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SMART CHARGE IIGAS HANDLING SYSTEM

Operational and Maintenance Manual

P/N 861-018Rev. E

Vacuum Instrument CorporationDesigners and Manufacturers of Leak Detectors, Gas Handling Equipment, and Complete Leak Detection Solutions

2099 Ninth Avenue Ronkonkoma, New York 11779Tel 631 737 0900 Fax 631 737 1541 [email protected] www.vicleakdetection.com
mailto:[email protected]://www.vacuuminst.com/http://www.vacuuminst.com/mailto:[email protected]

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TABLE OF CONTENTS

TABLE OF CONTENTS......................................................................................................................................... i

Section 1: Installation and Utility Connection

1.1 Installation ........................................................................................................................................................ 1

1.2 Utility Requirements......................................................................................................................................... 31.3 Theory of Operation.......................................................................................................................................... 51.4 Operation Cycle ................................................................................................................................................ 6

II. SYSTEM OPERATION ............................................................................................................................... 11

PRE-OPERATIONAL REQUIREMENTS ...................................................................................................... 11

AUTOMATIC MODE...................................................................................................................................... 13

MANUAL MODE ............................................................................................................................................ 17

MANUAL STEP MODE .................................................................................................................................. 20

III. OPERATOR INTERFACE .......................................................................................................................... 22

MENU PAGES & PARAMETERS .................................................................................................................. 23

SMART CHARGE DEFAULT TERM DEFINITIONS................................................................................... 25

IV. TRANSDUCER CALIBRATION (ZERO).................................................................................................. 28

V. ALARM/ FAULT CONDITION DEFINITION .......................................................................................... 29

VI. PNEUMATIC DIAGRAM

VII. ELECTRICAL DIAGRAM

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SMART CHARGE II MANUAL - INDUSTRIAL LEAK DETECTION DIVISION

861-018 Rev. E 1

Section 1 INSTALLATION AND UTILITY CONNECTION

1.1 Installation

1. Place the SMARTCHARGE II unit on a solid surface with good access to the front panel and rear manifold.Identify the rear utility manifold bulkhead from the following figures:

STANDARD SMARTCHARGE MANIFOLD

SMARTCHARGE WITH HIGH PRESSURE OPTION

NOTEBulkhead plates are labeled with all standard option connection ports. Check the order to verify the optionscontained on a particular unit.

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2. Refer to the UTILITY REQUIREMENTS section. Attach all utility connections to the unit. Whenmaking hose connections to 1/4" NPT fittings, use LOCTITE HIGH TEMPERATURE ANTI-GALLINGPIPE SEALANT, # 567. Loctite item # 56747 or equivalent.

NOTEDo not use Teflon tape on pipe fittings as the tape particles can cause a pump malfunction or a valve leak.

3. Read the THEORY OF OPERATION section of this manual before proceeding to the SYSTEMOPERATION section.

1.2 Utility Requirements

ELECTRICAL 110-Volt AC, 50 - 60 Hz, 6.5 Amps nominal.

PUMP VENT (VACUUM) 1/4" NPT Female (should be positioned to an exterior connection)

VENT (PART) 1/4" NPT Female (should be positioned to an exterior connection)

HELIUM INLET 1/4" NPT Female, use maximum rated pressure for unit. LOW PRESSURE UNIT, 300 PSI. HIGH PRESSURE UNIT, 750 PSI.

(FOR AIR/NITROGEN PROOF TEST OPTION)AIR/NITROGEN INLET 1/4" NPT Female, use maximum rated pressure for unit. LOW PRESSURE UNIT, 300 PSI. HIGH PRESSURE UNIT, 750 PSI.

(FOR HELIUM RECOVERY OPTION)He OUTLET TO RECOVERY SYSTEM

1/4" NPT Female

NOTE

Do not "TEE" vents together as this will cause damage to the vacuum pump.

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1.3 Theory of Operation

The Vacuum Instrument Corporation standard Smart Charge II System is designed to provide basic helium andair/nitrogen gas leak detection. Leak detection is accomplished through a series of test steps that, together, form acycle of events. The basic cycle events are venting, evacuation, vacuum decay (pressure rise) testing, heliumcharging, pressure decay testing, helium venting to zero (0) PSIG, and final gas evacuation. This system has thefollowing features:

1. A 3.6 CFM, diaphragm type, two-stage evacuation pump providing vacuum to 25.5" Hg.2. An operator panel providing controls and testing indication.3. System alarms for evacuation, vent and charge faults.4. Operator Interface that allows adjustment to all programmable timer and setpoint values for all pertinent

cycle events.5. A Siemens CPU214 (S7-200 series) Programmable Logic Controller.6. A panel Key Switch that provides a hardware lockout of setpoint and timer value changing.

