Test Parameters ............................................................................ 86
Chapter 16 – Percent Volume, Pressure Decay-Leak Std......................... 87
Timer Parameters .......................................................................... 88
Pressure Parameters..................................................................... 90
Test Parameters (Volume)............................................................. 91
Test Parameters (Pressure Decay-Leak std)................................. 91
Chapter 17 – Differential Pressure (DP) Decay-ΔP ................................... 95
How it works .................................................................................. 95
Test Setup ..................................................................................... 96
Timer Parameters .......................................................................... 98
Pressure Parameters..................................................................... 99
Test Parameters .......................................................................... 100
Chapter 18 – Diff Decay-Leak Rate ........................................................ 101
How it works ................................................................................ 101
Test Setup ................................................................................... 102
Timer Parameters ........................................................................ 104
Pressure Parameters................................................................... 105
Test Parameters .......................................................................... 106
Chapter 19 – Differential Pressure (DP) Decay-Leak Std ....................... 107
How it works ................................................................................ 107
Leak Standard Pneumatic Diagrams ........................................... 108
Test Setup ................................................................................... 109
Timer Parameters ........................................................................ 111
Pressure Parameters................................................................... 112
Test Parameters .......................................................................... 113
Program Calibration ..................................................................... 114
Initiating the Program Cal Sequence .................................................... 115

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Performance Factor .............................................................................. 115

Conditions for a Successful Calibration ................................................ 115
Calibration Parameters ................................................................ 117
Chapter 20 – Tooling Control .................................................................. 119
Menus .......................................................................................... 119
Advanced Tooling Control ........................................................... 121
Advanced Tooling Motion Example 1 ................................................... 122
Advanced Tooling Motion Example 2 ................................................... 122
Chapter 21 – Inputs and Outputs ............................................................ 125
Input and Output Connector Pinout ............................................. 126
Input Pinout and Wiring Table ............................................................... 127
Output Pinout and Wiring Table ............................................................ 127
I/O Power Pinout and Wiring Table ....................................................... 128
25 Pin Digital IO Cable Diagram and Pinout Table ...................... 128
Programmable Inputs and Outputs Menus .................................. 129
Inputs for Program Control .................................................................... 130
Inputs for Program Selection ................................................................ 133
Inputs for Program Calibration .............................................................. 133
Inputs for Tooling Motion ...................................................................... 134
Outputs for Test Cycles ........................................................................ 135
Outputs for Program Calibration ........................................................... 135
Outputs for Program Results and Test Results .................................... 136
Output Timing Diagram ............................................................... 138
Tooling Example .......................................................................... 139
Chapter 22 – EtherNet/IP ........................................................................ 141
Instrument EtherNet/IP Functionality ........................................... 141
Features ................................................................................................ 141
Compatibility .......................................................................................... 141
Standard Fixed, Defined Inputs/Outputs ............................................... 141
Setting EtherNet/IP User Defined Inputs and Outputs ................. 142
Additional Reference Document .................................................. 143
Establishing EtherNet/IP Communication .................................... 144
Additional Menus ......................................................................... 145
EtherNet/IP Monitor Screens ................................................................ 145
EtherNet/IP Inputs and Outputs ............................................................ 146
Chapter 23 – PROFINET ........................................................................ 147
Instrument PROFINET Functionality ........................................... 147
Features ................................................................................................ 147
Standard Fixed, Defined Inputs/Outputs ............................................... 147
Setting PROFINET User Defined Inputs and Outputs.................. 147
Additional Reference Document .................................................. 149
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Establishing PROFINET Communication .................................... 150

Additional Menus ......................................................................... 151
PROFINET Monitor Screens ................................................................. 151
PROFINET Inputs and Outputs ............................................................ 152
Chapter 24 – Communication ................................................................. 153
RS232 Connector Pinout ............................................................. 153
Establishing RS232 Communication ........................................... 154
CTS DataHub .............................................................................. 155
Establishing Ethernet (TCP/IP) Communication via TELNET ...... 155
Understanding the Header Information ........................................ 156
Test Results via RS232 or Ethernet (TCP/IP) communications ... 157
Streaming Measured Data ........................................................... 159
Parsing Data Packets .................................................................. 159
Reports ........................................................................................ 160
Chapter 25 – CTSnet LT ......................................................................... 161
Compatibility ................................................................................ 161
Initial Startup................................................................................ 161
Monitor Screen ............................................................................ 163
Summary Tab ........................................................................................ 163
IO Tab ................................................................................................... 164
Results Screen ............................................................................ 165
Results Tab ........................................................................................... 165
Counters Tab ........................................................................................ 166
Statistics Tab ......................................................................................... 166
Configuration Screen ................................................................... 167
Program Configuration Tab ................................................................... 167
Channel Configuration Tab ................................................................... 173
Global Configuration Tab ...................................................................... 176
Utilities Screen............................................................................. 182
Copy Program Tab ................................................................................ 182
Cal Reports Tab .................................................................................... 183
Update Firmware Tab ........................................................................... 183
Backup/Restore Tab ............................................................................. 184
Export Screen .............................................................................. 186
Users Screen ............................................................................... 187
Filtering User Log .................................................................................. 187
Exporting User Log ............................................................................... 188
Deleting User Log ................................................................................. 188
Chapter 26 – Webserver ......................................................................... 189
System Requirements ................................................................. 189
Viewing the Web Server .............................................................. 189
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Home Page.................................................................................. 189

Web Server Login ........................................................................ 190
Navigation - Web Server ............................................................. 191
Parameter Configuration via Web Server .................................... 197
Chapter 27 – Security ............................................................................. 199
Chapter 28 – Features ............................................................................ 201
Selecting the Display User Level ................................................. 201
Setting the Date & Time .............................................................. 201
Changing the Instrument Language ............................................ 201
Copy & Paste Programs .............................................................. 201
Instrument Backup & Restore ...................................................... 202
Instrument Cloning ...................................................................... 202
Adjusting the Light Bar Control .................................................... 202
Open Internal Leak Standard....................................................... 202
Selecting the Proper Internal Leak Standard ............................... 203
Self-Test ...................................................................................... 203
Update Firmware ......................................................................... 204
Changing the Functionality of the Prefill Timer ............................ 204
Exhaust Method........................................................................... 204
Saving a Barcode with Results .................................................... 205
Holding Pressure in the Part after Test (No Exhaust) .................. 205
Changing the Functionality of the Prefill Timer ............................ 205
Turning On/Off Pressure Correction ............................................ 206
Setting the Cal Method and Leak Standard Location .................. 206
Autorun ........................................................................................ 207
Malfunction evaluation as Reject ................................................. 207
Batch Calibration ......................................................................... 207
Prefill Pressure Check ................................................................. 208
Valve Detection ........................................................................... 208
Chapter 29 – Instrument Calibration ....................................................... 209
Verifying a Transducer ................................................................ 209
Calibrating a Transducer ............................................................. 209
Transducer 1 Cal Menu (Pressure) ....................................................... 209
Transducer 3 Cal Menu (Flow) ............................................................. 210
Calibrating an Electronic Regulator ............................................. 211
Chapter 30 – Monitor Screen Examples ................................................. 213
Monitor Screen Examples ........................................................... 213
Chapter 31 – Results Screen Examples ................................................. 217
Result Data Screens.................................................................... 217
– Messages & Error Codes .................................................. 219
Test Messages & Errors .............................................................. 219
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– Quik Test .......................................................................... 229

How it works ................................................................................ 229
Test Parameters .......................................................................... 230
– Environmental Drift Correction .......................................... 231
How it works ................................................................................ 231
– Electronic Regulator Compensation.................................. 233
How it works ................................................................................ 233
Test Parameters .......................................................................... 237
– Communication Code Tables ............................................ 239
Data Type or Header Codes ........................................................ 239
Program Evaluation Codes .......................................................... 239
Test Evaluation Codes ................................................................ 240
Segment Codes ........................................................................... 243
Test Data or Variable Identifier Codes......................................... 246
– Instrument Attachment and Clearance .............................. 254
Index ....................................................................................................... 256
Sentinel I28 Technical Specifications ...................................................... 259

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S E N T I N E L I 2 8 C H A P T E R 1 – I N T R O D U C T I O N

Chapter 1 – Introduction
This chapter explains the external pneumatic and electrical connections, and
introduces the simple menu structure and navigation of the instrument.

Thank you for purchasing the Sentinel I28TM precision leak test instrument. The Sentinel I28 is capable of
testing using a variety of pre-packaged test algorithms designed to get you testing as quickly and easily as
possible. Let’s get started!

Unpacking
Carefully remove the instrument from the shipping carton. Locate the AC power cord or the DC cable
supplied with the instrument. The test port should have a ColderTM quick connect test port with Self-Test
cap. Alternatively, you may install any suitable 1/4” NPTM fitting into the manifold test port. If this is not
a standard instrument, see the print packet that shipped with your instrument for the proper thread
specifications.

Instrument Attachment & Clearance

There are four (4) rear mounting holes for ¼ inch (6 mm) socket head cap screws, 3½ inches
(90 mm) long (for a ¼ inch minimum mounting plate thickness). The instrument is supplied with
four (4) ¼ inch – 28 x 3½ inch socket head cap screws for convenience.

Please allow 4 inch (100 mm) clearance under the instrument for installation of test line and for
hand clearance.

Note: These recommendations are also clarified in Appendix F with detailed hole to
hole dimensions in detailed “full scale” reference to the clearance dimension.

Installation
The leak test instrument is a modular, flexible instrument designed to operate in a manufacturing, clean
room, or lab environment. To operate trouble-free, it requires:

• Clean, dry instrument air for test and pilot air (recommend 0.3 and 5.0-micron coalescing filter)
- ISO 8573-1, Class 2 filters are recommended, with class 3 being acceptable.
• Vacuum for vacuum test applications
• Supply power: 24 VDC or 88-264 VAC 50/60 Hz auto sensing/switching electrical (based on
configuration)
• I/O: Switch to select internal or external 24 VDC electrical power for the inputs and outputs

Because this is a precision instrument, it is preferable to locate this instrument at least 15 feet (5 meters)
away from high electromagnetic energy devices (induction heat treat equipment and welders) whenever
possible. In addition, plants having poor quality electrical power or ground systems should consider using
isolation transformers on the power drops.

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Note: When supplying power, always be certain that there is nearly zero voltage
(< 1 V) difference between the neutral and earth ground wires connected to the
instrument.

DC Power Connection

CTS Part Number: CABLE,TURCK,RKM35D-6M

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User Interface Navigation

There are multiple monitoring screens available for the instrument. Selecting the Monitor icon will give you
access to all of these screens. This menu is also where the user selects to view the graphs available with the
unit.

The instrument is designed with a simple graphical icon-based interface. The Main Menu is
activated by pressing the Main Menu button.

The Arrow/Enter Selection buttons are used to navigate through the icons on the screen and
select the appropriate menus. The center arrow is the Enter button. It is used to select
parameters for editing and saving the edits once they are complete.

The Cancel/Back button is used go back to the previous menu. Multiple presses will
eventually exit you out of the menu structure entirely and place you on the Monitor Screen.
This button is also used to cancel out of any edits before saving.

The Information button is used to get a help screen that is associated with the parameter
corresponding to where the cursor is located.

The USB button is a shortcut directly to the USB menu.

The USB menu is located in Main Menu > Global Config > USB icon.

Note: When a USB memory stick mounted in the USB port, holding this button down
until it beeps will take a screen shot of the screen and save it to the USB memory stick. Do
not remove the USB memory stick until the instrument tells you it is finished writing the
image.

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The instrument is capable of storing up to 99 different programs. Switching

between these programs is done with the Program Select buttons on the front of
the instrument. The current program is shown in the lower right hand corner of
the screen designated by “P” and then a two-digit number corresponding to the current program number.

Hint: Press the “+” button for 2 seconds to prompt a screen to display in where the value
of a program may be selected using the arrow buttons. The up and down arrows
will increment and decrement the ones digit. The right and left arrows will
increment and decrement the tens digit.

Note: The Program may also be changed using Digital I/O (see Chapter 21), using
EtherNet/IPTM (see Chapter 22), or using RS232 or TCP/IP Communication
Methods (see Chapter 24).

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Menu Structure
Below is an overview of the menu structure for the instrument.

Note: Not all menus are available for all hardware configurations and Test Types.

Main
Note 1 Note 2
Menu

Monitor Global Result Program Program Channel

Auto Setup
Screens Config Data Cal Config Config

Monitor 1 RS232 1 Counters Test Type Hardware

Monitor 2 RS232 2 Results Link (x) Self-Test

Graph TCPIP Stats Timers Set Span

HW Inputs TCPIP 1 Pressures Units

HW Outputs Test (TST) Leak/Cal

Email

Cal Misc
IP Inputs USB
Misc
IP Outputs Misc
Autorun
Graph
HW Inputs
Version
HW Outputs
Security
IP Inputs
Note 3
Notes: Modes IP Outputs
1. See Chapter 30
2. See Chapter 31 Basic
Tooling
3. See Chapter 27
Viewing Security is enabled Advanced
in the Misc menu above Admin

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Chapter 2 – Setup
In this chapter, you are asked how you plan to use the instrument to conduct the test or
sequence of tests for the intended application. Based on the answers, you will be directed
to modify certain instrument settings.

Setting up the instrument to meet specific application requirements is most effectively accomplished by
answering a few questions. These questions will guide you through the initial stages of the setup and point
you to the appropriate chapters that detail specific instructions based on the answers.

It is highly recommended that each type of part being tested, whether they differ in volume or construction,
have their own set of parameters defined in the instrument using individual Programs. Both Pressure decay
leak testing and Differential Pressure decay leak testing are a volume dependent function. Flow testing can
be setup to be volume independent; however, to optimize the testing, it is recommended that each type of
part have its own set of parameters. In certain cases, it is possible to group similar parts together to use the
same parameters. In this case we recommend you talk to a CTS applications specialist to assure proper
functionality.

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Program Linking & Sequencing

The instrument is capable of conducting multiple tests on one part. For instance, it may be desirable to
conduct a mass flow test and a pressure decay test on a single part (some configurations do not have mass
flow capability). The instrument is also able to conduct these multiple tests on a part with multiple chambers
by multiplexing through multiple test ports (if configured).

Question:

Are you planning to conduct multiple tests on one part?

Yes: It is important that you understand the concepts of Parent Program Linking .
See Chapter 14 and then come back and continue the setup.

No: Proceed.

The instrument is capable of conducting tests on multiple parts in a set sequence (if configured). This may
be done to increase the efficiency of the operator. An operator may load up to four parts (if four test ports
were configured) and press start. The instrument will conduct leak tests on all four parts by multiplexing
through the different test ports, one at a time.

Question:

Are you planning to conduct tests on multiple unique parts?

Yes: It is important that you understand the concepts of Sequential Linking.

See the last page of Chapter 14 and then come back and continue the setup.

No: Proceed.

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Selection of Test Types

The first step in setting up the instrument is to select the type of test you want to conduct from the
pre-packaged test sequences. Repeating this step under a different program number will enable you
to configure up to 99 different test configurations. The Test Type Table on the following page
includes the different test types available in the instrument, a brief description, and the associated
chapter that details the pre-packaged test program. The availability of these test types is based on
the hardware configuration of the instrument.

Once you determine which test type is appropriate for your application go to
Program 1 (press the + or – buttons until you see a P01 in the lower right hand
corner of the screen.

Press the Main Menu button to view the icons in the Main Menu screen.

Select Program Config icon using the Arrow/Enter Selection buttons.

Select the Test type icon using the Arrow/Enter Selection buttons.

Select the appropriate test type using the Enter button to enable editing and then the up
and down arrows to view the options. When you see the desired selection press the
Enter button to select.

To simplify the instructions in this manual, the steps above are reduced to something similar to the
following: The Test Type menu is located in Main Menu > Program Config > Tst type icon.

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Test Type Table

Test Type Description
Measures the Pressure Loss (ΔP) over a fixed time. Determined from
Pressure Decay-ΔP
the pressure loss over the duration of the test timer. The result is
Chapter 3 presented in units of delta pressure.
Measures the Pressure Loss (ΔP/ΔT) over unit time. Determined from
Pressure Decay-ΔP/ΔT the pressure loss over the duration of the test timer divided by the test
Chapter 4 time. The result is presented in units of delta pressure over delta time.
Calculates the Leak Rate, based on pressure loss. Determined from the
Pressure Decay-Leak Std pressure loss over the duration of the test timer relating to the pressure
Chapter 5 loss of the leak standard and of the non-leaking master part. The result is
presented in units of flow.
Measures the Back Pressure (part blockage). Determined from the
Occlusion
pressure at the end of the test timer. The result is presented in units of
Chapter 6 pressure.

Pressure Verify Measures the Pressure at the isolated test port (no fill). Determined
from the pressure at the end of the Test segment timer. The result is
Chapter 7 presented in units of pressure.
Measures the Mass Flow needed to maintain the part at a set pressure.
Mass Flow
Typically used in applications where flow is expected. The result is
Chapter 8 presented in units of flow.

Measures the Mass Flow needed to maintain the part at a set pressure.
Mass Flow-Leak Std
Typically used in low leak applications. The result is presented in units of
Chapter 9 flow.
Measures the peak pressure before a Pressure Loss (ΔP) Event.
Ramp to ΔP Event Determines the maximum pressure before the pressure loss limit is
Chapter 10 exceeded as well as records the duration of time before the event. The
results are presented in units of pressure and time.
Measures the pressure at an Input Event. During test pressure ramp,
Ramp to Input Event monitors for trigger event on a digital input, then determines the
Chapter 11 pressure as well as records the duration of time before the event. The
results are presented in units of pressure and time.
Primarily used for testing the cracking point of a check valve. Measures
Ramp to Flow Event the point at which the flow crosses a threshold. Determines the
maximum pressure before the Flow Event limit is exceeded as well as
Chapter 12 records the duration of time before the event. The results are presented
in units of pressure and time.

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Test Type Description

Designed to make sure component can hold a pressure for a fixed
Ramp to Proof Test period of time. Result determined from the maximum pressure during
the test and duration of the test timer. The result is presented in units of
Chapter 13
pressure.
Facilitates linking individual programs into a single test sequence for
conducting multiple tests on one part or one part with multiple
Parent Program Linking
chambers. Contains tooling control parameters and link definitions.
Chapter 14 Each link defines the target program to execute and evaluation
conditions for additional program execution.
Facilitates testing multiple unique parts (often with multiple test ports).
Sequential linking
Each link defines the target program to execute and evaluation
Chapter 14 conditions for additional program execution.
Primarily used to test sealed parts where a convectional pressure or
Percent Volume
vacuum decay tests could fill up the volume of a gross leaking part
Chapter 15 during the fill stage.
Primarily used to test sealed parts where a convectional pressure or
Percent Volume, Pressure
vacuum decay tests could fill up the volume of a gross leaking part
Decay-Leak Std
during the fill stage. The volumetric fill test will test for gross leaks
Chapter 16 while the pressure decay – leak std test will test for fine leaks.

This test type is used for conducting a pressure decay test measuring a
Differential Pressure (DP) pressure loss over time utilizing a Differential Pressure (DP) transducer.
Decay-ΔP The result of this test is the pressure loss (or gain for a vacuum test)
Chapter 17 measured over a fixed period of time, presented in units of pressure.

This test type is used for conducting a Diff Decay-Leak rate test
Diff Decay-Leak Rate
measuring leak rate by utilizing a Differential Pressure (DP) transducer.
Chapter 18 The result of this test is the leak presented in units of flow.

Differential Pressure (DP) This test is used for conducting a Differential Pressure (DP) Decay Test
Decay-Leak Std with Leak Standard. Pressure loss is measured utilizing a Differential
Pressure (DP) transducer. The pressure loss is correlated to a leak rate
Chapter 19
using a leak standard. This test requires a two-cycle calibration routine
to correlate the pressure loss to a flow rate. The result of this test is
presented in units of flow.

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Before we begin setting the parameters of the program we need to determine some of the capabilities and
features required for the application.

Tooling Control
The instrument is capable of controlling tooling to possibly eliminate the need for a PLC or other computer
that would control cylinders and sealing.

Question:

Are you planning to use the Sentinel I28 to control any sealing operations?

Yes: It is important that you understand the concepts and safety requirements of
Tooling Control. See Chapter 20 and then come back and continue the setup.

No: Proceed.

Programming the Inputs and Outputs

The instrument comes with 12 inputs and 12 outputs (24VDC) that are user configurable for each program.

Question:

Are you planning to use the Sentinel I28 to control any ancillary devices using
discrete I/O or EtherNet/IPTM, or communicate with a PLC?

Yes: See Chapter 21 - Inputs and Outputs, Chapter 22 - EtherNet/IP, or Chapter 24 -

Communication, and then come back and continue the setup.

No: Proceed.

Channel Configuration
Setting the Units of Measure
The instrument has the capability to utilize different units of measure for each configured program. In
order to keep things simple and user friendly if you always use the same units of measure, you can set the
units in one place and have them apply instrument wide. This is done in the Channel Configuration menu.

Question:

Are you planning to use the same units of measure for every program?

Yes: Press the Main Menu button, select the Channel Config icon, then select the
Units icon. Change the Unit/Prec Define parameter to “Channel”. Set the

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desired units of measure on that same screen. These units will apply to
every program.

No: Press the Main Menu button, select the Channel Config icon, then select the
Units icon. Change the Unit/Prec Define parameter to “Program”. The Units
icon will now appear under the Program Config menu. When a program is
created, the units for the program will use the units under the Channel Config
menu as the default settings but the units can now be changed per program.

Note: The units set on the Channel Config screen are also the units used for
Self-Test, Auto Setup and transducer Set/Span routines.

Note: The precision displayed for each unit may also be set on this screen.

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Setting the Leak Standard Values

The instrument has the capability to utilize different leak standards for each configured program that uses
a leak standard. In order to keep things simple and user friendly if you always use the same leak standard,
you can set the leak standard value and pressure in one place and have it apply instrument wide to any
program that uses a leak standard. This is done in the Channel Configuration menu.

Question:

Are you planning to use the same leak standard for every program that requires a
leak standard?

Yes: Press the Main Menu button, select the Channel Config icon, then select the
Leak/Cal icon. Change the Leak Std/Cal Define parameter to “Channel”. Set
the leak standard value and the pressure at which it was calibrated on that
same screen. This leak standard value will apply to every program that
utilizes a leak standard for calibration.

No: Press the Main Menu button. Select the Channel Config icon. From the
Channel Config menu select the Leak/Cal icon. Change the Leak Std/Cal
Define parameter to “Program”. The leak standard parameters will now
appear on the TST:*** screen under the Program Config menu. When a
program is created, the units for the program will use the leak standard value
under the Channel Config menu as the default settings but now can be
changed per program.

Note: Every time the leak standard value changes due to a calibration or when a new leak
standard is used this value needs to be modified to reflect the new value.

Note: The parameter that determines where the physical leak standard is located (either
inside the instrument or connected to a port on the outside) is also located in the Leak/Cal
menu or the TST menu. However, to view this parameter you must be in the Display User
Level. To change the Display User Level, see Chapter 28 – Features.

Remember: Press the information button with the cursor on that parameter if
you want to know the definition of the options.

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Program Configuration
Now that you have created a program, configured the tooling and associated I/O, and set the channel level
parameters, it is time to set the regulators to the correct test pressure.

Pressure Select
To select the proper source for the test, we need to inform the instrument which regulator to use for this
program. This is located in Main Menu > Program Config > Misc icon. The parameter called Pressure
Select will need to be set to match the proper source. Find the regulator with the proper range. Locate the
label that has the Source Number on it and select that source for the Pressure Select parameter. There are
many possible options for this setting, depending on the hardware configuration. Options may include
Pressure, Vacuum, Venturi, Tank, Reference, Flow, Internal Leak Std, Downstream Flow, or Sequential
Test Ports. Instruments with only one pressure source will not allow editing of the Pressure Source
parameter.

Tank Source
If the Pressure Select is configured as a Tank Source, then an additional sub-parameter “Shut Off Delay” is
displayed. The Shut Off Delay is the user configured timer, defining how long to keep the Tank Source
valve active after usage. During typical test operation: after the Fill valve has de-energized the Shut Off
Delay timer will activate, and once expired the Tank Source valve will de-energize.

Selecting the Test Port

Next, select the proper test port (if the instrument hardware is configured with multiple test ports).

Question:

Does your instrument have multiple test ports (optional configuration)?

Yes: From the same Program Config - Misc menu select the Test Port Number you
want to conduct the test on. The port numbers will count upwards from left
to right.

No: Proceed.

Setting the Pneumatic Regulator

Question:

Does the pressure source you are using for this program have an electronic
regulator?

Yes: The electronic regulator has been setup and calibrated at the factory and is
ready to use. For calibrating the electronic regulator, see Chapter 29 –
Instrument Calibration.

No: Setting a mechanical pressure regulator is done in the Channel Config

screen under the Set/Span menu. In order to set the regulator, the test port

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will need to be blocked which will allow the instrument to hold pressure.
Standard units are supplied with a ColderTM quick connect fitting with an
attached Self-Test cap. If this instrument is not a standard setup this may
be done with a plug put in the test port. For proper plug thread
specifications, consult the print set shipped with your instrument.

Setting the Test Parameters

It is time to set the test parameters to fit your application. Refer to the chapter that is associated with the
test type chosen from Test Type Table earlier in this chapter.

Verifying Setup
Once you have everything programmed, run a repeatability study based on your company’s quality standards
to assure you are getting the results you desire.

Security
Now that the instrument is setup the way you want, make sure to lock down the parameters that you don’t
want changed until a key or password is used. See Chapter 27 – Security.

Backup the Instrument Settings

The setup of the instrument for one program is completed. You may now go back and setup multiple
programs. Once you have completed, it is highly recommended that you save a backup of the instrument
on a (FAT32) USB memory stick. For Instrument Backup and Restore see Chapter 28 – Features.

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S E N T I N E L I 2 8 C H A P T E R 3 – P R E S S U R E D E C A Y - ∆ P

Chapter 3 – Pressure Decay-∆P

This chapter explains the theory and parameters for conducting a pressure decay
test measuring a pressure loss over time. The result of this test is the pressure loss
(or gain for a vacuum test) measured over a fixed period of time, presented in
units of pressure.

The basic principle of operation of a pressure decay leak test instrument is to fill the test part to a specified
target test pressure, isolate the test part from the pressure or vacuum source, allow the pressure to stabilize,
and then measure the pressure loss due to a leak over a defined time.

The Charts below give an overview of the parameters used to set up a Pressure Decay-∆P Test. The Tables
that follow give detailed descriptions of each parameter and also document the Display User Level
associated with each parameter.

Note: To change the Display User Level, see Chapter 28 – Features.

Pressure Decay Test

Exhaust
Stabilize
Pre-fill

Test
Fill

Maximum Pressure

} Target Press Window

Pressure

Minimum Pressure

Time

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.

Checks for excessively leaking parts or lack of pressure. May

be set to “Percent of Fill Time” (default), for fixed fill time
tests, or set to “Not to Exceed Time”. For Changing the
Prefill Functionality of the Prefill Timer, see Chapter 28 – Features. Advanced, Admin
Maximum time to reach the minimum pressure. If the variable
is set to “Not to Exceed Time”, this segment will exit to the
next once the Minimum Pressure value is reached.

Time to enable part to reach the Target Pressure. It may also Basic
Fill
be used as time to stabilize part pressure with additional air. Advanced, Admin

Time to stabilize part pressure while isolated from the pressure Basic
Stabilize
regulator. This time directly affects the repeatability of the test. Advanced, Admin

The precise time over which to measure pressure drop or Basic

Test
decay or the precise end time to measure pressure rise. Advanced, Admin

Time to relieve or vent part pressure before signaling the end

Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.

When tooling control is specified, there can be up to five

Tooling
retract timers for up to five tooling motions. This is a not to Advanced, Admin
Retract
exceed timer when feedback is being utilized.

This is used as the duration for an external part marking

Part
device, and is a not to exceed timer when feedback is being Advanced, Admin
Mark
utilized.

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must be reached before the Prefill
setpoint is reached and must be maintained Basic
Minimum Pressure
through fill and stabilization segments or the Advanced, Admin
testing cycle will end as a Severe Leak.
The specified test pressure for the part. For
vacuum test pressures enter a positive value if psiv
was selected as the pressure unit, or enter a
Basic
Target Pressure negative value if psig was selected as the pressure
Advanced, Admin
unit. ((For example, the test pressure 9.7 psia
would be entered as 5 psiv or -5 psig.) Pressure
loss may be corrected to the Target Pressure.
The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.
This is a window (default +/– 100%) set around
the Target Pressure that must be maintained during
Target Pressure the Test segment of the testing cycle. It generates a
Advanced, Admin
Window Target Pressure Low or High Malfunction if the
actual pressure falls outside this window during
test.

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:PLO icon.

TST Parameter Description Display User Level

Basic
Low Limit Loss Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Loss Upper setpoint value used to evaluate test results.
Advanced, Admin

Test results are compared to two setpoints for pass

or fail status. There are three areas for evaluation of
Test Evaluation Advanced, Admin
results: above high limit, between limits, and below
low limit. See Table below for codes.
Activates Environmental Drift Correction.
EDC Enable Advanced, Admin
See Appendix C.
Options include 10%, 25%, 50%, 75%, and 90%.
EDC Percentage Advanced, Admin
See Appendix C.
EDC Quantity See Appendix C. Advanced, Admin

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

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S E N T I N E L I 2 8 C H A P T E R 4 – P R E S S U R E D E C A Y - ∆ P / ∆ T

Chapter 4 – Pressure Decay-∆P/∆T

This chapter explains the theory and parameters for conducting a pressure decay
test measuring the rate of change of pressure loss / time. The result of this test is
the rate of pressure change measured over a selected unit of time.

The basic principle of operation of a pressure decay leak test instrument is to fill the test part to a specified
target test pressure, isolate the test part from the source air and allow the pressure to stabilize, and then
measure the pressure loss due to a leak over a defined time.

The Charts below give an overview of the parameters used to set up a Pressure Decay-∆P/∆T Test. The
Tables that follow give detailed descriptions of each parameter and also document the Display User Level
associated with each parameter.

Note: To change the Display User Level, see Chapter 28 – Features.

Pressure Decay Test

Exhaust
Stabilize
Pre-fill

Test
Fill

Maximum Pressure

} Target Press Window

Pressure

Minimum Pressure

Time

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.

Checks for excessively leaking parts or lack of pressure. May

be set to “Percent of Fill Time” (default), for fixed fill time
tests, or set to “Not to Exceed Time. For Changing the
Prefill Functionality of the Prefill Timer, see Chapter 28 – Features. Advanced, Admin
Maximum time to reach the minimum pressure. If the
variable is set to “Not to Exceed Time”, this segment will exit
to the next once the Minimum Pressure value is reached.

Time to enable part to reach the Target Pressure. It may also Basic
Fill
be used as time to stabilize part pressure with additional air. Advanced, Admin

Time to stabilize part pressure while isolated from the

Basic
Stabilize pressure regulator. This time directly affects the repeatability
Advanced, Admin
of the test.
The precise time over which to measure pressure drop or Basic
Test
decay or the precise end time to measure pressure rise. Advanced, Admin

Time to relieve or vent part pressure before signaling the end

Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.

When tooling control is specified, there can be up to five

Tooling
retract timers for up to five tooling motions. This is a not to Advanced, Admin
Retract
exceed timer when feedback is being utilized.

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must be reached before the Prefill
setpoint is reached and must be maintained Basic
Minimum Pressure
through fill and stabilization segments or the Advanced, Admin
testing cycle will end as a Severe Leak.
The specified test pressure for the part. For
vacuum test pressures enter a positive value if psiv
was selected as the pressure unit, or enter a
Basic
Target Pressure negative value if psig was selected as the pressure
Advanced, Admin
unit. ((For example, the test pressure 9.7 psia
would be entered as 5 psiv or -5 psig.) Pressure
loss may be corrected to the Target Pressure.
The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.
This is a window (default +/– 50%) set around the
Target Pressure that must be maintained during the
Target Press Test segment of the testing cycle. It generates a
Advanced, Admin
Window Target Pressure Low or High Malfunction if the
actual pressure falls outside this window during
test.

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:DPT icon.

TST Parameter Description Display User Level

Basic
Low Limit Loss Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Loss Upper setpoint value used to evaluate test results.
Advanced, Admin

Test results are compared to two setpoints for pass

or fail status. There are three areas for evaluation of
Test Evaluation Advanced, Admin
results: above high limit, between limits, and below
low limit. See Table below for codes.
Activates Environmental Drift Correction.
EDC Enable Advanced, Admin
See Appendix C.
Options include 10%, 25%, 50%, 75%, and 90%.
EDC Percentage Advanced, Admin
See Appendix C.
EDC Quantity See Appendix C. Advanced, Admin

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

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S E N T I N E L I 2 8 C H A P T E R 5 – P R E S S U R E D E C A Y - L E A K S T D

Chapter 5 – Pressure Decay-Leak Std

This chapter explains the theory and parameters for conducting a pressure decay
test and correlating the pressure loss to a leak rate using a leak standard. This
test requires a two cycle calibration routine to correlate the pressure loss to a flow
rate. The result of this test is presented in units of flow.

This test type utilizes a two-point calibration sequence with a non-leaking master part to
record the zero leak pressure loss value and the additional pressure loss value due to the
flow rate of the leak standard on the second calibration cycle.

The basic principle of operation of a pressure decay leak test instrument is to fill the test part to a specified
target test pressure, isolate the test part from the source air and allow the pressure to stabilize, and then
measure the pressure loss due to a leak over a defined time. The leak test instrument translates the pressure
loss value measured over the fixed test time to a leak or flow rate.

The charts in this chapter give an overview of the parameters used to set up a Pressure Decay Test and
correlate the results to a flow rate using a leak standard. The Tables that follow give detailed descriptions
of each parameter and also document the Display User Level associated with each parameter.

Note: To change the Display User Level, see Chapter 28 – Features.

Pressure value gets zeroed at the beginning of test timer

A loss in pressure is denoted as a positive number

∆ Pressure (Converted to a Leak Rate in Flow Units)

= Leak standard
flow rate
Master Part + Leak Standard Pressure Loss

= Zero leak rate

= Negative leak
Master Part Pressure Loss rate (because it
is less than zero)

Test Time Test Evaluation Decision

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Auto Setup Sequence

The easiest way to setup the proper timers in the instrument, when using the leak rate test type, is by using
the Auto Setup routine. The Auto Setup routine resets the Input and Output functions for a program to
the default (inactive) values. Therefore, Auto Setup must be performed with the part manually sealed. After
completing the Auto Setup routine, the inputs, outputs, and tooling functions for the program will need to
be reconfigured.

Note: If you want to set up the program parameters manually or don’t want to have to
reconfigure the inputs and outputs after running Auto Setup, then proceed to Timer
Parameters.

