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Page 86

Input & Output

The I/O connector is typically used to connect Sprint LC to a
programmable logic controller (PLC) or other automation equipment. The
remote start signal tells Sprint LC to begin a test. Sprint LC has internal
contacts that can be used to tell an external device that the test passed or
failed, or that the test is completed. The following I/O example is for a
single channel or sequential Sprint LC.

See also page A11

Input

Sprint LC accepts a 24-volt DC input to begin a test. The 24-volts energize
a coil to close contacts that begin the tests or test series. Remote start
performs the same action as pressing the

START

switch on the front of the

test. Figure 36.

It is not recommended to use the foot switch input to start a test from an
external relay or PLC. The foot switch input is not isolated.

Output

Three conditions can be sensed and are available as dry contact (no
voltage) outputs. The contacts are rated for DC only. The constant current
capacity of each contact is 1.5 amps. The switching load must not exceed
10VA. (0.5 amp @ 100 VDC)
Three output conditions—

Pass (The product was accepted as good)
Fail (The product was rejected as bad)
Test Over (Test complete, Pass/Fail output is valid.)

I/O Pinout

Pins 6 & 7 = Pass
Pins 8 & 9 = Fail
Pin 20 = Supply for 24 volt start signal input
Pin 21 = Ground for 24 volt start signal input
Pins 24 & 25 = Test Over

Optional I/O:

The I/O feature is an optional item. The

connector is always present but the rest of the hardware

is only installed when it is purchased.

USER

TIP

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Summary of Contents for SPRINT LC

Page 1: ...SPRINT LC Uson MULTI AIR TESTER Owner s Guide ...

Page 2: ......

Page 3: ...ch trademarked names in any way Copyright 2007 Uson L P All Rights Reserved Permission to reproduce this document in any form in whole or in part is granted to Sprint LC owners with the restriction that all safety information cautions warnings and the copyright notice remain in place on such reproductions and that such copies are not for sale or external distribution Information in the Sprint LC O...

Page 4: ...1 Air Supply 22 Full Setup 23 Standard vs Optional Features 24 How This Guide is Organized 25 Turning On the Power 28 Switches and Buttons 30 Setup Menus 34 Navigation 36 Parameters Menu 39 Test Pressure Setting 40 Coupling 42 Test Params Sub Parameter Menu 47 Vacuum Testing 53 How Sprint LC Works 54 Connections 60 Run Display 62 Units of Measure 68 Serial Port 70 Input Output 86 ...

Page 5: ...ccess 138 Pressure Calibration 140 Flow Calibration 144 Timer Verification 152 Engineering Data 153 Physical Laws 154 Appendices Optional Features A 1 A Electronic Regulator A 1 B Fast Fill A 8 C Additional Manual Regulator A 9 D I O Pinout Options A 11 E Serial Commands A 15 F Pass Fail Jumps A 17 G Data Plotting A 19 H Program Names A 21 I Crack Testing A 23 J Start Options A 27 K Real Time Cloc...

Page 6: ...fore attempting any maintenance procedure discussed in this guide develop an understanding of the procedure and know exactly how to complete the task Tester Specific Information This guide covers the standard Sprint LC air tester Each Sprint LC could be a custom machine with fewer or added features such as external components or unique specifications Check any additional information included in th...

Page 7: ... press and alarm tone 3 Turn the LOCKOUT keyswitch to program position 3 Set the units of measure to use for pressure flow volume and flow time 3 Enter test parameters for the first program to run 3 Enter test parameters for additional programs if you re using more than one program Don t forget any required program linking 3 Set communication values for the serial port then connect peripherals to ...

Page 8: ...CREMENT FIGURE 1 Number Accelerator The ENTER BACK keypad becomes Accel Accelerate when the INCREMENT or DECREMENT keypads are held Tap ACCEL to make values change quickly forward or backward FIGURE 2 SPRINT LC 1 2 USER TIP Start Switch LOCKOUT Keyswitch ...

Page 9: ... next menu item In run mode increments the current test when held for three seconds INCREMENT Increase values such as pressure or time also enters GoTo Menus In run mode acts as a re test button DECREMENT Decrease a setup value such as pressure or time START Switch Begins a test cycle It will abort a test if pressed during the test cycle Figure 2 LOCKOUT Keyswitch Change between run and programmin...

Page 10: ...Page 10 Back Component Layout FIGURE 4 8c 1 3 5 6 7 8 9 10 8a 8c 4 2 ...

Page 11: ...d test fixtures 6 Timer Output A BNC connector providing an output for the internal timer It is used to verify timer accuracy for calibration purposes 7 Pressure Regulator Controls the air pressure applied to the product under test Use this control to set the test pressure 8 Power Entry Module The Entry Module has three parts a On Off Switch 1 is on 0 is off b Fuse Holder Holds two 2 Amp fast blow...

Page 12: ...sted Reject 9 993 psig 0 0 psig Run Display Layout FIGURE 5 Each message that can appear in the status box is explained on pages 14 and 15 Display Contrast Remember to set the contrast on the back of Sprint LC to get the best visibility on the liquid crystal display ...

Page 13: ...f rejects Counts the number of times the fail light turns on Counts up to a maximum of 65 535 5 Main Digital Readout Shows pressure drop flow or burst value depending on what kind of test is being run 6 Units of Measure Measurement units change depending on the type of program flow or pressure being run The desired units of measure are selected in the Units Setup Menus 7 Bar Graph An analog trend ...

Page 14: ...asing the START switch the test begins Pd Sprint is set to run a pressure decay test OCC Sprint is set to run an occlusion test Flow Sprint is set to run a flow test Burst Sprint is set to run a burst test Test Phase Status These messages display during a test and before pass or fail lights turn on Couple One or more coupling valves have opened or a test is in a wait period to allow an external fi...

Page 15: ...RR Test pressure was above or below the pressure error tolerance set in the parameters menu GROSS In a pressure decay test the test pressure fell below the minimum during stabilization phase LEAK In a pressure decay test the pressure decay exceeded the reject level setpoint OCC In an occlusion test the pressure decay did not reach the reject level setpoint LOW In a flow or burst test flow or burst...

Page 16: ...flow tolerance Repeated failures can indicate Sprint LC or external fixtures have set up problems If a fail light turns on during a test the operator can read the status box on the run display to see why the test was unsuccessful The status box might indicate GROSS LEAK HIGH or any of seven other messages Alert Tone The alert tone set with the volume control on the back of the Sprint LC turns on f...

Page 17: ...K keypad This menu allows the operator to change the current program print a program header print a test summary or clear the counters See page 29 Abort Press the START switch during the test and ABORT pops up in the run display status box show the process has stopped Aborted tests don t register on the tested or reject counters Linked Programs To get a pass light the product being tested needs to...

Page 18: ...roceeding Without Test Parameters If there are no existing test values it will be necessary to do some experimenting to arrive at values for pressures flow rates and times best suited to your product Very little effort to program Sprint LC is required after test parameters are established Yet coming up with test values can take a little work when starting from scratch The Over Testing Trap Optimum...

Page 19: ... generally require longer test times Choose the Desired Engineering Units Set units of measure before going to the parameters menu Sprint LC allows programming in units most familiar to the user and then switch to different units of measure for operation Sprint LC handles all conversions automatically USER TIP ESTABLISH TEST TIMES Shortest Time Longest Time Small and Rigid Small and Flexible Large...

Page 20: ...et the dump parameter to off In a flow test set test time long enough for the product under test to fill with pressure and produce a stable flow rate If repeated P ERR messages show up in the status box try widening the pressure error tolerance or adding more fill time Put Sprint LC to Work When everything is programmed and checked out Sprint LC is ready to work and start testing products A few ti...

Page 21: ...pressure This must be done to get the correct setting Has the pressure regulator changed from when the test pressure was set A change will cause pressure errors Is the display contrast correctly set using the control on the back Is the tone volume correctly set using the control on the back Is the LOCKOUT keyswitch in the correct position Is the product attached to the test port during all flow te...

Page 22: ... from Uson Call for free help in getting the air supply clean dry and regulated USER TIP Uson SPRINT LC 1 2 3 4 Step Down Regulator Compressor Mist Particulate Filter Sprint LC Sprint Needs Clean Dry Air Water vapor Particulate and excessive pressure can damage Sprint s internal components and affect product testing ...

Page 23: ... shipping damage report the problem immediately to the shipper who delivered your tester Air Connection Before connecting air or other gas to Sprint LC make certain the supply air is clean and dry and pressure does not exceed the maximum input for the Sprint LC f Connect supply air at maximum pressure of 150 psig or 5 psi above rated pressure Some Sprint LC models are equipped to handle higher sup...

Page 24: ...rs A Sprint LC machine could be a base Sprint LC PO with fewer features or have a combination of several options FIGURE 8 Uson SPRINT LC 1 2 3 4 Uson SPRINT LC 1 2 Uson SPRINT LC 1 2 Uson SPRINT LC 1 2 Uson SPRINT LC 1 2 Uson SPRINT LC 1 2 Your Sprint Configuration Multiple Test Ports Leak Flow and Burst Vacuum Pressure Decay Only ...

