Zaxis Isaac HD User Manual Download Page 69

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Maintenance/Troubleshooting

Warning! Disconnect power before servicing the unit.

Special Precautions

If at any time the cover is removed from the tester for service, verify that the flex-ribbons
connecting the display to the main PCB (printed circuit board) and the main PCB to the I/O are

seated and are square to the connectors. Out of alignment flex ribbons will cause damage to the
PCB.

Flex cables installed correctly.

Summary of Contents for Isaac HD

Page 1: ...1 User s Guide Ver 2 01...

Page 2: ...2 This page has been left blank intentionally...

Page 3: ...king with compressed gas Beware that hazardous voltages could be present inside the enclosure Only when you understand the procedure and you know exactly how to complete the task should you attempt an...

Page 4: ...oduct with written explanation of the problem may be returned freight prepaid to ZAXIS INC for examination repair or replacement at ZAXIS INC expense labor and material All such returns must have prio...

Page 5: ...sealed component chamber and custom test sequencing applications The Isaac can be configured from one to four test channels in a sequential or concurrent configuration depending upon applications This...

Page 6: ...cator marked with a 4 Test Ports Each port is a 1 8 27 F NPT similar to R1 8 BSPT British Standard Pipe Taper female threads This is where the DUT device under test is attached Test port positioning w...

Page 7: ...5 Power Entry Module This component includes the power cord socket on off switch and the fuse holder Power entry is capable of a range of 109 255 VAC 2A Fuse Service instructions 6 Secondary Air Conne...

Page 8: ...ard Pipe Thread Supply gas must be clean and dry 6 RS232 connector Mate Supplied wiring chart 7 TSi Touch Screen Interface Connector the i kit can be operated with or without the TSi attached 8 Ethern...

Page 9: ...p valves timer configuration Units Engineering units and the displayed sensor resolution Calibrate Access to the calibration of Pressure Vacuum and Flow Sensors Options The menu screen has eight optio...

Page 10: ...the Numeric and Alpha Numeric Keypad screens The Numeric Keypad screen is used to input values for timer and limit fields The Alpha Numeric Keypad screen is used in fields such as the program name fie...

Page 11: ...11 There are two run screens available to choose from Large Numeric single channel Large Numeric multi channel or Graph Mode Run Screen Graphics...

Page 12: ...ns Cycle between the run screen selections Graph Numeric and Bar Clear the previous test graph traces from the screen Graph only Change to Program Number Decrement Change to Program Number Increment T...

Page 13: ...0 050psi the top horizontal would be zero decay and the bottom of the screen would be 0 050psi decay Timer Bar During the Fill and Settle steps the center of the graph equals the set test pressure va...

Page 14: ...ds to the right of the test pressure This is the amount of tolerance on the test pressure During the Fill step a value outside the boundaries will result in a Hi or LO pressure error During the Settle...

Page 15: ...ary feature of the electronic regulator is the feedback loop During the fill step the processor will use the pressure transducer to adjust the output of the regulator to reach the test pressure The pe...

Page 16: ...pen to allow the pressure from the regulator out to the front port The pressure sensor will show the current pressure in the space below the valve on check box Adjust the regulator until the specified...

Page 17: ...e output is set at the beginning of the timer At the end of the cycle the outputs will deenergize in the opposite order Pre Test Op1 is output 1 To enable the output a minimum of 0 1 sec must be enter...

Page 18: ...e where the clamp valve will be used to release the part to allow pressure drop to occur to meet test limits Test details Hold clamps on Fail When this option is selected the clamps will remain in the...

Page 19: ...l the test part with regulated pressure Settle The amount of time after the pneumatic outputs have isolated the test part from any incoming pressure Note This time should be utilized to stabilize the...

Page 20: ...ternal or thermal dynamic forces cause the pressure to increase over the test time This limit must be enabled by checking the box If the increase limit is used the Evaluate at End of Test box must als...

Page 21: ...entimeters of water o inHg inches of mercury The atmospheric pressure used in the sccm leak rate calculation The default value is set to the pressure at sea level 14 70psia The Electronic Regulator re...

Page 22: ...cross the range In the calibration mode the pneumatic assembly will open to bring pressure vacuum or flow to the test port The sensors will also be active to show the current reading With a pressure o...

Page 23: ...box will appear To continue into the calibration screens press Calibrate Three sensor types are shown Pressure Vacuum and Flow Even though all three sensor types are shown each unit will have model s...

Page 24: ...st port of the Isaac to a pressure standard 2 Select the sensor number to be calibrated in the upper right corner Concurrent models have multiple sensors to calibrate 3 To apply regulated air to the s...

Page 25: ...et point When setting this point no pressure or flow should be present on the machine To exit and save the calibration press the button Caution If a calibration point data field is pressed unintention...