The Auto Setup routine is a unique patented process developed by Cincinnati Test Systems for the Sentinel
I28 instrument that makes the initial setup of the instrument to a new test part quick, easy and efficient.
The process will determine the best time sequence to test a part within the limits of a desired maximum
cycle time. If the desired maximum cycle time is set too short, the final test will not produce repeatable
results. Any leak test needs a certain amount of cycle time to achieve sufficient resolution and repeatability
that are dependent on the part volume, leak rate, test pressure, and part characteristics. The Auto Setup
routine will set the best possible test cycle within the maximum cycle time specified for the test.

Parameter Description Display User Level

Basic
Test Type Set this to Pressure Decay-Leak Std.
Advanced, Admin
Defines the program in which the parameters will be
Apply to Basic
written. This process will overwrite the current
Program # Advanced, Admin
parameters within the defined program.
This is the total desired time to complete the test on
the part excluding tooling motions. The Auto Setup
sequence will determine the best possible sequence of
testing within this maximum cycle time. This
optimized setup cannot produce acceptable resolution
Desired Cycle Basic
and repeatability if the total time is too short for the
Time Advanced, Admin
part volume, leak rate, test pressure, and part
construction. Utilize all the available time in the
manufacturing process to conduct this test. When
acceptable results are achieved, you may be able to
repeat the process and reduce the total cycle time.
This is the specified test pressure for the part. Auto
Basic
Target Pressure Setup will preset the Minimum Pressure at 80% and
Advanced, Admin
Maximum Pressure at 120%.
Set to the same pressure source as you did in Basic
Pressure Select
Chapter 2 - Pressure Select. Advanced, Admin

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Parameter Description Display User Level

This is the specified leak rate for the part. Auto Setup
will preset the Low Limit Leak at –20% of the High
Limit Leak. It will also set the Test Evaluation to FPF.
Basic
High Limit Leak FPF means “Fail over Hi Limit, Pass between Hi and
Advanced, Admin
Lo Limit and Fail if under Lo Limit”. These values and
settings can be changed after completing the Auto
Setup sequence.
This is the leak rate value on the calibrated leak
standard mounted either internal to the instrument on Basic
Leak Std Value
the pneumatic manifold or using an external leak Advanced, Admin
standard.
Leak Std This is the pressure value on the calibrated leak Basic
Pressure standard. Advanced, Admin
This defines whether one or two parts are used in the
calibration procedure. It also specifies if the Leak
Standard is located internally on the manifold where
Basic
Cal Method the Calibration Valve will automatically activate in the
Advanced, Admin
calibration procedure or located externally where it will
be added to the process by the operator or system
control.
Basic
Start Auto Setup This starts the Auto Setup procedure.
Advanced, Admin

Upon successful completion of the Auto Setup routine there is no need to continue the setup
parameters in the rest of this chapter unless you want to adjust parameters.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.

Checks for excessively leaking parts or lack of pressure. May

be set to “Percent of Fill Time” (default), for fixed fill time
tests, or set to “Not to Exceed Time”. For Changing the
Prefill Functionality of the Prefill Timer, see Chapter 28. Maximum Advanced, Admin
time to reach the minimum pressure. If the variable is set to
“Not to Exceed Time”, this segment will exit to the next once
the Minimum Pressure value is reached.

Time to enable part to reach the Target Pressure. It may also Basic
Fill
be used as time to stabilize part pressure with additional air. Advanced, Admin

Time to stabilize part pressure while isolated from the pressure Basic
Stabilize
regulator. This time directly affects the repeatability of the test. Advanced, Admin

The precise time over which to measure pressure drop or Basic

Test
decay or the precise end time to measure pressure rise. Advanced, Admin

Time to relieve or vent part pressure before signaling the end

Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.

When tooling control is specified, there can be up to five

Tooling Basic
retract timers for up to five tooling motions. This is a not to
Retract Advanced, Admin
exceed timer when feedback is being utilized.
Timer used during Program Cal sequence as a delay between
calibration cycles to allow the master part to recover to Basic
Relax
repeatable virgin state. (Too short relax times result in Advanced, Admin
decreasing pressure losses/flow results in successive tests.)

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must be reached before the Prefill
setpoint is reached and must be maintained Basic
Minimum Pressure
through fill and stabilization segments or the Advanced, Admin
testing cycle will end as a Severe Leak.
The specified test pressure for the part. For
vacuum test pressures enter a positive value if psiv
was selected as the pressure unit, or enter a
Basic
Target Pressure negative value if psig was selected as the pressure
Advanced, Admin
unit. ((For example, the test pressure 9.7 psia
would be entered as 5 psiv or -5 psig.) Pressure
loss may be corrected to the Target Pressure.
The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.
This is a window (default +/– 50%) set around the
Target Pressure that must be maintained during the
Target Press Test segment of the testing cycle. It generates a
Advanced, Admin
Window Target Pressure Low or High Malfunction if the
actual pressure falls outside this window during
test.

Pressure Decay
Test
Stabilize
Pre-fill

Exhau
Test
Fill

st

Maximum
Pressure

}
Pressure

Target Press
Window

Minimum
Pressure

Time

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:PLR icon.

TST Parameter Description Display User Level

Basic
Low Limit Rate Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Rate Upper setpoint value used to evaluate test results.
Advanced, Admin
Test results are compared to two setpoints for pass or
fail status. There are three areas for evaluation of results:
Test Evaluation Advanced, Admin
above high limit, between limits, and below low limit.
See Table below for codes.

Minimum pressure loss allowed during the first test in

Basic
Min Master Loss the Program Cal routine. Prevents the acceptance of a
Advanced, Admin
calibration of a blocked part or test line.

Maximum pressure loss allowed during the first test in

Basic
Max Master Loss the Program Cal routine. Prevents the acceptance of a
Advanced, Admin
calibration with a leaking part or fixture leaks.

Minimum pressure loss allowed during the second test

Min Mstr+Leak Basic
in the Program Cal routine. Prevents the acceptance of
Loss Advanced, Admin
a calibration with a blocked part or test line.

Maximum pressure loss allowed during the second test

in the Program Cal routine. Prevents the acceptance of a
Max Mstr+Leak Basic
calibration with excessive pressure loss due to part or
Loss Advanced, Admin
fixture leaks. Set slightly higher than max loss during
Program Cal.
Minimum pressure loss allowed that represents the
Basic
Min Leak Loss pressure loss due to the Leak Standard used to calibrate
Advanced, Admin
the instrument.
Maximum pressure loss allowed that represents the
Basic
Max Leak Loss pressure loss due to the Leak Standard used to calibrate
Advanced, Admin
the instrument.

Minimum value for Performance Factor calculated at

Min Perform completion of Program Cal routine. Resultant Basic
Factor evaluation of ratio of Master Part Loss to Master+Leak Advanced, Admin
Loss, Test Pressure, and loss due to Leak Std.

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Certified flow value of Leak Standard used to calibrate

Leak Std Cal instrument. This parameter is only viewable in this Basic
Flow location if the Leak Std/Cal Define parameter is set to Advanced, Admin
“Program”.
Certified pressure at which Leak Standard Flow was
Basic
Leak Std Cal Press calibrated. This parameter is only viewable in this location if
Advanced, Admin
the Leak Std/Cal Define parameter is set to “Program”.

Quik Test Enable Activates Quik Test. See Appendix B. Advanced, Admin
Options include 10%, 25%, 50%, 75%, and 90%.
Quik Test Timer Advanced, Admin
See Appendix B.
Quik Test LL
See Appendix B. Advanced, Admin
Band
Quik Test HL
See Appendix B. Advanced, Admin
Band
Activates Environmental Drift Correction.
EDC Enable Advanced, Admin
See Appendix C.
Options include 10%, 25%, 50%, 75%, and 90%.
EDC Percentage Advanced, Admin
See Appendix C.
EDC Quantity See Appendix C. Advanced, Admin

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

Note: If the instrument is configured multiple internal leak standards the user must select
which leak standard is to be used in the Program. See Selecting the Proper Internal Leak
Standard in Chapter 28 – Features.

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Program Calibration
In order to convert the pressure loss measured by the instrument to a leak (flow) rate, the instrument uses
a leak standard and needs to run the “Program Cal” procedure. This procedure requires at least one
known non-leaking part referred to as a “master part“. This procedure tests a non-leaking master part
connected to the instrument using the timers and pressures established for the program. The procedure
automatically tests the non-leaking master part twice with the Relax timer delay between tests. Within
each program that uses a leak standard, Program Cal can be configured to use one of four methods. See
Setting the Cal Method and Leak Standard Location in Chapter 28 – Features.

Remember: The Leak/Cal menu has a parameter called Leak Std/Cal Define
that determines the location for the leak standard settings.

When set to “Channel”, leak standard settings are located in the Channel Config menu.

When set to “Program”, leak standard settings are located in the Program menu.

Determine how you plan to use your leak test instrument. Review Setting the Leak Standard
Values section on page 14. It is critical to make sure the leak standard values are set correctly
for proper use. To view the Cal Method parameter, you must be in the Advanced or Admin
Display User Level. To change the Display User Level, see Chapter 28– Features.

Pressure value gets zeroed at the beginning of test

timer
A loss in pressure is denoted as a positive number

Measured
Master+Leak
Δpressure (Converted a Leak Rate )

Loss

Measured
Master Part
Loss
Rate
Corr Leak
High Limit

Std Flow
Rate
Low limit

Zero Leak

Leak Rate (Δpressure Converted Flow Units)

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Initiating the Program Cal Sequence

To initiate a Program Cal sequence, go to Main Menu > Program Cal icon, select OK and press Enter.
The Program Cal wizard will tell you to connect a non-leaking master part. Connect the non-leaking master
part to the instrument. Push the Start button to initiate the Program Cal sequence. The system will conduct
an initial test of the non-leaking master part to measure the pressure loss associated with a non-leaking part.
This represents the typical offset associated with testing parts within the environment of the test system.
The pressure loss value is saved as the Master Part Loss. The system will conduct a second test on a non-
leaking master part with a known calibrated leak standard included in the test. The pressure loss value result
for this test is saved as the Master+Leak Loss.

Performance Factor
Upon the successful completion of the Program Cal routine, the display will show the calculated
Performance Factor for the calibration. The Performance Factor is an estimate of the quality of the
calibration. It combines the ratio of the Hi Limit Leak result to the non-leaking master part result, the test
pressure, and difference between the Hi Lim result and the non-leaking master part result to scale its
anticipated performance. This value ranges from 0 to 100. It is generally desirable to have a Performance
Factor of 35 to 100. The actual acceptable Performance Factor can vary depending on the desired Gage
R&R performance of the test. Here is the Performance Factor equation:

Performance Factor = Cal Ratio x Pressure Loss Penalty x Time Penalty x 100

The pressure loss penalty is greater for smaller pressure loss values. The time penalty is greater for shorter
Test cycle timer values. Generally, longer stabilize and test cycle timer settings will produce higher
Performance Factors and improved Gage R&R performance.

Note: The instrument will require a Program Cal Sequence if any parameters that affect
the calibration are modified.

Conditions for a Successful Calibration

Several conditions must be met during the Program Calibration procedure for the instrument to accept and
store the calibration results. The conditions are based on the following measurements or calculations:
1. Master Part Loss
a. Must be greater than the Min Master Loss limit
b. Must be less than the Max Master Loss limit
c. Must be less than the Master+Leak Loss measurement
2. Master+Leak Loss
a. Must be greater than the Min Mstr+Leak Loss limit
b. Must be less than the Max Mstr+Leak Loss limit
c. Must be greater than the Master Loss measurement
3. Leak Loss
a. Must be greater than the Min Leak Loss limit
b. Must be less than the Max Leak Loss limit
4. Performance Factor
a. Must be greater than the Min Perform Factor limit

If the procedure does not meet these conditions, error messages are displayed at the completion of tests.

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If the Program Cal routine is successfully completed, “PROGRAM CALIBRATION PASSED” will be
displayed. If there are any problems during the Program Cal sequence an error will be displayed. If there
is an error, see Appendix A - Message and Error Codes.

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Calibration Parameters
The Calibration parameters menu is located in the Main Menu > Program Config > CAL:PLR
icon. These calibration parameters are values that are measured or calculated as a result of the
Program Cal routine for a Pressure Decay-Leak Std test.

Parameter Description Display User Level

Resultant evaluation of ratio of Master Part Loss to
Basic
Performance Factor Master+Leak loss, Test Pressure, and loss due to
Advanced, Admin
Leak Std.

Measured pressure at the beginning of the test

Basic
Master Part Press segment during the first test of the Program Cal
Advanced, Admin
process for the non-leaking master part.

Measured pressure at the beginning of the test cycle

of second test during Program Cal process for the Basic
Master+Leak Press
non-leaking master part with the leak standard Advanced, Admin
introduced to the pneumatic test circuit.

Viewable in Basic &

Measured pressure loss for the non-leaking master
Master Part Loss Advanced
part during the first test of Program Cal process.
Editable in Admin
Measured pressure loss during the second test of
Viewable in Basic &
Program Cal for the non-leaking master part with
Master+Leak Loss Advanced
the leak standard introduced to the pneumatic test
Editable in Admin
circuit.
Calculated pressure loss, based upon measured
Viewable in Basic &
pressure losses during the Program Cal routine.
Leak Loss Advanced
Corresponds to the actual pressure loss related to
Editable in Admin
the leak standard.
The calculated leak standard flow rate based on the
Program Target Pressure, the leak standard Basic
Corr. Leak Std Flow
calibrated pressure, and the leak standard calibrated Advanced, Admin
flow rate.

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S E N T I N E L I 2 8 C H A P T E R 6 – O C C L U S I O N

Chapter 6 – Occlusion
This chapter explains the theory and parameters for conducting an Occlusion
Test. The result of this test is the measured back pressure at the expiration of the
Test sequence.

The Occlusion Test is a back pressure test. The part is pressurized throughout the test from a fixed pressure
regulator setting. At the end of the Test timer the actual test pressure is compared to the Low Limit Pressure
and High Limit Pressure settings. Low Limit Pressure indicates high flow or minimum blockage or low
back pressure. High Limit Pressure indicates low flow or maximum blockage or high back pressure.

The Chart below give an overview of the parameters used to set up an Occlusion Test. The Tables that
follow give detailed descriptions of each parameter and also document the Display User Level associated
with each parameter.

Note: To change the Display User Level, see Chapter 28 – Features.

Occlusion Test
Maximum Pressure
Hi Limit Pressure
Target Pressure

Low Limit Pressure

Pressure

Test Time Exhaust

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.
At the end of this timer, the instrument will read the pressure
Basic
Test on the pressure transducer. This pressure is due to the
Advanced, Admin
backpressure created in the pneumatic circuit and part.
Time to relieve or vent part pressure before signaling the end
Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.
When tooling control is specified, there can be up to five
Tooling
retract timers for up to five tooling motions. This is a not to Advanced, Admin
Retract
exceed timer when feedback is being utilized.

Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

Basic
Target Pressure Target test pressure.
Advanced, Admin
The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:OCC icon.

TST Parameter Description Display User Level

Basic
Low Limit Pressure Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Pressure Upper setpoint value used to evaluate test results.
Advanced, Admin
Test results are compared to two setpoints for pass
or fail status. There are three areas for evaluation of
Test Evaluation Advanced, Admin
results: above high limit, between limits, and below
low limit. See Table below for codes.

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

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S E N T I N E L I 2 8 C H A P T E R 7 – P R E S S U R E V E R I F Y

Chapter 7 – Pressure Verify

This chapter explains the theory and parameters for conducting a Pressure Verify test.

The Pressure Verify test is intended to test parts that generate vacuum or pressure, or to verify that
the part was pre-charged to the correct pressure, or to verify that the part was evacuated or filled by
an external source.

The principle of operation is to close the isolation valve on the internal manifold to isolate the part.
The pressure transducer then reads the vacuum or pressure generated by the part or that is already in
the part. At the end of the test timer, the test pressure is compared to the low limit pressure and
high limit pressure settings. The Test Result is recorded with an overall ACCEPT/REJECT

If the Pressure Verify test was performed with the Self-Test cap on the test port, the only pressure
measured will be the small pressure that is trapped by the isolation valve as it actuates to close.

The Tables that follow give detailed descriptions of each parameter and also document the Display User
Level associated with each parameter.

Note: To change the Display User Level, see Chapter 28– Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description User Display Mode

Amount of time allocated to each segment for execution before
Basic
Test continuing. The pressure measurement is made at the end of
Advanced, Admin
the Test segment.
Time to relieve or vent part pressure before signaling the end
Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.

Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description User Display Mode

The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing cycle Advanced, Admin
will end as an Over Pressure Malfunction.

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:PVF icon.

TST Parameter Description User Display Mode

Basic
Low Limit Pressure Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Pressure Upper setpoint value used to evaluate test results.
Advanced, Admin

Test results are compared to two setpoints for pass

or fail status. There are three areas for evaluation of
Test Evaluation Advanced, Admin
results: Above high limit, Between limits, and Below
low limit. See Table below for codes

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (Default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

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S E N T I N E L I 2 8 C H A P T E R 8 – M A S S F L O W

Chapter 8 – Mass Flow

This chapter explains the theory and parameters for conducting a Mass Flow Test.
The result of this test is the measured flow rate at the moment the Test cycle timer
decrements to zero time. This test type is typically used for applications where a
“good” part is expected to flow a desired amount.

This test type utilizes a single calibration cycle with a non-leaking master part to set the
zero flow value. It is important to note that this calibration process creates a linear offset
of all the flow readings based on this single calibration point.

The basic principle of operation of a mass flow test leak test instrument is to fill the test part to a specified
target test pressure and allow the pressure regulator to maintain the target pressure in the part. The
instrument will measure the flow of air required to keep the part at the target pressure.

The Charts below give an overview of the parameters used to set up a Mass Flow Test. The Tables that
follow give detailed descriptions of each parameter and also document the Display User Level associated
with each parameter.

Note: To change the Display User Level, see Chapter 28– Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.

Checks for excessively leaking parts or lack of pressure. May

be set to “Percent of Fill Time” (default), for fixed fill time
tests, or set to “Not to Exceed Time”. For Changing the
Prefill Functionality of the Prefill Timer, see Chapter 28. Maximum Advanced, Admin
time to reach the minimum pressure. If the variable is set to
“Not to Exceed Time”, this segment will exit to the next once
the Minimum Pressure value is reached.

Time to enable part to reach the Target Pressure. It may also Basic
Fill
be used as time to stabilize part pressure with additional air. Advanced, Admin

Time to stabilize part pressure while isolated from the pressure Basic
Stabilize
regulator. This time directly affects the repeatability of the test. Advanced, Admin

The precise time over which to measure pressure drop or Basic

Test
decay or the precise end time to measure pressure rise. Advanced, Admin

Time to relieve or vent part pressure before signaling the end

Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.

When tooling control is specified, there can be up to five

Tooling
retract timers for up to five tooling motions. This is a not to Advanced, Admin
Retract
exceed timer when feedback is being utilized.

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must be reached before the Prefill
setpoint is reached and must be maintained Basic
Minimum Pressure
through fill and stabilization segments or the Advanced, Admin
testing cycle will end as a Severe Leak.
The specified test pressure for the part. For
vacuum test pressures enter a positive value if psiv
was selected as the pressure unit, or enter a
Basic
Target Pressure negative value if psig was selected as the pressure
Advanced, Admin
unit. ((For example, the test pressure 9.7 psia
would be entered as 5 psiv or -5 psig.) Pressure
loss may be corrected to the Target Pressure.
The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.
This is a window (default +/– 50%) set around the
Target Pressure that must be maintained during the
Target Press Test segment of the testing cycle. It generates a
Advanced, Admin
Window Target Pressure Low or High Malfunction if the
actual pressure falls outside this window during
test.

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:FLW icon.

TST Parameter Description Display User Level

Basic
Low Limit Flow Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Flow Upper setpoint value used to evaluate test results.
Advanced, Admin
Test results are compared to two setpoints for pass
or fail status. There are three areas for evaluation of
Test Evaluation Advanced, Admin
results: above high limit, between limits, and below
low limit. See Table below for codes.
The maximum value allowed for the Master Flow Basic
Max Master Flow
Offset parameter located on the Cal menu. Advanced, Admin
The minimum value allowed for the Master Flow Basic
Min Master Flow
Offset parameter located on the Cal menu. Advanced, Admin
Activates Environmental Drift Correction.
EDC Enable Advanced, Admin
See Appendix C.
Options include 10%, 25%, 50%, 75%, and 90%.
EDC Percentage Advanced, Admin
See Appendix C.
EDC Quantity See Appendix C. Advanced, Admin
Typically used with low leak applications. Enables
Enable Calibration the Program Cal function which allows a zero Advanced, Admin
offset to be created for a non-leaking master part.

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

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Program Calibration
In some applications, particularly low leak applications, it is advantageous to create a flow offset based on
testing a non-leaking master part. To enable flow offset, go to Main Menu > Program Config >
TST:FLW icon. Change the Enable Calibration parameter to “Yes”.

Initiating the Program Cal Sequence

To initiate a Program Cal sequence, go to Main Menu > Program Cal icon, select OK and press Enter.
The Program Cal wizard will tell you to connect a non-leaking master part. Connect the non-leaking master
part to the instrument. Push the Start button to initiate the Program Cal sequence. The system will conduct
a test of the non-leaking part to measure the flow associated with a non-leaking part. This represents the
typical offset associated with testing parts within the environment of the test system. The flow value is
saved as the Master Part Offset.

Note: The instrument will require a Program Cal Sequence if any parameters that affect
the calibration are modified.

One condition must be met during the Program Calibration procedure for the instrument to accept and
store the calibration result. The condition is:
The Master (part) Flow must be between the Min Master Flow and Max Master Flow limits.
If the procedure does not meet this condition, an error message is displayed at the completion of test.

If the Program Cal routine is successfully completed, “PROGRAM CALIBRATION PASSED” will be
displayed. If there are any problems during the Program Cal sequence an error will be displayed. See
Appendix A - Messages & Error Codes.

Calibration Parameters
The Calibration parameters menu is located in Main Menu > Program Config > CAL:FLW icon.
These calibration parameters are values that are measured or calculated as a result of the Program
Cal routine for a Mass Flow test.

Parameter Description Display User Level

The flow value measured during a Program
Viewable in Basic &
Calibration sequence is created as a zero offset.
Master Flow Offset Advanced
This value is stored in this parameter and is used as
Editable in Admin
an offset to subtract from the actual flow value.

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Direct Flow Parameter

The Direct Flow Parameter is viewed by going to the Main Menu > Program Config > Misc icon. This
parameter determines how the flow transducer is inserted in to the test circuit.

If the parameter is set to “Enabled: Prefill-Test” then the transducer is active during the Prefill through Test
timer. If the parameter is set to “Enabled: Fill-Test” then the transducer is active during the Fill to test timer.
If the parameter is set to “Disabled”, the transducer is bypassed during the Prefill and Fill timer and active
only during the Test timer.

Note: It may be advantageous to use direct flow when short test cycles are needed with
parts that are expected to flow a certain amount. With direct flow, the flow transducer is
inserted into the test circuit earlier and gives the flow sensor the entire cycle to stabilize
before making the final measurement at the end of the test segment.

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S E N T I N E L I 2 8 C H A P T E R 9 – M A S S F L O W - L E A K S T D

Chapter 9 – Mass Flow-Leak Std

This chapter explains the theory and parameters for conducting a Mass Flow Test
with a leak standard. The result of this test is the measured flow rate at the moment
the Test cycle timer decrements to zero time. This test type is typically used for low
leak applications.

The basic principle of operation of a mass flow test leak test instrument is to fill the test part to a specified
target test pressure and allow the pressure regulator to maintain the target pressure in the part. The
instrument will measure the flow of air required to keep the part at the target pressure.

This test type utilizes a two-point calibration sequence with a non-leaking master part to
set the zero flow value and the flow value at the leak standard value. It is important to note
that this calibration process creates a linear offset of the flow readings based on these two
points.

The charts in this chapter give an overview of the parameters used to set up a Mass Flow Test. The Tables
that follow give detailed descriptions of each parameter and also document the Display User Level
associated with each parameter.

Note: To change the Display User Level, see Chapter 28– Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.

Checks for excessively leaking parts or lack of pressure. May

be set to “Percent of Fill Time” (default), for fixed fill time
tests, or set to “Not to Exceed Time”. For Changing the
Prefill Functionality of the Prefill Timer, see Chapter 28 – Features. Advanced, Admin
Maximum time to reach the minimum pressure. If the variable
is set to “Not to Exceed Time”, this segment will exit to the
next once the Minimum Pressure value is reached.

Time to enable part to reach the Target Pressure. It may also Basic
Fill
be used as time to stabilize part pressure with additional air. Advanced, Admin

Time to stabilize part pressure while isolated from the pressure Basic
Stabilize
regulator. This time directly affects the repeatability of the test. Advanced, Admin

The precise time over which to measure pressure drop or Basic

Test
decay or the precise end time to measure pressure rise. Advanced, Admin

Time to relieve or vent part pressure before signaling the end

Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.

When tooling control is specified, there can be up to five

Tooling Basic
retract timers for up to five tooling motions. This is a not to
Retract Advanced, Admin
exceed timer when feedback is being utilized.
Timer used during Program Cal sequence as a delay between
calibration cycles to allow the master part to recover to Basic
Relax
repeatable virgin state. (Too short relax times result in Advanced, Admin
decreasing flow results in successive tests.)

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must be reached before the Prefill
setpoint is reached and must be maintained Basic
Minimum Pressure
through fill and stabilization segments or the Advanced, Admin
testing cycle will end as a Severe Leak.
The specified test pressure for the part. For
vacuum test pressures enter a positive value if psiv
was selected as the pressure unit, or enter a
Basic
Target Pressure negative value if psig was selected as the pressure
Advanced, Admin
unit. ((For example, the test pressure 9.7 psia
would be entered as 5 psiv or -5 psig.) Pressure
loss may be corrected to the Target Pressure.
The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.
This is a window (default +/– 50%) set around the
Target Pressure that must be maintained during the
Target Press Test segment of the testing cycle. It generates a
Advanced, Admin
Window Target Pressure Low or High Malfunction if the
actual pressure falls outside this window during
test.

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:FLC icon.

TST Parameter Description Display User Level

Basic
Low Limit Flow Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Flow Upper setpoint value used to evaluate test results.
Advanced, Admin
Test results are compared to two setpoints for pass
or fail status. There are three areas for evaluation of
Test Evaluation Advanced, Admin
results: above high limit, between limits, and below
low limit. See Table below for codes.

The minimum flow allowed for the first test during Basic
Min Master Flow
the Program Calibration sequence. Advanced, Admin

The maximum flow allowed for the first test during Basic
Max Master Flow
the Program Calibration sequence. Advanced, Admin

The minimum flow allowed for the second test

Min Master + Leak Basic
during the Program Calibration sequence when the
Flow Advanced, Admin
leak standard is in the test circuit.

The maximum flow allowed for the second test

Max Master + Leak Basic
during the Program Calibration sequence when the
Flow Advanced, Admin
leak standard is in the test circuit.
The minimum value allowed that represents the
Basic
Min Leak Flow flow due to the Leak Standard used to calibrate the
Advanced, Admin
instrument.
The maximum value allowed that represents the
Basic
Max Leak Flow flow due to the Leak Standard used to calibrate the
Advanced, Admin
instrument.
Activates Quik Test.
Quik Test Enable Advanced, Admin
See Appendix B.
Options include 10%, 25%, 50%, 75%, and 90%.
Quik Test Timer Advanced, Admin
See Appendix B.
Quik Test LL Band See Appendix B. Advanced, Admin
Quik Test HL Band See Appendix B. Advanced, Admin
Activates Environmental Drift Correction.
EDC Enable Advanced, Admin
See Appendix C.
Options include 10%, 25%, 50%, 75%, and 90%.
EDC Percentage Advanced, Admin
See Appendix C.
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EDC Quantity See Appendix C. Advanced, Admin

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

Note: If the instrument is configured with multiple internal leak standards, the user must
select which leak standard is to be used in the Program. See Selecting the Proper Internal
Leak Standard in Chapter 28 – Features.

Program Calibration
In order to scale the flow transducer to the “zero flow” reading measured by testing a non-leaking part
and the “reject” reading measured by testing the non-leaking part with a leak standard incorporated in the
circuit, the instrument needs to run the “Program Cal procedure”. This procedure requires at least one
known non-leaking part referred to as a “master part“. This procedure tests a non-leaking master part in
the seal fixture using the timers and pressures established for the program. The procedure automatically
tests the non-leaking master part twice with the Relax timer delay between tests. Within each program
that uses a leak standard, Program Cal can be configured to use one of four methods. See Setting the
Cal Method and Leak Standard Location in Chapter 28 – Features.

Remember: The Leak/Cal menu has a parameter called Leak Std/Cal Define
that determines the location for the leak standard settings.

When set to “Channel”, leak standard settings are located in the Channel Config menu.

When set to “Program”, leak standard settings are located in the Program menu.

Determine how you plan to use your leak test instrument. Review Setting the Leak Standard
Values section on page 14. It is critical to make sure the leak standard values are set correctly
for proper use. To view the Cal Method parameter, you must be in the Advanced or Admin
Display User Level. To change the Display User Level, see Chapter 28– Features.

Initiating the Program Cal Sequence

To initiate a Program Cal sequence, go to Main Menu > Program Cal icon, select OK and press Enter.
The Program Cal wizard will tell you to connect a non-leaking master part. Connect the non-leaking master
part to the instrument. Push the Start button to initiate the Program Cal sequence. The system will conduct
an initial test of the non-leaking master part to measure the flow associated with a non-leaking part. This
represents the typical offset associated with testing parts within the environment of the test system. The
flow value is saved as the Master Part Flow. The system will conduct a second test on a non-leaking master

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part with a known calibrated leak standard included in the test. The flow value result for this test is saved
as the Master+Leak Flow.

Note: The instrument will require a Program Cal Sequence if any parameters that affect
the calibration are modified.

Conditions for a Successful Calibration

Several conditions must be met during the Program Calibration procedure for the instrument to accept and
store the calibration results. The conditions are based on the following measurements or calculations:
1. Master Part Flow
a. Must be greater than the Min Master Flow limit
b. Must be less than the Max Master Flow limit
c. Must be less than the Master+Leak Flow measurement
2. Master+Leak Flow
a. Must be greater than the Min Mstr+Leak Flow limit
b. Must be less than the Max Mstr+Leak Flow limit
c. Must be greater than the Master Flow measurement
3. Leak Flow
a. Must be greater than the Min Leak Flow limit
b. Must be less than the Max Leak Flow limit

If the procedure does not meet these conditions, error messages are displayed at the completion of tests.

If the Program Cal routine is successfully completed, “PROGRAM CALIBRATION PASSED” will be
displayed. If there are any problems during the Program Cal sequence an error will be displayed. See
Appendix A – Message and Error Codes.

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Calibration Parameters
The Calibration parameters menu is located in the Main Menu > Program Config > CAL:FLC
icon. These calibration parameters are values that are measured or calculated as a result of the
Program Cal routine for a Mass Flow-Leak Std test.

Parameter Description Display User Level

Measured pressure at the beginning of the test
Basic
Master Part Press segment during the first test of the Program Cal
Advanced, Admin
process for the non-leaking master part.
Measured pressure at the beginning of the test
cycle of second test during Program Cal process Basic
Master+Leak Press
for the non-leaking master part with the leak Advanced, Admin
standard introduced to the pneumatic test circuit.
Viewable in Basic &
Measured flow for the non-leaking master part
Master Part Flow Advanced
during the first test of Program Cal process.
Editable in Admin
Measured flow during the second test of Program Viewable in Basic &
Master+Leak Flow Cal for the non-leaking master part with the leak Advanced
standard introduced to the pneumatic test circuit. Editable in Admin
Calculated flow, based upon measured flows during Viewable in Basic &
Leak Flow the Program Cal routine. Corresponds to the Advanced
actual flow related to the leak standard. Editable in Admin
The calculated leak standard flow rate based on the
Program Target Pressure, the leak standard Basic
Corr. Leak Std Flow
calibrated pressure, and the leak standard calibrated Advanced, Admin
flow rate.

Direct Flow Parameter

The Direct Flow Parameter is viewed by going to the Program Config ->Misc icon. This parameter
determines how the flow transducer is inserted into the test circuit.

If the parameter is set to “Enabled: Prefill-Test” then the transducer is active during the Prefill to test timer.
If the parameter is set to “Enabled: Fill-Test” then the transducer is active during the Fill to test timer.
If the parameter is set to “Disabled”, the transducer is bypassed during the Prefill and Fill timer and active
only during the Test timer.
Note: It may be advantageous to use direct flow when short test cycles are needed with
parts that are expected to flow a certain amount. With direct flow, the flow transducer is
inserted into the test circuit earlier and gives the flow sensor the entire cycle to stabilize
before making the final measurement at the end of the test segment.

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Chapter 10 – Ramp to ΔP Event

This chapter explains the theory and parameters for conducting a Ramp to Event
Test. The result of this test is the measured pressure at the point in time an event
occurs and the duration of time before the event.

A test type to evaluate parts that ‘crack’ or drastically change state under pressure that can be immediately
detected by monitoring for a sudden significant change in system pressure. The system pressure is typically
increased at a consistent rate (ramp) over a defined period of time. The pressure ramp can be controlled by
the instrument with an electronic regulator, or by a mechanical regulator through a fixed restriction.
The Chart below gives an overview of the parameters used to set up a Ramp to Event Test. The Tables
that follow give detailed descriptions of each parameter and also document the Display User Level
associated with each parameter.
Note: To change the Display User Level, see Chapter 28 – Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.
Maximum duration timer that is a not-to-exceed value. If an
Basic
Test event does not occur within this time period, the test will abort
Advanced, Admin
with a “NO EVENT” evaluation.
Time to relieve or vent part pressure before signaling the end
Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.
When tooling control is specified, there can be up to five
Tooling
retract timers for up to five tooling motions. This is a not to Advanced, Admin
Retract
exceed timer when feedback is being utilized.

Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.
Determines whether ramp is developed by
electronic regulator, manual flow restrictor or
Basic
Ramp Method combination of both. Options are visible only if
Advanced, Admin
the instrument is configured with an electronic
regulator.
Starting Pressure, only when controlled by the
instrument with an electronic regulator. This Basic
Starting Pressure
parameter is not visible if the Ramp Method is set Advanced, Admin
to “None” or “Mech Reg, Flow Control”.
Rate at which pressure is increased or decreased
during the test time, only when controlled by the
instrument with an electronic regulator. This Basic
Ramp Rate
parameter is not visible if the Ramp Method is set Advanced, Admin
to “None”, “Mech Reg, Flow Control” or
“E-Reg Fixed, Flow Control”.

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:RTE icon.

TST Parameter Description Display User Level

Basic
Low Limit Event Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Event Upper setpoint value used to evaluate test results.
Advanced, Admin
Test results are compared to two setpoints for pass
or fail status. There are three areas for evaluation of
Test Evaluation Advanced, Admin
results: above high limit, between limits, and below
low limit. See Table below for codes.
Pressure setpoint that must be crossed (ascending
pressure ramp or descending pressure ramp) during
the test timer before an event can be detected.
Basic
Crossover Pressure This parameter prevents capturing initial part
Advanced, Admin
stretch or any other system noise during the ramp
of pressure below this value. If set to “Zero”, this
requirement is disabled.
Determines the method utilized to trap for an
Basic
Event Type event: ΔP decrease from peak pressure, ΔP
Advanced, Admin
decrease over time or ΔP increase over time.