Page 25: ... appendices at the end of this guide explain menus and features used in machines that have common options installed such as electronic regulator fast fill or downstream sensors What is a Standard Sprint LC Sprint LC offers extreme flexibility for testing diverse products using various test types and techniques This Guide explains the most common features incorporated into a broad range of Sprint L...

Page 26: ...est ports Multiple channel machines are available in either sequential or concurrent models Sequential Sequential models have only one pressure sensor and optionally a flow sensor The machine can be setup to sequences through each of the channels one at a time It can also be setup to do any one of the available test type on any of the channels For example an LC 3PFB has three test ports It can do ...

Page 27: ... electrical connections are in place power up Sprint LC with the power switch on the back of the tester 1 top position is on 0 bottom position is off AC Power Line Conditioner Option If the Sprint LC is used in close proximity to electrical equipment that can induce electrical noise into AC power lines consider purchasing the optional AC Power Line Conditioner to supply power to Sprint LC This red...

Page 28: ...ion will help Uson technicians to provide the most effective help Figure 9 Run Display After the startup display the next display looks like that shown in figure 10 We call this the run display The run display shows test and setup information to operators during all tests For more information on the run display please refer to the quick setup section on pages 12 through 17 It is explained in detai...

Page 29: ...ads Print Program Header Use the PREVIOUS and NEXT Keypads to highlight and then press ENTER BACK to print the report over the RS 232 serial port The Heading contains all the setup parameter values for the current program All linked programs will also be printed Page 71 Print test Summary Use the PREVIOUS and NEXT Keypads to highlight and then press ENTER BACK to print the report over the RS 232 s...

Page 30: ...ation port Setup Menu The setup menu is the starting point for all programming and calibration functions When the LOCKOUT keyswitch is turned to program position Sprint LC pulls up the setup menu From the setup menu it is possible to go into all other menus needed to program the tester Figure 12 Although the highlight defaults to the test parameters option as in Figure 12 it is possible to select ...

Page 31: ...un mode keypad functions These are features that are available to the operator Next Program By pressing and holding the up arrow keypad the current program number is incremented Release the keypad when the desired program is displayed Previous Program By pressing and holding the down arrow keypad the current program number is decremented Release the keypad when the desired program is displayed Re ...

Page 32: ...isplay indicates what action the keypads have when pressed PREVIOUS In run Changes the current program and makes the selection the current test when held for 3 seconds In program Moves the highlight bar up Selects the previous item on a menu NEXT In run Changes the current program and makes the selection the current test when held for 3 seconds In program Moves the highlight bar down Selects the n...

Page 33: ...r decrease key press tone by adjusting the volume control on the back of the Sprint LC INCREMENT In run Re tests a failed product You cannot re test a passed product In program Increases a value program number or changes a program type Also opens the HELP screen in the main Setup menu and opens GoTo windows in select menus DECREMENT In run No action in run mode In program Decreases a value decreme...

Page 34: ...hether a product under test is accepted or rejected Options on the parameters menu change depending on whether you re setting up a pressure decay occlusion flow or burst test Please note that not all test types are available in every tester Sprint LC comes with ninety nine stored programs f Program 1 Pressure Decay f Program 2 Occlusion f Program 3 Flow f Program 4 Burst f Program 5 Pressure Decay...

Page 35: ... if it is intended to change calibration data Qualified technicians who have the necessary calibration instruments should be the ONLY people accessing this critical area Serial Port Menu This is where to set criteria for RS 232 communications It is possible to set baud rate number of data bits and number of stop bits Information sent from the Sprint LC serial port f Cycle number from the tested bo...

Page 36: ...n the map to reach various setup menus functions Figure 14 Turn the LOCKOUT The setup menu is the first menu shown keyswitch to program The default function is Test Parameters position and that is why that option is highlighted From here pressing NEXT advances to any of three other setup functions Return to this setup menu at any time by pressing the ENTER BACK keypad Enter Prev Next Help SPRINT L...

Page 37: ...g GoTo CP1 Time On Off Up to three couplings may be available Test Params GoTo Test Parameters based on test type Next Program Pressure Volume Flow Volume Flow Time Pressure Flow Time Baud Rate Data Bits Stop bits Parity Test Parameters Units Calibration Serial Port ...

Page 38: ... Main Parameters menu Sequential testers have an added line to select the active channel Note the parameter lines labeled Coupling and Test Params When these are highlighted press the INCREMENT keypad labeled as GoTo to move to the next menu to establish the associated settings These parameters are described later in this document Figure 15 Back Prev Next Inc Dec PROGRAM 1 Test Type PD Test Press ...

Page 39: ...pecific model of tester purchased Test Pressure Be sure to cap the test port when setting test pressure To set the test pressure first highlight the Test Pressure line on the program menu then press the INCREMENT keypad Immediately after the INCREMENT keypad is pressed Sprint LC opens the valve that directs pressure to the test port Adjust the regulator on the back until the desired test pressure ...

Page 40: ...alve that provides air to the test port and allows showing the current pressure setting of the pressure regulator in the setup menu Figure 16 5 Adjust the pressure regulator knob on the back of the tester until the desired test pressure is shown in the parameters menu Figures 4 and 16 6 When the pressure reads correctly press ENTER BACK 7 If linking tests repeat the procedure for each test to be r...

Page 41: ...when setting test pressure If the test port is not capped pressure drops because test pressure flows to atmosphere A test pressure set without blocking the test port may result in high Pressure Error P ERR when testing product PROGRAM 1 Test Type PD CAP Test Press 14 999 psig PORT Press Error 5 psig THEN Coupling GoTo PUSH Test Params GoTo INC Next Program 0 TO ADJ ...

Page 42: ...y function to make certain that each test is conducted within an established tolerance for test pressure Coupling Coupling time is the delay provided for external devices such as pneumatic seals or fixtures to fully activate This gives setup personnel added control over how the coupling valve s will turn on and off See page 60 61 and 56 for a pneumatic diagram To access the coupling sub parameter ...

Page 43: ...lization and test times follow When ordered with the coupling option Sprint LC is typically provided with a 3 way normally closed solenoid valve for the coupling control When off the coupling port is vented to atmosphere When active it supplies pilot pressure If ordered with a 4 way valve Sprint LC will have both normally open and normally closed connections The normally open connection will opera...

Page 44: ...ld Fail stands for hold on failure The purpose of the hold on failure function is to make certain the operator acknowledges a failure and dispenses with the failed product Hld Fail can be set to either YES active or NO inactive by using the INCREMENT and DECREMENT keypads A time value is not entered If set to YES and the test fails all enabled coupling valves remain activated to hold the product a...

Page 45: ... it is the amount of time the coupling valve is energized How the coupling time functions depends on whether or not a valve Cp1 Cp2 Cp3 is set to be on or off For clarity when one coupling valve is set to ON enabled for the first or second coupling times Sprint LC adds the label ON for the subsequent coupling times afterward This will be evident when setting coupling times Back Prev Next Inc Dec T...

Page 46: ...est seals disconnect air pressure from the bottom of the product 2 Air cylinders move up to open the top of the product 3 The shuttle holding the product moves back for reloading 4 Way Normally Open Valves Sprint LC is generally supplied with three way normally closed solenoid valves for coupling control As a special option Sprint LC can be ordered with one two or three internal four way coupling ...

Page 47: ...cates that a sub parameter menu is available To access the test parameters pop up menu highlight the Test Params line and then press the GoTo INCREMENT keypad The next page describes what Sprint LC shows when the pop up menu is displayed Figure 19 Back Prev Next Inc Dec PROGRAM 1 Test Type PD Test Press 10 000 psig Press Error 5 psig Coupling GoTo Test Params GoTo Next Program 0 ...

Page 48: ... test type General test parameters are described in the Sprint LC Owner s Guide INSERT GRAPHIC HERE Figure 20 Fill Time Amount of time the part is allowed to fill with air pressure before Sprint LC enters stabilization phase Back Prev Next Inc Dec PROGRAM 1 Test Type Flow Test Press 10 000 psig Press Error 5 psig Coupling GoTo Test Params GoTo Next Program 0 PRESSURE DECAY TEST Fill Time 2 0 sec S...

Page 49: ...urized product Dump can be set to one of three modes AUTO If the DECREMENT keypad is held to go below zero the word AUTO appears and dump is in an automatic mode When dump time is set to AUTO Sprint LC opens the dump valve and monitors the pressure trapped in the test circuit When the pressure declines to approximately 0 5 psig the dump valve closes and the dump time ends OFF Use the INCREMENT and...

Page 50: ...or a pressure drop but the accept reject settings are opposite of a pressure decay test In an occlusion test the pressure must drop MORE than the reject value to create a pass condition If the test pressure is 40 psig for example then a typical reject level might be a value such as 20 psig The product under test must vent or loose more than 20 psig within the allocated time to pass Testers that ha...