This system can be equipped with a series of factory options used to modify the cycle for specific customer applications. The table below provides option part numbers, applicable pressures and basic descriptions.

PART NUMBER PRESSURE DESCRIPTION

918-330 300 PSIG PROOF TEST OPTION-WITH HELIUM & N2 BACKFILL OPTION 918-331 * 750 PSIG PROOF TEST OPTION - ONLY WITH N2 BACKFILL

918-332 * 750 PSIG HIGH PRESSURE OPTION HELIUM ONLY

918-333 300 PSIG HELIUM RECOVERY OPTION

918-334 750 PSIG HELIUM RECOVERY OPTION

918-336 ALL 230 VAC TO 115 VAC VOLTAGE CONVERSION OPTION

918-337 ALL REMOTE I/O OPTION

* Need both If 918-332 is ordered, 918-331 is also needed.

There is one (1) standard Smart Charge II unit. Options are added for High Pressure operation (750 PSIG), Proof Test, Helium Recovery, Input Voltage Conversion and Remote I/O. The standard Smart Charge II unit is rated at300 PSIG and the high pressure at 750 PSIG. The definition of each of these options is as follows:

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Proof Test (Air/Nitrogen @ 300 or 750 PSIG) This is an additional leak test that provides a gross indication of the parts ability to maintain pressure of anAir/Nitrogen charge. This Air/Nitrogen charge is 300 or 750 PSIG.

NOTEFor the purpose of proof testing, the use of high pressure air or nitrogen gas is suitable. This gas is referred to asAir/Nitroten throughout the manual.

Two Step Test Is Performed1. During the Air/Nitrogen charge, the part is monitored for its ability to hold the charge. If the part has an

uncapped port or a very large hole it will prevent the charge pressure to build in the test part. If the charge pressure does not meet the charge pressure setpoint value within the watchdog timer value, the test will failand the cycle will be safely terminated.

2. After the Air/Nitrogen charge, the part is monitored for its ability to maintain the charge. If the part cannotmaintain the charge pressure setpoint value within the watchdog timer value, the test will fail and the cyclewill be safely terminated.

3. Once the product testing is completed, it can be back-filled with Nitrogen.

High Pressure Option (750 PSIG) This modification of the standard Smart Charge II allows it to work up to a pressure of 750 PSIG. Operationremains the same with an extended pressure range.

Helium Recovery Option This modification of the standard Smart Charge II allows the used Helium gas to be reclaimed to the externalVacuum Instrument Corporation gas recovery system. The Smart Charge II rear bulkhead panel Recover connection can be connected to an external Helium Recovery System. At the end of each cycle, the normally ventedHelium gas will be directed to the external gas recovery system.

230 VAC To 115 VAC Voltage Conversion Option This is a physical option on the unit that provides use of 230 VAC, 3 phase power. The transformer is mounted tothe rear of the unit frame.

Remote I/O OptionThis is an option on the unit that provides controller inputs and outputs. Inside the main enclosure are the terminal

blocks allowing external I/O connections.

The standard inputs to the unit are Cycle Start and Cycle End. These inputs allow an external system to start or stopa cycle.

The standard outputs are defined in the Output Configuration Table in the back of the manual. These outputs allowthe Smart Charge II unit to update the external PLC with the system status.

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1.4 Basic Operation

Complete setup of the system is possible through the Operator Interface. See the Operator Interface section of thismanual for details of menu structure.

The System Can Be Tested Using Three (3) Different Operating Modes As Follows

1. AUTOMATIC (AUTO) MODE2. MANUAL (MAN) MODE3. MANUAL STEP MODE.

The Automatic and Manual modes are selected by toggling the MAN function key. When the Automatic mode isselected, the function key LED will be off. When toggled to the Manual mode, the LED will illuminate solid. TheAutomatic mode is used to enable the complete automated test cycle using all programmed timer and setpointvalues. The Manual mode is used to enable the manually controlled cycle.