Minimum pressure differential (defined by the

event type as the peak pressure minus current
Basic
Event Δ Pressure pressure or the change in pressure over the event
Advanced, Admin
time) that must be obtained for the part to have
successfully had an ‘Event’.

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

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Chapter 11 – Ramp to Input Event

This chapter explains the theory and parameters for conducting a Ramp to Input Event
Test, which is primarily used for testing the electrical state of a device. This test type
measures the pressure at which the trigger event input occurs, determines the
maximum pressure before the event is trapped, and records the pressure and duration
of time before at the moment of the trigger event. The results are presented in units of
pressure and time.

This test type is used to evaluate parts that change state under pressure, where the change can be immediately
detected by monitoring a pressure switch, flow switch, or other device with a digital input. The system
pressure is either increased or decreased (ramp) over a defined period of time. The pressure ramp can be
controlled by the instrument via an electronic regulator, or by a mechanical regulator through a fixed
restriction. The digital input on the instrument which is set to Event Trigger and monitors for a rising or
falling edge or a level change from high to low or low to high. The Event Trigger can be ignored if the
duration is less than the Level Time setting.

The Chart below gives an overview of the parameters used to set up a Ramp to Input Event test. The
Tables that follow give detailed descriptions of each parameter and also document the Display User Level
associated with each parameter.

Note: To change the Display User Level, see Chapter 28– Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.
Maximum duration timer that is a not-to-exceed value. If an
Basic
Test event does not occur within this time period, the test will abort
Advanced, Admin
with a “NO EVENT” evaluation.
Time to relieve or vent part pressure before signaling the end
Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.
When tooling control is specified, there can be up to five
Tooling
retract timers for up to five tooling motions. This is a not to Advanced, Admin
Retract
exceed timer when feedback is being utilized.

Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.
Determines whether ramp is developed by
electronic regulator, manual flow restrictor or
Basic
Ramp Method combination of both. Options are visible only if
Advanced, Admin
the instrument is configured with an electronic
regulator.
Starting Pressure, only when controlled by the
instrument with an electronic regulator. This Basic
Starting Pressure
parameter is not visible if the Ramp Method is set Advanced, Admin
to “None” or “Mech Reg, Flow Control”.
Rate at which pressure is increased or decreased
during the test time, only when controlled by the
instrument with an electronic regulator. This Basic
Ramp Rate
parameter is not visible if the Ramp Method is set Advanced, Admin
to “None”, “Mech Reg, Flow Control” or
“E-Reg Fixed, Flow Control”.

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:RTI icon.

TST Parameter Description Display User Level

Basic
Low Limit Event Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Event Upper setpoint value used to evaluate test results.
Advanced, Admin
Test results are compared to two setpoints for pass
or fail status. There are three areas for evaluation of
Test Evaluation Advanced, Admin
results: above high limit, between limits, and below
low limit. See Table below for codes.
Pressure setpoint that must be crossed (ascending
pressure ramp or descending pressure ramp) during
the test timer before an event can be detected.
Basic
Crossover Pressure This parameter prevents capturing initial part
Advanced, Admin
stretch or any other system noise during the ramp
of pressure below this value. If set to “Zero”, this
requirement is disabled.
Determines the method utilized to trap for an
event: Edge (Rising or Falling) type requires a
Basic
Event Type directional change in input state. Level type
Advanced, Admin
requires a specific input state for a specified
duration.
Defines the direction of transition required on the
input to determine if an event has occurred. Rising Basic
Edge Type
Edge is a level transition from Low to High and Advanced, Admin
Falling Edge is a level transition from High to Low.
Defines the specific state the input must match to Basic
Level State
trap for an event. Advanced, Admin
The period of time over which the input must be
Basic
Level Time in the desired state to determine if an event has
Advanced, Admin
occurred.
The required initial state of the input that is verified Basic
Input Initial State
at the start of the test cycle. Advanced, Admin

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Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

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Chapter 12 – Ramp to Flow Event

This chapter explains the theory and parameters for conducting a Ramp to Flow Event
Test, which is primarily used for testing the cracking point of a check valve. This test
type measures the point at which the flow crosses a threshold, determines the
maximum pressure before the Flow Event limit is exceeded, and records the duration
of time before the event. The results are presented in units of pressure and time.

This test type is used to evaluate parts that change flow characteristics under pressure, where the change
can be immediately detected by monitoring the flow on the outlet side of the device. The system pressure
is either increased or decreased at a consistent rate (ramp) over a defined period of time. The pressure ramp
can be controlled by the instrument via an electronic regulator, or by a mechanical regulator through a fixed
restriction. The outlet side of the device is connected to the flow sensor port on the instrument and allows
the instrument to measure downstream flow through the device as the pressure ramps up.

The Chart below gives an overview of the parameters used to set up a Ramp to Flow Event test. The
Tables that follow give detailed descriptions of each parameter and also document the Display User Level
associated with each parameter.

Note: To change the Display User Level, see Chapter 28 – Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.
Maximum duration timer that is a not-to-exceed value. If an
Basic
Test event does not occur within this time period, the test will abort
Advanced, Admin
with a “NO EVENT” evaluation.
Time to relieve or vent part pressure before signaling the end
Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.
When tooling control is specified, there can be up to five
Tooling
retract timers for up to five tooling motions. This is a not to Advanced, Admin
Retract
exceed timer when feedback is being utilized.

Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.
Determines whether ramp is developed by
electronic regulator, manual flow restrictor or
Basic
Ramp Method combination of both. Options are visible only if
Advanced, Admin
the instrument is configured with an electronic
regulator.
Starting Pressure, only when controlled by the
instrument with an electronic regulator. This Basic
Starting Pressure
parameter is not visible if the Ramp Method is set Advanced, Admin
to “None” or “Mech Reg, Flow Control”.
Rate at which pressure is increased or decreased
during the test time, only when controlled by the
instrument with an electronic regulator. This Basic
Ramp Rate
parameter is not visible if the Ramp Method is set Advanced, Admin
to “None”, “Mech Reg, Flow Control” or
“E-Reg Fixed, Flow Control”.

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:RTF icon.

TST Parameter Description Display User Level

Basic
Low Limit Event Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Event Upper setpoint value used to evaluate test results.
Advanced, Admin
Test results are compared to two setpoints for pass
or fail status. There are three areas for evaluation of
Test Evaluation Advanced, Admin
results: above high limit, between limits, and below
low limit. See Table below for codes.
Pressure setpoint that must be crossed (ascending
pressure ramp or descending pressure ramp) during
the test timer before an event can be detected.
Basic
Crossover Pressure This parameter prevents capturing initial part
Advanced, Admin
stretch or any other system noise during the ramp
of pressure below this value. If set to “Zero”, this
requirement is disabled.

Minimum flow that must be obtained for the part Basic

Flow Event Limit
to have successfully had an ‘Event’. Advanced, Admin

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

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Chapter 13 – Ramp to Proof

This chapter explains the theory and parameters for conducting a Proof Test. The
result of this test is the maximum measured pressure during the ramp and test
sequences.

The system pressure is either increased or decreased at a consistent rate (ramp) over a period of time, and
then held at pressure for an additional period of time. The pressure ramp can be controlled by the
instrument with an electronic regulator or by a mechanical regulator through a fixed restriction. Parts are
evaluated based on whether or not pressure was achieved and maintained for the test time period.

The Charts below give an overview of the parameters used to set up a Proof Test. The Tables that follow
give detailed descriptions of each parameter and also document the Display User Level associated with each
parameter.

Note: To change the Display User Level, see Chapter 28 – Features.

Ramp to Proof Test Example

Pressure

Maximum Pressure

Target Pressure

Proof Pressure

Ramp Time Test Time

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.
Time period where the pressure ramp occurs. If an electronic
regulator is installed, the instrument will increment the pressure
Basic
Ramp according to the Ramp Rate up to the Target Pressure. During
Advanced, Admin
this period the system pressure is monitored, and if it exceeds
the Maximum Pressure value the test is immediately aborted.

Time period where the part is expected to maintain pressure.

Ramping has completed and the system pressure is monitored;
Basic
Test it must remain above the Proof Pressure parameter, and not
Advanced, Admin
exceed the Max Pressure parameter. If either scenario is
violated, the test is immediately aborted.
Time to relieve or vent part pressure before signaling the end
Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.
When tooling control is specified, there can be up to five
Tooling
retract timers for up to five tooling motions. This is a not to Advanced, Admin
Retract
exceed timer when feedback is being utilized.

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.
Determines whether ramp is developed by
electronic regulator, manual flow restrictor or
Basic
Ramp Method combination of both. Options are visible only if
Advanced, Admin
the instrument is configured with an electronic
regulator.
Starting Pressure, only when controlled by the
instrument with an electronic regulator. This Basic
Starting Pressure
parameter is not visible if the Ramp Method is set Advanced, Admin
to “None” or “Mech Reg, Flow Control”.
Pressure at which the proof test is to be conducted.
This parameter is not visible if the Ramp Method is Basic
Target Pressure
set to “None”, “Mech Reg, Flow Control” or Advanced, Admin
“E-Reg Fixed, Flow Control”.
Rate at which pressure is increased or decreased
during the test time, only when controlled by the
instrument with an electronic regulator. This Basic
Ramp Rate
parameter is not visible if the Ramp Method is set Advanced, Admin
to “None”, “Mech Reg, Flow Control” or
“E-Reg Fixed, Flow Control”.

Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST:PRF icon.

TST Parameter Description Display User Level

Minimum test pressure that must be maintained
during the test time. If at any point during the test Basic
Proof Pressure
time pressure falls below this value, the test is Advanced, Admin
immediately aborted and a Fail result is generated.

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Chapter 14 – Program Linking

This chapter explains the theory and parameters for conducting multiple tests by
linking programs together.

The applications for program linking fall into three basic categories: conducting multiple tests on one part,
one part with multiple chambers, or multiple unique parts.

Parent Program Linking

The Parent Program Linking test type is designed to group test results together for a single part. In certain
applications, it is desirable to conduct multiple tests on one part. These tests may either be run on the same
chamber within the part or on different chambers. In either case, it is desirable to group the test results
together and produce a global or “Parent” result.

This test type facilitates the linking of individual programs into a testing sequence and provides the overall
control of the tooling outputs and inputs, start and stop inputs, and program result outputs for the test
sequence. The following functions within each individual test program are ignored and controlled by the
Parent Program.

Functions Overridden and Controlled by the Parent Program Test Type

Tooling options
(See Advanced Tooling Control in Chapter 20)
Calibration functions
Autorun Methods
Barcode storage
Relax timer.

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Rules for Parent Program Linking

1. Child Programs may contain tooling logic, but only the tooling logic contained in the Parent
Program will be executed. This is covered under Advanced Tooling Control in Chapter 20.
2. A ‘Malfunction’ at any time or place in the test logic will result in a Vent/Halt.
3. If any of the Child Programs results are Reject, the Parent program result will be Reject. (Child
result evaluations will be logically AND’d.)
4. If the user starts a Parent Program, the Monitor screen will indicate that the Parent Program is
running. The Stop/Reset event during any Child Programs will not navigate the system away
from the Parent Program.

Example of Parent Program Linking

In the example sequence below the user is testing a valve. There are two sides of the valve that must pass
a fine leak test. If either side fails the fine leak test, a mass flow test is run on the failed side to determine if
it is possible to repair the leaking part.

Parent Part Program

Valve Casting Test P1

LINK 1 Start Point

Child Part Program
Fine Leak
Side 1 P2
Accept Either Reject

LINK 2
Child Part Program Child Part Program
Fine Leak Impreg Level Test
Side 2 P3 Side 1 P4
Accept Either Reject

Child Part Program

Impreg Level Test
Side 2 P5

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To program this test sequence, the user goes to Program Config and defines the test type for the Program
1 to be “Parent Program Linking” The test sequence example above requires two links.

The first link screen identifies the program where the testing in the Parent Program will begin and how
additional tests are initiated or linked to the first program based on the first test result. The link defines
the programs that will run next based on the Evaluation Condition.

The second link required by the example above targets Program 3. If Part 3 is Reject, then Program 5 will
run. If Program 3 is Accepted, the test sequence stops with a Program Accept light and a Program
Accept.

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Evaluation Condition Description

Directs only the accept parts for further testing using the program
Accept defined by “Accept Program”. For rejects, severe leaks, and
malfunctions the test sequence stops.
Directs only reject and severe leak parts for further testing using the
Reject program defined by “Reject Program”. For accepts and malfunctions
the test sequence stops.
Directs accept, reject and severe leak parts for further testing using the
programs defined by “Accept Program” if the test passes or “Reject
Accept/Reject
Program” if the test fails or a severe leak occurs. For malfunctions, the
test sequence stops.
Directs accept, reject and severe leak parts for further testing by one
additional test program using the program defined by “Next Program”
Any
for accept, reject, or severe leak tests. For malfunctions, the test
sequence stops.

Link Execution Pause

There are applications where it is desirable for the instrument to pause or delay execution between the
target program and the next program when utilizing the Parent Program Linking or Sequential Linking
test types. An example would be allowing the operator to manipulate a part between programs, such as
opening a valve, inserting a component or any action that requires an external event to take place before
testing can continue. This feature is defined within each link; thus it is possible to pause during one link
and not another.

Parameter Description Display User Level

This parameter will have three options: “No”,
“Continue on Start” and “Continue after Delay”. The
feature is disabled when set to “No”. “Continue on
Basic
Execution Pause Start” forces the instrument to pause and wait for a
Advanced, Admin
start indication to continue. “Continue after Delay”
forces the instrument to delay until the timer expires
then continue execution.
This parameter indicates the amount of time to delay
after the target program, before execution can
continue with the next program. The Delay timer is Basic
Delay
only visible when the Execution Pause option is set to Advanced, Admin
“Continue after Delay”; otherwise the parameter has
no affect.

Note: If you are using Parent Program Linking because you have part with multiple chambers
and the instrument is configured with multiple test ports, remember to select the appropriate test
port. This is described in the section titled Selecting the Test Port in Chapter 2 – Setup.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
Extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.
Time to relieve or vent part pressure before signaling the end
Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.
When tooling control is specified, there can be up to five
Tooling Basic
Retract timers for up to five tooling motions. This is a not to
Retract Advanced, Admin
exceed timer when feedback is being utilized.
Timer used during Program Cal sequence as a delay between
Child Program Links to allow the part to recover to repeatable Basic
Relax
virgin state. (Too short relax times result in decreasing Advanced, Admin
pressure losses or decreasing flow results in successive tests.)

Sequential Linking
The sequential linking test type is designed to run multiple unique parts conducting the tests by
multiplexing (often with multiple sequential test ports). This allows the operator to load and unload the
parts more efficiently. The test results are reported individually for each program. The functionality and
setup of this test type is very similar to the Parent Program Linking test type. The only differences are
that:
a) Each of the linked program results is stored individually.
b) Each result has no bearing on the accept/reject criteria of past or future linked programs
unless they are conditionally linked.
c) The cycle counters increment with each linked program completed.
d) The tooling control uses the defined motions in each of the linked programs (there is no
"Parental tooling control").

This is because this test type is designed to run multiple individual parts.

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Chapter 15 – Percent Volume

This chapter explains the theory and parameters for conducting a percent volume
test for measuring the volume of a test part relative to a reference part.

The Percent Volume test type is used to test for gross leakage by measuring the escape of pressure or
vacuum from a reference part filled with a metered volume of pressure or vacuum. Percent Volume test
type is useful for parts with high elasticity, which readily change volume, by using a pre-defined volume to
limit their maximum expansion during test. In addition, parts with internal openings connecting multiple
volumes can be verified to be open or closed.

This test type is used to determine the volume of a test part compared to the volume of a reference part.
The reference volume is initially filled and isolated from the supply. The test part remains isolated. The
reference volume pressure is measured at this point. The reference volume is then released into the test
part and allowed to stabilize. The pressure of the test part is measured at this point. The two pressure
measurements are then used to calculate the ratio of the test part volume to the reference volume.

The Charts below give an overview of the parameters used to set up a Percent Volume Test. The Tables
that follow give detailed descriptions of each parameter and also document the Display User Level
associated with each parameter.

Note: To change the Display User Level, see Chapter 28– Features.

Percent Volume Test Exhaust

Stab Ref
Fill Ref

Test

Maximum Pressure
Pressure

} Target Press Window

Minimum Pressure

Time

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.

Time to enable reference to reach the Target Pressure. It may

Basic
Fill Ref also be used as time to stabilize reference part pressure with
Advanced, Admin
additional air.
Time to stabilize reference pressure while isolated from the
Basic
Stab Ref pressure regulator and test part. This time directly affects the
Advanced, Admin
repeatability of the test.
The precise time over which to measure the relative volume Basic
Test
difference between the reference part and the test part. Advanced, Admin

Time to relieve or vent test part pressure before signaling the

Basic
Exhaust end of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.

When tooling control is specified, there can be up to five

Tooling
retract timers for up to five tooling motions. This is a not to Advanced, Admin
Retract
exceed timer when feedback is being utilized.

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must be reached before the Fill Ref
setpoint is reached and must be maintained Basic
Minimum Pressure
through the stabilization segment or the testing Advanced, Admin
cycle will end as a Severe Leak.
The specified test pressure for the part. For
vacuum test pressures enter a positive value if psiv
was selected as the pressure unit, or enter a
Basic
Target Pressure negative value if psig was selected as the pressure
Advanced, Admin
unit. ((For example, the test pressure 9.7 psia
would be entered as 5 psiv or -5 psig.) Pressure
loss may be corrected to the Target Pressure.
The value that must not be exceeded at any time to
complete a successful test. If the pressure goes Basic
Maximum Pressure
above the Maximum Test Pressure, the testing Advanced, Admin
cycle will end as an Over Pressure Malfunction.

Percent Volume Test

High Limit %Vref

Low Limit %Vref

%Ref Volume

Exhaust

Time

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST: %VR icon.

TST Parameter Description Display User Level

Basic
Low Limit %Vref Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit %Vref Upper setpoint value used to evaluate test results.
Advanced, Admin

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Chapter 16 – Percent Volume, Pressure

Decay-Leak Std
This chapter explains the theory and parameters for conducting a Percent
Volume, Pressure Decay Leak Test and correlating the pressure loss to a leak rate
using a leak standard. This test requires a two cycle calibration routine to
correlate the pressure loss to a flow rate. The result of this test is presented in
units of flow.

This test type utilizes a two-point calibration sequence with a non-leaking master part to
record the zero leak pressure loss value and the additional pressure loss value due to the
flow rate of the leak standard on the second calibration cycle.

The Percent Volume, Pressure Decay – Leak Std test type is used to test for both severe and fine leaks by
measuring the escape of pressure or vacuum from a reference part filled with a metered volume of pressure
or vacuum. This test type is useful for parts with high elasticity, which readily change volume, by using a
pre-defined volume to limit their maximum expansion during test. In addition, parts with internal openings
connecting multiple volumes can be verified to be open or closed. The Percent Volume portion of this test
type is used to find severe leaks, while the pressure decay – leak std portion is used to find fine leaks.

The basic principle of a Percent Volume, Pressure Decay Leak Test is to perform a percent volume test
followed by a calibrated pressure decay leak test. Details for the basic operation of a percent volume test
can be found in Chapter 15 – Percent Volume. Details for the basic operation of a pressure decay leak test,
including how to perform the required calibration sequence, can be found in Chapter 5 – Pressure Decay-
Leak std.

The charts in this chapter give an overview of the parameters used to set up a Percent Volume, Pressure
Decay Leak Test and correlate the results of the Pressure Decay Leak Test portion to a flow rate using a
leak standard. The Tables that follow give detailed descriptions of each parameter and also document the
Display User Level associated with each parameter.

Note: To change the Display User Level, see Chapter 28– Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description Display User Level

When tooling control is specified, there can be up to five
Tooling
extend timers for up to five tooling motions. This is a not to Advanced, Admin
Extend
exceed timer when feedback is being utilized.
Time to enable reference to reach the Target Pressure. It may
Basic
Fill Ref also be used as time to stabilize reference part pressure with
Advanced, Admin
additional air.
Time to stabilize reference pressure while isolated from the
Basic
Stab Ref pressure regulator and test part. This time directly affects the
Advanced, Admin
repeatability of the test.
The precise time over which to measure relative volume Basic
Test 1
difference between the reference part and the test part. Advanced, Admin
Time to stabilize test part pressure and reference part pressure
Basic
Stabilize while isolated from the pressure regulator. This time directly
Advanced, Admin
affects the repeatability of the test.
The precise time over which to measure pressure drop or Basic
Test 2
decay or the precise end time to measure pressure rise. Advanced, Admin
Time to relieve or vent part pressure before signaling the end
Basic
Exhaust of test. Need time to prevent blowing out debris or fixture
Advanced, Admin
seals.
When tooling control is specified, there can be up to five
Tooling Basic
retract timers for up to five tooling motions. This is a not to
Retract Advanced, Admin
exceed timer when feedback is being utilized.

Timer used during Program Cal sequence as a delay between

calibration cycles to allow the master part to recover to Basic
Relax
repeatable virgin state. (Too short relax times result in Advanced, Admin
decreasing pressure losses/flow results in successive tests.)

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Percent Volume Pressure Decay Leak Test

Exhaust
Stabilize
Stab Ref

Test 2
Fill Ref

Test 1
Pressure

Maximum Pressure

} Target Press Window

Minimum Pressure

Time

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

Pressure Description Display User Level

The value that must be reached before the Fill Ref
setpoint is reached, and must be maintained Basic
Minimum Pressure 1
through the Fill Stab segment or the testing cycle Advanced, Admin
will end as a Severe Leak.
The specified test pressure for the part during the
Test 1 segment. For vacuum test pressures enter a
positive value if psiv was selected as the pressure
unit, or enter a negative value if psig was selected Basic
Target Pressure 1
as the pressure unit. (For example, the test Advanced, Admin
pressure 9.7 psia would be entered as 5 psiv or -5
psig.) Pressure loss may be corrected to the
Target Pressure.
The value that must not be exceeded at any time
during the Fill Ref, Stab Ref or test 1 segments to
Basic
Maximum Pressure 1 complete a successful test. If the pressure goes
Advanced, Admin
above the Maximum Test Pressure, the testing
cycle will end as an Over Pressure Malfunction.
The value that must maintained through Stabilize
Basic
Minimum Pressure 2 and Test 2 segments or the testing cycle will end as
Advanced, Admin
a Severe Leak.
The specified test pressure for the part during the
Test 2 segment. For vacuum test pressures enter a
positive value if psiv was selected as the pressure
unit, or enter a negative value if psig was selected Basic
Target Pressure 2
as the pressure unit. ((For example, the test Advanced, Admin
pressure 9.7 psia would be entered as 5 psiv or -5
psig.) Pressure loss may be corrected to the
Target Pressure.
The value that must not be exceeded at any time
during the Stabilize or Test 2 segments to
Basic
Maximum Pressure 2 complete a successful test. If the pressure goes
Advanced, Admin
above the Maximum Test pressure, the testing
cycle will end as an Over Pressure Malfunction.
This is a window (default +/– 50%) set around
the Target Pressure that must be maintained
during the Test segment of the testing cycle. It
Target Press Window Advanced, Admin
generates a Target Pressure Low or High
Malfunction if the actual pressure falls outside this
window during test.

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Test Parameters (Volume)

The Test parameters menu is located in the Main Menu > Program Config > TST:%VR1 icon.

TST Parameter Description Display User Level

Basic
Low Limit %Vref Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit %Vref Upper setpoint value used to evaluate test results.
Advanced, Admin

Test Parameters (Pressure Decay-Leak std)

The Test parameters menu is located in the Main Menu > Program Config > TST:PLR2 icon.

TST Parameter Description Display User Level

Basic
Low Limit Rate Lower setpoint value used to evaluate test results.
Advanced, Admin
Basic
High Limit Rate Upper setpoint value used to evaluate test results.
Advanced, Admin
Test results are compared to two setpoints for pass or
fail status. There are three areas for evaluation of results:
Test Evaluation Advanced, Admin
above high limit, between limits, and below low limit.
See Table below for codes.
Minimum pressure loss allowed during the first test in
Basic
Min Master Loss the Program Cal routine. Prevents the acceptance of a
Advanced, Admin
calibration of a blocked part or test line.
Maximum pressure loss allowed during the first test in
Basic
Max Master Loss the Program Cal routine. Prevents the acceptance of a
Advanced, Admin
calibration with a leaking part or fixture leaks.
Minimum pressure loss allowed during the second test
Min Mstr+Leak Basic
in the Program Cal routine. Prevents the acceptance of
Loss Advanced, Admin
a calibration with a blocked part or test line.
Maximum pressure loss allowed during the second test
in the Program Cal routine. Prevents the acceptance of a
Max Mstr+Leak Basic
calibration with excessive pressure loss due to part or
Loss Advanced, Admin
fixture leaks. Set slightly higher than max loss during
Program Cal.
Minimum pressure loss allowed that represents the
Basic
Min Leak Loss pressure loss due to the Leak Standard used to calibrate
Advanced, Admin
the instrument.

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Maximum pressure loss allowed that represents the

Basic
Max Leak Loss pressure loss due to the Leak Standard used to calibrate
Advanced, Admin
the instrument.

Minimum value for Performance Factor calculated at

Min Perform completion of Program Cal routine. Resultant Basic
Factor evaluation of ratio of Master Part Loss to Master+Leak Advanced, Admin
Loss, Test Pressure, and loss due to Leak Std.
Certified flow value of Leak Standard used to calibrate
Leak Std Cal instrument. This parameter is only viewable in this Basic
Flow location if the Leak Std/Cal Define parameter is set to Advanced, Admin
“Program”.
Certified pressure at which Leak Standard Flow was
Leak Std Cal calibrated. This parameter is only viewable in this Basic
Press location if the Leak Std/Cal Define parameter is set to Advanced, Admin
“Program”.
Quik Test Enable Activates Quik Test. See Appendix B. Advanced, Admin
Options include 10%, 25%, 50%, 75%, and 90%.
Quik Test Timer Advanced, Admin
See Appendix B.
Quik Test LL
See Appendix B. Advanced, Admin
Band
Quik Test HL
See Appendix B. Advanced, Admin
Band
Activates Environmental Drift Correction.
EDC Enable Advanced, Admin
See Appendix C.
Options include 10%, 25%, 50%, 75%, and 90%.
EDC Percentage Advanced, Admin
See Appendix C.
EDC Quantity See Appendix C. Advanced, Admin

Test Evaluation Code Description

Above Hi Limit > Between Limits > Below Lo Limit Three zones of evaluation for Pass and Fail
PPF Pass if above low limit
PFF Pass if above high limit
F P F* (default) Pass if between high and low limits
FPP Pass if below high limit
FFP Pass if below low limit
PFP Pass if above the high limit or below the low limit

Note: If the instrument is configured multiple internal leak standards the user must select
which leak standard is to be used in the Program. See Selecting the Proper Internal Leak
Standard in Chapter 28 – Features.

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Pressure value gets zeroed at the beginning of test

timer
A loss in pressure is denoted as a positive number

Measured
Master+Leak
Δpressure (Converted a Leak Rate )

Loss

Measured
Master Part
Loss

Rate
Corr Leak
High Limit

Std Flow
Rate
Low limit

Zero Leak

Leak Rate (Δpressure Converted Flow Units)

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D E C A Y - Δ P

Chapter 17 – Differential Pressure (DP)

Decay-ΔP
This chapter explains the theory and parameters for conducting a pressure decay
test measuring a pressure loss over time utilizing a Differential Pressure (DP)
transducer. The result of this test is the pressure loss (or gain for a vacuum test)
measured over a fixed period of time, presented in units of pressure.

How it works
In order to detect leakage in a part, the change in pressure due to temperature and part elasticity must be
allowed to settle before taking any pressure readings.

With differential pressure, a reference part volume (should be identical to the nominal test part volume) is
pressurized simultaneously with the test part.

Leaks are determined by detecting the rate of pressure loss between the two parts.

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Test Setup
The test part and the reference volume are simultaneously pressurized to a preset pressure. The air in the
system is then allowed to stabilize, with the supply valves all closed. After the stabilization time, the
Differential Pressure Transducer is automatically zeroed.

During test, the pressure change in the test piece is compared to the pressure change in the reference
volume, using the Differential Pressure Transducer. If the test piece is leaking, the difference will increase
and be measured; an alarm limit may be set for a pass/fail decision.

The charts in this chapter give an overview of the parameters used to set up a Pressure Differential Test
and correlate the results to a flow rate using a leak standard. The Tables that follow give detailed descriptions
of each parameter and also document the Display User Level associated with each parameter.

Note: To change the Display User Level, see Chapter 28 – Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description User Display Mode

Tooling When tooling control is specified, there can be one extend timer Basic
Extend for one tooling motion. Advanced, Admin
Percentage of the fill timer where the minimum pressure limit is
Prefill not monitored. This allows time within the fill stage for the Advanced, Admin
instrument to achieve the minimum test pressure.
Time to enable part to reach the Charge Target Pressure. At the
end of this timer, the instrument will read the pressure on the
Basic
Charge pressure transducer.
Advanced, Admin
This parameter is only available if the Prefill Method selected is “Fixed
Charge”

Time to enable part to reach the Target Pressure. It may also be Basic
Fill
used as time to stabilize part pressure with additional air. Advanced, Admin

Amount of stabilization time utilized to isolate the test part and

Isolation Admin
reference volume prior to the test measurement.

Time to stabilize part pressure while isolated from the pressure Basic
Stabilize
regulator. This time directly affects the repeatability of the test. Advanced, Admin

At the end of this timer, the instrument will read the pressure on
Basic
Test the differential pressure transducer. This pressure is due to the
Advanced, Admin
backpressure created in the pneumatic circuit and part.
Time to relieve or vent part pressure before signaling the end of Basic
Exhaust
test. Need time to prevent blowing out debris or fixture seals. Advanced, Admin
When tooling control is specified, there can be one retract timers
Tooling
for one tooling motions. This is a not to exceed timer when Advanced, Admin
Retract
feedback is being utilized.

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

User Display
Pressure Description Mode
Minimum test pressure that must be met within the Pre- Basic
Minimum Pressure fill timer and maintained during the Fill and Stabilization Advanced,
timers. This is an early indication of a major leak Admin
Basic
Target test pressure. Also used as a setpoint for the
Target Pressure Advanced,
Electronic Regulator.
Admin
The value that must not be exceeded at any time to
Basic
complete a successful test. If the pressure goes above the
Maximum Pressure Advanced,
Maximum Test Pressure, the testing cycle (during Fill and
Admin
Stabilization) will end as an Over Pressure Malfunction.
Minimum charge pressure that must be met within the
Charge timer and maintained before the Fill timer. This
is an early indication of a major leak. If the pressure is
Basic
measured below the Charge Min Press at end of Charge
Charge Min Press Advanced,
segment, the testing cycle will end as a Below Charge
Admin
Malfunction.
This parameter is only available if the Prefill Method selected is
“Fixed Charge”
Target Charge pressure. Also used as a setpoint for the
Basic
Electronic Regulator in Charge segment.
Charge Target Press Advanced,
This parameter is only available if the Prefill Method selected is
Admin
“Fixed Charge”
The value that must not be exceeded at end of Charge
segment. If the pressure is measured above the Charge
Basic
Max Press at end of Charge segment, the testing cycle will
Charge Max Press Advanced,
end as an Above Charge Malfunction.
Admin
This parameter is only available if the Prefill Method selected is
“Fixed Charge”

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST: DPD icon.

User Display
TST Parameter Description Mode
Basic
Low Limit Loss Lower set point value used to evaluate test results.
Advanced, Admin
Basic
High Limit Loss Upper set point value used to evaluate test results.
Advanced, Admin
Defines the method for calculating the part pressure
decay during test: Loss – charged part decreasing Basic
Decay Direction
pressure or evacuated part decreasing vacuum, Advanced, Admin
Gain – part pressure increasing from external forces.
Manual compensation value which is added to the
Basic
Loss Offset measured loss when calculating the final pressure loss for
Advanced, Admin
the test.
When enabled, Environmental Drift Correction (EDC)
monitors and continually corrects final Leak Rate
EDC Enabled calculations based on the moving average shift of test Advanced, Admin
results within a band about the Master Part calibration
curve.
Percentage (Plus and Minus) band defined by a
percentage of High Limit about the Master Part Curve.
EDC Percentage Advanced, Admin
EDC continually accumulates and calculates an offset
for the test results.
Number of test results utilized in calculating the EDC
EDC Quantity Advanced, Admin
factor.

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Chapter 18 – Diff Decay-Leak Rate

This chapter explains the theory and parameters for conducting a Diff Decay-Leak rate test
measuring leak rate by utilizing a Differential Pressure (DP) transducer. The result of this test is the
leak presented in units of flow.

How it works
In order to detect leakage in a part, the change in pressure due to temperature and part elasticity must be
allowed to settle before taking any pressure readings.

With differential pressure, a reference part volume (should be identical to the nominal test part volume) is
pressurized simultaneously with the test part.

The Leak Rate is determined from the measured differential loss between the test port and the
reference volume over time, using the provided known part volume. This test will NOT require
calibration, and a Leak Standard is NOT required to determine the final leak rate.

The Leak rate is calculated by the following formula,

∆𝑃 𝑉𝑖𝑛𝑠𝑡 + 𝑉𝑝𝑎𝑟𝑡
Q =( × × 60.0) + 𝑂𝑓𝑓𝑠𝑒𝑡𝐸𝐷𝐶 + 𝑂𝑓𝑓𝑠𝑒𝑡𝐿𝑒𝑎𝑘 𝑅𝑎𝑡𝑒
∆𝑡 𝑃𝑠𝑡𝑑

Where:
Q = Leak Rate
ΔP/Δt = Pressure Loss over time
Pstd = Standard Pressure (14.696 psig). This parameter is configured matching Standard
Pressure definition used for instrument and leak calculation
Vinst = Instrument Volume. Volume of the instrument’s isolated pneumatic circuit up to
the test port. This parameter can be located at Main Menu->Channel Config->Hardware.
Vpart = Part Volume.

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Test Setup
The test part and the reference volume are simultaneously pressurized to a preset pressure. The air in the
system is then allowed to stabilize, with the supply valves all closed. After the stabilization time, the
Differential Pressure Transducer is automatically zeroed. Before the beginning of the test measurement, the
part and the reference volume are isolated from the supply valves for the time described in the Isolation
parameter.

During test, the pressure change in the test piece is compared to the pressure change in the reference
volume, using the Differential Pressure Transducer. If the test piece is leaking, the difference will increase
and be measured; an alarm limit may be set for a pass/fail decision.

The Tables that follow give detailed descriptions of each parameter and also document the Display User
Level associated with each parameter.

