Uson sprint iq Owner'S Manual Download Page 42

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Summary of Contents for sprint iq

Page 1: ...Owner s Guide...

Page 2: ...n reserves the right to modify or otherwise change specifications and or tester performance without notice Uson has made every attempt to completely describe the operation of the tester Uson shall not...

Page 3: ...Panel Features 7 2 2 1 Pass Fail Lights 9 2 2 2 Back Panel Components 10 2 2 3 Connecting Power 11 2 2 4 Switch On the Tester 12 2 2 5 Run Mode Display Overview 12 2 2 6 Mode Box Messages 14 2 2 7 St...

Page 4: ...ion Blockage Test 64 4 1 4 Flow Test 69 Flow Test Parameters 69 Leak Test Using Flow 71 Flow Sensor Over Pressure Limits 73 4 1 5 Burst Test 73 4 1 6 Creep Test 76 4 1 7 Crack Test 76 4 1 8 Pass Rejec...

Page 5: ...ponentially more hazardous as the pressure increases or as the volume of a system increases Testing equipment subjected to consistently high pressure ranges has an If the equipment is used in a manner...

Page 6: ...ressurized air escaping from a leak or a failure The hazard of flying particles is added when a sight glass or glass flow meter is introduced to the system The sudden burst of a part could generate su...

Page 7: ...e program position horizontal Set the units of measure to use for pressure flow volume and flow time Enter test parameters for the first program to run Enter test parameters for additional programs if...

Page 8: ...nd pressure doesn t exceed the maximum input listed on the rear panel Supply air is connected to the 1 8 inch female NPT bulkhead on the back of Sprint iQ Compressor Step down regulator Mist and Parti...

Page 9: ...t buttons Display The Sprint iQ has a 5 7 diagonal 320 x 240 color graphic liquid crystal display LCD with backlight Keypad The keypad has 6 keys Exit Use the Exit key to exit the Run Mode Options Men...

Page 10: ...en moving through the Test Parameters screen These keys will also change digits and characters in the Parameter Editor of certain menus Next and Previous Left and Right These keys are used to set para...

Page 11: ...s A green and red light is assigned for each installed channel A green pass light signals that the test cycle was completed and all test values were within tolerances stored in the program that ran on...

Page 12: ...number varies with tester configuration Fuse Power Switch Needle Valve depends on configuration Power Supply Connector Air Supply Connection Ethernet Port Optional Digital I O 2 Optional USB 2 0 Port...

Page 13: ...r cord to the rear panel of the tester at location shown on page 10 at location Lock it in position by turning the connector collar so that it firmly grips the receptacle 4 Finally connect the AC powe...

Page 14: ...hows the Run Mode display 2 2 5 Run Mode Display Overview Sprint iQ shows the Run Mode display during all test cycles in every test mode If multiple programs are linked Sprint iQ shows the run display...

Page 15: ...aph to help monitor progress on that channel The bar graph shows an analog trend of what the current test program is measuring This helps to show whether values are going up or down and how rapidly va...

Page 16: ...Creep Creep Flow Flow Flow FF Flow Fast Flush Gauge Gauge P Burst Pressure Burst P Decay Pressure Decay P Occ Pressure Occlusion P Occ Rate Pressure Occlusion Rate P Rise Pressure Rise P Rise Rate Pre...

Page 17: ...oupling valves have opened or a test is in a wait period to allow an external fixture to activate EOC End of cycle Fill Product is being filled with air Isolate A test is in isolate stage to ensure a...

Page 18: ...he Sprint iQ is ready for fine tuning When Test Parameters are not Available If there are no established test values some experimenting is needed to arrive at values for pressures flow rates and times...

Page 19: ...Optimum setup values are typically established after trial and error when working with known good and bad product samples One point to keep in mind is not to over test product Avoid setting leak tole...

Page 20: ...ting set the vent parameter to off In a flow test set test time long enough for the product under test to fill and produce a stable flow rate If repeated parts failures of good parts occur try widenin...

Page 21: ...ect pressure range Has the pressure regulator changed from when the test pressure was set A change will cause pressure errors Has the LOCKOUT keyswitch been set in the appropriate position for the des...