The Manual Step mode is used to enable the system diagnostic routine. This routine is used to verify proper operation of individual system components. The Manual Step mode can be enabled through the Diagnostic screen#3 from either Automatic or Manual modes. Again, there are NO watchdog timers enabled, leak or vacuum decaytests performed in this mode. The only active programmable functions are the pressure setpoints above atmospheric

pressure. This mode allows the operator to sequence all system valves for the purpose of troubleshooting.

Operation Cycle (Automatic and Manual mode)

The standard operation cycle consists of the following steps:1. READY TO CYCLE2. VENT BEFORE EVACUATION

3. EVACUATION with VACUUM DECAY (PRESSURE RISE) TEST4. HELIUM CHARGE5. SNIFF TEST6. FINAL VENT7. FINAL EVACUATION

NOTEOperation with N2 & backfill.

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5. PART EVACUATION with VACUUM DECAY (PRESSURE RISE) TEST - The part is evacuated asstated above. The Vacuum Decay (Pressure Rise) Test occurs while the part is fully evacuated. If anincrease in the pressure level of the part occurs, and this change value exceeds the programmed Reject Levelsetpoint before the Leak Test Time is elapsed, the part is rejected and a Large Leak Detected Fault prompt isdisplayed.

NOTEThe actual setpoint value and the programmed setpoint value differ approximately by a factor or 0.5 or 2 in Hg for each 1 psi. Therefore, for a programmed value of 20 in Hg (10 psi) the system will alarm at approximately 10 in Hg(5psi)

6. HELIUM CHARGE - The part is charged with helium by the opening of the Helium valve. The HeliumCharge function is pressure level dependent. This level is operator defined by the Helium Charge Levelsetpoint. If the time to reach this setpoint exceeds the Helium Charge Watchdog Time, the part is rejectedand a Helium Charge Fault is displayed.

7. PART SNIFF TEST - When the Helium Charge Level setpoint is met, the Helium valve closes and theoperator is prompted to perform the Sniff Test. This is the beginning of the Leak Test Time and the current

pressure value is captured. The pressure level is dynamically compared to the captured value for theduration of the leak test. If a decrease in the pressure level of the part occurs, and this pressure change valueexceeds the programmed Low Helium Charge Differential setpoint before the completion of the Sniff TestTime, the part is rejected and a Low Charge Fault prompt is displayed.\

8. FINAL VENT - The part is final vented by the opening of the Vent valve. The venting function is pressureand time dependent. If the part pressure remains above the Vent Level setpoint value, in excess of the VentWatchdog Time, the part is rejected and a Vent Fault is displayed.

9. HELIUM GAS RECOVERY (OPTION) - The test part gas is vented to an external Helium RecoverySystem by the opening of the helium recovery valve. The recovery function is pressure and time dependent.If the part pressure remains above the Helium Recovery Level value in excess of the Recovery WatchdogTime, the part is rejected and a Helium Recovery Fault is displayed.

10. FINAL EVACUATION - The part is Final Evacuated by the opening of the evacuation valve. Theevacuation function is performed by the part evacuation pump. The Final Evacuation function has three (3)

parts; a Delay To Evacuation Time, a pressure level dependant evacuation and a time dependant evacuation.First the evacuation is delayed for the duration of the Delay To Final Evac Timer. Next, the evacuation

begins and if the pressure rises above 45 PSIG at any time, the part is rejected and an Evac High Pressurefault is displayed. Lastly, if the pressure level rises above the Final Evac Fault level after the duration of theFinal Evacuation Time, the part is rejected and an Evacuation fault is displayed.

NOTEDuring an Air/Nitrogen Proof (Pressure Decay) Test or a Helium Pressure Decay Test a small pressure changeoccurs when the charge valve is closed. This change can be noted on the process graph during the StabilizationTime.

This small change in pressure occurs for two reasons:1. Adiabatic Heating - When a closed cavity is pressurized or evacuated, the air is normally heated above ambient

due to the gas compression or expansion. When this air heats or cools, the resulting pressure increases or decreases, respectively. During an evacuation cycle a pressure rise will occur and during a pressure cycle. Thisis a major factor for small pressure changes.

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2. System dynamics - The actual configuration of the system has an effect on gas pressure changes. An example of specific layout considerations would be piping size, pipe distance between components, valve types and supplygas pressures.

11. BACKFILL/PURGE OPTION - There are two modes of operation:a) BACKFILL - At the completion of a test, the part is back-filled to the customers programmed set point.b) N2 PURGE - At the completion of a test, the part is purged with N2 for the duration of the Watchdog

Timer. The will purge any residual helium from the test part.