Note: To change the Display User Level, Chapter 28 – Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description User Display Mode

Tooling When tooling control is specified, there can be one extend timer Basic
Extend 1 for one tooling motion. Advanced, Admin
Percentage of the fill timer where the minimum pressure limit is
Prefill not monitored. This allows time within the fill stage for the Advanced, Admin
instrument to achieve the minimum test pressure.
Time to enable part to reach the Charge Target Pressure. At the
end of this timer, the instrument will read the pressure on the
Basic
Charge pressure transducer.
Advanced, Admin
This parameter is only available if the Prefill Method selected is
“Fixed Charge”
Time to enable part to reach the Target Pressure. It may also be Basic
Fill
used as time to stabilize part pressure with additional air. Advanced, Admin

Time to stabilize part pressure while isolated from the pressure Basic
Stabilize
regulator. This time directly affects the repeatability of the test. Advanced, Admin

Amount of stabilization time utilized to isolate the test part and

Isolation Admin
reference volume prior to the test measurement.

At the end of this timer, the instrument will read the pressure on
Basic
Test the pressure transducer. This pressure is due to the backpressure
Advanced, Admin
created in the pneumatic circuit and part.
Time to relieve or vent part pressure before signaling the end of Basic
Exhaust
test. Need time to prevent blowing out debris or fixture seals. Advanced, Admin
When tooling control is specified, there can be up to five retract
Tooling
timers for up to five tooling motions. This is a not to exceed timer Advanced, Admin
Retract 1
when feedback is being utilized.
Timer used during Program Cal routine as a delay between
calibration cycles to allow the master part to recover to repeatable Basic
Relax
virgin state. (Too short relax times result in decreasing pressure Advanced, Admin
losses/flow results in successive tests.)

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

User Display
Pressure Description Mode
Minimum test pressure that must be met within the Pre- Basic
Minimum Pressure fill timer and maintained during the Fill and Stabilization Advanced,
timers. This is an early indication of a major leak Admin
Basic
Target test pressure. Also used as a setpoint for the
Target Pressure Advanced,
Electronic Regulator.
Admin
The value that must not be exceeded at any time to
Basic
complete a successful test. If the pressure goes above the
Maximum Pressure Advanced,
Maximum Test Pressure, the testing cycle (during Fill and
Admin
Stabilization) will end as an Over Pressure Malfunction.
Minimum charge pressure that must be met within the
Charge timer and maintained before the Fill timers. This
is an early indication of a major leak. If the pressure is
Basic
measured below the Charge Min Press at end of Charge
Charge Min Press Advanced,
segment, the testing cycle will end as a Below Charge
Admin
Malfunction.
This parameter is only available if the Prefill Method selected is
“Fixed Charge”
Target Charge pressure. Also used as a set point for the
Basic
Electronic Regulator in Charge segment.
Charge Target Press Advanced,
This parameter is only available if the Prefill Method selected is
Admin
“Fixed Charge”
The value that must not be exceeded at end of Charge
segment. If the pressure is measured above the Charge
Basic
Max Press at end of Charge segment, the testing cycle will
Charge Max Press Advanced,
end as an Above Charge Malfunction.
Admin
This parameter is only available if the Prefill Method selected is
“Fixed Charge”

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST: DDL icon.

User Display
TST Parameter Description Mode
Lower set point value used to evaluate test results of Basic
Low Limit Leak
parts. Advanced, Admin
Upper set point value used to evaluate test results of Basic
High Limit Leak
parts. Advanced, Admin
Defines the method for calculating the part pressure
decay during test: Loss – charged part decreasing
Decay Direction Admin
pressure, Gain – part increasing pressure from external
forces.
Volume of the part under test. This should include the
volume of all pressurized cavities of the part, seals, Basic
Part Volume
fittings and tubing leading up to the instrument’s test Advanced, Admin
port connection.
Manual compensation value which is added to the final
Leak Rate Offset Admin
calculated leak rate for the test.
When enabled, Environmental Drift Correction (EDC)
monitors and continually corrects final Leak Rate
EDC Enabled calculations based on the moving average shift of test Advanced, Admin
results within a band about the Master Part calibration
curve.
Percentage (Plus and Minus) band defined by a
percentage of High Limit about the Master Part Curve.
EDC Percentage Advanced, Admin
EDC continually accumulates and calculates an offset
for the test results.
Number of test results utilized in calculating the EDC
EDC Quantity Advanced, Admin
factor.

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Chapter 19 – Differential Pressure (DP)

Decay-Leak Std
This chapter explains the theory and parameters for conducting a Differential Pressure (DP)
Decay Test with Leak Standard. Pressure loss is measured utilizing a Differential Pressure
(DP) transducer. The pressure loss is correlated to a leak rate using a leak standard. This
test requires a two cycle calibration routine to correlate the pressure loss to a flow rate. The
result of this test is presented in units of flow.

This test type utilizes a two-point calibration sequence with a non-leaking master part to
record the zero leak pressure loss value and the additional pressure loss value due to the
flow rate of the leak standard on the second calibration cycle.

How it works
In order to detect leakage in a part, the change in pressure due to temperature and part elasticity must be
allowed to settle before taking any pressure readings.

With differential pressure, a reference part volume (should be identical to the nominal test part volume) is
pressurized simultaneously with the test part.

Leaks are determined by detecting the rate of pressure loss between the two parts. The instrument can be
configured optionally with internal or external leak standards. External leak standards can be driven
manually. Internal leak standards are driven by valves (V4) and may be manually forced open during
a test to simulate a leak in the test circuit. Open Leak Std is located in Main Menu > Channel
Config > Leak/Cal icon.

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Leak Standard Pneumatic Diagrams

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Test Setup
The test part and the reference volume are simultaneously pressurized to a preset pressure. The air in the
system is then allowed to stabilize, with the supply valves all closed. After the stabilization time, the
Differential Pressure Transducer is automatically zeroed.

During test, the pressure change in the test piece is compared to the pressure change in the reference
volume, using the Differential Pressure Transducer. If the test piece is leaking, the difference will increase
and be measured; an alarm limit may be set for a pass/fail decision

The charts in this chapter give an overview of the parameters used to set up a Pressure Differential Test
and correlate the results to a flow rate using a leak standard. The Tables that follow give detailed descriptions
of each parameter and also document the Display User Level associated with each parameter.

Note: To change the Display User Level, see Chapter 28 – Features.

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Timer Parameters
The Timers menu is located in the Main Menu > Program Config > Timers icon.

Timer Description User Display Mode

Tooling When tooling control is specified, there can be one extend timer Basic
Extend 1 for one tooling motion. Advanced, Admin
Percentage of the fill timer where the minimum pressure limit is
Prefill not monitored. This allows time within the fill stage for the Advanced, Admin
instrument to achieve the minimum test pressure.
Time to enable part to reach the Charge Target Pressure. At the
end of this timer, the instrument will read the pressure on the
Basic
Charge pressure transducer.
Advanced, Admin
This parameter is only available if the Prefill Method selected is
“Fixed Charge”
Time to enable part to reach the Target Pressure. It may also be Basic
Fill
used as time to stabilize part pressure with additional air. Advanced, Admin

Amount of stabilization time utilized to isolate the test part and

Isolation Admin
reference volume prior to the test measurement.

Time to stabilize part pressure while isolated from the pressure Basic
Stabilize
regulator. This time directly affects the repeatability of the test. Advanced, Admin

At the end of this timer, the instrument will read the pressure on
Basic
Test the pressure transducer. This pressure is due to the backpressure
Advanced, Admin
created in the pneumatic circuit and part.
Time to relieve or vent part pressure before signaling the end of Basic
Exhaust
test. Need time to prevent blowing out debris or fixture seals. Advanced, Admin
When tooling control is specified, there can be up to five retract
Tooling
timers for up to five tooling motions. This is a not to exceed timer Advanced, Admin
Retract 1
when feedback is being utilized.
Timer used during Program Cal routine as a delay between
calibration cycles to allow the master part to recover to repeatable Basic
Relax
virgin state. (Too short relax times result in decreasing pressure Advanced, Admin
losses/flow results in successive tests.)

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Pressure Parameters
The Pressure menu is located in the Main Menu > Program Config > Pressure icon.

User Display
Pressure Description Mode
Minimum test pressure that must be met within the Pre- Basic
Minimum Pressure fill timer and maintained during the Fill and Stabilization Advanced,
timers. This is an early indication of a major leak Admin
Basic
Target test pressure. Also used as a setpoint for the
Target Pressure Advanced,
Electronic Regulator.
Admin
The value that must not be exceeded at any time to
Basic
complete a successful test. If the pressure goes above the
Maximum Pressure Advanced,
Maximum Test Pressure, the testing cycle (during Fill and
Admin
Stabilization) will end as an Over Pressure Malfunction.
Minimum charge pressure that must be met within the
Charge timer and maintained before the Fill timers. This
is an early indication of a major leak. If the pressure is
Basic
measured below the Charge Min Press at end of Charge
Charge Min Press Advanced,
segment, the testing cycle will end as a Below Charge
Admin
Malfunction.
This parameter is only available if the Prefill Method selected is
“Fixed Charge”
Target Charge pressure. Also used as a setpoint for the
Basic
Electronic Regulator in Charge segment.
Charge Target Press Advanced,
This parameter is only available if the Prefill Method selected is
Admin
“Fixed Charge”
The value that must not be exceeded at end of Charge
segment. If the pressure is measured above the Charge
Basic
Max Press at end of Charge segment, the testing cycle will
Charge Max Press Advanced,
end as an Above Charge Malfunction.
Admin
This parameter is only available if the Prefill Method selected is
“Fixed Charge”

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Test Parameters
The Test parameters menu is located in the Main Menu > Program Config > TST: DPL icon.

User Display
TST Parameter Description Mode
Lower set point value used to evaluate test results of Basic
Low Limit Leak
parts. Advanced, Admin
Upper set point value used to evaluate test results of Basic
High Limit Leak
parts. Advanced, Admin
Defines the method for calculating the part pressure
decay during test: Loss – charged part decreasing Basic
Decay Direction
pressure, Gain – part increasing pressure from external Advanced, Admin
forces.
Minimum pressure loss allowable for the master part
Min Mstr+Leak Basic
with Leak Standard during the calibration cycle. Use to
Loss Advanced, Admin
prevent calibration to leaking master parts or fixtures.
Maximum pressure loss allowable for the master part
Max Mstr+Leak Basic
with Leak Standard during the calibration cycle. Use to
Loss Advanced, Admin
prevent calibration to leaking master parts or fixtures.
Minimum pressure loss allowed that represents the
Basic
Min Leak Loss pressure loss due to the Leak Standard used to calibrate
Advanced, Admin
the instrument.
Maximum pressure loss allowed that represents the
Basic
Max Leak Loss pressure loss due to the Leak Standard used to calibrate
Advanced, Admin
the instrument.
Minimum pressure loss allowable for the Master Part
Min Master Loss Basic
during the calibration cycle. Use to prevent calibration to
Advanced, Admin
the Self-Test cap.
Maximum pressure loss allowable for the Master Part
Basic
Max Master Loss during the calibration cycle. Use to prevent calibration to
Advanced, Admin
the Self-Test cap.
Minimum acceptable value for the Performance Factor
Min Perform Basic
compared after the calibration cycle to prevent improper
Factor Advanced, Admin
calibration.
When enabled, Environmental Drift Correction (EDC)
monitors and continually corrects final Leak Rate
EDC Enabled calculations based on the moving average shift of test Advanced, Admin
results within a band about the Master Part calibration
curve.
Percentage (Plus and Minus) band defined by a
percentage of High Limit about the Master Part Curve.
EDC Percentage Advanced, Admin
EDC continually accumulates and calculates an offset
for the test results.
Number of test results utilized in calculating the EDC
EDC Quantity Advanced, Admin
factor.

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Program Calibration
In order to convert the pressure loss measured by the instrument to a leak (flow) rate, the instrument uses
a leak standard and needs to run the “Program Cal” routine. This procedure requires at least one known
non-leaking part referred to as a “master part“. This procedure tests a non-leaking master part connected
to the instrument using the timers and pressures established for the program. The procedure
automatically tests the non-leaking master part twice with the Relax timer delay between tests. Within
each program that uses a leak standard, Program Cal can be configured to use one of four methods. See
Setting the Cal Method and Leak Standard Location in Chapter 28 – Features.

Remember: The Leak/Cal menu has a parameter called Leak Std/Cal Define
that determines the location for the leak standard settings.

When set to “Channel”, leak standard settings are located in the Channel Config menu.

When set to “Program”, leak standard settings are located in the Program menu.

Determine how you plan to use your leak test instrument. Review Setting the Leak Standard
Values section on page 14. It is critical to make sure the leak standard values are set correctly
for proper use. To view the Cal Method parameter, you must be in the Advanced or Admin
Display User Level. To change the Display User Level, see Chapter 28 – Features.

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Initiating the Program Cal Sequence

To initiate a Program Cal routine, go to Main Menu > Program Cal icon, select OK and press Enter.
The Program Cal wizard will tell you to connect a non-leaking master part. Connect the non-leaking master
part to the instrument. Push the Start button to initiate the Program Cal routine. The system will conduct
an initial test of the non-leaking master part to measure the pressure loss associated with a non-leaking part.
This represents the typical offset associated with testing parts within the environment of the test system.
The pressure loss value is saved as the Master Part Loss. The system will conduct a second test on a non-
leaking master part with a known calibrated leak standard included in the test. The pressure loss value result
for this test is saved as the Master+Leak Loss.

Performance Factor
Upon the successful completion of the Program Cal routine, the display will show the calculated
Performance Factor for the calibration. The Performance Factor is an estimate of the quality of the
calibration. It combines the ratio of the Hi Limit Leak result to the non-leaking master part result, the test
pressure, and difference between the Hi Lim result and the non-leaking master part result to scale its
anticipated performance. This value ranges from 0 to 100. It is generally desirable to have a Performance
Factor of 35 to 100. The actual acceptable Performance Factor can vary depending on the desired Gage
R&R performance of the test. Here is the Performance Factor equation:

Performance Factor = Cal Ratio x Pressure Loss Penalty x Time Penalty x 100

The pressure loss penalty is greater for smaller pressure loss values. The time penalty is greater for shorter
Test cycle timer values. Generally, longer stabilize and test cycle timer settings will produce higher
Performance Factors and improved Gage R&R performance.

Note: The instrument will require a Program Cal routine if any parameters that affect the
calibration are modified.

Conditions for a Successful Calibration

Several conditions must be met during the Program Calibration routine for the instrument to accept and
store the calibration results.
The conditions are based on the following measurements or calculations:
1. DP Master Part Loss
a. Must be greater than the Min Master Loss limit
b. Must be less than the Max Master Loss limit
c. Must be less than the Master+Leak Loss measurement
2. DP Master+Leak Loss
a. Must be greater than the Min Mstr+Leak Loss limit
b. Must be less than the Max Mstr+Leak Loss limit
c. Must be greater than the Master Loss measurement
3. DP Leak Loss
a. Must be greater than the Min Leak Loss limit
b. Must be less than the Max Leak Loss limit
4. Performance Factor
a. Must be greater than the Min Perform Factor limit

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If the Program Cal routine is successfully completed, “PROGRAM CALIBRATION PASSED” will be
displayed. If there are any problems during the Program Cal sequence an error will be displayed. If there
is an error, see Appendix A - Message and Error Codes.

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Calibration Parameters
The Calibration parameters menu is located in the Main Menu > Program Config > CAL: DPL icon.
These calibration parameters are values that are measured or calculated as a result of the Program
Cal routine for a Differential Pressure Decay-Leak Std test.

CAL Parameter Description User Display Mode

This is a Performance value generated by the actual
Performance Basic
calibration cycle to be compared to the Min Perform
Factor Advanced, Admin
Factor input as a Test Parameter.
Actual pressure data generated for the master part
Master Part Press Advanced, Admin
during the calibration cycle.
Actual pressure data generated for the master part with Basic
Master+Leak Press
Leak Standard during the calibration cycle. Advanced, Admin
Differential pressure loss during the calibration cycle of * Viewable in Basic
DP Master Part
the Master Part and stored to represent normal & Advanced
Loss
differential loss at the specified Target Pressure. Editable in Admin
Differential pressure loss during the calibration cycle of
* Viewable in Basic
DP Master+Leak the Master Part with Leak Standard and stored to
& Advanced
Loss represent normal loss + leak standard differential loss
Editable in Admin
at the specified Target Pressure.
Calculated differential pressure loss, based upon
*Viewable in Basic
measured differential pressure losses during the
DP Leak Loss & Advanced
Program Cal routine. Corresponds to the actual
Editable in Admin
differential pressure loss related to the leak standard.
Pressure loss during the calibration cycle of the Master * Viewable in Basic
Master Part Loss Part and stored to represent normal loss at the specified & Advanced
Target Pressure. Editable in Admin
Pressure loss during the calibration cycle of the Master
* Viewable in Basic
Part with Leak Standard and stored to represent normal
Master+Leak Loss & Advanced
loss + leak standard loss at the specified Target
Editable in Admin
Pressure.
Calculated pressure loss, based upon measured
*Viewable in Basic
pressure losses during the Program Cal routine.
Leak Loss & Advanced
Corresponds to the actual pressure loss related to the
Editable in Admin
leak standard.
The calculated leak standard flow rate based on the
Corr. Leak Std
Program Target Pressure, the leak standard calibrated Advanced, Admin
Flow
pressure, and the leak standard calibrated flow rate.

Note: * = These CAL parameters are for those customers who want to do CALS on a series of
parts so they can manually input the ideal settings for these parameters to compare again

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Chapter 20 – Tooling Control

This chapter explains the tooling control capability of the instrument. Tooling control is a
powerful feature that gives the instrument the ability to control cylinders and seal actuations.

Note: The instrument must be in Advanced or Admin Display User Level to view and
modify the tooling functionality. To change the Display User Level, see Chapter 28 –
Features.

The instrument includes user selectable digital inputs and outputs to increase the functionality and simplify
the application to various test requirements. The tooling functions are defined within each program. This
allows the flexibility to use different tooling functions; permitting the ability to seal unique ports for each
program. The tooling functions are located in Main Menu > Program Config > Tooling icon.

It is important that all precautions be taken when using the tooling control functions of the instrument. If
motions are being controlled, it is important to follow best engineering practices while designing the
circuitry. This may include using safety modules in the circuit.

In order to implement the tooling functions, they must be interfaced with the inputs and outputs. See
Chapter 21 – Inputs and Outputs.

Menus
Parameter Description Display User Level
The options for this parameter are On, Off, and
Disabled. On causes the tooling motion timers to
appear on the Timers menu. When On, the
instrument will perform these timers in the order
they are listed. It will also allow the associated
tooling outputs to appear in the selectable list in the
Tooling Option Advanced, Admin
Outputs menu. When Disabled, the tooling motion
timers still appear but are ignored. It will also allow
the associated tooling outputs to appear in the
selectable list; however, the outputs are not active in
this mode. When Off, the timers will not appear or
be active.
This parameter defines the number of motions
Number of Motions Advanced, Admin
intended to be used. You can have up to 5 motions.
For safety purposes, it may be desired to have 2
Two Inputs to Start independent inputs to activate a test cycle. The 2 Advanced, Admin
inputs are start and cycle.

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Parameter Description Display User Level

For safety purposes, it may be desired to use anti-
tie-down inputs to activate a test cycle. The anti-tie-
Anti-Tie-Down Advanced, Admin
down inputs (Start & Common) require that the
inputs go high within 50 to 500 msec. of each other.
This parameter is not editable. It determines that
the part present input is checked when the start
Part Present Check Advanced, Admin
input is received. This parameter is active only when
one of the Inputs is set to “Part Present”.
This parameter determines whether or not the
tooling will retract automatically after a reject. If it
is set to “No”, the instrument will wait until a
Retract on Reject Advanced, Admin
Stop/Reset input is received or the Stop button is
pressed before conducting any tooling retract timers
or outputs.
The options for this parameter are None, Both,
Reject, and Accept. Upon completion of a test an
Part Mark Advanced, Admin
output is available to mark Accept, Reject, or Both
for all programs.
Sometimes it is desirable to use proximity sensors or
pressure switches on cylinders or seals to determine
if and when they reach their intended location. The
Tooling Feedback
instrument has the ability to monitor these actions Advanced, Admin
1–5
using this parameter. This parameter may be set to
“Extend”, “Retract”, or “Both” to determine which
locations are to be monitored.
The options for this parameter are Yes and No. This
is if you want confirmation that a program marking
Part Mark Feedback Advanced, Admin
device has completed its response then the test
sequence continues on.

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Advanced Tooling Control

Advanced Tooling Control is used to control motions or sealing between linked
programs; therefore, it is only applicable if Parent Program Linking is being used.

There are applications where it may be required that one or more ports on the test part are blocked or
opened between tests to appropriately evaluate multiple chambers of the part. To accomplish this
additional part manipulation, tooling motions are required between program executions. Thus far we
have covered tooling motions pre-test (Tooling Extend) and post-test (Tooling Retract), this feature adds
a method for the instrument to preempt the pre/post-test tooling motions. Again, this feature is only for
the Parent Program Linking test type.

On the Program Config menu select the Link icon. The Link Motion parameter defines the Tooling
Motion to execute between the Target Program and the next appropriate program number. The options
available for this parameter are based on the tooling Number of Motions parameter defined on the
Tooling menu under the Part Config menu.

The instrument will automatically manage the pre-test and post-test tooling extend and tooling retract
motions. The user only needs to determine:
a) The total number of motions needed (with the Number of Motions parameter on the Tooling
menu within the Part Config menu).
b) How many motions may change between each linked Child program (with the Link Motion
Preempt parameter on the same Tooling menu).
c) Which motions are to occur between linked Child programs (with the numbered Link Motion
parameters on the Link menu under the Program Config menu).

The following rules define this operation:

1. The instrument will place Tooling Extend motions pre-test and Tooling Retract motions post-test
up to the number of defined tooling motions.
2. If any path in the decision tree contains a Link Motion configured with a Tooling Extend, with no
prior Link Motion configured as a Tooling Retract of the same motion number, the pre-test
Tooling Extend motion will not execute.
3. Only those Tooling Extend motions that have been executed either pre-test or using a Link
Motion, will have an associated Tooling Retract motion executed post-test.

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Advanced Tooling Motion Example 1

The instrument will attempt to extend all of the tooling motions at the beginning of the test unless there is
a matching Link Motion number configured as Extend (obviously there is no reason to extend the same
thing twice), thus the pre-test extend is preempted–in defining the link tooling the operator is dictating to
the instrument the appropriate tooling sequence. If there is a Link Motion number configured as Retract,
then later a Link Motion number configured as Extend of the same motion number, then it appears the
operator intended the tooling to be extended at test start (as an operator, if you defined a retract, it is
assumed you wanted the tooling to be extended beforehand). At the completion of the test, the
instrument is aware of what tooling motions are currently extended, thus only the appropriate retracts will
be executed.

The following example of Parent Program Linking has two tooling motions, with one link. The
instrument automatically places appropriate Tooling Extend motions pre-test and Tooling Retract
motions post-test. However, the operator configured a Link Motion as Tooling Extend 2, thus the
instrument will not execute the pre-test Tooling Extend 2.

Tooling Extend 1 Extend Motion

Tooling Extend 2 Preempted

Link 1
Program 4
Target

Link
Tooling Extend 2
Motion

Accept Reject

Program 5 Program 6

Tooling Retract 2 Tooling Retract 2

Tooling Retract 1 Tooling Retract 1

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Advanced Tooling Motion Example 2

Another example of a Parent Program Linking scenario (shown below) has three tooling motions,
with two links. The instrument automatically places appropriate Tooling Extend motions pre-test and
Tooling Retract motions post-test. Since the operator configured within Link 2 a Link Motion as
Tooling Extend 2, the instrument will not execute the pre-test Tooling Extend 2. The operator
configured within Link 1 a Link Motion as Tooling Retract 3, so the instrument will not execute the
post-test Tooling Retract 3. Also, following Program 5 the instrument will not execute the post-test
Tooling Retract 2, since the Tooling Extend 2 was never executed; however, after Program 3 and
Program 4, the Tooling Retract 2 and Tooling Retract 1 will both be executed.

Tooling Extend 1 Extend Motion

Tooling Extend 2
Preempted
Tooling Extend 3

Link 1
Program 1
Target

Link
Tooling Retract 3
Motion

Accept Reject

Link 2 Program 2 Program 5

Target
Tooling Retract 3
Link Retract Motion
Tooling Extend 2 Tooling Retract 2
Motion Tooling Retract Preempted
1
Accept Reject

Program 3 Program 4

Tooling Retract 3 Tooling Retract 3

Tooling Retract Tooling Retract
Retract Motion
2 2 Preempted
Tooling Retract Tooling Retract
1 1

It is helpful when designing a Parent Program Linking test to diagram the desired part operation
to appropriately define all the link parameters correctly to achieve the correct test sequence.

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Chapter 21 – Inputs and Outputs

This chapter explains the Input and Output (I/O) capabilities of the instrument.
The I/O parameters are located in Main Menu > Program Config > HW Input
and HW Output icons.

Note: The instrument must be in Advanced or Admin Display User Level to view and
modify the Input and Output functionality. To change the Display User Level, see Chapter
28 – Features.

The instrument includes user selectable digital inputs and outputs to increase the functionality and
simplify the application to various test requirements. The inputs and outputs are divided into two groups
– Universal and Program Specific. When a Universal input or output is assigned in a program, it is
automatically assigned and available within all programs. When a Program Specific input or output is
assigned in a program, that particular input or output is constrained to use only the inputs or outputs within
the same Functional Group. When the input or output is set to “Constrained” in a program, it will not
function within that program.

In order to remove the selection of an input or an output, change the parameter to either "Unassign" or
"Unassign all Prog". Selecting “Unassign all Prog” will remove the selection of the input or output for all
of the programs. Selecting “Unassign” will only remove the selection from the current program.
“Unassign” is not available for Universal inputs or outputs.

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Input and Output Connector Pinout

The instrument comes equipped with 12 programmable sinking inputs and 12 programmable sourcing
outputs. Both inputs and outputs are 24VDC. See Detail “A” below.

Detail A

DIGITAL INPUT/OUTPUT Detail B

1-6 (24VDC NOMINAL)
TOP CONNECTOR LEVEL I/O A
JUMPER FACTORY POSITION
FOR EXTERNAL POWER

DIGITAL INPUT/OUTPUT
7-12 (24VDC NOMINAL)
BOTTOM CONNECTOR LEVEL I/O B SWITCH JUMPER POSITION
FOR INTERNAL I/O POWER

Digital Outputs Current Draw:

• Maximum current draw for an
individual output is 500 mA
• Maximum current draw for all
combined outputs is 1A

The instrument is supplied with the option to elect to use the internal power for the I/O supply or an
external supply. If an external supply is used, the I/O Factory Jumper is already set to “External I/O
Power”. See I/O Jumper in “Detail B” above.

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Input Pinout and Wiring Table

Input Function Wire Color Connector Location Instrument Connector Cable Connector Pin Wire Color
1 User Selectable Black Top (I/O A) 1 1 Black

2 User Selectable Brown Top (I/O A) 2 2 Brown

3 User Selectable Red Top (I/O A) 3 3 Red
4 User Selectable Orange Top (I/O A) 4 4 Orange
5 User Selectable Yellow Top (I/O A) 5 5 Yellow

6 User Selectable Green Top (I/O A) 6 6 Green

7 User Selectable Black Bottom (I/O B) 1 1 Black

8 User Selectable Brown Bottom (I/O B) 2 2 Brown

9 User Selectable Red Bottom (I/O B) 3 3 Red
10 User Selectable Orange Bottom (I/O B) 4 4 Orange
11 User Selectable Yellow Bottom (I/O B) 5 5 Yellow

12 User Selectable Green Bottom (I/O B) 6 6 Green

User selectable or programmable inputs are listed in a table on the next page.

Output Pinout and Wiring Table

Output Function Wire Color Connector Location Instrument Connector Cable Connector Pin Wire Color
1 User Selectable Blue Top (I/O A) 7 7 Blue
2 User Selectable Violet Top (I/O A) 8 8 Violet
3 User Selectable Gray Top (I/O A) 9 9 Gray
4 User Selectable White Top (I/O A) 10 10 White
5 User Selectable Pink Top (I/O A) 11 11 Pink

6 User Selectable Light Green Top (I/O A) 12 12 Light Green

7 User Selectable Blue Bottom (I/O B) 7 7 Blue

8 User Selectable Violet Bottom (I/O B) 8 8 Violet
9 User Selectable Gray Bottom (I/O B) 9 9 Gray
10 User Selectable White Bottom (I/O B) 10 10 White
11 User Selectable Pink Bottom (I/O B) 11 11 Pink
12 User Selectable Light Green Bottom (I/O B) 12 12 Light Green

User selectable or programmable outputs are listed in a table on page 89.

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I/O Power Pinout and Wiring Table

Function Wire Color Connector Location Instrument Connector Cable Connector Pin Wire Color
IO Common Red/Black Top (I/O A) 20 20 Red/Black
IO Common Orange/Black Top (I/O A) 21 21 Orange/Black
IO Common Yellow/Black Top (I/O A) 22 22 Yellow/Black
IO Hot Green/Black Top (I/O A) 23 23 Green/Black
IO Hot Gray/Black Top (I/O A) 24 24 Gray/Black
IO Hot Pink/Black Top (I/O A) 25 25 Pink/Black
IO Common Red/Black Bottom (I/O B) 20 20 Red/Black
IO Common Orange/Black Bottom (I/O B) 21 21 Orange/Black
IO Common Yellow/Black Bottom (I/O B) 22 22 Yellow/Black
IO Hot Green/Black Bottom (I/O B) 23 23 Green/Black
IO Hot Gray/Black Bottom (I/O B) 24 24 Gray/Black
IO Hot Pink/Black Bottom (I/O B) 25 25 Pink/Black

25 Pin Digital IO Cable Diagram and Pinout Table

CTS Part Number: KIT,CTS,A12-770 (includes 2 cables with hardware)

PIN ID COLOR FUNCTION PIN ID COLOR FUNCTION

1 BLACK 14 BROWN/WHITE
2 BROWN 15 RED/WHITE
3 RED 16 ORANGE/WHITE
4 ORANGE 17 GREEN/WHITE
5 YELLOW 18 BLUE/WHITE
6 GREEN 19 VIOLET/WHITE
7 BLUE 20 RED/BLACK
8 VIOLET 21 ORANGE/BLACK
9 GRAY 22 YELLOW/BACK
10 WHITE 23 GREEN/BLACK
11 PINK 24 GRAY/BLACK
12 LIGHT GREEN 25 PINK/BLACK
13 BLACK/WHITE SHELL DRAIN

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Programmable Inputs and Outputs Menus

Input Options Output Options
Start Channel Malfunction
Start Program Tool Extend 1
Stop/Reset Tool Extend 2
Hold Tool Extend 3
Vent/Halt Tool Extend 4
Program Cal Tool Extend 5
Open Leak Std In Relax
Part Present Program Cal Mode
SPC Test Part Program Cal Master
Instrument Enable Program Cal Leak Std
Program Select B1 Press Select
Program Select B2 Prefill
Program Select B3 In Fill
Program Select B4 Fill Valve
Program Select B5 In Stabilize
Program Select B6 Isolation Valve
Program Select B7 In Test
Common Test Passed
Tool Ext Fdbk 1 Test Failed
Tool Ext Fdbk 2 Bellow LL
Tool Ext Fdbk 3 Between Lim
Tool Ext Fdbk 4 Above HL
Tool Ext Fdbk 5 In Exhaust
Ext Press Sw Program Accept
Event Trigger Program Reject
Tool Ret Fdbk 5 Severe Leak
Tool Ret Fdbk 4 Part Acc Mark
Tool Ret Fdbk 3 Part Rej Mark
Tool Ret Fdbk 2 Tool Retract 5
Tool Ret Fdbk 1 Tool Retract 4
Unassign Tool Retract 3
Tool Retract 2
Tool Retract 1
Unassign

The Inputs and Outputs above are listed in their menu selection order. All of the options may not
be available, depending on the test type and the tooling control setting (On or Off and Number of
Motions). Descriptions of these menu options are on the following pages are in related groups.

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Inputs for Program Control

Input Description
Start Channel Starts the active Program
The Start Channel and Common inputs are universal inputs, where each part
Common program can be set individually to use “Two Inputs to Start” or “Anti-Tie-
Down” logic.
The Vent/Halt input safely ceases the operation of any tooling motion,
removes all energy from the part by advancing through the exhaust segment
and stops operation. Any programmed tooling motion required to return to
Vent/Halt
the fully retracted positions must be initiated by the Stop/Reset input. While
the Vent/Halt input is high, no additional test activity or tooling resets can
occur. See description below.
Changes the Current Program to the one assigned to this input and Starts the
Start Program
Program.
The Stop/Reset input is available to stop tests and retract tooling. When a
stop/reset input is received the test cycle goes immediately through a
Stop/Reset Vent/Halt routine and then advances to retract the tooling. The Malfunction
output (if programmed) will go high at the end of the last tooling motion for
errors defined as malfunctions. See description below.
The Hold input halts or suspends the testing sequence as long as this input is
Hold high. This can be used to stop the testing while awaiting some other action to
occur.
Enabled by selecting Part Present as one of the inputs, the Part Present input
must be high before a start test input is received. It also must go low between
Part Present tests (after any tooling motion and before the start of the tooling motion for
the next test). If more than one input is set to “Part Present”, test will execute
only if all inputs are made high.
Enabled by selecting Ext Press Sw as one of the inputs, the External Pressure
Switch input must go high before the end of the fill segment. This input is
generally used to validate that the test part is properly charged by detecting
pressure downstream of a potential blockage point. For Occlusion test type
Ex Press Sw where fill segment is not present, Ext Press Sw input must go high before the
end of the test segment. If Ext Press Sw input is not made high during test
execution then a malfunction occurs. For more than one input of Ext Press
Sw, test will execute only if all inputs are made high before test segment of
Occlusion test and fill segment for other test types.
Enabled by selecting Instrument Enable as one of the inputs, the Instrument
Enable input must be high before a start test input is received. If the input
doesn’t go high before executing any test, it shows the malfunction message.
Instrument
If the input goes low in between test execution then test aborts and shows
Enable
malfunction message. For more than one input of Instrument Enable, test
will execute only if all inputs are made high and test aborts with malfunction
message if any one input is low or made low in between test execution.

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Vent/Halt Request
The design of a Vent/Halt request (including initial phase of the Stop/Reset request) is to cease operation
of tooling motions, safely remove all energy from the part, and stop operation.

A Vent/Halt request operation has multiple operations depending on the state of the instrument while
testing. For better understanding, the test sequence can be broken into three basic groups: Tooling Extend,
Part Testing, and Tooling Retract. The Program Evaluation (Accept Program/Reject
Program/Malfunction/Severe Leak) is always after the Tooling Retract.
Other than a user generated Vent/Halt input, a number of test errors will generate a Vent/Halt request.
Possible scenarios include:

Vent/Halt – Instrument Idle

While the instrument is idle, a high Vent/Halt input will prevent the instrument from performing any test
activity or tooling reset. Any type of Start or Stop request will be ignored until the Vent/Halt input is low.