Page 22: ...ton switch for starting and stopping a test The green button starts the test The red button stops or aborts the test 2 2 11 2 Remote Start Option The Remote Start Option enables three digital inputs f...

Page 23: ...e the test cycle has finished the test cycle is aborted Also Remote Stop can optionally be used to abort the test cycle at any time Anti Tie Down Start This start policy requires an external device th...

Page 24: ...22 Quick Start...

Page 25: ...ester will accept start commands so that the operator can view the test data on the graphs The Stop Switch is always enabled 3 0 2 Navigation There are two menu systems One is accessed by pressing Ent...

Page 26: ...To accept changes press the Enter key To abort a change without saving press the Exit key Use the exit key after all changes are made to return to the previous menu If a selected item is a menu e g P...

Page 27: ...alues when changing them with the Left and Right keys This symbol shows entries that require the Left Right Up and Down keys to make entries This entry method allows precise numbers and text entries t...

Page 28: ...iew Menu See page 28 Results Menu See page 28 Verification Function See page 31 Remember that Sprint iQ is available in many configurations Therefore each tester may not display every menu item shown...

Page 29: ...are listed below To help with staying oriented in the list the opening menu and any sub menus are shown Always bear in mind that not all functions and items shown here may be available on every Sprint...

Page 30: ...tatistics 6 Print Results 3 View Menu 1 Display format 2 Sensor Type 3 Channel 4 Phase 4 Results Menu 1 Profile Graph Highlight Profile Graph and press Enter to see the graph display Press the Enter a...

Page 31: ...ameter Editor Gauge Pressure Flow 3 Max Range Parameter Editor 00 000 to 99 999 4 Min Range Parameter Editor 00 000 to 99 999 2 Histogram Graph Highlight Histogram Graph and press Enter to see the gra...

Page 32: ...Parameter Editor 00 000 to 99 999 5 Min Range Parameter Editor 00 000 to 99 999 3 Trend Graph Highlight Trend Graph and press Enter to see the graph display Press the Enter again at the graph display...

Page 33: ...Max Range Parameter Editor 00 000 to 99 999 5 Min Range Parameter Editor 00 000 to 99 999 5 Verification Function When the selections have been set as desired press the Exit button to return to the Ru...

Page 34: ...ameter Menu and press Enter The Test Parameter Menu will open and the display will appear as shown below The navigation method is similar in all menus Test Parameter Menu See page 33 Data Menu See pag...

Page 35: ...ressure Decay Rate Pressure Occlusion Pressure Occlusion Rate Pressure Burst Crack Creep Pressure Rise Pressure Rise Rate Leak rate Flow Back Pressure Back Pressure Rate Sealed Component Fast Flush Te...

Page 36: ...tputs varies with tester configuration 1 Program Selection Parameter Editor 2 Couple Output Parameter Editor 1 2 3 4 3 Couple Control Parameter Editor On Off 4 Couple Time Parameter Editor 000 0 to 99...

Page 37: ...nu 1 Program Selection Parameter Editor 1 2 3 4 2 Pressure Parameter Editor 00 000 to 99 999 3 Pressure Error Parameter Editor 00 000 to 99 999 4 Fill Time Parameter Editor 00 0 to 99 9 Fast Fill Menu...

Page 38: ...rameter Editor 00 000 to 99 999 11 Pressure Error Parameter Editor 00 000 to 99 999 12 Ramp Start 13 Ramp Rate 14 Flow Range 15 Fill Time Parameter Editor 00 0 to 99 9 16 Stab Time Parameter Editor 00...

Page 39: ...Test 4 Leakrate Format Parameter Editor cycle through decimal formats 5 Leakrate Units Parameter Editor ml s ml m ml hr cc s cc m 6 Leak Master Value Parameter Editor 00 00 to 99 99 NOTE Decimal plac...

Page 40: ...to 50 15 Verification Interval Parameter Editor 0 hr to 23 hr 20 Reject Limit Menu 1 Program Selection 2 Common Limits Parameter Editor On Off 3 Channel 4 Reject Maximum Parameter Editor 00 000 to 99...