NOTEThe Backfill option is only available with the N2 option.

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DEFINITION TABLEEVENT TIMES:

T0: CYCLE STARTT1: VENT VALVE OPENST2: VENT DELAY BEGINST3: VENT DELAY ENDS

VENT VALVE CLOSESEVAC. VALVE OPENSEVAC. VALVE CLOSES

T4: STABILIZATION TIME BEGINST5: STABILIZATION TIME ENDS

PRESS RISE TEST BEGINST6: PRESS RISE TEST ENDS

He CHARGE VALVE OPENST7: He CHARGE VALVE CLOSES

STABILIZATION TIME BEGINST8: STABILIZATION TIME ENDS

PRESS DECAY TEST BEGINST9: PRESS DECAY TEST ENDS

VENT VALVE OPENST10: VENT DELAY BEGINST11: VENT DELAY ENDS

VENT VALVE CLOSESEVAC. VALVE OPENS

T12: EVAC. VALVE CLOSESCYCLE ENDS

OPERATIONAL EVENTS

1: PART INITIALLY CHARGED2: PRESSURE VENT3: TIME VENT4: EVACUATION5: STABILIZATION TIME6: PRESSURE RISE TEST7: He CHARGE8: PRESSURE STABILIZATION TIME

9: PRESSURE DECAY TESTSNIFF TEST10: PRESSURE VENT11: TIME VENT12: EVACUATION

SET POINTS

S1: VACUUM DECAY DIFFERENTIAL SETPOINTS2: He CHARGE LEVEL SETPOINTS3: He DECAY DIFFERENTIAL SETPOINT

Fault Condition Initiates Final Vent, Final Evacuation And Cycle End

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DEFINITION TABLEEVENT TIMES:

T1: PART INITIALLY VENTEDN2 CHARGE VALVE OPENS

T2: N2 CHARGE VALVE CLOSESSTABILIZATION TIME BEGINS

T3: STABILIZATION TIME ENDSPRESS DECAY (N2 PROOF) BEGINS

T4: PRESS DECAY (N2 PROOF) ENDSVENT VALVE OPENS

T5: VENT DELAY BEGINST6: VENT DELAY ENDS

EVAC VALVE OPENST7: EVAC VALVE CLOSES

He CHARGE VALVE OPENST8: He CHARGE VALVE CLOSES

STABILIZATION TIME BEGINST9: STABILIZATION TIME ENDS

PRESS DECAY (He) BEGINSSNIFF TIME BEGINS

T10: PRESS DECAY (He) ENDSSNIFF TIME ENDS

VENT VALVE OPENST11: VENT DELAY BEGINST12: VENT DELAY ENDS

VENT VALVE CLOSESEVAC VALVE OPENS

T13: EVAC VALVE CLOSESCYCLE ENDS

OPERATIONAL EVENTS

1: AIR/NITROGEN (N2) CHARGE2: PRESSURE STABILIZATION3: AIR/NITROGEN PRESSURE DECAY4: PRESSURE VENT5: TIME VENT6: EVAC

7: HELIUM (He) CHARGE8: PRESSURE STABILIZATION9: He PRESSURE DECAY TEST

SNIFF TEST10: He RECOVERY VALVE OPENS11: He RECOVERY VALVE CLOSES

EVAC VALVE OPENS12: TIMED EVAC BEGINS13: TIMED EVAC ENDS

EVAC VALVE CLOSES

SETPOINTS

S1: AIR/NITROGEN (N2) CHARGE LEVELS2: AIR/NITROGEN (N2) DECAY DIFFS3: HELIUM (He) CHARGE LEVELS4: HELIUM (He) DECAY DIFF

Fault Condition Initiates Final Vent, Final Evacuation And Cycle End

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II. SYSTEM OPERATION

WARNINGBefore servicing this unit always disconnect the main power to avoid an unsafe condition that could result in

personal injury.

Before a part can be disconnected from the system verify that the cycle has been completed and the pressure gaugereads 0 psig to avoid sudden high pressure gas expulsion and possible personal injury. The vacuum gauge shouldindicate approximately 12 in Hg at this time. This is a normal and safe condition.

Before a cycle can be initiated, a part must be connected to the system, avoiding sudden high pressure gas expulsionand possible personal injury.