Vent/Halt – Instrument execution during Tooling Extend Group

A Vent/Halt request will cause the output related to an executing Tooling Extend to be turned off. If the
extend output is completed, it will remain in its current state. Since the part has not been charged no exhaust
is necessary and execution will cease. A Tooling Reset is required.

Vent/Halt – Instrument execution during Part Testing Group

A Vent/Halt request will cause the instrument to exhaust any pressure within the part (if pressure was
achieved) and execution will cease. Any output relating to Tooling Extend will remain in its current state.
A Tooling Reset is required.

Vent/Halt – Instrument execution during Tooling Retract Group

A Vent/Halt request will cause the output relating to the current executing Tooling Retract to be turned
off. Since the part has already been exhausted, execution will cease. A Tooling Reset is required.

Stop/Reset Request
The design of a Stop request is to safely remove all energy from the part, place the tooling into a fully
retracted state, and stop operation. Depending on whether the instrument is actively testing or idle, the stop
request has two modes of operations.

Stop – Instrument Testing

• If actively testing, a Stop request will cause the instrument to exhaust any pressure within the
part (if pressure was achieved), and then execute a tooling reset sequence (only if tooling is
enabled). The retract motion will be executed into a known retracted state for the next test.

Stop – Instrument Idle

• If the instrument is idle or in a safe state with the part pressure exhausted, a Stop request will
cause the instrument to execute a tooling reset sequence (only if tooling is enabled). The retract
motion will be executed into a known retracted state for the next test.

Besides a user generated Stop, a number of test errors will generate a Stop/Reset request that causes a
Vent/Halt routine and continues with the tooling reset. The possible scenarios include: Transducer
Malfunction (zero or over-range), External Switch Fault (not low or high at appropriate time), Severe Leak,
Pressure Low/High, Calculation Faults, Calibration Errors, and General Program Fault (setup errors).

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In addition, Stop/Reset input is required:

• After any tooling motion or test malfunction where the instrument completed Vent/Halt to
safe state and stopped.
• Tooling must be reset to fully retracted position to start next test.

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Inputs for Program Selection

Input Description
Programs can be remotely selected using the Binary Program Selection inputs
or using one of the communication methods: RS232 or TCP/IP. The number
of required inputs for Binary Program Selection depends on the highest
program number of the program to which access is required.

Binary Program
Selection Program Numbers Binary Program Inputs
1 B1
2–3 B1 and B2
4–7 B1, B2, and B3
8 – 15 B1, B2, B3, and B4
16 – 31 B1, B2, B3, B4 and B5
32 – 63 B1, B2, B3, B4, B5, and B6
64 – 99 B1, B2, B3, B4, B5, B6, and B7

Note: Programs can also be remotely selected using one of the communication methods:
RS232 or TCP/IP, see Chapter 24 - Communication.

Inputs for Program Calibration

Input Description
The Program Cal input prepares the instrument to perform a Program Cal
Program Cal sequence. A Start input initiates the tooling motion and Program Cal
sequence.
The Open Leak Standard input will open the Leak Standard Calibration valve
(if equipped) during the Fill, Stabilization, Test, and Exhaust segments. The
valve will only open during the testing cycle when the input is high. If the
input goes low during the testing cycle, the Leak Std Calibration valve will
Open Leak Std
close. This input is generally used to automatically verify the calibration of a
system by indexing or placing a good part in the test fixture and adding the
internal leak standard to measure a part with the leak rate equal to the internal
leak standard.
The SPC Test Part input identifies the next part to test as an SPC Part (often
used when performing a test calibration verification test with a leak standard).
This input must be high when receiving the Start input. This will mark the
SPC Test Part
test results in the program result with an “*”. Also, the test result output
using the communication port will include the “*” to identify these parts for
separate analysis.

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Inputs for Tooling Motion

Input Description
This input must go high as a response to the Part Mark (Accept, Reject, or
Both) output within the Part Mark timer that starts at the end of the exhaust
timer when the Part Mark output is initiated. The Part Mark Feedback input
must be requested.
• Part Config/TOOLING – “Part Mark” must be set for “Accept”,
“Reject”, or “Both”.
Part Marking • Part Config/TOOLING – “Part Mark Feedback” set to “Yes”.
Feedback • Part Config/INPUT – Part Mark Feedback assigned to a terminal.
• Part Config/OUTPUT – “Part Acc Mark” and/or “Part Rej Mark”
assigned to terminal(s)
• Part Config/TIMER – Part Mark Timer set to a time.

Failure to receive this input before the end of the Part Mark Fdbk timer will
cause a Malfunction result and an “ERROR: PART MARK FAULT” display.
If enabled by selecting Tool Ext Fdbk #x as one of the inputs, it is required
that the Tool Extend Feedback input go high before the associated Tool Ext
Tool Ext Fdbk
Timer expires. If the timer expires before the input goes high the instrument
1–5
will issue a malfunction. A Stop/Reset will need to be initiated to reset the
tooling.
If enabled by selecting Tool Ret Fdbk #x as one of the inputs, it is required
that the Tool Retract Feedback input go high before the associated Tool Ret
Tool Ret Fdbk
Timer expires. If the timer expires before the input goes high the instrument
1–5
will issue a malfunction. A Stop/Reset will need to be initiated to reset the
tooling.

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Outputs for Test Cycles

Output Description
Pressure Select goes high during the entire test sequence from start of Prefill
Press Select or Fill segment to the end of Exhaust segment. This output can be used as
a Test Active output.
The Prefill output goes high during the Prefill portion of the Fill segment.
This output is frequently used to control an external fast-fill valve when
Prefill
testing large volume parts. The external fast-fill valve opens until the
instrument reaches the Minimum Pressure.
In Fill The Fill segment output goes high during the Fill segment.
This output mimics the Fill Valve functionality in the instrument. It goes high
Fill Valve
during the Prefill and Fill segments.
In Stabilize The Stabilization segment output goes high during the Stabilization segment.
This output mimics the Isolation Valve functionality in the instrument. It
Isolation Valve goes high just prior to the fill valve closing and stays energized until the end of
the Test segment.
In Test The Test segment output goes high during the Test segment.
The Exhaust segment output goes high during the Exhaust segment. This
output is frequently used to open an external exhaust valve that vents the test
In Exhaust
air from the part through a larger valve for fast exhaust or to bypass the
instrument and avoid polluting the instrument pneumatics with dirty part air.
The relax timer output goes high during the Relax segment between the two
tests of the Program Cal sequence. It would go high at the end of the first test
In Relax
Exhaust segment until the start of the second test Prefill or Fill segment. The
Relax segment is also functional between tests in the Auto Setup routine.

Outputs for Program Calibration

Output Description
The Program Cal Mode output goes high whenever the instrument is
performing a Program Cal cycle. It goes high at the beginning of the Prefill
Program Cal
or Fill timer for the first test of the Program Cal process. It stays high until
Mode
the end of the Exhaust segment for the second test of the Program Cal
Process.
The Program Calibration Master output goes high during the first complete
test of the Program Cal process starting at the beginning of the Prefill or Fill
Prog Cal Master
segment to the end of the Exhaust segment. This output is used to alert an
external process that the instrument is in the first test of calibration.
The Program Calibration Leak Standard output goes high during the second
complete test cycle of the Program Cal process when the Leak Standard is
Prog Cal LS added beginning with the Prefill or Fill segment to the end of the Exhaust
segment. This output is used to alert an external process that the instrument
is in the second test of calibration.

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Outputs for Program Results and Test Results

Output Description
The Program Accept output goes high at the completion of the tooling motion
Program Accept (if tooling is turned on) or at the completion of the Exhaust segment if the test
passes.
The Program Reject output goes high at the completion of the tooling motion
(if tooling is turned on) if the test fails. Program Rejects also include Severe
Program Reject
Leaks when Minimum Pressure is not reached before reaching the Prefill
setpoint or maintained during the Fill or Stabilization segments.
If a test has an error or disruption to the normal process and faults out of cycle
before the normal completion, a malfunction will occur. With tooling control
if the error or disruption occurs during initial tooling action, the tooling will
Malfunction retract. If the error or disruption occurs during the testing cycle, the test will
advance immediately to exhaust and the tooling will retract automatically. The
Malfunction output goes high at the end of the completion of the last tooling
motion.
If a test fails to reach Minimum Pressure before reaching the Prefill setpoint or
fails to maintain at least the Minimum Pressure during the Fill and Stabilization
Severe Leak
segments, the instrument will exhaust the pressure in the part and output
Severe Leak high.
Part Acc Mark output stamps or marks a part as Accept based on the Part
Part Acc Mark Result. This output goes high during the Park Mark Timer immediately at the
end of the Exhaust timer.
Part Rej Mark output stamps or marks a part as Reject based on the Part
Part Rej Mark Result. This output goes high during the Park Mark Timer immediately at the
end of the Exhaust timer.
Signals the completion of a test that passed at the start of the Exhaust segment.
Test Passed
This output stays on until the start of a new test.
Signals the completion of a failed test at the start of the Exhaust segment. This
Test Failed
output stays on until the start of a new test.
Below Low Limit goes high at the start of Exhaust segment when test results
Below LL
are below the Low Limit setpoint and stays high until the start of the next test.
Between Limits goes high at the start of Exhaust segment when test results are
Between Lim between the Low Limit and High Limit setpoints and stays high until the start
of the next test.
Above High Limit goes high at the start of Exhaust segment when test results
Above HL
are above the High Limit setpoint and stays high until the start of the next test.

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Outputs for Tooling Motion

Output Description
Tooling This output goes high during the Tooling Extend 1 segment. This option is
Extend 1 only available if Tooling is set to “On” or “Disabled”.
This output goes high during the Tooling Extend 2 segment. This option is
Tooling
only available if Tooling is set to “On” or “Disabled” and the Number of
Extend 2
Motions is equal to 2 or more.
This output goes high during the Tooling Extend 3 segment. This option is
Tooling
only available if Tooling is set to “On” or “Disabled” and the Number of
Extend 3
Motions is equal to 3 or more.
This output goes high during the Tooling Extend 4 segment. This option is
Tooling
only available if Tooling is set to “On” or “Disabled” and the Number of
Extend 4
Motions is equal to 4 or more.
This output goes high during the Tooling Extend 5 segment. This option is
Tooling
only available if Tooling is set to “On” or “Disabled” and the Number of
Extend 5
Motions is equal to 5 or more.

Output Description
This output goes high during the Tooling Retract 5 segment. This option is
Tooling
only available if Tooling is set to “On” or “Disabled” and the Number of
Retract 5
Motions is equal to 5 or more.
This output goes high during the Tooling Retract 4 segment. This option is
Tooling
only available if Tooling is set to “On” or “Disabled” and the Number of
Retract 4
Motions is equal to 4 or more.
This output goes high during the Tooling Retract 3 segment. This option is
Tooling
only available if Tooling is set to “On” or “Disabled” and the Number of
Retract 3
Motions is equal to 3 or more.
This output goes high during the Tooling Retract 2 segment. This option is
Tooling
only available if Tooling is set to “On” or “Disabled” and the Number of
Retract 2
Motions is equal to 2 or more.
Tooling This output goes high during the Tooling Retract 1 segment. This option is
Retract 1 only available if Tooling is set to “On” or “Disabled”.

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Output Timing Diagram

Tooling Retract 5

Tooling Retract 4

Tooling Retract 3

Tooling Retract 2

Tooling Retract 1
Tooling Extend 1

Tooling Extend 2

Tooling Extend 3

Tooling Extend 4

Tooling Extend 5

Stabilize

Exhaust
Prefill

Test
Fill
Tooling Extend 1

Tooling Extend 2

Tooling Extend 3

Tooling Extend 4

Tooling Extend 5

Press Select

In Prefill

In Fill

Fill Valve

In Stabilize

In Test

Isolate Valve

In Exhaust

Tooling Retract 1

Tooling Retract 2

Tooling Retract 3

Tooling Retract 4

Tooling Retract 5

Test Passed

Test Failed

Below Low Limit

Between Limits

Above High Limit

Program Accept

Program Reject

Severe Leak

Malfunction

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Tooling Example
The example below shows the power and flexibility of the Input and Output functionality. In this example
the inputs and outputs are being used to seal two different types of parts. The two different parts have
sealing ports in different locations. The part presence sensors select the program in the instrument that
controls the proper hardware based on the current part in the sealing nest.

Two Similar parts with a Output 1

Neutral or V-
common body but
Output 2 different port locations
Neutral or V- (A or B)
Part 1 has a port at A
Part 2 has a port at B

A
B

Input 4 & 6
Part Presence Seal B Input 3 & 5
Switch B Part Presence
Switch A

Start Stop
Button Button

Input 1 Input 2
IOH IOH

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Parameters Program #1 Program #2

Tooling Motion On On
Number of Motions 1 1
Part Present Check On Start On Start
Retract on Reject No No

Input Hardware Program #1 Program #2

Input 1 Start Button Start Channel Start Channel
Input 2 Stop Button Stop/Reset Stop/Reset
Input 3 Part Select Switch Program Select B1 Program Select B1
Input 4 Part Select Switch Program Select B2 Program Select B2
Input 5 Part Presence Sensor A Part Presence Constrained
Input 6 Part Presence Sensor B Constrained Part Presence

Output Hardware Program #1 Program #2

Output 1 Seal A Extend Tool Extend 1 Constrained
Output 2 Seal B Extend Constrained Tool Extend 1

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Chapter 22 – EtherNet/IP
This chapter explains the control capabilities of the I28 using the EtherNet/IPTM feature. The instrument is
able to communicate over Ethernet via TELNET. EtherNet/IP is a registered trademark of ODVA, Inc.

Instrument EtherNet/IP Functionality

EtherNet/IP is an industrial communication standard which encompasses the Common
Industrial Protocol (CIP™) deployed over standard Ethernet technology (IEEE 802.3 with
TCP/IP). While EtherNet/IP offers various optional topology methods, our implementation
utilizes the conventional star with standard Ethernet infrastructure devices.
Features
EtherNet/IP provides the following capabilities:
• Standard set of I/O functionality for machine control
• Modify the current active Program
• Send/receive ASCII barcode information to be stored with test result (Blackbelt and I28
instruments only)
• User configurable soft I/O functions (16 input, 16 output)
• Test result summary data, and query of full result measurement information
• Latch feature for multi-device communications heartbeat monitoring

EtherNet/IP does NOT provide:

• Real-time test data streaming
• Access or modification of instrument settings:
o Global configuration
o Channel configuration
o Program configuration

Compatibility
Provide full communication capabilities over EtherNet/IP™ with any Allen-Bradley
ControlLogix® or CompactLogix PLC™.

Standard Fixed, Defined Inputs/Outputs

Enabling EtherNet/IP allows a set of fixed defined I/O points that are preconfigured are already part
of EtherNet/IP structure. The following functionality is accessible by these predefined features.

• Start • Result Ready • Current Program Number

• Stop • Result Error • Change Program Number
• Vent/Halt • Result Unique ID • Test Evaluation
• Reset • Program Accept • Timestamp
• Instrument Ready • Program Reject • Latch status
• Malfunction

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Setting EtherNet/IP User Defined Inputs and Outputs

The instrument comes equipped with 16 programmable inputs and 16 programmable outputs.
The user can select up to 16 test or program specific I/O that are not in the Standard Fixed,
Defined I/O set (described on the first page of this chapter). The following lists of input and
output options are the same as the lists of hardware inputs and outputs described in the
Programmable I/O Table in the previous chapter titled Chapter 21 – Inputs and Outputs.

Input Options Output Options

Start Channel Malfunction
Start Program Tool Extend 1
Stop/Reset Tool Extend 2
Hold Tool Extend 3
Vent/Halt Tool Extend 4
Program Cal Tool Extend 5
Open Leak Std In Relax
Part Present Program Cal Mode
SPC Test Part Program Cal Master
Program Select B1 Program Cal Leak Std
Program Select B2 Press Select
Program Select B3 Prefill
Program Select B4 In Fill
Program Select B5 Fill Valve
Program Select B6 In Stabilize
Program Select B7 Isolation Valve
Common In Test
Tool Ext Fdbk 1 Test Passed
Tool Ext Fdbk 2 Test Failed
Tool Ext Fdbk 3 Bellow LL
Tool Ext Fdbk 4 Between Lim
Tool Ext Fdbk 5 Above HL
Ext Press Sw In Exhaust
Event Trigger Program Accept
Tool Ret Fdbk 5 Program Reject
Tool Ret Fdbk 4 Severe Leak
Tool Ret Fdbk 3 Part Acc Mark
Tool Ret Fdbk 2 Part Rej Mark
Tool Ret Fdbk 1 Tool Retract 5
Instrument Enable Tool Retract 4
Part Mark Fdbk Tool Retract 3
Unassign Tool Retract 2
Tool Retract 1
Unassign

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The Inputs and Outputs in the previous table are listed in their menu selection order. All of the
options may not be available, depending on the test type and the tooling control setting (On or
Off and Number of Motions). Descriptions of these menu options can be found in Chapter 21 –
Inputs and Outputs.

Additional Reference Document

For more information on communicating with any Allen-Bradley ControlLogix or CompactLogix
PLC, refer to the EtherNet/IP AOI Integration Manual. This document file will be located
on the USB flash drive that was provided with the CTS instrument. If you cannot locate this file
on the USB drive, it can be emailed to you. Contact the Cincinnati Test Systems Service
department. See the back cover of this manual for contact information.

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Establishing EtherNet/IP Communication

The communication parameters are located in Main Menu > Global Config > Network icon
menu. The first step in establishing communication with a PLC is to set EtherNet/IP to
“Enable”.

CAUTION: When changing the EtherNet/IP setting from “Enabled” to

“Disabled”, all of the user assigned IP Inputs and IP Outputs become
Unassigned. This is necessary because when EtherNet/IP is no longer
functional, any I/O that may cause program faults must be removed. This
includes Part Present, External Pressure Switch, etc. This means that all the
user assigned IP Inputs and IP Outputs must be set up again.

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Additional Menus
Turning on this feature will make 2 additional menu icons visible on the Monitor menu screens
and 2 additional menu icons visible on the Program Config menu screen.

EtherNet/IP Monitor Screens

Where there were 2 hardware input and output menu icons,
Where there were 2 Monitor menu icons for hardware inputs and outputs., now there are 2 more
menu icons to monitor the EtherNet/IP inputs and outputs.

Also see Chapter 30 – Monitor Screen Examples to see how the HW and IP monitor screens
appear.

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EtherNet/IP Inputs and Outputs

Where there were 2 Program Config menu icons for hardware inputs and outputs, now there will
be 2 additional menu icons where the EtherNet/IP inputs and outputs can be set.

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Chapter 23 – PROFINET
This chapter explains the control capabilities of the I28 instrument using the PROFINET feature.

Instrument PROFINET Functionality

PROFINET is an industrial communication standard for data communication over Industrial
Ethernet. While PROFINET offers various optional topology methods, our implementation utilizes
the conventional star with standard Ethernet infrastructure devices.
Features
PROFINET provides the following capabilities:
• Standard set of I/O functionality for machine control
• Modify the current active Program
• User configurable soft I/O functions (16 input, 16 output)
• Test Result data for the latest test
• Real-time data streaming
• Send/receive ASCII barcode information to be stored with test result

PROFINET does NOT provide:

• Access or modification of instrument settings:
o Global configuration
o Channel configuration
o Program configuration
• Test Result Data for a specific Result ID
• Full Result Data

Standard Fixed, Defined Inputs/Outputs

Enabling PROFINET allows a set of fixed defined I/O points that are preconfigured are already part of
PROFINET structure. The following functionality is accessible by these predefined features.

• Start • Program Accept • Current Program Number

• Stop • Program Reject • Change Program Number
• Vent/Halt • Malfunction • Test Active
• Reset
• Instrument Ready

Setting PROFINET User Defined Inputs and Outputs

The instrument comes equipped with 16 programmable inputs and 16 programmable outputs. The
user can select up to 16 test or program specific I/O that are not in the Standard Fixed, Defined
I/O set (described on the first page of this chapter). The following lists of input and output options

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are the same as the lists of hardware inputs and hardware outputs described in the Programmable
I/O Table in the previous chapter titled Chapter 21 – Inputs and Outputs.

Input Options Output Options

Start Channel Malfunction
Start Program Tool Extend 1
Stop/Reset Tool Extend 2
Hold Tool Extend 3
Vent/Halt Tool Extend 4
Program Cal Tool Extend 5
Open Leak Std In Relax
Part Present Program Cal Mode
SPC Test Part Program Cal Master
Instrument Enable Program Cal Leak Std
Program Select B1 Press Select
Program Select B2 Prefill
Program Select B3 In Fill
Program Select B4 Fill Valve
Program Select B5 In Stabilize
Program Select B6 Isolation Valve
Program Select B7 In Test
Common Test Passed
Tool Ext Fdbk 1 Test Failed
Tool Ext Fdbk 2 Bellow LL
Tool Ext Fdbk 3 Between Lim
Tool Ext Fdbk 4 Above HL
Tool Ext Fdbk 5 In Exhaust
Part Mark Fdbk Program Accept
Ext Press Sw Program Reject
Event Trigger Severe Leak
Tool Ret Fdbk 5 Part Acc Mark
Tool Ret Fdbk 4 Part Rej Mark
Tool Ret Fdbk 3 Tool Retract 5
Tool Ret Fdbk 2 Tool Retract 4
Tool Ret Fdbk 1 Tool Retract 3
Unassign Tool Retract 2
Tool Retract 1
Unassign

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Additional Reference Document

For more information on communicating with the instrument using PROFINET, refer to the
PROFINET Programmers Guide. This document file will be located on the USB flash drive that
was provided with the CTS instrument. If you cannot locate this file on the USB drive, it can be
emailed to you. Contact the Cincinnati Test Systems Service department. See the back cover of this
manual for contact information.

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Establishing PROFINET Communication

The communication parameters are in Main Menu > Global Config > Network icon menu. The
first step in establishing communication with a PLC is to set PROFINET to “Enable”. Upon
enabling PROFINET, the instrument will disable EtherNet/IP, and the instrument will reboot.
Upon startup, PROFINET will be functional. In addition, disabling PROFINET will also reboot
the instrument.

CAUTION: When changing the PROFINET setting from “Enabled” to “Disabled”, all of
the user assigned IP Inputs and IP Outputs become Unassigned. This is necessary because
when PROFINET is no longer functional, any I/O that may cause program faults must be
removed. This includes Part Present, External Pressure Switch, etc. This means that all the
user assigned IP Inputs and IP Outputs must be set up again.

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Additional Menus
Turning on this feature will make 2 additional menu icons visible on the Monitor menu screens and
2 additional menu icons visible on the Program Config menu screen.

PROFINET Monitor Screens

As highlighted in below screenshot, Monitor screen will have menu icons named “IP Input” and “IP
Output” for PROFINET inputs and outputs.

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PROFINET Inputs and Outputs

As highlighted in below screenshot, Program Config screen will have menu icons named “IP Input”
and “IP Output” for PROFINET inputs and outputs.

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Chapter 24 – Communication
The instrument is able to communicate over RS232 and/or Ethernet via TELNET.
This chapter explains how to setup communication with the instrument and how to
decode the test results output.

The communication parameters are located in Main Menu > Global Config icon.

RS232 Connector Pinout

The pinout for the RS232 connector, located on the side of the I28, is denoted in the diagram
below. Pins 1, 4, and 6 are internally connected, but are unused by the instrument.

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Establishing RS232 Communication

The RS232 parameters are located in Main Menu > Global Config > RS232 1 or RS232 2. The first step
in establishing RS232 communication with the instrument is to set the RS232 1 or RS232 2 Interface
parameter to “2-way” communication. Next, set the Baud parameter to match the baud rate of the device
that will be communicating with the instrument. The options are: 115200, 57600, 38400, 19200, or 9600
bits per second.

Note: The instrument always uses 8 data bits. The Parity is set to “None”.
The instrument uses 1 stop bit. The flow control is always set to “None”.

Once you have established communication with the desired device you may select whether you want the
instrument to “echo” back each character it receives on the TCP/IP 1 communication port. This setting
is located in the Main Menu > Global Config > RS232 1 icon > RS232 1 Echo or
Main Menu > Global Config > RS232 2 icon > RS232 2 Echo. If the parameter is set to “ON”, the
instrument will output an echo for each character it receives. If this parameter is set to “OFF”, the
instrument will not echo anything.

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CTS DataHub
The CTS DataHub interface is a custom interface designed to work with a QualityWorX CTS
Datahub setup. When CTS DataHub is enabled, the QualityWorX CTS Datahub setup will be able
to communicate with the I28 instrument to capture streaming and result data. This data is stored on
the QualityWorX CTS Datahub setup and allows for engineers and technicians to analyze and report
on a collection of data from your production line.

The CTS DataHub parameter is located in Main Menu > Global Config > Network. When CTS
DataHub is enabled, a new parameter Configuration Key will appear. This parameter is currently
unused.

To setup QualityWorx CTS Datahub, please refer to the QualityWorX CTS Datahub Getting
Started guide.

Establishing Ethernet (TCP/IP) Communication via TELNET

It is highly recommended that you consult with your company’s IT department regarding the configuration
of placing the instrument on any network. You should get the proper settings for the following parameters
from your company’s IT department.

The TCP/IP parameters are located in Main Menu > Global Config > TCP/IP. The first step in
establishing Ethernet communication with the instrument is to set the Obtain Network Settings parameter
to DHCP or Manual (static IP address). If set to “DHCP”, the Instrument IP Address becomes a read only
parameter. If set to “Manual”, then you will need to set the Instrument IP Address manually. You may
choose to let the instrument initially get its settings with DHCP and then change the setting to Manual to
edit the IP Address of the instrument or lock it so that it will not change.

The Mail Server IP Address parameter should be set to the address of the SMTP mail server.

The Subnet Mask parameter will need to be configured next. The most common configuration for this
parameter is “255.255.255.0” unless there is more than one subnet in which case a common configuration
is “255.255.0.0”.

The Gateway IP Address is the default gateway of the network domain.

The MAC Address is the hardware address of the instrument. This number is read-only.

Once you have established communication with the desired device you may select whether you want the
instrument to “echo” back each character it receives on the TCP/IP 1 communication port. This setting
is located in the Main Menu > Global Config > Telnet 1 icon. Select Telnet 1 Echo.
If the parameter is set to “On”, the instrument will output an echo for each character it receives.
If this parameter is set to “Off”, the instrument will not echo anything.

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Understanding the Header Information

All of the information that the instrument sends over the communication ports is preempted by header
information. This data is sent to help parse specific information. This header information is in the format
XXYYZZZ H. The header is followed by a Tab as shown in the table below:

Header Description
XX 8-Bit CRC in HEX. Used for error checking.
Sequence Code in HEX. The value increments
from 01 to FF. This value can be used as a
YY
verification that all data has been received and
nothing was missed by the receiving device.
ZZZ Data length in HEX.
Tab
H Data Type Code. See Data Type Code Table
Tab

Note: For the most up to date Data Type codes, type “TABLE HEADER” into the
instrument using the communication port. The instrument will return a list of about 8
Data Type Codes and descriptions. The table below is an example of the instrument
response.

Data Type Code Description

V Variable Edit
L List
M Message
Q Result List
T Streaming Started
S Streaming Value
X Streaming Stopped
R Result

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Test Results via RS232 or Ethernet (TCP/IP) communications

To see the menu settings described below, the communication interface must be set to “2-Way” and not to
“Barcode”. Depending on which type of communication is being used, these settings are located in:
Main Menu > Global Config > RS232 1 icon > RS232 1 Results, or
Main Menu > Global Config > RS232 2 icon > RS232 2 Results, or
Main Menu > Global Config > Telnet 1 icon > TCP/IP 1 Results.

In order for the instrument to send the test Result Data automatically once the test is complete the parameter
is set to “ON”. Once this parameter is turned on, the Result Field data parameters show on the screen.
Each parameter may be turned on or off depending on the information that is required for to accompany
each result. The Test Field parameter may be set to “All Result Information” or “First 2 Test Results”. The
“First 2 Test Results” will send the two primary results. The table below shows the format of the Test
Result Data.

Number of
Parameter Characters Format Example Text Description of Example
Channel # 4 C## C01 Channel 1
Port # 3 N# N1 Port 1
Program # 4 P## P01 Program 1
Link
4 R-- No Link
Information
Time 13 HH:MM:SS.XXX 16:15:14.123 16 hrs, 15 mins, 14.123 secs
Date 9 MM/DD/YY 40179 02/01/16
Unique Id 11 ########## 0000098353 Unique test number
Program
3 # A Accept
Evaluation
SPC Flag 2 # * SPC Test Data Result
Barcode 41 1…40 12345 Barcode Data
Test Field First 2 Test Results
Pressure Decay-Leak
Test Type 8 ### PLR
Std
Test
2 # P Pass
Evaluation
Test Data Identifier -
Test Data 1 22 TDI Data Unit LR 0.123456 sccm
Value - Unit
Test Data Identifier -
Test Data 2 22 TDI Data Unit LR 0.123456 sccm
Value - Unit
TAB Tab
TAB Tab
CR Carriage Return
LF Line Feed

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Test Field All Result Information

Pressure Decay-Leak
Test Type 8 ### PLR
Std
Test
2 # P Pass
Evaluation
Test Data Identifier -
Test Data 1 22 TDI Value Unit LR 0.123456 sccm
Value - Unit
Test Data Identifier -
Test Data 2 22 TDI Value Unit LR 0.123456 sccm
Value - Unit
| | | | |
Test Data Identifier -
Test Data X 22 TDI Value Unit LR 0.123456 sccm
Value - Unit
TAB Tab
TAB Tab
CR Carriage Return
LF Line Feed

Note: For the most up to date Test Data Identifier Codes, type “TABLE VARIABLE” into
the instrument using the communication port. The instrument will return a list of about 550
Test Data Identifier Codes and descriptions. See the full list in Appendix E.

Note: For the most up to date Test Evaluation Codes, type “TABLE EVALUATION” into
the instrument using the communication port. The instrument will return a list of about 120
Test Evaluation Codes and descriptions. See the full list in Appendix E.

Note: For the most up to date Program Evaluation Codes, type “TABLE RESULT” into
the instrument using the communication port. The instrument will return a list of about 12
Data Program Evaluation Codes and descriptions. See the full list in Appendix E.

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Streaming Measured Data

The instrument has the ability to stream measured data to one of the selected interfaces using RS232,
TCP/IP or USB in real time while the test is being conducted. This data may be collected and used for
analysis. The data is comma delimited. The table below shows the format of the streaming data.

Example
Parameter Format Text Description of Example
Comma
Channel # C## C01 Channel 1
Delimited
Comma
Program # P## P01 Program 1
Delimited
Comma
Segment XXX PRF Prefill Segment
Delimited
Comma TDI Value LR 0.123456 Test Data Identifier - Value -
Test Data
Delimited Unit sccm Unit
TAB Tab
TAB Tab
CR Carriage Return
LF Line Feed

Note: For the most up to date Segment Codes, type “TABLE SEGMENT” into the
instrument using the communication port. The instrument will return a list of about 120
Segment codes and Descriptions. See the full list in Appendix E.

Note: For the most up to date Test Data Identifier Codes, type “TABLE VARIABLE”
into the instrument using the communication port. The instrument will return a list of
about 550 Test Data Identifier codes and Descriptions. See the full list in Appendix E.

Note: Only ONE interface at a time can be selected for live streaming measurement data.

Parsing Data Packets

For users who are trying to parse data packets from the instrument, any line beginning with an asterisk “*”
should be parsed to be ignored, as these lines will not have header information to be parsed. An example
of these types of lines would be the Root menu displayed at instrument boot.

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Reports
The instrument is capable of generating a variety of reports through RS232, Ethernet, Email, or USB
memory port located on the front of the unit. The reports available are in the table below.

Report Description
Reports all of the test results for the current active program. The current
Cur Program Res
program can be seen in the bottom right hand corner of the display.
All Results Reports all of the test results in the instrument memory.
Chan Last 1000 Reports the last 1000 test results.
Chan Last 100 Reports the last 100 test results.
Chan Last 20 Reports the last 20 test results.
Chan Last Res Reports the last test result.
Reports all of the parameters and their settings within the Global Config
Global Config
menu.
Reports all of the parameters and their settings within the Channel Config
Channel Config
menu.
Reports all of the parameters and their settings within the current active
Cur Program Config program. The current program can be seen in the bottom right hand
corner of the display.
Reports all of the parameters and their settings within the Program Config
Program Config
menu.
Reports the Electronic Regulator Calibration data if the instrument is
Regulator Cal
configured with an electronic regulator.
Reports the Transducer Verification data of the last Transducer
Transducer Ver
Verification conducted on the instrument.
Reports the Transducer Calibration data of the last Transducer Calibration
Transducer Cal
conducted on the instrument.
Channel Cntrs Reports all of the counters in the instrument.

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Chapter 25 – CTSnet LT
This chapter explores the basic use of CTSnet LT. CTSnet LT is a PC based
graphical user interface that allows you to control, configure and monitor your
instrument, all from a single, easy-to-use application. Please refer to the quick
start guide on the USB drive included with your instrument for instructions on
installing the application.

Compatibility
CTSnet LT application will require Win 10 OS installed on PC.

Initial Startup
After Setting up your I28 instrument(s) on the network, launch CTSnet LT. Your instrument(s) will
appear on the Module Management screen. You can connect to an I28 by pressing the connect icon
on each available instrument. The connected instrument’s information will turn green to indicate
that it is connected.

Note: The CTSnet LT application can only connect to one I28 instrument at
time.

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Once an I28 instrument is connected, you will be taken to the home menu. From here you can fully
control and configure the I28 instrument to your specifications. This includes running and
monitoring tests and calibration.

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Monitor Screen
Summary Tab
The Summary tab will allow you to start, stop and hold tests. You can select the program being run
by using the drop-down selector. Program calibration, if available for the selected program, can be
performed from this tab as well.

The test can be visually monitored through its stages on the top plot. This plot displays the value of
the primary transducer against elapsed time, as well as marking each phase of the test with color
coordination. The bottom plot will display the value of the Secondary Transducer during the test
phase.

Each plot can be interacted with using the icons to the right of the plot or expanded to fit the screen
with the maximize button in the upper left of the plot.

Plots shown are for demonstration, actual view may differ based upon the selected test type.

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IO Tab
The I/O tab will allow you to monitor each input and output state in real time. This window can be
expanded to fit the full screen by pressing the maximize button on the upper left of the I/O list.

When EtherNet/IP is enabled, the EtherNet/IP IO states will also be displayed here.

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Results Screen
Results Tab
The Results tab displays the allowed number of results and allows for filtering by pressing the filter
button. Results can also be cleared by pressing the delete button.

Filtering Results

You can create filters to sort Result logs.

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Counters Tab
The Counters tab displays the number of cycles performed on the instrument including the number
of accept and reject cycles. These can be cleared to reset statistics.