Page 26: ...The second is a high accuracy flow element with an analog output or display Because both are calibrated and traceable either can be used to calibrate and Isaac This image is a typical flow calibration...

Page 27: ...reen Six buttons will be used for increasing or decreasing the output pressure of the regulator Small Increase Medium Increase Large Increase Small Decrease Medium Decrease Large Decrease The buttons...

Page 28: ...teresis perform the adjustments of the electronic regulator in the upward direction that is approach the target from a lower value without going over After the calibration has been performed press the...

Page 29: ...29 Options Menus The option screen has eight menu buttons 1 Touchscreen Calibration 2 Clock 3 I O Setup 4 Data Logging 5 Lock tester 6 Change PIN 7 Serial Port 8 Ethernet Settings...

Page 30: ...creen has been factory set Typical use of the Isaac will not require this function to be used Entering the calibration screen the user will be asked to touch specific targets to adjust the touch pad t...

Page 31: ...31 To modify either the time or date touch the field to be changed A keypad will pop up to make the desired changes Cycle power after changing each field...

Page 32: ...ion will start the cycle The input starts the test on the rising edge of the signal This selection is the default and allows the start button to run initiate the test Input 1 Start on Input 1 2 Anti t...

Page 33: ...mote control PLC etc The value from the input register will display when the input is held active See I O pin out chart for Input Test Values In this screen when an input is active its corresponding o...

Page 34: ...CKSHELL CONN CABLE CLAMP CPC SIZE 17 Tyco Electronics Part 206070 8 Digi Key A32516 ND PINS CONN PIN 24 28AWG GOLD CRIMP Tyco Electronics Part 66507 4 Digi Key A23004CT ND The plug back shell and pins...

Page 35: ...7 MSB 16 100 IN 10 NOT USED 17 200 IN 11 NOT USED 18 400 IN 12 ABORT 19 800 24VDC User to Supply 24VDC 20 OUT 1 BUSY 1 OUT 2 GLOBAL PASS 2 OUT 3 GLOBAL FAIL 3 OUT 4 CH 1 FAIL 4 OUT 5 CH 2 FAIL 5 OUT 6...

Page 36: ...36 I O Circuit Input Circuit Diagram Output Circuit Diagram...

Page 37: ...are active With the selection of Internal when an output is active the output pin will have 24VDC with respect to the GND pins The factory default is active high external supply The I O was designed...

Page 38: ...38 I O Timing Chart BINARY START BUSY PASS FAIL 1 2 Test 1 Test 2 3 1 Binary should be active 100ms min before the Start signal 2 Binary and Start signals should be released after Busy is verified...

Page 39: ...10 50 01 PROG 0 Flow2 Pass 99 13 0 1s Data Header for descriptive purpose not printed in data string Step Reading Time Second Fill 1 02 0 5 s Fill 1 02 0 4 s Fill 1 01 0 3 s Fill 1 01 0 2 s Fill 1 01...

Page 40: ...able to be edited Select the section to lock by touching its radio button Locking the calibration will not allow access into the screens entirely To lock the tester a PIN number 4 digits must be esta...

Page 41: ...and flow control are hard coded in the Isaac Data bits 8 Parity None Stop bits 1 Flow Control None The baud rate is selectable and has four selections 9600 19200 57600 and 115200 To receive data from...

Page 42: ...hree wire cable The RS232 connections are screen printed on the rear of the tester GND Ground Rx Receive Tx Transmit The mating connector is removable and is held in place by a friction fit The orange...

Page 43: ...43...

Page 44: ...laptop by running the command prompt found in Start Accessories or type command in the search bar of the start menu On the command line type ipconfig this will display all the data associated with the...

Page 45: ...an be saved for future use to avoid going through all the configurations We have chosen to call our example Isaac With a connection description made the next screen to appear is Connect To Hyper termi...

Page 46: ...23 Pressing OK will initiate the socket connection from HyperTerminal to the Isaac A successful connection will be show by the connected counter in the lower right corner of the HyperTerminal screen T...

Page 47: ...ask for a filename for the data Remember to make sure the extension is TXT With a file name chosen press start to begin the collection Any data sent from the Isaac will be recorded under the filename...

Page 48: ...are Mass Flow Flow T Mass Flow Flow Laminar Element Occlusion POccl Pressure Occlusion VOccl Vacuum Vacuum Decay VacD Burst Burst Crack Crack Creep Creep Pressure Increase PinC Chamber Test Chamber Pr...

Page 49: ...the plus tolerance a HI PRESSURE error will occur and will end the test If the fill time elapses without the pressure reaching the test pressure minus tolerance a LO PRESSURE error will occur and end...