NOTESa. Pressing the "Emergency Stop" (red mushroom head pushbutton) at any time will cause the test line to vent

immediately and return all valves to a safe condition. Electrical power to the vacuum pump, solenoid valvesand controller will be disconnected.b. Turning the AUTO\OFF\MAN selector switch to the "OFF" position will automatically vent the part and

terminate the cycle.c. Depressing the "CYCLE END" push button at any time will cause a systematic termination of the cycle and

return the machine to the READY condition.

PRE-OPERATIONAL REQUIREMENTS

There are Pre-Operational requirements that must be checked as follows: Verify that the system has been properly installed with all connections verified before beginning a Test

Cycle. Verify that all bottled gases and shop air are properly connected to the header and at the correct pressures. Verify that the vent lines are properly connected to the bulkhead. Verify that all the Setup Screens have been properly set. Verify that all the Machine Parameters have been properly set.

1. Rotate the Power Switch to the ON position. The following will be displayed on the Operator Interface.

UNIOP V X.XXOPERATION MODE

AUTOMATIC MODECRM POWER OFF

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2. Press the CRM power pushbutton, it will illuminate solid. The following will be displayed on the Operator Interface;

AUTOMATIC MODEREADY TO CYCLE

NOTEThe system will start-up in the last mode it was powered down in.

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AUTOMATIC MODE

Standard Unit Operational Steps1. Install part to test port.2. If the system was powered in Manual mode, press the MAN key to place it in Automatic mode. The MAN

LED should cease to illuminate.3. Press the PUMP key. The evacuation pump will be enabled and the PUMP LED will illuminate.4. Press the Cycle Start pushbutton. The system automatic (AUTO) cycle will run. The sequence of events

and Operator Interface screens are as follows:

The automatic mode is initiated.

AUTOMATIC MODEREADY TO CYCLE

The test part is vented.

AUTOMATIC MODEVENTING PART

The test part is evacuated.

AUTOMATIC MODEEVACUATING PART

The test part is leak tested.

AUTOMATIC MODELEAK TESTING PART

The test part is Helium charged.

AUTOMATIC MODEHELIUM CHARGE

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The test part is Sniff tested. A beep occurs to alert the operator of the beginning of the Sniff Test.

AUTOMATIC MODESNIFF TEST PART

A beep occurs to alert the operator of the ending of the Sniff Test.

The test part is Final Vented.

AUTOMATIC MODEFINAL VENT

The test part is Final Evacuated.

AUTOMATIC MODEFINAL EVACUATION

A double beep occurs to alert the operator of the ending of the cycle completion.

When the system is equipped with the Air/Nitrogen Proof Test option, the following screens will appear on thedisplay at the beginning of the cycle:

The test part is Air/Nitrogen charged.

AUTOMATIC MODE N2/AIR CHARGE

The test part is allowed to pressure stabilize.

AUTOMATIC MODESTABILIZING PRESSURE

The test part is Proof tested.

AUTOMATIC MODELEAK TESTING PART

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When the system is equipped with the Helium Recovery option, the following screens will appear on the display atthe end of the cycle:

The test part is vented to the Helium Recovery Port.

AUTOMATIC MODERECOVERING HELIUM

The test part is Evacuated.

AUTOMATIC MODEFINAL EVACUATION


NOTETo disable set to 14.0 psig

BACKFILL OPTION

From the Main Menu Scroll to access Backfill Charge Setup Screens.

BACKFILL CHARGE SETUP

#1 BACKFILL CHARGE LEVEL

#2 BACKFILL CHARGEWATCHDOG TIME

PRESS F1 TO EXITMORE SETUP

This screen allows access to the BackfillSetup parameters.

This is the pressure level the test part is back filled to at the end of a test. A value of -14.7 psiwill indicate that the backfill option is disabled

Maximum time allowed charging the part tothe charge pressure set point.

Pressing F1 to exit Backfill setup menu or pressing the arrow key for the followingadditional setup screens

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CYCLE SETUP

#1 NOT IN CYCLE/VENTOPEN F6 > CHANGE [ X ]

Cycle setup allows access to additional setupscreens

This indicates the status of the vent valve when not in testcycle. To open the vent valve press F6 a check [ ]indicates valve open. To close the vent valve pressing F6with an X [ X ] indicating vent

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MANUAL MODE

Standard Unit Operational Steps1. Install part to test port.2. Press the MAN key to place it in Manual mode. The MAN LED should illuminate solid.3. Press the PUMP key. The evacuation pump will be enabled and the PUMP LED will illuminate.4. Press the Cycle Start pushbutton. The system manual (MAN) cycle will run up to the Sniff Test. The Cycle

End pushbutton will be required to be pressed to continue the cycle to the end. The sequence of events andOperator Interface screens are as follows:

The manual mode is initiated.

