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A User’s Guide

Ver. 1.00

Isaac

Pressure Decay Leak Tester

Summary of Contents for Isaac PD

Page 1: ...A User s Guide Ver 1 00 Isaac Pressure Decay Leak Tester PD...

Page 2: ...00 Isaac Pressure Decay Leak Tester WEBSITE https zaxisinc com EMAIL info zaxisinc com PHONE 801 264 1000 HEADQUARTERS 2442 South 2570 West West Valley City UT 84119 Fixture Not Included Example of us...

Page 3: ...ester Always wear eye protection when working with compressed gas Beware of possible hazardous voltages present inside the enclosure Do not attempt any maintenance procedure discussed in this guide un...

Page 4: ...ording to ZAXIS INC literature the product 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 mat...

Page 5: ...sensors and a 24bit analog to digital convertor allows Zaxis to offer a leak tester with the highest sensitivity on the market This guide covers the standard Isaac PD Leak Testers All the current func...

Page 6: ...Pressure 4 2 Fixture 4 3 Settings 4 4 Units 4 5 Calibrate 5 Options 5 1 Touchscreen Calibration 5 2 Clock 5 3 I O Setup 5 4 Data Logging 5 5 Lock Tester 5 6 Change Pin 5 7 Ethernet Settings 6 Referen...

Page 7: ...Touch Screen Interface TSi The liquid crystal touch screen display is the primary control of the leak tester 2 Start Button Push to Start Push again during test to Abort 3 USB Port Port for USB storag...

Page 8: ...nication data output and command string input 4 M12 Femail I O connector 5 Test Port This component includes the power cord socket on off switch and the Fig 2 Bottom Panel of the Isaac PD fuse holder...

Page 9: ...b menus Pressure Fixture and Settings that control the parameters of the test Units Engineering units and the displayed sensor resolution Calibrate Calibration settings Options Contains eight user opt...

Page 10: ...peration 1 Numeric keypad screen used to input values for the timer and limit fields 2 Alpha Numeric keypad screen used in text fields Example The Program Name Field Examples of each are shown below F...

Page 11: ...42 South 2570 West West Valley City UT 84119 3 2 Run Mode Screen 1 Test Fail 2 Test Pass 3 Access Configuration Mode 4 Pressure over Time test graph 5 Test Result Value 6 Timer 7 Pressure in psig Fig...

Page 12: ...ur main menus with user configurable settings Prog Units Calibrate Options Program Settings Three menus control all the parameters associated with the test process Program Settings Engineering Units a...

Page 13: ...Tolerance The amount of tolerance on the test pressure Enter positive and negative limits in the data field to the right of the Test Pressure data field 4 Current Pressure Displays the current pressur...

Page 14: ...Pressure Tolerances 3 Check the Valve On box 4 The internal pneumatics will open to allow the pressure from the regulator out to the front port 5 The pressure sensor will show the current pressure in...

Page 15: ...Output Results Output the results via USB or Ethernet The fixture menu controls the fixturing valves These valves can be used to activate pneumatic fixturing tools or seals to capture the part for tes...

Page 16: ...ypad screen a Leaving the Post Test Op 1 timer at zero will de energize all valves at the end of the test 2 Under Hold Clamps on Fail select the on or off radio buttons c Select this option to keep th...

Page 17: ...oming pressure 4 Test The amount of time the test will measure the change in pressure 5 Data Logging Output the results via USB or Ethernet 6 Vent A safety mechanism to allow test pressure to be evacu...

Page 18: ...art to reach equilibrium 2 Press the Test data field and enter the amount of time the test will measure the change in pressure c This test observes for a decay in pressure d The decay is evaluated aga...

Page 19: ...ed product and tester air volume used to calculate an approximate leak rate i Enter a value of 0 in the Volume data field to disable calculation Output Results Select the check boxes for USB or Ethern...

Page 20: ...e inH2O inches of water column f kPa kilopascals g cmH20 centimeters of water column 2 Test Pressure Digits Use the radio buttons to select a resolution up to the thousandth power 3 Result Pressure D...

Page 21: ...are dynamic and can be adjusted to match the user s accuracy needs across the sensor range 4 5 Calibrate Introduction to Calibration How does it work In the calibration mode the pneumatic assembly wi...

Page 22: ...is for the sensor only not a leak calibra tion and is factory set Leak standards can be obtained from Zaxis Inc and can be used as a transfer standard to establish applicable leak rates All standards...

Page 23: ...ontinue into the calibration screens press Cali brate Pressing Back will take you to the about screen 3 Two Sensor types are shown a Pressure b Vacuum Calibration Verification Even though both sensor...

Page 24: ...to apply regulated air Calibration Points Set to units of psig Adjust the regulator to the desired pressure reading on the pressure standard and compare the reading of the sensor upper right corner Re...

Page 25: ...field of the calibration point to be modified 3 A numeric keypad will appear enter the value to be set and select enter 4 The current reading of the sensor will adjust to the corrections and display...

Page 26: ...PD Communications and Display Setup Screen Use these menus to control external functions to the test data collection and the I O interface There are eight menu options 1 Touchscreen Calibration 2 Clo...

Page 27: ...n The touchscreen has been factory set Typical use of the Isaac will not require this function to be used On the calibration screen the user is asked to touch specific targets with their stylus to adj...

Page 28: ...g 14 Clock Settings Screen To modify either the time or date touch the field to be changed with you finger or stylus A numeric keypad screen will open Changes will not appear until the unit s power ha...

Page 29: ...O connection will start the cycle The input starts the test on the trailing edge of the signal This selection is the default and allows the start button to run initiate the test Input 1 Start on Inpu...