Page 51: ...ecause those testers read directly in flow units Flow Test The flow test has two reject limits a minimum and a maximum They define the good window If the flow rate is within this window the product is accepted as good If the flow rate is lower than the minimum or higher than the maximum the fail light turns on and LOW or HIGH is displayed in the Sprint LC status box Burst Test The burst test also ...

Page 52: ...in parameter menu See Figure 19 on page 49 If it is not desired to link to any other program or if at the end of a linked series of tests set the next program to zero f The next discussion is vacuum testing Figure 21 Back Prev Next Inc Dec PROGRAM 2 Test Type VAC Test Press 10 000 psig Press Error 5 psig Coupling GoTo Test Params GoTo Next Program 0 VACUUM DECAY TEST Fill Time 2 0 sec Stab Time 1 ...

Page 53: ...tive pressure necessary The venturi converts positive air pressure to negative air pressure The vacuum test pressure is set in the same manner as positive pressure The vacuum is controlled by adjusting the positive pressure regulator that supplies the venturi If only vacuum tests are available on Sprint LC the vacuum regulator is located in the same place as the positive pressure regulator would b...

Page 54: ...re within specifications Test results are displayed with the front panel lights as either pass or fail based on setpoints entered into a program Choosing the Test Types Before entering test parameters it is necessary to decide what kind of test is best suited to the product Should a pressure decay test be used Or would a leak test using flow be better for detecting leaks Is it necessary to measure...

Page 55: ...w product is filled with air in the same way pressure decay testing works But unlike a pressure decay test a flow sensor is used to monitor air movement in the product Any flow detected in the product indicates a possible leak In a flow measurement test product is continuously subjected to air pressure flowing to atmosphere The flow sensor measures the volume of air passing through the product A p...

Page 56: ...IGURE 22 Self Contained Sprint LC has all valves and pneumatic components in one package to perform pressure decay occlusion flow and burst testing if so equipped Pressure Regulator Flow Sensor Flow A Valve 1 Press X ducer TestPort Port 1 Flow Control Flow B Valve 5 Pressure Decay Valve 3 Couple A Valve 8 Coupling Port Port 2 or on rear of tester Product Test Fixture Burst A Valve 4 Burst B Valve ...

Page 57: ...spheric pressure 3 PD When open supplies air for pressure decay test When closed traps air in the test circuit so the pressure sensor can measure a potential pressure drop 4 Burst A When closed prevents air flow through the needle valve When open allows air to slowly ramp up during a burst test 5 Flow B Same function as Flow A but downstream to the flow sensor 6 Burst B Same function as Burst A bu...

Page 58: ...l test part Pressure decay valve closes trapping air in test part Dump valve opens to atmosphere releasing air in test part Pressure value is tared and Pressure Change is measured Air Time Pressure Fill Time Stabilize Time Test Time Air Press X ducer TestPort Port 1 Pressure Decay Valve Product Dump Valve Atmosphere ...

Page 59: ...his listing Timers Used in Pressure Decay Occlusion Testing f Coupling Time f Fill Time f Stabilization Time f Test Time f Dump Time Timers Used in Flow Testing f Coupling Time f Fill Time f Test Time f Dump Time Timers Used in Burst Testing f Coupling Time f Test Time will stop sooner when event in sensed f Dump Time In run mode the run display shows the time in the info box labeled Test Time All...

Page 60: ...re needed to conduct pressure decay flow and burst tests The bulkhead labeled 2 is typically a coupling port if the tester is equipped with this feature This is where to connect external fixtures used to clamp or seal product to be tested The coupling port supplies air pressure at either full line pressure or to a regulator adjusted pressure Customers need to specify at the time of order If no cou...

Page 61: ...n open product when a sealing fixture is used to close the test circuit Also used for combination leak and flow testing FIGURE 26 Connecting Small Parts Small products such as catheters can attach directly to a fitting on the test port Uson SPRINT LC 1 2 Uson SPRINT LC 1 2 USER TIP Part to be tested Closed on back side Sealing Fixture to seal back side of open part ...

Page 62: ...n Flow Mode Before START is pressed for the first time the readout shows zero with the flow resolution of the tester typically 0 00 The readout continues to show zero during couple and fill times The readout shows the amount of air flow when Sprint LC goes into test phase and holds the flow rate recorded at the end of test time The last reading is held until START is pressed again to being a new t...

Page 63: ...ressure Decay Total amount of pressure drop measured at end of test time Flow Final flow measured at end of test time Burst Peak pressure attained during the test PD 0 PASS Mode Test Time Status PROGRAM 1 Test Press Tested Reject 9 993 psig 1 0 psig PD 1 2 TEST Mode Test Time Status PROGRAM 1 Test Press Tested Reject 9 993 psig 0 0 psig 003 ...

Page 64: ...ame format as described for the single channel testers They are displayed with a smaller font but convey the same information Two channel Example After the end of the test Four Channel Example During the test time FIGURE 28 PD 1 2 TEST Mode Test Time Status PROGRAM 1 Test Press Tested Reject 10 000 psig 0 0 Ch1 005 TEST Ch2 008 TEST Ch3 006 TEST Ch4 005 TEST PD 0 PASS Mode Test Time Status PROGRAM...

Page 65: ...ds on the test type being run and what phase the test is in Bar Graph in Pressure Decay Mode In fill phase the bar graph shows the product being pressurized Full scale equals preset test pressure This is the same in the stabilize time Figure 29 At the beginning of test time Sprint LC changes the resolution and the bar graph becomes a very high resolution trend indicator The full scale of the bar g...

Page 66: ...ll scale in a burst test is the maximum burst setpoint entered in the parameters menu The bar graph is perhaps most effective in burst mode because the moving bar shows the gradual pressure increase controlled by the needle valve Watching the bar graph can help when adjusting the flow control needle valve for the optimal ramp rate when burst testing Figure 30 During the test phase of a pressure de...

Page 67: ...same format as described previously for the single channel Sprint LC They have a smaller scale but convey the same information for the associated channel Figure 31 PD 1 2 TEST Mode Test Time Status PROGRAM 1 Test Press Tested Reject 10 000 psig 0 0 Ch1 005 TEST Ch2 008 TEST Ch3 006 TEST Ch4 005 TEST During the test phase of a pressure decay test Sprint magnifies the scale The slightest leak shows ...

Page 68: ...ts Sprint LC allows selecting English units of measure psig to program a test then return to the Units menu to select metric units Product testing can then be conducted with results displayed in metric format although programming was done in English units Changing Units Turn the LOCKOUT keyswitch to program mode Measurement units are set in the menu called Engineering Units which is reached throug...

Page 69: ...t LC For example if Sprint LC does not have a flow test then the flow units will not be available When Sprint LC does not have a flow test available it provides the option to calculate a flow rate cc per minute based on the volume and the pressure decay rate See pages 50 51 When the conversion is available the units menu has an option to set the volume units to either cubic centimeters cc or cubic...

Page 70: ...computers made by Hewlett Packard IBM or Apple Connect the null model RS 232 cable to the Sprint LC port labeled RS 232 IN Pins used transmit receive and ground See Figure 34 When importing a test data file into a commercial spreadsheet program accept the data file produced by Sprint LC in tab delimited format using the spreadsheet s import option Available Data At the end of a test or test series...

Page 71: ...st type pressure decay occlusion flow or burst f Test value from the main digital readout f Flow units f Result at the end of test OVR P P ERR LOW HIGH PASS or ABORT Burst Data f Cycle number from the Tested box f Program number f Test type pressure decay occlusion flow or burst f Test value from the main digital readout f Pressure units f Result at the end of test P ERR LOW HIGH NO PASS or ABORT ...

Page 72: ...to change serial port parameters Baud Rate The baud rate can be set for speeds from 1200 to 19200 Data Bits Set data bits to 7 or 8 Stop Bits Set stop bits for 1 or 2 Parity Parity is set at none and cannot be changed The default serial port settings are listed in Figure 33 FIGURE 33 Enter Prev Next Help SPRINT LC SET UP Test Parameters Units Calibration Serial Port Back Prev Next Inc Dec SERIAL P...

Page 73: ...plugs into a computer or printer Sprint Side 25 pin connector that plugs into the port labeled RS 232 IN on the back of Sprint Pin 2 on Sprint goes to pin 3 on the peripheral Pin 3 on Sprint goes to pin 2 on the peripheral Ground goes from pin 7 to pin 7 1 2 3 7 13 1 2 3 7 13 Ground Receive Transmit ...

Page 74: ... vendors sell communication programs such as Cross Talk and ProComm that allow communication between Sprint LC and a connected computer or terminal Running HyperTerminal supplied with Microsoft Windows is also an option Please read the instructions supplied with your computer and your communications program Cables Regardless of the software used to communicate with Sprint LC a null modem cable is ...

Page 75: ...ove both product quality and the manufacturing process The many included reports can be filtered and customized to fit most every need This is the simplest and most powerful way to collect data from the Sprint LC It can accept inputs from multiple testers and configure the data into real time easy to read graphs and reports By Day X Bar R Chart 7 00 7 50 8 00 8 50 9 00 9 50 10 00 10 50 11 00 1 2 3...