MANUAL MODEREADY TO CYCLE


MANUAL MODEVENTING PART


MANUAL MODEEVACUATING PART

The test part is leak tested.

MANUAL MODELEAK TESTING PART

The test part is HELIUM charged.

MANUAL MODEHELIUM CHARGE

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The test part is SNIFF tested. A beep occurs to alert the operator of the beginning of the SNIFF TEST.

MANUAL MODESNIFF TEST PART

A beep occurs to alert the operator of the ending of the SNIFF TEST.

The test part is FINAL VENTED.

MANUAL MODEFINAL VENT

The test part is FINAL EVACUATED.

MANUAL MODEFINAL EVACUATION


When the system is equipped with the AIR/NITROGEN PROOF TEST option, the following screens will appear onthe display at the beginning of the cycle:

The test part is AIR/NITROGEN charged.

MANUAL MODE N2/AIR CHARGE

The test part is allowed to pressure stabilize.

MANUAL MODESTABILIZING PRESSURE

The test part is PROOF tested.

MANUAL MODELEAK TESTING PART

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When the system is equipped with the HELIUM RECOVERY option, the following screens will appear on thedisplay at the end of the cycle:

The test part is vented to the HELIUM RECOVERY PORT.

MANUAL MODERECOVERING HELIUM

The test part is EVACUATED.



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MANUAL STEP MODE

STANDARD UNIT OPERATIONAL STEPS

1. Install part to test port.

2. Press the F3 key, DIAGNOSTICS. The following screen will appear;

DIAGNOSTICS

3. Press the Down Arrow key until SCREEN #3 appears as follows;

MANUAL STEP MODE"MAN" > ON/OFF

Press the MAN key to toggle the mode to MANUAL STEP. The MAN LED will illuminate and blink.

4. Press the CYCLE START push button. The manual step mode will run a diagnostic machine cycle by theoperator pressing the CYCLE START button once to start and the CYCLE START push button at the end of each step to continue. The operator must wait three (3) seconds between push button presses. This mode isused primarily as a diagnostic tool to troubleshoot problems in the AUTOMATIC and MANUAL

sequences. The sequence of events and console screens are as follows:

The manual step mode is initiated.

MANUAL STEP MODEPRESS CYCLE START


MANUAL STEP MODEPART VENT

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MANUAL STEP MODEEVACUATING PART

The test part is helium charge.

MANUAL STEP MODEHELIUM CHARGE

NOTE: THE PART IS FINAL VENTED AS THE LAST STEP. THIS PROMPT IS NOT DISPLAYED.

When the system is equipped with the AIR/NITROGEN PROOF TEST option, the following screens will appear onthe display at the beginning of the cycle:

The test part is AIR/NITROGEN charged.

MANUAL MODE N2/AIR CHARGE

When the system is equipped with the HELIUM RECOVERY option, the following screens will appear on thedisplay at the end of the cycle:

The test part is vented to the HELIUM RECOVERY PORT.

MANUAL MODERECOVERING HELIUM

The test part is EVACUATED.



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III. OPERATOR INTERFACE

The OPERATOR INTERFACE allows the operator to completely configure and operate the SMARTCHARGE IIsystem. The front panel of the interface contains a series of key switches and LED's. There are four (4) arrow keysthat allow movement through the menu structure. There are also six (6) function keys that have specific functions,which are continuously active.

FUNCTION KEYS

.The function keys have the following definitions:

F1: EXIT (RETURNS TO THE "READY TO CYCLE" PROMPT.F2: SETUPF3: DIAGNOSTICSF4: MACHINE CONFIGURATIONF5: (NOT USED)F6: (NOT USED)

SPECIAL KEYS

There are six special keys that have the defined functions as follows:

PUMP: PUMP ENABLEMAN: MODE ENABLEZERO: TRANSDUCER ZERO FUNCTIONHELP: PROVIDES A SERIES OF ON-LINE HELP SCREENSCLEAR: CLEARS VALUES FROM SCREENSENTER: CONFIRMS ENTERED VALUES

FunctionKeys

Arrow Keys

Operator Interface Front Panel

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MENU PAGES & PARAMETERS

These pages and parameters are accessed using the arrow keys. Pressing the 8 and 9 arrows permit movementthrough the parameters listed under each setup section. The 6 and 7 keys permit movement among the sectionsthemselves.