Page 41: ...r 0 0000 to 9 9999 21 Jump Menu 1 Program Selection 2 On Pass Pause Time Parameter Editor 00 0 to 99 9 3 On Pass Automatic Advance Parameter Editor On Off Jump Menu 1 Program Selection 001 2 On Pass P...

Page 42: ...Pass Next Program Parameter Editor Off 001 to 100 5 On Reject Pause Time Parameter Editor 00 0 to 99 9 6 On Reject Automatic Advance Parameter Editor On Off 7 On Reject Next Program Parameter Editor O...

Page 43: ...Menus 41 Data Menu 1 Clear All Counters 2 Audit Menu 3 Import Menu 4 Export Menu Audit Menu 1 Audit Printout Parameter Editor Disabled Enabled Statistics Menu Audit Menu 1 Audit Printout Disabled...

Page 44: ...figuration All Programs 3 Program Selected This selection is not available for modification for all selections made in Data Selected above Parameter Editor 001 to 100 4 Import Data File copy Press Ent...

Page 45: ...Configuration All programs 3 Program Selected This selection is not available for modification for all selections made in Data Selected above List Selection 001 to 100 4 Export Data File Copy Press En...

Page 46: ...Infinite Fill 4 Remote Start This selection is not available unless Remote Start has been enabled in Remote Control Accessory Menu by Uson Parameter Editor Off Conventional Fixture Anti Tie Down Inte...

Page 47: ...Seconds 8 Date Parameter Editor Date mm dd yyy Month Day Year 9 Language Parameter Editor American Chinese English French German Korean Portuguese Spanish 10 Display Contrast Parameter Editor 1 to 10...

Page 48: ...Flow 2 Sensor Input Parameter Editor 1 2 3 4 3 Sensor Range Parameter Editor 4 Channel Selection Hardware Menu 1 Calibration Menu 2 Serial Port Menu 3 Printer 4 Network Menu Calibration Menu 1 Sensor...

Page 49: ...n 1 Save Greyed out until calibration has been performed 2 Target Point 3 Regulator Setting 4 Target Point Calibrated 5 Sensor 1 6 Sensor 2 7 Sensor 3 8 Sensor 4 6 Set Factory Defaults 2 Serial Port M...

Page 50: ...48 Menus...

Page 51: ...talled programs in any way that is available with the features installed in the tester Values stored in factory installed programs need to be modified to the particular product to be tested Use the pr...

Page 52: ...nd the test is started 2 Sprint iQ pressurizes the part with pressure P to the desired test pressure set by the pressure regulator R1 by opening valves V1 and V2 during the Fill step 3 At the end of t...

Page 53: ...in user defined units of measure 6 At the end of Test step pressure trapped in the part is vented to atmosphere through V1 by opening V2 during the Vent step and Sprint iQ is ready to make the next te...

Page 54: ...ressure P is applied to the vacuum generator VG through valve V3 The vacuum level is set by the pressure regulator R1 3 Negative pressure is supplied from VG to the test port by opening valves V1 and...

Page 55: ...cc m Next Program 4 1 1 2 Test Pressure Test pressure is the amount of pressure the product is subjected to during a test Test pressure is a preset value both stored in the program and set with the pr...

Page 56: ...actual test pressure and the target test pressure 4 1 1 3 Pressure Error Pressure error is important because it tells Sprint to stop the test if the pressure goes too far above the preset test pressur...

Page 57: ...the start of fill time a valve opens to pressurize the product Fill duration depends on the size and construction of the part to be tested Optimum fill time pressurizes the part fast enough for a good...

Page 58: ...P1 and P2 is the total test pressure loss over the test time Test time must be long enough to distinguish between good and bad parts The smaller the leak the longer the time Vent Time Set vent to spe...

Page 59: ...pressure is the drop from the first pressure reading not the full pressure on the scale Reject Maximum Reject Minimum Reject Limits This the setting for the pressure limits allowed in a product durin...

Page 60: ...lly caused by a product having a severe defect or because external fixtures are not sealing the product If you repeatedly get gross error messages and neither the product or the fixture seals appear t...

