Furness controls FCO770 Manual Download Page 1

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Manufactured by:

FURNESS CONTROLS LIMITED

Beeching Road, Bexhill, East Sussex, TN39 3LJ, England.

Telephone (01424) 730316. Fax: (01424) 730317

FCO770

LEAK DETECTOR

USERS GUIDE

Summary of Contents for FCO770

Page 1: ...g Manufactured by FURNESS CONTROLS LIMITED Beeching Road Bexhill East Sussex TN39 3LJ England Telephone 01424 730316 Fax 01424 730317 Email sales furness controls com Web Site www furness controls com...

Page 2: ......

Page 3: ...ILL 14 INSTALLATION 15 GENERAL 15 LOCATION 15 PNEUMATICS 15 TEST ITEM 16 ELECTRICAL SUPPLY 16 WIRING CONSIDERATIONS 17 BASIC OPERATION 18 MENU NAVIGATION 19 MENU NAVIGATION DIAGRAM 20 MAIN OPERATOR DI...

Page 4: ...O A JIG 82 CONNECTING A VENT VALVE 82 CONFIGURING FOR A DUMP TEST 83 ELECTRICAL INPUT CONNECTION METHODS 84 CONTROL INPUT CIRCUITS 85 CONNECTING TO A PLC 86 MULTI JIG FUNCTION 87 CALIBRATE FLOW PROCED...

Page 5: ...FCO770 Users Guide Issue 1 Page 5 REVISION RECORD Issue Date Summary of changes 1 16 05 12 First Release...

Page 6: ...should be periodically checked and drained as necessary Failure to do so may invalidate the Guarantee The instrument air quality must be better than ISO8573 1 Class 1 4 2 This equates to Particle 0 1...

Page 7: ...ude large text instantaneous colour graphs trend graphs and data logging Retains up to 300 sets of test configurations for different products or components Each configuration may be given a meaningful...

Page 8: ...nts and sizes The touch screen is used to directly program the instrument and to show operational status and result values when testing Result Graphic A single area at the lower middle of the LCD scre...

Page 9: ...l occur Calibration Port The self sealing calibration port allows for easy checking of the instruments calibration without the need to connect into the test lines The calibration port is intended for...

Page 10: ...ing to a PLC or other control system The standard instrument has twelve user programmable inputs with an option for an additional twelve Output Terminals The active high outputs may be used for result...

Page 11: ...ti ic c C Co on nn ne ec ct ti io on ns s TEST Pneumatic Outputs P1 Jig P2 Vent P3 P4 P5 AIR SUPPLY MIN 5BAR MAX 10BAR REGULATOR SUPPLY REGULATED AIR IN REGULATED AIR OUT Test Test Ports The Test and...

Page 12: ...ing Jig Pilot P1 This is primarily intended to provide pilot air to control jig clamps usually via a 5 port valve and an air cylinder The port accepts 4mm O D Nylon tubing The jig pilot is activated a...

Page 13: ...0 3 seconds is recommended As many leak specifications are written in flow units it is easier to verify actual readings against the specification Flow conversions are carried out when the leak units...

Page 14: ...indicating a large gross leak 2 For some test items the pressure may be lost too quickly to be able to discriminate with method 1 In this case we have an option to continue filling during the test st...

Page 15: ...supply at the test pressure to the Regulated Air In port If the optional internal regulator is fitted then the regulated air in port is normally connected to the regulated air out port and the test su...

Page 16: ...nts distortion of the test piece E El le ec ct tr ri ic ca al l S Su up pp pl ly y Connect a suitably fused 24V DC supply to the instrument The instrument must be connected in compliance with all loca...

Page 17: ...ical noise induction on the wires Lead lengths should be kept to a minimum The shield should be grounded at one end only Inductive loads When inductive loads such as relays or solenoids are switched o...

Page 18: ...d define the test steps to perform TEST DATA Specify the type of test to perform and define its timings levels and limits BATCH SETTINGS Configure batch control or disable it for continuous testing UT...

Page 19: ...CO770 has a number of menus that have text to enter e g Test I D Product I D etc When editing text you will see a dialogue input box like this The text to edit appears highlighted blue in the cream co...