Page 76: ...Terminal accessory on the host PC Select an Icon In the Connect using box select the serial port to which the cable is connected Configure the communication options in HyperTerminal to match the Sprint LC 3 3 3 Start testing The Sprint LC will automatically send the test results at the end of each test 4 4 4 Import the information into a spreadsheet program for analysis At the end of each test the...

Page 77: ...described in the section on RS 232 in the Sprint LC Owner s Guide Baud Rate Make sure the baud rate set on the Sprint LC matches the baud rate established in the communication program on the host Data Bits Set Sprint LC to either 7 or 8 data bits to match your communication program Stop Bits Set Sprint LC to either 1 or 2 to match your communication program Parity Sprint LC is fixed at no parity M...

Page 78: ...ram If programs are linked together the parameters for each linked program are also printed The header also includes the column headings that will appear at the top of the test results The column headings include Cycle Prog Test Value Units and Result Test Results Report The Test Results report contains data in tab delimited columns The data appears under the headings generated by the Parameter Li...

Page 79: ...r 1 5 ON Hold Fail NO Fill Time 2 0 Stab Time 1 0 Test Time 3 0 Dump AUTO Next Program 2 Reject Level 050 Product Vol 0 Cycle Prog Test Value Units Result 1 1 PD 005 PSIG PASS 2 1 PD 004 PSIG PASS 3 1 PD 006 PSIG PASS 4 1 PD 055 PSIG LEAK PROGRAM 1 TOTAL TESTED 4 PASSED 3 REJECT 1 Parameter List Result Heading Test Results Summary ...

Page 80: ... logging report In this example program 1 is not linked to any other program TESTER 12345 1S SET UP PARAMETERS PROGRAM 1 TEST TYPE PD Test Press 10 000 Press Error 500 Coupling CP1 Timer 1 5 ON Hold Fail NO Fill Time 2 0 Stab Time 1 0 Test Time 3 0 Dump AUTO Next Program 0 Reject Level 050 Product Vol 0 Cycle Prog Test Value Units Result The current selected program is printed first followed by ad...

Page 81: ...old Fail NO Fill Time 2 0 Stab Time 1 0 Test Time 3 0 Dump AUTO Next Program 2 Reject Level 050 Product Vol 0 TESTER 12345 1S SET UP PARAMETERS PROGRAM 2 TEST TYPE OCC Test Press 10 000 Press Error 500 Coupling CP1 Timer 1 5 ON Hold Fail NO Fill Time 1 0 Stab Time 1 0 Test Time 1 0 Dump AUTO Next Program 0 Reject Level 6 666 Product Vol 0 Cycle Prog Test Value Units Result ...

Page 82: ...e Parameter List and Test Result Heading The Test Results report prints one test program at a time In the example below first two test cycles were run on Program 1 Then the current program was changed to Program 2 and two test cycles were run Finally two test cycle were run on Program 3 Example Result Report Cycle Prog Test Value Units Result 1 1 PD 005 PSIG PASS 2 1 PD 055 PSIG LEAK 1 2 Flow 110 ...

Page 83: ... a single channel tester run display at the end of a pressure decay test A partial list of error messages appears on the following page These error messages apply to all Sprint LC testers Test result messages appear in the status box on the run display These test result messages are the same as those in the Result column of the serial string output FIGURE 35 003 Status or Test Result message ...

Page 84: ... during the stabilize time LEAK The pressure decay exceeded the reject level during test time in a pressure decay test OCC Occlusion In an occlusion test the pressure decay did not reach the reject level setpoint HIGH The product exceeded the maximum flow or burst setpoint LOW The product did not meet the minimum flow or burst setpoint OVER Over Pressure In a flow test the pressure was above the m...

Page 85: ...s ENTER BACK The Summary report contains the program number the total number of tests the number of passes and the number of rejects associated with the program number An example of a Summary report is shown below In the example program 1 is linked to program 2 Example of a Summary Report PROGRAM 1 TOTAL TESTED 10 PASSED 9 REJECT 1 PROGRAM 2 TOTAL TESTED 9 PASSED 9 REJECT 0 ...

Page 86: ...t of the test Figure 36 It is not recommended to use the foot switch input to start a test from an external relay or PLC The foot switch input is not isolated Output Three conditions can be sensed and are available as dry contact no voltage outputs The contacts are rated for DC only The constant current capacity of each contact is 1 5 amps The switching load must not exceed 10VA 0 5 amp 100 VDC Th...

Page 87: ...Page 87 I O Connector Pinout Standard 25 pin D style connector FIGURE 36 Foot Switch Pinout Dry contact used to start Sprint LC FIGURE 37 25 1 24V Remote Start Test Over Fail Pass 1 2 4 3 ...

Page 88: ...cclusion f Program 3 Flow f Program 4 Burst The factory installed programs can be modified in any way For instance it is possible to set up all programs to measure flow if desired Values stored in factory installed programs need to be modified to the particular product Use the preset values as a convenient starting point in programming if that helps This section explains how to program six types o...

Page 89: ...t through the Sprint LC is important To begin set all timers at fairly long times 10 to 15 seconds longer if the part is larger than 1 liter it is possible to watch what is happening during tests Extra long times allow the opportunity to study the main digital readout bar graph and info box values on the run display Once familiar with what is happening with a particular product during a test it is...

Page 90: ...on on large or flexible products If the product is very small and made of rigid material the stabilization time can be set very low 5 At the end of stabilization time Sprint LC starts looking for a drop in pressure from the stabilized pressure Sprint LC goes into test phase only if test pressure is within the pressure error tolerance at the end of the stabilize phase 6 During test time Sprint LC c...

Page 91: ...mum decay Product Volume optional to calculate cc m Next Program FIGURE 38 Back Prev Next Inc Dec PROGRAM 1 Test Type PD Test Press 14 999 psig Press Error 5 psig Coupling GoTo Test Params GoTo Next Program 0 PRESSURE DECAY TEST Fill Time 2 0 sec Stab Time 1 0 sec Test Time 3 0 sec Dump AUTO Rej Level 050 psig Product Vol 1 0 cc 51 ccm Coupling Timer Setup Time CP1 1st 5 ON 2nd 0 OFF Occ Rel NO Hl...

Page 92: ...ws P ERR in the status box on the run display The preset test pressure should be very close to the actual pressure from which the product starts to drop If not the pressure regulator may have been moved or there is a problem with the supply air to the tester FIGURE 39 PD 3 0 Mode Test Time Status PROGRAM 1 Test Press Tested Reject 9 993 psig 0 0 psig The preset test pressure is shown in this box o...

Page 93: ... a test black curve in figure 40 The actual pressure could be different from the preset test pressure due to variations in product and small changes in the test system For this reason set the pressure error tolerance to allow for a range of acceptable test pressure The pressure error tolerance is the acceptable difference between the actual test pressure and the target test pressure Figure 41 Fill...

Page 94: ...Page 94 Fill Zero Pressure Error Window FIGURE 41 Positive Pressure Error FIGURE 42 Fill Stabilize Test Dump Zero TIME PRESSURE Test Pressure P ERR P ERR TIME PRESSURE Test Pressure P ERR P ERR PRESSURE ...

Page 95: ... as an equal plus and minus tolerance around a nominal test pressure value Figure 41 Enter one number in pressure units and Sprint LC sets both the high and low pressure error values Sprint LC monitors pressure error during the fill and stabilization phases of a pressure decay leak test In a flow test pressure error is checked at the end of test time to allow for the necessary pressure drop caused...

Page 96: ...sed the valves turn on at the start of the test and turn off when the test is finished Coupling time is generally the period in which the pneumatic or mechanical fixtures are applied to seal the product from atmosphere Often used in open ended products such as tubing catheters and containers If external fixtures are not used set the coupling for zero time off Refer to page 42 for more information ...

Page 97: ...he leak the longer the time Test Timer In a pressure decay test test time is the period when Sprint LC takes measurements to determine the amount of pressure drop from a stabilized pressure The instant the test enters test phase Sprint LC takes the first pressure reading and stores this value P 1 At the end of test phase Sprint LC takes a final reading and holds this value as P 2 The difference be...

Page 98: ...drop the first reading at the start of test phase and the last reading at the end of test phase Sprint LC uses the pressure drop to compare to the maximum allowable loss known as the reject level to decide whether a product is accepted as good or rejected as bad The reject limit to enter into the parameters menu is generally a low pressure value such as 0 050 psig because the reject pressure is th...

Page 99: ...t passes The instant the pressure drops exceeds the reject limit in test phase the test ends and the reject light turns on Figure 35 If dump is set to AUTO the dump valve opens and vents the pressure to atmosphere without waiting for the test phase to finish FIGURE 46 Fill Stabilize Test Dump Zero Couple TIME PRESSURE Reject Level PD Test Pass Decay stays above reject level during test phase Fill ...

Page 100: ...or messages when neither the product nor the fixture seals appear to be the problem consider increasing the fill time the pressure error tolerance or both Also at fault could be the test pressure setting Make sure the pressure regulator has not been moved and the actual applied pressure closely matches the preset test pressure FIGURE 47 3 GROSS Test Time Status PROGRAM 1 Press Tested Reject 93 psi...