Page 61: ...ation Menu The concept previously known to many as the comp cal ratio is employed in the Sprint iQ as the Pneumatic Signal Noise Ratio PSN ratio and is discussed page 60 Like the Comp Value and Cal Va...

Page 62: ...be in the range of 0 2 to 0 25 if 10 test repeatability is sufficient So for pressure decay tests the following rules are strongly recommended Comp Value 0 PSN Ratio Cal Comp 0 2 Cal Value 0 05 of fu...

Page 63: ...using the same basic pneumatic circuit employed in pressure decay The programming is the only difference since the part is not expected to maintain pressure The part is continuously pressurized while...

Page 64: ...t iQ s display shows why the part failed 5 At the end of the test any remaining pressure trapped in the part is vented to atmosphere through V1 by opening V2 only and Sprint iQ is ready to make the ne...

Page 65: ...w test in which the part passes the evaluation In this example the residual back pressure seen at the part s inlet while the outlet is vented to atmosphere was within the established reject minimum an...

Page 66: ...so the reject value must be greater than a given value For simplicity the definitions of all the parameters or how to program will not be explained here For more information see the explanation of a p...

Page 67: ...fixture The operator then pushes the START switch Or the start could be activated by automated equipment 2 The couple timer provides delay time needed to activate the fixture before starting the test...

Page 68: ...test in the series as long as the product passed all tests 8 At the end of all linked tests the operator or automated machinery removes the product and Sprint iQ is ready to begin the next test Test...

Page 69: ...rge flow rates stabilization time would allow the pressure to flow out before pressure drop readings can be taken in the test time Sprint iQ goes into test phase only if test pressure is within the pr...

Page 70: ...test Test pressure is set while flowing When setting the test pressure a known good part is used rather than simply blocking the test port By flowing through a part the pressure can be set at the leve...

Page 71: ...maximum limits set in the program Flow tests are often used to check for blocked passages in small tubing and other low flow devices Most parameters in a flow test are the same as a pressure decay tes...

Page 72: ...here In this case Sprint iQ displays an error message in the status box on the run display Flow Test Stabilization Stabilize phase is not available in a flow test so when setting up a flow test make s...

Page 73: ...vides more consistent flow readings If vent is active the vent valve opens and pressure is vented to atmosphere 4 1 4 2 Leak Test Using Flow You can use Sprint iQ to check for leaks using flow When se...

Page 74: ...first place If the maximum flow setting is set too close to zero and the time is kept short a high number of rejects could occur simply due to inconsistencies among the products tested Atmospheric and...

Page 75: ...int iQ looks for devices to open at some point during pressurization and rapidly drop toward zero pressure Achieving the burst is the desired outcome of the test When the burst occurs in the correct p...

Page 76: ...alue is a setpoint entered in the parameters menu Event value is the peak pressure minus the event pressure In other words how much the pressure drop is needed from a peak pressure to be considered a...

Page 77: ...ke place to be a pass If the burst occurs below the minimum setpoint the test is stopped and LoBurst appears in the status box on the run display The fail light turns on If pressure goes above the max...

Page 78: ...ax pressure setting Products not reaching the min max setpoint in the allowed test time are rejected Products opening to atmosphere bursting before reaching the min max setpoint are also rejected Use...

Page 79: ...nsor rather the placement of the sensor in the test circuit becomes an issue Being upstream from the product the normal sensor is subjected to constant makeup air To test products that open slowly or...

Page 80: ...e The peak pressure attained Upstream side The amount of pressure or flow rise Downstream side Both sensors are monitored at the same time To register as a pass the upstream peak pressure must be with...

Page 81: ...eparated into two groups On Pass and On Reject The lines associated with On Pass control actions that are only executed if the part passes and the test is accepted The lines associated with On Reject...

Page 82: ...ith each test type as seen in this listing Timers Used in Decay Occlusion Testing Couple Time Fill Time Stab Time Test Time Vent Time Timers Used in Flow Testing Couple Time Fill Time Test Time Vent T...