Page 20: ...UTION DIGITS FAIL 2 FILL ON FAIL END ON FAIL PREFILL PRESSURE PRODUCT NUMBER OFFSET VOLUME STATUS LINE COMBO 2 FUNCTION COMBO 2 INPUT 1 COMBO 2 INPUT 2 COMBO 3 FUNCTION COMBO 3 INPUT 1 COMBO 3 INPUT 2...

Page 21: ...ND PRODUCT No SEND PRODUCT RESULT SEND TEST COUNTER SEND TEST I D SEND TEST No COPY PRODUCT DATA COPY TEST DATA TEST DATA SEND TIME SEND DATE SEND BATCH I D SEND SERIAL No TYPE SERIAL TYPE SERIAL MASK...

Page 22: ...intenance Early Warning System See Warning System The default run time display indicates the status and results of the test along with a customizable user graphic Operators with appropriate access rig...

Page 23: ...duct under test GRAPH DISPLAY Shows a graph plotting the various stages of a test in real time whilst the test is running Pressure readings are plotted in blue with their scaling shown against the lef...

Page 24: ...values for the test selected The eraser button shown below the monitoring window can be pressed at any time To immediately clear the current plot TEST MONITORING OPTIONS The test selected for monitori...

Page 25: ...content of that product can be expanded out by pressing its corresponding button as below Above shows the various steps and corresponding tests that make up a typical product In this case there was 2...

Page 26: ...iately to the right of the Logged Data product view button Firstly the button can be pressed to show a tabulated view of data settings and results for that test Notice that all tests and their data ar...

Page 27: ...nd allow auto scrolling to continue as normal PRODUCT RESULT DATALOGGING OPTIONS Data logging options can be configured by clicking on the Data Logging options button This will bring up the following...

Page 28: ...y results are recalled when pressing the or button Pressing the Last button will immediately recall logged results prior to those being displayed Pressing the Next button will immediately recall logge...

Page 29: ...tiple steps GRAPH units are consumed at the rate of approximately 1 5 per single test and less for products containing multiple steps The Max Datalog memory reserved for storing graphs setting can be...

Page 30: ...ting Options o NO The product to test can only be selected from the Product entry above This can be pass code protected if required o FRONT PANEL The front panel may be used to select the product to t...

Page 31: ...the settings are hidden in the test data menu o Yes Enables a prefill pressure prefill timer and vent prefill timer to be set in each test LEAK E O T Normally the leak value is displayed during the t...

Page 32: ...and outputs then set the time to zero A Z DELAY The differential pressure measurement always takes a zero reference point at the start of the test stage of a leak test There are some rare application...

Page 33: ...buttons are enabled at the same time as the remote control start reset inputs Start and Reset signals may also be provided by Fbus Communications or a barcode reader VENT SENSOR When a vent valve with...

Page 34: ...ch decimal digit of the product Although binary can represent values 0 to 15 with 4 bits Binary Coded Decimal only uses values 0 9 for each decimal digit If you have less than 100 products then you do...

Page 35: ...trol functions of RESET START JIG SENSOR and VENT SENSOR USER I P A H Define the usage of each of the eight programmable inputs functions These are only used if an input bank is assigned for User I P...

Page 36: ...ESET o These may be used for remote control when the Basic Functions bank is programmed for an alternate use Reset is fail safe active low o RESET This active high reset input is for applications that...

Page 37: ...ht outputs are configured for the normal basic needs of the leak detector i e READY FAULT PRODUCT PASS PRODUCT FAIL JIG VENT REG2 PREFILL o EXTENDED RESULTS Used when individual step result outputs ar...

Page 38: ...o PASS FAIL 5 8 Used for multiple part testing The results of steps 5 to 8 are latched until reset There are four pass outputs A D and four fail outputs E H o STEP OUTPUTS 9 16 Each of the product ste...

Page 39: ...t may be used for jigging functions These apply a logical function to two signals from the Common Output Function List to give a new output signal The combo function block should be considered a havin...

Page 40: ...ST O P H STABILISATION STAGE WARNING SYSTEM TEST STAGE END OF TEST FAULT TIMER 1 PRESSURE LOW TIMER 2 PRESSURE HIGH COMBO 1 PRODUCT RESULT COMBO 2 PRODUCT PASS COMBO 3 PRODUCT FAIL COMBO 4 RESULT AIR...

Page 41: ...exactly The wild card characters are o 0 to 9 or required o A Z or required upper or lower case is accepted o A character is required but the actual character is not checked o Space Character positio...