Page 101: ...volume The tester assumes an atmospheric pressure of 14 7 psig 1 atmosphere when calculating the ccm rate Turn off flow rate calculation If the volume is set to zero then Sprint LC does not convert the leak rate to cubic centimeters per minute The test results remain in pressure decay Testers with Flow Testers with flow sensors do not have the Prod Volume parameter line because those testers read ...

Page 102: ...e pressure regulator to adjust the test pressure reading When the reading is set push the ENTER BACK keypad The highlight bar moves down to Pressure Error Read pages 40 41 for more information about setting the test pressure 4 Use the INCREMENT and DECREMENT keypads to set the value for pressure error Pressure error is how much overshoot or undershoot is allowed around the test pressure Pressure E...

Page 103: ... will be highlighted Fill time is the amount of time to give the product to fill with air before closing the valves Small products generally require a very short fill time and larger or flexible products require a longer fill time Use the INCREMENT and DECREMENT keypads to set the value for fill time FIGURE 48 Back Prev Next Inc Dec PROGRAM 1 Test Type PD Test Press 14 999 psig Press Error 5 psig ...

Page 104: ...the NEXT keypad to highlight Test Time Use the INCREMENT and DECREMENT keypads to set the value for test time Test time is the amount of time Sprint LC takes readings to monitor the pressure drop 9 Press the NEXT keypad to highlight Dump Dump can be set to Auto Off or a set time Dump opens the valve to atmosphere to vent the product between tests If it is intended to simply unplug the product to v...

Page 105: ...ert the pressure drop to a cc m flow rate If desiring test results in pressure decay then leave this value at zero Press BACK to exit back to the main parameter menu 11 Press the NEXT keypad to highlight Next Program Use the INCREMENT and DECREMENT keypads to set the number of the next program to link When not using linking set to zero 12 Press the BACK keypad when everything is entered and ready ...

Page 106: ...in a pressure decay test with the exception of the reject level The reject level is the reverse of a pressure decay leak test Rather than expecting the part to hold pressure we now expect the pressure to flow to atmosphere The occlusion test expects the pressure to drop more than the reject level For simplicity we will not repeat the definitions of all the parameters or how to program For more inf...

Page 107: ...nducted first then open the product to atmosphere and conduct an occlusion test Sealing the Product Occlusion tests can be conducted by using a clamping device to seal the product during the fill time and releasing the seal to allow the product to flow to atmosphere Alternatively the product can be opened to the atmosphere throughout the entire test Please refer to coupling valves starting on page...

Page 108: ...e drop readings For large flow rates stabilization time is not needed and can be set to zero 5 At the end of stabilization time Sprint LC starts looking for a drop in pressure from the stabilized pressure Sprint LC goes into test phase only if test pressure is within the pressure error tolerance 6 During test time the coupling is released and the test part is opened to atmosphere Sprint LC compare...

Page 109: ...the sealing device opens and allows the product to flow to atmosphere The significant pressure drop in the product indicates that the product under test flows freely to atmosphere and thus is not blocked Test Time Occlusion Test Fail If the flow path were to be blocked the product would fail because the air loss from the product would not be enough for pressure to drop more than the reject level i...

Page 110: ...essure drop readings can be taken in the test time Sprint LC goes into test phase only if test pressure is within the pressure error tolerance by the end of the fill phase Again no stabilize time is needed for large flow rates 6 During test time Sprint LC compares the pressure drop to the reject level IF the pressure decay or pressure loss is greater than the reject level at the end of test time t...

Page 111: ...hrough a part the pressure can be set at the level expected when the flow path is open Fill Time Occlusion Test Pass The significant flow through product keeps the test pressure from rising and thus is not blocked Fill Time Occlusion Test Fail If the flow path were to be blocked the test pressure will rise indicating that the flow path is blocked The test will fail in the fill time because the pre...

Page 112: ... a product and to pass that product if air flow is between a minimum and maximum tolerance in a program Figure 52 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 test with three exceptions 1 A flow test has no stabilization phase 2 Instead of one reject level a flow test has both mini...

Page 113: ...x Flow maximum flow Min Flow minimum flow Next Program Protect the Flow Sensor Do NOT run a flow test unless product is attached to the test port Without this restriction the high flow rate could damage the flow sensor FIGURE 53 Fill Test Zero Couple Flow Test Setpoints TIME PRESSURE FLOW Min Flow Max Flow Test Pressure P ERR P ERR Flow and Pressure are compared to Pass Fail limits at the end of t...

Page 114: ...pressure number Sprint LC sets the positive and negative pressure error around the nominal test pressure FIGURE 54 If air pressure at the end of test time is below the minimum pressure error value Sprint LC stops the test If dump is active Sprint LC vents the air to atmosphere Figure 54 In this case Sprint LC displays P ERR in the status box on the run display 0 P ERR Test Time Status PROGRAM 1 Pr...

Page 115: ...f test time is above the maximum pressure error value Sprint LC stops the test and if dump is active vents the air to atmosphere Figure 55 Sprint LC displays P ERR in the status box on the run display USER TIP Test Zero TIME PRESSURE Test Pressure P ERR P ERR Test Fails with P ERR if the pressure goes above the maximum Pressure setpoint High Pressure in a Flow Test 0 P ERR Test Time Status PROGRAM...

Page 116: ...int LC shows P ERR in the status box because pressure error has priority over flow tolerance FIGURE 56 If the air flow measured by the mass flow sensor is below the minimum setpoint at the end of test phase Figure 56 Sprint LC turns on the reject light and shows LOW in the status box on the run display If dump is active the dump valve opens and pressure is vented to atmosphere Fill Test Zero Coupl...

Page 117: ...ir flow measured by the mass flow sensor is above the maximum flow setpoint at the end of test phase Sprint LC turns on the reject light and shows HIGH in the status box on the run display If dump is active the dump valve opens and pressure is vented to atmosphere USER TIP 0 HIGH Test Time Status PROGRAM 1 Press Tested Reject 93 psig 1 1 sccm Fill Test Zero Couple High Flow Reject TIME FLOW Min Fl...

Page 118: ...le products If the acceptable leak rate is relatively small less than the rates discussed above a pressure decay test is probably your best choice for leak testing Call Uson to discuss your special testing needs We specialize in helping test engineers come up with the very best tests for a wide range of products When setting the maximum flow setpoint you ll need to experiment to find the best sett...

Page 119: ...y fill up and start flowing immediately The flow rate is displayed for both during the fill and test phases Figure 58 shows a leak test using flow Because the flow was between the minimum and maximum flow setpoints at then end of test time the product passed and PASS is displayed in the status box on the run display 0 PASS Test Time Status PROGRAM 2 Press Tested Reject 93 psig 1 1 sccm Fill Test Z...

Page 120: ...est pressure reading After the reading is set push the NEXT keypad The highlight bar moves down to Pressure Error Read pages 37 39 for more information about setting the test pressure 4 Use the INCREMENT and DECREMENT keypads to set the value for pressure error Pressure error is how much overshoot or undershoot is allowed around the test pressure Pressure error is needed to ensure the product reac...

Page 121: ...e air flow The last reading made during test time is used to decide whether the test was a pass or fail 8 Press the NEXT keypad to highlight Dump Dump can be set to Auto Off or a set time This opens the valve to atmosphere to vent the product In most flow tests the product itself is vented to atmosphere often making Dump unnecessary and it can be set to OFF However if pressure remains trapped with...

Page 122: ... whether the test was a pass or fail Use the INCREMENT and DECREMENT keypads to set the value for minimum flow Press BACK to exit back to the main parameter menu The minimum flow cannot be set higher than the maximum flow setpoint 11 Press the NEXT keypad to highlight Next Program Use the INCREMENT and DECREMENT keypads to set the number of the next program to link If not linking to another progra...

Page 123: ...ociated with each flow range Flow Range Over Pressure Limit 10 sccm 15 psig Max 50 sccm 15 psig Max 200 sccm 15 psig Max 1 000 sccm 15 psig Max 5 000 sccm 60 psig Max 20 000 sccm 60 psig Max Status Box Messages P ERR Pressure was above or below the pressure error window at the end of the test time HIGH Flow exceeded maximum flow setpoint LOW Flow did not reach minimum flow setpoint OVER The pressu...

Page 124: ...uilt around two test conditions Peak Pressure P Peak Pressure is a constantly updated value before the burst Sprint LC uses the peak pressure reading as the starting point to measure the event value After the event the final peak value is compared to the minimum and maximum burst setpoints to decide whether the product is accepted or rejected Event E Event is the amount of pressure drop from the p...

Page 125: ...URE 61 Test Zero Couple P E Burst Test Pass TIME PRESSURE Min Burst Max Burst Event Value Test Zero Couple P E Burst Test Pass TIME PRESSURE Min Burst Max Burst Event Value event above minimum burst event below minimum burst ...