Page 83: ...namable 1 diagnostic Test Channels Available 1 2 3 or 4 sequential or concurrent Pressure Ranges Available 3 5 10 15 30 50 100 200 300 and 500 psig Custom ranges also available Maximum Pressure Displ...

Page 84: ...sccm range dependant Mass Flow Sensor Repeatability 0 5 of Full Scale Mass Flow Units of Measure sccs sccm scch smls smlm smlh sls slm slh user selectable Base Unit Dimensions 8 9 W x 15 0 D x 10 8 H...

Page 85: ...um Sensitivity Dual USB Communication Ports Front Rear RS 232 Serial Communication Port Remote Control of Tester via RS 232 Serial Commands including Program Select Program Linking and Jumps Pass Fail...

Page 86: ...ata Statistics Histograms Downstream Sensor Electronic Programmable Regulator Ethernet LAN Communication Port Extended Chassis Fast Fill Foot Switch High Pressure High Pressure Coalescent Filter Manua...

Page 87: ...dry contact relay operated Function Pin No START 1 START ENABLE 20 RESET 2 BCD 0 21 BCD 1 3 BCD 2 22 BCD 3 4 BCD 4 23 BCD 5 5 BCD 6 24 BCD 7 6 INPUTS RETURN 25 PASS 1 7 PASS 1 26 FAIL 1 8 FAIL 1 27 P...

Page 88: ...mer value set in Sprint iQ s pressure decay program provided the test passes Because this timer is set in seconds merely divide by 60 to get the delta time in minutes Volume is the part volume plus Sp...

Page 89: ...essure caused by the atmosphere At average sea level barometric pressure is about 14 7 pounds per square inch or 29 9 inches of mercury This is equivalent to 101 3 Kilopascals Negative Pressure Vacuum...

Page 90: ...mass remains above a given point therefore less pressure is exerted At sea level the density of air is about 1 kg per cubic meter 8 oz per cubic foot Both pressure and density decrease by about a fac...

Page 91: ...r level Difference in air density is the primary reason users can observe slightly different results when temperature and gauge pressures are identical For this reason it is important to establish all...

Page 92: ...re and Density Pressure and density are considered mechanical properties of the fluid although they are also thermodynamic properties related to the temperature and entropy of the fluid For a small ch...

Page 93: ...roduct of the density designated by the Greek lower case letter rho D a characteristic length L and a characteristic velocity v all divided by the coefficient of viscosity designated by the Greek lowe...

Page 94: ...tively Boyle s Law is PV Constant where the value of the constant depends on the temperature and the amount of gas present Relationships between the temperature of the gas and its volume while keeping...

Page 95: ...nR or PV nRT When written this way it is called the Ideal Gas Law R is the gas constant and n is the number of moles of gas The gas constant can be examined experimentally as R 0 082 liter atm Kelvin...

Page 96: ...sors An adiabatic expansion is usually accompanied by a decrease in the gas temperature This can be observed in a common aerosol can which becomes cold after some compressed gas is released The reason...

Page 97: ...phere equals 14 7 psi To say a test was taken at one atmosphere means the test was made at or converted to average sea level Barometric Pressure Also called atmospheric pressure The force of air press...

Page 98: ...to the pressure or flow standard Calibration should be conducted only by qualified technicians who have proper training and resources to calibrate Sprint Calibration Table Technicians don t need to a...

Page 99: ...air Coupling time gives fixtures enough time to seal product before Sprint iQ applies test pressure Crack Test A crack test is setup to measure the pressure at which a product like a check valve open...

Page 100: ...y test vacuum Event The instant pressure drops below the event value during a burst or creep test Sprint iQ monitors pressure during a burst test or creep test and holds the maximum pressure value mea...

Page 101: ...se ramp up needed for burst and crack testing Users can precisely set the flow control for the exact pressure build up required for the product to be tested After the flow control is set for a particu...

Page 102: ...pressure constant as barometric pressure changes Gross Leak A leak that causes a drop below the negative pressure error during the stabilization phase Typically when a product under test has a gross l...

Page 103: ...A pressure drop over time can be stated as a leak rate For example 0 02 psi per second is a leak rate A leak rate can also be stated in flow units such as 4 cc minute Leak Test See Pressure Decay Test...