Page 42: ...gross leak check If the flow is too large to discriminate with this method it is possible to continue filling during the test stage and perform a back pressure test o PERMFILL Permanent Fill is not r...

Page 43: ...am me et te er rs s LEAK UNITS Choose the engineering units for the leak display The FCO770 can display the leak in either pressure units pressure rate units or flow units See the specification table...

Page 44: ...r than the desired pressure depending if it is a vacuum or pressure test or possibly upon the result of a previous test if used in a sequence To ensure that the item fills towards the required pressur...

Page 45: ...uld adjust the fill time to about 30 more than the time taken to fill to the required pressure STAB TIME Sets the time that the test item is allowed to stabilise for after the fill pressure has been r...

Page 46: ...output is deactivated when the test is started o TEST The output is only active once the test is started FEEDBACK A H Define which feedback inputs are required before the test is allowed to run The f...

Page 47: ...ers Guide Issue 1 Page 47 o OFF The input is expected to be inactive during the stabilisation time o CHANGE The input is checked at standby and is expected to change state before the stabilisation sta...

Page 48: ...tions o NO regulator 1 is used for the test o YES regulator 2 is used for the test o PREFILL regulator 2 is used if auto prefill is enabled o FILL regulator 2 is used for the test CHECK STANDBY PRESSU...

Page 49: ...esired pressure depending if it is a vacuum or pressure test or possibly upon the result of a previous test if used in a sequence To ensure that the item fills towards the required pressure rather tha...

Page 50: ...m is not unclamped while pressurised TEST O P A H For each of up to eight outputs define when the output is active Options o OFF The output is not activated for this test o ON The output is active for...

Page 51: ...tor Electrical or pneumatic outputs may be programmed to select an external regulator Options o NO regulator 1 is used for the test o YES regulator 2 is used for the test o PREFILL not intended for us...

Page 52: ...te correct positioning of the jig Each of up to eight possible inputs may be selected on 1 or off 0 e g to wait for inputs A and C the setting will be 10100000 Feedback is checked after the test outpu...

Page 53: ...the peak pressure is latched and used for the comparison against fail limits This is more useful for test items that cause the pressure to fall when they actuate SENSITIVITY At the start of the test t...

Page 54: ...ct positioning of the jig Each of up to eight possible inputs may be selected on 1 or off 0 e g to wait for inputs A and C the setting will be 10100000 Feedback is checked after the test outputs A H h...

Page 55: ...o 100 to completely disable the tolerance check PREFILL TIME This is normally only used for vacuum tests with air saving to allow time for the reference volume to be filled It is usual for positive pr...

Page 56: ...regulator 1 is used for the test o YES regulator 2 is used for the test o PREFILL regulator 2 is used if auto prefill is enabled o FILL regulator 2 is used for the test CHECK STANDBY PRESSURE Disable...

Page 57: ...essure level at which the instrument will indicate a fail in the negative leak region This should be set as a positive value PREFILL TIME Only used with auto prefill and only displayed if auto prefill...

Page 58: ...nputs must be configured in the I O Configuration menu FEEDBACK TIMEOUT The default feedback timeout is set to 0 0 which disables the timeout function The instrument will display Awaiting Feedback unt...

Page 59: ...H This resets the counters to zero and clears the Batch Complete status ready to start the next batch You will be prompted for confirmation If you do not use batch control this may be used to simply r...

Page 60: ...y to fit the 770 s display aspect The image should be saved as a JPEG or TIFF file and in the format Testxxxx JPG or Testxxxx TIF where xxxx the test number i e for test 13 the filename might be Test0...

Page 61: ...e FCO770 and you will be asked to remove the memory stick before proceeding Click OK when ready An information window will now pop up with details of the components available in the update together wi...

Page 62: ...tilities Menu button to activate this menu A menu screen similar to that below will then show Use the 4 direction buttons plus the Enter and ESC buttons to navigate this menu A description of their us...

Page 63: ...actory calibration o Press ENTER again to finish CALIBRATE D P Normal calibration is carried out at the factory and the information is stored securely in the instrument This information cannot be alte...

Page 64: ...nstruments settings to be printed Note that this menu option will not appear if the printer port is disabled in the Printer Settings menu Options Sub menu o PRODUCT DATA o TEST DATA o GLOBAL SETTINGS...