Page 126: ...t level Min Burst minimum burst level Burst Event amount of pressure drop to be detected Next Program Min and Max Burst Minimum and maximum burst setpoints establish a window in which a burst event must take place to be a pass If the burst occurs below the minimum setpoint the test is stopped and LOW appears in the status box on the run display The fail light turns on Figure 62 If pressure goes ab...

Page 127: ... Reject TIME PRESSURE Min Burst Max Burst Burst below minimum stops the test and the fail light turns on Test Zero Couple Burst Test High Reject TIME PRESSURE Min Burst Max Burst No event so test stops when pressure exceeds maximum set point Fail light turns on Dump ...

Page 128: ...ghlight Coupling Use the GoTo keypad to enter the pop up menu and set the values for coupling time If external fixtures connected to the coupling port are not in use set the coupling time to zero seconds and the setting to OFF Press the BACK keypad to exit 5 Press the NEXT keypad to highlight Test Params Use the GoTo keypad to enter the sub parameter pop up menu Fill Time will be highlighted Use t...

Page 129: ...st Event Burst event is the minimum pressure drop the product must cause from the peak pressure value to have Sprint LC determine that a burst occurred 10 Press the ENTER BACK keypad to highlight Next Program Use the INCREMENT and DECREMENT keypads to set the number of the next program to link If not linking to another program set the next program to zero 11 Press the ENTER BACK keypad when everyt...

Page 130: ...nly difference between a standard burst test and a creep test is that in a creep test the minimum and maximum burst setpoints are set to the same value Figure 68 Setting minimum and maximum setpoint to the same pressure causes Sprint LC to pass product reaching the min max pressure setting Products not reaching the min max setpoint in the allowed test time are rejected Figure 69 Products opening t...

Page 131: ... setpoint in the allowed time during a creep test This failure could have been caused by an incorrect setting on the regulator or flow control Or the product could be leaking If the pressure does not reach the min max setpoint before the test time ends NO is indicated in the status box on the run display Test Zero Couple Creep Test TIME PRESSURE Min and Max Pressure did not reach the min max setpo...

Page 132: ...me ran out In this case the product did not withstand the slow pressure increase and opened to atmosphere LOW is indicated in the status box on the run display Test Zero Couple P E Creep Test Fail TIME PRESSURE Min and Max Burst below min max stops the test and the fail light turns on t 0 LOW Test Time Status PROGRAM 3 Press Tested Reject 93 psig 1 1 psig ...

Page 133: ...Extra long times allow studying the main digital readout bar graph and info box values on the run display Having developed an understanding of what is happening with the product during a test it becomes possible to begin adjusting the pressure values and setpoints to catch the rejects Continue experimenting and then reduce the timers to get the fastest possible test while still catching rejects Us...

Page 134: ... the feet attaching threads when mounting Sprint LC to a surface or machine The Sprint LC base has four 6 by 32 attachment points The rubber feet are typically left on to act as a cushion Calibration The Sprint LC uses firmware calibration DO NOT enter calibration mode unless entering accurate new calibration data to linearize the pressure or flow transducers 10 66 in 6 12 in Rear 1 50 in ...

Page 135: ... the guide is studied and the consequences of starting a calibration are understood If Sprint LC is not due for a scheduled calibration but it appears to have an accuracy problem check all other possibilities and consult with Uson before starting a calibration For example Verify or compare against a standard first before changing calibration data Make sure the tester or test fixtures do not leak S...

Page 136: ...es follow the same procedures starting on page 138 Single and Sequential Calibration Sequential Sprint LCs have up to four ports but only have one pressure transducer They may also have a flow transducer The calibration menu looks and functions the same as in a single channel Sprint LC The calibration port in a sequential tester is port 1 When performing a pressure calibration air is sent out of t...

Page 137: ...of the Sprint LC to supply a calibrated standard for comparison to the Sprint LC same as in a single channel Sprint LC The difference here is all ports will be supplied with air pressure Setting Concurrent Calibration Points The concurrent calibration menu allows all pressure sensors to be calibrated at the same time Each transducer does have an individual reading as shown below However when the z...

Page 138: ...possible actions Stop and Leave Calibration To quit proceeding with calibration exit by pressing the ENTER BACK keypad when the Exit Calibration line is highlighted Sprint LC defaults to the Exit Calibration line Proceed with Calibration To proceed with calibration use the NEXT keypad to select the Enter Calibration line then press the ENTER BACK keypad After the ENTER BACK keypad is pressed Sprin...

Page 139: ...ion will not be present in testers without flow sensors FIGURE 76 Enter Prev Next EXIT CALIBRATION ENTER CALIBRATION STOP WARNING YOR ARE ABOUT TO CHANGE CALIBRATION Revision Level 3 XX Serial Number 12345 1S Enter Prev Next Exit Pressure Calibration Flow Calibration Time Verification ...

Page 140: ... Port Enter Prev Next EXIT CALIBRATION ENTER CALIBRATION STOP WARNING YOR ARE ABOUT TO CHANGE CALIBRATION Revision Level 3 XX Serial Number 12345 1S Enter Prev Next Exit Pressure Calibration Flow Calibration Time Verification Back Inc Dec Pressure Calibration Reading Sensor 002 psig Target 000 psig ...

Page 141: ...f the installed sensors Adjust the regulator on the back of the Sprint LC until the target number very closely matches the external pressure standard When the external standard closely matches the target number then store the calibration data point Store Calibration Data Points It is necessary to press and hold the START switch and then press the BACK keypad to store a new calibration setting Both...

Page 142: ...ure regulator on Sprint LC to make the pressure standard match the target value on the calibration menu Backward Calibration A common mistake is to match the pressure accept the calibration pressure by watching the reading value on Sprint LC Instead match the pressure from the pressure standard to the target number offered on the Sprint LC Match Uson SPRINT LC 1 2 Sprint LC Pressure Standard ...

Page 143: ...eypad once to advance the target to the next setpoint 5 00 psig in our example 5 Now slowly adjust the pressure regulator Watch the readout on the pressure standard For the remainder of this procedure ignore the value called reading on the calibration menu unless wanting to record the value as found data When the pressure standard reads the target value press and hold the white START switch while ...

Page 144: ...Next EXIT CALIBRATION ENTER CALIBRATION STOP WARNING YOR ARE ABOUT TO CHANGE CALIBRATION Revision Level 3 XX Serial Number 12345 1S Enter Prev Next Exit Pressure Calibration Flow Calibration Time Verification Back Reg Reg Inc Dec Flow Calibration Reading Flow Sensor 10 02 sccm Target 10 00 sccm Pressure 1 523 psig ...

Page 145: ...r a calibrated flow master or set of several masters Both methods are represented in the figure on the following page Flow Meter A flow meter is able to read and display a flow rate A flow restrictor is needed to limit the flow rate By adjusting the restrictor and or the pressure it is possible to produce the target flow rates Flow Master A calibrated flow master is a calibrated orifice that produ...

Page 146: ...ents to calibrate the mass flow transducer If the proper instruments with the necessary accuracy are not available return the Sprint LC to Uson for recalibration when needed Uson SPRINT LC 1 2 Sprint LC Flow Restrictor Flow Meter Uson SPRINT LC 1 2 Sprint LC Flow Master Pressure Standard ...

Page 147: ...ibration Sprint LC does not open the flow valves to prevent sensor damage and displays OVER in place of a pressure reading on the Pressure line at the bottom of the menu Flow calibration menu showing over pressure condition FIGURE 81 Flow Sensor Over Pressure Limits Flow Range Over Pressure Limit 10 sccm 15 psig Max 50 sccm 15 psig Max 200 sccm 15 psig Max 1 000 sccm 15 psig Max 5 000 sccm 60 psig...

Page 148: ...w restrictor and the flow standard with the correct pressure The advantage of this calibration setup is the elimination of the pressure to flow chart required when using a certified restrictor flow linearizer The restrictor used in Figure 82 can be any restrictor that provides enough restriction to generate flow in the range to be calibrated Variable flow control devices can be used if they can re...

Page 149: ...ess and hold the white START switch while momentarily pressing the ENTER BACK keypad The flow reading on Sprint LC should now read 00 4 Connect air pressure to the air input connector on the rear of the tester Connect the flow measuring meter and the flow restricting device to the test port Figure 81 5 Slowly adjust the pressure regulator When the flow standard reading matches the target value pre...

Page 150: ...rtificate of accuracy Read the pressure standard when setting the pressure to produce the air flow as specified in the pressure to flow chart Always use the more accurate standard to measure the pressure when using a flow linearizer If there is no access to a flow linearizer use individual fixed restrictors These are often used when calibrating Sprint LC at a single flow point A single flow point ...

Page 151: ...he calibration menu should now read 0 00 3 Connect air pressure to the air input connector on the rear of the tester Connect the flow master device to the test port Figure 83 4 Now slowly adjust the pressure regulator Watch the readout on the pressure standard When the pressure standard is at the right pressure to generate the target flow through the restrictor press and hold the white START switc...