Page 104: ...rst etc Sprint shows the current mode or test type in the test mode box on Sprint s run display Occlusion Test Occlusion testing is used to test products open passages by trapping pressure inside a pr...

Page 105: ...alid test is performed on each product A lack of test pressure that causes a drop in pressure to exceed the negative pressure error value during the fill period of product testing causes Sprint to sto...

Page 106: ...ply or a vacuum venturi controlled by a manual pressure regulator Sensor 2 configuration will define the operating range regulated supply input for the independent regulator concurrent tester and Sens...

Page 107: ...parameters screen When multiple programs are linked the programs become a test cycle See also Stored Programs PSIG Pounds per Square Inch Gauge A unit of measurement for air pressure measured with res...

Page 108: ...protocol to send test result data to printers and computers Run When the lockout key is in the vertical position Sprint is in Run Mode Sprint iQ is set to run when used in production testing The only...

Page 109: ...int starts the measurement phase Longer stabilization times are often required in products constructed of flexible materials Start Switch The green pushbutton Startup Screen The first screen that brie...

Page 110: ...a lookup table for sensor linearity adjustment Test Circuit The pneumatic tubing fittings valves and sensors that make up the internal air passages The volume of gas trapped inside the pressure decay...

Page 111: ...See Electronic Regulator Test Vacuum A negative value indicating the level of vacuum applied to the product under test Timers Sprint iQ uses microprocessor timers to establish time intervals for a var...

Page 112: ...led vent If vent is not required for instance if you want to unplug product to vent pressure set Vent to No Venturi Electronic This option is used to produce a vacuum level and requires an inlet press...

Page 113: ...ng the regulator control is a possibility when using the equipment in production settings Sprint iQ s Electronic Programmable Regulator option is a sophisticated electro pneumatic device programmed by...

Page 114: ...ms As many as 100 different test pressures can be entered 4 When in Run mode the Electronic Programmable Regulator automatically goes to the set test pressure to provide the desired pressure or ramp r...

Page 115: ...s Electronic Programmable Regulator precisely controls the ramping pressure Often cycle time can be saved and burst or crack event sensitivity increased by quickly jumping to a minimum starting pressu...

Page 116: ...114 Reference 45 pounds per square inch pressure then increase at a rate of 10 pounds per square inch every second...

Page 117: ...95 C cal 59 cal value 60 96 calculated leak rate 59 Calibration 96 calibration 59 Calibration Data 96 Calibration Menu 46 96 Channel number 13 Channel Selection 33 Charles s Law 92 clearing counters 9...

Page 118: ...alled programs 98 fail light 9 98 fast fill 84 104 113 Fast Fill Menu 35 fill 15 Fill Time 55 98 Filter 6 Firmware 98 Firmware version 12 Fixture Lid Start 21 Fixturing 99 Flow 14 99 Flow Control 73 9...

Page 119: ...Rate 101 leak rate 86 leak tolerance 51 Line Conditioner 101 Linked Programs 101 LoBurst 16 75 Local 20 Local Start Option 20 Lockout keyswitch 7 8 32 102 LoCrack 16 M Measurement Units 102 Menu calib...

Page 120: ...0 Power supply 5 11 Power Switch 10 pre fill 15 Pressure 87 90 105 Pressure Burst 14 Pressure Decay 14 103 Pressure Decay Rate 14 pressure drop 51 Pressure Error 54 57 103 Pressure Occlusion 14 Pressu...

Page 121: ...4 SCCM 106 Security key 106 111 Sensor 106 Sequential 107 Serial port 10 Serial Port Menu 47 101 Setpoint 16 107 Setup Menu 44 Splash screen 12 Stab 107 Stab Time 55 stabilize 15 Start Options 20 Star...

Page 122: ...Rate 14 V Rise 14 V Rise Rate 14 V SC 14 Vacuum 87 Vacuum Burst 14 Vacuum Decay 14 Vacuum Decay Rate 14 Vacuum Error 109 Vacuum Occlusion 14 Vacuum Occlusion Rate 14 Vacuum Rise 14 Vacuum Rise Rate 14...

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