The following is a list of SETUP sections:

PROOF CHARGE SETUP : LEAK TEST SETUP : VENT BEFORE HELIUM CHARGE SETUP : HELIUM CHARGE SETUP : SNIFF TEST SETUP : FINAL VENT SETUP : FINAL VENT SETUP : FINAL EVAC SETUP :BACKFILL CHARGE

The following are the parameters listed under each section:

PROOF CHARGE SETUP

#1 NITROGEN CHARGE LEVEL#2 NITROGEN CHARGE WATCHDOG

LEAK TEST SETUP

#1 PRESS. STABILIZE TIME#2 LEAK TEST TIME#3 REJECT LEVEL

#4 LOW N2 CHG. DIFF.

VENT BEFORE HELIUM CHARGE SETUP

#1 VENT WATCHDOG#2 VENT LEVEL

HELIUM CHARGE SETUP

#1 DELAY TO EVACUATE PART#2 EVACUATION TIME#3 EVACUATION FAULT LEVEL#4 HELIUM CHARGE LEVEL#5 HELIUM CHARGE WATCHDOG

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SNIFF TEST SETUP

#1 LOW He CHG DIFF LEVEL

FINAL VENT SETUP

#1 FINAL VENT WATCHDOG#2 FINAL VENT LEVEL

FINAL EVAC SETUP

#1 DELAY TO FINAL EVAC.#2 FINAL EVACUATION TIME#3 FINAL EVAC FAULT LEVEL

The following are the parameters listed under the DIAGNOSTICS section:

#1 CYCLE TIME#2 PRESSURE OFFSET#3 MANUAL STEP MODE#4 CPU PROGRAM#5 HMI PROGRAM

The following are the parameters listed under the MACHINE PARAMETERS section:

#1 TXDR FULL SCALEMaximum scaled range of the transducer

Factor setting for standard low-pressure unit 329.76Factory setting for High pressure unit 764.70

#2 MAXIMUM TXDR PRESSUREMaximum transducer operating pressure.

Factory setting for standard unit 315 psigFactory setting for high pressure unit 750 psig

#3 MAXIMUM MACHINE PRESSURE

Maximum operating pressure of unit

Factory setting for standard unit 300 psigFactory setting for high pressure unit 750 psig

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To change these values:

1. Press and HOLD the CLEAR button for 10 seconds.2. The letter ( U ) will appear on the display3. Press the INS button, the cursor will begin to flash4. Change the values to correspond with type of unit

NOTE: Changing the set up parameters to high pressure without changing the transducer or valving canresult in personal injury or may damage the unit..

HELP MENUS

The HELP function is a series of screens accessible using the 8 and 9 keys. It is used to globally change the prompts to the Spanish language and to define function keys.

SMART CHARGE DEFAULT TERM DEFINITIONS

Evacuation Time- Time the evac valve is open for Initial Evacuation.

Delay to Evac part- Length of dwell after part is vented until Evac begins... May be required toallow for full venting in some cases.

Evacuation Fault Level- Setpoint (in PSIG) that the transducer must reach during Evacuation time or afault will be triggered.

Pressure Stabilize Time- Length of dwell after evacuation valve closes until the Pressure Rise test begins. Allows for dynamic/thermal effects to subside.

Leak Test Time- Length of dwell during which the pressure rise is observed in the part.

Reject Level- Amount of pressure rise allowed during Leak Test time.

Low Vacuum Fault Level- Setpoint (in PSIG) for the pressure rise the part can experience after evacuation (during stabilize time) but before vacuum decay test begins.Guards against loss of vacuum level before decay test starts.

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Nitrogen Charge Level- Setpoint (in PSIG) that the transducer must reach during Nitrogen charge or afault will be triggered.

Nitrogen Charge Watchdog- Length of time allowable for transducer to reach Nitrogen charge level.

Pressure Stabilization Time- Length of dwell after nitrogen charge valve closes until Pressure Decay test begins.

Leak Test Time- Length of dwell during which the pressure drop is observed in the part.

Reject Level- Amount of pressure drop allowed during Pressure Decay test.