Page 152: ...and compare the standard to the target output Timer repeatability is better than plus or minus 0 01 second in 30 seconds The time base is derived from a crystal oscillator controlled by the main microprocessor Time Verification Menu FIGURE 84 The BNC connector on the rear of the Sprint supplies a TTL signal approximately 5VDC on and 0 VDC off Center is signal and collar is ground If the target tim...

Page 153: ...n the 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 the internal test circuit generally between 5 0 cubic centimeters and 15 0 cubic centimeters depending on model plus the volume of connections between the test port and the product The total volume for our example must be in ...

Page 154: ...th respect to surrounding air pressure the pressure exerted by the weight of the atmosphere Barometric pressure is the surrounding pressure 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 A vacuum can be defined as a volume of space that contains no matt...

Page 155: ...creases less 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 factor of 10 for every 16 km 10 miles increase in altitude Density does not depend solely on pressure For a given pressure density is inversely proportional to temperature This relationship k...

Page 156: ... or the object moves through the fluid Although a fluid can deform easily under an applied force the fluid s viscosity creates resistance to this force The viscosity of gases which is much less than that of liquids increases slightly as the temperature increases whereas that of liquids decreases when the temperature increases Fluid mechanics is mostly concerned with Newtonian fluids or those in wh...

Page 157: ...several meters as in a large room or other structure Equations for turbulent flow are more complex than the formulas for laminar flow For most answers they require empirical relations derived from controlled experiments Whether a flow is laminar or turbulent generally can be determined by calculating the Reynolds number Re of the flow The Reynolds number is the product of the density designated by...

Page 158: ...ibed and predicted by a set of equations or gas Laws These Laws were determined by measurements of actual gases and are valid for all substances in a gaseous state Measurements on gases were first published by Robert Boyle in 1660 He figured out that if an enclosed amount of gas is compressed until it is half its original volume while the temperature is kept constant the pressure will be doubled Q...

Page 159: ...th an equation a lot like Charles s Law P T Constant Generalized Gas Law We can combine Boyle s Charles s and Gay Lussac s Laws to express this generalized gas Law PV T Constant where the value of the constant depends on the amount of gas present and t is the absolute or Kelvin temperature Ideal Gas Law The Ideal Gas Law can be written in a slightly different manner from the Generalized Gas Law PV...

Page 160: ...cess takes place quickly enough to prevent any significant heat transfer This is essentially the case in a number of important devices including air compressors 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 for the temperature drop is that the gas is...

Page 161: ... of test pressures Different test pressures can be assigned to each of the stored programs and then multiple programs can be linked to form one continuous series of tests each with a unique test pressure Ramping pressures for burst testing can be established and assigned to any of the stored programs Operators simply select the test program and need not adjust the test pressure Requirements of the...

Page 162: ...est port when the electronic regulator option is used Different tests programs can have different test pressures Only one pressure can be established for one program A test sequence can have multiple test pressures by linking programs INCREMENT and DECREMENT keypads are used for setting Pressure with the electronic regulator FIGURE 86 Back Prev Next Inc Dec PROGRAM 1 Test Type PD Test Press 15 000...

Page 163: ... In Burst testing pressure increases until a pressure drop is measured indicating the part has opened burst or until time runs out Manual Ramp Option Your tester may also have the option to control the ramp rate manually with a needle valve If so there will be a micrometer style handle on the back of Sprint LC to adjust the needle valve The manual ramp is typically used on products with very small...

Page 164: ... Params GoTo Next Program 0 BURST TEST Ramp Start 3 000 psig Ramp Rate 8 psi s Test Time 5 0 sec Dump AUTO Max Burst 6 666 psig Min Burst 3 333 psig Burst Event 050 psig Back Prev Next Inc Dec PROGRAM 3 Test Type Flow Test Press 10 000 psig Press Error 5 psig Coupling GoTo Test Params GoTo Next Program 0 BURST TEST Ramp Start 3 000 psig Ramp Rate 8 psi s Test Time 5 0 sec Dump AUTO Max Burst 6 666...

Page 165: ...p up with the flow and the output pressure will begin to drop With the electronic regulator Sprint LC will read the pressure and automatically adjust the output to reach the set test pressure Setting Test Pressure and Test Type When the test type is changed the test pressure is checked to be sure it is not above the maximum pressure allowed for the selected test type If it is above the maximum it ...

Page 166: ... a calibrated external standard for comparison to the Sprint LC First use the INCREMENT and DECREMENT keypads to ramp up the target pressure Target increments are typically in ten or more steps depending on the range of the installed sensors If necessary use the PREVIOUS and NEXT keypads labeled as REG and REG to adjust the regulated pressure for calibration through the electronic regulator The pr...

Page 167: ...and to adjust the pressure supplied by the electronic regulator to the external pressure standard Menu used to select target and adjust pressure Using the electronic regulator Back Reg Reg Inc Dec Target 1 000 psig Pressure Calibration Reading Sensor 1 002 psig FIGURE 89 Flow Calibration The pressure output in the flow calibration is also controlled by the electronic regulator The pressure is adju...

Page 168: ...t Fill phase to fill the part more quickly The time is limited so that the timer runs out as the pressure gets close to the set test pressure Care should be taken not damage a part with too much pressure During the fill time the standard pressure regulator finishes filling the test pressure to the set value Over Pressure Setup A higher pressure can also be used to stress the test part or to reduce...

Page 169: ... be set the same for both channels Single Channel or Sequential Sprint Test pressure for each test program may be set using one of two regulators This allows test programs with two test pressures to be run without having to stop and manually adjust the regulator The Test Parameter menu is modified to have a sub parameter menu for the Test Press line Press the INCREMENT keypad GoTo to access the po...

Page 170: ...hannel and then repeat it for the second channel using the external regulator Single Channel or Sequential Sprint The calibration functions much the same as in a standard Sprint LC During a calibration the external or HIGH regulator is used to adjust the calibration pressure The internal regulator is not used in calibration If Sprint LC is within calibration tolerance during an accuracy check Uson...

Page 171: ... then the BCD inputs will not be populated Following are a few examples of configurations that cover most all of the possibilities Single channel and sequential testers share a common pinout as shown below See page 86 of the Sprint LC Owner s guide for more information on inputs and outputs BCD Program Select To change programs a BCD pattern is used according to the table on the following page An ...

Page 172: ...Program Bit 0 Bit 1 Bit 2 Bit 3 no change 1 X 2 X 3 X X 4 X 5 X X 6 X X 7 X X X 8 X 9 X X 10 X X 11 X X X 12 X X 13 X X X 14 X X X 15 X X X X 25 Fail 2 Pass 2 24V Remote Start Test Over 1 General Fail Pass 1 24V BCD Bit 3 24V BCD Bit 0 24V BCD Bit 1 24V BCD Bit 2 Appendix 12 ...

Page 173: ...he cycle ends and the tester is idle again Four Channel Concurrent without BCD FIGURE 94 Concurrent Pass Fail Outputs The pinout for concurrent testers will follow one of the three formats as shown in figures 93 94 and 95 With the concurrent multi channel versions the pinout will only have as many sets of Pass Fail outputs as it has channels or test ports A 2 channel will have 2 pass outputs A 3 c...

Page 174: ...a General fail output is used It is active if any combination of the test ports fail The individual pass outputs are of course active if the corresponding channel passes A fail is assumed for channels that do not have a pass output active Four Channel Concurrent with BCD 25 FIGURE 95 1 24V Remote Start Test Over General Fail Pass 1 24V BCD Bit 3 24V BCD Bit 0 24V BCD Bit 1 24V BCD Bit 2 Pass 3 Pas...

Page 175: ...and inputs follow a specific format as illustrated in the example below The command must follow this format and have the same number of characters to be recognized by Sprint LC Example Command 54321 1S ST 01 CR The format has five sections The start of string character the serial number of the Sprint LC the command code the program number and the end of string character The Serial number command c...

Page 176: ... string is the program number In our example we use 01 The valid range of program numbers is 01 to 99 In addition when clearing the counters 00 may be entered to clear all counters in all the programs The retest and reset functions do not require the second colon or program number They may be omitted when sending a retest or reset command End of String Character CR CR stands for a carriage return ...

Page 177: ...er menu is modified to have a sub parameter menu for the Next Program line Press the INCREMENT keypad GoTo to access the pop up menu See the figure on the next page On Pass vs On Fail The four settings are separated into two groups On Pass and On Fail The two lines associated with On Pass control actions that are only executed if the part passes and the test is accepted The two lines associated wi...

Page 178: ...e pause can be set to YES active or NO inactive The pause only occurs if the associated Program value is also active not zero For example if the On Pass Program is set to zero and the test passes the test will end and there will be no pause Even if the On Pass Pause is set to YES Next Program Sub Parameter Menu Back Prev Next Inc Dec PROGRAM 1 Test Type PD Test Press 10 000 psig Press Error 5 psig...

Page 179: ...a Plot Interval line It may be set to OFF or 0 1 through 1 0 second At the end of the test all of the stored values are reported through the serial port The time interval selected determines how many values are recorded The Sprint LC does not buffer the information so the RS 232 cable must be connected to collect the information See pages 70 and 72 for more information on the cable connection Plot...