Page 65: ...e is a build option for enhanced i o Inputs are grouped in banks of four Outputs are grouped in banks of eight Refer to the I O Configuration menu settings for signal usage Press the Esc button to exi...

Page 66: ...e serial ports The baud rate must be the same on the FCO770 and device being connected When using the LAN the baud rate must match the configuration of the LAN adaptor This is not used for USB Options...

Page 67: ...orts are available for selection the barcode reader would usually be connected to the RS232 port Options o DISABLED The barcode reader is not available o RS232 Uses the 9 way D rear panel connector o...

Page 68: ...s pairs There must be no ambiguity between the barcode data A valid product code MUST be scanned before a serial number code is accepted If a product identifier is scanned that matches the barcode i d...

Page 69: ...Space Character position is not checked START ON SCAN When the expected barcode data has been read the instrument can be commanded to automatically start a test Options No Yes SCAN ON FAIL When a pro...

Page 70: ...umber is automatically incremented after every result and appended to a prefix o AUTO ON PASS The six digit serial number is automatically incremented after every pass and appended to a prefix o BARCO...

Page 71: ...00 PARITY Select the type of parity error checking to use when sending data via the RS232 RS485 and LAN ports Parity is not used for the USB port The parity setting must be the same on the FCO770 and...

Page 72: ...Test Press T P Units Leak Leak Units Termination xxx xx xxxxxxx xxxxx xxxxxxx xxxx x x x 01 P 0 400 kPa 0 1 PA CR LF EOF o CUSTOM 1 This allows the printed result to be customised using the settings...

Page 73: ...6 Choose any combination of the six user defined text lines DATE Only if a real time clock is fitted TIME Only if a real time clock is fitted PRODUCT I D From the Product Data menu PRODUCT No The prod...

Page 74: ...within a green box When a MEWS warning is active values that are in error are shown within a red box LIMITS o Cycle Count million set in millions of cycles o Latency set in seconds o Leak Zero set as...

Page 75: ...ith a fault MEWS may be used to give a warning before the instrument fails o Calibration Due it is recommended that the calibration of this instrument is checked annually or as often as your quality s...

Page 76: ...o NO unlocked o SUPERVISOR all settings are locked o OPERATOR all settings locked except those that an operator requires e g the batch control menu SECURITY CODE Allows the user to set a personal secu...

Page 77: ...13 Fail 2 29 14 Pressure Gross 30 15 Pressure High 31 16 Pressure Low 32 1 2 4 3 6 5 0V 0V 24V 11 12 14 13 16 15 7 9 8 10 Optional 17 18 20 19 22 21 0V 0V 24V 27 28 30 29 32 31 23 25 24 26 The output...

Page 78: ...OM 13 20 21 17 16 19 18 22 23 24 COM 24V 0V The inputs are user programmable so the default setting shown may be changed if required The second connector is not fitted as standard There is a purchase...

Page 79: ...t CTS Clear to send input No connection Typical Printer Connections FCO770 D Connector PRINTER D Connector 9 way 25 way 9 way 3 Tx 3 Rx 2 Rx 5 GND 7 GND 5 GND 8 CTS 20 DTR 4 DTR Many serial printers u...

Page 80: ...at each end FCO770 D Connector COMPUTER D Connector 9 way 25 way 9 way 2 Rx 2 Tx 3 Tx 3 Tx 3 Rx 2 Rx 5 GND 7 GND 5 GND 4 DTR 5 CTS 8 CTS 8 CTS 6 DSR 6 DSR 1 CD 8 CD 1 CD 6 DSR 20 DTR 4 DTR These are...

Page 81: ...D Socket 9 way D Socket 9 way D Plug 9 way D Socket 9 way D Socket K2 Adaptor 8 3 2 7 5 RS232 RS485 RS485 RS232 7xx series instrument 73x series instrument Devices should be connected using screened t...

Page 82: ...C Co on nn ne ec ct ti in ng g a a V Ve en nt t V Va al lv ve e TEST ITEM REFERENC E ITEM 4mm O D V1 VENT VALVE V1 V2 MO1308 V2 TEST Pneumatic Outputs P1 Jig P2 Vent P3 P4 P5 AIR SUPPLY MIN 5BAR MAX 1...

Page 83: ...the test item in place to a minimum The diagram above shows the conventional dump test method with the Jig output controlling V2 An alternative method uses the prefill output to operate V2 This arrang...