Low N2 Diff Charge Level- Amount of pressure drop (in PSIG) (from Nitrogen charge level) allowable@ any time during testing or test is failed.

Vent Watchdog- Length of time allowable for part to vent to (vent level setting, in PSIG) before Helium charge.

Vent Level- Pressure (in PSIG) that system must vent to before initiating Evac. This isset above atmosphere, since pump can handle some pressure and venting to"zero" would take too long & produce false rejects. Note that delay to Evacalso allows for added venting.

Helium Charge Level- Setpoint (in PSIG) that the transducer must reach during Helium charge or a fault condition will occur.

Helium Charge Watchdog- Length of time allowable for transducer to reach Helium charge level.

Sniff Test Time- Set length of time from attaining full helium charge until the automaticventing of helium to allow for sniffing part.

Low Helium Charge Diff.- Amount of pressure drop (in PSIG) from Helium charge level allowable @any time during testing, or test is failed.

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IV. TRANSDUCER CALIBRATION (ZERO)

The pressure transducer is responsible for providing accurate test part pressure readings to the PLC. It isrecommended that this transducer be calibrated a minimum of once each day or each time the unit is powered-onfrom a cold start. Calibrate the transducer using these steps:

1. Start the system in accordance with Section II., SYSTEM OPERATION.

2. Press the F1 function key to advance to the "READY TO CYCLE" prompt.

3. Press the 9 key to access the "PRESSURE - DELTA" screen.

4. Press the ZERO key on the OPERATOR INTERFACE panel.

NOTE: THE SYSTEM MUST BE CALIBRATED WITH THE MANIFOLD AT ATMOSPHERICPRESSURE. FAILURE TO DO THIS WILL CAUSE INACCURATE TEST PRESSUREREADINGS. NEVER ZERO THE SYSTEM WHILE A CYCLE IS IN PROGRESS.

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V. ALARM/ FAULT CONDITION DEFINITION

VENT FAULT: If the part pressure remains above the VENT LEVEL setpoint value,in excess of the VENT WATCHDOG time, the part is rejected and aVENT FAULT is displayed.

EVACUATION FAULT: After the EVACUATION LEVEL setpoint has been reached; if the pressure level rises above the EVACUATION FAULT LEVEL after the duration of the EVACUATION TIME, the part is rejected and anEVACUATION FAULT is displayed.

EVAC. HIGH PRESSURE : If the pressure rises above 45 PSIG at any time, the part is rejectedand an EVAC HIGH PRESSURE fault is displayed.

HELIUM CHARGE FAULT: If the HELIUM CHARGE LEVEL setpoint is not met within theHELIUM CHARGE WATCHDOG time, the part is rejected and aHELIUM CHARGE FAULT is displayed.

LARGE LEAK DETECTED: If an increase in the pressure level of the part occurs, and this changevalue exceeds the programmed REJECT LEVEL setpoint before theLEAK TEST TIME is elapsed, the part is rejected and a LARGELEAK DETECTED fault prompt is displayed.

LEAK DETECTED FAULT: If an increase in the pressure level of the part occurs, and thisdifferential change value exceeds the programmed REJECT LEVELsetpoint before the LEAK TEST TIME is elapsed, the part is rejectedand a LEAK DETECTED FAULT prompt is displayed.

LOW CHARGE FAULT: If a decrease in the pressure level of the part occurs, and this pressurechange value exceeds the programmed LOW He. CHARGEDIFFERENTIAL setpoint before the completion of the SNIFF TESTTIME, the part is rejected and a LOW CHARGE FAULT prompt isdisplayed.

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LOW N2/AIR CHARGE FAULT: If, during the N2 STABILIZATION TIMER, the pressure falls 50PSI from the AIR/NITROGEN CHARGE LEVEL setpoint, a LOW

N2/AIR CHARGE FAULT is displayed.

N2/AIR CHARGE FAULT: If the time to reach the AIR/NITROGEN CHARGE LEVEL setpointexceeds the NITROGEN CHARGE WATCHDOG TIME, the part isrejected and an N2/AIR CHARGE FAULT is displayed.

He RECOVERY FAULT: If the part pressure remains above the He RECOVERY LEVEL valuein excess of the RECOVERY WATCHDOG time, the part is rejectedand a He RECOVERY FAULT is displayed.

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Vacuum Instrument Corporation2099 Ninth Avenue, Ronkonkoma, NY 11779Tel # (631) 737-0900 Fax # (631) 737-1541

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