Page 30: ...City UT 84119 5 3 I O Setup This screen allows the user to test the input bit pattern to help de bug wiring from the remote control PLC etc The value from the input register will display when the inp...

Page 31: ...cognised Figure 1 1 Shows a that either a USB Thumb Drive is inserted and rec ognised Figure 1 2 shows that a USB Thumb Drive isn t inserted or It isn t being rec ognised In the case that a thumb driv...

Page 32: ...rs to the Thumb Drive by pressing Save under the Parameters to USB Label You now have a backup of your test Parameters that can be easily loaded onto other machines by pressing the Load button In Figu...

Page 33: ...statistical data will be save to the Thumb Drive every 30 tests automatically USB Troubleshooting If your USB Thumb Drive isn t being recognised try these steps Go to Settings Data Logging and Press t...

Page 34: ...City UT 84119 5 5 Lock Tester Fig 15 Lock Tester Screen There are three lockable sections of the Isaac PD Select the section to lock by touching its radio button with your finger or stylus Locking th...

Page 35: ...64 1000 2442 South 2570 West West Valley City UT 84119 5 6 Change PIN Fig 16 Change PIN Screen To lock the tester a Personal Identification Number PIN 4 digits must be established The Current PIN from...

Page 36: ...ptop you will need a crossover Ethernet cable and a termi nal emulation program such as HyperTerminal Fig 17 TCP IP Settings Screen If your primary network connection is done wirelessly you will need...

Page 37: ...onnections 3 Scroll down to the section Ethernet adapter Local Area Connection and record the value of the IPv4 Address 4 On the Isaac PD under OPTIONS ETHERNET SETTINGS turn the DHCP selection to OFF...

Page 38: ...and fixture designs Operator Safety Zero access No pinch points Ergonomically designed Simple load unload Material Selection Stainless Steel Anodized Aluminum Delrin etc Sealing Forces Exerted forces...

Page 39: ...seconds simply divide by 60 to get the delta time in minutes Volume is the part volume plus the Isaac s internal test circuit approx 1cc plus the volume of connections between the Isaac s test port an...

Page 40: ...tely 14 7 pounds per square inch or 29 9 inches of mercury This is equivalent to 101 3 Kilopascals Negative Pressure Vacuum Vacuum is defined as a volume void of matter For practical purposes this mea...

Page 41: ...etric ton of air At an altitude of 3 km 2 miles however density is 30 less than at sea level This difference in air density can cause variations in flow readings from one location to another when elev...

Page 42: ...eases the flow becomes unstable and changes from laminar to turbulent flow In turbulent flow gas particles start moving in highly irregular and difficult to predict paths Eddies form transfers momentu...

Page 43: ...d amount of gas is compressed until 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...

Page 44: ...evaluated if any three are known The gas laws are valid for most gases at moderate temperatures and pressures At low temperatures and high pressures gases deviate from the above laws because the molec...

Page 45: ...e compressed gas is released The reason for the temperature drop is that the gas is released too quickly to absorb any significant heat energy from its surround ings Work performed in expanding the re...

Page 46: ...oning or changing weath er conditions 2 The word atmosphere can refer to a unit of measure equal to pres sure at average sea level By convention one atmosphere equals 1 bar To say a test was taken at...

Page 47: ...both pass and fail and the number of rejects fail only Running totals are displayed in the Test Cycles and Failures fields on the Main screen Counters Reset By selecting the Cycles or Failures numeric...

Page 48: ...pecify at the time of order whether they want coupling pressure to be line or test pressure Many fixturing options are possible Flow The amount of air passing through an object measured in cubic centi...

Page 49: ...d in the Isaac is a mass flow transducer which is both accurate and immune to room temperature fluctuations Foot Switch An optional switch that connects to the back of the Isaac that the operator can...

Page 50: ...program When the operator presses the START switch Isaac runs through a flow test then goes to a pressure test If product goes out of parameter at any point in either test the fail light turns on and...

Page 51: ...essure inside and then measuring pressure loss The abbreviation PD is often used in this guide to refer to pressure decay Pressure Regulator The Isaac uses a precision pressure regulator that controls...

Page 52: ...evel together with test time de termines the amount of acceptable leak rate S Set point A programmable threshold value usually a minimum and maximum value used to establish a testing tolerance Settle...

Page 53: ...ing 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 just two possible phases coupling...

Page 54: ...r type and arrangement of valves in an Isaac tester can be customized for special applications Vent Also called Dump or Exhaust The final step in a test The vent step is pri marily used as a safety to...

Page 55: ...ore servicing the unit Special Precautions If at any time the cover is removed from the tester for service verify that the flex rib bons connecting the display to the main Printed Circuit Board PCB an...

Page 56: ...d yield a decay value less than 0 005 psig 0 344 mbar Valve Manifold The most common place for leaks to occur is at the junction of the test port fitting to the valve mani fold Fig 20 Valve manifold V...

Page 57: ...led ring in the center of the valve count er clockwise Once separated the spider seal and spacer ring can be removed to inspect the valve seat and surrounding area for debris The spider seal could asl...

Page 58: ...t separator filter was 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 m...

Page 59: ...est West Valley City UT 84119 7 4 Fuse WARNING Disconnect power before removing fuse holder Fig 23 Fuse The installed fuses are 5 X 20mm 250V F 2 0A Both line and neutral are fused The fuse should be...

Page 60: ...y transport from desktop to wall mount or fixture Isaac PD metal backplate comes with four pre drilled holes for mounting screws Place Isaac PD on top two screws then screw bottom two screws Once secu...

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