Page 180: ...decay occlusion vacuum or burst test the pressure values are reported In a flow test both the pressure and flow values are reported After all the values are sent to the serial port the standard data logging string is also printed The serial string columns are separated by tabs Data Plotting with Concurrent Multi Channel In a concurrent Sprint LC data can be collected from only one channel or test ...

Page 181: ...re multiple test parts and test programs The names are shown in both the run mode and the program mode Choosing a Program Name There is a maximum of 24 characters Any printable character on the keyboard may be used The names may be changed as often as desired The program number is always included to the right of the program name All the program names are initialized to Program Example Program 1 FI...

Page 182: ... The program name option is selected by typing the letter P Sprint LC responds by asking for the program number Select the Program Number to rename 1 99 or 0 to Quit 4 4 The program number is typed in followed by Enter The Sprint LC then asks for the program name If a value is typed in that is not valid the same line asking for the program number is printed again Enter new Program Name 24 Chars Ma...

Page 183: ...lerances Crack testing is related to burst testing A burst test is used with products that open quickly to atmosphere and create a dip in pressure called an event In some products the event is too small or the pressure does not drop at all A crack test uses a second sensor downstream from the part to catch a pressure rise or flow coming out of the part Crack Test Pass FIGURE 100 Test Couple Pressu...

Page 184: ...k test Sprint LC is equipped with two sensors The standard transducer measures the pressure rise being feed to the test part on the upstream side The second sensor is the downstream sensor The crack event is a change in pressure or flow on the downstream side of the test part This downstream sensor can be either a pressure or flow sensor Two measured values are associated with an event value X The...

Page 185: ...for a crack test The parameters of a crack test are set in the same manner as a burst test See page 128 Crack Test Fail Pressure too high HIGH crack FIGURE 101 Test Vent Delay Zero Zero Sensor 2 downstream Sensor 1 upstream Min Burst Max Burst Test ends when Max is exceeded No Event TIME Pressure Press or Flow Appendix 25 ...

Page 186: ... vent delay option adds an additional timer before the Test Time The upstream pressure ramp is started during the Vent Delay time The down stream side is vented to atmosphere and the downstream sensor reading is ignored This allows any unwanted pressure or flow to be vented before the test time starts Back Prev Next Inc Dec PROGRAM 3 Test Type Flow Test Press 10 000 psig Press Error 5 psig Couplin...

Page 187: ...st The protective cover keeps fixture movements away from the operator The switch must remain closed through the entire test sequence If contact is broken then the test cycle will abort To start a new test the contact must be broken and then closed again Interlock Start This option is similar to the fixture lid start The foot switch input is again connected to a limit switch on a protective cover ...

Page 188: ...ignal to Sprint LC It is more than just two switches It requires that both are pressed at the same time so that one switch can not be tied down to disable it With this feature the START switch is again disabled and will not start a test The anti tie down device is connected to the foot switch input To start a test the foot switch input must be held through the coupling time or times if there are m...

Page 189: ...d parameter The highlighted setting may be adjusted with the INCREMENT and DECREMENT keypads FIGURE 103 When it is enabled a tab separated column is added to the serial string Program Header and Data Logging for the time stamp data The date is in month day year format and the time is reported in military 24 hr time with a hour min sec format The date and time are separated with a space Example Tes...

Page 190: ...Appendix 30 ...

Page 191: ... 16 Atmosphere 1 In this guide atmosphere means room air pressure Atmospheric pressure is nearly synonymous with barometric pressure an external force pushing on all sides of every object on earth s surface During a flow test product being tested must flow into atmosphere which causes a resistance to flow called backpressure Room atmosphere can change due to fluctuations in air conditioning or cha...

Page 192: ...d bulkheads on the front have a 10 by 32 pitch machine thread Many bulkhead options are possible Page 60 Burst Test One of Sprint LC s possible operating modes in addition to pressure decay and flow A burst test slowly fills a product through a flow valve set by users After the burst pressure rapidly drops to near zero Sprint LC captures the pressure immediately before the product ruptures or in s...

Page 193: ...bles Page 142 Concurrent Testing multiple ports or multiple parts at the same time is known as concurrent testing If the tester has multiple test ports and tests them all at the same time it is called a concurrent test See Sequential Contrast The contrast of the LCD can be adjusted for the best viewing It is adjusted with the contrast knob on the back of Sprint LC Page 11 12 Counters Sprint LC rec...

Page 194: ...s set up to measure the pressure at which a product like a check valve opens and allow air to flow through It is used with parts that do not open quickly enough to cause a drop in the upstream pressure An optional downstream sensor is required to measure a device that opens very slowly Crack testing differs from burst testing because the product does not suddenly drop to zero pressure as in a burs...

Page 195: ...ruct Sprint LC to vent pressure between tests Page 49 97 Electronic Regulator An optional device that automatically adjusts the test pressure to a preset value Multiple test programs with multiple test pressures may be linked together if this option is installed It also provides a way to avoid having the operator manually adjust the pressure for different test pressures Page A1 Event The instant p...

Page 196: ...stomers must specify at order whether they want coupling pressure to be line or test pressure Many fixturing options are possible Page 46 61 A27 Flow Control Sprint LC has a built in flow control to provide a slow pressure increase 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...

Page 197: ...hows flow rate in units that can be selected by the customer Page 55 56 112 123 Foot Switch An optional switch that connects to the jack on back of Sprint LC to perform the same function as pressing the START switch on the front panel Page 10 11 27 87 Gage Pressure A force referenced to barometric pressure Sprint LC uses a gage regulator to keep the pressure constant as barometric pressure changes...

Page 198: ...LC Page 86 87 A11 A14 Keypads The five membrane buttons on Sprint LC s front panel used to enter program values and other setup information ENTER BACK PREVIOUS NEXT INCREMENT and DECREMENT In this guide keypad names appear in small caps Page 8 30 33 LCD Abbreviation for liquid crystal display Sprint LC s display is an LCD device that provides setup prompts menu options test results and other syste...

Page 199: ...t operators from Sprint LC s setup and calibration functions The only way to access programming menu is to use the key and turn the switch to program vertical position Page 8 9 30 Main Digital Readout In the center of Sprint LC s run display the main digital readout is visible when Sprint LC is in run mode This readout shows the pressure and flow values during pressure decay flow and burst testing...

Page 200: ...set Page 38 52 Parameters line advancing In run mode advance from one parameters line to the next by pressing the NEXT right arrow keypad PLC Abbreviation for Programmable Logic Controller Industrial strength computers designed to accept analog inputs and to provide output for process control PLC s are used in a variety of automated control situations Sprint LC can send discrete test results to an...

Page 201: ...re regulator is adjusted during setup to set test pressure Page 10 11 40 Pressure Standard A precision measuring instrument that can be connected to Sprint LC as part of pressure or flow calibration The pressure standard must have the required accuracy stability and repeatability to measure Sprint LC s output The pressure standard must have current calibration documentation if the customer needs t...

Page 202: ...llowed in a pressure decay test This value is set in the program parameters setup menu The reject level together with test time determines the amount of acceptable leak rate Page 90 98 99 Re test how to Push the INCREMENT keypad up arrow when the test cycle has finished The initial test does not register on the Tested or Reject counters The re test function only works if the last test failed Opera...

Page 203: ...or Sprint LC uses two kinds of sensors a pressure sensor and a flow sensor As an option remote sensors can be connected to Sprint LC for automated processes Sequential Testing one test or one part after another is known as sequential testing If the tester has multiple test ports and test them one at a time in a sequence it is called a sequential test See Concurrent Setpoint A programmable threshol...

Page 204: ...irmware running the tester Page 28 Stored Programs A set of instructions parameters that can be set by the customer to run a variety of tests Sprint LC is shipped with four stored factory installed programs There are a total of 99 programs available Users can alter stored programs to meet specific product testing needs Programs are configured in Sprint LC s parameters menu and are kept in non vola...

Page 205: ...ime the operator removes the tested product One test cycle can have multiple tests by linking programs in Sprint LC s parameters menu Multiple tests in one cycle is sometimes called a test series Test Phases Each testing mode decay flow and burst has individual phases or intervals of testing Pressure decay has four possible time intervals that can be set coupling fill stabilization and test A flow...

Page 206: ...and stabilization phase In test phase the info box shows the last reading made during the stabilization phase In a flow test the pressure box shows preset test pressure during coupling time In fill and test times it shows actual applied pressure and holds the last pressure reading made at the end of test phase In burst preset pressure is displayed during coupling and test times Page 13 Timers Spri...

Page 207: ...ular solenoid valves that direct the flow of air through the measurement circuits The number type and arrangement of valves in a Sprint LC tester is dependant on the model and configuration Page 56 Volume The alert tone turns on for five seconds whenever the fail light goes on The loudness of the tone is set with the volume control on Sprint LC s back If turned completely down no tone is audible P...

Page 208: ...T E C H N I C A L FREE 281 671 2000 HELP Uson L P 8640 North Eldridge Parkway Houston Texas 77041 281 671 2000 service uson com Page R18 ...

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