Statistics Tab
The Statistics tab displays statistical analysis on the results from a selected program. The population
of data can be adjusted using the Stat History Length parameter.

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Configuration Screen
Program Configuration Tab

Selecting Test Types

The test type for the current program can be selected under the Tst Type menu. Refer to Chapter 2
– Setup for options. The drop-down menu at the top of the Program Config tab allows for
configuration of up to 99 programs.

Setting Timers
Navigating to the Timers menu under the Program Config tab will allow you to set the various stage
timers to the desired values. These timers may be preset at CTS for a specific set of test parameters.
Please contact CTS to get information on how to set timers for your specific test. Timers are set per
program and may vary depending on the selected test type.

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Setting Pressure
Navigating to the Pressure menu under the Program Config tab will allow you to set the target
pressure for the selected test, as well as the minimum and maximum constraints for the test to
continue.

Setting Test Parameters

Navigating to the Tst menu under the Program Config tab will allow you to set the constraints of
your test. For example: for a differential pressure decay test, the maximum pressure loss or gain
through the test port may be configured here. Refer to the Test Type Table for setting parameters.

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Miscellaneous settings
Navigating to the Misc menu under the Program Config tab will allow you to enter in a custom
name for the selected program, as well as copy programs from one program to another. Various
other settings, such as Electronic Regulator Control Method (if an electronic regulator is available),
Prefill Method, Pressure Correction and Exhaust Method. Refer to Chapter 28 for setting
parameters.

Hardware Input and Output

Navigating to the HW Input / Output menu under the Program Config tab will allow you to
configure up to 12 inputs and 12 outputs. Refer to Chapter 21 – Inputs and Outputs for setting
parameters.

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Ip Input and Output

Navigating to the Ip Input / Output menu under the Program Config tab will allow you to
configure up to 16 inputs and 16 outputs. Refer to Chapter 21 – Inputs and Outputs for setting
parameters.

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Tooling
Navigating to the Tooling menu under the Program Config tab will allow you to enable or disable
tooling motions. The part present check input may be executed before or after tooling motions.
Refer to Chapter 20 – Tooling Control

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Autorun
Navigating to the Autorun menu under the Program Config tab will allow you to configure
automatic tests, where the selected program will be run a selected number of times.
Refer to Chapter 28 - Autorun for setting parameters.

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Channel Configuration Tab

Hardware Configurations
Navigating to the Hardware menu under the Channel Config tab will allow you to view the factory
settings of your I28 instrument(s).

Self-Test
Navigating to the Self Tst menu under the Channel Config tab will allow you to check your I28
instrument(s) for internal leaks at a set pressure. Refer to Chapter 28 - Self-Test for more
information.

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Setting Units
Navigating to the Units menu under the Channel Config tab will allow you to define units for every
program. Refer to Chapter 2- Setting the Units of Measure for more information and for setting
parameters.

Leak and Calibration

Navigating to the Leak/Cal menu under the Channel Config tab will allow you to set the leak
standard parameters for the I28 instrument(s). Refer to Chapter 2- Setting the Leak Standard Values
for more information and for setting parameters.

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Calibration
Navigating to the Set/Span menu under the Channel Config tab will allow you to run verifications
on the transducers available in the I28 instrument as well as an Atmospheric Pressure Check to
determine the current atmospheric pressure. Calibrations are done by CTS service. Refer to Chapter
2 - Setup for more information.

Miscellaneous parameters
Navigating to the Misc menu under the Channel Config tab will allow you to set the maximum
allowable programs available up to 99 total.

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Global Configuration Tab

RS232 1 and RS232 2

The instrument can perform direct serial communication. Refer to Chapter 24 – Communication for
more information and setting parameters.

Network
Navigating to the Network menu under the Global Config tab will allow you to change the network
parameters for your I28 instrument(s). Please contact your IT department for valid network settings
before making changes and refer to Chapter 24– Communication for more information.

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Telnet Communications
Navigating to the Telnet menus under the Global Config tab will allow you set various parameters
regarding telnet communications. The I28 instrument can support 4 separate telnet channels at once:
Telnet 1, 2, 3 and 4. Refer to Chapter 24 - Communication for more information.

Email Settings
Navigating to the Email menu under the Global Config tab will allow you to create various email
reports. Refer to Chapter 24 – Communication for more information.

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USB settings
Navigating to the USB menu under the Global Config tab will allow you to generate reports onto
the USB device by directly connecting the USB device to the instrument.

Miscellaneous settings
Navigating to the Misc menu under the Global Config tab will allow you to change your I28
instrument’s display name, date, time and user level. Refer to Chapter 28 – Features for more
information and to set parameters.

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Graph
This menu when selected displays following options as per below screenshot.
Show Segment Markers, Graph During and Y Measurement.

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Version
Navigating to the Version menu under the Global Config tab will allow will display version
information about your I28 instrument(s).

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Security
Navigating to the Security menu under the Global Config tab will allow you to set a password for
your I28 instrument(s) as well as secure various features and functions of the instrument(s).

Whenever a secured feature or function is accessed, the user will be prompted to enter the security
password.

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Utilities Screen
Copy Program Tab

The Copy Program tab will allow you to copy any available program to one or more instruments.
1) Select the program you wish to copy from the list of available programs.
2) Select the instruments you wish to copy them to.
3) Select the program you wish to overwrite with the copied program and press Copy

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Cal Reports Tab

Navigating to the Transducer Calibration menu under the Cal Reports tab will allow you to view the
Transducer calibration/Verification and Electronic regulator Calibration results for all available
transducers.

Update Firmware Tab

This tab will allow you to update instrument firmware. Browse for and choose the firmware file and select
the device in which an update needs to be performed. Click on the Update button. The instrument firmware
will get updated and device will reboot. Please contact CTS to get more information on this.

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Backup/Restore Tab
This tab will allow you to create instrument backup of all settings, restore an instrument back up file, create
a backup file of all programs, restore a backup file of all programs as shown in below screenshots.

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Export Screen
The Export section will allow you to export a various results as .txt files.
You can also export System Debug Log to send to CTS for service needs.

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Users Screen
Pressing the user icon on the bottom left of the screen will display a log of user actions along with a
description of the action. This log can be filtered by pressing the filter icon, exported by pressing the
export icon or deleted by pressing the delete icon.

Filtering User Log

You can create filters to sort user logs.

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Exporting User Log

When exporting the user log, select a folder to export to, the number of entries and the output
format.

Deleting User Log

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Chapter 26 – Webserver
The instrument provides a rich web server to control and configure the instrument.
The Web Server can be used to display and update configuration, backup/restore
instrument configurations, upgrade instrument firmware, and navigate remotely.

System Requirements
To use the Web Server, you must have the following:
• a TCP/IP-based network
• a web browser installed on your computer, preferably either Google Chrome 60.0X or
Microsoft Internet Explorer 11.0X and above
Note: The web server can be accessed from any operating system that supports the
TCP/IP protocol and a web browser. You cannot view the embedded web server pages
from outside a firewall.

Viewing the Web Server

Launch your web browser. In the Address or Go to field, type the IP address assigned to the
instrument (for example: http://192.168.1.1). For more details on setting up the IP address on the
instrument, refer to Chapter 24 - Communication.

Home Page
The top section will always display the Identity information (Instrument name, Firmware Version,
Serial number, and MAC address) of the instrument. The Home page is shown in Figure 1.

Figure 1 Web page - Login Page

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Web Server Login

Once you click Login, the web server will prompt you for a User Name and Password. You must
login with the appropriate username and password to access the webserver features. For more
details on security, please refer to Chapter 27 - Security.

Figure 2 Security login

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Navigation - Web Server

The left section lists all available menus. Clicking a menu in the left section will update the right
section with content for the selected menu.

Figure 3 Web Page - Main Page

The Channel config page allows you to configure Channel Config parameters for the instrument.

Figure 4 Web Page - Channel Config

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The Global config page allows you to configure Global Config parameters for the instrument.

Figure 5 Web Page - Global Config

The Program config page allows user to configure Program Config parameters for the selected
program. To select a program, move the cursor onto “Program Config” menu. This will display
available slots in the instrument i.e. 1-9, 10-19, 20-29, 30-39, 40-49, 50-59, 60-69, 70-79, 80-89, 90-
99. Hold the cursor on 1-9 slot to display list of programs under it. Select the required program.
Information for this program will be displayed. This same technique can be used to select and
configure any other available program.

Figure 6 Web Page - Program Config

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The Reports menu allows user to generate a various Reports for the instrument. Click Reports
menu so display Test Results, Report Configuration and Log Reports tab. As per below screenshots,
expand individual tabs to display available report selections. User can choose any report and view
information as required.

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Figure 7 Web Page - Reports

The Navigation page gives user a similar user interface to the one available on the front display of
the instrument.

Figure 8 Web Page - Navigation

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The Backup Restore page allows user to generate a backup file of all the Program Configuration
settings and Restore any previously generated backup file.

Figure 9 Web Page - Backup/Restore

The Firmware Update page allows user to update the instrument’s main controller firmware, co-
processor firmware, IO-Board firmware.

Figure 10 Web Page - Firmware Update

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Parameter Configuration via Web Server

User can edit parameters listed on the right section of webpage. Once the value of any editable
parameter is changed, the updated value gets displayed with background color “Yellow.” “Edit in
progress, Please wait…” message is displayed to the user.. After some time the message
disappears and the changed parameter is displayed with white background.

Figure 11 Web page - Editing parameters

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This page is intentionally blank.

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Chapter 27 – Security
This chapter explains the instrument security parameters. The Security menu allows flexibility in
allowing access or locking functions with a password.
It is located in Main Menu > Global Config menu. The Security icon may be hidden. To make the
Security icon visible, the setting is located in Main Menu > Global Config > Misc icon. Select
Edit/View Security, press Enter, use arrows to select “On”, and press Enter. You will be taken to the
Security menu. The Security icon is now visible at the bottom of the Global Config screen.
When the instrument is secured with any of the settings in the Security menu, a password is required to
unlock that function of the instrument. The default password is “5555”. Anyone with access to this
manual will know the default password. To secure the instrument, the password must be changed.
Remember to write down the new password. If the new password is forgotten, Cincinnati Test Systems
Service department can provide a temporary password to unlock the instrument.
The table below describes all of the settings in the Security menu.
Parameter Description Display User Level
Edit allows setting a new password after entering the Basic
Change Password
old password. Advanced, Admin
Applies security to performing a program Basic
Secure Calibration
calibration. Advanced, Admin
Secure Select Applies security to changing test programs by Basic
Program pressing Change Program buttons. Advanced, Admin
Secure Program Basic
Applies security to changing test part parameters.
Config Advanced, Admin
Secure
Applies security to changing instrument Basic
Global/Chan
configuration parameters. Advanced, Admin
Config
Applies security to clearing test Result Data from Basic
Secure Clear Data
instrument. Advanced, Admin
Applies security to clearing the counter registers Basic
Secure Reset Cntrs
from instrument. Advanced, Admin
Secure Hold Basic
Applies security to hold function.
Function Advanced, Admin
Applies security to protect releasing the part on a
Secure Reject Basic
reject. This security option only works if Retract on
Release Advanced, Admin
Reject is set to “No” in the program Tooling menu.
Applies security to the Monitor screen. If set to
Secure Monitor “Yes”, the user will be unable to view any other Basic
Screen screens other than the last Monitor screen viewed Advanced, Admin
before being secured.
Allows the user to save a backup and/or restore
Basic
Backup/Restore various instrument settings. Note: The manifold
Advanced, Admin
code must match to restore channel settings.

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Note: The security feature is not applicable to commands over Serial, Telnet, EtherNet/IP
and Digital I/O.

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Chapter 28 – Features
This chapter explains essential features of the instrument.

Selecting the Display User Level

There are three user levels in the instrument. This is done to minimize the number of items shown on the
screen for basic users. More advanced users requiring more features may view these by changing this
parameter to the appropriate setting. Throughout the manual the parameter tables have denoted the Display
User Level required for viewing and editing access. The Display User Level is located in
Main Menu > Global Config > Misc icon. The three levels are “Basic”, “Advanced”, and “Admin”.

Suggestion: Set the Display User Level to the most basic level for your requirements.
Parameters may be locked from editing using Security, see Chapter 27 – Security.

Setting the Date & Time

The Date and Time parameters are located in Main Menu > Global Config > Misc icon. The date and
time are set at the factory. If you are in a different time zone, it may be desirable to change the date and
time on the instrument. The date format can be modified with the Date Format parameter. The time
format is 24 hour and cannot be changed.

Changing the Instrument Language

The instrument is a multi-language instrument and may be modified. The language setting is located in
Main Menu > Global Config > Misc icon.

Note: The instrument must be in Advanced or Admin Display User Level to view and
modify the instrument Language. To change the Display User Level, see Chapter 28–
Features.

Copy & Paste Programs

To simplify the setup, the instrument comes with the ability to copy all of the parameters from one program
to another program. Copy Program is located in the Main Menu > Program Config > Misc icon of the
program you want to copy. Select the Copy to Target Prog parameter and press Enter. Increment or
decrement the target program number where you want to “paste” the program and press Enter. Then,
change the Copy Program parameter to “Yes” and press Enter.

Note: The copied program will overwrite all parameters in the target program. Make
sure you want to overwrite this program before executing. If a program exists in the
target program number, the instrument will prompt to confirm that you want to continue.

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Instrument Backup & Restore

The Backup and Restore function of the instrument is a feature that allows the instrument to create a
backup file on a (FAT32) USB memory stick. This can be used to restore the instrument back to its
current state. There is no limit to the number of backup files you can have for an instrument. The files
are named using the following format: YYMMDD_I28_SERIALNUMBER_NUMBER. Backup files
are stored in a subfolder named Backup-Restore.

Note: The NUMBER at the end of the backup filename will increment for each backup
of the instrument saved on the same day.

To execute this function, press the USB button on the user interface of the instrument (or press Main
Menu > Global Config > USB icon). Move the cursor down to the Backup/Restore parameter. Make
sure a USB memory stick is placed in the USB port on the front of the instrument. Press Enter to activate
the edit function and select “Backup Instrument”. When it is complete a pop-up window will tell you it
was successful.

Instrument Cloning
This function should only be executed under the advice of CTS personnel. This feature is used for service
and support of our products. It enables a technician to replicate the exact instrument within our facility to
help with any questions or concerns. To execute this function, press the USB button on the user interface
of the instrument (or press Main Menu > Global Config > USB icon). Move the cursor down to the
“Backup/Restore” parameter. Make sure a USB memory stick is placed in the USB port on the front of
the instrument. Press Enter to activate the edit function and select “Instr Clone”. When it is complete a
pop-up window will tell you it was successful.

Adjusting the Light Bar Control

Light Feature Control is located in Main Menu > Global Config > Misc icon. The LED Light Bar on
the front of the instrument has four options. It can be set to “Always On”, “Always Off”, “3 Seconds On”
or “3 Sec ACC/REJ”. The “3 Seconds On” setting refers to all lights, including the white light during the
test cycle (if the test cycle is longer than 3 seconds). The “3 Sec ACC/REJ” refers to just the green/red
Accept/Reject light after a test is completed.

The Light Feature Brightness parameter, on the same menu, may be adjusted to 20%, 40%, 60%, 80%, or
100% of maximum brightness.

Open Internal Leak Standard

The instrument may be configured with one or more internal leak standards. Internal leak standard valves
may be manually forced open during a test to simulate a leak in the test circuit. Open Leak Std is located in
Main Menu > Channel Config > Leak/Cal icon.

Note: If the instrument is configured with an internal leak standard(s), the instrument
automatically introduces the leak standard during the appropriate segments of a Program
Cal routine.

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Selecting the Proper Internal Leak Standard

If the instrument is configured multiple internal leak standards the user must select which leak standard is
to be used in the Program. Leak Std Select is located in Main Menu > Program Config > Misc icon.
The Leak Std Select parameter defines which leak standard is used. This must be set for each program
utilized.

Self-Test
The Self-Test diagnostic provides a way to check the integrity of the instrument’s pneumatic circuit. This
is a great way to isolate a potential leak by allowing the user to verify the instrument is working correctly.
By isolating the instrument from the test part and the external tooling and plumbing, this special test will
verify that the instrument is performing properly and leak free.

The Self-Test diagnostic is located in Main Menu > Channel Config > Self-Test icon.

Parameter Description Display User Level

Enter the pressure setting of the pressure source Basic
Self-Test Pressure
chosen to use for the Self-Test diagnostic routine. Advanced, Admin
Specifies the pressure source to utilize for the Self- Basic
Self-Test Source
Test diagnostic routine. Advanced, Admin
The instrument performs two levels of Self-Test.
Level 1 is a general integrity test of the pneumatic Basic
Self-Test Level
circuit. Level 2 is more stringent and should be Advanced, Admin
used when testing for low leak or flow rates.
Basic
Start Self-Test Starts the diagnostic routine.
Advanced, Admin

Note: It is important that all test ports are plugged during a Self-Test. The instrument
will multiplex through the test ports to verify all circuits are operating leak free.

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Update Firmware
The instrument is able to update the firmware using the USB port on the front of the instrument. Upon a
proper Service request, a firmware update can be sent by an authorized CTS person by email for transfer to
a (FAT32) USB memory stick. The file sent will be saved as a ZIP file. Extract the ZIP file to the root
directory of the USB memory stick. This step creates the proper folder structure on a USB memory stick.
Safely remove the USB memory stick from your computer and insert the stick into the USB port on the
front of the instrument. Press the USB button on the user interface. Change the parameter “Update
Firmware” to “Yes” to start the update process. The instrument will list all of the firmware version files on
the screen. Select which file you want to use. This will start the update process.

Note: If the firmware version is a minor revision all of the parameter settings will be kept
the same. However, if the firmware version is a major revision all of the settings will be
cleared. See the firmware documentation to determine if the firmware version you are
upgrading from will cause the settings to be cleared. To be safe, always perform a Backup
Instrument and Instr Clone before updating firmware.

Changing the Functionality of the Prefill Timer

The Prefill timer function is located in Main Menu > Program Config > Misc icon. The parameter is
called Prefill Method. It can be set to “Percent of Fill Time”, “Not to Exceed Time”, “Controlled Fill” or
“Fixed Charge”.

When the Prefill Method is set to “Percent of the Fill Timer”, which is the default value, the Minimum
Pressure must be met before the value in the Prefill is exhausted. For example, if the Fill Timer is set to 10
seconds and the Prefill Timer is set to 80% then the part must reach Minimum Pressure within 8 seconds.
This allows for fixed fill times to be utilized.

When the Prefill Timer is set to “Not to Exceed Timer”, the instrument will begin the cycle in the Prefill
segment. Once the pressure reaches the Minimum Pressure, the instrument will exit the Prefill segment,
regardless of any time remaining, and enter the Fill segment.

When the Prefill Method is set to “Controlled Fill”, the instrument will begin the cycle in the Prefill Segment
and will ramp up the pressure from 0 to the target pressure within the specified Prefill timer. When
instrument enters the Fill segment the instrument is at target pressure.

Note: “Controlled Fill” method is available only when Electronic regulator is present in
the instrument.

When the Prefill Method is set to “Fixed Charge”, the instrument begins the cycle in the Charge Segment
and charge the pneumatic with desired “Charge Target Press”. At the end of charge timer pressure must
reach “Charge Min Press” and below “Charge Max Press”. Once successfully exited from the charge
segment, the instrument will start to fill the part with the charged pneumatic volume.

Exhaust Method
The Exhaust Method parameter is located in Main Menu > Program Config > Misc icon. It can be
set to “Dump” or “Controlled Exhaust”.

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When the Exhaust method is set to “Dump”, which is the default value, the instrument will open the
Exhaust valve and dump the pressure immediately after entering the Exhaust segment.

When the Exhaust Method is set to “Controlled Exhaust”, when the instrument enters the Exhaust
segment, the instrument will start ramping down the pressure from the last noted instrument pressure to 0
within the specified Exhaust timer. At the end of the Exhaust timer, the instrument will open the Exhaust
valve and dump any remaining pressure.

Note: “Controlled Exhaust” method is available only when an Electronic regulator is

present in the instrument.

Saving a Barcode with Results

Note: The instrument must be in Advanced or Admin Display User Level to view and
modify the communication port functionality. To change the Display User Level, see
Chapter 28– Features.

The instrument has the capability to store barcode data with each test result. The instrument will work with
any RS232 barcode scanner that has the ability to supply a barcode in an ASCII string (no longer than 40
characters) followed by a carriage return. To store the barcode information, it must be received before a
Start command is received by the instrument. There is an option to require the barcode data in order for
the Start command to be acknowledged.

The Barcode function is located in Main Menu > Global Config > RS232 1 icon > RS232 1 Interface
or Main Menu > Global Config > RS232 2 icon > RS232 2 Interface. Set the parameter to “Barcode”.
In the same menu, set the RS232 1 or RS232 2 Baud parameter to match the baud rate of the barcode
scanner communication.

Note: The data bits are always configured to 8. The parity is always set to None. The
number of stop bits is always set to 1. The flow control is always set to None.

If a barcode is required before a start signal is acknowledged, this parameter is located in

Main Menu > Program Config > Misc icon. Set the Barcode Required parameter to “Yes”.

Holding Pressure in the Part after Test (No Exhaust)

In some applications, it is desirable to keep the pressure in the part after the test sequence is complete.
Retain Part Press is located in Main Menu > Program Config > Misc icon. Set the Retain Part Press
parameter to “Yes”. The instrument will retain the pressure until either the part is removed from the sealing
fixture or a Stop signal is initiated.

Note: The instrument must be in Advanced or Admin Display User Level to view and
modify this functionality. To change the Display User Level, see Chapter 28– Features.

Changing the Functionality of the Prefill Timer

The Prefill timer function is located in Main Menu > Program Config > Misc icon. The parameter is
called Prefill Method. It can be set to “Percent of Fill Time” or “Not to Exceed Time”.

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When the Prefill Timer is set to “Percent of the Fill Timer”, which is the default value, the Minimum
Pressure must be met before the value in the Prefill is exhausted. For example, if the Fill Timer is set to 10
seconds and the Prefill Timer is set to 80% then the part must reach Minimum Pressure within 8 seconds.
This allows for fixed fill times to be utilized.

When the Prefill Timer is set to “Not to Exceed Timer”, the instrument will begin the cycle in the Prefill
segment. Once the pressure reaches the Minimum Pressure, the instrument will exit the Prefill segment,
regardless of any time remaining, and enter the Fill segment.

Turning On/Off Pressure Correction

In several test types the instrument uses pressure correction to enhance the performance of the instrument.
There are times where pressure correction may not be desirable. For these cases, the instrument has the
ability to select whether or not pressure correction is used. This is located in the
Main Menu > Program Config > Misc icon on the. Change the Pressure Correction parameter to the
desired setting.

Setting the Cal Method and Leak Standard Location

The Cal Method parameter is located in the Main Menu > Channel Config > Leak/Cal icon when
the Leak Standard is set to “Channel”. The Cal Method parameter is located in the Main Menu >
Program Config > Misc icon when the Leak Standard is set to “Program”.

Select Description Explanation

Parameter
One Part – Automatic test cycling Automatically tests same non-leaking master part twice;
Int. LS using Leak Standard the second time using a calibrated leak standard
located inside the mounted on the internal manifold. .
instrument
One Part - Manual testing of same Tests same non-leaking master part twice; the second
Ext LS part using Leak time using calibrated leak standard provided externally
Standard provided from the instrument. The instrument will prompt the
outside the instrument operator to attach the leak standard when it is time.
Multi-Part Manual testing of two Tests two different non-leaking master parts using the
– Int. LS parts using a Leak calibrated leak standard mounted on the internal
Standard located inside manifold. Any tooling must retract between tests to
the instrument change parts. A Start signal is required either by the
user interface or remotely using programmed start test
logic to initiate the second test after changing non-
leaking master parts.

This table is continued on the next page.

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Select Description Explanation

Parameter
Multi-Part Manual testing of two Tests two different non-leaking master parts using the
– Ext LS parts using Leak calibrated leak standard provided externally from the
Standard provided instrument. Any tooling must retract between tests to
outside instrument change parts. A Start signal is required either by the
user interface or remotely using programmed start test
logic to initiate the second test after changing non-
leaking master part with leak standard.

Autorun
Sometimes it is desired to have the instrument cycle automatically without any need for a person to press
the Start button or send a start signal using the digital inputs. The Autorun feature is designed to
accomplish this. Autorun is located in Main Menu > Program Config > Autorun icon. The following
menu will display on the screen.

Parameter Description Display User Level

The amount of time the instrument pauses in
Autorun Relax Advanced, Admin
between cycles.
There are two options for this parameter.
"Standard" which runs a normal leak test every
Autorun Method Advanced, Admin
cycle or "LS on 3rd" which opens the internal leak
standard (if supplied) every 3rd cycle.
The number of cycles left in the Autorun sequence.
Autorun Cycle
This parameter is used to determine how many Advanced, Admin
Count
cycles are conducted in an Autorun.
When this parameter is set to "Yes" a start
Autorun Enable Advanced, Admin
command will initiate the Autorun sequence.

Malfunction evaluation as Reject

Malfunction Eval is located in Main Menu > Program Config > Misc icon with the options of
Malfunction and Reject. Malfunction evaluation options allow the user to configure all the malfunction
messages, including all program calibration malfunctions messages either as Malfunction (Yellow color) or
as Reject (Red color) per setting. The digital outputs operation changes as follows: “Malfunction” and
“Program Reject”, both outputs will go high if Malfunction Eval is set as Reject.

Batch Calibration
The Batch Calibration feature allows multiple calibration sequences to be performed. Results are averaged
to calculate the final calibration values. The Batch Calibration parameter is located in the Main Menu >
Program Config > Leak/Cal icon and allows for enabling or disabling of batch program calibration
mode. When enabled, three more parameters “Batch Layout”, “Batch Quantity” & “Average Quantity”
are visible to user.

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Parameter Description Display User Level

Defines the layout of batch calibration. When Batch
Layout is set to “Alternating”, which is the default
value, the instrument performs the first ‘Master’
calibration, then the first ‘Master+Leak’ calibration,
then alternates between the two for the remaining
Batch Layout Advanced, Admin
batch quantity.

When Batch Layout is set to “Grouped”, the

instrument first performs all ‘Master’ calibrations,
then all ‘Master+Leak’ calibrations.
Defines the number of calibration sequences in the
Batch Quantity batch. Minimum value is 2 and maximum value is 25. Advanced, Admin

Defines the number of calibration sequences utilized

to average calibration data out of Batch quantity. The
Average Quantity Advanced, Admin
value must be less than or equal to Batch Quantity.

Prefill Pressure Check

Prefill Pressure Check is located in Main Menu > Program Config > Misc icon with the
options of Enabled and Disabled. Prefill pressure check determines the prefill pressure monitoring.
When enabled, the instrument monitors the pressure during Prefill time. When disabled, the instrument
skips the pressure monitoring during Prefill time.

Note: This parameter is only available if the Prefill Method selected is “Percent of Fill
Time” or “Pre-Pressure Time”.

Valve Detection
Valve Detection is located in Main Menu > Channel Config > Hardware icon with the options
of Enabled and Disabled. This feature, when enabled, allows the instrument to monitor for the
presence of pneumatic valves via electronic load detection.

Note: This parameter is only available for viewing, and the user cannot change the
settings.

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Chapter 29 – Instrument Calibration

This chapter explains the Set/Span parameters for the pressure transducer, flow
transducer, and electronic regulator.

Note: Your instrument may not have a flow transducer or an electronic regulator.

These parameters are located in Main Menu > Channel Configuration > Set/Span icon.

Verifying a Transducer
The transducer verification process is very similar to the calibration process. You must enter the external
master gauge value at each point to step through the sequence. You will be prompted to input values so the
Transducer Verification Report has this data for later review. This feature does not affect the calibration
of the instrument.

Note: A Transducer Verification Report may be downloaded from the instrument if

desired. See the Reports section on the last page of Chapter 24 - Communication.

Calibrating a Transducer
The transducers have been calibrated at the factory. A calibration of the transducer should be done
periodically according to the quality standards at your facility. The instrument is capable of doing a multiple
point calibration. The number of points is determined by the user. You may select up to 32 points for
calibration. You will need a calibrated master pressure gauge to calibrate the transducer on the instrument.
On the Set/Span menu select which transducer you want to calibrate. Press Enter to enable the edit
function. Change the value to “Yes”. The following menu will display on the screen.

Transducer 1 Cal Menu (Pressure)

Parameter Description Display User Level
The number of setpoints to be used for the
Basic
Number of Points transducer calibration procedure. Value must be 2
Advanced, Admin
to 32.
The user is able to define the setpoints at which the
Setpoints calibration occurs. The number of setpoints shown Basic
2 – 32 is based on the number of points selected in the Advanced, Admin
parameter above.
The maximum allowed linearity variance for a Basic
Linearity Limit
successful calibration. Advanced, Admin
Commences the calibration procedure. A wizard Basic
Start Calibration
will walk you through the calibration process. Advanced, Admin

Note: A Transducer Calibration Report may be downloaded from the instrument if

desired. See the Reports section on the last page of Chapter 24 - Communication.

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Transducer 3 Cal Menu (Flow)

Parameter Description Display User Level
The number of setpoints to be used for the
Basic
Number of Points transducer calibration procedure. Value must be 2
Advanced, Admin
to 32.
Determines whether one pressure value is utilized
for all setpoints or if individual pressure values are Basic
Pressure Mode
used for each setpoint when calibrating or verifying Advanced, Admin
the transducer.

This parameter is only visible if Pressure Mode is

set to "Multi Pressure”. The user is able to define
Setpoints Basic
the setpoints at which the calibration occurs. The
2 – 32 Advanced, Admin
number of setpoints shown is based on the number
of points selected in the parameter above.

This parameter is only visible if Pressure Mode is

set to "Single Pressure”. It is the desired pressure Basic
Cal Pressure
for all setpoints when calibrating or verifying the Advanced, Admin
transducer.

Allows the instrument to perform measurement

corrections when calibrating or verifying the Basic
Pressure Correction
transducer based on the relationship between the Advanced, Admin
setpoint pressure and the actual measured pressure.

The maximum allowed linearity variance for a Basic

Linearity Limit
successful calibration. Advanced, Admin
Commences the calibration procedure. A wizard Basic
Start Calibration
will walk you through the calibration process. Advanced, Admin

Note: A Transducer Calibration Report may be downloaded from the instrument if

desired. See the Reports section on the last page of Chapter 24 - Communication.

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Calibrating an Electronic Regulator

The electronic regulator has been calibrated at the factory. The instrument is capable of doing a multiple
point calibration. The number of points is determined by the user. You may select up to 20 points for
calibration. You will need a calibrated master pressure gauge to calibrate the electronic regulator on the
instrument. On the Set/Span menu select which electronic regulator you want to calibrate. Press Enter to
enable the edit function. Change the value to “Yes”. The following menu will display on the screen.

Parameter Description Display User Level

The number of setpoints to be used for the
Basic
Number of Points electronic regulator calibration procedure. Value
Advanced, Admin
must be 2 to 20.
The user is able to define the low voltage for the
Low Limit Voltage Admin
calibration process.
The user is able to define the high voltage for the
High Limit Voltage Admin
calibration process.
Commences the calibration procedure. A wizard Basic
Start Calibration
will walk you through the calibration process. Advanced, Admin

Note: The Low Limit Voltage and High Limit Voltage values are disregarded if both are
set to “0” (zero is the default setting). You should only change these values if the
instrument is not able to automatically analyze the electronic regulator range and perform
a proper calibration.

Note: The electronic regulator can remain active in between instrument test cycles or it
can be set to “Idle”. This parameter is edited by going to Channel Config and selecting
the Hardware icon. The parameter is called “E-Regulator Rest” and is available in Basic
Display User Level. To change the Display User Level, see Chapter 28 – Features.

Note: An Electronic Regulator Calibration Report may be downloaded from the

instrument if desired. See the Reports section on the last page of Chapter 24 -
Communication.

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Chapter 30 – Monitor Screen Examples

This chapter is a quick reference for the screens that display at power on and
when running the various tests established for your requirements.

Monitor Screen Examples

These screens are available by using the right arrow on the Arrow/Enter Navigation buttons.

Screen 1: Monitor 1 highlights the numerical pressure reading:

Screen 2: Monitor 2 highlights the location of the reading from the Min to the Max
allowable pressure:

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Screen 3: Graph highlights the pressure as it relates to time:

Note: You can zoom/adjust the graph by pressing the Enter button.
A menu will display on the right side of the screen. Additional graph
screen parameters are located in Main Menu > Global Config > Graph
icon.

Screen 4: Hardware Input highlights which of the possible 12 inputs are engaged:

Screen 5: Hardware Output highlights which of the possible 12 outputs are engaged:

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Screen 6: IP Input highlights which of the possible 16 inputs are engaged:

Screen 7: IP Output highlights which of the possible 16 outputs are engaged:

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Chapter 31 – Results Screen Examples

This chapter is a quick reference for the screens that display when running the
various tests established for your requirements. These are examples; your screens
will display similar but different data.

Result Data Screens

Counters Screen

Results screen

Stats Screen

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– Messages & Error

Codes
This appendix is a quick reference for the messages and error codes that display
on the screen and through the communication ports.

Test Messages & Errors

Note: For the most up to date Test Message and Error Codes type “TABLE
EVALUATION” into the instrument using the communication port. The instrument will
return a list of Data Type Codes and descriptions. (This table contains the same list of
codes found in the 3rd table of Appendix E.)

Message Code Description Corrective Actions

Program evaluation was successful, for
Program Accept A
multiple tests – all tests passed.
Auto Setup Seq
AC The Auto Setup Sequence is complete.
Complete
Program The test type is one that is capable of
Calibration AF conducting a program calibration and this
Failed sequence was not successful.
The test type is one that is capable of
Master Part
AM conducting a program calibration. The first
Complete
phase of the sequence is complete.
Program The test type is one that is capable of
Calibration AP conducting a program calibration and this
Passed sequence was successful.
The two inputs must
The two inputs (Start and Common) are go high within 0.05
Error: Anti-Tie- not held high during all of the “extend” seconds and be held
AT
Down tooling motions. There is no resultant high until the end of
output. all extend tooling
motions.
Check barcode reader
The instrument was expecting a barcode
wiring and
value to be received over the RS232 port.
Error: Barcode functionality. Make
BR The Barcode Required parameter was set to
Req to Start sure the Baud Rates
“Yes”, which requires a barcode before a
are set properly within
start command is enabled.
the instrument.