Page 84: ...s s SWITCH OR RELAY I P I P COMMON NPN PROXIMITY SWITCH TRANSISTOR DRIVE PNP PROXIMITY SWITCH TRANSISTOR DRIVE SWITCH OR RELAY CONTACTS SWITCH OR RELAY CONTACTS FCO7xx FCO7xx 24VDC 24VDC I P I P I P C...

Page 85: ...oned otherwise the minimum timings below should be observed START READY Up to 30mS 20mS Min 50mS Min RESET Single Switch The start signal is permanently connected and the instrument is controlled by t...

Page 86: ...CT THE OUTPUT SUPPLY AS APPROPRIATE CONNECT THE OUTPUT SUPPLY AS APPROPRIATE INTERNAL 24VDC 24VDC 0V INTERNAL 24VDC 24VDC 0V I P I P PLC PLC FAILO P 0V O P FCO7xx PLC WITH ACTIVE HIGH I P FCO7xx PLC W...

Page 87: ...for pass fail lamps at each jig Associated with this is a bank of inputs labelled Jig Result Reset that may be used to reset the latched results for each jig It is recommended that the Jig Result Res...

Page 88: ...system 2 Set a known leak on the test system 3 Calibrate the instrument to display the known leak Setting up a Leak Tight System Connect a known leak tight test item to the Test Port Connect an FCO21...

Page 89: ...t item fully vented At the end of the test a flow reading should be displayed Select the CALCULATE VOLUME On the FCO770 this can be found in the Utilities menu Extended Utilities menu and press the EN...

Page 90: ...ent on the test item its surroundings and the rate of production the digital filter can be varied to allow the leak detector to be optimised for any application Each leak test can have the tracking fu...

Page 91: ...until the variation is acceptable When the stabilisation time is altered the offset will need to be re learnt If during production there is significant temperature variation causing rapid drift in the...

Page 92: ...t jig and leak test until the leak is found If the instrument fails the self check then it will require servicing Cause The test item is not being allowed to stabilise Action Check that the fill and s...

Page 93: ...m or jig need to be eliminated Cause Variable external factors are affecting the test Action Check that there are no heat sources affecting the test item even overhead heaters have been known to cause...

Page 94: ...d to initially activate the internal valves MESSAGE F V STUCK ON The Fill Valve may be stuck in the energised position Contact your supplier MESSAGE T V STUCK OFF The Test Valve may be stuck in the de...

Page 95: ...ectrical interference MESSAGE ADC FAULT This indicates a fault in the analogue to digital conversation Contact your supplier MESSAGE DATAFLASH FAULT The memory used to store settings may be faulty Con...

Page 96: ...0 2000mb S 2 000 kPa 2000Pa 20 00mb 203 9mmWC 8 029inWC 200 0Pa S 2 000mb S 20 00 kPa 200 0mb 203 9cmWC 80 29inWC 2 000kPa S 20 00mb S 99 99cc s 999 9cc min 99 99cc min 9 999cc min 999 9cc hr 999 9cm...

Page 97: ...FCO770 Users Guide Issue 1 Page 97 331 4 133 0 360 0 366 0 302 8 146 7 181 9 DIMENSIONS B Be en nc ch h M Mo ou un nt te ed d C Ca as se e...

Page 98: ...Page 98 FCO770 Users Guide Issue 1 R Ra ac ck k M Mo ou un nt te ed d C Ca as se e 133 0 38 0 57 0 482 0 465 0 360 0 285 9 291 7 326 7 331 4...

Page 99: ...81 Continue On Condition 41 Continuous Fill 48 Control Input Circuits 85 Control Inputs 78 Control Outputs 77 Copy Product Data 64 Copy Test Data 65 Count On 59 D Date 64 Delay Between Steps 41 Descri...

Page 100: ...Banks 37 Output Terminals 10 77 P Parity 66 67 71 Peak Value 53 Persistent Menus 31 PLC 86 Pneumatic Connections 11 Pneumatics 15 Power Connector 10 Prefill Pressure 44 49 55 56 Prefill Time 45 50 55...

Page 101: ...42 Test Item 16 Test o p A H 46 50 52 54 58 Test Parameters Blockage Test 48 Test Parameters Coarse Leak Test 56 Test Parameters Dump Test 54 Test Parameters Leak Test 43 Test Parameters Permfill Tes...

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