Page 50: ...n To see the decay in the full timer length check the Evaluate at End of Test box An increase limit can be set to verify that no external or thermal dynamic forces cause the pressure to increase over...

Page 51: ...rformed with or without a fill step The fill step uses a bypass circuit to achieve test pressure in the unit under test The test can be setup without the fill step this will subject the device to fill...

Page 52: ...pressure decay test The coupling menu will behave as described earlier in the manual The optional Fast Fill step is included to allow for filling of large volumes before ramping begins The burst test...

Page 53: ...step is used and an occlusion test needs to see a large drop in pressure in the test step The clamping output can be used to drive devices or pinch tooling to clamp off the part prior to test During t...

Page 54: ...crack is more sensitive to smaller opening pressures or parts that weep open A second pressure sensor is set on the downstream side of the part and monitors for the crack event The downstream transduc...

Page 55: ...rator Safety o Zero access No pinch points o Ergonomically designed o Simple load unload Material Selection o Stainless Steel o Anodized Aluminum o Delrin etc Sealing Forces o Exerted forces should no...

Page 56: ...Occlusion pinch test fixture for a cassette with a tube set Two station Pressure Decay Mass Flow and Burst test pinch fixture with shield and interlock for operator safety Zaxis can deliver a complete...

Page 57: ...seconds simply divide by 60 to get the delta time in minutes Volume is the part volume plus Isaac s internal test circuit approx 1cc plus the volume of connections between Isaac s test port and the p...

Page 58: ...the atmosphere Diatomic oxygen represents nearly 21 The inert noble gas argon accounts for about 0 9 and the remaining 0 1 is composed of many trace gases the most significant being carbon dioxide an...

Page 59: ...e density of a gas is essentially unaffected For this reason gas and all liquids can be considered incompressible However if density changes are significant in flow problems then the flow must be cons...

Page 60: ...il it is half its original volume while the temperature is kept constant the pressure doubles Quantitatively Boyle s Law is PV Constant Where the value of the constant depends on the temperature and t...

Page 61: ...c processes in which the pressure of a gas is increased or decreased without any exchange of heat energy with the surroundings Any process that occurs without heat transfer is called an adiabatic proc...

Page 62: ...heads on the front are used for test and coupling ports Standard bulkheads on the front have a 1 8 NPT similar to R1 8 BSPT British Standard Pipe Taper female thread Isaac offers a variety of bulkhead...

Page 63: ...ust The final step in a test The vent step is primarily used as a safety to vent any pressure away from the operator before removal of the test part Disabling the Vent will not affect the test result...

Page 64: ...the resultant flow with a flow sensor Flow testing can be used in two ways 1 Flow Leak Detection Product is filled with air at a set pressure and then sealed from atmosphere as in a pressure decay te...

Page 65: ...rating modes e g pressure decay flow and burst Isaac shows the current mode in the test type box on Isaac s Main screen Operator The person who connects products to Isaac presses the START button and...

Page 66: ...pressure test time and reject levels entered by the user and stored in Isaac s battery backed RAM A program is setup in Isaacs Program screen The Isaac has 100 test programs Ramp To slowly increase pr...

Page 67: ...al phases or intervals of testing Pressure decay has four possible time intervals that can be set coupling fill settle and test A flow test has three phases coupling fill and test A burst test has jus...

Page 68: ...nds with a maximum setting of 999 9 seconds See Program Screen Units of Measure Isaac can display pressure flow and time in several user selectable measurement units Changing units of measure is made...

Page 69: ...ny time the cover is removed from the tester for service verify that the flex ribbons connecting the display to the main PCB printed circuit board and the main PCB to the I O are seated and are square...

Page 70: ...e parameters are listed below Running a capped port test with these parameters should yield a decay value less than 0 005psig 0 344mbar Valve manifold removed from machine for clarity Type 1 Valve Man...

Page 71: ...e valve in an open position The valve is accessed by loosening the knurled ring in the center of the valve counter clockwise Once separated the spider seal and spacer ring can be removed to inspect th...

Page 72: ...ort fitting to the valve manifold Valve 2 Valve 1 Pressure Transducer Pneumatic Diagram When the test pressure is vented the airflow path is through Valve 1 on and out to atmosphere through Valve 2 of...

Page 73: ...s on both the valve seat and piston seal face To re assemble verify the manifold body o rings are in place replace the cylinder head on the manifold pins will aid in alignment Tighten the cylinder hea...

Page 74: ...purchased the filter media can be inspected and cleaned Some units will have a regulator filter combination Disassembly of the filter portion is identical The filter size is 5 micron Filter element Pr...

Page 75: ...ning Disconnect power before removing fuse holder The installed fuses are 5 X 20mm 250V F 2 0A Both line and neutral are fused The fuse should be seated towards the insertion end of the cradle as show...

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