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Message Code Description Corrective Actions

During the Program Cal routine, the Increase the
Master+Leak instrument measured a greater pressure loss stabilization and
Loss<Master C1 for the master part by itself than for the possibly test time.
Loss master part with the leak in the second test. Verify the leak
This results in a Malfunction. standard.
Check the seals and
The pressure loss during the first test of master part for leaks,
Master Part
Program Cal on the master part exceeded or extend stabilization
Loss>Max C2
the Max Mstr+Leak Loss setpoint. This timer. Check that
Mstr+Leak Loss
results in a Malfunction. Max Mstr+Leak Loss
was correctly set.
Check the seals and
master part for leaks,
The pressure loss during the second test of or extend stabilization
Master +Leak
Program Cal on the master part exceeded timer. Check to leaks
Loss>Max C3
the Max Mstr+Leak Loss setpoint. This about leak standard.
Mstr+Leak Loss
results in a Malfunction. Check that Max
Mstr+Leak Loss was
correctly set.
Check the seals and
The flow value during the first sequence of master part for leaks,
Master
Program Cal on the master part exceeded or extend fill or test
Flow>Max C4
the Max Mstr+Leak Flow setpoint. This timers. Check that
M+L Flow
results in a Malfunction. Max Mstr+Leak Flow
was correctly set.
Check that the Min
Master Flow setpoint
Master was set correctly.
The master flow value was less than the
Flow<Min C5 Verify the test line is
Min Master Flow setpoint.
Master Flow connected to the test
port and not the
Self-Test cap.
Check the seals and
master part for leaks,
The flow value during the second sequence
Master+Leak or extend fill or test
of Program Cal on the master part
Flow>Max C6 timers. Check the leak
exceeded the Max Mstr+Leak Flow
M+L Flow standard. Check that
setpoint. This results in a Malfunction.
Max Mstr+Leak Flow
was correctly set.
Check the seals and
The flow value during the first sequence of master part for leaks,
Master
Program Cal on the master part exceeded or extend fill or test
Flow>Max C7
the Max Master Flow setpoint. This results timers. Check that
Master Flow
in a Malfunction. Max Master Flow was
correctly set.

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Message Code Description Corrective Actions

Check the seals and
master part for leaks,
The flow value during the second sequence
Master+Leak or extend fill or test
of Program Cal on the master part was less
Flow<Master C8 timers. Check the leak
than the measured Master Flow value. This
Flow standard. Check that
results in a Malfunction.
Max Master Flow was
correctly set.
The pressure loss reading during the first
Master test of Program Cal cycle for a pressure
Check for blockage in
Loss<Min C9 decay test was less than the Min Master
the test line of part.
Master Loss Loss setpoint. This results in a
Malfunction.

Cal Program
CA The Program Calibration was successful.
Accept

This result occurs from illegal program

configurations, calculation errors when
Calculation
CE trying to convert vacuum pressures to
Error
positive pressure readings, and other
occurrences.

Cal Required -
CF Not Used.
Limit Exceeded

Check that the

Minimum
The Performance Factor calculated at the
Min Perf Factor Performance Factor
CM end of Program Cal exceeds the Minimum
Error was correctly set.
Performance Factor set in the Test Factors.
Increase stabilize and
test timers.
The stabilization or test timers, target
Calibration pressure, Leak Std Flow, or Leak Std
Recalibrate the
Required- Pressure have been changed since the last
CP instrument for this
Parameters calibration and therefore the part needs to
program.
Changed be recalibrated. There is no output
resultant.
Cal Program The Program Calibration was not
CR
Reject successful.
DP Transducer
DF Not Used.
Fault

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Message Code Description Corrective Actions

DP Transducer
DO Not Used.
Over Range
DP Transducer
DZ Not Used.
Zero Bad

Elec Regulator The Electronic Regulator Calibration was

EC
Cal Complete successful.
Check the wiring of
the electronic
Elec Regulator The Electronic Regulator Calibration was regulator. Check that
EE
Cal Error not successful. the entry of each
pressure calibration
point was correct.
Part Evac Fault EF Not Used.
There was an error with the program.
Prog Error EP
Please contact the CTS Service department.

System Error - There was an error with the instrument.

ER
Service Req Please contact the CTS Service department.

The flow transducer measured a value out

Flow
of its range. The instrument stopped the
Transducer FO
test sequence to prevent damage to the
Over Range
sensor.

The flow sensor measured a value out of its

Error: Excessive
FX range. The instrument stopped the test
Flow
sequence to prevent damage to the sensor.
Check the flow sensor
The flow transducer was not sending the
Flow wiring. If this
proper voltage. The instrument checks to
Transducer Zero FZ happens multiple
make sure that the flow transducer is within
Bad times, replace the flow
range before the test sequence begins.
sensor.
Helium
Background HF Not Used.
Fault
The calibration data has been corrupted or
Invalid
ID not properly entered. Please calibrate the
Calibration Data
unit again.

I/O Fault IF Not Used.

Invalid I/O
IO Not Used.
Configuration

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Message Code Description Corrective Actions

Invalid Program The program selected does not exist or has Check BCD Input
IP
Selected not been configured. programming.
The same child program cannot be in the
Error: Duplicate same link structure. If it is desired to
LD
Target Link conduct the same test twice you will need
to copy the program.
The pressure loss reading during the first
Master
test of Program Cal cycle was greater than
Loss>Max L0
the Max Master Loss setpoint. This results
Master Loss
in a Malfunction.
Master+Leak
The pressure loss value during the second
Loss<Min
sequence of Program Cal on the master
Master+Leak L1
part was less than the Min Master +Leak
Loss
Loss setpoint. This results in a Malfunction

Measured Leak Loss of Program Cal was

Leak Loss<Min
L2 less than Min Leak Loss setpoint. This
Leak Loss
results in a Malfunction.

Measured Leak Loss of Program Cal was

Leak Loss >Max
L3 greater than Max Leak Loss setpoint. This
Leak Loss
results in a Malfunction

The flow value during the second sequence

Master+L Flow
of Program Cal on the master part was less
<Min Master+L L4
than the Min Master+Leak Flow setpoint.
Flow
This results in a Malfunction.

Measured Leak Flow of Program Cal was

Leak Flow<Min
L5 less than Min Leak Flow setpoint. This
Leak Flow
results in a Malfunction.

Measured Leak Flow of Program Cal was

Leak Flow>Max
L6 greater than Max Leak Flow setpoint. This
Leak Flow
results in a Malfunction

Leak Std Select Configuration Error. The instrument was

LE
Config Error not configured properly.
Check programming
Error: Link There was an error in the Linking
LL of the Parent/Child
Execution Loop Execution.
Structures.

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Message Code Description Corrective Actions

Error: No Links The instrument was expecting a link that
LN
Defined did not exist.
When the instrument conducts a Program
Calibration sequence on linked programs,
Error: Dissimilar
LO the links must execute in the same order for
Link Order
both the first and second sequences for
Program Calibration.
Error: Link
Program is LP A Parent Program may not be a link target.
Parent
Error: Link Prog
LU The linked program is undefined.
Undefined
Check operation of
the part marker.
Check wiring of the
Error: Part Mark The part mark feedback input did not
MF feedback input.
Fault receive the input in time.
Check wiring of the
valve to fire the part
marker.
No Event In a test that is looking for an event, this is
NE
Occurred the result when one does not occur.
Check pressure
regulator setting, cut
The instrument will stop conducting a test
Above Target seals, bad parts, or
PA if the pressure rises above the target
Pressure tooling control
pressure window setting.
pressure by testing
with master part.
Check pressure
regulator setting, cut
The instrument will stop conducting a test
Below Target seals, bad parts, or
PA if the pressure drops below the target
Pressure tooling control
pressure window setting.
pressure by testing
with master part.
The present input signal did not go low
Part Not between tests to indicate that the part was Remove the part after
PC
Changed removed from the fixture after the last test. each test.
This results in a Malfunction.

Part
There was an error in the way the program
Configuration PE
was configured.
Error

This is an error in the Auto Setup Sequence

Part Not Full PF that can occur if the instrument fails to fill
the part to the desired pressure.
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Message Code Description Corrective Actions

Test pressure was below Minimum Pressure

Test Pressure
PL during fill cycle. This results in a severe
Low
leak.

Check pressure
Test pressure was above the Maximum
Test Pressure regulator setting and
PH Pressure during fill or stabilization cycles
High tooling control
resulting in a Malfunction.
pressures
Check the part
Error: Part Not The part present input is set for the active
PP presence sensor and
Present program and the input was not received.
input wiring
This is an error in the Auto Setup Sequence
Part Not
PS that can occur if the instrument fails to
Stabilized
stabilize the part.

This is an error in the Auto Setup Sequence

Part Not
PX that can occur if the instrument fails to
Exhausted
exhaust the part.
Sequence
QC Sequence Complete
Complete
Program evaluation was not successful, for
Program Reject R multiple tests – if any test fails, the part is
rejected
Part Reject -
R1 Not Used.
Level 1
Part Reject -
R2 Not Used.
Level 2
Part Reject -
R3 Not Used.
Level 3
The source pressure set by the factory on
Source Pressure
RX the hardware configuration menu was
Exceeded
exceeded.
Stop Button
SB The stop button or input was received.
Pressed
Start Common
SC Not Used.
Input Low
Pressure Select Configuration Error. The instrument was
SE
Config Error not configured properly.

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Message Code Description Corrective Actions

Make sure the test line
was removed and the
test port plugged
Self-Test Failed SF The Self-Test failed. before the test was
conducted. One of
the internal valves may
be leaking.
Error: Stop The instrument cannot start a test if the
SH
Input High Stop input is high.
Stop Input
SI Stop Input Received.
Received
Severe Leak indicates the test process did Check pressure
not achieve Minimum Pressure before regulator setting, cut
reaching the Prefill setpoint or failed to seals, bad parts, or
Severe Leak SL
maintain Minimum Pressure during fill or tooling control
Stabilization timers. This results in a pressure by testing
Program Reject. with master part
Self-Test Passed SP Self-Test process indicates no internal leak.
System Pressure The system pressure of the unit was Check the pressure
SX
Exceeded exceeded. source and regulators
If a tooling error occurs involving any Push the Stop/Reset
motions, there will be a tooling error. Input and possibly
Tooling Not
TE Before the start of the next test, the tooling Common to return
Reset
needs to be reset by the Stop/Reset input. the tooling to the Start
This results in a Malfunction. position.
Error: Two-
Both Start Test and Common must go high
Input Req to TI
to start a test.
Start
Test Port Select
TP The instrument configuration is not correct.
Config Error
Error: Tooling The instrument may not start a sequence if
TR
not Retracted all of the tooling is not retracted.
Most tooling errors or some test errors may
require a tooling reset with the Stop/Reset
Tooling Reset TS
input. After completion of the reset, this
confirmation message is displayed.
Check feedback
If the instrument is configured for tooling sensor and input
Error: Tooling feedback this error will occur if the tooling wiring. Make sure the
TX
not Extended feedback input is not received within the tooling motion
time allocated. feedback timer is set
properly.

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Message Code Description Corrective Actions

Message sent when retain part pressure and
Vent Part Reset
VR tooling are both configured to be used.
Tooling
This message is sent upon a reset.
Transducer Cal The transducer calibration is complete and
XC
Complete was successful.
Transducer Cal There was an error when trying to calibrate Check transducer
XE
Error the transducer. wiring
Pressure
Transducer XF Not used.
Fault
Check the pressure
The External Pressure Switch input did not switch. Make sure
External Switch
XH go high before the end of the fill timer. that the path to the
did not go high
This results in a Malfunction. pressure switch is not
blocked.
The External Pressure Switch input did not Check pressure switch
External Switch
XL go low between tests. This results in a to make sure it is
did not go low
Malfunction. functioning.
During the testing process the pressure
Transducer Check the pressure
XO exceeded the range of the transducer. This
Over Range regulator setting
results in a Malfunction.
Transducer The transducer verification sequence is
XV
Verify Complete complete.
The pressure transducer’s atmospheric
Perform transducer
Transducer Zero pressure reading at the beginning of the
XZ calibration routine in
Bad testing cycle is outside of tolerance. This
Self-Test
results in a Malfunction.

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– Quik Test
This appendix explains the theory and parameters for reducing the test time for obviously good and
obviously bad parts, without sacrificing the accuracy for marginal parts. This capability is called Quik
Test in the instrument. Quik Test is available in the Pressure Decay-Leak Std test type that conducts a
Program Calibration using a leak standard.

How it works
Most manufacturing processes produce the desired quality of product a high majority of the time. These
parts easily pass the leak test being performed on them. Conversely, most defective parts reject by a wide
margin. Quik Test monitors the pressure or flow signal during the test and ends the test early for parts that
easily pass or easily reject. Any marginal parts that are within the parameters set by the Quik Test HL (High
Limit) Band and Quik Test LL (Low Limit) Band will utilize the entire Test time to ensure the accuracy of
the result.

At the desired time in the Test sequence determined by the Quik Test Percent parameter the instrument
calculates the projected leak rate and compares it with the Quik Test Low Limit and High Limit Bands. If
the projected leak rate is within either of these two bands, the test continues to the end of the test timer. If
the instrument’s projected leak rate is outside of these bands, it will stop the test, output the results according
to the Test Evaluation criteria, and display the projected leak rate.

Pressure Decay Test

Test
Quik Test

Exhaust
Stabilize
Pre-fill

Fill

} Quik Test LL Band

Pressure

Reject Limit
} Quik Test HL Band

Time

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The prior chart shows the master part curve, the Low Limit with its LL Quik Test band limit, and the High
Limit with its HL Quik Test band limit. If the pressure loss is within either the LL Quik Test band or HL
Quik test band at the QT% of Test Timer, the test will continue and complete the entire test cycle. If the
results are outside the limit bands at the QT% of Test Timer, the test will stop and the test result will reflect
the Test Evaluation criteria. Setting narrow bands about the Low Limit and High Limit is a very aggressive
approach that will greatly limit the number of tests that run to the end of the test timer. Set wider bands as
a more conservative approach to Quik Test.

An initial analysis of Quik Test should be performed before actually implementing this feature by
establishing the “QT Test Timer” at 10, 25, 50, 75, or 90% and setting “Quik Test” to OFF. A Program
Cal must be performed after setting the "Quik Test Timer" to measure the typical leak response curve for
the test. Test production parts over a reasonable time (up to 1000 parts in various production conditions).
The instrument projects a leak rate at the Quik Test Timer and then completes the full test cycle and
calculates the leak rate for the complete test. The instrument stores the test results that include both the
actual complete test result and a projected test result based on the Quik Test measurement. By comparing
the two leak rate results, a percent of error for the Quik Test feature can be calculated. If the results are
satisfactory, the Quik Test feature can be implemented by setting appropriate High Limit and Low Limit
Bands based on the test comparison and enabling Quik Test. This feature will save the time difference
between a full test time and the Quik Test Time for almost all of the accepted parts and most of the rejected
parts. If the results are not consistent to each other, test further by increasing the Quik Test Timer, re-
calibrate the instrument, and compare the results again.

Test Parameters
The Quik Test parameters menu is located in Main Menu > Program Config > TST:*** icon.

TST Parameter Description Display User Level

Quik Test Enable Activates Quik Test. Advanced, Admin
Defines the time as a percent of the Test sequence
Quik Test Timer Advanced, Admin
when the Quik Test function result is calculated.
The leak (flow) rate band around the Low Limit
within which the tests will continue to completion.
This value is the amount above and below the
Quik Test LL Band Advanced, Admin
nominal. For example, if this value is set to
0.5 scc/m and the Low limit is set to -5.0 scc/m,
the entire Quik Test LL Band is -4.5 to -5.5 scc/m.

The leak (flow) rate band around the High Limit

within which the tests will continue to completion.
This value is the amount above and below the
Quik Test HL Band Advanced, Admin
nominal. For example, if this value is set to 1.0
scc/m and the High limit is set to 10.0 scc/m, the
entire Quik Test LL Band is 9.0 to 11.0 scc/m.

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– Environmental Drift
Correction
This appendix explains the theory and parameters for implementing the
Environmental Drift Correction feature.

How it works
The environmental drift correction routine helps to maintain the calibration of the system by
continuously monitoring and calculating a correction factor for changes in the test conditions. This
routine dynamically compensates for slow changes in the test environment such as room temperature
changes, part temperature changes, test air temperature changes, part elasticity changes, part
absorption characteristics, etc. These factors influence the dynamics of how the test part reacts to the
testing process and the determination of the leak rate. “Environmental Drift Correction” defines how
wide of a band around the Master Part Loss or Master Part Flow value will be considered as normal
variations in flow rate for a non-leaking part. The “Environmental Drift Correction” (+EDC %) is
based on High Limit. The instrument continuously calculates a running average of test results that
fall within the band (EDC %) about the original non-leaking master part curve. It corrects each future
result by the calculated drift determined from previous test results. The drift value is calculated as
shown.

Σn Flow
Environmental Drift Correction = ––––––– - “Master Part Flow”
n
Typical settings for “Environmental Drift Correction” are 10%, 25%, 50%, 75%, and 90%. The sample
size is set as EDC quantity (3 or greater). Flexible parts require a greater “Environmental drift correction”
than rigid parts.

The “Environmental Drift Correction” effectively defines how much shift can occur. This limits the
routine from continuing to compensate for possible growing leaks in the seal or test pneumatics.

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The EDC parameters menu is located in Main Menu > Program Config > TST:*** icon.

TST:*** Parameter Description Display User Level

EDC Enable Enables Environmental Drift Correction Advanced, Admin
Defines the band about the master part curve
where test values are saved to calculate EDC drift.
EDC Percentage Advanced, Admin
Set as a percentage of the High Limit parameter.
Options include 10%, 25%, 50%, 75%, and 90%.
Defines the number of test results within the EDC
EDC Quantity Advanced, Admin
band used to calculate drift.

Environmental Drift Correction (EDC) will reset based on any of the following conditions:
1. Instrument power-cycle (due to limitations in instrument non-volatile storage)
2. Change of any variables that affect EDC calculations:
a. EDC Configuration change (modification the variables: EDC Enabled, EDC
Percentage, or EDC Quantity)
b. Test Limit change (modification of the variable: High Limit [Loss/Leak/Rate])
3. Program idle time-out: 1 hour elapsed since last test on matching program number

Note: The act of changing the selected active program does not reset the
Environmental Drift Correction feature. A user can switch between multiple programs
(EDC data is stored per program), as long as the amount of time from the last time
the similar program number was run does not exceed the 1-hour time-out.

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– Electronic Regulator
Compensation
This appendix explains the theory and parameters for implementing the Electronic
Regulator Compensation (ERC) feature.

How it works
The Electronic Regulator Compensation (ERC) routine helps the instrument to compensate for
electronic regulator calibration error (drift from calibrated setpoint). This allows the instrument to
reach the desired target pressure. The ERC method can be set to “Optimize Fill Pressure”, “Optimize
Test Pressure”, or “Optimize Source Pressure”.

The below graph represents a test with ERC disabled. In this example, the electronic regulator is
not calibrated for Target Pressure, so the pressure set during the test has deviated.

Exhaust
Stabilize
Pre-fill

Test
Fill

Target Pressure
Pressure

Ti
me

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In the “Optimize Fill Pressure” method, ERC enables the instrument to adjust the regulator
pressure setting to obtain the optimal measured fill pressure, as determined by the Target
pressure.

In this method, the electronic regulator setpoint is adjusted on subsequent tests to force the
measured fill pressure to match the target pressure, based upon the stored result history of previous
passed tests.

Stabilize

Exhaust
Pre-fill

Test
Fill

Target Pressure
Pressure

Test 1
Test 2
Test 3

Time

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In the “Optimize Test Pressure” method, ERC enables the instrument to adjust the regulator
pressure setting to obtain the optimal measured test pressure, as determined by the Target
pressure.

In this method, the electronic regulator setpoint is adjusted on subsequent tests to force the
measured test pressure to match the target pressure, based upon the stored result history of previous
passed tests.

Exhaust
Stabilize
Pre-fill

Test
Fill

Target Pressure
Pressure

Test 1
Test 2
Test 3

Time

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In the “Optimize Source Pressure” method, the electronic regulator will be continuously adjusted
during the fill segment to force the measured fill pressure to match the desired target pressure for
the test.

Exhaust
Stabilize
Pre-fill

Test
Fill
Target Pressure
Pressure

Time

Note:
1. The performance of “Optimize Test Pressure” or “Optimize Fill Pressure”
methods depends on multiple iterations since it is based on the history of previous
Accept tests. For these ERC methods, only tests that pass with the measured
pressure that is inside the ERC target window will be added to the history.
2. The “Optimize Source Pressure” method does not depend on the history of
previous Accept tests. Every time you run this test, the instrument will regulate
pressure to the desired target pressure for that test only.

ERC will reset based on any of the following conditions:

1. Instrument power-cycle (due to limitations in instrument non-volatile storage)
2. Change of any variable that affect ERC calculation
a. ERC Method
b. ERC Target Window
c. ERC Offset Limit
d. ERC Quantity

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Test Parameters
The ERC Test parameters menu is located in Main Menu > Program Config > MISC icon.

TST Parameter Description Display User Level

ERC method enables the instrument to adjust the
regulator pressure setting to obtain the optimal
ERC Method Advanced, Admin
measured pressure (fill pressure or test pressure), as
determined by the Target Pressure.
Percentage (plus and minus) window about the
target pressure, defining the maximum allowable
test pressure to be utilized in the calculation for the
ERC Target
ERC routine. Admin
Window
This parameter is only available if the ERC
Method selected is “Optimize Test Pressure” or
“Optimize Fill Pressure”
Maximum correction value, defined as a
percentage of the target pressure, allowed for the
ERC routine.
ERC Offset Limit Admin
This parameter is only available if the ERC
Method selected is “Optimize Test Pressure” or
“Optimize Fill Pressure”
Maximum number of test results within the ERC
target window used to calculate the ERC pressure
offset.
ERC Quantity Admin
This parameter is only available if the ERC
Method selected is “Optimize Test Pressure” or
“Optimize Fill Pressure”
Limits the maximum electronic regulator
incremental adjustment for the ERC routine,
ERC Increment Defined as the percentage of the window between
Admin
Limit the target pressure and the min/max pressure.
This parameter is only available if ERC Method
selected is “Optimize Source Pressure”
Defines the number of times the pressure must
crossover the desired target pressure when
ERC Crossover determining the period response rate of the
Admin
Limit electronics regulator.
This parameter is only available if ERC Method
selected is “Optimize Source Pressure”
Percentage of the electronic regulator response
period used to determine the ERC routine
ERC Rate/Period response rate Admin
This parameter is only available if ERC Method
selected is “Optimize Source Pressure”

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– Communication Code
Tables
This appendix lists the codes that are referenced in the notes of Chapter 24 Communication.

Each table can be generated within the communications interface by providing the associated
command denoted.

Data Type or Header Codes

Type “TABLE HEADER”
Data Type Code Description
1 V Variable Edit
2 L List
3 M Message
4 Q Result List
5 T Streaming Started
6 S Streaming Value
7 X Streaming Stopped
8 R Result Value

Program Evaluation Codes

Type “TABLE RESULT”
Program Evaluation Code Description
1 P TEST PASSED
2 F TEST FAILED
3 E TEST ERROR
4 S TEST SKIPPED
5 X TEST FAILED - LEVEL 1
6 Y TEST FAILED - LEVEL 2
7 Z TEST FAILED - LEVEL 3
8 M AUTO-CAL MASTER PART
9 L AUTO-CAL LEAK STANDARD PART
10 N TEST FAILED - NO EVENT
11 C TEST COMPLETE

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Test Evaluation Codes

type “TABLE EVALUATION”
Test Test
Evaluation Evaluation
Code Description Code Description
1 A PROGRAM ACCEPT 31 EE ELEC REGULATOR CAL ERROR
2 AC AUTOSETUP SEQ COMPLETE 32 EF PART EVAC FAULT
3 AF PROGRAM CALIBRATION FAILED 33 EI ERROR: INSTRUMENT NOT ENABLED
4 AL MASTER+LEAK PART COMPLETE 34 EP PROG ERROR
5 AM MASTER PART COMPLETE 35 ER SYSTEM ERROR - SERVICE REQ
6 AP PROGRAM CALIBRATION PASSED 36 FC CHAMBER PRESSURE HIGH
7 AT ERROR: ANTI-TIE DOWN 37 FO FLOW TRANSDUCER OVER-RANGE
8 BR ERROR: BARCODE REQ TO START 38 FX ERROR: EXCESSIVE FLOW
9 C1 MASTER+LEAK LOSS<MASTER LOSS 39 FZ FLOW TRANSDUCER ZERO BAD
10 C2 MASTER LOSS>MAX M+L LOSS 40 HF HELIUM BACKGROUND FAULT
11 C3 MASTER+LEAK LOSS>MAX M+L LOSS 41 IC INVALID INPUT CONFIGURATION
12 C4 MASTER FLOW>MAX M+L FLOW 42 ID INVALID CALIBRATION DATA
13 C5 MASTER FLOW<MIN MASTER FLOW 43 IE INPUT INITIAL STATE ERROR
14 C6 MASTER+LEAK FLOW>MAX M+L FLOW 44 IF I/O FAULT
15 C7 MASTER FLOW>MAX MASTER FLOW 45 IO INVALID I/O CONFIGURATION
16 C8 MASTER+LEAK FLOW<MASTER FLOW 46 IP INVALID PROGRAM SELECTED
17 C9 MASTER LOSS<MIN MASTER LOSS 47 IR CHAMBER RISE INPUT FAULT
18 CA CAL PROGRAM ACCEPT 48 IS ISOLATION FAILURE
19 CE CALCULATION ERROR 49 IX CHAMBER CROSSOVER INPUT FAULT
20 CF CAL REQUIRED - LIMIT EXCEEDED 50 L0 MASTER LOSS>MAX MASTER LOSS
21 CH CHARGE PRESSURE HIGH 51 L1 MASTER+LEAK LOSS<MIN M+L LOSS
22 CL CHARGE PRESSURE LOW 52 L2 LEAK LOSS<MIN LEAK LOSS
23 CM MIN PERF FACTOR ERROR 53 L3 LEAK LOSS>MAX LEAK LOSS
24 CP CAL REQUIRED - PARAM CHANGED 54 L4 MASTER+LEAK FLOW<MIN M+L FLOW
25 CR CAL PROGRAM REJECT 55 L5 LEAK FLOW<MIN LEAK FLOW
26 CX CHAMBER EVACUATION FAULT 56 L6 LEAK FLOW > MAX LEAK FLOW
27 DF DP TRANSDUCER FAULT 57 LD ERROR: DUPLICATE TARGET LINK
28 DO DP TRANSDUCER OVER-RANGE 58 LE LEAK STD SELECT CONFIG ERROR
29 DZ DP TRANSDUCER ZERO BAD 59 LL ERROR: LINK EXECUTION LOOP

30 EC ELEC REGULATOR CAL COMPLETE 60 LN ERROR: NO LINKS DEFINED

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type “TABLE EVALUATION”

Test Test
Evaluation Evaluation
Code Description Code Description
61 LO ERROR: DISSIMILAR LINK ORDER 91 S1 LD ZERO < MIN
62 LP ERROR: LINK PROG IS PARENT 92 S2 LD ZERO > MAX
63 LU ERROR: LINK PROG UNDEFINED 93 S3 LD LEAK < MIN
64 MC MASS SPEC CONTAMINATION 94 S4 LD LEAK > MAX
65 MF ERROR: PART MARK FAULT 95 SB STOP BUTTON PRESSED
66 MS MAN FILL SWITCH 96 SC START COMMON INPUT LOW
67 NE NO EVENT OCCURRED 97 SE PRESSURE SELECT CONFIG ERROR
68 OC ATMOSPHERIC PRESSURE COMPLETE 98 SF SELF-TEST FAILED
69 OE ATMOSPHERIC PRESSURE ERROR 99 SH ERROR: STOP INPUT HIGH
70 PA ABOVE TARGET PRESSURE 100 SI STOP INPUT RECEIVED
71 PB BELOW TARGET PRESSURE 101 SL SEVERE LEAK
72 PC ERROR: PART NOT CHANGED 102 SM SNIFFER MODE MISMATCH
73 PE PROGRAM CONFIGURATION ERROR 103 SN ERROR: SNIFFER NOT READY
74 PF PART NOT FULL 104 SP SELF-TEST PASSED
75 PH TEST PRESSURE HIGH 105 SR SNIFFER READY INPUT FAULT
76 PL TEST PRESSURE LOW 106 ST SNIFFER TYPE MISMATCH
77 PP ERROR: PART NOT PRESENT 107 SU SNIFFER UNITS MISMATCH
78 PR POWER RESET 108 SX SYSTEM PRESSURE EXCEEDED
79 PS PART NOT STABILIZED 109 TB T-GAS BACKGROUND FAULT
80 PV PROCESS FAULT 110 TC T-GAS CHAMBER CLEANUP FAULT
81 PX PART NOT EXHAUSTED 111 TE ERROR: TOOLING NOT RESET
82 QC SEQUENCE COMPLETE 112 TF T-GAS PART FILL FAULT
83 R PROGRAM REJECT 113 TI ERROR: TWO-INPUT REQ TO START
84 R1 PART REJECT - LEVEL 1 114 TL T-GAS LEAK STD FAULT
85 R2 PART REJECT - LEVEL 2 115 TM T-GAS MIN LEAK RATE FAULT
86 R3 PART REJECT - LEVEL 3 116 TP TEST PORT SELECT CONFIG ERROR
87 RF CHAMBER RISE FAULT 117 TR ERROR: TOOLING NOT RETRACTED
88 RH PRE-PRESSURE HIGH 118 TS TOOLING RESET
89 RL PRE-PRESSURE LOW 119 TX ERROR: TOOLING NOT EXTENDED

90 RX SOURCE PRESSURE EXCEEDED 120 VF VALVE LOAD FAULT

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type “TABLE EVALUATION”

Test
Evaluation
Code Description
121 VR VENT PART RESET TOOLING
122 WA WEIGHT ABOVE MAX
123 WB WEIGHT BELOW MIN
124 WC SCALE CONFIG ERROR
125 WH SCALE WEIGHT HIGH
126 WL SCALE WEIGHT LOW
127 WR SCALE NOT READY
128 WS SCALE NOT STABLE
129 XC TRANSDUCER CAL COMPLETE
130 XE TRANSDUCER CAL ERROR
131 XF PRESSURE TRANSDUCER FAULT
132 XH EXT SWITCH DID NOT GO HIGH
133 XL EXT SWITCH DID NOT GO LOW
134 XO TRANSDUCER OVER-RANGE
135 XP EXTERNAL XDCR PRESS
136 XV TRANSDUCER VERIFY COMPLETE
137 XZ TRANSDUCER ZERO BAD

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Segment Codes
type “TABLE SEGMENT”
Segment Segment
Code Description Code Description
1 %VR Percent of Reference Volume Test 31 DPT Rate of Pressure Loss Test
2 APC Setup - Atmospheric Pressure Check 32 DTV Setup - DP Transducer Verification
3 AR Autorun Relax 33 DTZ Setup - DP Transducer Zero
4 BAL Stabilize DP Xdcr Balance 34 ERA Setup - Electronic Regulator Analyze
5 CBC Chamber - blower control 35 ERS Setup - Electronic Regulator Setpoint
6 CC0 Chamber - circulation off 36 ERZ Setup - Electronic Regulator Zero
7 CC1 Chamber - circulation on 37 ESI Internal - Empty-Seq
8 CCX Chamber - accumulation rest 38 EST Fill Evac
9 CE0 Chamber - evacuate off 39 EXE Exhaust until Empty
10 CE1 Chamber - evacuate on 40 EXH Exhaust
11 CHA Exhaust - Chamber Output Rest 41 EXP Exhaust until Pressure
12 CIF Chamber - inlet blower off 42 EXT Tooling Motion Extend
13 CIO Chamber - inlet blower on 43 FFL Fill until Full
14 CLN Stabilize Chamber Cleanup 44 FGN General Fill
15 CO0 Chamber - outlet blower off 45 FLC Mass Flow - Leak Rate Test
16 CO1 Chamber - outlet blower on 46 FLL Fill (without pressure monitoring)
17 CP0 Chamber - pre-purge 47 FLR Precise Mass Flow Test (Differential Flow)
18 CPC Chamber - clamshell purge rings control 48 FLW Mass Flow Test
19 CPG Chamber - Exh/Purge 49 FRF Fill Reference
20 CPO Chamber - clamshell purge rings option 50 FRP Fill Ramp
21 CPR Chamber - clamshell purge rings rest 51 FST Fill Tracer
22 CST Fill Clean 52 FTS Setup - Flow Transducer Setpoint
23 CV0 Chamber - vent off 53 FTV Setup - Flow Transducer Verification
Differential Pressure Decay - Leak Rate
24 DDL 54 FTZ Setup - Flow Transducer Zero
(volume calculated)
25 DLY Delay 55 HVC Chamber - hardvac control
26 DPD Differential Pressure Decay Test 56 LKC Link Control
Differential Pressure Decay Test (no abs
27 DPD 57 LNK Link Decision
pressure)
Differential Pressure Decay - Leak
28 DPL 58 MVX Setup - Mix Verification
Standard Test (no abs pressure)
Differential Pressure Decay - Leak
29 DPL 59 OCC Occlusion Test (Backpressure)
Standard Test
30 DPS Setup - DP Transducer Setpoint 60 PLO Pressure Loss Test

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type “TABLE SEGMENT”

Segment Segment
Code Description Code Description
61 PLR Pressure Decay - Leak Standard Test 91 RTI Ramp to Digital Input Event Test
62 PMK Tooling Part Mark 92 RVN Refrigerant Vent
63 PRC Prefill - Charge Volume 93 SCI Setup - Scale Init
64 PRF Prefill/Fill 94 SD1 Setup - Sniffer idle
65 PRF Prefill until Pressure 95 SDP Stabilize for DP
66 PRF Proof Test 96 SDP Stabilize Balance DP
67 PRI Internal - Pre-Seq 97 SFS Stabilize Tracer
68 PRI Internal - Evaluate Part Result 98 SGL Fill Tracer Gross
69 PRP Prefill Pre-Pressure 99 SGS Stabilize Tracer Gross
70 PRS Step Proof 100 SI1 Setup - Sniffer Init
71 PSI Internal - Post-Seq 101 SI2 Setup - Sniffer Init 2
72 PTS Setup - Pressure Transducer Setpoint 102 SLE Tooling Seal Extend
73 PTV Setup - Pressure Transducer Verification 103 SLR Tooling Seal Retract
74 PTZ Setup - Pressure Transducer Zero 104 SME Setup - Manifold Exhaust
75 PVF Pressure Verify 105 SMF Setup - Manifold Fill
76 RCF Refrigerant Iso Off 106 SMI Setup - Manifold Isolate
77 RCX Refrigerant CS Isolation 107 SNF Sniffer Test
78 REC Exhaust - T-Gas 108 SNG Sniffer Gross Test
79 REF Refrigerant Fill 109 SNW Stabilize Tracer Wait
80 RET Tooling Motion Retract 110 SPF Fill Step
81 REV Exhaust - Re-Evacuate 111 SPL Setup - Pressure Select
82 RFE Refrigerant Evac 112 SPR Setup - Pre-Seq
83 RFM Refrigerant Manual Fill 113 SPS Setup - Post-Seq
84 RFS Stabilize Scale 114 SSD Stabilize Step Dwell
85 RFT Refrigerant Fill 115 SSR Setup - Set Regulator
86 RFX Refrigerant Stabilize 116 STE Stabilize Evac
87 RL Calibration Relax 117 STF Stabilize for Flow
88 RPS Refrigerant Part Switch 118 STG General Stabilize
89 RTE Ramp to Pressure Event Test 119 STR Setup - Transducer Residual
90 RTF Ramp to Flow Event Test 120 STR Stabilize Reference Volume

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type “TABLE SEGMENT”

Segment
Code Description
121 STS Stabilize until Slope
122 SVD Evac Test
123 SXT Stabilize for Xdcr Test
124 TMC Tooling Motion Control
125 XDR Transducer Test

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Test Data or Variable Identifier Codes

type “TABLE VARIABLE”
Test Data Test Data
Identifier Identifier
Code Description Code Description
1 %P Percent Precision 46 CHV Chamber Volume
2 2in Two Inputs to Start 47 CID CS Iso Delay
3 AAA Accum Autozero 48 CLF Corr. Leak Std Flow
4 AAV Accept Average 49 CLM Clamshell
5 ACT Auto-Cycle Tst Mode 50 CLP Check Limit Percent
6 AD Analog A/D 51 CLR Cal Required
7 AER Permit Early Reject 52 CLR Cumulative Leak
8 ALR Alt Leak Rate 53 CM Malfunction Cycles
9 APC Accept Percentage 54 CM Cal Method
10 APC Atm Pressure Check 55 CMN Clean Min Pressure
11 APP Accept Program 56 CMP Charge Min Press
12 AQ Average Quantity 57 CMX Maximum Pressure
13 ARC Autorun Cycle Count 58 COF Continue on Fail
14 ARE Autorun Enable 59 COL Cutoff Limit
15 ARM Autorun Method 60 CP Current Precision
16 ARR Autorun Relax 61 CPP Copy Program
17 ASA Short Autozero 62 CPR Charge Pressure
18 ASD Accept Std Dev 63 CPS TLR Change/Sec
19 ASM AutoSetup Method 64 CPT Consecutive Points
20 ASP Accept SPC Std Dev 65 CPT Consecutive Points
21 ATD Anti-Tie-Down 66 CR Reject Cycles
22 AZD Autozero Delay 67 CRA Clean Part Source
23 AZE Autozero Enable 68 CRF Pre-Purge
24 Ain Analog Input 69 CRS Chmbr Crossover
25 Aot Analog Output 70 CSC Cycles Since Cal
26 BC Batch Calibration 71 CSN Clear Since New Ctr
27 BCM Barcode Method 72 CSN Cycles Since New
28 BL Batch Layout 73 CST Custom Self Test
29 BQ Batch Quantity 74 CT Total Cycles
30 BR Barcode Required 75 CTE Continue to Evac
31 CA Accept Cycles 76 CTF Continue to Fill
32 CAP Calibrate Percent 77 CTG Target Pressure
33 CC Capability Code 78 CTP Copy to Target Prog
34 CCD Ch Evac Valve Dly 79 CTP Charge Target Press
35 CCP Clear Prog Counters 80 CTR Clean Part Timer
36 CCR Clear Chan Results 81 CTX Continue T-Gas Exh
37 CCS Clear Chan Counters 82 CXP Charge Max Press
38 CEF Chmbr Evac Limit 83 DA Analog D/A
39 CEV Chmbr Evac Close 84 DD Decay Direction
40 CFS Cleanup Setpoint 85 DFL Direct Flow
41 CGP Chmbr Pre-Purge 86 DKL DP Leak Loss
42 CGT Chmbr Pre-Purge 87 DL Diff Press Loss
43 CHM Post-Purge Method 88 DLL DP Master+Leak Loss
44 CHO Chmbr Post-Purge 89 DLR Diff Press Loss Rd
45 CHP Chamber Pressure 90 DLT Delay Timer

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type “TABLE VARIABLE”

Test Data Test Data
Identifier Identifier
Code Description Code Description
91 DML DP Master Part Loss 136 EVD Vacuum Decay
92 DMR DP Mstr Part Lss Rd 137 EVL Test Evaluation
93 DP Diff Pressure 138 EVM Allow Evac Limit
94 DPI DP iso Percent 139 EVP Event Pressure
95 DPP ¤ Press Precision 140 EVT Event Type
96 DVF Vent During Fill 141 EXD Evacuation Xdcr
97 DVM Test Mode 142 EXP Execution Pause
98 DVO Device Mode 143 FC Feature Code
99 Dt Date 144 FCC Force Cal Cycles
100 ECL ERC Crossover Limit 145 FCD FCal Date Limit
101 EDC EDC Offset 146 FCL FCal Cyc Limit
102 EDE EDC Enabled 147 FCM Force Cal Mode
103 EDP Event ¤P 148 FCT FCal Time Limit
104 EDP EDC Percentage 149 FCT Force Cal Time
105 EDQ EDC Quantity 150 FEL Flow Event Limit
106 EDT Event ¤T 151 FL Flow
107 EIL ERC Increment Limit 152 FLD Fine T-Gas Decay
108 EM Exhaust Method 153 FLF Fine T-Gas Fill
109 EMP Ext Xdcr Pressure 154 FMV Finish Mix Verify
110 ENB E-NOB 155 FNB FF-NOB
111 ENC Enable Calibration 156 FP Flow Precision
112 ENT Enable Tooling I/O 157 FPR Fill Pressure
113 EOL ERC Offset Limit 158 FPS Fine Sample
114 EPP Pressure Precision 159 FSW Final Src Weight
115 EPR Pressure Reference 160 FTA Fill
116 EPV Estimated Part Size 161 FTA Dwell
117 ERA Atm Pressure 162 FTX Test Failed Text
118 ERC ERC Method 163 Fdb Tooling Feedback
119 ERE ERC Enabled 164 GLD Gross T-Gas Decay
120 ERP ERC Rate/Period 165 GLF Gross T-Gas Fill
121 ERQ ERC Quantity 166 GLN Gross T-Gas Min
122 ERR E-Regulator Rest 167 GLT Gross T-Gas Target
123 ERV Re-Evac After Test 168 GLX Gross T-Gas Max
124 ESC Ext Switch Low Chk 169 GPS Gross Sample
125 ESN External Sniffer 170 GPT Gross Fill Pulse
126 ESP Exhaust Setpoint 171 HLE High Limit Event
127 ET Elapsed Time 172 HLF High Limit Flow
128 ETP Evacuation Setpoint 173 HLL High Limit Loss
129 ETP Fine T-Gas Target 174 HLP High Limit Pressure
130 ETW ERC Target Window 175 HLQ High Limit Leak
131 ETW ERC Target Window 176 HLR High Limit Rate
132 ETY Edge Type 177 HLV High Limit %Vref
133 EUP Pressure Unit 178 I/O I/O ID
134 EVA Evacuation Source 179 IET Event Type
135 EVC Eval Condition 180 IF Instrument Flow

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type “TABLE VARIABLE”

Test Data Test Data
Identifier Identifier
Code Description Code Description
181 IIS Input Initial State 226 LSS Leak Std Select
182 ILS Level State 227 LSV Leak Std Value
183 ILT Level Time 228 LV Launch Validation
184 IPR Close Inner Purge 229 ME Malfunction Eval
185 IS Input State 230 MF Master Part Flow
186 ISO Isolation 231 MFO Manual Fill
187 LAV Leak Alarm Volume 232 MFR Master Part Flow Rd
188 LCD Leak Std/Cal Define 233 MFT Manual Fill
189 LCD Leak Std Cal Date 234 ML Master Part Loss
190 LCF Correction Factor 235 MLF Min Mstr+Leak Flow
191 LDP Leak Det Precision 236 MLF Min Leak Flow
192 LDT Dev Zero Delay 237 MLL Min Leak Loss
193 LDU Leak Det Unit 238 MLR Master Part Loss Rd
194 LDZ Device Zero 239 MMF Min Master Flow
195 LF Master+Leak Flow 240 MMF Min Master Flow
196 LFC Leak Std Cal Flow 241 MML Max Master Loss
197 LFR Master+Leak Flow Rd 242 MML Min Mstr+Leak Loss
198 LIN Linearity 243 MML Min Master Loss
199 LKF Leak Flow 244 MNT Min Tare Weight
200 LKL Leak Loss 245 MO Master Flow Offset
201 LKM Link Motion 246 MOR Master Flow Offset
202 LL Master+Leak Loss 247 MPC Malfunction Percent
203 LLE Low Limit Event 248 MPF Min Perform Factor
204 LLF Low Limit Flow 249 MPP Max System Pressure
205 LLL Low Limit Loss 250 MQ Master Part QL
206 LLP Low Limit Pressure 251 MQD DP Mstr Part QL Rd
207 LLQ Low Limit Leak 252 MQD DP Master Part QL
208 LLR Master+Leak Loss Rd 253 MQF Master Part QF Rd
209 LLR Low Limit Rate 254 MQF Master Part QF
210 LLV Low Limit %Vref 255 MQR Master Part QL Rd
211 LMP Link Motion Preempt 256 MSL Reject Rate
212 LNL Linearity Limit 257 MSO MS Iso Open Delay
213 LOF Loss Offset 258 MSP Max Pressure - Opt
214 LQ Master+Leak QL 259 MSR Mark Severe Lk Rej
215 LQD DP Mstr+Lk QL Rd 260 MST Mass Spec Purge
216 LQD DP Master+Leak QL 261 MTM Min T-Gas Mode
217 LQF Master+Leak QF Rd 262 MTS T-Gas Source
218 LQF Master+Leak QF 263 MV T-Gas Mix Verify
219 LQR Master+Leak QL Rd 264 MVF T-Gas Tgt Press
220 LR Leak Rate 265 MVH Leakrate High Limit
221 LRC Leak Std Recert 266 MVL Leakrate Low Limit
222 LRO Leak Rate Offset 267 MVM T-Gas Leak Rate
223 LRO Leak Rate Offset 268 MVS Start Mix Verify
224 LSC Leak Std Chk 269 MVT T-Gas Fill Timer
225 LSP Leak Std Pressure 270 MXT Max Tare Weight

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type “TABLE VARIABLE”

Test Data Test Data
Identifier Identifier
Code Description Code Description
271 Mot Motion Number 316 PPC Part Present Check
272 Mot Number of Motions 317 PPC Prefill Press Check
273 NAM Program Name 318 PPE Pre-Press Enable
274 NBC Number of Barcodes 319 PPR Pre-Pressure
275 NLK Number of Links 320 PPS Pre-Press Select
276 NOP Number of Options 321 PPW Pre-Pressure Window
277 NPP Next Program 322 PQ Predicted Leak
278 NPS Number of Steps 323 PRF Prefill
279 NTP Sample Points 324 PRI Programmable Input
280 NUM Number of Programs 325 PRO Programmable Output
281 OLS Open Leak Std 326 PRR Pressure Restrict
282 OPT Option 327 PSL Pressure Select
283 OTL Open T-Gas Leak Std 328 PSL Pressure Select
284 P Master Gauge Press 329 PSL Pressure Select
285 P Instrument Pressure 330 PSP Setpoint Pressure
286 P Meas Pressure 331 PST Self Test Pressure
287 P%V Part %Vref 332 PSV Part Sniffer Type
288 PC Pneumatic Code 333 PT Target Pressure
289 PCL Leak Std Cal Press 334 PTF Prefill
290 PCR Pressure Correction 335 PTG Gross Prefill
291 PCT Chmbr Post-Purge 336 PTP ¤P/¤T Precision
292 PDL Press Delta Limit 337 PTS Port Select
293 PET Part Evac Limit 338 PTS Part Seal
294 PEV Part Evacuation 339 PTU ¤P/¤T Unit
295 PEX Partial Exhaust 340 PTX Test Passed Text
296 PF Performance Factor 341 PW Weight Precision
297 PFL Part Flow 342 Pp Part Pressure
298 PFM Prefill Method 343 Pr Ref Pressure
299 PG Target Pressure 344 Ps Standard Pressure
300 PKP Peak Pressure 345 Pt Program Number
301 PL Pressure Loss 346 Pt Apply to Program #
302 PLP Predicted Loss 347 Pt Target Pressure
303 PLQ Master+Leak Q-Press 348 Pt Test Pressure
304 PLR Pressure Loss Rd 349 QF Quik Flow
305 PLR DP Mstr+Lk Loss Rd 350 QHL Quik Test HL Band
306 PM Master Part Press 351 QL Quik Loss
307 PM Part Mark 352 QLL Quik Test LL Band
308 PMF Part Mark Feedback 353 QP Quik Test Pressure
309 PML Master+Leak Press 354 QPT Quantity Points
310 PMN Minimum Pressure 355 QTE Quik Test Enable
311 PMQ Master Part Q-Press 356 RAN Number of Points
312 PMX Maximum Pressure 357 RAP Analysis Pressure
313 PNM Sniffer Test Point 358 RAS Analysis Voltage
314 PP Pressure Precision 359 RAT Analysis Percent
315 PP Proof Pressure 360 RAV Reject Average

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type “TABLE VARIABLE”

Test Data Test Data
Identifier Identifier
Code Description Code Description
361 RC Elec Regulator Cal 407 SCF Cal Coefficient
362 RC1 EReg Zero DA Cal 408 SCL T-Gas LeakStd Value
363 RC2 EReg Span DA Cal 409 SCO Cal Offset
364 RC3 EReg Zero Base Cal 410 SCP Start Clean Part
365 RC4 EReg Span Base Cal 411 SCR Reject Rate Percent
366 RCA Analog Value 412 SCT Scale Type
367 RCD Last Cal Date 413 SDH ST DP High Limit
368 RCI Instrument Pressure 414 SDL ST DP Low Limit
369 RCP Retention Cutoff 415 SEV Leak Rate Window
370 RCS Setpoint Voltage 416 SF Standard Flow
371 RCT Last Cal Time 417 SGN Sample Gas Number
372 RCV Master Value 418 SIO Sniffer Init
373 RDI Restore Default I/O 419 SMP Sample Time
374 RDT Reg Dwell Timer 420 SN Step Number
375 RED Refrgnt Vent Close 421 SNR SNR
376 REG Regulator 422 SOD Shut Off Delay
377 REO Refrigerant Vent 423 SP Standard Pressure
378 REX Refrigerant Vent 424 SP Starting Pressure
379 RFC Fill Close Delay 425 SPM Fine Wait
380 RFL Reference Loss 426 SPT Gross Wait
381 RL Loss Rate 427 SR Set Regulator
382 RLC Run Leak Calibrate 428 SRC Start Calibration
383 RLR Loss Rate Rd 429 SRH ST RPL High Limit
384 RLV T-Gas LeakStd Value 430 SRH LD Leak Val Max
385 RMX EReg Span DA Cal 431 SRL LD Leak Val Min
386 RNP Number of Points 432 SRL ST RPL Low Limit
387 ROS Reject on Slope 433 SSW Starting Src Weight
388 RPC Reject Percentage 434 STH ST TPL High Limit
389 RPM Ramp Method 435 STL ST TPL Low Limit
390 RPP Retain Part Press 436 STL Self Test Level
391 RPP Reject Program 437 STM Self Test Method
392 RR Retract on Reject 438 STN Self Test Program
393 RR Ramp Rate 439 STP Target Press
394 RRT Reject Rate Total 440 STS Self Test Source
395 RSI Result Information 441 STS Start Self Test
396 RSP Slope Window 442 STT Self Test Limit
397 RSR Slope Change/Sec 443 STV Step Target Press
398 RST Stabilize 444 STW Target Window
399 RVH High Limit Voltage 445 SXC Start Calibration
400 RVH High Limit Voltage 446 SXT Start Xdcr Test
401 RVL Low Limit Voltage 447 SXV Start Verification
402 RVL Low Limit Voltage 448 SZH LD Zero Val Max
403 RVP Retain Volume Press 449 SZL LD Zero Val Min
404 RXM Pre-Evac Exhaust 450 Ser Serial Number
405 SAM Sample Size 451 Stn Channel Number
406 SAS Start AutoSetup 452 T Timer

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type “TABLE VARIABLE”

Test Data Test Data
Identifier Identifier
Code Description Code Description
453 T Timer 499 VAP Valve A PWM - Opt
454 TBF LD Background Limit 500 VAT Valve A Type - Opt
455 TEP T-Gas Exh Press 501 VBN Valve B Num - Opt
456 TI Iso Delay Timer 502 VBP Valve B PWM - Opt
457 TL Tooling Option 503 VBT Valve B Type - Opt
458 TLK Test Leak Rate 504 VC Valve Code
459 TLP Leak Rate Precision 505 VCN Valve C Num - Opt
460 TLR T-Gas Leak Rate 506 VCP Valve C PWM - Opt
461 TLU Leak Rate Unit 507 VCT Valve C Type - Opt
462 TML LD Min T-Gas Setpt 508 VDN Valve D Num - Opt
463 TMN Fine T-Gas Min 509 VDP Valve D PWM - Opt
464 TMP Temp Precision 510 VDT Valve D Type - Opt
465 TMX Fine T-Gas Max 511 VFL Virtual Flow
466 TP Time Precision 512 VHT Vent/Halt Tooling
467 TPP Target Program 513 VLD Valve Detection
468 TPW Target Press Window 514 VLP Volume Precision
469 TQ Quik Test Timer 515 VLV Valve Number
470 TR1 Trigger 1 516 VNP Number of Points
471 TRA T-Gas Source 517 VP Voltage Precision
472 TRM T-Gas Recovery 518 VPS Setpoint Pressure
473 TSM T-Gas Sampling 519 VPW Valve PWM
474 TT Test Sel Timer 520 VSP Setpoint Voltage
475 TT Test Execution Time 521 VWO Residual Offset
476 TTF TracerMate Flags 522 Vi Instrument Volume
477 TTY Test Type 523 Vp Part Volume
478 TTY Test Type 524 WGT Refrigerant Weight
479 TV Valve Delay Timer 525 WHL High Limit
480 TW Target Weight 526 WIN Stat History Length
481 TWN Min Fill Weight 527 WLL Low Limit
482 TWX Max Fill Weight 528 XAN Xdcr Zero LL
483 Tcy Desired Cycle Time 529 XAX Xdcr Base Max
484 Tm Timer Mode 530 XBH Xdcr Zero Hwin
485 Tm Time 531 XBL Xdcr Zero Lwin
486 UC Current Unit 532 XC Transducer Cal
487 UDP ¤ Pressure Unit 533 XC1 Xdcr Zero AD Cal
488 UF Flow Unit 534 XC2 Xdcr Span AD Cal
489 UP Pressure Unit 535 XC3 Xdcr Zero Base Cal
490 UP Percent Unit 536 XC4 Xdcr Span Base Cal
491 UPD Unit/Prec Define 537 XCA Analog Value
492 UT Time Unit 538 XCB Atm Pressure
493 UTM Temperature Unit 539 XCD Last Cal Date
494 UV Voltage Unit 540 XCF Instrument Flow
495 UV Volume Unit 541 XCI Instrument Pressure
496 UW Weight Unit 542 XCL Xdcr Curr Limit
497 V V 543 XCM Master Reading
498 VAN Valve A Num - Opt 544 XCP Cal Pressure

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S E N T I N E L I 2 8 A P P E N D I X E – C O M M U N I C A T I O N C O D E T A B L E S

type “TABLE VARIABLE”

Test Data Test Data
Identifier Identifier
Code Description Code Description
545 XCS Setpoint Pressure 567 XPR Pressure Reference
546 XCT Last Cal Time 568 XRL Xdcr Residual Limit
547 XCV Master Value 569 XRW Xdcr Residual Warn
548 XCX Xdcr Cal X Array 570 XSP Setpoint Pressure
549 XCY Xdcr Cal Y Array 571 XT Transducer
550 XFC Xdcr Filter Code 572 XT Xdcr Tare
551 XFP Flow Precision 573 XTG Xdcr Tare Range
552 XID Xdcr Iso Delay 574 XTR Xdcr Typ Residual
553 XIS Xdcr Span Inter Cal 575 XUF Flow Unit
554 XIZ Xdcr Zero Inter Cal 576 XUP Pressure Unit
555 XLF Max Mstr+Leak Flow 577 XV Transducer Verify
556 XLF Max Leak Flow 578 XVD Verify Date
557 XLL Max Leak Loss 579 XVF Instrument Flow
558 XMF Max Master Flow 580 XVI Instrument Pressure
559 XML Max Mstr+Leak Loss 581 XVM Master Reading
560 XMN Xdcr Base Min 582 XVS Setpoint Pressure
561 XMX Xdcr Base Max 583 XVT Verify Time
562 XNP Number of Points 584 XVV Master Value
563 XOP Crossover Pressure 585 XZC Xdcr Zero Check
564 XPC Pressure Correction 586 XZH Xdcr Zero HL
565 XPM Pressure Mode 587 XZL Xdcr Zero LL
566 XPP Pressure Precision 588 XZW Xdcr Zero Window
589 t Test Time

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S E N T I N E L I 2 8 A P P E N D I X F – I N S T R U M E N T A T T A C H M E N T & C L E A R A N C E

– Instrument Attachment and Clearance

NOTES:

1) THIS DRAWING IS
NOT TO SCALE.

2) ALL MEASUREMENTS ON
THIS PAGE ARE IN INCHS.

3) ALL INSTRUMENTS ARE

SHIPPED WITH (4) .25-28
X 3.5 INCH LONG SHCS.

4) RECOMMENDED 4 INCH
CLEARANCE UNDER
INSTRUMENT FOR TEST
PORT, PNEUMATIC
CONNECTIONS AND
HAND CLEARANCE.

5) THE HANGING HOLE USED TO

STABILIZE INSTRUMENT
FOR INSTALLATION, IS NOT
INTENDED TO SOLELY
SUPPORT INSTRUMENTATION.

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This page is intentionally blank.

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Index
Anti-Tie-Down, 120, 130, 219 Hold, 129, 130, 199
Auto Setup, 5, 13, 28, 29, 135, 219, 224, 225 Holding Pressure After Test, 205
Autorun, 207 I/O Wiring, 126
Backup & Restore Instrument, 202 Input Initial State, 67
Backup Instrument Settings, 16 Inputs, 12, 125, 129, 130, 133, 134, 141, 143, 144, 145, 148,
Barcode, 205 151, 152, 153, 214, 215
Binary Program Selection, 133 Inputs and Outputs, 12
Cal Method, 29, 34, 114, 206 IP Inputs, 5, 144, 146, 151, 152, 153, 215
Calibration Parameters, 37, 51, 59, 117 IP Outputs, 5, 144, 146, 151, 215
Cancel/Back button, 3 Leak Flow, 59
Channel Configuration, 12, 14, 141, 148, 209 Leak Flow, 58
Clone Instrument, 202 Leak Loss, 37, 117
Common, 120, 130, 219, 225, 226 Leak Loss, 35
Communication, 4, 12, 141, 144, 148, 151, 154, 156, 157, Leak Loss, 115
159, 209, 210, 211 Leak Standard, 10, 11, 14, 27, 29, 32, 33, 34, 37, 57, 87, 91,
Communication Code Tables, 239 92, 95, 96, 107, 109, 113, 114, 115, 117, 133, 135, 202,
Corr. Leak Std Flow, 37, 59 203, 206, 207
Counters Screen, 217 Leak Standard Values, 14, 34, 57, 114
Crossover Pressure, 63, 67 Leak Std Select, 203
CTSnet LT, 162 Level State, 67
Data Type Codes, 157, 219 Level Time, 67
Delay, 80 Light Bar Control, 202
Differential Pressure Decay-Leak Std, 117 Link, 80, 121, 122, 123, 158, 223, 224
Differential Pressure Transducer, 11, 96, 102, 107, 109 Main Menu, 3, 5, 9, 12, 13, 14
Digital IO Cable Diagram, 128 Manifold, 206
Direct Flow Parameter, 52, 59 Mass Flow, 10, 47, 53
Display User Level, 14, 17, 21, 27, 34, 39, 43, 47, 53, 57, 61, Mass Flow-Leak Std, 10, 53
65, 69, 73, 83, 87, 114, 201, 205, 211 Master Flow Offset, 50, 51
EDC, 20, 25, 33, 50, 56, 57, 92, 100, 106, 113, 231, 232 Master Part, 10, 27, 30, 34, 35, 37, 47, 50, 51, 53, 57, 59, 87,
Edge Type, 67 88, 100, 104, 106, 107, 111, 113, 114, 115, 117, 206, 207,
Electromagnetic Energy Devices, 1 220, 221, 223, 224, 226, 230, 231, 232
Electronic Regulator, 15, 61, 73, 211 Master Part Flow, 58, 59, 231
Electronic Regulator Calibration, 161, 211, 222 Master Part Loss, 34, 35, 37, 93, 115, 117
Electronic Regulator Calibration Report, 211 Master Part Press, 37, 59
Enter Button, 3, 9 Master+Leak Flow, 58, 59
Environmental Drift Correction, 25, 33, 50, 56, 92, 100, 106, Master+Leak Loss, 34, 35, 37, 93, 115, 117
113, 231, 232 Master+Leak Press, 37, 59
E-Regulator Rest, 211 Max Leak Flow, 56
EtherNet/IP, 4, 12, 141, 142, 143, 144, 145, 146, 148, 151 Max Master + Leak Flow, 56
Event Type, 63, 67 Max Master Flow, 56
Event Δ Pressure, 63 Message & Error Codes, 219
Example, 78, 122, 123, 139, 157, 158, 160, 204, 213 Min Leak Flow, 56
Execution Pause, 80 Min Master + Leak Flow, 56
Exhaust, 18, 22, 30, 40, 44, 48, 54, 62, 66, 70, 74, 81, 84, 88, Min Master Flow, 56
98, 104, 111, 129, 133, 135, 136, 205 Monitor Icon, 3
FAT32, 202 Monitor Screens, 5, 145, 152, 213
Features, 18, 22, 30, 48, 54, 141, 148, 201 Multiple Unique Parts, 8, 11, 77, 81
Fill, 18, 22, 30, 48, 52, 54, 59, 98, 104, 111, 129, 133, 135, Non-Leaking Master Part, 10, 34, 35, 37, 51, 57, 107, 114,
136, 204, 206 115, 206, 207
Fill the Test Part, 17, 21, 27, 47, 53 Number of Motions, 119, 121, 137, 140
Filters, 1 Occlusion, 10, 39
Global Configuration, 141, 148 Open Leak Std, 107, 129, 133, 202
Graph, 214 Orifice, 206
Hardware Inputs, 5, 149, 214 Outputs, 12, 125, 129, 135, 136, 137, 141, 143, 144, 145,
Hardware Outputs, 5, 149, 214 148, 151, 214, 215

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Parent Program Linking, 8, 11, 77, 78, 79, 80, 121 Start Program, 129, 130
Parsing Data, 160 Stats Screen, 217
Part Mark, 18, 120, 134, 136, 224 Stop/Reset, 78, 120, 129, 130, 131, 132, 134, 140, 226
Part Marking Feedback, 134 Streaming, 141, 148, 157, 160
Part Present, 120, 129, 130, 140, 144, 151 Target Pressure, 18, 19, 22, 23, 28, 30, 31, 37, 39, 40, 48, 49,
Part Present Check, 120, 140 54, 55, 59, 74, 75, 85, 90, 98, 99, 104, 105, 111, 112, 117,
Pass and Fail, 20, 25, 33, 41, 45, 50, 57, 63, 68, 71, 92 221, 224
Performance Factor, 35, 37, 113, 115, 117, 221 Target Test Pressure, 17, 21, 27, 40, 47, 53, 99, 105, 112
Pneumatic Regulator, 15 TCP/IP, 156, 160
Prefill, 18, 19, 22, 23, 30, 31, 48, 49, 54, 55, 85, 98, 104, 111, Technical Specifications Summary, 259
129, 135, 136, 160, 204, 206, 226 TELNET, 156
Prefill Timer Function, 204, 205 Test, 17, 18, 21, 22, 24, 30, 31, 40, 43, 44, 48, 53, 54, 66, 70,
Press Select, 129 84, 88, 90, 96, 98, 104, 109, 111, 112, 129, 135
Pressure Correction, 206, 210 Test Data Identifier Codes, 159, 160, 246, 247, 248, 249,
Pressure Decay-Leak Std, 10, 27, 28, 87, 159 250, 251
Pressure Decay-ΔP, 10, 17 Test Evaluation, 20, 25, 27, 29, 32, 33, 41, 45, 50, 56, 57, 63,
Pressure Decay-ΔP/ΔT, 10, 21 67, 68, 71, 91, 92, 99, 112, 141, 148, 158, 159, 229, 230
Pressure Regulator, 18, 22, 30, 39, 47, 48, 53, 54, 88, 98, Test Evaluation Codes, 159, 240, 241
104, 111, 224, 225, 226, 227 Test Failed, 129, 136
Pressure Select, 15, 28 Test Parameters, 16, 20, 25, 32, 41, 45, 50, 56, 63, 75, 86,
Pressure Verify, 10, 43 91, 100, 106, 113, 230, 237
PROFINET, 148 Test Passed, 129, 136
Program Cal, 5, 30, 32, 34, 35, 36, 37, 50, 51, 54, 57, 58, 59, Test Port, 1, 10, 15, 43, 203, 220, 226
81, 88, 91, 92, 104, 111, 114, 115, 116, 117, 129, 133, 135, Test Results, 20, 25, 32, 41, 45, 86, 91, 100, 106, 113, 154,
202, 220, 221, 223, 230 158, 231
Program Calibration, 34, 35, 51, 56, 57, 58, 114, 115, 199, Test Time, 10, 19, 27, 39, 85, 99, 112, 220, 221, 230
219, 221, 224, 229 Test Type, 5, 9, 10, 16, 219
Program Configuration, 15, 141, 148 Test Type Menu, 9
Program Evaluation Codes, 159 Test Type Table, 9
Program Linking, 8 Timer Parameters, 18, 22, 30, 40, 44, 48, 54, 62, 66, 70, 74,
Program Select Buttons, 4 81, 84, 88, 98, 111
Programmable Inputs and Outputs, 148 Tool Ext Fdbk, 134
Programmable Inputs and Outputs Menus, 129, 142 Tool Ret Fdbk, 134
Quik Test, 33, 56, 92, 229, 230 Tooling Control, 12, 18, 22, 30, 40, 54, 84, 88, 98, 104, 111,
Ramp Method, 66 119, 121, 224
Ramp Rate, 66 Tooling Extend, 18, 22, 30, 40, 48, 54, 62, 66, 70, 74, 81, 84,
Ramp to Flow Event, 10, 69 88, 98, 104, 111, 121, 122, 123, 131, 137
Ramp to Input Event, 65 Tooling Feedback, 120
Ramp to Proof Test, 11, 73 Tooling Motion, 18, 22, 28, 30, 40, 54, 84, 88, 98, 104, 111,
Ramp to ΔP Event, 10, 61 121, 122, 123, 132, 140, 219, 226
Relax, 30, 54, 81, 88, 129, 135 Tooling Option, 119
Reports, 161, 211 Tooling Retract, 18, 22, 30, 40, 48, 54, 62, 66, 70, 74, 81, 84,
Results Screen, 217 88, 98, 104, 111, 121, 122, 123, 131, 137
Retract on Reject, 120, 140 Transducer, 11, 13, 40, 43, 52, 57, 59, 95, 96, 98, 101, 102,
RS232, 4, 5, 133, 155, 158, 160, 161, 205, 219 104, 107, 109, 111, 209, 210, 221, 222, 227
Security, 5, 16, 199, 201 Transducer Calibrate, 209
Segment Codes, 160, 243, 244, 245 Transducer Calibration Report, 209, 210
Self-Test, 1, 13, 16, 43, 113, 203, 220, 226, 227 Transducer Verification, 227
Self-Test Failed, 226 Transducer Verification Report, 209
Self-Test Passed, 226 Transducer Zero Bad, 222, 227
Sequential Linking, 8, 11, 80, 81 TST Parameter, 20, 25, 32, 41, 45, 50, 56, 63, 67, 71, 75, 86,
Setup, 5, 7, 13, 16, 96, 109, 201 91, 230, 232, 237
Severe Leak, 19, 23, 31, 49, 55, 85, 90, 129, 131, 136, 225, Two Inputs to Start, 119, 130
226 Units of Measure, 12
SPC, 129, 133, 158 Update Firmware, 204
Stabilization Time, 96, 99, 102, 105, 109, 112 USB Memory Stick, 3, 16, 202, 204
Stabilize, 17, 18, 21, 22, 27, 30, 31, 48, 54, 88, 90, 96, 98, USB Menu, 3
102, 104, 109, 111, 115, 129, 135, 225, 229 USB Port, 202, 204
Stabilize Time, 17, 21, 27, 220, 221, 226 Vent/Halt, 78, 129, 130, 131, 132, 141, 148
Start Channel, 129 Verify Transducer, 209

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258 www.cincinnati-test.com
Sentinel I28 Technical Specifications
Outside Physical Dimensions
Wall mount model (W x H x D): 305 x 235 x 222 (mm) 12 x 9.25 x 8.75 (inches)
Electrical Specifications
Supply power: 100-240 VAC 50-60 Hz auto sensing/switching
Input power fuse: 3 Amp 250VAC, slow, 5X20MM, glass
I/O driver fuse: 1 Amp 250VAC, fast, 5X20MM, glass
Board fuse: 3.125 Amp 250VAC, fast, radial leads, plastic can, vertical plug in fuse
Output current limit for each output: 0.5 amp max
Output current limit for all outputs combined: 1 amp max
Instrument may operate at ± 10% of nominal voltage
Environmental Factors
Operating temperature Range: 5°C to 40° C (41°F to 104°F)
Maximum humidity 90% relative humidity, non-condensing
Maximum operating altitude 2,500 meters (8,200 feet)
Indoor use only, IP20
Inlet Ports & Connection Type Connection Type & Max Pressure Rating
P1 1/4-18 FNPT or 1/4-19 BSPT fitting Vacuum to 200 psi (1380 kPa) *
P2 1/4-18 FNPT or 1/4-19 BSPT fitting Vacuum to 200 psi (1380 kPa) *
Pilot 1/8 FNPT or 1/8 BSPT fitting 65 to 105 psi (540 kPa to 725 kPa)
Hi Press 1/4-18 FNPT or 1/4-19 BSPT fitting 0 to 500 psi (3450 kPa)
* See label on instrument enclosure to determine whether port is for pressure or vacuum
Air Cleanliness Specifications
Max Particulate Size: 0.3 micron
Max Dew Point: -30°C
Max Oil: 0.1mg/m3
Recommended Filter Sets (available separately)
Small filter (includes 5.0 micron and 0.3 micron filters) for parts less than 300 ml
Medium filter (includes 5.0 micron and 0.3 micron filters) for parts from 300 ml to 13,000 ml
Large filter (includes 5.0 micron and 0.3 micron filters) for parts larger than 13,000 ml

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 Contact Cincinnati Test Systems Service Department
By phone 513-202-5108 or by email [email protected] 8am-5pm eastern US
For after-hours, 24/7 emergency phone support, call 513-202-5174

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